Quick Table of Contents •Introduction. . . . . . . . . . . . . . . . . . 3 •Cab And Frame Access . . . . . . . . . . . 9 •Getting To Your Engine . . . . . . . . . . . . . . 11 •Controls And Displays . . . . . . . . . . . . . . . . . . 14 •Seat And Restraint Systems . . . . . . . . . . . . . . . . 72 •Driver’s Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 •Starting And Operating The Vehicle . . . . . . . . . . . . . . . . . 87 •Maintenance and Service . . . . . . . . . . . . . . . . .
INTRODUCTION Introduction How to Use This Manual This Operator's Manual contains useful information for the safe and efficient operation of your Medium Duty vehicle. It also provides information on maintaining your vehicle in the best condition, with an outline for performing safety checks and basic preventive maintenance inspections. We have tried to present the information you'll need to learn about your vehicle's functions, controls, and operation as clearly as possible.
INTRODUCTION NOTE WARNING When you see this word, the message that follows is especially vital. It signals a potentially hazardous situation which, if not avoided, could result in an injury or death. This message will tell you what the hazard is, what can happen if you don't heed the warning, and how to avoid it. Provides general information: for example, the note could warn you on how to avoid damaging your vehicle or how to drive the vehicle more efficiently.
INTRODUCTION Vehicle Safety Make sure your Medium Duty is in top working condition before heading out on the road—it is the responsible driver's duty to do so. Inspect the vehicle according to the “Driver's Check List”, page 81. WARNING! Do not drink and drive . Your reflexes, perceptions, and judgment can be affected by even a small amount of alcohol. You could have a serious—or even fatal accident—if you drive after drinking. Please do not drink and drive or ride with a driver who has been drinking.
INTRODUCTION A Special Word About Repairs Shop Manuals This is not a repair or workshop manual. Your Peterbilt Dealer's Service Center is the best place to have your Medium Duty repaired. You can find Peterbilt dealers all over the country with the equipment and trained personnel to quickly get you back on the road—and to keep you there. If you do decide to do complex repair work, you will need the Medium Duty Maintenance Manual.
INTRODUCTION Medium Duty Body Builders' Manual. Contains general guidelines on mechanical and electrical modifications required by your dealer to add bodies, accessories, and special equipment to straight-truck configurations. WARNING! Modifying your vehicle can make it unsafe. Some modifications can affect your vehicle's electrical system, stability, or other important functions. Before modifying your vehicle, check with your dealer to make sure it can be done safely.
INTRODUCTION Other Sources Another place to learn more about trucking is from local truck driving schools. Contact one near you to learn about courses they offer. –8– Federal and state agencies such as the department of licensing also have information you can ask for. The Interstate Commerce Commission can give you information about regulations governing transportation across state lines. Regulations that differ from state to state can be found at various agencies in state governments.
CAB AND FRAME ACCESS Cab and Frame Access Introduction To lock or unlock the doors from outside the cab: The following section covers procedures for accessing the cab and the frame. Door Lock and Keys • Insert the key in the door lock. • Turn the key toward the rear door frame to lock; forward to unlock. Cab and Frame Access Doors can be locked from the inside by using the lock button. Close the door then push the button down to lock.
CAB AND FRAME ACCESS WARNING! Do not step on vehicle components without antiskid surfaces or use components not designed for entry-and-exit use. You could fall and injure yourself if you step onto a slippery surface. For example: • Do not step onto the surface of a fuel tank. A fuel tank is not a step. The tank surface can get very slippery, and you might not be able to prevent a fall. Use only the steps and handholds provided, not chain hooks, quarter fenders, etc.
ENGINE ACCESS HOOD HOLD DOWNS AND TILT Engine Access Hood Hold Downs and Tilt The hood is locked in its closed position by an external latch on each side. These latches serve as hold downs and keep the hood from opening unexpectedly. CAUTION: If you do not latch the hood securely, it could open during operation and cause vehicle damage. Be sure to latch the hood securely before moving the vehicle. WARNING! A pivoting hood could hurt someone or be damaged itself.
HOOD HOLD DOWNS AND TILT ENGINE ACCESS Put one hand on the hood handle (just above the Peterbilt emblem), one foot on the bumper, and one foot on the ground. Tilt the hood forward until you hear it “lock”. WARNING! If the hood falls, anyone under it could be injured. Always make sure the lock is engaged to keep your hood open any time anyone gets under the hood for any reason. Never work under the hood unless the hood safety lock is engaged. To close the hood, you must first release the hood safety lock.
ENGINE ACCESS HOOD HOLD DOWNS AND TILT After lowering the hood, latch the hood closed with the hold downs. WARNING! If the hood is not latched securely, it could open during operation and cause an accident. Be sure the hood is latched securely before moving the vehicle.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS Controls and Displays Instruments and Controls Introduction Your Medium Duty dashboard is shown on the opposite page. – 14 – The dash includes standard gauges and switches. Your vehicle may come with all or some of the switches and gauges discussed here. The location of switches on the dash will vary depending on the options ordered and how your vehicle was configured.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS LEFT SIDE 1 2 3 4 5 6 7 8 9 16 17 18 15 10 11 12 13 14 20 Medium Duty (R05/09) 19 1 Engine Oil Pressure 2 DEF Gauge 3 Fuel Level 4 Tachometer 5 Driver Information Display 6 Speedometer 7 Primary Air Pressure 8 Secondary Air Pressure 9 Water Temperature 10 Headllights 11 Load Lights 12 Hazard Switch 13 Optional 14 Optional 15 Panel Lights 16 Optional 17 Cruise Control On/Off 18 Cruise Control Select 19 Menu
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS RIGHT SIDE 1 Radio 2 Navigation 3 HVAC Controls 4 Emission Controls 5 Engine Brake (on/off) 6 Engine Brake (Select) 10 7 Optional Switch* 11 8 Optional Switch* 12 9 Optional Switch* 13 14 15 16 10 Park Brake Controls 11 Transmission Display (Automatic) 12 Optional Switch 13 Optional Switch 1 2 3 4 14 Optional Switch 15 Optional USB Port 16 Optional Switch 5 6 *These switches are not shown.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS Menu Control Switch (MCS) The MCS has the following functions: The MCS is used to navigate the Driver Information Display unit. The Menu Control Switch is located on the D Panel as shown in the illustration below. • Rotating the MSC – Selecting display – Setting values • Pushing the MSC – Confirming desired selection Standard Warning Lights and Audible Alarm The warning lights and audible alarm may indicate a system malfunction.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS criticality. The most critical warning will be displayed on the top row and to the left. If more than six warnings are active, the menu control switch (MCS) can be used to scroll through the additional warnings. 3 2. Status Indicator: 2 1 1. Driver Information Display Additional lights and indicator symbols are displayed in the Status Indicator. They are limited to: a. Park Brake b. Transmission Gear (Automatic transmissions only) c. Warnings: 2.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS A red warning is active. First An amber warning is active. Second d. Cruise Control - active e. Clock alarm bell Third Refer to “Warning Light / Indicator Symbols” on page 20 for information on each symbol. Refer to “Warning Light / Indicator Symbols” on page 20 for information on each symbol. Instrument System Self Test: When the ignition switch is turned on the instrumentation system will undergo a Self Test.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS include but are not limited to headlight on, fifth wheel, stop engine, primary/secondary air, and driver door open warnings. Example: Engine, and then in alphabetical order. Warning Light / Indicator Symbols Symbol Name Optional Lights: Additional lights may be operational depending on individual vehicle specifications. These will be included in the Instrument System Self Test.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS Warning Light / Indicator Symbols Symbol Name Symbol Warning Light / Indicator Symbols Color Std Opt Page 10. Cruise Control, Active Symbol Name Symbol Color Std Opt Page 19. Engine, Overspeed Yellow 25 Yellow 25 12. Dump Truck, Trailer Body Up Yellow 25 13. Emissions, Diesel Particulate Filter (DPF) Yellow 25 14. Emissions, High Exhaust System Temperture (HEST) Yellow 25 11.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS Warning Light / Indicator Symbols Symbol Name Symbol Warning Light / Indicator Symbols Color Std Opt Page 28. Power Take-off (PTO) 29. Power Take-off (PTO), Pump Mode Symbol Name Symbol Color Std Opt Page 37. Transmission, Oil Filter Green 27 Green 27 38. Transmission, Oil Temperature High Green 27 39. Turn Signal, Left 27 40. Turn Signal, Right 27 41. Voltage Yellow 28 Yellow 28 Green 28 Green 29 30. Refrigerator 31.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS 2. Active Warnings, Number 5. Anti-Lock Brake System (ABS) Illuminates the total number of red and yellow active warnings. Use the MCS to view the active warnings if the display shows a > symbol. Illuminates during the Instrumentation System Self Test. Have the ABS system checked by a Peterbilt dealer if the ABS Warning Lamp stays on for more than 3 seconds. 3. Active Warnings, Triangle Illuminates when an yellow warning is active.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS 7. Axle, Inter-Axle Differential Locked (Tandem Axles) Illuminates during normal operating conditions to indicate a problem with the Trailer ABS System. This should be checked by a Peterbilt dealer as soon as possible. See “ABS Warning Lamps” on page 104 for more information. Illuminates when the inter-axle differential switch is ON thus locking the inter-axle differential. This powers the forward rear and the rear rear differentials equally.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS 10.Cruise Control, Active 15.Engine, Check Engine Illuminates when cruise control is active. Illuminates when a problem exists, but the vehicle can still be safely driven. Vehicle should be serviced to correct the problem but the situation should not be considered an emergency. 11.Dump Truck, Body Up Illuminates when Truck Dump Body is up. 12.Dump Truck, Trailer Body Up 16.Engine, Ether Start Illuminates when Trailer Dump Body is up. 13.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS 19. Engine, Overspeed 22. Engine, Wait To Start Illuminates when engine RPM is exceeded. Illuminates when engine grid heater is on (PACCAR PX-6 and PX-8). 20. Engine, Retarder (Brake) Illuminates when the engine retarder (compression brake or exhaust brake) switch is turned on. (Engine retarders are an option.) Illuminates when air actuated fifth wheel King Pin is unlocked. 24. Fifth Wheel, Slide Unlocked 21.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS 25. Lights, High Beam 28.Power Take-off (PTO) Illuminates when the high beams are on. This icon will flash with audible alarm if the headlamps are left on when the door is open. In addition, this icon will flash, but without an audible alarm, if there is a problem with the low beam headlights or the low beam headlight wiring. In such event, the high beam headlights will turn on at 50% normal brightness. Illuminates when the PTO is engaged.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS 33. Tire Inflation 37. Transmission, Oil Filter Illuminates when tire pressures need to be checked. (Tire Pressure Monitoring System is an option) Illuminates when service is required (Allison transmissions only). 38. Transmission, Oil Temperature High 34. Transmission, Auxiliary Illuminates to indicate auxiliary transmission is in neutral. 35. Transmission, Check Illuminates when transmission has recorded a fault code.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS Driver Information Display 40. Turn Signal, Right Blinks when the right turn signal or the hazard light function is operating. 41. Voltage Illuminates when transmission lubricant temperature is too high.The information display will provide the current oil temperature when the icon is illuminated. WARNING! Do not look at the Driver Information Display for prolonged periods while the vehicle is moving. Only glance at the monitor briefly while driving.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS • MCS button is pushed (independent of ignition key switch position) • clock alarm sounds In addition to a blank screen, the following are menu items and the information available within each menu selections. • driver or passenger door is opened • hazard warning lamp switch is on The various functions may be accessed by navigating through Menu Screens using the MCS. Refer to “Menu Control Switch (MCS)” on page 17 for more detail for the MCS.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS B. RPM Detail (Accessible while parked or driving) D. Trip Information NOTE: When accessing the trip information menu, push the MCS on this menu (bullet). To exit, push the MCS again. To reset the trip values, press the Trip Odometer Reset Button on the main gauge instrument cluster. RPM reading of actual engine RPM. Engine RPM within the bar graph indicates the engine is operating in the most efficient RPM range.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS – PTO Hours 6. Transmission Model – PTO Trip Hours 7. Transmission SW Version – PTO Trip Percentage (%) 8. ABS (Antilock Braking System) Make To reset the Trip Values, press the Trip Odometer Reset Button on the main gauge instrument cluster. E. Truck Information (Accessible only while parked) NOTE: When accessing the truck information menu, push the MCS on this menu (bullet). To exit, push the MCS again. 9. ABS Model 10. ABS SW Version 11.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS Found" or "Faults Found". If "Faults Found" is active, pushing the MCS will display new menus for more information. G. Transmission Display (Automated Transmissions only - Accessible while parked or driving) NOTE: Refer to the Automated Transmission Operator’s Manual for additional information.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS 1. When in the Settings Menu, scroll through the list of menu items. Press the MCS to select the item to change. 2. To Set Home, Local or Alarm Time: 3. Rotate the MCS knob to change the hour. Press the MCS.
CONTROLS AND DISPLAY STANDARD GAUGES Standard Gauges On the pages that follow you will find descriptions of some of the gauges on your instrument panel. For more information about using them in driving, see “Starting and Operating the Vehicle” Also check the Index under the name of the gauge or function you want to know more about. WARNING! Do not ignore a warning light or audbile alarm. These signals tell you something is wrong with your vehicle.
