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PART 1: INTRODUCTION

1. A Table 1 Preventative Maintenance PM Intervals When working underneath the vehicle with EM out appropriate safety stands but with the l A B c D E ee on fe ground mor supp orted At the first 15 000 30 000 60 000 120 000 240 000 make sure that 1 the vehicle is on hard 15 000mi miy mi 48 000 mi mi mi level ground 2 the parking brake is 24 000km 24 000 km 96 000 192 000 384 000 applied 3 all wheels are chocked front or at the km km 6 km Annu km and rear and 4 the engine cannot be first PM Monthly months ally started Remove the ignition key Y53 6007 R10 06 PART 8 MAINTENANCE AND SERVICE i NOTES e Where questions or discrepancies develop between these recommendations and compo nent supplier recommendations consult the supplier for specific recommendations Maintenance requirements of specific voca tional configurations will dictate whether the intervals used are determined based on mile age time in service hours operating etc These maintenance practices and intervals are intended as additional requirements and are not to replace in whole or in part the pretrip inspection requirements of the Commercial Driver s License CDL as established in the Federal Commercial Motor Vehicle Safety Act of 1986 If you operate your vehicle off highway or in very heavy duty applications such as mining logging or earth mov ing you will need to p
2. CAUTION To avoid engine damage do not let 114 Y53 6007 PART 7 STARTING amp OPERATING THE VEHICLE NOTE Often these recommendations are sec ondary to maintaining an adequate and safe speed relative to the surrounding traffic and road conditions il Operate the engine within the optimum engine rpm range and do not allow the rpm s to exceed the maximum gov erned speed See your Engine Operation and Mainte nance manual for information regarding engine rpm When the engine is used as a brake to control vehicle speed e g while driving down a grade do not allow the engine rpm to exceed maximum governed speed Under normal load and road conditions operate the engine in the lower end of the range Use of Tachometer The tachometer is an instrument that aids in obtaining the best performance of the engine and manual transmission serving as a guide for shifting gears Refer to the Engine Operation and Maintenance manual for optimum engine rpm R10 06 PART 7 STARTING amp OPERATING THE VEHICLE e If the engine rpm moves beyond the maximum gov erned speed indicating an overspeed condition apply the service brake or shift to a higher gear to bring engine rpm within the optimum speed range e When driving downhill shift to a lower gear use the engine brake if so equipped and use the service brake keeping the engine speed below 2 100 rpm When the engine speed reaches its maximum governed speed
3. E y a GAUGES The warning lights may indicate something is wrong with one of the vital systems on your vehicle Check the lights frequently and respond properly as soon as you see one go on These lights could save you from a serious acci dent Emission System Lamps This vehicle may be equipped with an exhaust system that meets 2007 EPA emission requirements The following lamps wil be on your dashboard Emissions Diesel Particulate Filter DPF IIluminates when diesel particulate trap is plugged This warning will also illuminate when regeneration operation is disabled Emissions High Exhaust System Temperature HEST IIluminates when the exhaust gas temperature and exhaust components become extremely hot lt 3 Ea DEF HEST 48 Y53 6007 PART 4 CONTROLS AND DISPLAYS Transmission Temperature Gauge 350 TRANS D TEMP lt 11427 Your Transmission Temperature Gauge indicates the tem perature of the oil in your transmission Watch this gauge to know when your transmission is overheating If it is have it checked by an authorized service representative Maximum transmission temperature may vary depending upon the transmission and type of lubricant It is typically 250 F 121 C check your transmission s owner s man ual R10 06 PART 4 CONTROLS AND DISPLAYS Front Drive Axle or Rear Drive Axle Temperature Gauge 300 RNT V y L y 7 Eo
4. GAUGES A 44 WARNING The air pressure warning light and the audible alarm indicate a dangerous situa tion 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 sud denly apply causing a wheel lockup loss of control or your vehicle to be overtaken by fol lowing vehicles You could be in an accident and severely injured If these alarms come on while you are driving bring your vehicle to a safe stop right away If the light and alarm do not turn off at start up do not try to drive the vehicle until the problem is found and fixed Y53 6007 PART 4 CONTROLS AND DISPLAYS Engine Oil Pressure Gauge C 11241A It is important to maintain oil pressure within acceptable limits Your engine manual will give you normal operating pressures for your particular engine A e If your oil pressure fails to rise within 10 seconds after your engine starts stop the engine and determine the cause CAUTION Continuing to operate your vehicle with in sufficient oil pressure will cause seri ous engine damage R10 06 PART 4 CONTROLS AND DISPLAYS e If your oil pressure suddenly drops while you are driv ing 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
5. Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval I A B C D E Tires amp Tires Check inflation pressure see page 156 Weekly cold using cali Wheels brated gauge Tires Inspect for cuts irregular wear missing lugs sidewall damage etc X Disc wheels Inspect the wheel disc for any cracks or surface irregularities Inspect the rim edge and bead seat area for damage Replace any damaged wheels X DO NOT ATTEMPT TO REPAIR Demountable rims Inspect the mounting ring rim gutter side ring and lock ring for damage x replace as required Wheel nuts and studs Check the tightness of the fasteners and tighten the fasteners to the speci X fied torque as required see page 164 Wheel nuts and studs Inspect for damaged hex corners stripped or damaged threads and x excessive corrosion clean or replace as required Power Reservoir Check the fluid level see page 150 X Steering Reservoir ON HIGHWAY Drain replace the filter and refill see page 150 X X Reservoir OFF HIGHWAY Drain replace the filter and refill see page 150 X X Steering gear Check the lash of the sector shaft adjust as required x 132 Y53 6007 R10 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Table 2 Preventative Maintenance Schedule Continued Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval A B C D E Power Steering gear Grease the trunnion bearing EP NLGI 2 li
6. Your Peterbilt contains a feature designed to eliminate cinching and provide improved safety and comfort Cinch ing 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 par ticularly over long distances To eliminate cinching simply activate the comfort feature at the appropriate time R10 06 Y53 6007 SEAT BELTS AND THEIR PROPER USE 1 Fasten your seat belt according to the directions 2 You are now ready to activate the Komfort Lok Lean forward to pull a little slack about 1 inch in the belt Be sure to allow only a small amount of slack See the Warning on a loose belt on the previous page 3 When the slack is right slide the comfort feature up When the slack is right flip the latch cover up cinch ing it into place This locks the Komfort Lok 4 To release the Komfort Lok latch reach up and pull the latch cover open down or simply pull down on the shoulder belt 5 When you want to get out of the cab release the latch then just push the button on the buckle Pregnant Women 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 won t harm the baby even in a crash And remember the best way to keep an unborn baby safe is to keep the mother safe 59 SEAT BELTS AND
7. 662 629 898 656 935 889 1268 1 12 508 724 689 982 718 1023 973 1386 sone 5 8 Capscrew Torque Torque Body Size inches Lb ft N m Lb ft N m thread 1 4 20 6 9 8 12 9 12 12 16 28 7 10 9 5 14 10 14 14 19 5 16 18 13 18 18 24 18 25 24 34 24 14 20 19 27 20 28 27 38 3 8 16 22 32 30 43 31 44 42 60 24 25 40 34 54 35 50 47 68 7 16 14 35 50 47 68 50 71 68 96 20 39 56 53 76 56 80 76 108 1 2 13 54 77 73 104 76 109 103 149 186 The torque values in the previous tables are based on the use of clean and dry threads Y53 6007 R10 06 PART 8 MAINTENANCE AND SERVICE Frame Fasteners e Go around your vehicle as per the Preventive Mainte nance Schedule and tighten all frame fasteners with a torque wrench e Always use the torque values listed in frame fastener table e Always torque fasteners from the nut end For standard capscrews e Always use the torque values listed the capscrew table e Reduce torque by 10 when engine oil is used as a lubricant e Reduce torque by 20 if new plated capscrews are used R10 06 Y53 6007 ENGINE ACCESSORIES Engine Accessories Accessory Drive Belts You can extend the reliability and service life of your vehi cle s drive belts with proper attention to installation adjustment and maintenance Neglect could cause belt failure The result could be the
8. Always start out in a low gear with a ceramic faced clutch Starting in higher gears even with a light load will cause a very jumpy start and excessive wear And don t allow your vehicle to roll in the opposite direc tion at all 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 Release Bearing Wear When you must idle your engine for any period of time shift your transmission to neutral and engage the clutch take your foot off the pedal This helps prevent unneces sary wear of your clutch release bearing And it is less tir ing for you too 80 Y53 6007 PART 7 STARTING amp OPERATING THE VEHICLE Clutch Adjustment Inspect manual and self adjusting clutches regularly to maintain correct clutch adjustment Have your dealer s service department perform any adjustments necessary Do not adjust your clutch by adjusting the external linkage without first checking and correcting if necessary the internal clutch adjustment Using only the external linkage adjustment could damage the clutch Clutch Brake Your clutch brake is used for stopping gear rotation to let you shift into 1st gear or reverse when your vehicle is at a standstill About the last 1 2 to 1 inch of clutch pedal travel activates your clutch brake So if you are stopped and want to shift dire
9. 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 With the engine cold top up with premixed coolant of the desired freeze protection concentration Add coolant through the pressure cap neck of the surge tank Pressure Cap Sight Gauge for Add 03003A Coolant level Surge Tank Pressure Cap 15 psi R10 06 Y53 6007 ENGINE COOLING SYSTEM Proper Coolant Level NOTE Do not overfill a cooling system Excess il coolant may result in overflow loss of antifreeze and reduced corrosion protection e The proper coolant level for a cold engine is at the base of the filler neck extension tube The proper coolant level for an engine at normal oper ating temperature is even with the pressure cap seal Refilling Your Radiator 1 Be sure the radiator and engine block drains are closed 2 Remove the surge tank pressure cap 3 Through the surge tank fill the system with premixed coolant Pour it in a steady flow until the radiator is full carefully Ethylene glycol antifreeze is poison ous Store in original fluid container only and always keep out of reach of children j WARNING Handle coolant and antifreeze
10. PB1328 Anti Lock Braking System 88 Automated Transmission 85 Auxiliary Transmission 85 Bobtail Brake Proportioning System 97 Brake Safety and Emergency 97 Digital Message Center 97 Driving Bobtail or with an Unloaded Trailer 106 Driving With Deflated Air Springs 112 Dual Range Two Speed Axles 83 Idling the Engine 77 If Your Vehicle Must Be Towed 85 213 Interaxle Differential 81 Manually Releasing Spring Brakes 101 Operating the Clutch 79 Overheated Brakes 98 Parking Brakes and Their Use 98 Pyrometer 106 Retarders 105 Setting Ride Height 109 Shifting The Transmission 79 Starting Procedure Cold Temperature 74 Normal Temperature 73 Stopping The Engine 107 Trailer Air Supply Valve 100 Warning Alarms 115 PART 11 SUBJECT INDEX Tire Load and Inflation Tables 161 Transmission lubrication 144 warmup 77 V Vehicle driving 69 Vehicle Identification Number 205 Vehicle inspections 69 Vehicle weight rating 162 W Wheels and tires replacement 166 Windshield washer reservoir 27 T Numerics Tachometer 114 49 CFR 565 Code of Federal Regulations 205 214 PB1328 22 02011 R10 02
11. 1234 5T1 80 120 oa e The Trip 2 odometer reads miles amp tenths e g 1234 5T2 ners e The hourmeter reads in hours e g 12345HR e The clock reads in hours amp minutes with A M or The speedometer message center SMC is a combina PM indicated at the end e g _ _ 12 34A or P tion of a speedometer and a message center The speed ometer indicates your vehicle s speed in both miles and If the clock alarm is set and activated the display will kilometers per hour The message center contains a 7 appear as character segmented LCD screen that can display the fol _ 12 34A or P lowing items e The clock alarm reads in hours amp minutes with A M e Odometer e Hourmeter or PM indicated as shown e g AL12 34A or P e Trip 1 odometer e Clock Trip 2 odometer e Clock alarm e Warning and Diagnostic messages see page 117 To set or reset a function follow the procedures below A0 Y53 6007 R10 06 PART 4 CONTROLS AND DISPLAYS il NOTE Neither the odometer nor the hourmeter can be reset 1 Turn the ignition switch to ON 2 Choose the desired function 3 Set or reset the function e Trip Odometers Press and hold the Reset switch until the mileage is reset to zero this will take about 3 seconds e Clock a R10 06 Press amp release the Reset switch the hours digit will flash Press amp hold the Select switch the hours dig its will increase until the
12. 2 lithium based moly filled HD grease U joints OFF HIGHWAY or xIx CITY DELIVERY Fuel amp Fuel tanks Inspect tanks brackets hoses and fittings for correct location tightness x Tanks abrasion damage and leaks repair or replace as required Fuel tank breathers Check for proper function clean the drain hoses X Fuel tank straps Tighten to proper torque value of 45 70 Lb ft 61 95 N m check annu ally once strap tension reaches a steady state i e after 2 3 retorquings X X i the measured torque is the same as previous reading Fuel tank steps Check for snug fit of side plates against tank and tank straps Check for damaged or broken steps missing bolts and missing grommet between x tank and side plate Replace missing or damaged parts and adjust for fit as required 134 Y53 6007 R10 06 PART 8 MAINTENANCE AND SERVICE Table 2 Preventative Maintenance Schedule Continued PREVENTIVE MAINTENANCE SCHEDULE 250XL slip members and U joints OFF HIGHWAY amp CITY Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval 1 A B C D E Driveshafts Models 1610 1810 amp SPL 90 Lubricate Si xX X slip member amp U joints Model SPL 100 slip member Lubricate Hits X amp U joints Models SPL 140 140HD 170 Lubricate 170HD 250 250HD slip mem X bers amp U joints Models SPL 140XL 170XL Lubricate 360 000 miles
13. 25 MINIMUM AIM DISTANCE H H line distance from floor mm 560 900 900 1200 1200 1372 R10 06 Vertical axis AM ZONE Yfyy f V 3 10 AIM ZONE VOL Beam pattern and aim zone Y53 6007 ELECTRICAL Ensure that the hood is properly adjusted Ensure that the hood is closed and completely latched Ensure that the tires are inflated to an on highway set ting Ensure that the headlamp surfaces are clean and dry Establish a horizontal line no more than 1 in 2 5 cm wide on a suitable aiming surface at the same height above a level surface as the optical center of the headlamp The optical center is identified on the cover lens by a small dot If a dot is not present the optical center is the center of the beam that is being aimed Determine the headlamp identifier from the cover lens of the headlamp Look for either the letters VOL or VOR Establish a second horizonal line no more than 1 in 2 5 cm wide below the H H line This is the A A line Turn the headlamp s adjuster until the aim zone visi ble in the beam pattern is level with the A A line on the aiming surface the lamp is now properly adjusted 181 TRANSMISSION AND DRIVE TRAIN 9 Repeat for opposite headlamp Low beams and high beams are integrated onl
14. 250XL slip members and U 576 000 km joints ON HIGHWAY amp LINE every 3 years HAUL Models SPL 140XL 170XL Lubricate R10 06 Y53 6007 135 PREVENTIVE MAINTENANCE SCHEDULE Table 2 Preventative Maintenance Schedule Continued PART 8 MAINTENANCE AND SERVICE Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval A B C D E Battery Battery cables Check the condition of the cables cushion clamps and routing Replace a Boxes Tool cushion clamp if the rubber has deteriorated Repair or tighten terminals x Boxes and and secure cables to prevent chafing Replace damaged cables cuts Steps cracks or excessive wear see page 174 Batteries Check for cracks and damage electrolyte level condition of terminals and xX tightness of holddowns see page 174 Battery box and tray Check the box integrity Clean the drain tube and check for acid leaks xX Check condition of all equipment mounted under the box 136 Y53 6007 R10 06 PART 8 MAINTENANCE AND SERVICE Table 2 Preventative Maintenance Schedule Continued PREVENTIVE MAINTENANCE SCHEDULE Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval A B C D E Electrical amp Headlamps Check the aim and adjust as required X lights Warning lights in light bar Check at the ignition start posi
15. Clean if necessary Small not operating properly the heater core may be particles may be removed with compressed air blown clogged Clean the heater core if necessary If the through the core in the opposite direction of normal air condition persists take the vehicle to a Peterbilt flow dealer for proper heater service or repair Air Conditioner pressed air could injure your eyes Wear eye WARNING Small particles blown by com protection any time you blow compressed air WARNING The air conditioning system is i A i AN under pressure If not handled properly it e Check all hoses for kinks deterioration chafing and could explode causing injury to you and your leaks Adjust kinked or chafing hoses to eliminate vehicle Any servicing that requires depres restrictions and prevent further wear surizing and recharging the air conditioning system must be conducted by a qualified technician with the right facilities to do the job e Check all components and connections for refrigerant leaks If you discover a leak don t try to tighten a con nection Tightening a connection may cause a worse o leak Have a qualified technician correct the problem e Check the compressor belt condition and proper ten sion Adjust 105 125 pounds NOTE A leaking evaporator or condenser core il cannot be repaired it must be replaced e Check the compressor and drive clutch for noise and vibration If you find problems have the system e Have
16. These are spring brakes which you activate by releasing air pressure from their chambers When they are not in use air pressure compresses the springs and releases the brakes But put ting the valve in the Park position exhausts air from the chambers and allows the springs to extend and apply the brakes Also if your system air drops below the safe oper ating level the spring brakes will apply automatically bringing your vehicle to a stop WARNING On trailers built before March 1975 AN you may not have parking brakes if the trailer reservoir pressure leaks down If you depend on them to hold your vehicle they could release causing a serious accident These older trailers have emergency brakes not designed for parking They will apply only if there is enough trailer reservoir pressure Don t use your trailer emergency brakes for parking Apply your tractor parking valve too R10 06 PART 7 STARTING amp OPERATING THE VEHICLE A RED YELLOW 02909 Red Yellow Controls R10 06 Y53 6007 BRAKE SAFETY AND EMERGENCY WARNING e Do not leave the cab without applying the parking brake The truck could roll and cause an injury accident Always apply the parking brake before you leave the cab e Stopping with the parking brake controls can cause a sudden wheel lock up loss of control or can cause you to be overtaken by following vehicles You could be severely injured Never pull out the parking brak
17. To awaken it press the Select switch The SMC will function nor mally while awake it will return to a sleep mode 20 seconds after a switch is last pressed H Further use and operation of the SMC is covered in PART 7 STARTING amp OPERATING THE VEHICLE of this man ual 42 Y53 6007 PART 4 CONTROLS AND DISPLAYS Tachometer RPM X100 11244B Your tachometer measures the engine speed in revolu tions per minute RPM Watching your tachometer is important to driving efficiently It will let you match driving speed and gear selection to the operating range of your engine If your engine speed gets too high you can select a higher gear to lower the RPM If your engine speed drops too low you can select a lower gear to raise the RPM R10 06 PART 4 CONTROLS AND DISPLAYS Air Application Gauge GAUGES The primary gauge shows the front reservoir air pressure This gauge will show you how much air pressure is being applied from your foot brake valve or trailer brake hand valve Primary And Secondary Air Pressure Gauges Air Reservoir These air pressure gauges indicate the amount of air pressure in the brake system in pounds per square inch psi R10 06 Y53 6007 C65 pst 100 150 PRIM gt PRES 1146 q 65 ae psi 100 The secondary gauge shows rear reservoir pressure 43
18. Use the tachom eter to determine optimum RPM for gear engage ment e Downshifts Press accelerator to increase engine and gear speed to the RPM required in the lower gear Use the tachometer to determine optimum RPM for gear engagement 4 Now quickly press the pedal to disengage the clutch Move the gear shift lever to the next gear speed posi tion 5 Release the pedal to engage the clutch Interaxle Differential On vehicles with tandem rear axles the interaxle differen tial allows each axle to turn independently Differential action between the tandems relieves stress on the rear axles and tires and provides better performance When operating normally on paved dry surfaces keep your truck s interaxle differential in the UNLOCK position 81 PUTTING THE VEHICLE IN MOTION SHIFT AT ANY SPEED EXCEPT IF AWHEEL IS SPINNING 03029 Switch In Unlock Position In the LOCK position continuous operation on a paved dry surface stresses the tandem axles possibly causing internal damage to them e Shift into the LOCK position to operate on slippery surfaces like Ice or snow with or without tire chains Dirt roads Loose sand mud or other off road conditions e Switch into LOCK when checking performance on a chassis dynamometer 82 Y53 6007 PART 7 STARTING amp OPERATING THE VEHICLE WARNING AN e Do not put the differential lock in the LOCK position while the wheels are spinni
19. sion Keep all batteries away from children WARNING Charger cables must be connected positive to positive to and negative to neg ative to Reversing polarity can damage the electrical system Never reverse battery poles Battery terminals should not be coated with improper grease Use petroleum jelly or commercially available noncorrosive nonconducting terminal coatings Y53 6007 PART 8 MAINTENANCE AND SERVICE Keep the battery clean and dry Look for any signs of damage Battery acid that may spill during charging should be washed off with a solution of warm water and baking soda to neutralize the acid If you accidentally get acid in your eyes or on your skin immediately rinse with cold water for several minutes and call a doctor Do not charge a frozen battery allow it to thaw out first And always allow the battery to thaw gradually do not apply direct heat Gas trapped in the ice may cause an explosion Never attempt to place the vehicle in motion or run the engine with batteries disconnected When fast charging remove the battery caps so pres sure doesn t accumulate Never use a fast charger as a booster to start the engine This can seriously damage sensitive elec tronic components such as relays radio etc as well as the battery charger Fast charging a battery is dan gerous and should only be attempted by a competent mechanic with the proper equipment R10 06 PART 8
20. will notice that it has a guard to protect you from activating it accidentally 2 3 2 4 03030 Range Selector R10 06 Y53 6007 WARNING Never shift the axle when moving downhill Engine driveline disengagement may occur eliminating engine retardation and allowing the wheels to spin faster than the current speed of the engine This may require severe braking to slow the vehicle down and can result in an injury accident Unlock the interaxle differential before starting Put the Range Selector in the LOW range Shift the transmission to start the truck moving Off Highway When you are driving on rough terrain and secondary roads or under a very heavy load keep the axle in the LOW range Shift your transmis sion to maintain the road speed you want When you go from off highway to highway driving shift the axle to the HIGH range this way a b Be sure the differential is UNLOCKED Keep the accelerator down and move the Range Selector lever to HIGH Keep driving with the accelerator down until you want the axle to shift 83 PUTTING THE VEHICLE IN MOTION d Then release the accelerator until the axle has shifted e You are now in the HIGH axle range on the highway Shift the transmission normally to reach your desired cruising speed 5 If you need to downshift the axle for more power a Keep the accelerator down amp move the Range Selector lever to LOW b Keep driving with
21. 4 CONTROLS AND DISPLAYS The ON OFF toggle switch turns the system ON or OFF e In Caterpillar and Cummins powered vehicles equipped with a Jacobs Engine Brake a second two or three mode switch is incorporated in the instrument panel With this system you can select either LOW or HIGH or LOW MEDIUM HIGH retarding For more information on when and how to use the engine brake in your vehicle see the owner s manual for the engine brake WARNING Using the engine brake when AN operating on surfaces with poor traction such as wet or icy slippery roads or gravel could cause loss of control Two Speed Rear Axle Range Switch 03030 R10 06 Y53 6007 DASH MOUNTED FEATURES 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 e The high range is a faster ratio for highway speeds For information on how to operate your two speed rear axle properly and safely see PART 7 STARTING amp OPERATING THE VEHICLE Interaxle Differential Lock Switch SHIFT AT ANY SPEED EXCEPT IF A WHEEL IS SPINNING 03029 The interaxle differential allows differential action between the forward rear and the rear rear driving axles The inter axle differential lock switch allows the operator to LOCK or 314 DASH MOUNTED FEATURES UNLOCK the differenti
22. 52 Y53 6007 PART 4 CONTROLS AND DISPLAYS Appliances in the Cab You may decide to equip your vehicle with a radio a refrig erator or other appliances and conveniences Be sure they are compatible with your truck s electrical system Secure them in the cab so they can t fly loose in a sudden stop WARNING In a sudden stop or collision a AN heavy object in your cab could strike you or anyone with you You could be injured or killed Secure any appliance such as a refrig erator or radio you add to your cab Refrigerator Follow the procedure below to operate the refrigerator CAUTION Leaving your refrigerator on when A the vehicle s engine is not running will rapidly run down your vehicle s batteries This may cause premature battery failure R10 06 PART 4 CONTROLS AND DISPLAYS H NOTES e For additional information about the refrigera tor refer to the refrigerator owner s manual that came with this appliance e Refrigerator cooling ability decreases as sleeper temperature increases The main power supply to the refrigerator and cooling fan located behind the refrigerator is controlled by a switch labeled REFRIG FAN located on the sleeper control panel R10 06 Y53 6007 GAUGES To turn the refrigerator and cooling fan on move the REFRIG FAN switch to ON then turn the thermostat dial located inside the refrigerator clockwise from the OFF setting To turn the refrigerator
23. AND DISPLAYS Trailer Brake Hand Valve 02975A This hand valve provides air pressure to apply the trailer brakes only It operates independently of the foot treadle valve main means of braking To use this brake fre quently instead of using the foot brake will wear out the trailer brake sooner H NOTE The trailer brake is not to be used as the STEERING COLUMN MOUNTED CONTROLS To operate the trailer brake hand valve pull down on the lever under the right side of the steering wheel See the Index under Brake Safety and Emergency for more complete information on when and how to use your trailer brake WARNING AN e It is dangerous to use air applied trailer brakes for parking or holding a vehicle Air system pressure can bleed down and release the brakes You could have a vehi cle roll away resulting in an accident You or others could be badly injured Always apply the parking brakes for parking or holding your vehicle on grade e Grabbing the trailer brake hand lever instead of the BrakeSaver lever could lead to an accident If you have these levers they may be close together on your steering wheel column Be sure you get the one you want The BrakeSaver lever is bent while the trailer parking brake lever is straight R10 06 Y53 6007 91 TILT TELESCOPING STEERING COLUMN Tilt Telescoping Steering Column Tilt Telescope Lever The telescoping feature of the steering wheel allows for ward
24. Brakes Have brake drum linings and disc brake pads inspected by a qualified mechanic for wear at regular intervals accord ing to the maintenance schedule In severe service or off highway applications inspect the linings more frequently Automatic Slack Adjusters Periodically check the Brake Chamber Stroke Replace the slack adjuster if proper stroke cannot be maintained Operational checks of automatic slack adjusters e Measure brake chamber stroke with the spring brake released and the air pressure no less than 100 psi 690 kPa e Brake Chamber Stroke is the difference between the applied and the retracted position of the air chamber pushrod R10 06 Y53 6007 BRAKE ADJUSTMENT e A correctly installed and functioning auto slack adjuster will produce the following strokes Chamber Type Stroke 36 rear brakes 11 2 21 4 38 57 mm 30 rear brakes 11 2 2 38 51 mm 16 20 amp 24 front brakes 1 13 4 25 4 44 4 mm CONTROL ARM SN 5 K SELF ADJUSTING BRAKE ADJUSTER STEP 2 APPLIED ANG 02945a RETRACTED Brake Chamber Stroke 155 TIRES WHEELS AND RIMS WARNING Manual adjustment of automatic AN slack adjusters is a dangerous practice that could have serious consequences It gives the operator a false sense of security about the effectiveness of the brakes Contact the Service Department at your dealership if the stroke ex
25. D Ol 11425 CAUTION Driving with very hot temperatures A in your rear drive axles can cause serious damage to axle bearings and seals Check axle lubrication if a driver temperature alarm sounds 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 condi tions you encounter Maximum axle temperature may R10 06 Y53 6007 GAUGES vary depending upon the axle and type of lubricant Very high temperatures signal a need to have your axle s lubrication checked Manifold Pressure Gauge lt o a gg 11453 1 PSI 30 Your manifold pressure gauge indicates the power your engine is putting out by showing the amount of turbo boost If the pressure indicated by your manifold pressure gauge goes down there may be something wrong with your engine Have it checked by a qualified service per son 49 GAUGES Pyrometer X A 500 F000 0 E 1500 Ey PYRO 11467 Your vehicle may be equipped with a pyrometer gauge The pyrometer gauge indicates engine exhaust gas tem perature Since it responds almost immediately to changes in exhaust gas temperature the pyrometer is an excellent indicator of engine output Monitor it in conjunction with the tachometer and manifold pressure gauge The pyrometer can be a useful aid to operating your vehicle
26. Do not replace U bolts and nuts with common U bolts or standard nuts These parts are crit ical to vehicle safety If the wrong U bolts or nuts are used the axle could loosen or sepa rate from the vehicle and cause a serious injury accident Use only U bolts and nuts of SAE Grade 8 specification or better R10 06 Fasteners Frame Fastener Torque Specifications Table 14 Frame Fastener Torque Specifications Fastener Fastener Torque Type Size Lb ft Nm 1 2 Inch 86 108 117 147 Bolt Locknut einen 130 163 176 221 Hardened Washer Mie 65 85 89 115 M16 155 195 210 264 M20 315 385 427 523 CAUTION When installing bolts on the frame A use only metric grade 10 9 bolts of the proper length Y53 6007 185 FASTENERS Standard Capscrew Torque Specifications Table 15 Capscrew Torgue Specifications PART 8 MAINTENANCE AND SERVICE Table 15 Capscrew Torgue Specifications Continued Number 5 8 20 58 87 79 118 86 123 117 167 9 16 12 78 111 105 151 110 158 149 214 18 87 124 118 168 123 176 167 239 5 8 11 108 154 147 209 153 218 208 296 18 122 174 166 236 173 247 235 335 3 4 10 192 273 260 370 271 386 367 523 16 214 305 290 414 303 431 411 583 7 8 9 309 441 419 598 437 624 593 846 14 341 486 462 659 482 589 654 799 1 8 464
27. If no trailer is connected or if a non ABS equipped trailer is connected the trailer ABS lamp will go off after a few seconds 90 Y53 6007 R10 06 PART 7 STARTING amp OPERATING THE VEHICLE A il R10 06 CAUTION The center pin of the 7 way trailer light line may be constantly powered for ABS Make sure it will not accidently turn on trailer equipment Do not splice into the non switchable Aux iliary circuit on the primary 7 way trailer light line Doing so may cause the trailer ABS to malfunction This circuit is dedi cated for trailer ABS power To add a switch able auxiliary circuit contact a Kenworth Dealership NOTES A properly connected ABS equipped trailer is a trailer with PLC hooked up to the J560 con nector a trailer without PLC that is hooked up to an optional ISO 3731 connector For doubles or triples PLC does not distinguish between trailers An ABS problem in any trailer will activate the trailer ABS warning lamp Y53 6007 ANTI LOCK BRAKING SYSTEM OPERATING INFORMATION 2 If an ABS equipped trailer is properly connected the trailer ABS warning lamp will remain illuminated for a few more seconds while the trailer ABS is tested e f no trailer ABS problems are detected the lamp will go off e If a trailer ABS problem is detected the lamp will remain on The driver should have the trailers ABS problem corrected before the vehicle is driven with
