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Peterbilt Conventional Trucks Operator`s Manual after 1-07

1. Symbol Name Symbol Color Std Opt Page Symbol Name Symbol Color Std Opt Page 10 Dump Truck Body U 19 Engine Retarder Brake a at Yellow 24 j Green e 25 O 00 11 Dump Truck Trailer Body Up lt a 20 Engine Stop Engine ra ai ellow e 25 O00 E 12 Emissions Diesel Particu 21 Engine Wait To Start late Filter DPF 2292 Yellow 24 Yellow 25 ee WAIT 13 Emissions High Exhaust E 22 Fifth Wheel King Pin Lock A a e a System Temperture HEST 5 2 Yelow e 24 G 14 Engine Check Engine 23 Fifth Wheel Slide Unlocked Yello e 24 _n Red o 25 Hy vom 24 Az 15 Engine Ether Start TEZA E j 24 Lights High Beam sine se si reen e 26 i 25 Message Waitin 16 Engine Heater EM valoi 5 P g g px Green e 26 17 Engine Low Coolant Level al j 26 Park Brake P Red e 26 Yellow as 18 Engine Overspeed sia E i 27 Power Take off PTO il Pome A 26 RPM PTO ag 20 Y53 6004 08 06 PART 4 CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS Warning Light Indicator Symbols Warning Light Indicator Symbols Symbol Name Symbol Color Std Opt Page Symbol Name Symbol Color Std Opt Page 28 Power Take off PTO Pump PUMP 37 Transmission Oil Tempera Mode MODE e 26 ture High Yellow e 27 29 Refrigerator 38 Turn Signal Left Fey Gree
2. 149 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Recommended SYSTEM COMPONENT MAINTENANCE TASK cae 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 position to verify bulbs function X see page 19 Turn Stop Reverse lights Visual check X and signals Alternator Check operation and output X Check tightness of the pulley nut X Check the tension of the drive belt see page 195 X Check tightness of the terminal hex nuts xX 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 X wires Fuel tank sending unit Check the mounting screws and electrical connections for worn X or damaged wires and connectors Power supply harnesses Check for worn or damaged insulation corroded terminals X engine transmission etc frayed wires and oil or fluid leaks on the connectors or wiring Wash to remove excess grease X 08 06 Y53 6004 150 PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Recommended SYSTEM COMPONENT MAINTENANCE TASK ee I A B C DIE Cab Hood Lubricate the lower hood pivot
3. Recommended SYSTEM COMPONENT MAINTENANCE TASK PMmtorva I A B C DIE Drive Axle Input shaft amp pinion shaft Check and adjust the endplay X Meritor Axle shaft Tighten the rear axle flange nuts to the specified torque value X Interaxle differential Check the operation X Drive Axle Axle Housing Change the oil in the differential carrier and the hubs and clean X X SISU the magnetic oil drain plugs Check the wheel bearing hubs and adjust if necessary X X Visually inspect for damage or leaks X X Check the oil level in the differential carrier and hubs X X Breather Check the breather for proper operation X Lube Filter Clean the suction filter for the optional pressure lubrication X system S cam brakes Overhaul the brakes degrease all moving parts check the X bushings and seals for wear 08 06 Y53 6004 136 PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Recommended SYSTEM COMPONENT MAINTENANCE TASK P interval A B C D E Rear U bolts Check the torque Tighten to specified torque value as required X Suspension see page 192 Frame amp crossmember bolts Check the torque Tighten to specified torque value as required X see page 194 Mounting brackets and Check the condition and the fastener torque Tighten to the X fasteners specified torque value as required see page 194 Drum Brakes Slack adjusters Check the push
4. Application Type Of Lubricant Mileage Interval City Delivery Synthetic 120 000 mi 192 000 km Synthetic with Pump 240 000 mi 384 000 and Filter km Mineral Base 120 000 mi 192 000 km Vocational Synthetic 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 vals Application Type Of Lubricant Mileage Interval Linehaul Synthetic 240 000 mi 384 000 km Synthetic with Pump 500 000 mi 800 000 and Filter km Mineral Base 120 000 mi 192 000 km 160 Y53 6004 e Change the lubricant filter every 120 000 miles 192 000 km Top off the lubricant level with a similar lubricant Eaton Dana Axle Lubrication e 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 08 06 PART 8 MAINTENANCE AND SERVICE No 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 E
5. Y53 6004 PART 7 STARTING amp OPERATING THE VEHICLE e If you don t desire to use the recovered A vehicle s brakes ensure that you cage the spring brakes before attempting to move the vehicle 4 Install recovery hitches and rigging CAUTION Connect recovery rigging only to A hitches intended for that purpose Do not attach to bumpers or brackets Connections to other structural parts could damage the vehicle 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 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 08 06 PART 7 STARTING amp OPERATING THE VEHICLE ANTI LOCK BRAKING SYSTEM OPERATING INFORMATION 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 2 After adding the specified type and amount of lubri j This will thoroughly circulate the lubricant through the assembly Anti Lock Braking System Operating Information This vehicle may be equipped with an anti lock braking system ABS This ABS reduces the possibility of wheel lock up If a whee
6. gt gt This symbol amp word signals something 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 D 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 have a serious or even fatal accident if you drive after drinking Please do not drink and drive or ride with a driver who has been drinking Y53 6004 PART 1 INTRODUCTION WARNING The use of alcohol drugs and cer tain medications will seriously impair percep tion reactions a
7. 12 000 5 443 lt MAXIMUM LOAD RATINGS gt 31 925 14 481 43 925 Ibs GVW 19 924 kg 03002 Example Of Weight Distribution 08 06 Y53 6004 177 AIR SYSTEM Air System A 178 WARNING Prior to the removal of any air system com ponent 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 pres sure has been depleted e Never exceed recommended air pressure and always wear safety glasses when working with air pressure Never look into air jets or direct them at anyone PART 8 MAINTENANCE AND SERVICE Never attempt to disassemble a compo nent until you have read and understood recommended procedures Some compo nents contain powerful springs and injury can result if not properly disassembled Use only proper tools and observe all pre cautions pertaining to use of those tools Completely bypassing a Bendix AD IS air dryer will bypass the system s
8. Nashville Factory 3 2003 4 2004 5 2005 6 2006 7 2007 8 2008 9 2009 O zero Glider Kit 215 FEDERAL SAFETY STANDARD CERTIFICATION LABEL PART 10 CONSUMER INFORMATION PART 10 CONSUMER INFORMATION 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 indi cates the date of manufacture and other pertinent infor mation is located on the left hand cab door post HORQFACTURED BY PETERBILT MOTORS CO FF DIVISION OF PACCAR Inc ZND oaie o seo crue ve C 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 216 Y53 6004 When you order it is IMPORTANT than you have the fol lowing information ready Your name and address e Serial number of the truck The name of the part you need 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 NHTSA Consumer Informa
9. PART 4 CONTROLS AND DISPLAYS PTO Hours PTO Trip Hours PTO Trip Percentage To reset the Trip Values press the Trip Odometer Reset Button on the main gauge instrument cluster E Truck Information Accessible only while parked NOTE When accessing the truck informa tion menu push the MCS on this menu bul let To exit push the MCS again Truck Information Chassis Number Engine Make Engine Model Engine SW Version Transmission Make oak WD Transmission Model 08 06 PART 4 CONTROLS AND DISPLAYS 08 06 7 Transmission SW Version 8 ABS Antilock Braking System Make 9 ABS Model 10 ABS SW Version 11 CECU Cab Electronic Control Unit Software Version 12 CECU Hardware Version Diagnostic Display Accessible only while parked NOTE Faults Found will only be active if a i red or yellow warning lamp is illuminated Diagnostics Faults Found The diagnostic display menu bullet will indicate a fault that is generated by the vehicle s Engine ABS and or Transmission systems While on this menu item the display will either indicate No Faults Y53 6004 DRIVER INFORMATION DISPLAY Found or Faults Found If Faults Found is active pushing the MCS will display new menus for more information Transmission Display Automated Transmissions only Accessible while parked or driving NOTE Refer to the Automated Transmission Operator
10. j WARNING Using the trailer hand brake or air STOPPING THE ENGINE 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 08 06 Y53 6004 121 SETTING RIDE HEIGHT enough to drain the moisture Don t deplete the entire air supply Be sure to close the drains before leaving the vehicle Opening Drains 4 Secure the vehicle Close all the windows and lock all the doors Setting Ride Height Vehicles equipped with rear air suspensions have their ride height and axle pinion angle s preset at the factory These are precision settings and should not be altered Incorrectly adjusted ride height may result in improper 122 Y53 6004 PART 7 STARTING amp OPERATING THE VEHICLE interaxle U joint working angles This can result in pre mature driveline wear and driveline vibration If your vehi cle is equipped with a Peterbilt rear air suspension and if it becomes necessary to reset the ride height you may temporarily set it by following the next procedure Proper ride height measurement and values are shown in the illustration and table below m eS Si i RIDE HEIGHT Ride Height Measurement Location for Tandem Axles Shown 08 06 PART 7 STARTING amp
11. should immediately stop and check for cracked brake drums cracked brake rotors or lining fires If neither 08 06 PART 7 STARTING amp OPERATING THE VEHICLE exists resume at slow speeds to help cool the brakes Schedule an appointment with an authorized service tech nician at your earliest convenience Parking Brakes and Their Use The yellow diamond shaped knob on your instrument panel controls your parking brakes 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 08 06 BRAKE SAFETY AND EMERGENCY RED YELLOW 02909 Y53 6004 Red Yellow Controls 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 j WARNING On trailers built before March 1975 113 BRAKE SA
12. 08 06 Y53 6004 APPEARANCE Interior Trim Dash Shell and Instrument Panels components do not use abrasive cleaners brushes chemical solvents or strong deter gents CAUTION To avoid possible damage to these 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 Excess water may damage the carpet Keep CAUTION Do not apply water directly to carpet carpet as dry as possible Use a clean lint free cloth or clean soft fiber brush e Clean with the cloth or brush dampened with a mild soap and water solution 205 APPEARANCE e Remove soap with a clean damp rag e If a stronger cleaning solution is required use a foam type carpet shampoo Vinyl and Fabric Upholstery upholstery do not use chemical solvents or CAUTION To avoid possible damage to the strong detergents on these components Use a clean lint free cloth Clean with the cloth dampened with a mild soap and water solution e Remove soap with a clean damp rag For difficult stains use a commercial fabric or vinyl cleaner Leather Upholstery upholstery do not use oils varnishes solvents abrasive cleaners or shoe poli
13. Drive Tire in Lower View 08 06 Y53 6004 171 PART 8 MAINTENANCE AND SERVICE TIRES WHEELS AND RIMS Tire Load and Inflation Tables Load Range Letters and Corresponding Ply Rating G 14 ply H 16 ply SINGLE RADIAL TIRES FOR VEHICLES IN HIGHWAY SERVICE Tire Load Tire Load Limits At Various Cold Inflation Pressures ps1 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 NOTE 1 Pressure listed is the minimum for the load 2 All tire load figures are in pounds 3 Figu
14. O DRL during periods of darkness or reduced visibility Do not use DRL as a substitute for headlamps or other lights during operations that require lighting of your vehicle Doing so could lead to an injury accident j WARNING Do not use daytime running lights Y53 6004 51 DASH AND DOOR MOUNTED FEATURES running lights DRL the high beam headlamps 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 If the headlamp switch is turned on the DRL system is overridden amp headlamps operate normally Panel Light Dimmer VQ i CAUTION On vehicles equipped with daytime The Panel Light Dimmer lets you vary the brightness of your instrument panel lights 52 Y53 6004 PART 4 CONTROLS AND DISPLAYS To Operate Your Panel Light Dimmer 4 Turn on either the headlights or clearance lights 2 To brighten the instrument lights rotate the thumb wheel up 3 To dim the instrument lights rotate the thumbwheel down ID and Clearance Lights Switch Spe cS O 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 are controlled by the control panel switch labelled CL LPS or with the symbol shown above 08 06 PART 4 CONTROLS AND DISPL
15. WARNING Do not carry loose objects in your AN 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 passenger You could be injured or even killed Secure all loose objects in the cab before moving 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 08 06 Y53 6004 PUTTING THE VEHICLE IN MOTION lubricant to circulate and coat the contacting surfaces of the gears Metal contacting metal in moving 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 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 T
16. WARNING Do not move the fifth wheel while 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 08 06 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 Manual VARASHIELD Wind Deflector The VARASHIELD Wind Deflector is a roof mounted adjustable shield for improving vehicle aerodynamics WARNING You could fall and be badly injured AN by trying to climb to the top of the cab without the right equipment Always use a ladder or scaffolding to get up to adjust your manual VARASHIELD If you have the manual VARASHIELD you will adjust it from the roof of the cab Move it to the desired angle with the telescoping strut that is secured by a bolt and locknut Proper VARASHIELD angle is affected by wind trailer height and the gap between the tractor and trailer Usu ally the VARASHIELD should be dow
17. You can repair cracked or damaged fiberglass fender shields with fiberglass and resin If you find damage at a fastening point you can gain additional strength by installing a suitable reinforcing plate This plate should be drilled to accept a rivet and laminated to the shield with fiberglass and resin 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 Your authorized dealership can perform all of these checks and repairs or replacements Air Intake System Do all checks and maintenance chores listed in this man ual under Engine Air Intake System and Air Cleaner See Index Check the induction tubing elbow connections clamps brackets and fasteners for deterioration cracks and 08 06 PART 8 MAINTENANCE AND SERVICE NOISE CONTROL SYSTEM security If you find an air leak anywhere between the air cleaner and the engine repair that leak immediately CAUTION Air leaks cause excessive noise and A may result in serious damage to the engine If you do not repair them the engine damage won t be covered by your warranty Repair all air leaks as soon as you find them 08 06 Y53 6004 213 NOISE CONTROL SYSTEM PART 8 MAINTENANCE AND SERVICE NOISE CONTROL SYSTEM MAINTENANCE LOG RECOMMENDED DATE amp REPAIR DATE amp REPAI
18. move the temperature selector to Cool then gradually increase the temperature when you see that the windshield is starting to warm up A 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 PART 4 CONTROLS AND DISPLAYS moisture from the cab After the windshield is clear adjust the mode blower speed and temperature to your comfort 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 2 gt gt of Ww Y53 6004 Be sure all heater air conditioner controls are off Start the engine Allow time for warm up CAUTION A cold compressor can cause refrig erant to liquefy and warp the valve plates or cause a hydraulic lock Warm the engine before starting the air conditioner CAUTION To avoid damage to the compressor amp blower motors turn off all controls when a sys tem is not in use Set the air control in the RECIRC mode Close all windows Idle the engine between 1000 and 1500 RPM and turn the blower speed control to High 08 06 PART 4 CONTROLS AND DISPLAYS 6 After the cab temperature cools to a comfortable level adjust the blower speed and con
19. movement while Moto mirrors are controlled for 2 way adjustable movement Mirror Selector Mirror Directional f i irror Directio Switch Control Paa S as 7 ZIT and make objects appear smaller and farther away than they really are You could have an accident if you are too close to another vehicle or other object Keep plenty of space between your vehicle and others when you turn or change lanes Remember that other objects are closer than they may appear j WARNING Convex mirrors can distort images 56 Y53 6004 PART 4 CONTROLS AND DISPLAYS NOTE The Power Mirror Switch does not control i the adjustment of the convex mirrors To Adjust Aerodynamic Style Mirrors 1 Move the mirror selector switch to the right or left from the neutral center position to select the desired mirror for adjustment 2 Depress the mirror directional control pad in one of its four arrow directions to adjust the mirror in out or up down pleted return the mirror selector switch back to the center neutral position to prevent uninten tional adjustments to the mirrors H NOTE After mirror adjustments have been com To Adjust Moto Mirrors 1 For in out mirror adjustment Move the mirror selector switch to the right or left from the neutral center posi tion to select the desired mirror for adjustment NOTE If the mirror is fixed non motorized on il the left side then the mirror sel
20. oil and charge air intake temperatures which can lead to overheating and possible engine damage If you must use a winterfront 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 2002 EPA compliant engine cooling system These winterfronts are specifically designed for use with new grill snap patterns NOTES e Keep the engine exhaust system and the vehi cle s cab sleeper ventilation system properly maintained It is recommended that the vehicle s exhaust system and cab sleeper be inspected By acompetent 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 91 ENGINE WARMUP il NOTES 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 e If other vehicles are parked next to you idling move your vehicle or do not stay in your vehicle for prolonged periods of time Idling the Engine Under most circumstances idling your engine for long periods merely wastes fuel In severe arctic weather con d
21. resulting in an accident 119 STOPPING THE ENGINE 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 the 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 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 120 Y53 6004 PART 7 STARTING amp OPERATING THE VEHICLE 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 o
22. 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 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 08 06 Y53 6004 DOOR LOCK AND KEYS 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 2 Remove the battery 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 DOOR LOCK AND KEYS To Synchronize A Ke
23. site Y53 6004 152 PART 8 MAINTENANCE AND SERVICE Lubricant Specifications WARNING Handle lubricants carefully Vehicle AN lubricants oil and grease are poisonous and can cause sickness They can also damage 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 dif ferent brands or types could damage vehicle components therefore drain or remove old lubricants from the unit before refilling it CAUTION Do not mix different types of lubri 08 06 Y53 6004 LUBRICANT SPECIFICATIONS 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 service guide in the Engine Operation Manual that came with your vehicle There the en
24. tion Display for prolonged periods while the vehicle is moving Only glance at the monitor briefly while driving Failure to do so can result in the driver not being attentive to the vehicle s road position which could lead to an accident and possible personal injury or equipment damage j WARNING Do not look at the Driver Informa The Driver Information Display located at the top of the instrument cluster displays important vehicle information through a constant monitoring of systems when any of the following conditions are met e ignition key in ON or ACC positions e ignition timer is active PART 4 CONTROLS AND DISPLAYS e MCS button is pushed independent of ignition key switch position e clock alarm sounds e driver or passenger door is opened e hazard warning lamp switch is on The various functions may be accessed by navigating through Menu Screens using the MCS Refer to Menu Control Switch MCS on page 16 for more detail for the MCS The bullets in the Menu Bar allow access to each item by pushing the MCS when the desired bullet is highlighted Menu Bar 28 Y53 6004 08 06 PART 4 CONTROLS AND DISPLAYS In addition to a blank screen the following are menu items and the information available within each menu selec tions NOTE Some Driver Information Display functions are i only accessible when the vehicle is parked Other functions are accessible while the vehicle is moving or when
25. 181 temperature 38 topping up 182 Dash 13 15 Defogging defrosting system 68 219 Door lock 58 Driver s Checklist 84 Driving vehicle inspection 84 E Economical driving 126 Electrical system batteries 184 battery charging 184 jump starting 189 Electrolyte 185 Engine overspeed 127 winterfronts 91 Engine Warmup 90 Environmental Protection 217 Exhaust fumes 130 F Federal motor vehicle safety standards 4 Federal Safety Standard Certification Label 216 Frame Fastener Torque Specifications 193 G Gauges and Displays 34 Air Application Gauge 43 Air Filter Restriction Indicator or Gauge 41 Drive Axle Temperature Gauge 44 Dual Air Pressure Gauge Air Reservoir 42 Engine Oil Pressure Gauge 37 220 Fuel Gauge 39 Manifold Pressure Gauge 42 Pyrometer 45 Speedometer Odometer 28 34 Tachometer 35 Transmission Temperature Gauge 43 Voltmeter 39 Warning Lights and Buzzers 16 Water Temperature Gauge 37 Glove Compartment 69 GVWR gross vehicle weight rating 177 H High beam 45 Hood Tilting 11 J Jumper cables 188 K Keyless Entry 7 Keys 6 Keys and Locks Ignition Switch 50 L Lowrance Navigation System 71 Lubrication Axle 159 160 coasting 127 Steering Gear 162 Y53 6004 08 06 Transmission 156 159 types and brands 153 Universal Joint 163 Wheel Bearing 161 Lubrication Index 154 Luggage Compartment s 70 M Maintenance Schedule 129 Mirrors 70 N Noise Control System 209 P P
26. 188 e Do not allow battery fluid to contact eyes skin fabrics or painted surfaces Always wear eye protection Battery acid that may spill during charging should be washed off with a solution of warm water and baking soda to neutralize the acid If you accidentally get acid in your eyes or on your skin immedi ately rinse with cold water for several minutes and call a doctor e Be careful that metal tools or any metal in contact with the positive terminal do not con tact the positive battery terminal and 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 circuits a short cir cuit may occur causing you to be injured plus electrical system failure and damage to the vehicle e 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 explosion Y53 6004 PART 8 MAINTENANCE AND SERVICE e 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 e The voltage of the booster battery must have a 12 volt rating And the capacity of the booster battery should not
