Contents

Safety 1

Emergency 2

Controls 3

Driving 4

Maintenance 5

Information 6

Index 7
Contents

©2017 PACCAR Inc - All Rights Reserved

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

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

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

i
 MAINTENANCE

PREVENTIVE MAINTENANCE SCHEDULE

Introduction . . . . . . . . . . . . . . . . . . 5-9
Maintenance Schedule . . . . . . . . . . . . 5-12
LUBRICANT SPECIFICATIONS
Introduction . . . . . . . . . . . . . . . . . 5-41
Engine . . . . . . . . . . . . . . . . . . . 5-41
Master Lubrication Index . . . . . . . . . . . . 5-44
Fuller Transmission Lubrication . . . . . . . . . 5-48
Allison Transmission Lubrication . . . . . . . . 5-50
Spicer Transmission Lubrication . . . . . . . . 5-50
Oil Changes . . . . . . . . . . . . . . . . . 5-51
5
Meritor Axle Lubrication . . . . . . . . . . . . 5-52
Eaton/Dana Axle Lubrication . . . . . . . . . . 5-53
Wheel Bearing Lubrication . . . . . . . . . . . 5-54
Universal Joint Lubrication . . . . . . . . . . . 5-55
Steering Gear Lubrication . . . . . . . . . . . 5-55

(03/17) Y53-6077-1B1 5-1

 MAINTENANCE

AIR SYSTEM
Introduction . . . . . . . . . . . . . . . . . 5-57
Air Dryer . . . . . . . . . . . . . . . . . . . 5-60
Air Tanks . . . . . . . . . . . . . . . . . . 5-62
Air Gauges and Air Leaks . . . . . . . . . . . 5-63
Air Compressor . . . . . . . . . . . . . . . . 5-64
BRAKE SYSTEM
Brake Adjustment . . . . . . . . . . . . . . . 5-66
CAB
Exterior Maintenance . . . . . . . . . . . . . 5-71
Cleaning, Protecting and Weather Stripping . . . 5-72
5 Safety Restraint System - Inspection . . . . . . 5-78
Windshield Wiper/Washer . . . . . . . . . . . 5-81
COOLING SYSTEM
Cooling system maintenance . . . . . . . . . 5-82
Engine (Block) Heater . . . . . . . . . . . . . 5-86

5-2 Y53-6077-1B1 (03/17)

 MAINTENANCE

ELECTRICAL
Electrical System . . . . . . . . . . . . . . . 5-87
Light Bulbs . . . . . . . . . . . . . . . . . . 5-88
Bulb Specifications . . . . . . . . . . . . . . 5-89
Fuses, Circuit Breakers and Relays . . . . . . . 5-89
Fuse Inspection and Replacement . . . . . . . 5-92
Adding Electrical Options . . . . . . . . . . . 5-92
Batteries . . . . . . . . . . . . . . . . . . . 5-93
Battery Care . . . . . . . . . . . . . . . . . 5-97
Battery Charging . . . . . . . . . . . . . . . 5-97
Electrical and Alternator Precautions . . . . . . 5-99
Remote Keyless Entry . . . . . . . . . . . . . 5-100
5
ENGINE
Engine Maintenance . . . . . . . . . . . . . 5-101
Engine Lubrication . . . . . . . . . . . . . . 5-102
Accessory Drive Belts . . . . . . . . . . . . . 5-105
Engine Fan . . . . . . . . . . . . . . . . . 5-106
Air Intake System . . . . . . . . . . . . . . . 5-107

(03/17) Y53-6077-1B1 5-3

 MAINTENANCE

Turbocharger . . . . . . . . . . . . . . . . . 5-107
Air Cleaners . . . . . . . . . . . . . . . . . 5-108
ServiSignal™ Mini Indicator . . . . . . . . . . 5-109
Exhaust System . . . . . . . . . . . . . . . 5-110
Engine Mounting . . . . . . . . . . . . . . . 5-110
FUEL SYSTEM
Location of Fuel Shut-off Valves. . . . . . . . . 5-111
Specification . . . . . . . . . . . . . . . . . 5-111
Fuel Filters . . . . . . . . . . . . . . . . . . 5-111
FRAME
Introduction . . . . . . . . . . . . . . . . . 5-112
5 FRONT AXLE AND SUSPENSION
Axle Lubrication . . . . . . . . . . . . . . . 5-116
Inspection . . . . . . . . . . . . . . . . . . 5-117
Wheel Alignment . . . . . . . . . . . . . . . 5-117
U-Bolt Torque . . . . . . . . . . . . . . . . 5-118

5-4 Y53-6077-1B1 (03/17)

 MAINTENANCE

HEATER AND AIR CONDITIONER

Introduction . . . . . . . . . . . . . . . . . 5-120
Heater. . . . . . . . . . . . . . . . . . . . 5-121
Air Conditioner . . . . . . . . . . . . . . . . 5-121
NOISE EMISSION CONTROL
Noise Emission Warranty . . . . . . . . . . . 5-123
Inspection and Maintenance Instructions . . . . . 5-124
Noise Control System - Maintenance Log . . . . 5-128
REAR AXLE AND SUSPENSION
General Maintenance . . . . . . . . . . . . . 5-131
Visual Inspection . . . . . . . . . . . . . . . 5-132
Rear Suspension Fasteners . . . . . . . . . . 5-132 5
Rear Axle Lubrication . . . . . . . . . . . . . 5-134
Rear Axle Alignment . . . . . . . . . . . . . 5-135
STEERING SYSTEM
Power Steering . . . . . . . . . . . . . . . . 5-136
Fluid Level and Refill . . . . . . . . . . . . . 5-137

(03/17) Y53-6077-1B1 5-5

 MAINTENANCE

Steering Shaft . . . . . . . . . . . . . . . . 5-138

DRIVELINE
Driveshaft Maintenance . . . . . . . . . . . . 5-139
U-Joints . . . . . . . . . . . . . . . . . . . 5-139
TIRES AND WHEEL
Tires . . . . . . . . . . . . . . . . . . . . 5-140
Wheel Mounting and Fastening . . . . . . . . . 5-146
Wheel Replacement with Disc Brake Option . . . 5-148
Disc Wheels . . . . . . . . . . . . . . . . . 5-150
WHEEL BEARING
Wheel Bearing Adjustment . . . . . . . . . . . 5-151
5 TRANSMISSION MAINTENANCE
Introduction . . . . . . . . . . . . . . . . . 5-152
Transmission Lubricants . . . . . . . . . . . . 5-153
Automatic Transmissions . . . . . . . . . . . 5-154

5-6 Y53-6077-1B1 (03/17)

 MAINTENANCE

CLUTCH
Introduction . . . . . . . . . . . . . . . . . 5-155
Clutch Adjustment - Normal Wear . . . . . . . . 5-155

(03/17) Y53-6077-1B1 5-7

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE
MAINTENANCE WARNING! WARNING!

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

(03/17) Y53-6077-1B1 5-9

 PREVENTIVE MAINTENANCE SCHEDULE

WARNING! WARNING! The following pages contain a table

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

5-10 Y53-6077-1B1 (03/17)

 PREVENTIVE MAINTENANCE SCHEDULE

interval. Refer to Oil Changes on

Off highway is defined for applications page 5-51 before you put a new
where the vehicle may be driven off vehicle into service.
the pavement on a regular basis, even
if it is an infrequent basis and/or for a • The initial fill of lubricant in
brief time period. manual transmissions must be
changed before the end of the first
Please contact an authorized maintenance interval. See Fuller
service dealership if there are Transmission Lubrication on page
questions regarding which interval 5-48 for specific information.
to follow. Consult the supplier for
specific recommendations where • If your vehicle is equipped with an
discrepancies develop between these automatic transmission, consult
recommendations in this table and the owner’s manual for it that came
component supplier recommendations. with your vehicle to obtain lubricant
check and change intervals.
• Engine lubricating oil change
intervals aren’t listed here. Refer 5
to your engine’s operating manual
for recommendations. For specific
information on maintenance
procedures consult your vehicle
maintenance manual.

• The initial fill of drive axle lubricant

must be changed before the end
of the first scheduled maintenance

(03/17) Y53-6077-1B1 5-11

 PREVENTIVE MAINTENANCE SCHEDULE

Maintenance Schedule
New Vehicle Maintenance Schedule

New Vehicle Maintenance Schedule

After First Miles (km)

First 3,000
Operation\Frequency 50 – 100 2,000 –5,000
Day 500 (800)
(80 – 160) (3218) (4800
–8000)
Steering Shaft U-Bolts. (OFF-HIGHWAY) See Steering System on page
X
5-136.
Wheel Mounting. See Wheel Mounting and Fastening on page 5-146. X
Front Axle U-Bolt Torque. See Front Spring Suspension U-Bolts on page
X
5-118.
Charge Air Cooler and Air Intake Pipe Clamps, re- torque fasteners. X
Rear Suspension Fasteners. See Rear Suspension Fasteners on page 5-132. X
5 Transmission Lubrication.
1. For Fuller transmission, see Fuller Transmission Lubrication on page
5-48.
2. For Allison transmission, see Allison Transmission Lubrication on page X
5-50.
3. For Spicer transmission, see Spicer Transmission Lubrication on page
5-50.
Axle Lubrication.
1. For Meritor axle, see Meritor Axle Lubrication on page 5-52. X
2. For Eaton/Dana axle, see Eaton/Dana Axle Lubrication on page 5-53.

5-12 Y53-6077-1B1 (03/17)

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Frame Fifth Wheel Check the kingpin lock and plate for wear and function; X
lubricate (NLGI #2 grease).
Inspect fifth wheel operation (shown on page 5-113) X
Frame Fasteners Check for tightness; tighten to the specified torque value as X
required (shown on page 5-114).
Crossmembers and Inspect for cracks and loose fasteners. Replace or tighten X
Mounting Brackets to the specified torque value as required (shown on page
5-114). 5
Engine Mounting Inspect engine mounts every 60,000 miles (96,560 km) X
(shown on page 5-110). Contact an authorized vehicle OEM
dealership if engine mounts need servicing.

(03/17) Y53-6077-1B1 5-13

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Front Axle Total Vehicle Alignment Check and adjust as required. X X
(Meritor)
Steering knuckle Inspect for wear and damage and endplay. Shim or replace X
spindles, thrust bearings, as required (shown on page 5-136).
kingpins, drawkeys, tie
rod ends, steering stops,
and bushings
Kingpin bushings, thrust Lubricate with approved grease. X
bearings, and tie rod ball
ends
5

Drawkeys Tighten nuts X X

5-14 Y53-6077-1B1 (03/17)

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

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

(03/17) Y53-6077-1B1 5-15

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Front Front Spring Inspect for cracked leaves, worn bushings, and excessive X
Suspension corrosion.
Spring Pins and Inspect for worn parts and excessive joint clearance. Shim X
Shackles or replace as required.
Shock Absorbers Inspect for leaking, body damage, and damaged or worn X
bushings. Replace as required. Check the shock mounting
stud torque.
Spring Pins Lubricate with approved grease. X
5 Check for proper function. X
U-bolts (ON HIGHWAY) Check the general condition and the tightness of the nuts. X X
Tighten the nuts to the specified torque value as required
(shown on page 5-118).
U-bolts (OFF HIGHWAY) Check the general condition and the tightness of the nuts. X
Tighten the U-bolts after the first day or two of operation.
Then tighten the nuts to the specified torque value as
required (shown on page 5-118).

5-16 Y53-6077-1B1 (03/17)

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Drive Axle Axle Housing Visually inspect for damage or leaks. X
(Dana)
Check oil level. Check “cold.” Torque the drain plug. X
Drain the lubricant while warm. Flush each unit with clean See information on page 5-53
flushing oil. Change the lubricant.
Air Shift Unit Check the lubricant level. X
Remove the housing cover and drain the lubricant. Wash X
the parts thoroughly and dry in air.
Breather Clean or replace. X 5
Lube Pump (ON Remove the magnetic strainer and inspect for wear particles. X
HIGHWAY) Wash in solvent and dry in air.
Lube Pump (OFF Remove the magnetic strainer and inspect for wear particles. X
HIGHWAY) Wash in solvent and dry in air.
Lube Filter (ON Change. X
HIGHWAY)
Lube Filter (OFF Change. X
HIGHWAY)

(03/17) Y53-6077-1B1 5-17

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Drive Axle Magnetic drain plug and Clean or replace. X
(Dana) breather (ON HIGHWAY)
Magnetic drain plug Clean or replace. X
and breather (OFF
HIGHWAY)

5-18 Y53-6077-1B1 (03/17)

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Drive Axle Axle Housing Check the “cold” fill level at the differential carrier plug for a X
(Meritor) pinion angle of less than 7 degrees, or at the axle bowl plug
for a pinion angle of greater than 7 degrees. Tighten the
plug to 35-50 Lb. ft. (47-68 N.m.)
Visually inspect for damage or leaks. X
Drain and replace the lubricant. See information on page 5-51
Lubricant filter Change the filter. X
Breather Check the operation. If the cap doesn’t rotate freely, replace. X 5
Input shaft and pinion Check and adjust the endplay. X
shaft
Axle shaft Tighten the rear axle flange nuts to the specified torque X
value.
Interaxle differential Check the operation. X

(03/17) Y53-6077-1B1 5-19

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Drive Axle Axle Housing Change the oil in the differential carrier and the hubs, and X X
(SISU) clean the magnetic oil drain plugs.
Check the wheel bearing hubs and adjust if necessary. X X
Visually inspect for damage or leaks. X X
Check the oil level in the differential carrier and hubs. X
Breather Check the breather for proper operation. X
Lube Filter Clean the suction filter for the optional pressure lubrication X
5 system.
S-cam brakes Overhaul the brakes; degrease all moving parts; check the X
bushings and seals for wear.

5-20 Y53-6077-1B1 (03/17)

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Rear U-bolts Check the torque. Tighten to specified torque value as X X
Suspension required (shown on page 5-133).
Frame and crossmember Check the torque. Tighten to specified torque value as X
bolts required (shown on page 5-114).

Mounting brackets and Check the condition and the fastener torque. Tighten to the X X
fasteners specified torque value as required (shown on page 5-114).
5

(03/17) Y53-6077-1B1 5-21

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Drum Slack adjusters Check the push rod travel and check the control arm for X
Brakes (All) cracks. Adjust at reline (shown on page 5-69).
Lubricate (NLGI #2 grease). X
Brake camshaft bearing Check for excessive camshaft paly in the axial and radial X
directions. Max allowable play is 0.003 in. Lubricate (NLGI
#2 grease).
Brake treadle valve Clean the area around the treadle, boot, and mounting plate. X
Check the pivot and mounting plate for integrity. Check the
5 plunger boot for cracks. Lubricate roller pin, pivot pin, and
plunger (NLGI #2 grease).
Brake air system Check air lines and fittings for leaks (shown on page 5-57). X
Adjust routing as required to prevent chafing. Check tank
mounting and condition.
Clean or replace the inline filters. X
Brake lining Inspect; replace as required. X

5-22 Y53-6077-1B1 (03/17)

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Disc Brakes Brake pads Inspect; replace as required. X
(Bendix®)
Brake disc/rotor Inspect for visible cracks, heat checking, galling, or scoring X
of surface. Check for runout (max allowable is 0.002 in.).
Caliper sliding function Ensure caliper slides freely with no obstructions or excessive X
play.
Caliper slide pins Inspect protective caps of the guide pins for damage or X
cracking.
System operation Check operation; inspect as per manufacturer’s service
literature.
X 5

(03/17) Y53-6077-1B1 5-23

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Hub, Drum, Hubs (non-LMS) Check the bearing endplay and adjust as required (shown X
and Hubcap on page 5-54).
Hubs (non-LMS) with Clean the components and check for excessive wear or X
outrunner seals damage. Change the oil and seal (shown on page 5-54).
Hubs (non-LMS) with Clean the components and check for excessive wear or X
standard seals damage. Change the oil and seal (shown on page 5-54).
Hub seals (all) Check for leaks; replace as required. X

5 LMS Hubs (Dana) Inspect for leaks. Check the bearing endplay and adjust as
required (shown on page 5-54).
X

LMS Hubs (Dana) with Service the bearings, seals and oil. This interval may be 500,000 miles/ 800,000 km
Synthetic Lubricant different depending on the results of the regular inspection.
(shown on page 5-54).
LMS Hubs (Dana) with Service the bearings, seals and oil. This interval may be 350,000 miles/ 560,000 km
Mineral Lubricant different depending on the results of the regular inspection.
(shown on page 5-54).

5-24 Y53-6077-1B1 (03/17)

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Hub, Drum, Brake drums Inspect for visible cracks, heat checking, galling or scoring of X
and Hubcap the braking surface, and for severe corrosion on the outside
surface. Check for out-of-round or oversize condition [0.080
in. (2 mm) more than the original diameter]. Replace as
required.
Hubcaps Clean the sight window. Check the center plug, mounting X
flange, and fill plug for leaks and for proper installation.
Replace broken or damaged parts. Check the lubricant level
and add as required.
5

(03/17) Y53-6077-1B1 5-25

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Main and Main and auxiliary Inspect for visible damage, signs of overheating, and leaks. X X
auxiliary transmission and transfer
transmis- case Check the drain plugs for tightness. X
sion
Mounting Brackets and Check the condition of the fasteners and their torque. X
Fasteners Tighten to the specified torque value as required.
Oil cooler Clean the fins (air-to-oil type) and body. Check the hose X
condition and for leaks; replace as required.
Main and aux. Check the oil level; refill as required. X
5 transmission
Main and auxiliary Drain lubricant while warm. Flush each unit with clean 500,000 miles/ 800,000 km
transmission (ON flushing oil.
HIGHWAY)
Main and auxiliary Drain lubricant while warm. Flush each unit with clean X X
transmission (OFF flushing oil.
HIGHWAY)

5-26 Y53-6077-1B1 (03/17)

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Auxiliary Cotta Transfer Case Inspect: Check oil level; inspect for leaks and any visible X
transmis- TR2205 damage.
sion Fabco Transfer Case
Initial oil change: Drain oil while warm; flush case with gear X X
TC142/TC143/TC170/
oil-compatible fluid; clean magnetic drain plug; refill. Do not
TC270
flush the case with any solvent.
Marmon-Harrington
Transfer Case Change oil. X
MVG2000/MVG2000SD
Air Intake Air intake piping, Check the system for broken pipes, leaks, joint integrity, X
mounting, and charge air cleanliness, and proper support (shown on page 5-109). 5
cooler
Air cleaner Replace the engine intake air cleaner element (shown on When required by air restriction
page 5-108). indicator or required by the engine
manufacturer's operator manual.
Clutch Clutch linkage Lubricate. X
Clutch release bearing Lubricate. X
Inspect and adjust when necessary (no adjustment required X
for SOLO type clutches)

(03/17) Y53-6077-1B1 5-27

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Cooling Hoses Check the radiator and heater hoses for leaks. X X
Extended Life Coolant Check the freeze point (shown on page 5-83). X
(ELC)
Check for contamination using test strips (shown on page X
5-82).
Replace blank water filter if applicable. X
Perform lab analysis (shown on page 5-82). X
If lab analysis shows coolant is unsuitable for continued use:
5 Flush, drain, and refill (shown on page 5-82).
Add ELC Extender (shown on page 5-82).
Flush, drain, and refill with new coolant (shown on page X
5-82).
Fan clutch Check for air leaks. (shown on page 5-106). X X
Check the fan drive bearings (turn the sheave in both
directions to check for worn hub bearings).
Solenoid valve Check the fan drive for proper engagement and X X
disengagement.

