How it Works
Peterbilt
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386 2017
User Manual
188 pgs1.77 Mb0
Table of contents
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Peterbilt 389 2017, 388 2017, 365 2017, 386 2017, 367 2017 User Manual

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Contents
Safety
Emergency
Controls
Driving
Maintenance
Index
1
2
3
4
5
6
7
Contents
©2017PACCARInc-AllRightsReserved
Thismanualillustratesanddescribestheoperationoffeaturesorequipmentwhichmaybeeitherstandardoroptionalon thisvehicle.Thismanualmayalsoincludeadescriptionoffeaturesandequipmentwhicharenolongeravailableorwere notorderedonthisvehicle.Pleasedisregardanyillustrationsordescriptionsrelatingtofeaturesorequipmentwhichare notonthisvehicle.
PACCARreservestherighttodiscontinue,changespecications,orchangethedesignofitsvehiclesatanytime,without noticeandwithoutincurringanyobligation.
TheinformationcontainedinthismanualisproprietarytoPACCAR.Reproduction,inwholeorinpart,byanymeansisstrictly prohibitedwithoutpriorwrittenauthorizationfromP ACCARInc.
TruckModelExample
i
PREVENTIVEMAINTENANCESCHEDULE
Introduction..................5-9
MaintenanceSchedule............5-12
LUBRICANTSPECIFICATIONS
Introduction.................5-41
Engine...................5-41
MasterLubricationIndex............5-44
FullerTransmissionLubrication.........5-48
AllisonTransmissionLubrication........5-50
SpicerTransmissionLubrication........5-50
OilChanges.................5-51
MeritorAxleLubrication............5-52
Eaton/DanaAxleLubrication..........5-53
WheelBearingLubrication...........5-54
UniversalJointLubrication...........5-55
SteeringGearLubrication...........5-55
MAINTENANCE
5
(03/17)Y53-6077-1B15-1
MAINTENANCE
AIRSYSTEM
Introduction.................5-57
AirDryer...................5-60
AirT anks..................5-62
AirGaugesandAirLeaks...........5-63
AirCompressor................5-64
BRAKESYSTEM
BrakeAdjustment...............5-66
CAB
ExteriorMaintenance.............5-71
Cleaning,ProtectingandWeatherStripping...5-72
5
COOLINGSYSTEM
SafetyRestraintSystem-Inspection......5-78
WindshieldWiper/Washer...........5-81
Coolingsystemmaintenance.........5-82
Engine(Block)Heater.............5-86
5-2Y53-6077-1B1(03/17)
MAINTENANCE
ELECTRICAL
ElectricalSystem...............5-87
LightBulbs..................5-88
BulbSpecications..............5-89
Fuses,CircuitBreakersandRelays.......5-89
FuseInspectionandReplacement.......5-92
AddingElectricalOptions...........5-92
Batteries...................5-93
BatteryCare.................5-97
BatteryCharging...............5-97
ElectricalandAlternatorPrecautions......5-99
RemoteKeylessEntry.............5-100
ENGINE
EngineMaintenance.............5-101
EngineLubrication..............5-102
AccessoryDriveBelts.............5-105
EngineFan.................5-106
AirIntakeSystem...............5-107
5
(03/17)Y53-6077-1B15-3
MAINTENANCE
Turbocharger.................5-107
AirCleaners.................5-108
ServiSignal™MiniIndicator..........5-109
ExhaustSystem...............5-110
EngineMounting...............5-110
FUELSYSTEM
LocationofFuelShut-offValves.........5-111
Specication.................5-111
FuelFilters..................5-11 1
FRAME
Introduction.................5-112
5
5-4Y53-6077-1B1(03/17)
FRONTAXLEANDSUSPENSION
AxleLubrication...............5-116
Inspection..................5-1 17
WheelAlignment...............5-117
U-BoltT orque................5-1 18
HEATERANDAIRCONDITIONER
NOISEEMISSIONCONTROL
REARAXLEANDSUSPENSION
STEERINGSYSTEM
Introduction.................5-120
Heater....................5-121
AirConditioner................5-121
NoiseEmissionWarranty...........5-123
InspectionandMaintenanceInstructions.....5-124
NoiseControlSystem-MaintenanceLog....5-128
GeneralMaintenance.............5-131
VisualInspection...............5-132
RearSuspensionFasteners..........5-132
RearAxleLubrication.............5-134
RearAxleAlignment.............5-135
PowerSteering................5-136
FluidLevelandRell.............5-137
MAINTENANCE
5
(03/17)Y53-6077-1B15-5
MAINTENANCE
SteeringShaft................5-138
DRIVELINE
DriveshaftMaintenance............5-139
U-Joints...................5-139
TIRESANDWHEEL
Tires....................5-140
WheelMountingandFastening.........5-146
WheelReplacementwithDiscBrakeOption...5-148
DiscWheels.................5-150
WHEELBEARING
WheelBearingAdjustment...........5-151
5
TRANSMISSIONMAINTENANCE
Introduction.................5-152
TransmissionLubricants............5-153
AutomaticTransmissions...........5-154
5-6Y53-6077-1B1(03/17)
MAINTENANCE
CLUTCH
Introduction.................5-155
ClutchAdjustment-NormalWear........5-155
5
(03/17)Y53-6077-1B15-7

PREVENTIVE MAINTENANCE SCHEDULE

Introduction
Preventivemaintenanceprogram beginswiththedailychecks.See Driver’sCheckListfortheseroutine checks.Routinevehiclecheckscan helpavoidmanylarge,expensive, andtimeconsumingrepairs.The vehiclewilloperatebetter,be safer,andlastlonger.Neglectof recommendedmaintenancecan voidyourvehicle’swarranty.Some maintenanceoperationsdemand skillsandequipmentyoumaynot have.Forsuchsituations,pleasetake yourvehicletoanauthorizedService Center.
PREVENTIVEMAINTENANCESCHEDULE
WARNING!
Beforeattemptinganyproceduresin theenginecompartment,stopthe engineandletitcooldown.Hot componentscanburnskinoncon­tact.Failuretocomplymayresultin death,personalinjury,equipmentor propertydamage.
WARNING!
Iftheenginemustbeoperatingtoin­spect,bealertandcautiousaround theengineatalltimes.Failureto complymayresultindeath,personal injury,equipmentorpropertydam­age.
WARNING!
Ifworkhastobedonewiththe enginerunning,always(1)setthe parkingbrake,(2)blockthewheels, and(3)ensurethattheshiftlever orselectorisinNeutral.Failureto complymayresultindeath,per­sonalinjury ,equipmentorproperty damage.
WARNING!
Exerciseextremecautiontoprevent neckties,jewelry ,longhair,orloose clothingfromgettingcaughtinthe fanbladesoranyothermovingen­gineparts.Failuretocomplymayre­sultindeath,personalinjury,equip­mentorpropertydamage.
5
(03/17)Y53-6077-1B15-9
PREVENTIVEMAINTENANCESCHEDULE
WARNING!
Disconnectthebatterygroundstrap wheneveryouworkonthefuelsys­temortheelectricalsystem.When youworkaroundfuel,donotsmoke orworknearheatersorotherre hazards.Keepanapprovedreex­tinguisherhandy.Failuretocomply mayresultindeath,personalinjury , equipmentorpropertydamage.
WARNING!
Alwayssupportthevehiclewithap­propriatesafetystandsifitisneces­sarytoworkunderneaththevehicle.
5
Ajackisnotadequateforthispur­pose.Failuretocomplymayresult indeath,personalinjury ,equipment orpropertydamage.
WARNING!
Whenworkingunderneaththevehi­clewithoutappropriatesafetystands butwiththewheelsontheground (notsupported),makesurethat(1) thevehicleisonhardlevelground, (2)theparkingbrakeisapplied,(3) allwheelsareblocked(frontand rear)and(4)removetheignition keysothattheenginecannotbe started.Failuretocomplymayresult indeath,personalinjury ,equipment orpropertydamage.
WARNING!
Neverstartorlettheenginerunin anenclosed,unventilatedarea.Ex­haustfumesfromtheenginecontain carbonmonoxide,acolorlessand odorlessgas.Carbonmonoxidecan befatalifinhaled.Failuretocomply mayresultindeath,personalinjury , equipmentorpropertydamage.
Thefollowingpagescontainatable ofmaintenancetaskswiththerelated intervalsforeachtaskontheright sideofthetable.Thetopofthetable displaysaguidetoamaintenance intervalanditsschedule.Some tasksaredependentonthevehicle application.Thesetaskswillbe shownasseparatetasksandwillhave thewords“ONHIGHWAY”,“CITY DELIVERY”or“OFF-HIGHWA Y” afterthedescription.Thesetasks aredifferentiatedbecausetheyare dependentonthevehicle’soperating environment.
Onhighwayisdenedforapplications wherethevehicleisNOTusedoffofa pavedroadduringnormaloperation.
CityDeliveryisdenedforapplications wherefrequentstartandstoppingis requiredduringnormaloperationand thehighwayisusedinfrequentlyand forshortperiodsoftime.
5-10Y53-6077-1B1(03/17)
PREVENTIVEMAINTENANCESCHEDULE
Offhighwayisdenedforapplications wherethevehiclemaybedrivenoff thepavementonaregularbasis,even ifitisaninfrequentbasisand/orfora brieftimeperiod.
Pleasecontactanauthorized servicedealershipifthereare questionsregardingwhichinterval tofollow.Consultthesupplierfor specicrecommendationswhere discrepanciesdevelopbetweenthese recommendationsinthistableand componentsupplierrecommendations.
•Enginelubricatingoilchange
intervalsaren’tlistedhere.Refer toyourengine’soperatingmanual forrecommendations.Forspecic informationonmaintenance proceduresconsultyourvehicle maintenancemanual.
•Theinitialllofdriveaxlelubricant
mustbechangedbeforetheend oftherstscheduledmaintenance
interval.RefertoOilChangeson page5-51beforeyouputanew vehicleintoservice.
•Theinitiallloflubricantin
manualtransmissionsmustbe changedbeforetheendoftherst maintenanceinterval.SeeFuller TransmissionLubricationonpage 5-48forspecicinformation.
•Ifyourvehicleisequippedwithan
automatictransmission,consult theowner’smanualforitthatcame withyourvehicletoobtainlubricant checkandchangeintervals.
5
(03/17)Y53-6077-1B15-11
PREVENTIVEMAINTENANCESCHEDULE
MaintenanceSchedule
NewVehicleMaintenanceSchedule
SteeringShaftU-Bolts.(OFF-HIGHWA Y)SeeSteeringSystemonpage 5-136.
WheelMounting.SeeWheelMountingandFasteningonpage5-146.
FrontAxleU-BoltT orque.SeeFrontSpringSuspensionU-Boltsonpage 5-118.
ChargeAirCoolerandAirIntakePipeClamps,re-torquefasteners.
5
RearSuspensionFasteners.SeeRearSuspensionFastenersonpage5-132.
TransmissionLubrication.
1.ForFullertransmission,seeFullerTransmissionLubricationonpage 5-48.
2.ForAllisontransmission,seeAllisonTransmissionLubricationonpage 5-50.
3.ForSpicertransmission,seeSpicerTransmissionLubricationonpage 5-50.
AxleLubrication.
1.ForMeritoraxle,seeMeritorAxleLubricationonpage5-52.
2.ForEaton/Danaaxle,seeEaton/DanaAxleLubricationonpage5-53.
NewVehicleMaintenanceSchedule
AfterFirstMiles(km)
Operation\Frequency
First
Day
X
50–100
(80–160)
X
500(800)
X
X
2,000
(3218)
X
3,000
–5,000
(4800
–8000)
X
X
5-12Y53-6077-1B1(03/17)
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Frame
(03/17)Y53-6077-1B15-13
FifthWheel
FrameFasteners
Crossmembersand MountingBrackets
EngineMounting
Checkthekingpinlockandplateforwearandfunction; lubricate(NLGI#2grease).
Inspectfthwheeloperation(shownonpage5-113)
Checkfortightness;tightentothespeciedtorquevalueas required(shownonpage5-114).
Inspectforcracksandloosefasteners.Replaceortighten tothespeciedtorquevalueasrequired(shownonpage 5-114).
Inspectenginemountsevery60,000miles(96,560km) (shownonpage5-110).ContactanauthorizedvehicleOEM dealershipifenginemountsneedservicing.
RecommendedPMInterval
IAB
X
C
X
X
DE
X
X
5
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
FrontAxle (Meritor)
5
TotalVehicleAlignment
Steeringknuckle spindles,thrustbearings, kingpins,drawkeys,tie rodends,steeringstops, andbushings
Kingpinbushings,thrust bearings,andtierodball ends
DrawkeysTightennutsXX
Checkandadjustasrequired.
Inspectforwearanddamageandendplay .Shimorreplace asrequired(shownonpage5-136).