27. 6004 65 DASH AND DOOR MOUNTED FEATURES PART 4 CONTROLS AND DISPLAYS A rotary knob B in the center portion controlling the movement of air within the cab This control is contin uously variable through five modes clockwise from left Panel Panel Floor Floor Defrost Floor Defrost Bc 7 02980A D E F e A rotary knob C in the right portion controlling the air temperature Conventional Cab Control Panel vehicle with air condi A push button switch D in the center left portion to tioner and PCC engage the air conditioner compressor only vehicles with air conditioning A push button switch E in the center right portion to A separate rocker switch on the dash will send power to select either fresh or recirculated air mode the bunk or sleeper control unit only vehicles with a sleeper unit see next illustration Conventional Cab Sleeper Comfort Control PCC option The PCC option lets the temperature knob function as a thermo stat that regulates duct temperatures based on the knob settings When active the COMFORT CONTROL icon F will be illuminated under the temperature knob C H NOTE For vehicles equipped with the Peterbilt 66 Y53 6004 08 06 PART 4 CONTROLS AND DISPLAYS DASH AND DOOR MOUNTED FEATURES REAR AIC Bunk or Sleeper Control Unit Power Switch The conventional sleeper control panel will have three The cab bunk control rock
28. 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 The lamp should remain off after this point unless a failure in the system is detected The truck tractor ABS lamp is located in the warning lamp cluster see page 19 104 Y53 6004 PART 7 STARTING amp OPERATING THE VEHICLE 9 OO O PTC218a 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 A CAUTION If the truck tractor ABS warning 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 trailer ABS warning lamp in the cab see page 19 08 06 PART 7 STARTING amp OPERATING THE VEHICLE A il OO PTC220 CAUTION If the trailer ABS warning lamp does not illuminate when the ignition is first turned on there is a problem with the bulb or wiring The driver should have this checked as soon as possible NOTE A successful warning lamp illumination and bulb check a
29. AND DISPLAYS Heater Air Conditioning Controls Your heat and air conditioning controls are mounted in the D instrument panel in conventional models Additionally the sleeper compartment may also contain a separate heating and cooling system with separate controls 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 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 open Failure to repair the source of the exhaust fumes may lead to personal harm A CAUTION Never idle your vehicle for prolonged 08 06 PART 4 CONTROLS AND DISPLAYS il 08 06 NOTES e Keep the engine exhaust system and the vehi cle s cab sleeper ventilation system properly maintained It is recommended that the vehicle 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
30. Illuminates when ether start switch is on 16 Engine Heater IIluminates when Engine Heater switch is on 17 Engine Low Coolant Level IIluminates with an audible alarm indicating critically low coolant level The vehicle must be serviced to correct the problem but the sit uation should not be considered an emer gency 08 06 PART 4 CONTROLS AND DISPLAYS on AN 08 06 18 Engine Overspeed Illuminates when engine RPM is exceeded 19 Engine Retarder Brake IIluminates when the engine retarder com pression brake or exhaust brake switch is turned on Engine retarders are an option 20 Engine Stop Engine Iluminates and an audible alarm tone will sound when a major engine system problem exists WARNING This should be considered an emergency You should stop the vehi cle as safely as possible and turn OFF the ignition The vehicle must be ser viced and the problem corrected before driving again Failure to do so may cause severe engine damage or cause an acci dent WAIT CA Y53 6004 INSTRUMENTS AND CONTROLS 21 Engine Wait To Start IIluminates when engine grid heater is on Cummins ISB and ISC engines 22 Fifth Wheel King Pin Lock IIluminates when air actuated fifth wheel King Pin is unlocked 23 Fifth Wheel Slide Unlocked IIluminates and an audible warning tone will sound when the air operated sliding fifth wheel switch is on thus unlocking the sliding fifth
31. Locked Tandem Axles IIluminates when the inter axle differential switch is ON thus locking the inter axle differ ential This powers the forward rear and the rear rear differentials equally When the switch is turned off inter axle differential unlocked the engine power is allowed to flow to any of the 4 drive tires based on the differ ential effect mostly to the forward rear differ ential This feature is standard on all tandem axles 8 Clock Alarm Bell Illuminates when the alarm is set It will flash when the clock alarm is active 23 INSTRUMENTS AND CONTROLS 24 9 Cruise Control Active Illuminates when cruise control is active 10 Dump Truck Body Up IIluminates when Truck Dump Body is up 11 Dump Truck Trailer Body Up IIluminates when Trailer Dump Body is up 12 Emissions Diesel Particulate Filter DPF IIluminates when diesel particulate trap is plugged This warning will also illuminate when regeneration operation is disabled 13 Emissions High Exhaust System Temperture HEST Iluminates when the exhaust gas tempera ture and exhaust components become extremely hot to ae T tata Y53 6004 PART 4 CONTROLS AND DISPLAYS 14 Engine Check Engine IIluminates when a problem exists but the vehicle can still be safely driven Vehicle should be serviced to correct the problem but the situation should not be considered an emergency 15 Engine Ether Start
32. Release Bearings BB Brake Shoe Anchor Pins HT NOTE The responsibility for meeting these spec Brake Cam Bearings HT ifications the quality of the product and its perfor mance in service rests with the lubricant supplier Slack Adjusters CL Starter Bearings CC Component Lubrication Index Turbocharger Aneroid cc Universal Joints EP Water Pump Be Cab Tilt Hydraulic Reservoir Hydraulic Jack D Shaft Spl CL ue ashi al Oil MIL L 5056B Wheel Bearings driven hubs HD 9s Speedometer Cables Lubriplate Aero Wheel Bearings nondriven hubs CD50 or equivalent Wheel Bearings all grease lubricated hubs WB Consult manufacturer or lubricant supplier for special details Steering Column CL Alternator Bearing BB Fan Hub BB Power Steering Reservoir ATF Steering Drag Link CL Steering Knuckles CL 08 06 Y53 6004 155 LUBRICANT SPECIFICATIONS PART 8 MAINTENANCE AND SERVICE Lubrication Change and Inspection For oil reservoirs with side filler plugs transmissions axles steering Off Hig hway Use gear boxes transfer cases etc the oil must be level with the filler opening Refer to the Eaton Fuller transmission manual for servic inprop r Oli Levai Proper Oil Level ing information Highway Use 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 02942 correct Fuller Transmission Lubrication Fulle
33. Tires Check inflation pressure see page 168 Weekly cold using Wheels calibrated gauge Inspect for cuts irregular wear missing lugs sidewall damage X etc Disc wheels Inspect the wheel disc for any cracks or surface irregularities X Inspect the rim edge and bead seat area for damage Replace any damaged wheels DO NOT ATTEMPT TO REPAIR Demountable rims Inspect the mounting ring rim gutter side ring and lock ring for X damage replace as required Wheel nuts and studs Check the tightness of the fasteners and tighten the fasteners to X the specified torque as required see page 174 Wheel nuts and studs Inspect for damaged hex corners stripped or damaged threads X and excessive corrosion clean or replace as required Power Reservoir Check the fluid level see page 162 X Steering Reservoir ON HIGHWAY Drain replace the filter and refill see page 162 x x Sy Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Recommended SYSTEM COMPONENT MAINTENANCE TASK cae A B C D E Power Reservoir OFF HIGHWAY Drain replace the filter and refill see page 162 X Steering Steering gear Check the lash of the sector shaft adjust as required X Grease the trunnion bearing X EP NLGI 2 lithium based moly filled HD grease Grease the input shaft seal X EP NLG
34. Wiper Mode Press Button For ID and Clearance Lights Flash If your ID and clearance lights are on they will flash off 46 Y53 6004 PART 4 CONTROLS AND DISPLAYS Windshield Wipers Washer Your vehicle is equipped with a two speed intermittent windshield wiper system A seven position rotary wiper switch located on the turn signal lever operates the wind shield wipers and washer see next illustration Rotate the end of the turn signal lever to change the wiper mode NOTE The ignition key must be turned to ON or il ACC for the wiper washer switches to operate The first position after OFF is the intermittent 1 cycle The next positions are intermittent 2 3 and 4 The last two positions are wiper low speed and wiper high speed See the wiper switch settings table that follows for inter mittent delay times 08 06 PART 4 CONTROLS AND DISPLAYS Wiper Switch Settings Wiper Switch Position Wiper Speed Off Off Intermittent 1 20 Second Delay Intermittent 2 17 Second Delay Intermittent 3 7 Second Delay Intermittent 4 4 Second Delay Low Low Speed High High Speed To Wash The Windshield Push the rotary wash wipe knob in towards steering col umn hold for more than 0 8 seconds and then release 08 06 STEERING COLUMN MOUNTED CONTROLS Hold the knob in to extend the washing cycle After the lever is released the wipers will shut off automati
35. accident Always apply the park ing brake before you leave the cab j WARNING Do not leave the cab without apply 08 06 Y53 6004 PUTTING THE VEHICLE IN MOTION WARNING e If your vehicle has a Freedomline trans mission be aware that it can roll backwards when stopped ona 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 e 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 99 PUTTING THE VEHICLE IN MOTION Transmission Retarder O Retarder Switch If you have this option it will act like a brake to slow your vehicle without using the brakes Take your foot off the throttle and operate the retarder switch When you do not need full retarder effect you can apply it intermittently off and on to cause gradual or partial slowing Continuous application of your retarder will cause your hydraulic fluid to get hotter Intermittent application will help prevent overheating 100 Y53 6004 PART 7 STARTING amp OPERATING THE VEHICLE WARNING Do not rely on your automatic trans mission hydraulic retarder to stop your vehicle If your engine shuts down the vehicle s retarder will cease to operate Always be ready to suddenly apply the service brakes Auxil
36. and drain the lubricant Wash the X parts thoroughly and dry in air Breather Clean or replace X 08 06 Y53 6004 134 PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Recommended SYSTEM COMPONENT MAINTENANCE TASK et cabal A B C DIE Drive Axle Lube Pump ON HIGHWAY Remove the magnetic strainer and inspect for wear particles X Dana Wash in solvent and dry in air Lube Pump OFF Remove the magnetic strainer and inspect for wear particles X HIGHWAY Wash in solvent 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 X Meritor pinion angle of less than 7 degrees or at the axle bowl plug for a pinion angle of greater than 7 degrees Tighten the plug to 35 50 Lb ft 47 68 N m Visually inspect for damage or leaks X Drain and replace the lubricant See information on page 159 Lubricant filter Change the filter X Breather Check the operation If the cap doesn t rotate freely replace X 135 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE
37. causing possible serious bodily injury WARNING Keep people or objects clear when opening or closing a hood Failure to do so can cause hood to strike or crush causing possible serious bodily injury and or property damage 08 06 PART 4 CONTROLS AND DISPLAYS YOUR INSTRUMENT PANEL PART 4 CONTROLS AND DISPLAYS Your Instrument Panel This part explains the location of the various features on your vehicle and describes their function For information on using these features in driving see the paragraphs that follow Please remember that each Peterbilt is custom made Your instrument panel may not look exactly like the one in the pictures that follow We have tried to describe the most common features and controls available You can pick out the parts that apply to you and read them to be fully informed on how your particular vehicle operates 08 06 Y53 6004 216s YOUR INSTRUMENT PANEL PART 4 CONTROLS AND DISPLAYS Typical Conventional Cab Instruments and LEFT SIDE Controls 1 Directional Signal and High Beam Indicators standard Note Custom warning lights are added in this area 2 Tachometer 3 Oil Pressure 4 Coolant Temperature 5 Voltmeter 6 Driver Information Display 7 Fuel Level 8 Primary Air Pressure 9 Secondary Air Pressure D gt A 2 10 10 Speedometer 1 Panel A 11 Ignition Key Switch 12 Headlamps 13 13 Clearance Lamps T t 14 Panel L
38. 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 128 Y53 6004 PART 7 STARTING amp OPERATING THE VEHICLE Use of Driver Information Display The Driver Information Display provides information to help the driver optimiize vehicle efficiency Refer to the section Driver Information Display on page 28 for details A driver will find the section describing Trip Information and the RPM Detail useful 08 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Preventive Maintenance Schedule Q 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 can void your vehicle s warranty Some mainte nance operations demand skills and equipment you may not have For such situations please take your vehicle to an authorized Peterbilt Service Center 08 06 Y53 6004 WARNING It can be da
39. internal components may initiate a chemical reaction that produces a new compound that will attack seals and other internal components e Do not mix different fluids CAUTION When adding fluid be sure to use Universal Joint Lubrication Refer to the Spicer Universal Joints and Driveshafts ser vice manual and lubrication specifications 08 06 PART 8 MAINTENANCE AND SERVICE Replacement 1 Replace both fluid and filter as per the chart below 2 Bleed the system if necessary Steering Fluid Inspect Rep lace Gear mi km mi km months Every 15 000 Every 240 000 TRW ATE 24 000 384 000 24 Every 15 000 Every 240 000 Sheppard ATE 24 000 384 000 24 Extremely low temperatures may require lower viscosity fluids consult your Peterbilt dealer for recommendations 08 06 Y53 6004 LUBRICANT SPECIFICATIONS 163 SERVICING SPECIFIC SYSTEMS AND UNITS Servicing Specific Systems And Units This section will help you keep your Peterbilt 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 righ
40. interval being used for oil changes is close to but does not exceed 70 000 miles 112 000 km 143 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Recommended SYSTEM COMPONENT MAINTENANCE TASK cae 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 180 X Clutch release linkage Check for excessive looseness and lubricate NLGI 2 grease X Clutch release bearing Lubricate X Clutch release shaft Lubricate X Cooling Hoses Check the radiator and heater hoses for leaks X Extended Life Coolant ELC Check the freeze point see page 181 xX Check for contamination using test strips see page 182 X Replace blank water filter if applicable X Perform lab analysis see page 182 X If lab analysis shows coolant is unsuitable for continued use Flush drain and refill see page 183 Add ELC Extender see page 182 Flush drain and refill with new coolant see page 183 X Fan clutch housing Check for air leaks see page 195 X Surge Tank Fill Cap Check fill cap seal at each oil change XIXIXIXIX 08 06 Y53 6004 144 PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Recommended SYSTEM COMPONENT MAINTENANCE TASK P interval I A B C DIE Tires amp
41. moving ar Unlock the interaxle differential before starting 2 Put the Range Selector in the LOW range Shift the transmission to start the truck moving 3 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 4 When you go from off highway to highway driving shift the axle to the HIGH range this way A Be sure the differential is UNLOCKED B Keep the accelerator down and move the Range Selector lever to HIGH C Keep driving with the accelerator down until you want the axle to shift D Then release the accelerator until the axle has shifted 97 PUTTING THE VEHICLE IN MOTION E You are now in the HIGH axle range on the high way 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 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 il e To avoid damaging your vehicle shift the axle at a slower speed until you are used to driving with the dual range axle NOTE If your vehicle has an automatic transmis sion it ma
42. 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 H In an ELC filled cooling system the freeze point should be maintained between 30 F and 45 F 34 C and 43 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 08 06 Y53 6004 181 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 cou
43. of factors that may affect the time required to reach your destination See the Supplemental Navigation System Owner s Manual for more information Y53 6004 PART 4 CONTROLS AND DISPLAYS 08 06 PART 5 SEAT AND RESTRAINT SYSTEMS Seat SEAT PART 5 SEAT AND RESTRAINT SYSTEMS For information on the features and adjustment of the seat see the seat manufacturer s literature included with the vehicle AN WARNING 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 sud denly and unexpectedly and can cause you to lose control of the vehicle Make all adjust ments to the seat while the vehicle is stopped After adjusting the seat and before driving off ensure that the seat is firmly latched in posi tion 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 08 06 injury and death in motor vehicle accidents It s not just an opinion it s a fact Seat belts save lives A Y53 6004 WARNING Do not drive vehicle without your seat belt and your riders belt fastened Riding without a safety belt properly fastened can lead to increased injury or death in an emer gency Unbelted riders could be thrown into the windshield or other parts o
44. parked Each function is identified in the fol lowing descriptions A Fuel Economy Accessible while parked or driving Current Econ 0 00 mpg Trip Econ 0 00 mpg 1 Current fuel economy Indicates instantaneous fuel economy 2 Trip fuel economy Indicates trip fuel economy 08 06 Y53 6004 DRIVER INFORMATION DISPLAY RPM Detail Accessible while parked or driving gt RPM reading of actual engine RPM Engine RPM within the bar graph indicates the engine is operat ing in the most efficient RPM range The display color will change if you are operating outside of this range Ignition Timer Accessible while parked only i Ign Timer Omin 15 30 Ignition timer is set from this menu The ignition timer may be set for up to 30 minutes 29 DRIVER INFORMATION DISPLAY D 30 Trip Information NOTE When accessing the trip information i menu push the MCS on this menu bullet To exit push the MCS again To reset the trip values press the Trip Odometer Reset But ton on the main gauge instrument cluster Trip Information Certain Trip Information functions area accessible when driving or when parked Trip Economy Trip Average Speed Other Trip Information functions are accessible only when parked Trip Distance Trip Engine Hours Trip Idle Hours Trip Idle Percentage Y53 6004
45. parts in the engine compartment j WARNING When disconnecting jumper 189 FUEL SYSTEM 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 ment cover step before entering the cab With out the battery cover you could slip and fall resulting in possible injury to yourself CAUTION Always reinstall the battery compart 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 190 Y53 6004 PART 8 MAINTENANCE AND SERVICE 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 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 your fuel tank drain the entire system Other wise the
46. periods 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 08 06 PART 4 CONTROLS AND DISPLAYS DASH AND DOOR MOUNTED FEATURES vary depending upon which engine you have For a N specific explanation of your cruise control see f SET the cruise control or engine manual included with your vehicle Cruise Control Switch H NOTE Cruise control functions and features may Ruse O ae In conventional models with Eaton transmissions the NOF SELECT cruise control switches may be located on the shift control knob see illustration GS gt O RESUME The master switch turns the cruise control ON or OFF The second switch allows you to SET the desired speed or RESUME the desired speed after the cruise control function has been interrupted when operating on road surfaces with poor traction wet icy or snow covered roads or in heavy traffic Accelerations caused by the Power Mirror Switch normal operation of the cruise control could cause you to lose control of the vehicle result f your vehicle is equipped with power mirrors the mirror ing in an injury accident controls will be located on the driver side door pad Aerody j WARNING Do not operate the cruise control 08 06 Y53 6004 55 DASH AND DOOR MOUNTED FEATURES namic style mirrors are controlled for 4 way adjustable
47. pump and engine will be damaged Don t try to dilute the gasoline by adding diesel fuel See Warning above Fuel Filters A CAUTION If anyone ever pours gasoline into Please follow these recommendations when you are changing your fuel filters or strainer elements Your engine 08 06 PART 8 MAINTENANCE AND SERVICE 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 e When installing spin on throwaway filters hand tighten them only to 1 2 to 2 3 turn after gasket con tact Mechanical tightening of these filters may distort or crack the filter head NOTE To expel air from density type strainer ele il ments soak them in clean fuel before installing them e When replacing a fuel filter element don t use a sub stitute Install only filter elements designed for fuel fil s 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 Throw away old gaskets Replace them with new ones to ensure a positive seal 08 06 Y53 6004 STEERING Position the shell and gasket properly Then tighten the cover nut or bolt just enough to prevent fuel leak age After starting the en
48. rod travel and check the control arm for cracks X All Adjust at reline see page 164 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 X Check the pivot and mounting plate for integrity Check the plunger boot for cracks Lubricate roller pin pivot pin and plunger NLGI 2 grease Rebuild through an authorized Peterbilt service facility X Brake air system Check air lines and fittings for leaks see page 164 Adjust X routing as 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 137 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE 08 06 Recommended SYSTEM COMPONENT MAINTENANCE TASK PM ntorva A B C D E Disc Brakes Brake pads Inspect replace as required X Bendix Brake disc rotor Inspect for visible cracks heat checking galling or scoring of X surface Check thickness minimum of 1 46 37 mm Caliper sliding function Ensure caliper slides freely with no obstructions or excessive X play see manufacturer s service literature for Checking Running Clearance Caliper function Inspect bearings seals tappet and boots of the guide pins for X damage or cracking Adjuster Check ope
