Quick Table of Contents •Introduction. . . . . . . . . . . . . . . . . . 3 •Cab And Frame Access . . . . . . . . . . . 9 •Getting To Your Engine . . . . . . . . . . . . . . 13 •Controls And Displays . . . . . . . . . . . . . . . . . . 16 •Seat And Restraint Systems . . . . . . . . . . . . . . . . 74 •Driver’s Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 •Starting And Operating The Vehicle . . . . . . . . . . . . . . . . . 89 •Maintenance and Service . . . . . . . . . . . . . . . . .
INTRODUCTION Introduction How to Use This Manual This Operator's Manual contains useful information for the safe and efficient operation of your Medium Duty vehicle. It also provides information on maintaining your vehicle in the best condition, with an outline for performing safety checks and basic preventive maintenance inspections. We have tried to present the information you'll need to learn about your vehicle's functions, controls, and operation as clearly as possible.
INTRODUCTION NOTE WARNING Provides general information: for example, the note may suggest how to operate the vehicle more efficiently. When you see this word, the message that follows is especially vital. It signals a potentially hazardous situation which, if not avoided, could result in an injury or death. This message will tell you what the hazard is, what can happen if you don't heed the warning, and how to avoid it. Example: NOTE: Pumping the accelerator will not assist in starting the engine.
INTRODUCTION Vehicle Safety Make sure your Medium Duty is in top working condition before heading out on the road—it is the responsible driver's duty to do so. Inspect the vehicle according to the “Driver's Check List”, page 83. WARNING! Do not drink and drive . Your reflexes, perceptions, and judgment can be affected by even a small amount of alcohol. You could have a serious—or even fatal accident—if you drive after drinking. Please do not drink and drive or ride with a driver who has been drinking.
INTRODUCTION A Special Word About Repairs Shop Manuals This is not a repair or workshop manual. Your Peterbilt Dealer's Service Center is the best place to have your Medium Duty repaired. You can find Peterbilt dealers all over the country with the equipment and trained personnel to quickly get you back on the road—and to keep you there. If you do decide to do complex repair work, you will need the Medium Duty Maintenance Manual.
INTRODUCTION Medium Duty Body Builders' Manual. Contains general guidelines on mechanical and electrical modifications required by your dealer to add bodies, accessories, and special equipment to straight-truck configurations. WARNING! Modifying your vehicle can make it unsafe. Some modifications can affect your vehicle's electrical system, stability, or other important functions. Before modifying your vehicle, check with your dealer to make sure it can be done safely.
INTRODUCTION information about regulations governing transportation across state lines. Regulations that differ from state to state can be found at various agencies in state governments.
CAB AND FRAME ACCESS Cab and Frame Access Introduction To lock or unlock the doors from outside the cab: The following section covers procedures for accessing the cab and the frame. Door Lock and Keys • Insert the key in the door lock. • Turn the key toward the rear door frame to lock; forward to unlock. Cab and Frame Access Doors can be locked from the inside by using the lock button. Close the door then push the button down to lock.
CAB AND FRAME ACCESS WARNING! Do not step on vehicle components without antiskid surfaces or use components not designed for entry-and-exit use. You could fall and kill or injure yourself if you step onto a slippery surface. For example: • Do not step onto the surface of a fuel tank. A fuel tank is not a step. The tank surface can get very slippery, and you might not be able to prevent a fall. • Use only the steps and handholds provided, not chain hooks, quarter fenders, etc.
CAB AND FRAME ACCESS NOTE: Any alteration (adding bulkheads, headache racks, tool boxes, etc.) behind the cab that affects the utilization of grab handles, deck plates, or frame access steps installed by Peterbilt should comply with Federal Motor Carrier Safety Regulation 399.
CAB AND FRAME ACCESS – 12 – Y53-6027 Medium Duty (R05/09)
ENGINE ACCESS HOOD HOLD DOWNS AND TILT Engine Access Hood Hold Downs and Tilt The hood is locked in its closed position by an external latch on each side. These latches serve as hold downs and keep the hood from opening unexpectedly. WARNING! Before opening 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.
HOOD HOLD DOWNS AND TILT ENGINE ACCESS Put one hand on the hood handle (just above the Peterbilt emblem), one foot on the bumper, and one foot on the ground. Tilt the hood forward until you hear it “lock”. WARNING! Always make sure the lock is engaged to keep your hood open while working in the engine compartment. Failure to do so may allow the hood to fall unexpectedly resulting in death or personal injury. To close the hood, you must first release the hood safety lock.
ENGINE ACCESS HOOD HOLD DOWNS AND TILT After lowering the hood, latch the hood closed with the hold downs. WARNING! If the hood is not latched securely, it could open during operation and cause an accident resulting in death or personal injury. Be sure the hood is latched securely before moving the vehicle.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS Controls and Displays Instruments and Controls Introduction Your Medium Duty vehicle’s dashboard is shown on the opposite page. – 16 – The dash includes standard gauges and switches. Your vehicle may come with all or some of the switches and gauges discussed here. The location of switches on the dash will vary depending on the options ordered and how your vehicle was configured.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS LEFT SIDE 1 2 3 4 5 6 7 8 9 16 17 18 15 10 11 12 13 14 20 1 19 2 DEF Gauge 3 Fuel Level 4 Tachometer 5 Driver Information Display 6 Speedometer 7 Primary Air Pressure 8 Secondary Air Pressure 9 Water Temperature 10 Headllights 11 Load Lights 12 Hazard Switch 13 Optional 14 Optional 15 Panel Lights 16 Optional 17 Cruise Control On/Off 18 Cruise Control Select 19 Menu Control Switch 20 Ignition Engine Oil Pr
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS RIGHT SIDE 3 4 5 6 Radio 2 Navigation 3 HVAC Controls 4 Emission Controls 5 Engine Brake (on/off) 6 Engine Brake (Select) 10 7 Optional Switch* 11 8 Optional Switch* 12 9 Optional Switch* 13 14 15 16 10 Park Brake Controls 11 Transmission Display (Automatic) 12 Optional Switch 13 Optional Switch 1 2 1 14 Optional Switch 15 Optional USB Port 16 Optional Switch *These switches are not shown.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS Menu Control Switch (MCS) • Rotating the MSC The MCS is used to navigate the Driver Information Display unit. The Menu Control Switch is located on the D Panel as shown in the illustration below. – Selecting display – Setting values • Pushing the MSC – Confirming desired selection Standard Warning Lights and Audible Alarm The warning lights and audible alarm may indicate a system malfunction.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS criticality. The most critical warning will be displayed on the top row and to the left. If more than six warnings are active, the menu control switch (MCS) can be used to scroll through the additional warnings. 3 2. Status Indicator: 2 1 1. Driver Information Display Additional lights and indicator symbols are displayed in the Status Indicator. They are limited to: a. Park Brake b. Transmission Gear (Automatic transmissions only) c. Warnings: 2.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS A red warning is active. First An amber warning is active. Second d. Cruise Control - active e. Clock alarm bell Third Refer to “Warning Light / Indicator Symbols” on page 22 for information on each symbol. Refer to “Warning Light / Indicator Symbols” on page 22 for information on each symbol. Instrument System Self Test: When the ignition switch is turned on the instrumentation system will undergo a Self Test.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS include but are not limited to headlight on, fifth wheel, stop engine, primary/secondary air, and driver door open warnings. Example: Engine, and then in alphabetical order. Warning Light / Indicator Symbols Symbol Name Optional Lights: Additional lights may be operational depending on individual vehicle specifications. These will be included in the Instrument System Self Test.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS Warning Light / Indicator Symbols Symbol Name Symbol Warning Light / Indicator Symbols Color Std Opt Page 10. Cruise Control, Active Symbol Name Symbol Color Std Opt Page 19. Engine, Overspeed Yellow 27 Yellow 27 12. Dump Truck, Trailer Body Up Yellow 27 13. Emissions, Diesel Particulate Filter (DPF) Yellow 27 14. Emissions, High Exhaust System Temperture (HEST) Yellow 27 11.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS Warning Light / Indicator Symbols Symbol Name Symbol Warning Light / Indicator Symbols Color Std Opt Page 28. Power Take-off (PTO) 29. Power Take-off (PTO), Pump Mode Symbol Name Symbol Color Std Opt Page 37. Transmission, Oil Filter Green 29 Green 29 38. Transmission, Oil Temperature High Green 29 39. Turn Signal, Left 30 40. Turn Signal, Right 30 41. Voltage Yellow 30 Yellow 31 Green 31 Green 31 30. Refrigerator 31.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS 2. Active Warnings, Number 5. Anti-Lock Brake System (ABS) Illuminates the total number of red and yellow active warnings. Use the MCS to view the active warnings if the display shows a > symbol. Illuminates during the Instrumentation System Self Test. Have the ABS system checked by a Peterbilt dealer if the ABS Warning Lamp stays on for more than 3 seconds. 3. Active Warnings, Triangle Illuminates when an yellow warning is active.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS 7. Axle, Inter-Axle Differential Locked (Tandem Axles) Illuminates during normal operating conditions to indicate a problem with the Trailer ABS System. This should be checked by a Peterbilt dealer as soon as possible. See “ABS Warning Lamps” on page 104 for more information. Illuminates when the inter-axle differential switch is ON thus locking the inter-axle differential. This powers the forward rear and the rear rear differentials equally.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS 10.Cruise Control, Active 15.Engine, Check Engine Illuminates when cruise control is active. Illuminates when a problem exists, but the vehicle can still be safely driven. Vehicle should be serviced to correct the problem but the situation should not be considered an emergency. 11.Dump Truck, Body Up Illuminates when Truck Dump Body is up. 12.Dump Truck, Trailer Body Up 16.Engine, Ether Start Illuminates when Trailer Dump Body is up. 13.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS 19. Engine, Overspeed 22. Engine, Wait To Start Illuminates when engine RPM is exceeded. Illuminates when engine grid heater is on (PACCAR PX-6 and PX-8). 20. Engine, Retarder (Brake) Illuminates when the engine retarder (compression brake or exhaust brake) switch is turned on. (Engine retarders are an option.) Illuminates when air actuated fifth wheel King Pin is unlocked. 24. Fifth Wheel, Slide Unlocked 21.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS 25. Lights, High Beam 27. Park Brake Illuminates when the high beams are on. This icon will flash with audible alarm if the headlamps are left on when the door is open. In addition, this icon will flash, but without an audible alarm, if there is a problem with the low beam headlights or the low beam headlight wiring. In such event, the high beam headlights will turn on at 50% normal brightness.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS 31. Seat Belt, Fasten Illuminates when tire pressures need to be checked. (Tire Pressure Monitoring System is an option) Illuminates when the ignition key is turned on as a reminder to fasten your seat belt. WARNING! Do not drive vehicle without your seat belt and your riders’ belts fastened. Riding without a safety belt which is properly fastened can lead to increased injury or death in an accident.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS 38. Transmission, Oil Temperature High 39. Turn Signal, Left Illuminates when transmission lubricant temperature is too high.The information display will provide the current oil temperature when the icon is illuminated. Blinks when the left turn signal or the hazard light function is operating. 40. Turn Signal, Right Blinks when the right turn signal or the hazard light function is operating. Trans. Temp.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS Driver Information Display • ignition timer is active • MCS button is pushed (independent of ignition key switch position) • clock alarm sounds • driver or passenger door is opened • hazard warning lamp switch is on WARNING! Do not look at the Driver Information Display for prolonged periods while the vehicle is moving. Only glance at the monitor briefly while driving.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS In addition to a blank screen, the following are menu items and the information available within each menu selections. B. RPM Detail (Accessible while parked or driving) NOTE: Some Driver Information Display functions are only accessible when the vehicle is parked. Other functions are accessible while the vehicle is moving or when parked. Each function is identified in the following descriptions. A.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS D. Trip Information – PTO Hours NOTE: When accessing the trip information menu, push the MCS on this menu (bullet). To exit, push the MCS again. To reset the trip values, press the Trip Odometer Reset Button on the main gauge instrument cluster. – PTO Trip Hours – PTO Trip Percentage (%) To reset the Trip Values, press the Trip Odometer Reset Button on the main gauge instrument cluster. E.
CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS Found" or "Faults Found". If "Faults Found" is active, pushing the MCS will display new menus for more information. G. Transmission Display (Automated Transmissions only - Accessible while parked or driving) 7. Transmission SW Version 8. ABS (Antilock Braking System) Make 9. ABS Model 10. ABS SW Version 11. CECU (Cab Electronic Control Unit) Software Version NOTE: Refer to the Automated Transmission Operator’s Manual for additional information. 12.
INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS • Display Format 12 Hour (AM/PM) or 24 Hour (military) • Home/Local Time • Alarm ON/OFF • Alarm Time To Set Home, Local or Alarm Time: • Units of measure 1. When in the Settings Menu, scroll through the list of menu items. Press the MCS to select the item to change. • Language (English, Spanish or French) 2. To Set Clock Display Format: 1. When in the Settings Menu, scroll through the list of menu items to "Format". 2.
