Table of contents
Why this handbook is so important! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warnings and Safety Regulations . . . . . . . . . . . 11
Safety alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Warnings and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Emergency equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Technical items of special importance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Jump starting vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cab, Instruments and Controls . . . . . . . . . . . . . 31
Entering and leaving the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Electrically operated windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Heated Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Electrical mirror adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Windshield wiper blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Roof console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Sun visors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Stepwell lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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Table of contents
Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Warning indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Control panel of heating/ventilation system. . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Air conditioning switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fan speed selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Temperature adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Air distribution selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Center console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Left-hand steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Right-hand steering column switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Steering wheel switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Adjustable steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Important points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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Table of contents
Master Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Layout of master display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Start-up phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Menu selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Menu overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Warning symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Inspections and Maintenance. . . . . . . . . . . . . . . 91
Overview of daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Opening the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Engine oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Topping up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Special coolant fill instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Windshield washer reservoir fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Air filter indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Wheels and tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Lighting and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Driver's seat and mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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Table of contents
Overview of weekly checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Power steering fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Brake system air drier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Draining the water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Cab maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Preventative maintenance before the winter season. . . . . . . . . . . . . . . . . . . 107
Diesel fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Cab heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Windshield washer reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Maintenance after the winter season. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
PDC & Voltage Converter . . . . . . . . . . . . . . . . . .109
Power distribution center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Steering lock/contact/starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4
Glow system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table of contents
Starting procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Engine speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Vehicle speed limitation for special applications. . . . . . . . . . . . . . . . . . . . . . 122
Driving style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
ABS brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Parking brake and service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Automatic Gearbox . . . . . . . . . . . . . . . . . . . . . . 129
Allison 2100 series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Emergency Repairs . . . . . . . . . . . . . . . . . . . . . . 133
Tilting the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Replacing the poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Replacing the fuel fine filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Draining the water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Releasing the parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Jacking up the front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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Table of contents
Jacking up the rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Changing the wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Tire inflating connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Replacing bulbs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Technical Data and Identification . . . . . . . . . . .157
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
tire pressure table (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Lubricant-, engine coolant- and fuel specifications. . . . . . . . . . . . . . . . . . . . 162
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Steering gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Cab tilting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Chassis number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Paint identification plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Vehicle identification label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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Table of contents
Consumer Information . . . . . . . . . . . . . . . . . . . 171
Federal safety standard certification label . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Alphabetical index . . . . . . . . . . . . . . . . . . . . . . . 177
7
Table of contents
8
WHY THIS HANDBOOK IS SO IMPORTANT!
This handbook contains the information which you, the driver, will need for optimum
efficiency, safety and comfort when operating this vehicle.
Besides giving instructions about operation and use, it also pays attention to
maintenance and minor repairs which you may be able to carry out yourself.
NOTE
This handbook is based on the chassis with its fittings as it originally left
the factory.
Depending upon the required body and equipment, the bodybuilder may have made
fundamental changes to various parts or systems, such as the instrument panel, the
lighting or the electric wiring.
The vehicles covered by this handbook consist of various types and models.
Certain descriptions or illustrations in this handbook may not correspond entirely to
the situation on your own vehicle. However, this has practically no influence on its
operation or maintenance.
Every new vehicle is designed to conform to all Federal Motor Vehicle Safety
Standards applicable at the time of manufacture. Even with these safety features,
continued safe and reliable operation depends greatly upon regular vehicle
maintenance. Follow the maintenance recommendations found in Preventive
Maintenance on page 107. This will help preserve your investment
9
Important
Make sure this handbook is in the vehicle at all times.
Read it carefully before making your first journey, especially the "Warnings and
safety precautions", "Cab, instruments and controls", "Inspections" and
"Driving" sections.
10
Warnings and Safety Regulations
11
Warnings and Safety Regulations
SAFETY ALERTS
Please read and follow all of the safety alerts contained in this manual. They are
there for your protection and information. These alerts can help you avoid injury to
yourself, your passengers, and it can also help prevent costly damage to the
vehicle. Safety alerts are highlighted by safety alert symbols and signal words such
as "WARNING", "CAUTION", or "NOTE". Please do not ignore any of these alerts.
Warnings
The safety message following this symbol and signal word provides a warning
against operating procedures which could cause injury or even death. They could
also cause equipment or property damage. The alert will identify the hazard, how to
avoid it, and the probable consequence of not avoiding the hazard.
Example:
WARNING
Do not carry additional fuel containers in your vehicle. Fuel
containers, either full or empty, may leak, explode, and cause or
feed a fire. Do not carry extra fuel containers. Even empty ones are
dangerous. Failure to comply may result in death or personal injury.
12
Warnings and Safety Regulations
Cautions
The safety alert following this symbol and signal word provides a caution against
operating procedures which could cause equipment or property damage. The alert
will identify the hazard, how to avoid it, and the probable consequence of not
avoiding the hazard.
Example:
CAUTION
Continuing to operate your vehicle with insufficient oil pressure will
cause serious engine damage. Failure to comply may result in
equipment or property damage
Notes
The alert following this symbol and signal word provides important information that
is not safety related but should be followed. The alert will highlight things that may
not be obvious and is useful to your efficient operation of the vehicle.
Example:
NOTE
Pumping the accelerator will not assist in starting the engine.
13
Warnings and Safety Regulations
WARNINGS AND SAFETY REGULATIONS
WARNING
To prevent damage to the vehicle and in order not to jeopardize
your health and/or safety, or that of other people, the following
warning and safety regulations must be strictly observed.
First read the instructions and warnings on the labels and stickers on the various
components and comply with them!
They have been put there for your health and safety, so do not ignore them!
Modifications to the vehicle
Modifying your vehicle can make it unsafe. Some modifications can affect your
vehicle's electrical system, stability, or other important functions. Before modifying
your vehicle, check with your dealer to make sure it can be done safely.
Improper modifications can cause death or personal injury.
14
Warnings and Safety Regulations
Environmental Protection
CALIFORNIA PROPOSITION 65 WARNING
• Diesel engine exhaust and some of its constituents are known to
the State of California to cause cancer, birth defects, and other
reproductive harm.
• Other chemicals in this vehicle are also known to the State of
California to cause cancer, birth defects or other reproductive
harm.
• Battery posts, terminals, and related accessories contain lead
and lead compounds, chemicals known to the State of California
to cause cancer and reproductive harm. Wash hands after
handling.
Components
Do not work on or near the fan with the engine running. Anyone near the engine fan
when it turns on could be seriously injured. If it is set at MANUAL, the fan will turn on
any time the ignition key switch is turned to the ON position. In AUTO, it could
engage suddenly without warning. Before turning on the ignition or switching from
AUTO to MANUAL, be sure no one is near the fan.
15
Warnings and Safety Regulations
Cooling system filler cap
WARNING
Do not remove the radiator fill cap while the engine is hot. Scalding
steam and fluid under pressure may escape. You could be badly
burned. Failure to comply may result in death or personal injury.
EMERGENCY EQUIPMENT
It is good practice to carry an emergency equipment kit in your vehicle. One day, if
you have a roadside emergency, you will be glad the following items are with you:
- Window scraper
- Snow brush
- Container or bag of sand or salt
- Emergency light
- Warning triangles
- Small shovel
- First aid kit
- Fire extinguisher
- Vehicle recovery hitches
(see Towing on page 147 for details).
16
Warnings and Safety Regulations
Fire extinguisher
Ensure that you are always in possession of a fire extinguisher It should be well
secured under the seat, within the driver's reach and easily accessible, also for
rescue workers and others providing assistance. Have the fire extinguisher checked
for operational readiness each year. If it has been used, have it refilled at the
earliest opportunity.
In the event of fire:
In the event of a fire, certain plastic seals can produce gases which together with
water form a corrosive acid. Do not touch any fire extinguisher fluid on the vehicle
without protective gloves.