28. MAINTENANCE AND SERVICE Slow Battery Charging NOTE Follow the instructions that come with i your battery charger It is not necessary to remove the battery from the compartment 1 Make sure the electrolyte level in each cell is between the MIN and MAX marks If the fluid level is below the MIN mark correct the condition 2 Disconnect the battery cables 3 Connect charger cables 4 Start charging the battery at a rate not over 6 amperes Normally a battery should be charged at no more than 10 percent of its rated capacity 5 After charging turn OFF charger and disconnect charger cables Jump Starting Batteries 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 Because of the var ious battery installations in optional electrical systems Peterbilt does not recommend that you attempt to jump start your vehicle If you have a battery problem contact a R10 06 Y53 6007 ELECTRICAL Peterbilt Dealer or a reputable towing service But if you are unable to do this and must jump start your vehicle then ensure that you follow the precautions and instruc tions below WARNING Batteries contain acid that can AN burn and gasses that can explode Ignoring safety procedures can cause you or others to be badly hurt e Never jump start a battery near fire flames or electrical sparks Batterie
29. Remove the battery 2 3 Install new battery 4 Reinstall cover 5 Synchronize the key fob Synchronization The key fob may need to be synchronized to the truck when the battery is replaced or when the key fob has not been used for an extended period time To Synchronize A Key Fob 1 Hold the key fob near the receiver NOTE The receiver is located behind the il Speedometer Tachometer cluster assembly 2 Press and hold both the Lock and Unlock buttons at the same time for approximately 7 seconds 3 When the key fob is resynchronized the doors will lock then immediately unlock 4 If the fob fails to synchronize it could be programmed to a different truck or could have failed Contact your dealer to re program your key fob Bo CLIMBING ONTO THE DECK PLATE PART 2 GETTING INTO amp OUT OF THE CAB AND FRAME ACCESS Climbing Onto the Deck Plate When you are climbing onto and off the deck plate main tain at least three points of contact with your hands on the grab handles and your feet on the steps WARNING A You can be hurt if you aren t careful climb ing onto and off the deck plate You can slip and fall especially if the surfaces are wet or icy or if you step in oil fuel or grease Keep steps clean Always maintain at least three points of contact between your hands and feet and the steps and deck plate Do not climb onto and off the deckplate use steps and grabhandle provided If th
30. U S A o a amp 2 CHASSIS WT O lt A Zz 02954 R10 06 Y53 6007 EXAMPLE VIN 1XP 9D2X9 6 X D 345678 Serial Number Model Year Plant Code X 1999 Y 2000 D Denton Factory 1 2001 2 2002 N Nashville Factory 3 2003 4 2004 5 2005 6 2006 7 2007 8 2008 9 2009 0 zero Glider Kit 205 PART 9 VEHICLE IDENTIFICATION NUMBERS 206 Y53 6007 R10 06 PART 10 CONSUMER INFORMATION FEDERAL SAFETY STANDARD CERTIFICATION LABEL PART 10 CONSUMER INFORMATION WARNING Diesel engine exhaust and some AN 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 Cal ifornia to cause cancer birth defects or other reproductive harm This warning requirement is mandated by California law Proposition 65 and does not result from any change in the manner in which Peterbilt trucks are manufac tured Federal Safety Standard Certification Label The National Highway Traffic Safety Administration regu lations require a label certifying compliance with Federal Safety Standards for United States and U S Territories be affixed to each motor vehicle and prescribe where such label may be located This certification label which indicates the date of manu facture and other pertinent information is located
31. an explosion or fire result ing in injury or death The fuel gauge shows the approximate amount of fuel in the fuel tanks 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 WARNING Carrying additional fuel containers AN in your vehicle is dangerous Full or empty they may leak explode and cause or feed a fire Don t carry extra fuel containers even empty ones Warning Lights and Buzzers WARNING Ignoring a warning light or buzzer AN could lead to an accident These signals tell you something is wrong with your vehicle It could be a failure in an important system such as your brakes Never ignore a warning signal Have the appropriate system checked right away R10 06 Y53 6007 GAUGES _ 75 Qecooeguuc S e a 09091 Ya Ne When you turn on your ignition the following will turn on for 3 5 seconds as a test to let you know they are work ing LAMPS e Left Turn e Fifth Wheel e Check Engine e Seat Belts e Stop Engine e Right Turn e Diff Lock e High Beam e ABS e Trailer ABS OPTIONAL LAMPS Additional lamps may be operational depending on how the truck is equipped These will also turn on for three seconds as a test to let you know they are working See ABS lamp information on page 89 After this self test period the module operates normally
32. and rear dry tank The dry tanks have a single check valve in the tank inlet The check valves prevent a com plete loss of air in the event of an air system failure tank or hose failure This ensures a controlled stop with 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 G NOTE A small amount of oil in the system may be normal and should not by itself be considered rea son to replace a desiccant cartridge oil stained desiccant can function adequately 170 Y53 6007 PART 8 MAINTENANCE AND SERVICE Every 900 operating hours or 30 000 miles 48 000 km or 3 months check for moisture in the air brake system by opening reservoirs drain valves or valves and checking for the presence of water A tablespoon of water in a res ervoir would point to the need for a desiccant cartridge change However the following should be considered first e Air usage is exceptionally high abnormal for a high way vehicle This may be due to accessory air demands or some other unusual air requirement that doesn t allow the compressor to load unload in a nor mal fashion or it may be due to excessive leaks in the air system e When more than a 30 degree F 17 degree C range of temperature occurs in one day small amounts of water can accumulate in the air brake system due to condensation Under these conditions the presence of small amounts
33. and use your service brakes only for stopping completely Operating this way will greatly prolong the life of your brakes j WARNING e In an emergency the retarder might not stop you fast enough to prevent an acci dent You could be badly hurt if you relied only on your retarder Use the service brakes for quick stops The retarder is not an emergency brake R10 06 A Y53 6007 BRAKE SAFETY AND EMERGENCY e The retarder is NOT intended as the primary brake for the vehicle nor is it an emergency brake The retarder only helps the service brakes by using pressure to slow the driv etrain Use the service brakes for quick stops e The service brakes must be used in an emergency The retarder alone might not stop you fast enough to prevent an acci dent You could be badly hurt if you relied only on the retarder Do not use the retarder when operating on road surfaces with poor traction such as wet icy or snow covered roads or gravel Retarders can cause the wheels to skid on a slippery surface You could lose control of the vehicle if the wheels begin to skid resulting in an accident 105 BRAKE SAFETY AND EMERGENCY Driving Bobtail or with an Unloaded Trailer We recommend that you do not use your engine retarder to slow down when you are bobtailing or pulling an empty trailer WARNING Using an engine retarder can AN cause a wheel lockup The trailer is not load ing the tires enough to give t
34. applies the service brakes based on the projected rollover risk to reduce the vehicle speed thereby reducing the tendency to roll over C_ RSP Example 92 Y53 6007 R10 06 PART 7 STARTING amp OPERATING THE VEHICLE ANTI LOCK BRAKING SYSTEM OPERATING INFORMATION Yaw Stability Yaw stability counteracts the tendency of a vehicle to spin about its vertical axis During operation if the friction between the road surface and the tires is not sufficient to oppose lateral side forces one or more of the tires can slide causing the truck tractor to spin These yaw events are referred to as either under steer where there is a lack of vehicle response to steering input due to tire slide on the steer axle or over steer where the tractor s rear end slides out due to tire slide on the rear axle situation Generally shorter wheelbase vehicles tractors for instance have less natural yaw stability while longer wheelbase vehicles straight trucks for instance have greater natural yaw stability Factors that influence yaw stability are wheelbase suspension steer ing geometry weight distribution front to rear and vehicle track width R10 06 Y53 6007 Yaw Control Yaw Control responds to a wide range of low to high fric tion surface scenarios including rollover jackknife and loss of control In the case of vehicle slide over steer or understeer situations the system will reduce the throttl
35. between moving parts in the gear This could result in worn compo nents The mixture of two different fluids although harmless to individual internal com ponents may initiate a chemical reaction that produces a new compound that will attack seals and other internal components Do not mix different fluids CAUTION When adding fluid be sure to use R10 06 PART 8 MAINTENANCE AND SERVICE Replacement 1 Replace fluid per the chart below 2 Bleed the system if necessary Table 10 Fluid and Filter Replacement Schedule Steering Fluid Inspect Replace Gear mi km mi km months TRW ATF Every 15 000 Every 240 000 24 000 384 000 24 ATF Every 15 000 Every 240 000 Sheppard 24 000 384 000 24 Extremely low temperatures may require lower viscosity fluids con sult your Peterbilt dealer for recommendations See TRW or Sheppard Service Manuals for additional fluid listings R10 06 Y53 6007 PREVENTIVE MAINTENANCE SCHEDULE Inspection side of cover so that no dirt can fall into the reser H NOTE Before removing reservoir cover wipe out voir 1 Check the fluid level add fluid if required 2 Check fluid for contamination discoloration or burnt smell correct source of such problems before replac ing fluid amp filter 151 SERVICING SPECIFIC SYSTEMS AND UNITS Servicing Specific Systems And Units This section will help you keep your Peterbi
36. cooling system the freeze point should be maintained between 30 F and 45 F 34 C and 43 C il NOTE Maximum recommended ELC concentra tion is 60 ELC and 40 water by volume a 60 40 coolant mixture The minimum recommended concentration is 40 Desired ELC 0 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 100 Water ratio Freeze point 32 25 20 15 10 5 5 12 23 34 50 65 75 84 70 55 43 30 5 F C 0 4 7 9 12 15 21 24 31 37 46 54 59 64 57 48 42 34 21 R10 06 Y53 6007 171 ENGINE COOLING SYSTEM ELC Condition Contamination and Inhibitor Concentra tion 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 Improper mainte nance may cause coolant degradation and could result in damage to the cooling system and engine components Consult your dealer or the ELC manufacturer s represen tative for recommended ELC test kits test
37. door frame EXAMPLE NOTE Weight Mass in pounds kilograms 7 880 3574 Axle Weight 4 120 1 869 Pay load Distribution gt _ 24 385 11061 7 540 3 420 12 000 5 443 MAXIMUM LOAD RATINGS 31 925 14 481 43 925 Ibs GVW 19 924 kg Example Of Weight Distribution Y53 6007 R10 06 PART 8 MAINTENANCE AND SERVICE Load Distribution Be sure any load you carry is distrib uted so that no axle has to support more than its load limit Wheels And Rims 02949 Po R NNN Hub Pilot Mount System R10 06 Ball Seat Mount System Y53 6007 VEHICLE LOADING Hub Drum and Stud Assembly The hub pilot mounting system uses M22x1 5 met ric threads about 7 8 in dia The stud stands out at least 1 9 in beyond the brake drum All studs are right hand threads Pilot bosses machined on the hub fit tightly to the wheel center bore The ball seat mounting system uses 3 4 x 16 or 1 1 8 x 16 threads The dual mounting studs provide 1 3 1 44 in standout Right hand and left hand threads are required Inner and outer cap nuts center the wheels by seating against wheel ball seats Wheels e Pilot mount wheels have stud holes that are reamed straight through no ball seats Center bore diameter is 8 21 32 in Budd Uni Mount 10 wheels have UNI MOUNT stamped on the disc e Ball seat wheels have spheric
38. engine exhaust system and the il vehicle s cab sleeper ventilation system properly maintained It is recommended that the vehicle s exhaust system and cab sleeper be inspected e by a competent technician every 15 000 miles e whenever a change is noticed in the sound of the exhaust system whenever the exhaust system underbody cab or sleeper is damaged 192 Y53 6007 PART 8 MAINTENANCE AND SERVICE NOTES Allow for the proper operation of the vehi cle ventilation system il e Keep the inlet grille at the base of the wind shield clear of snow ice leaves and other obstructions at all times e Keep the exhaust pipe area clear to help reduce the buildup of exhaust gases under the vehicle Perform the following checks every 3 months or 30 000 miles 48 000 km whichever occurs first Heater e Check all heater controls for full range operation e Check hoses connections and heater core for condi tion and leaks e Check the drain pan of the fresh air vent for trapped water before assuming that there is a leak in the heat ing system e If the heater core is leaking take the vehicle to a Peterbilt dealer for proper heater service or repair R10 06 PART 8 MAINTENANCE AND SERVICE CAB HEATER AIR CONDITIONER e Check the heater core for debris blocking the air flow e Check the evaporator core and condenser core for If the blower is functioning properly yet the heater is debris restricting air flow
39. initial drain is required on Eaton axles that are fac tory filled with an Eaton approved synthetic lubricant Mineral based lubes must be drained within the first 5000 miles 8000 km if converting to an Eaton approved synthetic lube Change the lubricant within the first 5000 miles 8000 km of operation after a carrier head replacement regardless of the lubricant type Refer to the Eaton Field Maintenance Manual for a particular axle for lubricant specifications See your Peterbilt dealer for Eaton approved lubricant brands Refer to the chart below for lubricant change interval PREVENTIVE MAINTENANCE SCHEDULE Table 9 Eaton Dana Axle Lubricant Change Intervals On High Maximum Onon Maximum Type of Highway way Change Change Lubricant 3 Severe Ser Mi km Interval f x Interval vice Mi km Mineral Based 120 000 Yearly 60 000 Yearly 192 000 96 000 Eaton Approved 240 000 2 Years 120 000 Yearly Synthetic 384 000 192 000 Eaton Approved 360 000 Synthetic in 576 000 axle with extended drain interval option Wheel Bearing Lubrication Oil lubricated Driven Hubs Use hypoid oil A P I GL 5 SAE 80W 90 or equivalent A minimum of 1 quart 921 ml of oil is required for proper lubrication of each drive hub Add oil through the filler hole in the hub if none add oil through the differential filler hole Note Remember to replace vent plug or threaded filler plug when done
40. joints and steering U joints for looseness to ensure a positive seal e Check tie rod for straightness e Check steering wheel for excessive freeplay Check e Position the shell and gasket properly Then tighten the simplest probable causes first the cover nut or bolt just enough to prevent fuel leak age Unequal tire pressures CAUTION Do not overtighten the valve Over Loose cap nuts tightening can damage the threads Bent tie rod Loose wheel bearing e After starting the engine check for leaks around the filter R10 06 Y53 6007 183 STEERING If these checks do not reveal the problem or if you correct them and still have a steering problem take your vehicle to an authorized dealer for evaluation Front End Alignment For driving safety and comfort and to prolong the life of your vehicle it is important to have proper front end align ment Check tire wear frequently Uneven tire wear is a sign that your front end or rear axles may be misaligned If you see uneven wear take your vehicle to a service cen ter familiar with aligning front ends on Peterbilt vehicles Rear Axle Alignment Continual road shock and load stresses may force your rear axles out of alignment If you detect rapid tire wear on the rear axles you may have misaligned axles If you sus pect you do have your rear axle alignment checked and adjusted by an authorized dealership U Bolt Tension for Front and Rear Axle
41. load rating whichever is less Overloading could result in premature tire failure causing you to loose control of your vehicle and result in an injury accident The maximum vehicle load rating GVWR is found on the Tire and Rim Data label on the driver s door Table 11 Effect of Load Pressure on Tire Life Vehicle Normal 20 40 60 80 100 Load Over Over Over Over Over Tire Pres Normal 20 30 35 45 55 sure Low Low Low Low Low Expected Normal 70 50 40 30 25 Total Tire Mileage Y53 6007 Overinflated tires Too much air pressure reduces the tire tread contact area and results in rapid wear in the center of the tread 157 TIRES WHEELS AND RIMS WARNING Overinflated tires can cause acci AN dents They wear more quickly than properly inflated tires And they are more subject to punctures cracks amp other damage They could fail and cause you to lose control of your vehicle Be sure all tires are inflated cor rectly according to the manufacturer s recom mendations The chart on page 161 gives you the right load and infla tion rates for different tire sizes Please follow it for the saf est and most economical use of your tires Consult the tire manufacturer for proper pressure settings with tires not listed in this table Matching tires Be sure to buy matched tires for your vehicle especially on the rear axles Mismatched tires can cause
42. minutes Then start the engine in the vehicle with the dead battery If the engine fails to start do not continue to crank the starter but contact the near est Authorized Service Center 179 ELECTRICAL WARNING When disconnecting jumper cables make sure they do not get caught in any moving parts in the engine compartment 7 Reverse the above sequence exactly when removing the jumper cables Take care that your first step is to remove the cable from the chassis or ground of the vehicle that was jump started Removing and Installing Batteries partment cover step before entering the cab Without the battery cover you could slip and fall resulting in possible injury to yourself CAUTION Always reinstall the battery com Whenever you have to install a battery or remove one fol low these guidelines for the safety of yourself and the bat tery Ensure all switches on the vehicle are turned Off e Disconnect the ground cable first when removing a battery e Connect the ground cable last when installing a bat tery 180 Y53 6007 PART 8 MAINTENANCE AND SERVICE Headlamp Adjustment Follow the procedure below to adjust a headlamp NOTE This lamp has provisions for vertical adjustment only Access the adjuster through the hole in the lens see the illustration below Optical Center Vertical Adjustment TORX 20 R10 06 PART 8 MAINTENANCE AND SERVICE POSITION VEHICLE a WALL
43. more efficiently and avoiding sud 50 Y53 6007 PART 4 CONTROLS AND DISPLAYS den changes in engine operating temperature See your engine owner s manual for maximum temperature recom mendations Voltmeter lt 11497 Your voltmeter displays the battery voltage Normally it should show 12V to 14V volts il NOTE Even with a healthy charge start system the voltmeter may fall well below 12V during engine cranking If voltage drops below 12V and stays there have the electrical system checked R10 06 PART 4 CONTROLS AND DISPLAYS Air Filter Restriction Indicator Gauge 40 AIR FILTER 11495 This gauge indicates the condition of the engine air cleaner and is measured by inches of water H20 A clean filter should register 7 H2O may vary with system design a filter whose life is over will register approxi mately 20 H2O for Cummins engines or 25 H20 for Caterpillar engines R10 06 Y53 6007 GAUGES Filter Re striction Gauge reading 25 HO may cause damage to the engine Inspect the filter and replace if necessary Holes in the paper element render an air cleaner useless and may cause the Air Filter Restriction Gauge to give a false reading even if the element is clogged Replace the element if it is damaged Shift Pattern Display A CAUTION Continued operation with the Air The correct shift pattern for your vehicle appears
44. most circumstances idling your engine for long periods merely wastes fuel In severe arctic weather con ditions however you may need longer idling to be sure all parts of your engine are fully lubricated 77 PUTTING THE VEHICLE IN MOTION A A WARNING To reduce the chance of personal injury and or vehicle damage from overheated engines which can result in a fire never leave the engine idling without an alert driver present If the engine should overheat as indicated by the engine coolant temperature light immediate action is required to correct the condition Continued unattended opera tion of the engine even for a short time may result in serious engine damage or a fire CAUTION Do not allow your engine to idle at low rpm s 400 600 rpm longer than five min utes Long periods of idling after the engine has reached operating temperatures can decrease engine temperature and cause gummed piston rings clogged injectors and possible engine damage from lack of lubrica tion The normal torsional vibrations gener ated can also cause transmission wear 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 And don t allow your engine to idle longer than five minutes 78 PART 7 STARTING amp OPERATING THE VEHICLE Putting The Vehicle In Motion This section dis
45. move to a 12 00 position with their LED warning lights on for 5 seconds Gauge pointers will then move to their actual gauge readings and their LED warning lights will go off e The speedometer message center SMC will dis play the odometer NOTE If the SMC displays other messages or if il other alarms activate after the key is turned ON see the Warning Alarms section at the end of this part on page 115 5 Turn the key to start 73 COLD TEMPERATURE STARTING PROCEDURE CAUTION Never operate the starter motor A while the engine is running The starter and flywheel gears could clash or jam severely damaging them NOTE Some starters are equipped with overcrank protection Check the Engine Operation and Main tenance Manual for details If the engine does not start within 30 seconds release the starter button To avoid overtaxing the starter motor or the batteries don t use the starter for more than 30 seconds Let the starter motor cool and the batteries recover for 2 minutes before trying again If the engine still won t start after a couple of tries check the manual override shut down valve and fuel lines for possible fuel starvation or air leaks Starting failure may mean fuel isn t reaching the injectors 1 As soon as the engine starts begin to watch the oil pressure gauge Check your engine manufacturer s manual for the right pressure for your engine If the oil pressure doesn
46. of moisture is normal and should not be considered as an indication that the dryer is not performing properly e An outside air source may have been used to charge the air system in which case this air did not pass through the drying bed R10 06 PART 8 MAINTENANCE AND SERVICE Engine Cooling System Your engine s cooling system is standard with Extended Life Coolant ELC ELC consists of a mixture of ethylene glycol water and organic acid technology chemical inhib itors ELC prevents corrosion and scale formation as well as provides freezing and boiling point protection A CAUTION The engine cooling system has very specific maintenance and inspection requirements Failure to follow requirements can damage the engine Engine damage can include but is not limited to Freezing Boiling Corrosion ePitted cylinder liners ENGINE COOLING SYSTEM This information is found in the engine manufac turers owner s manual It is the owner s respon sibility to follow all requirements listed in the engine manufacturers owner s manual A What To Check In An ELC filled Cooling System ELC Concentration Check the level of freeze boilover protection which is determined by the ELC concentration Use a glycol refrac tometer to determine glycol level Add ELC to obtain the ELC to water ratio required to provide the protection you need Use the chart below to help determine how much ELC you need to add In an ELC filled
47. on the left hand cab door post R10 06 Y53 6007 SULTABLE_TERE AIM CHOICE RIM SIZE P TIRE SIE i oye fr How To Order Parts When you need replacement parts for your Peterbilt vehi cles contact your nearest authorized Peterbilt dealer who may be located from the Peterbilt Authorized U S and Canadian Dealers listing Cat No 5212 When you order it is IMPORTANT than you have the fol lowing information ready e Your name and address e Serial number of the truck e The name of the part you need e The name and number of the component for which the part is required The quantity of parts you need e How you want your order shipped 207 NHTSA CONSUMER INFORMATION NHTSA Consumer Information The National Highway Traffic Safety Administration requires that the following information be included in the owner s manual of motor vehicles manufactured after September 1 1990 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 If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy cam paign However NHTSA cannot get in
48. on your control panel or windshield or on a medallion in the shift knob It is important that you know more about your trans mission than just the shift pattern Please read the manu facturer s manual that is included with your vehicle Mirrors WARNING Optional convex outside rearview AN mirrors make objects appear smaller and far ther away than they really are You could have an accident if you were too close to another vehicle or other object Keep plenty of space between your vehicle and others when you turn or change lanes Remember that other objects are closer than they seem 51 GAUGES Your vehicle is equipped with outside mirrors to enable you to see to the sides and behind your vehicle Be sure they are adjusted properly before you drive off You will have the best field of view to the side if you adjust each mirror so you can just see the side of your vehicle in the inboard part of the mirror Luggage Compartment s An interior luggage compartment is under the bunk in the sleeper The exterior compartment is beneath the bunk opening from the driver s side on the outside of the cab WARNING Carrying objects loose in your cab AN or sleeper can be dangerous In a sudden stop or even going over a bad bump they could fly forward and strike you or a passen ger possibly causing serious injury Secure loose objects Carry any heavy objects in the exterior luggage compartment and close it securely
49. or on the side of the road day or night A hard to see vehicle can result in an injury accident Another vehicle could run into you if you do not set your flashers Always move the vehicle a safe distance off the road when stalled or stopped for repairs Of course in normal stopping in traffic such as at a stop light you do not use your flashers WARNING Your disabled vehicle can be dan gerous for you and others The hot exhaust system could ignite dry grass spilled fuel or other substances Do not park or operate your vehicle where the exhaust system could con tact dry grass brush spilled fuel or any other material that could cause a fire 19 STEERING COLUMN MOUNTED CONTROLS High Beam Headlights High Beam Headlight Switch All Peterbilt vehicles come equipped with a combination turn signal and high beam low beam switch To switch your headlights lower or higher gently pull the turn signal lever up towards the steering wheel until you hear the switch click and the beam changes 20 Y53 6007 PART 4 CONTROLS AND DISPLAYS Electric Horn Your Peterbilt has an electric horn To sound the horn press on the bar in the center of the steering wheel Electric Horn Bar Air Horn Your Model 387 has an air horn in addition to an electric horn Control the air horn by pulling on the lanyard extend ing from the overhead header panel R10 06 PART 4 CONTROLS
50. parts may seriously damage your transmission So don t drive in one gear for long until the transmission lubricant has had a chance to coat those contacting surfaces R10 06 Y53 6007 PUTTING THE VEHICLE IN MOTION Operating the Clutch Riding the Clutch The clutch pedal is not a footrest Driving with your foot on the clutch pedal will allow your clutch to slip causing excessive heat and wear You can damage your vehicle this way Clutch Travel speed range to start the vehicle in motion The use of a higher gear or speed range forces undue strain on the engine clutch other transmission components and may cause damage 4 CAUTION Always use first gear or a low To put your vehicle into motion push down on the clutch pedal until the clutch brake makes contact This contact will occur at about 1 2 inch to 1 inch from the end of pedal stroke Select a gear low enough to let your vehicle start forward with the throttle at idle until the clutch is fully engaged 79 PUTTING THE VEHICLE IN MOTION The total stroke of the clutch pedal is about 10 inches The first 1 3 4 to 2 inches is free travel After that is the release stroke the part that fully releases the clutch The last 1 2 to 1 inch engages the clutch brake If your vehicle is new watch the free travel in your clutch carefully for the first few hundred miles As your clutch lining wears and high spots get worn smooth you will get less free travel
51. possible If the vehicle must be driven under these conditions drive only with the windows slightly open Failure to repair the source of the exhaust fumes may lead to per sonal harm NOTES Keep the engine exhaust system and the vehicle s ventilation system properly maintained It is recommended that the vehicle s exhaust sys tem and cab be inspected e by a competent technician every 15 000 miles e when a change is noticed in the sound of the exhaust system e if the exhaust system underbody or cab is damaged NOTE To allow for proper operation of the vehicle ventilation system keep the inlet grille at the base of the windshield clear of snow ice leaves and other obstructions at all times R10 06 PART 4 il il H R10 06 CONTROLS AND DISPLAYS NOTE Do not stay in the vehicle with the engine running or idling for more than 10 minutes with the vehicle s Heater AC ventilation system in RECIRC or at LOW FAN SPEED Even with the ventilation system On running the engine while parked or stopped for prolonged periods of time is not recommended NOTE 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 NOTES When idling for short periods of time e Set the heating or cooling system to Heat or A C e Set the fan to Medium or High speed e Set the cont
52. proper tools You could be injured or you could make your vehicle unsafe Do only those maintenance items you are fully trained and equipped to do Before attempting any procedures in the engine compartment stop the engine and let it cool down Hot components can burn skin on contact Be alert and cautious around the engine at all times while the engine is running If work has to be done with the engine run ning always 1 set the parking brake 2 chock the wheels and 3 ensure that the Shift lever or selector is in Neutral Exercise extreme caution to prevent neck ties jewelry long hair or loose clothing from getting caught in the fan blades or any other moving engine parts 119 PREVENTIVE MAINTENANCE SCHEDULE 120 e Disconnect the battery ground strap when ever 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 e Always support the vehicle with appropriate safety stands if it is necessary to work underneath the vehicle A jack is not ade quate for this purpose il PART 8 MAINTENANCE AND SERVICE Never start or let the engine run in an enclosed unventilated area Exhaust fumes from the engine contain carbon monoxide a colorless and odorless gas Carbon mon oxide can be fatal if inhaled NOTE Suitable wheel chocks are at a minimum an 18 inch 46 cm long 4x4
53. symbol Press once Light will turn on at high intensity above With the electric wipers the wipers will come on for a short time when the washer starts 02894A Washer Press again Light will shift to low intensity 26 Y53 6007 R10 06 PART 4 CONTROLS AND DISPLAYS WARNING Do not drive with worn or dirty AN wiper blades They can reduce visibility mak ing driving hazardous Clean blades regularly to remove road film and wax build up Use an alcohol based cleaning solution and a lint free cloth and wipe along the blades CAUTION Do not use antifreeze or engine A coolant in the windshield washer reservoir damage to seals and other components will result Intermittent Windshield Wiper Control Two speed intermittent windshield wipers are controlled by the control panel knob with the symbol shown above To turn on the wipers rotate the knob to the right As you turn the knob further to the right intermittent delay decreases until the knob encounters the first position for continuous operation Turn the knob further right to the next position for higher speed continuous operation Turn off the wipers by rotating the knob to the left R10 06 Y53 6007 DASH MOUNTED FEATURES Air Suspension Deflate Switch Dump Valve AIR SUSPENSION 03035 Your Model 387 may have an air suspension deflation switch that allows the air in the suspension to be exhausted from a switch on the dash The purpose o
54. temperature gauge If the fan clutch engages at low engine temperature or cycles on and off more fre quently than it should receives false signals have the problem corrected at your dealership Air Intake System Engine heat vibration and age combine to loosen air intake connections and cause cracks in the tubing and elbows Leaks in the intake system allow abrasive dust to enter the engine and quickly cause expensive damage During your daily walk around inspection carefully check all tubing elbows clamps supports and fasteners for condition and tightness Under normal operating conditions we recommend com plete disassembly and cleaning of the air intake system annually R10 06 PART 8 MAINTENANCE AND SERVICE Under severe operating conditions such as heavy off highway use the disassembly and cleaning should be more frequent Replace any defective parts With the pos sible exception of mounting brackets don t repair defec tive parts Air Cleaners The following service information is basic to all air cleaner makes and models Service the air cleaner filter elements as specified in the Preventive Maintenance Schedule If your vehicle is equipped with an optional air inlet restriction indicator ser vice the filter elements when the air inlet restriction indica tor locks in the extreme Up position Paper elements require care and proper handling because they are critical to engine service life Turboc
