MODEL 270 OPERATOR’S MANUAL
California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Other chemicals in this vehicle are also known to the State of California to cause cancer, birth defects, or other reproductive harm. Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
PB1340A.book Page i Friday, September 1, 2000 7:40 AM Foreword FOREWORD How to use this handbook This handbook contains information for you, the driver, to enable you to operate the vehicle as efficiently and safely as possible and generally to make your driving easier and more satisfying. Besides subjects such as operating instructions, attention also focuses on maintenance and minor repairs which you may be able to carry out yourself.
PB1340A.book Page ii Friday, September 1, 2000 7:40 AM Foreword help you avoid injury to yourself, your passengers, and help prevent costly damage to the vehicle. Key symbols and “signal words” are used to indicate what kind of message is going to follow. Pay special attention to instructions preceded by symbols and signal words “WARNING”, “CAUTION”, or “NOTE”. Please do not ignore any of these alerts. © PACCAR Inc. 9/00 All rights reserved.
PB1340A.book Page iii Friday, September 1, 2000 7:40 AM Foreword WARNING CAUTION When you see this word, the message that follows is especially vital. It signals a potentially hazard ous situ at io n which, if not avoided, could result in death or serious injury. This message will tell you what the hazard is, what can happen if you don’t heed the warning, and how to avoid it. Example: WARNING! Never carry additional fuel containers in the vehicle.
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PB1340A.book Page v Friday, September 1, 2000 7:40 AM CONTENTS Foreword How to use this handbook................. i Safety Signals ................................... i Contents General Safety Precautions ..............................1 General ............................................ 1 Engine.............................................. 1 Cooling System................................ 1 Components..................................... 2 Electrical ..........................................
PB1340A.book Page vi Friday, September 1, 2000 7:40 AM Contents Windshield Washer Fluid Level ..... 56 Tires .............................................. 56 Driving General .............................................. 57 Ignition Switch .................................. 57 Starting Procedure ........................... 58 Operating the Transmission ............ 58 Introduction.................................... 58 Operating Manual Transmissions .. 59 Putting the Vehicle in Motion .........
PB1340A.book Page 1 Friday, September 1, 2000 7:40 AM Safety Precautions GENERAL Safety Precautions The following list of safety precautions against possible safet y haza rd s is not exhaustive and, therefore all s a f et y re l a t e d wo r ks h o p practices and precautions must be exercised. General Ensure all War nings and Cautions listed in this publication are strictly adhered to. Always read carefully the instructions printed on labels or stamped on components and obey them completely.
PB1340A.book Page 2 Friday, September 1, 2000 7:40 AM Safety Precautions General Components Electrical Ensure that all personnel are clear of any rotating parts or moving components. Batteries contain electrolyte (sulfuric acid) which is a highly corrosive and toxic substance. Accidental skin/eye contact with battery electrolyte can cause serious personal injury.
PB1340A.book Page 3 Friday, September 1, 2000 7:40 AM Safety Precautions steering lock or its wiring. Under no circumstances must the ignition switch be separated from the steering lock. Oils and Lubricants Many liquids and other substances used in commercial vehicles are highly toxic. These must not be consumed or inhaled and, as far as possible, must be kept from skin contact.
PB1340A.book Page 4 Friday, September 1, 2000 7:40 AM Safety Precautions • Disconnect all Electronic Control M odule (E CM ) co nnecto rs ( on electronic engines). • Do not use the ECM or engine ground stud for the ground of the welding probe. • Ensure that the ground connection for the welder is as close to the weld point as possible. This ensures maximum weld current and minimum risk to damage of electrical components on the vehicle.
PB1340A.book Page 5 Friday, September 1, 2000 7:40 AM Items of Special Importance Items of Special Importance To prevent damage to the vehicle, the following instructions must be strictly observed. Break-in The following “break-in” recommendations should be applied during the first 1,000 miles (1,600 km) of a new vehicle: • Do not operate at full engine power in any gear. • Do not allow the engine to labor in any gear.
PB1340A.book Page 6 Friday, September 1, 2000 7:40 AM Items of Special Importance • Before stopping the engine, allow it to idle for one to two minutes (particularly if the engine has been subjected to a high speed journey or high engine loadings). This procedure will ensure an adequate oil supply to the turbocharger bearings while the rotor assembly is cooling, thus improving the life span of the turbocharger bearings. • Any abnormal noises or vibrations from the turbocharger must be reported immediately.
PB1340A.book Page 7 Friday, September 1, 2000 7:40 AM Items of Special Importance • Ensure that all lights are switched off when not required. • Vehicles fitted with a liftgate: Avoid excessive and severe battery drain when operating the liftgate. Battery Charging WARNING! Battery posts, terminals and related accessories contain lead and lead com pounds, ch emicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
PB1340A.book Page 8 Friday, September 1, 2000 7:40 AM Items of Special Importance WARNING! Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces. Always wear eye protection. Batt ery acid that may spill during charging should be washed off with a solution of warm water and baking soda to neutralize the acid. If you accidentally get acid in your eyes or on your skin, immediately rinse with cold water for several minutes and call a doctor.
PB1340A.book Page 9 Friday, September 1, 2000 7:40 AM Items of Special Importance caps and cover the filler openings with a cloth before proceeding. After jump star ting the vehicle, dispose of the cloth. WAR NI NG! I f yo u d o n ot cover the filler openings on the battery, electrolyte could boil out of the openings and hurt someone or damage the vehicle . R eplace caps securely if the battery has the full level of electrolyte. If the electrolyte is low and no water is available, cover with a cloth.