Cab
WARNING
Do not carry loose objects in your cab, it can be dangerous. In a
sudden stop, or even going over a bump in the road, they could fly
through the air and strike you or a passenger. You could be injured
or even killed. Secure all loose objects in the cab before moving the
vehicle. Carry any heavy objects such as luggage in the exterior
storage compartment and close it securely.
First aid kit
Ensure that you are always in possession of a first aid kit and replace first aid items
as soon as possible after use to have the kit always ready.
17
Warnings and Safety Regulations
Tire chains
If you need tire chains, install them on both sides of each driving axle.
CAUTION
Chains on the tires of only one tandem axle can damage the
driveline U-joints and the interaxle differential. Your repairs could
be costly and time-consuming.
Approaching Your Vehicle
- Check the overall appearance and condition. Are windows, mirrors, and lights
clean and unobstructed?
- Check beneath the vehicle. Are there signs of fuel, oil, or water leaks?
- Check for damaged, loose, or missing parts. Are there parts showing signs of
excessive wear or lack of lubrication? Have a qualified mechanic examine any
questionable items and repair them without delay.
- Check your load. Is it secured properly?
Oils and lubricants
Various kinds of oil and other lubricants used on the vehicle may constitute a health
hazard if they come into contact with the skin. This also applies to engine coolant,
windshield washer fluid, refrigerant in air conditioning systems, battery acid and
diesel fuel. So avoid direct contact as much as possible.
18
The engine and the surrounding area must be free of inflammable materials to avoid
the risk of fire.
Exercise caution when changing hot oil; it can cause serious bodily injury.
Warnings and Safety Regulations
WARNING
Air conditioning refrigerant can be hazardous to your health. Do not
expose yourself to leaking refrigerant for prolonged periods near
excessive heat, open flames, or without proper ventilation. Failure
to do so may result in death or personal injury.
Maintenance activities
When carrying out maintenance work under the cab, make sure the cab is fully tilted
and locked to prevent it from falling back accidentally.
Following a collision, only tilt the cab in an emergency situation. The tilting
mechanism may be damaged. (The end stop may no longer be on the lifting
cylinder.)
WARNING
Always support the vehicle with appropriate safety stands if it is
necessary to work underneath the vehicle. A jack is not adequate
for this purpose.
Maintenance of air conditioning system
WARNING
Excessive heat may cause the pressurized components of the air
conditioning system to explode. Never weld, solder, steam clean, or
use a blow torch near any part of the air conditioning system.
Failure to comply may result in personal injury, death, equipment or
property damage.
19
Warnings and Safety Regulations
WARNING
Air conditioning refrigerant can be hazardous to your health. Do not
expose yourself to leaking refrigerant for prolonged periods near
excessive heat, open flames, or without proper ventilation. Failure
to do so may result in death or personal injury or death.
WARNING
The air conditioning system is under pressure. If not handled
properly during servicing, it could explode. Any servicing that
requires depressurizing and recharging the air conditioning system
must be conducted by a qualified technician with the right facilities
to do the job. Failure to comply may result in personal injury, death,
equipment or property damage.
Environment
Pollution constitutes a serious threat to the environment. To keep pollution to a
minimum, the following rules should be observed:
- Do not dump used oil, fuel, lubricants, hydraulic fluid or coolants in drains,
sewers, in landfills or on the ground. This is illegal. These fluids should be
returned to the designated authority or appropriate chemical waste collection
company for recycling or destruction. All used fluids should be stored separately.
- Make sure that the vehicle is serviced regularly according to the instructions and
recommendations. A properly serviced vehicle helps optimize fuel economy and
reduce the level of harmful constituents in the exhaust gases.
20
Warnings and Safety Regulations
TECHNICAL ITEMS OF SPECIAL IMPORTANCE
To prevent damage to the vehicle, the following instructions must be strictly
observed.
Running-in
During the running-in period it is best not to subject the new vehicle to excessive
loads. This also applies when an overhauled engine, transmission or differential has
been installed. Therefore, for the first 1,500 km (932 miles): drive carefully and
avoid accelerating sharply.
The following technical items of special importance apply to both the runningin period and to the period thereafter.
After a cold start continue to drive in a low gear and at a moderate engine speed
until the engine coolant temperature is out of the blue zone.
While driving, check the instrument panel regularly and take appropriate action if
you notice anything unusual, such as strange engine or transmission noises,
smoke, or poor performance. Do not let the engine idle for longer than necessary.
This is harmful to the engine and also causes unnecessary pollution of the
environment.
Be aware that engine stalling while driving will lead to power steering failure.
Consequently, the vehicle will be more difficult to steer.
The engine cooling system is thermostatically controlled.
Removing the thermostat when the coolant temperature is (too) high serves no
useful purpose and is strongly advised against, since this will only cause the engine
temperature to rise to an even higher level.
The turbocharger is a precision component. You should therefore immediately
report any abnormal noise that seems to be coming from this component.
21
Warnings and Safety Regulations
Air leakage
If the pressure in the air reservoirs drops rapidly with the engine switched off, this
indicates a leak. Since this affects the safety of the brake system, the leak must be
traced and repaired as quickly as possible.
System voltage
The cab system of this vehicle are on 24-Volt while other areas remain 12-Volt.
When replacing or fitting electrical or electronic components, always verify that they
are suitable for this system voltage.
Batteries
WARNING
Never disconnect the battery leads while the engine is running!
Always disconnect the battery negative (ground) lead before carrying out repairs or
service on the electrical system.
WARNING
Before attempting any work on the batteries or electrical system,
remove all jewelry. If metal jewelry or other metal comes in contact
with electrical circuits, a short circuit may occur causing you to be
injured, as well as causing electrical system failure and damage.
22
Warnings and Safety Regulations
Charging
WARNING
Thaw out frozen batteries before charging them. Remove all the
filler caps before charging.
WARNING
Charger cables must be connected positive to positive (+ to +) and
negative to negative (- to -). If connected improperly, batteries could
explode. Failure to comply may result in personal injury, death,
equipment or property damage.
WARNING
Always make sure the battery charger is OFF before connecting or
disconnecting the cable clamps. To reduce the danger of
explosions and resulting death or personal injury, do not connect
or disconnect charger cables while the charger is operating.
Charging Reminders
- Use protective eyewear.
- Keep all batteries away from children.
- Never reverse battery poles.
- Never attempt to place the vehicle in motion, or run the engine with batteries
disconnected.
- Keep the battery clean and dry.
- Look for any signs of damage.
23
Warnings and Safety Regulations
- Battery terminals should not be coated with improper grease. Use petroleum
jelly or commercially available, noncorrosive, nonconductive terminal coatings.
- Never use a fast charger as a booster to start the engine. This can seriously
damage sensitive electronic components such as relays, radio, etc., as well as
the battery charger. Fast charging a battery is dangerous and should only be
attempted by a competent mechanic with the proper equipment.
Battery capacity
Using electrical components, such as the cab heater or refrigerator when the engine
is not running, power will be drawn from the batteries.
Approximately half the battery capacity is required to start the engine.
If this is the case over a protracted period, particularly during low temperatures, the
result may be that the electrical components have used so much power that there is
not enough to start the engine.
If the high current draw electrical components, such as the cab heater, refrigerator,
coffee percolator, microwave oven or tail-lift are used, it is recommended that you
obtain batteries of an adequate higher capacity in consultation with your dealer.
Welding
24
For welding on the vehicle and/or superstructure, see the "Bodybuilders Manual".
Not following the welding instructions can cause damage to the electronic
components.
Warnings and Safety Regulations
JUMP STARTING VEHICLES
Introduction
Jump starting a vehicle is not a recommended practice due to the various battery
installations and electrical options. However, if your battery is discharged (dead),
you may be able to start it by using energy from a good battery in another vehicle.
This is termed jump starting. Be sure to follow the precautions and instructions
below.
WARNING
Batteries contain acid that can burn and gasses that can explode.