55. that trailer attached Advanced ABS with Stability Control This vehicle may be equipped with an optional Electronic Stability Program ESP ESP is a feature for ABS equipped vehicles that reduces the risk of rollovers jack knifing and other loss of control ESP features include Roll Stability Program RSP and Yaw Control During operation the ECU of the Bendix Advanced ABS system constantly compares performance models to the vehicle s actual movement using the wheel speed sen sors of the ABS system as well as lateral yaw and steer ing angle sensors If the vehicle shows a tendency to leave an appropriate travel path or if critical threshold val 91 ANTI LOCK BRAKING SYSTEM OPERATING INFORMATION PART 7 STARTING amp OPERATING THE VEHICLE ues are approached the system will intervene to assist the driver Roll Stability Program Bendix RSP an element of the overall ESP system addresses rollover conditions In the case of a potential roll event the ECU will override the throttle and quickly apply brake pressure at all wheel ends to slow the vehicle combination The level of braking application during an RSP event will be proportional to roll risk A Real World Example Of How The RSP System Operates Excessive speed for road conditions creates forces that exceed the threshold at which a vehicle is likely to C rollover on a higher friction surface The system automatically reduces engine torque and
56. the Range Selector in LOW R10 06 Y53 6007 PUTTING THE VEHICLE IN MOTION Automatic and Automated Transmission An automatic or automated transmission makes shifting much easier It remains important to completely under stand how to operate the transmission to optimize its effi ciency Please read the manual for your automatic or automated transmission included with your vehicle WARNING If your vehicle has a Freedom AN line transmission be aware that it can roll backwards when stopped on a hill or grade or when starting from a stop on a hill or grade This could cause serious damage or personal injury Observe the following guidelines When stopped on a hill or grade press the brake pedal When starting from a stop on a hill or grade quickly remove your foot from the brake pedal and firmly press on the accelerator pedal Auxiliary Transmission If you have an auxiliary transmission see your transmis sion manufacturer s manual for its proper operation 85 PUTTING THE VEHICLE IN MOTION PART 7 STARTING amp OPERATING THE VEHICLE If Your Vehicle Must Be Towed 2 Cover open hubs when removing drive axle shafts Follow these directions to ensure your vehicle is not dam aged when towing is required 1 Lift driving wheels off the ground or remove the drive line and axle shafts before towing the vehicle CAUTION Failure to lift the driving wheels off CAUTION Water dirt and other mate
57. the air conditioning system fully inspected annu checked thoroughly A malfunctioning clutch usually ally by your dealer indicates trouble elsewhere in the system R10 06 Y53 6007 193 APPEARANCE Special Precautions A 194 WARNING Excessive heat may cause your air conditioning system to explode Never weld solder steam clean or use a blow torch near any part of the air conditioning system If a refrigerant leak develops in the presence of excessive heat or an open flame hazardous gases may be generated These gases may cause unconsciousness or death If the sys tem is leaking refrigerant e Stay away from the hot engine until the exhaust manifold has cooled Don t permit any open flame in the area Even a match or a cigarette lighter may gen erate a hazardous quantity of phosgene gas Don t smoke in the area Inhaling gaseous refrigerant through a cigarette may cause violent illness PART 8 MAINTENANCE AND SERVICE Appearance Painted Surfaces A CAUTION Do not aim the water jet directly at door locks or hatch Tape the key holes to pre vent water from seeping into the lock cylin ders Water in lock cylinders should be removed with compressed air To prevent locks from freezing in the winter squirt glyc erin or lock deicer into the lock cylinders e Wash frequently to remove grime and caustic depos its that may stain the finish Apply cool or lukewarm water You may want to use
58. the oil level refill as required see page 148 X X lliary trans Transfer Case Drain lubricant while warm Flush each unit with clean flushing oil mission x Meritor Main amp aux Freedomline Transmission Change the oil see page 148 500 000 miles iliary trans 800 000 km mission ZFMeritor Air Intake Air intake piping mounting Check the system for broken pipes leaks joint integrity cleanliness and xX and charge air cooler proper support see page 188 Engine air intake tubing Disassemble clean check for cracks leaks and joint integrity X Cold starting aids Check for leaks and proper operation see page 74 X Air cleaner Replace the element as indicated see page 189 When required by the air restriction indicator R10 06 Y53 6007 129 PREVENTIVE MAINTENANCE SCHEDULE Table 2 Preventative Maintenance Schedule Continued PART 8 MAINTENANCE AND SERVICE Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval A B C D E Clutch Clutch pedal shaft Check for excessive looseness and lubricate NLGI 2 grease X Clutch pedal Check for proper free pedal see page 182 X Clutch release linkage Check for excessive looseness and lubricate NLGI 2 grease X Clutch release bearing Lubricate X Clutch release shaft Lubricate X 130 Y53 6007 R10 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Table 2 Preventative Ma
59. they stored properly 71 SAFE VEHICLE OPERATION 11 12 13 14 15 16 17 18 Is the trailer spare wheel secure Inflated Is the landing gear up and the handle secured Check the 5th wheel Is the kingpin locked Is the sliding 5th wheel locked Check for loose or missing suspension fasteners Check springs or other suspension parts for damage such as cracks gouges distortions bulges or chaf ing Check the air system Are there leaks Drain excess moisture from all air supply tanks Make sure the drain valves are closed This procedure is also required for air supply tanks equipped with auto matic drain valves In Cab Checklist CAUTION To avoid injury while entering or 72 leaving the cab keep your feet in contact with the steps and your hands on the handhold Always have three points of contact as you enter or exit a cab See PART 2 GETTING Y53 6007 PART 6 DRIVER S CHECKLIST INTO amp OUT OF THE CAB AND FRAME ACCESS of this manual for more informa tion Adjust the seats Fasten and adjust safety restraint belts See PART 5 SEAT AND RESTRAINT SYSTEMS or the Index under Restraint Systems Sleeper Restraints Check and inspect condition See PART 5 SEAT AND RESTRAINT SYSTEMS or the Index under Restraint Systems Adjust the steering column Check mirror adjustment Operate air powered devices to circulate lubricants H
60. to fall too far forward possibly causing head and neck inju ries You could strike the wheel or the wind shield Adjust your belt so that there is no more than one inch 25 mm of slack j WARNING A too loose seat belt can lead to e Watch that you don t twist the belt in the process of put Incorrect under arm ting it on A twisted belt won t work as well to protect you WARNING Wearing the shoulder belt under your arm could lead to serious injury In a crash your body would move too far forward increasing the chance of head and neck injury The belt would apply too much force to the ribs which aren t as strong as your shoul der bones You could also suffer internal inju ries Wear the shoulder belt over your shoulder 02930 Twisted Belt Y53 6007 R10 06 PART 5 SEAT AND RESTRAINT SYSTEMS WARNING You could be seriously injured by AN a twisted belt In a crash the full width of the belt wouldn t be protecting you And the twisted belt could cut into your body Straighten the belt before buckling it If you can t have your dealer or service person fix it To connect your shoulder lap belt Grasp the belt tongue and pull in a smooth slow motion across your chest and lap Insert the tongue into the buckle on the inboard side of the seat Push down until you hear a click Pull on the belt to make sure it is buckled Check that it is positioned correctly on your body Comfort Feature
61. when the x Air Condi Defrost Defog mode is selected tioning Heater amp air conditioner Perform the checks listed on page 192 X Cab air filter Clean replace after a maximum of three cleanings X Heater amp air conditioner Full operational and diagnostic check X Exhaust System Check for leaks and proper support see page 190 t X 138 Y53 6007 R10 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Table 2 Preventative Maintenance Schedule Continued Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval I A B C D E Air Air compressor governor Replace air strainer X Air lines Check condition and routing to prevent chafing X System Lubricate See page 168 Inline filters Replace elements or clean with solvent Air dryer Perform the checks listed on page 170 X Air dryer ON HIGHWAY Overhaul 360 000 miles 576 000 km Air dryer OFF HIGHWAY Overhaul xX Engine Basic Engine The maintenance and service interval recommendations for the specific engine are the maintenance requirements specified in the engine manufac turers Operations and Maintenance Manual included with the vehicle Strict adherence to these recommendations is required to maintain war ranty coverage The maintenance and service interval recommendations for the engines vary significantly depending on the manufacturer and the model of the engine As a
62. where almost con TEF stant movement of the seat belt webbing occurs 5 A P lt 7 because of relative movement between the seat and Web cut or frayed Q Web cut or frayed at or extremely worn D loop web guide the cab at latch area SS ON 3 Check the comfort feature for cracks or possible dam age and that it works properly 4 Check the buckle and latch for proper operation and 4 to determine if the latch plate is worn deformed or damaged 7 A Buckle casting ae I broken 7 gt 03004A R10 06 Y53 6007 65 INSPECTION OF THE RESTRAINT SYSTEM 5 Inspect the retractor web storage device that is mounted on the floor or B pillar of the vehicle for dam age The retractor is the heart of the occupant restraint system and can often be damaged if abused even unintentionally Check retractor web storage device operation to ensure that it is not locked up and that it spools out and retracts webbing properly erly can cause excessive movement of the j WARNING Failure to adjust tether belts prop 66 seat in an accident This could lead to greater injuries for you Tether belts should be adjusted so that they are taut when the seat is in its most upward and forward position If adjustable tethers are being used be sure they are adjusted in accordance with installation instructions Tethers must also be inspected for web wear just as with the seat belt systems Mounti
63. with Pump and Filter 240 000 mi 384 000 km Mineral Base Synthetic 120 000 mi 192 000 km 120 000 mi 192 000 km Synthetic with Pump and Filter 120 000 mi 192 000 km Mineral Base 120 000 mi 192 000 km Drive Axle program Application Under Meritor s Advanced Lube Rear Drive Axle program Sacha the axles listed below are exempt from an initial lubricant change Table 7 Available Advanced Lube Axles RS 17 145 RS 23 180 RT 40 145 RT 44 145P RS 19 145 RS 26 180 RT 40 145P RT 46 160 RS 21 145 RS 30 180 SQ 100A RT 46 160P City Delivery RS 23 160 RT 34 145 SQ 100AP RT 52 160 RS 23 161 RT 34 145P RT 44 145 RT 52 160P Meritor rear axles that do not appear on the list above will continue to require an initial drain at 3000 5000 miles 4800 8000 km Vocational e Refer to the Meritor Field Maintenance Manual for a particular axle for lubricant specifications e See your Peterbilt dealer for Meritor approved lubri cant brands 148 Y53 6007 R10 06 PART 8 MAINTENANCE AND SERVICE Change the lubricant filter every 120 000 miles 192 000 km Top off the lubricant level with a similar lubricant Eaton Dana Axle Lubrication R10 06 The original mineral based lubricant must be drained within 3000 5000 miles 4800 8000 km on all Eaton axles This initial change is very important because it flushes out break in contaminants that might other wise cause premature wear No
64. x Brakes reline see page 152 All Slack adjusters Lubricate NLGI 2 grease X Brake camshaft bearing Lubricate NLGI 2 grease X Brake treadle valve Clean the area around the treadle boot and mounting plate Check the pivot and mounting plate for integrity Check the plunger boot for cracks X Lubricate roller pin pivot pin and plunger NLGI 2 grease Brake treadle valve Rebuild through an authorized Peterbilt service facility X Brake air system Check air lines and fittings for leaks see page 152 Adjust routing as x required to reduce chafing Check tank mounting and condition Brake air system Clean or replace the inline filters X Brake lining Inspect replace as required X 126 Y53 6007 R10 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Table 2 Preventative Maintenance Schedule Continued Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval A B C DE Disc Brakes Brake pads Inspect replace as required X All Brake disc rotor Inspect for visible cracks heat checking galling or scoring of surface xX Check thickness minimum of 1 46 37 mm Caliper sliding function Ensure caliper slides freely with no obstructions or excessive play see X manufacturer s service literature for Checking Running Clearance Caliper function Inspect bearings seals tappet and boots of the guide p
65. you can find these subjects Use the Quick Table of Contents to find information on a large subject like Maintenance Cross referenced citations also help you get the informa tion you need If some other part of the manual contains further information on the subject you are reading about we ll indicate that in a cross reference like this See PART 6 DRIVER S CHECKLIST You won t have to go searching for more information Finally you ll find a helpful Subject Index It s in the back of the manual and alphabetically lists the subjects cov ered So if you want information on brakes for example just look under Brake in the Subject Index You ll find all the pages listed where brakes or braking are discussed 2ga A SPECIAL WORD ABOUT REPAIRS A Special Word About Repairs Your Peterbilt dealer s service center is the best place to have your vehicle repaired You can find Peterbilt dealers all over the country with the equipment and trained personnel to get you back on the road quickly and keep you there Your vehicle is a complex machine Anyone attempting repairs on it needs good mechanical training and the proper tools If you are sure you have these requirements then you can probably perform some repairs yourself However all warranty repairs must be performed by an authorized Peterbilt service facility If you aren t an experi enced mechanic or don t have the right equipment please leave all r
66. 0 miles 8000 km of over the road service In off highway use the change should be made after 24 hours but before 100 hours of service have elapsed R10 06 Y53 6007 PREVENTIVE MAINTENANCE SCHEDULE Refilling Remove all dirt around filler plug Refill with new oil of the grade recommended for the existing season and prevail ing service Fill to the bottom of the level testing plug posi tioned on the side of the transmission Do not overfill the transmission Overfilling usually results in oil breakdown due to excessive heat and aeration from the churning action of the gears Early breakdown of the oil will result in heavy varnish and sludge deposits that plug up oil ports and build up on the splines and bearings Overflow of oil can also escape onto clutch or parking brakes When add ing oil do not mix different types of oil 147 PREVENTIVE MAINTENANCE SCHEDULE Meritor Axle Lubrication il NOTE Axles utilized in 100 off highway use are not eligible for Meritor s Advanced Lube Rear PART 8 MAINTENANCE AND SERVICE e Refer to the following chart for lubricant change inter vals Table 8 Lubricant Change Intervals Type Of Lubricant Mileage Interval Synthetic 240 000 mi 384 000 km Synthetic with Pump and Filter 500 000 mi 800 000 km Mineral Base Synthetic 120 000 mi 192 000 km 120 000 mi 192 000 km Synthetic
67. 10 177 Do not exceed the speed rating of tires Exceeding the speed rating may result in sud den tire failure and loss of vehicle control regulations per section Follow all warnings and cautions contained within the tire and wheel manufacturers litera ture Only properly trained personnel should ser vice tire and rim assemblies Do not exceed the load rating of your tires molded on the side wall of your tire or the maximum vehicle load rating whichever is less Overloading could result in premature tire failure causing you to loose control of your vehicle and result in an injury accident The maximum vehicle load rating GVWR is found on the Tire and Rim Data label on the driver s door R10 06 PART 8 MAINTENANCE AND SERVICE VEHICLE LOADING Table 13 Cap Nut Torque Specifications R12 01 TORQUES FOR INNER amp OUTER CAP NUTS WHEEL AND NUT STUD SIZE CONFIGURATION Lb Ft N m Stud Piloted Disc 3 4 16 Inner Wheels 1 1 8 16 Outer 50 500 610 680 Heavy Duty Stud 15 16 12 Inner Piloted Disc Wheels 1 5 16 12 750 900 1025 1225 Outer PHP 10 Budd Uni Mount 10 WHD 8 M22 x 1 5 6H 450 500 610 680 Rim Clamp Nut Torque Cast Spoke Wheel 1 2 Dia 80 90 110 120 Assembly on Dia 160 185 220 250 i 3 4 Dia Crisscross Sequence For Demountable Rims ue a R10 06 Y53 6007 167 YOUR VEHICLE S AIR SYSTEM Your Vehicle s
68. 2941A Typical Height Control Valve Top View R10 06 PART 7 STARTING amp OPERATING THE VEHICLE Yn SUPPLY FROM FORWARD AIR TANK on GSES C m EXHAUST gt AIR BAG DELIVERY TO RH AIR BAG S SETTING RIDE HEIGHT e On dual valve systems begin with the LH valve on the next step 2 Loosen the fasteners mounting a height control valve to its bracket MOUNTING NUTS vy DELIVERY TO LH AIR BAG S LINK ROD 02941B Typical Height Control Valve Rear View Looking Forward H NOTES e At least one of the mounting holes in the height control valve bracket will be slotted to permit rotating the valve R10 06 CAUTION e The rear of a vehicle will drop about 3 1 2 inches 88 mm when the air springs are deflated Ensure that no persons or objects that could be injured or damaged are under the vehicle before deflating the air springs To minimize risk of damage or injury do not use a dump valve to deflate the air springs Rotate the height control valve s manually to ensure positive control of air spring deflation To minimize risk of injury keep away from air springs as they are being inflated 3 Rotate the valve either clockwise or counterclockwise until air pressure in the air springs provides the ride height specified for that suspension Measure the ride height from the bottom of the fram
69. 3 4 5 6 4 7 8 3 9 02971B 16 Y53 6007 PART 4 CONTROLS AND DISPLAYS LEFT SIDE ID Clearance Lamps Switch Ignition Switch Headlamps Switch Voltmeter Oil Pressure Tachometer Warning Light Bar Speedometer Message Center SMC Water Temperature 10 17 18 Air Cleaner Restriction Primary Air Pressure Secondary Air Pressure Fuel SMC Select Reset Switch Dome Light Switch Windshield Wiper Washer Panel Dimmer Cigarette Lighter R10 06 PART 4 CONTROLS AND DISPLAYS 12 14 16 10 11 E 17 5 13 15 7 gB 8 0090 go o Ol oo PBEE 02972A R10 06 RIGHT SIDE A WO ND oa Parking Brake Valve Trailer Air Supply Valve Heater AC Control Panel Fog Lights Switch Engine Fan Switch 6 ID Clearance Lamps Flash Y53 6007 Switch Trailer Brake Lever Cruise Control Switch Transmission Temperature Cruise Control Switch Pyrometer YOUR INSTRUMENT PANEL 12 13 14 15 16 17 18 19 20 21 Engine Brake Engine Brake Load Lights Switch Interaxle Differential Lock Switch 5th Wheel Lock Switch Air Suspension Switch Radio CB Radio Selected Option Switch Mirror Heater Switch 17 STEERING COLUMN MOUNTED CONTROLS PART 4 CONTROLS AND DISPLAYS Ste
70. 38 Y53 6007 PART 4 CONTROLS AND DISPLAYS To operate your lighter push the knob in After a few moments the lighter will automatically pop out ready to use After use insert the knob but don t push it in The lighter circuit is protected by a 10 ampere polyswitch to prevent damage should the lighter get stuck in the IN posi tion If this fuse needs replacement check to ensure that the lighter is not stuck before replacing the fuse WARNING Do not exceed the voltage amper AN age capacity of the cigarette lighter It could result in a fire Follow all warnings and instructions in the operator s manual for the appliance you are using The lighter receptacle may be used to power auxiliary equipment that does not draw more than 10 amperes maximum Ashtray WARNING Paper or other combustible sub AN stances in an ashtray could cause a fire Keep all burnable materials besides smoking mate rials out of the ashtray R10 06 PART 4 CONTROLS AND DISPLAYS Glove Compartment To open your glove compartment pull the latch To close it push the cover up and press to latch it The glove compartment can be locked Turn your glove box key clockwise right to lock and counterclockwise left to unlock be dangerous In an accident or sudden stop you or a passenger could be thrown against the cover and injured Keep the cover closed when the vehicle is in motion j WARNING An open glove compart
71. 4 Start the engine 5 Idle at low RPM 173 ELECTRICAL 6 Complete the filling Do it as quickly as possible 7 Idle the engine until it reaches normal operating tem perature 8 Fill the radiator as necessary to raise the coolant level to the proper reading Replace the surge tank pres sure cap Check the coolant level after each trip when the engine has cooled 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 Electrical the vehicle s electrical system or power distri bution box All electrical repairs should be performed by a qualified service technician Improper repair or modifications will void your warranty and or cause serious damage to your vehicle CAUTION Do not modify or improperly repair 174 Y53 6007 PART 8 MAINTENANCE AND SERVICE Battery Care Regular attention to the charging system will help prolong the service life of your batteries Here are some common causes of battery failure e Overcharge This condition may result from improper voltage regulator adjustment It results in overheating of the battery warped plates and evaporation of elec trolyte Undercharge Your voltage regulator may be mal functioning or is improperly a
72. Air System WARNING Prior to the removal of any air sys AN tem component always block and hold the vehicle by a secure means other than the vehicle s own brakes Depleting air system pressure may cause vehicle to roll Keep hands away from chamber push rods and slack adjusters they may apply as system pressure drops After completing any repairs to the air sys tem always test for air leaks and check the brakes for safe operation before putting the vehicle in service e Never connect or disconnect a hose or line containing air pressure It may whip as air escapes Never remove a component or pipe plug unless you are certain all system pressure has been depleted e Never exceed recommended air pressure and always wear safety glasses when work ing with air pressure Never look into air jets or direct them at anyone 168 Y53 6007 PART 8 MAINTENANCE AND SERVICE Never attempt to disassemble a component until you have read and understood recom mended procedures Some components contain powerful springs and injury can result if not properly disassembled Use only proper tools and observe all precau tions pertaining to use of those tools The operation of the vehicle s braking system and many vehicle accessories depends upon the storage and appli cation of a high pressure air supply Your vehicle s compressor takes outside air and com presses it usually to 100 120 psi The compressed air then goes to th
73. Allow time for the oil to seep Y53 6007 149 PREVENTIVE MAINTENANCE SCHEDULE through the bearings when initially filling a hub Maintain the differential oil level by adding oil until its surface is even with the bottom of the filler hole see page 144 Oil lubricated Nondriven Hubs Use CD50 synthetic transmission fluid SAE 50W or equiv alent A minimum of 9 oz 270 ml of lubricant is required for proper lubrication of an LMS hub 10 13 oz 295 400 ml is required for a non LMS hub depending on wheel design Allow time for the fluid to seep through the bearings when initially filling a hub When properly filled the fluid level will lie between the fluid level line and 1 4 above the line Note Remember to replace vent plug when done Grease Lubricated Hubs Repack the hub bearing with clean wheel bearing grease after disassembling cleaning and inspecting 150 Y53 6007 PART 8 MAINTENANCE AND SERVICE Universal Joint Lubrication Refer to the Spicer Universal Joints and Driveshafts ser vice manual and lubrication specifications Steering Gear Lubrication fluid of the same type While many fluids have the same description and intended purpose they should not be mixed due to incompatible additives If incompatible insoluble fluids are mixed in a power steering system air bub bles can be produced at the interface of the two fluids This can cause cavitation which reduces the lubrication
74. Axle Steering knuckles thrust Inspect for wear and damage and for endplay Shim or replace as required X bearings kingpins drawkeys see page 184 tie rod ends steering stops amp bushings Kingpin bushings amp tie rod Lubricate with approved grease X ball ends Total Vehicle Alignment Check and adjust as required X X Drawkeys Tighten nuts X X Front Front Spring Inspect for cracked leaves worn bushings amp excessive corrosion X Suspension Spring Pins amp Shackles Inspect for worn parts and excessive joint clearance Shim or replace as X required 122 Y53 6007 R10 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Table 2 Preventative Maintenance Schedule Continued Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval I A B C D E Front Spring Pins Lubricate X Suspension Shock Absorbers Inspect for leaking body damage and damaged or worn bushings X Replace as required Shock Absorbers Check for proper function X U bolts ON HIGHWAY Check the general condition and the tightness of the nuts Tighten the nuts X X to the specified torque value as required see page 184 U bolts OFF HIGHWAY Check the general condition and the tightness of the nuts Tighten the nuts X to the specified torque value as required see page 184 Drive Axle Axle Housing Visually inspect for damage or leaks X Dana A
75. CLE BRAKE SAFETY AND EMERGENCY 3 Slide out the release stud 02936C 4 Insert the release stud through the opening in the spring chamber where the cap was removed Insert it into the pressure plate Turn the release stud 1 4 turn clockwise in the pressure plate This secures the cross pin into the cross pin area of the pressure plate and locks it into the manual release position R10 06 Y53 6007 103 BRAKE SAFETY AND EMERGENCY PART 7 STARTING amp OPERATING THE VEHICLE 5 Assemble the release stud washer and nut on the release stud 6 With a wrench turn the release stud assembly nut until the compression spring is 90 95 caged While doing this check to make sure the push rod adapter push rod or service push rod is retracting Do not overtorque the release stud assembly S Cam F RN type maximum 50 ft Ilb Wedge type maximum 30 ft K J 2937C RY lb The spring brake is now mechanically released j 0 104 Y53 6007 R10 06 PART 7 STARTING amp OPERATING THE VEHICLE Retarders Various retarders are available which function against the engine driveline or transmission These are devices that use your engine s power to slow down your vehicle They save wear and tear on your service brakes and can be a safety feature too because they can keep your brakes from overheating Ideally you should always slow your vehicle with your retarder where permitted by law
76. FOR VEHICLES IN HIGHWAY SERVICE TIRE LOAD AND INFLATION TABLES Tire Load Tire Load Limits At Various Cold Inflation Pressures psi Size Range 70 75 80 85 90 95 100 105 110 115 120 11R22 5 G 4530 4770 4990 5220 5510 5730 5950 6175 11R22 5 H 4530 4770 4990 5220 5510 5730 5950 6175 6320 6465 6610 11R24 5 G 4820 5070 5310 5550 5840 6095 6350 6610 11R24 5 H 4820 5070 5310 5550 5840 6095 6350 6610 6790 6970 7160 275 70R22 5 H 4850 5050 5250 5480 5705 5945 6195 6450 6720 7000 295 75R22 5 G 4500 4725 4940 5155 5370 5510 5780 5980 6175 285 75R24 5 G 4545 4770 4940 5210 5420 5675 5835 6040 6175 DUAL RADIAL TIRES FOR VEHICLES IN HIGHWAY SERVICE 11R22 5 G 4380 4580 4760 4950 5205 5415 5625 5840 11R22 5 H 4380 4580 4760 4950 5205 5415 5625 5840 5895 5950 6005 11R24 5 G 4660 4870 5070 5260 5510 5675 5840 6005 11R24 5 H 4660 4870 5070 5260 5510 5675 5840 6005 6205 6405 6610 275 70R22 5 H 4430 4610 4795 5005 5210 5430 5660 5890 6135 6395 295 75R22 5 G 4095 4300 4540 4690 4885 5070 5260 5440 5675 285 75R24 5 G 4135 4340 4540 4740 4930 5205 5310 5495 5675 NOTES e Pressure listed is the minimum for the load e All tire load figures are in pounds e Figures in Bold face indicate maximum recommended load Source Bridgestone Tire 2 02 R10 06 Y53 6007 161 VEHICLE LOADING Vehicle Loading A 162 WARNING Do not exceed the specified load
77. Gauge 44 Fuel Gauge 46 Manifold Pressure Gauge 49 Primary And Secondary Air Pressure Gauges 43 Pyrometer 50 Speedometer Message Center 40 Tachometer 42 Transmission Temperature Gauge 48 Voltmeter 50 Warning Lights and Buzzers 47 Water Temperature Gauge 45 Glove Compartment 39 GVWR gross vehicle weight rating 162 H Headlamp adjustment 180 Heater and air conditioner 37 J Jumper cables 178 K Keys 8 Keys and Locks Ignition Switch 22 L Lubrication Axle 148 149 coasting 114 PB1328 22 02011 R10 02 PART 11 SUBJECT INDEX Steering Gear 150 Transmission 144 types and brands 140 Universal Joint 150 Wheel Bearing 149 Lubrication Index 142 Luggage Compartment s 52 M Maintenance Schedule 119 Mirrors 51 N Noise Control System 199 P Parking brake brake system operation 99 use 119 R Refrigerator 52 Restraint Systems 55 Comfort Feature 59 Inspection 63 Shoulder Belt 56 Sleeper Bunk Restraints 60 Tether Belts 62 S Safe vehicle operation 69 Safety stands 120 22 02011 R10 02 Seat 55 Servicing Specific Systems Air Intake System 188 Air System 168 Anti lock Braking System ABS 190 Brake Adjustment 152 Cab Heater Air Conditioner 192 Electrical 174 Engine Accessories 187 Engine Cooling System 171 Fasteners 185 Steering 183 Tires Wheels And Rims 156 Transmission And Drive Train 182 Shifting gears 114 115 Standard Capscrew Torque Specifications 186 Starting and Operating 73
78. NOTE The above items should be checked daily as a minimum They are in addition to not in place of Federal Motor Carrier Safety Regula tions These may be purchased by writing to Superintendent of Documents U S Government Printing Office Washington DC 20402 R10 06 PART 7 STARTING amp OPERATING THE VEHICLE NORMAL TEMPERATURE STARTING PROCEDURE PART 7 STARTING amp OPERATING THE VEHICLE Since each Model 387 is custom equipped all engine operation instructions in this manual are general You will want to consult the manual for your engine to find out details about your specific engine s needs You may need to use a slightly different procedure from the one outlined here Also check the ATA Truck Driver s Handbook in your glove box It will give you tips on starting shifting and driving a truck Below are instructions for both normal temperature starting and cold weather starting Normal Temperature Starting Procedure When the outside temperature is above 50 F 10 C you can use the following procedure 1 Set the parking brake 2 Put your main transmission in Neutral 3 Disengage depress the clutch with manual trans mission R10 06 Y53 6007 4 Turn the key switch to ON e If your vehicle is equipped with a digital message center DMC the DMC display will come on in the Clock mode e The multiplex instrumentation system will begin a self test Gauge pointers will
79. PART 1 INTRODUCTION HOW TO FIND WHAT YOU WANT PART 1 INTRODUCTION This manual contains useful information for the safe and efficient operation of your Peterbilt Model 387 It also pro vides 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 opera tion and to present it as clearly as possible We hope you ll find this manual easy to use Please remember though this manual is not a training manual It can t tell you everything you need to know about driving your Peterbilt vehicle For that you need a good training program or truck driving school If you have not been trained get the proper training before you drive Only qualified drivers should drive this vehicle There will be times when you need to take this manual out of your Peterbilt When you do please be sure to return it to the cab when you are finished using it That way it will be there when you need it the next time or when you pass the vehicle on to the next user R10 06 Y53 6007 How To Find What You Want There are several tools built into this manual to help you find what you need quickly and easily First is the Quick Table of Contents Located at the front of the manual this lists the main subjects covered and gives page numbers where
80. THEIR PROPER USE PART 5 SEAT AND RESTRAINT SYSTEMS bunk remove all items from the top of the bunk mattress and arrange bedding so that items will not slide down the mattress and fall behind the bunk A CAUTION To avoid damage when lifting a The bunk restraint is attached to the sleeper in six loca tions see illustration below 1 Two buckles at the upper rear wall 2 Two buckles at the side walls 3 Bolts in two places at the lower rear wall There is also a buckle at the driver s side front of the bunk for easy entry exit of the sleeper with the bunk restraint in use Pregnant Woman With Belt Properly Worn Sleeper Bunk Restraints If your cab is equipped with a sleeper be sure to use the restraint device You may have belts which either are over the bunk or cover the opening Of course you do not need to use a restraint if you sleep in a parked vehicle But any one using the sleeper while the truck is in motion should be restrained in a safety device 60 Y53 6007 R10 06 PART 5 SEAT AND RESTRAINT SYSTEMS SEAT BELTS AND THEIR PROPER USE e The lower rear wall The restraint is attached to the lower rear wall by bolts that do not require removal for use or stowage of the bunk restraint You will notice that if your Peterbilt has an upper bunk it has no restraint device This is because no one should ever be in an upper bunk when the vehicle is moving WARNING AN In an accident an unrestra