PB1340A.book Page 10 Friday, September 1, 2000 7:40 AM Protecting the Environment Remove jumper cables: WARNING! Wh en disco nnecting jumper cables, make sure they do not get caught in any moving parts in the engine compartment. You could be seriously injured. • Reverse the above procedure exactly when removing the jumper cables.
PB1340A.book Page 11 Friday, September 1, 2000 7:40 AM Cleaning the Vehicle Cleaning the Vehicle Before cleaning the vehicle, check for evidence of leakage around the engine, axles, transmission, etc., because this will not be possible when carrying out service operations after the vehicle has been cleaned. When a high-pressure cleaner is used, take special note of the following points: • Ensure that all doors, windows, and cab grille are correctly closed. • Do not spray directly on seals.
PB1340A.book Page 12 Friday, September 1, 2000 7:40 AM Cleaning the Vehicle Cleaning the Cab The external paintwork of the cab is subject to attack by aggressive substances, the severity of which depends upon the specific transport role and operating conditions of the vehicle, for example salt scattered on icy roads, and air pollution. The paintwork must therefore be cleaned regularly.
PB1340A.book Page 13 Friday, September 1, 2000 7:40 AM Cab Getting to Know Your Vehicle GETTING TO KNOW YOUR VEHICLE Cab You could slip and fall if the steps are wet or icy, or if you step in fuel, oil, or grease. The equipment, controls, and switches within the cab may vary depending on the vehicle specification.
PB1340A.book Page 14 Friday, September 1, 2000 7:40 AM Cab Doors Do not drive the vehicle if the doors are not closed. To open the vent window: depress the sliding collar and push handle A downwards. To open the door: pull handle B upwards. – 14 – Getting to Know Your Vehicle To lock the door from the inside: depress button C. – Ensure that the area in front of the cab is clear. To open the door window: turn the window crank D. Both doors can be locked and unlocked from the outside with the key.
PB1340A.book Page 15 Friday, September 1, 2000 7:40 AM Cab Tilting • Ensure that all cab doors and cab grille are closed and secure. • Rotate the tilt pump spool valve pin (A) to the up position. • Using the pump handle from the tool kit, operate the hydraulic tilt pump until the cab attains its fully tilted position.
PB1340A.book Page 16 Friday, September 1, 2000 7:40 AM Cab Getting to Know Your Vehicle instrument panel. This war ning light must remain extinguished when the ignition is switched on. • Using a suitable implement inser ted into the slot provided, release the trim cover (1) and then extract it from its slotted location in the mirror head. Door Mirrors • As applicable, release/tighten the mirror head retaining bolt (2) to 11 lb. ft. (15 Nm).
PB1340A.book Page 17 Friday, September 1, 2000 7:40 AM Cab Getting to Know Your Vehicle ror arms to remain in position during normal conditions; this enables the mirror arms to be folded forward or rearward against the cab when maneuvering the vehicle in a confined space. WARNING! It is unsafe to drive without full visibility to the rear. Do not attempt to drive the vehicle with the mirror arms in the folded position.
PB1340A.book Page 18 Friday, September 1, 2000 7:40 AM Cab Getting to Know Your Vehicle and lift the seat cushion. When the seat cushion is fully upright, it will automatically lock in position; depress the lock control lever to release the seat cushion. Driver’s Seat (adjustable) The driver’s seat has the following adjustment modes: Fore/aft adjustment Pull up bar 1 and slide the seat to the required position.
PB1340A.book Page 19 Friday, September 1, 2000 7:40 AM Cab Getting to Know Your Vehicle WA R NI N G ! D o n o t d ri v e vehicle without your seat belt and your riders’ belt fastened. Riding w ithout a safety belt properly fastened can lead to increased injury or death in an emergency. Unb elted rid ers cou ld be thrown into the windshield or other parts of the cab or could be thrown out of the cab. They co uld strike another person. Injuries can be much worse when riders are unbelted.
PB1340A.book Page 20 Friday, September 1, 2000 7:40 AM Cab • Before securing a seat belt, ensure that the webbing is not twisted, looped or obstructed in any way that could impair the operating mechanism. • Optimal safety can be offered by a seat belt only when it is properly tightened. • Never have repairs or modifications made to the seat belts. • Replace the seat belt when the webbing is worn or damaged.
PB1340A.book Page 21 Friday, September 1, 2000 7:40 AM Cab Getting to Know Your Vehicle Storage Tray Glove Box Your truck may be equipped with a fixed storage tray. The storage tray is of a pre-formed construction incorporating storage bins and cup holders. All vehicles are equipped with a lockable glove box. NOTE: The “Operator’s Manual” is stored in the glove box. Keep this book in the cab at all times.
PB1340A.book Page 22 Friday, September 1, 2000 7:40 AM Cab Sun Visors The cab is fitted with 3 sun visors which are provided for the driver and passenger. The sun visors can be swung down to block the sun.
PB1340A.book Page 23 Friday, September 1, 2000 7:40 AM Cab Getting to Know Your Vehicle The cour tesy light switch has three positions: Position A: the light will only illuminate when the door is opened. Position B: light is switched off. Position C: light is on permanently. Roof Vent (option) Rotate the control knob (A) to open and raise the roof vent to the required position. Courtesy Lights All cabs are equipped with two courtesy lights which are fitted in the cab roof lining above each door.