Ignoring safety procedures may result in death, personal injury,
equipment or property damage.
WARNING
Never jump start a battery near fire, flames, or electrical sparks.
Batteries generate explosive gases that could explode. Keep
sparks, flame, and lighted cigarettes away from batteries. Failure to
comply may result in death, personal injury, equipment or property
damage.
WARNING
Never remove or tamper with battery caps. Ignoring this could allow
battery acid to come in contact with the eyes, skin, fabrics, or
painted surfaces. Failure to comply may result in death, personal
injury, equipment or property damage. Be careful that metal tools
(or any metal in contact with the positive terminal) do not contact
the positive battery terminal and any other metal on the vehicle at
the same time. Remove metal jewelry and avoid leaning over the
battery.
25
Warnings and Safety Regulations
To Jump Start Your Vehicle
WARNING
When jump starting using a booster battery, it is best to jump start
with an equivalently powered vehicle. Verify that the booster battery
has the same volt and CCA specifications as the dead battery
before attempting to jump start. Failure to comply may cause an
explosion resulting in death, personal injury, equipment or property
damage.
CAUTION
Applying a higher voltage booster battery will cause expensive
damage to sensitive electronic components such as relays, and the
radio. Failure to comply may result in equipment damage. Improper
hook-up of jumper cables or not following these procedures can
damage the alternator or cause serious damage to both vehicles.
WARNING
Heed all warnings and instructions of the jumper cable
manufacturer. Failure to comply may result in personal injury, death
and equipment or property damage.
26
Warnings and Safety Regulations
Preparing the vehicles:
1 Remove any jewelry that may come in contact with the battery terminals.
2 Select a jumper cable that is long enough to attach to both vehicles in a way that
ensures neither vehicle touches each other.
3 Position the two vehicles together, but do not allow them to touch.
4 Turn OFF all lights, heater, radio, and any other accessory on both vehicles.
5 Set the parking brakes: pull out the Yellow button located on the dash.
6 Shift the transmission into park position or neutral for manual transmissions.
(See “Shifting Gears” on page 130 and “PARKING BRAKE AND SERVICE
BRAKE” on page 125, for transmission shifting and parking brake information.)
7 If either vehicle is equipped with battery disconnects ensure they are in the
"OFF" position prior to connecting the two vehicles.
27
Warnings and Safety Regulations
Connect the batteries:
1 Attach one end of a jumper cable to the positive (+) terminal of the discharged
(dead) battery. This will have a large red + or P on the battery case, post, or
clamp.
2 Attach the other end of the same cable to the positive (+) terminal of the good
(booster) battery.
3 Attach the remaining jumper cable FIRST to the negative (-) terminal (black or
N) of the good battery.
4 Attach the other end of the negative cable to a bare metal part not bolted to the
engine block.
IMPORTANT: Always connect positive (+) to positive (+) and negative (-) to
negative (-).
5 If either vehicle is equipped with battery disconnects, ensure that they are in the
"ON" position.
6 Start the vehicle that has the good battery first. Let it run for 5 minutes.
7 Start the vehicle that has the discharged (dead) battery. If the engine fails to
start, do not continue to crank the starter and contact the nearest authorized
dealer
28
Warnings and Safety Regulations
Remove jumper cables:
WARNING
When disconnecting jumper cables, make sure they do not get
caught in any moving parts in the engine compartment. Failure to
comply may result in death, personal injury, equipment or property
damage.
Reverse the above procedure exactly when removing the jumper
cables. With the engine running, disconnect jumper cables from
both vehicles in the exact reverse order (Steps 4-1), making sure to
first remove the negative cable from the vehicle with the discharged
battery.
NOTE
Review the warranty policy before performing any maintenance
procedures. An extended warranty may be voided if unauthorized
maintenance is performed during this period.
CAUTION
Do not modify or improperly repair the vehicles electrical system or
power distribution center. All electrical repairs should be performed
by an authorized dealer. Improper repair or modifications will void
your warranty and/or cause serious damage to your vehicle.
29
D0 02 014
Wait 2 minutes after
key-off before
disconnecting battery power.
Disconnecting battery power
sooner can result in damage
to vehicle DEF system.
P53-6080-000
30
Warnings and Safety Regulations
Disconnect Switch
This vehicle has a disconnect switch. Ensure that your vehicle ignition has been
turned off for at least 40 seconds before switching the disconnect switch to the OFF
position
NOTE
Wait 2 minutes after key-off before disconnecting battery power.
Disconnecting battery power sooner can result in damage to vehicle
DEF.
Cab, Instruments and Controls
31
Cab, Instruments and Controls
D0 00 632
ENTERING AND LEAVING THE VEHICLE
WARNING
Always reinstall steps before entering the cab or accessing the
deck plate. Without steps you could slip and fall. Be careful
whenever you get into or out of your vehicle's cab. Always maintain
at least three points of contact with your hands on the grab handles
and your feet on the steps. Failure to comply may result in personal
injury or death.
WARNING
Jumping out of the cab or getting into the cab without proper
caution is dangerous. You could slip and fall, which could lead to
personal injury or death. Keep steps clean. Clean any fuel, oil, or
grease off of the steps before entering the cab. Use the steps and
grab handles provided, and always keep at least three points of
contact between your hands and feet and the truck. Look where you
are going.
The picture shows the best way to enter and exit a Cab-Over Engine Cab.
32
Cab, Instruments and Controls
D0 00 604
D0 00 611
DOORS
WARNING
To help lessen the chance and/or severity of death or personal
injury in case of an accident, always lock the doors while driving.
Along with using the lap shoulder belts properly, locking the doors
helps prevent doors from inadvertently opening and occupants
from being ejected from the vehicle.
Opening the door
Pull the handle to open the door from the inside.
Locking the door from the inside
Press the door handle downwards.
Standard version
Both doors can be locked and unlocked from the outside using the key.
33
D0 00 585-1
Cab, Instruments and Controls
Central door locking
Unlocking
To open the doors of a vehicle with central door locking, use the same procedure
described before.
The door on the co-driver's side can be locked/unlocked using the switch on the
center console.
Locking
- Both doors are locked when one of the doors is closed with the key.
- Avoid locking yourself out!
ELECTRICALLY OPERATED WINDOWS
The switches only work when the ignition is switched on.
The driver's and co-driver's windows can be opened and closed with the switches in
the driver's door. The switch in the co-driver's door can only open and close the codriver's window.
HEATED MIRRORS
With the switch for mirror/windscreen heating , the exterior mirrors (excluding curb
mirror) and the windscreen heating, if fitted, can be heated. When you press the
switch again, the mirror heating is switched off the windshield heating remains
active for about 12 minutes. If you press the switch again within 12 minutes, the
windscreen heating is switched off and the mirror heating is switched on again.
Operate the switch once more to switch everything off.
34
Cab, Instruments and Controls
0
D0 00 612
MIRRORS
The mirror housing and mounting bracket is fixed to the cab. Only the face of the
mirror is adjustable within the mirror housing.
The mirror bracket can be folded back against the cab and will return to its original
position once the bracket is swung out again.
All models have Flat glass mirror.
ELECTRICAL MIRROR ADJUSTMENT
The electric mirrors can be adjusted by means of the switch in the driver's door.
Select the right or left mirror by turning the button either to the right or left position.
Move the switch forwards, backwards, left or right, to adjust the mirror.
WINDSHIELD WIPER BLADES
To prevent damage to the wiper blades during operation in winter conditions,
always check that the blades are not frozen to the windshield. This can be
prevented by placing something between wiper blades and windshield. Switch off
the windshield wipers before turning off the ignition.
WARNING
Clean blades regularly with a damp cloth to remove road film and
wax build-up. Do not drive with worn or dirty wiper blades. They can
reduce visibility, making driving hazardous which may lead to an
injury accident resulting in personal injury or death.