STANDARD GAUGES CONTROLS AND DISPLAY Tachometer distance that can be shown on the odometer is “1 999 999” before it rolls over to zero. The trip odometer displays how far the vehicle has gone on a particular trip. The trip odometer will display in miles on an English speedometer or in kilometers on a metric speedometer, in one tenth divisions. The maximum distance that can be shown on the trip odometer is “9999.9” before it rolls over to zero.
CONTROLS AND DISPLAY STANDARD GAUGES Engine Hours / Outside Air Temperature Hour Meter Snowflake Symbol the first 3 seconds, then stay on until the temperature goes above 37°F or 28°C. Outside Air Temperature The LCD display in the lower part of the tachometer contains the engine hour meter and the outside air temperature display. The temperature can display using Standard or Metric units. Press the trip reset button on the Speedometer 4 times within 4 seconds.
STANDARD GAUGES CONTROLS AND DISPLAY Engine Oil Pressure Gauge • If your oil pressure suddenly drops while you are driving, bring the vehicle to a stop as soon as possible in a safe location off the road and turn off the engine. Wait a few minutes to allow oil to drain into the oil pan, and then check the oil level. Add oil if necessary. If the problem persists, contact an authorized service center. Check the engine manufacturer’s manual for the correct oil pressure ranges for your engine.
CONTROLS AND DISPLAY STANDARD GAUGES water temperature gauge should register between 165° and 205°F (74° and 90°C). Under certain conditions, somewhat higher temperatures may be acceptable. But the maximum allowable temperature is 210°F (99°C) with the cooling system pressurized, except for certain special engines. Check your engine manual to be sure. Engine Overheating WARNING! Do not remove the radiator fill cap while the engine is hot.
STANDARD GAUGES CONTROLS AND DISPLAY the warning light does not go off or the temperature gauge does not begin to drop, then turn the engine off. CAUTION: Use Ultra Low Sulfur Diesel fuel only. Failure to do so may damage components of the Diesel Particulate Filter (DPF). • If the overheating came from severe operating conditions, the temperature should have cooled by this time. If it has not, stop the engine and let it cool before checking to see if the coolant is low.
CONTROLS AND DISPLAY STANDARD GAUGES capacity. DEF fluid is required to meet certain emission requirements. Do not allow your DEF tank to remain empty. Please refer to your emission supplemental manual for more details about DEF fluid. CAUTION: Use Diesel Exhaust Fluid only. Failure to do so may damage components of the Diesel Particulate Filter (DPF).
OPTIONAL GAUGES CONTROLS AND DISPLAY WARNING! The air pressure warning light and the audible alarm indicate a dangerous situation. There is not enough air pressure in the reservoirs for repeated braking and the brake system has failed. If air pressure falls below 60 psi (414 kPa) the spring brakes could suddenly apply, causing a wheel lockup, loss of control, or your vehicle to be overtaken by following vehicles. You could be in an accident and severely injured.
CONTROLS AND DISPLAY OPTIONAL GAUGES tional indicator lights appear on the instrument panel. To operate the signal, move the lever in the direction of the turn. Each time the turn indicator is activated the audbile alarm emits a short beep. CAUTION: Driving with very hot temperatures in your rear drive axles can cause serious damage to axle bearings and seals. Have your axle lubrication checked if you notice a sign of overheating.
OPTIONAL GAUGES CONTROLS AND DISPLAY High Beam Headlamps ID And Clearance Lights Flash NOTE: The headlamps must be “ON” for the high beam switch to operate. • To switch your headlamps to lower or higher beam, gently pull the turn signal lever towards the steering wheel, until you hear the switch click and the beam changes. The blue indicator light in the instrument panel will be ON when the high beam is being used. To flash, press the button on the end of the turn signal lever and hold.
CONTROLS AND DISPLAY OPTIONAL GAUGES The first position after OFF is the intermittent #1 cycle. The next positions are intermittent #2, #3, and #4. The last two positions are wiper low speed and wiper high speed. See the wiper switch settings table that follows for intermittent delay times. Wiper Switch Settings WARNING! Do not drive with worn or dirty wiper blades. They can reduce visibility, making driving hazardous. Clean blades regularly to remove road film and wax build-up.
OPTIONAL GAUGES CONTROLS AND DISPLAY To Wash The Windshield Electric Horn Push the rotary wash/wipe knob in (towards steering column), hold for more than 0.8 seconds and then release. Hold the knob in to extend the washing cycle. After the lever is released, the wipers will shut off automatically or resume the wiper’s setting speed. Your Peterbilt has an electric horn. To operate, press on the horn symbol near the center of the steering wheel.
CONTROLS AND DISPLAY OPTIONAL GAUGES See “Brake Safety and Emergency” on page 112 for more complete information on when and how to use your trailer brake. Or see the Index, under Brake NOTE: The trailer brake is not to be used as the main means of braking. To use this brake frequently instead of using the foot brake will wear out the trailer brake sooner. WARNING! It is dangerous to use air-applied trailer brakes for parking or holding a vehicle. Air system pressure can bleed down and release the brakes.
DASH- AND DOOR-MOUNTED FEATURES CONTROLS AND DISPLAY To activate these features, locate the Tilt/Telescoping handle on the left side of the steering column. To adjust the steering wheel, PUSH and HOLD the pedal down fully. Push or pull the wheel to the desired height and angle, then RELEASE the pedal to lock the wheel at the correct position.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES • IGN & ACC:This position allows you to turn on the engine and all accessory power. • START:Starter activation to start engine. Hazard Flasher The four-way Emergency Flasher switch is located to the right of the ignition key switch. With the switch in the ON position, the emergency flasher makes all four turn signals (front and rear) flash simultaneously. The flasher works independently of the ignition switch.
DASH- AND DOOR-MOUNTED FEATURES CONTROLS AND DISPLAY release the parking brake. If the headlight switch is ON, the DRL system is overridden, and headlights operate normally. WARNING! Do not use daytime running lights (DRL) during periods of darkness or reduced visibility. Do not use DRL as a substitute for headlights or other lights during operations that require lighting of your vehicle. Doing so could lead to an injury accident.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES Panel Light Dimmer ID and Clearance Lights Switch The Panel Light Dimmer lets you vary the brightness of your instrument panel lights. To Operate Your Panel Light Dimmer: 1. Turn on either the headlights or clearance lights. 2. To brighten the instrument lights, rotate the thumbwheel up. 3. To dim the instrument lights, rotate the thumbwheel down.
DASH- AND DOOR-MOUNTED FEATURES CONTROLS AND DISPLAY Fog Lights Switch Air Suspension Deflate Switch (Dump Valve) AIR SUSPENSION If your vehicle has fog lights, turn them ON or OFF with the control panel switch with the symbol shown above. NOTE: Across the U.S.A. and Canada, State/Provincial requirements vary as to when high beams and fog lights can and cannot be used together. Some states allow only four lights to be used together, while some allow more.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES CAUTION: Operating a vehicle with air suspension bags either overinflated or underinflated may cause damage to driveline components. If a vehicle must be operated under such conditions, do not exceed 5 mph. WARNING! Do not operate the cruise control when operating on road surfaces with poor traction (wet, icy, or snow covered roads) or in heavy traffic.
DASH- AND DOOR-MOUNTED FEATURES CONTROLS AND DISPLAY cruise set speed by using the service brake pedal. The system will not allow cruise control operation if it does not pass the ‘rationality check’. The Driver Information Display will prompt you to press the service brake pedal if it has not been pressed since the vehicle has been started.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES CAUTION: Do not leave the three position switch in the STOP position unless you need to cancel or stop regeneration. Leaving the switch in the STOP position for extended periods of time will result in increased soot levels in the DPF. Power Mirror Switch If your vehicle is equipped with power mirrors, the mirror controls will be located on the driver side door pad.
DASH- AND DOOR-MOUNTED FEATURES CONTROLS AND DISPLAY Mirror Heat Switch To Adjust Moto Mirrors 1. Move the mirror selector switch to the right or left from the neutral center position to select the desired mirror for adjustment. NOTE: If the mirror is fixed (non-motorized) on the left side, then the mirror selector switch will ONLY allow selection of the neutral and right mirror switch positions. Mirror Heat Switch Button Mirror Heat Indicator Light 2.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES NOTE: The effects of direct sunlight, or the use of mirror heat, will increase the outside air temperature displayed while the vehicle is stationary. Power Window Switch Driver Window Switch Power Door Lock Switch Passenger Window Switch Your vehicle is probably equipped with power windows. Power window rocker switches are located on the door pads (a switch for the passenger window is also on the driver side door pad, as shown above).
DASH- AND DOOR-MOUNTED FEATURES CONTROLS AND DISPLAY Manual Control Lever Manual and Automatic Control Switch This hand-operated control lever provides modulated application of the BrakeSaver in the manual or ON mode (see next illustration). How much braking you get depends on how much you move the lever. With the switch in the AUTOMATIC position, the BrakeSaver will be fully applied automatically when the operator has the vehicle in gear and takes his or her foot off the accelerator pedal.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES Jacobs Engine Brake or Cummins “C” Brake Switch The ON/OFF switch turns the system ON or OFF. The second switch performs the progressive braking function that controls the amount of retarding. • If you have the two-mode system, you can select HIGH or LOW. • If you have the three-mode system, you can select low, medium, or high retarding.
DASH- AND DOOR-MOUNTED FEATURES CONTROLS AND DISPLAY WARNING! Placing the differential lock in the “LOCK” position while your wheels are spinning could cause loss of control or axle damage. You could be hurt. Switch to “LOCK” only when your wheels are not spinning. See “Interaxle Differential” on page 95 for more information on using your interaxle differential. For information on how to operate your two-speed rear axle properly and safely, see “Dual Range (Two Speed) Axles” on page 97.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES Vehicles having an air slide fifth wheel have a fifth wheel slider lock controlled by a switch on the instrument panel. By placing the switch in the unlock position, you can slide the fifth wheel to various positions to adjust weight distribution. There is a guard over this switch to protect you against accidentally activating or releasing the lock.
DASH- AND DOOR-MOUNTED FEATURES (2) Trailer Air Supply Control (Red) CONTROLS AND DISPLAY See “Using the Brake System” on page 101 for more information. (1) Parking Brake Control (Yellow) - for vehicles with hydraulic brakes: 02394 Combination (Tractor/Trailer) Parking Brake Control Valves 2. Shift the transmission into its PARK position. (See Pages 98 and 143 for transmission shifting and parking brake information.) 3. Turn the key to OFF. 4. Remove the key.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES 2. Apply the parking brake. Pull upward on the parking brake lever until it reaches an over (top) center position. (The PARK light on the dash will come on.) NOTE: Ensure the lever is over center. The light will come on prior to brake being fully applied.
HEATER-AIR CONDITIONING CONTROLS CONTROLS AND DISPLAY Heater-Air Conditioning Controls NOTES: Your heat and air conditioning controls are mounted in the “D” instrument panel in conventional models. Additionally, the sleeper compartment may also contain a separate heating and cooling system with separate controls. •Keep the engine exhaust system and the vehicle’s cab/sleeper ventilation system properly maintained.
CONTROLS AND DISPLAY HEATER-AIR CONDITIONING CONTROLS •If you are required to idle your vehicle for long periods of time, install an auxiliary heater or automatic idle control. These auxiliary devices can reduce fuel consumption and save you money. •If other vehicles are parked next to you idling, move your vehicle or do not stay in your vehicle for prolonged periods of time.
HEATER-AIR CONDITIONING CONTROLS • CONTROLS AND DISPLAY . B A C 02980A D E F NOTE: For vehicles equipped with the Peterbilt Comfort Control (PCC) option: The PCC option lets the temperature knob function as a thermostat that regulates duct temperatures based on the knob settings. When active, the “COMFORT CONTROL” icon (F) will be illuminated under the temperature knob (C).
CONTROLS AND DISPLAY CIGARETTE LIGHTER CAUTION: During extreme cold weather, do not blow hot defroster air onto cold windshields. This could crack the glass. Turn the air flow control lever to Defrost and adjust the fan speed accordingly while the engine warms. If the engine is already warm, move the temperature selector to Cool, then gradually increase the temperature when you see that the windshield is starting to warm up. 4. Close all windows. 5.
CUPHOLDERS/ASHTRAY CONTROLS AND DISPLAY prevent damage should the lighter get stuck in the IN position. If this fuse needs replacement, check to ensure that the lighter is not stuck before replacing the fuse. WARNING! Do not exceed the voltage/amperage capacity of the cigarette lighter. It could result in a fire . Follow all warnings and instructions in the operator's manual for the appliance you are using.
CONTROLS AND DISPLAY SHIFT PATTERN DISPLAY Shift Pattern Display The correct shift pattern for your vehicle appears on your control panel or windshield or on a medallion in the shift knob. It is important that you know more about your transmission than just the shift pattern. Please read the manufacturer’s manual that is included with your vehicle.
ACCESSORIES CONTROLS AND DISPLAY Accessories Peterbilt Navigation System Your vehicle may be equipped with a Peterbilt Navigation System. This system is a Global Positioning Satellite (GPS)-linked computer. It receives input from multiple sources to locate your vehicle. Read and understand the Supplemental Navigation System Owner’s Manual and observe the Warnings, Cautions, and Notes that follow before using the system.