PB1340A.book Page 24 Friday, September 1, 2000 7:40 AM Cab Getting to Know Your Vehicle Courtesy interior light The cour tesy interior light switch (1) has three positions: Position A: light is switched off. Position B: light is switched off. Position C: light is switched on. A Interior Light Unit All cabs are equipped with an interior light unit which is fitted in the cab center roof panel.
PB1340A.book Page 25 Friday, September 1, 2000 7:40 AM Instruments and Controls cigarette lighter socket it is essential to ensure that: • only 12 volt (negative ground) electrical equipment is connected to the cigarette lighter power socket. • the power consumption of any electrical component does not exceed 10 amps. Instruments and Controls General Th e ins tr u men ts an d con tr ol s a re located on the instrument panel, center console, center roof console, and steering column.
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PB1340A.book Page 27 Friday, September 1, 2000 7:40 AM Instruments and Controls 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Tachometer PTO warning light High beam warning light Hazard switch warning light Turn signal warning light - vehicle Cruise control warning light Cab-lock warning light Oil pressure warning light Low air pressure warning light Battery charge warning light Parking brake warning light Not used Getting to Know Your Vehicle 13. 14. 15. 16. 17. 18. 19. 20.
PB1340A.book Page 28 Friday, September 1, 2000 7:40 AM Instruments and Controls Switches, Gauges, and Warning Lights on the Instrument Panel 1. Tachometer White field: low-idling speed Green Field: economical speed range Yellow field: maximum power range Red field: excessive/overspeed range (not permitted) Getting to Know Your Vehicle 3. High Beam Warning Light 7.
PB1340A.book Page 29 Friday, September 1, 2000 7:40 AM Instruments and Controls WARNING! The air pressure warning light and the audible alarm indicate a dangerous situation: there is not enough air pressure in the reservoirs for repeated braking and, except when the engine is started, indicates the brake system has failed. Without the use of your serv i c e b ra k e s yo u r s p r i n g brakes could suddenly apply cau sing a wheel lo ck-up, loss of control, or over-take by following vehicles.
PB1340A.book Page 30 Friday, September 1, 2000 7:40 AM Instruments and Controls Getting to Know Your Vehicle 14. ABS Warning Light 15. Maintenance - Water in Fuel This warning light monitors the vehicle anti-lock braking system (ABS). This warning light will illuminate when: This warning light will illuminate if the wa te r / f u e l s e p ar a t or n e e d s t o b e drained.
PB1340A.book Page 31 Friday, September 1, 2000 7:40 AM Instruments and Controls 19. Wait to Start Light This warning light will illuminate when the air intake heater is ON. Do not attempt to start the engine until the light goes out. Getting to Know Your Vehicle but the vehicle can still be safely driven. The vehicle should be serviced to correct the problem, but the situation should not be considered an emergency. 20.
PB1340A.book Page 32 Friday, September 1, 2000 7:40 AM Instruments and Controls 23. Coolant Temperature Gauge The coolant operating temperature should be between 165°F (74°C) and 198°F (92°C). At a temperature of less than 140°F (60°C) the engine should not be fully loaded by the driver. If the coolant temperature suddenly rises and/or the gauge pointer enters the red field, then the following items should be checked: Getting to Know Your Vehicle • The coolant level. See “Coolant Level” on page 51.
PB1340A.book Page 33 Friday, September 1, 2000 7:40 AM Instruments and Controls accident. For clear visibility and safe driving it is extremely important for you to follow the instructions on the use of the ventilation/heating and defogging/defrosting system. If in doubt, consult your dealer. Maximum heating output and fast defrosting can be obtained only after the engine has reached operating temperature.
PB1340A.book Page 34 Friday, September 1, 2000 7:40 AM Instruments and Controls Getting to Know Your Vehicle A bi-level mode exists when the slide control is placed between Windshield and Floor positions or between Floor and Panel (Fresh) positions. The optional air conditioner compressor is engaged when the control is placed in Windshield mode (top-most position). RECIRC Air vents and defoggers Slide control (2) Controls the air distribution within the cab.
PB1340A.book Page 35 Friday, September 1, 2000 7:40 AM Instruments and Controls The center panel incorporates a central defogger with two integral side vents for defogging the entire width of the windshield. NOTE: The central defogger outlet is fitted with a protective mesh to prevent the entry of foreign objects. To maintain maximum air flow efficiency, do not place objects on the protective mesh or obstruct the central defogger in any way.
PB1340A.book Page 36 Friday, September 1, 2000 7:40 AM Getting to Know Your Vehicle Instruments and Controls Heating To heat the cab: select the desired air distribution (2) and temperature (3) to hot (red position on the control). Adjust the fan speed (1) as desired. 4 A/C 200 100 3 250 2 0 75 130 175 CAUTION: During extreme cold weather, do not blow hot air onto cold windshields. This could crack the glass.
PB1340A.book Page 37 Friday, September 1, 2000 7:40 AM Instruments and Controls Defogging N OT E : I f e q u i p p e d w i t h optional air conditioning, the air conditioning system is active when the Defrost mode is selected. To defog the windshield: select air distr ibution to Windshield or between Wind shield/F loor and tur n th e fan speed switch (1) to high. Set the temperature control (3) to hot (red position on the control).