CONTROLS AND DISPLAY STANDARD GAUGES Standard Gauges On the pages that follow you will find descriptions of some of the gauges on your instrument panel. For more information about using them in driving, see “Starting and Operating the Vehicle” Also check the Index under the name of the gauge or function you want to know more about. WARNING! Do not ignore a warning light or audbile alarm. These signals tell you something is wrong with your vehicle.
STANDARD GAUGES CONTROLS AND DISPLAY Tachometer distance that can be shown on the odometer is “1 999 999” before it rolls over to zero. The trip odometer displays how far the vehicle has gone on a particular trip. The trip odometer will display in miles on an English speedometer or in kilometers on a metric speedometer, in one tenth divisions. The maximum distance that can be shown on the trip odometer is “9999.9” before it rolls over to zero.
CONTROLS AND DISPLAY STANDARD GAUGES Engine Hours / Outside Air Temperature Hour Meter Snowflake Symbol the first 3 seconds, then stay on until the temperature goes above 37°F or 28°C. Outside Air Temperature The LCD display in the lower part of the tachometer contains the engine hour meter and the outside air temperature display. The temperature can display using Standard or Metric units. Press the trip reset button on the Speedometer 4 times within 4 seconds.
STANDARD GAUGES CONTROLS AND DISPLAY Engine Oil Pressure Gauge • If your oil pressure suddenly drops while you are driving, bring the vehicle to a stop as soon as possible in a safe location off the road and turn off the engine. Wait a few minutes to allow oil to drain into the oil pan, and then check the oil level. Add oil if necessary. If the problem persists, contact an authorized service center. Check the engine manufacturer’s manual for the correct oil pressure ranges for your engine.
CONTROLS AND DISPLAY STANDARD GAUGES water temperature gauge should register between 165° and 205°F (74° and 90°C). Under certain conditions, somewhat higher temperatures may be acceptable. But the maximum allowable temperature is 210°F (99°C) with the cooling system pressurized, except for certain special engines. Check your engine manual to be sure. during severe operating conditions such as climbing a long hill on a hot day or stopping after high-speed driving.
STANDARD GAUGES CONTROLS AND DISPLAY CAUTION: Keep the engine running if the engine is overheating and the low coolant alarm is not on. Allowing the engine to run with coolant in the system will help protect the engine from overheating whick will reduce the damage to the engine. Fuel Gauge • With the transmission in neutral, check to be certain the oil pressure gauge reads normal. Increase the engine speed to about 1100 - 1200 RPM, maximum. Return the idle speed to normal after 2 or 3 minutes.
CONTROLS AND DISPLAY STANDARD GAUGES CAUTION: The fuel gauge shows the approximate amount of fuel in the fuel tanks. Besides empty and full, the gauge also indicates 1/4, 1/2, and 3/4 of total capacity. You will want to keep your fuel tanks at least half full to reduce condensation of moisture in the tanks. This moisture can damage your engine. capacity. DEF fluid is required to meet certain emission requirements. Do not allow your DEF tank to remain empty.
OPTIONAL GAUGES CONTROLS AND DISPLAY WARNING! The air pressure warning light and the audible alarm indicate a dangerous situation. There is not enough air pressure in the reservoirs for repeated braking and the brake system has failed. If air pressure falls below 60 psi (414 kPa) the spring brakes could suddenly apply, causing a wheel lockup, loss of control, or your vehicle to be overtaken by following vehicles. You could be in an accident involving death or personal injury.
CONTROLS AND DISPLAY OPTIONAL GAUGES Forward Drive Axle Temperature Gauge Rear Drive Axle Temperature Gauge These gauges indicate the temperature of the lubricant in your vehicle’s axle(s). These temperatures will vary with the kind of load you are carrying and the driving conditions you encounter. Maximum axle temperature may vary, depending upon the axle and type of lubricant. Very high temperatures signal a need to have your axle(s) lubrication checked.
OPTIONAL GAUGES CONTROLS AND DISPLAY operate the signal, move the lever in the direction of the turn. Each time the turn indicator is activated the audbile alarm emits a short beep. • To switch your headlamps to lower or higher beam, gently pull the turn signal lever towards the steering wheel, until you hear the switch click and the beam changes. The blue indicator light in the instrument panel will be ON when the high beam is being used.
CONTROLS AND DISPLAY OPTIONAL GAUGES Press In For Washer Pump Rotate To Change Wiper Mode See the wiper switch settings table that follows for intermittent delay times. WARNING! Clean blades regularly with a damp cloth to remove road film and wax buildup. Do not drive with worn or dirty wiper blades. They can reduce visibility, making driving hazardous which may lead to an injury accident resulting in death or personal injury.
OPTIONAL GAUGES CONTROLS AND DISPLAY (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. Wiper Switch Settings Check the windshield washing fluid level daily. If necessary, fill to top. Clean all inside and outside windows regularly. Use an alcohol-based cleaning solution and wipe dry with either a lint-free or a chamois cloth.
CONTROLS AND DISPLAY OPTIONAL GAUGES Air Operated Horn (Option) WARNING! If you have these levers, they may be close together on your steering wheel column. Exercise care to choose the appropriate lever. The BrakeSaver lever is located lower and closer to the driver on the steering column (see page 59). Activating the trailer hand brake lever instead of the BrakeSaver lever could lead to an accident resulting in death or personal injury. Your Medium Duty vehicle may be equipped with an air horn.
DASH- AND DOOR-MOUNTED FEATURES CONTROLS AND DISPLAY Tilt- Telescoping Steering Column Depending on your vehicle’s configuration, you may have either a Tilt or a Tilt/Telescoping 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 handle on the left side of the steering column. To adjust the steering wheel, PULL and HOLD the handle.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES • OFF:In this position all systems are off, and you can remove your key. • IGN & ACC:This position allows you to turn on the engine and all accessory power. • START:Starter activation to start engine. OFF ACC ONLY IGN & ACC START Hazard Flasher The four-way Emergency Flasher switch is located to the right of the ignition key switch.
DASH- AND DOOR-MOUNTED FEATURES CONTROLS AND DISPLAY release the parking brake. If the headlight switch is ON, the DRL system is overridden, and headlights operate normally. WARNING! Do not use daytime running lights (DRL) during periods of darkness or reduced visibility. Do not use DRL as a substitute for headlights or other lights during operations that require lighting of your vehicle. Doing so could lead to an accident resulting in death or personal injury.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES Panel Light Dimmer ID and Clearance Lights Switch The Panel Light Dimmer lets you vary the brightness of your instrument panel lights. To Operate Your Panel Light Dimmer: 1. Turn on either the headlights or clearance lights. 2. To brighten the instrument lights, rotate the thumbwheel up. 3. To dim the instrument lights, rotate the thumbwheel down.
DASH- AND DOOR-MOUNTED FEATURES CONTROLS AND DISPLAY Fog Lights Switch Air Suspension Deflate Switch (Dump Valve) AIR SUSPENSION If your vehicle has fog lights, turn them ON or OFF with the control panel switch with the symbol shown above. NOTE: Across the U.S.A. and Canada, State/Provincial requirements vary as to when high beams and fog lights can and cannot be used together. Some states allow only four lights to be used together, while some allow more.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES CAUTION: Operating a vehicle with air suspension bags either overinflated or underinflated may cause damage to driveline components. If a vehicle must be operated under such conditions, do not exceed 5 mph. WARNING! Do not operate the cruise control when operating on road surfaces with poor traction (wet, icy, or snow covered roads) or in heavy traffic.
DASH- AND DOOR-MOUNTED FEATURES CONTROLS AND DISPLAY designed to ensure that a driver is able to cancel the cruise set speed by using the service brake pedal. The system will not allow cruise control operation if it does not pass the ‘rationality check’. The Driver Information Display will prompt you to press the service brake pedal if it has not been pressed since the vehicle has been started.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES CAUTION: Do not leave the three position switch in the STOP position unless you need to cancel or stop regeneration. Leaving the switch in the STOP position for extended periods of time will result in increased soot levels in the DPF which can affect engine performance or disable the engine. Power Mirror Switch If your vehicle is equipped with power mirrors, the mirror controls will be located on the driver side door pad.
DASH- AND DOOR-MOUNTED FEATURES CONTROLS AND DISPLAY 2. Depress the mirror directional control pad towards the arrows pointing left or right to adjust the mirror in/out. NOTE: After mirror adjustments have been completed, return the mirror selector switch back to the center (neutral) position, to prevent unintentional adjustments to the mirrors. To defrost the mirrors in cold weather, depress the mirror heat switch button and release.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES Your vehicle is probably equipped with power windows. Power window rocker switches are located on the door pads (a switch for the passenger window is also on the driver side door pad, as shown above). To open or close a window, depress the switch for that window at the end that displays a downward- or upward-directed arrow, respectively, in the window symbol on the switch face. Release the switch to stop window movement.
DASH- AND DOOR-MOUNTED FEATURES CONTROLS AND DISPLAY Manual Control Lever This hand-operated control lever provides modulated application of the BrakeSaver in the manual or ON mode (see next illustration). How much braking you get depends on how much you move the lever. Jacobs Engine Brake or Cummins “C” Brake Switch The ON/OFF switch turns the system ON or OFF. The second switch performs the progressive braking function that controls the amount of retarding.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES • If you have the two-mode system, you can select HIGH or LOW. • If you have the three-mode system, you can select low, medium, or high retarding. WARNING! Do not use the Jacob’s brake as the primary means of slowing or stopping the vehicle. The Jacob’s brake is designed to be used in conjunction with the service brakes. Failure to do this may cause death or personal injury.
DASH- AND DOOR-MOUNTED FEATURES CONTROLS AND DISPLAY Two-Speed Rear Axle (Range) Switch Fifth Wheel Lock (Slider Adjustment) Switch . . FIFTH WHEEL RANGE SELECTOR If your vehicle is equipped with a two-speed rear axle, you can select the axle range by the dash mounted switch shown above. The low range provides maximum torque for operating off-highway. The high range is a faster ratio for highway speeds. WARNING! Do not move the fifth wheel while the tractor-trailer is in motion.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES the fifth wheel to various positions to adjust weight distribution. There is a guard over this switch to protect you against accidentally activating or releasing the lock. Parking Brake Valve and Trailer Air Supply Valve PULL TO APPLY PARKING BRAKE PUSH TO RELEASE Before you leave the cab, apply all parking brakes. - for vehicles with air brakes: 1. Apply all parking brakes. Pull out the Yellow Parking Brake Control knob (1) located on the dash.
DASH- AND DOOR-MOUNTED FEATURES (2) Trailer Air Supply Control (Red) CONTROLS AND DISPLAY WARNING! Before operating your vehicle after it has been parked, do not forget to push in the parking brake valve to release the parking brakes. Failure to release your parking brakes before putting the vehicle into motion can cause fire or loss of control of the vehicle, which can result in death or personal injury. (1) Parking Brake Control (Yellow) See “Using the Brake System” on page 104 for more information.
CONTROLS AND DISPLAY DASH- AND DOOR-MOUNTED FEATURES CAUTION: Unless it is an emergency, do not pull upward on the parking brake lever while the vehicle is moving. Attempting to stop with the parking brake could cause damage to the driveline, transmission, or the parking brake mechanism itself. Using the Parking Brake 1. Come to a complete stop. 2. Apply the parking brake. Pull upward on the parking brake lever until it reaches an over (top) center position. (The PARK light on the dash will come on.
HEATER-AIR CONDITIONING CONTROLS CONTROLS AND DISPLAY Heater-Air Conditioning Controls Your heat and air conditioning controls are mounted in the “D” instrument panel in conventional models. Additionally, the sleeper compartment may also contain a separate heating and cooling system with separate controls. the windows open. Failure to repair the source of the exhaust fumes may lead to death, injury or personal harm.
CONTROLS AND DISPLAY HEATER-AIR CONDITIONING CONTROLS •If you are required to idle your vehicle for long periods of time, install an auxiliary heater or automatic idle control. These auxiliary devices can reduce fuel consumption and save you money. •If other vehicles are parked next to you idling, move your vehicle or do not stay in your vehicle for prolonged periods of time.
HEATER-AIR CONDITIONING CONTROLS • CONTROLS AND DISPLAY • To defog the windshield, select the Defrost mode and turn the blower speed to high. Set the temperature knob to hot (the red position on the control). The air conditioner is automatically activated to remove moisture from the cab. After the windshield is clear, adjust the mode, blower speed, and temperature to your comfort. .
CONTROLS AND DISPLAY CIGARETTE LIGHTER CAUTION: During extreme cold weather, do not blow hot defroster air onto cold windshields. This could crack the glass. Turn the air flow control lever to Defrost and adjust the fan speed accordingly while the engine warms. If the engine is already warm, move the temperature selector to Cool, then gradually increase the temperature when you see that the windshield is starting to warm up. 4. Close all windows. 5.
CUPHOLDERS/ASHTRAY CONTROLS AND DISPLAY not push it in. The cigarette lighter circuit is protected by a 10-ampere fuse to prevent damage should the lighter get stuck in the IN position. If this fuse needs replacement, check to ensure that the lighter is not stuck before replacing the fuse. WARNING! Do not exceed the voltage/amperage capacity of the cigarette lighter. It could result in a fire causing death or personal injury.