5-28 Y53-6077-1B1 (03/17)

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Tires and Tires Check inflation pressure (shown on page 5-140). Weekly “cold” using calibrated
Wheels gauge
Inspect for cuts, irregular wear, missing lugs, sidewall X
damage, etc.
Disc wheels Inspect the wheel disc for any cracks or surface irregularities. X
Inspect the rim edge and bead seat area for damage.
Replace any damaged wheels - DO NOT ATTEMPT TO
REPAIR.
Demountable rims Inspect the mounting ring, rim gutter, side ring, and lock ring X 5
for damage; replace as required.
Wheel nuts and studs Check the tightness of the fasteners and tighten the X
fasteners to the specified torque as required (shown on
page 5-146).
Inspect for damaged hex corners, stripped or damaged X
threads, and excessive corrosion; clean or replace as
required.

(03/17) Y53-6077-1B1 5-29

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Power Reservoir Check the fluid level (shown on page 5-55). X
Steering
Reservoir (ON Drain, replace the filter, and refill (shown on page 5-55). X X
HIGHWAY)
Reservoir (OFF Drain, replace the filter, and refill (shown on page 5-55). X X
HIGHWAY)
Steering gear Check the lash of the sector shaft; adjust as required. X
Grease the trunnion bearing (EP NLGI #2 lithium-based, X
5 moly-filled, HD grease).
Grease the input shaft seal (EP NLGI #2 lithium-based, X
moly-filled, HD grease).
Power assist cylinder Lubricate the ball joints. Inspect for leaking rod seals, X
damaged ball joint boots, and damage to cylinder rod or
barrel.
Hoses and tubes Check for leaks and chafing. X
Steering linkage Check all joints for excessive lash; replace as required X
(shown on page 5-136).

5-30 Y53-6077-1B1 (03/17)

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Power Draglink tube clamp and Check the torque; tighten to specified torque value as X X
Steering ball socket required.
Pitman arm clamp bolt Check the torque; tighten to specified torque value as X X
and nut required.
Steering intermediate Check the torque on the pinch bolt and nut. X X
shaft
Steering intermediate Lubricate [EP NLGI #2 HD grease, +325° F to -10° F (+163° X X
shaft U-joints (ON C to -23° C) range].
HIGHWAY) 5
Steering intermediate Lubricate [EP NLGI #2 HD grease, +325° F to -10° F (+163° X X
shaft U-joints (OFF C to -23° C) range].
HIGHWAY or CITY
DELIVERY)
Draglink and tie rod Lubricate (EP NLGI #2 lithium-based, moly-filled, HD X X
arm ball sockets (ON grease).
HIGHWAY)
Draglink and tie rod Lubricate (EP NLGI #2 lithium-based, moly-filled, HD X X
arm ball sockets (OFF grease).
HIGHWAY or CITY
DELIVERY)
(03/17) Y53-6077-1B1 5-31
 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Fuel and Fuel tanks Inspect tanks, brackets, hoses, and fittings for correct X
Tanks location, tightness, abrasion damage, and leaks; repair or
replace as required.
Fuel tank breathers Check for proper function; clean the drain hoses. X
Fuel tank straps Check the strap tightness; tighten to proper torque value X X
as required:
Aluminum tank: 30 Lb. ft. (41 N.m.)
Cylindrical Steel tank: 8 Lb. ft. (11 N.m.)
5

5-32 Y53-6077-1B1 (03/17)

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

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

(03/17) Y53-6077-1B1 5-33

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

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

5-34 Y53-6077-1B1 (03/17)

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Battery Battery cables Check the condition of the cables, cushion clamps, nylon tie X
Boxes, Tool straps, and routing. Replace a cushion clamp if the rubber
Boxes, and has deteriorated. Repair or tighten terminals, and secure
Steps cables to prevent chafing. Replace damaged cables (cuts,
cracks, or excessive wear) (shown on page 5-87).
Batteries (ON HIGHWAY Check for cracks and damage, electrolyte level, condition of X
and LINE HAUL) terminals, and tightness of holddowns (shown on page 5-87).
Batteries (OFF- Check for cracks and damage, electrolyte level, condition of X
HIGHWAY) terminals, and tightness of holddowns (shown on page 5-87).
5
Battery box and tray (ON Check the box integrity. Clean the drain tube and check for X
HIGHWAY and LINE acid leaks. Check condition of all equipment mounted under
HAUL) the box.
Battery box and tray Check the box integrity. Clean the drain tube and check for X
(OFF-HIGHWAY) acid leaks. Check condition of all equipment mounted under
the box.
Battery Cable Fasteners Check battery cable fasteners and tighten as necessary to X
10-15 Lb. ft. (13.6-20.3 N.m.) as specified on the battery
label.

(03/17) Y53-6077-1B1 5-35

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Electrical Headlamps Check the aim and adjust as required. X
and lights
Warning lights in light bar Check at the ignition start position to verify bulbs and driver X
information display function.
Turn, Stop, Reverse Visual check. X
lights and signals
Alternator Check operation and output. X
Check tightness of the pulley nut. X
5 Check the tension of the drive belt (shown on page 5-105). X
Check tightness of the terminal hex nuts. X
Starter Check torque on hex nuts. X
ECM connector Check the tightness of the ECM connector. X
Wheel sensors Check for damaged sensors and connectors, and worn or X
frayed wires.
Fuel and diesel exhaust Check the mounting screws and electrical connections for X X
fluid tank sending unit worn or damaged wires and connectors.

5-36 Y53-6077-1B1 (03/17)

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Electrical Power supply harnesses Check for worn or damaged insulation, corroded terminals, X
and lights (engine, transmission, frayed wires, and oil or fluid leaks on the connectors or
etc.) wiring.
Wash to remove excess grease. X
Cab Hood Lubricate the lower hood pivot (only if lube fittings are X
structure, present).
doors and
hoods Hinges and latch Lubricate with silicone spray. X
Body and cab holddown
bolts
Check the condition and tightness. X 5
Heating and Air conditioner Operate the system. X
Air Condi-
tioning Heater and air Perform the checks listed shown on page 5-120. X
conditioner
Full operational and diagnostic check. X
Condenser Clear any debris from the front of the condenser. X

(03/17) Y53-6077-1B1 5-37

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Aftertreat- System Check for leaks and proper support (shown on page 5-123). X
ment Sys-
tem Diesel particulate filter Clean filter. Refer to the Engine Maintenance
Manual.
Diesel exhaust fluid tank Inspect the tank, straps, brackets, hoses and fittings for X
abrasion damage, leaks, tightness and fully engaged
connectors.
Diesel exhaust fluid Replace filter. Refer to the Engine Maintenance
supply module Manual.
5

5-38 Y53-6077-1B1 (03/17)

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Air Air compressor governor Replace air strainer. X
Air lines Check condition and routing to prevent chafing. X
System Lubricate (shown on page 5-60). X
Inline filters Replace elements or clean with solvent. X
Air dryer Perform the checks listed (shown on page 5-57). X
Air dryer (ON HIGHWAY) Overhaul. 360,000 miles/576,000 km
Air dryer (OFF
HIGHWAY)
Overhaul. X 5

(03/17) Y53-6077-1B1 5-39

 PREVENTIVE MAINTENANCE SCHEDULE

PREVENTIVE MAINTENANCE (PM) INTERVALS

Recommended PM Interval
SYSTEM COMPONENT MAINTENANCE TASK
I A B C D E
Engine Basic Engine Maintenance and service interval recommendations are detailed in the engine manufacturer’s
Operations and Maintenance Manual included with the vehicle. The engine manufacturer’s
recommendations vary depending engine model. Information is also available from authorized
dealers, the engine manufacturer’s authorized service centers, and the engine manufacturer’s
web site.
Safety Three-point Safety Belt Inspect. 20,000 miles/32,000km
System If the vehicle is exposed to
severe environmental or working
conditions, more frequent
5 inspections may be necessary.

5-40 Y53-6077-1B1 (03/17)

 LUBRICANT SPECIFICATIONS

LUBRICANT at top economy and in prolonging Engine

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

(03/17) Y53-6077-1B1 5-41

 LUBRICANT SPECIFICATIONS

WARNING! WARNING! NOTE

Exhaust fumes from the engine Never idle your vehicle for prolonged Keep the engine exhaust system
contain carbon monoxide, a color- periods of time if you sense that ex- and the vehicle’s cab ventilation
less and odorless gas. A poorly haust fumes are entering the cab. system properly maintained. It is
maintained, damaged, or corroded Investigate the cause of the fumes recommended that the vehicle’s ex-
exhaust system can allow car- and correct it as soon as possible. haust system and cab be inspected:
bon monoxide to enter the cab or If the vehicle must be driven under
sleeper. Failure to properly main- • By a competent technician every
these conditions, drive only with the
tain your vehicle could cause car- 15,000 miles/ 24,000 km,
windows slightly open. Failure to re-
bon monoxide to enter the cab and pair the source of the exhaust fumes • Whenever a change is noticed in
cause death, personal injury or seri- may lead to death, personal injury or the sound of the exhaust system,
ous illness. serious illness.
• Whenever the exhaust system,
underbody, cab or sleeper is
damaged.

5
NOTE
Use only an exact replacement parts
in Aftertreatment exhaust system.
Using a noncompliant replacement
part could violate emissions require-
ments and also void the emission
system’s warranty.

5-42 Y53-6077-1B1 (03/17)

 LUBRICANT SPECIFICATIONS

Pipe and Hose Clamps

Use the following table for torque

specifications to check pipe and hose
clamps.
Pipe and Hose Clamp Torque Values

APPLICATION APPROVED CLAMP TORQUE

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

(03/17) Y53-6077-1B1 5-43

 LUBRICANT SPECIFICATIONS

Master Lubrication Index

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

5-44 Y53-6077-1B1 (03/17)

 LUBRICANT SPECIFICATIONS

NOTE
The responsibility for meeting these
specifications, the quality of the
product, and its performance in ser-
vice rests with the lubricant supplier.

For oil reservoir with side filler plugs

(transmission, axles, steering gear
boxes, transfer cases, etc.) the oil
must be level with the filler opening.

1 Improper Oil Level 5

2 Proper Oil Level

Use care when checking the oil level

with a finger. Just because you can
reach the oil level with a finger, does
not mean the oil level is correct.

(03/17) Y53-6077-1B1 5-45

 LUBRICANT SPECIFICATIONS

Component Lubrication Index

Universal Joints EP*
Drive Shaft Splines CL*
Steering Column CL
Alternator Bearing BB*
Fan Hub BB*
Power Steering Reservoir ATF
Steering Drag Link CL
Steering Knuckles CL
Spring Pins CL
Clutch Release Bearings BB
Brake Shoe Anchor Pins HT
Brake Cam Bearings HT
5 Slack Adjusters CL
Starter Bearings CC
Turbocharger Aneroid CC
Water Pump BB*
Suspension Fittings (other than threaded pins and bushings) EP
Steering Axle: Grease Fittings on Steering Arm; Tie Rod Ends; Drag EP
Link; King Pins
Steering Shaft Grease Fittings EP

5-46 Y53-6077-1B1 (03/17)

 LUBRICANT SPECIFICATIONS

Component Lubrication Index

Brake Treadle Hinge and Roller Engine oil
Lock Cylinders Lock lubricant
Door Hinges Not required - Teflon bushings
Door Latches and Striker Plates Polyethylene grease stick
Door Weatherstrip Silicone lubricant
Hub-piloted Aluminum Wheels Coat the wheel pilot or hub pads with Freylube #3 lubricant (light
colored) or Chevron Zinc lube. Do not get lubricant on the face of
the wheel or the hub.
Manual Transmission Hydraulic Clutch DOT3 or DOT4 (Brake Fluid)
*Consult manufacturer or lubricant supplier for special details.

(03/17) Y53-6077-1B1 5-47

 LUBRICANT SPECIFICATIONS

Fuller Transmission Lubrication Change and Inspection

Lubrication Off-Highway Use

Fuller transmissions are designed so Refer to the Eaton Fuller transmission

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

5-48 Y53-6077-1B1 (03/17)

 LUBRICANT SPECIFICATIONS

Recommended Lubricants

Type Grade (SAE) Ambient Temperature

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

(03/17) Y53-6077-1B1 5-49

 LUBRICANT SPECIFICATIONS

Allison Transmission Spicer Transmission Recommended Lubricants

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

Type Grade (SAE) Ambient Temperature

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

5-50 Y53-6077-1B1 (03/17)

 LUBRICANT SPECIFICATIONS

Type Grade (SAE) Ambient Temperature

Synthetic Engine Oil meeting MIL-L-2104D or CD50 All
MIL-L-46152B, API-SF or API-CD CD30
*Synthetic Gear Oil Meeting MIL-2105C or EP75W90 All
API-GL5 EP75W140
*EP Gear Oils are not recommended when lubricant operating temperatures are above 230° F (110° C).

Oil Changes 24 hours but before 100 hours of Refilling

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

(03/17) Y53-6077-1B1 5-51

 LUBRICANT SPECIFICATIONS

Meritor Axle Lubrication

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

AVAILABLE ADVANCED LUBE AXLES

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

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

5-52 Y53-6077-1B1 (03/17)

 LUBRICANT SPECIFICATIONS

Application Type Of Lubricant Mileage Interval

On Highway Synthetic 240,000 mi. (384,000 km)
Synthetic with Pump and Filter 500,000 mi. (800,000 km)
Mineral Base 120,000 mi. (192,000 km)
City Delivery Synthetic 120,000 mi. (192,000 km)
Synthetic with Pump and Filter 240,000 mi. (384,000 km)
Mineral Base 120,000 mi. (192,000 km)
Off Highway Synthetic 120,000 mi. (192,000 km)
Synthetic with Pump and Filter 120,000 mi. (192,000 km)
Mineral Base 120,000 mi. (192,000 km)

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

(03/17) Y53-6077-1B1 5-53

 LUBRICANT SPECIFICATIONS

• Refer to the Eaton Field • See your dealer for • Refer to the chart below for
Maintenance Manual for a Eaton-approved lubricant brands. lubricant change interval.
particular axle for lubricant
specifications.

Type of Lubricant On-Highway Mi. (km) Maximum Change On/Off Highway Severe Maximum Change
Interval Service Mi. (km) Interval
Mineral-Based 120,000 (192,000) Yearly 60,000 (96,000) Yearly
Eaton-Approved 240,000 (384,000) 2 Years 120,000 (192,000) Yearly
Synthetic
Eaton-Approved 350,000 (560,000)
Synthetic in axle with
extended drain interval
option

Wheel Bearing Lubrication done.) Allow time for the oil to seep Oil-lubricated Nondriven Hubs
Oil-lubricated Driven Hubs through the bearings when initially
filling a hub. Maintain the differential Use CD50 synthetic transmission fluid
5 Use hypoid oil, A.P.I.-GL-5 SAE oil level by adding oil until its surface is SAE 50W or equivalent. A minimum of
75W-90FE synthetic gear lubricant even with the bottom of the filler hole 9 oz. (270 ml) of lubricant is required
or equivalent. A minimum of 1 quart (see illustration on page 5-45). for proper lubrication of an LMS™ hub;
(921 ml) of oil is required for proper 10-13 oz. (295-400 ml) is required for
lubrication of each drive hub. Add oil a non-LMS hub, depending on wheel
through the filler hole in the hub; if design. Allow time for the fluid to seep
none, add oil through the differential through the bearings when initially
filler hole. (Note: Remember to replace filling a hub. When properly filled, the
vent plug or threaded filler plug when

5-54 Y53-6077-1B1 (03/17)

 LUBRICANT SPECIFICATIONS

fluid level will lie between the fluid level Universal Joint Lubrication Steering Gear Lubrication
line and 1/4” above the line. Fluid Refill
Refer to the Spicer Universal Joints
NOTE and Driveshafts service manual and The following recommendations are
lubrication specifications. for general purpose steering systems
Remember to replace vent plug
(both TRW and Sheppard).
when done.
• For normal temperatures, use
Automatic Transmission Fluid
(ATF) Type E or F or Dexron® III.

• For cold temperatures of -22º F

(-30º C) and above use ATF Type
A.

• For extremely cold temperatures

between -22º F (-30º C) and -40º
F (-40º C) use ATF Type B.
5

(03/17) Y53-6077-1B1 5-55

 LUBRICANT SPECIFICATIONS

Inspection
If incompatible (insoluble) fluids are
NOTE mixed in a power steering system,
air bubbles can be produced at the
Before removing reservoir cover,
interface of the two fluids. This can
wipe outside of cover so that no dirt
cause cavitation, which reduces the
can fall into the reservoir.
lubrication between moving parts in
1. Check the fluid level; add fluid if the gear. This could result in worn
required. components.

2. Check fluid for contamination, The mixture of two different fluids,

discoloration, or burnt smell; although harmless to individual
correct source of such problems internal components, may initiate a
before replacing fluid and filter. chemical reaction that produces a new
compound that will attack seals and
CAUTION other internal components.
When adding fluid, be sure to use
5 fluid of the same type. While many
Do not mix different fluids.
fluids have the same description and
intended purpose, they should not
be mixed due to incompatible ad-
ditives. Mixing incompatible fluids
may lead to equipment damage.

5-56 Y53-6077-1B1 (03/17)

 AIR SYSTEM

AIR SYSTEM
WARNING! WARNING!
Introduction Prior to the removal of any air sys- Never connect or disconnect a hose
tem component, always block and or line containing air pressure. It
WARNING! hold the vehicle by a secure means may whip as air escapes. Never re-
other than the vehicle's own brakes. move a component or pipe plug un-
Do not attempt to modify, alter, repair
Depleting air system pressure may less you are certain all system pres-
or disconnect any component of the
cause the vehicle to roll unexpect- sure has been depleted. Failure to
air system. Repairs or modifications
edly resulting in an accident causing comply may result in death, personal
to the air system, other than what
death or personal injuries. Keep injury, equipment or property dam-
is described in this section, should
hands away from chamber push age.
only be performed by an authorized
rods and slack adjusters, they may
dealer. Failure to comply may result
apply as system pressure drops. WARNING!
in death or personal injury.
Never exceed recommended air
WARNING! pressure and always wear safety
After completing any repairs to the glasses when working with air pres-
air system, always test for air leaks, sure. Never look into air jets or direct 5
and check the brakes for safe opera- them at anyone. Failure to comply
tion before putting the vehicle in ser- may result in death, personal injury,
vice. Failure to comply may result in equipment or property damage.
death, personal injury, equipment or
property damage.

(03/17) Y53-6077-1B1 5-57

 AIR SYSTEM

compressed air then goes to the

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

Your vehicle’s compressor takes

outside air and compresses it, usually
to 100-120 psi (689-827 kPa). The

5-58 Y53-6077-1B1 (03/17)

 AIR SYSTEM

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

(03/17) Y53-6077-1B1 5-59

 AIR SYSTEM

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

5-60 Y53-6077-1B1 (03/17)

 AIR SYSTEM

and non-compressing cycle) in a Overhaul Bendix® AD-IS Series Air Dryer

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

The AD-IS Series air dryer has

incorporated into its design various

(03/17) Y53-6077-1B1 5-61

 AIR SYSTEM

components that have typically been Air Tanks basis. Operate air devices daily to
installed separately on the vehicle (see circulate lubricants within the unit.
below for components/areas affected):
Periodically: Clean filter screens
• Pressure protection valves ahead of the valves by removing the
screens and soaking them in solvent.
• Safety valve
Blow them dry with pressurized air
• Governor and plumbing before reinstalling them.