35
Cab, Instruments and Controls
D0 02 001
ROOF CONSOLE
WARNING
Overhead compartments are not intended for personnel use or for
items exceeding their designed weight limits. Exceeding the weight
limits may cause the shelf to collapse and or items may fall out in a
sudden stop which may lead to personal injury or death.
SUN VISORS
As a protection against sun glare, the sun visors can be folded down. The sun visor
on the driver's side can also serve as a side window shade.
STEPWELL LIGHTING
In both doors, a lamp is fitted at the bottom to light the stepwell. This will light up as
soon as the door is opened.
36
Cab, Instruments and Controls
D0 01 197
INTERIOR LIGHTING
The interior lighting operates independently of the position of the contact key. The
interior light comes on when the door is opened. When the doors are open for more
than 15 minutes, the interior lamps will be extinguished. The lamp stays lit by
operating the switch on the lamp.
37
Cab, Instruments and Controls
D001183
! !
1 2 7 98
10 11 12 13 14 15 16
1718
19
2021
22
23
3 4 5 6
DASHBOARD
38
Cab, Instruments and Controls
1 Instrument panel
2 Dimmer, dashboard lighting
3 (unused)
4 (unused)
5 Front fog lamps
6 Menu selection switch
7 Ashtray with 12V auxiliary socket
8 Hazard warning lights
9 (unused)
10 (unused)
11 (unused)
12 (unused)
13 (unused)
14 (unused)
15 PTO operation
16 (unused)
17 Air conditioning
18 12V connection
19 Heater, fan speed selector switch in fresh air position or re-circulation
position
20 Heater, temperature control
21 Heater, air distribution selector switch
22 (unused)
23 Lighting switch
39
Cab, Instruments and Controls
10
mph
20
30
40
50
60
70
80
90
STOP
145
60
0
30
35
60
80
100
120
40
20
25
20
10
6
15
ABS
C
+
F
AM
PM
DIESEL
EXHAUST
FLUID
I H J KGF
23
B
D EA C
D001198-1
L
INSTRUMENT PANEL
40
Cab, Instruments and Controls
A Speedometer
B Fuel gauge
C Master display
D Coolant temperature gauge
E Tachometer
F Reset button, trip odometer
G Odometer and trip meter
H Warning indicators
I Diesel exhaust fluid
JCircuit 1
K Outside temperature and clock
41
Cab, Instruments and Controls
A. SPEEDOMETER
This vehicle’s speedometer is equipped with double scale divisions. Either major
divisions in mph and minor divisions in kph or major divisions in kph and minor
divisions in mph.
B. FUEL GAUGE
The fuel gauge only operates when the contact is on.
Factor in the delay on the gauge when the contact is turned on.
C. MASTER DISPLAY
See "MASTER DISPLAY".
D. COOLANT TEMPERATURE GAUGE
The engine should not be operated under full load if the temperature is in the blue
field.
The engine is at operating temperature when the temperature gauge is vertical, or
slightly further.
If the coolant temperature suddenly rises and/or the pointer is in the red field, the
following points should be checked:
- coolant level (caution – danger of scalding; see "Topping up coolant" in
"INSPECTIONS AND MAINTENANCE");
- poly V-belt and water hoses;
- fan clutch.
42
Cab, Instruments and Controls
E. REV COUNTER
Green area: economical
White: less economical
Blue area: only permitted when driving downhill and for optimal use of the engine
brake
Red area: not permitted
F. TRIP METER RESET BUTTON
The trip meter is set to zero with the reset button.
G. ODOMETER AND TRIP METER
The total distance is displayed in "km" or "mls" in the top section of the display.
H. WARNING INDICATORS
See section concerned.
I. DIESEL EXHAUST FLUID GAUGE
The Diesel Emission Fluid gauge indicates the total (approximate) amount of DEF in
the tank. In addition to indicating empty and full, the gauge also indicates the DEF
level in graduated increments. When the DEF level in the tank reaches 10% full, a
red warning light in the gauge illuminates. When the DEF level in the tank reaches
5%, Refer to your PACCAR Engine After-Treatment Control Operator's Manual for
more information.
43
Cab, Instruments and Controls
J. AIR PRESSURE GAUGE, CIRCUITS 1
The air pressure gauge indicates the air pressure in the reservoirs of one of the
service brake circuits. If the pressure in one of the circuits drops below 65 psi
(448.15 kPa), an audible alarm is generated and the warning symbol "Air system
pressure too low" will illuminate in the master display. When the pressure is higher
than 66.5 psi (458.5 kPa), the brakes can be released with the parking brake lever.
The audible alarm and warning symbol are only generated when the ignition key is
on. The gauge also operates when the ignition key is off.
The vehicle must not be driven when the audible alarm sounds or when the
pressure in one of the circuits is lower than approx. 65 psi (448.15 kPa).
NOTE
The air pressure warning will be activated when primary or secondary air
systems drops below 65 psi.
K. OUTSIDE TEMPERATURE AND CLOCK
The display is activated when the contact is on.
The clock is shown in the top section of the display.
The outside temperature is displayed in the bottom section in degrees C or
degrees F.
44
Cab, Instruments and Controls
D0 00 786-1
A
B
E
H
J
3 2
1 6
5
1
1 2 3
4
4
21
5 1
3
ABS
STOP
WARNING INDICATORS
45
Cab, Instruments and Controls
A1 Tachograph
A2 Front fog lights
A3 Parking brake
A4 Water in fuel
A5 Work lamp/loadspace lighting
A6 ABS symbol
B1 Fuel level low
E1 Engine warning
E2 Pre-Heating
E3 PTO engaged
E4 DEF level
H1 Left direction indicator, truck or tractor
H2 Main beam
H3 Central "STOP" warning indicator
H4 Right direction indicator, truck or tractor
J Brake air
46
Cab, Instruments and Controls
A1. Tachograph fault
See messages in Tachograph operation manual.
A2. Front fog lights
This warning indicator lights up if the front fog lights are switched on.
A3. (unused)
A4. Parking brake
This warning indicator lights up if the parking brake is applied, or when the pressure
in the air system is too low to enable the parking brake to be released.
A5. Water In Fuel
A6. Work lamp/loadspace lighting
The warning indicator lights up when the work lamp/loadspace lighting is switched
on.
47
ABS
Cab, Instruments and Controls
A7. ABS
The yellow warning symbol "ABS truck fault" is activated if a fault in the ABS system
of the truck or tractor.
B1. Fuel level low
This warning indicator lights up when the reserve fuel level is reached. The fuel
reserve then is about 10% of the tank capacity. Refuel as soon as possible.
E1. (unused)
E2. Engine warning
This warning will be activated when the system requires attention, general danger
spot or failure of emission system.
E3. Pre-Heating
If the ignition key is on, the engine ECU automatically determines the necessary
preglowing and afterglowing times.
The necessary preglowing and afterglowing times depend on the temperature that
is measured by the engine management system.
If the preglowing or afterglowing function is activated by the engine ECU, this
warning indicator lights up.
48
Cab, Instruments and Controls
E4. (unused)
E5. PTO engaged
This warning indicator lights up when the PTO is switched on.
E6. DEF level
This warning will be activated if DEF level is lower than 10%.
H1. Left direction indicator, truck or tractor
This warning indicator flashes together with the direction indicators on the truck or
tractor.
H2. (unused)
H3. Main beam
This warning indicator lights up if the main beam is switched on or the headlight
flash is operated.
49
STOP
Cab, Instruments and Controls
H4. Central "STOP" warning indicator
The central "STOP" warning lights up when there is a serious fault in one of the
vehicle functions. The master display shows which vehicle function has triggered
the warning.
WARNING
This should be considered an emergency. You should stop the
vehicle as safely as possible and turn OFF the ignition. The vehicle
must be serviced and the problem corrected before driving again.
Failure to do so may cause severe engine damage or cause an
accident involving personal injury or death.
H5. (unused)
H6. (unused)
H7. Right direction indicator, truck or tractor
This warning indicator flashes together with the direction indicators on the truck or
tractor.