PB1340A.book Page 38 Friday, September 1, 2000 7:40 AM Instruments and Controls Getting to Know Your Vehicle 27. Air Pressure Gauge “Secondary” 29. Air Pressure Gauge “Primary” Air gauge “1” constantly monitors the air pressure in the front brake reservoir. At reservoir air pressures below 80 psi (5.5 bar) a warning buzzer will sound and a warning light, mounted in the instrument panel, will illuminate; the warning buzzer and warning light are only operative when the ignition is switched on.
PB1340A.book Page 39 Friday, September 1, 2000 7:40 AM Instruments and Controls 30 20 60 50 80 40 20 10 40 Getting to Know Your Vehicle 55 60 100 miles 120 70 km/h 80 mph 30. Speedometer/Odometer The speedometer indicates the vehicle speed in miles per hour (MPH) and in kilometers per hour (kph) The odometer records the distance traveled by the vehicle, either in miles or kilometers, depending on which unit is installed in the vehicle. 31. Fuse Box - Left 32.
PB1340A.book Page 40 Friday, September 1, 2000 7:40 AM Instruments and Controls Getting to Know Your Vehicle 33. Cruise Control Set/Resume Switch This switch allows the desired speed to be set or resumed after the cruise control function is turned on or interrupted. CRUISE ON/OFF 35. Hazard Warning Light Switch A ct iva ti ng t h is r ocke r t yp e swi tch causes all the tur n signals to flash simultaneously; a warning light on the instrument panel will illuminate while the hazard lights are working.
PB1340A.book Page 41 Friday, September 1, 2000 7:40 AM Instruments and Controls Getting to Know Your Vehicle WARNING! Never drive your v e h icl e wi t h t h e p a rk i n g br ake applied. A lw ays release the parking brakes prior to moving the vehicle. Fai lu re t o d is en ga g e th e parking brakes prior to moving your vehicle could result in excessive heat build-up in the brake system, resulting in a fire. OPERATING LEVER, PARKING BRAKE This lever is used to actuate the parking brake.
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PB1340A.book Page 43 Friday, September 1, 2000 7:40 AM Instruments and Controls Getting to Know Your Vehicle A A Interior Light The interior light unit incorporates a directable reading light and a courtesy interior light; both lights are independently operated using the interior light unit mounted switches. Refer to the “Cab” section of this handbook for the interior light unit operating procedures. Mirror Heating Switch The door mirror heating can be activated with this switch.
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PB1340A.book Page 45 Friday, September 1, 2000 7:40 AM Instruments and Controls Getting to Know Your Vehicle Position J: p o s i t i o n f o r sw i t c h i n g between low beam or high beam. Adjustable Steering Column WARNING! Do not adjust the steering column while the vehicle is in motion, it could cause loss of control. You would not be able to steer properly and could have an accident. Make all adjustments to the steering colu m n wh i le t h e v eh icl e is stopped.
PB1340A.book Page 46 Friday, September 1, 2000 7:40 AM Chassis Getting to Know Your Vehicle Momentarily depress the switch (up to ½ sec.) and then release to obtain a single wipe of the windshield. Depress the switch for between ½ to 1½ secs to activate the intermittent wipe function; depress the switch for ½ to 1½ secs to cancel the intermittent wipe mode. NOTE: A single wipe can be carried out between intermittent wipes without cancelling the intermittent wipe cycle.
PB1340A.book Page 47 Friday, September 1, 2000 7:40 AM Daily and Weekly Maintenance DAILY AND WEEKLY MAINTENANCE Driver’s Check List To keep your truck 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.
PB1340A.book Page 48 Friday, September 1, 2000 7:40 AM Daily and Weekly Maintenance CAUTION: Do not tighten belts beyond specified limits. Dam ag e to b earings and belts may occur. 2. Engine Belt—check tension and condition of belts per engine manufacturer’s Operation and Maintenance Manual. 3. Fuel Filter/Water Separator Draining—check and drain. Depending on the fuel storage facility, more frequent draining may be required. 4. Windshield washer reservoir fluid level—fill if necessary.
PB1340A.book Page 49 Friday, September 1, 2000 7:40 AM Daily and Weekly Maintenance 3. Tires and Wheels—are they inflated properly? Are all wheel cap nuts in place and torqued properly—tighten if necessary. Check fr ont wh ee l b ea r ing o il leve ls. Inspect all tires and wheels for damage—correct if found. 4. Suspension—check for loose or missing fasteners. Check damage to spr ings or other suspension parts. 5. Brake Components—check lines, linkages, chambers, parking and service brake operation. 6.
PB1340A.book Page 50 Friday, September 1, 2000 7:40 AM Daily Maintenance 9. Storage Compartment—all loose items stowed securely. Is the fire extinguisher fully charged? Is your r oad emergency kit complete? Compartments closed? 10. Fuel—check fuel. Is there enough fuel? N OT E : T h e a b o v e i t e m s (Engine Compartment, Chassi s a nd Cab, a nd Pre st a r t Checks) should be checked daily, as a minimum. They are in addition to, not in place of Federal Motor Carrier Safety Regulations.
PB1340A.book Page 51 Friday, September 1, 2000 7:40 AM Daily and Weekly Maintenance Daily Maintenance Before attempting to check the coolant level, ensure that the following safety instructions are observed: 5. If necessary, add oil through the filler opening (2). Always use oil of the same brand and grade. Never overfill with oil! NOTE: Difference between the MAX and MIN marks on the dipstick is approximately 1 3/4 quarts (2 liters).