CONTROLS AND DISPLAY ACCESSORIES NOTE: The map database is the most current available at the time of production. The database is designed to provide you with route suggestions and does not take into account the relative safety of a suggested route or of factors that may affect the time required to reach your destination. See the Supplemental Navigation System Owner’s Manual for more information. • To close, push the cover up and press to latch it.
SEATS Seats Introduction Standard Driver's Seat This section covers the operation and safe use of your Medium Duty seats. For further information on features and adjustment of the seat, see the manufacturer's literature included with the vehicle. The standard driver's seat can be adjusted forward and rearward. These movements are each controlled by levers located on the FRONT of the seat.
SEATS Safety Restraint Belts CHUGGER-SNUBBER LOCK-OUT FEATURE Move handle down to unlock BACKREST TILT Rotate knob for infinite selection of settings The right and left seats are equipped with 3-point lap/ shoulder belts; the center seat has a 2-point seat belt. Safety belts have proven to be the single most effective means available for reducing the potential for either serious injury or death in motor vehicle accidents.
SEATS WARNING! Do not drive vehicle without your seat belt and your riders’ belts fastened. Riding without a safety belt which is properly fastened can lead to increased injury or death in an accident. Unbelted riders could be thrown into the windshield or other parts of the cab or could be thrown out of the cab. They could strike another person. Injuries can be much worse when riders are unbelted. Always fasten your seat belt and be sure anyone riding with you does the same. 2.
SEATS • Belts should fit snugly across the pelvis and chest. Make sure any slack is wound up on the retractor. To unfasten the belt: Push in the release button on the buckle. The belt will spring out of the buckle. • To release a locked belt, lean back to take the body pressure off of the belt. • To store a lap-shoulder belt, allow the belt to wind up on the retractor by guiding the belt tongue until the belt comes to a stop.
SEATS • Be sure, also, that your belt is not too loose. A loose belt could allow you to slide under it in an accident, and that could bring the belt up around your abdomen. • Do not twist the belt in the process of putting it on. A twisted belt will not work as well to protect you. WARNING! Always wear your seat belt low over your pelvic bones. • You can be seriously injured if your belt is buckled too high. In a crash, it would apply force to your abdomen, not your pelvic bones.
SEATS Safety Restraint Tips NOTE: Per FMCSR 392.60 - Unauthorized Persons Not to be Transported. Federal law prohibits the transportation of persons in commercial vehicles unless they are specifically authorized in writing by the motor carrier. See the cited FMCSR for a complete description of the regulation and exemptions. • Any authorized person riding in your vehicle should wear a seat belt. A responsible operator sees to it that everyone in the vehicle rides safely—and that means with a seat belt.
SEATS WARNING! Do not remove, modify, or replace the tether belt system with a different tether system. A failed or missing tether belt could allow the seat base to fully extend in the event of an accident leading to greater injuries or death. • If any seat belt is not working properly, see an Authorized Service Center for repair or replacement. WARNING! Before driving or riding in a vehicle, ensure that there is adequate head clearance at maximum upward travel of seat.
SEATS Komfort–Lok® Latch Your Peterbilt contains a feature designed to eliminate cinching and provide improved safety and comfort. Cinching is the condition where a belt becomes continually tighter around you during a rough, bouncy ride. The need for this feature increases with rough road conditions, particularly over long distances. To eliminate cinching, simply activate the Komfort–Lok® feature at the appropriate time: 4.
SEATS During Pregnancy Pregnant women should always wear combination lap/ shoulder belts. The lap belt portion must be worn snugly and as low as possible across the pelvis. To avoid pressure on the abdomen, the belt must never pass over the waist. Sometimes pregnant women worry that in a crash the seat belt could hurt the baby. But if a woman wears her belt properly—low over her pelvis, below her abdomen—the belt will not harm the baby, even in a crash.
DRIVER'S CHECK LIST Driver's Check List Safe Vehicle Operation To keep your Medium Duty in top shape and maintain a high level of safety for you, your passengers, and your load, make a thorough inspection every day before you drive. You will save maintenance time later, and the safety checks could help prevent a serious accident. Please remember, too, that the Federal law requires a pre-trip inspection and so do commercial trucking companies. You are not expected to become a professional mechanic.
DRIVER'S CHECK LIST WARNING! Do not exceed the specified load rating. Overloading can result in loss of vehicle control and serious personal injury, either by causing component failures or by affecting vehicle handling. Exceeding load ratings can also shorten the service life of the vehicle. WARNING! Do not drink and drive . Your reflexes, perceptions, and judgment can be affected by even a small amount of alcohol. You could have a serious—even fatal—accident if you drive after drinking.
DRIVER'S CHECK LIST GAWR: is the Gross Axle Weight Rating. This is the total weight that one axle is designed to transmit to the ground. You will find this number listed on the driver's door edge. Load Distribution: be sure any load you carry is distributed so that no axle has to support more than its GAWR. WARNING! An unevenly distributed load or a load too heavy over one axle can affect the braking and handling of your vehicle, which could result in an accident.
DRIVER'S CHECK LIST Engine Compartment Checks — Daily 1. Engine Fluid Levels—add more if necessary. • Engine oil • Coolant (check while engine is cold) • Power steering fluid level • If your truck has hydraulic brakes, check the fluid level in the master cylinder reservoir. See page 154 for more information. 2. Engine Belt—check tension and condition of belts. This is important to ensure proper air compressor and engine operation. • Measure the belt tension at the longest span of the belt.
DRIVER'S CHECK LIST WARNING! Diesel fuel in the presence of an ignition source (such as a cigarette) could cause an explosion. You could be seriously injured. A mixture of gasoline or alcohol with diesel fuel increases this risk of explosion. •Do not remove a fuel tank cap near an open flame. •Use only the fuel and/or additives recommended for your engine. 6. If your truck has hydraulic brakes, check: • the brake system for leaks • hydraulic lines for cracks or kinks • calipers for leaks 7.
DRIVER'S CHECK LIST 3. Mirrors—check and readjust mirrors if necessary. 4. Lights—turn ignition key to the IGN & ACC position and check for warning lights and buzzer. Check operation of turn signals and emergency lights. 5. Instruments—check all instruments. 6. Windshield—check operation of windshield wipers and washers. 7. Horn—check operation of horn. 2. Wheel Cap Nuts—are they all in place and torqued properly—tighten if necessary. See “Wheel Cap Nut Torque,” Page 173. 3.
STARTING AND OPERATING THE VEHICLE Starting and Operating the Vehicle Introduction For detailed information on starting and operating the engine, refer to the Engine Operation and Maintenance Manual provided with your Medium Duty. Because each vehicle is custom-equipped, all engine operation instructions presented in this section are general. You will want to consult the engine manual to find out details about your vehicle's specific engine requirements.
STARTING AND OPERATING THE VEHICLE NOTE: When any one of the following is true, oil should be applied to the turbocharger oil inlet port: (1) if the engine has not been started for more than 25 days; or (2), the outside temperature is very cold; or (3), the oil filter has been changed. •With an oil can, squirt approximately one-half cup (120 ml) of clean, specified engine oil into the turbocharger oil inlet port.
STARTING AND OPERATING THE VEHICLE TO START” indicator lamp turns ON, wait until the indicator lamp goes OFF (approximately 60 seconds) before attempting to start the engine. (For each engine and ambient temperatures, warm-up cycles will vary.) 7. Turn the ignition switch to the IGN & START position to engage the starter. Crank the engine until it starts. If the engine does not start within 30 seconds, release the key.
STARTING AND OPERATING THE VEHICLE CAUTION: Never operate the starter motor while the engine is running. The starter and flywheel gears could clash or jam, severely damaging them. • Wait until normal engine oil pressure registers on the gauge before idling or accelerating the engine beyond 1000 rpm. • Watch the air pressure gauge. Wait until both pointers register at least 100 psi (689 kPa) before releasing the spring brake and moving the vehicle.
STARTING AND OPERATING THE VEHICLE Engine Block Heater (Option) To preheat the engine before starting, plug the optional engine block heater into a properly grounded AC electrical source. Do not start the engine with the heater plugged in. WARNING! Engine block heaters can cause fires resulting in serious personal injury and/ or property damage if not properly maintained and operated. Regularly inspect the engine block heater wiring and connector for damaged or frayed wires.
STARTING AND OPERATING THE VEHICLE With each engine make, the air intake heating system works differently. To understand fully how your engine's heating system operates, see the engine Operation and Maintenance Manual for details. On most systems the engine block temperature is monitored at startup; other systems monitor the engine oil pressure, coolant temperature, and time, as well. When the pre-set conditions are met, the heater automatically engages.
STARTING AND OPERATING THE VEHICLE NOTE: In colder climates where the temperatures are often below freezing, sufficient warmup for turbocharged engines is especially important. Chilled external oil lines leading to the turbocharger will slow the oil flow until the oil warms, reducing oil available for the bearings. Watch the engine oil pressure gauge for a warming trend before increasing engine idle speed (rpm).
STARTING AND OPERATING THE VEHICLE WARNING! Do not work on or near the fan with the engine running. Anyone near the engine fan when it turns on could be seriously injured. If it is set at MANUAL, the fan will turn on any time the ignition key switch is turned to the ON position. In AUTO, it could engage suddenly without warning. Before turning on the ignition or switching from AUTO to MANUAL, be sure no workers are near the fan.
STARTING AND OPERATING THE VEHICLE • To decrease the cruise set speed, hold the SET/ RESUME switch in the RESUME position and coast to a lower speed. Engaging the Cruise Control • To increase the cruise set speed, hold the SET/ RESUME switch in the SET position; this will accelerate the vehicle to a higher speed.
OPERATING THE TRANSMISSION STARTING AND OPERATING THE VEHICLE Operating the Transmission 6, 9, 10, and 11–Speed Manual Introduction The 6–speed synchronized manual transmission has 6 forward speeds and 1 reverse. The 9–speed transmission has 9 forward and 2 reverse speeds, consisting of a 5– speed low range section and a 4–speed high range section. Your Medium Duty is equipped with either a manual or automatic transmission with special features and gearing to meet your particular needs.
STARTING AND OPERATING THE VEHICLE OPERATING THE TRANSMISSION Putting the Vehicle in Motion After making sure the vehicle's oil and air pressure are correct and all other parts and systems are in proper working condition: 1. If your truck is equipped with a hand throttle, disengage the hand throttle before driving the vehicle. 2. Fully depress the clutch pedal until the clutch brake makes contact (see page 98). The contact will occur at about 1 inch or less from the floorboard.
OPERATING THE TRANSMISSION STARTING AND OPERATING THE VEHICLE The best engine performance and maximum economy is obtained if gears are properly selected. This efficiency is achieved by always selecting gears within optimum engine rpm, which is where maximum torque and power are obtained. For further information, see “More Driving Tips and Techniques” on page 127. Shifting Gears in a New Vehicle Shift carefully in a new vehicle. The transmission may be a little stiff at first.
STARTING AND OPERATING THE VEHICLE OPERATING THE TRANSMISSION During Normal Driving To double clutch: If you want to shift directly into any gear other than first or reverse, depress the clutch pedal only far enough to release the clutch. Pushing the clutch to the floor applies the clutch brake and could cause gear hang-up. CAUTION: Be careful not to apply the clutch brake while the vehicle is moving.
OPERATING THE TRANSMISSION STARTING AND OPERATING THE VEHICLE Release Bearing Wear When you must idle your engine for any period of time, shift your transmission to Neutral and disengage the clutch (take your foot OFF of the pedal). This helps prevent unnecessary wear to your clutch release bearing, and it is less tiring for you, too. Clutch Adjustment Operating Automatic Transmissions Inspect manual clutches according to the manufacturer's recommendations.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM Using the Brake System NOTE: Today’s diesel engines have significant torque and startability power at low RPMs. Combinations of engine speed and available torque may overpower the vehicle’s parking brakes. WARNING! Never drive your vehicle with the parking brakes applied. Always release the parking brakes prior to moving the vehicle.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE Brake Operation WARNING! Do not drive through water deep enough to wet brake components, as it may cause the brakes to work less efficiently than normal. The vehicle's stopping distance may be longer than expected, and the vehicle may pull to the left or right when brakes are applied, which could contribute to an accident.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM Using the Parking Brake Before you leave the cab: The yellow diamond-shaped knob on the dash controls the truck/tractor parking brakes. These are spring brakes that you activate by releasing air pressure from their chambers. When they are not in use, air pressure compresses the springs and releases the brakes.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE To release the trailer brakes ONLY: (2) Trailer Air Supply Control (Red) (1) Parking Brake Control (Yellow) • Push IN the Red knob on the dash. The truck or tractor will remain parked. To release the full combination of brakes: 02394 Combination (Tractor/Trailer) Parking Brake Control Valves • Push IN BOTH knobs on the dash.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM WARNING! If the air pressure falls below 60 psi (414 kPa) the spring brakes may stop the vehicle abruptly, which could result in an accident and/or injuries. Observe the red warning lamps on the gauges. If one comes on, do not continue to drive the vehicle until it has been properly repaired or serviced. WARNING! Do not use the trailer hand brake or service brakes to park and hold an unattended vehicle—use the parking brakes.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE The parking brakes act on the rear wheels only. They are spring-applied, with air pressure used to release them. Release air is supplied by both the front and rear circuit reservoirs through a double check valve.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM WARNING! Do not use the trailer hand brake or service brakes to park and hold an unattended vehicle—use the parking brakes. Because service brakes work with air pressure, these brakes could slowly release. Your vehicle could roll, causing a serious accident. Someone could be hurt or killed. Never rely on the service brakes to hold a parked vehicle.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE Front Brakes — Truck Rear Brakes — Truck The following applies to full truck configurations: The following applies to full truck configurations: If air pressure is lost in the front circuit, the vehicle front brakes will not operate. Check valves isolate the rear circuit, so the rear service brakes and parking brakes are unaffected. The spring brakes will not automatically apply as long as rear service pressure is maintained.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM WARNING! Efficiency of emergency braking depends on the amount of air available in the front circuit reservoir, which is sufficient for a limited number of brake applications and releases. • REMEMBER: when the remaining system pressure drops below 60 psi (414 kPa), the spring brake is automatically applied, stopping the vehicle abruptly, potentially causing serious injury.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE Use engine compression to assist the service brakes by not depressing the clutch pedal until the engine reaches idle speed. Overheated Brakes Under normal braking conditions, the energy generated will bring the internal brake drum temperature to about 500°F (260°C). This is well within the safe zone: the maximum safe temperature of lining for drum type brakes is usually about 800°F (427°C).