50
J. Brake air
This warning is printed on the gauge. It will not be activated, since it lights up with
the gauge light.
Cab, Instruments and Controls
CONTROL PANEL
! !
! !
2 3 4 5 6
23
21 20
19 18 17
D0 00 705-1
51
Cab, Instruments and Controls
2 Dimmer, dashboard lighting
3 (unused)
4 (unused)
5 Front fog lights
6 Master display menu selection switch
17 Air conditioning
18 12-V connection
19 Heater, fan speed selector switch in fresh air position or re-circulation
position
20 Heater, temperature control
21 Heater, air distribution selector switch
23 Lighting switch
52
Cab, Instruments and Controls
2. DIMMER, DASHBOARD LIGHTING
When the lighting is switched on, the dashboard lighting will also illuminate. The
setting wheel enables dimming of the lighting.
3. SWITCH FOR CROSS-AXLE DIFFERENTIAL LOCK
The cross-axle differential lock can be activated with this switch.
NOTE
This switch has a lock.
The differential lock should be engaged:
- with the vehicle stationary or moving very slowly;
- with the clutch pedal depressed.
NOTE
For vehicles with automatic gearbox, the vehicle must be stationary and
the gearbox in Neutral (N).
See also "DRIVING"
53
Cab, Instruments and Controls
5. FOG LAMPS, FRONT
There is a two position switch to operate the rear fog lamps.
6. MASTER DISPLAY MENU SELECTION SWITCH
See "MASTER DISPLAY".
17. AIR CONDITIONING
See "CONTROL PANEL OF HEATING/VENTILATION SYSTEM"
18. 12V CONNECTION
There are two auxiliary connections for a 12-V accessory. Accessories connecting
to these auxiliary connections should not exceed a combined load of 180 Watts.
19, 20, 21. HEATER CONTROLS
See "CONTROL PANEL OF HEATING/VENTILATION SYSTEM
54
Cab, Instruments and Controls
23. LIGHTING SWITCH
The vehicle lighting switch is a rotary switch with three positions:
position "0": lighting switched off
position "1": parking and marker lights on
position "2": headlamps, parking and marker lights on
55
Cab, Instruments and Controls
CONTROL PANEL OF HEATING/VENTILATION SYSTEM
21 20 19 17
17 Air conditioning
19 Fan speed selector switch in fresh air or re-circulation position
20 Temperature adjustment
21 Air distribution
17. AIR CONDITIONING
See "AIR CONDITIONING SWITCH"
19. FAN SPEED
See "FAN SPEED SELECTOR SWITCH"
D0 00 672
56
20. TEMPERATURE CONTROL
See "TEMPERATURE CONTROL"
21. AIR DISTRIBUTION
SEE "AIR DISTRIBUTION SELECTOR SWITCH"
Cab, Instruments and Controls
D0 00 566D0 00 566
AIR CONDITIONING SWITCH
The cab air can be heated, cooled or dehumidified using the air conditioning unit.
The air conditioning unit only functions if:
- the engine is running
- the fan is running.
Use of the air conditioning
1. When the air conditioning is in use, the windows must remain closed.
2. To reduce the temperature quickly, first use maximum air speed. Later, the air
speed can be reduced.
3. Avoid direct cold draught on your body.
4. Make sure that the temperature difference between the inside and outside of the
cab does not exceed 40°F (5°C) when you leave the cab. You are therefore
advised to switch off the air conditioning towards the end of your journey.
5. Air conditioning consumes extra power and increases the fuel consumption.
6. On extreme angles (slopes, ruts and difficult terrain) switch off the air
conditioning, to protect the compressor pump against unlubricated operation.
7. Regularly (once a month) switch on the air conditioning briefly, even if cooling is
not required (e.g. in winter). This will help prevent serious damage to the system
(including compressor blockage).
57
Cab, Instruments and Controls
Cooling
1. Switch the air conditioning on.
2. Switch the recirculation to position 1, 2 or 3.
3. Turn the temperature control switch to the desired position. For maximum
cooling set the knob to the far left position in the blue area.
4. Open the side and center vents.
While heating, it is possible to use the air conditioning to remove moisture from the
air in the cab. This has the advantage that demisting of the window glass will be
quicker.
Dehumidification
1. Switch the air conditioning on.
2. Turn the Fan Speed Switch to the Fresh Air setting.
3. Open the vents on the center console and side windows and set them as
desired.
4. Control the temperature as desired.
5. Adjust the volume of air using the fan speed selector switch.
NOTE
The air conditioning system is switched off when the engine coolant
temperature becomes too high. This will protect the engine.
58
Cab, Instruments and Controls
WARNING
Excessive heat may cause the pressurized components of the air
conditioning system to explode. Never weld, solder, steam clean, or
use a blow torch near any part of the air conditioning system.
Failure to comply may result in personal injury, death, equipment or
property damage.
WARNING
Air conditioning refrigerant can be hazardous to your health. Do not
expose yourself to leaking refrigerant for prolonged periods near
excessive heat, open flames, or without proper ventilation. Failure
to do so may result in death or personal injury.
NOTE
If the air conditioning system fails to work properly, it must be repaired by
qualified personnel as soon as possible, to avoid further damage to the
system.
59
Cab, Instruments and Controls
D0 00 644
D0 00 614
FAN SPEED SELECTOR SWITCH
FRESH AIR POSITION OR RE-CIRCULATION POSITION
The fan has two speeds: one applies to re-circulation the other to fresh air. The recirculation position is suited to quickly de-mist or cool the cab with the air
conditioning, quickly heat the cab, de-frost the windows with the heater and keep
out undesirable odors.
NOTE
You are advised to switch on the re-circulation without air conditioning for
short periods only to prevent the air quality inside the cab from degrading
and moisture from increasing.
Fan speeds with fresh outside air ventilation valve open
Fan speeds with re-circulation valve closed, hardly any supply of
fresh outside air
TEMPERATURE ADJUSTMENT
The supply of heat can be smoothly set from 0% (blue) to 100% (red).
60
To achieve faster heating when the temperature outside is low, switch on the recirculation. In damp weather conditions it is recommended to reopen the recirculation flap after heating to prevent the windows from misting.
Cab, Instruments and Controls
D0 00 643
AIR DISTRIBUTION SELECTOR SWITCH
Dashboard
Dashboard vents and footwell
Footwell vent
Footwell and windshield vents
Defrost
61
Cab, Instruments and Controls
CENTER CONSOLE
62
7 8 9
10 11 12 13 14 15 16
D000706-3
Cab, Instruments and Controls
7 Ashtray with 12V auxiliary connection
8 Hazard warning lights
9 (unused)
10 (unused)
11 (unused)
12 (unused)
13 (unused)
14 (unused)
15 PTO operation
16 (unused)
63
Cab, Instruments and Controls
7. ASHTRAY
In the center console there is an ashtray with auxiliary connection for the driver and
co-driver.
Do not connect any accessories above 180 Watt or any combination of accessories
that would require a combined amount greater than 180 Watts.
To remove the ashtray, there are two springs on the top of the tray which should be
pressed in, after which the tray can be removed.
8. HAZARD WARNING LIGHTS
When this switch is pressed, all the direction indicator lights flash simultaneously.
The hazard warning lights are switched off by depressing the switch again. The
warning light in the switch indicates that the hazard warning is switched on.
9. (unused)
11. (unused)
13. (unused)
64
15. PTO OPERATION
With this switch, the Power Take Off can be engaged, if necessary in combination
with the variable speed engine control. Engage the PTO only when the programmed
engaging conditions are met.
Cab, Instruments and Controls
B D
C
A
D0 00 600
LEFT-HAND STEERING COLUMN SWITCH
AHorn
B Main beam
C Direction indicator, right
D Direction indicator, left
A. HORN
The horn is operated with button A.