PB1340A.book Page 52 Friday, September 1, 2000 7:40 AM Daily Maintenance 1. Remove the filler cap (1) and check that the engine coolant is level with the lower lip of the filler neck; if necessar y, fill the surge tank with approved coolant. CAUTION: The use of unapproved coolants can cause severe damage to the cooling system and its components. Should the cooling system require an excessive amount of coolant, the complete system must be inspec ted for lea ks and repair ed ( co nsult yo ur dealer).
PB1340A.book Page 53 Friday, September 1, 2000 7:40 AM Daily and Weekly Maintenance Weekly maintenance Weekly maintenance WARNING! Ensure that the parking brake is on or all wheels are chocked prior to inspecting the power steering fluid level. NOTE: Suitable wheel chocks are at a minimum an 18-inch (46 cm) long 4x4. CAUTION: Do not operate t h e v e h i cl e i f t h e p ow e r steering fluid level is low.
PB1340A.book Page 54 Friday, September 1, 2000 7:40 AM Weekly maintenance Daily and Weekly Maintenance tem is repaired and both braking circuits, including all pneumatic and mechanical components, are working properly. WARNING! Ensure that the fol l owi n g s af et y i ns t ru ctions are strictly observed: Brake System Air Dryer (optional equipment) WARNING! Do not operate the vehicle in the event of a malfunction in any air circuit.
PB1340A.book Page 55 Friday, September 1, 2000 7:40 AM Daily and Weekly Maintenance Weekly maintenance Clutch Fluid Level CAUTION: Should the clutch fluid reservoir require an excessive amount o f hydraulic fluid, the complete system must be inspected for leaks and repaired if necessary (consult your dealer). WARNING! Hydraulic fluid is a t ox i c s u b st a n ce wh i ch must not be consumed or allowed to come into skin contact. 1. Open the cab front panel to gain access to the clutch reservoir. 2.
PB1340A.book Page 56 Friday, September 1, 2000 7:40 AM Weekly maintenance Daily and Weekly Maintenance Windshield Washer Fluid Level 1. Open the cab front panel to access the reservoir filler tube. 2. Remove the filler cap and refill the reservoir with a suitable windshield cleaning solution. N OT E : D u r i n g t h e w i n t e r period, it is recommended that a suitable solution with antifreeze protection is used. – 56 – Tires • Check the tread depth of the tires.
PB1340A.book Page 57 Friday, September 1, 2000 7:40 AM General Driving DRIVING General switch while the vehicle is in motion because this may cause the steering wheel lock to engage. Before starting the engine or setting out on a trip, always check: Position A: rest position The key can be removed. When the key is removed from the switch, the steering wheel is locked. • The vehicle for water, fuel, or oil leaks. • The seat and mirrors for correct positioning.
PB1340A.book Page 58 Friday, September 1, 2000 7:40 AM Starting Procedure Starting Procedure WARNING! Ensure that the fo ll ow in g s af et y i n st r u ctions are strictly observed: – Do not start the engine in a confined space or unventilated area. Exhaust fumes contain toxic gases which, if inhaled, can prove fatal. – Before driving away, ensure that all warning lights have been extinguished and the warning buzzer has ceased to sound.
PB1340A.book Page 59 Friday, September 1, 2000 7:40 AM Operating the Transmission read the specific instructions contained in the transmission manufacturer’s Driver/Operator’s Instruction Manual. Operating Manual Transmissions If your truck has an automatic transmission, go to page 62. If your truck has an automated manual transmission, such as the Eaton® Autoshift™, go to page 63. Your transmission has six forward gears with full synchromesh engagement, and one reverse gear.
PB1340A.book Page 60 Friday, September 1, 2000 7:40 AM Operating the Transmission CAUTION: Always use first gear or a low speed range to start the vehicle in motion. The use of a higher gear or speed range forces undue strain on the engine, clutch, other transmission components, and may cause damage. 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 and shift the transmission into first gear.
PB1340A.book Page 61 Friday, September 1, 2000 7:40 AM Operating the Transmission WARNI NG! Do n ot c oa st w it h t h e t r an s mi ss i on in neutral or with the clutch p e d a l d e p res s e d— it i s a dangerous practice. Without the use of the retarding power of the drivetrain, your vehicle can reach dangerous speeds. At very high speeds you may not be able to put the transmission in any gear.
PB1340A.book Page 62 Friday, September 1, 2000 7:40 AM Operating the Transmission • 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. Operating Automatic Transmissions An automatic transmission makes shifti n g m u c h e a s i e r, o f c o u r s e .
PB1340A.book Page 63 Friday, September 1, 2000 7:40 AM Operating the Transmission The MD transmission is programmed to restrict full operation until specific temperatures are reached. See the transmission manufacturer’s Operator’s Manual for details. Driving The Eaton® Autoshift™ transmission is an automated manual transmission. The Autoshift™ is a partially automated the Autoshift™ computer detects that conditions are r ight for a shift.
PB1340A.book Page 64 Friday, September 1, 2000 7:40 AM Operating the Transmission Driving Cruise Control This feature improves fuel mileage and reduces driver fatigue by maintaining a constant vehicle speed. The cruise control will only operate above a programmed minimum vehicle speed of 30 mph for the Cummins ISB engine. • To decrease the cruise set speed, hold the SET/RESUME switch in the SET position and coast to a lower speed.