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM should remain off after this point unless a failure in the system is detected. The truck/tractor ABS lamp is located in the warning lamp cluster. ABS CAUTION: If the trailer ABS warning lamp does not illuminate when the ignition is first turned on, there is a problem with the bulb or wiring. The driver should have this checked as soon as possible.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE NOTE: A “properly connected” ABS-equipped trailer is WARNING! Do not rely on an anti-lock brake system that is functioning improperly. You could lose control of the vehicle resulting in a severe accident and serious personal injury. If your ABS lamp goes on while you are driving or stays on after the self-check, your anti-lock system might not be working. The ABS may not function in an emergency.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM torque. Do not allow the Wheel Spin Control lamp to remain on continuously for an extended length of time. Extended, continuous use of the ASR / ATC can cause overheating of the drive wheel brakes. Engine torque or vehicle speed should be reduced to eliminate wheel spin and prevent excessive application of the ASR / ATC system. To operate the trailer brake hand valve: • Pull down on the lever. • The valve is self-returning.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE WARNING! Do not use an engine retarder when you are driving bobtail or with an unloaded trailer. Using engine retarders while bobtailing or with an unloaded trailer can cause a wheel lockup resulting in less control and/or jackknife. The trailer may not load the rear tractor tires enough to provide necessary traction.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM WARNING! The service brakes must be used in an emergency. The engine or retarder alone might not stop you fast enough to prevent an accident. You could be badly hurt if you relied only on the engine retarder. • Make sure the brake is OFF before starting the engine. • After the engine is started, warmed up, and you are ready to get under way, turn the exhaust brake switch ON for added braking effect.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE Compressed Air Tanks: The wet (supply) and dry (ser- Brake Components The following is a brief description of the air/brake system. It is intended to supply you with general information on how the system works. For complete information see the Medium Duty Maintenance Manual. Compressor: supplies air to the system. System pressure is controlled by the governor.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM • Modulates spring brake application in proportion to front service application in the event of a rear service failure. • Prevents compounding of service and spring applications. Relay valve (full truck): speeds up the application of the rear service brake. It also incorporates a quick–release feature. Brake Proportioning (BP-R1) valve (tractor): t h i s v a l v e delivers air to the tractor's service brake chambers.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE to the trailer, and (3) protect the tractor air supply in case of separation of the air lines connecting the tractor to the trailer. Hydraulic Brakes WARNING! Do not operate the vehicle in the event of a malfunction in any air or hydraulic circuit. Such a malfunction may prevent the brake system from operating properly, and could result in an injury accident.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM WARNING! The brake system is a critical vehicle safety system. For the safety of you and others around you, have the vehicle submitted for periodic preventive maintenance checks as well as having any suspected problems immediately checked by an Authorized Service Center. Failure to properly maintain your brake system can lead to serious injury accidents. Brake Components The following is a brief description of the hydraulic brake system.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE Hydraulic Booster: The hydraulic booster applies additional hydraulic force from the power steering gear to the master cylinder piston when the brake pedal is applied. Parking Brake Lamp: illuminates when the parking brake is engaged (the lever is in the up position.) Parking Brake Lever: the hand lever located in the cab which engages or disengages the driveline drum brake.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM • Downshift - Putting the transmission into a lower gear will help slow the vehicle. Avoid driving through deep puddles or flowing water if possible. If not possible, you should to the following: • Pump the brakes - Pumping the brake pedal may generate enough hydraulic pressure to stop the vehicle. • Slow down. • Use the parking brake - The parking or emergency brake is separate from the hydraulic system.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE sion. You could get hung up in NEUTRAL and lose the benefit of engine braking. “Coasting” is illegal, and also VERY dangerous. OFF, there may be a stored fault code. If the lamp remains ON when a speed in excess of 4 mph (6 km/h) is reached, there may be an active fault in the ABS system. Anti-Lock Braking System This vehicle is equipped with an Anti-Lock Braking System (ABS). ABS reduces the likelihood of a wheel locking.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM Parking Brake Burnishing This procedure is recommended for new vehicles where less lever actuation force is required. This procedure is mandatory whenever the driveline brake shoes or brake drum are replaced. WARNING! If a new drum or new brake shoes are installed, the driveline brake must be burnished.
OPERATING THE REAR/DRIVE AXLE STARTING AND OPERATING THE VEHICLE Operating the Rear/Drive Axle Introduction This section covers the operation of your Rear/Drive Axle. These instructions apply to the most common features of drive axles. Refer to the manufacturer’s instructions for further information on the operation of your axle. If your vehicle is equipped with a Rockwell Tractech™ Nospin single rear axle, the wheel differential lock feature automatically engages and disengages.
STARTING AND OPERATING THE VEHICLE OPERATING THE REAR/DRIVE AXLE • Dirt roads. • Loose sand, mud, or other rough road conditions. Inter–Axle Differential Lock Operation WARNING! Do not use the inter-axle differential lock when travelling downhill or at speeds above 25 mph (40 km/h). When it is engaged under these conditions, your vehicle will exhibit “understeer” handling characteristics.
OPERATING THE REAR/DRIVE AXLE STARTING AND OPERATING THE VEHICLE NOTE: If your vehicle has an automatic transmission, it may be necessary to shift the transmission to the Neutral position momentarily to allow the main inter-axle differential lock splines to fully engage or disengage. Turning Radius When Unlocked (Disengaged) 4. Drive the vehicle through the poor traction area, keeping your speed under 25 mph (40 km/h).
STARTING AND OPERATING THE VEHICLE MORE DRIVING TIPS AND TECHNIQUES More Driving Tips and Techniques Use of Driver Information Display WARNING! Low air pressure could make the brakes unsafe for driving. Before driving the vehicle, make sure the pressure does pump up to over 100 psi for normal brake operation. If the air pressure does not pump up to at least 100 psi, don’t try to move the vehicle. The Driver Information Display provides information to help the driver optimiize vehicle efficiency.
DRIVING TIPS AND TECHNIQUES STARTING AND OPERATING THE VEHICLE ure or damage to the clutch and transmission and overloads the brake system. Engine Overspeed CAUTION: To avoid engine damage, do not let the engine rpm go beyond the maximum governed rpm—valve damage could result if overspeed conditions occur. Coasting with the transmission in neutral also prevents proper transmission component lubrication.
STARTING AND OPERATING THE VEHICLE DRIVING TIPS AND TECHNIQUES Refer to the Engine Operation and Maintenance manual for optimum engine rpm. • If the engine rpm moves beyond the maximum governed speed, indicating an overspeed condition, apply the service brake or shift to a higher gear to bring engine rpm within the optimum speed range. • Shift into higher or lower gears (or apply the service brake) to keep engine rpm near the lower end of the optimum operating range.
DRIVING TIPS AND TECHNIQUES STARTING AND OPERATING THE VEHICLE Air Suspension Height/Air Pressure Your vehicle may have an air suspension. A deflation switch on the dash allows you to exhaust the air in the suspension, which allows you to lower the height of your vehicle for loading. On tractors, the deflate switch allows you to lower the fifth wheel to slide under a trailer. A guard on the switch prevents you from accidentally deflating the suspension.
STARTING AND OPERATING THE VEHICLE DRIVING TIPS AND TECHNIQUES WARNING! To prevent possible injury and damage to property, ensure that a vehicle is parked and the wheels chocked before beginning this procedure. CAUTION: Completing this procedure will enable you to safely reach the nearest authorized Peterbilt repair facility to have ride height and pinion angle reset using the proper equipment and technique. Do this as soon as possible to avoid potential driveline damage.
DRIVING TIPS AND TECHNIQUES STARTING AND OPERATING THE VEHICLE WARNING! Be extremely careful when deflating the air springs. The rear of the vehicle will drop about 3-1/2 inches (88 mm) when the air springs are deflated. Make sure that no persons or objects that could be injured or damaged are under the vehicle. To minimize the risk of damage or injury, do not use the dump valve to deflate the air springs. Operate the height control valve(s) manually to ensure positive control of air spring deflation.
STARTING AND OPERATING THE VEHICLE DELIVERY TO RH AIR BAG(S) SUPPLY FROM FORWARD AIR TANK MOUNTING NUTS DRIVING TIPS AND TECHNIQUES 3. Rotate the valve either clockwise or counterclockwise until air pressure in the air springs provides the ride height specified for that suspension.
DRIVING TIPS AND TECHNIQUES STARTING AND OPERATING THE VEHICLE Driving with Deflated Air Springs WARNING! Low air pressure could make brakes unsafe for driving by not providing sufficient air brake application pressure in an emergency, which could lead to an injury accident. Before driving the vehicle, make sure the air pressure pumps up to over 100 psi for normal brake operation. If it does not reach 100 psi, do not try to move the vehicle.
STARTING AND OPERATING THE VEHICLE DRIVING TIPS AND TECHNIQUES Your Medium Duty may be equipped with either a fixed or an air-controlled sliding fifth wheel. Either type should self-lock when a trailer king pin trips the locking dogs as the tractor is backed under a trailer. Fifth Wheel Jaw Lock To unlock the fifth wheel lock: FIFTH WHEEL • Pull out on the lever (usually located on the left-hand side of the fifth wheel) until it remains in an overcenter position.
DRIVING TIPS AND TECHNIQUES STARTING AND OPERATING THE VEHICLE WARNING! Do not move of the fifth wheel while the tractor-trailer is in motion. Your load could shift suddenly, causing you to lose control of the vehicle, which can result in a serious accident. Never operate the vehicle with the switch in the UNLOCK position. Always inspect the fifth wheel after you lock the switch to be sure the fifth wheel lock is engaged.
STARTING AND OPERATING THE VEHICLE VEHICLE RECOVERY AND SPRING BRAKES Vehicle Recovery and Spring Brakes Introduction Your Medium Duty is equipped with built-in recovery provisions, designed for short distance use only. If your vehicle must be recovered, disconnect the driveline at the rear U– joint, and remove or support the rearmost section of the driveline.
VEHICLE RECOVERY AND SPRING BRAKES STARTING AND OPERATING THE VEHICLE Vehicle Recovery Guidelines Recovery Rigging Refer to the guidelines below when towing to prevent possible damage: To connect to the Medium Duty, attach the towing chain or cable and the hitches to the (2) tow recievers through the center access hole in the bumper. • Use proper towing equipment to prevent damage to the vehicle. CAUTION: Connect only to the towing provisions, as described on the following pages.
STARTING AND OPERATING THE VEHICLE VEHICLE RECOVERY AND SPRING BRAKES 2. Into the inter-axle differential, add 2 pints (.94 liter) of approved lubricant. • See “Recommended Lubrication Types,” Page 136. 3. After adding the specified type and amount of lubricant, drive the vehicle. It should be unloaded. Drive 1 to 2 miles (1.5 to 3 km) at a speed lower than 25 mph (40 km/h). This will thoroughly circulate the lubricant through the assembly.
VEHICLE RECOVERY AND SPRING BRAKES STARTING AND OPERATING THE VEHICLE To move a vehicle immobilized by the spring brakes due to loss of air pressure in the brake system, perform the following procedure: 1. Remove the cap from the spring chamber. 2. Remove the release stud assembly from the side pocket, and remove the release nut and washer from the release stud. 4. Insert the release stud through the opening in the spring chamber where the cap was removed. Insert it into the pressure plate.
STARTING AND OPERATING THE VEHICLE VEHICLE RECOVERY AND SPRING BRAKES 6. With a wrench, turn the release stud assembly nut until the compression spring is 90– 95 percent caged. While doing this, check to make sure the push rod (adapter push rod or service push rod) is retracting. Do not over-torque the release stud assembly. (S–Cam type maximum: 50 ft-lb, Wedge type maximum: 30 ft-lb.) The spring brake is now m echan ically released.