CONTROLS AND DISPLAY SHIFT PATTERN DISPLAY Shift Pattern Display The correct shift pattern for your vehicle appears on your control panel or windshield or on a medallion in the shift knob. It is important that you know more about your transmission than just the shift pattern. Please read the manufacturer’s manual that is included with your vehicle.
ACCESSORIES CONTROLS AND DISPLAY Accessories Peterbilt Navigation System Your vehicle may be equipped with a Peterbilt Navigation System. This system is a Global Positioning Satellite (GPS)-linked computer. It receives input from multiple sources to locate your vehicle. Read and understand the Supplemental Navigation System Owner’s Manual and observe the Warnings, Cautions, and Notes that follow before using the system.
CONTROLS AND DISPLAY ACCESSORIES NOTE: The map database is the most current available at the time of production. The database is designed to provide you with route suggestions and does not take into account the relative safety of a suggested route or of factors that may affect the time required to reach your destination. See the Supplemental Navigation System Owner’s Manual for more information. • To close, push the cover up and press to latch it.
SEATS Seats Introduction Standard Driver's Seat This section covers the operation and safe use of your Medium Duty vehicle’s seats. For further information on features and adjustment of the seat, see the manufacturer's literature included with the vehicle. The standard driver's seat can be adjusted forward and rearward. These movements are each controlled by levers located on the FRONT of the seat.
SEATS Safety Restraint Belts CHUGGER-SNUBBER LOCK-OUT FEATURE Move handle down to unlock BACKREST TILT Rotate knob for infinite selection of settings The right and left seats are equipped with 3-point lap/ shoulder belts; the center seat has a 2-point seat belt. Safety belts have proven to be the single most effective means available for reducing the potential for either serious injury or death in motor vehicle accidents.
SEATS WARNING! Do not drive vehicle without your seat belt and your riders’ belts fastened. Riding without a safety belt which is properly fastened can lead to increased death or injury in an accident. Unbelted riders could be thrown into the windshield or other parts of the cab or could be thrown out of the cab. They could strike another person. Injuries can be much worse when riders are unbelted. Always fasten your seat belt and be sure anyone riding with you does the same. 2.
SEATS • Belts should fit snugly across the pelvis and chest. Make sure any slack is wound up on the retractor. To unfasten the belt: Push in the release button on the buckle. The belt will spring out of the buckle. • To release a locked belt, lean back to take the body pressure off of the belt. • To store a lap-shoulder belt, allow the belt to wind up on the retractor by guiding the belt tongue until the belt comes to a stop.
SEATS • Be sure, also, that your belt is not too loose. A loose belt could allow you to slide under it in an accident, and that could bring the belt up around your abdomen. • Do not twist the belt in the process of putting it on. A twisted belt will not work as well to protect you. WARNING! Always wear your seat belt low over your pelvic bones. • You can be killed or seriously injured if your belt is buckled too high. In a crash, it would apply force to your abdomen, not your pelvic bones.
SEATS Safety Restraint Tips NOTE: Per FMCSR 392.60 - Unauthorized Persons Not to be Transported. Federal law prohibits the transportation of persons in commercial vehicles unless they are specifically authorized in writing by the motor carrier. See the cited FMCSR for a complete description of the regulation and exemptions. • Any authorized person riding in your vehicle should wear a seat belt. A responsible operator sees to it that everyone in the vehicle rides safely—and that means with a seat belt.
SEATS WARNING! Do not remove, modify, or replace the tether belt system with a different tether system. A failed or missing tether belt could allow the seat base to fully extend in the event of an accident leading to greater injuries or death. • If any seat belt is not working properly, see an Authorized Service Center for repair or replacement. WARNING! Before driving or riding in a vehicle, ensure that there is adequate head clearance at maximum upward travel of seat.
SEATS Komfort–Lok® Latch Your Peterbilt contains a feature designed to eliminate cinching and provide improved safety and comfort. Cinching is the condition where a belt becomes continually tighter around you during a rough, bouncy ride. The need for this feature increases with rough road conditions, particularly over long distances. To eliminate cinching, simply activate the Komfort–Lok® feature at the appropriate time: 4.
SEATS During Pregnancy Pregnant women should always wear combination lap/ shoulder belts. The lap belt portion must be worn snugly and as low as possible across the pelvis. To avoid pressure on the abdomen, the belt must never pass over the waist. Sometimes pregnant women worry that in a crash the seat belt could hurt the baby. But if a woman wears her belt properly—low over her pelvis, below her abdomen—the belt will not harm the baby, even in a crash.
DRIVER'S CHECK LIST Driver's Check List Safe Vehicle Operation To keep your Medium Duty 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. Please remember, too, that the Federal law requires a pretrip inspection and so do commercial trucking companies. You are not expected to become a professional mechanic.
DRIVER'S CHECK LIST WARNING! Do not drink and drive . Your reflexes, perceptions, and judgment can be affected by even a small amount of alcohol. You could have a serious—even fatal—accident if you drive after drinking. Please do not drink and drive or ride with a driver who’s been drinking. WARNING! Do not exceed the specified load rating. Overloading can result in loss of vehicle control and death or serious personal injury, either by causing component failures or by affecting vehicle handling.
DRIVER'S CHECK LIST GAWR: is the Gross Axle Weight Rating. This is the total weight that one axle is designed to transmit to the ground. You will find this number listed on the driver's door edge. Load Distribution: be sure any load you carry is distributed so that no axle has to support more than its GAWR. WARNING! An unevenly distributed load or a load too heavy over one axle can affect the braking and handling of your vehicle, which could result in an accident causing death or personal injury.
DRIVER'S CHECK LIST Engine Compartment Checks — Daily 1. Engine Fluid Levels—add more if necessary. • Engine oil • Coolant (check while engine is cold) • Power steering fluid level • If your truck has hydraulic brakes, check the fluid level in the master cylinder reservoir. See page 154 for more information. 2. Engine Belt—check tension and condition of belts. This is important to ensure proper air compressor and engine operation. • Measure the belt tension at the longest span of the belt.
DRIVER'S CHECK LIST WARNING! Diesel fuel in the presence of an ignition source (such as a cigarette) could cause an explosion. You could be killed or seriously injured. A mixture of gasoline or alcohol with diesel fuel increases this risk of explosion. •Do not remove a fuel tank cap near an open flame. 5. Brake Components—check lines, linkages, chambers, camtubes (for cracks or broken parts), and brake operation. 6.
DRIVER'S CHECK LIST 2. If your vehicle is equipped with an adjustable steering column, adjust the steering wheel to a comfortable position. 3. Mirrors—check and readjust mirrors if necessary. 4. Lights—turn ignition key to the IGN & ACC position and check for warning lights and buzzer. Check operation of turn signals and emergency lights. 5. Instruments—check all instruments. 6. Windshield—check operation of windshield wipers and washers. 7. Horn—check operation of horn. 8.
STARTING AND OPERATING THE VEHICLE Starting and Operating the Vehicle Introduction For detailed information on starting and operating the engine, refer to the Engine Operation and Maintenance Manual provided with your Medium Duty vehicle. Because each vehicle is custom-equipped, all engine operation instructions presented in this section are general. You will want to consult the engine manual to find out details about your vehicle's specific engine requirements.
STARTING AND OPERATING THE VEHICLE NOTE: When any one of the following is true, oil should be applied to the turbocharger oil inlet port: (1) if the engine has not been started for more than 25 days; or (2), the outside temperature is very cold; or (3), the oil filter has been changed. •With an oil can, squirt approximately one-half cup (120 ml) of clean, specified engine oil into the turbocharger oil inlet port.
STARTING AND OPERATING THE VEHICLE TO START” indicator lamp turns ON, wait until the indicator lamp goes OFF (approximately 60 seconds) before attempting to start the engine. (For each engine and ambient temperatures, warm-up cycles will vary.) 7. Turn the ignition switch to the IGN & START position to engage the starter. Crank the engine until it starts. If the engine does not start within 30 seconds, release the key.
STARTING AND OPERATING THE VEHICLE CAUTION: Never operate the starter motor while the engine is running. The starter and flywheel gears could clash or jam, severely damaging them. • Wait until normal engine oil pressure registers on the gauge before idling or accelerating the engine beyond 1000 rpm. • Watch the air pressure gauge. Wait until both pointers register at least 100 psi (689 kPa) before releasing the spring brake and moving the vehicle.
STARTING AND OPERATING THE VEHICLE Engine Block Heater (Option) To preheat the engine before starting, plug the optional engine block heater into a properly grounded AC electrical source. Do not start the engine with the heater plugged in. WARNING! Engine block heaters can cause fires resulting in death or serious personal injury and/or property damage if not properly maintained and operated. Regularly inspect the engine block heater wiring and connector for damaged or frayed wires.
STARTING AND OPERATING THE VEHICLE With each engine make, the air intake heating system works differently. To understand fully how your engine's heating system operates, see the engine Operation and Maintenance Manual for details. On most systems the engine block temperature is monitored at startup; other systems monitor the engine oil pressure, coolant temperature, and time, as well. When the pre-set conditions are met, the heater automatically engages.
STARTING AND OPERATING THE VEHICLE NOTE: In colder climates where the temperatures are often below freezing, sufficient warmup for turbocharged engines is especially important. Chilled external oil lines leading to the turbocharger will slow the oil flow until the oil warms, reducing oil available for the bearings. Watch the engine oil pressure gauge for a warming trend before increasing engine idle speed (rpm).
STARTING AND OPERATING THE VEHICLE • During the time it takes you to drink a cup of coffee, your engine can cool as much as 60° F (33° C) below normal operating temperature. To keep the engine warm during a short break, turn it off. Do not allow your engine to idle longer than five minutes. Engine Fan Switch (Option) Your Medium Duty vehicle may have an engine fan switch installed as an option.
STARTING AND OPERATING THE VEHICLE Cruise Control (Option) 2. Accelerate the vehicle to the desired cruise speed. 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, 15 mph for the CAT 3126B engine, 30 mph for the Cummins ISC engine. 3. Toggle the SET/RESUME switch lever to the SET position to set the cruise speed.
OPERATING THE TRANSMISSION STARTING AND OPERATING THE VEHICLE and read the specific instructions contained in the transmission manufacturer's manual that is included with your vehicle. Reengaging the Cruise Control 1. Move the ON/OFF switch to the ON position. or NOTE: You will find a shift pattern diagram in the cab. Check to be sure you know the correct sequence for your particular transmission. 2. Toggle the SET/RESUME lever to the RESUME position.
STARTING AND OPERATING THE VEHICLE OPERATING THE TRANSMISSION Transmission Warm–Up 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 your transmission oil before starting out on the road. 2. Fully depress the clutch pedal until the clutch brake makes contact (see page 100). The contact will occur at about 1 inch or less from the floorboard.
OPERATING THE TRANSMISSION STARTING AND OPERATING THE VEHICLE 5. Release the clutch pedal, then gradually accelerate to permit smooth starting, 6. Do not allow your vehicle to roll (even a little) in the opposite direction during clutch engagement. If you need to start up on an incline, apply your service brakes before you release the parking brake. Then release your service brakes as you engage the clutch and apply throttle.
STARTING AND OPERATING THE VEHICLE OPERATING THE TRANSMISSION stroke of the clutch pedal is about 10 inches. The first part is the release stroke: the part that fully releases the clutch. The last inch engages the clutch brake. CAUTION: Be careful not to apply the clutch brake while the vehicle is moving. The purpose of the clutch brake is to stop the transmission so that you can shift into a starting gear without grinding gears.
OPERATING THE TRANSMISSION STARTING AND OPERATING THE VEHICLE • Upshifts: let the engine and gears slow down to the rpm required for the next gear. • Downshifts: press accelerator, increase engine and gear speed to the rpm required in the lower gear. 4. Now quickly press the pedal to disengage the clutch and move the gear shift lever to the next gear speed position. Inspect manual clutches according to the manufacturer's recommendations.
