Contents Safety 1 Emergency 2 Controls 3 Driving 4 Maintenance 5 Information 6 Index 7
Contents ©2012 Paccar Inc - All Rights Reserved This manual illustrates and describes the operation of features or equipment which may be either standard or optional on this vehicle. This manual may also include a description of features and equipment which are no longer available or were not ordered on this vehicle. Please disregard any illustrations or descriptions relating to features or equipment which are not on this vehicle.
Truck Model Example i
SAFETY 1 INTRODUCTION How to Use This Manual . . . . How to Find What You Want . . Safety Alerts . . . . . . . . . Vehicle Safety . . . . . . . . A Special Word About Repairs . Additional Sources of Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 1-3 1-4 1-6 1-8 1-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 1-12 1-13 1-14 Hood Hold Downs. . . . . . . . . . . . . . . Hood Tilt . . . . .
SAFETY SEATS AND RESTRAINTS 1 Introduction . . . . . . . . Safety Restraint Belts . . . . Tether Belts . . . . . . . . Komfort-Lok® Feature . . . . During Pregnancy. . . . . . Belt Damage and Repair . . . Sleeper Bunks and Restraints Safety Restraint Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 1-21 1-23 1-24 1-25 1-26 1-26 1-29 . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION INTRODUCTION How to Use This Manual This manual contains useful information for the safe and efficient operation of your Peterbilt 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—and to present it as clearly as possible.
INTRODUCTION 1 and alphabetically lists the subjects covered. So if you want information on brakes, for example, just look under Brake in the Subject Index. You’ll find all the pages listed where brakes or braking are discussed. 1-4 Safety Alerts Please read and follow all of the safety alerts contained in this manual. They are there for your protection and information. These alerts can help you avoid injury to yourself, your passengers, and help prevent costly damage to the vehicle.
INTRODUCTION CAUTION Example: 1 CAUTION NOTE The safety alert following this symbol and signal word provides a caution against operating procedures which could cause equipment or property damage. The alert will identify the hazard, how to avoid it, and the probable consequence of not avoiding the hazard. The alert following this symbol and signal word provides important information that is not safety related but should be followed.
INTRODUCTION 1 Vehicle Safety WARNING Do not drink alcohol 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. Failure to comply may result in death, personal injury, equipment or property damage. WARNING Do not text and drive.
INTRODUCTION been trained, get the proper training before you drive. Only qualified drivers should drive this vehicle. California Proposition 65 Warning • Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. • Other chemicals in this vehicle are also known to the State of California to cause cancer, birth defects or other reproductive harm.
INTRODUCTION 1 Environmental Protection WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Other chemicals in this vehicle are also known to the State of California to cause cancer, birth defects or other reproductive harm. This warning requirement is mandated by California law (Proposition 65) and does not result from any change in the manner in which vehicles are manufactured.
INTRODUCTION must be performed by an authorized service facility. If you aren’t an experienced mechanic, or don’t have the right equipment, please leave all repairs to an authorized service facility. They are the ones equipped to do the job safely and correctly. Maintenance Manuals. If you do decide to do any complex repair work, you’ll need the maintenance manuals. Order them from your authorized dealer.
INTRODUCTION 1 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. Federal and state agencies such as the department of licensing also have information. The Interstate Commerce Commission can give you information about regulations governing transportation across state lines.
CAB AND FRAME ACCESS CAB AND FRAME ACCESS Safety WARNING Always reinstall steps before entering the cab or accessing the deck plate. Without steps you could slip and fall. Failure to comply may result in death or personal injury. Be careful whenever you get into or out of your vehicle’s cab. Always maintain at least three points of contact with your hands on the grab handles and your feet on the steps. 1 WARNING Jumping out of the cab or getting into the cab without proper caution is dangerous.
CAB AND FRAME ACCESS 1 Door Lock and Keys Door Lock Doors can be locked from the inside by using the lock button. Close the door then push the button down to lock. Doors automatically unlock when you open them from inside, and can be locked from the outside with the key or the optional remote keyless entry key fob. WARNING To reduce the chance of death or personal injury, always lock the doors while driving.
CAB AND FRAME ACCESS Remote Keyless Entry (RKE) (Optional) This vehicle may be equipped with a Remote Keyless Entry (RKE) system that adds security and convenience to your vehicle. The system will lock or unlock the driver’s door and passenger’s door with the key fob and alert you with parking lights when the selected doors are locked or unlocked. The system includes two key fobs that provide secure rolling code technology that prevents someone from recording the entry signal.
CAB AND FRAME ACCESS 1 Batteries Synchronization The key fob uses one CR2032, 3V battery. Batteries should last approximately three years, depending on use. Consistently reduced range is an indicator that the battery needs replacement. Batteries are available at most discount, hardware and drug stores. The key fob may need to be synchronized to the truck when the battery is replaced or when the key fob has not been used for an extended period of time.
CAB AND FRAME ACCESS WARNING Keep steps clean. Clean any fuel, oil, or grease off the steps before entering the cab or accessing the deck plate. Stepping on a slippery surface can cause a fall which may result in death or personal injury. 1 The following pictures show you the right way to get on and off the area behind your cab. WARNING Always reinstall steps before entering the cab or accessing the deck plate. Without steps you could slip and fall.
GETTING TO YOUR ENGINE 1 GETTING TO YOUR ENGINE Hood Hold Downs Hood hold downs keep a hood from opening unexpectedly. CAUTION A hood not latched securely could open during operation and cause vehicle damage. Be sure to latch the hood securely. 1-16 1.
GETTING TO YOUR ENGINE Hood Tilt 2. Pull Latch to Open 1 3. Pull Up to Separate To open your hood, unlock the hood hold downs by unlatching them. Put one or both hands on the top of the hood front. Tilt the hood forward by pulling at the top of the hood keeping your feet on the ground for stability. Keep pulling on the hood until you are certain that the hood hold open device is engaged.
GETTING TO YOUR ENGINE Hood Hold-Open Device 1 The hood is equipped with a hood hold-open device. In order for the hood hold-open device to become engaged, the vehicle hood must be fully open. Once the vehicle hood is fully open, the hold-open latch will automatically engage and will need to be disengaged by the operator. The release lever for the hood hold open device is located near the front hinge of the hood. Press the lever in to disengage the hood hold open device.
GETTING TO YOUR ENGINE 1 WARNING Before opening or closing the hood, make sure your footing is secure and stable. Failure to do so may cause the hood to close uncontrollably which may result in death or personal injury. WARNING Always ensure the hood hold-open latch is engaged to keep the hood fully open any time anyone gets under the hood for any reason. Failure to do so may cause the hood to close uncontrollably which may result in death or personal injury.
SEATS AND RESTRAINTS 1 SEATS AND RESTRAINTS Introduction This section covers the operation and safe use of your seats. For further information on features and adjustment of the seat, see the manufacturer's Service and Operation Manual included with the vehicle. Seat Adjustment WARNING Do not adjust the driver's seat while the vehicle is moving. The seat could move suddenly and unexpectedly and can cause the driver to lose control of the vehicle.
SEATS AND RESTRAINTS levers located either beneath or at the sides of the seat. Driver's Seat with Air Suspension WARNING Before driving or riding in vehicle, ensure that there is adequate head clearance at maximum upward travel of seat. Injury may occur if head clearance is not adequate. Failure to comply may result in death or personal injury. Reclining Seats Raise the seat all the way up so that the seat will tilt back and completely clear objects behind you.
SEATS AND RESTRAINTS 1 Lap/Shoulder Belt Your vehicle is equipped with a seat belt indicator in the warning light display above the speedometer/tachometer (see “Seat Belt, Fasten” on page 3-42). The combination lap-shoulder belt is equipped with a locking mechanism. The system adjusts automatically to a person's size and movements as long as the pull on the belt is slow. Hard braking or a collision locks the belt. The belt will also lock when driving up or down a steep hill or in a sharp curve. 5.
SEATS AND RESTRAINTS If the belt is locked, lean the body back to remove any tension in the belt. After releasing the belt, allow the belt to retract completely by guiding the belt tongue until the belt comes to a stop. 1 Safety Restraint Belts Lap Belt Correct Shoulder Belt Incorrect (too high on hips) WARNING Proper seat belt adjustment and use is important to maximize occupant safety. Failure to wear or adjust the safety belt properly may result in death or personal injury.
SEATS AND RESTRAINTS 1 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. Failure to comply may result in death or personal injury. To adjust an external tether belt • Make sure that the tether belt is attached to the cab floor and seat frame. It should be routed through the buckle on each side. • Often the attachments are made using a split-type hook.
SEATS AND RESTRAINTS During Pregnancy See Safety Restraint Belt Warning on page 1-23 3. When the slack is right, push on the portion labeled ON, which will cinch it into place. This locks the Komfort-Lok. 4. To release the Komfort-Lok, push down on the portion labeled OFF, or simply pull down on the shoulder belt. 5. When you want to get out of the cab, release the latch, then just push the button on the buckle. 1 Pregnant women should always wear combination lap/shoulder belts.
SEATS AND RESTRAINTS Belt Damage and Repair 1 Damaged belts in the cab must be replaced. Belts that have been stretched, cut, or worn out may not protect you in an accident. Sleeper Bunks and Restraints If any seat belt is not working properly, see an Authorized Service Center for repair or replacement. Pregnant Woman with Belt Properly Worn For further information on seat belts and seat belt maintenance, see Safety Restraint System - Inspection on page 5-65.
SEATS AND RESTRAINTS the vehicle is in motion. Your vehicle may have belts and/or a net restraint system which are over the bunk or cover the opening. If your vehicle has an upper and lower bunk, the upper bunk can be folded up out of the way to provide you with more room in the sleeper. Fold the upper bunk up and insert the metal end of the bunk retaining belts into the buckles. WARNING Be sure the restraint system is used when anyone is occupying the sleeper while the vehicle is moving.
SEATS AND RESTRAINTS 1 WARNING Any loose items on the upper or lower bunk should be moved to a secured place before driving the vehicle. Failure to comply may result in death, personal injury, equipment or property damage. Upper Rear Sleeper Storage Your vehicle may be equipped with an upper storage shelf that extends over the lower bunk and across the rear of the sleeper. The following warning applies: WARNING Overhead compartments are not intended for items exceeding their designed weight limits.
SEATS AND RESTRAINTS Safety Restraint Tips • Do not wear a belt over rigid or breakable objects in or on your clothing, such as eye glasses, pens, keys, etc., as these may cause injury in an accident. • Any authorized person sleeping in your vehicle while it is moving should use the bunk restraint. • Any authorized person sitting in the sleeper area on the sofa bed (if equipped) while it is moving should wear a seat belt.
SEATS AND RESTRAINTS to keep you and your passengers safe. 1 • If any seat belt or bunk restraint is not working properly, see an authorized dealer for repair or replacement.
START-UP START-UP Safe Vehicle Operation Introduction For your safety, as well as those around you, be a responsible driver: The following section covers start-up procedures for getting your vehicle ready for the road. • If you drink alcohol, do not drive. • Do not drive if you are tired, ill, or under emotional stress. Safe driving is only possible with the proper concentration on the driving task. Keep distraction to a minimum to improve your concentration.
START-UP 1 WARNING WARNING The use of alcohol, drugs, and certain medications will seriously impair perception, reactions, and driving ability. These circumstances can substantially increase the risk of an accident. Failure to comply may result in death, personal injury, equipment or property damage. Do not text and drive. Your reaction time, perceptions and judgment can be affected while texting or using any other form of mobile messaging while driving.
START-UP components installed from the factory on to the vehicle and their designed specifications. (Axle weight ratings are listed on the driver's door edge.) The following are some definitions of weight you should know: GVWR: is the Gross Vehicle Weight Rating. This is the MAXIMUM WEIGHT your vehicle is allowed to carry, including the weight of the empty vehicle, loading platform, occupants, fuel, and any load. Never exceed the GVWR of your vehicle.
START-UP 1 Emergency Equipment Driver's Check List It is good practice to carry an emergency equipment kit in your vehicle. One day, if you have a roadside emergency, you will be glad the following items are with you: To keep your vehicle 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.
START-UP Approaching Your Vehicle • • • • Check the overall appearance and condition. Are windows, mirrors, and lights clean and unobstructed? Check beneath the vehicle. Are there signs of fuel, oil, or water leaks? Check for damaged, loose, or missing parts. Are there parts showing signs of excessive wear or lack of lubrication? Have a qualified mechanic examine any questionable items and repair them without delay. Check your load.
START-UP 1 9. Check clutch hydraulic fluid. 4. Chassis and Cab Checks Daily Before entering the cab and operating the vehicle, check the following equipment for proper maintenance: 1. Lights - are any exterior lights cracked or damaged? Perform an exterior light test using the dash mounted switch next to the steering wheel. See Exterior Lighting Self-Test on page 3-63. 2. Windows and Mirrors - are they clean and adjusted properly? 3.
START-UP they are not being used, are they stored properly? a. Is the trailer spare wheel secure and inflated? b. Is the landing gear up and the handle secured? 11. Check the fifth wheel. Is the kingpin locked? a. Is the sliding fifth wheel locked? Cab Interior - Daily 1. 2. Seat - adjust the seat for easy reach of controls and visibility. Seat Belts - fasten and adjust safety restraint belts (which may include restraints in the sleeper). 3. Steering Column - adjust for easy reach and visibility.
START-UP 1 Weekly Operations 1. Battery - check battery and terminals. 2. Wheel Cap Nuts - are they all in place and torqued properly tighten if necessary. See Wheel Cap Nut Torque on page 5-140. 3. Other Controls and Wiring - check for condition and adjustment 4. Steering Components - check pitman arm, draglink, and power steering hoses, etc., for loose, broken, or missing parts. 5. HVAC Fresh Air Filter - check for condition and cleanliness. 6. Other Engine Compartment Checks a.
EMERGENCY WHAT TO DO IF... You Need Roadside Assistance . . . Low Air Alarm Turns On . . . . . . Stop Engine Lamp Turns On . . . . Engine Oil Pressure Lamp Turns On. Engine is Overheating . . . . . . . Fuse or Relay Blows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2-3 2-4 2-4 2-5 2-6 Introduction . . . . . . . . . . . . . . . . . . 2-8 2 JUMP STARTING VEHICLES VEHICLE RECOVERY AND SPRING BRAKES Vehicle Recovery Guidelines . .
WHAT TO DO IF... WHAT TO DO IF... You Need Roadside Assistance Call toll-FREE 1-800-4-PETERBILT (1-800-473-8372) to talk to someone at the PACCAR Customer Center. • Open 24-7-365 days a year • They can help you get roadside assistance. • They have a custom mapping system which locates Peterbilt dealers and Independent Service Providers (ISPs) near you and lists types of services offered, hours of operation and contact information.
WHAT TO DO IF... Stop Engine Lamp Turns On WARNING 2 If the air pressure falls below 60 psi (414 kPa) the spring brakes may stop the vehicle abruptly, which could cause an accident resulting in death or personal injury. 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. If the light and alarm do not turn off at startup, do not try to drive the vehicle until the problem is found and fixed.
WHAT TO DO IF... 6. 7. Wait a few minutes to allow oil to drain into the engine oil pan, and then check the oil level. (See Oil Level Check on page 5-92, for details on checking oil level.) Add oil if necessary. If the problem persists, contact an authorized dealer as soon as possible. CAUTION Continuing to operate your vehicle with insufficient oil pressure may cause severe engine damage or cause an accident which may result in equipment or property damage.
WHAT TO DO IF... 3 to 5 minutes before shutting it off. This allows the engine to cool gradually and uniformly. 7. 2 If 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. For further information on engine temperature and operating engines properly, see the Engine Operation and Maintenance Manual and Starting & Operating the Vehicle on page 4-5.
WHAT TO DO IF... CAUTION Before replacing a fuse, turn OFF all lights and accessories and remove the ignition key to avoid damaging the electrical system. CAUTION Never patch fuses with tin foil or wire. This may cause serious damage elsewhere in the electrical circuit, and it may cause a fire. CAUTION If a circuit keeps blowing fuses, have the electrical system inspected for a short circuit or overload by an authorized dealer as soon as possible.
JUMP STARTING VEHICLES JUMP STARTING VEHICLES 2 Introduction Jump starting a vehicle is not a recommended practice due to the various battery installations and electrical options. However, if your battery is discharged (dead), you may be able to start it by using energy from a good battery in another vehicle. This is termed jump starting. Be sure to follow the precautions and instructions below. WARNING Batteries contain acid that can burn and gasses that can explode.
JUMP STARTING VEHICLES To Jump Start Your Vehicle WARNING When jump starting using a battery booster, it is best to jump start with an equivalently powered vehicle. Verify that the booster battery has the same volt and CCA specifications as the dead battery before attempting to jump start. Failure to comply may cause an explosion resulting in death, personal injury, equipment or property damage.
JUMP STARTING VEHICLES 7. If either vehicle is equipped with battery disconnects ensure they are in the "OFF" position prior to connecting the two vehicles. Connect the batteries: 1. 2 Attach one end of a jumper cable to the positive (+) terminal of the discharged (dead) battery. This will have a large red + or P on the battery case, post, or clamp. 2. Attach the other end of the same cable to the positive (+) terminal of the good (booster) battery. 3.
JUMP STARTING VEHICLES Remove jumper cables: WARNING When disconnecting jumper cables, make sure they do not get caught in any moving parts in the engine compartment. Failure to comply may result in death, personal injury, equipment or property damage. 2 Reverse the above procedure exactly when removing the jumper cables. With engine running, disconnect jumper cables from both vehicles in the exact reverse order, making sure to first remove the negative cable from the vehicle with the discharged battery.
VEHICLE RECOVERY AND SPRING BRAKES VEHICLE RECOVERY AND SPRING BRAKES 2 Vehicle Recovery Guidelines Your vehicle is equipped with removable Recovery Hitches, designed for short distance recovery purposes only. Use only the provided hitches, according the following instructions. When using this connection, do not transport your vehicle over long distances. (If your vehicle does not have the proper hitches, contact your dealer.
VEHICLE RECOVERY AND SPRING BRAKES Recovery Procedure 1. 1 Review and understand all the cautions and warnings of this section, see Vehicle Recovery Guidelines on page 2-12. 2. Install the recovery hitches, see Recovery Hitch Installation on page 2-15. 3. Disconnect the drive axle shafts and cover the open hubs. This is necessary because if the transmission is driven by the driveshaft (rear wheels on the ground), no lubricant will reach the gears and bearings, causing damage to the transmission. 4.
VEHICLE RECOVERY AND SPRING BRAKES WARNING Before towing a vehicle, test your air brakes to ensure that you have properly connected and inspected the recovery vehicle’s brake system. Failure to do so could lead to a loss of vehicle control which may result in an accident involving death or personal injury. 2 7. Follow state/provincial and local laws that apply to vehicles in tow. 8. Do not tow vehicles at speeds in excess of 55 mph (90 km/h).