VEHICLE RECOVERY AND SPRING BRAKES STARTING AND OPERATING THE VEHICLE Comply with the following instructions to avoid transmission damage: • Always start the vehicle in motion with the shift lever in first gear. • Be sure that the transmission is fully engaged in gear before releasing the clutch pedal (manual only). • Do not shift into reverse while the vehicle is moving. • Do not permit the vehicle to be towed for long distances without removing the driveshaft.
STARTING AND OPERATING THE VEHICLE SHUT–DOWN Shut–Down WARNING! Do not use the trailer hand brake or service brakes to park and hold an unattended vehicle—use the parking brakes. Because service brakes work with air pressure, these brakes could slowly release. Your vehicle could roll, causing a serious accident. Someone could be hurt or killed. Never rely on the service brakes to hold a parked vehicle.
SHUT–DOWN STARTING AND OPERATING THE VEHICLE Turbocharger 3. Drain water from the air reservoirs. • While the engine and air supply system are still warm, drain moisture from the air reservoirs. Open the reservoir drains just enough to drain the moisture. Do not deplete the entire air supply. Be sure to close the drains before leaving the vehicle. 4. Secure the vehicle, close all the windows, and lock all doors. Before Stopping the Engine Do not shut off the engine immediately.
STARTING AND OPERATING THE VEHICLE SHUT–DOWN WARNING! Do not carry additional fuel containers in your vehicle. Fuel containers, either full or empty, may leak, explode, and cause or feed a fire. Do not carry extra fuel containers, even empty ones are dangerous. Specification: Use only Diesel Fuel, Grade 2–D, as rec- WARNING! Diesel fuel in the presence of an ignition source (such as a cigarette) could cause an explosion. You could be seriously injured.
Introduction Preventive Maintenance PREVENTIVE MAINTENANCE INTRODUCTION Safety Precautions This section will help you keep your Medium Duty in good running condition. There are a number of checks you can do, and you may be able to do some of the service work yourself. But please, let your Peterbilt Dealer or Authorized Service Center do any work you do not have the tools or skill to perform.
Preventive Maintenance Introduction • When working underneath the vehicle without appropriate safety stands but with the wheels on the ground (not supported), make sure that (1) the vehicle is on hard level ground, (2) the parking brake is applied, (3) all wheels are chocked (front and rear) and (4) the engine cannot be started. Remove the ignition key. • Never start or let the engine run in an enclosed, unventilated area.
Introduction Preventive Maintenance tive harm. This warning requirement is mandated by California law (Proposition 65) and does not result from any change in the manner in which Peterbilt Motors Company trucks are manufactured. and the Peterbilt Electronic Parts Catalog (ECAT). When ordering replacement parts, please provide the Medium Duty Chassis Serial Number. See Page 259. WARNING! Handle lubricants carefully. Vehicle lubricants (oil and grease) can be poisonous and cause sickness.
Preventive Maintenance Maintenance Schedule and Lubrication MAINTENANCE SCHEDULE AND LUBRICATION Introduction The following section summarizes preventive maintenance and lubrication requirements for the maintenance of your Medium Duty. For specific maintenance procedures and complete lubrication instructions of specific components consult the Medium Duty Maintenance Manual and manufacturer's service manuals.
Maintenance Schedule and Lubrication Preventive Maintenance Maintenance Intervals Table 1, ”Recommended Maintenance Intervals”, shows service intervals for normal and heavy-duty operations. For additional “Engine Cooling System” information see Table 1 Page 174. For additional “Air System” information see Page 192. NOTE: Different lubricants or service intervals than those listed below may be required.
Preventive Maintenance Table 1 Maintenance Schedule and Lubrication Recommended Maintenance Intervals ITEM Rear Wheel Bearings INTERVAL 100,000 COMMENTS With LMS Wheel End Package Rear Brake Camshafts 10,000–15,000 Synthetic Grease With Special Fittings Fifth Wheel 10,000–15,000 40 to 60K For Adjustment Spring Pins 10,000–15,000 With Rubber Bushed Pins – No Service Front & Rear Slack Adjusters 10,000–15,000 Synthetic Grease With Special Fittings King Pins 10,000–15,000 Front Wheel Bearin
Maintenance Schedule and Lubrication Table 1 Preventive Maintenance Recommended Maintenance Intervals ITEM INTERVAL COMMENTS Hydraulic Brakes Brake Pad Lining Inspection 7,500 mile Rotor Inspection 15,000 miles or 15 mos Park Brake Inspection 15,000 miles or 15 mos Minimum 3/16 in.
Preventive Maintenance Maintenance Schedule and Lubrication Maintenance Schedule TABLE KEY NOTE: If a scheduled service interval is shaded, skip to the next interval. The frequency of each service operation is identified by open (non-shaded areas). Use Table 2, ”Maintenance Schedule,” as a guide to plan service work. Be sure and follow the frequency recommendations for your vehicle. Table 2 C2 Federal Annual Inspection 120,000 miles/192,000 km only.
Maintenance Schedule and Lubrication Table 2 Preventive Maintenance Maintenance Schedule 15,000 mi 24,000 km 60,000 mi 96,000 km OPERATION \ FREQUENCY COMMENTS 7,500 mi 12,000 km INTERVAL A B C A B C Wiper Blade Condition Horns (Electric and Air) Mirrors SAFETY EQUIPMENT Drain Water from Air Tanks Air Tank Check Valve Emergency Operation of Spring Brakes Air Press. Build–up time: _______ min. Governed Air Pressure: _______ psi Air Press. Drop–Brakes not Applied: ___ Air Press.
Preventive Maintenance Table 2 Maintenance Schedule and Lubrication Maintenance Schedule Emergency Flasher Brake Lights Backup/Loading Lights License Plates: Permits and Mounting Mud Flaps / Serviceable Fuel Tank Mounting Exhaust System–Condition and Mounting Bolts Frame Fastener Torque: does NOT apply to Le Jeune frame fasteners.
Maintenance Schedule and Lubrication Table 2 Preventive Maintenance Maintenance Schedule COMMENTS 60,000 mi 96,000 km 15,000 mi 24,000 km OPERATION \ FREQUENCY 7,500 mi 12,000 km INTERVAL Fan Shroud Fan Assembly and Idler Pulley Check Water Pump for Leaks / Play Radiator – Exterior Condition No Service Required Replace Engine Coolant C4 Fill as Required – Extended Drain Per Manufacturer Specifications.
Preventive Maintenance Table 2 Maintenance Schedule and Lubrication Maintenance Schedule COMMENTS 60,000 mi 96,000 km 15,000 mi 24,000 km OPERATION \ FREQUENCY 7,500 mi 12,000 km INTERVAL Drain Water from Fuel System 25,000 Mile Change Interval – Must Meet Engine Co. Requirements Engine Oil – Change Oil Filters – Replace Fuel Filters – Replace Engine Tune–up Cranking System: Visual Inspect.
Maintenance Schedule and Lubrication Table 2 Preventive Maintenance Maintenance Schedule COMMENTS 60,000 mi 96,000 km 15,000 mi 24,000 km OPERATION \ FREQUENCY 7,500 mi 12,000 km INTERVAL King Pin Wear Steer Axle Wheel Bearing - End Play Adjustment and Inspection Front Hub Lubricant Level Spring Leaves 350,000 Miles With LMS Outer Ends • No Leak – No Service Tighten U-bolts after the first 500 miles (800 km). Rear suspension fasteners: retorque after first 2,000 miles (3218 km).
Preventive Maintenance Table 2 Maintenance Schedule and Lubrication Maintenance Schedule COMMENTS 60,000 mi 96,000 km 15,000 mi 24,000 km OPERATION \ FREQUENCY 7,500 mi 12,000 km INTERVAL Synthetic Grease Required – Special Fitting No Service Required Front & Rear Brake Camshaft Tube Lubrication Clutch Pedal Shaft Clutch Linkage Suspension Fittings Clutch Release Bearing Driveline Center Bearing Automatic Slack Adjusters Brakes: Lining Remaining (replace as required) RF ______ RRF ______ RRR ______
Maintenance Schedule and Lubrication Table 2 Preventive Maintenance Maintenance Schedule 15,000 mi 24,000 km 60,000 mi 96,000 km OPERATION \ FREQUENCY COMMENTS 7,500 mi 12,000 km INTERVAL A B C (Color of charge indicator for each battery) 1 ______ 2 ______ 3 ______ 4 ______ TIRES AND WHEELS Missing Valve Caps and Stem Locks Cracks or Loose Wheel lugs Tandem Mating Irregular Wear Tire Pressure (Record below) Remaining Tread (Record below) Tires & Wheels Inspection Right – 160 – Y53-6008A Mediu
Preventive Maintenance Table 2 Maintenance Schedule and Lubrication Maintenance Schedule 15,000 mi 24,000 km 60,000 mi 96,000 km OPERATION \ FREQUENCY COMMENTS 7,500 mi 12,000 km INTERVAL A B C A B Left Air Pressure Adjusted to: _____________ ALIGNMENT Toe–in: ______________ in (mm) Caster: L ________ R ________ Rear Axle Alignment ROAD TEST C2 C Steering / Steering Play Shifting Brakes Engine Operation (noises, surging, black smoke) Throttle Linkage Jake Brake Operation Seat Belts Air Sea
Maintenance Schedule and Lubrication Table 2 Preventive Maintenance Maintenance Schedule 15,000 mi 24,000 km 60,000 mi 96,000 km OPERATION \ FREQUENCY COMMENTS 7,500 mi 12,000 km INTERVAL A B C A B C Air Conditioner Instruments and Gauges: Speedometer/odometer Tachometer Oil Pressure Engine Temperature Illumination BODY Interior Liner Damage Door Operation Roll–up Door Tracks – Lubricate Lift–gate Operation OTHER Hood Pivots Fifth Wheel Components Brake Treadle Hinge and Roller Lock Cylinder
Preventive Maintenance Maintenance Schedule and Lubrication Lubrication Specifications You will find a complete Engine Lubrication Service Guide in the Engine Operation and Maintenance Manual. There, the engine manufacturer explains more fully all the maintenance operations you and a qualified service mechanic will need. And please remember: one key to keeping your Medium Duty running at top economy and in prolonging its life is proper lubrication servicing.
Maintenance Schedule and Lubrication Preventive Maintenance Lubrication Types APPLICATION Use Table 3 on page 166 and the list of lubricants below to identify the type of lubricant to use on your Medium Duty. For a quick summary of each lubrication point, see Table 1 on page 150. ATF: DEXRON® III/MERCON®-approved automatic transmission fluid BB: Ball Bearing grease CB: Engine oil for mild to moderate requirements CC/CD: Engine oil for severe requirements (MIL–L–2104B / MIL–L–45199B w/ 1.
Preventive Maintenance Maintenance Schedule and Lubrication Oil Reservoirs For oil reservoirs with side filler plugs (transmissions, axles, steering gear boxes, transfer cases, etc.), the oil must be level with the filler opening. NOTE: Use care when checking the oil level with a finger. Just because you can reach the oil level with a finger, does not mean the oil level is correct.
Maintenance Schedule and Lubrication Table 3 Preventive Maintenance Recommended Lubrication Types COMPONENTS RECOMMENDED LUBRICANT Power Steering Gear Automatic Transmission Fluid (ATF) Driveline U-Joints Slip-Joint Splines Hood Pivots Fan Drive Fifth Wheel Components Clutch Pedal Shaft Clutch Linkage Other chassis grease fittings not covered below. EP chassis grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2.
Preventive Maintenance Table 3 Maintenance Schedule and Lubrication Recommended Lubrication Types COMPONENTS RECOMMENDED LUBRICANT Cam Brake Camshaft Splines; Disc Brake Shaft Splines and Slide Pin Retainers; Brake Clevis Pins Antiseize type grease, Rockwell specification 0-637. Brake Camshaft Bushings EP Chassis grease, lithium 12-hydroxystearate base, NLGI 2. CAUTION: Do not contaminate brake linings with grease.
Maintenance Schedule and Lubrication Preventive Maintenance NOTE: Keep the engine exhaust system and the vehicle’s cab ventilation system properly maintained. It is recommended that the vehicle’s exhaust system and cab be inspected: • By a competent technician every 15,000 miles. • Whenever a change is noticed in the sound of the exhaust system. • Whenever the exhaust system, underbody, cab or sleeper is damaged.
Preventive Maintenance Engine Maintenance ENGINE MAINTENANCE WARNING! Hot engine oil can be dangerous. You could be seriously burned. Let the engine oil cool down before changing it. Engine Lubrication Proper engine lubrication depends on ambient temperature and where the vehicle will be operated. Use the recommended oil for the weather conditions outside.
Engine Maintenance Preventive Maintenance Fuel System Specification: Use only Diesel Fuel, Grade 2-D, as recommended by engine manufacturers. If you need further information on Grade 2-D fuel specifications, consult the Engine Operation Manual in the glove compartment. Please follow these recommendations when you are changing your fuel filters or strainer elements. Your vehicle's engine will run better and last longer if you do.
Preventive Maintenance Engine Maintenance NOTE: To expel air from density-type strainer elements, soak them in clean fuel before installing them. • Throw away old gaskets. Replace them with new ones to ensure a positive seal. • Position the shell and gasket properly. Then tighten the cover nut or bolt just enough to prevent fuel leakage. • After starting the engine, check for leaks around the filter. A. Close valve and run engine until smooth idle is established, then repeat drain procedures, or B.