• Plumbing of the front and rear WARNING!

service air tanks
If the supply and service air tanks
• Plumbing to accessory systems are not drained at the recommended
frequency, water could enter the
These components are required to air lines and valves. This could
meet the Federal Motor Vehicle Safety cause corrosion or blockage, which
Standards (FMVSS 121 - Air Brake could compromise the brake system
5 Systems). As the Warning above safety and potentially cause an ac-
states, any other type of air dryer To eject moisture from the air system cident. Failure to comply may result
installed in the place of an AD-IS Series tanks, pull the line that is connected to in death, personal injury, equipment
will require changes, modifications the moisture ejection valve. Continue or property damage.
and/or additions to your vehicle’s air pulling until the air comes out free of
system to maintain compliance with water.
FMVSS 121.
Daily: The supply and service air
tanks, must be drained on a daily

5-62 Y53-6077-1B1 (03/17)

 AIR SYSTEM

Air Gauges and Air Leaks

CAUTION If the light and alarm do not turn off at
Your vehicle comes with air pressure start-up, do not try to drive the vehicle
Do not use penetrating oil, brake
gauges for two separate systems, until the problem is found and fixed. If
fluid, or wax-based oils in the air sys-
Primary and Secondary: the Primary the pressure in either or both systems
tem. These fluids may cause severe
gauge indicates pressure in the rear is too low for normal brake operation,
damage to air system components.
braking system; the Secondary gauge i.e., the pointer of one gauge falls
indicates pressure in the front braking below 65 psi (448 kPa), a warning light
• Maintain the air compressor to
system. Each gauge indicates the on the gauge will glow and the audible
prevent excessive oil bypass.
amount of air pressure in pounds per alarm will sound.
• Replace worn seals in valves and square inch (psi).
air motors as they are needed. NOTE
Your authorized dealer carries WARNING! Park brakes lock up at 60 psi (414
rebuild kits for most units. Do not operate the vehicle if leak- kPa), the audible alarm will sound at
age in the air system is detected. 65 psi (448 kPa).
Conduct the following procedure
and contact an authorized dealer (or 5
any other properly equipped service
center) if a leak is detected. Failure
to check the brakes or follow these
procedures could cause a system
failure, increasing the risk of an Primary Air Pressure Gauge
accident and may result in death,
personal injury, equipment or prop-
erty damage.

(03/17) Y53-6077-1B1 5-63

 AIR SYSTEM

5. Start the engine and build up the

Air Compressor
Operation
air pressure again.
6. Stop the engine, and apply the All compressors, regardless of make
brakes fully. Apply the brake pedal or model, run continuously while the
and hold it down for five minutes. engine is running. System pressure
Secondary Air Pressure Gauge The pressure drop should not is controlled by the governor. The
exceed 3.0 psi (21 kPa) per governor acts in conjunction with
Follow the procedure below to minute. the unloading mechanism in the
check the compressed air system compressor cylinder block to start
for leaks: 7. If you detect excessive leakage and stop compression of air. The
(air pressure loss greater than 3.0 compressor is unloaded when the
1. Periodically, or after maintenance psi (21 kPa) after five minutes of
or replacement of air system system pressure reaches 120 psi (827
brake application), a leakage test kPa) and compression is reestablished
components: should be made at the air line when system pressure falls to 100 psi
2. Build up air pressure in the system connections and at all air brake (690 kPa).
to the governor cutout point or until control units. These tests should
5 120 psi (827 kPa) is reached. determine where air is escaping.

3. Stop the engine and release the

service brakes.
4. Without applying the brake pedal,
observe the rate of air pressure
drop. This rate should not exceed
2.0 psi (14 kPa) per minute.

5-64 Y53-6077-1B1 (03/17)

 AIR SYSTEM

Preventive Maintenance presence of excessive carbon. If

excessive carbon is found, clean
The following service checks are or replace the compressor cylinder
provided for your information only and head. Also, check compressor
should be performed by a certified discharge line for carbon, and
mechanic. Contact your dealer or the clean or replace the discharge line
engine manufacturer's Maintenance if necessary.
Manual for further information on
servicing air compressors. • Disassemble compressor and
thoroughly clean and inspect
After completing any repairs to the air all parts. Repair or replace
system, always test for air leaks, and all worn or damaged parts, or
check the brakes for safe operation replace compressor with a factory
before putting the vehicle in service. exchange unit.

Below is a list of areas to maintain for CAUTION

the air compressor:
When draining the engine cooling
system is required, to prevent dam-
5
• Inspect compressor air filter
element, if so equipped, and age from freezing, the compressor
replace element if clogged. Check must also be drained at the cylinder
compressor mounting and drive head and block. Engine damage
for alignment and belt tension. could occur if the cooling system is
Adjust if necessary. not periodically drained and main-
tained. See Cooling System on page
• Remove compressor discharge 5-82 for further information.
valve cap nuts and check for

(03/17) Y53-6077-1B1 5-65

 BRAKE SYSTEM

BRAKE SYSTEM specifications can affect the whole

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

5-66 Y53-6077-1B1 (03/17)

 BRAKE SYSTEM

Air Disc Brakes

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

(03/17) Y53-6077-1B1 5-67

 BRAKE SYSTEM

• Have a qualified mechanic • Chock the wheels.

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

Regularly inspect caliper for Running

Clearance:

• Stop the vehicle on level ground

and let the brakes cool down. Hot
brake calipers can burn skin on
contact.

5-68 Y53-6077-1B1 (03/17)

 BRAKE SYSTEM

Drum Brakes Automatic Slack Adjusters

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

• Brake Chamber Stroke is the

difference between the applied
and the retracted position of the
air chamber pushrod.
5
• A correctly installed and
functioning auto slack adjuster will
produce the following strokes:

Brake Chamber Stroke

(03/17) Y53-6077-1B1 5-69

 BRAKE SYSTEM

WARNING!
Manual adjustment of automatic
slack adjusters is a dangerous prac-
tice that could have serious con-
sequences. It gives the operator
a false sense of security about the
effectiveness of the brakes. Con-
tact the Service Department at your
dealership if the stroke exceeds the
above specifications. A stroke ex-
ceeding these values may indicate
a problem with the slack adjuster or
the brake foundation.

5-70 Y53-6077-1B1 (03/17)

 CAB

CAB Chrome and Aluminum Surfaces • Under corrosive conditions, such

as driving on salted roads, clean
Exterior Maintenance To prevent rust, keep chromed parts
aluminum parts with steam or high
Painted Surfaces clean and protected with wax at all
pressure water from a hose. A
times, especially in winter conditions
mild soap solution will help. Rinse
Wash painted surfaces frequently to where the roads are salted.
thoroughly.
remove grime and caustic deposits • If necessary, use a commercial
which may stain the finish. See chrome cleaner to remove light
Cleaning, Protecting, and Weather rust.
Stripping on page 5-72.
• Chrome surfaces are best
cleaned with fresh water. Wipe
dry to preserve their luster. A
commercial chrome cleaner will
remove light rust. After cleaning,
wax flat surfaces and apply a thin
coat of rust preventive lubricant 5
around bolts or other fasteners.

• Clean aluminum wheels and

bumpers with warm water. Tar
remover will get rid of heavy
deposits of road grime. To prevent
spotting, wipe aluminum surfaces
dry after washing.

(03/17) Y53-6077-1B1 5-71

 CAB

Tail Pipe Surface Cleaning Stainless Steel Cleaning, Protecting and

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

5-72 Y53-6077-1B1 (03/17)

 CAB

Vehicle Cleaning • Do not use any solution that can

WARNING! damage the body paint.
Precautions
Do not clean the underside of chas-
sis, fenders wheel covers, etc. • Most chemical cleaners are
WARNING! concentrates that require dilution.
without protecting your hands and
Handle cleaning agents carefully. arms. You may cut yourself on • Only use spot removing fluids in
Cleaning agents may be poisonous. sharp-edged metal parts. Failure well ventilated areas.
Keep them out of the reach of chil- to comply may result in death, per-
dren. Failure to comply may result sonal injury, equipment or property • Any vehicle is subjected to
in death, personal injury, equipment damage. deterioration from industrial
or property damage. fumes, ice, snow, corrosive road
WARNING! salt, etc., to name just a few
WARNING! causes. A well-cared-for vehicle
Moisture, ice, and road salt on can look like new many years
Do not use gasoline, kerosene, brakes may affect braking efficiency. later. Regular and correct care
naphtha, nail polish remover or other Test the brakes carefully after each will contribute to maintaining the
volatile cleaning fluids. They may vehicle wash. Failure to comply
be toxic, flammable or hazardous may result in death, personal injury,
beauty and the value of your 5
vehicle.
in other ways. Failure to comply equipment or property damage.
may result in death, personal injury, Your dealer has a number of
equipment or property damage. • Observe all caution labels. vehicle-care products and can advise
you on which ones to use for cleaning
• Always read directions on the
the exterior and interior of your vehicle.
container before using any
product.

(03/17) Y53-6077-1B1 5-73

 CAB

Washing the Exterior plated, and polished metal

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

° Do not use stiff brushes, paper

towels, steel wool, or abrasive
cleaning compounds because
they will scratch painted,

5-74 Y53-6077-1B1 (03/17)

 CAB

Cleaning the Chassis Cleaning Interior Vinyl and

NOTE Upholstery
• Hose dirt and grime from the
To allow enough time for your truck's
entire chassis. Then, if an oil • Wipe vinyl upholstery and lining
finish to cure, wait at least thirty days
leak develops, you will be able to with a good commercial upholstery
after the date of manufacture before
detect it easier. cleaner. Do not use acetone or
waxing.
lacquer thinner.
• Do not apply wax in the hot sun. • Corrosive materials used for ice
and snow removal and dust control • Clean fabric upholstery with
• Never dust off dry surfaces with can collect on the underbody. If upholstery shampoo specially
a cloth because it will scratch these materials are not removed, formulated for this purpose. Follow
the finishes. accelerated corrosion (rust) can instructions on the container.
occur on underbody parts such as
fuel lines, frames, floor pan, and
exhaust system, even though they
have been provided with corrosion
protection.

At least every spring, flush these

5
materials from the under body with
plain water. Be sure to clean any
area where mud and other debris can
collect. Sediment packed in closed
areas of the frame should be loosened
before being flushed. If desired, your
dealer can do this service for you.

(03/17) Y53-6077-1B1 5-75

 CAB

Passenger Door Lower View

Window NOTE
Always make sure that a gasket is
There may be occasions when the
installed properly so the weep slots
inner view window must be removed
will be indexed correctly. The notch
for maintenance cleaning and/or
in the gasket is to face forward on
damage. Follow this procedure when
the RH side. This places the weep
installing and removing an inner view
slots at the bottom of the window
window. The recommended tool for To install a window, slide the glass
opening (see next illustration).There
removal of the glass is a glass stick, from the rear of the door toward the
is a ridge on the bottom surface of
although other tools may be used removal slot until the forward edge of
the gasket (see next illustration).
provided proper caution is observed. the glass is against the inside edge of
Install the glass outboard of this
ridge. The polished satin finish on the seal (see next illustration; arrow
CAUTION indicates forward).
the glass, which leaves a rounded
The use of screwdrivers, gasket edge, rests against the edge of the
tools, knives or other similar in- ridge.The installation and removal
5 struments may damage the seal or will be easier by using water or soap
break the glass. Use a glass stick as a lubricant on the edge of the
as a tool whenever possible when glass.
removing or installing a window. If
another tool must be used, exercise
extreme care when performing this
procedure with such a tool.

5-76 Y53-6077-1B1 (03/17)

 CAB

Use the glass stick to leverage the

glass out of the seal.

Continue this process along the entire

front edge of the seal until the glass is
free.

Press and slide the glass into the aft

5
When the forward edge of the glass portion of the seal to seat it.
reaches the forward inside edge of the
seal, the glass should pivot outboard To remove an inner view window,
into the remaining seal (see arrow in insert the glass stick into the removal
next illustration). slot, then use the glass stick to push
the glass as far aft as possible.

(03/17) Y53-6077-1B1 5-77

 CAB

Safety Restraint System - vehicle requires thorough inspection

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

Due to these factors, the three-point

safety belt system installed in your

5-78 Y53-6077-1B1 (03/17)

 CAB

Inspection Guidelines other parts of the cab interior.

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

(03/17) Y53-6077-1B1 5-79

 CAB

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

5-80 Y53-6077-1B1 (03/17)

 CAB

be certain it is only replaced with Windshield Wiper/Washer Washer Reservoir

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

(03/17) Y53-6077-1B1 5-81

 COOLING SYSTEM

COOLING SYSTEM What to Check in an ELC-filled

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

In an ELC-filled cooling system, the

freeze point should be maintained
between -30° F and -45° F (-34° C and
-43° C).

5-82 Y53-6077-1B1 (03/17)

 COOLING SYSTEM

Desired ELC/Water ratio:

10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90%
Freeze point °F (°C)
+25 +20 +15 +10 +5 -5 -12 -23 -34 -50 -65 -75 -84 -70 -55 -43 -30
(-4) (-7) (-9) (-12) (-15) (-21) (-24) (-31) (-37) (-46) (-54) (-59) (-64) (-57) (-48) (-42) (-34)
Items in bold are the recommended levels of concentration.
ELC Condition (Contamination and representative for recommended ELC
Inhibitor Concentration) test kits, test strips, and laboratory
sample procedures.
Perform a visual inspection of the
ELC. It should have no cloudiness ELC Extender
or floating debris. Determine the
chemical inhibitor concentration level Add ELC extender if necessary at the
by using an ELC-specific test kit or maintenance interval under “Cooling”.
test strips. Inhibitor concentration level
determines corrosion protection. If you Coolant Filter 5
are concerned about possible coolant
quality, contamination, or mechanical If your vehicle came with a
problems, submit a coolant sample for non-chemical filter (“blank filter”),
analysis. Improper maintenance may replace it only with a blank filter at the
cause coolant degradation and could interval specified in the Preventive
result in damage to the cooling system Maintenance Schedule on page 5-12.
and engine components. Consult Never use filters that contain SCAs in
your dealer or the ELC manufacturer’s an ELC-filled system.

(03/17) Y53-6077-1B1 5-83

 COOLING SYSTEM

Topping Off
NOTE
WARNING! If frequent topping off is necessary
Removing the fill cap on a hot en- and there are no visible signs of
gine can cause scalding coolant coolant leaks when the engine is
to spray out and burn you badly. cold, check for leaks with the engine
If the engine has been in opera- operating at normal temperature.
tion within the previous 30 minutes,
be very careful in removing the fill Top off the cooling system when
cap. Protect face, hands, and arms coolant does not rise to the level
against escaping fluid and steam by Surge Tank
indicated as ‘MIN’ on the surge tank.
covering the cap with a large, thick The surge tank is translucent which
rag. Do not try to remove it until the allows the coolant level to be seen. NOTE
surge tank cools down or if you see Add coolant through the surge tank fill Do not use the pressure cap to fill the
any steam or coolant escaping. In cap. Do not remove the pressure cap surge tank with fluid.
any situation, remove the cap very to fill the cooling system.
5 slowly and carefully. Be ready to Proper Coolant Level
back off if any steam or coolant be-
gins to escape.
NOTE
Do not overfill a cooling system. Ex-
cess coolant may result in overflow,
loss of antifreeze, and reduced cor-
rosion protection.

5-84 Y53-6077-1B1 (03/17)

 COOLING SYSTEM

rate until the surge tank is full (to

• The minimum fluid level is
the base of the fill neck). It may be
9. Fill the surge tank as necessary
determined by the line on the to raise the coolant level to ½ in.
necessary to pause for 1 minute
surge tank indicated by the letters above the “MIN” level.
and then re-fill if the fluid level
“MIN”. This indicator is located
dropped. 10. Operate the engine at high idle
below the fill cap.
for another 10 minutes and then
5. Close any drain valves that were
• The cooling system will need fluid fill the surge tank again to ½ in.
opened in Step 1.
if the surge tank level does not rise above the “MIN” level.
to the “MIN” line regardless if the 6. Start the engine and idle at low
11. Replace the surge tank fill cap.
system is hot or cold. RPM.

Refilling Your Radiator 7. During low rpm idle, air will purge Check the coolant level after each trip.
from the cooling system which will Add coolant as necessary. You may
1. If your cooling system is built with lower the coolant level in the surge find your coolant level is not up to the
drain valves in the upper engine tank. Continue to fill the surge correct level soon after you have filled
coolant pipe, open them before tank until the coolant level remains the radiator. This may be because all
filling the surge tank. approximately ½ in. above the the trapped air in the system has not
2. Close any open coolant drains in "MIN" line. This may take up to 2 yet been purged. It takes a little time 5
the system. minutes, depending on the outside for all of the air to leave the system
temperature. after you fill your radiator.
3. Remove the surge tank fill cap
(do not remove the surge tank 8. Operate the engine throttle
pressure cap). until the operating temperature
stabilizes (when the thermostat
4. Fill the system with premixed opens).
coolant through the surge tank fill
cap. Pour coolant at a steady flow

(03/17) Y53-6077-1B1 5-85

 COOLING SYSTEM

Engine (Block) Heater

Use a solution of half ethylene glycol
WARNING! antifreeze and half water for best
heater performance. Do not use
Do not use the heater if there are
more than 65 percent concentration of
any signs of problems. Engine block
antifreeze, as a shortened heater life
heaters can cause fires resulting in
will result.
death, personal injury, equipment
or property damage if not properly After servicing the cooling system,
maintained and operated. Regu- operate the vehicle for a day or two
larly inspect the engine block heater before using the heater. Trapped
wiring and connector for damaged air inside the engine needs time to
or frayed wires. Contact your au- escape.
thorized dealer or the manufacturer
of the heater if you are in need of
repairs or information. Failure to
comply may result in death, per-
5 sonal injury, equipment or property
damage.

CAUTION
Always unplug the block heater be-
fore starting your engine. Damage
to the cooling system could occur if
not turned OFF (unplugged).

5-86 Y53-6077-1B1 (03/17)

 ELECTRICAL

ELECTRICAL Low Voltage Disconnect (LVD)

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

(03/17) Y53-6077-1B1 5-87

 ELECTRICAL

Light Bulbs Headlight Replacement

WARNING!
Do not use the Spare Battery A and WARNING!
B circuits or other circuits that are Optional HID headlights have high
controlled by the LVD to power elec- voltage circuits and should only be
tronic engine controls, ABS circuits, serviced by a trained technician. At-
or safety/work-related lighting. Be- tempting to service the HID ballast
fore adding any device to the vehi- without proper training may result in
cle's electrical system, consult your severe electrical shock which could
nearest authorized dealer or read lead to death or personal injury. Turn the bulb lock ring
the contents of TMC RP-136. Fail- counterclockwise and remove
ure to do so may cause equipment the bulb. Do not allow the glass of
damage or lead to personal injury. the new headlamp bulb to come into
contact with anything. The glass could
NOTE become contaminated and cause bulb
failure. Reassemble in reverse order.
The determination of what cir-
5 cuits/loads that were connected to
the LVD was based upon the rec-
ommendation from Technology and
Maintenance Council (TMC) of the
American Trucking Association. To
review the recommended practice,
see TMC RP-136.

5-88 Y53-6077-1B1 (03/17)

 ELECTRICAL

Headlight Aiming Bulb Specifications Fuses, Circuit Breakers and

Bulb Location Type of Bulb
Relays
The headlights were properly
aimed at the factory to meet safety Low Beam H11-LL (SAE), Fuses, circuit breakers, and relays are
specifications. If the headlights need to Halogen H7 (ECE) (long
life version not
located in the Power Distribution Box
be adjusted, please have an authorized required) to the left of the steering column behind
dealership aim the headlights. the clutch pedal. Additional fuses are
Low Beam HID D1-S
located in the engine compartment
High Beam HB3A – LL (long
Halogen life version not (driver's side bulkhead) and also
required) in the sleeper under bunk storage
Daytime Running 4157K (SAE), compartment.
Lamp/ Position 3157K (ECE)
Lamp/Turn Signal/
Side Marker
Rear tail light/ Turn Not applicable –
Signal LED lighting
Interior map/dome/ Not applicable –
indirect light LED lighting 5

(03/17) Y53-6077-1B1 5-89

 ELECTRICAL

In-Cab Fuse Label

5-90 Y53-6077-1B1 (03/17)

 ELECTRICAL

Sleeper Fuse Label 5

(03/17) Y53-6077-1B1 5-91

 ELECTRICAL

Fuse Inspection and Adding Electrical Options

Replacement
WARNING!
If a fuse is blown, see What to do if Do not add a fuse with a rating
fuse or relay blows in the Driving and higher than 30 amps. Follow the
Operating Instructions manual. circuit protection size/type recom-
mended by the component manu-
facturer. Installing a fuse or circuit
breaker greater than designated
may damage the electrical system
which could lead to equipment dam-
age and/or personal injury.