STARTING AND OPERATING THE VEHICLE OPERATING THE TRANSMISSION Operating Automatic Transmissions There may not be a “park” position with your automatic transmission. Always be sure you apply the parking brake before leaving the cab. An automatic transmission makes shifting much easier, however it is important to understand how to operate the transmission efficiently. Please read the transmission manufacturer’s operation manual supplied with your vehicle.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE Using the Brake System NOTE: Today’s diesel engines have significant torque and startability power at low RPMs. Combinations of engine speed and available torque may overpower the vehicle’s parking brakes. WARNING! Never drive your vehicle with the parking brakes applied. Always release the parking brakes prior to moving the vehicle.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM Brake Operation WARNING! Do not drive through water deep enough to wet brake components, as it may cause the brakes to work less efficiently than normal. The vehicle's stopping distance may be longer than expected, and the vehicle may pull to the left or right when brakes are applied, which could contribute to an accident that could cause death or personal injury.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE Using the Parking Brake Before you leave the cab: The yellow diamond-shaped knob on the dash controls the truck/tractor parking brakes. These are spring brakes that you activate by releasing air pressure from their chambers. When they are not in use, air pressure compresses the springs and releases the brakes.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM To release the trailer brakes ONLY: (2) Trailer Air Supply Control (Red) (1) Parking Brake Control (Yellow) • Push IN the Red knob on the dash. The truck or tractor will remain parked. To release the full combination of brakes: 02394 Combination (Tractor/Trailer) Parking Brake Control Valves • Push IN BOTH knobs on the dash.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE WARNING! If the air pressure falls below 60 psi (414 kPa) the spring brakes may stop the vehicle abruptly, which could result in an accident involving death or personal injuries. Observe the red warning lamps on the gauges. If one comes on, do not continue to drive the vehicle until it has been properly repaired or serviced. WARNING! Do not use the trailer hand brake or service brakes to park and hold an unattended vehicle—use the parking brakes.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM The parking brakes act on the rear wheels only. They are spring-applied, with air pressure used to release them. Release air is supplied by both the front and rear circuit reservoirs through a double check valve.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE WARNING! Do not use the trailer hand brake or service brakes to park and hold an unattended vehicle—use the parking brakes. Because service brakes work with air pressure, these brakes could slowly release. Your vehicle could roll, causing a serious accident. Someone could be hurt or killed. Never rely on the service brakes to hold a parked vehicle.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM Front Brakes — Truck Rear Brakes — Truck The following applies to full truck configurations: The following applies to full truck configurations: If air pressure is lost in the front circuit, the vehicle front brakes will not operate. Check valves isolate the rear circuit, so the rear service brakes and parking brakes are unaffected. The spring brakes will not automatically apply as long as rear service pressure is maintained.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE WARNING! Efficiency of emergency braking depends on the amount of air available in the front circuit reservoir, which is sufficient for a limited number of brake applications and releases. • REMEMBER: when the remaining system pressure drops below 60 psi (414 kPa), the spring brake is automatically applied, stopping the vehicle abruptly, potentially causing death or serious injury.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM Use engine compression to assist the service brakes by not depressing the clutch pedal until the engine reaches idle speed. Overheated Brakes Under normal braking conditions, the energy generated will bring the internal brake drum temperature to about 500°F (260°C). This is well within the safe zone: the maximum safe temperature of lining for drum type brakes is usually about 800°F (427°C).
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE should remain off after this point unless a failure in the system is detected. The truck/tractor ABS lamp is located in the warning lamp cluster. ABS CAUTION: If the trailer ABS warning lamp does not illuminate when the ignition is first turned on, there is a problem with the bulb or wiring. The driver should have this checked as soon as possible.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM NOTE: A “properly connected” ABS-equipped trailer is WARNING! Do not rely on an anti-lock brake system that is functioning improperly. You could lose control of the vehicle resulting in a severe accident, causing death or personal injury. If your ABS lamp goes on while you are driving or stays on after the self-check, your anti-lock system might not be working. The ABS may not function in an emergency.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE torque. Do not allow the Wheel Spin Control lamp to remain on continuously for an extended length of time. Extended, continuous use of the ASR / ATC can cause overheating of the drive wheel brakes. Engine torque or vehicle speed should be reduced to eliminate wheel spin and prevent excessive application of the ASR / ATC system. To operate the trailer brake hand valve: • Pull down on the lever. • The valve is self-returning.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM WARNING! Do not use an engine retarder when you are driving bobtail or with an unloaded trailer. Using engine retarders while bobtailing or with an unloaded trailer can cause a wheel lockup resulting in less control and/or jackknife. The trailer may not load the rear tractor tires enough to provide necessary traction.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE WARNING! The service brakes must be used in an emergency. The engine or retarder alone might not stop you fast enough to prevent an accident. You could be killed or injured if you relied only on the engine retarder. • Make sure the brake is OFF before starting the engine. • After the engine is started, warmed up, and you are ready to get under way, turn the exhaust brake switch ON for added braking effect.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM Compressed Air Tanks: The wet (supply) and dry (ser- Brake Components The following is a brief description of the air/brake system. It is intended to supply you with general information on how the system works. For complete information see the Medium Duty Maintenance Manual. Compressor: supplies air to the system. System pressure is controlled by the governor.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE • Modulates spring brake application in proportion to front service application in the event of a rear service failure. • Prevents compounding of service and spring applications. Relay valve (full truck): speeds up the application of the rear service brake. It also incorporates a quick–release feature. Brake Proportioning (BP-R1) valve (tractor): t h i s v a l v e delivers air to the tractor's service brake chambers.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM to the trailer, and (3) protect the tractor air supply in case of separation of the air lines connecting the tractor to the trailer. Hydraulic Brakes WARNING! Do not operate the vehicle in the event of a malfunction in any air or hydraulic circuit. Such a malfunction may prevent the brake system from operating properly, and could result in an accident, causing death or personal injury.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE NOTE: Today’s diesel electronic engines have significant torque and startability power at low RPM. Combinations of engine speed and available torque may over-power the vehicle’s parking brakes. WARNING! The brake system is a critical vehicle safety system.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM Electrohydraulic Pump: The Electrohydraulic (EH) pump is used as a backup boost pump. The EH pump turns on and provides fluid pressure to the hydraulic booster in the event power steering fluid stops flowing through the booster head. Front and Rear Wheel Calipers: translate hydraulic fluid pressure into force applied at each wheel-end brake rotor to retard wheel motion.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE 4. Turn on the emergency flasher and use other warning devices to alert other motorists. ! SERVICE BRAKE WARNING INDICATOR Wet or Overheated Brakes BRAKE • Wet Brakes If the buzzer sounds while driving, or if the BRAKE light comes on, do the following: Here are some things you can do to assist in slowing the vehicle: If you have been driving in heavy rain or deep standing water, your brakes will get wet.
STARTING AND OPERATING THE VEHICLE USING THE BRAKE SYSTEM While traveling down steep hills, gravity will tend to speed you up. You must go slow enough that your brakes can hold you back without getting too hot. If you ride the brake pedal and the brakes get too hot, they may “fade”, causing you to press even harder in an attempt to maintain your desired stopping power. The brakes may even fade so much that you won’t be able to slow down or stop at all.
USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE WARNING! No indication will be given via the dashboard warning lights or buzzer if tires of the wrong size are installed on your vehicle. The Anti-Lock Brake System (ABS) is calibrated for the specific tire revolutions per mile. Use of a tire and/or wheel size different from that originally installed on your vehicle may cause the ABS system to not function during a hard braking event.
STARTING AND OPERATING THE VEHICLE OPERATING THE REAR/DRIVE AXLE Operating the Rear/Drive Axle Introduction This section covers the operation of your Rear/Drive Axle. These instructions apply to the most common features of drive axles. Refer to the manufacturer’s instructions for further information on the operation of your axle. If your vehicle is equipped with a Rockwell Tractech™ Nospin single rear axle, the wheel differential lock feature automatically engages and disengages.
OPERATING THE REAR/DRIVE AXLE STARTING AND OPERATING THE VEHICLE Inter–Axle Differential Lock Operation • Dirt roads. • Loose sand, mud, or other rough road conditions. WARNING! Do not use the inter-axle differential lock when travelling downhill or at speeds above 25 mph (40 km/h). When it is engaged under these conditions, your vehicle will exhibit “understeer” handling characteristics.
STARTING AND OPERATING THE VEHICLE OPERATING THE REAR/DRIVE AXLE NOTE: If your vehicle has an automatic transmission, it may be necessary to shift the transmission to the Neutral position momentarily to allow the main inter-axle differential lock splines to fully engage or disengage. Turning Radius When Unlocked (Disengaged) 4. Drive the vehicle through the poor traction area, keeping your speed under 25 mph (40 km/h).
MORE DRIVING TIPS AND TECHNIQUES STARTING AND OPERATING THE VEHICLE More Driving Tips and Techniques Use of Driver Information Display WARNING! Low air pressure could make the brakes unsafe for driving. Before driving the vehicle, make sure the pressure does pump up to over 100 psi for normal brake operation. If the air pressure does not pump up to at least 100 psi, don’t try to move the vehicle as it may cause an accident, possibly resulting in death or personal injury.
STARTING AND OPERATING THE VEHICLE DRIVING TIPS AND TECHNIQUES ure or damage to the clutch and transmission and overloads the brake system. Engine Overspeed CAUTION: To avoid engine damage, do not let the engine rpm go beyond the maximum governed rpm—valve damage could result if overspeed conditions occur. Coasting with the transmission in neutral also prevents proper transmission component lubrication.
DRIVING TIPS AND TECHNIQUES STARTING AND OPERATING THE VEHICLE Refer to the Engine Operation and Maintenance manual for optimum engine rpm. • If the engine rpm moves beyond the maximum governed speed, indicating an overspeed condition, apply the service brake or shift to a higher gear to bring engine rpm within the optimum speed range. • Shift into higher or lower gears (or apply the service brake) to keep engine rpm near the lower end of the optimum operating range.
STARTING AND OPERATING THE VEHICLE DRIVING TIPS AND TECHNIQUES Air Suspension Height/Air Pressure Your vehicle may have an air suspension. A deflation switch on the dash allows you to exhaust the air in the suspension, which allows you to lower the height of your vehicle for loading. On tractors, the deflate switch allows you to lower the fifth wheel to slide under a trailer. A guard on the switch prevents you from accidentally deflating the suspension.
DRIVING TIPS AND TECHNIQUES STARTING AND OPERATING THE VEHICLE WARNING! To prevent possible death, injury and damage to property, ensure that a vehicle is parked and the wheels chocked before beginning this procedure. CAUTION: Completing this procedure will enable you to safely reach the nearest authorized Peterbilt repair facility to have ride height and pinion angle reset using the proper equipment and technique. Do this as soon as possible to avoid potential driveline damage.
STARTING AND OPERATING THE VEHICLE DRIVING TIPS AND TECHNIQUES WARNING! Be extremely careful when deflating the air springs. The rear of the vehicle will drop about 3-1/2 inches (88 mm) when the air springs are deflated. Make sure that no persons that could be killed or injured or any objects that could be damaged are under the vehicle. ALIGNMENT PIN OR DOWEL CONTROL ARM To minimize the risk of damage death or injury, do not use the dump valve to deflate the air springs.
DRIVING TIPS AND TECHNIQUES STARTING AND OPERATING THE VEHICLE DELIVERY TO RH AIR BAG(S) SUPPLY FROM FORWARD AIR TANK MOUNTING NUTS 3. Rotate the valve either clockwise or counterclockwise until air pressure in the air springs provides the ride height specified for that suspension.
STARTING AND OPERATING THE VEHICLE DRIVING TIPS AND TECHNIQUES WARNING! Low air pressure could make brakes unsafe for driving by not providing sufficient air brake application pressure in an emergency, which could lead to an accident resulting in death or personal injury. Before driving the vehicle, make sure the air pressure pumps up to over 100 psi for normal brake operation. If it does not reach 100 psi, do not try to move the vehicle.
DRIVING TIPS AND TECHNIQUES STARTING AND OPERATING THE VEHICLE Your Medium Duty vehicle may be equipped with either a fixed or an air-controlled sliding fifth wheel. Either type should self-lock when a trailer king pin trips the locking dogs as the tractor is backed under a trailer. Fifth Wheel Jaw Lock To unlock the fifth wheel lock: FIFTH WHEEL • Pull out on the lever (usually located on the left-hand side of the fifth wheel) until it remains in an overcenter position.
STARTING AND OPERATING THE VEHICLE DRIVING TIPS AND TECHNIQUES WARNING! Do not move of the fifth wheel while the tractor-trailer is in motion. Your load could shift suddenly, causing you to lose control of the vehicle, which can result in a accident causing death or personal injury. Never operate the vehicle with the switch in the UNLOCK position. Always inspect the fifth wheel after you lock the switch to be sure the fifth wheel lock is engaged.
VEHICLE RECOVERY AND SPRING BRAKES STARTING AND OPERATING THE VEHICLE Vehicle Recovery and Spring Brakes Introduction Your Medium Duty vehicle is equipped with built-in recovery provisions, designed for short distance use only. If your vehicle must be recovered, disconnect the driveline at the rear U–joint, and remove or support the rearmost section of the driveline.
STARTING AND OPERATING THE VEHICLE VEHICLE RECOVERY AND SPRING BRAKES Vehicle Recovery Guidelines Recovery Rigging Refer to the guidelines below when towing to prevent possible damage: To connect to the Medium Duty vehicle, attach the towing chain or cable and the hitches to the (2) tow recievers through the center access hole in the bumper. • Use proper towing equipment to prevent damage to the vehicle. CAUTION: Connect only to the towing provisions, as described on the following pages.
VEHICLE RECOVERY AND SPRING BRAKES STARTING AND OPERATING THE VEHICLE 2. Into the inter-axle differential, add 2 pints (.94 liter) of approved lubricant. • See “Recommended Lubrication Types,” Page 136. 3. After adding the specified type and amount of lubricant, drive the vehicle. It should be unloaded. Drive 1 to 2 miles (1.5 to 3 km) at a speed lower than 25 mph (40 km/h). This will thoroughly circulate the lubricant through the assembly.