B. MAIN BEAM
Position B: The main beam is activated when the lights are on. The main beam
indicator on the instrument panel will also light up. To switch off the main beam, the
switch must be turned back through the "click" position towards the steering wheel.
If the lights are off, or if the switch has not been pushed through the "click" position,
it can be used to give signals.
C. DIRECTION INDICATOR, RIGHT
Position C: Right turn signal: on the instrument panel, the right direction indicator
will flash and there will also be an audible signal. To briefly operate the direction
indicators (changing lanes, etc.), the switch can be pushed slightly against the
spring pressure. It will spring back when released.
D. DIRECTION INDICATOR, LEFT
Position D: Left turn signal: on the instrument panel, the left direction indicator will
flash and there will also be an audible signal. To briefly operate the direction
indicators (changing lanes, etc.), the switch can be pushed slightly against the
spring pressure. It will spring back when released.
65
Cab, Instruments and Controls
D001199
4
1
2
3
RIGHT-HAND STEERING COLUMN SWITCH
The right-hand steering column switch has the following functions:
1 Position 1: Intermittent wipe.
2 Position 2: Wipe speed (low).
3 Position 3: Wipe speed (high).
4 Position A: Wipe/wash.
66
Cab, Instruments and Controls
A
B
C
D
E
F
D0 01 190-3
STEERING WHEEL SWITCHES
Depending on the vehicle version, the steering wheel either has or does not have
steering wheel switches.
Left-hand switches
A (unused)
B (unused)
C Engine brake
Right-hand switches
D Variable speed limiter
E Cruise control, resume, off
F Cruise control setting/engine speed control
67
Cab, Instruments and Controls
D0 00 616
ADJUSTABLE STEERING COLUMN
The position of the steering column is adjustable. To adjust, pull the handle towards
you and simultaneously move the steering column to the desired position. The
steering column is locked by releasing the handle. A pneumatically adjustable
steering column is available as an option.
WARNING
Make all adjustments to the steering mechanism while the vehicle is
stopped. Adjusting the Tilt-Telescoping Steering Wheel while the
vehicle is in motion could cause loss of control. You wouldn't be
able to steer properly and could have an accident resulting in
personal injury or death.
68
Seats
69
Seats
IMPORTANT POINTS
WARNING
Make all adjustments to the steering mechanism while the vehicle is
stopped. Adjusting the Tilt-Telescoping Steering Wheel while the
vehicle is in motion could cause loss of control. You wouldn't be
able to steer properly and could have an accident resulting in death
or personal injury.
- -You must read this section thoroughly and acquaint yourself with the seat
controls.
- The vehicle air pressure must be a minimum of 100 PSI 7 bar.
- Never operate several controls at once.
- The armrest should be folded away before entering/leaving the vehicle.
- The co-driver's seat is not suitable for a child's seat.
- The seat and its component parts must be checked for wear from time to time.
- The seat may only be repaired by trained personnel.
70
Seats
D0 00 694-1
6
5
4
3
2
1
Driver's seat
Operation:
1 Seat fore/aft adjustment
2 Shock absorber setting: The suspension characteristics of the seat (in
terms of comfort) can be optimized by means of the infinitely adjustable
shock absorber (from "hard" to "soft") for each driving situation.
- Position switch up: minimum damping ("soft" comfort)
- Position switch down: maximum damping ("hard" comfort)
NOTE
The shock absorber must always be set tight enough to
withstand conditions on a poor road surface.
3 Seat squab angle adjustment
4 Seat height adjustment
5 Entry/exit aid
- Knob down (seat in driving position): seat drops to its lowest position
(= entry/exit aid)
- Knob up (with lowered seat): seat returns to the last set height
6 Backrest angle adjustment.
71
Seats
D000534
SEAT BELTS
Safety Restraint System - Inspection
The seat belt system, including webbing, buckles, latches, and mounting hardware,
endures heavy use in heavy-duty vehicles, much more than seat belt systems in
passenger cars. All users should be aware of the factors contributing to this heavy
use and reduced belt life.
WARNING
Failure to properly inspect and maintain restraint systems can lead
to injury or loss of life. Without periodic inspection and
maintenance to detect unsafe conditions, seat restraint
components can wear out or not protect you in an accident.
Factors contributing to reduced seat belt life:
- High mileage heavy trucks, often accumulate mileage in excess of 500,000 total
miles (800,000 km) during the vehicle lifetime. This is much greater than a
typical passenger car, which frequently will not exceed 125,000 total miles
(200,000 km).
- Seat and cab movement in trucks, there is almost constant movement of the belt
due to ride characteristics and seat design. The constant movement of the belt
inside the restraint hardware and the potential for the belt to come in contact
with the cab and other vehicle parts, contributes to the wear of the entire system.
- Environmental conditions, such as dirt and ultraviolet rays from the sun, will
reduce the life of the seat belt system.
72
Seats
Due to these factors, the three-point safety belt system installed in your vehicle
requires thorough inspection every 20,000 miles (32,000 km). If the vehicle is
exposed to severe environmental or working conditions, more frequent inspections
may be necessary. Any seat belt system that shows cuts, fraying, extreme or
unusual wear, significant discoloration due to UV (ultraviolet) exposure, abrasion to
the seat belt webbing, or damage to the buckle, latch plate, retractor hardware or
any other obvious problem should be replaced immediately, regardless of mileage.
WARNING
It is important to remember that any time a vehicle is involved in an
accident, the entire seat belt system must be replaced. Unexposed
damage caused by the stress of an accident could prevent the
system from functioning properly the next time it is needed. Failure
to comply may result in personal injury or death.
Inspection Guidelines
Follow these guidelines when inspecting for cuts, fraying, extreme or unusual wear
of the webbing, and damage to the buckle, retractor, hardware, or other factors.
Damage to these areas indicates that belt system replacement is necessary.
WARNING
Replace the entire belt system (retractor and buckle side) if
replacement of any one part is necessary. Unexposed damage to
one or more components could prevent the system from
functioning properly the next time it is needed. Failure to comply
may result in personal injury or death.
73
74
Seats
1. Check the web wear in the system. The webbing must be closely examined to
determine if it is coming into contact with any sharp or rough surfaces on the
seat or other parts of the cab interior. These areas are typical places where the
web will experience cutting or abrasion. Cuts, fraying, or excessive wear would
indicate the need for replacement of the seat belt system.
2. The pillar web guide (D-loop) is the area where almost constant movement of
the seat belt webbing occurs because of relative movement between the seat
and cab.
3. Check the Comfort Clip for cracks or possible damage and check for proper
operation.
4. Check buckle and latch for proper operation and to determine if latch plate is
worn, deformed, or damaged.
5. Inspect the retractor web storage device, which is mounted on the floor of the
vehicle, for damage.
The retractor is the heart of the occupant restraint system and can often be
damaged if abused, even unintentionally. Check operation to ensure that it is not
locked up and that it spools out and retracts webbing properly.
6. If tethers are used, be sure they are properly attached to the seat and, if
adjustable, that they are adjusted in accordance with installation instructions.
Tethers must also be inspected for web wear and proper tightness of mounting
hardware.
7. Mounting hardware should be evaluated for corrosion, and for tightness of bolts
and nuts.
8. Check web in areas exposed to ultraviolet rays from the sun. If the color of the
web in these areas is gray to light brown, the physical strength of the web may
have deteriorated due to exposure to the sun's ultraviolet rays. Replace the
system.