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

5-92 Y53-6077-1B1 (03/17)

 ELECTRICAL

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

(03/17) Y53-6077-1B1 5-93

 ELECTRICAL

In-Cab Battery Box

WARNING! WARNING!
Your vehicle may be equipped
Replace only with AGM (Group 31) Electrical damage or battery ex-
with Absorbed Glass Mat (AGM)
batteries. Use of other batteries plosion can occur when improperly
batteries located in the cab under the
could result in acid leaks causing charging batteries. Refer to the
passenger’s seat. The glass mat in
personal injury in the event of a ve- Battery Charging on page 5-97 for
AGM batteries are designed to absorb
hicle accident. Failure to comply appropriate charging instructions.
the battery acid inside the battery that
may result in death, personal injury, Failure to comply may result in
can leak or spill out in conventional
equipment or property damage. death, personal injury, equipment or
batteries. This design feature allows
property damage.
batteries to be positioned in any
orientation without risk of leaking. WARNING!
Battery cables and air/electrical har-
To access the batteries: nesses are mounted to the bottom of
1. Remove 6 fasteners securing the the floor. Do not drill or screw into
passenger side seat base to the floor pan without first checking the
battery box assembly. location of the cables, harnesses or
5 any other component that might be
2. Remove the seat and seat base damaged. Damaging any compo-
as one unit to gain access to the nent could result in electrical shock
batteries. which could cause personal injury
and/or loss of a critical truck sys-
tem. Failure to comply may result in
death, personal injury, equipment or
property damage.

5-94 Y53-6077-1B1 (03/17)

 ELECTRICAL

Removing and Installing Batteries:

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

(03/17) Y53-6077-1B1 5-95

 ELECTRICAL

Replacing Parts Removed for

Follow the procedure below to reinstall Access WARNING!
batteries on the vehicle:
1. Replace battery cover. Fairings not installed properly could
1. Place batteries in vehicle and come loose and cause other mo-
tighten bolt of holding plate. 2. Install 2 bolts in step strut. Torque torists to have an injury accident. It
to 24-32 lb-ft (33-43 Nm). is important that fairings be installed
2. Reconnect positive cable.
3. Install fairing and install 4 bolts. properly. Failure to comply may re-
3. Reconnect ground (negative) Torque to 6-7 lb-ft (8-9 Nm). sult in death, personal injury, equip-
ground cable. ment or property damage.
4. Install steps by installing 2 bolts in
WARNING! each step. Torque to 24-32 lb-ft
(33-43 Nm). WARNING!
Battery replacement may alter or Before attempting any work on the
disturb battery cable routing. Check WARNING! batteries or electrical system, re-
to insure battery cables are free move all jewelry. If metal jewelry or
from any point of chaffing. Failure Always reinstall the steps before en-
tering the cab. Without the steps you other metal comes in contact with
to comply may result in death, per- electrical circuits, a short circuit may
5 sonal injury, equipment or property could slip and fall, resulting in possi-
occur causing you to be injured, as
damage. ble injury to yourself.
well as electrical system failure and
damage.

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 ELECTRICAL

Battery Care Battery Charging

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

Overcharge: this condition results WARNING!

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

Vibration: loose battery hold-downs To help reduce the risk of personal

may cause battery plate failure. injuries, follow these guidelines
carefully when recharging a battery:
Short Circuits: these discharge the
battery by draining electricity. • Before attempting any service
in the electrical installation,

(03/17) Y53-6077-1B1 5-97

 ELECTRICAL

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

5-98 Y53-6077-1B1 (03/17)

 ELECTRICAL

Slow Battery Charging Electrical and Alternator

WARNING! Precautions
NOTE Always make sure the battery
Follow the instructions that come charger is OFF before connecting Take the following precautions to
with your battery charger. or disconnecting the cable clamps. avoid burning out alternator diodes:
To reduce the danger of explosions • Do not start the engine
• It is not necessary to remove the and resulting death or personal in- with alternator disconnected
battery from the compartment. jury, do not connect or disconnect (connections removed) from the
charger cables while the charger is circuit.
WARNING! operating.
Charger cables must be connected • Before welding, disconnect all
1. Disconnect the battery cables. electronic connections to the
positive to positive (+ to +) and neg-
ative to negative (- to -). If con- 2. Connect charger cables. vehicle batteries.
nected improperly, batteries could • Remove battery power cable and
3. Start charging the battery at a rate
explode. Failure to comply may re- insulate it from the vehicle.
not over 6 amperes. Normally, a
sult in death, personal injury, equip-
battery should be charged at no 5
ment or property damage. • Do not run the engine with the
more than 10 percent of its rated
batteries disconnected.
capacity.
4. After charging, turn OFF charger • Do not disconnect the battery
and disconnect charger cables. cables or alternator connection
cables with the engine running.

• Never turn the ignition switch from

the ON position to the START
position with the engine running.

(03/17) Y53-6077-1B1 5-99

 ELECTRICAL

• When charging the battery Remote Keyless Entry

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

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 ENGINE

ENGINE
WARNING! NOTE
Engine Maintenance Never idle your vehicle for prolonged Keep the engine exhaust system
periods of time if you sense that ex- and the vehicles cab ventilation
WARNING! haust fumes are entering the cab. system properly maintained. It is
Investigate the cause of the fumes recommended that the vehicles ex-
Exhaust fumes from the engine con-
and correct it as soon as possible. haust system and cab be inspected:
tain carbon monoxide, a colorless
If the vehicle must be driven under
and odor less gas. Do not breathe • By a competent technician every
these conditions, drive only with the
the engine exhaust gas. A poorly 15,000 miles,
windows open. Failure to repair the
maintained, damaged or corroded
source of the exhaust fumes may re- • Whenever a change is noticed in
exhaust system can allow carbon
sult in death, personal injury, equip- the sound of the exhaust system,
monoxide to enter the cab. Entry of
ment or property damage.
carbon monoxide into the cab is also • Whenever the exhaust system,
possible from other vehicles nearby. underbody or cab is damaged.
Failure to properly maintain your ve-
hicle could cause carbon monoxide
to enter the cab and cause death or 5
personal injury.

(03/17) Y53-6077-1B1 5-101

 ENGINE

Engine Lubrication Inspection of the Engine Oil Level

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

5-102 Y53-6077-1B1 (03/17)

 ENGINE

Topping Up the Engine Oil Pipe and Hose Clamps

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

1. Engine Oil High Level 5

2. Engine Oil Low Level

(03/17) Y53-6077-1B1 5-103

 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 Miniature 3600L 1.1-1.7 10-15
(for hoses less than 9/16 diameter)
Exhaust Clamps Breeze V-Band 54 480

5-104 Y53-6077-1B1 (03/17)

 ENGINE

Accessory Drive Belts

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

Follow this procedure to install an NOTE

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

(03/17) Y53-6077-1B1 5-105

 ENGINE

Engine Fan • With the engine idling and the

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

5-106 Y53-6077-1B1 (03/17)

 ENGINE

Air Intake System Turbocharger

CAUTION
Engine heat, vibration, and age When servicing the air intake and
Do not use air intake pipes and con-
combine to loosen air intake exhaust systems on a turbocharged
nections as a step or to pull your-
connections and cause cracks in engine, check the items listed below.
self up. This could loosen the con-
the tubing and elbows. Leaks in the
nections and open the system to un-
intake system allow abrasive dust to WARNING!
filtered air which could damage the
enter the engine and quickly cause Do not operate engine with tur-
engine.
expensive damage. During your daily bocharger intake piping discon-
walk-around inspection, carefully nected. A suction is created when
check all tubing, elbows, clamps, the engine is running. This suction
supports and fasteners for condition could draw your hand or anything
and tightness. else near it into the impeller fan. You
• Check the Charge-Air-Cooler for could be injured. Always keep the
air leaks annually. The air leaks intake piping connected when you
can be caused by cracked tubes will be running the engine.
or header. For service see your 5
authorized dealer. Lubricating System: Check the oil
lines, housing, and connections. Look
for leaks, damage, or deterioration.
Leaks could mean you have damaged
oil lines or oil seals.

Manifold: With the engine operating,

check for leaking manifold or flange
gaskets.

(03/17) Y53-6077-1B1 5-107

 ENGINE

Air Cleaners must be pivoted to provide access for

High Frequency Vibration: Vibration servicing the filter element.
may indicate turbo rotor imbalance. The following service information is
Have your dealer investigate this basic to all air cleaner makes and
immediately. If you detect any models.
deficiencies, take the vehicle to an
authorized dealer for servicing. Delay CAUTION
could lead to severe and expensive
Failure to replace air filter at proper
damage to your vehicle.
intervals may result in passage of
dirt/debris into the engine or the
“dusting” of an engine resulting in
significant engine damage.
Replacing the Engine Air Intake
Service the air cleaner filter elements Filter
as specified in the Preventive
Maintenance Schedule on page 5-12. 1. Loosen (do not remove) upper
5 This vehicle is equipped with an air inlet 5/16 in. mounting hardware.
restriction indicator. Service the filter 2. Remove acorn nut and flat washer,
elements when the air inlet restriction then pivot upper stabilizer rod
indicator locks in the extreme Up away from cab.
position. Paper elements require care
and proper handling because they are 3. Loosen the two rearmost M6 hex
critical to engine service life. If your socket head screws on the lower
vehicle has an external air cleaner clamp.
and cab-mounted mirrors, the mirror

5-108 Y53-6077-1B1 (03/17)

 ENGINE

remove and replace the air cleaner ServiSignal™ Mini Indicator

NOTE filter element.
The two forward screws secure the The ServiSignal™ Mini Indicator is
cover to the base. The two rearmost CAUTION installed on the air cleaner or air
screws provide the clamping force on induction piping so it has access to
To prevent possible engine damage,
the main support tube. clean filtered air. As the filter plugs
torque the four hex nuts attaching
and restriction increases, a red flag
the air cleaner cover assembly to the
appears in the window. When it
body assembly to 8 Lb. ft. (10 N.m)
reaches the red zone, the air filter
after installing the new air cleaner fil-
should be replaced. The indicator can
ter element.
be reset by pressing the button at the
5. After installation of the new filter end of the indicator.
element, rotate the main support
tube forward and reinstall the
upper stabilizer rod to its mounting
bracket.
6. In any sequence, tighten the upper 5
fasteners to a torque of 13 - 17 Lb.
ft. (17 - 23 N.m).

1. Steps 1 and 6 7. Tighten the two rearmost screws

2. Steps 2, 5, and 6 in the lower clamp to a torque of 4
3. Steps 3 – 7 - 4.5 Lb. ft. (5 - 6 N.m).

4. Rotate the main support tube

rearward to provide clearance to

(03/17) Y53-6077-1B1 5-109

 ENGINE

Exhaust System Engine Mounting

CAUTION
The exhaust system is part of the Periodic Inspection: Inspect engine Do not re-torque or reuse existing
noise and emission control system. mounts every 60,000 miles (96,560 flange head bolts. These bolts are
Periodically check the exhaust for km). Check for the following: factory set to the specified torque.
wear, exhaust leaks, and loose or If bolts are loose or damaged, they
missing parts. For details see Noise • Inspect both mount and leg
fasteners. Check for loose must be replaced with the new bolts.
Emission Control on page 5-123. Failure to comply may result in
or broken bolts. Replace as
necessary. equipment or property damage.
Please refer to the Engine Operator's
Manual for more details on how to
• Check mount and leg for fractures,
maintain the emission's components in
breaks or deformation. Replace
the exhaust system.
as necessary.
Please refer to the aftertreatment • Check for complete insertion
manual for emissions related of motor mount. Replace as
components such as the DEF system necessary.
5 and DPF.
• New leg to mount flange head
bolts should be torqued to 210-230
Lb-Ft (284-311 Nm).

5-110 Y53-6077-1B1 (03/17)

 FUEL SYSTEM

FUEL SYSTEM Specification Fuel Filters

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

CAUTION
If anyone ever pours gasoline into
your fuel tank, drain the entire sys-
tem. Otherwise, the pump and en- 5
gine will be damaged. Don’t try to
dilute the gasoline by adding diesel
fuel (See Warning above).

(03/17) Y53-6077-1B1 5-111

 FRAME

FRAME Emergency Welding Welding Precautions

Introduction WARNING! In the event of emergency welding of a

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

5-112 Y53-6077-1B1 (03/17)

 FRAME

weld point as possible. This Painting Fifth Wheel Maintenance

ensures maximum weld current
and minimum risk to damage Do not electrostatically paint your Proper preventive maintenance is
of electrical components on the truck or any component on your essential to trouble-free service and
vehicle. truck without first removing all of safe operation of the fifth wheel.
the electronic components from the
truck. It is not possible to list all of Every 15,000 miles or monthly:
the electronics that could be affected,
but a few examples include the
• Refer to specific manufacturer's
literature for any special
alternator, engine Electronic Control
instructions.
Unit (ECU), transmission ECU, ABS
ECU, navigation devices, diagnostic • Steam clean the fifth wheel.
devices, and monitoring devices.
• Check lock guard operation using
a commercial lock tester.

• Clean and oil all moving parts.

• Lubricate the lock mechanism with

5
a lithium-base grease.

• All grease fittings (especially those

which grease the top surface of
the fifth wheel).

(03/17) Y53-6077-1B1 5-113

 FRAME

Frame Fastener Torque

Every 60,000 miles or 6 months: Requirements Standard Grade 8 UNF or UNC and Metric

• Refer to specific manufacturer's

Tighten all frame fasteners with a FAS- TORQUE *
literature for any special TENER
torque wrench. Torque specifications SIZE Nm Lb-Ft
instructions.
apply to the following fasteners with
5/16 22-30 16-22
• Remove fifth wheel from vehicle. lightly lubricated threads.
3/8 41-54 30-40
Refer to the Shop Manual, “Fifth
Wheel Removal.” NOTE 7/16 75-88 55-65

Whenever possible, torque all frame 1/2 109-122 80-90

• Steam clean the fifth wheel and
9/16 156-190 115-140
fasteners on the nut end, not the bolt
mounting brackets.
head. 5/8 224-265 165-195
• Check all moving parts for 3/4 394-462 290-340
excessive wear or damage. 7/8 517-626 380-460
Replace all worn or broken parts.
1 952-1,129 700-830
• Complete two-month service 1-1/8 1,346- 990-1,170
5 procedure. 1,591
1-1/4 1,877- 1,380-
• Install fifth wheel. Refer to 2,217 1,630
the Shop Manual, “Fifth Wheel METRIC WITH NYLON INSERT NUTS
Installation.”
M5 8-12 6-9
M6 9-15 7-11
M8 23-31 17-23
M10 33-43 24-32

5-114 Y53-6077-1B1 (03/17)

 FRAME

FAS- TORQUE * Sliding Fifth Wheels

TENER
SIZE Nm Lb-Ft
Lubricate bearing surface of support
M12 75-101 55-75 bracket through the grease fittings on
M16 163-217 120-160 the side of the fifth wheel plate. Use a
M20 352-460 260-340 water resistant lithium-base grease.
* ESNA Style Lock Nut, with nylon insert.
Lubricate nylon insert nut lightly with SAE NOTE
20/30 oil.
The plate must be lifted up slightly
to relieve the weight of the bracket
while applying grease.

(03/17) Y53-6077-1B1 5-115

 FRONT AXLE AND SUSPENSION

FRONT AXLE AND Kingpin Lubrication Suspension Lubrication

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

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

5-116 Y53-6077-1B1 (03/17)

 FRONT AXLE AND SUSPENSION

Inspection Wheel Alignment

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

Check for cracks, wear marks, splits,

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

Visually inspect shock absorbers and

rubber bushings.

(03/17) Y53-6077-1B1 5-117

 FRONT AXLE AND SUSPENSION

U-Bolt Torque Chevron zinc lubricant (SAE 20 or 30

WARNING! oils acceptable but not preferred).
It is important that U-bolts remain tight. Do not operate the vehicle if the
Severe use of your vehicle will cause U-bolts are not properly tightened. WARNING!
them to loosen faster. But all vehicles Loose U-bolts will cause the axle Do not replace U-bolts and nuts with
need to have their U-bolts checked and to not be properly secured to the common U-bolts or standard nuts.
tightened regularly. Be sure someone suspension, which could cause loss These parts are critical to vehicle
with the proper training and the right of vehicle control and an accident. safety. If the wrong U-bolts or nuts
tools checks and tightens the U-bolts Loose U-bolts can also cause un- are used, the axle could loosen or
on your vehicle. even tire wear and poor alignment. separate from the vehicle and cause
Failure to comply may result in a serious accident. Use only U-bolts
New springs can settle in after service,
death, personal injury, equipment or and nuts of SAE Grade 8 specifi-
relieving the tension on the U-bolts.
property damage. cation or better. Failure to comply
Loose U-bolts can cause leaf spring
breakage, axle misalignment, hard may result in death, personal injury,
steering and abnormal tire wear. U-bolts are difficult to tighten unless equipment or property damage.
you have the right equipment. If you
5 All vehicles should have suspension cannot tighten them correctly yourself, Front Spring Suspension U-Bolts, Grade 8
U-bolts tightened after the first 500 be sure to have them checked and
U-BOLT TORQUE
miles (800 km) of operation. Re-torque tightened regularly by an authorized SIZE
the front spring pinch bolts and shackle mechanic. Nm Lb-Ft
DIAME-
pinch bolts. TER
Tighten U-bolt nuts to the specified (Inch Di-
torque value with the vehicle loaded to mensions)
its normal gross weight. The following 3/4 333-408 245-300
torque values apply to U-bolts and 7/8 598-734 440-540
nuts with clean threads lubricated with

5-118 Y53-6077-1B1 (03/17)

 FRONT AXLE AND SUSPENSION

U-BOLT TORQUE
SIZE
Nm Lb-Ft
DIAME-
TER
(Inch Di-
mensions)
1 925-1,060 680-780
1-1/8 1,470- 1,080-
1,660 1,220
1-1/4 1,890- 1,390-
2,120 1,560
1-1/2 3,130- 2,300-
3,860 2,840

(03/17) Y53-6077-1B1 5-119

 HEATER AND AIR CONDITIONER

HEATER AND AIR • Whenever the exhaust system, Special Precautions

CONDITIONER underbody or cab is damaged
WARNING!
Introduction To allow for proper operation of the Excessive heat may cause the pres-
vehicle ventilation system, proceed as surized components of the air con-
The combination heater-air conditioner follows: ditioning system to explode. Never
provides comfort for those in the cab weld, solder, steam clean, or use a
• Keep the inlet grille at the base of
blow torch near any part of the air
through accurate control of the cab the windshield clear of snow, ice,
environment in all weather conditions. conditioning system. Failure to com-
leaves and other obstructions at
Regular attention to the items below ply may result in death, personal in-
all times.
will help you keep the heater-air jury, equipment or property damage.
conditioner unit running well. • Keep the exhaust pipe area clear
to help reduce the buildup of WARNING!
Keep the vehicle's ventilation system, exhaust gas under the vehicle.
engine exhaust system and cab Air conditioning refrigerant can be
joints properly maintained. It is • Check the drain tube of the fresh hazardous to your health. Do not
air inlet for trapped water before expose yourself to leaking refriger-
5 recommended that the vehicle's
ant for prolonged periods near ex-
exhaust system and cab be serviced assuming that there is a leak in the
as follows: heating system. cessive heat, open flames, or with-
out proper ventilation. Failure to do
• Inspected by a competent so may result in death or personal in-
technician every 15,000 miles jury.
• Whenever a change is noticed in
the sound of the exhaust system If a refrigerant leak develops in the
presence of excessive heat or an
open flame, hazardous gases may be

5-120 Y53-6077-1B1 (03/17)

 HEATER AND AIR CONDITIONER

generated. If you become aware of a Heater Air Conditioner

refrigerant leak on your vehicle have
your system serviced immediately and • Check all heater controls for WARNING!
observe the following precautions: full-range operation.
The air conditioning system is under
• Check hoses, connections, and pressure. If not handled properly
Stay away from the hot engine until the
heater core for condition and during servicing, it could explode.
exhaust manifold has cooled.
leaks. Any servicing that requires depres-
Do not permit any open flame in the surizing and recharging the air con-
area. Even a match or a cigarette CAUTION ditioning system must be conducted
lighter may generate a hazardous During extreme cold weather, do not by a qualified technician with the
quantity of poisonous gas. blow hot defroster air onto cold wind- right facilities to do the job. Failure
shields. This could crack the glass. to comply may result in death, per-
Do not smoke in the area. Inhaling Turn the air direction lever to Defrost sonal injury, equipment or property
gaseous refrigerant through a cigarette and adjust the fan speed accordingly damage.
may cause violent illness. while the engine warms. If the en-
gine is already warm, move the tem- • Listen to the compressor and drive
perature selector to Cool, then grad- clutch for noise and vibration. 5
ually increase the temperature when If you find problems, have the
you see that the windshield is start- system checked thoroughly. A
ing to warm-up. malfunctioning clutch usually
indicates trouble elsewhere in the
system.