STARTING AND OPERATING THE VEHICLE VEHICLE RECOVERY AND SPRING BRAKES To move a vehicle immobilized by the spring brakes due to loss of air pressure in the brake system, perform the following procedure: 1. Remove the cap from the spring chamber. 2. Remove the release stud assembly from the side pocket, and remove the release nut and washer from the release stud. 4. Insert the release stud through the opening in the spring chamber where the cap was removed. Insert it into the pressure plate.
VEHICLE RECOVERY AND SPRING BRAKES STARTING AND OPERATING THE VEHICLE 6. With a wrench, turn the release stud assembly nut until the compression spring is 90– 95 percent caged. While doing this, check to make sure the push rod (adapter push rod or service push rod) is retracting. Do not over-torque the release stud assembly. (S–Cam type maximum: 50 ft-lb, Wedge type maximum: 30 ft-lb.) The spring brake is now m echan ically released.
STARTING AND OPERATING THE VEHICLE VEHICLE RECOVERY AND SPRING BRAKES Comply with the following instructions to avoid transmission damage: • Always start the vehicle in motion with the shift lever in first gear. • Be sure that the transmission is fully engaged in gear before releasing the clutch pedal (manual only). • Do not shift into reverse while the vehicle is moving. • Do not permit the vehicle to be towed for long distances without removing the driveshaft.
SHUT–DOWN STARTING AND OPERATING THE VEHICLE Shut–Down WARNING! Do not use the trailer hand brake or service brakes to park and hold an unattended vehicle—use the parking brakes. Because service brakes work with air pressure, these brakes could slowly release. Your vehicle could roll, causing an accident resulting in death or personal injury. Someone could be hurt or killed. Never rely on the service brakes to hold a parked vehicle.
STARTING AND OPERATING THE VEHICLE SHUT–DOWN Turbocharger 3. Drain water from the air reservoirs. • While the engine and air supply system are still warm, drain moisture from the air reservoirs. Open the reservoir drains just enough to drain the moisture. Do not deplete the entire air supply. Be sure to close the drains before leaving the vehicle. 4. Secure the vehicle, close all the windows, and lock all doors. Before Stopping the Engine Do not shut off the engine immediately.
SHUT–DOWN STARTING AND OPERATING THE VEHICLE WARNING! Do not carry additional fuel containers in your vehicle. Fuel containers, either full or empty, may leak, explode, and cause or feed a fire, possibly causing death or personal injury. Do not carry extra fuel containers, even empty ones are dangerous. Specification: Use only Diesel Fuel, Grade 2–D, as rec- WARNING! Diesel fuel in the presence of an ignition source (such as a cigarette) could cause an explosion.
STARTING AND OPERATING THE VEHICLE Medium Duty (R05/09) SHUT–DOWN Y53-6027 – 149 –
Introduction Preventive Maintenance PREVENTIVE MAINTENANCE INTRODUCTION This section will help you keep your Medium Duty vehicle in good running condition. There are a number of checks you can do, and you may be able to do some of the service work yourself. But please, let your Peterbilt Dealer or Authorized Service Center do any work you do not have the tools or skill to perform.
Preventive Maintenance Introduction •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 hazard. Keep an approved fire extinguisher handy. •Always support the vehicle with appropriate safety stands if it is necessary to work underneath the vehicle. A jack is not adequate for this purpose.
Introduction Preventive Maintenance erly. Non-compliance with environmental regulations can result in fines and/or jail terms. Contact your local government agency for information concerning proper disposal. 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, and other reproductive harm.
Preventive Maintenance Maintenance Schedule and Lubrication MAINTENANCE SCHEDULE AND LUBRICATION Introduction The following section summarizes preventive maintenance and lubrication requirements for the maintenance of your Medium Duty vehicle. For specific maintenance procedures and complete lubrication instructions of specific components consult the Medium Duty Maintenance Manual and manufacturer's service manuals.
Maintenance Schedule and Lubrication Preventive Maintenance Maintenance Intervals Table 1, ”Recommended Maintenance Intervals”, shows service intervals for normal and heavy-duty operations. For additional “Engine Cooling System” information see Table 1 Page 178. For additional “Air System” information see Page 196. NOTE: Different lubricants or service intervals than those listed below may be required.
Preventive Maintenance Table 1 Maintenance Schedule and Lubrication Recommended Maintenance Intervals ITEM Rear Wheel Bearings INTERVAL 100,000 COMMENTS With LMS Wheel End Package Rear Brake Camshafts 10,000–15,000 Synthetic Grease With Special Fittings Fifth Wheel 10,000–15,000 40 to 60K For Adjustment Spring Pins 10,000–15,000 With Rubber Bushed Pins – No Service Front & Rear Slack Adjusters 10,000–15,000 Synthetic Grease With Special Fittings King Pins 10,000–15,000 Front Wheel Bearin
Maintenance Schedule and Lubrication Table 1 Preventive Maintenance Recommended Maintenance Intervals ITEM INTERVAL COMMENTS Hydraulic Brakes Brake Pad Lining Inspection 7,500 mile Rotor Inspection 15,000 miles or 15 mos Park Brake Inspection 15,000 miles or 15 mos Minimum 3/16 in.
Preventive Maintenance Maintenance Schedule and Lubrication Maintenance Schedule TABLE KEY NOTE: If a scheduled service interval is shaded, skip to the next interval. The frequency of each service operation is identified by open (non-shaded areas). Use Table 2, ”Maintenance Schedule,” as a guide to plan service work. Be sure and follow the frequency recommendations for your vehicle. Table 2 C2 Federal Annual Inspection 120,000 miles/192,000 km only.
Maintenance Schedule and Lubrication Table 2 Preventive Maintenance Maintenance Schedule 15,000 mi 24,000 km 60,000 mi 96,000 km OPERATION \ FREQUENCY COMMENTS 7,500 mi 12,000 km INTERVAL A B C A B C Wiper Blade Condition Horns (Electric and Air) Mirrors SAFETY EQUIPMENT Drain Water from Air Tanks Air Tank Check Valve Emergency Operation of Spring Brakes Air Press. Build–up time: _______ min. Governed Air Pressure: _______ psi Air Press. Drop–Brakes not Applied: ___ Air Press.
Preventive Maintenance Table 2 Maintenance Schedule and Lubrication Maintenance Schedule Emergency Flasher Brake Lights Backup/Loading Lights License Plates: Permits and Mounting Mud Flaps / Serviceable Fuel Tank Mounting Exhaust System–Condition and Mounting Bolts Frame Fastener Torque: does NOT apply to Le Jeune frame fasteners.
Maintenance Schedule and Lubrication Table 2 Preventive Maintenance Maintenance Schedule COMMENTS 60,000 mi 96,000 km 15,000 mi 24,000 km OPERATION \ FREQUENCY 7,500 mi 12,000 km INTERVAL Fan Shroud Fan Assembly and Idler Pulley Check Water Pump for Leaks / Play Radiator – Exterior Condition No Service Required Replace Engine Coolant C4 Fill as Required – Extended Drain Per Manufacturer Specifications.
Preventive Maintenance Table 2 Maintenance Schedule and Lubrication Maintenance Schedule COMMENTS 60,000 mi 96,000 km 15,000 mi 24,000 km OPERATION \ FREQUENCY 7,500 mi 12,000 km INTERVAL Drain Water from Fuel System 25,000 Mile Change Interval – Must Meet Engine Co. Requirements Engine Oil – Change Oil Filters – Replace Fuel Filters – Replace Engine Tune–up Cranking System: Visual Inspect.
Maintenance Schedule and Lubrication Table 2 Preventive Maintenance Maintenance Schedule COMMENTS 60,000 mi 96,000 km 15,000 mi 24,000 km OPERATION \ FREQUENCY 7,500 mi 12,000 km INTERVAL King Pin Wear Steer Axle Wheel Bearing - End Play Adjustment and Inspection Front Hub Lubricant Level Spring Leaves 350,000 Miles With LMS Outer Ends • No Leak – No Service Tighten U-bolts after the first 500 miles (800 km). Rear suspension fasteners: retorque after first 2,000 miles (3218 km).
Preventive Maintenance Table 2 Maintenance Schedule and Lubrication Maintenance Schedule COMMENTS 60,000 mi 96,000 km 15,000 mi 24,000 km OPERATION \ FREQUENCY 7,500 mi 12,000 km INTERVAL Synthetic Grease Required – Special Fitting No Service Required Front & Rear Brake Camshaft Tube Lubrication Clutch Pedal Shaft Clutch Linkage Suspension Fittings Clutch Release Bearing Driveline Center Bearing Automatic Slack Adjusters Brakes: Lining Remaining (replace as required) RF ______ RRF ______ RRR ______
Maintenance Schedule and Lubrication Table 2 Preventive Maintenance Maintenance Schedule 15,000 mi 24,000 km 60,000 mi 96,000 km OPERATION \ FREQUENCY COMMENTS 7,500 mi 12,000 km INTERVAL A B C Sealed Type – Condition: (Color of charge indicator for each battery) 1 ______ 2 ______ 3 ______ 4 ______ TIRES AND WHEELS Missing Valve Caps and Stem Locks Cracks or Loose Wheel lugs Tandem Mating Irregular Wear Tire Pressure (Record below) Remaining Tread (Record below) Tires & Wheels Inspection Right
Preventive Maintenance Table 2 Maintenance Schedule and Lubrication Maintenance Schedule 15,000 mi 24,000 km 60,000 mi 96,000 km OPERATION \ FREQUENCY COMMENTS 7,500 mi 12,000 km INTERVAL A B C A B Left Air Pressure Adjusted to: _____________ ALIGNMENT Toe–in: ______________ in (mm) Caster: L ________ R ________ Rear Axle Alignment ROAD TEST C2 C Steering / Steering Play Shifting Brakes Engine Operation (noises, surging, black smoke) Throttle Linkage Jake Brake Operation Seat Belts Air Sea
Maintenance Schedule and Lubrication Table 2 Preventive Maintenance Maintenance Schedule 15,000 mi 24,000 km 60,000 mi 96,000 km OPERATION \ FREQUENCY COMMENTS 7,500 mi 12,000 km INTERVAL A B C A B C Air Conditioner Instruments and Gauges: Speedometer/odometer Tachometer Oil Pressure Engine Temperature Illumination BODY Interior Liner Damage Door Operation Roll–up Door Tracks – Lubricate Lift–gate Operation OTHER Hood Pivots Fifth Wheel Components Brake Treadle Hinge and Roller Lock Cylinder
Preventive Maintenance Maintenance Schedule and Lubrication Lubrication Specifications You will find a complete Engine Lubrication Service Guide in the Engine Operation and Maintenance Manual. There, the engine manufacturer explains more fully all the maintenance operations you and a qualified service mechanic will need. And please remember: one key to keeping your Medium Duty vehicle running at top economy and in prolonging its life is proper lubrication servicing.
Maintenance Schedule and Lubrication Preventive Maintenance Lubrication Types APPLICATION Use Table 3 on page 170 and the list of lubricants below to identify the type of lubricant to use on your Medium Duty vehicle. For a quick summary of each lubrication point, see Table 1 on page 154.
Preventive Maintenance Maintenance Schedule and Lubrication Oil Reservoirs For oil reservoirs with side filler plugs (transmissions, axles, steering gear boxes, transfer cases, etc.), the oil must be level with the filler opening. NOTE: Use care when checking the oil level with a finger. Just because you can reach the oil level with a finger, does not mean the oil level is correct.
Maintenance Schedule and Lubrication Table 3 Preventive Maintenance Recommended Lubrication Types COMPONENTS RECOMMENDED LUBRICANT Power Steering Gear Automatic Transmission Fluid (ATF) Driveline U-Joints Slip-Joint Splines Hood Pivots Fan Drive Fifth Wheel Components Clutch Pedal Shaft Clutch Linkage Other chassis grease fittings not covered below. EP chassis grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2.
Preventive Maintenance Table 3 Maintenance Schedule and Lubrication Recommended Lubrication Types COMPONENTS RECOMMENDED LUBRICANT Cam Brake Camshaft Splines; Disc Brake Shaft Splines and Slide Pin Retainers; Brake Clevis Pins Antiseize type grease, Rockwell specification 0-637. Brake Camshaft Bushings EP Chassis grease, lithium 12-hydroxystearate base, NLGI 2. CAUTION: Do not contaminate brake linings with grease.
Maintenance Schedule and Lubrication – 172 – Preventive Maintenance Y53-6027 Medium Duty (R05/09)
Preventive Maintenance Engine Maintenance ENGINE MAINTENANCE NOTE: Keep the engine exhaust system and the vehicle’s cab ventilation system properly maintained. It is recommended that the vehicle’s exhaust system and cab be inspected: • By a competent technician every 15,000 miles. • Whenever a change is noticed in the sound of the exhaust system. • Whenever the exhaust system, underbody, cab or sleeper is damaged.
Engine Maintenance Preventive Maintenance Oil Draining: • Refer to the engine manufacturer's Engine Operation and Maintenance Manual supplied with your vehicle for information about draining and refilling engine oil, engine crankcase capacity, engine oil type, and changing oil filters, etc. WARNING! Hot engine oil can be dangerous. You could be seriously burned. Let the engine oil cool down before changing it. • Drain the oil into a container designed for this purpose.