49. 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 Allison Transmission Lubrication Refer to your transmission manual furnished separately for lubrication information Y53 6004 157 LUBRICANT SPECIFICATIONS 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 additives 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 158 PART 8 MAINTENANCE AND SERVICE Ambient Type Grade SAE Temperature Heavy Duty Engine Oil MIL L 30 40 or 50 Above 0 F 2104D or MIL L 46152B API SF 18 C or API CD MIL L 2104B or C or MIL L 46152 designations are 30 Below 0 F acceptable 18 C 90 Above 0 F 18 C Mineral gear oi
50. so that the idler pulley swings toward the belt routing Figure 1 shows an example of the rotation direction to release the ten sioner 2 Slip the belt around the idler pulley attached to the automatic tensioner 08 06 Y53 6004 ENGINE ACCESSORIES 3 Release the automatic tensioner 4 Check the belt alignment on each pulley The belt must fall between the flanges of each pulley 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 195 AIR INTAKE SYSTEM e Check the fan assembly mounting bolts for tightness Inspect the fan blades for damage 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 working while the engine is warming up When the clutch engages note the reading on the vehicle s panel mounted coolant temperature gauge If the fan clutch engages at low engine temperature or cycles on and off more frequently than it should receives false signals have the problem corrected at your dealership Viscous Fan Drives Check the clutch operation by starting the engine when it is cold When the truck is cold the viscous fan clutch will require more time to disengage This time wil
51. the exhaust system Whenever the exhaust system underbody cab or sleeper is damaged e To allow for proper operation of the vehicle ven tilation system keep the inlet grille at the base of the windshield clear of snow ice leaves and other obstructions at all times 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 DASH AND DOOR MOUNTED FEATURES e If you are required to idle your vehicle for long periods of time install an auxiliary heater or auto matic idle control These auxiliary devices can reduce fuel consumption and save you money e If other vehicles are parked next to you idling move your vehicle or do not stay in your vehicle for prolonged periods of time e When idling for short periods of time Set the heating or cooling system to Heat or A C Set the fan to Medium or High speed Set the controls to FRESH AIR To Set the Heater Air Conditioning Controls Conventional Cab The Conventional cab s controls will have one control unit on the dash and may have a rocker switch for the bunk control unit see illustrations that follow A rotary knob A in the left portion controlling the blower speed with five settings including OFF Y53
52. 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 even 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 e 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 08 06 PART 5 SEAT AND RESTRAINT SYSTEMS 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 dis
53. tires on your steering axles Replacing Tires Front Replace front tires when less than 4 82 in of tread remains Check at three places equally spaced around the tire Drive Axles or Trailers Replace tires on drive axles or trailers when less than 2 32 in of tread depth remains in any major groove Check at three places equally spaced around the tire See the next illustration for recommended measuring points for tread depth 08 06 PART 8 MAINTENANCE AND SERVICE e Recommended points 02946 e Recommended points 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 anytime 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 driving axle dem axle can damage the driveline U joints and the interaxle differential Your repairs could be costly amp time consuming Speed Restricted Tires CAUTION Chains on the tires of only one tan speed restricted tires Check each tire s side wall for maximum rated speed Vehicle should not be operated at sustained speed in excess of maximum rated speed Failure to comply with these speed restrictions could cause sudden tire failure which can result in prop erty damage or personal injury j WARNING This vehicle may be equipped with Steer Tire Points in Upper View
54. to turn on the engine and all accessory power e START Starter activation to start engine Hazard Flasher The four way Emergency Flasher switch is located to the right of the ignition key switch With the switch in the ON position the emergency flasher makes all four turn signals front and rear flash simultaneously The flasher works independently of the ignition switch You should always use the flasher if the vehicle is disabled or parked under emergency conditions 08 06 PART 4 CONTROLS AND DISPLAYS a O WARNING Use your Hazard Flasher Warning System any time you have to stop off the road or on the side of the road day or night A hard to see vehicle can result in an injury accident Another vehicle could run into you if you do not set your flashers and follow the placement of emergency signals per FMCSR 392 22 Always move the vehicle a safe distance off the road when stalled or stopped for repairs A disabled vehicle can be dangerous 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 contact dry grass brush spilled fuel or any other material that could cause a fire DASH AND DOOR MOUNTED FEATURES Headlamps The headlamps are controlled by the control panel switch showing the next symbol When the headlights are ON the dash lights side and tail lamps are also on a
55. wheel The light and an audible warning tone should NOT be considered an emer gency but simply as a reminder to turn off the switch to lock the sliding fifth wheel before driving This switch should not be operated while driving Sliding fifth wheels are an option 25 INSTRUMENTS AND CONTROLS uv e il 26 24 Lights High Beam IIluminates when the high beams are on This icon will flash with audible alarm if the headlamps are left on when the door is open 25 Message Waiting Illuminates with telematic equipped messag ing 26 Park Brake Illuminates in the status indicator when park ing brakes are applied and the vehicle is sta tionary This symbol will also illuminate in the Driver Information Display if the parking brakes are applied and the vehicle is in motion 27 Power Take off PTO Illuminates when the PTO is engaged NOTE Do not drive vehicle with PTO engaged PUMP MODE A gt e Y53 6004 PART 4 CONTROLS AND DISPLAYS 28 Power Take off PTO Pump Mode IIluminates with remote throttle application Indicates pump mode is active 29 Refrigerator Illuminates to indicate that the refrigerator is on and ignition is off 30 Seat Belt Fasten IIluminates when the ignition key is turned on as a reminder to fasten your seat belt 31 Suspension Dump IIluminates when suspension air bags are deflated 32 Tire Inflation IIluminates wh
56. whenever possible e Use protective eyewear 08 06 Y53 6004 ELECTRICAL distilled water It could come in contact with a terminal creating a short circuit resulting in severe injury or damage to your vehicle CAUTION Never use a metallic funnel to add e Maintain the full level of electrolyte in the batteries 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 gravity The specific gravity should be between 1 258 1 265 or the electrolyte level within MIN and MAX marks 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 e 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 185 ELECTRICAL metal on the vehicle that is in contact with the posi tive terminal could cause a short circuit or an explo sion Keep all batteries away from children nected positive to positive to and nega j WARNING Charge
57. will maintain the design integrity of the mounting points for the seat belt assembly Once the need for replacement of the seat belt has been determined be certain that it is only replaced with the rec ommended replacement seat belt The occupant restraint 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 83 SAFE VEHICLE OPERATION PART 6 DRIVER S CHECKLIST 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 interfere with the safe and efficient transp
58. 1 44 in standout Right hand and left hand Each mounting system is engineered for use threads are required Inner and outer cap nuts center the wheels by seating against wheel ball seats 08 06 Y53 6004 173 TIRES WHEELS AND RIMS 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 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 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 Disc Wheels To check the torque on disc wheels follow the crisscross sequence shown See the Specifications chart for proper torque specification a 4745 A Y53 6004 PART 8 MAINTENANCE AND SERVICE WARNING 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 eventually come off maybe causing you to lose control of your vehicle Be sure to use the right com ponents and the right tools e The end of the whe
59. 3 6004 PART 4 CONTROLS AND DISPLAYS Air Horn Your Peterbilt 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 Trailer Brake Hand Valve This hand valve provides air pressure to apply the trailer brakes only It operates independently of the foot treadle valve To operate the trailer brake hand valve Pull down on the lever under the right side of the steering wheel 08 06 PART 4 CONTROLS AND DISPLAYS WARNING Activating the trailer hand brake M 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 Exercise care to choose the appropriate lever The BrakeSaver lever is located lower and closer to the driver on the steering column see page 59 See Brake Safety and Emergency on page 112 for more complete information on when and how to use your trailer brake Or see the Index under Brake out the trailer brake sooner WARNING It is dangerous to use air applied M trailer brakes for parking or holding a vehicle Air system pressure can bleed down and release the brakes You could have a vehicle roll away resulting in an accident You or oth ers could be badly injured Always apply the parking brakes for parking or holding your vehicle on grade NOTE The trailer brake is not to be used as the main mean
60. 53 6004 ANTI LOCK BRAKING SYSTEM ABS 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 a malfunction 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 lock system until the vehicle has been brought CAUTION Do not attempt to recycle the anti to a full stop If one wheel on any driven axle continues to slip or spin for approximately 4 seconds this will cause the anti lock con troller 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 warning 199 CAB HEATER AIR CONDITIONER 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 illumi nate and remain on for 3 to 5 sec
61. 7 73 104 76 109 103 149 e Go around your vehicle as per the Preventive Mainte Veco 38 87 Caki 50143 dls Be nance Schedule on page 129 and tighten all frame 9 16 12 78 111 105 151 110 158 149 214 fasteners with a torque wrench 9 16 18 87 124 118 168 123 176 167 239 e Always use the torque values listed in the frame fas 5 8 11 108 154 147 209 153 218 208 296 tener table 5 8 18 422 174 166 236 173 247 235 335 Always torque fasteners from the nut end 3 4 10 192 273 260 370 271 386 367 523 For standard capscrews 3 4 16 214 305 290 414 303 431 411 583 e Always use the torque values listed in the capscrew table 7 8 9 309 441 419 598 437 624 593 846 194 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE e Reduce torque by 10 when engine oil is used as a lubricant e Reduce torque by 20 if new plated capscrews are used 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 and maintenance Neglect could cause belt failure The result could be the loss of the electrical or air system as well as possible engine damage from overheating So it s a very good idea to check your belts frequently and replace them as soon as you detect trouble Follow this procedure to install an accessory drive belt 1 Route the new belt around the pulleys and then rotate the automatic tensioner
62. ANCE AND SERVICE Recommended SYSTEM COMPONENT MAINTENANCE TASK ene AI B C D E Auxiliary Cotta Transfer Case Inspect Check oil level inspect for leaks and any visible X transmission TR2205 damage Initial oil change Drain oil while warm flush case with gear oil compatible fluid clean magnetic drain plug refill Do not flush the case with any solvent Change oil xX Fabco Transfer Case Inspect Check oil level inspect for leaks and any visible X TC142 TC143 TC170 damage TC270 Initial oil change Drain oil while warm flush case with gear oil compatible fluid clean magnetic drain plug refill Do not flush the case with any solvent Change oil x Marmon Harrington Inspect Check oil level inspect for leaks and any visible X Transfer Case MVG2000 damage MVG2000SD Initial oil change Drain oil while warm flush case with gear oil compatible fluid clean magnetic drain plug refill Do not flush the case with any solvent Change oil x 141 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Recommended SYSTEM COMPONENT MAINTENANCE TASK PH interval IJ A B C DIE Air Intake Air intake piping mounting Check the system for broken pipes leaks joint integrity X and charge air cooler cleanliness and proper support see page 196 Cold starting aids Check for leaks and proper ope
63. ART 7 STARTING amp OPERATING THE VEHICLE NOTES e At least one of the mounting holes in the height control valve bracket will be slotted to permit rotating the valve il e On dual valve systems begin with the LH valve a 4 Ol Vv DELIVERY TO LH AIR BAG S a weg 02941B Typical Height Control Valve Rear View Looking Forward 24242 on the next step 2 Loosen the fasteners mounting a height control valve to LINK ROD its bracket AN WARNING The rear of a vehicle will drop about 3 1 2 inches 88 mm when the air springs are deflated Ensure that no persons or objects that could be injured or damaged are under L the vehicle before deflating the air springs e 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 e To minimize risk of injury keep away from air springs as they are being inflated Y53 6004 08 06 08 06 PART 7 STARTING amp OPERATING THE VEHICLE 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 frame rail to the approx imate centerline of the rearmost drive axle hub e For tandem axles make the vertical measure ment at the centerline of the suspension see i
64. AYS Dome Light The center mounted dome light is operated by gently pushing on the lens until a click is heard The same action turns the light on or off depending on its previous state Fog Lights Switch a O If your vehicle has fog lights turn them ON or OFF with the control panel switch with the symbol shown above NOTE Across the U S A and Canada State Pro i vincial requirements vary as to when high beams and fog lights can and cannot be used together Some states allow only four lights to be used together while some allow more How your lights 08 06 Y53 6004 DASH AND DOOR MOUNTED FEATURES are arranged will affect whether you can operate head lights and fog lights concurrently always comply with the state or provincial requirements where you are driving Air Suspension Deflate Switch Dump Valve ier AIR SUSPENSION Your Peterbilt vehicle may have an air suspension defla tion switch which allows the air in the suspension to be exhausted from a switch on the dash The purpose of this feature is to allow you to lower your tractor to get under a trailer You may notice a guard over the switch This pre vents you from accidentally deflating the suspension WARNING Operating the Air Suspension Ax Deflate Switch Dump Valve while driving can lead to an accident Sudden deflation while 53 DASH AND DOOR MOUNTED FEATURES your vehicle is moving can affect handling and con t
65. Conventional MANUAL Models CLASS PAYS 2007 EPA Compliant Vehicles Quick Table of Contents Introduction 00 1 Cab And Frame Access 5 Getting To Your Engine 11 Controls And Displays 13 Seat And Restraint Systems 73 Drivers Checklists 0000 0 cece eee eee 84 Starting And Operating The Vehicle 88 Maintenance and Service 0 22 129 Vehicle Identification 2 2 eee 215 Consumer Information 0 00 ccc eee eee 216 SUDJECEINGEX 2 ver te el nena ae alates Sais df eal dee ie eae Hendin 4 219 California Proposition 65 Warning e Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm e Other chemicals in this vehicle are also known to the State of California to cause cancer birth defects or other reproductive harm e Battery posts terminals and related accessories contain lead and lead com pounds chemicals known to the State of California to cause cancer and repro ductive harm Wash hands after handling 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 vehicle It also provides information on maintaining your vehicle in the best condi tion with an outline for performing safe
66. Do not drive with your seat belt loose A seat belt that is too loose can allow you to fall too far forward possibly causing head and neck injuries You could strike the wheel or the windshield Adjust your belt so that there is no more than 1 in 25mm of slack e Do not wear the shoulder belt under your arm or otherwise out of position In a crash your body would move too far forward increas ing the chance of head and neck injury Also the belt would apply too much force to the ribs which are not as strong as your shoulder bones and could cause you to suffer internal injuries Wear the shoulder belt over your shoulder PART 5 SEAT AND RESTRAINT SYSTEMS Do not twist the belt in the process of put ting it on A twisted belt will not work as well to protect you In a crash the full width of the belt would not be protecting you A twisted belt could cut into your body and cause serious injuries Straighten the belt before buckling it If you are unable to wear it without twisting it have your dealer or service person repair it as soon as possible Komfort Lok Feature 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 K
67. ES WARNING Verify legal weight and height restrictions for the route suggested by the Navigation System Failure to verify height restrictions could lead to personal injury Fail ure to verify weight restrictions could result in a traffic infraction WARNING Only glance at the Navigation System monitor while driving Prolonged peri ods of viewing while driving could result in an accident and possible personal injury WARNING Do not program the Navigation System while driving Always stop your vehi cle when programming or changing the set tings on the Navigation System Programming the system while driving can cause you to take your eyes off the road which could result in an accident Failure to do so could lead to serious injury or equipment damage CAUTION Do not rely on the Navigation System to route you to the closest emergency services Not all emergency services are in the database 741 CAB FEATURES i tt 72 NOTE Regardless of how and where the naviga tion system directs you it is your responsibility to operate the vehicle in a safe and legal manner NOTE Ensure the volume level of all audio devices is set to a level that still allows you to hear outside traffic and emergency vehicles NOTE The map database is the most current available at the time of production The database is designed to provide you with route suggestions and does not take into account the relative safety of a suggested route or
68. FETY AND EMERGENCY A 114 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 brake valve while the vehicle 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 PART 7 STARTING amp OPERATING THE VEHICLE il your vehicle could result in excessive heat build up in the brake system resulting in a fire 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 To apply all your parking brakes pull the yellow knob Out The parking brakes will set And the trailer air supply v
69. Fasteners Check for tightness tighten to the specified torque value as X required see page 194 Crossmembers and Inspect for cracks and loose fasteners Replace or tighten to the X Mounting Brackets specified torque value as required see page 194 Front Axle Total Vehicle Alignment Check and adjust as required X Arvin Steering knuckle spindles Inspect for wear and damage and endplay Shim or replace as xX Meritor thrust bearings kingpins required see page 191 drawkeys tie rod ends steering stops amp bushings Kingpin bushings thrust Lubricate with approved grease X bearings amp tie rod ball ends Drawkeys Tighten nuts X Front Axle Total Vehicle Alignment Check and adjust as required X Dana Kingpin bushings thrust Check and adjust as required X bearings amp tie rod ball ends ON HIGHWAY 08 06 Y53 6004 132 PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Recommended SYSTEM COMPONENT MAINTENANCE TASK re aoe IJ A B C DIE Front Axle Kingpin bushings thrust Lubricate with approved grease X Dana bearings amp tie rod ball ends OFF HIGHWAY AND VOCATIONAL Steering knuckle spindles Inspect for wear and damage and for endplay Shim or replace X thrust bearings kingpins as required drawkeys tie rod ends steering stops amp bushings ON HIGHWAY Steering knuckle spindles Inspect for wear and damage and for endplay Shim or replace X thrust bea
70. G 8 AN e Diesel fuel in the presence of an ignition source such as a cigarette could cause an 9 explosion You could be seriously injured A mixture of gasoline or alcohol with diesel fuel increases this risk of explosion Use only the 40 fuel recommended for your engine Hot fuel vapors are combustible and can 11 cause an explosion or fire resulting in injury or death Do not remove a fuel tank cap near an open flame 12 13 1 Be sure all wheel studs and cap nuts are secure 14 Check wheel cap nut torque weekly refer to the 15 instructions on page 176 16 2 Check tires for condition and proper inflation 17 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 6 Check emergency flashers and exterior lamps 20 86 Y53 6004 18 19 PART 6 DRIVER S CHECKLIST Check the fuel tanks Is there enough fuel Are the tank caps secure Visually inspect the fuel tank mounting hardware Are the tank straps tight Is the webbing in place If equipped with fuel tank steps are they damaged or broken Is the grommet windlace in place between the tank and side plate Are bolts missing or loose Check the air cleaner and muffler s Are they tight and secure Check the trailer connections Are they secure and the lines cle
71. I 2 lithium based moly filled HD grease Power assist cylinder Lubricate the ball joints Inspect for leaking rod seals damaged X ball joint boots and damage to cylinder rod or barrel Hoses and tubes Check for leaks and chafing X Steering linkage Check all joints for excessive lash replace as required X see page 191 Draglink tube clamp Check the torque tighten to specified torque value as required X and ball socket Pitman arm clamp bolt Check the torque tighten to specified torque value as required X and nut Steering intermediate shaft Check the torque on the pinch bolt and nut X Steering intermediate shaft Lubricate EP NLGI 2 HD grease X U joints ON HIGHWAY 325 F to 10 F 163 C to 23 C range 08 06 Y53 6004 146 PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Recommended SYSTEM COMPONENT MAINTENANCE TASK freer A B C D E Power Steering intermediate shaft Lubricate EP NLGI 2 HD grease X Steering U joints OFF HIGHWAY or 325 F to 10 F 163 C to 23 C range CITY DELIVERY Draglink and tie rod arm ball Lubricate EP NLGI 2 lithium based moly filled HD grease X sockets ON HIGHWAY Draglink and tie rod arm ball Lubricate EP NLGI 2 lithium based moly filled HD grease X sockets OFF HIGHWAY or CITY DELIVERY Fuel amp Tanks Fuel tanks Inspect tanks brackets hoses and fittings for correct lo