VEHICLE RECOVERY AND SPRING BRAKES Recovery Hitch Installation If your vehicle is not equipped with the proper recovery hitch assembly, contact an authorized dealer to obtain the proper equipment. Use the following procedure to install the Vehicle Recovery Hitches. See Recovery Hitch Assembly illustration for part identification. 1. 2. With lock pins removed, insert hitches through bumper and into the square hitch socket. 3. Align the hole in the tow hitch with the square hitch socket hole. 4.
VEHICLE RECOVERY AND SPRING BRAKES 2 Driver Controlled Main Differential Lock 1 2 1. Air Line (remove to install Caging Bolt) Caging Bolt (in storage location) Lift driving wheels off the ground or remove the driveline and axle shafts before towing the vehicle. 2-16 CAUTION CAUTION Failure to lift the driving wheels off the ground or remove the driveline and axle shafts before towing the vehicle could seriously damage your vehicle.
VEHICLE RECOVERY AND SPRING BRAKES This action will lock the differential by pushing a piston into a “lock” position. CAUTION Failure to install the caging bolt when towing vehicles with driver-control main differential lock can result in damage by failing to lock internal components in position. CAUTION CAUTION A recovered vehicle will have no operational brake system. Additionally, the rear axle spring brakes will probably be applied. Connect recovery rigging only to hitches intended for that purpose.
VEHICLE RECOVERY AND SPRING BRAKES Recovery Hitch Capacities 2 The maximum rated loads for vehicle recovery varies depending on the direction or angle of pull. These capacities are listed in the table below and are for the two hitches working together, simultaneously. Hitch Capacities DIRECTION OF PULL MAXIMUM CAPACITY (Lb) * 80,000 14,600 Directly Forward Directly Vertical or Horizontally to the Side 20,000 45º in any Direction * Both hitches pulled simultaneously.
VEHICLE RECOVERY AND SPRING BRAKES Recovery Rigging • To connect to the vehicle, follow the suggested rigging methods below. Never loop a single chain or cable through both hitches (3). • Use a spreader or equalizer bar to distribute the load on both hitches (1). • Use a double chain or cable setup that distributes the load equally to both hitches. See 1 or 2 in Recovery Rigging illustration. 1. Spreader Bar or Equalizer Preferred • cable no closer than 6 ft. from the vehicle (2).
VEHICLE RECOVERY AND SPRING BRAKES Returning Vehicle to Service 2 You will have to add lubricant to prevent damage after your vehicle has been towed. 1. Into the pinion cage, add 1 pint (.47 liter) of lubricant or into the interaxle differential, add 2 pints (.94 liter) of approved lubricant. 2. 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).
VEHICLE RECOVERY AND SPRING BRAKES WARNING Do not operate a vehicle when the spring brakes have been manually released. Driving a vehicle after its spring brakes are manually released is extremely dangerous. The brakes may not function. Failure to comply may result in death, personal injury, equipment or property damage. WARNING Always secure the vehicle with wheel chocks, chains, or other safe means to prevent rolling before manually releasing the spring brakes.
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 lb-ft, Wedge type maximum: 30 lb-ft). The spring brake is now mechanically released.
VEHICLE RECOVERY AND SPRING BRAKES • Be sure that transmission is fully engaged in gear before releasing the clutch pedal (manual only). • Do not shift into reverse while the vehicle is moving. • If the vehicle needs to be recovered from being stuck, do not permit the vehicle to be towed for long distances without removing the driveshaft. Tire Chains If you need tire chains, install them on both sides of the driving axle.
CONTROLS INSTRUMENT PANEL Getting To Know Your Instrument Panel . . . . . . 3-5 Instrument Cluster . . . . . . . . . . . . . . . 3-7 Instrument Cluster Description . . . . . . . . . . 3-8 Driver Information Display . . . . . . . . . . . 3-14 Driver Information Display Description . . . . . . 3-15 How To Navigate The Functions In The Instrument Cluster Display . . . . . . . . . . . . . . . 3-20 3 WARNING SYMBOLS Guide to the Warning Symbols . . . . . . . . . Description of Warning Symbols . . . . . . . .
CONTROLS Engine, Oil Pressure . . . . . . . . . . . . . Engine, Oil Temperature . . . . . . . . . . . . Manifold Pressure Gauge . . . . . . . . . . . Fuel Pressure Gauge . . . . . . . . . . . . . Transmission Temperature Gauge. . . . . . . . Drive Axle Temperature Gauge (Forward and Rear) Suspension Load Air Pressure, #1, #2 . . . . . . Tractor Brake Application Air Pressure . . . . . . Trailer Brake Application Air Pressure . . . . . . Trailer Air Tank Air Pressure . . . . . . . . . .
CONTROLS Exterior Lights Self Test . . . . . . . . . . . . 3-77 HEATING AND AIR CONDITIONING Air Conditioning Controls. . . . . . . Introduction . . . . . . . . . . . . Automatic Air Conditioning . . . . . . Semi-Automatic Control Mode . . . . MAX Defrost . . . . . . . . . . . . Manual Override . . . . . . . . . . Sleeper Heater - A/C Controls (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-78 3-79 3-81 3-82 3-83 3-83 3-87 . . . . . . . . . . . . . . . . . . . .
INSTRUMENT PANEL INSTRUMENT PANEL Getting To Know Your Instrument Panel This part explains the location of the various features on your vehicle and describes their function. For information on using these features in driving, see the paragraphs that follow. Please remember that each vehicle is custom-made. Your instrument panel may not look exactly like the one in the pictures that follow. We have tried to describe the most common features and controls available.
INSTRUMENT PANEL 3 1. 2. 3. 4. 3-6 Instrument Cluster Gauge (or Optional PACCAR Navigation) Switches Air Conditioning 5. 6. 7. 8. 9. Cup Holder Glove Box Overhead Storage Park Brake Controls Radio 10. 11. 12. 13.
INSTRUMENT PANEL Instrument Cluster 3 1. 2. 3. 4. Speedometer Tachometer Engine Coolant Temperature Fuel Level (primary) 5. 6. 7. 8. 9. Engine Oil Pressure Diesel Exhaust Fluid (DEF) Primary Air Pressure Secondary Air Pressure Driver Information Display 10. 11. 12. 13.
INSTRUMENT PANEL Instrument Cluster Description Instrument System Self Test 3 When the ignition switch is turned on the instrumentation system will undergo a Self Test. This test will verify the operation of the gauges and warnings. During the Instrumentation System Self Test, multiple warning icons will be displayed in a sequence. The total sequence should only take no more than 10 seconds to complete. Refer to Warning Light/Indicator Symbols on page 3-30 for information on each symbol.
INSTRUMENT PANEL Check Messages 1. Speedometer 2. Tachometer Check messages are provided to give the operator additional information regarding systems that require attention due to a system malfunction and/or operating conditions that may hinder safe and proper performance for the vehicle. Some messages can be managed by the operator while others may require an authorized dealer repair. The Speedometer indicates the vehicle speed in miles per hour (mph) and in kilometers per hour (km/h).
INSTRUMENT PANEL Operation and Maintenance Manual for RPM recommendations.) 3 The tachometer will illuminate a small green light just below the numbers of the gauge. This is to indicate the engine speed for optimal fuel economy. See Optimal Engine Speed on page 4-58 for more information on how to use this indicator during normal operation. 3. Engine, Coolant Temperature The water temperature gauge shows the temperature of the engine coolant.
INSTRUMENT PANEL 5. Engine, Oil Pressure NOTE WARNING For Export vehicles, the fuel gauges will not state: ULTRA LOW SULFUR DIESEL FUEL ONLY. Do not carry fuel containers or any container used to store combustible liquids. Failure to comply may result in death, personal injury, equipment or property damage. NOTE This vehicle may be manufactured with different fuel systems and different draw tube locations.
INSTRUMENT PANEL Check the engine manufacturer's manual for the correct oil pressure ranges for your vehicle's engine. 3 If the oil pressure suddenly drops, or the audible alarm and engine oil pressure warning light come on while driving, please refer to Engine Oil Pressure Lamp Turns On on page 2-4 regarding what to do if oil pressure is insufficient. For further information on engine gauges and operating your engine properly, refer to Engine Maintenance on page 5-91. 6.
INSTRUMENT PANEL Please refer to Low Air Alarm Turns On on page 2-3 for instructions on what to do if the air system becomes inoperative. NOTE Be sure the air pressure registers more than 100 psi (690 kPa) in both service systems before you move the vehicle. NOTE If the pressure in either or both circuits falls below 65 psi (448 kPa), a red warning light in the gauge will turn on and an audible alarm tone will sound when the engine is running.
INSTRUMENT PANEL 9. Driver Information Display 10. Trip Reset The display can show multiple warning lights. Warning information will appear momentarily and then will minimize in the screen. Reviewing the warnings can be done by navigating the menu via the Menu Control Switch. The cluster mounted trip reset button is the only way to zero trip data. After toggling the trip ODO (short pushes to select Trip A, B, C, or D) to the desired trip, HOLD the trip reset button, that resets the displayed trip data.
INSTRUMENT PANEL Driver Information Display Description WARNING Do not look at the Instrument Cluster Display for prolonged periods while the vehicle is moving. Only glance at the monitor briefly while driving. Failure to do so can result in the driver not being attentive to the vehicle’s road position or situation, which could lead to an accident and possible death, personal injury or equipment damage.
INSTRUMENT PANEL 1. Odometer/Trip Odometer The Odometer/Trip Meter comes on when the door is opened and when the ignition key is in the ACC or ON position. 3 The odometer displays the distance your vehicle has traveled. The display can be configured to display Metric units or English units. The current trip odometer displays how far the vehicle has gone on a particular trip and can display in increments of a tenth of a unit. The maximum distance that can be shown on the trip odometer is 9999.
INSTRUMENT PANEL The outside air temperature display uses a sensor (located at the bottom of the driver's side mirror assembly) to measure outside air temperature only. It is not capable of displaying the temperature of the road surface on either the temperature display or the snowflake icon. Additionally, the outside air temperature reading may be affected by exposure to direct sunlight. 3. Clock The clock presents either the home time or the local time when the clock is set.
INSTRUMENT PANEL 3 4. Active Warnings 5. Cruise Control Indicator Active warnings will appear in this area in addition to areas around the center of the display. Active Warnings are those pop-up messages that have come up on the screen and/or been suppressed with an MCS button push. If there are warning icons active while in the cruise control is enabled, icons will appear on each side of the cruise control icon. If there are multiple warnings, the display will show how many are active.
INSTRUMENT PANEL 7. Header 8. MCS Knob Cue 9. Main Content Area This area displays the function category in which the MCS knob and display software are currently set. Depending on the display operation, the text color may change to indicate a user selection. Used to provide the driver with screen navigation feedback.
INSTRUMENT PANEL How To Navigate The Functions In The Instrument Cluster Display Menu Control Switch (MCS) 3 The MCS is used to navigate the instrument display. It comprises of a back button and a push and spin knob. The Menu Control Switch is located on the right side panel. The MCS knob can perform two functions. It can select and set values when spun and enter your settings when pushed. The MCS button has a BACK button located above the knob. Pressing this button will go back to the previous menu.
INSTRUMENT PANEL • Virtual gauges - This menu item provides dynamic information to the operator. • Ignition timer - Use this menu to set the time to idle the engine after removing the ignition key. • Trip Information - Use this information to get trip summary details. • Truck Information - Provides information about the vehicle. • Active Warnings - Use this menu to view vehicle fault codes and messages. • Settings - Use this menus to change preferences.
INSTRUMENT PANEL Navigating at the Branch Level Navigating at the Leaf Level Description of Menu Screens 3 Blank Screen Leaf Level At this level, there are no more options to choose from. The MCS can be used to scroll through various information and the back button can be used to revert up to the branch (1 push) or the trunk (2 pushes) levels of the system. 3-22 This screen is available in both parked and driving modes.
INSTRUMENT PANEL The blank screen mode is selected through the rotary MCS knob. The Display OFF Mode is selected by pressing the button above the MCS knob for more than 2 seconds. Virtual Gauges Ignition Timer 3 The virtual gauges function is selected through the rotary MCS knob and is available in both parked and driving modes. Virtual gauges provide dynamic information about the vehicle's performance.
INSTRUMENT PANEL Fuel Economy 3 This function displays the dynamic fuel economy performance of the vehicle. It shows Average Speed, Average Fuel Economy, and a dynamic instantaneous indication of fuel economy above or below the current average. The screen is available when driving. Average fuel economy is computed by the fuel consumed during the trip (see the next section for Trip information). The fuel economy for a trip will be reset when that trip odometer is reset.
INSTRUMENT PANEL • PTO Trip Fuel Used • PTO Trip Economy The cluster mounted trip reset button is used to zero and clear accumulated trip data. Short presses toggle between the odometer view, and the 4 trips. Holding the button when on a particular trip will zero the stored data and also automatically set the cleared trip to “active” status. Truck Information 2. NOTE a. Engine Make Only available truck information will be shown (i.e., manual transmissions do not have a software version). b.
INSTRUMENT PANEL Warning and Faults to see the different warnings. The highest priority warning defaults to the top of the stack. Diesel Exhst Fluid Poor Quality When the vehicle is parked, the “Warnings and Faults” function will access suppressed pop-ups that are counted and presented in the upper left corner of the screen. Refill with new DEF to Prevent Derate 1 3 3 12:39PM 25,326Mi 1. how many faults, shown in a scrollable stack format 2. which ECU the fault is being generated from 3.
INSTRUMENT PANEL Settings To Turn Alarm ON/OFF: Fault Details Example This menu is available only when the vehicle is parked. Various settings may be changed using this function. The operator can change the time format (12hr/24hr), the time of day and alarm settings, units of measure for the display (mile/kilometer) and the language being displayed. Changing settings functions are typically done one of two ways.
INSTRUMENT PANEL To Set Home, Local or Alarm Time: 6. Press the button above the MCS to Exit. Display Mode The display off mode is available at any time in menu navigation, but the screen minimize mode can only be done when on this screen. 3 NOTE 1. When in the Settings Menu, scroll through the list of menu items. 2. Press the MCS to select the item to change. 3. Rotate the MCS knob to change the hour. Press the MCS. 4. Rotate the MCS knob to change the minutes. Press the MCS. 5.
WARNING SYMBOLS WARNING SYMBOLS Guide to the Warning Symbols The warning lights and audible alarm may indicate a system malfunction. Check the lights frequently, and respond properly as soon as you see one go on. These lights could save you from a serious accident. When multiple warning icons are shown on the instrument cluster, they will appear at first and then minimize.
WARNING SYMBOLS Warning Light/Indicator Symbols Symbol Name Symbol Msg Page Color Std/Opt 1. Axle, Traction Control Yellow OPT on page 3-37 2. Brakes, Anti-Lock Brake System (ABS) Yellow STD on page 3-37 3. Brakes, Low Air Red STD on page 2-3 4. Brake, Park Brake Red STD on page 3-38 5.
WARNING SYMBOLS Symbol Name Symbol Msg Page Color Std/Opt 6. Brakes, Trailer Anti-Lock Brake System (ABS) Yellow STD on page 3-38 7. Differential, Inter Axle Diff Lock Yellow OPT on page 3-60. 3 8. Dump Truck, Body Up 9. Dump Truck, Gate 10. Dump Truck, Trailer Body Up 11.
WARNING SYMBOLS Symbol Name Symbol Msg Page Color Std/Opt 12. Emissions, High Exhaust System Temperature (HEST) Yellow STD on page 3-39 13. Emissions, Malfunction Indicator Lamp (MIL) Yellow STD on page 3-40 14. Engine, Check Engine Yellow STD on page 3-40 15. Engine, Engine Fan Green STD on page 3-40 16. Engine, Heater Yellow OPT on page 3-40 17.
WARNING SYMBOLS Symbol Name 18. Engine, Retarder (Brake) 19. Engine, Stop Engine Symbol Msg Page Color Std/Opt Green OPT on page 3-40 Red STD on page 3-40 3 20. Engine, Wait To Start Yellow OPT on page 3-41 21. Fuel, Water In Fuel (WIF) Yellow OPT on page 3-41 22. Lane Departure Warning (LDW) Yellow OPT on page 3-41 Blue STD on page 3-41 23.
WARNING SYMBOLS Symbol Name Symbol Msg Page Color Std/Opt 24. Power Take-off (PTO) Yellow OPT on page 3-41 25. Power Take-off (PTO), Pump Mode Green OPT on page 3-41 26. Refrigerator Green OPT on page 3-41 27. Seat Belt, Fasten Red STD on page 3-41 28. Suspension Dump Yellow STD on page 3-42 29.
WARNING SYMBOLS Symbol Name 30. Transmission, Auxiliary 31. Transmission, Check Symbol Msg Page Color Std/Opt Yellow OPT on page 3-42 Red OPT on page 3-42 3 32. Transmission, Oil Temperature High Yellow OPT on page 3-42 33. Transmission, Retarder (may include BrakeSaver when applicable) Yellow OPT ● on page 3-42 34.
WARNING SYMBOLS Symbol Name Msg Page Color Std/Opt 35. Turn Signal, Left Green STD on page 3-42 36.
WARNING SYMBOLS Description of Warning Symbols 1. Axle, Traction Control (ATC or Automatic Traction Control) A. Illuminates during the power-on self test when the ignition is turned ON. It turns off after a few seconds if no system problems are detected. If an ATC problem is detected, the ATC Warning lamp will turn on and stay on. B. Flashes when the ATC is regulating wheel spin. (Refer to Automatic Traction Control for more information.) C.
WARNING SYMBOLS 3 dealer if the ABS Warning Lamp stays on for more than 3 seconds. 6. Brakes, Trailer Anti-Lock Brake System (ABS) Illuminates during normal operating conditions to indicate a problem with the ABS System. See ABS Warning Lamps on page 4-21 for more information. Illuminates during the Instrumentation System Self Test and the tractor/truck is connected with a ABS equipped trailer. Illuminates when a problem exists with the optional Wheel Spin Control feature.
WARNING SYMBOLS differentials equally. When the switch is turned off (inter-axle differential unlocked) the engine power is allowed to flow to any of the 4 drive tires based on the differential effect (mostly to the forward rear differential). (This feature is standard on all tandem axles). 8. Dump Truck, Body Up Illuminates when Truck Dump Body is up. 11. Emissions, Diesel Particulate Filter (DPF) Illuminates when diesel particulate filter is plugged.