Preventive Maintenance Engine Maintenance WARNING! Use Ultra Low Sulfur Diesel fuel only. Failure to do so may damage components of the engine and Diesel Particulate Filter (DPF). Please follow these recommendations when you are changing your fuel filters or strainer elements. Your vehicle's engine will run better and last longer if you do. See the engine manufacturer's recommendations for proper water and micron requirements.
Engine Maintenance Preventive Maintenance If entrapped water exceeds sump volume, you can either: A. Close valve and run engine until smooth idle is established, then repeat drain procedures, or B. Remove filter from mounting head, completely drain all fluid, and reassemble filter assembly. Be sure to follow new filter assembly instructions. 2. Close drain valve by turning valve screw clockwise approximately 1 1/2 to 2 turns.
Preventive Maintenance Engine Maintenance What to do if you run out of DEF and are stranded. call a dealership. Engine Accesories: 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.
Engine Cooling System Preventive Maintenance To Check the Fan: • Check the fan assembly mounting bolts for tightness. Inspect the blades for damage. • Check the clutch operation by starting the engine when it is cold. Then idle it at about 800 RPM. Listen for air leaks. • Check that the fan is not working while the engine is warming. When the clutch engages, note the reading on the vehicle's panel—mounted coolant temperature gauge.
Preventive Maintenance Engine Cooling System itors. ELC prevents corrosion and scale formation as well as provides freezing and boiling point protection. What To Check In An ELC-filled Cooling System ELC Concentration CAUTION: The engine cooling system has very specific maintenance and inspection requirements. Failure to follow requirements can damage the engine.
Engine Cooling System Preventive Maintenance ELC Condition (Contamination and Inhibitor Concentration) Topping Off Perform a visual inspection of the ELC. It should have no cloudiness or floating debris. Determine the chemical inhibitor concentration level by using an ELC-specific test kit or test strips. Inhibitor concentration level determines corrosion protection. If you are concerned about possible coolant quality, contamination, or mechanical problems, submit a coolant sample for analysis.
Preventive Maintenance Engine Cooling System FILL COOLANT EXPANSION TANK Check the coolant level after each trip. Add coolant as necessary. You may find your coolant level is not up to the correct level soon after you have filled the radiator. This may be because all the trapped air in the system has not yet been purged. It takes a little time for all the air to leave the system after you fill your radiator. Refilling Your Radiator 1. 2. 3. 4.
Engine Cooling System Preventive Maintenance Engine (Block) Heater (option) WARNING! Do not use the heater if there are any signs of problems. Engine block heaters can cause fires resulting in death, serious personal injury and/or property damage if not properly maintained and operated. Regularly inspect the engine block heater wiring and connector for damaged or frayed wires. Contact your Authorized Service Center or the manufacturer of the heater if you are in need of repairs or information.
Preventive Maintenance Cooling Engine Cooling System Hoses Check the radiator and heater hoses for leaks. X X Extended Life Coolant (ELC) Check the freeze point (see page 178). X Check for contamination using test strips (see page 179). X Replace blank water filter if applicable. X Perform lab analysis (see page 179). X If lab analysis shows coolant is unsuitable for continued use Flush, drain, and refill (see page 178). Add ELC Extender (see page 179).
Brake System Preventive Maintenance BRAKE SYSTEM All of the following areas are interrelated and must conform to original specifications: If your truck has an air brake system, see the pages below. If your truck has a hydraulic brake system, please go to “Hydraulic Brake System” on page 188. • • • • Introduction To operate your vehicle safely, you need some understanding of its brake systems. Brake adjustment and brake balance must be set carefully to allow equal stopping forces at all wheels.
Preventive Maintenance Brake System WARNING! Do not use any replacement part in the brake system unless it conforms exactly to original specifications. A nonconforming part in your vehicle's brake system could cause a malfunction resulting in an 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 Preventive Maintenance • Do not use moly-disulfide loaded grease or oil (they may shorten the service life of the slack adjuster). • Do not use pressure-release grease fittings when lubricating the slack adjuster. Your Medium Duty vehicle is equipped with automatic brake (slack) adjusters. Periodically, brake adjustment should be checked using the following procedure: Checks and Adjustments All vehicle operators should check the brakes regularly. Always adjust the brakes when they are cool.
Preventive Maintenance Brake System WARNING! Manual adjustment of automatic slack adjusters is a dangerous practice that could result in an accident involving death or injury. It gives the operator a false sense of security about the effectiveness of the brakes. Contact the Service Department at your dealership if the stroke exceeds the above specifications. A stroke exceeding these values may indicate a problem with the slack adjuster or the brake foundation.
Brake System Preventive Maintenance Constant manual adjustment of automatic slack adjusters can shorten the life of the internal clutch. If the installation appears to be free of damage, but the applied stroke range could not be achieved, the slack adjuster must be replaced. NOTE: The brake adjuster alone does not ensure proper brake operation. Inspect all brake components. All brake components work together and must be checked periodically to ensure the brake system works properly.
Preventive Maintenance Brake System WARNING! Do not use any replacement part in the brake system unless it conforms exactly to original specifications. A nonconforming part in your vehicle's brake system could cause a malfunction resulting in an accident causing death or injury. Consult you local dealer for suitable replacement parts. Brake Fluid Check and Refill WARNING! Do not work on the brake system without the parking brake set, the keys removed from the vehicle, and wheels chocked securely.
Brake System Preventive Maintenance WARNING! If the brake fluid reservoir requires an excessive amount of hydraulic fluid, the complete system must be inspected for leaks and repaired if necessary (consult your nearest Peterbilt dealer). Failure to keep the brake system in good repair may lead to loss of braking and possibly cause an accident resulting in death or serious personal injury.
Preventive Maintenance Brake System It is recommended that all disc brake pads be replaced at the same time since this will maintain balanced braking. At a minimum, replace all disc brake pads on one axle, both ends, at the same time. BRAKE PADS ANCHOR PLATES Calipers Visually inspect calipers for brake fluid leakage, damaged or defective pistons or piston boots. If there is evidence of leakage, damage, or other defects the caliper should be replaced or repaired.
Brake System Preventive Maintenance Visually inspect brake shoe lining for wear, cracks, or breakage. If linings are worn down to 2.5 mm (0.10 in), they must be replaced. Inspect brake drum for deep scores, heat spots, cracks, or damage. Replace if needed. BRAKE SHOE LININGS Anti–Lock Braking System (ABS) Your Medium Duty vehicle is equipped with an anti-lock braking system. For detailed service information, see the Peterbilt Medium Duty Maintenance Manual.
Preventive Maintenance Brake System • During wheel balancing, dyno testing, or any time the ignition is on with part of the ABS disconnected, a failure code will be recorded. Consult with your Peterbilt Dealer or Authorized Service Center for information on clearing the failure code. If, due to operating conditions, a brake application causes either wheel on the same axle to begin skidding, wheel speed sensors immediately signal the anti-lock controller in the modulator assembly.
Brake System Preventive Maintenance WARNING! Do not operate the vehicle in the event of a malfunction in any air or hydraulic circuit. Such a malfunction may prevent the brake system from operating properly, and could result in an accident causing death or serious personal injury. The vehicle should not be operated until the system is repaired and both braking circuits, including all pneumatic, hydraulic, and mechanical components are working properly.
Preventive Maintenance Air System AIR SYSTEM can result if not properly disassembled. Use only proper tools and observe all precautions pertaining to the use of those tools. Introduction WARNING! Prior to the removal of any air system component, always block and hold the vehicle by a secure means other than the vehicle's own brakes. Depleting air system pressure may cause the vehicle to roll unexpectedly resulting in an accident causing death or injuries.
Air System Preventive Maintenance Scheduled Maintenance Contamination of the air supply system is the major cause of problems in air-operated components such as brake valves, wiper motors, and suspension height control valves. To keep contaminants to the lowest possible level, follow these maintenance procedures. Table 5 Use Table 5, ”Air System Scheduled Maintenance,” to schedule service operations and air system tests.
Preventive Maintenance Table 5 Air System Air System Scheduled Maintenance MAXIMUM INTERVALS EACH MONTH TEST EACH WEEK SIX MONTHS ANNUALLY (100,000 mi) (160,000 km) • Automatic Drain Valve Safety Valve Quick Release Valve Manual Drain Valve • • • Air System Function Test Scheduled maintenance should be performed on the Medium Duty vehicle’s air system, as outlined in the Medium Duty Maintenance Manual and Table 5.
Air System Preventive Maintenance • Maintain the air compressor to prevent excessive oil bypass. See the Medium Duty Maintenance Manual for maintenance details. • Replace worn seals in valves and air motors as they are needed. Your Peterbilt Dealer carries rebuild kits for most units. REAR PRIMARY (SERVICE) TANK FRONT SECONDARY (SERVICE) TANK DRAIN VALVE WET (SUPPLY) TANK UNDER FRONT SERVICE TANK 02602 Your Medium Duty vehicle comes with a primary and secondary air pressure guage.
Preventive Maintenance Air System WARNING! Do not operate the vehicle if leakage in the air system is detected. Conduct the following procedure and contact an Authorized Service Center (or any other properly equipped service center) if a leak is detected. Failure to check the brakes or follow these procedures could cause a system failure, increasing the risk of an accident resulting in death or personal injury. Follow the procedure below to check the compressed air system for leaks: 1.
Air System Preventive Maintenance CAUTION: When draining the engine cooling system is required, to prevent damage from freezing, the compressor must also be drained at the cylinder head and block. Engine damage could occur if the cooling system is not periodically drained and maintained. See “Engine Cooling System,” Page 178 , and the Medium Duty Maintenance Manual for further information. pressors.
Preventive Maintenance Air System reduced braking capability). Other vehicles use a Bendix AD-IS air dryer which eliminates the need for a wet tank and check valves in the dry tanks. NOTE: A small amount of oil in the system may be normal and should not, by itself, be considered reason to replace a desiccant cartridge; oil-stained desiccant can function adequately.
Air System Preventive Maintenance • Check the Charge-Air-Cooler for air leaks annually. The air leaks can be caused by cracked tubes or header. For service see your Peterbilt Dealer or Authorized Service Center. Turbocharger When servicing the air intake and exhaust systems on a turbocharged engine, check the items listed below. WARNING! Do not operate engine with the turbocharger intake piping disconnected. A suction is created when the engine is running.
Preventive Maintenance Air System COVER AIR INTAKE ASSEMBLY 00455B 02603 Air Intake Assembly Air Cleaner - Filter Element To remove the air filter: To install air cleaner element: 1. Remove the two thumb screws. 2. Remove air cleaner service cover. 3. Remove the filter element. 1. Slide air cleaner element into housing. 2. Install air cleaner end cap. 3. Install thumbscrews around air cleaner housing end cap. Clean out the inside of the air cleaner body and outlet tube with a dry rag.
Tires and Wheels Preventive Maintenance TIRES AND WHEELS Introduction Keeping the tires in good condition is essential to the safe, efficient operation of your Medium Duty vehicle. Regular, frequent inspection and the right care will give you the assurance of safe and reliable tire operation. WARNING! Use only original equipment manufactured (OEM) components.
Preventive Maintenance Tires and Wheels Speed Restricted Tires WARNING! This vehicle may be equipped with speed restricted tires. Check each tire’s sidewall for maximum rated speed. Vehicle should not be operated at sustained speed in excess of maximum rated speed. Failure to comply with these speed restrictions could cause sudden tire failure which can result in death, personal injury or property damage. Tire Inspection and Replacement vehicle.
Tires and Wheels Preventive Maintenance CAUTION: Pressure should be checked when the tires are cool. Warm or hot tires cause pressure buildup and will give you an inaccurate reading. So never deflate a warm tire to the specified pressure. Tire Inflation Most tire wear problems are caused by underinflation as the result of slow leaks. So you will want to check tire pressure regularly. Give the tires a visual test every day, and check inflation with a gauge every week.
Preventive Maintenance 00138a TREAD CONTACT WITH ROAD Tires and Wheels Underinflation: causes abnormal tire deflection, which builds up excessive heat, running the risk of failure. It also causes irregular wear. Overinflation: r e d u c e s t h e tread contact area with the road surface, concentrating all of the vehicle weight on the center of TREAD CONTACT the tread. This causes premaWITH ROAD ture wear of the tire.
Tires and Wheels Table 6 Preventive Maintenance Effect of Load Pressure on Tire Life Vehicle Load Normal 20% Over 40% Over 60% Over 80% Over 100% Over Tire Pressure Normal 20% Low 30% Low 35% Low 45% Low 55% Low 70% 50% 40% 30% 25% Expected Total Tire Mileage Normal Wheel Mounting and Fastening After the vehicle travels about 50 to 100 miles (80 to 160 km), wheel mountings “seat in” and will lose some initial torque. Check hub/wheel mountings after this initial period and retighten.
Preventive Maintenance Tires and Wheels Proper Torque and Sequence Proper wheel torque can best be obtained on level ground. Install lug nuts and finger-tighten in the numerical sequence as shown below, see “Crisscross Tightening Sequence” on page 212. This procedure will ensure that the wheel is drawn evenly against the hub. Torque each nut to the torque value listed in Table 7 on page 210. Medium Duty (R05/09) Y53-6027 WARNING! Tighten wheel cap nuts properly.