Lubricatewithapprovedgrease.X
RecommendedPMInterval
IAB
XX
5-14Y53-6077-1B1(03/17)
DE
C
X
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
FrontAxle (Dana)
(03/17)Y53-6077-1B15-15
TotalVehicleAlignment
Kingpinbushings,thrust bearings,andtierodball ends(ONHIGHWA Y)
Kingpinbushings,thrust bearings,andtierodball ends(OFF-HIGHWAY)
Steeringknuckle spindles,thrustbearings, kingpins,drawkeys, tierodends,steering stops,andbushings(ON HIGHWAY)
Steeringknuckle spindles,thrustbearings, kingpins,drawkeys, tierodends,steering stops,andbushings (OFF-HIGHWAY)
Checkandadjustasrequired.
Lubricatewithapprovedgrease.X
Lubricatewithapprovedgrease.X
Inspectforwearanddamageandforendplay.Shimor replaceasrequired.
Inspectforwearanddamageandforendplay.Shimor replaceasrequired.
RecommendedPMInterval
IAB
XX
C
X
DE
X
5
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Front Suspension
5
FrontSpringInspectforcrackedleaves,wornbushings,andexcessive
SpringPinsand Shackles
ShockAbsorbersInspectforleaking,bodydamage,anddamagedorworn
SpringPins
U-bolts(ONHIGHWAY)Checkthegeneralconditionandthetightnessofthenuts.
U-bolts(OFFHIGHWAY)Checkthegeneralconditionandthetightnessofthenuts.
corrosion.
Inspectforwornpartsandexcessivejointclearance.Shim orreplaceasrequired.
bushings.Replaceasrequired.Checktheshockmounting studtorque.
Lubricatewithapprovedgrease.X
Checkforproperfunction.
Tightenthenutstothespeciedtorquevalueasrequired (shownonpage5-118).
TightentheU-boltsaftertherstdayortwoofoperation. Thentightenthenutstothespeciedtorquevalueas required(shownonpage5-118).
RecommendedPMInterval
IAB
X
XX
X
5-16Y53-6077-1B1(03/17)
DE
C
X
X
X
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
DriveAxle (Dana)
(03/17)Y53-6077-1B15-17
AxleHousing
AirShiftUnit
Breather
LubePump(ON HIGHWAY)
LubePump(OFF HIGHWAY)
LubeFilter(ON HIGHWAY)
LubeFilter(OFF HIGHWAY)
Visuallyinspectfordamageorleaks.
Checkoillevel.Check“cold.”T orquethedrainplug.
Drainthelubricantwhilewarm.Flusheachunitwithclean ushingoil.Changethelubricant.
Checkthelubricantlevel.
Removethehousingcoveranddrainthelubricant.Wash thepartsthoroughlyanddryinair.
Cleanorreplace.
Removethemagneticstrainerandinspectforwearparticles. Washinsolventanddryinair.
Removethemagneticstrainerandinspectforwearparticles. Washinsolventanddryinair.
Change.
Change.
RecommendedPMInterval
IAB
Seeinformationonpage5-53
C
X
X
X
X
X
DE
X
X
X
X
5
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Magneticdrainplugand
(Dana)
breather(ONHIGHWA Y)
Magneticdrainplug andbreather(OFF HIGHWAY)
Cleanorreplace.
Cleanorreplace.
RecommendedPMInterval
IAB
5
5-18Y53-6077-1B1(03/17)
DE
C
X DriveAxle
X
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
DriveAxle (Meritor)
(03/17)Y53-6077-1B15-19
AxleHousing
LubricantlterChangethelter.
Breather
Inputshaftandpinion shaft
AxleshaftTightentherearaxleangenutstothespeciedtorque
InteraxledifferentialChecktheoperation.
Checkthe“cold”lllevelatthedifferentialcarrierplugfora pinionangleoflessthan7degrees,orattheaxlebowlplug forapinionangleofgreaterthan7degrees.Tightenthe plugto35-50Lb.ft.(47-68N.m.)
Visuallyinspectfordamageorleaks.
Drainandreplacethelubricant.
Checktheoperation.Ifthecapdoesn’trotatefreely,replace.
Checkandadjusttheendplay .
value.
RecommendedPMInterval
IAB
Seeinformationonpage5-51
C
X
X
X
DE
X
5
X
X
X
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
DriveAxle (SISU)
5
AxleHousing
Breather
LubeFilter
S-cambrakesOverhaulthebrakes;degreaseallmovingparts;checkthe
Changetheoilinthedifferentialcarrierandthehubs,and cleanthemagneticoildrainplugs.
Checkthewheelbearinghubsandadjustifnecessary.
Visuallyinspectfordamageorleaks.
Checktheoillevelinthedifferentialcarrierandhubs.
Checkthebreatherforproperoperation.
Cleanthesuctionlterfortheoptionalpressurelubrication system.
bushingsandsealsforwear .
RecommendedPMInterval
IAB
XX
XX
XX
5-20Y53-6077-1B1(03/17)
DE
C
X
X
X
X
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Rear Suspension
(03/17)Y53-6077-1B15-21
U-bolts
Frameandcrossmember bolts
Mountingbracketsand fasteners
Checkthetorque.T ightentospeciedtorquevalueas required(shownonpage5-133).
Checkthetorque.T ightentospeciedtorquevalueas required(shownonpage5-114).
Checktheconditionandthefastenertorque.Tightentothe speciedtorquevalueasrequired(shownonpage5-114).
RecommendedPMInterval
IAB
XX
XX
C
DE
X
5
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Drum Brakes(All)
Slackadjusters
BrakecamshaftbearingCheckforexcessivecamshaftpalyintheaxialandradial
Braketreadlevalve
5
BrakeliningInspect;replaceasrequired.X
Checkthepushrodtravelandcheckthecontrolarmfor cracks.Adjustatreline(shownonpage5-69).
Lubricate(NLGI#2grease).
directions.Maxallowableplayis0.003in.Lubricate(NLGI #2grease).
Cleantheareaaroundthetreadle,boot,andmountingplate. Checkthepivotandmountingplateforintegrity .Checkthe plungerbootforcracks.Lubricaterollerpin,pivotpin,and plunger(NLGI#2grease).
Checkairlinesandttingsforleaks(shownonpage5-57). Adjustroutingasrequiredtopreventchang.Checktank mountingandcondition.
Cleanorreplacetheinlinelters.
RecommendedPMInterval
IAB
X
X
X Brakeairsystem
5-22Y53-6077-1B1(03/17)
DE
C
X
X
X
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
DiscBrakes (Bendix®)
(03/17)Y53-6077-1B15-23
BrakepadsInspect;replaceasrequired.X
Brakedisc/rotorInspectforvisiblecracks,heatchecking,galling,orscoring
ofsurface.Checkforrunout(maxallowableis0.002in.).
CaliperslidingfunctionEnsurecaliperslidesfreelywithnoobstructionsorexcessive
play.
CaliperslidepinsInspectprotectivecapsoftheguidepinsfordamageor
cracking.
SystemoperationCheckoperation;inspectaspermanufacturer’sservice
literature.
RecommendedPMInterval
IAB
C
X
X
X
X
DE
5
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Hub,Drum, andHubcap
5
Hubs(non-LMS)Checkthebearingendplayandadjustasrequired(shown
Hubs(non-LMS)with outrunnerseals
Hubs(non-LMS)with standardseals
Hubseals(all)Checkforleaks;replaceasrequired.
LMSHubs(Dana)Inspectforleaks.Checkthebearingendplayandadjustas
LMSHubs(Dana)with SyntheticLubricant
LMSHubs(Dana)with MineralLubricant
onpage5-54).
Cleanthecomponentsandcheckforexcessivewearor damage.Changetheoilandseal(shownonpage5-54).
Cleanthecomponentsandcheckforexcessivewearor damage.Changetheoilandseal(shownonpage5-54).
required(shownonpage5-54).
Servicethebearings,sealsandoil.Thisintervalmaybe differentdependingontheresultsoftheregularinspection. (shownonpage5-54).
Servicethebearings,sealsandoil.Thisintervalmaybe differentdependingontheresultsoftheregularinspection. (shownonpage5-54).
RecommendedPMInterval
IAB
500,000miles/800,000km
350,000miles/560,000km
5-24Y53-6077-1B1(03/17)
DE
C
X
X
X
X
X
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
andHubcap
Brakedrums
Hubcaps
(03/17)Y53-6077-1B15-25
Inspectforvisiblecracks,heatchecking,gallingorscoringof thebrakingsurface,andforseverecorrosionontheoutside surface.Checkforout-of-roundoroversizecondition[0.080 in.(2mm)morethantheoriginaldiameter].Replaceas required.
Cleanthesightwindow.Checkthecenterplug,mounting ange,andllplugforleaksandforproperinstallation. Replacebrokenordamagedparts.Checkthelubricantlevel andaddasrequired.
RecommendedPMInterval
IAB
X
C
X Hub,Drum,
DE
5
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Mainand auxiliary transmis­sion
5
Mainandauxiliary transmissionandtransfer case
MountingBracketsand Fasteners
OilcoolerCleanthens(air-to-oiltype)andbody .Checkthehose
Mainandaux. transmission
Mainandauxiliary transmission(ON HIGHWAY)
Mainandauxiliary transmission(OFF HIGHWAY)
Inspectforvisibledamage,signsofoverheating,andleaks.
Checkthedrainplugsfortightness.
Checktheconditionofthefastenersandtheirtorque. Tightentothespeciedtorquevalueasrequired.
conditionandforleaks;replaceasrequired.
Checktheoillevel;rellasrequired.
Drainlubricantwhilewarm.Flusheachunitwithclean ushingoil.
Drainlubricantwhilewarm.Flusheachunitwithclean ushingoil.
RecommendedPMInterval
IAB
XX
500,000miles/800,000km
XX
5-26Y53-6077-1B1(03/17)
DE
C
X
X
X
X
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Auxiliary transmis­sion
Clutch
(03/17)Y53-6077-1B15-27
CottaTransferCase TR2205 FabcoTransferCase TC142/TC143/TC170/ TC270 Marmon-Harrington TransferCase MVG2000/MVG2000SD
Airintakepiping, mounting,andchargeair cooler
Aircleaner
Clutchlinkage
Clutchreleasebearing
Inspect:Checkoillevel;inspectforleaksandanyvisible damage.
Initialoilchange:Drainoilwhilewarm;ushcasewithgear oil-compatibleuid;cleanmagneticdrainplug;rell.Donot ushthecasewithanysolvent.
Changeoil.
Checkthesystemforbrokenpipes,leaks,jointintegrity, cleanliness,andpropersupport(shownonpage5-109).
Replacetheengineintakeaircleanerelement(shownon page5-108).
Lubricate.X
Lubricate.X
Inspectandadjustwhennecessary(noadjustmentrequired forSOLOtypeclutches)
RecommendedPMInterval
IAB
X
XX
Whenrequiredbyairrestriction indicatororrequiredbytheengine
manufacturer'soperatormanual.
X
C
X
X AirIntake
DE
5
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Cooling
5
Hoses
ExtendedLifeCoolant (ELC)
Fanclutch
SolenoidvalveCheckthefandriveforproperengagementand
Checktheradiatorandheaterhosesforleaks.
Checkthefreezepoint(shownonpage5-83).
Checkforcontaminationusingteststrips(shownonpage 5-82).
Replaceblankwaterlterifapplicable.
Performlabanalysis(shownonpage5-82). Iflabanalysisshowscoolantisunsuitableforcontinueduse: Flush,drain,andrell(shownonpage5-82). AddELCExtender(shownonpage5-82).
Flush,drain,andrellwithnewcoolant(shownonpage 5-82).
Checkforairleaks.(shownonpage5-106). Checkthefandrivebearings(turnthesheaveinboth directionstocheckforwornhubbearings).
disengagement.
RecommendedPMInterval
IAB
XX
XX
XX
5-28Y53-6077-1B1(03/17)
DE
C
X
X
X
X
X
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Tiresand Wheels
(03/17)Y53-6077-1B15-29
Tires
Discwheels
DemountablerimsInspectthemountingring,rimgutter ,sidering,andlockring
Wheelnutsandstuds
Checkinationpressure(shownonpage5-140).Weekly“cold”usingcalibrated
Inspectforcuts,irregularwear,missinglugs,sidewall damage,etc.
Inspectthewheeldiscforanycracksorsurfaceirregularities. Inspecttherimedgeandbeadseatareafordamage. Replaceanydamagedwheels-DONOTA TTEMPTTO REPAIR.
fordamage;replaceasrequired.
Checkthetightnessofthefastenersandtightenthe fastenerstothespeciedtorqueasrequired(shownon page5-146).
Inspectfordamagedhexcorners,strippedordamaged threads,andexcessivecorrosion;cleanorreplaceas required.