81. WARNING Do not carry additional fuel con AN tainers in your vehicle Fuel containers either full or empty may leak explode and cause or feed a fire Do not carry extra fuel containers even empty ones are dangerous e Diesel fuel in the presence of an ignition source such as a cigarette could cause an explosion You could be seriously injured A mixture of gasoline or alcohol with diesel fuel increases this risk of explosion Do not remove a fuel tank cap near an open flame e Use only the fuel and or additives recom mended for your engine 107 STOPPING THE ENGINE Final Stop To make sure your vehicle is ready to go after a long stop such as over night please follow the suggestions below Your vehicle will be easier to get going when you are ready and it will be safer for anyone who might be around it Please remember too that in some states it is illegal to leave the engine running and the vehicle unattended Final Stopping Procedures 1 Set the parking brake before leaving the driver s seat To hold your vehicle while it is parked don t rely on e Air Brakes e Hand Control Valve for Trailer Brakes e Engine Compression brakes to hold a parked vehicle is dangerous Because they work with air pressure these brakes could come loose Your vehicle could roll causing a serious accident Someone could be hurt or killed Always set the parking brakes Never rely on the trailer hand brake or truck air
82. a mild soap e Avoid washing your vehicle in bright sunlight A WARNING Handle cleaning agents carefully Cleaning agents may be poisonous Keep them out of the reach of children e Road tar may be removed with a special commercial tar remover or mineral spirits Y53 6007 R10 06 PART 8 MAINTENANCE AND SERVICE Waxing offers added protection against staining and oxidation But to allow enough time for your truck s fin ish to cure wait about ninety days after the date of manufacture before waxing Don t wax in the hot sun Don t friction burn the paint with a buffing machine Aluminum and Chrome Surfaces R10 06 Clean aluminum wheels and bumpers with warm water Tar remover will get rid of heavy deposits of road grime To prevent spotting wipe aluminum surfaces dry after washing Under corrosive conditions such as driving on salted roads clean aluminum parts with steam or high pres sure water from a hose A mild soap solution will help Rinse thoroughly Chrome surfaces are best cleaned with fresh water Wipe dry to preserve their luster A commercial chrome cleaner will remove light rust After cleaning wax flat surfaces and apply a thin coat of rust preven tive lubricant around bolts or other fasteners APPEARANCE Stainless Steel Follow this procedure to clean and restore the finish of stainless steel components 1 In a plastic pail mix 4 tsp of alum a powder found in grocery st
83. a torque wrench to check all cap screws including those at the flanges Refer to the engine manufacturer s service manual for proper tightening sequence and torque values R10 06 Y53 6007 NOISE CONTROL SYSTEM Joints and Clamps Check for leaks and tighten as necessary Check for dete rioration or dents in pipes and clamps which could allow exhaust to escape Piping Check for rust corrosion and damage If piping is perfo rated at any point temporary patching or lagging is acceptable until you can have permanent repairs made On turbocharged engines check joints at the flanges and mounting brackets for tightness Mufflers H NOTE Use only exact replacement components in exhaust systems Certain components contain integral catalytic converters essential for compli ance with EPA emission standards Using a non compliant component as a replacement could violate these standards and also void the emis sion system s warranty 201 NOISE CONTROL SYSTEM Check clamps and mounting brackets for security Check internal baffling for security You can do this by listening for rattling sounds while tapping the muffler with a rubber mallet or revving the engine up and down through its nor mal operating range Check muffler for rust and corrosion Exhaust Tail Pipe s Check the mounting security Tighten as necessary The miter cut at the tip of the pipe must be facing the rear of the truck Do not modify the en
84. air all air leaks as soon as you find them laminated to the shield with fiberglass and resin R10 06 Y53 6007 203 NOISE CONTROL SYSTEM PART 8 MAINTENANCE AND SERVICE Table 16 Noise Control System Maintenance Logs RECOMMENDED DATE amp REPAIR DATE amp REPAIR WORK PERFORMED COMPONENT INTERVAL R O NUMBER FACILITY WORK PERFORMED po NUMBER FACILITY amp MILES LOCATION LOCATION Exhaust System Rout ing Integrity 25 000 Muffler Internal Baffles 250 000 Shutters Shrouds 25 000 Hood Insulation Blanket 19 009 Engine Mounted Hose Insultators 10 000 Fasteners Inner Fender Shields 50 000 Cab Skirt Fasteners 50 000 Air Intake System 5 000 Integrity Element Clutch Type FanDrive 10 000 204 Y53 6007 R10 06 PART 9 VEHICLE IDENTIFICATION NUMBERS PART 9 VEHICLE IDENTIFICATION NUMBERS Each vehicle completed by Peterbilt Motors Company uses a Vehicle Identification Number VIN that contains the model year designation of your Peterbilt The practice is in compliance with 49 CFR 565 Code of Federal Regu lations The Vehicle Identification Number is on the brass Peterbilt name plate and also on the foil labels on the left hand door post The VIN contains 17 digits The 10th digit is the code for the model year of your vehicle The example VIN below from a 1999 model shows how this code works O A DIVISION OF PAGAR DENTON TEXAS
85. al The guard over this switch pre vents you from accidentally activating the lock See Inter axle Differential on page 81 for more information on using your interaxle differential WARNING Placing the differential lock in the AN LOCK position while your wheels are spin ning could cause loss of control or axle dam age You could be hurt Switch to LOCK only when your wheels are not spinning Fifth Wheel Lock Slider Adjustment Switch 0 1 CAB CONTROL 03031 32 Y53 6007 PART 4 CONTROLS AND DISPLAYS Vehicles having an air slide fifth wheel have a fifth wheel slider lock controlled by a switch on the instrument panel By placing the switch in the unlock position you can slide the fifth wheel to various positions to adjust weight distri bution There is a guard over this switch to protect you against accidentally activating or releasing the lock WARNING Do not move the fifth wheel while AN the tractor trailer is in motion Movement of the fifth wheel while a tractor trailer is moving can cause a serious accident Your load could shift suddenly causing you to lose control of the vehicle 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 is engaged slide tracks if a slider should be cleaned and lubricated periodically to ensure smooth turn ing and sliding action Failure to keep thes
86. al chamfers machined on each stud hole Center bore diameter is 8 23 32 in 163 VEHICLE LOADING PART 8 MAINTENANCE AND SERVICE Wheel Nuts Hub pilot nut has a hex body and a flange for clamp ing against wheel face Hex size is 33 mm same as 1 5 16 in Inner and outer cap nuts mate with spherical cham fers on wheels Inner nut has 13 16 in square end Outer nut has 1 1 2 in hex WARNING Mismatched wheel components AN are dangerous Equipment that does not exactly match original specifications or that is mismatched could cause your wheels to break and separate from the vehicle The resulting accident could be very serious Each mounting system is engineered for use only with its correct mating part Be sure properly matched components are used for each type of mounting Wheel Cap Nut Torque At the first 100 miles have all wheel cap nuts torqued to their specified value After that check wheel cap nuts at least once a week Contact the Service Department at your dealership for information on the proper installation 164 Y53 6007 procedure for the wheels on your truck This is a job you may not be able to do yourself You need the right torquing equipment to do it WARNING AN e Ensure that the bolts and nuts are clean and free of any oils or grease Failure to do so will result in improper wheel clamping which can result in an injury accident e Tighten wheel cap nuts properly If they are
87. and cooling fan off turn the thermostat dial inside the refrigerator counterclock wise to the OFF setting then move the REFRIG FAN switch to OFF To turn only the refrigerator off turn the thermostat dial counterclockwise to OFF 53 GAUGES 54 Y53 6007 PART 4 CONTROLS AND DISPLAYS R10 06 PART 5 SEAT AND RESTRAINT SYSTEMS SEAT PART 5 SEAT AND RESTRAINT SYSTEMS Seat For information on the features and adjustment of the seat see the seat manufacturer s literature included with the vehicle WARNING AN e Do not drive or ride with your seat back in the reclined position You could be injured by sliding under the seat belts in a collision e Do not adjust the driver s seat while the vehicle is moving The seat could move suddenly and unexpectedly and can cause you to lose control of the vehicle Make all adjustments to the seat while the vehicle is stopped After adjusting the seat and before driving off ensure that the seat is firmly latched in position R10 06 Y53 6007 Seat Belts And Their Proper Use Seat or safety belts have proven to be the single most effective means available for reducing the risk of serious injury and death in motor vehicle accidents It s not just an opinion it s a fact Seat belts save lives WARNING Do not drive vehicle without your AN seat belt and your riders belt fastened Riding without a safety belt properly fastened can lead to inc
88. and rearward movement of the wheel The tilting fea ture allows you to move the wheel up and down 22 Y53 6007 PART 4 CONTROLS AND DISPLAYS WARNING Adjusting the Tilt Telescoping AN Steering Wheel while the vehicle is in motion could cause loss of control You would not be able to steer properly and could have an acci dent Make all adjustments to the steering mechanism while the vehicle is stopped To position the wheel Locate the Tilt Telescope Lever on the floor to the left of the steering column Push this lever toward the floor Move the steering wheel to the desired angle and height Release the lever to lock in the correct position Dash Mounted Features Keys and Locks The same key fits your ignition doors and sleeper lug gage compartment Frame mounted tool box locks lock ing fuel tank caps and glove boxes each have individual keys R10 06 PART 4 CONTROLS AND DISPLAYS Ignition Switch OFF ACC ONLY IGN amp ACC START 02977A Your ignition switch has four positions e ACC Accessory With your key in this position you can play the radio or use other accessories but your engine won t start e OFF In this position all systems are off and you can remove your key DASH MOUNTED FEATURES e IGN amp ACC This position allows you to turn on the engine and all accessory power e START Starter activation to start engine Headlights The headlights are contro
89. anging your fuel filters or strainer elements Your engine will run better and last longer if you do See the engine manufacturer s recommendations for proper water and micron requirements e When removing filters cover any electrical equipment and wiring that might get soaked with fuel Diesel fuel may permanently damage electrical insulation R10 06 PART 8 MAINTENANCE AND SERVICE STEERING e When installing spin on throwaway filters hand Steering tighten them only to 1 2 to 2 3 turn after gasket con tact Mechanical tightening of these filters may distort Guidelines For Checking A Steering System or crack the filter head WARNING A steering system that is not work NOTE To expel air from density type strainer ele AN ing properly can cause an accident You coul d ments soak them in clean fuel before installing lose control of your vehicle if the steering is them not in good order For driving safety give your steering gear and components the following e When replacing a fuel filter element don t use a sub visual checks frequently Check them espe stitute Install only filter elements designed for fuel fil cially after trips over rough roads tration First clean and inspect the shell Then insert the new element and fill the container at least 2 3 full of clean fuel before installing the shell e Check draglink clamp for looseness or interference e Throw away old gaskets Replace them with new ones e Check ball
90. appen if you don t heed the warning and how to avoid it For example WARNING Attempting repair work without sufficient training service manuals and the proper tools can be dangerous You could be injured or you could make your vehicle unsafe Do only those tasks you are fully qual ified to do CAUTION This symbol amp word signals some thing that could damage your vehicle You might receive an injury too For example CAUTION Continuing to operate a vehicle with insufficient oil pressure will cause seri ous engine damage NOTE Gives you information we feel you d like to have It could have to do with care of your vehicle or with driving more efficiently VEHICLE SAFETY il Please take the time to read these messages when you see them And remember NOTE A cold compressor can cause refrigerant to liquefy and warp the valve plates or cause a hydraulic lock Warm the engine before starting the air conditioner WARNING Something that could injure you seriously CAUTION Something that could cause injury to you or your vehicle NOTE Useful information Vehicle Safety Make sure your Peterbilt 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 PART 6 DRIVER S CHECKLIST WARNING Do not drink and drive Your AN reflexes perceptions and judgment can be affected by even a small amount of alcohol You could
91. arm dra glink power steering hoses etc 7 Check the fuel tanks Is there enough fuel Are the tank caps secure WARNING 9 Drain the fuel water separator AN Checking the Luggage Compartment 1 Check the fire extinguisher charge 2 Check the road emergency kit Is it complete Checking Outside the Vehicle 1 Be sure all wheel studs and cap nuts are secure Check wheel cap nut torque weekly refer to the instructions on page 164 2 Check tires for condition and proper inflation 3 Check the front wheel bearing lube level 4 Check parking spring brakes as to the condition and tightness of air lines breathers clamp rings amp bolts mounting studs and release bolts 5 Check turn signal operation R10 06 Y53 6007 e Diesel fuel in the presence of an ignition source such as a cigarette could cause an explosion You could be seriously injured A mixture of gasoline or alcohol with diesel fuel increases this risk of explosion Use only the fuel recommended for your engine e Hot fuel vapors are combustible and can cause an explosion or fire resulting in injury or death Do not remove a fuel tank cap near an open flame Visually inspect the fuel tank mounting hardware Are the tank straps tight Is the webbing in place Check the air cleaner and exhaust system Are they tight and secure Check the trailer connections Are they secure and the lines clear If they are not being used are
92. aulic oil trans mission and axle oil engine coolant diesel fuel air condi tioning refrigerant R12 R134a and PAG oil batteries etc may contaminate the environment if spilled or not dis posed of properly Contact your local government agency for information concerning proper disposal R10 06 Y53 6007 ENVIRONMENTAL PROTECTION State of California California Vehicle Code Section 9951 Disclosure of Recording Device Your vehicle may be equipped with one or more recording devices commonly referred to as event data recorders EDR or sensing and diagnostic modules SDM If you are involved in an accident the device s may have the ability to record vehicle data that occurred just prior to and or during the accident For additional information on your rights associated with the use of this data contact the California Department of Motor Vehicles Licensing Operations Division or http www dmv ca gov pubs vctop d03_6 vc9951 htm 209 STATE OF CALIFORNIA PART 10 CONSUMER INFORMATION 210 Y53 6007 R10 06 PART 11 SUBJECT INDEX PART 11 SUBJECT INDEX A Alarms 115 Anti lock brakes 89 19 0 Appearance 194 Appliances in the Cab 52 B Battery compartment cover 180 electrolyte 175 recharging 175 slow battery charging 177 Brake operation 89 Brake system Electronic Stability Control 91 truck amp tractor 89 C Cap Nut Torque Specifications 167 Cleaning the vehi
93. blower to whatever speed makes you most comfortable The sleeper control panel will have two controls see next illustration WARNING Do not drive with visibility reduced l by fog condensation or frost on the wind A rotary knob in the left portion controlling the blower Shield Your view may be obscured which speed with four settings could result in an injury accident For clear visibility and safe driving it is extremely im 36 Y53 6007 R10 06 PART 4 CONTROLS AND DISPLAYS portant for you to follow the instructions per taining to the function and use of the ventilation heating and defogging defrosting system If in doubt consult your dealer Maxi mum heating output and fast defrosting can be obtained only after the engine has reached operating temperature not blow hot defroster air onto cold wind shields 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 gradu ally increase the temperature when you see that the windshield is starting to warm up 4 CAUTION During extreme cold weather do e To defog the windshield select the Defrost mode and turn the blower speed to high Set the tempera ture knob to hot the red position on the control The air conditioner is automatically activated to remove moisture from the cab After the windshield i
94. brakes to hold a parked vehicle j WARNING Using the trailer hand brake or air 108 Y53 6007 PART 7 STARTING amp OPERATING THE VEHICLE 2 If you are parked on a steep grade block the wheels Blocked Wheels 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 Don t deplete the entire air supply Be sure to close the drains before leaving the vehicle R10 06 PART 7 STARTING amp OPERATING THE VEHICLE SETTING RIDE HEIGHT Incorrectly adjusted ride height may result in improper interaxle U joint working angles This can result in prema ture driveline wear and driveline vibration If your vehicle is equipped with a Peterbilt rear air suspension and if it becomes necessary to reset the ride height you may tem porarily set it by following the next procedure Proper ride height measurement and values are shown in the illustra tion and table below C SUSPENSION er peN ee Opening Drains Gans vi toot ll too LIF cose HHO 4 Secure the vehicle Close all the windows and lock all o a OA J the doors i 20 ha Ce RIDE HEIGHT Setting Ride Height Vehicles equipped with rear air suspensions have their ride height and axle pinion ang
95. breathe the engine exhaust gas A poorly maintained damaged or corroded exhaust system can allow carbon monoxide to enter the cab or sleeper Entry of carbon monoxide into the cab is also possible from other vehicles nearby Failure to properly maintain your vehicle could cause carbon monoxide to enter the cab sleeper and causes serious illness CAUTION Never idle your vehicle for pro longed periods of time if you sense that exhaust fumes are entering the cab or sleeper Investigate the cause of the fumes and correct it as soon as possible If the vehicle must be driven under these conditions drive only with the windows slightly open Failure to repair the source of the exhaust fumes may lead to personal harm PART 7 STARTING amp OPERATING THE VEHICLE A Y53 6007 CAUTION The use of a winterfront can result in excessive engine coolant oil and charge air intake temperatures which can lead to overheating and possible engine damage If you must use a winterfront e Refer to the Engine Operation and Mainte nance Manual for operating restrictions and recommendations e Use only a winterfront available from your Peterbilt dealer that is compatible with a EPA compliant engine cooling system These winterfronts are specifically designed for use with new grill snap pat terns R10 06 PART 7 STARTING amp OPERATING THE VEHICLE il NOTES e Keep the engine exhaust system and the vehi cle s cab sleepe
96. ceeds the above specifications A stroke exceeding these values may indicate a problem with the slack adjuster or the brake foundation Tires Wheels And Rims Tires WARNING You can be badly injured trying to AN fix tires Don t mount or dismount a tire your self have any wheel service performed by an expert And stand away from the tire assembly while the expert is working Your tires are a very important part of your vehicle s whole braking system How fast you can stop depends on how much friction you get between the road and your tires In addition keeping your tires in good condition is essential to the safe efficient operation of your vehicle Regular fre 156 Y53 6007 PART 8 MAINTENANCE AND SERVICE quent inspection and the right care will give you the assur ance of safe and reliable tire operation Here are some tips on maintaining your tires Checking Inflation Pressure Give your tires a visual test every day and check inflation with a gauge every week e When checking tire pressure inspect each tire for damage to sidewalls cuts cracks uneven wear rocks between duals etc If a tire appears underinflated check for damage to the wheel assembly Don t forget to check between dual wheels If you find wheel dam age have an expert tire service repair it e Maximum tire pressure will be indicated on the side wall of a tire e Check pressure only when the tires are cool Warm or hot tires cau
97. cle 4 CAUTION Connect recovery rigging only to 5 Follow all state provincial and local laws that apply to vehicles in tow 6 Do not tow vehicles at speeds in excess of 55 mph 90 kph Returning a Towed Vehicle to Service You will have to add lubricant to prevent damage after your vehicle has been towed 88 Y53 6007 PART 7 STARTING amp OPERATING THE VEHICLE 1 Into the pinion cage add 1 pint 47 liter of lubricant OR Into the inter axle differential add 2 pints 94 liter of lubricant See the Index under Lubricant Specifica tions for the lubricant required by each axle 2 After adding the specified type and amount of lubri cant 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 Anti Lock Braking System Operating Information A Model 387 is equipped with an anti lock braking system ABS This ABS reduces the possibility of wheel lock up If a wheel is about to lock during braking the ABS will automatically adjust air pressure to the brake chambers on the appropriate wheel s to prevent wheel lock up The ABS is automatically turned on when the ignition switch is turned on R10 06 PART 7 STARTING amp OPERATING THE VEHICLE WARNING AN e The brake system is a critical vehicle safety system For the safety of you and others around you have the vehic
98. cle 194 Consumer Information 208 Controls Air Horn 22 Air Suspension Deflate Switch Dump Valve 27 Brakesaver 30 Cigarette Lighter 38 22 02011 R10 02 Cruise Control Switch 30 Dome Light Switch 26 Electric Horn 20 Engine Brake 30 Engine Fan Switch 28 Fifth Wheel Lock Slider Adjustment Switch 32 Fog Lights Switch 25 Hazard Flasher 19 Headlights 23 Heater Air Conditioning Controls 34 Interaxle Differential Lock Switch 31 Manual Override 23 Mirror Heat Switch 29 Panel Light Knob 24 Parking Brake Valve and Trailer Air Supply Valve 33 Power Mirror Switch 29 Tilt Telescoping Steering Column 22 Trailer Brake Hand Valve 21 Turn Signal and Indicator Lights 18 Windshield Wipers and Washers 26 Cooling system PB1328 coolant level 173 extended life coolant 171 173 temperature 45 topping up 172 211 D Dash 15 Defogging defrosting system 37 Door lock 194 Driver s Checklist 69 Driving vehicle inspection 69 E Economical driving 113 Electrical system batteries 176 battery charging 176 jumper cables 178 Electrolyte 175 Engine overspeed 114 Engine Warmup 75 Environmental Protection 209 Exhaust fumes 120 F Federal motor vehicle safety standards 6 Federal Safety Standard Certification Label 207 Frame Fastener Torque Specifications 185 G Gauges and Displays 39 Air Application Gauge 43 Air Filter Restriction Indicator or Gauge 51 212 PART 11 SUBJECT INDEX Engine Oil Pressure
99. ctly into 1st or reverse depress the clutch pedal until contact with the clutch brake is made to stop transmission gear rotation If you have a butt tooth condition and can t shift the trans mission gradually release the clutch Then the drive gear can roll enough to allow the teeth to line up properly and complete the shift R10 06 PART 7 STARTING amp OPERATING THE VEHICLE brake while the vehicle is moving The pur pose of the clutch brake is to stop the trans mission so that you can shift into a starting gear without grinding Applying the clutch brake when the vehicle is moving causes a braking effect on the entire vehicle This wear naturally shortens the service life of your clutch brake A CAUTION Be careful not to apply the clutch Double Clutching Whether you are upshifting or down shifting it is best to double clutch Double clutching is easier on your trans mission and on your engine helping your vehicle match engine speed with driveline speed and achieving clash free shifts To double clutch 1 Push down the clutch pedal to disengage the clutch 2 Move the gear shift lever to neutral 3 Release the pedal to engage the clutch This lets you control the RPM of the mainshaft gears Thus you can match the RPM of the mainshaft gears to those of the output shaft R10 06 Y53 6007 PUTTING THE VEHICLE IN MOTION e Upshifts Let the engine and gears slowdown to the RPM required for the next gear
100. cusses the clutch and transmission opera tion to get your Peterbilt underway A A Y53 6007 WARNING Do not carry loose objects in your cab it can be dangerous In a sudden stop or even going over a bump in the road they could fly through the air and strike you or a passen ger You could be injured or even killed Secure all loose objects in the cab before moving the vehicle CAUTION Do not try to put the vehicle in motion before pressure in the system reaches 100 psi 689 kPa because the wheels are locked by the spring brake action Unneces sary stress and possible brake malfunction could occur if the vehicle is forced to move before the air system reaches 100 psi 689 kPa R10 06 PART 7 STARTING amp OPERATING THE VEHICLE Shifting The Transmission You will find a shift pattern either on a decal in your cab or on a medallion in the shift knob Check to be sure you know the correct sequence for your particular transmis sion Refer to the transmission manual included with your vehicle for complete instructions in the operation of your transmission Shifting Gears in a New Vehicle Shift carefully in a new vehicle The transmission may be a little stiff at first So be careful to avoid gear clashing When you are operating a new vehicle or one that has been exposed to cold weather you want the transmission lubricant to circulate and coat the contacting surfaces of the gears Metal contacting metal in moving
101. d of the pipe in any way Fan Shroud WARNING The engine fan can engage at any AN time without warning Anyone near the fan when it turns on could be badly injured Before turning on the ignition be sure that no one is near the fan Do not work on the fan with the engine run ning Check all fasteners for tightness Check for stress cracks in the shroud Make sure the shroud is adjusted so that it does not touch the fan blades 202 Y53 6007 PART 8 MAINTENANCE AND SERVICE Hood Insulation Blanket Fasteners Check all fasteners for condition and security Repair or replace any broken or defective fasteners Blanket Check for chafing tears etc Patch it if necessary Find the cause of the damage If any component or accessory is causing wear or damage and can t be relocated put reinforcing pads on the blanket at the site of wear Engine Mounted Noise Insulators Fasteners Check for condition and security How you do this will depend on the method of attaching the noise insulators on the engine and around the oil pan bolts snap fasteners or straps Tighten loose fasteners repair or replace any worn or damaged fasteners R10 06 PART 8 MAINTENANCE AND SERVICE NOISE CONTROL SYSTEM Insulators e Check cab skirts sills and brackets for overall condi tion and repair them as necessary Damaged rubber fender shields or cab skirting cannot be repaired You will need to replace it Check insulators arou
102. damage or leaks X 124 Y53 6007 R10 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Table 2 Preventative Maintenance Schedule Continued Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval 1 A B C D E Drive Axle Axle Housing Drain and replace the lubricant See information on page Meritor 148 Lubricant filter Change the filter X Breather Check the operation If the cap doesn t rotate freely replace X Input shaft amp pinion shaft Check and adjust the endplay X Axle shaft Tighten the rear axle flange nuts to the specified torque value X Interaxle differential Check the operation X Rear U bolts Check the torque Tighten to specified torque value as required see page x x Suspension 184 D Frame amp crossmember bolts Check the torque Tighten to specified torque value as required see page x 185 Mounting brackets and fas Check the condition and the fastener torque Tighten to the specified x x teners torque value as required see page 185 R10 06 Y53 6007 125 PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Table 2 Preventative Maintenance Schedule Continued Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval I A B C D E Drum Slack adjusters Check the push rod travel and check the control arm for cracks Adjust at
103. ding of the tire which could cause a failure resulting in loss of vehicle control and an injury accident j WARNING Do not replace original equipment TIRES WHEELS AND RIMS e Recommended points 02946 e Recommended points Steer Tire Points in Upper View Drive Tire in Lower View R10 06 Y53 6007 159 TIRES WHEELS AND RIMS safer have their radial and lateral run out checked at your dealer And of course you should have your tires balanced any time you change a tire H NOTE To prolong your tires life and make them Tire chains If you need tire chains install them on both sides of each driv ing axle axle can damage the driveline U joints and the interaxle differential Your repairs could be costly amp time consuming CAUTION Chains on the tires of only one tandem 160 Y53 6007 PART 8 MAINTENANCE AND SERVICE Speed Restricted Tires AN 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 maxi mum rated speed Failure to comply with these speed restrictions could cause sudden tire fail ure which can result in property damage or per sonal injury R10 06 PART 8 MAINTENANCE AND SERVICE Tire Load and Inflation Tables Table 12 Load Range Letters and Corresponding Ply Rating G 14 ply H 16 ply SINGLE RADIAL TIRES
104. djusted the drive belt is slipping or your vehicle has undergone long periods of standing idle or short distance driving These con ditions result in battery plates becoming covered with a hard coating Vibration Loose battery hold downs may cause bat tery plate failure e Short Circuits These discharge a battery by drain ing electricity e Dirty or Loose Connections Bad connections may stop the flow of electrical power to and from the bat tery R10 06 PART 8 MAINTENANCE AND SERVICE ELECTRICAL Recharging Batteries e Always make sure the battery charger is OFF before Except for using small trickle chargers to maintain battery connecting or disconnecting the cable clamps condition you should have your vehicle s batteries WARNING Always shield your eyes and avoid charged by a qualified service facility To help reduce the AN leaning over the battery whenever possible risk of personal injuries follow these guidelines carefully when recharging a battery e Use protective eyewear WARNING A battery contains gas that is AN explosive and flammable It could injure you CAUTION Never use a metallic funnel to add severely A spark or flame near a battery on distilled water It could come in contact with a charge may cause it to explode with great terminal creating a short circuit resulting in force severe injury or damage to your vehicle e Allow no sparks or open flame anywhere near the e Maintain the ful
105. e Check for out of x round or oversize condition 0 080 in 2 mm more than the original diame ter Replace as required Hubcaps Clean the sight window Check the center plug mounting flange and fill plug for leaks and for proper installation Replace broken or damaged X parts Check the lubricant level and add as required Main amp aux Main amp auxiliary transmission Inspect for visible damage signs of overheating and leaks xix iliary trans and transfer case SSON Main amp auxiliary transmission Check the drain plugs for tightness x and transfer case Oil cooler Clean the fins air to oil type and body Check the hose condition and for x leaks replace as required 128 Y53 6007 R10 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Table 2 Preventative Maintenance Schedule Continued Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval I A B C D E Main amp aux Main amp auxiliary transmission Check the oil level refill as required see page 144 and page 146 X iliary trans Main amp auxiliary transmission Drain the lubricant while warm Flush each unit with clean flushing oil 500 000 miles oi ON HIGHWAY 800 000 km Main amp auxiliary transmission Drain the lubricant while warm Flush each unit with clean flushing oil x xX OFF HIGHWAY Main amp aux Transfer Case Check