• Check the evaporator core, filter,

and condenser core for debris
restricting air flow. Clean if

(03/17) Y53-6077-1B1 5-121

 HEATER AND AIR CONDITIONER

necessary. Small particles may to worsen. Have a qualified

be removed with compressed technician correct the problem.
air blown through the core in the
opposite direction of normal air NOTE
flow. A leaking evaporator or condenser
core cannot be repaired; it must be
WARNING! replaced.
Wear eye protection any time you
blow compressed air. Small parti- Have the air conditioning system fully
cles blown by compressed air could serviced annually by your authorized
injure your eyes. dealer. Qualified service technicians
will have to evacuate and recharge the
• Check the engine belt for condition system.
and proper tension.

• Check all hoses for kinks,

deterioration, chafing, and leaks.
5 Adjust kinked or chafing hoses to
eliminate restrictions and prevent
further wear.

• Check all components and

connections for refrigerant leaks.
If you discover a leak, do not try to
tighten a connection. Tightening
a connection may cause a leak

5-122 Y53-6077-1B1 (03/17)

 NOISE EMISSION CONTROL

NOISE EMISSION Tampering with Noise Control Air Intake System

CONTROL System
• Removing or rendering inoperative
Federal law prohibits the following the air cleaner/silencers or intake
Noise Emission Warranty acts or the causing thereof: piping.

This section describes responsibilities Engine Cooling System

(1) The removal or rendering
for the vehicle noise emissions. For inoperative by any person other than • Removing or rendering inoperative
information about exhaust emissions, for purposes of maintenance, repair, or the fan clutch.
please refer to the aftertreatement replacement, of any device or element
system operators manual. of design incorporated into any new • Removing the fan shroud.
vehicle for the purpose of noise control Engine
There are specific components on prior to its sale or delivery to the
the vehicle that are designed to meet ultimate purchaser or while it is in use, • Removing or rendering engine
certain Environmental Protection or (2) the use of the vehicle after such speed governor inoperative so as
Agency (EPA) emissions and noise device or element of design has been to allow engine speed to exceed
regulations. To maintain conformance removed or rendered inoperative by manufacturer's specifications.
with the regulations, these components any person. 5
need to be functional and properly • Modifying ECU parameters.
maintained. Among those acts presumed to Exhaust System
constitute tampering are the acts listed
below: • Removing or rendering inoperative
exhaust system components.

(03/17) Y53-6077-1B1 5-123

 NOISE EMISSION CONTROL

Fuel System • Cutting holes in, or cutting away Inspection and Maintenance
• Removing or rendering engine part of noise insulators. Instructions
speed governor inoperative, • Removing hood-mounted noise The following instructions are based on
allowing engine speed to exceed insulation. inspection of the noise control system
manufacturer's specifications.
at regular intervals as indicated in the
• Removing of air signal attenuator Noise Control System Maintenance
on engines equipped with this Log on page 5-129.
device.
If, during periodic inspection and
• Removing of diesel exhaust fluid maintenance of other systems and
tank and system. components, it is found that parts of the
noise control system require attention,
Inner Fender Shields and Cab Skirts
we recommend that those parts be
• Removing shield or skirts. inspected at more frequent intervals
to assure adequate maintenance and
• Cutting away parts of shields, performance.
5 skirts or damaged or loose
portions of shields or skirts.
Noise Insulating Blankets

• Removing noise insulators from

engine block or from around the
oil pan.

5-124 Y53-6077-1B1 (03/17)

 NOISE EMISSION CONTROL

Air Intake System Engine Mounted Noise Insulators Exhaust System

• Do all checks and maintenance • Check condition. Is the insulator • Check for exhaust leaks,
procedures listed in this manual secure? How you do this will which would indicate a leaking
under Engine Air Intake System depend on the method of attaching manifold gasket; replace gasket if
and Air Cleaner. See Air Dryer on the noise insulators on the engine necessary.
page 5-60. and around the oil pan (bolts,
snap fasteners, or straps). Tighten • Check cap screws for tightness,
• Check the induction tubing, elbow loose fasteners and repair or including those at the flanges.
connections, clamps, brackets, replace any worn or damaged Refer to the engine manufacturer's
and fasteners for deterioration, fasteners. service manual for proper
cracks, and security. tightening sequence and torque
• Check insulators around fasteners values.
• If you find an air leak anywhere and stress points, especially
between the air cleaner and where they may be affected by
the engine, repair that leak engine vibration. Repair any
immediately. cracked or damaged mounting

CAUTION
points. Use suitable reinforcing 5
plates to ensure that the insulators
Air leaks cause excessive noise and will remain in position.
may result in serious damage to the
engine. If you do not repair them the
engine damage will not be covered
by your warranty. Repair all air leaks
as soon as you find them.

(03/17) Y53-6077-1B1 5-125

 NOISE EMISSION CONTROL

Joints and Clamps Selective Catalyst Reduction (SCR) Piping

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

5-126 Y53-6077-1B1 (03/17)

 NOISE EMISSION CONTROL

Diesel Particulate Filters (DPF) Engine Fan and Shroud Hood Insulation Blanket

• Check diesel particulate filter WARNING! • Check all fasteners for condition
(DPF), clamps, and mounting and security. Repair or replace
brackets. Tighten if necessary. Do not work on the fan with the en- any broken or defective fasteners.
Inspect diesel particulate filter gine running. The engine fan can
(DPF) for signs of rust or corrosion. engage at any time without warning. • Check for chafing or tears. Patch
Anyone near the fan when it turns on it if necessary. Find the cause of
• Check internal baffling. You can could be injured. Before turning on the damage. If any component
do this by listening for rattling the ignition, be sure that no one is or accessory is causing wear or
sounds while tapping on the diesel near the fan. damage and cannot be relocated,
particulate filter (DPF) with a put reinforcing pads on the blanket
rubber mallet or revving the engine • Check all fasteners for tightness. at the site of wear.
up and down through its normal Check for stress cracks in the
operating range. shroud. Make sure the shroud is
adjusted so that it does not touch
the fan blades.

• Check to verify that the fan is

5
disengaged (not turning) with
the engine running at normal
operating temperatures (from cold
to the point that the fan engages).

• Check fan blade mounting bolts.

Inspect fan blades to be sure they
are not cracked or bent.

(03/17) Y53-6077-1B1 5-127

 NOISE EMISSION CONTROL

Inner Fender Shields and Cab Skirts Noise Control System -

• Check all fasteners that hold the
Maintenance Log
fender shields in place.
To ensure your vehicles noise control
• Check fender shields for tire requirements are maintained, record
marks, worn spots, or damage maintenance checks. Use the
from objects thrown from tire following log sheet and retain copies
treads. of documents regarding maintenance
services performed and parts replaced
• Check cab skirts, sills, and on the vehicle.
brackets for overall condition
and repair them as necessary.
Damaged rubber fender shields
or cab skirting cannot be repaired.
You will need to replace it.

5-128 Y53-6077-1B1 (03/17)

 NOISE EMISSION CONTROL

Noise Control System - Maintenance Log

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

(03/17) Y53-6077-1B1 5-129

 NOISE EMISSION CONTROL

Recom-
Repair Work Repair Work
mended Date & R.O. Date & R.O.
Component Facility & Facility &
Interval No. Performed No. Performed
Location Location
(Miles)
Clutch Type 10,000
Fan Drive

5-130 Y53-6077-1B1 (03/17)

 REAR AXLE AND SUSPENSION

REAR AXLE AND

WARNING! WARNING!
SUSPENSION
Failure to maintain the specified Do not operate the vehicle if the
General Maintenance torque values or to replace worn U-bolts are not properly tightened.
parts can cause component system Loose U-bolts will cause the axle
WARNING! failure, possibly resulting in an ac- to not be properly secured to the
cident. Improperly tightened (loose) suspension, which could cause loss
Do not work on the vehicle without suspension U-bolts can lead to un- of vehicle control and an accident.
the parking brake set and wheels safe vehicle conditions, including: Loose U-bolts can also cause un-
blocked securely. If the vehicle is hard steering, axle misalignment, even tire wear and poor alignment.
not secured to prevent uncontrolled spring breakage or abnormal tire Failure to comply may result in
vehicle movement, it could roll and wear. See Front Spring Suspension death, personal injury, equipment or
may result in death, personal injury, U-bolts on page 5-118 for proper property damage.
equipment or property damage. torque specifications. Failure to
comply may result in death, per-
CAUTION
Your vehicle's suspension, by sonal injury, equipment or property
design, requires a minimal amount of damage. Do not spray the suspension with
maintenance. However, suspensions chemical products or mineral oil; it
5
in over-the-road operations require can cause damage to the bushings.
periodic inspection to ensure trouble-
free performance. NOTE
Failure to follow these recommenda-
tions could void warranty.

(03/17) Y53-6077-1B1 5-131

 REAR AXLE AND SUSPENSION

Visual Inspection • Visually check for loose or missing Rear Suspension Fasteners
fasteners, cracks in hanger, or
For all vehicles, mandatory To maintain the performance of the
axle connection brackets.
maintenance procedures include air suspension, check fastener torque
retightening of U-bolts and complete • Check that springs are centered in values after the first 2,000 miles (3,218
inspection. However, even with proper hangers and in good condition. km) of service and every 60,000 miles
maintenance, many factors affect the (96,000 km) thereafter.
service life of springs and suspension • Check for cracks, wear marks,
components, such as: fatigue, vehicle splits, or other defects on the Torque recommendations apply to
gross weight, type of load, road surface of the spring. fasteners supplied and installed by
conditions, and vehicle speed. vehicle manufacture. The values listed
• Replace defective parts. Because in the tables below, are for cadmium
It is important that U-bolts remain tight. repaired springs cannot be plated or phosphate and oil fasteners
Severe use of your vehicle can cause fully restored to their original only.
them to loosen faster. But all vehicles service life, replace the complete
need to have their U-bolts checked and assembly if cracks or other defects U-bolts are difficult to tighten unless
tightened regularly. Be sure someone are detected. you have the right equipment. If you
5 with the proper training and the right • After replacement of any part or
cannot tighten them correctly yourself,
tools checks and tightens the U-bolts be sure to have them checked and
discovery of loose components,
on your vehicle. tightened regularly by an authorized
check the torque of all fasteners.
mechanic.
• After the first 500 miles (800 km) of • New springs settle-in after the
operation, inspect the suspension vehicle's initial service, causing
periodically, as noted below: the U-bolts to become loose.

5-132 Y53-6077-1B1 (03/17)

 REAR AXLE AND SUSPENSION

U-Bolt Torque
NOTE Rear Suspension U-Bolts, Grade 8
(lubricated*)
NOTE Whenever possible, torque all fas-
To ensure an accurate torque read- teners on the nut end, not the bolt U-BOLT TORQUE**
ing, use properly maintained and head. SIZE
DIAME-
calibrated torque wrenches. Clean TER Nm Lb-Ft
the nut and bolt. No dirt, grit, or rust Rear Suspension Fasteners (Metric and THREAD
should be present. Standard)
3/4 333-408 245-300
SIZE/ TORQUE * 7/8 598-734 440-540
WARNING! TYPE
Nm Lb-Ft 1 925-1,060 680-780
Do not operate the vehicle if the M16 nylon- 163-217 120-160 1-1/8 1,470- 1,080-
U-bolts are not properly tightened. insert nuts 1,660 1,220
Loose U-bolts will cause the axle M20 nylon- 352-460 260-340 1-1/4 1,890- 1,390-
to not be properly secured to the insert nuts 2,120 1,560
suspension, which could cause loss M20 all- 427-475 315-350 1-1/2 3,130- 2,300-
of vehicle control and an accident. metal lock 3,860 2,840
Loose U-bolts can also cause un- nuts 5
*Chevron Zinc Lubricant or SAE 20/30 oil
even tire wear and poor alignment. 1/2 in. nut 109-122 80-90 should be used on U-Bolt threads
Failure to comply may result in 3/4 in. nut 394-462 290-340 **Torque requirements apply to
manufacturer proprietary suspensions. All
death, personal injury, equipment or 1-1/4 in. 1,877- 1,380- other suspensions must refer and adhere
property damage. nut 2,217 1,630 to original manufacturer's shop manual.
* Torque requirements apply to
manufacturer proprietary suspensions. All • Load the vehicle to its normal
other suspensions must refer and adhere
to original manufacturer's shop manual.
gross weight before tightening
U-bolts. Loading the vehicle

(03/17) Y53-6077-1B1 5-133

 REAR AXLE AND SUSPENSION

ensures proper adjustment of the Rear Axle Lubrication

U-bolt and spring assembly. NOTE
Check oil level with the vehicle parked In all cases, lubricant supplier as-
WARNING! on level ground and the fluid warm. sumes full responsibility for the per-
The level should be even with the formance of their product, and for
Do not replace U-bolts and nuts with
bottom of the filler hole. product and patent liability.
common U-bolts or standard nuts.
These parts are critical to vehicle
safety. If the wrong U-bolts or nuts For recommended types and brands of
are used, the axle could loosen or lubricants, contact your dealer.
separate from the vehicle and cause
a serious accident. Use only U-bolts
and nuts of SAE Grade 8 specifi-
cation or better. Failure to comply
may result in death, personal injury,
equipment or property damage.
CAUTION
5 Do not mix lubricants of different
grades; although, mixing different
brands of the same grade lubricant
(meeting MIL L2105C), is accept-
able. Lubricants of different grades
are not compatible and could dam-
age the axle.

5-134 Y53-6077-1B1 (03/17)

 REAR AXLE AND SUSPENSION

Dana Spicer and Fabco Rear Axle Alignment

All Vehicles with Dana Spicer
No initial drain is required on Dana and Fabco Axles: See Preventive Continual road shock and load
Spicer axles that are factory filled with Maintenance Schedule on page 5-12. stresses may force the rear axles
an Dana Spicer-approved synthetic Contact your dealer for approved out of alignment. If you detect rapid
lubricant. synthetic lubricant brands. tire wear on the rear axles, you may
have misaligned axles. If you suspect
• Petroleum-based lubricants must • Dana Spicer Axles with synthetic rapid tire wear, have your rear axle
be drained within the first 5,000 lubrication and Out Runner Seals: alignment checked and adjusted by an
miles (8,000 km) if converting to drain, flush, and refill at 500,000 authorized dealer.
an approved synthetic lubricant. miles (804,000 km).
In addition to pre-delivery inspections,
Initial Change: See Preventive Axle Housing Breather Vent: suspension alignment should be
Maintenance Schedule on page 5-12 checked when any one of the following
for standard rear axle service intervals. • Check and clean the axle housing
breather vent at each oil level conditions exist:
Change mineral-based lubricant in
other Dana Spicer and Fabco axle check. • Discovery of loose suspension
assemblies (new or rebuilt) within the
Meritor:
fasteners. (Loose, defined as any 5
first 3,000 to 5,000 miles (4,800 to torque below the recommended
8,000 km). • See Meritor Lubrication torque value.)
Maintenance Manual (MM1).
• For petroleum-based axles, use • Discovery of elongated holes in a
lubricants meeting MIL L2105C/D suspension component.
grade specifications or approved
synthetic lubrication. Do not use • Bushing replacement.
oil additives. • Excessive or abnormal tire wear.

(03/17) Y53-6077-1B1 5-135

 STEERING SYSTEM

STEERING SYSTEM • wheels out of alignment

WARNING!
Power Steering Do not operate the vehicle if the • wheel bearings improperly
steering system is not working prop- adjusted
Oil (under low pressure) provides the erly. You could lose control of your
power to operate the steering gear. It vehicle if the steering system is not If you cannot correct the problem,
also serves to lubricate moving parts in good working condition, which check with an authorized dealer.
and remove heat. A loss of steering could result in a serious accident.
efficiency will occur if too much heat For driving safety, visually check Your vehicle is equipped with integral
builds up in the system. the steering gear and components. power steering. The system includes
Frequent checks are important for an engine-driven fluid pump, a fluid
driving safety, especially after trav- reservoir, the steering gear, and
eling over rough roads. Failure to connecting hoses. Because of the
comply may result in death, per- hydraulic power assist, little effort is
sonal injury, equipment or property required to turn the steering wheel.
damage. When no input is applied through the
steering wheel, the steering gear will
5 return to the neutral position. If, for
If the steering feels unbalanced from
any reason, the power assist system
side-to-side while turning, check for
goes out, steering the vehicle is still
the following possible causes:
possible, yet it will require much
• unequal tire pressures greater effort.

• vehicle overloaded or unevenly Visually check the following parts:

distributed load
• Crosstube: Is it straight?

5-136 Y53-6077-1B1 (03/17)

 STEERING SYSTEM

• Draglink tube clamp: Check for Fluid Level and Refill

• Maximum/Minimum level is
looseness or interference. indicated on the reservoir. These
Have the power steering fluid and
same levels are also indicated by
• Ball joints and steering U-joints: filters changed at an authorized dealer.
two lines on the dipstick in the
Check for looseness.
CAUTION reservoir.
• Steering wheel for excessive
• There are two ways to check
When adding fluid, be sure to use
free-play. Check the simplest
fluid of the same type. While many whether the power steering fluid
probable causes first:
fluids have the same description and is at its proper level. Both checks
a. unequal tire pressures intended purpose, they should not are with the engine NOT running.
be mixed due to incompatible ad-
b. loose cap nuts 1. If you check the fluid with the
ditives. Mixing incompatible fluids
engine and steering system
c. bent crosstube may lead to equipment damage.
COLD, the fluid level should be
d. lack of lubrication. at/or above the Minimum indicator
• Check and completely change the
level and should generally not
• If these checks do not reveal the fluid level according to Preventive
exceed the middle point between
problem, or if you correct them Maintenance Schedule on page 5
Maximum and Minimum level
and still have a steering problem, 5-12. Use the following procedure:
indicators.
take your truck to an authorized
dealer for evaluation. NOTE 2. If you check the fluid with the
engine and steering system
Before removing reservoir cover,
WARM, the fluid should NOT
wipe outside of cover so that no dirt
exceed the Maximum level
can fall into the reservoir.
indicator and should generally
not drop below the middle point

(03/17) Y53-6077-1B1 5-137

 STEERING SYSTEM

between the Maximum and Steering Shaft

Minimum level indicators. WARNING!
The following are common torque If this chassis is equipped with an
Fluid Filter Replacement specifications for most steering shafts. electronic stability system (ESP) and
• Torque on U-joint pinch bolt and any part of the steering system (e.g.,
nut (7/16 in) 74–81 Nm (55 to 60 linkage, steering driveline, column,
lb-ft), lubricated. front-end alignment, etc) is repaired,
removed, or disassembled in any
• Torque on Pitman arm clamp bolt way, or if the steering angle sensor is
and nut (3/4 in): 406–433 Nm (300 replaced, the steering angle sensor
to 320 lb-ft), lubricated. must be recalibrated. Any repairs or
adjustments to any part of the steer-
• For off-highway vehicles, tighten ing system must be performed by an
the U-bolts after the first day or two authorized dealer. Failure to comply
of operation. Then check weekly. may result in death, personal injury,
equipment or property damage.
5 CAUTION
Servicing the power steering system
without bleeding it of trapped air may
cause damage to the power steering
pump.