72. ING SYSTEM OPERATING INFORMATION 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 Bobtail Brake Proportioning System il Peterbilt tractors without anti lock brake systems ABS are typically equipped with a bobtail brake proportioning system When a trailer is not connected the drive axle brake application pressure will automatically be limited by the proportioning system When driven in a bobtail mode these tractors will require greater brake pedal application NOTE The following information is applicable only to tractor configurations built on or after March 1 1997 and not registered in the United States 111 BRAKE SAFETY AND EMERGENCY to provide the equivalent braking to a bobtail tractor not equipped with a proportioning system WARNING Because of the increased use of N the steer axle brakes when driving bobtail alwa
73. Number 215 Vehicle inspections 84 Vehicle weight rating 177 W Warning Light Symbols table 19 Wheels and tires replacement 175 Windshield washer reservoir 47 Numerics 49 CFR 565 Code of Federal Regulations 215 Y53 6004 08 06
74. OLS WARNING After you complete a turn shut the 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 instrument panel will flash until the turn signal is turned off High Beam Headlamps H NOTE The headlamps must be ON for the high beam switch to operate e To switch your headlamps to lower or higher beam gently pull the turn signal lever towards the steering wheel until you hear the switch click and the beam changes The blue indicator light in the instrument panel will be ON when the high beam is being used e To return to previous beam pull the lever towards the 08 06 Y53 6004 steering wheel again 45 STEERING COLUMN MOUNTED CONTROLS Headlamp Flash To activate headlamp flash gently push the turn signal lever away from the steering wheel until you hear and feel the switch click Release lever to deactivate e If your headlamps are off low beams will flash on If your headlamps are on they will dim Maximum duration of dimming is 3 seconds When the function ends your headlamps will return to low beams ID And Clearance Lights Flash To flash press the button on the end of the turn signal lever and hold To cancel the flash release the button Press In For Washer Pump Rotate To Change
75. OPERATING THE VEHICLE Proprietary Rear Ride Height inches mm Air Suspension Single Drive Tandem Drive Air Leaf N A 11 70 297 Air Trac 11 00 279 11 00 279 Low Air Leaf 6 50 165 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 damage to property ensure that a vehicle is parked and the wheels chocked before begin ning this procedure j WARNING To prevent possible injury and 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 A CAUTION Completing this procedure will NOTE Suitable wheel chocks are at a minimum il an 18 inch 46 cm long 4x4 08 06 Y53 6004 i SETTING RIDE HEIGHT Ensure the air supply and delivery plumbing of the height control valve is consistent with the following illustrations P O ALIGNMENT PIN OR DOWEL CONTROL ARM LINK BOLT ya ja lq FROM DUMP VALVE SWITCH FORWARD 02941A Typical Height Control Valve Top View 123 SETTING RIDE HEIGHT DELIVERY TO RH AIR BAG S SUPPLY FROM FORWARD AIR TANK a MOUNTING NUTS ta EXHAUST gt P
76. PLAYS Restriction Gauge reading 25 in HO may cause your engine Have it checked by a qualified service per damage to the engine Inspect the filter and son replace if necessary Holes in the paper element render an air cleaner useless and may cause the Fuel Pressure Gauge Air Filter Restriction Gauge to give a false read ing even if the element is clogged Replace the element if it is damaged Manifold Pressure Gauge f CAUTION Continued operation with the Air Filter gauge goes down there may be something wrong with Your vehicle may also have a fuel pressure gauge in your vehicle is dangerous Full or empty they may leak explode and cause or feed a a fire Don t carry extra fuel containers even Your manifold pressure gauge indicates the power your empty ones engine is putting out by showing the amount of turbo boost If the pressure indicated by your manifold pressure j WARNING Carrying additional fuel containers 42 Y53 6004 08 06 PART 4 CONTROLS AND DISPLAYS Air Application Gauge This gauge shows how much air pressure is being applied from your foot brake valve or trailer brake hand valve OPTIONAL GAUGES Transmission Temperature Gauge 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 representat
77. R WORK PERFORMED COMPONENT INTERVAL R O NUMBER FACILITY amp WORK PERFORMED R O NUMBER FACILITY amp MILES LOCATION LOCATION EXHAUST SYSTEM ROUTING 25 000 INTEGRITY MUFFLER INTERNAL 250 000 BAFFLES SHUTTERS 25 000 SHROUDS ENGINE MOUNTED HOSE INSULATORS 10 000 FASTENERS INNER 50 000 FENDER SHIELDS CAB SKIRT 50 000 FASTENERS AIR INTAKE SYSTEM INTEGRITY 5 000 ELEMENT CLUTCH TYPE 10 000 FAN DRIVE 214 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE NOISE CONTROL SYSTEM 08 06 Y53 6004 915 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 PAGSAR O o DENTON TEXAS U S A CHASSIS WT o a amp O lt Ss 02954 08 06 Y53 6004 EXAMPLE VIN 1XP 9D2X9 6 X D 345678 Model Year Serial Number Plant Code X 1999 Y 2000 D Denton Factory 1 2001 2 2002 N
78. RT 7 STARTING amp OPERATING THE VEHICLE 08 06 PART 7 STARTING amp OPERATING THE VEHICLE 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 08 06 Y53 6004 117 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 H type maximum 50 ft lb Wedge type maximum 30 ft 7 lb The spring brake is now mechanically released 2937C 0 118 Y53 6004 08 06 PART 7 STARTING amp OPERATING THE VEHICLE A WARNING Disassembling the spring brake chamber is dangerous and could cause seri ous injury These chambers contain a power ful spring that is compressed Sudden release of this spring could cause you to be badly injured Do not disassemble a spring brake chamber Retarders Various retarders are avai
79. RVICE because they are critical to engine service life If your vehicle has an external air cleaner and cab mounted mir rors the mirror must be pivoted to provide access for ser vicing the filter element STEPS 1 6 ae STEPS 3 7 08 06 Y53 6004 AIR INTAKE SYSTEM 1 Loosen do not remove upper 5 16 in mounting hardware 2 Remove acorn nut and flat washer then pivot upper stabilizer rod away from cab 3 Loosen the two rearmost M6 hex socket head screws on the lower clamp to the base The two rearmost screws provide the clamping force on the main support tube 4 Rotate the main support tube rearward to provide clearance to remove and replace the air cleaner filter element H NOTE The two forward screws secure the cover torque the four hex nuts attaching the air cleaner cover assembly to the body assembly to 8 Lb ft 10 N m after installing the new air cleaner filter element 5 After installation of the new filter element rotate the main support tube forward and reinstall the upper sta bilizer rod to its mounting bracket 6 In any sequence tighten the upper fasteners to a torque of 13 17 Lb ft 17 23 N m 7 Tighten the two rearmost screws in the lower clamp to a torque of 4 4 5 Lb ft 5 6 N m CAUTION To prevent possible engine damage 197 EXHAUST SYSTEM Turbocharger When servicing the air intake and exhaust systems on a turbocharged engi
80. SC Confirming desired selection Standard Warning Lights and Audible Alarm The warning lights and audible alarm may indicate a sys tem malfunction Check the lights frequently and respond properly as soon as you see one go on These lights could save you from a serious accident WARNING Do not ignore a warning light or AN audbile alarm These signals tell you some thing 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 08 06 PART 4 CONTROLS AND DISPLAYS 1 Driver Information Display 2 Status Indicator 3 Lower Light Bar Warning lights and indicator symbols will be shown in both areas 1 and 2 Area 3 is dedicated to the turn and high beam indicator symbols 1 Driver Information Display The display can show up to six warning lights Warnings do not have fixed positions and are displayed in order of criticality The most critical warning will be displayed on the top row and to the left If more than six warnings are 08 06 Y53 6004 INSTRUMENTS AND CONTROLS active the menu control switch MCS can be used to scroll through the additional warnings 2 Status Indicator Additional lights and indicator symbols are displayed in the Status Indicator They are limited to a Park Brake b Transmission Gear only c Warnings Automatic transmissions 1 Number of active w
81. 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 08 06 Y53 6004 WARNING The fluid in ether starting systems is extremely flammable and poisonous If ignited it could burn you badly If you swallow it it can be harmful or fatal e Do not smoke when testing installing or servicing an ether starting unit Service it ina well ventilated area away from heat open flames or sparks If swallowed do not induce vomiting Call a physician immediately e Wear goggles to avoid getting fluid in your eyes Avoid getting it on your skin and avoid breathing the fumes If fluid does get in your eyes or fumes irritate your eyes flush for 15 minutes with large amounts of clean water Contact an eye specialist e Do not move or relocate the ether cylinder or tubing from its original installation It must be mounted to protect it from engine exhaust heat and from moving parts which could dam age it e Do not store the spare cylinder in the cab 89 ENGINE WARMUP In warm weather when you will not need the ether starting system remove the ether boitle from your truck and store it safely Return the protective cap to the bottle mounting connec tor In cold weather the engine
82. WARNING Low air pressure could make the AN 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 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 Driving Tips And Techniques CAUTION Operating a vehicle with air sus This section covers additional driving tips and techniques on how to drive your vehicle 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 126 Y53 6004 PART 7 STARTING amp OPERATING THE VEHICLE 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 damage 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 o
83. air system pressure When operating the tractor bobtail The red knob must remain out to protect the tractor air system pressure 08 06 Y53 6004 BRAKE SAFETY AND EMERGENCY 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 brakes may be manually released to allow the vehicle to be towed This sections details how to release a drum or an air disc brake WARNING AN e Do not operate a vehicle when the spring brakes have been released manually Driving a vehicle that has had its spring brakes manu ally released is extremely dangerous You would probably have no brakes at all You could have a serious or fatal accident e 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 rolling before manually releasing the spring brakes NOTE The primary purpose of the manual release feature is to permit the vehicle to be towed to a repair facility H 115 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 116 Y53 6004 PA
84. alve red octagon knob will automatically pop out releasing air pressure and setting the trailer brakes A 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 To release your truck or tractor brakes ONLY push in the yellow knob Your trailer will remain parked e To release the trailer brakes ONLY push in the red knob The truck or tractor will remain parked Y53 6004 08 06 PART 7 STARTING amp OPERATING THE VEHICLE 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
85. ance schedule In severe service or off sees highway applications inspect the linings more frequently ARM Q AZ O A Automatic Slack Adjusters 8 No Periodically check the Brake Chamber Stroke Replace sabia the slack adjuster if proper stroke cannot be maintained ET fa Operational checks of automatic slack adjusters APPLIED AIR HAMBER O e Measure brake chamber stroke with the spring brake l CI T released and the air pressure no less than 100 psi sTEP 690 kPa Brake Chamber Stroke e Brake Chamber Stroke is the difference between the applied and the retracted position of the air chamber pushrod 02945a 08 06 Y53 6004 167 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 exceeds 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 depe
86. ar If they are not being used are they stored properly 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 Check that cab latch or hood hold downs are hooked 08 06 PART 6 DRIVER S CHECKLIST In Cab Checklist CAUTION To avoid injury while entering or A 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 CAB AND FRAME ACCESS of this manual for more information Adjust the seats 2 Fasten and adjust safety restraint belts See PART 5 SEAT AND RESTRAINT SYSTEMS or the Index under Restraint Systems 3 Sleeper Restraints Check and inspect condition See PART 5 SEAT AND RESTRAINT SYSTEMS or the Index under Restraint Systems 08 06 Y53 6004 SAFE VEHICLE OPERATION 4 Adjust the steering column 5 Check mirror adjustment 6 Operate air powered devices to
87. arking brake 113 R Remote Keyless Entry 7 Restraint Systems 73 Inspection 80 Komfort Lok Feature 76 Shoulder Belt 74 Sleeper Bunk Restraints 78 Tether Belts 79 S Safe vehicle operation 84 Safety stands 130 Seat 73 Servicing Specific Systems 164 Air Intake System 196 08 06 Air System 178 Anti lock Braking System ABS 198 Brake Adjustment 164 Cab Heater Air Conditioner 200 Electrical 184 Engine Accessories 195 Engine Cooling System 181 Fasteners 193 Steering System 191 Tires Wheels And Rims 168 Transmission And Drive Train 180 Shifting gears 127 128 Standard Capscrew Torque Specifications 193 Starting and Operating 88 Anti Lock Braking System 103 Automatic And Automated Transmissions 99 Auxiliary Transmission 100 Bobtail Brake Proportioning System 111 Brake Safety and Emergency 112 Clutch Operation 93 Driving Bobtail or with an Unloaded Trailer 120 Driving With Deflated Air Springs 125 Dual Range Two Speed Axles 97 Idling the Engine 92 Interaxle Differential 95 Overheated Brakes 112 Parking Brakes and Their Use 113 Retarders 100 119 221 Setting Ride Height 122 Shifting The Transmission 93 Spring Brakes 115 Starting Procedure Cold Temperature 89 Normal Temperature 88 Stopping The Engine 120 Trailer Air Supply Valve 115 T Tachometer 127 Towing 100 Transmission lubrication 156 U Units of Measure 33 222 V Vehicle driving 84 Vehicle Identification
88. arnings A red warning is active A An amber warning is active d Cruise Control active e Clock alarm bell Refer to Warning Light Indicator Symbols on page 19 for information on each symbol 17 INSTRUMENTS AND CONTROLS Instrument System Self Test When the ignition switch is turned on the instrumentation system will undergo a Self Test This test will verify the operation of the gauges and warnings During the Instrumentation System Self Test three screens will sequentially display warning icons approxi mately 3 seconds each screen on the Information Dis play These are First OO a ELORE A a as fal amp Third Refer to Warning Light Indicator Symbols on page 19 for information on each symbol Second 18 Y53 6004 PART 4 CONTROLS AND DISPLAYS Completing this sequence will indicate a successful Self Test Have your instrumentation system checked by a qualitfied service technician if does not successfully com plete Audible Alarm The audible alarm will sound during the Instrumentation System Self Test The audible alarm will also sound in conjunction with most warning lights These events include but are not limited to headlight on fifth wheel stop engine primary secondary air and driver door open warnings Optional Lights Additional lights may be operational depending on individ ual vehicle specifications These will be
89. ate a tire that has been run flat or is seriously low on air without first removing the tire from the rim and inspecting for damage e Follow OSHA regulations per section 1910 177 e Do not exceed the speed rating of tires Exceeding the speed rating may result in sud den tire failure and loss of vehicle control Follow all warnings and cautions contained within the tire and wheel manufacturers litera ture e Only properly trained personnel should ser vice tire and rim assemblies 175 TIRES WHEELS AND RIMS 02951 Crisscross Sequence For Demountable Rims PART 8 MAINTENANCE AND SERVICE CAP NUT TORQUE SPECIFICATIONS R12 01 PHP 10 Budd Uni Mount 10 WHD 8 M22 x 1 5 6H 450 500 610 680 Rim Clamp Nut Torque Di 80 90 110 120 Cast Spoke Wheel o Assembly Fena 160 185 220 250 3 4 Dia 225 245 305 335 CAP NUT TORQUE SPECIFICATIONS R12 01 TORQUES FOR INNER amp WHEEL AND NUT OUTER CAP NUTS CONFIGURATION STUD SIZE Lb Ft N m Stud Piloted Disc 3 4 16 Inner Wheels 1 1 8 16 Outer 430 500 610 680 15 16 12 Inner Heavy Duty Stud Piloted Disc Wheels 1 5 16 12 750 900 1025 1225 Outer 176 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE Vehicle Loading WARNING AN e The components of your vehicle are designed to provide satisfactory service if the vehicle is not loaded in excess of ei
90. ates the need for a wet tank and check valves in the dry tanks H son to replace a desiccant cartridge oil stained desiccant can function adequately 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 cocks 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 NOTE A small amount of oil in the system may be normal and should not by itself be considered rea 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 180 Y53 6004 PART 8 MAINTENANCE AND SERVICE 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 of moisture is normal and should not be considered as an indication that the dryer is not performing properly An outside air source may have been used to charge the air system in which case this air did not pass through the drying bed Transmission And Drive Train Clutch Adjustment Clutch pedal free t
91. aton 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 LUBRICANT SPECIFICATIONS On High Maximum oe Type of Highway way Change Lubricant Mi km Interval Severe Ser vice Mi km Maximum Change Interval Eaton Approved 350 000 Synthetic in 560 000 axle with extended drain interval option Wheel Bearing Lubrication Oil lubricated Driven Hubs Use hypoid oil A P 1 GL 5 SAE 80W 90 or equivalent A minimum of 1 quart 921 ml of oil is required for proper Newt On High Maximum Priel Maximum lubrication of each drive hub Add oil through the filler hole Lubricant Pipe paid Severe Ser re in the hub if none add oil through the differential filler PEE j SEREM pice mMi km 9e hole Note Remember to replace vent plug or threaded Mineral Based 120 000 Yearly 60 000 Yearly filler plug when done Allow time for the oil to seep 192 000 96 000 through the bearings when initially filling a hub Maintain Eaton Approved 240 000 2 Years 120 000 Yearly the differential oil level by adding oil until its surface is Synthetic 384 000 192 000 even with the bottom of the filler hole see page 155 08 06 Y53 6004 161 LUBRICANT SPECIFICATIONS Oil lubricated Nondriven Hubs Use CD50 synthetic transmi
92. be lower than that of the discharged battery Use of batteries of different voltage or substantially different capacity rating may cause an explosion To avoid serious personal injury and damage to the vehicle heed all warnings and instruc tions of the jumper cable manufacturer The jumper cables must be long enough so that the vehicles do not touch e 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 dam age the alternator or cause serious damage to both vehicles or yourself 08 06 PART 8 MAINTENANCE AND SERVICE e 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 could also cause serious damage to both vehi CAUTION Departures from these procedures cles Improper use of a booster battery to start a vehicle may cause an explosion To Jump Start Your Vehicle 1 2 08 06 Wear eye protection and remove rings metal watch bands and any other metal jewelry Set the 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 electri
93. cal 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 6004 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 with a cloth if no water is available and your fluid is low j WARNING If you do not cover the filler open 4 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 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 cables make sure they do not get caught in any moving
94. cally or resume the wiper s setting speed To activate the wipers for one swipe without activating the washer mist function push the turn signal lever in towards the steering column and release in less than 0 5 seconds The wipers will perform a single swipe and then resume the wiper s setting speed 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 A e Do not use antifreeze or engine coolant in the windshield washer reservoir damage to seals and other components will result j WARNING Do not drive with worn or dirty e If the electric pump is operated for a long period more than 15 seconds with a dry res ervoir the pump motor may be damaged Y53 6004 47 STEERING COLUMN MOUNTED CONTROLS Check the windshield washing fluid level daily If neces sary fill to top Clean all inside and outside windows regularly Use an alcohol based cleaning solution and wipe dry with either a lint free or a chamois cloth Avoid running the wiper blades over a dry windshield to prevent scratching the glass Spray on washer fluid first A scratched windshield will reduce visibility Electric Horn Your Peterbilt has an electric horn To operate press on the horn symbol near the center of the steering wheel 48 Y5
95. cation X tightness abrasion damage and leaks repair or replace as required Fuel tank breathers Check for proper function clean the drain hoses X Fuel tank straps Check the strap tightness tighten to proper torque value as X required Aluminum tank 30 Lb ft 41 N m Cylindrical Steel tank 8 Lb ft 11 N m Fuel tank steps Check for snug fit of side plates against tank and tank straps X Check for damaged or broken steps missing bolts and missing grommet between tank and side plate Replace missing or damaged parts and adjust for fit as required 147 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Recommended SYSTEM COMPONENT MAINTENANCE TASK Cee IJ A B C DIE Driveshafts Models SPL 90 slip member Lubricate xI Xx amp U joints Model SPL 100 slip member Lubricate X amp U joints Models SPL 140 140HD Lubricate xX 170 170HD 250 250HD slip members amp U joints Models SPL 140XL 170XL Lubricate 350 000 miles joints ON HIGHWAY amp LINE HAUL every 3 years Models SPL 140XL 170XL Lubricate X 250XL slip members and U joints OFF HIGHWAY amp CITY 08 06 Y53 6004 148 PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Recommended SYSTEM COMPONENT MAINTENANCE TASK P interval I A B C DIE Battery Battery cables ON Check the condition of the cable
96. cement of the seat belt system 81 INSPECTION OF THE RESTRAINT SYSTEM Web cut or frayed Q a Web cut or frayed at 4 or extremely worn con D loop web guide at latch area N Buckle casting PART 5 SEAT AND RESTRAINT SYSTEMS The D loop web guide is the area where almost con stant movement of the seat belt webbing occurs because of relative movement between the seat and the cab Check the Komfort Latch for cracks or possible damage and that it works properly Check the buckle and latch for proper operation and to determine if the latch plate is worn deformed or damaged 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 broken i j WARNING Failure to adjust tether belts prop Cre 03004A 6 82 Y53 6004 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 ins