106. e and then brake one or more of the four corners of the vehicle in addition to potentially applying the trailer brakes thus applying a counter force to better align the vehicle with an appropriate path of travel For example in an over steer situation the system applies the outside front brake while in an under steer condition the inside rear brake is applied 93 ANTI LOCK BRAKING SYSTEM OPERATING INFORMATION PART 7 STARTING amp OPERATING THE VEHICLE A Real World Example Of How Yaw Control Operates Excessive speed exceeds the threshold creating a situation where a vehicle is likely to spin and jackknife The Bendix Yaw Control system reduces engine throttle and selectively applies brakes to reduce the vehicle speed thereby reducing the tendency to jackknife 94 Yaw Control Example IMPORTANT SAFETY INFORMATION ABOUT THE STABILITY SYSTEM ESP May Reduce The Vehicle Speed Automati cally To minimize unexpected deceleration and reduce the risk of a collision the operator must e Avoid aggressive driving maneuvers such as sharp turns or abrupt lane changes at high speeds which might trigger the stability system e Always operate the vehicle safely drive defensively anticipate obstacles and pay attention to road weather and traffic conditions ABS ATC and ESP stability systems are no substitute for prudent careful driving Towing Doubles Or Triples May Reduce The Effec
107. e surfaces lubricated can lead to frame or drive line damage CAUTION Both the fifth wheel plate and the R10 06 PART 4 CONTROLS AND DISPLAYS Parking Brake Valve and Trailer Air Supply Valve AN Your parking brake valve is a yellow diamond shaped knob located below the right instrument panel It controls the parking brakes To apply all parking brakes pull the yellow or parking brake knob out The truck or tractor parking brakes will set and the Trailer Air Supply Valve red octagon knob will automatically trip pop out and set the trailer parking brakes To release both truck tractor and trailer parking brakes push in BOTH yellow and red knobs For full infor mation on using parking brakes see section titled Park ing Brakes and Their Use on page 98 for more information R10 06 Y53 6007 DASH MOUNTED FEATURES WARNING Do not leave the cab without applying the parking brake The truck could roll and cause an injury accident Always apply the parking brake before you leave the cab Stopping with the parking brake controls can cause a sudden wheel lock up loss of control or can cause you to be overtaken by following vehicles You could be severely injured Never pull out the parking brake valve while the vehicle is moving Do not use the trailer hand brake or service brakes to park and hold an unattended vehi cle use the parking brakes Because ser vice brakes work with air pr
108. e C4 transmission fluid torque fluid EP Extreme Pressure Lubricant GL Straight mineral gear lubricant HD Hypoid Gear Oil A P I GL 5 SAE 80W 90 HT High Temperature grease Timken Spec 0 616 MP Multipurpose gear lubricant MIL L 2105B WB Wheel Bearing grease Timken Spec 0 610 il Y53 6007 NOTE The responsibility for meeting these spec ifications the quality of the product and its perfor mance in service rests with the lubricant supplier R10 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Table 4 Component Lubrication Index Universal Joints EP CL HD Drive Shaft Splines Wheel Bearings driven hubs Wheel Bearings nondriven hubs CD50 Wheel Bearings all grease lubricated hubs WB Steering Column CL Alternator Bearing BB Fan Hub BB Power Steering Reservoir ATF Steering Drag Link CL Steering Knuckles CL Spring Pins CL R10 06 Y53 6007 Table 4 Component Lubrication Index Continued Clutch Release Bearings BB Brake Shoe Anchor Pins HT Brake Cam Bearings HT Slack Adjusters CL Water Pump BB Cab Tilt Hydraulic Reservoir Hydraulic Jack Oil MIL L 5056B Speedometer Cables Lubriplate Aero or equivalent Consult manufacturer or lubricant supplier for special details 143 PREVENTIVE MAINTENANCE SCHEDULE For oil reservoirs with side filler plugs trans
109. e lamp should remain off after this point unless a failure in the system is detected 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 CAUTION If the truck tractor ABS warning The truck tractor ABS lamp is located in the warning lamp cluster See illustration on page 47 89 ANTI LOCK BRAKING SYSTEM OPERATING INFORMATION PART 7 STARTING amp OPERATING THE VEHICLE O am OO Trailer ABS Warning Lamp Trucks tractors and trailers built on and after March 1 2001 are equipped with power line communication PLC per U S FMVSS 121 including a PLC Trailer ABS warn ing lamp in the cab see page 47 OO 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 CAUTION If the trailer ABS warning lamp and bulb check at ignition on does not indicate that the trailer you may be connected to has trailer ABS You should personally inspect every trailer to determine its braking system H NOTE A successful warning lamp illumination A trailer ABS warning lamp will illuminate for a bulb check when the ignition switch is first turned on whether or not a trailer is connected to the vehicle If the bulb check is satisfactory the lamp will next do either of the following 1
110. e personal injury WARNING For vehicles equipped with ESP Electronic Stability Program do not replace the vehicle s steering wheel Using a different steering wheel could cause ESP to malfunc tion causing a loss of vehicle control possibly resulting in severe personal injury Steering Angle Sensor Re Calibration Whenever maintenance or repair work is performed to the steering mechanism linkage gear adjustment of the wheel track or if the steering angle sensor is replaced or 96 Y53 6007 PART 7 STARTING amp OPERATING THE VEHICLE the steering wheel is changed or re centered the Steer ing Angle Sensor must be re calibrated WARNING If the Steering Angle Sensor is not AN re calibrated the Yaw Control system will not function properly which could result in a loss of control of your vehicle Wheel Spin Control Warning Lamp Your truck tractor ABS may have an acceleration slip reg ulation ASR or automatic traction control ATC feature This feature is controlled by a switch as shown in the next illustration Either of these features is monitored by a warning lamp located on the main dash 03034 R10 06 PART 7 STARTING amp OPERATING THE VEHICLE The Wheel Spin Control warning lamp will briefly illumi nate and then go out when the ignition switch is first turned on The Wheel Spin Control warning lamp will illu minate whenever the ASR or ATC system detects drive w
111. e rail to the approx imate centerline of the rearmost drive axle hub Y53 6007 111 PART 7 STARTING amp OPERATING THE VEHICLE A SETTING RIDE HEIGHT For tandem axles make the vertical measurement at the centerline of the suspension see illustration on page 109 e For a single axle make the measurement in front of the axle in the area forward of the tires but not past the suspension bracket WARNING Your brakes could fail if you con tinue driving with deflated air springs Air escaping from the system will lower the air pressure which could cause a spring brake to engage The spring brake may cause your brakes to drag and burn up the linings Don t 4 When at the correct ride height ensure that the height continue to operate in this condition control valve lever is in the neutral position then install either the built in alignment pin or a 1 8 inch 3 You can get to a repair facility if you do the following 1 Remove the height control link connected to the axle mm dowel see page 111 Torque the mounting fasteners to 55 75 Lb in 6 2 8 5 N m Remove the alignment pin or dowel Repeat Steps 2 through 6 above for the RH valve on and to the suspension air valve control arm This will cause the air valve control arm to center in the closed position 2 The air system can then be pumped up to normal pressure for continued operation vehicles with a dual valve system Dri
112. e reservoirs to be stored until needed When you operate your air brakes the stored compressed air flows into the chambers where it is used to apply your truck and trailer brakes That is why when you push down on your brake pedal you don t feel the same amount of pressure on the pedal that you do when you apply the brakes on your car All you are doing on your truck is opening an air valve to allow air to flow into the brake chambers R10 06 PART 8 MAINTENANCE AND SERVICE Air Supply System WARNING Do not operate the vehicle if leakage AN in the air system is detected Conduct the follow ing procedure and contact an authorized Peter bilt Dealer 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 injury accident 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 WARNING If the supply and service tanks are AN not drained at the recommended frequency water could be sent to all air lines and valves This could cause corrosion which could com promise the brake system safety and potentially cause an accident Daily Drain moisture from the supply and service air tanks e Operate air de
113. e started your engine idle it at approxi mately 600 RPM while you check A R10 06 oil pressure air pressure alternator output WARNING Do not start or let the engine run in an enclosed unventilated area Exhaust fumes from the engine contain carbon monox ide a colorless and odorless gas Carbon monoxide can be fatal if inhaled ENGINE WARMUP 2 After a few minutes of idling at 600 RPM increase your idle speed to 900 or 1000 RPM Continue your warmup This procedure allows oil to warm and flow freely while pistons liners shafts and bearings expand slowly and evenly In extremely cold tempera tures you may have to increase idle speed il NOTE In colder climates where the temperature is often below freezing the warmup for turbo charged 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 temperature or pressure gauge for a warming trend before increasing engine idle speed RPM 3 Continue the engine warmup until the coolant temper ature reaches at least 130 F 54 C At this temper ature you can use partial throttle Wait until the coolant temperature is at least 160 F 71 C before operating at full throttle Y53 6007 75 ENGINE WARMUP A 76 WARNING Exhaust fumes from the engine contain carbon monoxide a colorless and odorless gas Do not
114. e valve while the vehi cle is moving e Do not use the trailer hand brake or service brakes to park and hold an unattended vehi cle 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 e Never drive your vehicle with the parking brake applied Always release the parking brakes prior to moving the vehicle Failure to disengage the parking brakes prior to moving your vehicle could result in excessive heat build up in the brake system resulting in a fire 99 BRAKE SAFETY AND EMERGENCY PART 7 STARTING amp OPERATING THE VEHICLE NOTE Today s diesel electronic engines have significant torque and startability power at low RPM Combinations of engine speed and avail able torque may over power the vehicle s parking brakes il To apply all your parking brakes pull the yellow knob Out The parking brakes will set And the trailer air supply valve red octagon knob will automatically pop out releasing air pressure and setting the trailer brakes motion before pressure in the system reaches 100 psi 689 kPa because the wheels are locked by the spring brake action Unneces sary stress and possible brake malfunction could occur if the vehicle is forced to move before the air system reaches 100 psi 689 kPa To rel
115. e your vehicle or cause an accident when you put the transmission in gear The engine speed could exceed the maximum governed speed and cause a serious accident due to mechanical failures Do not coast with the transmission in neutral or with the clutch pedal depressed Besides being illegal and danger ous coasting is also expensive It causes premature fail ure or damage to the clutch and transmission and overloads the brake system 113 DRIVING TIPS AND TECHNIQUES Coasting with the transmission in neutral also prevents proper transmission component lubrication During coast ing the transmission is driven by the rear wheels and the countershaft gear which lubricates the transmission com ponents by oil splash will only be turning at idle speed Descending a Grade A WARNING Do not hold the brake pedal down too long or too often while going down a steep or long grade This could cause the brakes to overheat and reduce their effectiveness As a result the vehicle will not slow down at the usual rate To reduce the risk of personal injury and or an accident before going down a steep or long grade reduce speed and shift the trans mission into a lower gear to help control your vehicle speed Failure to follow procedures for proper downhill operation could result in loss of vehicle control Engine Overspeed the engine rpm go beyond the maximum gov erned rpm valve damage could result if over speed conditions occur
116. ease your truck or tractor brakes ONLY push in the yellow knob Your trailer will remain parked CAUTION Do not try to put the vehicle in e To release the trailer brakes ONLY push in the red knob The truck or tractor will remain parked 100 Y53 6007 e To release the full combination of brakes push in BOTH yellow and red knobs Trailer Air Supply Valve The red octagon knob controls the air supply to the trailer To supply air to the trailer system and release the trailer parking brakes e Allow the tractor air system pressure to build up to operating level e Push the red knob in e Hold the red knob in by hand until the trailer air pres sure builds to a pre set level about 45 psi At this point it will remain in The yellow knob will remain out the tractor will remain parked If you ever have a failure or disconnect of the air supply hose to the trailer the trailer parking brakes will set The red knob will automatically pop out and seal off the tractor air reservoirs to protect the tractor air system pressure When operating the tractor bobtail The red knob must remain out to protect the tractor air system pressure R10 06 PART 7 STARTING amp OPERATING THE VEHICLE Manually Releasing Spring Brakes There may be an occasion when you need to tow the vehi cle but the air system does not produce enough operating pressure to release the parking brakes For these situa tions the spring brake
117. epairs to an authorized service facility They are the ones equipped to do the job safely and cor rectly A WARNING Attempting repair work without suf ficient training service manuals and the proper tools can be dangerous You could be injured or you could make your truck unsafe Do only those tasks you are fully qualified to do Y53 6007 PART 1 INTRODUCTION Maintenance Manuals If you do decide to do any com plex repair work you ll need the Peterbilt Maintenance manuals Order them from your authorized dealer Please provide your Chassis Serial Number when you order to be sure you get the correct manuals for your vehicle Allow about four weeks for delivery There will be a charge for these manuals Final Chassis Bill of Material A complete nonillustrated computer printout listing of the parts used to custom build your Peterbilt vehicle is available through the Peterbilt dealer from whom your purchased your vehicle A WARNING Modifying your vehicle can make it unsafe Some modifications can affect your truck s electrical system stability or other important functions Before modifying your vehicle check with your dealer to make sure it can be done safely Additional Sources of Information Operators manuals are also supplied by the manufactur ers of components such as the engine seats transmis sion and radio in your Peterbilt If you are missing any of these manuals ask your Peterbilt dealer to suppl
118. ere is no deck plate or if proper steps and grab handles aren t provided don t climb onto the area behind the cab Peterbilt did not intend for the area to be a step if handrails or proper steps are not provided nents without antiskid surfaces or use com ponents not designed for entry and exit use You could fall and injure yourself if you step on a slippery surface For example j WARNING Do not step on vehicle compo You could fall and injure yourself if you step onto a fuel tank surface A fuel tank is not a step The tank surface can get very slippery and you might not be able to prevent a fall Don t step onto the surface of a fuel tank Use only the steps and handholds provided not chain hooks quarter fenders etc e Always reinstall steps before entering the cab or accessing the deck plate Without steps you could slip and fall resulting in possible injury to yourself NOTE Any alteration adding bulkheads head i ache racks tool boxes etc behind the cab or sleeper that affects the utilization of grab handles deck plates or frame access steps installed by Peterbilt must comply with FMCSR 399 The pictures that follow show you the right way to get on and off the area behind your cab 10 Y53 6007 R10 06 PART 2 GETTING INTO amp OUT OF THE CAB AND FRAME ACCESS CLIMBING ONTO THE DECK PLATE A f a Three points of contact as you reach the deck area L i T Three points o
119. erform maintenance checks and ser R10 06 PREVENTIVE MAINTENANCE SCHEDULE vices more frequently The charts on the following pages show the maintenance intervals for recommended main tenance practices H Y53 6007 NOTES e Engine lubricating oil change intervals aren t listed here Refer to your engine s operating manual for recommendations For specific information on maintenance procedures con sult your vehicle maintenance manual The initial fill of drive axle lubricant must be changed before the end of the first scheduled maintenance interval Refer to the information on page 148 before you put a new vehicle into service The initial fill of lubricant in manual transmis sions must be changed before the end of the first maintenance interval See page 144 for specific information 121 PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Table 2 Preventative Maintenance Schedule Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval I A B C D E Frame Fifth Wheel Check the kingpin lock and plate for wear and function lubricate NLGI 2 X grease Frame Fasteners Check for tightness tighten to the specified torque value as required see X page 185 Crossmembers and Mounting Inspect for cracks and loose fasteners Replace or tighten to the specified X Brackets torque value as required see page 185 Front
120. ering Column Mounted Controls Your turn signal lever is mounted on the left side of the steering column below the steering wheel Green direc Turn Signal and Indicator Lights tional indicator lights appear on the instrument panel NOTE The ignition key must be turned to ON for il the signal switch to operate To operate the signal move the lever in the direction of the turn WARNING After you complete a turn shut the AN system off by returning the lever to the OFF center position The switch s lever action is NOT self canceling Failure to shut off a turn signal could confuse other drivers and result in an injury accident An indicator light in the Turn Signal instrument panel will flash until the turn signal is turned off 18 Y53 6007 R10 06 PART 4 CONTROLS AND DISPLAYS STEERING COLUMN MOUNTED CONTROLS Hazard Flasher Pull it out to activate the system All turn signals will flash at once To turn it off move the turn signal lever up or down a aA AN ee T Hazard Flasher AN The four way Hazard Flasher switch is on the turn signal body just underneath the turn signal lever It will operate with the key switch in the ON or OFF position Use your hazard flasher whenever you are off the road or on the side of the road or in a potentially hazardous situation R10 06 Y53 6007 WARNING Use your Hazard Flasher Warning System any time you have to stop off the road
121. essure 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 vehi cle 33 DASH MOUNTED FEATURES A WARNING Never drive your vehicle with the parking brake applied Always release the parking brakes prior to moving the vehicle Failure to disengage the parking brakes prior to moving your vehicle could result in exces sive heat build up in the brake system result ing in a fire Heater Air Conditioning Controls Your heat and air conditioning controls are mounted in the right hand instrument panel Additionally the sleeper com partment may also contain a separate heating and cooling system with separate controls A 34 WARNING Exhaust fumes from the engine contain carbon monoxide a colorless and odorless gas Do not breathe the engine exhaust gas A poorly maintained damaged or corroded exhaust system can allow carbon monoxide to enter the cab Entry of carbon monoxide into the cab is also possible from other vehicles nearby Failure to properly maintain your vehicle could cause carbon monoxide to enter the cab sleeper and causes serious illness A il il Y53 6007 PART 4 CONTROLS AND DISPLAYS CAUTION Never idle your vehicle for pro longed periods of time if you sense that exhaust fumes are entering the cab Investi gate the cause of the fumes and correct it as soon as
122. f contact Three points of contact as you step to the deckplate R10 06 Y53 6007 11 CLIMBING ONTO THE DECK PLATE 12 PART 2 GETTING INTO amp OUT OF THE CAB AND FRAME ACCESS Y53 6007 R10 06 PART 3 GETTING TO YOUR ENGINE HOOD TILT PART 3 GETTING TO YOUR ENGINE Hood Tilt Follow this procedure to tilt the hood hood be sure there are no people or objects in the way A hood could hurt someone in the way of its opening or descent j WARNING Before opening or closing the 1 To open your hood find the hood release handle on the cab floor beside the drivers seat release handle R10 06 Y53 6007 13 HOOD TILT release and pop open to a neutral position approxi PART 3 GETTING TO YOUR ENGINE could be injured Always ensure that a hood is 2 Grasp the lever and turn it towards you The hood will j WARNING If the hood falls anyone under it mately 2 above the closed position to control movement during opening Do not 4 tilt the hood with these dampers discon nected Replace damaged worn or leaking dampers as soon as possible Tilting a hood with the dampers disconnected or defective may cause the hood to tilt too rapidly You could be injured and the hood could be dam aged j WARNING The hood uses hydraulic dampers fully tilted open any time anyone gets under a hood for any reason To close the hood firmly push upward and rearward on the hood o
123. f this feature is to allow you to lower your tractor to get under a trailer You will notice a guard over the switch This pre vents you from accidentally deflating the suspension WARNING Operating the Air Suspension AN Deflate Switch Dump Valve while driving can lead to an accident Sudden deflation while your vehicle is moving can affect handling and control Use this switch only when your vehicle is not moving 207 DASH MOUNTED FEATURES PART 4 CONTROLS AND DISPLAYS pension bags either overinflated or underin flated may cause damage to driveline components If a vehicle must be operated under such conditions do not exceed 5 mph Engine Fan Switch CAUTION Operating a vehicle with air sus 03023 The engine fan switch allows you to control the engine fan manually or automatically With the ignition key switch ON and the fan switch in the ON position the engine fan will be on regardless of engine temperature With the engine 28 Y53 6007 fan switch in the AUTOMATIC position the engine fan will automatically turn on when the engine coolant reaches a temperature of about 200 F WARNING Do not work on the fan with the AN engine running Anyone near the engine fan when it turns on could be badly injured If it is set at ON it will turn on any time the ignition key switch is turned to the ON position In AUTOMATIC it could engage suddenly with out warning Before turning
124. g the care label on the belts Let them dry com pletely before allowing them to retract If any seat belt is not working properly see an autho rized Peterbilt dealer for repair or replacement Y53 6007 PART 5 SEAT AND RESTRAINT SYSTEMS Tether Belts Tether belts are installed on suspension seats They help secure the seat to the floor to restrain it in case of a sud den stop or an accident A WARNING Do not remove modify or replace the tether belt system with a different tether sys tem A failed or missing tether belt could allow a seat base to fully extend in the event of an acci dent leading to greater injuries or death Tether Adjustment j WARNING e Failure to adjust tether belts properly can cause excessive movement of the seat in an accident This could lead to greater injuries for you Tether belts should be adjusted so that they are taut when the seat is in its most upward and forward position Before driving or riding in a vehicle ensure that there is adequate head clearance at maximum upward travel of seat Serious R10 06 PART 5 SEAT AND RESTRAINT SYSTEMS injury may occur if head clearance is not adequate Shorten the tether belt as neces sary to provide adequate head clearance e Make sure the tether belt is attached to the cab deck and seat frame It should be routed through the buckle on each side To lengthen the tether turn the buckle to a right angle to the webbing The
125. grab handles and your feet on the steps into the cab without proper caution is danger ous You could slip and fall possibly suffering a serious injury Keep steps clean Clean any fuel oil or grease off of the steps before entering the cab Use the steps and grab han dles provided and always keep at least three points of contact between your hands and feet and the truck Look where you are going j WARNING Jumping out of the cab or getting The illustrations that follow show the best ways to enter and exit a cab Vehicle With External Grab Handle R10 06 Y53 6007 7s DOOR LOCK AND KEYS Vehicle Without External Grab Handle Door Lock and Keys Doors can be locked from the inside by using the lock but ton Close the door then push the button down to lock Doors automatically unlock when you open them from inside and can be locked from the outside with the key only Y53 6007 PART 2 GETTING INTO amp OUT OF THE CAB AND FRAME ACCESS WARNING To lessen the chance and or sever AN ity of personal injury in case of an accident always lock the doors while driving Along with using the lap shoulder belts properly locking the doors helps prevent occupants from being thrown from the vehicle To lock or unlock the doors from outside the cab insert the key in the lock Turn the key toward the rear to lock for ward to unlock Remote Keyless Entry optional This vehicle may be equipped with a Rem
126. harger When servicing the air intake and exhaust systems on a turbocharged engine check the items that follow If you detect any deficiencies take the vehicle to an authorized dealer for servicing Delay could lead to severe and expensive damage to your vehicle R10 06 A A A Y53 6007 AIR INTAKE SYSTEM WARNING The exhaust piping muffler con verter muffler or independent converter become extremely hot during engine opera tion and can cause serious burns to the skin Allow adequate cooling time before working on or near any part of the exhaust system WARNING If your vehicle becomes disabled the hot exhaust system could ignite dry grass brush spilled fuel or other material that can cause fires Do not park or operate your vehicle in areas where the hot exhaust system could cause a fire CAUTION This truck may be equipped with a converter muffler or independent converter unit in order to meet both noise and exhaust emissions requirements Removal or tamper ing with the converter muffler or independent converter will not improve engine perfor mance Also tampering is against the rules that are established by the U S Code of Fed eral Regulations The converter muffler or independent converter may only be replaced with an approved part 189 EXHAUST SYSTEM A WARNING Do not operate engine with turbo charger intake piping disconnected Working around a turbocharger with the intake piping rem
127. have a serious or even fatal acci dent if you drive after drinking Please do not drink and drive or ride with a driver who has been drinking Y53 6007 PART 1 INTRODUCTION WARNING The use of alcohol drugs and cer AN tain medications will seriously impair percep tion reactions and driving ability These circumstances can substantially increase the risk of an accident and personal injury Please remember this manual is not a training manual It cannot tell you everything you need to know about driving your Peterbilt vehicle For that you need a good training program or truck driving school If you have not been trained get the proper training before you drive Only qualified drivers should drive this vehicle Every new Peterbilt vehicle is designed to conform to all Federal Motor Vehicle Safety Standards applicable at the time of manufacture However even with these safety fea tures continued safe and reliable operation depends greatly upon regular vehicle maintenance The vehicle must be operated within the range of its mechanical capa bilities and the limits of its load ratings See the Tire and Rim Weight Ratings label on the driver s door edge R10 06 PART 2 GETTING INTO amp OUT OF THE CAB AND FRAME ACCESS PART 2 GETTING INTO amp OUT OF THE CAB AND FRAME ACCESS Be careful whenever you get into or out of your vehicle s cab Always maintain at least three points of contact with your hands on the
128. he parking brakes Place the transmissions of both vehicles in Neutral Do not let the vehicles touch one another Turn the ignition key to Off in the vehicle with the discharged battery Also turn off lights heater and any other unnecessary electrical load If either battery has vent caps remove them and check the fluid level If it is OK replace the caps before going further If the level is low add distilled water and replace the caps before proceeding If no water is available remove the caps and cover the filler openings with a cloth before proceeding After jump starting the vehicle dispose of the cloth Y53 6007 ELECTRICAL ings on the battery electrolyte could boil out of the openings and hurt someone or damage the vehicle Replace caps securely if there is enough fluid in the battery or cover witha cloth if no water is available and your fluid is low j WARNING If you do not cover the filler open Attach one end of a jumper cable to the dead battery s positive terminal This will have a large red or P on the battery case post or clamp Attach the other end of the same cable to the positive terminal of the good battery Attach the remaining jumper cable FIRST to the neg ative battery terminal black or N of the good bat tery and then to the chassis or ground of the vehicle being jump started Start the engine in the vehicle with the good battery Let it run a few
129. he service brakes not to function resulting in the sudden application of the spring brakes causing wheel lock up loss of control or overtake by following vehicles You could be in an accident and severely injured 97 BRAKE SAFETY AND EMERGENCY e Unless you have an anti lock braking sys AN tem always avoid completely depressing the service brake pedal if possible even during emergency braking Depressing the brake pedal too aggressively can cause the wheels to lock which can lead to an uncon trolled skid and could cause an accident 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 linings for drum type brakes is usually about 800 F 427 C But if service brakes are used improperly or for prolonged periods internal brake drum temperatures may commonly exceed 800 F 427 C Such brake overheating may be detected by a burning smell or smoke coming from a drum If this occurs you should immediately stop and check for cracked brake drums or lining fires If neither exists get back behind the wheel and resume a slow speed as soon as possible to cool the brakes 98 Y53 6007 PART 7 STARTING amp OPERATING THE VEHICLE Parking Brakes and Their Use The yellow diamond shaped knob on your instrument panel controls your parking brakes
130. he traction you may need When you are bobtail or unloaded you can have a serious accident if your wheels lock suddenly during braking You could be injured Don t use your retarder when you are driving bobtail or with an unloaded trailer Pyrometer Maintaining Correct Operating Temperature The optional pyrometer indicates engine exhaust gas tem perature Because it responds almost immediately to changes in exhaust temperature the pyrometer is an excellent indicator of engine output 106 Y53 6007 PART 7 STARTING amp OPERATING THE VEHICLE If you watch engine speed and exhaust temperature ranges the pyrometer can help you operate your truck more efficiently and avoid sudden changes in engine operating temperature CAUTION Do not allow the pyrometer reading A to exceed the specified maximum operating temperature If the pyrometer has no label specifying the maximum operating tempera ture for the pyrometer contact your engine distributor for a recommendation NOTE Different size injectors or changes in alti il tude may affect engine operating and exhaust temperatures Procedure For Reducing High Pyrometer Temperature Readings 1 If the pyrometer indicates excessive temperature ease up slightly on the throttle 2 If RPM and speed drop downshift one gear to help lower the exhaust temperature 3 Observe the pyrometer reading If the temperature continues to be high continue downshifting until acce
131. heel spin The lamp will remain illuminated as long as wheel spin is detected and the ASR or ATC system is applying the drive wheel brakes or reducing engine 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 sys tem Except for checking for proper illumination of the ABS and Wheel Spin Control warning lamps when first starting the vehicle and for monitoring these lamps while driving no special operating procedures are required For detailed system description see service literature for your specific ABS that was provided with your vehicle R10 06 Y53 6007 BRAKE SAFETY AND EMERGENCY Brake Safety and Emergency To stop your vehicle in an emergency vary the service brake application pressure to provide maximum braking force without locking the wheels Use engine compression to assist the service brakes i e don t depress the clutch pedal until the engine reaches idle speed WARNING AN e Do not operate the vehicle in the event of a malfunction in any air circuit The vehicle should not be operated until the system is repaired and both braking circuits includ ing all pneumatic and mechanical compo nents are working properly Loss of system air can cause t
132. hway Vehicles Enaine Oil and Mineral Gear EP and Multipurpose Gear 180 200 220 240 260 280 300 A R10 06 Intermittent Peak Temperature F of Oil in Transmission Sump CAUTION Exceeding the recommended oil change intervals may be harmful to the life of the transmission and the transmission oil cooler PREVENTIVE MAINTENANCE SCHEDULE Recommended Lubricants Table 5 Recommended Lubricants cant Type Grade SAE Ambient Temperature Heavy Duty Engine Oil MIL L 2104B C 50 Above 10 F 12 C or D API SF or API CD Previous API des 40 Above 10 F 12 C ignations are acceptable 30 Below 10 F 12 C Mineral gear oil 90 Above 10 F 12 C with rust and oxida tion inhibitor API 80W Below 10 F 12 C GL 1 Synthetic Lubri 50 All See your Peterbilt dealer for approved brands Y53 6007 145 PREVENTIVE MAINTENANCE SCHEDULE Spicer Transmission Lubrication It is extremely important to use the proper lubricants and maintain the correct oil levels in Spicer units This will ensure proper lubrication and operating temperatures in these units Recommended Lubricants The lubricants listed below are recommended in order of preference for use in all Spicer mechanical transmis sions auxiliaries and transfer cases Do not use extreme pressure additives such as those found in multipurpose or rear axle type lubricants These additive