1. Replace both fluid and filter.

2. Bleed the system if necessary.

5-138 Y53-6077-1B1 (03/17)

 DRIVELINE

DRIVELINE U-Joints
For SPL170XL and SPL250XL, the
U-joint lube interval changes after the
Driveshaft Maintenance initial lube at 350,000 miles. After
the first lube interval, the U-joint
The slip joints and universal joints of
needs lubrication every 150,000 miles.
the driveshaft should be lubricated
Inspection of the U-joints is the same
periodically.
regardless of when the U-joint grease
Use a good quality lithium-soap-base interval occurs.
or equivalent extreme pressure (E.P.)
grease: NLGI Grade 2. WARNING!
Improper lubrication of U-joints can
Dana SPL U-joints and driveshafts cause them to fail prematurely. The
The slip joints and universal joints of
should be inspected every time driveshaft could separate from the
the drive shaft should be lubricated
a vehicle comes in for scheduled vehicle and result in an accident.
according to Preventive Maintenance
maintenance (Refer to Spicer Make sure lubricant is purged at all
Schedule on page 5-12.
Driveshaft service manual DSSM-0100 four ends of each U-joint and loosen
(3264-SPL) for detailed instructions.) caps if necessary. Also, regularly
5
Use a good quality lithium-soap-base
or equivalent extreme pressure (E.P.) inspect U-joints for excessive wear
Use only Spicer Driveshaft approved or movement, and repair or replace
grease: NLGI Grade 2.
lubricants when greasing Spicer SPL as necessary. Failure to comply
U-joints. Use only Spicer Driveshaft approved may result in death, personal injury,
lubricants when greasing Spicer SPL equipment or property damage.
U-joints.

(03/17) Y53-6077-1B1 5-139

 TIRES AND WHEEL

TIRES AND WHEEL Regular, frequent inspection and the Checking Inflation Pressure
right care will give you the assurance
Tires of safe and reliable tire operation. Give your tires a visual test every day,
Here are some tips on maintaining and check inflation with a gauge every
WARNING! your tires. week:

Do not repair damaged tires unless • When checking tire pressure,

you are fully qualified and equipped inspect each tire for damage to
to do so. Wheel and tire assem- sidewalls, cuts, cracks, uneven
blies cannot be worked on without wear, rocks between duals, etc. If
proper tools and equipment, such a tire appears underinflated, check
as: safety cages or restraining de- for damage to the wheel assembly.
vices. Have all tire repairs per- Don’t forget to check between dual
formed by an expert. Stand away wheels. If you find wheel damage,
from the tire assembly while the ex- have an expert tire service repair
pert is working. Failure to do this it.
may result in death or injury.
5 • Maximum tire pressure will be
indicated on the sidewall of a tire.
Your tires are a very important part of
your vehicle’s whole braking system. • Check pressure only when the
How fast you can stop depends in tires are cool. Warm or hot tires
large measure on how much friction cause pressure buildup and will
you get between the road and your give you an inaccurate reading.
tires. In addition, keeping your tires in So never deflate a warm tire to the
good condition is essential to the safe, specified pressure.
efficient operation of your vehicle.

5-140 Y53-6077-1B1 (03/17)

 TIRES AND WHEEL

Underinflated Tires
WARNING! WARNING!
Low pressure is a tire’s worst enemy.
Do not operate a vehicle with under- Do not attempt to raise the vehicle to
Underinflation allows tires to flex
inflated tires. The extra heat caused remove or install a damaged tire and
improperly, causing high temperatures
by underinflation can cause sudden wheel assembly if you are not fully
to build up. Heat causes early tire
tire failure such as a tire fire or blow qualified and not equipped with the
damage such as flex break, radial
out, which can cause an accident re- proper tools and equipment. Do not
cracks, and ply separation. Low
sulting in death or personal injury. attempt to re-inflate a tire that has
pressure may affect control of your
Low pressure may affect control at been run flat. Obtain expert help.
vehicle, especially at the front wheels.
the front wheels, which could result A person can be seriously injured
Most tire wear problems are caused
in an accident involving death or per- or killed if using the wrong service
by underinflation as the result of slow
sonal injury. Keep your tires inflated methods. Truck tires and wheels
leaks, so you’ll want to check tire
to the manufacturer's recommended should be serviced only by trained
pressure regularly. Lower tire pressure
air pressure. personnel using proper equipment.
does not provide better traction on ice
Follow OSHA regulations per sec-
or snow.
tion 1910.177.
5
NOTE
Follow all warnings and cautions
contained within the tire and wheel
manufacturer's literature.

(03/17) Y53-6077-1B1 5-141

 TIRES AND WHEEL

Overloaded Tires
1 3
Overloading your truck is as damaging
Proper-Inflation: Over-Inflation: to your tires as underinflation. The
the correct profile reduces the tread
for full contact with contact area with following chart shows how neglect or
the road. the road surface, deliberate abuse can affect the life of
TREAD CONTACT concentrating all of your tires.
WITH ROAD the vehicle weight
TREAD on the center of the
CONTACT WITH tread. This causes
ROAD premature wear of
the tire.
2

Under-Inflation:
causes abnormal
tire deflection, which
builds up excessive
heat, running the
risk of failure. It
5 TREAD
CONTACT WITH also causes irregular
ROAD wear.

EFFECT OF LOAD PRESSURE ON TIRE LIFE

Vehicle Load Normal 20% Over 40% Over 60% Over 80% Over 100% Over
Tire Pressure Normal 20% Low 30% Low 35% Low 45% Low 55% Low
Expected Total
Normal 70% 50% 40% 30% 25%
Tire Mileage

5-142 Y53-6077-1B1 (03/17)

 TIRES AND WHEEL

Overinflated Tires Matching Tires

WARNING!
Too much air pressure reduces the tire Be sure to buy matched tires for
Do not install regrooved or rein-
tread contact area and results in rapid your vehicle, especially on the rear
forcement-repaired tires on steering
wear in the center of the tread. axles. Mismatched tires can cause
axles. They could fail unexpectedly
stress between axles and cause the
and cause you to lose control of
WARNING! temperature of your axle lubricant to
your vehicle resulting in an accident
Overinflated tires can cause acci- get too hot. Matched tires will help
causing death or personal injury.
dents. They wear more quickly than your driveline last longer and will give
properly inflated tires and are more you better tire mileage.
subject to punctures, cracks, and
other damage. They could fail and WARNING!
cause you to lose control of your ve- Do not mismatch tires, it can be dan-
hicle resulting in an accident causing gerous. Never mix tires of different
death or personal injury. Be sure all design such as steel belted radials
tires are inflated correctly according and bias ply tires, etc. Mixing tire
to the manufacturer's recommenda- types and sizes will adversely affect 5
tions. the road-holding ability of both types
of tires and can lead to loss of vehi-
cle control and causing death or per-
sonal injury.

(03/17) Y53-6077-1B1 5-143

 TIRES AND WHEEL

Replacing Tires Greenhouse Gas Certified Tires

WARNING!
Front: Replace front tires when less Do not replace original equipment Replacing a tire that is greenhouse
than 4/32 in. of tread remains. Check tires with load ratings less than the gas certified.
at three places equally spaced around original tires. Doing so could lead to
the tire. unintentional overloading of the tire, NOTE
which could cause a failure resulting The tires installed on this vehicle
Drive Axles or Trailers: Replace tires
in loss of vehicle control and an ac- at the factory as original equipment
on drive axles or trailers when less than
cident. Failure to comply may result are certified for Greenhouse Gas
2/32 in. of tread depth remains in any
in death, personal injury, equipment and Fuel Efficiency regulations. Re-
major groove. Check at three places
or property damage. placement tires must be of equal or
equally spaced around the tire. See
lower rolling resistance level (TRRL
the next illustration for recommended
NOTE or Crr). Consult with your tire sup-
measuring points for tread depth.
plier(s) for appropriate replacement
To prolong your tires’ life and make tires.
them safer, have their radial and lat-
eral run-out checked at your dealer.
5 And of course, you should have your
tires balanced anytime you change a
tire.

Steer Tire Points (left), Drive Tire

Points (right)

5-144 Y53-6077-1B1 (03/17)

 TIRES AND WHEEL

Tire Chains Speed Restricted Tires

Maintaining a greenhouse gas
certified tire. If you need tire chains, install them on WARNING!
both sides of each driving axle.
In order to limit the rolling resistance of This vehicle may be equipped with
the tires and optimize fuel economy, speed restricted tires. Check each
CAUTION
the maintenance procedures specified tire’s sidewall for maximum rated
Chains on the tires of only one tan- speed. The vehicle should not be
by the tire manufacture must be
dem axle can damage the driveline operated at sustained speed in
followed.
U-joints and the interaxle differen- excess of maximum rated speed.
For warranty information, See Original tial. Your repairs could be costly and Failure to comply with these speed
Equipment Tires on page 6-10. time-consuming. restrictions could cause sudden tire
failure which can result in death,
personal injury or property damage.

(03/17) Y53-6077-1B1 5-145

 TIRES AND WHEEL

Wheel Mounting and Wheel Cap Nut Torque

WARNING!
Fastening
Never use oil or grease on studs or At the first scheduled lube interval,
After the vehicle travels about 50 to 100 nuts; improper torque readings will have all wheel cap nuts torqued to
miles (80 to 160 km), wheel mountings result, which could cause improper their specified value listed in Wheel
seat in and will lose some initial torque. wheel clamping and could lead to Cap Nut Torque chart below. After
Check hub/wheel mountings after this a wheel failure resulting in an acci- that, check wheel cap nuts at least
initial period and retighten. dent. Failure to comply may result once a week. Contact an authorized
in death, personal injury, equipment dealer for information on the proper
or property damage. installation procedure for the wheels
on your truck. This is a job you may
not be able to do yourself. You need
the right torquing equipment to do it.
Wheel Cap Nut Torque

WHEEL and NUT STUD SIZE TORQUE FOR INNER and OUTER CAP NUTS and RIM CLAMP
CONFIGURATION NUTS
5 Nm Lb-Ft
Steel or Aluminum Disc-Type 3/4-16 610-680 450-500
Wheel; Double Cap Nut
Mounting; 1-1/8-16 610-680 450-500
Standard 7/8 Radius Ball Seat
Heavy-Duty Steel Disc-Type 15/16-12 1,020-1,220 750-900
Wheel; Double Cap Nut
Mounting; 1-1/8-16 1,020-1,220 750-900
1-3/16 Radius Ball Seat: 1-15/16-12 1,020-1,220 750-900

5-146 Y53-6077-1B1 (03/17)

 TIRES AND WHEEL

WHEEL and NUT STUD SIZE TORQUE FOR INNER and OUTER CAP NUTS and RIM CLAMP
CONFIGURATION NUTS
Nm Lb-Ft
Hub-Piloted Disc-Type Wheel M22-1.5 610-680 450-500
w/Two Piece Flanged Cap Nuts:
Steel or Aluminum Wheel
PHP-10; Budd Uni-Mount-10;
WDH-8
Stud Backnuts (when used) 3/4-16 240-270 175-200
1-14 240-410 175-300
Rim Clamp Nut Torque
1/2” Dia. 110-120 80-90
Cast Spoke Wheel Assembly
5/8” Dia. 220-250 160-185
3/4” Dia. 305-335 225-245

Threads should be clean and dry. Do Proper Torque and Sequence procedure will ensure that the wheel is
not lubricate wheel nuts or studs. drawn evenly against the hub. Torque 5
Proper wheel torque can best be each nut to the torque value listed in
obtained on level ground. Install lug Wheel Cap Nut Torque on page 5-146.
nuts and finger-tighten in the numerical
sequence as shown below. See Nut
Tightening Sequence for Hub Piloted
Disc Wheels on page 5-148 or Nut
Tightening Sequence for Stud Piloted
Disc Wheels on page 5-148. This

(03/17) Y53-6077-1B1 5-147

 TIRES AND WHEEL

Wheel Replacement with

WARNING!
Disc Brake Option
Tighten wheel cap nuts properly.
If they are not tightened properly, WARNING!
wheel nuts could eventually cause Use only the wheel brand, size and
the wheel to become loose, to fail, Nut Tightening Sequence for Stud part number originally installed. Use
and/or to come off while the vehicle Piloted Disc Wheels of a different wheel brand or size
is moving, possibly causing loss of could cause valve stem to interfere
control and may result in death, per- with a brake component which could
sonal injury, equipment or property lead to loss of vehicle control. Fail-
damage. ure to comply may result in death,
personal injury, equipment or prop-
erty damage.

Vehicles equipped with front disc

brakes are fitted with wheels designed
5 Nut Tightening Sequence for Hub specifically for disc brake applications.
Piloted Disc Wheels If it ever becomes necessary to
replace an original equipment wheel,
the replacement wheel must be the
same brand and size as the take-off
wheel. On vehicles equipped with 22.5
in. disc wheels, installing the wrong
replacement wheel could result in
the wheel valve stem making contact

5-148 Y53-6077-1B1 (03/17)

 TIRES AND WHEEL

with the disc brake assembly. When

installing any replacement wheel, WARNING! WARNING!
always inspect the tires/wheels to If the hood falls, anyone under it Improperly mounting and demount-
ensure there is adequate clearance could be injured. Always make sure ing tire and rim assemblies is dan-
between other vehicle components. that the hood hold open device en- gerous. Failure to observe proper
gages when the hood is in its open precautions could cause the tire-rim
With the hood open, check for position any time anyone gets under assembly to burst explosively, caus-
clearance between the wheel and disc the hood for any reason. ing death or personal injury. See
brake assembly. Use a hydraulic jack
• The hood could hurt someone the wheel manufacturer's literature
to raise the front of the vehicle off
that is in the way of its descent. for the proper way to mount and de-
the ground to allow the wheel to spin
Before lowering the hood, be mount your tires and rims. Follow
freely. While rotating the wheel, check
sure no objects or people are in their precautions exactly.
to ensure there is adequate clearance
between the wheel and disc brake the way.
assembly.
WARNING!
Always support the vehicle with ap- 5
propriate safety stands if it is neces-
sary to work underneath the vehicle.
A jack is not adequate for this pur-
pose.

(03/17) Y53-6077-1B1 5-149

 TIRES AND WHEEL

Disc Wheels
WARNING!
Use the correct components and
tools when working on wheels.
Grooves in the wheel disc or other
damage to the disc can weaken the
wheel and cause it to eventually
come off. This could cause you to
lose control of your vehicle, and
may result in an accident. Failure
to comply may result in death, per-
sonal injury, equipment or property
damage.

The end of the wheel wrench must

5 be smooth. Burrs on the end of the
wrench can tear grooves in the disc.
These grooves may lead to cracks in
the disc, and can cause it to fail.

5-150 Y53-6077-1B1 (03/17)

 WHEEL BEARING

WHEEL BEARING
Wheel Bearing Adjustment
For safe, reliable operation and
adequate service life, your wheel
bearings must be adjusted properly at
the recommended intervals. Contact
your authorized dealer to make sure
the wheel bearings are properly
adjusted.

(03/17) Y53-6077-1B1 5-151

 TRANSMISSION MAINTENANCE

TRANSMISSION Oil Change

For more details, please refer to
MAINTENANCE the maintenance section in the Change fluid according to change
transmission manufacturer’s manual procedures specified in the
Introduction or service literature. Transmission Service Manual.
Use the recommended types of oil
Proper maintenance of the CAUTION as specified in the Operation and
transmission will ensure that the Service Manual (included with vehicle).
vehicle will operate efficiently. When adding oil, types and brands
of oil should not be intermixed be- Select from the appropriate lubricant
cause of possible incompatibility, for varying ambient (outside air)
To check the transmission fluid level,
which could decrease the effec- temperatures.
park the vehicle on level ground. For
an automatic transmission the oil level tiveness of the lubrication or cause
should be checked with the engine component failure.
idling and the transmission fluid at
operating temperature. Checking the Initial Change: drain and replace
fluid of a manual transmission may be according to Preventive Maintenance
5 done with the engine off. Schedule on page 5-12; for some
transmissions this may not be required.
The recommended fluid replacement
intervals contain an initial change and
a separate interval for the changes
after the initial drain. When the oil
needs to be replaced, be sure to refer
to the manufacturer’s literature on
the correct grade and type of oil to
purchase.

5-152 Y53-6077-1B1 (03/17)

 TRANSMISSION MAINTENANCE

Transmission Lubricants Service Intervals Standard Transmission Oil Level

Manual Transmission
For recommended types and brands NOTE
Manual transmissions are designed so of all lubricants, see the transmission
The vehicle must be parked on level
that the internal parts operate in a bath manufacturer's Service Manual and
ground.
of oil circulated by the motion of gears Preventive Maintenance Schedule on
and shafts. page 5-12.
See the Transmission Operator's
Check all hoses for kinks, deterioration, Manual for information on checking the
chafing, and leaks. Adjust kinked or transmission oil level.
chafing hoses to eliminate restrictions
and prevent further wear. To ensure
proper inspection, it may be necessary
to inspect under and inside frame rails
and unclip harnesses, hoses and cable
bundles.

(03/17) Y53-6077-1B1 5-153

 TRANSMISSION MAINTENANCE

Automatic Transmissions Automatic Transmission Oil Level

Service Intervals
NOTE
Check daily with engine idling. See
The vehicle must be parked on level
Preventive Maintenance Schedule on
ground.
page 5-12 for service intervals.

See the Transmission Operator's

Manual for information on checking the
transmission oil level.

5-154 Y53-6077-1B1 (03/17)

 CLUTCH

CLUTCH When the clutch wears, the release Clutch Adjustment - Normal
bearing gradually moves toward the Wear
Introduction engine, decreasing free pedal and free
travel. When all free pedal and free Clutch pedal free travel is usually 1 3/4
Free pedal is the distance the clutch travel are gone, the clutch requires in. to 2 in. (34 to 51 mm). This should
pedal moves by applying only slight adjustment. be your guide for determining whether
pressure. During free pedal the your truck needs clutch adjustment.
release yoke in the transmission The clutch is adjusted by turning an Also, if it becomes increasingly difficult
moves until its bearing pads contact adjustment ring that is built into the to shift into gears, or the truck creeps
the release bearing. This movement of clutch. When the ring is turned, the with the clutch pedal depressed, your
the release yoke is called free travel. release bearing moves back toward clutch needs adjustment. See the
Thus, free pedal and free travel are the transmission, restoring free pedal Maintenance Manual for the proper
directly related to each other. and clutch free travel. Under normal adjustment procedures.
clutch wear this is the only adjustment
As the clutch pedal is depressed needed. Do not attempt to change any Some vehicles have automatic clutch
further, with harder pressure, the other component. adjustment. If yours doesn't have this
release yoke moves the release feature, adjustment will have to be
bearing away from the engine. This done by a trained certified mechanic. 5
causes the clutch plate to release from Have the adjustment done before
the driven disks in the clutch. This is clutch pedal free travel is reduced to
called release travel. And finally, on the minimum allowable 1/2 in. (13
9-, 10-, and 11-speed transmissions, mm).
as the pedal is pushed to the last 1/2
to 1 inch of travel, the release bearing
contacts and engages the clutch brake.
This is called clutch brake squeeze.