PB1340A.book Page 65 Friday, September 1, 2000 7:40 AM Steering Driving Reengaging the Cruise Control Brakes 1. Move the ON/OFF switch to the ON position. or Anti-Lock Braking System (ABS) 2. Toggle the SET/RESUME switch to the RESUME position. Steering The ste er ing gea r is hydra ulical ly assisted. As excessive pressure may damage the hydraulic pump, stop turning the steering wheel when the wheels are at full lock or are blocked by an obstacle.
PB1340A.book Page 66 Friday, September 1, 2000 7:40 AM Brakes – Do not adapt your normal driving style when driving a vehicle equipped with ABS. It is essential that the braking system is operated in a safe and conventional manner. – ABS does not shorten the overall veh icle b raking (stopping) distance. – In the event of an ABS malfu nction, th e ABS will be automatically disengaged and the ABS warning light will illuminate.
PB1340A.book Page 67 Friday, September 1, 2000 7:40 AM Brakes The parking brake control operates the spring brake actuators to apply the rear brakes on the vehicle. Move the control lever (1) fully rearward to apply the parking brakes; a locking sleeve (2) will lock the control lever in position. To release the parking brake, lift the locking sleeve and move the control lever fully forward to the off position.
PB1340A.book Page 68 Friday, September 1, 2000 7:40 AM Brakes exhaust brake only helps the service brakes by using pressure to slow the drivetrain. Use t he serv ice brake s for q ui ck stops. Driving • After the engine is started, warmed up, and you are ready to get under way, turn the exhaust brake switch ON for added braking effect.
PB1340A.book Page 69 Friday, September 1, 2000 7:40 AM Stopping Stopping Parking When the vehicle is parked on a grade, one or more of the following precautions should also be taken: • Chock the wheels at front and rear. NOTE: Suitable wheel chocks are at a minimum an 18-inch (46 cm) long 4x4. • Angle the front wheels so that the vehicle will not move into the traffic stream if it is accidentally set in motion. Driving Apply the parking brake with the parking brake lever.
PB1340A.book Page 70 Friday, September 1, 2000 7:40 AM Diesel Fuel Diesel Fuel Cold Weather Recommendations When diesel fuel is subjected to low temperatures (below 21°F or -6°C), paraffin wax particulates will form within the fuel which will eventually create blockages in the fuel system.
PB1340A.book Page 71 Friday, September 1, 2000 7:40 AM General Periodical maintenance PERIODICAL MAINTENANCE General The durability, safety, trade-in value, and reliability of your vehicle largely depends on the care you give it. This includes regular servicing in accordance with the maintenance schedules specified here. The driving style of the crew members and how they care for the vehicle have a direct influence on the condition of the vehicle.
PB1340A.book Page 72 Friday, September 1, 2000 7:40 AM General Periodical maintenance Maintenance and Lubrication Intervals NOTE: Different lubricants or ser vice intervals than those listed below may be required. normal pick-up and delivery operations. For all other applications, see your dealer for intervals.
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PB1340A.book Page 75 Friday, September 1, 2000 7:40 AM General Periodical maintenance Maintenance Schedule TABLE KEY Use Table 2, ”Maintenance Schedule,” as a guide to plan service work. Be sure and follow the frequency recommendations for your vehicle. Also refer to engine manufacturer’s maintenance guidelines. Table 2 NOTE: If a scheduled service interval is shaded, skip to the next interval..
PB1340A.book Page 76 Friday, September 1, 2000 7:40 AM General Table 2 Periodical maintenance Maintenance Schedule Wiper Operation Wiper Blade Condition Horns (Electric and Air) - Operation Mirrors - Cracks or Mounting SAFETY EQUIPMENT Drain Water from Air Tanks Air Tank Check Valve Emergency Operation of Spring Brakes Air Press. Build–up time: Governed Air Pressure: Air Press. Drop–Brakes not Applied: ___ Air Press.
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PB1340A.book Page 78 Friday, September 1, 2000 7:40 AM General Table 2 Periodical maintenance Maintenance Schedule Drain Water from Fuel System Engine Oil – Change Oil Filters – Replace Fuel Filters – Replace Cranking System: Visual Inspect.
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PB1340A.book Page 83 Friday, September 1, 2000 7:40 AM General Lubrication Specifications You will find a complete Engine Lubrication Service Guide in the Engine Operation and Maintenance Manual. There, the engine manufacturer explains more fully all the maintenance operations you and a qualified service mechanic will need. And please remember: one key to keeping your vehicle running at top performance and in prolonging its life is proper lubrication servicing.
PB1340A.book Page 84 Friday, September 1, 2000 7:40 AM General Periodical maintenance Lubrication Types Use Table 4 on page 86 and the list of lubricants below to identify the type of lubricant to use on your vehicle. Table 3 Lubricant Applications APPLICATION LUBRICANT Universal Joints EP BB: Ball Bearing grease Drive Shaft Splines CL CB: Engine oil for mild to moderate requirements Wheel Bearings HD CC/CD: Engine oil for severe requirements (MIL–L–2104B /MIL–L– 45199B w/ 1.
PB1340A.book Page 85 Friday, September 1, 2000 7:40 AM General Periodical maintenance Oil Reservoirs For oil reservoirs with side filler plugs (transmissions, rear axles, transfer cases, etc.), the oil must be level with the filler opening. NOTE: Use care when checking the oil level with a finger. Just because you can reach the oil level with a finger, does not mean the oil level is correct.