133. ined person lying in a sleeper bunk could be seriously injured He or she could be thrown from the bunk Be sure anyone occupying the sleeper is restrained while a vehicle is moving e Be sure that no one ever rides in the upper bunk That person would be thrown out in e The upper rear wall Access to the bunk is easiest an ERTI and could be very seriously when these connections are buckled and the front injureg buckle is detached Passengers The side walls The tenting straps are attached to the side wall sills with easy to use buckles Anyone riding in your vehicle should wear a seat belt The responsible operator sees to it that everyone in the vehicle rides safely and that means with a seat belt R10 06 Y53 6007 61 SEAT BELTS AND THEIR PROPER USE Some Other Safety Restraint Tips 62 Don t wear belts over rigid or breakable objects in or on your clothing Such things might be eyeglasses pens keys etc These could cause injury in an acci dent Damaged belts in the cab or sleeper must be replaced Belts that have been stretched cut or worn out may not protect you in an accident Avoid catching belts in the doors or seat hardware They could be damaged Don t modify or disassemble the seat belts in your vehicle They won t be available to keep you and your passengers safe Never bleach or dye seat belts chemicals can weaken them Do however keep them clean by fol lowin
134. ins for damage or x cracking Adjuster Check operation inspect as per manufacturer s service literature X Hub Drum Hubs non LMS Check the bearing endplay and adjust as required see page 164 x amp Hubcap Meritor Unitized Wheel End Hubs non LMS with outrun Clean the components and check for excessive wear or damage Change x ner seals the oil and seal see page 164 Hubs non LMS with stan Clean the components and check for excessive wear or damage Change x dard seals the oil and seal see page 164 Hub seals all Check for leaks replace as required X R10 06 Y53 6007 127 PREVENTIVE MAINTENANCE SCHEDULE Table 2 Preventative Maintenance Schedule Continued PART 8 MAINTENANCE AND SERVICE Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval I A B C D E Hub Drum LMS Hubs Dana Check the bearing endplay and adjust as required see page 164 X amp Hubcap LMS Hubs Dana with Clean the components and check for excessive wear or damage Change 500 000 miles the oil and seal see page 164 800 000 km Synthetic Lubricant LMS Hubs Dana with Clean the components and check for excessive wear or damage Change 360 000 miles the oil and seal see page 164 576 000 km Mineral Lubricant Brake drums Inspect for visible cracks heat checking galling or scoring of the braking surface and for severe corrosion on the outside surfac
135. intenance Schedule Continued Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval A B C D E Cooling Components Check the radiator and heater hoses for leaks X Radiator Pressure Cap Check radiator pressure cap X X X X X System ELC Check the freeze point see page 171 X System ELC Check for contamination using test strips see page 172 X System ELC Replace blank water filter if applicable X System ELC Perform lab analysis of coolant to determine suitability for continued use X see page 172 System ELC Flush drain and refill with new coolant if lab analysis shows coolant is x unsuitable for continued use see page 173 System ELC Add ELC Extender if lab analysis shows coolant is suitable for continued x use see page 172 System ELC Flush drain and refill with new coolant see page 173 X System Conv Coolant Check the freeze point X System Conv Coolant Check inhibitor nitrite concentration using test strips X System Conv Coolant Replace water filter if applicable X System Conv Coolant Flush drain and refill with new coolant X Fan clutch housing Check for leaks X R10 06 Y53 6007 131 PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Table 2 Preventative Maintenance Schedule Continued
136. l Ilevel of electrolyte in the batteries charging area This reduces the volume of gas in the cells The elec trolyte level should always be between 0 4 0 6 in 10 15mm above plates Fill with distilled water only After distilled water has been added wait at least a half hour to measure solution density specific WARNING Always make sure the battery gravity The specific gravity should be between AN charger is OFF before connecting or disconnect 1 258 1 265 or the electrolyte level within MIN and ing the cable clamps Do not connect or discon nect charger cables while the charger is operating to reduce the danger of explosions e Charge a battery only in a well ventilated area such as outdoors or in a fully open garage which contains no pilot lights or other flames MAX marks R10 06 Y53 6007 175 ELECTRICAL A 176 Before attempting any work on the batteries or electri cal system remove all jewelry If metal jewelry or other metal comes in contact with electrical circuits a short circuit may occur causing you to be injured plus electrical system failure and damage To avoid short circuits and damage to yourself or the vehicle never place metal tools or jumper cables on the battery or nearby Metal that accidentally comes in contact with the positive battery terminal or any other metal on the vehicle that is in contact with the posi tive terminal could cause a short circuit or an explo
137. lace faulty cables as an assembly When servicing brakes hubs or axle recoat the ABS sensors with anti seize compound Make sure the sensor is pushed against the pulse wheel after the R10 06 PART 8 MAINTENANCE AND SERVICE hub is reinstalled On rear axles the sensor should be pushed fully into the mounting block before reinstall ing the hub e Check ABS wiring harnesses and piping periodically for chafing or other problems No regular mainte nance is required on the ABS components e During wheel balancing dyno testing or any time the ignition is on with part of the ABS disconnected a fail ure code will be recorded After servicing or testing of the vehicle is completed clear the failure codes 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 The controller responds instantly by signaling the solenoids in the modulator which activate the air valves reducing application pressure as needed to prevent the wheels from locking up If this over riding correction is effective application pressure is allowed to build up to the original input Any malfunction of the anti lock system on one or more axles will cause the system to fail safe and the panel mounted amber warning light will come on indicating both R10 06 Y53 6007 ANTI LOCK BRAKING SYSTEM ABS a malf
138. le s preset at the factory Ride Height Measurement Tandem Axles Location These are precision settings and should not be altered R10 06 Y53 6007 109 SETTING RIDE HEIGHT Proprietary Rear Air Ride Height inches mm Suspension Single Drive Tandem Drive Air Leat N A 11 70 297 Air Trac 11 00 279 11 00 279 Low Air Leaf 8 50 216 8 50 216 Low Low Air Leaf N A 6 50 165 FLEX Air N A 8 50 216 These values are for a fully laden vehicle Follow this procedure to temporarily set ride height A A il 110 WARNING To prevent possible injury and damage to property ensure that a vehicle is parked and the wheels chocked before begin ning this procedure CAUTION Completing this procedure will enable you to safely reach the nearest autho rized 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 NOTE Suitable wheel chocks are at a minimum an 18 inch 46 cm long 4x4 Y53 6007 1 PART 7 STARTING amp OPERATING THE VEHICLE Ensure the air supply and delivery plumbing of the height control valve is consistent with the following illustrations O ae ALIGNMENT PIN OR DOWEL CONTROL ARM LINK BOLT alt s e L OF E FROM DUMP VALVE SWITCH FORWARD 0
139. le submitted for periodic preventive maintenance checks as well as having any suspected problems immediately checked by an Authorized Ser vice Center Failure to properly maintain your brake system can lead to serious injury accidents 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 acci dent e Do not rely on an anti lock brake system that is functioning improperly You could lose control of the vehicle resulting in a severe accident and personal injury If any ABS lamp goes on while you are driving or stays on after the self check that anti lock system might not be working That ABS R10 06 Y53 6007 ANTI LOCK BRAKING SYSTEM OPERATING INFORMATION may not function in an emergency You will still have conventional brakes but not anti lock brakes If any warning lamp indicates a problem have that ABS checked ABS Warning Lamps Truck Tractor ABS Warning Lamp A truck tractor ABS warning lamp illuminates when the ignition switch is first turned on and will remain on until the system self test has been completed successfully Nor mally this ABS lamp will remain on until a speed of no more than 9 mph has been reached and the speed sen sors have been checked for correct output Th
140. ll a truck be operated or configured as a tractor without significant modifications to the air brake system in order to retain compliance with FMVSS 121 Contact your Peterbilt dealer for instructions Once a brake system is set to specifications changing any one of its components or any combination of compo nents may cause the system to not work as well All parts have to work together to perform as they should Any replacement components in your brake system should be exactly equal to the original components Any changes from the original specifications can affect the whole sys R10 06 PART 8 MAINTENANCE AND SERVICE tem All of the following areas are interrelated and must conform to original specifications e Tire Size e Drum brakes Cam Radius Wedge Angle Drum Radius Brake Linings Brake Chambers Slack Adjusters e Disc Brakes a mMOUQOW D gt A Disc Rotors WARNING A nonconforming part in your AN brake system could cause an accident Sizes and types are so related to one another that a seemingly unimportant change in one may result in a change in how well your brakes work for you on the road If parts don t work together properly you could lose control of your vehicle Be sure any replacement parts in your brake system conform exactly to origi nal specifications R10 06 Y53 6007 BRAKE ADJUSTMENT All vehicle operators should check their brakes regularly Always adjust your brakes
141. lled by the control panel switch showing this symbol When the headlights are ON the dash lights side and tail lamps are also on ning lights DRL the inboard park and turn lamps go on automatically at reduced brightness if the engine is running and the headlamp switch is turned off The daytime running lights are turned off automatically while the parking brake is engaged H NOTE On vehicles equipped with daytime run R10 06 Y53 6007 23 DASH MOUNTED FEATURES WARNING Do not use daytime running lights DRL during periods of darkness or reduced visibility Do not use DRL as a substitute for headlights or other lights during operations that require lighting of your vehicle Doing so could lead to an injury accident Panel Light Knob 02891 The Panel Light Knob lets you vary the brightness of your instrument panel lights To Operate Your Panel Light Knob 1 Turn on either the headlights clearance lights or fog driving lights with IGN on PART 4 CONTROLS AND DISPLAYS 2 To brighten the instrument panel lights turn the knob clockwise to the right 3 To dim the instrument lights or to turn them off turn the knob counterclockwise to the left ID and Clearance Lights Switches These are the amber lights on top of your cab the lights on the front and sides of the trailer and the red lights on the rear of a truck or trailer They may be turned on and off by the switch located on the lowe
142. loss of the electrical or air system as well as possible engine damage from overheat ing So it s a very good idea to check your belts frequently and replace them as soon as you detect trouble Follow this procedure to install an accessory drive belt 1 Route the new belt around the pulleys and then rotate the automatic tensioner so that the idler pulley swings toward the belt routing Refer to figure below an example of the rotation direction to release the ten sioner 2 Slip the belt around the idler pulley attached to the automatic tensioner 3 Release the automatic tensioner 4 Check the belt alignment on each pulley The belt must fall between the flanges of each pulley 187 AIR INTAKE SYSTEM Fan Clutch Fan WARNING Engine fans engage suddenly AN without warning and can badly hurt you Stay away from the fan when the engine is running Your truck may be equipped with an On Off or Viscous Fan Drive Follow these guidelines to check your engine fan e Check the fan assembly mounting bolts for tightness Inspect the fan blades for damage 188 Y53 6007 PART 8 MAINTENANCE AND SERVICE On Off Fan Drives Check the clutch operation by starting the engine when it is cold Idle the engine at about 800 RPM Listen for air leaks Check that the fan is not work ing while the engine is warming up When the clutch engages note the reading on the vehicle s panel mounted coolant
143. lt vehicle in good running condition There are a number of checks you can do and you may be able to do some of the ser vice work yourself But please let your dealer s service department do any work you don t have the tools or skill to perform Authorized service mechanics are trained in the proper technical and safety procedures to fix your Peterbilt vehicle right WARNING It is dangerous to work on a vehi AN cle without the right know how and proper tools You could be badly injured and you could damage the vehicle Do only work you know you are fully capable of doing and for which you have the right tools Brake Adjustment WARNING To prevent uncontrolled vehicle movement and reduce risk of personal injury park the vehicle on a hard level surface apply the parking brake and chock all wheels securely 152 Y53 6007 PART 8 MAINTENANCE AND SERVICE To operate your vehicle safely and profitably you need some understanding of its brake systems For more on brakes see the Index under Brakes Brake adjustment and brake balance must be set carefully to 1 make the most efficient use of the forces available for braking and 2 allow equal stopping forces at all wheels CAUTION The air brake system of this vehicle A was configured for ONE of the following opera tions tractor or truck and complies with the respective portions of FMVSS 121 A tractor shall not be operated or configured as a truck nor sha
144. ly remove the cap care fully and slowly turn the cap part way to allow excess pressure to escape Then push down and turn for final removal The cooling system may overheat if the coolant level is below normal or if there is a sudden loss of coolant such as a worn hose splitting It may also temporarily overheat during severe operating conditions such as climbing a long hill on a hot day or stopping after high speed driving If the Engine Coolant Temperature warning light comes on or you have any other reason to suspect the engine may be overheating e Stop the vehicle but DON T TURN OFF THE ENGINE unless a low water warning device indicates a loss of coolant e 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 46 Y53 6007 PART 4 CONTROLS AND DISPLAYS Return the idle speed to normal after 2 or 3 minutes If the warning light doesn t go off or the temperature gauge doesn t begin to drop then turn the engine off If the overheating came from severe operating conditions the temperature should have cooled by this time If it has not stop the engine and let it cool before checking to see if the coolant is low Fuel Gauge FUEL 11435 R10 06 PART 4 CONTROLS AND DISPLAYS WARNING Do not remove a fuel tank cap near AN an open flame Hot fuel vapors are combusti ble and can cause
145. me it left Peterbilt s con trol with all applicable U S EPA Noise Control Regula tions This warranty covers this vehicle as designed built and equipped by Peterbilt and is not limited to any particular part component or system of the vehicle manufactured by Peterbilt Defects in design assembly or in any part com ponent or system of the vehicle as manufactured by Peter bilt which at the time it left Peterbilt s control caused noise emissions to exceed Federal standards are covered by this warranty for the life of the vehicle Tampering with Noise Control System Prohibited Federal law prohibits the following acts or the causing thereof R10 06 Y53 6007 NOISE CONTROL SYSTEM 1 The removal or rendering inoperative by any person other than for maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the operation of the vehicle after such device or ele ment of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tampering are Engine Cooling System e Removing or rendering inoperative the fan clutch e Removing the fan shroud Air Intake System Removing or rendering inoperative the air cleaner silenc ers or intake piping Exhaust System e Removing or rendering inoperative the exhaust s
146. ment can R10 06 GAUGES Gauges On the pages that follow you will find descriptions of some of the gauges on your instrument panel For more infor mation about using them in driving see PART 7 START ING amp OPERATING THE VEHICLE Also check the Index Y53 6007 under the name of the gauge or function you want to know more about WARNING Do not ignore a warning light or AN buzzer These signals tell you something is wrong with your vehicle It could be a failure in an important system such as the brakes which could lead to an accident Have the appropriate system checked immediately functions monitored by the multiplex instrumenta tion system instrument system are contained within the individual gauges of the system The alarms for other controls or systems that you may have will be displayed separately on the instru ment panel They are described further in PART 7 STARTING amp OPERATING THE VEHICLE of this manual H NOTE All of the warning lights and alarms for 39 GAUGES PART 4 CONTROLS AND DISPLAYS Speedometer Message Center SMC A Select Reset switch on the right side of the dash con trols the display The odometer is normally displayed on the screen To choose another function press and release the Select switch until it appears 60 100 e The odometer reads miles amp tenths e g 123456 7 i e The Trip 1 odometer reads miles amp tenths e g 70
147. minimum perform the operations listed below R10 06 Y53 6007 139 PREVENTIVE MAINTENANCE SCHEDULE Lubricant Specifications WARNING Handle lubricants carefully Vehi AN cle lubricants oil and grease are poisonous and can cause sickness They can also dam age the paint on the vehicle In this section you will find the basic information you need to do the routine lubrication your vehicle requires Of course you will want to schedule service more frequently if you are operating under severe conditions such as extreme heat or cold with very heavy loads off road etc For any special service requirements consult your service manuals and your lubricant supplier And please remem ber one key to keeping your truck running at top economy and in prolonging its life is proper lubrication servicing Neglecting this essential aspect of vehicle care can cost time and money in the long run cants Mixing lubricants oil and grease of different brands or types could damage vehi cle components therefore drain or remove old lubricants from the unit before refilling it CAUTION Do not mix different types of lubri 140 Y53 6007 PART 8 MAINTENANCE AND SERVICE Engine H Proper engine lubrication depends on the outside temper atures where you will be driving Use the oil recom mended for the conditions you are most likely to be facing You will find a complete engine lubrication ser
148. missions axles steering gear boxes transfer cases etc the oil must be level with the filler opening Proper Oil Levet R Improper Oii Level A 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 aad Fuller Transmission Lubrication Fuller transmissions are designed so that the internal parts operate in a bath of oil circulated by the motion of gears and shafts Grey iron parts have built in channels where needed to help lubricate bearings and shafts All parts will be amply lubricated if these procedures are closely fol lowed 1 Maintain oil level check it regularly PART 8 MAINTENANCE AND SERVICE 2 Change oil regularly 3 Use the correct grade and type of oil 4 Buy oil from a reputable dealer Lubrication Change and Inspection Off Highway Use Refer to the Eaton Fuller transmission manual for servic ing information Highway Use e Refer to the Eaton Fuller transmission manual for ser vicing information e Refer to the oil change vs temperature chart that fol lows for special oil change information The intermit tent peak temperature is the maximum temperature observed for a short time in a fully loaded vehicle per forming normally 144 Y53 6007 R10 06 PART 8 100 000 75 000 50 000 Oil Change Interval miles 25 000 MAINTENANCE AND SERVICE Oil Change vs Temperature For On Hig
149. n pull the buckle To shorten the tether pull on the strap Inspection of the Restraint System WARNING Failure to properly inspect and maintain restraint systems can lead to serious injury or loss of life Without periodic inspec tion and maintenance to detect unsafe condi tions seat restraint components can wear out or not protect you in an accident The typical three point seat systems in passenger cars may seem very similar to the three point seat belt system in heavy duty vehicles but there are some key differences that all users of this system should be aware of R10 06 Y53 6007 INSPECTION OF THE RESTRAINT SYSTEM In typical passenger vehicle automotive seat belt applications the normal life of the vehicles is usually 8 to 10 years and the total mileage frequently does not exceed 125 000 miles 200 000 km Heavy duty vehi cles often see this type of mileage in a very short period of time and accumulation of mileage in excess of 500 000 miles 800 000 km during the vehicle life time is not unusual A significant difference in the two systems is the amount of movement of webbing in the system In an automotive application there is little movement of the seat belt system except when the user puts on or takes off the belt In trucks however there is almost constant movement of the belt through hardware due to ride characteristics and seats which are designed to move in order to enhance driver comfort There can e
150. nd demount ing 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 manufac turer s literature for the proper way to mount and demount your tires and rims Follow their pre cautions exactly WARNING Use only components marketed by PACCAR Parts Use of non original equipment could cause wheel breakage and wheel separa tion from vehicle Each mounting system is engineered only for use with its correct mating part Be sure that properly matched components are used for each type of mounting The compar ison chart on page 142 illustrates the differ ences between parts used in hub piloted mount and ball seat mount applications Only PACCAR Parts supplied hub piloted or ball seat mounted wheels may be used on this vehicle If you are not fully qualified and not equipped with the proper tools and equipment do not attempt to raise the vehicle or remove or install the damaged tire and wheel assembly Obtain expert help A person can be seriously injured and or damage can result from using the wrong service methods Truck tires and Y53 6007 PART 8 MAINTENANCE AND SERVICE wheels should be serviced only by trained personnel using proper equipment Do not reinflate a tire that has been run flat or is seri ously low on air without first removing the tire from the rim and inspecting for damage Follow OSHA 19
151. nd fasteners and stress points especially where they may be affected by engine vibra tion Repair any cracked or damaged mounting points Use suitable reinforcing plates to ensure that the insula Your authorized dealership can perform all of these tors will remain in position checks and repairs or replacements Inner Fender Shields and Cab Skirts Air Intake System Fasteners e Do all checks and maintenance chores listed in this manual under Engine Air Intake System and Air Check all fasteners for security especially the self tapping Cleaner See Index hex head screws Remove and replace any loose rivets e Check the induction tubing elbow connections Shields and Skirts g clamps brackets and fasteners for deterioration e Check shields and skirts for cracks at mounting and cracks and security If you find an air leak anywhere stress points Check fender shields for tire marks between the air cleaner and the engine repair that worn spots or damage from objects thrown from tire leak immediately treads You can repair cracked or damaged fiberglass fender shields with fiberglass and resin CAUTION Air leaks cause excessive noise and may result in serious damage to the If you find damage at a fastening point you can gain engine If you do not repair them the engine additional strength by installing a suitable reinforcing damage won t be covered by your warranty plate This plate should be drilled to accept a rivet and Rep
152. ne no None OIL PRES Engine oil pres Engine Oil yes OILOK IM DIAG System Fault None no None sure is low Pressure IM LIN System Fault None no None SMC MEM System Fault None no None IM SLFT System Fault None no _ None TRANTMP Main transmis Main Trans yes TRAN OK LOW AIR1 Low air pressure Primary air yes AIR1 OK sion oil tempera mission Oil in air tank 1 pressure ture is high Temperature R10 06 Y53 6007 117 WARNING ALARMS PART 7 STARTING amp OPERATING THE VEHICLE 118 Y53 6007 R10 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Preventive Maintenance Schedule Your preventive maintenance program begins with the daily checks you perform See PART 6 DRIVER S CHECKLIST for these If you check your Peterbilt vehicle regularly you can avoid many large expensive and time consuming repairs Your vehicle will operate better be safer and last longer Neglect of recommended mainte nance may in some cases void your vehicle s warranty So for your safety and the life of your vehicle please follow the Maintenance Schedule Remember there may be maintenance operations that demand skills and equip ment you don t have If so please take your vehicle to an expert mechanic for your safety and your vehicle s safety R10 06 A Y53 6007 WARNING It can be dangerous to attempt maintenance work without sufficient training and the
153. ng freely slipping you could lose control of the vehicle or cause axle damage you could be injured Switch to LOCK only when the wheels are not spinning Do not operate the vehicle on dry pavement with the differential locked it could lead to an injury accident On dry pavement you will not be able to steer well with the differ ential locked Lock the differential only when operating on surfaces with poor trac tion such as wet slippery roads or loose gravel Do not use the differential lock during downhill operation or at speeds above 25 mph 40 km h When it is engaged under these conditions your vehicle will exhibit understeer handling characteristics This understeer condition will cause your vehicle to not turn as quickly and more steering effort will be required which can cause an injury accident R10 06 PART 7 STARTING amp OPERATING THE VEHICLE PUTTING THE VEHICLE IN MOTION To reduce load on the drive train ease up on the throttle Using Your Dual Range Axle pedal whenever you shift into LOCK or UNLOCK Dual Range Two Speed Axles AN If you have this option dual range axles provide two rear axle ratios for operating under heavy loads or off highway as well as for over the road trucking The Low range pro vides maximum torque for off road work The High range is a faster ratio for highway speeds and conditions A switch on your instrument panel controls this function You 1
154. ng hardware should be evaluated for corrosion and for tightness of bolts and nuts PART 5 SEAT AND RESTRAINT SYSTEMS 8 Check web in areas exposed to ultraviolet rays from the sun If the color of the web in these areas is gray to light brown the physical strength of this web may have deteriorated due to exposure to the sun s ultravi olet rays replace the system retractor and buckle side if replacement of any one part is necessary Unexposed damage to one or more components could prevent the system from functioning properly the next time it is needed which could result in severe injury or even death j WARNING Replace the entire belt system If the inspection indicates that any part of the seat belt system requires replacement the entire system must be replaced both retractor and buckle side An installation guide is attached to every replacement belt This set of instructions is entitled THREE POINT SEAT BELT INSTALLATION GUIDE There are separate seat belt instruction guides for suspension and fixed bench seats Use the proper guide for your type of seat and follow the instructions very closely It is vitally important that all com ponents must be remounted back in the same position as Y53 6007 R10 06 PART 5 SEAT AND RESTRAINT SYSTEMS the original components that were removed This will maintain the design integrity of the mounting points for the seat belt assembly Once the need for replacement of the
155. ng message is displayed instead of the functions but the message will reappear in 60 odometer it is being generated by the multiplex seconds The audible alarm will always be on instrumentation system e Warning messages from system alarms with Look in the summary to identify the alarm out an audible alarm can be dismissed by gauge pressing the Reset switch To view dismissed Go to the description of that gauge in PART 4 active messages turn the ignition off and CONTROLS AND DISPLAYS and take the back on actions indicated to correct the condition 116 Y53 6007 R10 06 PART 7 STARTING amp OPERATING THE VEHICLE WARNING ALARMS 2 Continue to check and act on all warning messages Activation Deactivation 3 AT ae Display ie Gauge LED Buzz y until the odometer is displayed Condition Display LOW AIR2 Low air pressure Secondary yes AIR2 OK Multiplex Instrumentation System Alarm Summary in air tank 2 air pressure LO WATER Coolant level is Engine Water yes WATER OK 7 Activation Deactivation low Level Display Condition Gauge LED Buzz Display NO DATA System Fault None no None H20 TMP Coolant tempera Engine Water yes H2O0T OK ture is high Temperature ODO ERR System Fault None no None IM CAL System Fault None no None OIL TMP Engine oil tem Engine Oil yes OILT OK perature is high Temperature IM CFG System Fault No
156. not tightened properly wheel nuts could eventually cause the wheel to become loose to fail and or to come off while the vehicle is moving possibly causing loss of control and or personal injury or damage to the vehicle Wheel Bearing Adjustment For safe reliable operation and adequate service life your wheel bearings must be checked and adjusted properly The person best equipped to do this is your authorized dealer s service mechanic R10 06 PART 8 MAINTENANCE AND SERVICE Disc Wheels To check the torque on disc wheels follow the crisscross sequence shown See the Specifications chart for proper torque specification WARNING AN e Grooves in the wheel disc or other damage to the disc can lead to a serious accident The disc will be weakened and can eventu ally come off maybe causing you to lose control of your vehicle Be sure to use the right components and the right tools e The end of the wheel wrench must be smooth Burrs on the end of the wrench can tear grooves in the disc especially on alu minum wheels These grooves may lead to cracks in the disc and can cause it to fail VEHICLE LOADING Crisscross Sequence For Disc Wheels Demountable Rims To check the torque on demountable rims follow the criss cross sequence shown See the Specifications chart for proper torque specification R10 06 Y53 6007 165 VEHICLE LOADING A A 166 WARNING Improperly mounting a
157. nterfere with the safe and efficient transportation of R10 06 Y53 6007 yourself and your load If you do find something wrong and can t fix it yourself please have a qualified mechanic fix it right away For your safety as well as those around you be a respon sible driver e If you drink do not drive e Do not drive if you are tired ill or under emotional stress Much has gone into the manufacturing of your Peterbilt including advanced engineering techniques rigid quality control and demanding inspections These manufactur ing processes will be enhanced by you the safe driver who observes the following e knows amp understands how to operate a vehicle and all its controls e maintains the vehicle properly e uses driving skills wisely 69 SAFE VEHICLE OPERATION A 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 acci dent if you drive after drinking Please do not drink and drive or ride with a driver who has been drinking The use of alcohol drugs and certain medications will seriously impair perception reactions and driving ability These circumstances can substantially increase the risk of an accident and personal injury The daily checks listed below are the foundation of your overall preventive maintenance program See PART 8 MAINTENANCE AND SERVICE fo
158. ntly Regularly inspect for pad rotor wear e Park on level ground and chock the wheels e Temporarily release the parking brakes e Compare the relative position of two notches one located on the caliper and the other on the carrier See the illustration below to determine if the brakes require a detailed inspection by a qualified mechanic 154 Y53 6007 e Have a qualified mechanic perform a detailed inspec tion if the notches are not found The pads and rotors should be measured and compared against the man ufacturers specifications located in the brake manu facturer s service manual Location of Inspection Brake Caliper Grooves Assembly aot Notch in Caliper Notches Line Up Time to Schedule Inspection of Pads and Rotors Brake Carrier Assembly Brake Rotor Regularly inspect caliper for Running Clearance e Stop the vehicle on level ground and let the brakes cool down Hot brake calipers can burn skin on con tact e Chock the wheels Temporarily release the parking brakes e Grab the caliper and move it This movement is Run ning Clearance R10 06 PART 8 MAINTENANCE AND SERVICE e Proper Running Clearance is 0 08 2 mm of move ment of the brake caliper approximately the thickness of a nickel in the inboard outboard direction e Have a qualified mechanic provide further inspection if the caliper does not move or appears to move more than the specified clearance Drum