WARNING SYMBOLS WARNING 3 If this light is on, temperature of the tail pipe, exhaust pipes, diesel particular filter (DPF), selective catalytic reduction (SCR) device and surrounding components including enclosures and steps becomes elevated during engine operation or any regeneration event and can cause serious burns to the skin. Allow adequate cooling time before approaching, working on or near any part of the exhaust system or surrounding components. 13.
WARNING SYMBOLS WARNING This should be considered an emergency. You should stop the vehicle as safely as possible and turn OFF the ignition. The vehicle must be serviced and the problem corrected before driving again. Failure to do so may cause severe engine damage or cause an accident involving death or personal injury. 22. Lane Departure Warning (LDW) high beam headlights will turn on at 50% normal brightness. 24.
WARNING SYMBOLS 27. Seat Belt, Fasten Illuminates when the ignition key is turned on as a reminder to fasten your seat belt. 28. Suspension Dump 3 Illuminates when suspension air bags are deflated. 29. Tire Inflation Illuminates when tire pressures need to be checked. (Tire Pressure Monitoring System is an option.) 30. Transmission, Auxiliary Illuminates to indicate auxiliary transmission is in neutral. 3-42 31. Transmission, Check Illuminates when transmission has recorded a fault code.
OPTIONAL GAUGES OPTIONAL GAUGES Axle, Pusher Air Pressure Axle, Tag Air Pressure Introduction Listed here are gauges that may or may not be on your dashboard or the center instrument cluster. For vehicles with a telematic navigation screen, optional gauges will be part of the screen functions. Please refer to the navigation system supplement for further details about its functions and how it works.
OPTIONAL GAUGES Fuel Filter Restriction 3 This gauge tells you the condition of the fuel filter by indicating the restriction from the fuel filter to the fuel pump. Check the engine manual for proper restriction. Replace the filter with an approved filter only. Do not substitute the wrong micron element. NOTE The maximum allowable restriction could vary according to the type or make of engine. Consult the engine manufacturers manual or engine dealer for fuel restriction specifications.
OPTIONAL GAUGES Engine, Oil Temperature Manifold Pressure Gauge The Engine Oil Temperature gauge indicates the engine oil temperature. If the oil temperature exceeds the maximum limits, a red warning light in the gauge will turn on. Do not exceed maximum engine oil temperature recommended by the engine manufacturer. (See the Engine Operation and Maintenance Manual for details.) Your manifold pressure gauge indicates the power your engine is putting out by showing the amount of turbo boost.
OPTIONAL GAUGES Transmission Temperature Gauge 3 Your Transmission Temperature Gauge indicates the temperature of the oil in your transmission. Watch this gauge to know when your transmission is overheating. If it is, have it checked by an authorized service representative. Maximum transmission temperature may vary, depending upon the transmission and type of lubricant. Check your transmission’s owner’s manual.
OPTIONAL GAUGES Suspension Load Air Pressure, #1, #2 Tractor Brake Application Air Pressure Trailer Brake Application Air Pressure Suspension Load Air Pressure #1 The Tractor Brake Application Air Pressure gauge indicates the amount of air pressure applied to the tractor brakes. The Trailer Brake Application Air Pressure gauge indicates the amount of air pressure applied to the trailer brakes during brake foot valve and/or hand brake control valve applications.
OPTIONAL GAUGES Trailer Air Tank Air Pressure 3 The Trailer Air Tank Air Pressure gauge indicates the amount of air pressure in the trailer brake air tank. Transfer Case Oil Temperature Transmission Oil Temperature, Auxiliary The Transfer Case Oil Temperature gauge indicates the temperature of the oil in the transfer case. If the oil temperature exceeds maximum limits, a red warning light in the gauge will turn on. Do not exceed maximum oil temperature recommended by the manufacturer.
OPTIONAL GAUGES Transmission Retarder Oil Temperature The Transmission Retarder Oil Temperature gauge indicates the temperature of the oil in the transmission retarder. 3 NOTE Watch this gauge to know when the transmission is overheating. Do not exceed maximum oil temperature recommended by the manufacturer. (See the Transmission Operation and Maintenance Manual for details.
SWITCHES SWITCHES Dash Switches This custom vehicle will have a wide variety of switch controlled equipment. However, this particular vehicle may 3 not have every switch identified in this section of the operator manual. Some air device switches on the dash may require that the vehicle either be at a specific speed, park brakes set or another device to be on or off for the air device to operate.
SWITCHES Symbol Name Symbol Color Standard Option Page 5. Axle, Diff-Lock - Single Rear Amber ● See Axle, Diff-Lock - Single Rear on page 3-60. 6. Axle, Inter-Axle Differential Locked (Tandem) Amber ● See Axle, Inter-Axle Differential Locked (Tandem) on page 3-60. 7. Axle, Two Speed Green ● 8. Batteries, Low Voltage Disconnect (LVD) None 9. Brakes, ABS Off-Road Amber 3 See Axle, Two Speed on page 3-60. See Batteries, Low Voltage Disconnect (LVD) on page 3-60.
SWITCHES Symbol Name Symbol Color Standard Option Page 12. Dump Truck Gate Red ● See Dump Truck Gate on page 3-60. 13. Engine, Brake Level None ● See Engine, Brake Level on page 3-60. 14. Engine, Brake On/Off Green ● See Engine, Brake On/Off on page 3-60. 15. Engine, Cruise Control On/Off Green ● See Engine, Cruise Control On/Off on page 3-61. 16. Engine, Cruise Control Set/Resume None ● See Engine, Cruise Control Set/Resume on page 3-61. 17.
SWITCHES Symbol Name Symbol Color Standard Option Page 19. Engine, Remote Throttle Amber ● See Engine, Remote Throttle on page 3-61. 20. Engine, Shutdown None ● See Engine, Shutdown on page 3-61. 21. Exhaust, Diesel Particulate Filter (DPF) Regeneration None 22. Fifth Wheel Slide Red ● See Fifth Wheel Slide on page 3-62. 23. Fuel Heater Amber ● See Fuel Heater on page 3-62. 24. Generic Air, Accessory Green ● See Generic Air, Accessory on page 3-62.
SWITCHES Symbol Name Symbol Color Option ● 26. Ignition Key Switch 3 Standard Page See Ignition Key Switch on page 3-90. 27. Lights, Auxiliary Green ● See Lights, Auxiliary on page 3-62. 28. Lights, Beacon Green ● See Lights, Beacon on page 3-62. 29. Lights, Daytime Running (Override) Green ● See Lights, Daytime Running on page 3-62. 30. Lights, Dome None ● 31. Lights, Exterior Lights Self Test None ● 32. Lights, Flood Amber 3-54 See Lights, Dome on page 3-63.
SWITCHES Symbol Name Symbol Color Standard Option 33. Lights, Flood ISO 3732 Spare Amber ● 34. Lights, Fog Green ● Page See Lights, Flood ISO 3732 Spare on page 3-63. 3 See Lights, Fog on page 3-63. 35. Lights, Hazard Red ● See Lights, Hazard on page 3-63 36. Lights, Headlight None ● See Lights, Headlight on page 3-64. 37. Lights, Marker/Clearance None ● See Lights, Marker/Clearance on page 3-64. 38.
SWITCHES Symbol Name 3 Symbol Color Standard Option ● Page See Lights, Marker/Clearance/Trailer on page 3-64. 39. Lights, Marker/Clearance/Trailer None 40. Lights, Park Light None 41. Lights, Spot Green ● 42. Mud & Snow Traction Control None ● 43. Pintle Hook Green ● See Tow Hook on page 3-64. 44. Power Take-off (PTO) Amber ● See Power Take-off (PTO) on page 3-64. 45. Power Take-off (PTO), Forward Amber ● 3-56 ● See Lights, Park Light on page 3-64.
SWITCHES Symbol Name Symbol Color Standard Option Page 46. Power Take-off (PTO), Rear Amber ● See Power Take-off (PTO), Rear on page 3-65. 47. Suspension, Axle, Pusher Green ● See Suspension, Axle, Pusher on page 3-65. 48. Suspension, Axle, Tag Green ● See Suspension, Axle, Tag on page 3-65. 49. Suspension, Dump Amber ● See Suspension, Dump on page 3-65. 50. Suspension, Lift Amber ● See Suspension, Lift on page 3-65. 51.
SWITCHES Symbol Name 3 Symbol Color Standard Option Page 53. Trailer, Axle (3rd Axle) Lift Green ● See Trailer, Axle (3rd Axle) Lift on page 3-66. 54. Trailer, Axle Lift Forward Green ● See Trailer, Axle Lift Forward on page 3-66. 55. Trailer, Axle Lift Rear Green ● See Trailer, Axle Lift Rear on page 3-66. 56. Trailer, Belly Dump Red ● See Trailer, Belly Dump on page 3-66. 57. Trailer, Dump Gate Red ● See Trailer, Dump Gate on page 3-66. 58.
SWITCHES Option Page Red ● See Trailer, Dump Gate Rear on page 3-66. 61. Trailer, Hotline Green ● See Trailer, Hotline on page 3-66. 62. Trailer, Suspension Air Dump Amber ● See Trailer, Suspension Air Dump on page 3-66. 63. Transmission, Transfer Case Amber ● See Transmission, Transfer Case on page 3-66. 64. Transmission, Transfer Case 2 Speed Amber ● See Transmission, Transfer Case 2 Speed on page 3-66. 65. Winch Clutch Green ● Symbol Name 60.
SWITCHES 1. Axle Diff-Lock - Dual Turn switch on to engage Front and Rear Axle Diff Lock. 2. Axle Diff-Lock - Forward Rear Turn switch on to engage Forward Rear Axle Diff Lock. 3. Axle Diff Lock - Steer Turn switch on to engage Front Axle Diff Lock. 3 4. Axle Diff-Lock Rear Rear Turn switch on to engage Rear Rear Axle Diff Lock. 5. Axle Diff Lock - Single Rear Turn switch on to engage Single Rear Axle Diff Lock. 6.
SWITCHES vehicle, see the engine brake owner’s manual for additional engine brake information. 15. Engine, Cruise Control On/Off Turn switch on to activate Cruise Control System. SET RESUME 16. Engine, Cruise Control Set/Resume The Cruise Control Set/Resume switch allows you to SET the desired speed or RESUME the desired speed after the cruise control function has been interrupted.
SWITCHES 20. Engine, Shutdown Test Momentarily push switch in to activate the shutdown system. 21. Exhaust, Diesel Particulate Filter (DPF) Regeneration Switch Manually controls the diesel particulate filter regeneration process. Refer to Engine After-treatment Controls Operator's Manual for additional information. 3 22. Fifth Wheel Slide Turn switch on to “Unlock” Fifth Wheel Slide mechanism. The switch is guarded to protect you from accidentally activating or releasing the lock.
SWITCHES 29. Lights, Daytime Running Lights (DRL) (with optional over-ride switch) Three controls (or conditions) will affect whether the system is ON or OFF: • headlight (master) switch • engine cranking • parking brake If the headlight switch is turned OFF, the DRL system engages automatically after the engine starts and you release the parking brake. If the headlight switch is ON, the DRL system is overridden, and headlights operate normally.
SWITCHES 35. Lights, Hazard 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. You should always use the flasher if the vehicle is disabled or parked under emergency conditions. 3 WARNING Use your Hazard Warning Light System any time you have to stop off the road or on the side of the road, day or night. A hard-to-see vehicle can result in an injury accident.
SWITCHES 44. Power Take-off (PTO) Turn switch on to engage PTO. Your vehicle may be equipped with a dash mounted switch that controls PTO engagement/disengagement. When the operator activates the switch for the PTO, the status indicator lamp (located on the switch) will immediately illuminate even though PTO engagement may not have occurred.
SWITCHES 52. Trailer, Air Supply The red octagon knob controls the air supply to the trailer. 60. Trailer, Dump Gate Rear Turn switch on to open Trailer Rear Dump Gate. 53. Trailer, Axle (3rd Axle) Lift Turn switch on to lift 3rd Trailer Axle. 61. Trailer Hotline Turn switch on to supply electrical power to trailer accessories. 54. Trailer, Axle Lift Forward Turn switch on to lift Forward Trailer Axle. 3 55. Trailer, Axle Lift Rear Turn switch on to lift Rear Trailer Axle. 56.
SWITCHES 1. Tilt/Telescoping Steering Column Depending on your vehicle’s configuration, you may have either a Tilt/Telescoping or a fixed steering column. • The tilt feature allows forward and rearward movement of the wheel. • The telescoping feature allows you to move the wheel up and down. To activate these features, locate the Tilt/Telescoping lever. WARNING Make all adjustments to the steering mechanism while the vehicle is stopped.
SWITCHES 2. Turn Signal/High Beam Switch • To signal a right turn, push the lever forward (clockwise). NOTE • The ignition key must be turned to ON for the signal/switch to operate. To signal a left turn, pull the lever back (counterclockwise). • Each time the turn indicator is activated the audible warning emits a short beep. The lever-action turn signal/high beam switch is located on the left side of the steering column.. Each time a turn indicator is activated the buzzer emits a short beep.
SWITCHES WARNING After you complete a turn, shut the system off by returning the lever to the “OFF” (center) position. Failure to shut off a turn signal could confuse other drivers and result in an injury accident. An indicator light in the instrument panel will flash until the turn signal is turned off. High Beam To return to previous beam: pull the lever towards the steering wheel again. • The high beams can be momentarily flashed with or without the headlights being on.
SWITCHES Windshield Wipers/Washer ID and Clearance Lights Flash 3 Your vehicle is equipped with a two-speed, intermittent windshield wiper system. The windshield wiper system is integrated with the exterior lights so that the low beam headlights will turn on when the windshield wipers turn on. To override this function, turn the headlights on and then off again and the low beams will turn off.
SWITCHES To activate the wipers for one swipe without activating the washer (“mist” function), push the turn signal lever in (towards the steering column) and release in less than 0.5 seconds. The wipers will perform a single swipe and then resume the wiper’s setting speed. WARNING Clean blades regularly with a damp cloth to remove road film and wax build-up. Do not drive with worn or dirty wiper blades.
SWITCHES Steering Wheel Controls (Optional) System Description The steering wheel contains controls for commonly used functions so that the operator does not have to take their hands off of the steering wheel to operate. CAUTION 3 Under no circumstances should you attempt to service the steering wheel, clockspring, or any of the electrical wiring in the multiplex system, or any steering components (steering column, steering driveline or steering gear).
SWITCHES Operating the System Horn - Depressing the bottom center bar activates the electric horn. Cruise Control - Vehicles with steering wheel controls will have cruise control options on the right hand of the wheel instead of the switches on the dashboard. These optional switches for cruise control include a third switch to allow the operator to accelerate or coast while maintaining cruise control operation. For complete operating instructions, see Cruise Control on page 4-36. 3 Left Switch Pod 1. 2.
SWITCHES WARNING 3 Do not operate the cruise control when operating on road surfaces with poor traction (wet, icy, or snow covered roads) or in heavy traffic. Accelerations caused by the normal operation of the cruise control could cause you to lose control of the vehicle resulting in an injury accident. Door Mounted Controls Introduction If your vehicle is equipped with power mirrors, the mirror controls will be located on the driver side door pad. Mirrors can be adjusted in 4 directions.
SWITCHES 1. Mirror Heat Button WARNING WARNING Adjust all mirrors before driving. Adjusting the mirrors while driving can cause you to take your eyes off the road, which could result in an accident. Failure to do so could lead to serious injury or equipment damage. Convex mirrors can distort images and make objects appear smaller and farther away than they really are. You could have an accident if you are too close to another vehicle or other object.
SWITCHES 2. Power Mirror Switch If your vehicle is equipped with power mirrors, the directional controls for both mirrors are located near the top of the driver side door trim pad. 1. Move the mirror selector switch to the right or left from the neutral center position to select the desired mirror for adjustment. 2. Depress the mirror directional control pad in one of its four arrow directions to adjust the mirror in/out or up/down.
SWITCHES 5. Power Window Switch Exterior Lights Self Test • Lo beam headlamps Power window rocker switches are located on the door pads. Depress the switch to open the window or pull up on the switch to close the window. Release the switch to stop window movement. The drivers side window has an express down feature. Pushing on the switch all the way down until the switch bumps will activate the express down feature. Release the button and the window will continue to open until it is completely open.
HEATING AND AIR CONDITIONING HEATING AND AIR CONDITIONING Air Conditioning Controls 3 1. 2. 3. 4. 5. 6. 3-78 Fan Control Dial AUTO Mode Temperature Control Dial MAX Defrost Dash & Floor Dash 7. 8. 9. 10. Floor & Defrost Defrost Sleeper Override, Indicates Sleeper HVAC is On (for vehicles with a sleeper) Floor 11. 12.
HEATING AND AIR CONDITIONING Introduction Your vehicle's air conditioning system is capable of controlling the cabin air temperature automatically or in a manual override mode so that the driver may customize the air conditioner for specific needs (clearing fog or thin ice on the windshield). When in Automatic mode the air conditioning system can aid cold vehicle startup procedures by utilizing the fresh air/recirculated air option without operator interaction.
HEATING AND AIR CONDITIONING 3 WARNING WARNING NOTE Exhaust fumes from the engine contain carbon monoxide, a colorless and odorless gas. Do not breathe the engine exhaust gas. A poorly maintained, damaged or corroded exhaust system can allow carbon monoxide to enter the cab. Entry of carbon monoxide into the cab is also possible from other vehicles nearby. Failure to properly maintain your vehicle could cause carbon monoxide to enter the cab, resulting in death or personal injury.
HEATING AND AIR CONDITIONING Automatic Air Conditioning CAUTION NOTE Do not stay in the vehicle with the engine running or idling for more than 10 minutes with the vehicle's Heater and A/C ventilation system in RECIRC or at LOW FAN SPEED. Even with the ventilation system on, running the engine while parked or stopped for prolonged periods of time is not recommended. If you are required to idle your vehicle for long periods of time, install an auxiliary heater or automatic idle control.
HEATING AND AIR CONDITIONING If the air conditioner is using fresh air in AUTO mode, the operator may select recirculated air to avoid temporary external odors or pollution without exiting AUTO mode. The system may have difficulties in obtaining the desired cabin temperature if the temperature setting is repeatedly changed. 3 NOTE 1 Sunlight Sensor Pressing the AUTO button will enable the automatic air conditioning system.
HEATING AND AIR CONDITIONING MAX Defrost Defrost the system will not allow the air to be recirculated. When utilizing Max Defrost, the system will not allow the compressor to be turned off by the user. The air conditioner’s MAX Defrost function automatically distributes outside air through the windshield defroster vents and de-mister vents. The AC compressor will also be engaged when the outside temperature is above 34ºF (1ºC) to remove humidity from the air.