PB1340A.book Page 86 Friday, September 1, 2000 7:40 AM General Periodical maintenance Table 4 Recommended Lubrication Types COMPONENTS RECOMMENDED LUBRICANT Power Steering Gear Chevron Torque Fluid C4, Dexron III, or Mercon Driveline U-Joints Slip-Joint Splines Cab Pivots Clutch Pedal Shaft Other chassis grease fittings not covered below. EP chassis grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2.
PB1340A.book Page 87 Friday, September 1, 2000 7:40 AM General Periodical maintenance Table 4 Recommended Lubrication Types COMPONENTS RECOMMENDED LUBRICANT Brake Camshaft Bushings EP Chassis grease, lithium 12-hydroxystearate base, NLGI 2. CAUTION: Do not contaminate brake linings with grease. Steering Shaft Grease Fittings EP chassis grease, lithium 12-hydroxystearate base, NLGI 2. Brake Treadle Hinge and Roller Engine oil Lock Cylinders Lock lubricant.
PB1340A.book Page 88 Friday, September 1, 2000 7:40 AM General Maintenance in Special and Exceptional Operating Conditions When the vehicle is operated under exceptional conditions, it is important to consult your local dealer as it may be necessary to change the service intervals to suit the operating conditions. The service intervals can be adapted, as necessary, in consultation with the local dealer to suit the appropr iate operating conditions.
PB1340A.book Page 89 Friday, September 1, 2000 7:40 AM General Periodical maintenance NOTE: All new vehicles are factory filled with a 50% antifreeze solution which will give frost protection down to -34°F (-36°C). I CAUTION: The use of antifreeze that does not conform to the required specification can cause severe damage to the cooling system and its components. The anti-freeze mixture must remain in the cooling system during the summer months. 1. Remove the filler cap from the surge tank. 2.
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PB1340A.book Page 91 Friday, September 1, 2000 7:40 AM Emergency repairs EMERGENCY REPAIRS Vehicle Tool Kit All vehicles are equipped with an extension handle for tilting the cab. It is secured within the passenger’s seat stowage compartment (twin seat) or, alternatively, secured behind the passenger’s seat (single seat). Replacing The Drive Belt IMPORTANT: Always install the correct replacement drive belt. Refer to the engine manufacturer’s Operation and Maintenance Manual.
PB1340A.book Page 92 Friday, September 1, 2000 7:40 AM Emergency repairs 8. Clean the pulleys and ensure that they are free of any contaminants (oil/fuel/dirt). 9. Install a new belt. 10. Pivot the compressor to tighten the belt and hold the tension by setting the adjustment screw. Torque the mounting screws to 17 to 23 lb. ft. (23 to 31 Nm). 11. Lower the cab and re-connect the batteries, positive terminal first. For detailed information, refer to the Engine Operation and Maintenance Manual provided.
PB1340A.book Page 93 Friday, September 1, 2000 7:40 AM Emergency repairs WAR N I N G ! Do n o t d r i v e vehicle with malfunctioning brakes. If one of the brake circuits should become i no pe rat ive , b ra ki ng d is t ances will in crease substantially and handling characteristics while braki n g w il l b e af fe c t ed . Yo u could lose control of your vehicle, be severely injured, or cause an accident. Have it towed to the nearest dealer or qualified workshop for repair.
PB1340A.book Page 94 Friday, September 1, 2000 7:40 AM Emergency repairs 4. Slide out the release stud. 5. Insert the release stud through the opening in the spring chamber wher e the cap w as r em oved . Insert it into the pressure plate. Turn the release stud 1/4 turn clockwise in the pressure plate. This secures the cross pin into the cross pin area of the pressure plate and locks it into the manual release position. – 94 – 6. Assemble the release stud washer and nut on the release stud. 7.
PB1340A.book Page 95 Friday, September 1, 2000 7:40 AM Emergency repairs Changing wheels • It is recommended that suitable supports are positioned beneath the appropriate axle when jacking the vehicle. Locate the hydraulic jack under the road spring of the appropriate axle, as close as possible to the road wheel.
PB1340A.book Page 96 Friday, September 1, 2000 7:40 AM Emergency repairs WARNING! Grooves in the wheel disc or other damage to the disc can lead to a serious accident. The disc will be weakened and can eventually come off, maybe causing you to lose control of your vehicle. Be sure to use the right components and the right tools. Crisscross torque sequence for disc wheels 6. Install the wheel and gradually tighten the wheel nuts in a crisscross sequence to 450 to 500 lb. ft. (610 to 680 Nm).
PB1340A.book Page 97 Friday, September 1, 2000 7:40 AM Emergency repairs large (caused, for example, by a difference in tread depths and/or tire pressures). The ABS is not designed to deal with excessive differences of this nature, as a result the system will disengage and the ABS warning light will illuminate. Dependent upon the type of tires fitted to the front and rear axles, this problem may occur with a worn tire which is under-inflated by approx 29 psi.
PB1340A.book Page 98 Friday, September 1, 2000 7:40 AM Emergency repairs WARNING! Do not attempt to tow the vehicle when it is fully laden. If the engine will n o t ru n , t he re w il l b e n o power assist to the steering and no air supply for the brakes. Being towed by another vehicle: • Ensure that the steering lock of the t o we d ve h ic l e i s d i s en g ag e d (unless the vehicle is being towed with its front wheels hoisted clear of the road).