159. objects are closer than they may appear j WARNING Convex mirrors can distort images R10 06 Y53 6007 29 DASH MOUNTED FEATURES Cruise Control Switch SET CRUISE CRUISE ON OFF SELECT 0 x RESET 03025 03026 The master switch turns the cruise control ON or OFF The second switch allows you to SET the desired speed or RESET the desired speed after the cruise control func tion has been interrupted WARNING Do not operate the cruise control AN when operating on road surfaces with poor trac tion wet icy or snow covered roads or in heavy traffic Accelerations caused by the nor mal operation of the cruise control could cause you to lose control of the vehicle resulting in an injury accident 30 Y53 6007 PART 4 CONTROLS AND DISPLAYS NOTE Cruise control functions and features may vary depending upon which engine you have For specific explanation of your cruise control see the cruise control or engine manual included with your vehicle Engine Brake 03028 When an engine brake is energized the power producing diesel engine is converted into a power absorbing air compressor to retard the vehicle e The brake is energized whenever the drivers foot is completely removed from the accelerator pedal e The brake is deenergized during driving by pressure on the accelerator pedal and during shifting by depressing the clutch pedal R10 06 PART
160. on the ignition or switching from AUTOMATIC to ON be sure no one is near the fan be damaged if the fan turns on suddenly when you don t expect it Keep all tools and equip ment such as rags away from the fan and take care no one turns on the ignition when some one is working near the fan CAUTION The fan or equipment near it could CAUTION Do not operate the engine fan in A the manual ON position for extended peri ods of time The fan hub was designed for intermittent operation Sustained operation will shorten the fan hub s service life as well as reduce fuel economy R10 06 PART 4 CONTROLS AND DISPLAYS Mirror Heat Switch O 03022 Mirror heat is controlled by the control panel switch shown above If the vehicle is equipped with this switch mirror heat can be switched on to help remove frost and ice from the mirror glass DASH MOUNTED FEATURES Power Mirror Switch The power mirror control controls the adjustment of the right or left outside mirrors depending on the option selected It is located in the driver side armrest NOTE The Power Mirror Switch does not control il the adjustment of the convex mirrors and make objects appear smaller and farther away than they really are You could have an accident if you are too close to another vehi cle or other object Keep plenty of space between your vehicle and others when you turn or change lanes Remember that other
161. ores or drugstores with 32 oz of water warm water will dissolve alum faster but cool will work Apply the alum water solution with a pad of steel wool 0000 grade or finer GENTLY wipe the component lengthwise no pressure is necessary Itis the chemical reaction between the carbon steel of the wool and the alum solution that cleans the stain less not the scrubbing or abrasive action of applica tion You may also use any stainless cleaner recom mended for cleaning boat parts Interior Cleaning Cab Interiors Peterbilt cab and sleeper interiors are built using a variety Y53 6007 of different materials including fabrics carpet polyure 195 APPEARANCE thane and painted plastic surfaces These cleaning pro cedures will ensure that interior components remain in good condition for the life of the vehicle General Cleaning Guidelines WARNING AN e Cleaning agents may contain hazardous agents Thoroughly read understand and follow the manufacturer s instructions when using a cleaning agent to avoid possible personal injury and property damage Handle cleaning agents carefully Keep them out of the reach of children Commer cial cleaning agents may be poisonous CAUTION To avoid possible property damage e Do not spray any kind of liquid directly at instruments or controls Apply cleaner to a rag first and then clean instruments and gauges Excess fluid may damage the use and f
162. ote Keyless Entry RKE system that adds security and convenience to your vehicle The system will lock or unlock the driver s door and passenger s door with the key fob and alert you with parking lights when the selected door s are locked or unlocked The system includes two key fobs that provide secure rolling code technology that prevents someone from recording the entry signal Operation To Unlock The Driver s Door R10 06 PART 2 GETTING INTO amp OUT OF THE CAB AND FRAME ACCESS Press the UNLOCK button once The driver s door will unlock and the parking lights will come on for 40 sec onds To Unlock The Passenger s Door Press the UNLOCK button once and press again within 5 seconds The passenger door will unlock To Lock Both Doors Press the LOCK button The doors will lock and the parking lights will come on for 2 seconds If the doors are open they will not lock The range of the RKE sys tem should be approximately 30 ft This will be reduced if it is operated close to other RF sources such as TV radio transmitters and cell towers Batteries The key fob uses one CR2032 3V battery Batteries should last approximately three years depending on use Consistently reduced range is an indicator that the battery needs replacement Batteries are available at most dis count hardware and drug stores To Replace The Battery 1 Remove rear cover from key fob R10 06 Y53 6007 DOOR LOCK AND KEYS
163. oved can be dangerous A suction is cre ated when the engine is running This suction could draw your hand or anything else near it into the impeller fan You cold be seriously injured Always keep the intake piping con nected when you will be running the engine Lubricating System Check the oil lines housing and connections Look for leaks damage or deterioration Leaks could mean you have damaged oil lines or oil seals Manifold With the engine operating check for leaking manifold or flange gaskets High Frequency Vibration Vibration may indicate turbo rotor imbalance Have your dealer investigate this immediately Exhaust System Details of inspection and maintenance of your exhaust system are covered under Noise Control System Check the Index for page reference 190 PART 8 MAINTENANCE AND SERVICE Anti lock Braking System ABS For details of use and maintenance of your anti lock sys tem see the anti lock braking system service literature that came with your truck Below are some general notes on repairing your anti lock braking system Y53 6007 The foundation brake system must be in proper work ing order to ensure the best ABS performance Before welding anywhere on the vehicle detach the ABS ECU connector and all other electronic control units Never detach the ECU connector with the ignition turned on Do not attempt to repair ABS ASR ATC electrical cables that are outside the vehicle Rep
164. pray the suspension with damage to the bushings Storing and Reintroducing Vehicles Into Service To help maintain a vehicle in storage as well as ease its reintroduction into service perform the following actions at least monthly 198 Y53 6007 PART 8 MAINTENANCE AND SERVICE e Wash and protect painted and metal surfaces and also weatherstripping as outlined in the preceding Appearance information Operate the vehicle to circulate fluids and lubricants that have settled to the lowest part of a component This will provide protection against corrosion on gears and bearings and keep seals resilient Before starting the engine do the following Check the engine oil level and fill as required Check and maintain batteries as outlined on page 174 Drain any condensation from the fuel water sepa rator if so equipped Start the engine and bring to normal operating temperature Operate the air conditioning system at least 10 minutes Drive the vehicle a short distance to allow lubri cants to circulate in the transmission and axles R10 06 PART 8 MAINTENANCE AND SERVICE Noise Control System 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 manu factured by Peterbilt Motors Company was designed built and equipped to conform at the ti
165. ptable operating temperatures can be main tained R10 06 PART 7 STARTING amp OPERATING THE VEHICLE Stopping The Engine Before Stopping The Engine A hot engine stores a great amount of heat And it doesn t cool down immediately after you shut it off Always cool your engine down before shutting it off You will greatly increase its service life Idle the engine at 1000 RPM for five minutes Then low idle for thirty seconds before shutdown This will allow cir culating coolant and lubricating oil to carry away heat from the cylinder head valves pistons cylinder liners turbo charger and bearings This way you can prevent serious engine damage that may result from uneven cooling Turbochargers This cooling down practice is especially important on a turbocharged engine The turbocharger contains bearings and seals that are subjected to hot exhaust gases While the engine is operating heat is carried away by circulating oil If you stop the engine suddenly after a hard run the temperature of the turbocharger could rise as much as R10 06 Y53 6007 STOPPING THE ENGINE 100 F 55 C above the temperature reached during oper ation A sudden rise in temperature like this could cause the bearings to seize or the oil seals to loosen Refuel Before the Final Stop Air space in your fuel tanks allows water to condense there To prevent this condensation while you are stopped fill your tanks to 95 of capacity
166. r left control panel labeled CL LPS and showing the symbol below iia 02892 24 Y53 6007 R10 06 PART 4 CONTROLS AND DISPLAYS When your clearance lights are turned on you may blink or flash them by operating the flash switch located on the right side of the dash showing the symbol below Press and release this rocker switch to flash your clearance lights 03912 1 DASH MOUNTED FEATURES Fog Driving Lights Switch 03021 If your vehicle has fog driving lights turn them ON or OFF with the control panel switch shown above beams and fog lights can and cannot be used together Further some states allow only four lights to be used together some allow more Whether you have dual or composite lights will affect how many lights you can have on at one time Always comply with the state requirements where you are driving H NOTE State requirements vary as to when high R10 06 Y53 6007 25 DASH MOUNTED FEATURES PART 4 CONTROLS AND DISPLAYS Dome Light Switch Press a third time Light will turn off Windshield Wipers and Washers O Dak T A Wiper To turn on the wipers rotate the knob to the right As the knob is rotated the speed of the wipers increases To turn A momentary switch controls the main dome light off the wipers rotate the knob to the left e OFF O Position Light is off e ON I Position To use the washer push the knob showing the
167. r the complete preven tive maintenance schedule for your vehicle Approaching the Vehicle 1 70 Check the overall appearance and condition Are win dows mirrors and lights clean and unobstructed Check beneath the vehicle Are there signs of fuel oil or water leaks 3 PART 6 DRIVER S CHECKLIST Check for damaged loose or missing parts Are there parts showing signs of excessive wear or lack of lubri cation Have a qualified mechanic examine any ques tionable items and repair them without delay Checking Under the Hood or Cab With the engine stopped 1 Y53 6007 Check the engine oil level top up as necessary Refer to your engine s operating manual for the type of oil to use Check the engine coolant level while the engine is cold Top up as necessary with premixed coolant Refer to the instructions on page 172 for adding cool ant to the proper level Check the engine belts Refer to the instructions on page 187 to check belt condition and adjust tension Check brake lines and hoses Check all other accessories controls belts hoses and wiring for condition and adjustment Check the windshield washer fluid level top up as necessary R10 06 PART 6 DRIVER S CHECKLIST SAFE VEHICLE OPERATION 7 Check the power steering fluid reservoir top up as 6 Check emergency flashers and exterior lamps necessary 8 Check the steering components pitman
168. r ventilation system properly maintained It is recommended that the vehi cle s exhaust system and cab sleeper 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 e Do not stay in the vehicle with the engine run ning or idling for more than 10 minutes with the vehicle s Heater and A C ventilation system in RECIRC or at LOW FAN SPEED Even with the ventilation system On running the engine while parked or stopped for prolonged periods of time is not recommended If other vehicles are parked next to you idling move your vehicle or do not stay in your vehicle for prolonged periods of time R10 06 Y53 6007 TRANSMISSION WARMUP Transmission Warmup In cold weather you may find shifting sluggish when you first start the engine Transmission warmup is especially important at this time but it is always a good idea to warm up your transmission before starting out on the road To warm up the transmission lubricating oil during engine warmup with a single transmission e Check that the transmission is in Neutral e Release the clutch pedal If you have a two transmission combination e Put the main transmission in gear e Put the auxiliary transmission in Neutral This will allow the transmission countershaft to turn agitating the oil and warming it Idling the Engine Under
169. rating Overloading can result in loss of vehi cle control and personal injury either by caus ing component failures or by affecting vehicle handling Exceeding load ratings can also Shorten the service life of the vehicle e The components of your vehicle are designed to provide satisfactory service if the vehicle is not loaded in excess of either the gross vehicle weight rating GVWR or the maximum front and rear gross axle weight ratings GAWRs Axle weight rat ings are listed on the driver s door edge Supervise all loading to ensure that 1 the Gross Vehicle Weight Rating GVWR is not exceeded and 2 the load is distributed cor rectly so that the weight distribution is within the limits of the front and rear axle load ratings Severe damage to your vehi cle difficult handling or an accident could occur if your vehicle is not loaded properly PART 8 MAINTENANCE AND SERVICE e An unevenly distributed load or a load too heavy over one axle can affect the braking and handling of your vehicle and cause an accident Even if your load is under the legal limits be sure it is distributed evenly GVW GVW is the Gross Vehicle Weight This is the TOTAL WEIGHT your vehicle is designed to carry Never carry so heavy a load that you exceed the GVW rating of your Peterbilt vehicle Axle Weight Your front and rear axles are rated accord ing to the load they are designed to carry You will find this number listed on the driver s
170. reased injury or death in an emer gency 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 fas ten your seat belt 55 SEAT BELTS AND THEIR PROPER USE PART 5 SEAT AND RESTRAINT SYSTEMS The lap portion should be worn as low on the hips as possible Person In Crash Unbelted Shoulder Belt a Your combination shoulder lap belt needs proper adjust ment Properly worn belt 56 Y53 6007 R10 06 PART 5 SEAT AND RESTRAINT SYSTEMS SEAT BELTS AND THEIR PROPER USE The shoulder portion should fit snugly across your body It should always be worn over the shoulder next to the door It you put the belt under your arm it can t protect you properly Improperly worn belt your belt is buckled too high In a crash it would apply force to your abdomen not your pelvic bones This could cause serious inter Correct over arm nal injuries Always wear your seat belt low over your pelvic bones j WARNING You can be seriously injured if R10 06 Y53 6007 57 SEAT BELTS AND THEIR PROPER USE PART 5 SEAT AND RESTRAINT SYSTEMS AN 58 e 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 abdo men injury in a crash It can allow you
171. rial can enter an open hub or axle This can contami nate the axle fluid and cause possible damage to components Ensure that the hubs are cov ered with plastic whenever a drive axle shaft is removed the ground or remove the driveline and axle 3 For vehicles with driver controlled main differential shafts before towing the vehicle could seri lock install the caging bolt before removing the axle ously damage your vehicle All lubricating shafts for towing and clutch application oil pressure is pro vided by an engine driven pump which does not work when the engine is stopped When A vehicles are towed either by wrecker or piggy back lubricant in the top front of the drive axle will drain to the rear This will leave the top components dry resulting in friction that will seriously damage these components 86 Y53 6007 CAUTION To avoid damaging your vehicle shift the axle at slower travel speeds until you are used to driving with a dual range axle R10 06 PART 7 STARTING amp OPERATING THE VEHICLE a Remove the air line and firmly cap Air Line Remove to Install A Caging Bolt Je oe Caging Bolt Storage Location Illustration of Driver Controlled Main Differential Lock b Remove the caging bolt from its storage hole c Screw the caging bolt into the air line hole When fully engaged a 0 25 0 5 in 6 1 2 mm space will remain between the air cylinder and the bolt head This action
172. rnament to start the hood tilting back wards Continue to push until the hood moves through its neutral position The hood will continue to tilt back wards Apply a firm push to the hood ornament to engage the hood latches located on both sides of the firewall WARNING If the hood is not latched securely 3 Proceed to the front of the vehicle and face the hood AN it could open during operation and cause an Grasp the hood ornament on the top of the crown molding Pull forward and down until the hood is fully open and rotation stops 14 Y53 6007 accident Be sure the hood is latched securely before moving the vehicle R10 06 PART 4 CONTROLS AND DISPLAYS YOUR INSTRUMENT PANEL PART 4 CONTROLS AND DISPLAYS This part explains the location of the various features on We have tried to describe the most common features and your vehicle and describes their function For information controls available so your vehicle may not have some of on using these features in driving see the paragraphs the ones that appear in this section You can pick out the below parts that apply to you and read them to be fully informed on how your particular vehicle operates Your Instrument Panel youn p Please remember that each Model 387 is custom made Your instrument panel may not look exactly like the one in the pictures that follow R10 06 Y53 6007 15 YOUR INSTRUMENT PANEL Typical Cab Instruments and Controls 2 5
173. rols to FRESH AIR E NOTE If other vehicles are parked next to you idling move your vehicle or do not stay in your vehicle for prolonged periods of time Y53 6007 DASH MOUNTED FEATURES To Set the Heater Air Conditioning Controls The cab s control panel may have up to six controls see illustration below e A rotary knob A in the upper left portion controlling the blower speed with four settings A rotary knob B in the upper center portion control ling the movement of air within the cab This control is continuously variable through five modes clockwise from left Panel Panel Floor Floor Defrost Floor Defrost A rotary knob C in the upper right portion controlling the air temperature A rocker switch D in the lower left portion to engage the air conditioner compressor 35 DASH MOUNTED FEATURES PART 4 CONTROLS AND DISPLAYS e A rocker switch E on the lower center portion to send e A rotary knob in the right portion controlling the air power to the bunk or sleeper control panel temperature e A rocker switch F in the lower right portion to select i F 02981B either fresh or recirculated air mode 4 m A Crne OF PACCAR A e The cab bunk control rocker switch must be ON for the sleeper controls to function e To heat the cab select the desired air mode and set pana the temperature knob to hot the red position on the control and the
174. s It is important that U bolts remain tight Off highway use of your vehicle will cause them to loosen faster But all vehi cles need to have their U bolts checked and tightened 184 Y53 6007 PART 8 MAINTENANCE AND SERVICE regularly Be sure someone with the proper training and the right tools checks and tightens the U bolts on your Peterbilt The proper torque requirements are specified in the Peterbilt Maintenance Manual for your vehicle WARNING U bolts that are too loose can AN cause an injury accident Loose U bolts can cause uneven tire wear poor alignment and loss of control of your vehicle You probably can t tighten U bolts correctly yourself But be sure to have them checked and tightened reg ularly by an authorized mechanic e For on highway vehicles tighten the U bolts after the first 15 000 miles 24 000 km Then tighten them every 60 000 miles 96 000 km after that e For off highway vehicles tighten the U bolts after the first day or two of operation Then tighten them every 15 000 miles 24 000 km after that Failure to maintain the specified torque values or to replace worn parts can cause compo nent system failure possibly resulting in an injury accident Improperly tightened loose suspension U bolts can lead to unsafe vehi R10 06 FASTENERS PART 8 MAINTENANCE AND SERVICE cle conditions including hard steering axle misalignment spring breakage or abnormal tire wear
175. s are not required in Spicer transmissions and may in some cases create transmission problems Multipurpose oils as a group have relatively poor oxidation stability a high rate of sludge formation and a greater tendency to react with or corrode the steel and bronze parts 146 Y53 6007 PART 8 MAINTENANCE AND SERVICE Table 6 Recommended Lubricants Ambient Type Grade SAE Temperature Heavy Duty Engine Oil MIL L Above 0 F 2104D or MIL L 46152B API SF 90 40 or 50 18 C or API CD MIL L 2104B or C or MIL L 46152 designations are 30 Below 0 F acceptable 18 C Above 0 F 99 18 C Mineral gear oil R amp O type API GL 1 80 Below 0 F 18 C Synthetic Engine Oil meeting MIL CD50 L 2104D or MIL L 46152B API CD30 All SF or API CD Synthetic Gear Oil Meeting MIL EP75W90 All 2105C or API GL5 EP75W140 EP Gear Oils are not recommended when lubricant operating temper atures are above 230 F 110 R10 06 PART 8 MAINTENANCE AND SERVICE Oil Changes of oil should not be intermixed because of possible incompatibility which could decrease the effectiveness of the lubrication or cause component failure CAUTION When adding oil types and brands An initial oil change and flush should be performed after the transmission has been placed in actual service This change should be made any time after 3000 miles 4800 km but never longer than 500
176. s clear adjust the mode blower speed and temperature to your comfort R10 06 Y53 6007 DASH MOUNTED FEATURES To cool the cab turn on the A C switch set the tem perature knob to cool the blue position on the con trol and the blower to high until the cab becomes cool Then you can turn down the blower if you wish For Efficient Cooling 1 Be sure all heater air conditioner controls are off 2 Start the engine Allow time for warm up CAUTION A A cold compressor can cause refrigerant to liquefy and warp the valve plates or cause a hydraulic lock Warm the engine before starting the air conditioner Turn off all controls when the system is not in use Doing so will avoid damage to the air conditioning system components 3 Set the air control in the RECIRC mode 4 Close all windows 5 Idle the engine between 1000 and 1500 RPM and turn the blower speed control to high 37 DASH MOUNTED FEATURES 6 After the cab temperature cools to a comfortable level adjust the blower speed and controls to keep the desired condition il NOTE When the air conditioner isn t in regular use operate it for at least 15 minutes at least once a month or every 5 000 miles 8 000 Km whichever comes first This will lubricate the seals in the air conditioning system The air condition ing system is active when the Defrost mode is selected Cigarette Lighter 02912 Lighter
177. s generate explosive gases Keep sparks flame and lighted cigarettes away from batteries Do not allow battery fluid to contact eyes skin fabrics or painted surfaces Always wear eye protection Battery acid that may spill during charging should be washed off with a solution of warm water and baking soda to neutralize the acid If you acciden tally get acid in your eyes or on your skin immediately rinse with cold water for sev eral minutes and call a doctor e Be careful that metal tools or any metal in contact with the positive terminal do not contact the positive battery terminal and 177 ELECTRICAL 178 any other metal on the vehicle at the same time Remove metal jewelry avoid leaning over a battery If metal jewelry or other metal comes in contact with electrical cir cuits a Short circuit may occur causing you to be injured plus electrical system failure and damage to the vehicle Do not try to jump start or charge a frozen battery Even a battery with ice particles on the electrolyte surface is dangerous Allow it to thaw out first And always allow battery to thaw gradually do not apply direct heat Gas trapped in the ice may cause an explo sion Do not try to jump start a vehicle if the elec trolyte level in the battery of either vehicle is low Maintain the full level of electrolyte in the batteries This reduces the volume of gas in the cells The voltage of the booster battery must ha
178. s may be manually released to allow the vehicle to be towed This section details how to release a drum or an air disc brake H WARNING AN e Do not operate a vehicle when the spring brakes have been released manually Driv ing a vehicle that has had its spring brakes manually released is extremely dangerous You would probably have no brakes at all You could have a serious or fatal accident Releasing the spring brakes on an unse cured vehicle could lead to an accident The truck could roll causing severe injury Always secure the truck with wheel chocks chains or other safe means to prevent roll ing before manually releasing the spring brakes R10 06 Y53 6007 BRAKE SAFETY AND EMERGENCY e Disassembling the spring brake chamber is dangerous and could cause serious injury These chambers contain a powerful spring that is compressed Sudden release of this spring could cause you to be badly injured Do not disassemble a spring brake cham ber NOTE The primary purpose of the manual release feature is to permit the vehicle to be towed to a repair facility 101 BRAKE SAFETY AND EMERGENCY To release spring brakes manually 1 Remove the cap from the spring chamber 2 Remove the release stud assembly from the side pocket remove the release nut and washer from the release stud e Y53 6007 PART 7 STARTING amp OPERATING THE VEHICLE R10 06 PART 7 STARTING amp OPERATING THE VEHI
179. s must be properly secured and evenly distrib damage or the inherently mobile nature of some loads for example hanging meat live animals or partially laden tankers e The vehicle has an unusually high or off set center of gravity CG e One side of the vehicle drops off the pavement at an angle that is too large to be counteracted by a reduc tion in speed The vehicle is used to haul double or triple trailer com binations R10 06 Y53 6007 uted at all times e Drivers need to exercise extreme caution at all times and avoid sharp turns sudden steering inputs or abrupt lane changes at high speeds particularly if the vehicle hauls loads that could shift the vehicle or load has a high or off set center of gravity CG when loaded or the vehicle tows doubles or triples 95 ANTI LOCK BRAKING SYSTEM OPERATING INFORMATION Truck Chassis Modifications The ESP system was specifically calibrated and validated only for your vehicle s original factory built configuration If your vehicle s chassis components are altered for exam ple a wheelbase extension or reduction tag axle addition or removal tractor to truck conversion or steering system component change the ESP system must be disabled immediately by a qualified mechanic WARNING Failure to disable ESP Electronic AN Stability Program when modifying a vehicle could result in a loss of vehicle control possi bly resulting in sever
180. se pressure buildup and will give you an inaccurate reading So never deflate a warm tire to the specified pressure Lower tire pressure does not give you more traction on ice or snow This is an old myth that refuses to die Underinflation actually reduces traction steering con trol and tire load capacity R10 06 PART 8 MAINTENANCE AND SERVICE Underinflated Tires Low pressure is a tire s worst enemy Underinflation allows tires to flex improperly causing high temperatures to build up Heat causes early tire damage such as flex break radial cracks and ply separation Low pressure may affect control of your vehicle especially at the front wheels Most tire wear problems are caused by underinflation as the result of slow leaks so you ll want to check tire pressure regularly WARNING Underinflated tires could cause a AN serious accident The extra heat caused by underinflation can cause sudden tire failure Low pressure may affect control at the front wheels You could be seriously hurt in an accident that could result Keep your tires inflated to the manufacturer s recommended limit Overloaded tires Overloading your truck is as damaging to your tires as underinflation The following chart shows how neglect or deliberate abuse can affect the life of your tires R10 06 TIRES WHEELS AND RIMS WARNING Do not exceed the load rating of AN your tires molded on the side wall of your tire or the maximum vehicle
181. seat belt has been determined be certain that it is only replaced with the rec ommended replacement seat belt The occupant restraint INSPECTION OF THE RESTRAINT SYSTEM system has been developed and tested specifically for this vehicle If the vehicle was originally equipped with a lap belt it cannot be replaced with a three point shoulder har ness system because the cab mounting points are not structurally designed for a three point seat belt R10 06 Y53 6007 07 INSPECTION OF THE RESTRAINT SYSTEM 68 Y53 6007 PART 5 SEAT AND RESTRAINT SYSTEMS R10 06 PART 6 DRIVER S CHECKLIST SAFE VEHICLE OPERATION PART 6 DRIVER S CHECKLIST Safe Vehicle Operation To keep your vehicle in top shape and to maintain its high level of safety for you your passengers and your load make a thorough inspection every day before you drive You ll save maintenance time later and the safety checks could help prevent a serious accident Please remember too that Federal law requires a pre trip inspec tion and so do commercial trucking companies For more information you can refer to Federal Motor Car rier Safety Regulation 392 7 which tells you that interstate commercial motor vehicles are not to be driven unless the driver is sure that certain parts and accessories are in working order You aren t expected to become a professional mechanic The purpose of your inspections is to find anything that might i
182. stress between axles and cause the temperature of your axle lubricant to get too hot Matched tires will help your drive line last longer and will give you better tire mileage 158 Y53 6007 PART 8 MAINTENANCE AND SERVICE WARNING AN Mismatched tires are dangerous Mixing tire types may lessen the road holding ability of both types of tires You can lose control and be injured Never mix tires of different design such as steel belted radials and bias ply tires Make sure too that you use the right size tires on each wheel Some vehicles require different sizes on front and rear wheels For safety always use the rec ommended size and type of tires Regrooved tires or tires with reinforcement repairs can be dangerous on steering axles They could cause you to lose control of your vehicle Do not install regrooved or reinforcement repaired tires on your steer ing axles A Replacing Tires Front Replace front tires when less than 4 32 in of tread remains Check at three places equally spaced around the tire R10 06 PART 8 MAINTENANCE AND SERVICE Drive Axles or Trailers Replace tires on drive axles or trailers when less than 2 32 in of tread depth remains in any major groove Check at three places equally spaced around the tire See the next illustration for recommended measuring points for tread depth tires with load ratings less than the original tires Doing so could lead to unintentional overloa
183. strips and lab oratory sample procedures ELC Extender Add ELC extender if necessary at the maintenance inter val under Cooling on page 131 Coolant Filter If your vehicle came with a non chemical filter blank fil ter replace it only with a blank filter at the interval speci fied in the Preventive Maintenance Schedule on 24178 Y53 6007 PART 8 MAINTENANCE AND SERVICE page 119 Never use filters that contain SCAs in an ELC filled system Topping Off WARNING Removing the fill cap on a hot AN engine can cause scalding coolant to spray out and burn you badly If the engine has been in operation within the previous 30 minutes be very careful in removing the fill cap Pro tect face hands and arms against escaping fluid and steam by covering the cap with a large thick rag Do not try to remove it until the surge tank cools down if you see any steam or coolant escaping In any situation remove the cap very slowly and carefully Be ready to back off if any steam or coolant begins to escape NOTE If frequent topping off is necessary and there are no visible signs of coolant leaks when the engine is cold check for leaks with the engine operating at normal temperature WARNING Handle coolant and antifreeze A carefully Ethylene glycol antifreeze is poison ous Store in original fluid container only and always keep out of reach of children R10 06 PART 8 MAINTENANCE AND SERVICE