HEATING AND AIR CONDITIONING What Each Control Does *Defrost and De-mister Vents Fresh Air/Recirculation Switch Fan Speed Adjustment *Fresh air and air conditioning are automatically turned ON. Temperature Control Dial 3 Turning this dial clockwise from the OFF position turns the fan ON and increases the fan speed.
HEATING AND AIR CONDITIONING Sleeper Override Switch (for vehicles with a sleeper) Press this button if the user wants to control the on/off function of the sleeper heating and air conditioning unit. Using this button does not allow this control unit to control sleeper blower speed or sleeper temperature. It only turns the sleeper heating and air conditioning unit on or off.
HEATING AND AIR CONDITIONING If the outside air is not cold enough to cool the cab, press to engage the compressor which will deliver colder air. For more cooling effect, you may need to press the switch back to recirculation mode. 3 Using this function in "manual" mode will provide the maximum heating performance. The air conditioner removes moisture from the air while the heater heats the air.
HEATING AND AIR CONDITIONING CAUTION During extreme cold weather, do not blow hot defroster air onto cold windshields. This could crack the glass. Turn the Air Flow Control Dial to Defrost and adjust the fan speed accordingly while the engine warms. If the engine is already warm, move the Temperature Control Dial to cool, then gradually increase the temperature when you see that the windshield is starting to warm up. Failure to comply may result in equipment damage.
ACCESSORIES ACCESSORIES Cigarette Lighter and Ashtray (Option) Radio (Option) 3 As an option, your vehicle has either an AM/FM Stereo Receiver, which may or may not have a CD, or may have the stereo system integrated with your Navigation and telematics unit. For instructions on how to operate your particular radio, see the supplemental operating manual for those units. NOTE WARNING The cigarette lighter will operate with the ignition key in either the OFF, ACC (accessory), or ON position.
ACCESSORIES Cab Storage Glove Box A glove box is provided to store important documents, the vehicle literature set (including this Operator's Manual) and other related materials. WARNING Do not drive with the glove box open, it can be dangerous. In an accident or sudden stop, you or a passenger could be thrown against the cover and be injured. To reduce the risk of personal injury during an accident or sudden stop, keep the glove box closed when the vehicle is in motion.
ACCESSORIES Ignition Key Switch The ignition key switch (located to the left of the steering column) has four positions: ACC (Accessories), OFF, ON, and START. 3 OFF: In this position all accessories are OFF (except those listed below) and you can remove the key.
ACCESSORIES Vehicle Telematic System Your vehicle may be equipped with an onboard telematics 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 Telematics and Navigation System Owner’s Manual and observe the Warnings, Cautions, and Notes that follow before using the system. WARNING Verify legal weight and height restrictions for the route suggested by the telematic system.
ACCESSORIES Care of the Display Screen Screen Display On/Off From time to time it may be necessary to clean the display screen. To clean the screen, dampen a clean, soft, lint-free cloth with water only. A mild glass cleaner that does not contain alcohol or ammonia may also be used. Cleaners that contain alcohol and/or ammonia will eventually dry-out, crack and "yellow" the screen. Wipe the screen gently back and forth. You can also use a commercial cleaner especially designed for LCD screens. 1.
ACCESSORIES Warning/Informational Screen 4. To turn the system off, press and hold the POWER/LIGHT button for 3 seconds. WARNING Do not let this device distract you while driving. Always concentrate on your driving. Distractions could cause an accident resulting in injuries to you or others. IMPORTANT Disclaimer: Map data may be inaccurate and navigation routes may not be available for larger size vehicles.
ACCESSORIES Passenger Side Pull Out Tray 3 Rotate the mirror up or down to get the desired view. The dashboard for the front passenger contains a pull out tray for writing convenience. To use the tray, push in on the panel and allow the tray to pop out. Firmly pushing the tray back into the dashboard will lock it back in place.
STARTING & OPERATING STARTING & OPERATING Introduction . . . . . . . . Normal Weather . . . . . . Cold Weather . . . . . . . Engine Block Heater (Option). Engine Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 4-5 4-6 4-6 4-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 4-11 4-12 4-13 Operating Hydraulic Clutch (Manual Transmission) Operating Manual Transmissions . . . . . . . .
STARTING & OPERATING More Transmission Tips . . . . . . . . . . . . 4-19 OPERATING THE BRAKE SYSTEM Introduction . . . . . . . . . . . . . . . . . Retarders . . . . . . . . . . . . . . . . . . Parking Brake . . . . . . . . . . . . . . . . 4-21 4-32 4-34 CRUISE CONTROL Cruise Control Switch . . . . . . . . . . . . . Adaptive Cruise Control (Optional) . . . . . . . 4-36 4-38 Differential Lock . . . . . . . . . . . . . . . Dual Range (Two-Speed) Rear Axle . . . . . . . Auxiliary Axles - Pusher or Tag . .
STARTING & OPERATING DRIVING TIPS AND TECHNIQUES Introduction . . . . . . . Coasting . . . . . . . . . Descending a Grade . . . Engine Overspeed . . . . Fuel - Excess Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56 4-56 4-57 4-57 4-60 Sleeper Bunk. . . . . . . . . . . . . . . . . 4-62 SLEEPER BUNKS 4 STOPPING THE ENGINE Before Stopping the Engine Refueling . . . . . . . . Refuel Before the Final Stop Final Stop . . . . . .
STARTING & OPERATING STARTING & OPERATING Introduction Since each vehicle is custom-equipped, all engine operation instructions in this manual are general. You will want to consult the manual for your engine to find out details about your specific engine’s needs. You may need to use a slightly different procedure from the one outlined here. Below are instructions for both normal-temperature starting and cold-weather starting.
STARTING & OPERATING manual for the right pressure for your engine. If the oil pressure doesn’t rise within a few seconds, stop the engine. Find out what is wrong before restarting the engine. 7. Slowly engage (release) the clutch after the engine has started. 8. Wait for the oil pressure gauge to reach normal operating pressure before operating the vehicle or idling faster than 1000 rpm.
STARTING & OPERATING CAUTION Always unplug heater before starting the engine. Damage to the cooling system could occur if the heater is not turned OFF (unplugged). Depending on engine make, when the temperature falls below -10° F (-24° C), the block heater is required. • • Use a solution of half ethylene glycol antifreeze and half water for best heater performance. Do not exceed 65 percent concentration of antifreeze, as a shortened heater life will result.
STARTING & OPERATING WARNING CAUTION NOTE Exhaust fumes from the engine contain carbon monoxide, a colorless and odorless gas. A poorly maintained, damaged, or corroded exhaust system can allow carbon monoxide to enter the cab or sleeper. Failure to properly maintain your vehicle could cause carbon monoxide to enter the cab and cause death or personal injury.
STARTING & OPERATING NOTE • Do not stay in the vehicle with the engine running or idling for more than 10 minutes with the vehicle’s Heater and A/C ventilation system in RECIRC or at LOW FAN SPEED. Even with the ventilation system On, running the engine while parked or stopped for prolonged periods of time is not recommended. • If other vehicles are parked next to you idling, move your vehicle or do not stay in your vehicle for prolonged periods of time.
STARTING & OPERATING Transmission In cold weather (below 32° F (0° C), you may find shifting sluggish when you first start up. Transmission warm-up is especially important at this time, but it is always a good idea to warm-up your transmission before starting out on the road. To warm-up the transmission, follow these procedures. 4 To warm-up the transmission lubricating oil during engine warm-up, with a single transmission (manual and automatic): 1. Put the transmission in Neutral. 2.
OPERATING THE ENGINE OPERATING THE ENGINE 5. Stationary PTO Operation Cancelling Cruise Control The cruise control buttons for this vehicle may be used to control the engine rpm when the vehicle is stationary and the operator wants to use the PTO on the engine. Use the cruise control options in the same manner as with the vehicle in motion, but instead of setting vehicle speed, the engine speed (RPM) is set instead.
OPERATING THE ENGINE 4 Winterfronts WARNING NOTE Do not work on or near the fan with the engine running. Anyone near the engine fan when it turns on could be 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.
OPERATING THE ENGINE Engine Control Display NOTE The winterfront is designed to minimize the temperature differences across the radiator and reduce the possibility of cooling module damage. Aftermarket winterfronts may not provide the proper airflow distribution and could cause cooling module damage. Your vehicle may come with an optional Engine and Driver Information Display. This instrument records information on engine diagnostics, scheduled maintenance, driving conditions, and general trip information.
OPERATING THE TRANSMISSION OPERATING THE TRANSMISSION Operating Hydraulic Clutch (Manual Transmission) 4 Manual transmissions will also have a clutch pedal situated to the left of the brake pedal. Pressing down on the clutch pedal will disengage the clutch and will allow the transmission gears to be shifted. At the beginning of the pedal stroke, there will be about ½ inch (13 mm) of movement before any resistance is felt.
OPERATING THE TRANSMISSION Putting the Vehicle in Motion CAUTION After making sure the vehicle's oil and air pressure are correct and all other parts and systems are in proper working condition: 1. Fully depress the clutch pedal (for manual transmission) until the clutch brake makes contact. a. b. The total stroke of the clutch pedal is about 6 inches (152 mm). The first ½ inch (13 mm) is free travel. After the free travel comes the release stroke, which is the part that fully releases the clutch.
OPERATING THE TRANSMISSION obtained. For further information, see More Driving Tips and Techniques on page 4-56. 4 4-16 Shifting Gears in a New Vehicle Clutch Brake and Travel Shift carefully in a new vehicle. The transmission may be a little stiff at first. Avoid gear clashing, by closely following these procedures. The clutch brake is used for stopping transmission gears, allowing you to easily shift into first gear or reverse without grinding gears.
OPERATING THE TRANSMISSION During Normal Driving Double Clutching 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. Fully depressing the pedal applies the clutch brake and could cause gear hang-up. Whether you are upshifting or down shifting, it is best to double clutch.
OPERATING THE TRANSMISSION Automatic and Automated Transmissions An automatic or automated transmission makes shifting much easier. It remains important to completely understand how to operate the transmission to optimize its efficiency. Please read the manual for your automatic or automated transmission included with your vehicle. 4 For automated transmissions, there is no “park” position. So you will need to apply the parking brake before leaving the cab.
OPERATING THE TRANSMISSION Auxiliary Transmission WARNING If your vehicle has an automated transmission, be aware that it can roll backwards when stopped on a hill or grade, or when starting from a stop on a hill or grade. Failure to comply may result in death, personal injury, equipment or property damage. Observe the following guidelines: • When stopped on a hill or grade, press the brake pedal.
OPERATING THE TRANSMISSION 4 • Never downshift when the vehicle is moving too fast. • Never slam or jerk the shift lever to complete gear engagement. • Never coast with the transmission in neutral and the clutch disengaged. • To provide smooth gear engagements while shifting, use proper coordination between shift lever and clutch. Double clutching is a very effective means to increase the service life of your transmission.
OPERATING THE BRAKE SYSTEM OPERATING THE BRAKE SYSTEM Introduction This vehicle’s brake system functions with the use of compressed air generated from the engine’s air compressor. The compressed air is stored in various air tanks to ensure that air pressure is available whenever the driver needs it. Compressed air is delivered to the brake system through the valve at the brake pedal and is controlled with various valves and braking circuits.
OPERATING THE BRAKE SYSTEM 4 WARNING WARNING WARNING The Anti-Lock 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 dealer. Failure to properly maintain your brake system can lead to serious accidents. Failure to comply may result in death, personal injury, equipment or property damage.
OPERATING THE BRAKE SYSTEM When driven in a bobtail mode, these tractors will require greater brake pedal application to provide the equivalent braking to a bobtail tractor not equipped with a proportioning system. Trailer ABS Power Line Communication (PLC) North American on-highway vehicles are equipped with a separate electrical circuit to power the anti-lock brake system (ABS) on towed vehicle(s).
OPERATING THE BRAKE SYSTEM NOTE CAUTION For doubles or triples, the lamp does not distinguish between trailers. An ABS problem in any of the trailers will activate the Trailer ABS Warning Lamp. The center pin of the 7-way trailer light line may be constantly powered for ABS. Make sure it will not accidently turn on trailer equipment. NOTE 4 If you change the intended service in any way (i.e. number of axles, multiple trailers, add switchable trailer accessories, etc.
OPERATING THE BRAKE SYSTEM Advanced ABS with Stability Control This vehicle may be equipped with an optional Electronic Stability Program (ESP). ESP is a feature for ABS-equipped vehicles that reduces the risk of rollovers, jackknifing and other loss of control situations. ESP features include Roll Stability Program (RSP) and Yaw Control.
OPERATING THE BRAKE SYSTEM 4 Yaw Stability Yaw Control Yaw stability counteracts the tendency of a vehicle to spin about its vertical axis. During operation, if the friction between the road surface and the tires is not sufficient to oppose lateral (side) forces, one or more of the tires can slide, causing the truck/tractor to spin. Yaw Control responds to a wide range of low- to high-friction surface scenarios including rollover, jackknife and loss of control.
OPERATING THE BRAKE SYSTEM ESP May Reduce The Vehicle Speed Automatically To minimize unexpected deceleration and reduce the risk of a collision the operator must: • Avoid aggressive driving maneuvers, such as sharp turns or abrupt lane changes at high speeds, which might trigger the stability system. • Always operate the vehicle safely, drive defensively, anticipate obstacles and pay attention to road, weather and traffic conditions.
OPERATING THE BRAKE SYSTEM • 4 There are mechanical problems with suspension leveling of the tractor or trailer resulting in uneven loads, • The vehicle is maneuvering on a high banked road creating either additional side forces due to the weight (mass) of the vehicle or a deviation between expected & actual yaw rates, • Gusty winds are strong enough to cause significant side forces on the vehicle and any towed vehicles.
OPERATING THE BRAKE SYSTEM WARNING For vehicles equipped with ESP “Electronic Stability Program” do not replace the vehicle’s steering wheel with an aftermarket or different part number than originally supplied. Using a different steering wheel could cause ESP to malfunction causing a loss of vehicle control possibly resulting in an accident involving death or personal injury.
OPERATING THE BRAKE SYSTEM 4 is applying the drive wheel brakes or reducing engine torque. Do not allow the traction 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.
OPERATING THE BRAKE SYSTEM traction surfaces such as loose gravel, sand and dirt. use, the ASR Warning Lamp blinks continuously. Off-Road ABS Function Switch (option) Your vehicle may be equipped with a separate switch to activate an Off-Road ABS function. This function is NOT to be used for On-Highway driving but is intended to be used to improve stopping performance in Off-Highway conditions (e.g. loose gravel and mud).
OPERATING THE BRAKE SYSTEM • 4 At speeds between 10 and 25 mph, the ABS control software is modified to allow short periods (0.25 seconds) of locked-wheel cycles. • At speeds below 10 mph, the ABS control software is turned off to allow locked wheels. • When the Off-Road ABS function is enabled, the Retarder Disable output is turned off. That is, the engine retarders are left to function without ABS intervention. For additional information, see the Off-Road ABS pamphlet in your vehicle’s glove box.
OPERATING THE BRAKE SYSTEM only helps the service brakes by using pressure to slow the drivetrain. Use the service brakes for quick stops. Do not use the retarder when operating on road surfaces with poor traction (such as wet, icy, or snow covered roads or gravel). Retarders can cause the wheels to skid on a slippery surface. Driving Bobtail or with an Unloaded Trailer We recommend that you do not use your engine retarder to slow down when you are bobtailing or pulling an empty trailer.
OPERATING THE BRAKE SYSTEM WARNING Parking Brake Do not rely on your automatic transmission hydraulic retarder to stop your vehicle. If your engine shuts down, the vehicle’s retarder will cease to operate which may lead to an accident involving death or personal injury. Always be ready to suddenly apply the service brakes. Parking brakes work in reverse action of the regular brakes. When the parking brakes are engaged, air is exhausted from the spring chambers which allow the spring to engage the brakes.
OPERATING THE BRAKE SYSTEM brakes but will not disengage the trailer parking brakes (if applicable). Either knob will pop back out if the system pressure is not above 60 psi (414 kPa). The instrument panel display will provide a message any time the parking brakes (vehicle or the trailer) are set and the vehicle is put into motion.
CRUISE CONTROL CRUISE CONTROL Cruise Control Switch This vehicle may have cruise control switches located on the steering wheel instead of the switches on the dash board. The instructions are still the same. Please see Steering Wheel Controls on page 3-72 to determine where the cruise control switches are located. 4 For information about the Adaptive Cruise Control, see Adaptive Cruise Control on page 4-38. • To Turn On: Press the ON/OFF button. • To Turn Off: Press the ON/OFF button.
CRUISE CONTROL • Press the ON/OFF button if the vehicle has dash board mounted cruise control switches or the CANCEL button if the vehicle has cruise control switches on the steering wheel. Setting Idle Speed 1. Ensure parking brakes are applied. 2. Ensure transmission is in Neutral. 3. Engage PTO per the manufacturer's operating instructions. 4. Press the "ON" button. 5. Press the "SET" button to obtain the desired engine rpm. Resuming Cruise Control 1. 2.
CRUISE CONTROL In vehicles with Eaton transmissions, the cruise control switches may be located on the shift control knob. 4 Adaptive Cruise Control (Optional) This vehicle may have an adaptive cruise control system that enhances the cruise control function. The adaptive cruise control system uses a radar sensor to detect the following distance to vehicles in front. The system will attempt to maintain either a safe distance or the vehicle speed depending on what is selected by the driver.
CRUISE CONTROL repeating at a rate of 42 tones per minute. Level 2 (Amber) Following Distance Alert This warning is active when the following distance is less than what is set in the system. This warning is more severe than the Level 3 Following Distance Alert. The system will emit a double beep repeating at a rate of 80 tones per minute (40 double beeps per minute). Level 1 (Red) Following Distance Alert This warning is active when the following distance is less than what is set in the system.
CRUISE CONTROL WARNING The Wingman® ACB sensor may not be able to detect vehicles and objects with limited metal surfaces (such as recreational vehicles, horse-drawn buggies, motorcycles, logging trailers, etc.). Failure to understand the system limitation may result in death, serious injury, and/or property damage. 4 4-40 Fault Alert This warning is presented to alert the operator that the ACB system is malfunctioning and will be disabled.
AXLE AXLE Differential Lock The vehicle may be equipped with switches to lock the either of the rear axle differentials. Depending on how the vehicle is specified, a combination individual switches may be available that can lock the interaxle driveline and/or any combination of the forward rear or rear-rear driving axles. The interaxle differential switch allows each axle to turn independently.
AXLE Dual Range (Two-Speed) Rear Axle Your vehicle may be equipped with a two-speed or dual range axle (option). You can select two rear axle ratios for operating under heavy loads or rough terrain as well as for over the road hauling. 4 The Low Range provides maximum torque for hauling heavy loads or traveling over rough terrain. The High Range is a faster ratio for highway speeds and general over the road conditions. A switch on the accessory switch panel controls the Dual Range Rear Axle.