RecommendedPMInterval
IAB
X
X
X
X
X
C
gauge
DE
5
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Power Steering
5
Reservoir
Reservoir(ON HIGHWAY)
Reservoir(OFF HIGHWAY)
Steeringgear
Powerassistcylinder
Hosesandtubes
SteeringlinkageCheckalljointsforexcessivelash;replaceasrequired
Checktheuidlevel(shownonpage5-55).
Drain,replacethelter,andrell(shownonpage5-55).
Drain,replacethelter,andrell(shownonpage5-55).
Checkthelashofthesectorshaft;adjustasrequired.
Greasethetrunnionbearing(EPNLGI#2lithium-based, moly-lled,HDgrease).
Greasetheinputshaftseal(EPNLGI#2lithium-based, moly-lled,HDgrease).
Lubricatetheballjoints.Inspectforleakingrodseals, damagedballjointboots,anddamagetocylinderrodor barrel.
Checkforleaksandchang.
(shownonpage5-136).
RecommendedPMInterval
IAB
X
XX
XX
X
5-30Y53-6077-1B1(03/17)
DE
C
X
X
X
X
X
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Power Steering
(03/17)Y53-6077-1B15-31
Draglinktubeclampand ballsocket
Pitmanarmclampbolt andnut
Steeringintermediate shaft
Steeringintermediate shaftU-joints(ON HIGHWAY)
Steeringintermediate shaftU-joints(OFF HIGHWAYorCITY DELIVERY)
Draglinkandtierod armballsockets(ON HIGHWAY)
Draglinkandtierod armballsockets(OFF HIGHWAYorCITY DELIVERY)
Checkthetorque;tightentospeciedtorquevalueas required.
Checkthetorque;tightentospeciedtorquevalueas required.
Checkthetorqueonthepinchboltandnut.
Lubricate[EPNLGI#2HDgrease,+325°Fto-10°F(+163° Cto-23°C)range].
Lubricate[EPNLGI#2HDgrease,+325°Fto-10°F(+163° Cto-23°C)range].
Lubricate(EPNLGI#2lithium-based,moly-lled,HD grease).
Lubricate(EPNLGI#2lithium-based,moly-lled,HD grease).
RecommendedPMInterval
IAB
XX
XX
XX
XX
XX
XX
XX
C
DE
5
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Fueland Tanks
Fueltanks
Fueltankbreathers
Fueltankstraps
Inspecttanks,brackets,hoses,andttingsforcorrect location,tightness,abrasiondamage,andleaks;repairor replaceasrequired.
Checkforproperfunction;cleanthedrainhoses.
Checkthestraptightness;tightentopropertorquevalue asrequired: Aluminumtank:30Lb.ft.(41N.m.) CylindricalSteeltank:8Lb.ft.(11N.m.)
RecommendedPMInterval
IAB
XX
5
5-32Y53-6077-1B1(03/17)
DE
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X
X
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Driveshafts
(03/17)Y53-6077-1B15-33
ModelsSPL-90,1710 and1810slipmember andU-joints
ModelSPL-100slip memberandU-joints
ModelsSPL­140/140HD/170/ 170HD/250/250HDslip membersandU-joints (ONHIGHWAYand LINEHAUL)
Lubricate*.
Inspect.U-jointinspectionsshould
Lubricate*.
Inspect.U-jointinspectionsshould
Lubricate*.
Inspect.U-jointinspectionsshould
RecommendedPMInterval
IAB
XX
beperformedeverytimea vehiclecomesinforscheduled
maintenance.**
X
beperformedeverytimea vehiclecomesinforscheduled
maintenance.**
beperformedeverytimea vehiclecomesinforscheduled
maintenance.**
C
X
DE
5
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Driveshafts
5
ModelsSPL­140/140HD/170/ 170HD/250/250HDslip membersandU-joints (OFFHIGHWAY)
ModelsSPL-140XL/ 170XL/250XLslip membersandU-joints (ONHIGHWA YandLINE HAUL)
ModelsSPL-140XL/ 170XL/250XLslip membersandU-joints (OFFHIGHWAYand CITY)
*UseonlySpicerDriveshaftapprovedlubricantswhengreasingSpicerU-joints. **RefertoSpicerDriveshaftservicemanualDSSM-0100(3264-SPL)fordetailedinstructions.
Lubricate*.
Inspect.U-jointinspectionsshould
Lubricate*.350,000mi(560,000km)1st
Inspect.U-jointinspectionsshould
Lubricate*.
Inspect.U-jointinspectionsshould
RecommendedPMInterval
IAB
X
beperformedeverytimea vehiclecomesinforscheduled
intervalandthenevery100,000mi
(160,00km)afterthat.
beperformedeverytimea vehiclecomesinforscheduled
beperformedeverytimea vehiclecomesinforscheduled
5-34Y53-6077-1B1(03/17)
DE
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maintenance.**
maintenance.**
X
maintenance.**
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Battery Boxes,T ool Boxes,and Steps
(03/17)Y53-6077-1B15-35
Batterycables
Batteries(ONHIGHWAY andLINEHAUL)
Batteries(OFF­HIGHWAY)
Batteryboxandtray(ON HIGHWAYandLINE HAUL)
Batteryboxandtray (OFF-HIGHWAY)
BatteryCableFastenersCheckbatterycablefastenersandtightenasnecessaryto
Checktheconditionofthecables,cushionclamps,nylontie straps,androuting.Replaceacushionclampiftherubber hasdeteriorated.Repairortightenterminals,andsecure cablestopreventchang.Replacedamagedcables(cuts, cracks,orexcessivewear)(shownonpage5-87).
Checkforcracksanddamage,electrolytelevel,conditionof terminals,andtightnessofholddowns(shownonpage5-87).
Checkforcracksanddamage,electrolytelevel,conditionof terminals,andtightnessofholddowns(shownonpage5-87).
Checktheboxintegrity.Cleanthedraintubeandcheckfor acidleaks.Checkconditionofallequipmentmountedunder thebox.
Checktheboxintegrity.Cleanthedraintubeandcheckfor acidleaks.Checkconditionofallequipmentmountedunder thebox.
10-15Lb.ft.(13.6-20.3N.m.)asspeciedonthebattery label.
RecommendedPMInterval
IAB
X
X
X
X
C
X
X
DE
5
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Electrical andlights
5
Headlamps
Warninglightsinlightbar
Turn,Stop,Reverse lightsandsignals
Alternator
StarterChecktorqueonhexnuts.
ECMconnectorCheckthetightnessoftheECMconnector .
Wheelsensors
Fuelanddieselexhaust uidtanksendingunit
Checktheaimandadjustasrequired.
Checkattheignitionstartpositiontoverifybulbsanddriver informationdisplayfunction.
Visualcheck.X
Checkoperationandoutput.
Checktightnessofthepulleynut.
Checkthetensionofthedrivebelt(shownonpage5-105).
Checktightnessoftheterminalhexnuts.
Checkfordamagedsensorsandconnectors,andwornor frayedwires.
Checkthemountingscrewsandelectricalconnectionsfor wornordamagedwiresandconnectors.
RecommendedPMInterval
IAB
X
XX
5-36Y53-6077-1B1(03/17)
DE
C
X
X
X
X
X
X
X
X
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Electrical andlights
Cab structure, doorsand hoods
Heatingand AirCondi­tioning
(03/17)Y53-6077-1B15-37
Powersupplyharnesses (engine,transmission, etc.)
Hood
HingesandlatchLubricatewithsiliconespray.X
Bodyandcabholddown bolts
Airconditioner
conditioner
CondenserClearanydebrisfromthefrontofthecondenser.
Checkforwornordamagedinsulation,corrodedterminals, frayedwires,andoiloruidleaksontheconnectorsor wiring.
Washtoremoveexcessgrease.X
Lubricatethelowerhoodpivot(onlyiflubettingsare present).
Checktheconditionandtightness.
Operatethesystem.
Performthecheckslistedshownonpage5-120.
Fulloperationalanddiagnosticcheck.X
RecommendedPMInterval
IAB
X
X
C
X
X Heaterandair
X
DE
X
5
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Aftertreat­mentSys­tem
SystemCheckforleaksandpropersupport(shownonpage5-123).
DieselparticulatelterCleanlter.RefertotheEngineMaintenance
DieselexhaustuidtankInspectthetank,straps,brackets,hosesandttingsfor
Dieselexhaustuid supplymodule
abrasiondamage,leaks,tightnessandfullyengaged connectors.
Replacelter.RefertotheEngineMaintenance
RecommendedPMInterval
IAB
X
5
5-38Y53-6077-1B1(03/17)
DE
C
Manual.
X
Manual.
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
Air
(03/17)Y53-6077-1B15-39
AircompressorgovernorReplaceairstrainer.X
Airlines
SystemLubricate(shownonpage5-60).
Inlinelters
Airdryer
Airdryer(ONHIGHWAY)Overhaul.360,000miles/576,000km
Airdryer(OFF HIGHWAY)
Checkconditionandroutingtopreventchang.
Replaceelementsorcleanwithsolvent.X
Performthecheckslisted(shownonpage5-57).
Overhaul.
RecommendedPMInterval
IAB
C
X
X
X
DE
X
5
PREVENTIVEMAINTENANCESCHEDULE
PREVENTIVEMAINTENANCE(PM)INTERVALS
SYSTEMCOMPONENTMAINTENANCETASK
EngineBasicEngine
SafetyThree-pointSafetyBelt
System
Maintenanceandserviceintervalrecommendationsaredetailedintheenginemanufacturer’s OperationsandMaintenanceManualincludedwiththevehicle.Theenginemanufacturer’s recommendationsvarydependingenginemodel.Informationisalsoavailablefromauthorized dealers,theenginemanufacturer’sauthorizedservicecenters,andtheenginemanufacturer’s website.
Inspect.
5
RecommendedPMInterval
IAB
20,000miles/32,000km Ifthevehicleisexposedto severeenvironmentalorworking conditions,morefrequent inspectionsmaybenecessary.
5-40Y53-6077-1B1(03/17)
DE
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LUBRICANTSPECIFICATIONS

LUBRICANT SPECIFICATIONS
Introduction
WARNING!
Handlelubricantscarefully.Vehi­clelubricants(oilandgrease)can bepoisonousandcausedeath,per­sonalinjuryorsickness.Theycan alsodamagethepaintonthevehi­cle.
Inthissectionyouwillndthebasic informationyouneedtodotheroutine lubricationyourvehiclerequires.Of courseyouwillwanttoschedule servicemorefrequentlyifyouare operatingundersevereconditions suchasextremeheatorcold,with veryheavyloads,off-road,etc.For anyspecialservicerequirements, consultyourservicemanualsandyour lubricantsupplier .Pleaseremember: onekeytokeepingyourtruckrunning
attopeconomyandinprolonging itslifeisproperlubricationservicing. Neglectingthisessentialaspectof vehiclecarecancosttimeandmoney inthelongrun.
CAUTION
Donotmixdifferenttypesoflubri­cants.Mixinglubricants(oiland grease)ofdifferentbrandsortypes coulddamagevehiclecomponents; therefore,drain(orremove)oldlu­bricantsfromtheunitbeforerelling it.
Engine
Properenginelubricationdepends ontheoutsidetemperatureswhere youwillbedriving.Usetheoil recommendedfortheconditionsyou aremostlikelytobeoperatingin.You willndacompleteenginelubrication serviceguideintheEngineOperation Manualthatcamewithyourvehicle. Theengineoperatormanualcontains specicmaintenancetasksthatyouor aqualiedservicetechnicianneedto performtomaintaintheengine.
5
(03/17)Y53-6077-1B15-41
LUBRICANTSPECIFICATIONS
WARNING!
Exhaustfumesfromtheengine containcarbonmonoxide,acolor­lessandodorlessgas.Apoorly maintained,damaged,orcorroded exhaustsystemcanallowcar­bonmonoxidetoenterthecabor sleeper.Failuretoproperlymain­tainyourvehiclecouldcausecar­bonmonoxidetoenterthecaband causedeath,personalinjuryorseri­ousillness.
5
WARNING!
Neveridleyourvehicleforprolonged periodsoftimeifyousensethatex­haustfumesareenteringthecab. Investigatethecauseofthefumes andcorrectitassoonaspossible. Ifthevehiclemustbedrivenunder theseconditions,driveonlywiththe windowsslightlyopen.Failuretore­pairthesourceoftheexhaustfumes mayleadtodeath,personalinjuryor seriousillness.
NOTE
Keeptheengineexhaustsystem andthevehicle’scabventilation systemproperlymaintained.Itis recommendedthatthevehicle’sex­haustsystemandcabbeinspected:
•Byacompetenttechnicianevery 15,000miles/24,000km,
•Wheneverachangeisnoticedin thesoundoftheexhaustsystem,
•Whenevertheexhaustsystem, underbody,caborsleeperis damaged.
NOTE
Useonlyanexactreplacementparts inAftertreatmentexhaustsystem. Usinganoncompliantreplacement partcouldviolateemissionsrequire­mentsandalsovoidtheemission system’swarranty.