Engine Maintenance Preventive Maintenance Emission Components Engine Accesories: Accessory Drive Belts Deisel Exhaust Fluid Tank You can extend the reliability and service life of your vehicle's drive belts with proper attention to installation, and maintenance. Neglect could cause belt failure. The result could be the loss of the electrical or air system as well as possible engine damage from overheating.
Preventive Maintenance Engine Maintenance To Check the Fan: • Check the fan assembly mounting bolts for tightness. Inspect the blades for damage. • Check the clutch operation by starting the engine when it is cold. Then idle it at about 800 RPM. Listen for air leaks. • Check that the fan is not working while the engine is warming. When the clutch engages, note the reading on the vehicle's panel—mounted coolant temperature gauge.
Engine Cooling System Preventive Maintenance • The leading edge of any fan blade must be 1 in. (25 mm) from the inside edge of the shroud. itors. ELC prevents corrosion and scale formation as well as provides freezing and boiling point protection. Exhaust System The exhaust system is part of the noise control system. Periodically check the exhaust for wear and loose or missing parts. For details, see “Noise and Emission Control” on page 251.
Preventive Maintenance Engine Cooling System What To Check In An ELC-filled Cooling System NOTE: Maximum recommended ELC concentration is 60% ELC and 40% water by volume (a 60/ 40 coolant mixture). The minimum recommended concentration is 40%. ELC Concentration Check the level of freeze/boilover protection, which is determined by the ELC concentration. Use a glycol refractometer to determine glycol level. Add ELC to obtain the ELC to water ratio required to provide the protection you need.
Engine Cooling System Preventive Maintenance Topping Off WARNING! Removing the fill cap on a hot engine can cause scalding coolant to spray out and burn you badly. If the engine has been in operation within the previous 30 minutes, be very careful in removing the fill cap. Protect face, hands, and arms against escaping fluid and steam by covering the cap with a large, thick rag. Do not try to remove it until the surge tank cools down if you see any steam or coolant escaping.
Preventive Maintenance Engine Cooling System correct level soon after you have filled the radiator. This may be because all the trapped air in the system has not yet been purged. It takes a little time for all the air to leave the system after you fill your radiator. Engine (Block) Heater (option) Refilling Your Radiator 1. 2. 3. 4. 5. 6. 7. 8. 9. Be sure the radiator and engine block drains are closed. Move the heater control to maximum heat position.
Engine Cooling System Preventive Maintenance Use a solution of half ethylene glycol antifreeze and half water for best heater performance. Do not use more than 65 percent concentration of antifreeze, as a shortened heater life will result. After servicing the cooling system, operate the vehicle for a day or two before using the heater. Trapped air inside the engine needs time to escape. PREVENTIVE MAINTENANCE (PM) INTERVALS I A B C At the first 15,000 mi./ 15,000 mi./24,000 km/ 30,000 mi.
Preventive Maintenance Cooling Engine Cooling System Hoses Check the radiator and heater hoses for leaks. X X Extended Life Coolant (ELC) Check the freeze point (see page 174). X Check for contamination using test strips (see page 175). X Replace blank water filter if applicable. X Perform lab analysis (see page 175). X If lab analysis shows coolant is unsuitable for continued use Flush, drain, and refill (see page 174). Add ELC Extender (see page 175).
Brake System Preventive Maintenance BRAKE SYSTEM All of the following areas are interrelated and must conform to original specifications: If your truck has an air brake system, see the pages below. • • • • If your truck has a hydraulic brake system, please go to “Hydraulic Brake System” on page 184. Introduction To operate your vehicle safely, you need some understanding of its brake systems. Brake adjustment and brake balance must be set carefully to allow equal stopping forces at all wheels.
Preventive Maintenance Brake System WARNING! Do not use any replacement part in the brake system unless it conforms exactly to original specifications. A nonconforming part in your vehicle's brake system could cause a malfunction resulting in an injury accident. Sizes and types are so related to one another that a seemingly unimportant change in one may result in a change in how well the brakes work for you on the road.
Brake System Preventive Maintenance • Do not use pressure-release grease fittings when lubricating the slack adjuster. Checks and Adjustments All vehicle operators should check the brakes regularly. Always adjust the brakes when they are cool. • Park the vehicle on a level surface and block the wheels before attempting any brake checks or adjustments. Brake Linings WARNING! Do not use brake linings with a thickness below the specified minimum.
Preventive Maintenance Brake System WARNING! Manual adjustment of automatic slack adjusters is a dangerous practice that could have serious consequences. It gives the operator a false sense of security about the effectiveness of the brakes. Contact the Service Department at your dealership if the stroke exceeds the above specifications. A stroke exceeding these values may indicate a problem with the slack adjuster or the brake foundation.
Brake System Preventive Maintenance Constant manual adjustment of automatic slack adjusters can shorten the life of the internal clutch. If the installation appears to be free of damage, but the applied stroke range could not be achieved, the slack adjuster must be replaced. NOTE: The brake adjuster alone does not ensure proper brake operation. Inspect all brake components. All brake components work together and must be checked periodically to ensure the brake system works properly.
Preventive Maintenance Brake System WARNING! Do not use any replacement part in the brake system unless it conforms exactly to original specifications. A nonconforming part in your vehicle's brake system could cause a malfunction resulting in an injury accident. Consult you local dealer for suitable replacement parts. Brake Fluid Check and Refill WARNING! Do not work on the brake system without the parking brake set, the keys removed from the vehicle, and wheels chocked securely.
Brake System Preventive Maintenance WARNING! If the brake fluid reservoir requires an excessive amount of hydraulic fluid, the complete system must be inspected for leaks and repaired if necessary (consult your nearest Peterbilt dealer). Failure to keep the brake system in good repair may lead to loss of braking and possibly cause serious personal injury. Make sure that the fluid level registers on or above the fluid level mark molded on the reservoir - add more if necessary, as follows: 1.
Preventive Maintenance Brake System BRAKE PADS ANCHOR PLATES BRAKE PADS CALIPERS CALIPERS ROTORS FRONT REAR SYSTEM COMPONENTS Calipers - Visually inspect calipers for brake fluid leakage, damaged or defective pistons or piston boots. If there is evidence of leakage, damage, or other defects the caliper should be replaced or repaired. Disc brake rotors - Visually inspect rotors for scoring, warping, cracks, bluing or heat spots or other damage or defects.
Brake System Preventive Maintenance Visually inspect brake shoe lining for wear, cracks, or breakage. If linings are worn down to 2.5 mm (0.10 in), they must be replaced. Inspect brake drum for deep scores, heat spots, cracks, or damage. Replace if needed. BRAKE SHOE LININGS Anti–Lock Braking System (ABS) Your Medium Duty is equipped with an anti-lock braking system. For detailed service information, see the Peterbilt Medium Duty Maintenance Manual.
Preventive Maintenance Brake System • During wheel balancing, dyno testing, or any time the ignition is on with part of the ABS disconnected, a failure code will be recorded. Consult with your Peterbilt Dealer or Authorized Service Center for information on clearing the failure code. If, due to operating conditions, a brake application causes either wheel on the same axle to begin skidding, wheel speed sensors immediately signal the anti-lock controller in the modulator assembly.
Brake System Preventive Maintenance WARNING! Do not operate the vehicle in the event of a malfunction in any air or hydraulic circuit. Such a malfunction may prevent the brake system from operating properly, and could result in an injury accident. The vehicle should not be operated until the system is repaired and both braking circuits, including all pneumatic, hydraulic, and mechanical components are working properly.
Preventive Maintenance Air System AIR SYSTEM Introduction WARNING! Prior to the removal of any air system component, always block and hold the vehicle by a secure means other than the vehicle's own brakes. Depleting air system pressure may cause the vehicle to roll unexpectedly resulting in an accident and/or injuries. Keep hands away from chamber push rods and slack adjusters, they may apply as system pressure drops. •Never connect or disconnect a hose or line containing air pressure.
Air System Preventive Maintenance Scheduled Maintenance Table 5 Use Table 5, ”Air System Scheduled Maintenance,” to schedule service operations and air system tests.
Preventive Maintenance Air System WARNING! If the supply and service tanks are not drained at the recommended frequency, water could enter the air lines and valves. This could cause corrosion or blockage, which could compromise the brake system safety and potentially cause an injury accident. Air System Function Test Scheduled maintenance should be performed on the Medium Duty air system, as outlined in the Medium Duty Maintenance Manual and Table 5.
Air System Preventive Maintenance CAUTION: Do not use penetrating oil, brake fluid, or wax-based oils in the air system. These fluids may cause severe damage to air system components. WARNING! Do not operate the vehicle if leakage in the air system is detected. Conduct the following procedure and contact an Authorized Service Center (or any other properly equipped • Maintain the air compressor to prevent excessive oil bypass. See the Medium Duty Maintenance Manual for maintenance details.
Preventive Maintenance Air System 7. If you detect excessive leakage (air pressure loss greater than 3.0 psi after five minutes of brake application), a leakage test should be made at the air line connections and at all air brake control units. These tests should determine where air is escaping. Air Compressor Operation All compressors, regardless of make or model, run continuously while the engine is running. System pressure is controlled by the governor.
Air System Preventive Maintenance CAUTION: When draining the engine cooling system is required, to prevent damage from freezing, the compressor must also be drained at the cylinder head and block. Engine damage could occur if the cooling system is not periodically drained and maintained. See “Engine Cooling System,” Page 174 , and the Medium Duty Maintenance Manual for further information.
Preventive Maintenance Air System amounts of moisture is normal and should not be considered as an indication that the dryer is not performing properly. • An outside air source may have been used to charge the air system, in which case this air did not pass through the drying bed. Turbocharger When servicing the air intake and exhaust systems on a turbocharged engine, check the items listed below.
Air System Preventive Maintenance High Frequency Vibration: Vibration may indicate turbo rotor imbalance. Have your Peterbilt Dealer or Authorized Service Center investigate this immediately. If you detect any deficiencies, take the vehicle to an Authorized Service Center for servicing. Delay could lead to severe and expensive damage to your vehicle. Service the air cleaner periodically. If the vehicle operates in areas with heavy dust, maintenance should be more frequent.
Preventive Maintenance Air System 3. Remove the filter element. 4. Clean out the inside of the air cleaner body and outlet tube with a dry rag. COVER To install air cleaner element: 1. Slide air cleaner element into housing. 2. Install air cleaner end cap. 3. Install thumbscrews around air cleaner housing end cap. 00455B NOTE: The air cleaner is internally sealed by a radial seal around Inlet tube of air cleaner element.
Tires and Wheels Preventive Maintenance TIRES AND WHEELS Introduction Keeping the tires in good condition is essential to the safe, efficient operation of your Medium Duty. Regular, frequent inspection and the right care will give you the assurance of safe and reliable tire operation. General Safety Requirements WARNING! Use only original equipment manufactured (OEM) components.
Preventive Maintenance Tires and Wheels Speed Restricted Tires WARNING! This vehicle may be equipped with speed restricted tires. Check each tire’s sidewall for maximum rated speed. Vehicle should not be operated at sustained speed in excess of maximum rated speed. Failure to comply with these speed restrictions could cause sudden tire failure which can result in property damage or personal injury. Tire Inspection and Replacement vehicle. For dual wheel assemblies, check between the wheels for damage.
Tires and Wheels Preventive Maintenance Tire Inflation Most tire wear problems are caused by underinflation as the result of slow leaks. So you will want to check tire pressure regularly. Give the tires a visual test every day, and check inflation with a gauge every week. When checking tire pressure, inspect each tire for damage to sidewalls, cuts, cracks, uneven wear, rocks between dual wheels (tires), etc. If a tire appears underinflated, check for damage to the wheel assembly.
Preventive Maintenance Tires and Wheels Overinflation: r e d u c e s t h e tread contact area with the road surface, concentrating all of the vehicle weight on the center of TREAD CONTACT the tread. This causes premaWITH ROAD ture wear of the tire. • Too much air pressure reduces the tire tread contact area and results in rapid wear in the center of the tire. It also causes tires to run hard and makes them more vulnerable to impact and other road hazard damage.
Tires and Wheels Preventive Maintenance Wheel Mounting and Fastening Wheel Bearing Adjustment After the vehicle travels about 50 to 100 miles (80 to 160 km), wheel mountings “seat in” and will lose some initial torque. Check hub/wheel mountings after this initial period and retighten. Wheel Cap Nut Torque At the first scheduled lube interval, have all wheel cap nuts torqued to their specified value. See Table 7, “Wheel Cap Nut Torque,” Page 205 After that, check wheel cap nuts at least once a week.
Preventive Maintenance Table 7 Tires and Wheels Wheel Cap Nut Torque WHEEL & NUT CONFIGURATION Steel Disc-Type Wheel; Double Cap Nut Mounting; Standard 7/8” Radius Ball Seat or Flanged Nuts: Alum.
Tires and Wheels Table 7 Preventive Maintenance Wheel Cap Nut Torque WHEEL & NUT CONFIGURATION STUD SIZE Dayton: 5/8-11 Front & Rear DYNAMIC TORQUE FOR INNER & OUTER CAP NUTS & RIM CLAMP NUTS N.