AXLE Starting-Up 1. Unlock the inter-axle differential before starting. 2. Put the Range Selector in the LOW range. Shift the transmission to start the vehicle moving. 3. When you are driving on rough terrain and secondary roads, or under a very heavy load, keep the axle in the LOW range. Shift the transmission to maintain proper road speed. WARNING Never shift the axle when moving downhill.
AXLE LOW to HIGH (Cruising) When you go from rough terrain to highway driving, shift the axle to the HIGH range following this procedure: 1. 2. 3. 4 4. Be sure the differential is UNLOCKED. HIGH to LOW (Rough Terrain) If you need to downshift the axle for more power or you are driving on rough terrain: 1. Maintain your vehicle speed (accelerator depressed) and move the Range Selector lever to HIGH. Maintain your vehicle speed (accelerator depressed) and move the Range Selector lever to LOW. 2.
AXLE GAWR and the load that is being carried. The vehicle will have switches on the dash to control the position of the auxiliary axles. In certain situations, however, the system will override the controls to protect the axle system. Any liftable and steerable auxiliary axles will rise off of the ground when the parking brakes are engaged or when the vehicle is put in reverse.
AXLE Axle Creep Rating Definition Creep Ratings Low speed, off-highway (work site) axle loads, which exceed the standard gross axle weight rating (GAWR) of a particular axle. 4 Operator's using vehicles equipped with liftable auxiliary axles must consider creep ratings when any liftable axle is unloaded or in the raised position. Liftable auxiliary axles should only be raised (or unloaded) to improve maneuverability in an off-road use or when vehicle is unloaded.
AXLE CAUTION A change in tire size on either the auxiliary axles or the drive/steer axles can change the calibration of the auxiliary axles. If tires are installed with a different loaded radius, the calibration procedure must be repeated. Failure to do so can cause equipment damage.
AXLE General Calibration Guidelines These instructions are general in nature. For more specific instructions, review the pusher or tag suspension manufacturers maintenance manual or contact the nearest authorized dealer. some non-liftable axles, inflate air suspension). 4. NOTE 4 Perform this procedure at or near a weight scale. Procedure can be performed while parked on the weight scale if scale is available. 1. Park loaded vehicle on level surface with wheels blocked. 2.
AXLE Maximizing Drive Axle Traction Coupling To A Loaded Trailer Adjust the pressure regulator control knob to a lower pressure until desired traction is obtained. By reducing air pressure at pusher or tag axle, load will be transferred to drive axles. Do not overload drive axles. Inflate air springs of the auxiliary axles to the desired pressure after coupling to a loaded trailer while still maintaining proper traction of the drive axles.
AXLE Non-liftable (Non-steerable) Axles Some suspensions require dump valve calibration. Example: Neway dead axles do not lift, but the air can be dumped out of them to unload them when empty. Air pressure is controlled via an adjustable regulator. These axles need to be calibrated for load. 4 Contact your authorized dealer or axle/suspension manufacturer for dump valve calibration procedures.
SUSPENSION SUSPENSION Setting Ride Height Vehicles equipped with rear air suspensions have their ride height and axle (pinion) angle(s) preset at the factory. These are precision settings and should not be altered. Incorrectly adjusted ride height may result in improper interaxle U-joint working angles. This can result in pre-mature driveline wear and driveline vibration.
SUSPENSION NOTE 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. 4 NOTE Typical Height Control Valve (Location on Vehicle) Suitable wheel chocks are at a minimum an 18-inch (46 cm) long 4x4. 1. Ensure that the tractor is fully laden during this procedure.
SUSPENSION WARNING • • • The rear of a vehicle will drop about 3 1/2 inches (88 mm) when the air springs are deflated. Ensure that no persons or objects that could be killed, injured or damaged are under the vehicle before deflating the air springs. To minimize risk of death, personal injury or property damage, do not use a dump valve to deflate the air springs. Rotate the height control valve(s) manually to ensure positive control of air spring deflation.
SUSPENSION Driving with Deflated Air Springs If an air spring is ruptured, there will be enough air pressure to drive the vehicle to a safe stop off the highway to investigate the problem. WARNING 4 Do not continue to drive with ruptured air springs. The air loss can cause the spring brakes to apply allowing your brakes to drag and burn up the linings, which could lead to an accident causing death or personal injury. Do not continue to operate the vehicle in this condition.
AFTER-TREATMENT SYSTEM AFTER-TREATMENT SYSTEM Introduction This vehicle will has an exhaust After-Treatment System (ATS), to control vehicle exhaust emissions, which consist of a Diesel Particulate Filter (DPF), Selective Catalyst Reduction (SCR), Regeneration Switch and warning lights. The DPF will trap soot from the engine exhaust gases. The SCR uses Diesel Exhaust Fluid to reduce the levels of NOx in the engine exhaust. The ATS will periodically clean (regenerate) the DPF.
DRIVING TIPS AND TECHNIQUES DRIVING TIPS AND TECHNIQUES Introduction This section covers additional driving tips and techniques on how to drive your vehicle more efficiently. 4 Coasting WARNING Do not coast with the transmission in neutral or with the clutch pedal depressed—it is a dangerous practice. Coasting in neutral may result in damage to your drivetrain when you try to re-engage the transmission.
DRIVING TIPS AND TECHNIQUES Descending a Grade Engine Overspeed WARNING CAUTION Do not hold the brake pedal down too long or too often while going down a steep or long grade. This could cause the brakes to overheat and reduce their effectiveness. As a result, the vehicle will not slow down at the usual rate.
DRIVING TIPS AND TECHNIQUES Use of Tachometer The tachometer is an instrument that aids in obtaining the best performance of the engine and manual transmission, serving as a guide for shifting gears. to the engine. However, the governor has no control over the engine rpm when it is being driven by the vehicle's transmission, for example, on steep downgrades. Apply service brakes or shift to a higher gear. Refer to the Engine Operation and Maintenance manual for optimum engine rpm.
DRIVING TIPS AND TECHNIQUES WARNING Do not look at the Instrument Cluster Display for prolonged periods or at it repeatedly in a short period of time while the vehicle is moving. Extended glance durations to instrument cluster and or overly frequent glances inside the vehicle can cause a loss of attention to the situations on the roadway and vehicle’s road position, which could lead to an accident and possible death or personal injury or equipment damage. during steady state driving.
DRIVING TIPS AND TECHNIQUES Fuel - Excess Consumption Maintenance The vehicle's fuel consumption is connected to three important factors: maintenance, driving habits, and general condition of the road, traffic conditions, and vehicle load. Proper maintenance will keep the vehicle running like new even after long periods of use. The driver must perform the daily and weekly checks of the vehicle.
DRIVING TIPS AND TECHNIQUES Driving Habits General Condition Wrong driving habits must be corrected and the recommendations on economic driving should be followed. Other factors affecting fuel consumption are related to loads and type of roads on which the vehicle operates. It is not always possible to choose the most adequate road, but it must be kept in mind that the ideal road is the one that allows a steady speed in high gear, without requiring frequent braking and acceleration.
SLEEPER BUNKS SLEEPER BUNKS WARNING Sleeper Bunk If your vehicle has an upper and lower bunk, the upper bunk can be folded up out of the way to provide you with more dressing area in the sleeper cab. The lower bunk has storage underneath it to stow your luggage and other belongings. The upper bunk weight limit is 320 lb. (145 kg). 4 WARNING Be sure the restraint system is used when anyone is occupying the sleeper while the vehicle is moving.
SLEEPER BUNKS Sleeper Occupant Restraint WARNING Be sure the restraint system is used when anyone is occupying the sleeper while the vehicle is moving. In an accident, an unrestrained person lying in a sleeper bunk could be injured. He or she could be thrown from the bunk. Failure to comply may result in death or personal injury. WARNING Be sure no one ever rides unsecured in the upper bunk. That person could be thrown out in an accident and could be injured. Do not use the upper bunk while you are moving.
STOPPING THE ENGINE STOPPING THE ENGINE Turbochargers Refueling Before Stopping the Engine This cooling-down practice is especially important on a turbocharged engine. The turbocharger contains bearings and seals that are subjected to hot exhaust gases. While the engine is operating, heat is carried away by circulating oil. If you stop the engine suddenly, the temperature of the turbocharger could rise as much as 100°F (55°C) above the temperature reached during operation.
STOPPING THE ENGINE WARNING Diesel fuel in the presence of an ignition source (such as a cigarette) could cause an explosion. 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. Failure to comply may result in death, personal injury, equipment or property damage.
STOPPING THE ENGINE Final Stop Final Stopping Procedures To make sure your vehicle is ready to go after a long stop (such as over night), please follow the suggestions below. Your vehicle will be easier to get going when you are ready, and it will be safer for anyone who might be around it. Please remember, too, that in some states it is illegal to leave the engine running and the vehicle unattended. 1. Set the parking brake before leaving the driver’s seat.
STOPPING THE ENGINE air supply. Be sure to close the drains before leaving the vehicle. 4 Opening Drains 4. Secure the vehicle. Close all the windows and lock all the doors.
MAINTENANCE PREVENTIVE MAINTENANCE SCHEDULE Introduction . . . . . . . . . . . . . . . . . . 5-9 Maintenance Schedule . . . . . . . . . . . . 5-12 LUBRICANT SPECIFICATIONS Introduction . . . . . . . . . Engine . . . . . . . . . . . Master Lubrication Index . . . . Fuller Transmission Lubrication . Allison Transmission Lubrication Spicer Transmission Lubrication Oil Changes . . . . . . . . . Meritor Axle Lubrication . . . . Eaton/Dana Axle Lubrication . . Wheel Bearing Lubrication . . .
MAINTENANCE AIR SYSTEM Introduction . . . . . . Air Dryer . . . . . . . . Air Tanks . . . . . . . Air Gauges and Air Leaks Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47 5-50 5-52 5-53 5-54 Brake Adjustment . . . . . . . . . . . . . . . 5-56 Exterior Maintenance . . . . . . . . . . Cleaning, Protecting and Weather Stripping Safety Restraint System - Inspection . . . Windshield Wiper/Washer . . . . . .
MAINTENANCE ELECTRICAL Electrical System . . . . . . . . . Light Bulbs . . . . . . . . . . . . Bulb Specifications . . . . . . . . Fuses, Circuit Breakers and Relays . Fuse Inspection and Replacement . Adding Electrical Options . . . . . Batteries . . . . . . . . . . . . . Battery Care . . . . . . . . . . . Battery Charging . . . . . . . . . Electrical and Alternator Precautions Remote Keyless Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE Turbocharger . . Air Cleaners . . Filter Minder . . Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-97 5-98 5-99 5-99 FUEL SYSTEM Location of Fuel Shut-off Valves. . . . . . . . . 5-100 Specification . . . . . . . . . . . . . . . . . 5-100 Fuel Filters . . . . . . . . . . . . . . . . . . 5-100 FRAME Introduction . . . . . . . . . . . . . . . . .
MAINTENANCE Air Filters . . . . . . . . . . . . . . . . . . 5-111 Heater. . . . . . . . . . . . . . . . . . . . 5-113 Air Conditioner . . . . . . . . . . . . . . . . 5-114 NOISE AND EMISSION CONTROL Noise Emission Warranty . . . . . . . . . . . 5-115 Inspection and Maintenance Instructions . . . . . 5-117 Noise Control System - Maintenance Log . . . . 5-122 REAR AXLE AND SUSPENSION General Maintenance . . . Visual Inspection . . . . . Rear Suspension Fasteners Rear Axle Lubrication . . .
MAINTENANCE DRIVELINE Driveshaft Maintenance . . . . . . . . . . . . 5-134 U-Joints . . . . . . . . . . . . . . . . . . . 5-134 TIRES AND WHEEL Tires . . . . . . . . . . . . . . . . . Wheel Mounting and Fastening . . . . . . Wheel Replacement With Disc Brake Option Disc Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . 5-135 5-140 5-142 5-144 WHEEL BEARING Wheel Bearing Adjustment . . . . . . . . . . . 5-145 TRANSMISSION MAINTENANCE 5 Introduction . . . . . . . . . . . . . . . . .
MAINTENANCE Clutch Adjustment . . . . . . . . . . . . . . 5-150 Clutch Adjustment - Normal Wear . . . . . . . .
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE SCHEDULE Introduction Preventive maintenance program begins with the daily checks. See Driver’s Check List on page 1-34 for these routine checks. Routine vehicle checks can help avoid many large, expensive, and time consuming repairs. The vehicle will operate better, be safer, and last longer. Neglect of recommended maintenance can void your vehicle’s warranty. Some maintenance operations demand skills and equipment you may not have.
PREVENTIVE MAINTENANCE SCHEDULE WARNING WARNING WARNING Disconnect the battery ground strap whenever you work on the fuel system or the electrical system. When you work around fuel, do not smoke or work near heaters or other fire hazards. Keep an approved fire extinguisher handy. Failure to comply may result in death, personal injury, equipment or property damage.
PREVENTIVE MAINTENANCE SCHEDULE dependent on the vehicle’s operating environment. recommendations in this table and component supplier recommendations. On highway is defined for applications where the vehicle is NOT used off of a paved road during normal operation. • Engine lubricating oil change intervals aren’t listed here. Refer to your engine’s operating manual for recommendations. For specific information on maintenance procedures consult your vehicle maintenance manual.
PREVENTIVE MAINTENANCE SCHEDULE Maintenance Schedule New Vehicle Maintenance Schedule New Vehicle Maintenance Schedule Operation\Frequency 5 Steering Shaft U-Bolts. (OFF-HIGHWAY) See Steering System on page 5-130. Wheel Mounting. See Wheel Mounting and Fastening on page 5-140. Front Axle U-Bolt Torque. See Front Spring Suspension U-Bolts on page 5-108. Charge Air Cooler and Air Intake Pipe Clamps, re- torque fasteners. Rear Suspension Fasteners. See Rear Suspension Fasteners on page 5-126.
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Frame COMPONENT Fifth Wheel Frame Fasteners Front Axle (Meritor) MAINTENANCE TASK Check the kingpin lock and plate for wear and function; lubricate (NLGI #2 grease). Inspect fifth wheel operation (shown on page 5-126) Check for tightness; tighten to the specified torque value as required (shown on page 5-104). Inspect for cracks and loose fasteners.
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Front Axle (Dana) 5 5-14 COMPONENT Total Vehicle Alignment Kingpin bushings, thrust bearings, & tie rod ball ends (ON HIGHWAY) Kingpin bushings, thrust bearings, & tie rod ball ends (OFF-HIGHWAY) Steering knuckle spindles, thrust bearings, kingpins, drawkeys, tie rod ends, steering stops, & bushings (ON HIGHWAY) Steering knuckle spindles, thrust bearings, kingpins, drawkeys, tie rod ends, steering stops, & bushings (OFF-HIGHWAY
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Front Suspension COMPONENT Front Spring Spring Pins & Shackles Shock Absorbers Spring Pins U-bolts (ON HIGHWAY) U-bolts (OFF HIGHWAY) MAINTENANCE TASK Inspect for cracked leaves, worn bushings, & excessive corrosion. Inspect for worn parts and excessive joint clearance. Shim or replace as required. Inspect for leaking, body damage, and damaged or worn bushings. Replace as required. Check the shock mounting stud torque.
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Drive Axle (Dana) 5 5-16 COMPONENT Axle Housing MAINTENANCE TASK Visually inspect for damage or leaks. Check oil level. Check “cold.” Torque the drain plug. Drain the lubricant while warm. Flush each unit with clean flushing oil. Change the lubricant. Air Shift Unit Check the lubricant level. Remove the housing cover and drain the lubricant. Wash the parts thoroughly and dry in air. Breather Clean or replace.
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Drive Axle (Meritor) Drive Axle (SISU) COMPONENT Axle Housing Lubricant filter Breather Input shaft & pinion shaft Axle shaft Interaxle differential Axle Housing Breather Lube Filter S-cam brakes MAINTENANCE TASK Check the “cold” fill level at the differential carrier plug for a pinion angle of less than 7 degrees, or at the axle bowl plug for a pinion angle of greater than 7 degrees. Tighten the plug to 35-50 Lb. ft.
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Rear Suspension 5 5-18 COMPONENT U-bolts MAINTENANCE TASK Frame & crossmember bolts Check the torque. Tighten to specified torque value as required (shown on page 5-127). Check the torque. Tighten to specified torque value as required (shown on page 5-104). Mounting brackets and fasteners Check the condition and the fastener torque. Tighten to the specified torque value as required (shown on page 5-104).
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Drum Brakes (All) COMPONENT Slack adjusters Brake camshaft bearing Brake treadle valve Brake air system Brake lining MAINTENANCE TASK Check the push rod travel and check the control arm for cracks. Adjust at reline (shown on page 5-59). Lubricate (NLGI #2 grease). Check for excessive camshaft paly in the axial and radial directions. Max allowable play is 0.003 in. Lubricate (NLGI #2 grease).
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Disc Brakes (Bendix®) COMPONENT Brake pads Brake disc/rotor Caliper sliding function Caliper slide pins System operation 5 5-20 MAINTENANCE TASK Inspect; replace as required. Inspect for visible cracks, heat checking, galling, or scoring of surface. Check for runout (max allowable is 0.002 in.). Ensure caliper slides freely with no obstructions or excessive play.
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Hub, Drum, & Hubcap COMPONENT Hubs (non-LMS) Hubs (non-LMS) with outrunner seals Hubs (non-LMS) with standard seals Hub seals (all) LMS Hubs (Dana) LMS Hubs (Dana) with Synthetic Lubricant LMS Hubs (Dana) with Mineral Lubricant Brake drums Hubcaps MAINTENANCE TASK Check the bearing endplay and adjust as required (shown on page 5-45). Clean the components and check for excessive wear or damage.
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Main & auxiliary transmission 5 Auxiliary transmission 5-22 COMPONENT Main & auxiliary transmission and transfer case Mounting Brackets and Fasteners Oil cooler Main & aux.
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Air Intake Clutch Cooling COMPONENT MAINTENANCE TASK I Recommended PM Interval A B D E C X Air intake piping, mounting, Check the system for broken pipes, leaks, joint integrity, and charge air cooler cleanliness, and proper support (shown on page 5-99). Air cleaner Replace the engine intake air cleaner element (shown on page When required by air restriction indicator or required by the engine 5-97).
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM COMPONENT Tires & Wheels Tires Disc wheels Demountable rims Wheel nuts and studs 5 5-24 Recommended PM Interval I A B D E C Check inflation pressure (shown on page 5-135). Weekly “cold” using calibrated gauge X Inspect for cuts, irregular wear, missing lugs, sidewall damage, etc. X Inspect the wheel disc for any cracks or surface irregularities. Inspect the rim edge and bead seat area for damage.