5-42Y53-6077-1B1(03/17)
LUBRICANTSPECIFICATIONS
PipeandHoseClamps
Usethefollowingtablefortorque specicationstocheckpipeandhose clamps.
PipeandHoseClampTorqueV alues
TORQUEAPPLICATIONAPPROVEDCLAMP
NmLb-In
RadiatorandHeatExchangerHoses
HeaterHoses
AirIntakePipesHi-TorqueHTM-L11.3-14.2100-125
PlasticAirIntakePipes
ChargeAirIntakeHoses
Fuel,Oil&WaterHeatExchangers (forhoseslessthan9/16diameter)
Constant-TorqueCT-L
ConstantT ension
Constant-T orqueCT-L
FlexSeal667
B92966-750-60
Miniature3600L1.1-1.710-15
10.2-12.590-110
notrequirednotrequired
4.5
7.9-11.370-100
40(maximum)
5
(03/17)Y53-6077-1B15-43
LUBRICANTSPECIFICATIONS
MasterLubricationIndex
ATF
BB
CBEngineoilformildtomoderaterequirements
CC/CDEngineoilforsevererequirements(MIL-L-2104B/MIL-L-45199Bw/1.85%max.sulfatedashcontent)
CDEngineoilmeetingAPI“Fiveenginetestsequence”
CD50SAE50Wsynthetictransmissionuid
CEEngineoilmeetingseveredutyservicerequirementsfordirect-injectionturbochargedengines
CJ-4EngineoilforPACCARMXandCumminsEGRengines
CL
EP
GLStraightmineralgearlubricant
5
HD
HT
MP
DOT3orDOT4
LubricantSymbolKey
MD3orMERCON®-approvedautomatictransmissionuid
Hightemperatureballbearinggrease.ChevronSRIMobileGreaseHP ,T exacoMultifax2orequivalent
Multipurposechassisgrease
ExtremePressureLubricant(Lithium12-hydroxystearatebaseNGLI2)
HypoidGearOil,A.P .I.-GL-5,SAE75W-90FEsyntheticgearlubricant
HighT emperaturegrease(T imkenSpec.0-616)
Multipurposegearlubricant(MIL-L-2105B)
BrakeFluid
5-44Y53-6077-1B1(03/17)
NOTE
Theresponsibilityformeetingthese specications,thequalityofthe product,anditsperformanceinser­vicerestswiththelubricantsupplier.
Foroilreservoirwithsidellerplugs (transmission,axles,steeringgear boxes,transfercases,etc.)theoil mustbelevelwiththelleropening.
LUBRICANTSPECIFICATIONS
1ImproperOilLevel 2ProperOilLevel
Usecarewhencheckingtheoillevel withanger.Justbecauseyoucan reachtheoillevelwithanger,does notmeantheoilleveliscorrect.
(03/17)Y53-6077-1B15-45
5
LUBRICANTSPECIFICATIONS
UniversalJoints
DriveShaftSplinesCL*
SteeringColumnCL
AlternatorBearing
FanHub
PowerSteeringReservoir
SteeringDragLinkCL
SteeringKnucklesCL
SpringPinsCL
ClutchReleaseBearings
BrakeShoeAnchorPins
BrakeCamBearings
5
SlackAdjustersCL
StarterBearingsCC
TurbochargerAneroid
WaterPump
SuspensionFittings(otherthanthreadedpinsandbushings)
SteeringAxle:GreaseFittingsonSteeringArm;TieRodEnds;Drag Link;KingPins
SteeringShaftGreaseFittings
ComponentLubricationIndex
EP*
BB*
BB*
ATF
BB
HT
HT
CC
BB*
EP
EP
EP
5-46Y53-6077-1B1(03/17)
ComponentLubricationIndex
BrakeTreadleHingeandRollerEngineoil
LockCylinders
DoorHinges
DoorLatchesandStrikerPlates
DoorWeatherstrip
Hub-pilotedAluminumWheels
ManualTransmissionHydraulicClutchDOT3orDOT4(BrakeFluid)
*Consultmanufacturerorlubricantsupplierforspecialdetails.
Locklubricant
Notrequired-T eonbushings
Polyethylenegreasestick
Siliconelubricant
CoatthewheelpilotorhubpadswithFreylube#3lubricant(light colored)orChevronZinclube.Donotgetlubricantonthefaceof thewheelorthehub.
LUBRICANTSPECIFICATIONS
5
(03/17)Y53-6077-1B15-47
LUBRICANTSPECIFICATIONS
FullerTransmission Lubrication
Fullertransmissionsaredesignedso thattheinternalpartsoperateina bathofoilcirculatedbythemotionof gearsandshafts.Greyironpartshave built-inchannelswhereneededto helplubricatebearingsandshafts.All partswillbeamplylubricatedifthese proceduresarecloselyfollowed:
1.Maintainoillevel;checkit regularly.
2.Changeoilregularly.
3.Usethecorrectgradeandtypeof
5
oil.
4.Buyoilfromareputabledealer.
LubricationChangeandInspection Off-HighwayUse
RefertotheEatonFullertransmission manualforservicinginformation.
HighwayUse
•RefertotheEatonFuller
transmissionmanualforservicing information.
•Refertotheoilchangevs.
temperaturechartthatfollowsfor specialoilchangeinformation.The “intermittentpeaktemperature” isthemaximumtemperature observedforashorttimeina fullyloadedvehicleperforming normally.
CAUTION
Exceedingtherecommendedoil changeintervalsmaybeharmfulto thelifeofthetransmissionandthe transmissionoilcooler.
5-48Y53-6077-1B1(03/17)
RecommendedLubricants
LUBRICANTSPECIFICATIONS
Type
HeavyDutyEngineOilMIL-L-2104B,C,orD; API-SF ,orAPI-CD
Mineralgearoilwithrustandoxidation inhibitorAPI-GL-1
SyntheticLubricant*
*Seeyourdealerforapprovedbrands.
Grade(SAE)
50
40
30
90
80W
50All
AmbientTemperature
Above10°F(-12°C)
Above10°F(-12°C)
Below10°F(-12°C)
Above10°F(-12°C)
Below10°F(-12°C)
5
(03/17)Y53-6077-1B15-49
LUBRICANTSPECIFICATIONS
AllisonTransmission Lubrication
LubricationChangeandInspection
•Refertoyourtransmission
•RefertotheAllisonTransmission
5
manual(furnishedseparately)for lubricationinformation.
manualforservicinginformation.
Type
orMIL-L-46152B,API-SForAPI-CD (MIL-L-2104BorCorMIL-L-46152 designationsareacceptable)
Mineralgearoil(RandOtype)API-GL-1
SpicerTransmission Lubrication
Itisextremelyimportanttousethe properlubricantsandmaintainthe correctoillevelsinSpicerunits.This willensureproperlubricationand operatingtemperaturesintheseunits.
Grade(SAE)
30,40,or50
30
90
80
RecommendedLubricants
Thelubricantslistedbeloware recommended,inorderofpreference, foruseinallSpicermechanical transmissions,auxiliaries,and transfercases.Donotuseextreme pressureadditivessuchasthose foundinmultipurposeorrearaxle-type lubricants.Theseadditivesarenot requiredinSpicertransmissions, andmayinsomecasescreate transmissionproblems.Multipurpose oils,asagroup,haverelativelypoor oxidationstability,ahighrateofsludge formation,andagreatertendencyto reactwithorcorrodethesteeland bronzeparts.
AmbientTemperature
Above0°F(-18°C) HeavyDutyEngineOilMIL-L-2104D
Below0°F(-18°C)
Above0°F(-18°C)
Below0°F(-18°C)
5-50Y53-6077-1B1(03/17)
LUBRICANTSPECIFICATIONS
Type
SyntheticEngineOilmeetingMIL-L-2104Dor MIL-L-46152B,API-SForAPI-CD
*SyntheticGearOilMeetingMIL-2105Cor API-GL5
*EPGearOilsarenotrecommendedwhenlubricantoperatingtemperaturesareabove230°F(1 10°C).
OilChanges
CD50 CD30
EP75W90 EP75W140
24hoursbutbefore100hoursof
Grade(SAE)
servicehaveelapsed.
CAUTION
Whenaddingoil,typesandbrands ofoilshouldnotbeintermixedbe­causeofpossibleincompatibility, whichcoulddecreasetheeffec­tivenessofthelubricationorcause componentfailure.
Aninitialoilchangeandushshould beperformedafterthetransmission hasbeenplacedinactualservice. Thischangeshouldbemadeanytime after3000miles(4800km)butnever longerthan5000miles(8000km)of over-the-roadservice.Inoff-highway use,thechangeshouldbemadeafter
AmbientTemperature
All
All
Relling
Removealldirtaroundllerplug.Rell withnewoilofthegraderecommended fortheexistingseasonandprevailing service.Filltothebottomofthe leveltestingplugpositionedonthe sideofthetransmission.Donot overllthetransmission.Overlling usuallyresultsinoilbreakdowndue toexcessiveheatandaerationfrom thechurningactionofthegears.Early breakdownoftheoilwillresultinheavy varnishandsludgedepositsthatplug upoilportsandbuilduponthesplines andbearings.Overowofoilcanalso escapeontoclutchorparkingbrakes. Whenaddingoil,donotmixdifferent typesofoil.
5
(03/17)Y53-6077-1B15-51
LUBRICANTSPECIFICATIONS
MeritorAxleLubrication
Axlesutilizedin100%off-highway usearenoteligibleforMeritor’sAd­vancedLubeRearDriveAxlepro­gram.
RS-17-145RS-23-180
RS-19-145RS-26-180
RS-21-145RS-30-180SQ-100A
RS-23-160
RS-23-161
5
Meritorrearaxlesthatdonotappear onthelistabovewillcontinueto requireaninitialdrainat3000-5000 miles(4800-8000km).
•RefertotheMeritorField
MaintenanceManualfora particularaxleforlubricant specications.
UnderMeritor’sAdvancedLubeRear
NOTE
DriveAxleprogram,theaxleslisted belowareexemptfromaninitial lubricantchange:
AV AILABLEADVANCEDLUBEAXLES
RT-40-145RT-44-145P
RT-40-145PRT-46-160
RT-46-160P
RT-34-145
RT-34-145PRT-44-145RT-52-160P
SQ-100AP
RT-52-160
•Seeyourdealerfor
Meritor-approvedlubricant brands.
•Refertothefollowingchartfor
lubricantchangeintervals:
5-52Y53-6077-1B1(03/17)
LUBRICANTSPECIFICATIONS
Application
OnHighway
CityDelivery
OffHighway
•Changethelubricantlterevery
120,000miles(192,000km).T op offthelubricantlevelwithasimilar lubricant.
TypeOfLubricant
Synthetic240,000mi.(384,000km)
SyntheticwithPumpandFilter500,000mi.(800,000km)
MineralBase
Synthetic120,000mi.(192,000km)
SyntheticwithPumpandFilter240,000mi.(384,000km)
MineralBase
Synthetic120,000mi.(192,000km)
SyntheticwithPumpandFilter120,000mi.(192,000km)
MineralBase
120,000mi.(192,000km)
120,000mi.(192,000km)
120,000mi.(192,000km)
Eaton/DanaAxleLubrication
•Theoriginalmineral-based
lubricantmustbedrainedwithin 3000-5000miles(4800-8000 km)onallEatonaxles.This initialchangeisveryimportant becauseitushesoutbreak-in contaminantsthatmightotherwise causeprematurewear .
•Mineral-basedlubesmustbe
•Changethelubricantwithinthe
•Noinitialdrainisrequiredon
Eatonaxlesthatarefactorylled
MileageInterval
withanEaton-approvedsynthetic lubricant.
drainedwithintherst5000miles (8000km)ifconvertingtoan Eaton-approvedsyntheticlube.
rst5000miles(8000km)of operationafteracarrierhead replacement,regardlessofthe lubricanttype.
5
(03/17)Y53-6077-1B15-53
LUBRICANTSPECIFICATIONS
•RefertotheEatonField
MaintenanceManualfora particularaxleforlubricant specications.
TypeofLubricantOn-HighwayMi.(km)MaximumChange
Mineral-Based
Eaton-Approved Synthetic
Eaton-Approved Syntheticinaxlewith extendeddraininterval option
WheelBearingLubrication
Oil-lubricatedDrivenHubs
5
Usehypoidoil,A.P .I.-GL-5SAE 75W-90FEsyntheticgearlubricant orequivalent.Aminimumof1quart (921ml)ofoilisrequiredforproper lubricationofeachdrivehub.Addoil throughthellerholeinthehub;if none,addoilthroughthedifferential llerhole.(Note:Remembertoreplace ventplugorthreadedllerplugwhen
•Seeyourdealerfor
Eaton-approvedlubricantbrands.
Interval
120,000(192,000)
240,000(384,000)
350,000(560,000)
Yearly
2Years
done.)Allowtimefortheoiltoseep
On/OffHighwaySevere
60,000(96,000)
120,000(192,000)
•Refertothechartbelowfor
lubricantchangeinterval.