Tires and Wheels Table 7 Preventive Maintenance Wheel Cap Nut Torque WHEEL & NUT CONFIGURATION Steel Disc-Type Wheel; Double Cap Nut Mounting; Standard 7/8” Radius Ball Seat or Flanged Nuts: Alum.
Preventive Maintenance Table 7 Tires and Wheels Wheel Cap Nut Torque WHEEL & NUT CONFIGURATION STUD SIZE Dayton: 5/8-11 Front & Rear DYNAMIC TORQUE FOR INNER & OUTER CAP NUTS & RIM CLAMP NUTS N.
Tires and Wheels Preventive Maintenance Demounted Rims WARNING! Improperly mounting and demounting tire and rim assemblies is dangerous. Failure to observe proper precautions could cause the tire-rim assembly to burst explosively, causing serious injury or death. See the wheel manufacturer's literature for the proper way to mount and demount your tires and rims. Follow their precautions exactly. To check the torque on demountable rims, follow the crisscross sequence shown below.
Preventive Maintenance Table 8 Tires and Wheels Comparing Hub-piloted and Ball-seat Wheels BALL–SEAT MOUNT HUB–PILOTED MOUNT 00187 00203 Hub, Drum, and Stud Assembly Hub-piloted mountings use M22 x 1.5 metric threads (about 7/8 in. diameter). The stud stands out at least 1.94 in. beyond the brake drum. All studs are right-hand threads. Pilot bosses (machined surfaces) on the hub, fit tightly to the wheel center bore. Ball-seat (stud-piloted) mountings use 3/4x16 or 1-1/8x16 threads.
Tires and Wheels Preventive Maintenance Tire Replacement NOTE: To prolong the tires' life and make them safer, have their radial and lateral run-out checked at your Peterbilt Dealer. And of course have the tires balanced any time you change a tire. Front: replace front tires when less than 4/32 in. of tread depth remains. Check depth at three places equally spaced around the tire. Matching Tires Drive Axles or Trailers: replace tires on drive axles when less than 2/32 in.
Preventive Maintenance Tires and Wheels Wheel and Tire Replacement WARNING! The Anti-Lock Brake System (ABS) is calibrated for the specific tire revolutions per mile. Use of a tire and/or wheel size different from that originally installed on your vehicle may cause the ABS system to not function during a hard braking event. This could cause an accident resulting in death or serious personal injury.
Heater and Air Conditioner Preventive Maintenance HEATER AND AIR CONDITIONER • Do not permit any open flame in the area. Even a match or a cigarette lighter may generate a hazardous quantity of poisonous gas. 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.
Preventive Maintenance Heater and Air Conditioner CAUTION: During extreme cold weather, do not blow hot air onto cold windshields. This could crack the glass. Turn the air direction lever to Defrost and reduce the fan speed while the engine warms. If the engine is already warm, move the temperature selector to Cool, then gradually increase the temperature when you see that the windshield is starting to warm-up. Air Conditioner WARNING! The air conditioning system is under pressure.
Electrical System Preventive Maintenance ELECTRICAL SYSTEM CAUTION: Do not modify or improperly repair the vehicle’s electrical system or power distribution box. All electrical repairs should be performed by an authoriz ed Peterbilt dealer. Improper repair or modifications will void your warranty and/or cause serious damage to your vehicle. Location Of Fuses Fuses are located inside the cab, left side, next to the driver’s door.
Preventive Maintenance Electrical System All the electrical circuits have fuses to protect them from a short circuit or overload. If something electrical on your chassis stops working, the first thing you should check for is a blown fuse. 1. Turn OFF all lights and accessories and remove the ignition key to avoid damaging the electrical system.. 2. Determine from the chart on the fuse panel which fuse controls that component. 3. Remove that fuse and see if it is blown. 4.
Electrical System Preventive Maintenance Battery cables have a protective insulation covering the metal cable. Contact your authorized service center to have the cables replaced if you find any chafing, tears or breaks in the insulation and the cable is visible through the tear or break. The cover is held in place by two latches one on each side. WARNING! Always reinstall the battery compartment cover (step) before entering the cab.
Preventive Maintenance Electrical System WARNING! Before attempting any work on the batteries or electrical system, remove all jewelry. If metal jewelry or other metal comes in contact with electrical circuits, a short circuit may occur causing death, injury or property damage. Removing and Installing Batteries: 1. 2. 3. 4. Battery Care Regular attention to the charging system will help prolong the service life of the batteries.
Electrical System Preventive Maintenance Jump Starting Vehicles Because of the various battery installations and optional electrical systems, Peterbilt does not recommend that you attempt to jump start your vehicle. If you have a battery problem, it is best to contact a Peterbilt Dealer or a reputable towing service. 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.
Preventive Maintenance Electrical System To Jump Start Your Vehicle WARNING! The voltage of the booster battery must have a 12–volt rating. And the capacity of the booster battery should not be lower than that of the discharged battery. Use of batteries of different voltage or substantially different capacity rating may cause an explosion and death or serious personal injury.
Electrical System Preventive Maintenance • Then start the vehicle that has the discharged (dead) battery. Connect the batteries: WARNING! When connecting jumper cables, make sure they can not get caught in any moving parts in the engine compartment. You could be killed or seriously injured. 1. 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.
Preventive Maintenance Electrical System WARNING! Batteries can kill or injure you severely. They contain acid, produce poisonous and explosive gases, and supply levels of electric current high enough to cause burns. A spark or flame near a battery on charge may cause it to explode with great force. To help reduce the risk of personal injuries, follow these guidelines carefully when recharging a battery: • Before attempting any service in the electrical installation, disconnect the battery negative cable.
Electrical System Preventive Maintenance WARNING! Always shield your eyes and avoid leaning over the battery whenever possible. Electrolyte in batteries could splash up into your eyes causing severe burns and/or serious personal injury. • Battery terminals should not be coated with improper grease. Use petroleum jelly or commercially available, noncorrosive, nonconductive terminal coatings.
Preventive Maintenance Electrical System 5. After charging, turn OFF charger and disconnect charger cables. Bulb Replacement 1141BULB Warning lamp module #37 or 73 (T1 3/4 wedge base Electrical and Alternator Precautions Tail Lights To replace the tail lamps, remove lens. The bulbs are all of the bayonet type. 1. To remove the bulbs, turn bayonet counter clockwise and pull out. 2. To install, fit the bulb in the socket, push in and turn bayonet clockwise. Replacement Bulbs DESCRIPTION PART NO.
Electrical System Preventive Maintenance • 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.
Preventive Maintenance Cab Maintenance CAB MAINTENANCE Exterior Maintenance Painted Surfaces Wash painted surfaces frequently to remove grime and caustic deposits which may stain the finish. See “Cleaning, Protection and Weather–Stripping” on page 230. Chrome and Aluminum Surfaces To prevent rust, keep chromed parts clean and protected with wax at all times, especially in winter conditions where the roads are salted. • If necessary, use a commercial chrome cleaner to remove light rust.
Cab Maintenance Preventive Maintenance Cleaning, Protection and Weather–Stripping Frequent washings of the vehicle are required to remove grime and contaminants that can stain and oxidize paint and accelerate corrosion of plated and polished metal surfaces. Waxing offers added protection against staining and oxidation. But to allow enough time for your truck's finish to cure, wait about 30 days after the date of manufacture before waxing.
Preventive Maintenance Cab Maintenance CAUTION: Do not aim the water jet directly at door locks or latch. Tape the key holes to prevent water from seeping into the lock cylinders. Water in lock cylinders should be removed with compressed air. To prevent locks from freezing in the winter, squirt glycerin or lock deicer into the lock cylinders. 4. Wipe everything dry with a chamois to avoid water spots. • To prevent water spotting, dry off the cosmetic surfaces with a clean cloth or chamois. 5.
Cab Maintenance Preventive Maintenance At least every spring, flush these materials from the under body with plain water. Be sure to clean any area where mud and other debris can collect. Sediment packed in closed areas of the frame should be loosened before being flushed. If desired, your Peterbilt Dealer or Authorized Service Center can do this service for you.
Preventive Maintenance Cab Maintenance • Always test a commercial cleaning agent on an inconspicuous area of the surface to be cleaned before using it.
Cab Maintenance Preventive Maintenance • Remove soap with a clean, damp rag. Safety Restraint System — Inspection • If a stronger cleaning solution is required, use a foamtype carpet shampoo. The seat belt system, including webbing, buckles, latches, and mounting hardware, endures heavy use in medium-duty vehicles—much more than seat belt systems in passenger cars. All users should be aware of the factors contributing to this heavy use and reduced belt life.
Preventive Maintenance Cab Maintenance WARNING! It is important to remember that any time a vehicle is involved in an accident, the entire seat belt system must be replaced. Unexposed damage caused by the stress of an accident could prevent the system from functioning properly the next time it is needed, which could result in severe injury or even death.
Cab Maintenance Preventive Maintenance parts of the cab interior. These areas are typical places where the web will experience cutting or abrasion. Cuts, fraying, or excessive wear would indicate the need for replacement of the seat belt system. 2. The pillar web guide (D-loop) is the area where almost constant movement of the seat belt webbing occurs because of relative movement between the seat and cab. 3. Check the Komfort-Lok Latch for cracks or possible damage and check for proper operation.
Preventive Maintenance Cab Maintenance 4. Check buckle and latch for proper operation and to determine if latch plate is worn, deformed, or damaged. 5. Inspect the retractor web storage device, which is mounted on the floor of the vehicle, for damage. The retractor is the heart of the occupant restraint system and can often be damaged if abused, even unintentionally. Check operation to ensure that it is not locked up and that it spools out and retracts webbing properly.
Cab Maintenance Preventive Maintenance Windshield Wipers/Washer Check wiper blades annually or every 60,000 miles (96,000 km). Anco 18-inch (450mm) wiper blades are recommended. The windshield washer tank is located inside the engine compar tment below the radiator expansion tank. See “Washer Reservoir” on page 201. Check the windshield washing fluid level weekly. If necessary, fill to top.
Preventive Maintenance Transmission and Clutch TRANSMISSION AND CLUTCH Transmission Lubricants CAUTION: When adding oil, types and brands of oil should not be intermixed because of possible incompatibility, which could decrease the effectiveness of the lubrication or cause component failure.
Transmission and Clutch Table 9 Preventive Maintenance Transmission Lubrication — Manual transmissions Eaton-Fuller AMBIENT TEMPERATURE RANGE RECOMMENDED LUBRICANT (See Note) MODEL VISCOSITY (SAE) DEG. C DEG. F HD engine oil: API CE or CF-4. Above -12 Above +10 50 Synthetic oil: Chevron RPM Synthetic Transmission Fluid, or equal, meeting MIL-L-2104D and Eaton PS-081 specifications. Above -40 Above -40 50 NOTE: Do not use multi-viscosity or EP (extreme pressure) gear oil (e.g.
Preventive Maintenance Transmission and Clutch As the clutch pedal is depressed further, with harder pressure, the release yoke moves the release bearing away from the engine. This causes the clutch plate to release from the driven disks in the clutch. This is called release travel. And finally, on 9-, 10-, and 11-speed transmissions, as the pedal is pushed to the last 1/2 to 1 inch of travel, the release bearing contacts and engages the clutch brake. This is called clutch brake squeeze.
Transmission and Clutch Preventive Maintenance Automatic Transmissions Automatic Transmission Oil Level NOTE: The vehicle must be parked on level ground. Service Intervals Check daily with engine idling. See Table 1, “Recommended Maintenance Intervals,” Page 154 for service intervals. Maintain the oil level and check it daily. Oil should be up to the “HOT” mark on the dipstick when (1) the engine is running, (2) the transmission is at operating temperature, and (3) the transmission is in Neutral.
Preventive Maintenance Steering and Driveline STEERING AND DRIVELINE If you cannot correct the problem, check with an Authorized Service Center. Power Steering Oil (under low pressure) provides the power to operate the steering gear. It also serves to lubricate moving parts and remove heat. A loss of steering efficiency will occur if too much heat builds up in the system. WARNING! Do not operate the vehicle if the steering system is not working properly.
Steering and Driveline Preventive Maintenance If these checks do not reveal the problem, or if you correct them and still have a steering problem, take your truck to an authorized Peterbilt Dealer for evaluation. RESERVOIR Fluid Level and Refill Have the power steering fluid and filters changed at an Authorized Service Center. • Check and completely change the fluid level according to Table 1, “Recommended Maintenance Intervals,” Page 154.
Preventive Maintenance Steering and Driveline Fluid Refill Use Automatic Transmission Fluid (ATF) Type E or F or Dexron® II. For other approved brands and types of fluid, see the Medium Duty Maintenance Manual. SLIP JOINT Steering Driveline • Torque on U–joint pinch bolt and nut 45–55 lb. ft. (61-75 N.m.), lubricated. • Torque on Pitman arm clamp bolt and nut: 180-210 lb. ft. (244-285 N.m.), lubricated.