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Power Steering COMPONENT MAINTENANCE TASK Reservoir Reservoir (ON HIGHWAY) Reservoir (OFF HIGHWAY) Steering gear Check the fluid level (shown on page 5-46). Drain, replace the filter, and refill (shown on page 5-46). Drain, replace the filter, and refill (shown on page 5-46). Check the lash of the sector shaft; adjust as required. Grease the trunnion bearing (EP NLGI #2 lithium-based, moly-filled, HD grease).
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Power Steering 5 Fuel & Tanks COMPONENT MAINTENANCE TASK Steering intermediate shaft U-joints (ON HIGHWAY) Steering intermediate shaft U-joints (OFF HIGHWAY or CITY DELIVERY) Draglink and tie rod arm ball sockets (ON HIGHWAY) Draglink and tie rod arm ball sockets (OFF HIGHWAY or CITY DELIVERY) Fuel tanks Lubricate [EP NLGI #2 HD grease, +325° F to -10° F (+163° C to -23° C) range].
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Driveshafts COMPONENT MAINTENANCE TASK Models SPL-90, 1710 and Lubricate*. 1810 slip member & U-joints Inspect. Model SPL-100 slip member & U-joints Lubricate*. Inspect. Models SPL-140/140HD/170/ 170HD/250/250HD slip members & U-joints (ON HIGHWAY & LINEHAUL) Lubricate*. Inspect. Recommended PM Interval I A B D E C X X U-joint inspections should be performed every time a vehicle comes in for scheduled maintenance.
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Driveshafts 5 COMPONENT Models SPL-140/140HD/170/ 170HD/250/250HD slip members & U-joints (OFF HIGHWAY) Models SPL-140XL/170XL/250XL slip members and U-joints (ON HIGHWAY & LINE HAUL) MAINTENANCE TASK Lubricate*. Inspect. Lubricate*. Inspect. Recommended PM Interval I A B D E C X U-joint inspections should be performed every time a vehicle comes in for scheduled maintenance.
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM COMPONENT Battery Boxes, Battery cables Tool Boxes, and Steps MAINTENANCE TASK Check the condition of the cables, cushion clamps, nylon tie straps, and routing. Replace a cushion clamp if the rubber has deteriorated. Repair or tighten terminals, and secure cables to prevent chafing. Replace damaged cables (cuts, cracks, or excessive wear) (shown on page 5-75).
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Electrical & lights COMPONENT Headlamps Warning lights in light bar Turn, Stop, Reverse lights and signals Alternator 5 MAINTENANCE TASK Check the aim and adjust as required. Check at the ignition start position to verify bulbs and driver information display function (shown on page 3-30). Visual check. Check operation and output. Check tightness of the pulley nut. Check the tension of the drive belt (shown on page 5-95).
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Heating & Air Conditioning COMPONENT Air conditioner Heater & air conditioner Cabin fresh air filter (ON HIGHWAY) Cabin fresh air filter (OFF-HIGHWAY) Condenser Sleeper air filter Recirc cab air filter (ON HIGHWAY) Recirc cab air filter (OFF-HIGHWAY) Aftertreatment System System Diesel particulate filter Diesel exhaust fluid tank MAINTENANCE TASK Operate the system. Perform the checks listed shown on page 5-110.
PREVENTIVE MAINTENANCE SCHEDULE PREVENTIVE MAINTENANCE (PM) INTERVALS SYSTEM Air Engine 5 Safety 5-32 COMPONENT Air compressor governor Air lines System Inline filters Air dryer Air dryer (ON HIGHWAY) Air dryer (OFF HIGHWAY) Basic Engine Three-point Safety Belt System Recommended PM Interval A B D E C Replace air strainer. X X Check condition and routing to prevent chafing. X Lubricate (shown on page 5-47). Replace elements or clean with solvent. X X Perform the checks listed (shown on page 5-47).
LUBRICANT SPECIFICATIONS LUBRICANT SPECIFICATIONS Introduction at top economy and in prolonging its life is proper lubrication servicing. Neglecting this essential aspect of vehicle care can cost time and money in the long run. WARNING CAUTION Handle lubricants carefully. Vehicle lubricants (oil and grease) can be poisonous and cause death, personal injury or sickness. They can also damage the paint on the vehicle. Do not mix different types of lubricants.
LUBRICANT SPECIFICATIONS WARNING WARNING NOTE Exhaust fumes from the engine contain carbon monoxide, a colorless and odorless gas. A poorly maintained, damaged, or corroded exhaust system can allow carbon monoxide to enter the cab or sleeper. Failure to properly maintain your vehicle could cause carbon monoxide to enter the cab and cause death, personal injury or serious illness. Never idle your vehicle for prolonged periods of time if you sense that exhaust fumes are entering the cab.
LUBRICANT SPECIFICATIONS Pipe and Hose Clamps Use the following table for torque specifications to check pipe and hose clamps. Pipe and Hose Clamp Torque Values APPLICATION Radiator & Heat Exchanger Hoses Heater Hoses Air Intake Pipes Plastic Air Intake Pipes Charge Air Intake Hoses Fuel, Oil & Water Heat Exchangers (for hoses less than 9/16 diameter) APPROVED CLAMP Constant-Torque CT-L Constant Tension Hi-Torque HTM-L Constant- Torque CT-L Flex Seal 667 B9296 Miniature 3600L TORQUE Nm 10.2-12.
LUBRICANT SPECIFICATIONS Master Lubrication Index ATF BB CB CC/CD CD CD50 CE CJ-4 CL EP GL HD HT MP DOT3 or DOT4 5 Lubricant Symbol Key MD3 or MERCON®-approved automatic transmission fluid High temperature ball bearing grease. Chevron SRI Mobile Grease HP, Texaco Multifax 2 or equivalent Engine oil for mild to moderate requirements Engine oil for severe requirements (MIL-L-2104B /MIL-L-45199B w/ 1.85% max.
LUBRICANT SPECIFICATIONS Component Lubrication Index Universal Joints EP* Drive Shaft Splines CL* Steering Column CL Alternator Bearing BB* Fan Hub BB* ATF Power Steering Reservoir Steering Drag Link CL Steering Knuckles CL Spring Pins CL BB Clutch Release Bearings HT Brake Shoe Anchor Pins HT Brake Cam Bearings Slack Adjusters CL Starter Bearings CC Turbocharger Aneroid CC Water Pump BB* EP Suspension Fittings (other than threaded pins & bushings) EP Steering Axle: Grease Fittings on Steering Arm; Tie Rod
LUBRICANT SPECIFICATIONS Component Lubrication Index Manual Transmission Hydraulic Clutch DOT3 or DOT4 (Brake Fluid) *Consult manufacturer or lubricant supplier for special details.
LUBRICANT SPECIFICATIONS Fuller Transmission Lubrication Fuller transmissions are designed so that the internal parts operate in a bath of oil circulated by the motion of gears and shafts. Grey iron parts have built-in channels where needed to help lubricate bearings and shafts. All parts will be amply lubricated if these procedures are closely followed: 1. Maintain oil level; check it regularly. 2. Change oil regularly. 3. Use the correct grade and type of oil. 4. Buy oil from a reputable dealer.
LUBRICANT SPECIFICATIONS Recommended Lubricants Type Heavy Duty Engine Oil MIL-L-2104B, C, or D; API - SF, or API-CD Mineral gear oil with rust and oxidation inhibitor API-GL-1 Synthetic Lubricant* *See your dealer for approved brands.
LUBRICANT SPECIFICATIONS Allison Transmission Lubrication Lubrication Change and Inspection • Refer to your transmission manual (furnished separately) for lubrication information. • Refer to the Allison Transmission manual for servicing information. Spicer Transmission Lubrication It is extremely important to use the proper lubricants and maintain the correct oil levels in Spicer units. This will ensure proper lubrication and operating temperatures in these units.
LUBRICANT SPECIFICATIONS Type Grade (SAE) EP75W90 All *Synthetic Gear Oil Meeting MIL-2105C or API-GL5 EP75W140 *EP Gear Oils are not recommended when lubricant operating temperatures are above 230° F (110° C). Oil Changes 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.
LUBRICANT SPECIFICATIONS Meritor Axle Lubrication NOTE Axles utilized in 100% off-highway use are not eligible for Meritor’s Advanced Lube Rear Drive Axle program.
LUBRICANT SPECIFICATIONS Application City Delivery Off Highway • Change the lubricant filter every 120,000 miles (192,000 km). Top off the lubricant level with a similar lubricant. 5 Type Of Lubricant Synthetic Synthetic with Pump and Filter Mineral Base Synthetic Synthetic with Pump and Filter Mineral Base Eaton/Dana Axle Lubrication • • • 5-44 The original mineral-based lubricant must be drained within 3000-5000 miles (4800-8000 km) on all Eaton axles.
LUBRICANT SPECIFICATIONS Type of Lubricant Mineral-Based Eaton-Approved Synthetic Eaton-Approved Synthetic in axle with extended drain interval option On-Highway Mi. (km) 120,000 (192,000) 240,000 (384,000) 350,000 (560,000) Maximum Change Interval On/Off Highway Severe Service Mi. (km) Yearly 60,000 (96,000) 2 Years 120,000 (192,000) Wheel Bearing Lubrication Oil-lubricated Driven Hubs Oil-lubricated Nondriven Hubs Use hypoid oil, A.P.I.-GL-5 SAE 75W-90FE synthetic gear lubricant or equivalent.
LUBRICANT SPECIFICATIONS Steering Gear Lubrication Fluid Refill Inspection NOTE The following recommendations are for general purpose steering systems (both TRW and Sheppard). 5 • For normal temperatures, use Automatic Transmission Fluid (ATF) Type E or F or Dexron® III. • For cold temperatures of -22º F (-30º C) and above use ATF Type A. • For extremely cold temperatures between -22º F (-30º C) and -40º F (-40º C) use ATF Type B.
AIR SYSTEM AIR SYSTEM Introduction WARNING Do not attempt to modify, alter, repair or disconnect any component of the air system. Repairs or modifications to the air system, other than what is described in this section, should only be performed by an authorized dealer. Failure to comply may result in death or personal injury. WARNING 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.
AIR SYSTEM WARNING WARNING Never attempt to disassemble a component until you have read and understood recommended procedures. Some components contain powerful springs and injury can result if not properly disassembled. Use only proper tools and observe all precautions pertaining to use of those tools. Failure to comply may result in death, personal injury, equipment or property damage. Completely bypassing a Bendix® AD-IS air dryer will bypass the system’s pressure protection valves.
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 accident involving death or personal injury. Daily Periodically • Drain moisture from the supply and service air tanks. • • Operate air devices to circulate lubricants within the unit.
AIR SYSTEM Twice a Year Air Dryer • The function of the air dryer is to collect and remove air system contaminants in solid, liquid and vapor form before they enter the brake system. It provides clean, dry air to the components of the brake system, which increases the life of the system and reduces maintenance costs. • Maintain the air compressor to prevent excessive oil by-pass. See your maintenance manual for details. Replace worn seals in valves and air motors as they are needed.
AIR SYSTEM and non-compressing cycle) in a normal fashion or it may be due to excessive leaks in the air system. • • In areas where more than a 30° F (17° C) range of temperature occurs in one day, small amounts of water can accumulate in the air brake system due to condensation. Under these conditions, the presence of small amounts of moisture is normal and should not be considered as an indication that the dryer is not performing properly. An outside air source has been used to charge the air system.
AIR SYSTEM Air Tanks WARNING The AD-IS Series air dryer has incorporated into its design various components that have typically been installed separately on the vehicle (see below for components/areas affected). 5 • Pressure protection valves • Safety valve • Governor and plumbing • Plumbing of the front and rear service air tanks • Plumbing to accessory systems These components are required to meet the Federal Motor Vehicle Safety Standards (FMVSS 121 - Air Brake Systems).
AIR SYSTEM Your authorized dealer carries rebuild kits for most units. Air Gauges and Air Leaks Your vehicle comes with air pressure gauges for two separate systems, Primary and Secondary: the Primary gauge indicates pressure in the rear braking system; the Secondary gauge indicates pressure in the front braking system. Each gauge indicates the amount of air pressure in pounds per square inch (psi).
AIR SYSTEM 5. Start the engine and build up the air pressure again. 6. Stop the engine, and apply the brakes fully. Apply the brake pedal and hold it down for five minutes. The pressure drop should not exceed 3.0 psi (21 kPa) per minute. 7. If you detect excessive leakage (air pressure loss greater than 3.0 psi (21 kPa) after five minutes of brake application), a leakage test should be made at the air line connections and at all air brake control units.
AIR SYSTEM Preventive Maintenance The following service checks are provided for your information only and should be performed by a certified mechanic. Contact your dealer or the engine manufacturer's Maintenance Manual for further information on servicing air compressors. After completing any repairs to the air system, always test for air leaks, and check the brakes for safe operation before putting the vehicle in service. presence of excessive carbon.
BRAKE SYSTEM BRAKE SYSTEM Brake Adjustment WARNING Do not work on the brake system without the parking brake set and wheels chocked securely. If the vehicle is not secured to prevent uncontrolled vehicle movement, it could roll and cause death, serious personal injury or damage to the vehicle. 5 To operate your vehicle safely and profitably, you need some understanding of its brake systems. For more on brakes, see the Index, under Brakes.
BRAKE SYSTEM WARNING 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 accident causing death or personal injury. 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 • Have a qualified mechanic perform a detailed inspection if the notches are not found. The pads and rotors should be measured and compared against the manufacturers specifications located in the brake manufacturer’s service manual. • Chock the wheels. • Temporarily release the parking brakes. • Grab the caliper and move it. This movement is Running Clearance. • Proper Running Clearance is 0.
BRAKE SYSTEM Drum Brakes Automatic Slack Adjusters Have brake drum linings and disc brake pads inspected by a qualified mechanic for wear at regular intervals according to the maintenance schedule. In severe service or off-highway applications inspect the linings more frequently. Periodically check the Brake Chamber Stroke. Replace the slack adjuster if proper stroke cannot be maintained.
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.
CAB CAB Exterior Maintenance Painted Surfaces Wash painted surfaces frequently to remove grime and caustic deposits which may stain the finish. See Cleaning, Protecting, and Weather Stripping on page 5-62. 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. • Chrome surfaces are best cleaned with fresh water.
CAB Tail Pipe Surface Cleaning WARNING Always allow hot surfaces to cool down before attempting to work near them. Failure to comply may result in death or personal injury. 5 To maintain your quality finish, wash with a soft cloth, mild soap and water or glass cleaner. A non-abrasive chrome polish (e.g. Windex®) can be used sparingly on hard to clean areas. Do Not clean your high heat chrome using scouring pads, abrasive chrome polish, highly acidic chemical cleaners or any other abrasive cleaners.
CAB Vehicle Cleaning WARNING Precautions Do not clean the underside of chassis, fenders wheel covers, etc. without protecting your hands and arms. You may cut yourself on sharp-edged metal parts. Failure to comply may result in death, personal injury, equipment or property damage. WARNING Handle cleaning agents carefully. Cleaning agents may be poisonous. Keep them out of the reach of children. Failure to comply may result in death, personal injury, equipment or property damage.
CAB Washing the Exterior 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. 1. 2. 5 3. 5-64 Begin by spraying water over the dry surface to remove all loose dirt before applying the car wash and wax solution. Do not wash the vehicle in direct sunshine.
CAB Cleaning the Chassis • • Hose dirt and grime from the entire chassis. Then, if an oil leak develops, you will be able to detect it easier. Corrosive materials used for ice and snow removal and dust control can collect on the underbody. If these materials are not removed, accelerated corrosion (rust) can occur on underbody parts such as fuel lines, frames, floor pan, and exhaust system, even though they have been provided with corrosion protection.
CAB Factors contributing to reduced seat belt life: • Heavy trucks typically accumulate twice as many miles as the average passenger car in a given time period. • Seat and cab movement in trucks causes almost constant movement of the belt due to ride characteristics and seat design. The constant movement of the belt inside the restraint hardware and the potential for the belt to come in contact with the cab and other vehicle parts, contributes to the wear of the entire system.
CAB Inspection Guidelines Follow these guidelines when inspecting for cuts, fraying, extreme or unusual wear of the webbing, and damage to the buckle, retractor, hardware, or other factors. Damage to these areas indicates that belt system replacement is necessary. other parts of the cab interior. These areas are typical places where the web will experience cutting or abrasion. Cuts, fraying, or excessive wear would indicate the need for replacement of the seat belt system. 2.
CAB the sun's ultraviolet rays. Replace the system. 4 5 6 7 8 Buckle casting broken. Retractor Web Storage for damage. (located behind trim panel) Tethers for web wear and proper tightness of mounting hardware. Mounting hardware for corrosion, proper tightness of bolts and nuts. Web for deterioration, due to exposure to the sun WARNING 5 Seat Belt Inspection Points 1 2 3 5-68 Web cut or frayed or extremely worn at latch area. Web cut or frayed at D-loop web guide. Comfort Clip cracked or damaged.
CAB Windshield Wiper/Washer The windshield wiper system is maintenance free. Check wiper blades annually or every 60,000 miles (96,000 km). Washer Reservoir CAUTION Do not use antifreeze or engine coolant in the windshield washer reservoir, damage to seals and other components will result. Daily: Check reservoir water level, located in the engine compartment. If necessary, refill to the proper level.
COOLING SYSTEM COOLING SYSTEM CAUTION Cooling system maintenance Your engine’s cooling system is standard with Extended Life Coolant (ELC). ELC consists of a mixture of ethylene glycol, water, and organic acid technology chemical inhibitors. ELC prevents corrosion and scale formation as well as provides freezing and boiling point protection. The engine cooling system has very specific maintenance and inspection requirements. Failure to follow requirements can damage the engine.
COOLING SYSTEM between -30° F and -45° F (-34° C and -43° C). Desired ELC/ Water ratio: Freeze point °F (°C) Items in 0% 10% 15% 20% 25% 30% 35% 40% 45% 50% 55% 60% 65% 70% 75% 80% 85% 90% 100% +32 (0) +25 (-4) +20 (-7) +15 (-9) +10 (-12) +5 (-15) -5 (-21) -12 (-24) -23 (-31) -34 (-37) -50 (-46) -65 (-54) -75 (-59) -84 (-64) -70 (-57) -55 (-48) -43 (-42) -30 (-34) -5 (-21) bold are the recommended levels of concentration.
COOLING SYSTEM Topping Off NOTE WARNING 5 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 or if you see any steam or coolant escaping.