ServiceMi.(km)
Oil-lubricatedNondrivenHubs
MaximumChange
Interval
Yearly
Yearly
throughthebearingswheninitially llingahub.Maintainthedifferential oillevelbyaddingoiluntilitssurfaceis evenwiththebottomofthellerhole (seeillustrationonpage5-45).
UseCD50synthetictransmissionuid SAE50Worequivalent.Aminimumof 9oz.(270ml)oflubricantisrequired forproperlubricationofanLMS™hub; 10-13oz.(295-400ml)isrequiredfor anon-LMShub,dependingonwheel design.Allowtimefortheuidtoseep throughthebearingswheninitially llingahub.Whenproperlylled,the
5-54Y53-6077-1B1(03/17)
LUBRICANTSPECIFICATIONS
uidlevelwillliebetweentheuidlevel lineand1/4”abovetheline.
NOTE
Remembertoreplaceventplug whendone.
UniversalJointLubrication
RefertotheSpicerUniversalJoints andDriveshaftsservicemanualand lubricationspecications.
SteeringGearLubrication
FluidRell
Thefollowingrecommendationsare forgeneralpurposesteeringsystems (bothTRWandSheppard).
•Fornormaltemperatures,use
AutomaticTransmissionFluid (ATF)TypeEorForDexron®III.
•Forcoldtemperaturesof-22ºF
(-30ºC)andaboveuseATFT ype A.
•Forextremelycoldtemperatures
between-22ºF(-30ºC)and-40º F(-40ºC)useATFTypeB.
5
(03/17)Y53-6077-1B15-55
LUBRICANTSPECIFICATIONS
Inspection
NOTE
Beforeremovingreservoircover , wipeoutsideofcoversothatnodirt canfallintothereservoir.
1.Checktheuidlevel;adduidif required.
2.Checkuidforcontamination, discoloration,orburntsmell; correctsourceofsuchproblems beforereplacinguidandlter.
CAUTION
Whenaddinguid,besuretouse
5
uidofthesametype.Whilemany uidshavethesamedescriptionand intendedpurpose,theyshouldnot bemixedduetoincompatiblead­ditives.Mixingincompatibleuids mayleadtoequipmentdamage.
Ifincompatible(insoluble)uidsare mixedinapowersteeringsystem, airbubblescanbeproducedatthe interfaceofthetwouids.Thiscan causecavitation,whichreducesthe lubricationbetweenmovingpartsin thegear.Thiscouldresultinworn components.
Themixtureoftwodifferentuids, althoughharmlesstoindividual internalcomponents,mayinitiatea chemicalreactionthatproducesanew compoundthatwillattacksealsand otherinternalcomponents.
Donotmixdifferentuids.
5-56Y53-6077-1B1(03/17)

AIRSYSTEM

AIRSYSTEM
Introduction
WARNING!
Donotattempttomodify ,alter,repair ordisconnectanycomponentofthe airsystem.Repairsormodications totheairsystem,otherthanwhat isdescribedinthissection,should onlybeperformedbyanauthorized dealer.Failuretocomplymayresult indeathorpersonalinjury .
WARNING!
Priortotheremovalofanyairsys­temcomponent,alwaysblockand holdthevehiclebyasecuremeans otherthanthevehicle'sownbrakes. Depletingairsystempressuremay causethevehicletorollunexpect­edlyresultinginanaccidentcausing deathorpersonalinjuries.Keep handsawayfromchamberpush rodsandslackadjusters,theymay applyassystempressuredrops.
WARNING!
Aftercompletinganyrepairstothe airsystem,alwaystestforairleaks, andcheckthebrakesforsafeopera­tionbeforeputtingthevehicleinser­vice.Failuretocomplymayresultin death,personalinjury,equipmentor propertydamage.
WARNING!
Neverconnectordisconnectahose orlinecontainingairpressure.It maywhipasairescapes.Neverre­moveacomponentorpipeplugun­lessyouarecertainallsystempres­surehasbeendepleted.Failureto complymayresultindeath,personal injury,equipmentorpropertydam­age.
WARNING!
Neverexceedrecommendedair pressureandalwayswearsafety glasseswhenworkingwithairpres­sure.Neverlookintoairjetsordirect thematanyone.Failuretocomply mayresultindeath,personalinjury , equipmentorpropertydamage.
5
(03/17)Y53-6077-1B15-57
AIRSYSTEM
WARNING!
Neverattempttodisassemblea componentuntilyouhavereadand understoodrecommendedproce­dures.Somecomponentscontain powerfulspringsandinjurycanre­sultifnotproperlydisassembled. Useonlypropertoolsandobserve allprecautionspertainingtouse ofthosetools.Failuretocomply mayresultindeath,personalinjury , equipmentorpropertydamage.
5
WARNING!
CompletelybypassingaBendix® AD-ISairdryerwillbypassthesys­tem’spressureprotectionvalves. Thiscouldleadtolossofairpres­sureordamagetothevehicle’s airsystem,whichcouldcausean accidentinvolvingdeathorper­sonalinjury .Alwaysadheretothe manufacturer’sprocedureifitis necessaryinanemergencytotem­porarilybypassanAD-IS-seriesair dryer.Failuretocomplymayresult indeath,personalinjury ,equipment orpropertydamage.
Theoperationofthevehicle’sbraking systemandmanyvehicleaccessories dependsuponthestorageand applicationofahigh-pressureair supply.
Yourvehicle’scompressortakes outsideairandcompressesit,usually to100-120psi(689-827kPa).The
compressedairthengoestothe reservoirstobestoreduntilneeded. Whenyouoperateyourairbrakes,the storedcompressedairowsintothe chamberswhereitisusedtoapply yourtruckandtrailerbrakes.Thatis why,whenyoupushdownonyour brakepedal,youdon’tfeelthesame amountofpressureonthepedalthat youdowhenyouapplythebrakeson yourcar.Allyouaredoingonyour truckisopeninganairvalvetoallow airtoowintothebrakechambers.
Contaminationoftheairsupplysystem isthemajorcauseofproblemsin air-operatedcomponentssuchas brakevalves,andsuspensionheight controlvalves.T okeepcontaminants tothelowestpossiblelevel,follow thesemaintenanceprocedures.
5-58Y53-6077-1B1(03/17)
AIRSYSTEM
WARNING!
Ifthesupplyandservicetanksare notdrainedattherecommended frequency,watercouldenterthe airlinesandvalves.Thiscould causecorrosionorblockage,which couldcompromisethebrakesystem safetyandpotentiallycauseanac­cidentinvolvingdeathorpersonal injury.
Daily
•Drainmoisturefromthesupply
andserviceairtanks.
•Operateairdevicestocirculate
lubricantswithintheunit.
Periodically
•Cleanlterscreensaheadofthe
valvesbyremovingthescreens andsoakingtheminsolvent.Blow themdrywithpressurizedair beforereinstallingthem.
5
(03/17)Y53-6077-1B15-59
AIRSYSTEM
TwiceaYear
•Maintaintheaircompressorto
preventexcessiveoilby-pass. Seeyourmaintenancemanualfor details.
•Replacewornsealsinvalvesand
airmotorsastheyareneeded.
5
AirDryer
Thefunctionoftheairdryeristocollect andremoveairsystemcontaminantsin solid,liquidandvaporformbeforethey enterthebrakesystem.Itprovides clean,dryairtothecomponentsof thebrakesystem,whichincreases thelifeofthesystemandreduces maintenancecosts.
NOTE
Becausenotwovehiclesoperate underidenticalconditions,mainte­nanceandmaintenanceintervals willvary .Experienceisavaluable guideindeterminingthebestmain­tenanceintervalforanyonepartic­ularoperation.
Every900operatinghoursor25,000 miles(40,200km)oreverythree(3) monthscheckformoistureintheair brakesystembyopeningairtanks,
draincocks,orvalvesandcheckingfor presenceofwater.
NOTE
Asmallamountofoilinthesystem maybenormalandshouldnot,init­self,beconsideredareasontore­placethedesiccantcartridge.Oil staineddesiccantcanfunctionade­quately.
Atablespoonofwaterfoundinthe airtankwouldpointtotheneedfora desiccantcartridgechange.However, thefollowingconditionscanalso causewateraccumulationandshould beconsideredbeforereplacingthe desiccantcartridge.
•Airusageisexceptionallyhigh
andnotnormalforahighway vehicle.Thismaybedueto accessoryairdemandsorsome unusualairrequirementthat doesnotallowthecompressor toloadandunload(compressing
5-60Y53-6077-1B1(03/17)
AIRSYSTEM
andnon-compressingcycle)ina normalfashionoritmaybedueto excessiveleaksintheairsystem.
•Inareaswheremorethana30°
F(17°C)rangeoftemperature occursinoneday,smallamounts ofwatercanaccumulatein theairbrakesystemdueto condensation.Underthese conditions,thepresenceofsmall amountsofmoistureisnormal andshouldnotbeconsideredas anindicationthatthedryerisnot performingproperly .
•Anoutsideairsourcehasbeen
usedtochargetheairsystem. Thisairdidnotpassthroughthe dryingbed.
Overhaul
Maintenanceintervalstypicalfor on-highwayoperationwouldbe2-3 years,350,000milesor10,800hours.
Maintenanceintervalstypicalforhigh dutycycleusagesuchastransitbus, refusehauler,dumptruck,cement mixersandoff-highwayoperation wouldbe1year,100,000milesor 3,600hours.
NOTE
Reviewthewarrantypolicybefore performinganymaintenanceproce­dures.Anextendedwarrantymay bevoidedifunauthorizedmainte­nanceisperformedduringthispe­riod.
Bendix®AD-ISSeriesAirDryer
Yourvehiclemaybeequippedwitha Bendix®AD-ISseriesairdryer.Any airdryerreplacementshouldbemade withanidenticalcomponent.
WARNING!
Ifadifferentairdryerbrandormodel isinstalledonthevehicleotherthan whatwasoriginallyinstalled,itcould causetheairsystemtonotperform correctlyunlessthefullairsystem designisreviewedandmodica­tionsmadetocomplywithFederal MotorVehicleSafetyStandards (FMVSS)121-AirBrakeSystems. Failuretoabidebythiswarningand maintaincompliancetoFMVSS121 couldcauselossofvehiclecontrol andmayleadtodeathorserious personalinjury .
TheAD-ISSeriesairdryerhas incorporatedintoitsdesignvarious
5
(03/17)Y53-6077-1B15-61
AIRSYSTEM
componentsthathavetypicallybeen installedseparatelyonthevehicle(see belowforcomponents/areasaffected):
•Pressureprotectionvalves
•Safetyvalve
•Governorandplumbing
•Plumbingofthefrontandrear
serviceairtanks
•Plumbingtoaccessorysystems
Thesecomponentsarerequiredto meettheFederalMotorVehicleSafety Standards(FMVSS121-AirBrake Systems).AstheWarningabove
5
states,anyothertypeofairdryer installedintheplaceofanAD-ISSeries willrequirechanges,modications and/oradditionstoyourvehicle’sair systemtomaintaincompliancewith FMVSS121.
AirTanks
Toejectmoisturefromtheairsystem tanks,pullthelinethatisconnectedto themoistureejectionvalve.Continue pullinguntiltheaircomesoutfreeof water.
Daily:Thesupplyandserviceair tanks,mustbedrainedonadaily
basis.Operateairdevicesdailyto circulatelubricantswithintheunit.
Periodically:Cleanlterscreens aheadofthevalvesbyremovingthe screensandsoakingtheminsolvent. Blowthemdrywithpressurizedair beforereinstallingthem.
WARNING!
Ifthesupplyandserviceairtanks arenotdrainedattherecommended frequency,watercouldenterthe airlinesandvalves.Thiscould causecorrosionorblockage,which couldcompromisethebrakesystem safetyandpotentiallycauseanac­cident.Failuretocomplymayresult indeath,personalinjury ,equipment orpropertydamage.
5-62Y53-6077-1B1(03/17)
AIRSYSTEM
CAUTION
Donotusepenetratingoil,brake uid,orwax-basedoilsintheairsys­tem.Theseuidsmaycausesevere damagetoairsystemcomponents.
•Maintaintheaircompressorto
preventexcessiveoilbypass.
•Replacewornsealsinvalvesand
airmotorsastheyareneeded. Yourauthorizeddealercarries rebuildkitsformostunits.
AirGaugesandAirLeaks
Yourvehiclecomeswithairpressure gaugesfortwoseparatesystems, PrimaryandSecondary:thePrimary gaugeindicatespressureintherear brakingsystem;theSecondarygauge indicatespressureinthefrontbraking system.Eachgaugeindicatesthe amountofairpressureinpoundsper squareinch(psi).
WARNING!