184. switch is released Scroll through 12 hours to change between A M and P M Press amp release the Reset switch the hours digits will stop flashing and the minutes digits will begin to flash Press amp hold the Select switch the minutes digits will increase until the switch is released Y53 6007 GAUGES e Press amp release the Reset switch the min utes digits will stop flashing The clock is now set e Clock Alarm a Press amp release the Reset switch the hours digit will flash b Press amp hold the Select switch the hours dig its will increase until the switch is released Scroll through 12 hours to change between A M and P M c Press amp release the Reset switch the hours digits will stop flashing and the minutes digits will begin to flash d Press amp hold the Select switch the minutes digits will increase until the switch is released e Press amp release the Reset switch the min utes digits will stop flashing The alarm is now set and activated the symbol will show in the clock display to indicate this To turn the alarm OFF or ON press amp hold the Select switch for 3 seconds while viewing any display zj GAUGES To deactivate the buzzer when the alarm sounds press amp release the Select switch Note The alarm will automati cally deactivate after 60 seconds NOTE When the ignition is OFF the SMC will be in a sleep blank mode
185. system and cab sleeper be inspected e By a competent technician every 15 000 miles 24 000 km e Whenever a change is noticed in the sound of the exhaust system Whenever the exhaust system underbody cab or sleeper is damaged A Y53 6007 PREVENTIVE MAINTENANCE SCHEDULE NOTE Use only exact replacement components in exhaust systems Certain components contain integral catalytic converters essential for compli ance with EPA emission standards Using non compliant components as a replacement could violate these standards and also void the emis sion system s warranty WARNING Hot engine oil can be dangerous You could be seriously burned Let the engine oil cool down before changing it 4141 PREVENTIVE MAINTENANCE SCHEDULE Master Lubrication Index PART 8 MAINTENANCE AND SERVICE Table 3 Lubricant Symbol Key Table 3 Lubricant Symbol Key ATF Dextron III Mercon approved Automatic Trans mission Fluid BB Ball Bearing grease CB Engine oil for mild to moderate requirements CC CD Engine oil for severe requirements MIL L 2104B MIL L 45199B w 1 85 max sulfated ash content CD Engine oil meeting API Five engine test sequence CD50 SAE50W synthetic transmission fluid CE Engine oil meeting severe duty service require ments for direct injection turbocharged engines 142 CJ 4 Engine oil CL Multipurpose chassis grease C4 Typ
186. t rise within a few seconds stop the engine Find out what is wrong before restarting the engine 74 Y53 6007 PART 7 STARTING amp OPERATING THE VEHICLE 2 Slowly engage release the clutch after the engine has started 3 Wait until normal engine oil pressure registers on the gauge before idling or accelerating the engine beyond 1000 RPM Cold Temperature Starting Procedure In cold weather fast engine starting helps relieve the loads on the electrical system and cranking motor Using the special cold starting equipment will help starting If you follow a few simple guidelines you will extend the ser vice life of your engine e Keep the electrical system in top condition e Use the best quality fuel of the recommended grade e Use recommended engine lubricating oil WARNING Do not use ether or starting fluid in AN conjunction with flame start air intake heating systems Flame start systems use an open flame inside the manifold to heat the air fuel mix ture for cold weather starting If ether is also used with flame start the air fuel will ignite inside the manifold which could cause an explo sion and severe injury R10 06 PART 7 STARTING amp OPERATING THE VEHICLE Engine Warmup The purpose of engine warmup is to allow oil film to be established between pistons and liners shafts and bear ings while your engine gradually reaches operating tem perature Warmup Procedure 1 After you v
187. tely regardless of mileage 64 Y53 6007 PART 5 SEAT AND RESTRAINT SYSTEMS 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 j WARNING It is important to remember that One of the most critical areas to be inspected is the seat belt webbing Constant movement of the belt actually means the webbing is experiencing wear as it travels in and out of the retractor through the pillar loop web guide and through the various pieces of hardware associated with the belt The following guidelines detail how to inspect for cuts fraying extreme or unusual wear of the webbing etc and damage to the buckle retractor hard ware or other factors which indicate that belt replacement is necessary 1 Check the web wear in the system The webbing must be closely examined to determine if it is coming into contact with any sharp or rough surfaces on the seat or other parts of the cab interior These areas are typ R10 06 PART 5 SEAT AND RESTRAINT SYSTEMS INSPECTION OF THE RESTRAINT SYSTEM ical places where the web will experience cutting or abrasion Cuts fraying or excessive wear would indi 1 2 cate the need for replacement of the seat belt system 2 The D loop web guide is the area
188. the accelerator down until you want to downshift the axle c Then release and depress the accelerator pedal quickly to increase the engine RPM d The axle will shift to the LOW range Important Tips on Operating Your Dual Range Axle NOTE If your vehicle has an automatic transmis il sion it may be necessary to shift it to the Neutral position momentarily to allow the main differential lock splines to fully engage or disengage 84 Y53 6007 PART 7 STARTING amp OPERATING THE VEHICLE e To avoid damaging your vehicle shift the axle at a slower speed until you are used to driving with the dual range axle e When driving on a surface with good traction keep the interaxle differential unlocked You can drive with the axle in LOW or HIGH range SHIFT AT ANY SPEED EXCEPT IF A WHEEL IS SPINNING 03029 Interaxle In Unlock e When you are driving with poor traction lock the dif ferential When you have the differential locked drive with the axle in LOW range only R10 06 PART 7 STARTING amp OPERATING THE VEHICLE SHIFT AT ANY SPEED EXCEPT IF AWHEEL IS SPINNING 03029A Interaxle In Lock e Always UNLOCK the interaxle differential before shift ing the axle speed range CAUTION If you shift the axle range with the A interaxle differential in LOCK you could do serious damage to your axles Never shift the axle range with the differential locked e Park the truck with
189. the injection pump governor cuts off fuel to the engine However the governor has no control over the engine rpm when it is being driven by the vehicle s trans mission for example on steep downgrades Apply service brakes or shift to a higher gear Fuel economy and engine performance are also directly related to driving habits e The best results in trip time and fuel economy are obtained while driving the vehicle at a steady speed e Shift into higher or lower gears or apply the service brake to keep engine rpm near the lower end of the optimum operating range e Avoid rapid acceleration and braking R10 06 Y53 6007 WARNING ALARMS Warning Alarms A warning alarm occurs when some condition in the vehi cle requires attention A warning alarm cannot be turned off or manually reset Once triggered an alarm will con tinue to exist until the unacceptable condition or fault in a function is corrected Warning alarms can be generated by two main sources in a Model 387 the multiplex instrumen tation system and if equipped the digital message center Multiplex Instrumentation System Alarms NOTES In addition to the warning messages mentioned in this part if any of the following con ditions occur after startup and self test the multi plex instrumentation system should be serviced e The speedometer message center SMC pointer exhibits windshield wiper like motion and the display reads NO DATA e One or more ga
190. the oil level Add oil if necessary If the problem persists contact an authorized service cen ter Water Temperature Gauge 11242A The water temperature gauge shows the temperature of the engine coolant Under normal operating conditions the water temperature gauge should register between 165 R10 06 Y53 6007 GAUGES and 210 225 F 99 and107 C depending on the engine Under certain conditions somewhat higher tem peratures may be acceptable But the maximum allowable temperature is 225 F 107 C with the cooling system pressurized except for certain special engines Check your engine manual to be sure Engine Overheating WARNING Do not remove the radiator fill cap AN while the engine is hot Scalding steam and fluid under pressure may escape and cause serious personal injuries You could be badly burned e Wait until the coolant temperature is below 122 F 50 C e Protect face hands and arms by covering the cap with a large thick rag to protect against escaping fluid and steam Carefully and slowly turn the cap one quar ter of a turn or until it reaches the first stop allowing excess pressure to escape push down and turn for final removal 45 GAUGES Wait until the coolant temperature is below 122 F 50 C Protect your face hands and arms by covering the cap with a large thick rag to protect you against escaping fluid and steam Before you complete
191. thium based moly filled HD x Steering grease Steering gear Grease the input shaft seal EP NLGI 2 lithium based moly filled HD x grease Power assist cylinder Lubricate the ball joints Inspect for leaking rod seals damaged ball joint xX boots and damage to cylinder rod or barrel Hoses and tubes Check for leaks and chafing xX Steering linkage Check all joints for excessive lash replace as required see page 183 X Draglink tube clamp and ball Check the torque tighten to specified torque value as required X socket Pitman arm clamp bolt and Check the torque tighten to specified torque value as required x nut Steering intermediate shaft Check the torque on the pinch bolt and nut xX Steering intermediate shaft Lubricate EP NLGI 2 HD grease 325 F to 10 F 163 C to xX U joints ON HIGHWAY 23 C range Steering intermediate shaft Lubricate EP NLGI 2 HD grease 325 F to 10 F 163 C to U joints OFF HIGHWAY or 23 C range X CITY DELIVERY R10 06 Y53 6007 133 PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Table 2 Preventative Maintenance Schedule Continued Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval I A B C D E Power Draglink and tie rod arm ball Lubricate EP NLGI 2 lithium based moly filled HD grease xX x Steering sockets ON HIGHWAY Steering intermediate shaft Lubricate EP NLGI
192. tion to verify bulbs function see page 47 X Turn signal Visual check X Stop lights Visual check X Reverse lights Visual check X Alternator Check operation and output X Alternator Check tightness of the pulley nut X Alternator Check the tension of the drive belt see page 187 X Alternator Check tightness of the terminal hex nuts X Starter Check torque on hex nuts X ECM connector Check the tightness of the ECM connector X Wheel sensors Check for damaged sensors and connectors and worn or frayed wires X Fuel tank sending unit Check the mounting screws and electrical connections for worn or dam x aged wires and connectors Power supply harnesses Check for worn or damaged insulation corroded terminals frayed wires x engine transmission etc and oil or fluid leaks on the connectors or wiring Power supply harnesses Wash to remove excess grease x engine transmission etc R10 06 Y53 6007 137 PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Table 2 Preventative Maintenance Schedule Continued Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval I A B C D E Cab struc Hood Lubricate the lower hood pivot only if lube fittings are present X lero Hinges and latch Lubricate with silicone spray X Body amp cab holddown bolts Check the condition and tightness xX Heating amp Air conditioner Operate the system NOTE The air conditioning system is active
193. tive ness Of Stability Systems ESP is designed and optimized for trucks and for tractors that tow single trailers If a tractor equipped with ESP is used to power multiple trailer combinations known as doubles or triples the effectiveness of the ESP system may be greatly reduced Y53 6007 R10 06 PART 7 STARTING amp OPERATING THE VEHICLE ANTI LOCK BRAKING SYSTEM OPERATING INFORMATION ing doubles or triples with a vehicle equipped high speeds j WARNING Exercise extreme care when tow e f very rapidly winding steering inputs are inputted at with Electronic Stability Program Excessive speed and aggressive maneuvers such as sharp turns sudden steering inputs or abrupt lane changes should be avoided because these maneuvers could cause loss of vehicle control possibly resulting in severe personal injury Limitations Of Stability Systems The ESP stability system s effectiveness may be greatly There are mechanical problems with suspension lev eling of the tractor or trailer resulting in uneven loads The vehicle is maneuvering on a high banked road creating either additional side forces due to the weight mass of the vehicle or a deviation between expected amp actual yaw rates Gusty winds are strong enough to cause significant side forces on the vehicle and any towed vehicles reduced if To Maximize The Effectiveness Of ESP e The load shifts due to improper retention accident e Load
194. uge pointers exhibit wiper like motion e A gauge pointer stays at zero with its red light flashing e A gauge pointer goes to and remains at a 2 00 position with its red light on steady 115 WARNING ALARMS PART 7 STARTING amp OPERATING THE VEHICLE A multiplex instrumentation system alarm can be sig nalled by up to four indicators An alarm s warning message on the SMC will preempt all other SMC displays until the condition that is causing the e A warning message will appear on the SMC display alarm is corrected This preemption includes other warn all alarms ing messages from earlier alarms and some of these e The light emitting diode LED warning light in the alarms may not have other indicators Therefore it is very function s gauge will go on all alarms except ABS important that you check the SMC to be aware of all alarm and multiplex instrumentation system faults conditions that may exist in your vehicle s systems espe e An audible alarm will sound cially during the start up procedure Follow these steps to e A light bar icon will light check all SMC warning messages NOTES 1 Observe the first message displayed after the SMC il l comes on e Warning messages from system alarms with an audible alarm can be temporarily overridden e If the odometer is displayed continue with the start by pressing the Reset switch You can then up procedure press the Select switch to scroll through other e ifa warni
195. unction and automatic shut down of the system If the air system is intact indicated by the pressure gauges the service brakes will continue to function nor mally but without benefit of the anti lock feature WARNING Although the brakes will continue to AN operate with a malfunction in either circuit the vehicle should not be operated until the system is repaired and both braking circuits including all pneumatic and mechanical components are working properly CAUTION Do not attempt to recycle the anti A lock system until the vehicle has been brought to a full stop NOTE If one wheel on any driven axle continues to slip or spin for approximately 4 seconds this will cause the anti lock controller for that axle to go into the fail safe mode and the warning light will give a shutdown signal In this case the anti lock system can be turned back on and the warn ing light extinguished by turning the key switch OFF and ON after the vehicle has been brought to a full stop When the key switch is turned back on the warning light will illuminate and remain on for 3 to 5 seconds This is a built in function test of the warning light 191 CAB HEATER AIR CONDITIONER Cab Heater Air Conditioner 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 will help you keep your unit running well NOTES Keep the
196. unction of instruments and gauges 196 Y53 6007 PART 8 MAINTENANCE AND SERVICE e Always test a commercial cleaning agent on an inconspicuous area of the surface to be cleaned before using it Never clean interior components with chemicals or solvents such as Gasoline Naphtha Acetone Turpentine Benzene Carbon Tetrachloride Lacquer Thinner Nail Polish Remover Ammonia based Products Clean difficult stains such as oil grease and mustard as soon as possible The longer a stain goes untreated the more dif ficult it is to remove e Avoid application of conditioning products containing silicones or waxes to the top surface of the dash panel This may cause glare that can be a driver distraction R10 06 PART 8 MAINTENANCE AND SERVICE Interior Trim Dash Shell and Instrument Panels A CAUTION To avoid possible damage to these components do not use abrasive cleaners brushes chemical solvents or strong deter gents Use a clean lint free cloth Clean with the cloth dampened with a mild soap and water solution Remove soap with a clean damp rag For difficult stains on painted plastic surfaces such as the dash shell use Dupont Sontara cleaner part number PS 3909S The product is available from Dupont as a presaturated wipe Carpet A R10 06 CAUTION Do not apply water directly to carpet Excess water may damage the carpet Keep carpet as dr
197. ve 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 substan Y53 6007 PART 8 MAINTENANCE AND SERVICE tially different capacity rating may cause an explosion To avoid serious personal injury and damage to the vehicle heed all warn ings and instructions of the jumper cable manufacturer The jumper cables must be long enough so that the vehicles do not touch Applying a higher voltage booster battery will cause expensive damage to sensitive electronic components such as relays and the radio Improper hook up of jumper cables or not following these procedures can damage the alternator or cause serious damage to both vehicles or yourself Battery posts terminals and related acces sories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling To avoid serious personal injury and dam age to the vehicle heed all warnings and instructions of the jumper cable manufac turer R10 06 R10 06 PART 8 MAINTENANCE AND SERVICE could also cause serious damage to both vehicles Improper use of a booster battery to start a vehicle may cause an explosion A CAUTION Departures from these procedures To Jump Start Your Vehicle 1 Wear eye protection and remove rings metal watch bands and any other metal jewelry Set t
198. ven be movement of the webbing in the seat belt system when the belt in not being used Relative movement between the seat and the cab which nor mally occurs whenever the truck is in operation can cause wear of the seat belt webbing 63 INSPECTION OF THE RESTRAINT SYSTEM Environmental conditions represent another major dif ference in the systems in automobiles and heavy duty and specialty vehicles Unlike the automotive environ ment heavy duty and specialty vehicles may be very dirty and have more exposure to the sun s damaging ultraviolet rays thus resulting in a reduction of the life of the seat belt system The high mileage associated with heavy duty vehicles and possible wear of the 3 point seat belt system the contin ual relative movement of the system the possible contact with the vehicle seat or other parts of the cab structure and the potential exposure of this system to severe envi ronmental conditions make it crucial to inspect the three point seat belt systems regularly It is recommended that the seat belt system in a vehicle be inspected every 20 000 miles 32 000 km or more often if the vehicle is exposed to severe environmental conditions Any seat belt system that shows cuts fraying extreme or unusual wear significant discoloration due to UV exposure abrasion to the seat belt webbing or dam age to the buckle latch plate retractor hardware or any other obvious problem should be replaced immedia
199. vice guide in the Engine Operation Manual that came with your vehicle There the engine manufacturer explains more fully all the maintenance operations that you and a qualified service mechanic need to perform on your engine NOTE The engine in this vehicle may comply with 2007 EPA emission standards Consult the engine manufacturer s manual for changed lubri cation and maintenance requirements WARNING Exhaust fumes from the engine AN contain carbon monoxide a colorless and odorless gas Do not breathe the engine exhaust gas A poorly maintained damaged or corroded exhaust system can allow carbon monoxide to enter the cab or sleeper Entry of carbon monoxide into the cab is also possible from other vehicles nearby Failure to properly maintain your vehicle could cause carbon monoxide to enter the cab sleeper and causes serious illness R10 06 PART 8 A il R10 06 MAINTENANCE AND SERVICE CAUTION Never idle your vehicle for pro longed periods of time if you sense that exhaust fumes are entering the cab or sleeper Investigate the cause of the fumes and correct it as soon as possible If the vehicle must be driven under these conditions drive only with the windows slightly open Failure to repair the source of the exhaust fumes may lead to personal harm NOTES Keep the engine exhaust system and the vehicle s cab sleeper ventilation system properly maintained It is recommended that the vehicle s exhaust
200. vices to circulate lubricants within the unit R10 06 Y53 6007 YOUR VEHICLE S AIR SYSTEM Periodically e Clean filter screens ahead of the valves by removing the screens and soaking them in solvent Blow them dry with pressurized air before reinstalling them Twice a Year e Add approximately 1 4 oz 7 5 ml of light viscosity lubricant to the air line leading to the wiper motor Acceptable lubricants are Dow Corning 200 fluid 200 CS viscosity and Sprague Wiper Lube If you have alcohol dryers installed in the air system the alcohol can wash away lubricants from the wiper motors CAUTION Don t use penetrating oil brake fluid A or wax based oils in the air system These fluids may cause severe damage to air system compo nents e Maintain the air compressor to prevent excessive oil by pass See your shop manual for maintenance details e Replace worn seals in valves and air motors as they are needed 169 YOUR VEHICLE S AIR SYSTEM Air Dryer WARNING Use of incorrect air dryer could AN cause air system failure leading to loss of vehicle control and serious personal injury or death If your vehicle is equipped with a Ben dix AD IS air dryer it is important that future replacements be identical or similar in design Any deviation from the Bendix AD IS type air dryer would require changes to the vehicle air system Some vehicles use a dual air system consisting of a wet tank forward dry tank
201. ving With Deflated Air Springs 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 A If an air spring is ruptured there will be enough air pres sure to drive the vehicle to a safe stop off the highway to investigate the problem Hise Y53 6007 R10 06 PART 7 STARTING amp OPERATING THE VEHICLE pension bags either overinflated or underin flated may cause damage to driveline components If a vehicle must be operated under such conditions do not exceed 5 mph A CAUTION Operating a vehicle with air sus Driving Tips And Techniques This section covers additional driving tips and techniques on how to drive your Peterbilt more efficiently For further information read the American Trucking Association s ATA Truck Driver s Handbook It will give you more tips on starting shifting and driving your vehicle R10 06 Y53 6007 DRIVING TIPS AND TECHNIQUES Coasting WARNING Do not coast with the transmis AN sion in neutral or with the clutch pedal depressed it is a dangerous practice With out the use of the retarding power of the driv etrain your vehicle can reach dangerous speeds At very high speeds you may not be able to put the transmission in any gear At high speeds you could seriously damag
202. volved in individual problems between you your dealer and Peterbilt Motors Company 208 Y53 6007 PART 10 CONSUMER INFORMATION To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 366 0123 in Washing ton D C or write to Administrator NHTSA 400 Seventh Street S W Washington D C 20590 You can also get other information about auto safety from the Hotline Canadian Consumer Information Canandian customers who wish to report a safety related defect to Transport Canada Defect Investigations and Recalls may telephone the toll free hotline 1 800 333 0510 or contact Transport Canada by mail at Transport Canada ASFAD Place de Ville Tower C 330 Sparks Street Ottawa ON K1A ON5 For additional road safety information please visit the Road Safety website at http www tc gc ca roadsafety menu htm R10 06 PART 10 CONSUMER INFORMATION Environmental Protection WARNING Diesel engine exhaust and some AN 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 Cal ifornia to cause cancer birth defects or other reproductive harm This warning requirement is mandated by California law Proposition 65 and does not result from any change in the manner in which Peterbilt trucks are manufac tured Some of the ingredients in engine oil hydr
203. when they are cool WARNING Brake linings and pads with a AN thickness below the specified minimum will have exposed rivets Use of such linings can damage the braking surface and also reduce brake efficiency which could cause an acci dent or system failure Air System Build up air pressure in the system to the governor cut out point Stop the engine Release the parking brakes push in the yellow knob Watch the rate of air pressure drop The rate of drop should not be more than 2 psi 14 kPa per minute e Now start the engine and build up the air pressure again e Stop the engine Ensure that the parking brakes are still released i e the yellow knob is pushed in Fully apply the service brakes 153 BRAKE ADJUSTMENT PART 8 MAINTENANCE AND SERVICE e Watch the rate of air pressure drop registered by the air gauge The rate of drop should not be more than 3 psi 21 kPa per minute e If you find excessive leakage a leakage test should be made at the air line connections and at all air brake control units To perform a leakage test refer to the detailed instructions in the Peterbilt Maintenance Manual or take your vehicle to an authorized Peterbilt dealer Air Disc Brakes Have brake pads inspected by a qualified mechanic for wear at regular intervals according to the Preventive Maintenance Schedule on page 119 In severe service or off highway applications inspect the linings more fre que
204. will lock the differential by pushing a pis ton into a lock position R10 06 Y53 6007 PUTTING THE VEHICLE IN MOTION CAUTION Failure to install the caging bolt when towing vehicles with driver control main differential lock can result in damage by fail ing to lock internal components in position WARNING Ensure there are no open air lines on the recovered vehicle if the recovery vehi cle and recovered vehicle brake systems are connected An open air line on the recovered vehicle will cause a leak in the air brake sys tem of the recovery vehicle possibly causing an accident and personal injury CAUTION A recovered vehicle will have no operational brake system Additionally the rear axle spring brakes will probably be applied If you desire to use the recovered vehicle s brakes ensure that the vehicles air system is connected to that of the recovery vehicle Also ensure that any air line that has been removed from a driver controlled main dif ferential lock is firmly capped to prevent loss of air pressure from the recovery vehi cle 87 ANTI LOCK BRAKING SYSTEM OPERATING INFORMATION e If you don t desire to use the recovered vehicle s brakes ensure that you cage the spring brakes before attempting to move the vehicle 4 Install recovery hitches and rigging hitches intended for that purpose Do not attach to bumpers or brackets Connections to other structural parts could damage the vehi
205. xle Housing Check oil level Check cold Torque the drain plug X Axle Housing Drain the lubricant while warm Flush each unit with clean flushing oil See information on page Change the lubricant 149 Air Shift Unit Check the lubricant level X Air Shift Unit Remove the housing cover and drain the lubricant Wash the parts thor x oughly and dry in air R10 06 Y53 6007 123 PREVENTIVE MAINTENANCE SCHEDULE Table 2 Preventative Maintenance Schedule Continued PART 8 MAINTENANCE AND SERVICE Recommended SYSTEM COMPONENT MAINTENANCE TASK PM Interval A B C D E Drive Axle Breather Clean or replace X Dana Lube Pump ON HIGHWAY Remove the magnetic strainer and inspect for wear particles Wash in sol x vent and dry in air Lube Pump OFF HIGHWAY Remove the magnetic strainer and inspect for wear particles Wash in sol x vent and dry in air Lube Filter ON HIGHWAY Change X Lube Filter OFF HIGHWAY Change X Magnetic drain plug and Clean or replace x breather ON HIGHWAY Magnetic drain plug and Clean or replace x breather OFF HIGHWAY Drive Axle Axle Housing Check the cold fill level at the differential carrier plug for a pinion angle of less than 7 degrees or at the axle bowl plug for a pinion angle of greater X Meritor than 7 degrees Tighten the plug to 35 50 Lb ft 47 68 N m Axle Housing Visually inspect for
206. y as possible Use a clean lint free cloth or clean soft fiber brush Clean with the cloth or brush dampened with a mild soap and water solution APPEARANCE Remove soap with a clean damp rag If a stronger cleaning solution is required use a foam type carpet shampoo Vinyl and Fabric Upholstery A CAUTION To avoid possible damage to the upholstery do not use chemical solvents or strong detergents on these components Use a clean lint free cloth Clean with the cloth dampened with a mild soap and water solution Remove soap with a clean damp rag For difficult stains use a commercial fabric or vinyl cleaner Leather Upholstery A Y53 6007 CAUTION To avoid possible damage to the upholstery do not use oils varnishes solvents abrasive cleaners or shoe polish on these com ponents Use a clean lint free cloth 197 APPEARANCE e Clean with the cloth dampened with lukewarm water e Dry with a clean cloth e For difficult stains use a commercial leather cleaner Weatherstripping Occasionally spray weatherstripping on doors and win dows with silicone compound to help preserve resiliency This is especially useful in freezing weather to prevent doors and windows from sticking shut with ice Chassis Hose dirt and grime from the entire chassis Then if an oil leak develops you will be able to detect it easier chemical products or mineral oil it can cause CAUTION Do not s
207. y low beams need adjustment The high beams should be level wht the H H line once the low beams are adjusted the the A A line Transmission And Drive Train Clutch Adjustment Clutch pedal free travel is usually 1 3 4 in to 2 in 34 to 51 mm This should be your guide for determining whether your truck needs clutch adjustment Some vehicles have automatic clutch adjustment If yours doesn t have this feature adjustment will have to be done by a trained certi fied mechanic Have the adjustment done before clutch pedal free travel is reduced to the minimum allowable 1 2 in 13 mm Fuel System Location of Fuel Shut off Valves Fuel shut off valves for the fuel crossover line are on the bottom of the secondary fuel tank at the crossover line connection They are optional on the primary fuel tank 182 Y53 6007 PART 8 MAINTENANCE AND SERVICE Specification Use only diesel fuel as recommended by engine manufac turers WARNING A mixture of gasoline or alcohol AN with diesel fuel in the presence of an ignition source such as a cigarette could cause an explosion You could be seriously injured Use only the recommended diesel fuel CAUTION If anyone ever pours gasoline into A your fuel tank drain the entire system Other wise the pump and engine will be damaged Don t try to dilute the gasoline by adding die sel fuel See Warning above Fuel Filters Please follow these recommendations when you are ch
208. y them R10 06 PART 1 INTRODUCTION Your Model 387 s glove box also contains a copy of the Truck Driver s Handbook published by the American Trucking Association Refer to it for important information on driving your vehicle Another place to learn more about trucking is a local truck driving school Contact one near you to find out what kinds of instruction it offers Federal and state agencies also have information you can ask for The Interstate Commerce Commission can give you information about regulations governing transporta tion across state lines And various agencies in state gov ernments are sources for regulations that differ from state to state Warnings We ve put a number of warning messages in this manual They are there for your protection and information Please read them and follow them They can help you to avoid injury to yourself and your passengers as well as to pre vent costly damage to your vehicle We ve used certain symbols and signal words to indicate what kind of mes sage is going to follow When you see these symbols amp words you know that you need to pay special attention Please don t ignore any of these signals R10 06 gt gt BP Y53 6007 WARNINGS WARNING When you see this symbol amp word the message that follows is especially vital This signals something that can cause seri ous injury or death This message will tell you what the hazard is what can h
209. ys tem components e Inner Fender Shields and Cab Skirts 199 NOISE CONTROL SYSTEM e Removing shields or skirts e Cutting away parts of shields skirts or damaged or loose portions of shields or skirts Fuel System e Removing or rendering engine speed governor inop erative allowing engine speed to exceed manufac turer s specifications e Removing air signal attenuator on engines equipped with this device 200 Y53 6007 PART 8 MAINTENANCE AND SERVICE Noise Insulating Blankets e Removing noise insulators from engine block or from around the oil pan e Cutting holes in or cutting away part of noise insula tors e Removing hood mounted noise insulation Engine Electronic Control Unit ECU Modifying ECU parameters R10 06 PART 8 MAINTENANCE AND SERVICE Inspection amp Maintenance Instructions for Noise Control System The following instructions are based on regular inspection of the noise control system If during regular inspection or maintenance of other systems or components you find something wrong with parts of the noise control system inspect those parts more frequently to be sure they are performing up to specification At the end of this section you will find the Maintenance Log This is a schedule of inspection and maintenance intervals for each compo nent Exhaust System Manifold Check for exhaust leaks and condition of gaskets Replace any blown gaskets Use

PART 1: INTRODUCTION

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