Front Axle and Suspension Preventive Maintenance FRONT AXLE AND SUSPENSION SPRING AND SHACKLE PINCH BOLTS Inspection For all vehicles, mandatory maintenance procedures include retightening all U–bolts and inspecting the suspension for loose fasteners, abnormal wear, or damage. However, even with proper maintenance, the service life of leaf springs is affected by many factors, such as: fatigue, vehicle gross weight, type of load, road conditions, and vehicle speed.
Preventive Maintenance Front Axle and Suspension • Thoroughly clean hubs and bearings with solvent and a stiff bristle brush, then dry and inspect components for wear or damage. Re-lubricate with approved axle lubricant. KINGPIN (TOP) Kingpin Lubrication • Lubricate with approved lubricant. Lubricate knuckle thrust bearings, knuckle pins, and tie rod ends. See Table 1, “Recommended Maintenance Intervals,” Page 154. Lack of lubrication causes premature wear and hard steering.
Front Axle and Suspension Preventive Maintenance WARNING! Do not operate the vehicle if the U– bolts are not properly tightened. Loose U–bolts do not properly secure the axle to the suspension. This could cause loss of vehicle control and an accident resulting in death or injury. Loose U–bolts can also cause uneven tire wear and poor alignment. CAUTION: Do not spray the suspension with chemical products or mineral oil; it can cause damage to the bushings.
Preventive Maintenance Rear Axle and Suspension REAR AXLE AND SUSPENSION WARNING! Failure to maintain the specified torque values or to replace worn parts can cause component system failure, possibly resulting in an accident causing death or injury. Improperly tightened (loose) suspension U–bolts can lead to unsafe vehicle conditions, including: hard steering, axle misalignment, spring breakage or abnormal tire wear. See the Fastener Torque Tables for proper torque specifications.
Rear Axle and Suspension Preventive Maintenance It is important that U–bolts remain tight. Severe use of your vehicle can cause them to loosen faster. But all vehicles need to have their U–bolts checked and tightened regularly. Be sure someone with the proper training and the right tools checks and tightens the U–bolts on your Medium Duty vehicle. Rear Axle Lubrication • Check oil level with the vehicle parked on level ground and the fluid warm.
Preventive Maintenance Rear Axle and Suspension Table 11 Drive Axle Lubrication MODEL EATON, ROCKWELL RECOMMENDED LUBRICANTS AMBIENT TEMPERATURE RANGE °F EP gear oil, MIL-L-2105D, API GL-5. -26 to +38 -15 to +100 80W-90 Synthetic Lubricant: Chevron RPM Synthetic Gear Lubricant, or equal, meeting MIL-L-2105D and Eaton PS-037 specification. -40 to +38 -40 to +100 75W-90 • No initial drain is required on Eaton axles that are factory filled with an Eaton-approved synthetic lubricant.
Rear Axle and Suspension Preventive Maintenance Rear Suspension Fasteners 3 Continual road shock and load stresses may force the rear axles out of alignment. If you detect rapid tire wear on the rear axles, you may have misaligned axles. Have your rear axle alignment checked and adjusted by a Peterbilt Dealer or Authorized Service Center.
Preventive Maintenance Rear Axle and Suspension WARNING! Do not replace U–bolts and nuts with common U–bolts or standard nuts. These parts are critical to vehicle safety. If the wrong U–bolts or nuts are used, the axle could loosen or separate from the vehicle and cause an accident resulting in death or injury. Use only U–bolts and nuts of SAE Grade 8 specification or better. WARNING! Do not operate the vehicle if the U– bolts are not properly tightened.
Rear Axle and Suspension Preventive Maintenance Grade 8 Capscrew Torque Specifications Capscrew Body Size (inches-thread) – 254 – Torque Lb. ft. N.m.
Preventive Maintenance Frame and Fifth Wheel FRAME AND FIFTH WHEEL Engine Painting Do not electrostatically paint electronically controlled engines or vehicles with these engines. Frame Rails WARNING! Do not cut, splice or weld on frame rails or drill through the top or bottom flanges. T h e s e o p e r at io n s co u l d a f fec t f r a m e r ai l strength leading to a failure resulting in an accident causing death or injury. Always leave frame repairs to your Peterbilt Dealer.
Frame and Fifth Wheel Preventive Maintenance Sliding Fifth Wheel • 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. – 256 – Y53-6027 NOTE: The plate must be lifted up slightly to relieve the weight of the bracket while applying grease.
Preventive Maintenance Noise and Emission Control NOISE AND EMISSION CONTROL Tampering with Noise Control System Federal law prohibits the following acts or the causing thereof: Noise Emission Warranty Peterbilt Motors Company warrants to the first person who purchases this vehicle (for purposes other than resale) and to each subsequent purchaser: that this vehicle, as manufactured by Peterbilt Motors Company, was designed, built and equipped to conform, at the time it left Peterbilt's control, with all
Noise and Emission Control Preventive Maintenance Engine • Removing or rendering engine speed governor inoperative so as to allow engine speed to exceed manufacturer's specifications. • Modifying ECU parameters. • Check the induction tubing, elbow connections, clamps, brackets, and fasteners for deterioration, cracks, and security. • If you find an air leak anywhere between the air cleaner and the engine, repair that leak immediately.
Preventive Maintenance Noise and Emission Control Piping Exhaust Tail Pipe • Check exhaust piping for rust, corrosion, or damage. Replace deteriorated piping before holes appear. If piping is perforated at any point, temporary patching or lagging is acceptable until you can have permanent repairs made. On turbocharged engines, check joints at flanges and mounting brackets for tightness. • Check the mounting. Tighten as necessary.
Noise and Emission Control Preventive Maintenance Maintenance Log Transmission and Driveline • Substituting a different main transmission or drive line components, other than design-specified units, may result in increased vehicle noise emission. To ensure your Medium Duty vehicle's noise control requirements are maintained, record maintenance checks. Use the following log sheet (see Table 12) and retain copies of documents regarding maintenance services performed and parts replaced on the vehicle.
Preventive Maintenance Noise and Emission Control Table 12 Maintenance Log Medium Duty (R05/09) Y53-6027 – 261 –
Noise and Emission Control Preventive Maintenance Table 12 Maintenance Log – 262 – Y53-6027 Medium Duty (R05/09)
Preventive Maintenance Consumer Information and Vehicle Identification CONSUMER INFORMATION AND VEHICLE IDENTIFICATION Canadian Consumer Information Reporting Safety Defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Peterbilt Motors Company.
Consumer Information and Vehicle Identification Preventive Maintenance Vehicle Identification All Peterbilt vehicles are identified by a 17–digit Vehicle Identification Number (VIN). This unique numeral and letter combination identifies the manufacturer, the model year it was built, and other vehicle attributes. The VIN is in compliance with 49CFR565, Code of Federal Regulations.
Preventive Maintenance Consumer Information and Vehicle Identification Chassis Number Locations A2378 The chassis/serial number is shown in three places: • Right frame rail, top flange, about 3 ft.
Consumer Information and Vehicle Identification Preventive Maintenance Complete Vehicle Certification Label VEHICLE NAME PLATE The Complete Vehicle Certification label certifies that the vehicle complies with all applicable Federal Motor Vehicle Safety Standards.
Preventive Maintenance Consumer Information and Vehicle Identification WARNING! Do not exceed the specified load rating. Overloading can result in loss of vehicle control and an accident involving death or personal injury, either by causing component failures or by affecting vehicle handling. Exceeding load ratings can also shorten the service life of the vehicle. NOTE: GVW is the TOTAL SCALE WEIGHT the vehicle is designed to carry.
Consumer Information and Vehicle Identification Preventive Maintenance Federal Safety Standard Certification Label The NHTSA regulations require a label certifying compliance with Federal Safety Standard, for United States and U.S. Territories, be affixed to each motor vehicle and prescribe where such label may be located. This certification label, which indicates the date of manufacture and other pertinent information, is located on the driver's side door frame.
A Accessories 72 Air conditioner 217 refrigerant 151 Air Dryer 200 Air filter 202 Air horns 49 Air intake 201, 257 Air leaks 199 Air pressure gauge 198 Air suspension deflated air spring 137 switch, operation 133 Air tanks 87, 119, 147 Alternator precautions 227 Anti-lock brakes 112, 115, 125 Automatic transmission 88, 103, 242 fluid 245 oil level 242 Axle weight rating 84, 85, 132, 267 B Ball bearing grease 168 Ball seat mounted wheels 213 Battery access 220 care 221 compartment cover 10 electrolyte 225
trailer charge 110 treadle valve 119 Brake Fluid Check 189 Brake Fluid Reservoir 122 Brake Master Cylinder 122 Brake Warning Lamp 123 C Cab access 9 heater maintenance 216 maintenance 234 Calipers 191 Charge air cooler 202 Chassis grease 168 number 264, 265 Cleaning the vehicle 230 Clutch 98 clutch adjustment 102 clutch brake 100 clutch travel 100 fan drive 259 operating the clutch 98 riding the clutch 102 Coasting 102 Component lubrication index 168 Compressed air reservoir 87, 119, 197 Compressor 119 –
Cruise control operation 97 Cruise Control On/Off 17 Cruise Control Select 17 D Daily operations 86 dash 16 dashboard 16 Daytime running lights 52 DEF 43, 176 DEF Gauge 17 Defogging/defrosting system 68 Deisel Exhaust Fluid 176 Department of transportation regulation 392.
identification 268 idling 95 lubrication 173 oil draining 174 oil level check 174 overspeed 131 retarder 117 rpm 147 service notes 173 starting procedure 89 stopping the engine 147 vital engine systems 94 warmup procedure 94 weekly checks 88 winterfronts 90 Engine Oil Pressure 17 Environmental protection 152 Ether 89 Exhaust brake 117, 118 fumes 151 air controlled 138 fixed 138 lock switch 138 maintenance 255 sliding maintenance 256 Frame precautions 255 Front axle 247 front axle identification 268 Front b
Warning Lights and Buzzers 19 Water Temperature Gauge 40 GAWR defined 85 GAWR - gross axle weight rating 84, 132, 267 GCW - gross combination weight 84 Glove compartment 73 Governor 119 Grease index 168 GVWR defined 84 GVWR - gross vehicle weight rating 84, 132, 207, 267 H Hand brake 116, 146 Hazard flasher 124 Hazard Switch 17 Headllights 17 Heater and air conditioner maintenance 216 High beam 46 Hood Latch and Tilt 11, 13 hood lock release cable 14 Hub piloted and ball seat parts 213 HVAC 18 Hydraulic Bo
front axle 247 front suspension 247 idling 94, 95 power steering 243, 244 rear axle 250, 251, 252 transmission 239, 240 types and brands 167 wheel bearings 247 M Maintenance manual 6 schedule 153 Manual transmission 98 lubricants 239 oil level 240 shifting gears 98 master cylinder 121 Menu Control Switch 17 Modifications 151 Modulating valve 119 Muffler 259 N NHTSA consumer information 263 Noise and emission control 257 air intake system 257 engine 258 exhaust system 258 fan drive 257 – 274 – inspection
fluid level 244 fluid refill 245 lubrication 243 Primary Air Pressure 17 Q Quick-release valve 120 R Radio 18, 73 Rear axle 250 housing breather vent 252 identification 268 lubrication 250, 251, 252 oil change 250 oil level 250 Rear brake system 105 Rear suspension 249 fasteners (standard) 249 Rear Wheel Calipers 123 Recovering vehicles 140 Regeneration Switch 56 Relay valve 120 Release bearing wear 102 Repairs 6 Retarders engine 117 rpm 94, 100, 147 S Safety belt adjustment 77 passengers 79 restraint b
Single check valve 120 Slack adjusters 186 Speedometer 17 Spring brakes - manual release 142 Spring pins 247 Springs 246 Starting Procedure Cold Temperatures 92 Normal Temperatures 90 Steering Column-Mounted Controls 45 Steering maintenance 243 Stopping procedures 146 Storage compartment 73 Suspension 249 fasteners 249 fasteners, torque 249 T Tachometer 17, 131 Tether belts 80, 237 adjustment 80 Tire chains 145 inflation pressure 206 inspection 205 replacement, tread depth 214 Towing 142, 145 vehicle recov
Vehicle inspections 83 W WAIT TO START light 91 Warning Light Symbols table 22 Warranty 151, 153, 249, 257, 258 Water Temperature 17 Weekly operations 88 Weight rating 84, 132 Welding 227 Wet Brakes 124 Wet tank 119 Wheel and Tire Replacement, hydraulic brakes 215 Wheel bearing grease 168 lubrication 246 Medium Duty (R05/09) wheel cylinders 121 Wheels and tires load rating 207 overinflation 207 proper inflation 206 replacement 204, 214 tightening sequence 208 tire inspection 205 tread depth 214 underinfl
– 278 – Y53-6027 Medium Duty (R05/09)
Other Publications Order either of the two publications shown below through your Peterbilt dealer. There is a charge for each. Allow four weeks for delivery. 02956A Custom Maintenance Manual This manual contains both proprietary and supplier service information specifically compiled for the components on your vehicle. The material in this manual is the same as that used by Peterbilt dealers. It includes inspection, maintenance, overhaul, and troubleshooting procedures.
Y53-6027 05-09 Printed in the U.S.A. Peterbilt Motors Company, A PACCAR Company, P.O.