Seats
Seat Belt Inspection Points
1. Web cut or frayed or extremely worn at latch area.
2. Web cut or frayed at D-loop web guide.
3. Comfort Clip cracked or damaged.
4. Buckle casting broken.
5. Retractor Web Storage for damage. (located behind trim panel)
6. Tethers for web wear and proper tightness of mounting hardware.
7. Mounting hardware for corrosion, proper tightness of bolts and nuts.
8. Web for deterioration, due to exposure to the sun.
WARNING
Failure to adjust tether belts properly can cause excessive
movement of the seat in an accident. Tether belts should be
adjusted so that they are taut when the seat is in its most upward
and forward position. Failure to comply may result in personal
injury or death. Once the need for replacement of the seat belt has
been determined, be certain it is only replaced with an authorized
PACCAR Parts replacement seat belt. If the inspection indicates
that any part of the seat belt system requires replacement, the
entire system must be replaced. An installation guide is attached to
every replacement belt. Utilize the proper guide for your type of
seat, and follow the instructions very closely. It is vitally important
that all components be reinstalled in the same position as the
original components that were removed and that the fasteners are
torqued to specification. This will maintain the design integrity of
the mounting points for the seat belt assembly. Contact your dealer
if you have any questions concerning seat belt replacement.
75
Seats
Wearing seat belts
- The belt must be tight against the body and not distorted.
- With a three-point type belt, the shoulder section must be across center of the
shoulder, not against the neck. The pelvis section should be as low as possible
across the pelvis, not across the abdomen.
- Do not put any hard, sharp or fragile objects such as pens, glasses or phones
between your body and the seat belt.
Checking the seat belts
- Give a short pull on the seat-belt to test the locking mechanism.
- Repeat this check regularly, for example when putting on the seat belt, in order
to check the mechanism.
During this test, the belt must lock. This means that it must not be possible to
pull the seat belt out of the retracting unit after locking.
The locking mechanism should be immediately replaced and/or repaired if it is
defective.
- Inspect the belts regularly for wear. Have the complete assembly replaced at
once if the belt is worn or damaged.
76
Master Display
77
Master Display
GENERAL
In the master display a menu can be displayed to show the driver all the information
regarding the function and operation of the various systems in as useful a way as
possible.
The master display is a part of the Central Warning System. In addition, the system
contains a menu selection switch, a buzzer and a central "STOP" warning lamp
under the master display.
The master display consists of three different fields; an indication bar, an
information screen (yellow or red) and an information screen (yellow).
78
Master Display
LAYOUT OF MASTER DISPLAY
A Indication bar
B Information screen (yellow and red)
C Information screen (yellow)
1 Number of active red warnings
2 Number of active yellow warnings
3 Alarm function engaged
4 Gear engaged, AS Tronic Lite or automatic gearbox (AGC-A)
5 Speed set
6 Vehicle speed setting functions (review)
7 (unused)
D001192-3
79
Master Display
START-UP PHASE
If the ignition has been switched on and the engine is not yet running, the start-up
screen is shown in the master display.
The following warning symbols, if present, are then displayed:
- Oil pressure (red)
- Alternator voltage (red)
- Steering circuit 1 output (red)
- ABS of prime mover (yellow)
NOTE
When starting a vehicle equipped with an Allison automatic gearbox, the
transmission fault warning symbol appears in the main display; this
symbol disappears once the engine is started.
During the start-up phase, the "STOP" warning lamp and the acoustic signal are
inactive.
Approximately 3 seconds after switching on the ignition, the yellow warning symbols
will disappear. During these 3 seconds, no other warnings can be displayed.
The red warning symbols should disappear from the screen approximately
2.5 seconds after the engine has been started.
If the oil pressure, charging voltage or steering circuit 1 output is still too low after
these 2.5 seconds, the warning screen will become active, in which the relevant red
warning symbol appears with the accompanying text. The "STOP" warning lamp
and audible alarm will also be activated.
80
Master Display
If there is a less serious fault, the respective yellow symbol with the accompanying
text will appear on the screen and an acoustic signal will be heard for a certain time.
If the indication bar mentions several red and/or yellow warnings, the other
warnings can be called up by turning the menu selector switch one step further each
time. This takes place in order of priority. This means that the most important
warning will be displayed first.
A red warning cannot be removed from the screen when the engine is running.
The red warning symbol can be turned off when the engine is not running. This is so
that it is possible to use other menu options (if you return to the main screen, the
warnings will re-appear).
Yellow warnings can be switched off at any time.
The message detailing the number of warnings present remains active at all times.
A continuous audible alarm tone accompanies a red warning.
A pulsating audible alarm tone accompanies a yellow warning and sounds four
times.
81
Master Display
D000711
D000555
MENU SELECTOR SWITCH
By pressing the menu selector switch, the main menu will be selected and the
selector bar will become visible.
Turning the menu selector switch will switch between screens in the main menu.
The triangle on the right-hand side of the display shows the direction in which you
can proceed.
By pressing the menu selector switch, the function/information chosen will be
selected, after which sub-menu 1 will appear, if present. If there is no sub-menu 1,
the menu function will be turned off.
By turning the menu selector switch you will browse through sub-menu 1.
The triangle on the right-hand side of the display shows the direction in which you
can proceed.
By pressing in the menu selector switch, the function/information chosen will be
selected, after which sub-menu 2 will appear, if present. If there is no sub-menu 2,
the menu function will be switched off.
82
Master Display
D000556
By turning the menu selector switch, sub-menu 2 can be accessed.
The triangle on the right-hand side of the display shows the direction in which you
can proceed.
By pressing the menu selector switch, the menu function will be switched off.
83
Master Display
MENU OVERVIEW
Main menu Sub-menu 1 Sub-menu 2
Vehicle information Fuel consumption - Current
- Average
- Average trip
Turbocharger pressure
Oil level
Service inspection - Date
- Distance
PTO counter - PTO 1 counter
- PTO consumption
Chassis number
Back
Faults All faults
Back
84
Master Display
Main menu Sub-menu 1 Sub-menu 2
Trip info Trip info - Distance
-Time
- Average speed
- Average consumption
- Fuel consumption
Trip reset
Close
Settings Language 1 or 2
Alarm on/off
Setting alarm - Setting alarm: hours
- Setting alarm: minutes
- Alarm time
Time, local/home
Set local time
Clock AM/PM/24H
Display miles/km
Close
Close
85
Master Display
FAULTS
Serious fault
A red warning symbol is activated when there is a serious fault.
When a red warning symbol is activated, the "STOP" warning lamp and an audible
alarm are activated at the same time.
WARNING
This should be considered an emergency. You should stop the
vehicle as safely as possible and turn OFF the ignition. The vehicle
must be serviced and the problem corrected before driving again.
Failure to do so may cause severe engine or DPF damage, or cause
an accident which may result in personal injury or death.
Less serious fault
A yellow warning symbol is activated if there is a less serious fault.
When yellow warnings appear you may continue driving but action must be taken at
the first opportunity to remedy the fault. Have an authorized Service dealer correct
the problem as soon as possible.
WARNING
As the vehicle may behave differently from normal, the vehicle must
be driven with extra caution.
86
Master Display
WARNING SYMBOLS
Red warnings
Oil pressure low
If the oil pressure suddenly drops, or the audible alarm and engine oil pressure
warning light come on while driving, do the following:
1. Slow down carefully.
2. Move a safe distance off the road and stop.
3. Place the transmission in park and set the parking brake. (See Stopping on
page 112 and Automatic Gearbox on page 128-134, for transmission shifting
and parking brake information.)
4. Turn OFF the engine.
5. Turn ON the emergency flasher and use other warning devices to alert other
motorists.
6. Wait a few minutes to allow oil to drain into the engine oil pan, and then check
the oil level. (See "ENGINE OIL LEVEL" in "INSPECTIONS AND
MAINTENANCE" on page 93, for details on checking oil level.)
7. Add oil if necessary. If the problem persists, contact an authorized dealer as
soon as possible.
CAUTION
Continuing to operate your vehicle with insufficient oil pressure
may cause severe engine damage or cause an accident which may
result in equipment or property damage. It is important to maintain
oil pressure within acceptable limits. If oil pressure drops below the
minimum psi a Red Warning Lamp on the oil pressure gauge and
the Stop Engine Lamp will come ON.
87
Master Display
Cab lock open
See "Cab tilting" in "EMERGENCY REPAIRS".
Air pressure low
This warning symbol is active when the pressure in one of the service brake circuits
is lower than 65 psi or 4.48 bar.