Preventive Maintenance Tires and Wheels Demounted Rims WARNING! Improperly mounting and demounting tire and rim assemblies is dangerous. Failure to observe proper precautions could cause the tire-rim assembly to burst explosively, causing serious injury or death. See the wheel manufacturer's literature for the proper way to mount and demount your tires and rims. Follow their precautions exactly. To check the torque on demountable rims, follow the crisscross sequence shown below.
Tires and Wheels Table 8 Preventive Maintenance Comparing Hub-piloted and Ball-seat Wheels BALL–SEAT MOUNT HUB–PILOTED MOUNT 00187 00203 Hub, Drum, and Stud Assembly Hub-piloted mountings use M22 x 1.5 metric threads (about 7/8 in. diameter). The stud stands out at least 1.94 in. beyond the brake drum. All studs are right-hand threads. Pilot bosses (machined surfaces) on the hub, fit tightly to the wheel center bore. Ball-seat (stud-piloted) mountings use 3/4x16 or 1-1/8x16 threads.
Preventive Maintenance Tires and Wheels Tire Replacement NOTE: To prolong the tires' life and make them safer, have their radial and lateral run-out checked at your Peterbilt Dealer. And of course have the tires balanced any time you change a tire. Front: replace front tires when less than 4/32 in. of tread depth remains. Check depth at three places equally spaced around the tire. Matching Tires Drive Axles or Trailers: replace tires on drive axles when less than 2/32 in.
Tires and Wheels Preventive Maintenance Wheel and Tire Replacement WARNING! The Anti-Lock Brake System (ABS) is calibrated for the specific tire revolutions per mile. Use of a tire and/or wheel size different from that originally installed on your vehicle may cause the ABS system to not function during a hard braking event. This could cause an accident or serious personal injury.
Preventive Maintenance Heater and Air Conditioner HEATER AND AIR CONDITIONER – Stay away from the hot engine until the exhaust manifold has cooled. – Do not permit any open flame in the area. Even a match or a cigarette lighter may generate a hazardous quantity of poisonous gas. – Do not smoke in the area. Inhaling gaseous refrigerant through a cigarette may cause violent illness.
Heater and Air Conditioner Preventive Maintenance CAUTION: During extreme cold weather, do not blow hot air onto cold windshields. This could crack the glass. Turn the air direction lever to Defrost and reduce the fan speed while the engine warms. If the engine is already warm, move the temperature selector to Cool, then gradually increase the temperature when you see that the windshield is starting to warm-up. Air Conditioner WARNING! The air conditioning system is under pressure.
Preventive Maintenance Electrical System ELECTRICAL SYSTEM CAUTION: Do not modify or improperly repair the vehicle’s electrical system or power distribution box. All electrical repairs should be performed by an authoriz ed Peterbilt dealer. Improper repair or modifications will void your warranty and/or cause serious damage to your vehicle. Location Of Fuses Fuses are located inside the cab, left side, next to the driver’s door. CAUTION: Never patch fuses with tin foil or wire.
Electrical System Preventive Maintenance All the electrical circuits have fuses to protect them from a short circuit or overload. If something electrical on your chassis stops working, the first thing you should check for is a blown fuse. 1. Turn OFF all lights and accessories and remove the ignition key to avoid damaging the electrical system.. 2. Determine from the chart on the fuse panel which fuse controls that component. 3. Remove that fuse and see if it is blown. 4.
Preventive Maintenance Electrical System The battery compartment is located on the left side of the vehicle, under the cab access steps. WARNING! Before attempting any work on the batteries or electrical system, remove all jewelry. If metal jewelry or other metal comes in contact with electrical circuits, a short circuit may occur causing you to be injured, as well as electrical system failure and damage. The cover is held in place by two latches one on each side.
Electrical System Preventive Maintenance Overcharge: this condition results from improper voltage regulator adjustment. It results in overheating of the battery, warped plates, and evaporation of electrolyte. Undercharge: the voltage regulator is malfunctioning or is improperly adjusted, the drive belt is slipping, or your vehicle has undergone long periods of standing idle or short distance driving. These conditions result in battery plates becoming covered with a hard coating.
Preventive Maintenance Electrical System WARNING! Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces. Always wear eye protection. Battery acid that may spill during charging should be washed off with a solution of warm water and baking soda to neutralize the acid. If you accidentally get acid in your eyes or on your skin, immediately rinse with cold water for several minutes and call a doctor.
Electrical System Preventive Maintenance before proceeding. If no water is available, remove the caps and cover the filler openings with a cloth. After jump starting the vehicle, dispose of the cloth. WARNING! If you do not cover the filler openings on the battery, electrolyte could boil out of the openings and hurt someone or damage the vehicle. Replace caps securely if the battery has the full level of electrolyte. If the electrolyte is low and no water is available, cover with a cloth.
Preventive Maintenance Electrical System WARNING! Batteries can injure you severely. They contain acid, produce poisonous and explosive gases, and supply levels of electric current high enough to cause burns. A spark or flame near a battery on charge may cause it to explode with great force. If the engine fails to start, do not continue to crank the starter but contact the nearest Authorized Service Center.
Electrical System Preventive Maintenance • When fast charging, remove the battery caps so pressure does not accumulate. • Always make sure the battery charger is OFF before connecting or disconnecting the cable clamps. • To avoid short circuits and damage to yourself or the vehicle, never place metal tools or jumper cables on the battery or nearby.
Preventive Maintenance Electrical System Bulb Replacement Slow Battery Charging NOTE: Follow the instructions that come with your battery charger. • It is not necessary to remove the battery from the compartment. WARNING! Charger cables must be connected positive to positive (+ to +) and negative to negative (– to –). If connected improperly, batteries could explode causing serious personal injury. • Always make sure the battery charger is OFF before connecting or disconnecting the cable clamps.
Electrical System Preventive Maintenance Electrical and Alternator Precautions Take the following precautions to avoid burning out alternator diodes: • Do not start the engine with alternator disconnected (connections removed) from the circuit. • Before welding, disconnect all electronic connections to the vehicle batteries. • Remove battery power cable and insulate it from the vehicle. See “Welding” on page 249 for more information. • Do not run the engine with the batteries disconnected.
Preventive Maintenance Cab Maintenance CAB MAINTENANCE Exterior Maintenance Painted Surfaces Wash painted surfaces frequently to remove grime and caustic deposits which may stain the finish. See “Cleaning, Protection and Weather–Stripping” on page 224. Chrome and Aluminum Surfaces To prevent rust, keep chromed parts clean and protected with wax at all times, especially in winter conditions where the roads are salted. • If necessary, use a commercial chrome cleaner to remove light rust.
Cab Maintenance Preventive Maintenance Cleaning, Protection and Weather–Stripping Frequent washings of the vehicle are required to remove grime and contaminants that can stain and oxidize paint and accelerate corrosion of plated and polished metal surfaces. Waxing offers added protection against staining and oxidation. But to allow enough time for your truck's finish to cure, wait about 30 days after the date of manufacture before waxing.
Preventive Maintenance Cab Maintenance CAUTION: Do not aim the water jet directly at door locks or latch. Tape the key holes to prevent water from seeping into the lock cylinders. Water in lock cylinders should be removed with compressed air. To prevent locks from freezing in the winter, squirt glycerin or lock deicer into the lock cylinders. 4. Wipe everything dry with a chamois to avoid water spots. • To prevent water spotting, dry off the cosmetic surfaces with a clean cloth or chamois. 5.
Cab Maintenance Preventive Maintenance At least every spring, flush these materials from the under body with plain water. Be sure to clean any area where mud and other debris can collect. Sediment packed in closed areas of the frame should be loosened before being flushed. If desired, your Peterbilt Dealer or Authorized Service Center can do this service for you.
Preventive Maintenance Cab Maintenance • Always test a commercial cleaning agent on an inconspicuous area of the surface to be cleaned before using it.
Cab Maintenance Preventive Maintenance • Remove soap with a clean, damp rag. Safety Restraint System — Inspection • If a stronger cleaning solution is required, use a foamtype carpet shampoo. The seat belt system, including webbing, buckles, latches, and mounting hardware, endures heavy use in medium-duty vehicles—much more than seat belt systems in passenger cars. All users should be aware of the factors contributing to this heavy use and reduced belt life.
Preventive Maintenance Cab Maintenance WARNING! It is important to remember that any time a vehicle is involved in an accident, the entire seat belt system must be replaced. Unexposed damage caused by the stress of an accident could prevent the system from functioning properly the next time it is needed, which could result in severe injury or even death.
Cab Maintenance Preventive Maintenance parts of the cab interior. These areas are typical places where the web will experience cutting or abrasion. Cuts, fraying, or excessive wear would indicate the need for replacement of the seat belt system. 2. The pillar web guide (D-loop) is the area where almost constant movement of the seat belt webbing occurs because of relative movement between the seat and cab. 3. Check the Komfort-Lok Latch for cracks or possible damage and check for proper operation.
Preventive Maintenance Cab Maintenance 4. Check buckle and latch for proper operation and to determine if latch plate is worn, deformed, or damaged. 5. Inspect the retractor web storage device, which is mounted on the floor of the vehicle, for damage. The retractor is the heart of the occupant restraint system and can often be damaged if abused, even unintentionally. Check operation to ensure that it is not locked up and that it spools out and retracts webbing properly.
Cab Maintenance Preventive Maintenance Windshield Wipers/Washer Check wiper blades annually or every 60,000 miles (96,000 km). Anco 18-inch (450mm) wiper blades are recommended. The windshield washer tank is located inside the engine compar tment below the radiator expansion tank. See “Washer Reservoir” on page 201. Check the windshield washing fluid level weekly. If necessary, fill to top.
Preventive Maintenance Transmission and Clutch TRANSMISSION AND CLUTCH Transmission Lubricants CAUTION: When adding oil, types and brands of oil should not be intermixed because of possible incompatibility, which could decrease the effectiveness of the lubrication or cause component failure.
Transmission and Clutch Table 9 Preventive Maintenance Transmission Lubrication — Manual transmissions Eaton-Fuller AMBIENT TEMPERATURE RANGE RECOMMENDED LUBRICANT (See Note) MODEL VISCOSITY (SAE) DEG. C DEG. F HD engine oil: API CE or CF-4. Above -12 Above +10 50 Synthetic oil: Chevron RPM Synthetic Transmission Fluid, or equal, meeting MIL-L-2104D and Eaton PS-081 specifications. Above -40 Above -40 50 NOTE: Do not use multi-viscosity or EP (extreme pressure) gear oil (e.g.
Preventive Maintenance Transmission and Clutch As the clutch pedal is depressed further, with harder pressure, the release yoke moves the release bearing away from the engine. This causes the clutch plate to release from the driven disks in the clutch. This is called release travel. And finally, on 9-, 10-, and 11-speed transmissions, as the pedal is pushed to the last 1/2 to 1 inch of travel, the release bearing contacts and engages the clutch brake. This is called clutch brake squeeze.
Transmission and Clutch Preventive Maintenance Automatic Transmissions Automatic Transmission Oil Level NOTE: The vehicle must be parked on level ground. Service Intervals Check daily with engine idling. See Table 1, “Recommended Maintenance Intervals,” Page 150 for service intervals. Maintain the oil level and check it daily. Oil should be up to the “HOT” mark on the dipstick when (1) the engine is running, (2) the transmission is at operating temperature, and (3) the transmission is in Neutral.
Preventive Maintenance Steering and Driveline STEERING AND DRIVELINE If you cannot correct the problem, check with an Authorized Service Center. Power Steering Oil (under low pressure) provides the power to operate the steering gear. It also serves to lubricate moving parts and remove heat. A loss of steering efficiency will occur if too much heat builds up in the system. WARNING! Do not operate the vehicle if the steering system is not working properly.
Steering and Driveline Preventive Maintenance If these checks do not reveal the problem, or if you correct them and still have a steering problem, take your truck to an authorized Peterbilt Dealer for evaluation. RESERVOIR Fluid Level and Refill Have the power steering fluid and filters changed at an Authorized Service Center. • Check and completely change the fluid level according to Table 1, “Recommended Maintenance Intervals,” Page 150.
Preventive Maintenance Steering and Driveline Fluid Refill Use Automatic Transmission Fluid (ATF) Type E or F or Dexron® II. For other approved brands and types of fluid, see the Medium Duty Maintenance Manual. SLIP JOINT Steering Driveline • Torque on U–joint pinch bolt and nut 45–55 lb. ft. (61-75 N.m.), lubricated. • Torque on Pitman arm clamp bolt and nut: 180-210 lb. ft. (244-285 N.m.), lubricated.
Front Axle and Suspension Preventive Maintenance FRONT AXLE AND SUSPENSION SPRING AND SHACKLE PINCH BOLTS Inspection For all vehicles, mandatory maintenance procedures include retightening all U–bolts and inspecting the suspension for loose fasteners, abnormal wear, or damage. However, even with proper maintenance, the service life of leaf springs is affected by many factors, such as: fatigue, vehicle gross weight, type of load, road conditions, and vehicle speed.
Preventive Maintenance Front Axle and Suspension • Thoroughly clean hubs and bearings with solvent and a stiff bristle brush, then dry and inspect components for wear or damage. Re-lubricate with approved axle lubricant. KINGPIN (TOP) Kingpin Lubrication • Lubricate with approved lubricant. Lubricate knuckle thrust bearings, knuckle pins, and tie rod ends. See Table 1, “Recommended Maintenance Intervals,” Page 150. Lack of lubrication causes premature wear and hard steering.