97. circulate lubricants After Engine Warmup 1 Check automatic transmission oil if equipped NOTE The above items should be checked daily i 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 87 NORMAL TEMPERATURE STARTING PROCEDURE PART 7 STARTING amp OPERATING THE VEHICLE PART 7 STARTING amp OPERATING THE VEHICLE Since each vehicle is custom equipped all engine opera tion 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 start ing 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 4 Turn the key switch to ON 88 Y53 6004 CAUTION Never operate the starter motor A while the engine is running The starter and flywheel gears could c
98. cknut 5 8 Inch 130 163 176 221 Hardened Washer M12 65 85 89 115 M16 155 195 210 264 M20 315 385 427 523 use only metric grade 10 9 bolts of the proper CAUTION When installing bolts on the frame length Standard Capscrew Torque Specifications e Failure to maintain the specified torque val SAE Grade ues or to replace worn parts can cause com Number 5 8 ponent system failure possibly resulting in an injury accident Improperly tightened Capscrew Torque Torque loose suspension U bolts can lead to Body Size unsafe vehicle conditions including hard Me Lb ft N m Lb ft N m Steering axle misalignment spring breakage treet or abnormal tire wear 1 4 20 6 9 8 12 9 12 12 16 1 4 28 7 10 9 5 14 10 14 14 19 Y53 6004 193 FASTENERS PART 8 MAINTENANCE AND SERVICE SAE Grade SAE Grade 5 Number Number 5 16 18 13 18 18 24 18 25 24 34 7 8 14 341 486 462 659 482 589 654 799 5 16 24 14 20 19 27 20 28 27 38 1 8 464 662 629 898 656 935 889 1268 3 8 16 22 32 30 43 31 44 42 60 1 12 508 724 689 982 718 1023 973 1386 3 8 24 25 40 34 54 35 50 47 68 The torque values in the previous tables are based on the 7116 14 35 50 47 68 50 71 68 96 use of clean and dry threads 7 16 20 39 56 53 76 56 80 76 108 Frame Fasteners 1 2 13 54 7
99. coloration due to UV exposure abrasion to the seat belt webbing or damage to the buckle latch plate retractor hardware or any other obvious problem should be replaced immediately regardless of mileage WARNING It is important to remember that AN 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 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 08 06 Y53 6004 INSPECTION OF THE RESTRAINT SYSTEM 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 ical places where the web will experience cutting or abrasion Cuts fraying or excessive wear would indi cate the need for repla
100. connector and all other electronic control seals i l A units e Manifold With the engine operating check for leaking Never detach the ECU connector with the ignition manifold or flange gaskets turned on 198 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE e Do not attempt to repair ABS ASR ATC electrical cables that are outside the vehicle Replace faulty cables as an assembly e 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 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 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 08 06 Y
101. 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 110 Y53 6004 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 08 06 PART 7 STARTING amp OPERATING THE 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 switch l Rca D O 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 wheel 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 08 06 Y53 6004 ANTI LOCK BRAK
102. d 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 218 Y53 6004 08 06 A Anti lock brakes 104 Appearance 203 Appliances in the Cab 71 B Battery compartment cover 190 electrolyte 185 recharging 185 slow battery charging 186 Belts seat 73 Brake operation 103 Brake system Electronic Stability Control 106 truck amp tractor 104 C Cap Nut Torque Specifications 176 Cleaning the vehicle 203 Consumer Information 216 Controls Air Horn 48 Air Suspension Deflate Switch Dump Valve 53 Brakesaver 59 Cruise Control Switch 55 Dome Light Switch 53 Electric Horn 48 Engine Fan Switch 54 08 06 Fifth Wheel Lock Slider Adjustment Switch 62 Fog Lights Switch 53 Hazard Flasher 50 Headlamps 51 Heater Air Conditioning Controls 64 ID and Clearance Lights Switch 52 Interaxle Differential Lock Switch 61 Jacobs Engine Brake or Cummins C Brake Switch 60 Mirror Heat Switch 57 Panel Light Dimmer 52 Parking Brake Valve and Trailer Air Supply Valve 63 Power Door Lock Switch 58 Power Mirror Switch 55 Power Window Switch 58 Tilt Telescoping Steering Column 49 Trailer Brake Hand Valve 48 Turn Signal and Indicator Lights 45 Two Speed Rear Axle Range Switch 62 VARASHIELD Wind Deflector Switch 63 Windshield Wipers and Washers 46 Cooling system coolant level 183 extended life coolant
103. ding traffic and road conditions H 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 272 DRIVING TIPS AND TECHNIQUES e If the engine rom 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 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
104. 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 infor mation about regulations governing transportation across state lines And various agencies in state governments 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 j WARNING When you see this symbol amp word the message that fol lows is especially vital This signals something that can 08 06 Y53 6004 WARNINGS cause serious injury or death This message will tell you what the hazard is what can happen if you don t heed the warning and how to avoid it 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
105. e chocked front and rear and 4 the engine cannot be started Remove the ignition key Never start or let the engine run in an enclosed unventilated area Exhaust fumes from the engine contain carbon monoxide a colorless and odorless gas Carbon monoxide can be fatal if inhaled an 18 inch 46 cm long 4x4 PART 8 MAINTENANCE AND SERVICE i NOTE Suitable wheel chocks are at a minimum PREVENTIVE MAINTENANCE PM INTERVALS A B C D E At the first 15 000 mi 24 000 km or at the first PM 15 000 mi 24 000 km Monthly 30 000 mi 48 000 km 60 000 mi 96 000 km 6 months 120 000 mi 192 000 km Annu ally 240 000 mi 384 000 km Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE NOTES il e Where questions or discrepancies develop il between these recommendations and component supplier recommendations consult the supplier for specific recommendations e Maintenance requirements of specific voca tional configurations will dictate whether the inter vals used are determined based on mileage time in service hours operating etc e These maintenance practices and intervals are intended as additional requirements and are not to replace in whole or in part the pretrip inspec tion 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 o
106. e engine brake manufacturer s owner s manual that is included with your vehicle Interaxle Differential Lock Switch 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 UNLOCK the differential The guard over this switch pre vents you from accidentally activating the lock fi AS C Z Wy SHIFT AT ANY SPEED EXCEPT IF A WHEEL IS SPINNING 61 DASH AND DOOR MOUNTED FEATURES A See Interaxle Differential on page 95 for more informa tion on using your interaxle differential Two Speed Rear Axle Range Switch WARNING Placing the differential lock in the 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 s Q RANGE SELECTOR If your vehicle is equipped with a two speed rear axle you can select the axle range by the dash mounted switch shown above The low range provides maximum torque for operating off highway The high range is a faster ratio for highway speeds 62 Y53 6004 PART 4 CONTROLS AND DISPLAYS For information on how to operate your two speed rear axle properly and safely see Dual Range Two Speed Axles on page 97 Fifth Wheel Lock Slider Adjustment Switch s oo FIFTH WHEEL
107. e job safely and correctly Maintenance Manuals f 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 i Os Y53 6004 PART 1 INTRODUCTION 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 WARNING Modifying your vehicle can make it AN 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 Operator s 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 supply them Your new Peterbilt 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 08 06 PART 1 INTRODUCTION trucking is a local truck
108. ear 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 94 Y53 6004 PART 7 STARTING amp OPERATING THE VEHICLE sary wear of your clutch release bearing And it is less tir ing for you too 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 directly 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 08 06 PART 7 STARTING amp OPERATING THE VEHICLE can roll enough to allow the teeth to line up properly and complete the shift CAUTION Be careful not to apply the clutch A brake while the ve
109. eat will increase the outside air tempera ture displayed while the vehicle is stationary 57 DASH AND DOOR MOUNTED FEATURES Power Window Switch PART 4 CONTROLS AND DISPLAYS Power Door Lock Switch Driver Window Passenger Sets a es Window Switch Your vehicle is probably equipped with power windows Power window rocker switches are located on the door pads a switch for the passenger window is also on the driver side door pad as shown above To open or close a window depress the switch for that window at the end that displays a downward or upward directed arrow respec tively in the window symbol on the switch face Release the switch to stop window movement 58 Y53 6004 Your vehicle is probably equipped with power door locks Power door lock rocker switches are located on the door pads switch on the driver side door pad is shown above To lock or unlock both cab doors as well as a sleeper door depress any door lock switch at the end that displays a closed or open padlock symbol respectively on the switch face 08 06 PART 4 CONTROLS AND DISPLAYS DASH AND DOOR MOUNTED FEATURES Manual and Automatic Control Switch see next illustration How much braking you get depends on how much you move the lever Cc O With the switch in the AUTOMATIC position the Brake Saver will be fully applied automatically when the operator has the vehicle in gear and ta
110. ecked by a Peterbilt dealer if the ABS Warning Lamp stays on for more than 3 seconds IIluminates during normal operating condi tions to indicate a problem with the ABS Sys tem See ABS Warning Lamps on page 104 for more information IIluminates when a problem exists with the optional Wheel Spin Control feature See Advanced ABS with Stability Control on page 106 more information 08 06 PART 4 CONTROLS AND DISPLAYS 9 OO 08 06 6 Anti Lock Brake System ABS Trailer IIluminates during the Instrumentation Sys tem Self Test and the tractor truck is con nected with a ABS equipped trailer IIluminates during normal operating condi tions to indicate a problem with the Trailer ABS System This should be checked by a Peterbilt dealer as soon as possible See ABS Warning Lamps on page 104 for more information NOTE e Tractors Trucks and trailers built after 3 1 01 must be able to turn on an In Cab Trailer ABS Warning Lamp per U S FMVSS121 The industry chose Power Line Communication PLC as the standard method to turn it on See Trailer ABS Warning Lamp on page 104 for more information Y53 6004 INSTRUMENTS AND CONTROLS e On trailers built prior to 3 1 01 verify trailer ABS system status via the required external warning lamp mounted on the trailer The indicator lamp on the trailer should be yellow and identified with the letters ABS 7 Axle Inter Axle Differential
111. ector switch will ONLY allow selection of the neutral and right mir ror switch positions 08 06 PART 4 CONTROLS AND DISPLAYS 2 Depress the mirror directional control pad towards the arrows pointing left or right to adjust the mirror in out NOTES i e Because the Moto mirrors have only 2 way adjustment the mirror directional control pad is also restricted in its movement to left or right ONLY e After mirror adjustments have been completed return the mirror selector switch back to the cen ter neutral position to prevent unintentional adjustments to the mirrors Mirror Heat Switch Mirror Heat Indicator Light Mirror Heat p Switch Button Your vehicle may be equipped with optional heated mirrors Mirror heat is controlled by the mirror heat switch button which is part of the mirror switch module located on the driver side door pad Motorized mirrors with mirror heat 08 06 Y53 6004 DASH AND DOOR MOUNTED FEATURES have an automatic 15 minute time out feature where the mirror heat only module is automatically deactivated To defrost the mirrors in cold weather depress the mirror heat switch button and release The mirror heat symbol in the button will illuminate to indicate the mirror heat func tion has been activated Pressing and releasing the button again turns the mirror heat and the indicator light Off H NOTE The effects of direct sunlight or the use of mirror h
112. ed axles If you suspect you do have your rear axle alignment checked and adjusted by an authorized dealership 192 Y53 6004 PART 8 MAINTENANCE AND SERVICE U Bolt Tension for Front and Rear Axles 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 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 08 06 PART 8 MAINTENANCE AND SERVICE A 08 06 WARNING U bolts that are too loose can 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 FASTENERS Fasteners Frame Fastener Torque Specifications Fastener Fastener Torque Type Size Lb ft N m 1 2 Inch 86 108 117 147 Bolt Lo
113. eeded Speedometer The speedometer indicates the vehicle speed in miles per hour mph and in kilometers per hour km h The speed ometer also includes an odometer trip meter and trip reset button 34 Y53 6004 PART 4 CONTROLS AND DISPLAYS Trip Reset Button The LCD display in the lower part of the speedometer contains the odometer and trip meter The odometer displays the total distance your vehicle has traveled It will display in miles on an English speedometer or in kilometers on a metric speedometer The maximum 08 06 PART 4 CONTROLS AND DISPLAYS distance that can be shown on the odometer is 1 999 999 before it rolls over to zero The trip odometer displays how far the vehicle has gone on a particular trip The trip odometer will display in miles on an English speedometer or in kilometers on a metric speedometer in one tenth divisions The maximum dis tance that can be shown on the trip odometer is 9999 9 before it rolls over to zero To reset the trip odometer press and hold the trip reset button on the speedometer The numbers will reset to 0 and begin to count new miles km traveled This also resets the trip values in the Driver Information Display The trip reset button also toggles all displays between English and Metric See page 36 il NOTE The Odometer Trip Meter comes on when the door is opened or the key is in the accessory or igni
114. el wrench must be smooth Burrs on the end of the wrench can tear grooves in the disc especially on alumi num wheels These grooves may lead to cracks in the disc and can cause it to fail 02950 Crisscross Sequence For Disc Wheels 08 06 PART 8 MAINTENANCE AND SERVICE Demountable Rims To check the torque on demountable rims follow the criss cross sequence shown See the Specifications chart for proper torque specification WARNING AN e Use only components marketed by PACCAR Parts Use of non original equipment could cause wheel breakage and wheel separation from vehicle Each mounting system is engi neered only for use with its correct mating part Be sure that properly matched compo nents are used for each type of mounting The comparison chart on page 142 illustrates the differences between parts used in hub piloted mount and ball seat mount applica tions Only PACCAR Parts supplied hub piloted or ball seat mounted wheels may be used on this vehicle 08 06 Y53 6004 TIRES WHEELS AND RIMS e If you are not fully qualified and not equipped with the proper tools and equip ment 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 wheels should be serviced only by trained personnel using proper equipment Do not reinfl
115. en tire pressures need to be checked Tire Pressure Monitoring System is an option 08 06 PART 4 CONTROLS AND DISPLAYS 08 06 33 Transmission Auxiliary IIluminates to indicate auxiliary transmission is in neutral 34 Transmission Check Iluminates when transmission has recorded a fault code This icon may also appear in the Transmission Display menu of the Driver Information Display unit see item G page 31 If the user is in this display menu the icon does not indicate a fault code 35 Transmission Do Not Shift Iluminates with automatic transmissions equipped with Don t Shift output 36 Transmission Oil Filter IIluminates when service is required Allison transmissions only Y53 6004 lt 4 gt INSTRUMENTS AND CONTROLS 37 Transmission Oil Temperature High llluminates when transmission lubricant tem perature is too high CAUTION This should be considered an emergency You should stop the vehicle as safely as possible and turn OFF the ignition The vehicle must be serviced and the prob lem corrected before driving again Failure to do so may cause severe transmission dam age 38 Turn Signal Left Blinks when the left turn signal or the hazard light function is operating 39 Turn Signal Right Blinks when the right turn signal or the haz ard light function is operating zofa DRIVER INFORMATION DISPLAY Driver Information Display Information Display
116. er switch must be ON for the controls two for vehicles without air conditioning see sleeper controls to function illustration that follows To heat the cab select the desired air mode and set e A rotary knob A in the left portion controlling the the temperature knob to hot the red position on the blower speed with four settings control and the blower to whatever speed makes you A rotary knob B in the right portion controlling the air most comfortable temperature e A rocker switch or a push button switch C to engage the air conditioner compressor vehicles equipped with air conditioning 08 06 Y53 6004 67 68 DASH AND DOOR MOUNTED FEATURES WARNING Do not drive with visibility reduced by fog condensation or frost on the wind shield Your view may be obscured which could result in an injury accident For clear vis ibility and safe driving it is extremely important for you to follow the instructions pertaining to the function and use of the ventilation heating and defogging defrosting system If in doubt consult your dealer Maximum heating output and fast defrosting can be obtained only after the engine has reached operating temperature A CAUTION During extreme cold weather do not blow hot defroster air onto cold windshields This could crack the glass Turn the air flow con trol lever to Defrost and adjust the fan speed accordingly while the engine warms If the engine is already warm
117. er 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 08 06 PART 7 STARTING amp OPERATING THE VEHICLE 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 3 Continue the engine warmup until the coolant temper tain 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 j WARNING Exhaust fumes from the engine con CAUTION Never idle your vehicle for pro il 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 08 06 Y53 6004 ENGINE WARMUP CAUTION The use of a winterfront can result in excessive engine coolant
118. erature on page 36 for another method to change units 4 Rotate the MCS knob to change the minutes To Set Language Press the MCS 1 When in the Settings Menu scroll through the 5 Rotate the MCS to toggle AM PM Press the list of menu items to Language Press the MCS MCS 6 Rotate the MCS to select Exit Press the MCS to 2 Rotate the MCS to display either English Span exit the settings function ish or French Press the MCS knob to select the To Turn Alarm ON OFF desredianguaga 1 When in the Settings Menu scroll through the list of menu items to Alarm Press the MCS 2 Press the MCS to turn the alarm ON or OFF To Set Units of Measure 08 06 Y53 6004 2335 STANDARD GAUGES Standard 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 under the name of the gauge or function you want to know more about WARNING Do not ignore a warning light or AN audbile alarm These signals tell you some thing 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 Some gauges will display a red LED warning light with some accompanied by an audible alarm whenever the limits of the function being displayed are exc
119. ess along the entire front edge of the seal until the glass is free 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 e Wash and protect painted and metal surfaces and also weatherstripping as outlined in the preceding Appearance information e 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 184 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 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE Drive the vehicle a short distance to allow lubri cants to circulate in the transmission and axles 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 time it left Peterbilt s con tr
120. evel Idle the engine until the operating temperature stabi lizes Fill the surge tank as necessary to raise the coolant level to the MIN level Replace the surge tank fill cap 183 ELECTRICAL 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 Electrical the vehicle s electrical system or power distribu tion box All electrical repairs should be per formed by a qualified service technician Improper repair or modifications will void your warranty and or cause serious damage to your vehicle Battery Care A CAUTION Do not modify or improperly repair 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 184 Y53 6004 PART 8 MAINTENANCE AND SERVICE e Undercharge Your voltage regulator may be malfunc tioning or is improperly adjusted the drive belt is slip ping or your vehicle has undergone long periods of standing idle or short distance driving The
121. f 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 Person In Crash Unbelted 73 SEAT BELTS AND THEIR PROPER USE PART 5 SEAT AND RESTRAINT SYSTEMS Lap Shoulder Belt The combination lap shoulder belt is equipped with a lock ing mechanism The system adjusts automatically to a person s size and movements as long as the pull on the belt is slow Hard braking or a collision locks the belt The belt will also lock when driving up or down a steep hill or in a sharp curve To fasten the belt 1 Grasp the belt tongue and pull the belt in a continuous slow motion across your chest and lap 2 Insert the belt tongue into the buckle on the inboard side of the seat 3 Push down until the tongue locks securely with an audible click Pull on the belt to check for proper fas tening e Pull the shoulder section to make sure the belt fits snugly across the chest e The shoulder belt must be positioned over the shoul der it must never rest against the neck Belts should fit snugly across the pelvis and chest Make sure any slack is wound up on the retractor 74 Y53 6004 To unfasten the belt 1 Push in the release button on the buckle The belt will spring out of the buckle Unfastening a belt 2 To release a locked belt lean back to take the body pressure off of the belt 3 To store a lap