Donotoperatethevehicleifleak­ageintheairsystemisdetected. Conductthefollowingprocedure andcontactanauthorizeddealer(or anyotherproperlyequippedservice center)ifaleakisdetected.Failure tocheckthebrakesorfollowthese procedurescouldcauseasystem failure,increasingtheriskofan accidentandmayresultindeath, personalinjury,equipmentorprop­ertydamage.
Ifthelightandalarmdonotturnoffat start-up,donottrytodrivethevehicle untiltheproblemisfoundandxed.If thepressureineitherorbothsystems istoolowfornormalbrakeoperation, i.e.,thepointerofonegaugefalls below65psi(448kPa),awarninglight onthegaugewillglowandtheaudible alarmwillsound.
NOTE
Parkbrakeslockupat60psi(414 kPa),theaudiblealarmwillsoundat 65psi(448kPa).
5
PrimaryAirPressureGauge
(03/17)Y53-6077-1B15-63
AIRSYSTEM
SecondaryAirPressureGauge
Followtheprocedurebelowto checkthecompressedairsystem forleaks:
1.Periodically,oraftermaintenance orreplacementofairsystem components:
2.Buildupairpressureinthesystem tothegovernorcutoutpointoruntil
5
120psi(827kPa)isreached.
3.Stoptheengineandreleasethe servicebrakes.
4.Withoutapplyingthebrakepedal, observetherateofairpressure drop.Thisrateshouldnotexceed
2.0psi(14kPa)perminute.
5.Starttheengineandbuildupthe airpressureagain.
6.Stoptheengine,andapplythe brakesfully.Applythebrakepedal andholditdownforveminutes. Thepressuredropshouldnot exceed3.0psi(21kPa)per minute.
7.Ifyoudetectexcessiveleakage (airpressurelossgreaterthan3.0 psi(21kPa)afterveminutesof brakeapplication),aleakagetest shouldbemadeattheairline connectionsandatallairbrake controlunits.Thesetestsshould determinewhereairisescaping.
AirCompressor
Operation
Allcompressors,regardlessofmake ormodel,runcontinuouslywhilethe engineisrunning.Systempressure iscontrolledbythegovernor.The governoractsinconjunctionwith theunloadingmechanisminthe compressorcylinderblocktostart andstopcompressionofair.The compressorisunloadedwhenthe systempressurereaches120psi(827 kPa)andcompressionisreestablished whensystempressurefallsto100psi (690kPa).
5-64Y53-6077-1B1(03/17)
AIRSYSTEM
PreventiveMaintenance
Thefollowingservicechecksare providedforyourinformationonlyand shouldbeperformedbyacertied mechanic.Contactyourdealerorthe enginemanufacturer'sMaintenance Manualforfurtherinformationon servicingaircompressors.
Aftercompletinganyrepairstotheair system,alwaystestforairleaks,and checkthebrakesforsafeoperation beforeputtingthevehicleinservice.
Belowisalistofareastomaintainfor theaircompressor:
•Inspectcompressorairlter
element,ifsoequipped,and replaceelementifclogged.Check compressormountinganddrive foralignmentandbelttension. Adjustifnecessary .
•Removecompressordischarge
valvecapnutsandcheckfor
presenceofexcessivecarbon.If excessivecarbonisfound,clean orreplacethecompressorcylinder head.Also,checkcompressor dischargelineforcarbon,and cleanorreplacethedischargeline ifnecessary .
•Disassemblecompressorand
thoroughlycleanandinspect allparts.Repairorreplace allwornordamagedparts,or replacecompressorwithafactory exchangeunit.
CAUTION
Whendrainingtheenginecooling systemisrequired,topreventdam­agefromfreezing,thecompressor mustalsobedrainedatthecylinder headandblock.Enginedamage couldoccurifthecoolingsystemis notperiodicallydrainedandmain­tained.SeeCoolingSystemonpage 5-82forfurtherinformation.
5
(03/17)Y53-6077-1B15-65

BRAKESYSTEM

BRAKESYSTEM
BrakeAdjustment
WARNING!
Donotworkonthebrakesystem withouttheparkingbrakesetand wheelschockedsecurely .Ifthe vehicleisnotsecuredtoprevent uncontrolledvehiclemovement,it couldrollandcausedeath,serious personalinjuryordamagetothe vehicle.
Tooperateyourvehiclesafely andprotably ,youneedsome
5
understandingofitsbrakesystems. Formoreonbrakes,seetheIndex, underBrakes.
Brakeadjustmentandbrakebalance mustbesetcarefullyto(1)make themostefcientuseoftheforces availableforbrakingand(2)allow equalstoppingforcesatallwheels.
CAUTION
Theairbrakesystemofthisvehicle wasconguredforONEofthefol­lowingoperations:tractorortruck, andcomplieswiththerespective portionsofFMVSS121.Atractor shallnotbeoperatedorcongured asatruck,norshallatruckbeop­eratedorconguredasatractor, withoutsignicantmodicationsto theairbrakesysteminordertore­taincompliancewithFMVSS121. Contactyourdealerforinstructions.
Onceabrakesystemissetto specications,changinganyoneof itscomponentsoranycombinationof componentsmaycausethesystem tonotworkaswell.Allpartshave toworktogethertoperformasthey should.Anyreplacementcomponents inyourbrakesystemshouldbeexactly equaltotheoriginalcomponents. Anychangesfromtheoriginal
specicationscanaffectthewhole system.Allofthefollowingareas areinterrelatedandmustconformto originalspecications:
•TireSize
•Drumbrakes
a.CamRadius
b.WedgeAngle
c.DrumRadius
d.BrakeLinings
e.BrakeChambers
f.SlackAdjusters
•DiscBrakes
a.DiscRotors
5-66Y53-6077-1B1(03/17)
BRAKESYSTEM
WARNING!
Donotuseanyreplacementpartin thebrakesystemunlessitconforms exactlytooriginalspecications.A nonconformingpartinyourvehi­cle'sbrakesystemcouldcausea malfunctionresultinginanaccident causingdeathorpersonalinjury . Sizesandtypesaresorelatedto oneanotherthataseeminglyunim­portantchangeinonemayresult inachangeinhowwellthebrakes workforyouontheroad.Ifparts donotworktogetherproperly,you couldlosecontrolofyourvehicle, whichcouldcauseaseriousacci­dent.
Allvehicleoperatorsshouldcheck theirbrakesregularly .
WARNING!
Donotusebrakeliningswithathick­nessbelowthespeciedminimum. Suchliningswillhaveliningrivets exposedthatcandamagethebrake drumandreducebrakeefciency, whichcouldcausedeath,personal injuryorsystemfailure.
AirDiscBrakes
Havebrakepadsinspectedbya qualiedmechanicforwearatregular intervalsaccordingtothePreventive MaintenanceScheduleonpage5-12. Insevereserviceoroff-highway applicationsinspecttheliningsmore frequently.
Regularlyinspectforpad/rotorwear:
•Parkonlevelgroundandchock
thewheels.
•T emporarilyreleasetheparking
brakes.
•Comparetherelativeposition
oftwonotches;onelocatedon thecaliperandtheotheronthe carrier.Seetheillustrationbelow todetermineifthebrakesrequire adetailedinspectionbyaqualied mechanic.
5
(03/17)Y53-6077-1B15-67
BRAKESYSTEM
5
•Haveaqualiedmechanic
performadetailedinspection ifthenotchesarenotfound. Thepadsandrotorsshould bemeasuredandcompared againstthemanufacturer's specicationslocatedinthebrake manufacturer’sservicemanual.
CaliperDetail
1.BrakeCaliperAssembly
2.LocationofInspection Grooves
3.NotchesLine-Up(Timeto scheduleinspectionofPads andRotors)
4.BrakeRotor
5.BrakeCarrierAssembly
RegularlyinspectcaliperforRunning Clearance:
•Stopthevehicleonlevelground
andletthebrakescooldown.Hot brakecaliperscanburnskinon contact.
•Chockthewheels.
•T emporarilyreleasetheparking
brakes.
•Grabthecaliperandmoveit.This
movementisRunningClearance.
•ProperRunningClearanceis
0.08inch(2mm)ofmovementof thebrakecaliper(approximately thethicknessofanickel)inthe inboard/outboarddirection.
•Haveaqualiedmechanicprovide
furtherinspectionifthecaliper doesnotmoveorappearstomove morethanthespeciedclearance.
5-68Y53-6077-1B1(03/17)
BRAKESYSTEM
DrumBrakes
Havebrakedrumliningsanddisc brakepadsinspectedbyaqualied mechanicforwearatregularintervals accordingtothemaintenance schedule.Insevereserviceor off-highwayapplicationsinspectthe liningsmorefrequently .
AutomaticSlackAdjusters
PeriodicallychecktheBrakeChamber Stroke.Replacetheslackadjusterif properstrokecannotbemaintained.
Operationalchecksofautomatic slackadjusters
•Measurebrakechamberstroke
withthespringbrakereleasedand theairpressurenolessthan100 psi(690kPa).
•BrakeChamberStrokeisthe
differencebetweentheapplied andtheretractedpositionofthe airchamberpushrod.
•Acorrectlyinstalledand
functioningautoslackadjusterwill producethefollowingstrokes:
ChamberT ypeStroke
36(rearbrakes)1-1/2"-2-1/4"
30(rearbrakes)1-1/2"-2"
16,20and24(front brakes)
(38-57mm)
(38-51mm)
1"-1-3/4" (25.4-44.4mm)
BrakeChamberStroke
5
(03/17)Y53-6077-1B15-69
BRAKESYSTEM
WARNING!
Manualadjustmentofautomatic slackadjustersisadangerousprac­ticethatcouldhaveseriouscon­sequences.Itgivestheoperator afalsesenseofsecurityaboutthe effectivenessofthebrakes.Con­tacttheServiceDepartmentatyour dealershipifthestrokeexceedsthe abovespecications.Astrokeex­ceedingthesevaluesmayindicate aproblemwiththeslackadjusteror thebrakefoundation.
5
5-70Y53-6077-1B1(03/17)
CAB
CAB
ExteriorMaintenance
PaintedSurfaces
Washpaintedsurfacesfrequentlyto removegrimeandcausticdeposits whichmaystainthenish.See Cleaning,Protecting,andWeather Strippingonpage5-72.
ChromeandAluminumSurfaces
Topreventrust,keepchromedparts cleanandprotectedwithwaxatall times,especiallyinwinterconditions wheretheroadsaresalted.
•Ifnecessary,useacommercial
chromecleanertoremovelight rust.
•Chromesurfacesarebest
cleanedwithfreshwater.Wipe drytopreservetheirluster.A commercialchromecleanerwill removelightrust.Aftercleaning, waxatsurfacesandapplyathin coatofrustpreventivelubricant aroundboltsorotherfasteners.
•Cleanaluminumwheelsand
bumperswithwarmwater.Tar removerwillgetridofheavy depositsofroadgrime.T oprevent spotting,wipealuminumsurfaces dryafterwashing.
•Undercorrosiveconditions,such
asdrivingonsaltedroads,clean aluminumpartswithsteamorhigh pressurewaterfromahose.A mildsoapsolutionwillhelp.Rinse thoroughly.
5
(03/17)Y53-6077-1B15-71
CAB
TailPipeSurfaceCleaning
Alwaysallowhotsurfacestocool downbeforeattemptingtoworknear them.Failuretocomplymayresult indeathorpersonalinjury .
Tomaintainyourqualitynish,wash withasoftcloth,mildsoapandwater orglasscleaner.Anon-abrasive chromepolishcanbeusedsparingly onhardtocleanareas.DoNotclean yourhighheatchromeusingscouring pads,abrasivechromepolish,highly acidicchemicalcleanersoranyother
5
abrasivecleaners.
StainlessSteel
WARNING!
Evenhighqualitystainlesssteelparts canrustunderprolongedexposure tosaltwater,especiallywhenthe salt-ladenmoistureisheldagainst themetalsurfacebyroadgrime.It is,therefore,importanttofrequently cleansaltymoistureandgrimefrom stainlesssteelsurfaces.
•Ifsurfacerustisencountered,
washthesurfaceandusea commercialpolishingcompound tocleanofftherust,followedbya coatingofwax.
•Neverusesteelwoolwhen
cleaningstainlesssteelbecause minuteparticlesofthesteelwool canembedinthesurfaceofthe stainlesssteelandcauserust staining.
Cleaning,Protectingand WeatherStripping
Frequentwashingsofthevehicle arerequiredtoremovegrimeand contaminantsthatcanstainand oxidizepaintandacceleratecorrosion ofplatedandpolishedmetalsurfaces.
Waxingoffersaddedprotectionagainst stainingandoxidation.Buttoallow enoughtimeforyourtruck'snishto cure,waitabout30daysafterthedate ofmanufacturebeforewaxing.Donot applywaxinthehotsunanddonot frictionburnthepaintwithabufng machine.
Occasionallysprayweather-stripping ondoorsandwindowswithsilicone compoundtohelppreserveresiliency. Thisisespeciallyusefulinfreezing weathertopreventdoorsandwindows fromstickingshutwithice.