Front Axle and Suspension Preventive Maintenance WARNING! Do not operate the vehicle if the U– bolts are not properly tightened. Loose U–bolts do not properly secure the axle to the suspension. This could cause loss of vehicle control and an injury accident. Loose U–bolts can also cause uneven tire wear and poor alignment. CAUTION: Do not spray the suspension with chemical products or mineral oil; it can cause damage to the bushings.
Preventive Maintenance Rear Axle and Suspension REAR AXLE AND SUSPENSION WARNING! Failure to maintain the specified torque values or to replace worn parts can cause component system failure, possibly resulting in an injury accident. Improperly tightened (loose) suspension U–bolts can lead to unsafe vehicle conditions, including: hard steering, axle misalignment, spring breakage or abnormal tire wear. See the Fastener Torque Tables for proper torque specifications.
Rear Axle and Suspension Preventive Maintenance It is important that U–bolts remain tight. Severe use of your vehicle can cause them to loosen faster. But all vehicles need to have their U–bolts checked and tightened regularly. Be sure someone with the proper training and the right tools checks and tightens the U–bolts on your Medium Duty. Rear Axle Lubrication • Check oil level with the vehicle parked on level ground and the fluid warm. The level should be even with the bottom of the filler hole.
Preventive Maintenance Rear Axle and Suspension Table 11 Drive Axle Lubrication MODEL EATON, ROCKWELL RECOMMENDED LUBRICANTS AMBIENT TEMPERATURE RANGE °F EP gear oil, MIL-L-2105D, API GL-5. -26 to +38 -15 to +100 80W-90 Synthetic Lubricant: Chevron RPM Synthetic Gear Lubricant, or equal, meeting MIL-L-2105D and Eaton PS-037 specification. -40 to +38 -40 to +100 75W-90 • No initial drain is required on Eaton axles that are factory filled with an Eaton-approved synthetic lubricant.
Rear Axle and Suspension Preventive Maintenance Rear Suspension Fasteners 3 Continual road shock and load stresses may force the rear axles out of alignment. If you detect rapid tire wear on the rear axles, you may have misaligned axles. Have your rear axle alignment checked and adjusted by a Peterbilt Dealer or Authorized Service Center.
Preventive Maintenance Rear Axle and Suspension WARNING! Do not replace U–bolts and nuts with common U–bolts or standard nuts. These parts are critical to vehicle safety. If the wrong U–bolts or nuts are used, the axle could loosen or separate from the vehicle and cause a serious injury accident. Use only U–bolts and nuts of SAE Grade 8 specification or better. Grade 5 Capscrew Torque Specifications Capscrew Body Size (inches-thread) 1/4-20 Torque Lb. ft. N.m. 6—9 8—12 9.
Rear Axle and Suspension Preventive Maintenance Grade 8 Capscrew Torque Specifications Capscrew Body Size (inches-thread) – 248 – Torque Lb. ft. N.m.
Preventive Maintenance Frame and Fifth Wheel FRAME AND FIFTH WHEEL NOTE: Welding to frame rail may void frame rail warranty. Introduction WARNING! Do not cut or splice frame rails or drill through the top or bottom flanges. These operations could affect frame rail strength leading to a failure resulting in serious personal injury and/or an accident. Always leave frame repairs to your Peterbilt Dealer.
Frame and Fifth Wheel Preventive Maintenance Fifth Wheel Maintenance Every 6 Months or 50,000 Miles: Proper preventive maintenance is essential to trouble-free service and safe operation of the fifth wheel. Every 2 Months or 25,000 Miles: • Refer to specific manufacturer's literature for any special instructions. • Steam clean the fifth wheel. • Check lock guard operation using a commercial lock tester. • Clean and oil all moving parts. • Lubricate the following parts with a lithium-base grease.
Preventive Maintenance Noise and Emission Control NOISE AND EMISSION CONTROL Tampering with Noise Control System Federal law prohibits the following acts or the causing thereof: Noise Emission Warranty Peterbilt Motors Company warrants to the first person who purchases this vehicle (for purposes other than resale) and to each subsequent purchaser: that this vehicle, as manufactured by Peterbilt Motors Company, was designed, built and equipped to conform, at the time it left Peterbilt's control, with all
Noise and Emission Control Preventive Maintenance Engine • Removing or rendering engine speed governor inoperative so as to allow engine speed to exceed manufacturer's specifications. • Modifying ECU parameters. • Check the induction tubing, elbow connections, clamps, brackets, and fasteners for deterioration, cracks, and security. • If you find an air leak anywhere between the air cleaner and the engine, repair that leak immediately.
Preventive Maintenance Noise and Emission Control Piping Exhaust Tail Pipe • Check exhaust piping for rust, corrosion, or damage. Replace deteriorated piping before holes appear. If piping is perforated at any point, temporary patching or lagging is acceptable until you can have permanent repairs made. On turbocharged engines, check joints at flanges and mounting brackets for tightness. • Check the mounting. Tighten as necessary.
Noise and Emission Control Preventive Maintenance Maintenance Log Transmission and Driveline • Substituting a different main transmission or drive line components, other than design-specified units, may result in increased vehicle noise emission. To ensure your Medium Duty's noise control requirements are maintained, record maintenance checks. Use the following log sheet (see Table 12) and retain copies of documents regarding maintenance services performed and par ts replaced on the vehicle.
Preventive Maintenance Noise and Emission Control Table 12 Maintenance Log Medium Duty (R05/09) Y53-6008A – 255 –
Noise and Emission Control Preventive Maintenance Table 12 Maintenance Log – 256 – Y53-6008A Medium Duty (R05/09)
Preventive Maintenance Consumer Information and Vehicle Identification CONSUMER INFORMATION AND VEHICLE IDENTIFICATION Canadian Consumer Information Reporting Safety Defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Peterbilt Motors Company.
Consumer Information and Vehicle Identification Preventive Maintenance Vehicle Identification All Peterbilt vehicles are identified by a 17–digit Vehicle Identification Number (VIN). This unique numeral and letter combination identifies the manufacturer, the model year it was built, and other vehicle attributes. The VIN is in compliance with 49CFR565, Code of Federal Regulations.
Preventive Maintenance Consumer Information and Vehicle Identification Chassis Number Locations A2378 The chassis/serial number is shown in three places: • Right frame rail, top flange, about 3 ft.
Consumer Information and Vehicle Identification Preventive Maintenance Complete Vehicle Certification Label VEHICLE NAME PLATE The Complete Vehicle Certification label certifies that the vehicle complies with all applicable Federal Motor Vehicle Safety Standards.
Preventive Maintenance Consumer Information and Vehicle Identification WARNING! Do not exceed the specified load rating. Overloading can result in loss of vehicle control and serious personal injury, either by causing component failures or by affecting vehicle handling. Exceeding load ratings can also shorten the service life of the vehicle. NOTE: GVW is the TOTAL SCALE WEIGHT the vehicle is designed to carry. This includes the weight of the empty vehicle, loading platform, occupants, fuel, and any load.
Consumer Information and Vehicle Identification Preventive Maintenance Federal Safety Standard Certification Label The NHTSA regulations require a label certifying compliance with Federal Safety Standard, for United States and U.S. Territories, be affixed to each motor vehicle and prescribe where such label may be located. This certification label, which indicates the date of manufacture and other pertinent information, is located on the driver's side door frame.
Preventive Maintenance Medium Duty (R05/09) Consumer Information and Vehicle Identification Y53-6008A – 263 –
INDEX INDEX A Accessories 70 Air conditioner 212 refrigerant 147 Air Dryer 196 Air filter 198 Air horns 46 Air intake 197, 251 Air leaks 194 Air pressure gauge 194 Air suspension deflated air spring 134 switch, operation 130 Air tanks 85, 116, 144 Alternator precautions 222, 249 Anti-lock brakes 109, 112, 122 Automatic transmission 86, 100, 236 fluid 239 oil level 236 Axle weight rating 82, 83, 129, 261 B Ball bearing grease 164 Ball seat mounted wheels 208 Battery access 214 – 264 – care 215 compartmen
INDEX system - towing and spring brakes 139 system checks 180, 184 system malfunction 139 system park - tractor 107 trailer brake hand valve 113 trailer charge 107 treadle valve 116 Brake Fluid Check 185 Brake Fluid Reservoir 119 Brake Master Cylinder 119 Brake Warning Lamp 120 C Cab access 9 heater maintenance 211 maintenance 228 Calipers 187 Charge air cooler 197 Chassis grease 164 number 258, 259 Cleaning the vehicle 224 Clutch 96 clutch adjustment 100 clutch brake 98 clutch travel 98 fan drive 253 oper
INDEX Cooling system conventional coolant 176 extended life coolant 175 temperature 39 topping up 176 Cruise control operation 94 Cruise Control On/Off 15 Cruise Control Select 15 D Daily operations 84 dash 14 dashboard 14 Daytime running lights 50 DEF 40, 172 DEF Gauge 15 Defogging/defrosting system 66 Deisel Exhaust Fluid 172 Department of transportation regulation 392.
INDEX belt tension 84, 216 block heater 91 compression 143 daily checks 84 fan switch 94 heater 177, 210, 213 identification 262 idling 93 lubrication 169 oil draining 169 oil level check 169 overspeed 128 retarder 114 rpm 144 service notes 169 starting procedure 87 stopping the engine 144 vital engine systems 92 warmup procedure 92 weekly checks 86 winterfronts 88 Engine Oil Pressure 15 Environmental protection 147 Ether 87 Exhaust brake 114, 115 fumes 147 Medium Duty (R05/09) F Fan blade 253 switch 94 F
INDEX G Gauges and Displays 35 Drive Axle Temperature Gauge 42 Engine Oil Pressure Gauge 38 Fuel Gauge 40 Speedometer / Odometer 29, 35 Tachometer 36 Voltmeter 40 Warning Lights and Buzzers 17 Water Temperature Gauge 38 GAWR defined 83 GAWR - gross axle weight rating 82, 129, 261 GCW - gross combination weight 82 Glove compartment 71 Governor 116 Grease index 164 GVWR defined 82 GVWR - gross vehicle weight rating 82, 129, 203, 261 H Hand brake 113, 143 Hazard flasher 121 Hazard Switch 15 Headllights 15 He
INDEX Low air pressure 134 Lubrication 181, 241 axle 240 brakes 181 chart 165 coasting 128 driveshaft 239 engine 169 front axle 241 front suspension 241 idling 92, 93 power steering 237, 238 rear axle 244, 245, 246 transmission 233, 234 types and brands 163 wheel bearings 241 M Maintenance manual 6 schedule 149 Manual transmission 96 lubricants 233 oil level 234 shifting gears 96 master cylinder 118 Menu Control Switch 15 Modifications 147 Modulating valve 116 Medium Duty (R05/09) Muffler 253 N NHTSA co
INDEX use 62, 88, 97, 121, 143, 146, 218 valve 117 Parking Brake Burnishing 123 Parking Brake Component Inspection 187 Parking Brake Indicator 63 Parking Brake Lever 120 Parts catalog 6, 7, 148 Power steering 237 fluid level 238 fluid refill 239 lubrication 237 Primary Air Pressure 15 Q Quick-release valve 117 R Radio 16, 71 Rear axle 244 housing breather vent 246 identification 262 lubrication 244, 245, 246 oil change 244 oil level 244 Rear brake system 102 Rear suspension 243 fasteners (standard) 243 Re
INDEX Service Brake Components 186 Shackle pinch bolts 242 Shift pattern/diagram 96, 98 Shifting gears 88, 96, 97, 98, 99, 100, 128, 129, 142 Shifting gears in a new vehicle 98 Shock absorber 240 Shop manuals 6 Shoulder belt 75 Single check valve 117 Slack adjusters 182 Speedometer 15 Spring brakes - manual release 139 Spring pins 241 Springs 240 Starting Procedure Cold Temperatures 90 Normal Temperatures 88 Steering Column-Mounted Controls 43 Steering maintenance 237 Stopping procedures 143 Storage compart
INDEX U U-Bolt torque 242 Underbody maintenance 225 Underinflated tires 202 V Vehicle driving 81 loading 82 weight rating 82, 129, 261 Vehicle inspections 81 W WAIT TO START light 89 Warning Light Symbols table 20 Warranty 147, 149, 243, 249, 251, 252 Water Temperature 15 Weekly operations 86 Weight rating 82, 129 Welding 222, 249 Wet Brakes 121 Wet tank 116 – 272 – Wheel and Tire Replacement, hydraulic brakes 210 Wheel bearing grease 164 lubrication 240 wheel cylinders 118 Wheels and tires 200 general
Other Publications Order either of the two publications shown below through your Peterbilt dealer. There is a charge for each. Allow four weeks for delivery. 02956A Custom Maintenance Manual This manual contains both proprietary and supplier service information specifically compiled for the components on your vehicle. The material in this manual is the same as that used by Peterbilt dealers. It includes inspection, maintenance, overhaul, and troubleshooting procedures.
Y53-6008A 06/09 Printed in the U.S.A. Peterbilt Motors Company, A PACCAR Company, P.O.
