Content

Introduction, environmental concerns and recommendations, event data recorder, customer assistance center, reporting safety defects

Vehicle identification

• Component information label
• Federal motor vehicle safety standard labels
• Canadian motor vehicle safety standard labels
• Component GWR label
• Emissions labels

Vehicle access

• Door locks and handles
• Grab handles and access steps
• Back-of-cab access
• Hood opening and closing

Instruments

• Warning and indicator lights
• Standard instruments
• Optional instruments
• Overhead instrument panel, optional

Driver controls

• Control panels
• Ignition switch
• Lighting controls
• Horn controls
• Powertrain controls
• Windshield wiper controls
• Brake controls
• Adjustable steering column controls
• Suspension/trailer connection controls
• Climate controls
• Seat controls

Climate controls

• Climate control options
• Cab climate control panels
• Sleeper climate control panels

Seats and restraints

• Seats, general information
• Western star high-back seat
• Bostrom seat
• National seat
• Abts seat
• Seat belts and tether belts
• Sleeper compartment restraints

Cab and sleeper features

• Windows and mirrors
• Cab amenities
• Sleeper amenities

Electrical system

• Vehicle power distribution
• Battery disconnect switches
• Battery access

Engine starting, operation, and shutdown

• Engine starting
• Engine operation
• Engine shutdown
• Engine cooling

Optional engine systems

• Engine protection—warning and shutdown
• Engine idle limiting
• Cruise control
• Auxiliary braking applications
• Power takeoff (PTO) governor

Emissions and fuel efficiency

• Greenhouse gas emissions and fuel consumption standards
• EPA-regulated emissions aftertreatment systems
• Diesel exhaust fluid and tank, EPA10 and newer engines

Brake systems

• Air brake system
• Meritor WABCO antilock braking system
• Roll-stability control

Steering system

• Power steering system

Manual transmissions and clutch

• Eaton Fuller transmission operation tips
• Eaton Fuller Splitter and Range-Shift transmissions
• Eaton Fuller Deep reduction transmissions Clutch

Automated and automatic transmissions

• Eaton Fuller Automated transmissions
• Allison automatic transmissions

Drive axles

• Drive axles with differential lock
• Interaxle lock

Fifth wheels

• Fifth wheels, general information
• Fifth wheel coupling
• Fifth wheel uncoupling
• Fifth wheel slide

Trailer couplings

• Trailer couplings
• Air-suspension dump valve
• Premier trailer couplings

Headlight aiming

• Preliminary checks
• Checking headlight aim
• Adjusting headlight aim

Vehicle appearance and care

• Cab washing and polishing
• Care of chrome parts
• Dashboard care
• Vinyl upholstery cleaning
• Velour upholstery cleaning
• Star gauge face care
• Care of exterior lights

In an emergency

• Hazard warning lights
• Fire extinguisher
• Emergency kit
• Emergency filter replacement, DAVCO fuel / water separator
• Starting with jumper cables
• Towing

Pre- and post-trip checklists

• Periodic inspections and maintenance, general information
• Checklists
• Fluids added

Pre- and post-trip inspections and maintenance

• Safety precautions
• Daily pretrip inspections and maintenance
• Weekly post-trip inspections and maintenance
• Monthly post-trip inspections and maintenance

Maintenance manual contents

General information

• Determining scheduled maintenance intervals
• Initial maintenance (IM) operations
• Lubrication and fluid level check
• M1 maintenance interval operations table
• M2 maintenance interval operations table
• M3 maintenance interval operations table
• M4 maintenance interval operations table
• Maintenance operation sets table
• Maintenance service table
• Noise emission controls maintenance
• Torque specifications tables
• Vehicle maintenance schedule tables
• Verification of inspections log

Engine

• Engine belt inspection
• Engine noise panel inspection (noise emission control)
• Engine-support fasteners check (noise emission control)
• Pacbrake® inspection and maintenance
• Safety precautions

Air intake

• Air cleaner element inspection and replacement
• Charge air cooler inspection
• Intake piping inspection

Air compressor

• Air compressor inspection
• Safety precautions

Alternators and starters

• Alternator and starter check
• Battery check
• Safety precautions

Engine cooling / radiator

• Coolant inspection
• Cooling system inspection (noise emission control)
• Cooling system pressure-flush
• Pressure / filler cap test
• Safety precautions

Clutch

• Clutch release bearing lubrication
• Clutch release cross-shaft lubrication
• Clutch replacement, detroit™ automated transmissions
• Fluid change, hydraulic clutch control
• Fluid level check, hydraulic clutch control
• Safety precautions
• Sleeve assembly bronze bushing lubrication

Transmission

• Allison transmission fluid and filter change
• Allison and Eaton Fuller transmission breather check
• Detroit automated transmission air filter replacement
• Detroit automated transmission fluid change and magnetic plug cleaning
• Detroit automated transmission fluid level inspection
• ESS transmission filter and boot inspection
• Manual transmission air filter / regulator check, and clean or replace
• Manual transmission fluid change
• Safety precautions
• Transmission fluid level inspection
• Transmission inspection

Frame and frame components

• Fifth wheel inspection
• Fifth wheel lubrication
• Frame fastener torque check
• Holland fifth wheel sliding mechanism inspection
• Premier 690 coupling inspection
• Safety precautions
• Trailer electrical connector lubrication

Suspension

• Safety precautions
• Suspension inspection
• Suspension lubrication
• Suspension U-bolt torque check

Front axle

• Front axle wheel bearing lubrication
• Front drive axle lubricant change
• Front drive axle lubricant level check
• Knuckle pin lubrication
• Safety precautions
• Tie rod inspection
• Tie rod lubrication
• Wheel alignment check

Rear axle

• Axle lubricant and filter change, and magnetic strainer cleaning and check
• Drive axle breather check
• Drive axle lubricant level check
• Safety precautions
• Two-speed-axle shift unit lubricant level check

Wheels and tires

• Tire check
• Wheel nut and rim nut torque check

Driveline

• Driveline inspection
• Driveline lubrication
• Safety precautions

Brakes

• Air brake system valve inspection
• Air dryer desiccant replacement
• Air dryer inspection
• Alcohol evaporator cleaning and inspection
• Brake inspection
• Camshaft bracket lubrication
• Safety precautions
• Slack adjuster lubrication
• Versajust slack adjuster inspection and lubrication

Steering

• Drag link inspection
• Drag link lubrication
• Power steering fluid and filter changing
• Power steering gear lubrication
• Safety precautions
• Steering shaft lubrication

Fuel

• Fuel filter replacement
• Fuel separator sight bowl cleaning and element replacement
• Fuel tank band nut tightening
• Safety precautions

Exhaust

• CAT CGI bellows replacement
• Exhaust System Inspection (noise emission control)
• Safety precautions

Cab

• Aerodynamic component inspection
• Cab suspension inspection
• Mirror folding check
• Safety precautions

Doors

• Door seal, door latch, door hinge, and door check lubrication

Heater and air conditioner

• Air conditioner inspection
• HVAC air filter cleaning and replacement
• Safety precautions

Hood, grille, and cab fenders

• Hood rear support lubrication