122. ff highway or in very heavy duty applications such as mining logging or earth mov ing you will need to perform maintenance checks and ser vices more frequently The charts on the following pages show the maintenance intervals for recommended main tenance practices 08 06 Y53 6004 PREVENTIVE MAINTENANCE SCHEDULE NOTES e Engine lubricating oil change intervals aren t listed here Refer to your engine s operating man ual for recommendations For specific information on maintenance procedures consult your vehicle maintenance manual e The initial fill of drive axle lubricant must be changed before the end of the first scheduled maintenance interval Refer to Oil Changes on page 159 before you put a new vehicle into ser vice e The initial fill of lubricant in manual transmis sions must be changed before the end of the first maintenance interval See Fuller Transmission Lubrication on page 156 for specific information e If your vehicle is equipped with an automatic transmission consult the owner s manual for it that came with your vehicle to obtain lubricant check and change intervals 131 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Recommended SYSTEM COMPONENT MAINTENANCE TASK peeve Al B C D E Frame Fifth Wheel Check the kingpin lock and plate for wear and function lubricate X NLGI 2 grease Frame
123. ficient oil pressure will cause serious CAUTION Continuing to operate your vehicle A engine damage e If your oil pressure fails to rise within 10 seconds after your engine starts stop the engine and determine the cause 08 06 Y53 6004 STANDARD GAUGES 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 the oil level Add oil if necessary If the problem persists contact an authorized service cen ter Check the engine manufacturer s manual for the correct oil pressure ranges for your engine Water Temperature Gauge The water temperature gauge shows the temperature of the engine coolant Under normal operating conditions the 37 STANDARD GAUGES water temperature gauge should register between 165 and 205 F 74 and 90 C Under certain conditions somewhat higher temperatures may be acceptable But the maximum allowable temperature is 210 F 99 C with the cooling system pressurized except for certain special engines Check your engine manual to be sure Engine Overheating WARNING Do not remove the radiator fill cap AN while the engine is hot Scalding steam and fluid under pressure may escape and cause serious personal injuries You could be badly burned Wait until the coolant temperature i
124. ge 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 172 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 169 TIRES WHEELS AND RIMS 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 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 j WARNING e 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 recommended size and type of tires 170 Y53 6004 PART 8 MAINTENANCE AND SERVICE e 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 reinforce ment repaired
125. gine check for leaks around the filter Steering Guidelines For Checking A Steering System ing properly can cause an accident You could lose control of your vehicle if the steering is not in good order For driving safety give your steering gear and components the following visual checks frequently Check them espe cially after trips over rough roads j WARNING A steering system that is not work Check tie rod for straightness Check draglink clamp for looseness or interference Check ball joints and steering U joints for looseness Check steering wheel for excessive freeplay Check the simplest probable causes first Unequal tire pressures 191 STEERING Loose cap nuts Bent tie rod Loose wheel bearing 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 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 front or rear axle tires you may have misalign
126. gine 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 comply with 2007 EPA emission standards Consult the engine manufacturer s manual for changed lubrication and maintenance requirements WARNING Exhaust fumes from the engine con AN tain 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 monox ide into the cab is also possible from other vehi cles nearby Failure to properly maintain your vehicle could cause carbon monoxide to enter the cab sleeper and causes serious illness 153 LUBRICANT SPECIFICATIONS A il 154 CAUTION Never idle your vehicle for prolonged periods of time if you sense that exhaust fumes are entering the cab or sleeper Investigate the PART 8 MAINTENANCE AND SERVICE Master Lubrication Index Lubricant Symbol Key DEXRON III MERCON approved automatic transmission fluid Ball Bearing grease Engine oil for mild to moderate requirements Engine oil for severe requirements MIL L 2104B MIL L 45199B w 1 85 max sulfated ash content Engine oil meeting API Five engine test sequence SAE50W synthetic transmission fluid Engine oil meeting severe duty service require
127. h Stability Control A Real World Example Of How The RSP This vehicle may be equipped with an optional Electronic System Operates Stability Program ESP ESP is a feature for ABS Excessive speed for road equipped vehicles that reduces the risk of rollovers jack conditions creates forces knifing and other loss of control ESP features include Roll that exceed the threshold at Stability Program RSP and Yaw Control which a vehicle is likely to 7 9 p rollover on a higher friction During operation the ECU of the Bendix Advanced ABS surface 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 ues are approached the system will intervene to assist the driver Roll Stability Program The system automatically Bendix RSP an element of the overall ESP system reduces engine torque and addresses rollover conditions In the case of a potential applies the service brakes based on the projected rollover roll event the ECU will override the throttle and quickly risk to reduce the vehicle apply brake pressure at all wheel ends to slow the vehicle speed thereby reducing the combination The level of braking application duringan tendency to roll over tL RSP event will be proportional to roll risk RSP Exa
128. h 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 08 06 TIRES WHEELS AND RIMS 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 6004 Overinflated tires Too much air pressure reduces the tire tread contact area and results in rapid wear in the center of the tread 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 dama
129. hange and Inspection e Refer to your transmission manual furnished sepa rately for lubrication information e Refer to the Allison Transmission manual for servicing information Meritor Axle Lubrication H Under Meritor s Advanced Lube Rear Drive Axle program the axles listed below are exempt from an initial lubricant change NOTE Axles utilized in 100 off highway use are not eligible for Meritor s Advanced Lube Rear Drive Axle program due to excessive heat and aeration from the churning AVAILABLE ADVANCED LUBE AXLES action of the gears Early breakdown of the oil will result in RS bla RS 23 180 RT 40 145 RT 44 145P heavy varnish and sludge deposits that plug up oil ports RS 19 145 RS 26 180 RT 40 145P RT 46 160 and build up on the splines and bearings Overflow of oil 08 06 Y53 6004 159 LUBRICANT SPECIFICATIONS PART 8 MAINTENANCE AND SERVICE AVAILABLE ADVANCED LUBE AXLES RS 21 145 RS 30 180 SQ 100A RT 46 160P 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 Refer to the Meritor Field Maintenance Manual for a particular axle for lubricant specifications See your Peterbilt dealer for Meritor approved lubri cant brands Refer to the following chart for lubricant change inter
130. he driver when the out side temperate approaches freezing 32 F or 0 C by dis playing a snowflake symbol The symbol will turn on when the temperature drops below 34 F or 11 C and flash for the first 3 seconds then stay on until the temperature goes above 37 F or 28 C 36 Y53 6004 PART 4 CONTROLS AND DISPLAYS The temperature can display using Standard or Metric units Press the trip reset button on the Speedometer 4 times within 4 seconds This will also change the units shown by the Driver Information Display Refer to To Set Units of Measure on page 33 for another method to change units NOTE The OAT will come on when the door is i open and the key switch is in the accessory or ignition position The OAT display will turn off when the ignition switch is turned off NOTE The OAT uses a sensor located at the il bottom of the driver s side mirror assembly to measure outside air temperature only It is not capable of displaying the temperature of the road surface on either the temperature display or the snowflake icon NOTE The effects of direct sunlight or the use of il mirror heat will increase the outside air tempera ture displayed while the vehicle is stationary 08 06 PART 4 CONTROLS AND DISPLAYS Engine Oil Pressure Gauge It is important to maintain oil pressure within acceptable limits Your engine manual will give normal operating pres sures for your engine with insuf
131. hicle 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 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 08 06 Y53 6004 PUTTING THE VEHICLE IN MOTION Upshifts Let the engine and gears slowdown to the RPM required for the next gear Use the tachometer to determine optimum RPM for gear engagement 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
132. hold downs keep a hood from opening unexpectedly TE ee MOOG Torwar ensure no people or objects are in the way A hood could hurt someone in the way of its descent If the hood falls anyone under it could be injured Always ensure the hood hold open latch is engaged to keep the hood open any time anyone gets under the hood for CAUTION A hood not latched securely could A open during operation and cause vehicle damage Be sure to latch the hood securely j WARNING Before opening or closing a hood any reason Latched Uniatched 02961 Hood Tilt To open your hood unlock the hood hold downs by unlatching them Put one hand on the top of the hood 08 06 Y53 6004 11 HOOD TILT Hood Hold Open Device The hood is equipped with a hood hold open device In order for the hood hold open device to become engaged the vehicle hood must be fully open Once the vehicle hood is fully open the hold open latches will automatically engage and will need to be disengaged by the operator To disengage the latch for hood closure rotate the release lever fully forward A 12 Y53 6004 PART 3 GETTING TO YOUR ENGINE WARNING Ensure the hood is fully opened Failure to fully open the hood will prevent engagement of the hold open device causing possible seri ous bodily injury e Ensure the hold open device is engaged when underneath hood A closing hood can crush
133. iary Transmission If you have an auxiliary transmission see your transmis sion manufacturers manual for its proper operation If Your Vehicle Must Be Towed 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 08 06 PART 7 STARTING amp OPERATING THE VEHICLE the ground or remove the driveline and axle PUTTING THE VEHICLE IN MOTION A Remove the air line and firmly cap Air Line Remove to Install CAUTION Failure to lift the driving wheels off Shafts before towing the vehicle could seri ously damage your vehicle All lubricating and clutch application oil pressure is pro vided by an engine driven pump which does not work when the engine is stopped When 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 2 Cover open hubs when removing drive axle shafts Caging Bolt Caging Bolt Storage Location CAUTION Water dirt and other material can A 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 3 For vehicles with driver controlled main differentia
134. ight Dimmer 12 14 15 Hazard Flasher fe fe T T fe 11 15 Ne A io o Panel C 14 Y53 6004 08 06 PART 4 CONTROLS AND DISPLAYS YOUR INSTRUMENT PANEL Conventional RIGHT SIDE f ZN Peun 1 Oil Temperature g 3 2 Transmission Oil Temperature 3 Front Driver Oil Temperature 4 f 5 6 C 4 Brake Application Pressure 6 NF ON CO 9 5 Air Cleaner Restriction J 6 Rear Driver Oil Temperature ed 7 Air Suspension Deflate 10 8 Fifth Wheel Lock Panel B 9 Interaxle Differential Lock 10 Exhaust Regeneration Display 11 Engine Fan 1 12 18 14 15 12 Fuel Tank Selector 13 Engine Brake On Off F i 0 A i 14 Engine Brake Selector j v Sl m 15 Radio K D U LEA cot 16 HVAC Control Panel ia f i 7 s 17 Cruise Control Select 18 Cruise Control On Off 19 18 17 16 19 Menu Control Switch MCS 08 06 Y53 6004 15 INSTRUMENTS AND CONTROLS Instruments And Controls Menu Control Switch MCS The MCS is used to navigate the Driver Information Dis play unit The Menu Control Switch is located on the D Panel as shown in the illustration below Rotating the switch will scroll through the list Push the switch to enter The MCS has the following functions e Rotating the MSC Selecting display Setting values 16 Y53 6004 PART 4 CONTROLS AND DISPLAYS e Pushing the M
135. included in the Instrument System Self Test NOTE Some optional lights may illuminate even though your vehicle is not equipped with that par ticular feature 08 06 PART 4 CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS Warning Light Indicator Symbols Warning Light Indicator Symbols The following is a list of Warning Light Indicator Symbols rh Symbol Name Symbol Color Std Opt Page Reading left to right the table header identifies 1 Active Warnings Exclamation a 2 i e the Symbol Name Point the appearance of the Symbol 2 Active Warnings Number 1 wen S 22 e the Symbol Color when it is illuminated i 3 Active Warnings Triangle e whether the symbol is standard Std or optional Opt A Yellow 22 the Page Number reference for additional information 4 Alternator ea Symbols are listed by major component sections 5 Anti Lock Brake System Example Engine and then in alphabetical order ABS Yelow IS 6 Anti Lock Brake System ABS Trailer Yellow 23 7 Axle Inter Axle Differential AM Locked Tandem Axles x A wj e 23 ei 8 Clock Alarm Bell IN Yellow 23 9 Cruise Control Active o Yellow 24 08 06 Y53 6004 19 INSTRUMENTS AND CONTROLS Warning Light Indicator Symbols PART 4 CONTROLS AND DISPLAYS Warning Light Indicator Symbols
136. indexed cor rectly The notch in the gasket is to face forward on the RH side This places the weep slots at the bottom of the window opening see next illustra tion e There is a ridge on the bottom surface of the gasket see next illustration Install the glass out board of this ridge The polished satin finish on the glass which leaves a rounded eage rests against the edge of the ridge e The installation and removal will be easier by using water or soap as a lubricant on the edge of the glass Y53 6004 APPEARANCE ad 66 OUTBOARD pee 5 1 2 5 36 27 7 11 5 3 1 1 To install a window slide the glass from the rear of the door toward the removal slot until the forward edge of the glass is against the inside edge of the seal see next illustration arrow indicates forward Removal Slot b 207 APPEARANCE 2 When the forward edge of the glass reaches the for ward inside edge of the seal the glass should pivot outboard into the remaining seal see arrow in next illustration j 208 Press and slide the glass into the aft portion of the seal to seat it To remove an inner view window insert the glass stick into the removal slot then use the glass stick to push the glass as far aft as possible Use the glass stick to leverage the glass out of the seal PART 8 MAINTENANCE AND SERVICE 6 Continue this proc
137. interior luggage compartment is under the bunk in the Conventional 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 passenger possibly causing serious injury Secure loose objects Carry any heavy objects in the exterior luggage compartment and close it securely 08 06 PART 4 CONTROLS AND DISPLAYS Appliances in the Cab You may decide to equip your vehicle with a radio a refriger ator or other appliances and conveniences Be sure they are compatible with your truck s electrical system Secure them in the cab so they cannot fly loose in a sudden stop killed Secure any appliance such as a refrig erator or radio you add to your cab Peterbilt Navigation System WARNING In a sudden stop or collision a heavy object in your cab could strike you or anyone with you You could be injured or even Your vehicle may be equipped with a Peterbilt Navigation System This system is a Global Positioning Satellite GPS linked computer It receives input from multiple sources to locate your vehicle Read and understand the Supplemental Navigation System Owner s Manual and observe the Warnings Cautions and Notes that follow before using the system 08 06 A A A A Y53 6004 CAB FEATUR
138. ippery roads or loose gravel e 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 under steer handling characteristics This under steer condition will cause your vehicle to not turn as quickly and more steering effort will be required which can cause an injury acci dent 08 06 PART 7 STARTING amp OPERATING THE VEHICLE To reduce load on the drive train ease up on the throttle pedal whenever you shift into LOCK or UNLOCK Dual Range Two Speed Axles 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 will notice that it has a guard to protect you from activating it accidentally A c Q RANGE SELECTOR Range Selector 08 06 Y53 6004 PUTTING THE VEHICLE IN MOTION How to use your dual range axle 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 j WARNING Never shift the axle when
139. itions however you may need longer idling to be sure all parts of your engine are fully lubricated 92 PART 7 STARTING amp OPERATING THE VEHICLE 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 Con tinued unattended operation 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 Y53 6004 08 06 PART 7 STARTING amp OPERATING THE VEHICLE Putting The Vehicle In Motion This section discusses the clutch and transmission opera tion to get your Peterbilt underway
140. ive Maximum transmission temperature may vary depending upon the transmission and type of lubricant Check your transmission s owner s manual 08 06 Y53 6004 AAS OPTIONAL GAUGES Forward Drive Axle Temperature Gauge Rear Drive Axle Temperature Gauge These gauges indicate the temperature of the lubricant in your vehicle s axle s These temperatures will vary with the kind of load you are carrying and the driving condi tions you encounter Maximum axle temperature may vary depending upon the axle and type of lubricant Very high temperatures signal a need to have your axle s lubri cation checked A 44 Y53 6004 PART 4 CONTROLS AND DISPLAYS CAUTION Driving with very hot temperatures in your rear drive axles can cause serious damage to axle bearings and seals Have your axle lubri cation checked if you notice a sign of overheat ing 08 06 PART 4 CONTROLS AND DISPLAYS Steering Column Mounted Controls Turn Signal and Indicator Lights NOTE The ignition key must be turned to ON for i the signal switch to operate Your turn signal lever is mounted on the left side of the steer ing column below the steering wheel Green directional indi cator lights appear on the instrument panel To operate the signal move the lever in the direction of the turn Each time the turn indicator is activated the audbile alarm emits a short beep A STEERING COLUMN MOUNTED CONTR
141. kes his or her foot off the accelerator pedal With the switch in the ON position the BrakeSaver will be applied constantly regardless of whether the operator has the vehicle in gear or his or her foot off the accelerator Manual Control Lever This hand operated control lever provides modulated application of the BrakeSaver in the manual or ON mode 08 06 Y53 6004 59 DASH AND DOOR MOUNTED FEATURES PART 4 CONTROLS AND DISPLAYS A Control Air Pressure gauge and an Engine Oil Temper Jacobs Engine Brake or Cummins C Brake ature gauge are provided with the BrakeSaver Switch The ON OFF switch turns the system ON or OFF The second switch performs the progressive braking function that controls the amount of retarding 2 Mode and 3 Mode Systems 60 Y53 6004 08 06 PART 4 CONTROLS AND DISPLAYS e If you have the two mode system you can select HIGH or LOW e If you have the three mode system you can select low medium or high retarding In conventional models with Eaton transmissions the engine brake switch may be located on the shift control knob see illustration NO lt a WA 08 06 Y53 6004 DASH AND DOOR MOUNTED FEATURES 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 For more information on when and how to use the engine brake in your vehicle see th
142. l R amp O type API GL 1 80 Below 0 F 18 C Synthetic Engine Oil meeting MIL CD50 All L 2104D or MIL L 46152B API CD30 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 C Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE Oil Changes oil should not be intermixed because of possible incompatibility which could decrease the effec tiveness of the lubrication or cause component failure CAUTION When adding oil types and brands of 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 5000 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 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 LUBRICANT SPECIFICATIONS can also escape onto clutch or parking brakes When add ing oil do not mix different types of oil Allison Transmission Lubrication Lubrication C
143. l lock install the caging bolt before removing the axle shafts for towing Illustration of Driver Controlled Main Differential Lock A Remove the caging bolt from its storage hole B 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 will lock the differential by push ing a piston into a lock position 08 06 Y53 6004 101 PUTTING THE VEHICLE IN MOTION when towing vehicles with driver control main differential lock can result in damage by fail ing to lock internal components in position CAUTION Failure to install the caging bolt 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 ppossibly causing an accident and personal injury A operational brake system Additionally the rear CAUTION A recovered vehicle will have no axle spring brakes will probably be applied e 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 differ ential lock is firmly capped to prevent loss of air pressure from the recovery vehicle 102
144. l depend on the engine RPM Run the engine above idle and you will audibly notice the fan turning off If the fan clutch does not disen gage 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 196 Y53 6004 PART 8 MAINTENANCE AND SERVICE 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 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 on page 129 If your vehicle is equipped with an optional air inlet restriction indicator service the filter elements when the air inlet restriction indicator locks in the extreme Up position Paper elements require care and proper handling 08 06 PART 8 MAINTENANCE AND SE
145. l ensure that interior components remain in good condition for the life of the vehicle General Cleaning Guidelines A Y53 6004 WARNING Cleaning agents may contain hazardous agents Thoroughly read understand and fol low the manufacturer s instructions when using a cleaning agent to avoid possible per sonal injury and property damage e Handle cleaning agents carefully Keep them out of the reach of children Commercial 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 function of instruments and gauges 08 06 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 e 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 e Clean difficult stains such as oil grease and mustard as soon as possible The longer a stain goes untreated the more difficult it is to remove e Avoid application of conditioning products containing silicones or waxes to the top sur face of the dash panel This may cause glare that can be a driver distraction
146. l is about to lock during braking the ABS will automatically adjust air pressure to the brake cham bers on the appropriate wheel s to prevent wheel lock up The ABS is automatically turned on when the ignition switch is turned on 08 06 Y53 6004 WARNING e The brake system is a critical vehicle safety system For the safety of you and others around you have the vehicle submitted for periodic preventive maintenance checks as well as having any suspected problems imme diately checked by an Authorized Service Center Failure to properly maintain your brake system can lead to serious injury acci dents 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 103 ANTI LOCK BRAKING SYSTEM OPERATING INFORMATION WARNING Do not rely on an anti lock brake AN 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 may not function in an emergency You will still have conventional brakes but not anti lock brakes If any warning lamp indicates a prob lem have that ABS checked