(03/17) Y53-6077-1B1 5-155

 CLUTCH

Clutch Linkage

This vehicle is equipped with a rod

and lever mechanical clutch linkage.
Lubricate each pivot point on the clutch
linkage.

5-156 Y53-6077-1B1 (03/17)

 INFORMATION

CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Vehicle Identification . . . . . . . . . . . . . . 6-3
General VIN Information . . . . . . . . . . . . . 6-3
Component Identification. . . . . . . . . . . . . 6-7
CONSUMER INFORMATION
Federal Safety Standard Certification Label . . . . 6-8
How to Order Parts . . . . . . . . . . . . . . . 6-8
NHTSA Consumer Information . . . . . . . . . . 6-8
Canadian Consumer Information . . . . . . . . . 6-9
VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY
Original Equipment Tires . . . . . . . . . . . . 6-10
Greenhouse Gas (GHG) Components Other Than
Tires . . . . . . . . . . . . . . . . . . . 6-11
Your Warranty Rights and Obligations . . . . . . 6-11 6
Manufacturer's Warranty Coverage . . . . . . . 6-12
Owner's Warranty Responsibilities . . . . . . . 6-12
Replacement Parts . . . . . . . . . . . . . . 6-13

(03/17) Y53-6077-1B1 6-1

 INFORMATION

PACCAR Responsibilities . . . . . . . . . . . 6-14

Warranty Limitations. . . . . . . . . . . . . . 6-14

6-2 Y53-6077-1B1 (03/17)

 CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

CONSUMER Example VIN: General VIN Information

INFORMATION VIN Locations

AND VEHICLE The full, 17-digit VIN is located on the

IDENTIFICATION Weight Rating Data Label. The label is
located on the driver's side door edge
1 Manufacturer Identifier
or on the driver's side door frame.
Vehicle Identification 2 Vehicle Attributes
3 Reserved Space
Each vehicle completed by Peterbilt
Motors Company uses a Vehicle 4 Model Year
Identification Number (VIN) that 5 Assembly Plant
contains the model year designation 6 Serial Number (Chassis Number)
of your Peterbilt. The practice is in
compliance with 49 CFR 565, Code of Model Year
Federal Regulations. J = 2018
K = 2019
The Vehicle Identification Number is
on the Peterbilt labels on the left hand L = 2020
door post. The VIN contains 17 digits. M = 2021
The 10th digit is the code for the model Glider Kit Identification
year of your vehicle. The example VIN
below shows how this code works: 0 (zero) = Glider Kit
6
Plant Code

D = Denton Factory

(03/17) Y53-6077-1B1 6-3

 CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Chassis Number Certification Labels Components and Weights Label

The Chassis Number refers to the last Your vehicle information and The Components and Chassis Weight
six characters of the VIN. This number specifications are documented on Label is located on either the driver’s
will allow your dealer to identify your labels. As noted below, each label side door edge or on the driver’s
vehicle. You will be asked for this contains specific information pertaining side door frame. It includes chassis
number when you bring it in for service. to vehicle capacities and specifications number, chassis weight and gross
that you should be aware of. weight, plus model information for the
Chassis Number Locations vehicle, engine, transmission, and
axles.
• Right frame rail, top flange, about
3 ft. from the front end

• Cab back, left-hand rear panel,

lower edge

• Tire, Rim and Weight Rating Data

label (truck)

• Components and Weights label

• Noise Emission label

6 • Paint Identification label

6-4 Y53-6077-1B1 (03/17)

 CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Tire, Rim and Weight Rating Data Noise Emission Label

Label WARNING!
Do not exceed the specified load rat- The Noise Emission Label is located
The Tire, Rim and Weight Rating ing. Overloading can result in loss in the driver's side door frame. It
Data Label is located on the driver’s of vehicle control and personal in- contains information regarding U.S.
side door edge or on the driver’s side jury, either by causing component noise emission regulations, chassis
door frame. It contains the following failures or by affecting vehicle han- number, and date of manufacture.
information: dling. Exceeding load ratings can
Paint Identification Label
• GVWR - Gross Vehicle Weight also shorten the service life of the
Rating vehicle. The Paint Identification Label contains
the paint colors used by the factory
• GAWR FRONT, INTERMEDIATE The components of your vehicle to paint your vehicle. It lists frame,
and REAR - Gross Axle Weight are designed to provide satisfactory wheels, cab interior and exterior
Ratings for Front, Intermediate service, if the vehicle is not loaded colors. This label is located inside the
and Rear Axle in excess of either the gross vehicle glove box.
weight rating (GVWR), or the maximum
• TIRE/RIM SIZES AND INFLATION
front and rear gross axle weight ratings
PRESSURES - Tire/Rim Sizes
(GAWRs).
and Cold Pressure Minimums

• VIN including CHASSIS NUMBER NOTE

GVW is the TOTAL SCALE WEIGHT 6
the vehicle is designed to carry. This
includes the weight of the empty ve-
hicle, loading platform, occupants,
fuel, and any load.

(03/17) Y53-6077-1B1 6-5

 CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Federal Safety Standard Greenhouse Gas Certification

Certification Label Emission Emissions Related
Control Components
This vehicle may be equipped with Identifier
The NHTSA regulations require a label components that are identified as
VSL, VSLS, Engine Software
certifying compliance with Federal Greenhouse Gas Certified components VSLE, or parameters that affect
Safety Standards, for United States (GHG). A label on the door is printed VSLD the Vehicle Speed
and U.S. Territories, be affixed to with codes that identify the components Limiter
each motor vehicle and prescribe manufactured on the vehicle that are IRT5, IRTE Engine software
where such label may be located. part of the GHG certification. The parameters that affect
the automatic engine
This certification label, which indicates codes are translated in the following shutdown timer
the date of manufacture and other table:
ATS Aerodynamic side skirts
pertinent information, is located on and/or fuel tank fairings
the driver’s side door edge or on the
ARF Aerodynamic roof fairing
driver’s side door frame.
ARFR Adjustable height
aerodynamic roof fairing
TGR Gap reducing fairing
(tractor to trailer)
LRRA, Greenhouse Gas (GHG)
LRRD, or Tires
LRRS

6-6 Y53-6077-1B1 (03/17)

 CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Component Identification 1. Axle Specification Number, usually

stamped on the right rear side of
Each of the major components on
the axle housing. This number
your vehicle has an identification label
identifies the complete axle.
or tag. For easy reference, record
component numbers such as, model, 2. Axle Housing Number Tag, usually
serial, and assembly number. located on the left forward side
of the housing arm. This tag
Engine: For further information, identifies the axle housing.
please refer to the Engine Operation
and Maintenance Manual. 3. Axle Differential Carrier
Identification, usually located
Transmission: For both manual on the top side of the differential
and automatic transmissions, the carrier. The following information
identification number is stamped on a is either stamped, or marked with a
tag affixed to the right rear side of the metal tag: Model No., Production
transmission case. Assembly No., Serial No., Gear
Ratio, and Part Number.
Clutch: Enclosed in clutch housing.
Location depends on manufacturer.

Steer Axle: The front axle serial 6

number is stamped on a plate located
on the center of the axle beam.

Drive Axles: The drive axle numbering

system includes three labels or stamps:

(03/17) Y53-6077-1B1 6-7

 CONSUMER INFORMATION

CONSUMER How to Order Parts NHTSA Consumer

INFORMATION Information
Replacement parts may be obtained
from an authorized dealership. If you believe that your vehicle has
Federal Safety Standard a defect, which could cause a crash
Certification Label When you order, it is IMPORTANT or could cause death or personal
that you have the following information injury, you should immediately inform
The National Highway Traffic Safety ready: the National Highway Traffic Safety
Administration regulations require Administration (NHTSA) in addition to
a label certifying compliance with • Your name and address.
notifying the vehicle manufacturer.
Federal Safety Standards, for United • Serial number of the truck.
States and U.S. Territories, be affixed If NHTSA receives similar complaints,
to each motor vehicle and prescribe • The name of the part you need. it may open an investigation, and
where such label may be located. if it finds that a safety defect exists
This certification label, which indicates • The name and number of the
in a group of vehicles, it may order
the date of manufacture and other component for which the part is
a recall and remedy campaign.
pertinent information, is located on the required.
However, NHTSA cannot get involved
left hand cab door post. • The quantity of parts you need. in individual problems between you,
your dealer, and vehicle manufacturer.
• How you want your order shipped.
Contacting NHTSA is possible through
6 telephone, written mail and email.
NHTSA also has a website where you
can input your comments directly to
them on the web. Please use any of
the four ways to contact NHTSA:

6-8 Y53-6077-1B1 (03/17)

 CONSUMER INFORMATION

Canadian Consumer
Toll Free 888-327-4236
(800-4249153 TTY) Information
8:00 am to 10:00 pm ET
Monday-Friday Canadian customers who wish to report
Office of Defects a safety-related defect to Transport
Investigations/CRD Canada, Defect Investigations and
NVS-216 Recalls, may telephone the toll free
1200 New Jersey Ave SE.
Washington, D.C. 20590
hotline 1-800-333-0510, or contact
Transport Canada by mail at:
www www.safercar.gov
@ nhtsa.webmaster@dot.gov Transport Canada, ASFAD
Place de Ville Tower C
330 Sparks Street
Ottawa ON K1A 0N5

For additional road safety information,

please visit the Road Safety website
at:

www.tc.gc.ca

(03/17) Y53-6077-1B1 6-9

 VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY

VEHICLE EMISSIONS LIMITATIONS LISTED ABOVE. This OR LOST PROFITS; VEHICLE

LIMITED EXPRESS Vehicle Emissions Limited Express DOWNTIME; COMMUNICATION
Warranty relating to original equipment EXPENSES; LODGING AND/OR
WARRANTY tires begins on the date of delivery of MEAL EXPENSES; FINES;
the vehicle to the first purchaser or APPLICABLE TAXES OR BUSINESS
Original Equipment Tires lessee and accrued time and mileage is COSTS OR LOSSES; ATTORNEY’S
calculated when the vehicle is brought FEES; AND ANY LIABILITY YOU MAY
PACCAR Inc warrants the tires in for correction of the Warrantable HAVE IN RESPECT TO ANY OTHER
installed as original equipment on Emissions Failures relating to the PERSON OR ENTITY RELATING
this vehicle only against defects in original equipment tires. TO WARRANTABLE EMISSIONS
materials and workmanship which FAILURES.
cause the vehicle to fail to comply PACCAR MAKES NO OTHER
with applicable U.S. and Canadian VEHICLE EMISSIONS WARRANTIES This Vehicle Emissions Limited
greenhouse gas emission limits RELATING TO THE ORIGINAL Express Warranty relating to
(“Warrantable Emissions Failures”). EQUIPMENT TIRES, EXPRESS original equipment tires is limited
This vehicle emissions limited express OR IMPLIED. WHERE PERMITTED to emissions compliance only.
warranty relating to original equipment BY LAW, PACCAR EXPRESSLY The tires are separately warranted
tires is valid for two (2) years or 24,000 DISCLAIMS ANY WARRANTY OF by their manufacturer for defects in
miles, whichever occurs first. MERCHANTABILITY OR FITNESS materials and workmanship other than
FOR A PARTICULAR PURPOSE those which cause non-compliance
YOUR SOLE AND EXCLUSIVE RELATING TO VEHICLE EMISSIONS. with U.S. and Canadian GHG
6 REMEDY AGAINST PACCAR Inc PACCAR AND THE SELLING regulations, subject to limitations and
IS LIMITED TO THE REPAIR OR DEALER SHALL NOT BE LIABLE FOR conditions contained within the tire
REPLACEMENT OF ORIGINAL INCIDENTAL OR CONSEQUENTIAL manufacturer’s warranty agreement.
EQUIPMENT TIRES, SUBJECT TO DAMAGES INCLUDING, BUT NOT You are responsible for the safe
PACCAR’S TIME AND MILEAGE LIMITED TO: LOSS OF INCOME operation and maintenance of the

6-10 Y53-6077-1B1 (03/17)

 VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY

vehicle and its tires. PACCAR does Greenhouse Gas (GHG) Your Warranty Rights and
not warrant wear and tear of the tires. Components Other Than Obligations
Tires
This vehicle is warranted for
This GHG vehicle Warranty applies to components that directly impact the
the vehicle (hereafter, vehicle) certified manufacturers greenhouse gas (GHG)
with the US Environmental Protection certification with the US Environmental
Agency. Protection Agency. PACCAR must
warrant these components for the
periods of time listed below provided
there has been no abuse, neglect or
improper maintenance of the vehicle.

If a GHG-related part on your vehicle

is found to have a defect in material or
assembly, the part will be repaired or
replaced by PACCAR.

(03/17) Y53-6077-1B1 6-11

 VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY

Manufacturer's Warranty Owner's Warranty programming) or using non-Original

Coverage Responsibilities Equipment replacement parts.

This warranty coverage is provided for The vehicle owner is responsible for If there are any questions
five years or 100,000 miles (160,000) performing required maintenance that regarding these warranty rights
km, whichever first occurs, from the is listed in your engine and vehicle and responsibilities, please contact
date of delivery of the vehicle to Operator’s Manuals. The owner is the vehicle OEM manufacturer at the
the first purchaser or first lessee. responsible for presenting the vehicle customer center telephone number
Where a Warrantable Condition exists, to a service location as soon as a provided with the vehicle operating
PACCAR will diagnose and repair problem exists. Any warranty repairs instructions.
the vehicle, parts and labor included, should be completed in a reasonable
at no cost to the first purchaser or amount of time. Prior to the expiration of the applicable
first lessee and each subsequent warranty, Owner must give notice of
purchaser or lessee. This warranty Retain all receipts covering any warranted failure to an authorized
does not override any extended maintenance on this equipment. PACCAR dealer and deliver the vehicle
warranty purchased to cover specific PACCAR cannot deny warranty solely to such facility for repair.
vehicle components. for the lack of receipts or for the
failure to ensure the performance of all Owner is responsible for incidental
scheduled maintenance. costs such as: communication
expenses, meals, lodging incurred by
PACCAR may deny warranty coverage Owner or employees of Owner as a
6 if a vehicle component has failed due to result of a Warrantable Condition.
abuse, neglect, improper maintenance,
unapproved modifications (both Owner is responsible for downtime
physical components and computer expenses, cargo damage, fines, all
applicable taxes, all business costs,

6-12 Y53-6077-1B1 (03/17)

 VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY

and other losses resulting from a Replacement Parts the emission control parts performed
Warrantable Condition. by a facility other than an authorized
PACCAR recommends that any PACCAR dealer and may elect to
Owner is responsible for maintaining service parts used for maintenance, use parts other than new or genuine
all emissions related engine and repair or replacement of GHG approved rebuilt parts and assemblies
vehicle computer program settings components be new or genuine for such maintenance, replacement
in accordance with manufacturer approved rebuilt parts and assemblies. or repair; however, the cost of such
specifications. This responsibility The use of non-genuine engine or service or parts and subsequent
includes GHG specific settings vehicle replacement parts that are not failures resulting from such service
that may not be altered before the equivalent to the PACCAR engine or or parts may not be fully warranted
GHG-related expiration mileage has OEM vehicle manufacturer’s original if the manufacturer determines that
been reached for each system. part specification as built from the the replacement part is not of similar
factory may impair the engine and material and function as the OEM part
Owner is responsible for maintaining vehicle emissions control system from assembled to the vehicle at the factory.
all physical parts related to working or functioning effectively, and
GHG-regulations in the as-built may jeopardize your GHG warranty
configuration and in proper working coverage.
order for the full regulatory useful life
of 435,000 miles for Class 8 vehicles, In addition, genuine vehicle or engine
185,000 miles for Class 6-7, and parts must be replaced with the same
110,000 for Class 5. material and function as the part
assembled on the vehicle from the 6
factory.

The owner may elect to have

maintenance, replacement or repair of

(03/17) Y53-6077-1B1 6-13

 VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY

PACCAR Responsibilities Warranty Limitations adequate coolants or lubricants;

overfueling; overspeeding; lack of
The warranty coverage begins when Sole and exclusive remedy against maintenance of cooling, lubricating
the vehicle is delivered to the first PACCAR and the Selling Dealer or intake systems; improper storage,
purchaser or first lessee. Repairs arising from the purchase and use starting, warm-up, run-in or shutdown
and service will be performed by any of this vehicle is limited to the repair practices; unauthorized modifications
authorized PACCAR dealer using or replacement of “warrantable to the vehicle and its components.
new or genuine approved rebuilt parts failures”, for replacement parts that PACCAR is also not responsible for
and assemblies PACCAR will utilize are similar in material and function failures caused by incorrect oil, fuel
replacement parts that are selected to OEM specifications and subject to or diesel exhaust fluid or by water,
and installed to support the GHG PACCAR’s time, mileage, and hour dirt or other contaminants in the fuel,
compliance certification. PACCAR limitations of the greenhouse gas oil or diesel exhaust fluid. Failure
will repair parts found by PACCAR to warranty. The maximum time, mileage of replacement parts used in repairs
be defective without charge for parts and hour limitations of the warranty due to the above non-warrantable
or labor (including diagnosis which begin with the Date of Delivery to the conditions is not warrantable.
results in determination that there has first purchaser or first lessee. The
been a failure of a warranted part). accrued time, mileage, or hours is This warranty is void if the vehicle is
calculated when the vehicle is brought altered with parts that do not meet the
in for correction of warrantable failures. material and functional specifications
as manufactured from the factory.
PACCAR is not responsible for Any alterations to vehicle or engine
6 failures or damage resulting from what computer settings will void GHG
PACCAR determines to be abuse, warranty and potentially cause the
neglect or uncontrollable acts of nature, vehicle to become non-compliant
including, but not limited to: damage with the GHG regulation of the EPA
due to accident; operation without Clean Air Act. Any alterations to

6-14 Y53-6077-1B1 (03/17)

 VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY

GHG specific settings prior to the WARRANTIES MADE BY PACCAR IN VEHICLES OR PROPERTY,
GHG related expiration mileage for REGARD TO THIS VEHICLE. ATTACHMENTS, TRAILERS AND
each system will void GHG warranty CARGO; LOSS OR DAMAGE
and potentially cause the vehicle THIS LIMITED GHG WARRANTY TO PERSONAL CONTENTS;
to become non-compliant with the IS THE SOLE WARRANTY MADE COMMUNICATION EXPENSES;
GHG regulation of the EPA Clean Air BY PACCAR AND THE SELLING LODGING AND/OR MEAL
Act. This warranty is void if certain DEALER. EXCEPT FOR THE ABOVE EXPENSES; FINES; APPLICABLE
GHG components are not properly LIMITED WARRANTY, PACCAR AND TAXES OR BUSINESS COSTS OR
maintained and thus cannot perform to THE SELLING DEALER MAKE NO LOSSES; ATTORNEYS’ FEES; AND
their designed capability. OTHER WARRANTIES, EXPRESS ANY LIABILITY YOU MAY HAVE IN
OR IMPLIED. PACCAR AND THE RESPECT TO ANY OTHER PERSON
PACCAR is not responsible for failures SELLING DEALER EXPRESSLY OR ENTITY.
resulting from improper repair or the DISCLAIM ANY WARRANTY OF
use of parts which are not genuine MERCHANTABILITY OR WARRANTY
approved parts. OF FITNESS FOR A PARTICULAR
PURPOSE.
PACCAR is not responsible for the
material and labor costs of emission PACCAR AND THE SELLING
control parts and assemblies replaced DEALER SHALL NOT BE LIABLE FOR
during Scheduled Maintenance of INCIDENTAL OR CONSEQUENTIAL
the engine as specified in PACCAR DAMAGES INCLUDING, BUT NOT
Operator’s Manuals. LIMITED TO: LOSS OF INCOME 6
OR LOST PROFITS; ENGINE OR
THIS WARRANTY, TOGETHER VEHICLE DOWNTIME; THIRD PARTY
WITH THE EXPRESS COMMERCIAL DAMAGE, INCLUDING DAMAGE
WARRANTIES ARE THE SOLE OR LOSS TO OTHER ENGINES,