5-72Y53-6077-1B1(03/17)
CAB
VehicleCleaning
Precautions
WARNING!
Handlecleaningagentscarefully. Cleaningagentsmaybepoisonous. Keepthemoutofthereachofchil­dren.Failuretocomplymayresult indeath,personalinjury ,equipment orpropertydamage.
WARNING!
Donotusegasoline,kerosene, naphtha,nailpolishremoverorother volatilecleaninguids.Theymay betoxic,ammableorhazardous inotherways.Failuretocomply mayresultindeath,personalinjury , equipmentorpropertydamage.
WARNING!
Donotcleantheundersideofchas­sis,fenderswheelcovers,etc. withoutprotectingyourhandsand arms.Y oumaycutyourselfon sharp-edgedmetalparts.Failure tocomplymayresultindeath,per­sonalinjury ,equipmentorproperty damage.
WARNING!
Moisture,ice,androadsalton brakesmayaffectbrakingefciency. Testthebrakescarefullyaftereach vehiclewash.Failuretocomply mayresultindeath,personalinjury , equipmentorpropertydamage.
•Observeallcautionlabels.
•Alwaysreaddirectionsonthe
containerbeforeusingany product.
•Donotuseanysolutionthatcan
damagethebodypaint.
•Mostchemicalcleanersare
concentratesthatrequiredilution.
•Onlyusespotremovinguidsin
wellventilatedareas.
•Anyvehicleissubjectedto
deteriorationfromindustrial fumes,ice,snow,corrosiveroad salt,etc.,tonamejustafew causes.Awell-cared-forvehicle canlooklikenewmanyyears later.Regularandcorrectcare willcontributetomaintainingthe beautyandthevalueofyour vehicle.
Yourdealerhasanumberof vehicle-careproductsandcanadvise youonwhichonestouseforcleaning theexteriorandinteriorofyourvehicle.
5
(03/17)Y53-6077-1B15-73
CAB
CAUTION
Donotaimthewaterjetdirectlyat doorlocksorlatch.Tapethekey holestopreventwaterfromseeping intothelockcylinders.Waterinlock cylindersshouldberemovedwith compressedair.T opreventlocks fromfreezinginthewinter ,squirt glycerinorlockdeicerintothelock cylinders.
5
WashingtheExterior
1.Beginbysprayingwateroverthe drysurfacetoremoveallloosedirt beforeapplyingthecarwashand waxsolution.
°Donotwashthevehiclein
directsunshine.
°Donotspraywaterdirectly
intothecabvents.
2.Usingsoapywater,washthe vehiclewithacleansoftclothor asoftbrushmadeforautomotive cleaning.
°Usecoolorwarmwaterand
amild,householdtypesoap. Strongindustrialdetergents andcleaningagentsarenot recommended.
°Donotusestiffbrushes,paper
towels,steelwool,orabrasive cleaningcompoundsbecause theywillscratchpainted,
plated,andpolishedmetal surfaces.
3.Rinsesurfacesfrequentlywhile washingtoushawaydirtthat mightscratchthenishesduring thewashingoperation.
4.Wipeeverythingdrywitha chamoistoavoidwaterspots.
°T opreventwaterspotting,dry
offthecosmeticsurfaceswith acleanclothorchamois.
5.Removeroadtarwithan automotivetypetarremoveror mineralspirits.
6.Aftercleaninganddrying,applya qualityautomotivewax.
5-74Y53-6077-1B1(03/17)
CAB
NOTE
Toallowenoughtimeforyourtruck's nishtocure,waitatleastthirtydays afterthedateofmanufacturebefore waxing.
•Donotapplywaxinthehotsun.
•Neverdustoffdrysurfaceswith aclothbecauseitwillscratch thenishes.
CleaningtheChassis
•Hosedirtandgrimefromthe
entirechassis.Then,ifanoil leakdevelops,youwillbeableto detectiteasier.
•Corrosivematerialsusedforice
andsnowremovalanddustcontrol cancollectontheunderbody .If thesematerialsarenotremoved, acceleratedcorrosion(rust)can occuronunderbodypartssuchas fuellines,frames,oorpan,and exhaustsystem,eventhoughthey havebeenprovidedwithcorrosion protection.
Atleasteveryspring,ushthese materialsfromtheunderbodywith plainwater.Besuretocleanany areawheremudandotherdebriscan collect.Sedimentpackedinclosed areasoftheframeshouldbeloosened beforebeingushed.Ifdesired,your dealercandothisserviceforyou.
CleaningInteriorVinyland Upholstery
•Wipevinylupholsteryandlining
withagoodcommercialupholstery cleaner.Donotuseacetoneor lacquerthinner.
•Cleanfabricupholsterywith
upholsteryshampoospecially formulatedforthispurpose.Follow instructionsonthecontainer.
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(03/17)Y53-6077-1B15-75
CAB
PassengerDoorLowerView Window
Theremaybeoccasionswhenthe innerviewwindowmustberemoved formaintenancecleaningand/or damage.Followthisprocedurewhen installingandremovinganinnerview window.Therecommendedtoolfor removaloftheglassisaglassstick, althoughothertoolsmaybeused providedpropercautionisobserved.
CAUTION
Theuseofscrewdrivers,gasket tools,knivesorothersimilarin­strumentsmaydamagethesealor
5
breaktheglass.Useaglassstick asatoolwheneverpossiblewhen removingorinstallingawindow.If anothertoolmustbeused,exercise extremecarewhenperformingthis procedurewithsuchatool.
NOTE
Alwaysmakesurethatagasketis installedproperlysotheweepslots willbeindexedcorrectly.Thenotch inthegasketistofaceforwardon theRHside.Thisplacestheweep slotsatthebottomofthewindow opening(seenextillustration).There isaridgeonthebottomsurfaceof thegasket(seenextillustration). Installtheglassoutboardofthis ridge.Thepolishedsatinnishon theglass,whichleavesarounded edge,restsagainsttheedgeofthe ridge.Theinstallationandremoval willbeeasierbyusingwaterorsoap asalubricantontheedgeofthe glass.
Toinstallawindow,slidetheglass fromtherearofthedoortowardthe removalslotuntiltheforwardedgeof theglassisagainsttheinsideedgeof theseal(seenextillustration;arrow indicatesforward).
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Usetheglasssticktoleveragethe glassoutoftheseal.
Continuethisprocessalongtheentire frontedgeofthesealuntiltheglassis free.
Whentheforwardedgeoftheglass reachestheforwardinsideedgeofthe seal,theglassshouldpivotoutboard intotheremainingseal(seearrowin nextillustration).
(03/17)Y53-6077-1B15-77
Pressandslidetheglassintotheaft portionofthesealtoseatit.
Toremoveaninnerviewwindow, inserttheglassstickintotheremoval slot,thenusetheglasssticktopush theglassasfaraftaspossible.
5
CAB
SafetyRestraintSystem­Inspection
Theseatbeltsystem,including webbing,buckles,latches,and mountinghardware,enduresheavy useinheavy-dutyvehicles,muchmore thanseatbeltsystemsinpassenger cars.Allusersshouldbeawareofthe factorscontributingtothisheavyuse andreducedbeltlife.
WARNING!
Failuretoproperlyinspectandmain­tainrestraintsystemscanleadtoin­juryorlossoflife.Withoutperiodic inspectionandmaintenancetode-
5
tectunsafeconditions,seatrestraint componentscanwearoutornotpro­tectyouinanaccident.
Factorscontributingtoreducedseat beltlife:
•Heavytruckstypicallyaccumulate
twiceasmanymilesasthe averagepassengercarinagiven timeperiod.
•Seatandcabmovementin
truckscausesalmostconstant movementofthebeltduetoride characteristicsandseatdesign. Theconstantmovementofthebelt insidetherestrainthardwareand thepotentialforthebelttocome incontactwiththecabandother vehicleparts,contributestothe wearoftheentiresystem.
•Environmentalconditions,suchas
dirtandultravioletraysfromthe sun,willreducethelifeoftheseat beltsystem.
Duetothesefactors,thethree-point safetybeltsysteminstalledinyour
vehiclerequiresthoroughinspection every20,000miles(32,000km).If thevehicleisexposedtosevere environmentalorworkingconditions, morefrequentinspectionsmaybe necessary.
Anyseatbeltsystemthatshowscuts, fraying,extremeorunusualwear, signicantdiscolorationduetoUV (ultraviolet)exposure,abrasiontothe seatbeltwebbing,ordamagetothe buckle,latchplate,retractorhardware oranyotherobviousproblemshould bereplacedimmediately,regardless ofmileage.
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WARNING!
Itisimportanttorememberthatany timeavehicleisinvolvedinanac­cident,theentireseatbeltsystem mustbereplaced.Unexposeddam­agecausedbythestressofanacci­dentcouldpreventthesystemfrom functioningproperlythenexttimeit isneeded.Failuretocomplymayre­sultindeathorpersonalinjury.
InspectionGuidelines
Followtheseguidelineswhen inspectingforcuts,fraying,extreme orunusualwearofthewebbing, anddamagetothebuckle,retractor, hardware,orotherfactors.Damageto theseareasindicatesthatbeltsystem replacementisnecessary .
WARNING!
Replacetheentirebeltsystem(re­tractorandbuckleside)ifreplace­mentofanyonepartisnecessary . Unexposeddamagetooneormore componentscouldpreventthesys­temfromfunctioningproperlythe nexttimeitisneeded.Failureto complymayresultindeathorper­sonalinjury.
1.Checkthewebwearinthesystem. Thewebbingmustbeclosely examinedtodetermineifitis comingintocontactwithanysharp orroughsurfacesontheseator
otherpartsofthecabinterior. Theseareasaretypicalplaces wherethewebwillexperience cuttingorabrasion.Cuts,fraying, orexcessivewearwouldindicate theneedforreplacementofthe seatbeltsystem.
2.Thepillarwebguide(D-loop)is theareawherealmostconstant movementoftheseatbelt webbingoccursbecauseof relativemovementbetweenthe seatandcab.
3.ChecktheKomfort-Latchfor cracksorpossibledamageand checkforproperoperation.
4.Checkbuckleandlatchforproper operationandtodetermineif latchplateisworn,deformed,or damaged.
5.Inspecttheretractorwebstorage device,whichismountedonthe oorofthevehicle,fordamage. Theretractoristheheartofthe
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CAB
occupantrestraintsystemandcan oftenbedamagedifabused,even unintentionally.Checkoperation toensurethatitisnotlockedup andthatitspoolsoutandretracts webbingproperly .
6.Iftethersareused,besurethey areproperlyattachedtothe seatand,ifadjustable,thatthey areadjustedinaccordancewith installationinstructions.T ethers mustalsobeinspectedforweb wearandpropertightnessof mountinghardware.
7.Mountinghardwareshouldbe
5
evaluatedforcorrosion,andfor tightnessofboltsandnuts.
8.Checkwebinareasexposedto ultravioletraysfromthesun.Ifthe colorofthewebintheseareasis graytolightbrown,thephysical strengthofthewebmayhave deterioratedduetoexposureto
thesun'sultravioletrays.Replace thesystem.
SeatBeltInspectionPoints
1Webcutorfrayedor
extremelywornatlatch area.
2WebcutorfrayedatD-loop
webguide.
3ComfortClipcrackedor
damaged.
4Bucklecastingbroken. 5RetractorWebStoragefor
damage.(locatedbehind trimpanel)
6Tethersforwebwearand
propertightnessofmounting hardware.
7Mountinghardwarefor
corrosion,propertightness ofboltsandnuts.
8Webfordeterioration,due
toexposuretothesun
WARNING!
Failuretoadjusttetherbeltsproperly cancauseexcessivemovementof theseatinanaccident.T etherbelts shouldbeadjustedsothattheyare tautwhentheseatisinitsmostup­wardandforwardposition.Failure tocomplymayresultindeathorper­sonalinjury.
Oncetheneedforreplacementof theseatbelthasbeendetermined,
5-80Y53-6077-1B1(03/17)
CAB
becertainitisonlyreplacedwith anauthorizedPACCARParts replacementseatbelt.
Iftheinspectionindicatesthatany partoftheseatbeltsystemrequires replacement,theentiresystemmust bereplaced.Aninstallationguideis attachedtoeveryreplacementbelt. Utilizetheproperguideforyourtypeof seat,andfollowtheinstructionsvery closely.Itisvitallyimportantthatall componentsbereinstalledinthesame positionastheoriginalcomponents thatwereremovedandthatthe fastenersbetorquedtospecication. Thiswillmaintainthedesignintegrity ofthemountingpointsfortheseatbelt assembly.Contactyourdealerifyou haveanyquestionsconcerningseat beltreplacement.
WindshieldWiper/Washer
Thewindshieldwipersystemis maintenancefree.Checkwiperblades annuallyorevery60,000miles(96,000 km).