COOLING SYSTEM • • rate until the surge tank is full (to the base of the fill neck). It may be necessary to pause for 1 minute and then re-fill if the fluid level dropped. The minimum fluid level is determined by the line on the surge tank indicated by the letters “MIN”. This indicator is located below the fill cap. The cooling system will need fluid if the surge tank level does not rise to the “MIN” line regardless if the system is hot or cold. Refilling Your Radiator 1.
COOLING SYSTEM Engine (Block) Heater WARNING 5 Do not use the heater if there are any signs of problems. Engine block heaters can cause fires resulting in death, personal injury, equipment or property damage if not properly maintained and operated. Regularly inspect the engine block heater wiring and connector for damaged or frayed wires. Contact your authorized dealer or the manufacturer of the heater if you are in need of repairs or information.
ELECTRICAL ELECTRICAL Electrical System WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Low Voltage Disconnect (LVD) Purpose The LVD may increase battery life and prevent unnecessary jump start conditions by ensuring that an unattended load does not deplete the battery charge to a level that will prevent you from starting your vehicle.
ELECTRICAL WARNING Do not use the Spare Battery A & B circuits or other circuits that are controlled by the LVD to power electronic engine controls, ABS circuits, or safety/work-related lighting. Before adding any device to the vehicle's electrical system, consult your nearest authorized dealer or read the contents of TMC RP-136. Failure to do so may cause equipment damage or lead to personal injury.
ELECTRICAL Vocational - Headlight Replacement Turn the bulb lock ring counterclockwise and remove the bulb. Do not allow the glass of the new headlamp bulb to come into contact with anything. The glass could become contaminated and cause bulb failure. Reassemble in reverse order. Headlight Aiming Bulb Specifications The headlights were properly aimed at the factory to meet safety specifications. If the headlights need to be adjusted, please have an authorized dealership aim the headlights.
ELECTRICAL Fuses, Circuit Breakers and Relays Fuses, circuit breakers, and relays are located in the Power Distribution Box to the left of the steering column behind the clutch pedal. Additional fuses are located in the engine compartment (drivers side bulkhead) and also in the sleeper under bunk storage compartment.
ELECTRICAL 5 Engine Area Fuse Label 5-79
ELECTRICAL 5 In-Cab Fuse Label 5-80
ELECTRICAL 5 Sleeper Fuse Label 5-81
ELECTRICAL Fuse Inspection and Replacement If a fuse is blown, see What to do if fuse or relay blows on page 2-6 for more information. Adding Electrical Options WARNING Do not add a fuse with a rating higher than 30 amps. Follow the circuit protection size/type recommended by the component manufacturer. Installing a fuse or circuit breaker greater than designated may damage the electrical system which could lead to equipment damage and/or personal injury.
ELECTRICAL NOTE WARNING If you are unfamiliar with proper electrical repair practices and procedures, see your authorized dealer for assistance. Never install a circuit breaker in a circuit that is designated as “fuseonly” circuit(s). Fuse-only circuits are marked with an * on the reverse side of the Power Distribution Box cover. Using a circuit breaker in those fuse-only circuits may cause the circuit to overheat when a short exists which could lead to equipment damage and/or personal injury.
ELECTRICAL In-Cab Battery Box Your vehicle may be equipped with Absorbed Glass Mat (AGM) batteries located in the cab under the passenger’s seat. The glass mat in AGM batteries are designed to absorb the battery acid inside the battery that can leak or spill out in conventional batteries. This design feature allows batteries to be positioned in any orientation without risk of leaking. To access the batteries: 1. Remove 6 fasteners securing the passenger side seat base to the battery box assembly. 2.
ELECTRICAL WARNING CAUTION Batteries release gases that are flammable. Batteries are equipped with vent tubes and flash arrestors which vent battery gases out of the cab. Ensure all vent tubes, flash arrestors and grommets are properly installed and ensure they are clear and functioning properly. Failure to reinstall or keep the vent tubes and grommets clear or ensure the flash arrestor(s) are functioning properly could result in personal injury or equipment damage.
ELECTRICAL NOTE Make sure to reconnect the ground (negative) cable last. 1. Place batteries in vehicle and tighten bolt of holding plate. 2. Reconnect positive cable. 3. Reconnect ground (negative) ground cable. Replacing Parts Removed for Access 1. Replace battery cover. 2. Install 2 bolts in step strut. Torque to 24-32 lb-ft (33-43 Nm). 3. Install fairing and install 4 bolts. Torque to 6-7 lb-ft (8-9 Nm). 4. Install steps by installing 2 bolts in each step. Torque to 24-32 lb-ft (33-43 Nm).
ELECTRICAL Battery Care Regular attention to the charging system will help prolong the service life of the batteries. Here are some common causes of battery failure: Dirty or Loose Connections: improper connections may stop the flow of electrical power to and from the battery. Battery Charging Except for using small trickle charges to maintain battery condition, you should have your vehicle's batteries charged by a qualified service facility.
ELECTRICAL disconnect the battery negative cable. • Allow no sparks or open flame anywhere near the charging area. • Charge a battery only in a well-ventilated area, such as outdoors or in a fully open garage which contains no pilot lights or other flames. Gases generated during the charging process must be allowed to escape. • 5 • Always make sure the battery charger is OFF before connecting or disconnecting the cable clamps.
ELECTRICAL as relays, radio, etc., as well as the battery charger. Fast charging a battery is dangerous and should only be attempted by a competent mechanic with the proper equipment. Slow Battery Charging WARNING 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.
ELECTRICAL Electrical and Alternator Precautions • Take the following precautions to avoid burning out alternator diodes: • Do not reverse the cables of the alternator, starter motor, or battery. • Do not polarize the alternator. The alternator should not be polarized like a generator. To ensure correct polarity, use a test lamp or a voltmeter. • • 5 Do not start the engine with alternator disconnected (connections removed) from the circuit.
ENGINE ENGINE Engine Maintenance WARNING Exhaust fumes from the engine contain carbon monoxide, a colorless and odor less gas. Do not breathe the engine exhaust gas. A poorly maintained, damaged or corroded exhaust system can allow carbon monoxide to enter the cab. Entry of carbon monoxide into the cab is also possible from other vehicles nearby. Failure to properly maintain your vehicle could cause carbon monoxide to enter the cab and cause death or personal injury.
ENGINE Engine Lubrication Refer to the engine manufacturer's Engine Operation and Maintenance Manual supplied with your vehicle for information about draining and refilling engine oil, engine crank case capacity, engine oil type, and changing oil filters, etc. WARNING 5 Hot engine oil can be dangerous. You could be burned. Let the engine oil cool down before changing it. Failure to comply may result in death, personal injury, equipment or property damage. 5-92 Inspection of the Engine Oil Level 1.
ENGINE 7. Reinstall the dipstick and twist to lock it in place. 1. 2. Topping Up the Engine Oil Pipe and Hose Clamps 1. Top up with oil, if necessary, via the filler opening. Use the correct grade in the correct quantity. For oil replacement, please see engine Operator’s Manual included with this chassis. Use the following table for torque specifications to check pipe and hose clamps. 2. After topping up, wait 1 minute and check the oil level again. 3.
ENGINE Pipe and Hose Clamp Torque Values APPLICATION Radiator & Heat Exchanger Hoses Heater Hoses Air Intake Pipes Charge Air Intake Hoses Fuel, Oil & Water Heat Exchangers (for hoses less than 9/16 diameter) Exhaust Clamps 5 5-94 APPROVED CLAMP Constant-Torque CT-L Constant Tension Hi-Torque HTM-L Flex Seal 667 B9296 Miniature 3600L Breeze V-Band TORQUE Nm 10.2-12.5 not required 11.3-14.2 7.9-11.3 6-7 1.1-1.
ENGINE Accessory Drive Belts 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. So it's a very good idea to check your belts frequently and replace them as soon as you detect trouble. 2. Slip the belt around the idler pulley attached to the automatic tensioner. 3.
ENGINE Engine Fan WARNING Do not work on the fan with the engine running. The engine fan can engage at any time without warning. Before turning on the ignition, be sure that no one is near the fan. Failure to comply may result in death or personal injury. Your truck may be equipped with an On/Off or Viscous Fan Drive. Follow these guidelines to check your engine fan: 5 Check the fan bearings for fan hub bearing looseness, loss of lubricant and any abnormal conditions.
ENGINE Air Intake System Turbocharger CAUTION Engine heat, vibration, and age combine to loosen air intake connections and cause cracks in the tubing and elbows. Leaks in the intake system allow abrasive dust to enter the engine and quickly cause expensive damage. During your daily walk-around inspection, carefully check all tubing, elbows, clamps, supports and fasteners for condition and tightness. • Check the Charge-Air-Cooler for air leaks annually.
ENGINE High Frequency Vibration: Vibration may indicate turbo rotor imbalance. Have your dealer investigate this immediately. If you detect any deficiencies, take the vehicle to an authorized dealer for servicing. Delay could lead to severe and expensive damage to your vehicle. Air Cleaners The following service information is basic to all air cleaner makes and models.
ENGINE Replacing the Engine Air Intake Filter 1. Open hood. 2. Loosen a total of 4 screws. (screws will not come out of the housing) 3. Remove lid. 4. Remove filter. Filter Minder Exhaust System The exhaust system is part of the noise and emission control system. Periodically check the exhaust for wear, exhaust leaks, and loose or missing parts. For details see Noise and Emission Control on page 5-115.
FUEL SYSTEM FUEL SYSTEM Specification Fuel Filters Location of Fuel Shut-off Valves Use only diesel fuel as recommended by engine manufacturers. Please follow these recommendations when you are changing your fuel filters or strainer elements. Your engine will run better and last longer if you do. See the engine manufacturer’s recommendations for proper water and micron requirements.
FUEL SYSTEM NOTE To expel air from density-type strainer elements, soak them in clean fuel before installing them. • When replacing a fuel filter element, don’t use a substitute. Install only filter elements designed for fuel filtration. First clean and inspect the shell. Then insert the new element and fill the container at least 2/3 full of clean fuel before installing the shell. • Throw away old gaskets. Replace them with new ones to ensure a positive seal. • Position the shell and gasket properly.
FRAME FRAME Emergency Welding Introduction WARNING Do not cut, splice or weld frame rails or drill through the top or bottom flanges of the rails. These operations could affect frame rail strength leading to a failure resulting in an accident. Rail failures resulting from such modifications are not warrantable. Failure to comply may result in death, personal injury, equipment or property damage. WARNING Frame welding is NOT recommended.
FRAME weld point as possible. This ensures maximum weld current and minimum risk to damage of electrical components on the vehicle. Painting Fifth Wheel Maintenance Do not electrostatically paint your truck or any component on your truck without first removing all of the electronic components from the truck.
FRAME Every 60,000 miles or 6 months: 5 • Refer to specific manufacturer's literature for any special instructions. • Remove fifth wheel from vehicle. Refer to the Shop Manual, “Fifth Wheel Removal.” • Steam clean the fifth wheel and mounting brackets. • Check all moving parts for excessive wear or damage. Replace all worn or broken parts. • Complete two-month service procedure. • Install fifth wheel. Refer to the Shop Manual, “Fifth Wheel Installation.
FRAME Sliding Fifth Wheels Lubricate bearing surface of support bracket through the grease fittings on the side of the fifth wheel plate. Use a water resistant lithium-base grease. NOTE The plate must be lifted up slightly to relieve the weight of the bracket while applying grease.
FRONT AXLE AND SUSPENSION FRONT AXLE AND SUSPENSION Axle Lubrication Change bearing lubrication when seals are replaced, or brakes are relined. See Preventive Maintenance Schedule on page 5-12. 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. 5 Kingpin Lubrication Suspension Lubrication Lubricate with approved lubricant.
FRONT AXLE AND SUSPENSION Inspection Wheel Alignment 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.
FRONT AXLE AND SUSPENSION U-Bolt Torque It is important that U-bolts remain tight. Severe use of your vehicle will 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 vehicle. New springs can settle in after service, relieving the tension on the U-bolts. Loose U-bolts can cause leaf spring breakage, axle misalignment, hard steering and abnormal tire wear.
FRONT AXLE AND SUSPENSION Front Spring Suspension U-Bolts, Grade 8 U-BOLT SIZE DIAMETER (Inch Dimensions) 3/4 7/8 1 1-1/8 1-1/4 1-1/2 TORQUE Nm Lb-Ft 333-408 598-734 925-1,060 1,470-1,660 1,890-2,120 3,130-3,860 245-300 440-540 680-780 1,080-1,220 1,390-1,560 2,300-2,840 5 5-109
HEATER AND AIR CONDITIONER HEATER AND AIR CONDITIONER Introduction The combination heater-air conditioner provides comfort for those in the cab through accurate control of the cab environment in all weather conditions. Regular attention to the items below will help you keep the heater-air conditioner unit running well. 5 Keep the vehicle's ventilation system, engine exhaust system and cab joints properly maintained.
HEATER AND AIR CONDITIONER open flame, hazardous gases may be generated. If you become aware of a refrigerant leak on your vehicle have your system serviced immediately and observe the following precautions: 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 the side of the filter element with the airflow direction that is clearly marked on the air intake housing. 6. 5 7. Replace the filter cover on the air intake housing and slide the cover forward in vehicle. An audible snap sound can be heard when the cover is correctly in place. If the snap feature is damaged there are two screw features that may be utilized to retain the cover in place. Close and secure hood of vehicle.
HEATER AND AIR CONDITIONER element such that it points into the HVAC housing. will allow the filter to be removed in an upward direction. 4. 5. Insert the filter and make sure the retention tab has re-engaged to secure the filter. Close the bunk. Heater • Check all heater controls for full-range operation. • Check hoses, connections, and heater core for condition and leaks. CAUTION During extreme cold weather, do not blow hot defroster air onto cold windshields. This could crack the glass.
HEATER AND AIR CONDITIONER Air Conditioner necessary. Small particles may be removed with compressed air blown through the core in the opposite direction of normal air flow. WARNING The air conditioning system is under pressure. If not handled properly during servicing, it could explode. Any servicing that requires depressurizing and recharging the air conditioning system must be conducted by a qualified technician with the right facilities to do the job.
NOISE AND EMISSION CONTROL NOISE AND EMISSION CONTROL Tampering with Noise Control System Noise Emission Warranty Federal law prohibits the following acts or the causing thereof: There are specific components on the vehicle that are designed to meet certain EPA emissions and noise regulations. To maintain conformance with the regulations, these components need to be functional and properly maintained.
NOISE AND EMISSION CONTROL Air Intake System Fuel System • • Removing or rendering inoperative the air cleaner/silencers or intake piping. Engine Cooling System • Removing or rendering inoperative the fan clutch. • Removing the fan shroud. • Removing of air signal attenuator on engines equipped with this device. • Removing of diesel exhaust fluid tank and system.
NOISE AND EMISSION CONTROL Inspection and Maintenance Instructions The following instructions are based on inspection of the noise control system at regular intervals as indicated in the Noise Control System Maintenance Log on page 5-123. If, during periodic inspection and maintenance of other systems and components, it is found that parts of the noise control system require attention, we recommend that those parts be inspected at more frequent intervals to assure adequate maintenance and performance.
NOISE AND EMISSION CONTROL Exhaust System Joints and Clamps • Check for exhaust leaks, which would indicate a leaking manifold gasket; replace gasket if necessary. • Check cap screws for tightness, including those at the flanges. Refer to the engine manufacturer's service manual for proper tightening sequence and torque values. • • 5 5-118 Check for leaks, and tighten as necessary. Check for deterioration or dents in pipes and clamps which could allow exhaust to escape.
NOISE AND EMISSION CONTROL Piping • 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. Diesel Particulate Filters (DPF) • Check diesel particulate filter (DPF), clamps, and mounting brackets. Tighten if necessary.
NOISE AND EMISSION CONTROL steps to replace the DEF supply pump filter: 1. Turn off the vehicle and allow the vehicle to cool down. Take special precaution with hot exhaust piping. WARNING The exhaust piping can become extremely hot during engine operation and can cause personal injury including serious burns to the skin. Allow adequate cooling time before working near any part of the exhaust system. 5 2. Remove the pump protective plate mounted on the bottom of the DEF tank. 5-120 3.
NOISE AND EMISSION CONTROL Exhaust Tail Pipe • Engine Fan and Shroud Check the mounting. Tighten as necessary. The miter cut at the tip of the pipe must be facing the rear of the vehicle. Do not modify the end of the pipe in any way. WARNING Do not work on the fan with the engine running. The engine fan can engage at any time without warning. Anyone near the fan when it turns on could be injured. Before turning on the ignition, be sure that no one is near the fan. • Check all fasteners for tightness.
NOISE AND EMISSION CONTROL Inner Fender Shields and Cab Skirts Noise Control System Maintenance Log • Check all fasteners that hold the fender shields in place. • Check fender shields for tire marks, worn spots, or damage from objects thrown from tire treads. To ensure your vehicles noise control requirements are maintained, record maintenance checks. Use the following log sheet and retain copies of documents regarding maintenance services performed and parts replaced on the vehicle.
NOISE AND EMISSION CONTROL Noise Control System - Maintenance Log Recommended Interval (Miles) 25,000 Exhaust System Routing Integrity 25,000 Shutters Shrouds Hood Insulation 10,000 Blanket Engine Mounted 10,000 Hose Insulators Fasteners Inner Fender 50,000 Shields 50,000 Cab Skirts Fasteners 5,000 Air Intake System Integrity Element 10,000 Clutch Type Fan Drive Component Date & R.O. No. Repair Facility WorkPerformed & Location Date & R.O. No.
REAR AXLE AND SUSPENSION REAR AXLE AND SUSPENSION General Maintenance WARNING Do not work on the vehicle without the parking brake set and wheels blocked securely. If the vehicle is not secured to prevent uncontrolled vehicle movement, it could roll and may result in death, personal injury, equipment or property damage. 5 Your vehicle's suspension, by design, requires a minimal amount of maintenance.
REAR AXLE AND SUSPENSION Visual Inspection NOTE Failure to follow recommendations could warranty. these void For all vehicles, mandatory maintenance procedures include retightening of U-bolts and complete inspection. However, even with proper maintenance, many factors affect the service life of springs and suspension components, such as: fatigue, vehicle gross weight, type of load, road conditions and vehicle speed. It is important that U-bolts remain tight.
REAR AXLE AND SUSPENSION Rear Suspension Fasteners U-Bolt Torque NOTE To maintain the performance of the air suspension, check fastener torque values after the first 2,000 miles (3,218 km) of service and every 60,000 miles (96,000 km) thereafter. Torque recommendations apply to fasteners supplied and installed by vehicle manufacture. The values listed in the tables below, are for cadmium plated or phosphate and oil fasteners only. 5 U-bolts are difficult to tighten unless you have the right equipment.