Coolant Level Low
This warning symbol will come on when the coolant level is below the minimum
permissible level. Check the coolant level (caution – danger of scalding; see
"Topping up coolant" in "INSPECTIONS AND MAINTENANCE")
Coolant temperature high
This warning symbol will come on when the coolant temperature exceeds the
maxi-mum permissible value. Check the following points:
the coolant level (caution – danger of scalding; see "Topping up coolant" in
"INSPECTIONS AND MAINTENANCE");
the poly V-belt and water hoses; the fan clutch.
Engine fault
Serious fault in the electronic unit.
88
Transmission fault
If the vehicle is equipped with an automatic gearbox, see "Faults" in "AUTOMATIC
GEARBOX".
Master Display
ABS
Yellow warnings
Truck ABS fault
This symbol is activated when:
there is a fault in the ABS of the prime mover;
Engine fault
Depending on the fault, the engine can switch over to emergency control.
PTO fault
Engine speed control does not meet the conditions. See "Engine speed control" in
"DRIVING".
Oil pressure low
Check the engine oil level See also "Daily inspections" in "INSPECTIONS AND
MAINTENANCE".
Water separator fuel filter
Check the fuel prefilter/water separator. See "Weekly inspections" in
"INSPECTIONS AND MAINTENANCE".
89
Master Display
No warning
Coolant level sensor
This symbol will light up if the coolant level sensor is not latched into it
proper position. The sensor is part of the filler cap.
Key to abbreviations
ABS Anti-lock Braking System
PTO Power Take Off
VIC Vehicle Intelligence Center
90
Inspections and Maintenance
91
Inspections and Maintenance
OVERVIEW OF DAILY CHECKS
Overview of the driver's daily checks:
- engine oil level
- coolant level, fill cap secure
- fluid level in windshield washer reservoir
- air filter indicator
- tires and rims
- lighting and instruments
- driver's seat and mirrors
-trailer
Visual check before starting the trip:
- check that no situation can occur (such as loose objects, improperly attached
load etc.) that may put other road users at risk.
NOTE
Cleaning rags, flammable materials, accumulated dirt etc. in the vicinity
of the exhaust system must be removed as these create a fire hazard.
OPENING THE FRONT PANEL
92
Open the front panel by gripping it at the bottom and lifting it up. The front panel will
tilt upwards and is held in place by two gas struts.
Inspections and Maintenance
D0 00 721
2 1
ENGINE OIL LEVEL
1. Ensure that the vehicle is standing on a flat and level surface.
2. Open the front panel.
3. Pull the dipstick (2) out of the holder.
4. Wipe the dipstick clean with a lint-free cloth.
5. Re-place the dipstick in its holder. Withdraw the dipstick again and check the oil
level.
NOTE
It takes approx. 20 minutes for all the oil to run into the sump when the
engine is "warm". If the dipstick is checked immediately after switching
the engine off or immediately after oil has been added, the level shown
on the dipstick will be too low.
6. Fill oil through the filler opening (1) until the oil level reaches the maximum mark.
Only use engine oil that meets specifications. See "TECHNICAL DATA".
NOTE
For the difference between the minimum and maximum engine oil level,
see "TECHNICAL DATA".
93
Inspections and Maintenance
TOPPING UP COOLANT
WARNING
When the coolant is hot, there is an overpressure in the cooling
system. If circumstances dictate that it is necessary to top up the
coolant when the engine is warm, unscrew the filler cap carefully
one turn to relieve the overpressure. Take adequate precautions
against burning by, for example, placing a cloth over the cap.
Coolant is a toxic fluid. Contact with the skin should therefore be
avoided. Also see "Lubricant, engine coolant and fuel
specifications" in "TECHNICAL DATA"
WARNING
To prevent damage to the engine block, topping up with cold
coolant when the engine is hot must be done slowly and with the
engine running.
WARNING
Do not loosen the filler cap of the cooling system when the cab is
tilted. The filler cap houses the coolant level sensor. Take
necessary precautions to protect the sensor from damage when
removing it.
94
Inspections and Maintenance
D0 02 003
1. Turn the rotary knob for the heating temperature control to "maximum hot".
2. Open the front panel.
3. Remove the black filler cap from the cooling system reservoir.
4. Run the engine for several minutes.
5. Stop the engine and check the coolant level.
6. If necessary, top up to the bottom of the filler opening.
Always use coolants which meet specifications. See "TECHNICAL DATA".
NOTE
Take care not to damage the coolant level sensor when removing and
replacing the reservoir filler cap.
95
Inspections and Maintenance
D0 02 017
2
1
SPECIAL COOLANT FILL INSTRUCTIONS
CAUTION
RADIATOR FILL PROCEDURE REQUIRED FOR THIS VEHICLE
1. Remove the surge tank pressure cap (do not remove the surge tank coolant
level sensor cap).
2. Fill system with premixed coolant to “MAX” level on surge tank and allow coolant
level to settle.
3. Repeat step 2 until coolant level stays at “MAX” level.
4. Start the engine and idle at low RPM for 2 minutes.
5. Top off surge tank to “MAX” level while engine is at low idle.
6. Run engine at high idle until operating temperature is reached (~ 200° F).
7. Return engine to low idle and top off surge tank to “MAX” level if needed.
8. Run engine at high idle for 10 minutes.
9. Return engine to low idle and top off surge tank to “MAX” level.
10. Allow engine to cool and top off surge tank to “MAX” level if necessary.
11. Replace the surge tank pressure cap.
CAUTION
Failure to follow this procedure and maintain proper coolant level
can cause engine damage.
96
It is OK for a hot system to have coolant above the “MAX” level, but a cold system
should not have coolant above the “MAX” level.
Inspections and Maintenance
D0 00 608
WINDSHIELD WASHER RESERVOIR FLUID LEVEL
1. Open the front panel.
2. Check the fluid level in the screen washer reservoir.
3. Top up, if necessary, via the filler opening.
NOTE
When topping up, it is recommended to add a windshield cleaner to the
water in the windshield washer reservoir.
During the winter period, add windshield wash antifreeze.
AIR FILTER INDICATOR
The air filter indicator is behind the grille at the front of the cab. If the indicator is in
R
T
E
E
S
C
H
A
N
G
E
F
I
L
T
A
I
R
F
I
L
T
E
R
D
E
R
N
E
H
W
R
E
R
O
T
A
C
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D
I
N
the red area (showing the text "service"), the air filter is seriously fouled and must be
replaced. Consult an authorized Service dealer. Clogged air filters lead to
increased fuel consumption and loss of power.
D0 02 004
97
Inspections and Maintenance
WHEELS AND TIRES
- Remove any stones, etc. from the tread and from between the tires (if twin
wheels are fitted).
- Check for evidence of wear and damage and for nails or other foreign objects
caught in the tires.
- Check the attachment of the wheels.
- Check the tire pressures (do not forget the spare wheel). The tire pressures
should be checked and corrected while the tires are cold. See chapter on
"Technical data" or the back page of this book for the correct tire pressures.
NOTE
If a worn tire is underinflated by 30 psi, the ABS control will be
inoperative under extreme conditions! Also see "Changing the wheel" in
the "EMERGENCY REPAIRS" section of this manual.
LIGHTING AND INSTRUMENTS
- Check the vehicle lighting, brake lights and instruments for correct operation.
- Also check the operation of the horn, windshield wipers and washers.
98
Inspections and Maintenance
A
B
C
D
E
D0 01 062
DRIVER'S SEAT AND MIRRORS
Set the seat and mirrors to the correct positions.
Mirrors with field of vision projected on the ground
A Side window
B Dead angle mirror
C Wide view mirror
D Main mirror
E Pavement mirror
OVERVIEW OF WEEKLY CHECKS
Overview of the driver's weekly checks:
- clutch fluid level
- Power steering fluid level
- Brake system air drier
- Draining the fuel system water separator
- Batteries
99
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