147. lable 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 and use your service brakes only for stopping completely Operating this way will greatly prolong the life of your brakes 08 06 A Y53 6004 BRAKE SAFETY AND EMERGENCY WARNING e In an emergency the retarder might not stop you fast enough to prevent an accident 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 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 accident You could be badly hurt if you relied only on the retarder e Do not use the retarder when operating on road surfaces with poor traction such as wet icy or snow covered roads or gravel Retard ers can cause the wheels to skid on a slippery surface You could lose control of the vehicle if the wheels begin to skid
148. lash or jam severely damaging them NOTE Some starters are equipped with overcrank i protection Check the Engine Operation and Main tenance Manual for details 5 Turn the ignition key to the START position 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 two minutes before trying again If the engine still won t start after a couple of tries check the manual override shutdown valve and fuel lines for possible fuel starvation or air leaks Starting failure may mean fuel isn t reaching the injectors 6 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 08 06 PART 7 STARTING amp OPERATING THE VEHICLE COLD TEMPERATURE STARTING PROCEDURE pressure doesn t rise within a few seconds stop the Ether Metering Equipment engine Find out what is wrong before restarting the engine 7 Slowly engage release the clutch after the engine AN has started 8 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
149. ld 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 strips and lab oratory sample procedures ELC Extender Add ELC extender if necessary at the maintenance inter val under Cooling on page 144 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 182 Y53 6004 PART 8 MAINTENANCE AND SERVICE page 129 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 il Top off the cooling system when coolant does not rise
150. le for your vehicle Approaching the Vehicle 1 Check the overall appearance and condition Are win dows mirrors and lights clean and unobstructed 2 Check beneath the vehicle Are there signs of fuel oil or water leaks 3 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 SAFE VEHICLE OPERATION Checking Under the Hood or Cab With the engine stopped 1 9 Check the engine oil level top off as necessary Refer to your engine s operating manual for the type of oil to use Check the engine coolant level Top off as necessary with premixed coolant Refer to the instructions on page 183 for adding coolant to the proper level Check the condition of the engine belt s 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 off as necessary Check the power steering fluid reservoir top off as necessary Check the steering components pitman arm draglink power steering hoses etc Drain the fuel water separator Checking the Luggage Compartment Check the fire extinguisher charge and check the road emergency kit 08 06 Y53 6004 85 SAFE VEHICLE OPERATION Checking Outside the Vehicle 7 WARNIN
151. le trailer combinations known as doubles or triples the effectiveness of the ESP system may be greatly reduced 108 Y53 6004 08 06 PART 7 STARTING amp OPERATING THE VEHICLE ANTI LOCK BRAKING SYSTEM OPERATING INFORMATION ing doubles or triples with a vehicle equipped 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 j WARNING Exercise extreme care when tow Limitations Of Stability Systems The ESP stability system s effectiveness may be greatly If very rapidly winding steering inputs are inputted at high speeds 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 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
152. llustration on page 123 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 When at the correct ride height ensure that the height control valve lever is in the neutral position then install either the built in alignment pin or a 1 8 inch 3 mm dowel see page 123 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 vehicles with a dual valve system SETTING RIDE HEIGHT Driving With Deflated Air Springs 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 A 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 continue to operate in this condition You can get to a repair facility if you do the following 1 Remove the height control link connected to the axle 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 Y53 6004 pressure for continued operation 125 DRIVING TIPS AND TECHNIQUES
153. ments for direct injection turoocharged engines Engine oil for Cummins EGR engines Multipurpose chassis grease Extreme Pressure Lubricant Straight mineral gear lubricant Hypoid Gear Oil A P I GL 5 SAE 80W 90 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 ATF slightly open Failure to repair the source of the exhaust fumes may lead to personal harm BB NOTES CB Keep the engine exhaust system and the vehi CC CD cle s cab sleeper ventilation system properly maintained It is recommended that the vehicle s exhaust system and cab sleeper be inspected oe e By a competent technician every 15 000 miles CD50 24 000 km e Whenever a change is noticed in the sound of GE the exhaust system e Whenever the exhaust system underbody cab Cl 4 or sleeper is damaged CL NOTE Use only an exact replacement DPF in EP exhaust systems Using a noncompliant DPF as a replacement could violate these standards and GL also void the emission system s warranty F HT Y53 6004 High Temperature grease Timken Spec 0 616 08 06 PART 8 MAINTENANCE AND SERVICE LUBRICANT SPECIFICATIONS Lubricant Symbol Key Component Lubrication Index MP Multipurpose gear lubricant MIL L 2105B Spring Pins CL WB Wheel Bearing grease Timken Spec 0 610 Clutch
154. mple 106 Y53 6004 08 06 PART 7 STARTING amp OPERATING THE VEHICLE 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 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 throttle and then brake one or more of the four corners of the 08 06 Y53 6004 ANTI LOCK BRAKING SYSTEM OPERATING INFORMATION vehicle in addition to potentially applying the trailer brakes thus applying a counter force t
155. n at 0 degrees when the tractor is operating without a trailer or pulling a flatoed With all other trailers you adjust the VARA 08 06 Y53 6004 DASH AND DOOR MOUNTED FEATURES SHIELD to its best angle by noticing the lower manifold boost pressure at cruise as indicated by the manifold pressure gauge or the reduction in road dirt deposited on the front of the trailer Parking Brake Valve and Trailer Air Supply Valve 02908 Single Valve Your parking brake valve is a yellow diamond shaped knob located in the center console of conventional cab models It controls the parking brakes for straight truck or tractor trailer combinations 63 DASH AND DOOR MOUNTED FEATURES YELLOW 02909 WARNING Stopping with the parking brake AN controls can cause a sudden wheel lock up loss of control or can cause you to be over taken by following vehicles You could be severely injured Never pull out the parking brake valve while the vehicle is moving 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 the Index under Brakes 64 Y53 6004 PART 4 CONTROLS
156. n e 26 s lt a Green 27 30 Seat Belt Fasten 39 Turn Signal Right A Red 26 g D gt Green e 27 31 Suspension Dump l at Yellow 26 Aa 32 Tire Inflation x Yellow e 26 33 Transmission Auxiliary a Yellow e 27 34 Transmission Check C Red e pad 35 Transmission Do Not Shift SS Red e 27 36 Transmission Oil Filter ot Yellow e 27 08 06 Y53 6004 a4 a INSTRUMENTS AND CONTROLS Warning Light Indicator Symbol Descriptions 1 Active Warnings Exclamation Point 99 IIluminates when a red warning is active Use the MCS knob to view the warnings that are active Refer to the preceeding Figure Warning Light Indicator Symbols on page 19 for warning color classification 2 Active Warnings Number IIluminates the total number of red and yellow active warnings Use the MCS to view the active warnings if the display shows a gt sym bol 3 Active Warnings Triangle IIluminates when an yellow warning is active Use the MCS knob to view the warnings that are active Refer to the preceeding Figure Warning Light Indicator Symbols on page 19 for warning color classification 9 Y53 6004 PART 4 CONTROLS AND DISPLAYS 4 Alternator IIluminates if the alternator is not charging For alternators with warning lamp output signal 5 Anti Lock Brake System ABS Iluminates during the Instrumentation Sys tem Self Test Have the ABS system ch
157. nd driving ability These circumstances can substantially increase the risk of an accident and personal injury A 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 08 06 PART 2 CAB AND FRAME ACCESS PART 2 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 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 ha
158. ndicate 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 ae A SPECIAL WORD ABOUT REPAIRS A Special Word About Repairs WARNING Attempting repair work without suf AN 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 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 How ever all warranty repairs must be performed by an autho rized Peterbilt service facility If you aren t an experienced mechanic or don t have the right equipment please leave all repairs to an authorized service facility They are the ones equipped to do th
159. nds and feet and the truck Look where you are going j WARNING Jumping out of the cab or getting 08 06 Y53 6004 DOOR LOCK AND KEYS The picture below shows the best way to enter and exit a Conventional Cab 02958B 08 06 PART 2 CAB AND FRAME ACCESS 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 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 j WARNING To lessen the chance and or sever 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 Keys and Locks The same key fits your ignition doors and sleeper lug gage compartment Frame mounted tool box locks and locking fuel tank caps each have individual keys 08 06 PART 2 CAB AND FRAME ACCESS Remote Keyless Entry optional This vehicle may be equipped with a Remote Keyless Entry RKE system that adds security and convenience to your vehicle The system will lock or unlock the driver s door and passenger s door with the key fob and alert you with parking lights when the selected door
160. nds in large measure on how much friction you get between the road and your tires In addition keeping your tires in good con dition is essential to the safe efficient operation of your vehicle Regular frequent inspection and the right care 168 Y53 6004 PART 8 MAINTENANCE AND SERVICE will give you the assurance of safe and reliable tire opera tion 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 Check pressure only when the tires are cool Warm or hot tires cause pressure buildup and will give you an inaccurate reading So never deflate a warm tire to the specified pressure 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 08 06 PART 8 MAINTENANCE AND SERVICE Underinflated Tires Low pressure is a tire s worst enemy Underinflation allows tires to flex improperly causing hig
161. ne 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 WARNING Do not operate engine with turbo AN charger intake piping disconnected Working around a turbocharger with the intake piping removed 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 could be seriously injured Always keep the intake piping con nected when you will be running the engine e 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 PART 8 MAINTENANCE AND SERVICE e 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 on page 209 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 The foundation brake system must be in proper work ing order to ensure the best ABS performance e Before welding anywhere on the vehicle detach the ABS ECU
162. ngerous to attempt maintenance work without sufficient training and the 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 e Before attempting any procedures in the engine compartment stop the engine and let it cool down Hot components can burn skin on contact e 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 e 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 129 PREVENTIVE MAINTENANCE SCHEDULE A 130 Disconnect the battery ground strap whenever you work on the fuel system or the electrical system When you work around fuel do not smoke or work near heaters or other fire hazard Keep an approved fire extinguisher handy Always support the vehicle with appropri ate safety stands if it is necessary to work underneath the vehicle A jack is not ade quate for this purpose When working underneath the vehicle without appropriate safety stands but with the wheels on the ground not supported make sure that 1 the vehicle is on hard level ground 2 the parking brake is applied 3 all wheels ar
163. o 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 107 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 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 acollision 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 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 Effective 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 multip
164. of gravity CG 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 e The vehicle is used to haul double or triple trailer com binations 08 06 Y53 6004 Loads must be properly secured and evenly distrib uted at all times 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 109 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 severe personal injury WARNING For vehicles equipped with ESP Electronic Stability Program do not replace the vehicle s steering wheel Using a different steering wheel
165. of air pressure drop The rate of drop should not be more than 2 psi 14 kPa per minute Now start the engine and build up the air pressure again Stop the engine Ensure that the parking brakes are still released i e the yellow knob is pushed in Fully apply the service brakes 165 BRAKE ADJUSTMENT 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 129 In severe service or off highway applications inspect the linings more fre quently 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 166 Y53 6004 PART 8 MAINTENANCE AND SERVICE Have a qualified mechanic perform a detailed inspec tion if the no
166. ol 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 08 06 Y53 6004 NOISE CONTROL SYSTEM Tampering with Noise Control System Prohibited Federal law prohibits the following acts or the causing thereof 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 e Noise Insulating Blankets Removing noise insulators from engine block or from around the oil pan Cutting holes in or cutting away part of noise insula tors Removing hood mounted noise insulation e Engine Electronic Control Unit ECU 209 NOISE CONTROL SYSTEM Modifying ECU parameter
167. omfort Lok fea ture at the appropriate time 1 Fasten your seat belt according to the directions Y53 6004 08 06 PART 5 SEAT AND RESTRAINT SYSTEMS 2 You are now ready to activate the Komfort Lok Lean forward to pull a little slack maximum of one inch measured from the belt to your chest in the belt Be sure to allow only a small amount of slack see the Warning on a loose belt 3 When the slack is right flip the latch cover up cinch ing it into place This locks the Komfort Lok Komfort Lok SEAT BELTS AND THEIR PROPER USE 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 remem ber the best way to keep an unborn baby safe is to keep the mother safe 08 06 Y53 6004 77 SEAT BELTS AND THEIR PROPER USE 02932A 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
168. onds This is a built in function test of the warning light 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 il 200 Y53 6004 PART 8 MAINTENANCE AND SERVICE NOTES Keep the engine exhaust system and the 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 e whenever the exhaust system underbody cab or sleeper is damaged e Allow for the proper operation of the vehicle ventilation system 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 08 06 PART 8 MAINTENANCE AND SERVICE Heater 08 06 Check all heater controls for full range operation Check hoses connections and heater core for condi tion and leaks Check the drain pan of the fresh air vent for trapped water before assuming that there is a leak in the heat ing system If the hea
169. only if lube fittings are present X rea Hinges and latch Lubricate with silicone spray X hoods Body amp cab holddown bolts Check the condition and tightness X Heating amp Air Air conditioner Operate the system X S Heater amp air conditioner Perform the checks listed on page 200 X Cab air filter Clean replace after a maximum of three cleanings xX Heater amp air conditioner Full operational and diagnostic check X Exhaust System Check for leaks and proper support see page 198 X Air Air compressor governor Replace air strainer X Air lines Check condition and routing to prevent chafing X System Lubricate see page 178 X Inline filters Replace elements or clean with solvent X Air dryer Perform the checks listed on page 179 X Air dryer ON HIGHWAY Overhaul 360 000 miles 576 000 km 151 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE 08 06 Recommended SYSTEM COMPONENT MAINTENANCE TASK Cee AI B C D E Air Air dryer OFF HIGHWAY Overhaul X Engine Basic Engine Maintenance and service interval recommendations are detailed in the engine manufacturer s Operations and Maintenance Manual included with the vehicle The engine manufacturer s recommendations vary depending engine model Information is also available from Peterbilt dealers the engine manufacturer s authorized service centers and the engine manufacturer s web
170. ortation of yourself and your load If you do find something wrong 84 Y53 6004 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 maintains the vehicle properly e uses driving skills wisely 08 06 PART 6 DRIVER S CHECKLIST reflexes perceptions and judgment can be affected by even a small amount of alcohol You could have a serious or even fatal accident if you drive after drinking Please do not drink and drive or ride with a driver who has been drink ing The use of alcohol drugs and certain medi cations will seriously impair perception reactions and driving ability These circum stances can substantially increase the risk of an accident and personal injury j WARNING Do not drink and drive Your The daily checks listed below are the foundation of your overall preventive maintenance program See PART 8 MAINTENANCE AND SERVICE for the complete preven tive maintenance schedu
171. ot step on vehicle compo 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 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 pos sible injury to yourself NOTE Any alteration adding bulkheads head 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 on the next page show you the right way to get on and off the area behind your cab CLIMBING ONTO THE DECK PLATE PART 2 CAB AND FRAME ACCESS Hold handles as you Maintain three points Maintain three points of Maintain three points of step up of contact contact as you reach the contact as you step to deck area deckplate S102 08 06 08 06 PART 3 GETTING TO YOUR ENGINE HOOD HOLD DOWNS PART 3 GETTING TO YOUR ENGINE Hood Hold Downs front one foot on the bumper and one foot on the ground Tilt the hood f d Hood
172. ould cause corrosion which could com promise the brake system safety and potentially cause an accident Daily e Drain moisture from the supply and service air tanks e Operate air devices to circulate lubricants within the unit 08 06 Y53 6004 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 Maintain the air compressor to prevent excessive oil by pass See your maintenance manual for details e Replace worn seals in valves and air motors as they are needed 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 and rear dry tank The dry tanks have a single check 179 TRANSMISSION AND DRIVE TRAIN 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 elimin
173. outed through the buckle on each side e To lengthen the tether turn the buckle to a right angle to the webbing Then pull the buckle To shorten the tether pull on the strap 79 INSPECTION OF THE RESTRAINT SYSTEM 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 e 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 80 Y53 6004 PART 5 SEAT AND RESTRAINT SYSTEMS seat belt system except when the user puts on or takes off the belt In trucks however
174. perating 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 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 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 08 06 PART 7 STARTING amp OPERATING THE VEHICLE 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 Air Brakes 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 brakes to hold a parked vehicle
175. pliant DPF as a replacement could violate these standards and also void the emission sys tem s warranty Turbo Emission Control Components 08 06 PART 8 MAINTENANCE AND SERVICE The vehicle may have emission control components to meet 2007 EPA requirements Refer to the engine manu facturer s service manual for the maintenance of these components Joints and Clamps Check for leaks and tighten as necessary Check for deterioration or dents in pipes and clamps which could allow exhaust to escape NOTE The EPA requires 2007 compliant vehicles il to have a leak free exhaust system Replace Piping components as necessary to ensure EPA compli ance Check for rust corrosion and damage Replace any piping if it is perforated at any point Temporary patch ing or lagging is not acceptable NOTE The EPA requires 2007 compliant vehicles il to have a leak free exhaust system Replace exhaust piping as necessary to ensure EPA com pliance Diesel Particulate Filter DPF 08 06 Y53 6004 NOISE CONTROL SYSTEM NOTE Use only an exact replacement DPF in exhaust systems Using a noncompliant DPF as a replacement could violate these standards and also void the emission system s warranty il Check the DPF for looseness Tighten loose mounting bolts as necessary 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 no
176. pressure protection valves This could lead to loss of air pressure or damage to the vehicle s air system which could cause an accident or personal injury Always adhere to the manufacturer s procedure if it is neces sary in an emergency to temporarily bypass an AD IS series air dryer 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 the 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 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE 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 Contamination of the air supply system is the major cause of problems in air operated components such as brake valves 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 c