(03/17) Y53-6077-1B1 6-15

 Index

Index
5th wheel primary air pressure gauge. . . . . 5-63 Battery chargning . . . . . . . . . . . . . . . . . . 5-97
maintenance . . . . . . . . . . . . . . . . . . . . 5-113 secondary air pressure gauge . 5-63 Bendix® AD-IS series air dryer . . . 5-61
turbocharger . . . . . . . . . . . . . . . . . . . . 5-107 Brake adjustment . . . . . . . . . . . . . . . . . . 5-66
A Air system maintenance. . . . . . . . . . . 5-57 Brake system
Air tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-62 adjustment . . . . . . . . . . . . . . . . . . . . . . . 5-66
Accessory drive belts . . . . . . . . . . . . . 5-105 Allison transmission lubrication . . . 5-50 Bulb replacement
Adding electrical options . . . . . . . . . . 5-92 Automatic Slack Adjusters . . . . . . . . 5-69 headlight . . . . . . . . . . . . . . . . . . . . . . . . . 5-88
Air cleaners. . . . . . . . . . . . . . . . . . . . . . . . 5-108 Automatic transmissions Bulb specifications . . . . . . . . . . . . . . . . . 5-89
Air compressor . . . . . . . . . . . . . . . . . . . . . 5-64 oil level . . . . . . . . . . . . . . . . . . . . . . . . . . 5-154
Air disc brakes service intervals . . . . . . . . . . . . . . . . 5-154
maintenance . . . . . . . . . . . . . . . . . . . . . 5-67 C
Axle lubrication . . . . . . . . . . . . . . . . . . . . 5-116
Air dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60 Canadian consumer information. . . .6-9
Air dryer (Bendix® AD-IS series) . 5-61 Certification labels
Air dryer overhaul . . . . . . . . . . . . . . . . . . 5-61 B components and weights label . . .6-4
Air intake system. . . . . . . . . . . . . . . . . . 5-107 Batteries federal safety standard certification
Air system battery access . . . . . . . . . . . . . . . . . . . 5-93 label . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
air cleaners . . . . . . . . . . . . . . . . . . . . . 5-108 battery care . . . . . . . . . . . . . . . . . . . . . . 5-97 noise emission label . . . . . . . . . . . . . .6-5
air compressor. . . . . . . . . . . . . . . . . . . 5-64 battery charging . . . . . . . . . . . . . . . . . 5-97 paint identification label . . . . . . . . . . .6-5
air dryer . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60 removing and installing tire, rim and weight rating data
air gauges and air leaks . . . . . . . . 5-63 batteries. . . . . . . . . . . . . . . . . . . . . 5-95 label . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
air intake system . . . . . . . . . . . . . . . 5-107 Battery access . . . . . . . . . . . . . . . . . . . . . 5-93 Checking tire inflation pressure. . 5-140 7
draining air tanks . . . . . . . . . . . . . . . . 5-62 Battery care . . . . . . . . . . . . . . . . . . . . . . . . 5-97 Chrome and aluminum surfaces. . 5-71

(03/17) Y53-6077-1B1 Index-1

 Index

Cleaning vinyl and upholstery . . . . 5-75 Drum brakes engine mounting. . . . . . . . . . . . . . . . 5-110
Cleaning, protecting and weather maintenance . . . . . . . . . . . . . . . . . . . . . 5-69 exhaust system . . . . . . . . . . . . . . . . . 5-110
stripping . . . . . . . . . . . . . . . . . . . . . . . 5-72 identification . . . . . . . . . . . . . . . . . . . . . . .6-7
Clutch lubrication . . . . . . . . . . . . . . . . . . . . . . . 5-102
clutch linkage adjustment. . . . . . 5-155 E pipe and hose clamp torque
identification . . . . . . . . . . . . . . . . . . . . . . .6-7 Eaton/Dana axle lubrication. . . . . . . 5-53 values . . . . . . . . . . . . . . . 5-43, 5-103
Clutch maintenance . . . . . . . . . . . . . . 5-155 ELC concentration . . . . . . . . . . . . . . . . . 5-82 Engine (block) heater. . . . . . . . . . . . . . 5-86
Component identification reference 6-7 Electrical and alternator Engine fan . . . . . . . . . . . . . . . . . . . . . . . . . 5-106
Components and weights label . . . . .6-4 precautions . . . . . . . . . . . . . . . . . . . . 5-99 Engine lubrication . . . . . . . . . . . . . . . . . 5-102
Consumer information Electrical system Engine maintenance. . . . . . . . . . . . . . 5-101
Federal safety standards . . . . . . . . .6-8 adding electrical options . . . . . . . . 5-92 Engine Mounting . . . . . . . . . . . . . . . . . . 5-110
how to order parts . . . . . . . . . . . . . . . . .6-8 batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93 Exhaust system . . . . . . . . . . . . . . . . . . . 5-110
Coolant Level. . . . . . . . . . . . . . . . . . . . . . . 5-84 battery care . . . . . . . . . . . . . . . . . . . . . . 5-97 Extended life coolant (ELC)
Cooling system battery charging . . . . . . . . . . . . . . . . . 5-97 What to Check in an ELC-filled
adding coolant . . . . . . . . . . . . . . . . . . . 5-84 electrical and alternator Cooling System . . . . . . . . . . . . 5-82
fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-106 precautions . . . . . . . . . . . . . . . . . 5-99 Exterior maintenance . . . . . . . . . . . . . . 5-71
fan clutch. . . . . . . . . . . . . . . . . . . . . . . . 5-106 fuses, circuit breakers and Exterior washing . . . . . . . . . . . . . . . . . . . 5-74
maintenance . . . . . . . . . . . . . . . . . . . . . 5-82 relays. . . . . . . . . . . . . . . . . . . . . . . . 5-89
Cooling system maintenance . . . . . 5-82 removing and installing
batteries. . . . . . . . . . . . . . . . . . . . . 5-95
F
Electrical system maintenance . . . 5-87 Federal safety standard certification
D Emergency welding. . . . . . . . . . . . . . . 5-112 label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Disc wheels. . . . . . . . . . . . . . . . . . . . . . . . 5-150 Engine Fifth wheel
Drive axles air cleaners . . . . . . . . . . . . . . . . . . . . . 5-108 maintenance . . . . . . . . . . . . . . . . . . . . 5-113
7 identification . . . . . . . . . . . . . . . . . . . . . . .6-7 air intake system . . . . . . . . . . . . . . . 5-107 Frame fastener torque
Driveshaft Maintenance . . . . . . . . . . 5-139 drive belts . . . . . . . . . . . . . . . . . . . . . . . 5-105 requirements . . . . . . . . . . . . . . . . . 5-114

Index-2 Y53-6077-1B1 (03/17)

 Index

Front axle and suspension Headlight replacement . . . . . . . . . . . . 5-88 air cleaners . . . . . . . . . . . . . . . . . . . . . 5-108
maintenance . . . . . . . . . . . . . . . . . 5-116 Heater and air conditioner . . . . . . . 5-120 air conditioner. . . . . . . . . . . . . . . . . . . 5-121
Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . 5-111 air conditioner. . . . . . . . . . . . . . . . . . . 5-121 air intake system . . . . . . . . . . . . . . . 5-107
Fuel shut-off valves . . . . . . . . . . . . . . . 5-111 heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-121 air system . . . . . . . . . . . . . . . . . . . . . . . . 5-57
Fuel system Heater and air conditioner Allison transmission lubrication 5-50
fuel filters. . . . . . . . . . . . . . . . . . . . . . . . 5-111 maintenance . . . . . . . . . . . . . . . . . 5-120 brake adjustment . . . . . . . . . . . . . . . . 5-66
shut-off valves . . . . . . . . . . . . . . . . . . 5-111 How to order parts . . . . . . . . . . . . . . . . . . .6-8 brake inspection . . . . . . . . . . . . . . . . . 5-67
Fuller transmission lubrication . . . . 5-48 chrome and aluminum surfaces 5-71
Fuses, circuit breakers and relays 5-89 cleaning vinyl and upholstery . . 5-75
I clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-155
In-cab battery box. . . . . . . . . . . . . . . . . . 5-94 cooling system. . . . . . . . . . . . . . . . . . . 5-82
G Inspection of the engine oil level 5-102 Eaton/Dana axle lubrication . . . . 5-53
Gauges electrical system. . . . . . . . . . . . . . . . . 5-87
primary air pressure. . . . . . . . . . . . . 5-63 emergency welding . . . . . . . . . . . . 5-112
secondary air pressure . . . . . . . . . 5-63 K
engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-101
GAWR - Gross Axle Weight Rating 6-5 Kingpin lubrication . . . . . . . . . . . . . . . . 5-116 exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-71
General VIN information. . . . . . . . . . . . .6-3 frame fastener torque
Greenhouse Gas (GHG) Components
Other Than Tires. . . . . . . . . . . . . . 6-11
L requirements . . . . . . . . . . . . . . 5-114
frame fastener torque table. . . . 5-114
Greenhouse Gas Certification . . . . . .6-6 Low voltage disconnect (LVD) . . . . 5-87
front axle and suspension
Greenhouse gas certified tires. . . 5-144 Lubricant specifications . . . . . . . . . . . 5-41
lubrication . . . . . . . . . . . . . . . . . . 5-116
GVWR - Gross Vehicle Weight Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
fuel system. . . . . . . . . . . . . . . . . . . . . . 5-111
Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5 Fuller transmission lubrication . 5-48
M heater . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-121
H Maintenance inspection . . . . . . . . . . . . . . . . . . . . . . . 5-117
7
Headlight aiming . . . . . . . . . . . . . . . . . . . 5-89 5th wheel. . . . . . . . . . . . . . . . . . . . . . . . 5-113 lubricant specifications. . . . . . . . . . 5-41

(03/17) Y53-6077-1B1 Index-3

 Index

maintenance schedule . . . . . . . . . . 5-12 stainless steel. . . . . . . . . . . . . . . . . . . . 5-72 N

Meritor axle lubrication. . . . . . . . . . 5-52 steering and driveline . . . . . . . . . . 5-136
New Vehicle Maintenance
new vehicle maintenance steering gear lubrication . . . . . . . . 5-55
Schedule . . . . . . . . . . . . . . . . . . . . . . 5-12
schedule . . . . . . . . . . . . . . . . . . . . 5-12 tail pipe surface cleaning . . . . . . . 5-72
NHTSA consumer information . . . . . .6-8
noise emission control tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-140
Noise control inspections . . . . . . . . 5-124
standards . . . . . . . . . . . . . . . . . . 5-123 transmission . . . . . . . . . . . . . . . . . . . . 5-152
air intake system . . . . . . . . . . . . . . . 5-125
oil changes. . . . . . . . . . . . . . . . . . . . . . . 5-51 U-bolt torque . . . . . . . . . . . . . . . . . . . . 5-118
diesel particulate filters . . . . . . . . 5-127
painted surfaces. . . . . . . . . . . . . . . . . 5-71 U-bolt torque table . . . . . . . . . . . . . 5-118
engine fan and shroud . . . . . . . . . 5-127
passenger door lower view universal joint lubrication . . . . . . . 5-55
engine mounted noise
window . . . . . . . . . . . . . . . . . . . . . . 5-76 vehicle cleaning . . . . . . . . . . . . . . . . . 5-73
insulators. . . . . . . . . . . . . . . . . . . 5-125
preventive maintenance . . . . . . . . . .5-9 washing chassis . . . . . . . . . . . . . . . . . 5-75
exhaust system . . . . . . . . . . . . . . . . . 5-125
preventive maintenance (pm) washing exterior . . . . . . . . . . . . . . . . . 5-74
hood insulation blanket . . . . . . . . 5-127
intervals . . . . . . . . . . . . . . . . . . . . . 5-13 wheel alignment . . . . . . . . . . . . . . . . 5-117
inner fender shields and cab
rear axle alignment. . . . . . . . . . . . . 5-135 wheel bearing lubrication . . . . . . . 5-54
skirt . . . . . . . . . . . . . . . . . . . . . . . . . 5-128
rear axle and suspension. . . . . . 5-131 windshield wiper/washer. . . . . . . . 5-81
joints and clamps. . . . . . . . . . . . . . . 5-126
rear axle lubrication . . . . . . . . . . . . 5-134 Maintenance Procedures
maintenance log. . . . . . . . . . . . . . . . 5-128
rear suspension fasteners torque inspection of the engine oil
piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-126
table . . . . . . . . . . . . . . . . . . . . . . . . 5-133 level . . . . . . . . . . . . . . . . . . . . . . . . 5-102
Noise emission control
rear suspension U-bolt torque topping up the engine oil . . . . . . 5-103
maintenance . . . . . . . . . . . . . . . . . 5-123
table . . . . . . . . . . . . . . . . . . . . . . . . 5-133 Maintenance schedule . . . . . . . . . . . . . .5-9
Noise emission label. . . . . . . . . . . . . . . . .6-5
safety restraint system - Manufacturer's Warranty
inspection . . . . . . . . . . . . . . . . . . . 5-78 Coverage . . . . . . . . . . . . . . . . . . . . . . 6-12
safety restraint system - inspection Master lubrication index . . . . . . . . . . . 5-44 O
guidelines . . . . . . . . . . . . . . . . . . . 5-79 Matching tires . . . . . . . . . . . . . . . . . . . . . 5-143 Oil changes. . . . . . . . . . . . . . . . . . . . . . . . . 5-51
sliding fifth wheel . . . . . . . . . . . . . . . 5-115 Meritor axle lubrication . . . . . . . . . . . . 5-52
7 Spicer transmission lubrication. 5-50
Original Equipment Tires . . . . . . . . . . 6-10
Overinflated tires . . . . . . . . . . . . . . . . . . 5-143

Index-4 Y53-6077-1B1 (03/17)

 Index

Overloaded tires . . . . . . . . . . . . . . . . . . 5-142 Rear suspension U-bolt torque fluid level and refill . . . . . . . . . . . . . 5-137
Owner's Warranty Coverage . . . . . . 6-12 table. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-133 Steering gear lubrication . . . . . . . . . . 5-55
Refilling your radiator . . . . . . . . . . . . . . 5-85 Steering system maintenance
P Remote Keyless Entry (RKE) . . . . 5-100 steering shaft . . . . . . . . . . . . . . . . . . . 5-138
removing and installing batteries . 5-95 Suspension lubrication . . . . . . . . . . . 5-116
PACCAR Responsibilities . . . . . . . . . 6-14 Replacement Parts . . . . . . . . . . . . . . . . 6-13
Paint identification label . . . . . . . . . . . . .6-5 Replacing tires . . . . . . . . . . . . . . . . . . . . 5-144
Painted surfaces . . . . . . . . . . . . . . . . . . . 5-71 T
Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-113
Tail pipe surface cleaning . . . . . . . . . 5-72
Passenger door lower view S Tire and rim data label
window. . . . . . . . . . . . . . . . . . . . . . . . . 5-76
Pipe and hose clamp torque Safety restraint belts GAWR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
values. . . . . . . . . . . . . . . . . . 5-43, 5-103 inspection . . . . . . . . . . . . . . . . . . . . . . . . 5-78 Tire chains . . . . . . . . . . . . . . . . . . . . . . . . . 5-145
Preventive Maintenance (PM) Safety restraint system Tire, rim and weight rating data
Intervals . . . . . . . . . . . . . . . . . . . . . . . 5-13 inspection . . . . . . . . . . . . . . . . . . . . . . . . 5-78 label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
ServiSignal Mini Indicator . . . . . . . . 5-109 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-140
Sliding 5th wheel greenhouse gas certified tires. 5-144
R maintenance . . . . . . . . . . . . . . . . . . . . 5-115 inflation check . . . . . . . . . . . . . . . . . . 5-140
Rear axle alignment . . . . . . . . . . . . . . 5-135 Sliding Fifth wheel replacement. . . . . . . . . . . . . . . . . . . . . 5-144
Rear axle and suspension maintenance . . . . . . . . . . . . . . . . . . . . 5-115 tire chains . . . . . . . . . . . . . . . . . . . . . . . 5-145
maintenance . . . . . . . . . . . . . . . . . 5-131 Speed restricted tires . . . . . . . . . . . . . 5-145 Tires and wheels
rear suspension fasteners . . . . . 5-132 Spicer transmission lubrication . . . 5-50 wheel cap nut torque
visual inspection. . . . . . . . . . . . . . . . 5-132 Stainless steel. . . . . . . . . . . . . . . . . . . . . . 5-72 sequence . . . . . . . . . . . . . . . . . . 5-147
Rear axle lubrication. . . . . . . . . . . . . . 5-134 Steer axle wheel cap nut torque table . . . . 5-146
Rear suspension fasteners . . . . . . 5-132 identification . . . . . . . . . . . . . . . . . . . . . . .6-7 wheel mounting and fastening 5-146
Rear suspension fasteners torque Steering and driveline Topping up the engine oil . . . . . . . . 5-103 7
table. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-133 maintenance . . . . . . . . . . . . . . . . . 5-136 Transmission

(03/17) Y53-6077-1B1 Index-5

 Index

identification . . . . . . . . . . . . . . . . . . . . . . .6-7 W
lubricants. . . . . . . . . . . . . . . . . . . . . . . . 5-153 Warranty
maintenance . . . . . . . . . . . . . . . . . . . . 5-152 Greenhouse Gas (GHG)
oil change . . . . . . . . . . . . . . . . . . . . . . . 5-152 Components Other Than
Transmission maintenance . . . . . . 5-152 Tires . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Turbocharger . . . . . . . . . . . . . . . . . . . . . . 5-107 Limitations . . . . . . . . . . . . . . . . . . . . . . . 6-14
Manufacturer's warranty
U coverage . . . . . . . . . . . . . . . . . . . . 6-12
Original equipment tires . . . . . . . . 6-10
U-bolt torque . . . . . . . . . . . . . . . . . . . . . . 5-118 Owner's warranty coverage . . . . 6-12
U-Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-139 PACCAR responsibilities . . . . . . . 6-14
Underinflated tires . . . . . . . . . . . . . . . . 5-141 Replacement parts . . . . . . . . . . . . . . 6-13
Universal joint lubrication. . . . . . . . . . 5-55 Rights and obligations . . . . . . . . . . 6-11
Warranty Limitations . . . . . . . . . . . . . . . 6-14
V Warranty Rights and Obligations . 6-11
Washing chassis . . . . . . . . . . . . . . . . . . . 5-75
Vehicle cleaning. . . . . . . . . . . . . . . . . . . . 5-73 Welding (emergency). . . . . . . . . . . . . 5-112
Vehicle identification Wheel alignment . . . . . . . . . . . . . . . . . . 5-117
chassis number. . . . . . . . . . . . . . . . . . . .6-4 Wheel bearing adjustment . . . . . . . 5-151
chassis number locations. . . . . . . . .6-4 Wheel bearing lubrication . . . . . . . . . 5-54
VIN number . . . . . . . . . . . . . . . . . . . . . . . .6-3 Wheel cap nut torque. . . . . . . . . . . . . 5-146
VIN number locations . . . . . . . . . . . . .6-3 Wheel mounting and fastening . . 5-146
Vinyl and upholstery Wheel replacement with disc brake
cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75 option . . . . . . . . . . . . . . . . . . . . . . . . . 5-148
7 Windshield wiper/washer. . . . . . . . . . 5-81
maintenance . . . . . . . . . . . . . . . . . . . . . 5-81

Index-6 Y53-6077-1B1 (03/17)