PB1340A.book Page 99 Friday, September 1, 2000 7:40 AM Emergency repairs Side Marker Lights NOTE: Marker light is a sealed assembly and must be replaced as a unit; the bulb alone cannot be replaced. 1. Remove two torx head screws (1). 4. Remove the sheet metal nut and carefully pry marker light off adhesive-backed foam. 5. If necessary, replace adhesivebacked foam pad. 6. Replace marker light. 7. Replace tie wraps. Side Lights 1 1. Find the tab on the yellow lens.
PB1340A.book Page 100 Friday, September 1, 2000 7:40 AM Emergency repairs 2. Remove the bulb from the unit. NOTE: When replacing the lens cover, ensure that it is correctly located and secure. Courtesy light Interior light unit 1. Carefully pry the courtesy light assembly from the cab roof lining. 2. Detach the bulb(s) from the unit. Each lens cover in the interior light unit is pr ovid ed with an a cce ss slot to enable the internal lens catch to be released.
PB1340A.book Page 101 Friday, September 1, 2000 7:40 AM Emergency repairs 1 2 1. The two screws for adjusting the alignment of the headlights are accessible through the holes provided at the front of each headlight surround. 2. Adjusting screw (1) is for vertical alignment of the light beam. Adjusting screw (2) is for horizontal alignment of the light beam. NOTE: Passenger side access hole for adjustment is to the right of the headlight.
PB1340A.book Page 102 Friday, September 1, 2000 7:40 AM Emergency repairs NOTE: All vehicles are fitted with a roof mounted antenna and a fully shielded extension lead. NOTE: The radio power supply is controlled by the ignition switch.
PB1340A.book Page 103 Friday, September 1, 2000 7:40 AM Emergency repairs Noise and Emission Control Noise Emission Warranty PACCAR Inc warrants to the first person who purchases this vehicle (for purposes other than resale) and to each subsequent purchaser: that this vehicle, as manufactured by PACCAR Inc, was designed, built and equipped to confor m, at the time it left PACCAR Inc’s control, with all applicable U.S. EPA Noise Control Regulations.
PB1340A.book Page 104 Friday, September 1, 2000 7:40 AM Noise and Emission Control Exhaust System • Removing or rendering inoperative exhaust system components. Fuel System • Removing or rendering engine speed governor inoperative, allowing engine speed to exceed manufacturer's specifications. • Removing of air signal attenuator o n eng in es equ ipped with this device. Inner Fender Shields • Removing shield. • Cutting away parts of shields or d am a ge d or lo os e p or t io ns o f shields.
PB1340A.book Page 105 Friday, September 1, 2000 7:40 AM Emergency repairs • Check exhaust manifold cap screws for tightness, including those at the flanges. Refer to the engine manufacturer 's ser vice m a n u a l fo r p r o p e r t i g h t e n i n g sequence and torque values. Joints and Clamps • Check for leaks, and tighten as necessary. Check for deterioration or dents in pipes and clamps which could allow exhaust to escape. Piping • Check exhaust piping for rust, corrosion, or damage.
PB1340A.book Page 106 Friday, September 1, 2000 7:40 AM Noise and Emission Control Transmission and Driveline • Substituting a different main transmission or drive line components, other than design-specified units, may result in increased vehicle noise emission and/or undesireable vibrations.
PB1340A.book Page 107 Friday, September 1, 2000 7:40 AM Consumer Information and Vehicle Identification Reporting Safety Defects CONSUMER INFORMATION AND VEHICLE IDENTIFICATION Reporting Safety Defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Tr a ff ic S a fe t y A d mi n is tr at i on (NHTSA) in addition to notifying PACCAR Inc.
PB1340A.book Page 108 Friday, September 1, 2000 7:40 AM Vehicle Identification Consumer Information and Vehicle Identification • The Chassis/Serial Number refers to the last seven characters of the VIN, including the assembly plant designator (eleventh character position) and a six-digit serial number. This number will allow your Dealer to identify your vehicle. You will be asked for this number when you bring your vehicle in for service.
PB1340A.book Page 109 Friday, September 1, 2000 7:40 AM Consumer Information and Vehicle Identification Complete Vehicle Certification Label Incomplete Vehicle Certification Label The Complete Vehicle Cer tification label certifies that the vehicle complies with all applicable Federal Motor Vehicle Safety Standards. It is located on the driver’s side door frame and contains the following information: The Incomplete Vehicle Certification Label (for trucks) is located on the driver’s door frame.
PB1340A.book Page 110 Friday, September 1, 2000 7:40 AM Vehicle Identification NOT E: GVW is the TOTAL SCALE WEIGHT the vehicle is d e s i g n e d t o c a r r y. T h i s in clu de s th e weig ht o f t he empty vehicle, loading platform, occupants, fuel, and any load. The tire size and rim size (and the cold inflation pressure to match that combination) listed under “Suitable Tire-Rim Choice” on the Certification Label are only representative examples for the specified axle ratings.
PB1340A.book Page 111 Friday, September 1, 2000 7:40 AM Consumer Information and Vehicle Identification Vehicle Identification Component Identification Each of the major components on your vehicle has an identification label or tag. For easy reference, record component numbers such as, model, serial, and assembly number. See the “Vehicle Component Register” (last page of this manual). Engine: F o r f u r t h e r i n f o r m a t i o n , please refer to the Engine Operation and Maintenance Manual.
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Your servicing Dealer is Peterbilt Motors Company P.O. Box 90208 Denton, Texas 76202 PB1340A -/- 9/00 Printed in U.S.A.