REAR AXLE AND SUSPENSION Rear Suspension U-Bolts, Grade 8 (lubricated*) U-BOLT SIZE TORQUE** DIAMETER Nm Lb-Ft THREAD 333-408 245-300 3/4 598-734 440-540 7/8 1 925-1,060 680-780 1,470-1,660 1,080-1,220 1-1/8 1,890-2,120 1,390-1,560 1-1/4 3,130-3,860 2,300-2,840 1-1/2 *Chevron Zinc Lubricant or SAE 20/30 oil should be used on U-Bolt threads **Torque requirements apply to manufacturer proprietary suspensions. All other suspensions must refer and adhere to original manufacturers shop manual.
REAR AXLE AND SUSPENSION Dana Spicer and Fabco CAUTION Do not mix lubricants of different grades; although, mixing different brands of the same grade lubricant (meeting MIL L2105C), is acceptable. Lubricants of different grades are not compatible and could damage the axle. No initial drain is required on Dana Spicer axles that are factory filled with an Dana Spicer-approved synthetic lubricant. All Vehicles with Dana Spicer and Fabco Axles: See Preventive Maintenance Schedule on page 5-12.
REAR AXLE AND SUSPENSION Rear Axle Alignment 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. If you suspect rapid tire wear, have your rear axle alignment checked and adjusted by an authorized dealer. In addition to pre-delivery inspections, suspension alignment should be checked when any one of the following conditions exist: • Discovery of loose suspension fasteners.
STEERING SYSTEM STEERING SYSTEM WARNING Power Steering Do not operate the vehicle if the steering system is not working properly. You could lose control of your vehicle if the steering system is not in good working condition, which could result in a serious accident. For driving safety, visually check the steering gear and components. Frequent checks are important for driving safety, especially after traveling over rough roads.
STEERING SYSTEM • Draglink tube clamp: Check for looseness or interference. • Ball joints and steering U-joints: Check for looseness. • Steering wheel for excessive free-play. Check the simplest probable causes first: • Fluid Level and Refill • Maximum/Minimum level is indicated on the reservoir. These same levels are also indicated by two lines on the dipstick in the reservoir. • There are two ways to check whether the power steering fluid is at its proper level.
STEERING SYSTEM between the Maximum and Minimum level indicators. Fluid Filter Replacement Steering Shaft The following are common torque specifications for most steering shafts. CAUTION 5 Servicing the power steering system without bleeding it of trapped air may cause damage to the power steering pump. 5-132 1. Replace both fluid and filter as per the chart below. 2. Bleed the system if necessary. • Torque on U–joint pinch bolt and nut (7/16 in) 74–81 Nm (55 to 60 lb-ft), lubricated.
STEERING SYSTEM WARNING If this chassis is equipped with an electronic stability system (ESP) and any part of the steering system (e.g. linkage, steering driveline, column, front-end alignment, etc) is repaired, removed, or disassembled in any way, or if the steering angle sensor is replaced, the steering angle sensor must be recalibrated. Any repairs or adjustments to any part of the steering system must be performed by an authorized dealer.
DRIVELINE DRIVELINE U-Joints Driveshaft Maintenance The slip joints and universal joints of the driveshaft should be lubricated periodically. Use a good quality lithium-soap-base or equivalent extreme pressure (E.P.) grease: NLGI Grade 2. 5 Dana SPL U-joints and driveshafts should be inspected every time a vehicle comes in for scheduled maintenance (Refer to Spicer Driveshaft service manual DSSM-0100 (3264-SPL) for detailed instructions).
TIRES AND WHEEL TIRES AND WHEEL Tires WARNING Do not repair damaged tires unless you are fully qualified and equipped to do so. Wheel and tire assemblies cannot be worked on without proper tools and equipment, such as: safety cages or restraining devices. Have all tire repairs performed by an expert. Stand away from the tire assembly while the expert is working. Failure to do this may result in death or injury. Your tires are a very important part of your vehicle’s whole braking system.
TIRES AND WHEEL Underinflated Tires Low pressure is a tire’s worst enemy. Underinflation allows tires to flex improperly, causing high temperatures to build up. Heat causes early tire damage such as flex break, radial cracks, and ply separation. Low pressure may affect control of your vehicle, especially at the front wheels. Most tire wear problems are caused by underinflation as the result of slow leaks, so you’ll want to check tire pressure regularly.
TIRES AND WHEEL Overloaded tires 1 3 Proper-Inflation: the correct profile for full contact with the road. TREAD CONTACT WITH ROAD TREAD CONTACT WITH ROAD 2 Over-Inflation: reduces the tread contact area with the road surface, concentrating all of the vehicle weight on the center of the tread. This causes premature wear of the tire. Overloading your truck is as damaging to your tires as underinflation. The following chart shows how neglect or deliberate abuse can affect the life of your tires.
TIRES AND WHEEL Matching tires WARNING Overinflated tires can cause accidents. They wear more quickly than properly inflated tires and are more subject to punctures, cracks, and other damage. They could fail and cause you to lose control of your vehicle resulting in an accident causing death or personal injury. Be sure all tires are inflated correctly according to the manufacturer's recommendations. 5 5-138 WARNING Be sure to buy matched tires for your vehicle, especially on the rear axles.
TIRES AND WHEEL Replacing Tires Front: Replace front tires when less than 4/32 in. of tread remains. Check at three places equally spaced around the tire. Drive Axles or Trailers: Replace tires on drive axles or trailers when less than 2/32 in. of tread depth remains in any major groove. Check at three places equally spaced around the tire. See the next illustration for recommended measuring points for tread depth.
TIRES AND WHEEL Speed Restricted Tires WARNING This vehicle may be equipped with speed restricted tires. Check each tire’s sidewall for maximum rated speed. The 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 death, personal injury or property damage.
TIRES AND WHEEL WHEEL & NUT CONFIGURATION STUD SIZE Heavy-Duty Steel Disc-Type Wheel; Double Cap Nut Mounting; 1-3/16 Radius Ball Seat: Hub-Piloted Disc-Type Wheel w/Two Piece Flanged Cap Nuts: Steel or Aluminum Wheel PHP-10; Budd Uni-Mount-10; WDH-8 Stud Backnuts (when used) 15/16-12 1-1/8-16 1-15/16-12 M22-1.5 TORQUE FOR INNER & OUTER CAP NUTS & RIM CLAMP NUTS Nm Lb-Ft 1,020-1,220 750-900 1,020-1,220 750-900 1,020-1,220 750-900 610-680 450-500 3/4-16 1-14 240-270 240-410 1/2” Dia. 5/8” Dia.
TIRES AND WHEEL Wheel Replacement With Disc Brake Option WARNING Tighten wheel cap nuts properly. If they are not tightened properly, wheel nuts could eventually cause the wheel to become loose, to fail, and/or to come off while the vehicle is moving, possibly causing loss of control and may result in death, personal injury, equipment or property damage.
TIRES AND WHEEL with the disc brake assembly. When installing any replacement wheel, always inspect the tires/wheels to ensure there is adequate clearance between other vehicle components. With the hood open, check for clearance between the wheel and disc brake assembly. Use a hydraulic jack to raise the front of the vehicle off the ground to allow the wheel to spin freely.
TIRES AND WHEEL Disc Wheels WARNING Use the correct components and tools when working on wheels. Grooves in the wheel disc or other damage to the disc can weaken the wheel and cause it to eventually come off. This could cause you to lose control of your vehicle, and may result in an accident. Failure to comply may result in death, personal injury, equipment or property damage. 5 The end of the wheel wrench must be smooth. Burrs on the end of the wrench can tear grooves in the disc.
WHEEL BEARING WHEEL BEARING Wheel Bearing Adjustment For safe, reliable operation and adequate service life, your wheel bearings must be adjusted properly at the recommended intervals. Contact your authorized dealer to make sure the wheel bearings are properly adjusted.
TRANSMISSION MAINTENANCE TRANSMISSION MAINTENANCE Introduction Proper maintenance of the transmission will ensure that the vehicle will operate efficiently. 5 To check the transmission fluid level, park the vehicle on a level ground. For an automatic transmission the oil level should be checked with the engine idling and the transmission fluid at operating temperature. Checking the fluid of a manual transmission may be done with the engine off.
TRANSMISSION MAINTENANCE Transmission Lubricants Manual Transmission Manual transmissions are designed so that the internal parts operate in a bath of oil circulated by the motion of gears and shafts. Service Intervals For recommended types and brands of all lubricants, see the transmission manufacturer's Service Manual and Preventive Maintenance Schedule on page 5-12. Check all hoses for kinks, deterioration, chafing, and leaks.
TRANSMISSION MAINTENANCE Automatic Transmissions Service Intervals Check daily with engine idling. See Preventive Maintenance Schedule on page 5-12 for service intervals. Automatic Transmission Oil Level NOTE The vehicle must be parked on level ground. See the Transmission Operator's Manual for information on checking the transmission oil level.
CLUTCH CLUTCH Clutch Hydraulic Fluid Introduction Visually inspect the clutch fluid from the reservoir. There are molded lines with the letters MIN to indicate minimum fluid level and MAX to indicate the maximum fluid level recommended for proper operation. Be sure to maintain the fluid between the MIN and MAX levels indicated on the plastic reservoir. If the fluid level repeatedly goes below the MIN line, then it is time to have your clutch adjusted or the hydraulic system to be inspected for service.
CLUTCH Clutch Adjustment Some clutches are self-adjusting however; there are manually adjusted clutches that will require the operator to know when to adjust the clutch. The clutch will need adjustment when your clutch pedal stroke seems to get longer and its effectiveness at a seamless shift becomes less. 5 Another sign of the clutch needing adjustment is the level of the fluid in the reservoir.
INFORMATION CONSUMER INFORMATION AND VEHICLE IDENTIFICATION Vehicle Identification . . . . . . . . . . . . . . General VIN Information . . . . . . . . . . . . . Component Identification. . . . . . . . . . . . . 6-3 6-3 6-6 CONSUMER INFORMATION Federal Safety Standard Certification Label How to Order Parts . . . . . . . . . . . NHTSA Consumer Information . . . . . . Canadian Consumer Information . . . . . . . . . . . . . . . . . . . . .
CONSUMER INFORMATION AND VEHICLE IDENTIFICATION CONSUMER INFORMATION AND VEHICLE IDENTIFICATION Vehicle Identification Each vehicle completed by Peterbilt Motors Company uses a Vehicle Identification Number (VIN) that contains the model year designation of your Peterbilt. The practice is in compliance with 49 CFR 565, Code of Federal Regulations. The Vehicle Identification Number is on the Peterbilt labels on the left hand door post. The VIN contains 17 digits.
CONSUMER INFORMATION AND VEHICLE IDENTIFICATION Chassis Number Certification Labels The Chassis Number refers to the last six characters of the VIN. This number will allow your dealer to identify your vehicle. You will be asked for this number when you bring it in for service. Your vehicle information and specifications are documented on labels. As noted below, each label contains specific information pertaining to vehicle capacities and specifications that you should be aware of.
CONSUMER INFORMATION AND VEHICLE IDENTIFICATION Tire and Rim Data Label The Tire, Rim and Weight Rating Data Label is located on the driver’s side door edge or on the driver’s side door frame.
CONSUMER INFORMATION AND VEHICLE IDENTIFICATION Paint Identification Label The Paint Identification Label contains the paint colors used by the factory to paint your vehicle. It lists frame, wheels, cab interior and exterior colors. This label is located inside the glove box. Federal Safety Standard Certification Label The NHTSA regulations require a label certifying compliance with Federal Safety Standards, for United States and U.S.
CONSUMER INFORMATION AND VEHICLE IDENTIFICATION 1. Axle Specification Number, usually stamped on the right rear side of the axle housing. This number identifies the complete axle. 2. Axle Housing Number Tag, usually located on the left forward side of the housing arm. This tag identifies the axle housing. 3. Axle Differential Carrier Identification, usually located on the top side of the differential carrier. The following information is either stamped, or marked with a metal tag: Model No.
CONSUMER INFORMATION CONSUMER INFORMATION Federal Safety Standard Certification Label The National Highway Traffic Safety Administration regulations require a label certifying compliance with Federal Safety Standards, 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 left hand cab door post.
CONSUMER INFORMATION www @ Toll Free 888-327-4236 (800-4249153 TTY) 8:00 am to 10:00 pm ET Monday-Friday Office of Defects Investigations/CRD NVS-216 1200 New Jersey Ave SE. Washington, D.C. 20590 www.safercar.gov nhtsa.webmaster@dot.
Index Index 5th wheel maintenance 5-103 A Accessories cigarette lighter 3-88 radio 3-88 Adding electrical options 5-82 Additional sources of information 1-9 California proposition 65 warning 1-7 data recorder 1-7 installed equipment - operator's manuals 1-9 other sources 1-10 Adjustable auxiliary axles 4-44 liftable/non-steerable pusher calibration 4-47 liftable/steerable calibration 4-47 tag axle calibration 4-47 Aero Hood - Headlight replacement 5-76 After-treatment system introduction 4-55 Air compres
Index Anti-lock brakes (ABS) electronic stability program (ESP) 4-25 roll stability program (RSP) 4-25 Appliances 3-89 Automatic transmissions oil level 5-148 service intervals 5-148 Auxiliary axles 4-44 B 7 Batteries battery access 5-83 battery care 5-87 battery charging 5-87 jump starting vehicles 2-8 removing and installing batteries 5-85 Brake gauges tractor air brake pressure 3-47 tractor primary/secondary air brake pressure 3-12 trailer air brake pressure 3-47 trailer air tank pressure 3-48 Brake s
Index Data recorder 1-7 Daytime running light (DRL) 3-63 Deck plate access 1-14 DEF filter 5-119 Diesel Exhaust Fluid Tank 5-119 Displays/menu screens clock display 3-27 driver information display 3-20 fuel economy 3-24 ignition timer 3-23 settings 3-27 to set time 3-28 trip information 3-24 truck information 3-25 virtual gauges 3-23 warning and faults 3-26 Door lock 1-12 key fob synchronization 1-14 remote keyless entry (RKE) system 1-13 Drive axles identification 6-6 Driver information display 3-14 fuel e
Index Engine maintenance 5-91 Engine operation engine block heater 4-6 engine control display 4-13 engine cool down 4-64 engine fan control 4-11 winterfronts 4-12 F Fifth wheel maintenance 5-103 Filter Minder 5-99 Frame fastener torque requirements 5-104 Front axle and suspension maintenance 5-106 Fuel gauges fuel filter restriction 3-44 fuel tank(s) level 3-10 Fuel shut-off valve 4-65 Fuel specification 4-64 Fuel system fuel filters 5-100 shut-off valves 5-100 7 Index-4 Fuses, circuit breakers and relay
Index H Headlight aiming 5-77 Headlight switch 3-64 Heater and air conditioner 5-110 air conditioner 5-114 heater 5-113 Heater and air conditioner maintenance 5-110 Heating and air conditioning air flow control dial 3-84 cooling 3-85 defrost vents 3-84 dehumidify 3-86 fan control dial 3-84 floor and defrost vents 3-84 floor vents 3-84 fresh air/recirculation switch 3-84 heating 3-86 instrument panel and de-mister vents 3-84 instrument panel, de-mister and floor vents 3-84 sleeper heater - A/C controls 3-87
Index 7 clutch 5-149 cooling system 5-70 driver's check list 1-34 Eaton/Dana axle lubrication 5-44 electrical system 5-75 emergency welding 5-102 engine 5-91 exterior 5-61 frame fastener torque requirements 5-104 frame fastener torque table 5-104 front axle and suspension lubrication 5-106 fuel system 5-100 Fuller transmission lubrication 5-39 heater 5-113 inspection 5-107 lubricant specifications 5-33 maintenance schedule 5-12 Meritor axle lubrication 5-43 noise and emission control standards 5-115 oil c
Index engine fan and shroud 5-121 engine mounted noise insulators 5-117 exhaust system 5-118 exhaust tail pipe 5-121 hood insulation blanket 5-121 inner fender shields and cab skirt 5-122 joints and clamps 5-118 maintenance log 5-122 piping 5-119 O Oil changes 5-42 Oil gauges auxiliary transmission oil temperature 3-48 engine oil pressure 3-11, 3-44 engine oil temperature 3-45 transfer case oil temperature 3-48 transmission retarder oil temperature 3-49 Operating procedure automatic and automated transmiss
Index 7 driver's seat with air suspension 1-21 reclining seats 1-21 standard driver's seat 1-20 Seat belts 1-20 adjustments 1-20 belt damage and repair 1-26 during pregnancy 1-25 Komfort-Lok feature 1-24 lap/shoulder belt 1-22 safety restraint tips 1-29 Seats adjustments 1-20 Komfort-Lok feature 1-24 tether belts 1-23 To adjust an external tether belt 1-24 Seats and restraints 1-20 Shut-down fuel specification 4-65 location of fuel shut-off valves 4-65 refueling 4-64 sleeper bunk 4-62 Sleeper bunk 4-62 sl
Index dump truck gate switch 3-52 engine fan override switch 3-52 engine fan switch 4-11 engine heater switch 3-52 exterior lights self test switch 3-54 fifth wheel slide switch 3-53 flood light switch 3-54 fog light switch 3-55 forward power take-off (PTO) switch 3-56 forward trailer axle lift switch 3-58 fresh air/recirculation switch 3-84 fuel heater switch 3-53 hazard light switch 3-55 headlight switch 3-55 ignition key 3-54 ignition key switch 3-62 low voltage disconnect (LVD) 3-51 marker light switch
Index tire chains 5-139 Tires and wheels wheel cap nut torque sequence 5-141 wheel cap nut torque table 5-140 wheel mounting and fastening 5-140 Transmission identification 6-6 lubricants 5-147 maintenance 5-146 oil change 5-146 shifting gears in a new vehicle 4-16 transmission tips 4-19 Transmission maintenance 5-146 Transmission temperature gauges auxiliary transmission oil temperature 3-48 Transmissions automatic and automated 4-18 auxiliary transmission 4-19 transmission retarder 4-33 Turbocharger 5-97
Index engine, stop engine 3-40 engine, wait to start 3-41 lane departure warning (LDW) 3-41 lights, high beam 3-41 malfunction indicator lamp 3-40 park brake 3-38 power take-off (PTO) 3-41 power take-off (PTO), pump mode 3-41 rationality check 3-38 refrigerator 3-41 seat belt, fasten 3-42 service transmission 3-42 suspension dump 3-42 tire inflation 3-42 transhigh 3-42 transmission, auxiliary 3-42 transmission, check 3-42 turn signal, left 3-42 turn signal, right 3-42 water in fuel (WIF) 3-41 wheel spin con