WasherReservoir
CAUTION
Donotuseantifreezeorengine coolantinthewindshieldwasher reservoir,damagetosealsandother componentswillresult.
Daily:Checkreservoirwaterlevel, locatedintheenginecompartment.If necessary,relltotheproperlevel.
5
(03/17)Y53-6077-1B15-81

COOLINGSYSTEM

COOLINGSYSTEM
Coolingsystem maintenance
Yourengine’scoolingsystemis standardwithExtendedLifeCoolant (ELC).ELCconsistsofamixtureof ethyleneglycol,water ,andorganic acidtechnologychemicalinhibitors. ELCpreventscorrosionandscale formationaswellasprovidesfreezing andboilingpointprotection.
5
CAUTION
Theenginecoolingsystemhasvery specicmaintenanceandinspection requirements.Failuretofollowre­quirementscandamagetheengine. Enginedamagecanincludebutis notlimitedto:
•Freezing
•Boiling
•Corrosion
•Pittedcylinderliners
Thisinformationisfoundintheen­ginemanufacturer'sowner’sman­ual.Itistheowner’sresponsibil­itytofollowallrequirementslistedin theenginemanufacturer'sowner’s manual.
WhattoCheckinanELC-lled CoolingSystem ELCConcentration
Checktheleveloffreeze/boilover protection,whichisdeterminedby theELCconcentration.Useaglycol refractometertodetermineglycollevel. AddELCtoobtaintheELCtowater ratiorequiredtoprovidetheprotection youneed.Usethechartbelowtohelp determinehowmuchELCyouneed toadd.
NOTE
MaximumrecommendedELCcon­centrationis60%ELCand40%wa­terbyvolume(a60/40coolantmix­ture).Theminimumrecommended concentrationis40%.
InanELC-lledcoolingsystem,the freezepointshouldbemaintained between-30°Fand-45°F(-34°Cand
-43°C).
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COOLINGSYSTEM
DesiredELC/Waterratio:
10%15%20%25%30%35%40%45%50%55%60%65%70%75%80%85%90%
Freezepoint°F(°C)
+25 (-4)
Itemsinboldaretherecommendedlevelsofconcentration.
+20 (-7)
+15 (-9)
+10
(-12)
+5
(-15)
ELCCondition(Contaminationand InhibitorConcentration)
Performavisualinspectionofthe ELC.Itshouldhavenocloudiness oroatingdebris.Determinethe chemicalinhibitorconcentrationlevel byusinganELC-specictestkitor teststrips.Inhibitorconcentrationlevel determinescorrosionprotection.Ifyou areconcernedaboutpossiblecoolant quality,contamination,ormechanical problems,submitacoolantsamplefor analysis.Impropermaintenancemay causecoolantdegradationandcould resultindamagetothecoolingsystem andenginecomponents.Consult yourdealerortheELCmanufacturer’s
-5
(-21)
-12
(-24)
-23
(-31)
-34
(-37)
representativeforrecommendedELC testkits,teststrips,andlaboratory sampleprocedures.
ELCExtender
AddELCextenderifnecessaryatthe maintenanceintervalunder“Cooling”.
CoolantFilter
Ifyourvehiclecamewitha non-chemicallter(“blanklter”), replaceitonlywithablanklteratthe intervalspeciedinthePreventive MaintenanceScheduleonpage5-12. NeveruseltersthatcontainSCAsin anELC-lledsystem.
-50
(-46)
-65
(-54)
-75
(-59)
-84
(-64)
-70
(-57)
-55
(-48)
-43
(-42)
-30
(-34)
5
(03/17)Y53-6077-1B15-83
COOLINGSYSTEM
ToppingOff
WARNING!
Removingthellcaponahoten­ginecancausescaldingcoolant tosprayoutandburnyoubadly. Iftheenginehasbeeninopera­tionwithintheprevious30minutes, beverycarefulinremovingthell cap.Protectface,hands,andarms againstescapinguidandsteamby coveringthecapwithalarge,thick rag.Donottrytoremoveituntilthe surgetankcoolsdownorifyousee anysteamorcoolantescaping.In anysituation,removethecapvery slowlyandcarefully.Bereadyto
5
backoffifanysteamorcoolantbe­ginstoescape.
NOTE
Iffrequenttoppingoffisnecessary andtherearenovisiblesignsof coolantleakswhentheengineis cold,checkforleakswiththeengine operatingatnormaltemperature.
Topoffthecoolingsystemwhen coolantdoesnotrisetothelevel indicatedas‘MIN’onthesurgetank. Thesurgetankistranslucentwhich allowsthecoolantleveltobeseen. Addcoolantthroughthesurgetankll cap.Donotremovethepressurecap tollthecoolingsystem.
SurgeT ank
NOTE
Donotusethepressurecaptollthe surgetankwithuid.
ProperCoolantLevel
NOTE
Donotoverllacoolingsystem.Ex­cesscoolantmayresultinoverow, lossofantifreeze,andreducedcor­rosionprotection.
5-84Y53-6077-1B1(03/17)
COOLINGSYSTEM
•Theminimumuidlevelis
determinedbythelineonthe surgetankindicatedbytheletters “MIN”.Thisindicatorislocated belowthellcap.
•Thecoolingsystemwillneeduid
ifthesurgetankleveldoesnotrise tothe“MIN”lineregardlessifthe systemishotorcold.
RellingY ourRadiator
1.Ifyourcoolingsystemisbuiltwith drainvalvesintheupperengine coolantpipe,openthembefore llingthesurgetank.
2.Closeanyopencoolantdrainsin thesystem.
3.Removethesurgetankllcap (donotremovethesurgetank pressurecap).
4.Fillthesystemwithpremixed coolantthroughthesurgetankll cap.Pourcoolantatasteadyow
rateuntilthesurgetankisfull(to thebaseofthellneck).Itmaybe necessarytopausefor1minute andthenre-lliftheuidlevel dropped.
5.Closeanydrainvalvesthatwere openedinStep1.
6.Starttheengineandidleatlow RPM.
7.Duringlowrpmidle,airwillpurge fromthecoolingsystemwhichwill lowerthecoolantlevelinthesurge tank.Continuetollthesurge tankuntilthecoolantlevelremains approximately½in.abovethe "MIN"line.Thismaytakeupto2 minutes,dependingontheoutside temperature.
8.Operatetheenginethrottle untiltheoperatingtemperature stabilizes(whenthethermostat opens).
9.Fillthesurgetankasnecessary toraisethecoolantlevelto½in. abovethe“MIN”level.
10.Operatetheengineathighidle foranother10minutesandthen llthesurgetankagainto½in. abovethe“MIN”level.
11.Replacethesurgetankllcap.
Checkthecoolantlevelaftereachtrip. Addcoolantasnecessary.Y oumay ndyourcoolantlevelisnotuptothe correctlevelsoonafteryouhavelled theradiator.Thismaybebecauseall thetrappedairinthesystemhasnot yetbeenpurged.Ittakesalittletime foralloftheairtoleavethesystem afteryoullyourradiator.
5
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COOLINGSYSTEM
Engine(Block)Heater
WARNING!
Donotusetheheaterifthereare anysignsofproblems.Engineblock heaterscancauseresresultingin death,personalinjury,equipment orpropertydamageifnotproperly maintainedandoperated.Regu­larlyinspecttheengineblockheater wiringandconnectorfordamaged orfrayedwires.Contactyourau­thorizeddealerorthemanufacturer oftheheaterifyouareinneedof repairsorinformation.Failureto complymayresultindeath,per­sonalinjury ,equipmentorproperty
5
damage.
CAUTION
Alwaysunplugtheblockheaterbe­forestartingyourengine.Damage tothecoolingsystemcouldoccurif notturnedOFF(unplugged).
Useasolutionofhalfethyleneglycol antifreezeandhalfwaterforbest heaterperformance.Donotuse morethan65percentconcentrationof antifreeze,asashortenedheaterlife willresult.
Afterservicingthecoolingsystem, operatethevehicleforadayortwo beforeusingtheheater.Trapped airinsidetheengineneedstimeto escape.
5-86Y53-6077-1B1(03/17)

ELECTRICAL

ELECTRICAL
ElectricalSystem
WARNING!
Batteryposts,terminalsandrelated accessoriescontainleadandlead compounds,chemicalsknowntothe StateofCaliforniatocausecancer andreproductiveharm.Washhands afterhandling.
CAUTION
Donotmodifyorimproperlyrepair thevehicleselectricalsystemor powerdistributionbox.Allelectrical repairsshouldbeperformedbyan authorizeddealer.Improperrepair ormodicationswillvoidyourwar­rantyand/orcauseseriousdamage toyourvehicle.
LowVoltageDisconnect(L VD)
Purpose
TheLVDmayincreasebatterylife andpreventunnecessaryjump startconditionsbyensuringthatan unattendedloaddoesnotdeplete thebatterychargetoalevelthatwill preventyoufromstartingyourvehicle.
Operation
TheLVDwilldisconnectnon-vital batteryloadswhenbatteryvoltage dropsbelow12.3Vfor3minutesand thekeyswitchisintheACCorOFF position.Duringthelast2minutesthe LVDwillemitaslowaudiblebeep.30 secondsbeforedisconnectingloads thealarmwillchangetoafastbeep. Thebatteryvoltagemustcomeback upaboveacertainvoltagebeforethe LVDwillreset.
SeeanauthorizeddealeriftheLVD failstoreconnectloadsduringnormal operation.
CircuitsDisconnectedByLVD
•CabDomeLamps
•CabAccessories
•SpareBatteryAandB
NOTE
AllL VDcircuitsarecolor-codedblue onthecentralelectricalpanelcover label.
5
(03/17)Y53-6077-1B15-87
ELECTRICAL
WARNING!
DonotusetheSpareBatteryAand Bcircuitsorothercircuitsthatare controlledbytheL VDtopowerelec­tronicenginecontrols,ABScircuits, orsafety/work-relatedlighting.Be­foreaddinganydevicetothevehi­cle'selectricalsystem,consultyour nearestauthorizeddealerorread thecontentsofTMCRP-136.Fail­uretodosomaycauseequipment damageorleadtopersonalinjury .
NOTE
Thedeterminationofwhatcir-
5
cuits/loadsthatwereconnectedto theLVDwasbasedupontherec­ommendationfromT echnologyand MaintenanceCouncil(TMC)ofthe AmericanTruckingAssociation.To reviewtherecommendedpractice, seeTMCRP-136.
LightBulbs
WARNING!
OptionalHIDheadlightshavehigh voltagecircuitsandshouldonlybe servicedbyatrainedtechnician.At­temptingtoservicetheHIDballast withoutpropertrainingmayresultin severeelectricalshockwhichcould leadtodeathorpersonalinjury.
HeadlightReplacement
Turnthebulblockring counterclockwiseandremove thebulb.Donotallowtheglassof thenewheadlampbulbtocomeinto contactwithanything.Theglasscould becomecontaminatedandcausebulb failure.Reassembleinreverseorder.
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ELECTRICAL
HeadlightAiming
Theheadlightswereproperly aimedatthefactorytomeetsafety specications.Iftheheadlightsneedto beadjusted,pleasehaveanauthorized dealershipaimtheheadlights.
BulbSpecications
BulbLocation
LowBeam Halogen
LowBeamHID
HighBeam Halogen
DaytimeRunning Lamp/Position Lamp/TurnSignal/ SideMarker
Reartaillight/Turn Signal
Interiormap/dome/ indirectlight
TypeofBulb
H11-LL(SAE), H7(ECE)(long lifeversionnot required)
D1-S
HB3A–LL(long lifeversionnot required)
4157K(SAE), 3157K(ECE)
Notapplicable– LEDlighting
Notapplicable– LEDlighting
Fuses,CircuitBreakersand Relays
Fuses,circuitbreakers,andrelaysare locatedinthePowerDistributionBox totheleftofthesteeringcolumnbehind theclutchpedal.Additionalfusesare locatedintheenginecompartment (driver'ssidebulkhead)andalso inthesleeperunderbunkstorage compartment.
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(03/17)Y53-6077-1B15-89
ELECTRICAL
5
In-CabFuseLabel
5-90Y53-6077-1B1(03/17)
ELECTRICAL
SleeperFuseLabel
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5
ELECTRICAL
FuseInspectionand
AddingElectricalOptions
Replacement
WARNING!
Ifafuseisblown,seeWhattodoif fuseorrelayblowsintheDrivingand OperatingInstructionsmanual.
5
FusePuller
Donotaddafusewitharating higherthan30amps.Followthe circuitprotectionsize/typerecom­mendedbythecomponentmanu­facturer.Installingafuseorcircuit breakergreaterthandesignated maydamagetheelectricalsystem whichcouldleadtoequipmentdam­ageand/orpersonalinjury .
CAUTION
Followallmanufacturers'circuitpro­tectionrecommendationsforthe componentsandwiresbeingadded. Failuretocomplymayresultin equipmentdamage.
5-92Y53-6077-1B1(03/17)
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