177. pressure in the rear res ervoir Ensure the air pressure registers more than 100 psi in both service systems before you move the vehicle If the pressure in either circuit is too low for normal brake oper ation the warning light will glow and the audible alarm will sound 40 Y53 6004 PART 4 CONTROLS AND DISPLAYS 08 06 PART 4 CONTROLS AND DISPLAYS A 08 06 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 OPTIONAL GAUGES Optional Gauges Air Filter Restriction Indicator or Gauge SB AIR FILTER This gauge indicates the condition of the engine air cleaner and is measured by inches of water H20 A clean filter should register 7 in H2O may vary with sys tem design and a filter whose life is over will register approximately 25 in H20 Y53 6004 41 OPTIONAL GAUGES PART 4 CONTROLS AND DIS
178. r 2 or 3 minutes If 08 06 PART 4 CONTROLS AND DISPLAYS STANDARD GAUGES the warning light does not go off or the temperature Fuel Gauge gauge does not begin to drop then turn the engine off If the overheating came from severe operating condi tions 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 Voltmeter an open flame Hot fuel vapors are combusti ble and can cause an explosion or fire result ing in injury or death j WARNING Do not remove a fuel tank cap near Failure to do so may damage components of the CAUTION Use Ultra Low Sulfer Diesel fuel only A Diesel Particulate Filter DPF The fuel gauge shows the approximate amount of fuel in The voltmeter displays the voltage at which your batteries the fuel tanks Besides empty and full the gauge also indi are being charged while the engine is operating cates 1 4 1 2 and 3 4 of total capacity You will want to keep your fuel tanks at least half full to reduce condensa 08 06 Y53 6004 39 STANDARD GAUGES tion of moisture in the tanks This moisture can damage your engine Primary Secondary Air Pressure Gauge Air Reservoir The air pressure gauge indicates the amount of air pres sure in the brake system in pounds per square inch psi The primary gauge shows front reservoir air pressure e The secondary gauge shows
179. r cables must be con 186 tive to negative 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 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 Y53 6004 PART 8 MAINTENANCE AND SERVICE 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 Slow Battery Charging Ti NOTE Follow the instructions that come with your battery charger It is not necessary to
180. r transmissions are designed so that the internal parts operate in a bath of oil circulated by the motion of gears and shafts Grey iron parts have built in channels where needed to help lubricate bearings and shafts All parts will be amply lubricated if these procedures are closely followed 1 Maintain oil level check it regularly 2 Change oil regularly 3 Use the correct grade and type of oil 4 Buy oil from a reputable dealer 156 Y53 6004 Refer to the Eaton Fuller transmission manual for ser vicing information 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 08 06 PART 8 MAINTENANCE AND SERVICE H A 08 06 OIL CHANGE vs TEMPERATURE FOR ON HIGHWAY VEHICLES Engine OW and Minera Gear Olt intermittent Peak Temperature F of Oli In Transmission Sump CAUTION Exceeding the recommended oil change intervals may be harmful to the life of the transmission and the transmission oil cooler LUBRICANT SPECIFICATIONS Recommended Lubricants cant Type Grade SAE Ambient Temperature Heavy Duty Engine 50 Above 10 F 12 C Oil MIL L 21048B C or D API SF or API CD 40 Above 10 F 12 C 30 Below 10 F 12 C Mineral gear oil 90 Above 10 F 12 C with
181. r 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 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 08 06 PART 7 STARTING amp OPERATING THE VEHICLE countershaft gear which lubricates the transmission com ponents by oil splash will only be turning at idle speed Descending a Grade WARNING Do not hold the brake pedal down AN 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 CAUTION To avoid engine damage do not let A the engine rpm go beyond the maximum gov erned rpm valve damage could result if over speed conditions occur 08 06 Y53 6004 DRIVING TIPS AND TECHNIQUES NOTE Often these recommendations are sec ondary to maintaining an adequate and safe speed relative to the surroun
182. ration inspect as per manufacturer s service X literature Y53 6004 138 PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Recommended SYSTEM COMPONENT MAINTENANCE TASK pees A B C DIE Hub Drum Hubs non LMS Check the bearing endplay and adjust as required X amp Hubcap Meritor Unitized Wheel End See page 174 Hubs non LMS with Clean the components and check for excessive wear or X outrunner seals damage Change the oil and seal see page 161 Hubs non LMS with Clean the components and check for excessive wear or X standard seals damage Change the oil and seal see page 161 Hub seals all Check for leaks replace as required X LMS Hubs Dana Check the bearing endplay and adjust as required X see page 174 LMS Hubs Dana with Clean the components and check for excessive wear or 500 000 miles Synthetic Lubricant damage Change the oil and seal see page 161 800 000 km LMS Hubs Dana with Clean the components and check for excessive wear or 350 000 miles Mineral Lubricant damage Change the oil and seal see page 161 560 000 km Brake drums Inspect for visible cracks heat checking galling or scoring of the X braking surface and for severe corrosion on the outside surface Check for out of round or oversize condition 0 080 in 2 mm more than the original diameter Replace as required Hubcaps Clean the sigh
183. ration see page 89 X Air cleaner Replace the engine intake air cleaner element see page 196 When required by air restriction indicator 08 06 Y53 6004 142 PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTENANCE AND SERVICE Recommended SYSTEM COMPONENT MAINTENANCE TASK PMInterval I A B C D E When an air restriction indicator is not installed use the air cleaner manufacturer s recommendation except as specified below Exceptions to Air Cleaner Element Replacement Intervals for Vehicles in either 100 Class AA or 100 Class A On Highway Usage Models 365 367 and 386 with C11 C13 engine and engine mounted air cleaner Replace the element every 140 000 miles 224 000 km OR at engine oil change if the interval being used for oil changes is close to but does not exceed 140 000 miles 224 000 km Models 367 and 386 with C15 engine and engine mounted air cleaner Replace the element every 90 000 miles 144 000 km OR at engine oil change if the interval being used for oil changes is close to but does not exceed 90 000 miles 144 000 km Model 386 with C15 engine Replace the element every 90 000 miles 144 000 km OR at engine oil change if the interval being used for oil changes is close to but does not exceed 90 000 miles 144 000 km Models 365 367 and 386 with firewall mounted air cleaner Replace the element every 70 000 miles 112 000 km OR at engine oil change if the
184. ravel 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 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 93 PUTTING THE VEHICLE IN MOTION forward with the throttle at idle until the clutch is fully engaged 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 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 W
185. ravel 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 08 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 require ments Failure to follow requirements can dam age the engine Engine damage can include but is not limited to Freezing e Boiling e Corrosion Pitted cylinder liners 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 ENGINE COOLING SYSTEM 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
186. remove the battery from the compartment 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 08 06 PART 8 MAINTENANCE AND SERVICE ELECTRICAL 2 Disconnect the battery cables WARNING Batteries contain acid that can 3 Connect charger cables AN burn and gasses that can explode Ignoring 4 Start charging the battery at a rate not over 6 safety procedures can cause you or others to amperes Normally a battery should be charged at no be badly hurt more than 10 percent of its rated capacity Never jump start a battery near fire flames 5 After charging turn OFF charger and disconnect or electrical sparks Batteries generate explo charger cables sive gases Keep sparks flame and lighted cigarettes away from batteries 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 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 08 06 Y53 6004 187 ELECTRICAL
187. res in Bold face indicate maximum recommended load Source Bridgestone Tire 2 02 08 06 Y53 6004 172 PART 8 MAINTENANCE AND SERVICE TIRES WHEELS AND RIMS Wheels And Rims 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 UNIMOUNT stamped on the disc Ball seat wheels have spherical chamfers machined on each stud hole Center bore diameter is 8 23 32 in 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 Hub Pilot Mount SystemBall Seat Mount System e Inner and outer cap nuts mate with spherical cham Hub Drum and Stud Assembly fers on wheels Inner nut has 13 16 in square end F Outer nut has 1 1 2 in hex The hub pilot mounting system uses M22x1 5 met ric threads about 7 8 in dia The stud stands out at WARNING Mismatched wheel components least 1 9 in beyond the brake drum All studs are right AN are dangerous Equipment that does not hand threads Pilot bosses machined on the hub fit exactly match original specifications or that is tightly to the wheel center bore mismatched could cause your wheels to The ball seat mounting system uses 3 4 x 16 or break and separate from the vehicle The 1 1 8 x 16 threads The dual mounting studs provide resulting accident could be very serious 1 3
188. rings kingpins as required drawkeys tie rod ends steering stops amp bushings OFF HIGHWAY AND VOCATIONAL Front Front Spring Inspect for cracked leaves worn bushings amp excessive X Suspension corrosion Spring Pins amp Shackles Inspect for worn parts and excessive joint clearance Shim or X replace as required 133 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Recommended SYSTEM COMPONENT MAINTENANCE TASK PH interval IJ A B C DIE Front Shock Absorbers Inspect for leaking body damage and damaged or worn X Suspension bushings Replace as required Check the shock mounting stud torque Check for proper function X U bolts ON HIGHWAY Check the general condition and the tightness of the nuts X X Tighten the nuts to the specified torque value as required see page 192 U bolts OFF HIGHWAY Check the general condition and the tightness of the nuts X Tighten the nuts to the specified torque value as required see page 192 Drive Axle Axle Housing Visually inspect for damage or leaks X Dana Check oil level Check cold Torque the drain plug X Drain the lubricant while warm Flush each unit with clean See information on flushing oil Change the lubricant page 160 Air Shift Unit Check the lubricant level X Remove the housing cover
189. rol Use this switch only when your vehicle is not moving sion bags either overinflated or underinflated may cause damage to driveline components If a vehicle must be operated under such condi tions do not exceed 5 mph Engine Fan Switch CAUTION Operating a vehicle with air suspen Cc O 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 54 Y53 6004 PART 4 CONTROLS AND DISPLAYS 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 on the ignition or switching from AUTOMATIC to ON be sure no one is near the fan CAUTION The fan or equipment near it could be damaged if the fan turns on suddenly when you don t expect it Keep all tools and equipment such as rags away from the fan and take care no one turns on the ignition when someone is working near the fan CAUTION Do not operate the engine fan in the manual ON position for extended
190. s Engine Cooling System Removing or rendering inoperative the fan clutch Removing the fan shroud Air Intake System Removing or rendering inoperative the air cleaner silencers or intake piping Exhaust System Removing or rendering inoperative the exhaust sys tem components Inner Fender Shields and Cab Skirts Removing shields or skirts Cutting away parts of shields skirts or damaged or loose portions of shields or skirts Fuel System Removing or rendering engine speed governor inop erative allowing engine speed to exceed manufac turer s specifications 210 Y53 6004 PART 8 MAINTENANCE AND SERVICE Removing air signal attenuator on engines equipped with this device 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 NOTE Vehicles with engines built to meet 2007 il EPA Emission Requirements also have a Diesel Particulate Filter DPF Use only an exact replacement DPF in exhaust systems Using a noncom
191. s cushion clamps and routing X Boxes Tool HIGHWAY amp LINE HAUL Replace a cushion clamp if the rubber has deteriorated Repair Boxes and or tighten terminals and secure cables to prevent chafing Steps Replace damaged cables cuts cracks or excessive wear see page 184 Battery cables Check the condition of the cables cushion clamps and routing X VOCATIONAL amp SEVERE Replace a cushion clamp if the rubber has deteriorated Repair SERVICE or tighten terminals and secure cables to prevent chafing Replace damaged cables cuts cracks or excessive wear see page 184 Batteries ON HIGHWAY amp Check for cracks and damage electrolyte level condition of X LINE HAUL terminals and tightness of holddowns see page 184 Batteries VOCATIONAL amp Check for cracks and damage electrolyte level condition of X SEVERE SERVICE terminals and tightness of holddowns see page 184 Battery box and tray ON Check the box integrity Clean the drain tube and check for acid X HIGHWAY amp LINE HAUL leaks Check condition of all equipment mounted under the box Battery box and tray Check the box integrity Clean the drain tube and check for acid X VOCATIONAL amp SEVERE leaks Check condition of all equipment mounted under the box SERVICE Battery Cable Fasteners Check battery cable fasteners and tighten as necessary to 10 X 15 Lb ft 13 6 20 3 N m as specified on the battery label
192. s Manual for additional information This menu will show gear number that coincides with the current transmission gear selected The menu also displays the transmission icon to let the user know what screen they are in Does not indicate a fault code Settings Menu Accessible only while parked The Settings menu screen allows the driver to view and or change the following menu items 31 DRIVER INFORMATION DISPLAY PART 4 CONTROLS AND DISPLAYS e Display Format 12 Hour AM PM or 24 Hour military Exit Home Local Time Alarm Off n WORS Time Home lt aarm ON Format 12Hr_ M Alarm Time Units of measure To Set Home Local or Alarm Time Language English Spanish or French 1 When in the Settings Menu scroll through the list of menu items Press the MCS to select the item to change Settings Unit Standard Set Alarm Time Set Home Time Set Local Time To Set Clock Display Format 1 When in the Settings Menu scroll through the 3 Rotate the MCS knob to change the hour Press list of menu items to Format the MCS 2 Press the MCS to display either 12 hour AM PM or 24 hour military time 32 Y53 6004 08 06 PART 4 CONTROLS AND DISPLAYS DRIVER INFORMATION DISPLAY 1 When in the Settings Menu scroll through the list of menu items to Units Press the MCS 2 Press the MCS to display either Standard or Metric units Refer to Engine Hours Outside Air Temp
193. s 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 e 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 38 Y53 6004 PART 4 CONTROLS AND DISPLAYS 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 completely 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 DO NOT 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 Return the idle speed to normal afte
194. s of braking To use this brake fre quently instead of using the foot brake will wear 08 06 Y53 6004 STEERING COLUMN MOUNTED CONTROLS Tilt Telescoping Steering Column Depending on your vehicle s configuration you may have either a Tilt Telescoping or a fixed steering column e The tilt feature allows forward and rearward move ment of the wheel e The telescoping feature allows you to move the wheel up and down To activate these features locate the Tilt Telescoping pedal 49 DASH AND DOOR MOUNTED FEATURES WARNING Adjusting the Tilt Telescoping AN Steering Wheel while the vehicle is in motion could cause loss of control You wouldn t be able to steer properly and could have an acci dent Make all adjustments to the steering mechanism while the vehicle is stopped To adjust the steering wheel PUSH and HOLD the pedal down fully Push or pull the wheel to the desired height and angle then RELEASE the pedal to lock the wheel at the correct position Dash And Door Mounted Features Ignition Switch Your ignition switch has four unmarked positions OFF ACC ONLY IGN amp ACC START 50 Y53 6004 PART 4 CONTROLS AND DISPLAYS 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 e IGN amp ACC This position allows you
195. s quantity of phosgene gas Don t smoke in the area Inhaling gaseous refrigerant through a cigarette may cause vio lent illness H NOTE A leaking evaporator or condenser core 202 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE APPEARANCE before waxing Don t wax in the hot sun Don t friction burn the paint with a buffing machine Aluminum and Chrome Surfaces Appearance Painted Surfaces 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 cylinders Water in lock cylinders should be removed with compressed air To prevent locks from freezing in the winter squirt glycerin or lock deicer into the lock cylinders A Wash frequently to remove grime and caustic deposits that may stain the finish Apply cool or lukewarm water You may want to use a mild soap Avoid washing your vehicle in bright sunlight A Road tar may be removed with a special commercial tar remover or mineral spirits WARNING Handle cleaning agents carefully Cleaning agents may be poisonous Keep them out of the reach of children Waxing offers added protection against staining and oxi dation But to allow enough time for your truck s finish to cure wait about ninety days after the date of manufacture 08 06 Y53 6004 Clean aluminum wheels and bumpers with warm water Tar remover will get rid of heavy deposits of road grime To preven
196. se condi tions 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 draining electricity e Dirty or Loose Connections Bad connections may stop the flow of electrical power to and from the bat tery Recharging Batteries Except for using small trickle chargers to maintain battery condition you should have your vehicle s batteries charged by a qualified service facility To help reduce the risk of personal injuries follow these guidelines carefully when recharging a battery 08 06 PART 8 MAINTENANCE AND SERVICE WARNING A battery contains gas that is AN explosive and flammable It could injure you severely A spark or flame near a battery on charge may cause it to explode with great force e Allow no sparks or open flame anywhere near the charging area 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 WARNING Always make sure the battery AN charger is OFF before connecting or discon necting the cable clamps Do not connect or disconnect charger cables while the charger is operating to reduce the danger of explo sions e Always make sure the battery charger is OFF before connecting or disconnecting the cable clamps WARNING Always shield your eyes and avoid AN leaning over the battery
197. sh on these com ponents CAUTION To avoid possible damage to the Use a clean lint free cloth 206 Y53 6004 PART 8 MAINTENANCE AND SERVICE 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 Passenger Door Lower View Window There may be occasions when the inner view window must be removed for maintenance cleaning and or dam age Follow this procedure when installing and removing an inner view window The recommended tool for removal of the glass is a glass stick although other tools may be used provided proper caution is observed 08 06 PART 8 MAINTENANCE AND SERVICE CAUTION The use of screw drivers gasket tools knives or other similar instruments may damage the seal or break the glass Use a glass stick as a tool whenever possible when removing or installing a window If another tool must be used exercise extreme care when performing this procedure with such a tool NOTES e Always make sure that a gasket is installed properly so the weep slots will be
198. shoulder belt allow the belt to wind up on the retractor by guiding the belt tongue until the belt comes to a stop 08 06 PART 5 SEAT AND RESTRAINT SYSTEMS SEAT BELTS AND THEIR PROPER USE Proper Safety Belt Adjustment to the door it should never rest against your neck It you aor put the belt under your arm it can t protect you properly Your combination lap shoulder belt may need adjustment Adjust safety belts properly e Be sure also that your belt is not too loose A loose belt could allow you to slide under it in an accident e The lap belt should be worn as low and tight on the and that could bring the belt up around your abdomen hips as possible Make sure any slack is taken up by the belt mechanism e Do not twist the belt in the process of putting it on A twisted belt will not work as well to protect you The shoulder belt should fit snugly across your body It should be positioned midway over the shoulder nearer Lap Belt Shoulder Belt Too High on Hips a Correct Incorrect Correct over arm Incorrect under arm Incorrect twisted Safety Restraint Belts 08 06 Y53 6004 75 SEAT BELTS AND THEIR PROPER USE WARNING e Always wear your seat belt low over your pelvic bones e You can be seriously injured if your belt is buckled too high In a crash it would apply force to your abdomen not your pelvic bones This can result in serious internal injuries e
199. ssion 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 Steering Gear Lubrication Inspection NOTE Before removing reservoir cover wipe outside of cover so that no dirt can fall into the i reservoir 1 Check the fluid level add fluid if required 162 Y53 6004 PART 8 MAINTENANCE AND SERVICE 2 Check fluid for contamination discoloration or burnt smell correct source of such problems before replac ing fluid amp filter 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 bubbles can be pro duced at the interface of the two fluids This can cause Cavitation which reduces the lubrication between moving parts in the gear This could result in worn components e The mixture of two different fluids although harmless to individual
200. t ignition on does not indicate that a trailer has trailer ABS You should person ally inspect every trailer to determine its braking system 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 08 06 ANTI LOCK BRAKING SYSTEM OPERATING INFORMATION If no trailer is connected or if a non ABS equipped Y53 6004 trailer is connected the trailer ABS lamp will go off after one second H NOTES e 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 e For doubles or triples PLC does not distinguish between trailers An ABS problem in any trailer will activate the trailer ABS warning lamp 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 If no trailer ABS problems are detected the lamp will go off 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 that trailer attached 105 ANTI LOCK BRAKING SYSTEM OPERATING INFORMATION PART 7 STARTING amp OPERATING THE VEHICLE Advanced ABS wit
201. t 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 164 Y53 6004 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 shall 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 componen
202. t modify the end 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 running 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 211 NOISE CONTROL SYSTEM Engine Mounted Noise Insulators Fasteners Check for condition and security How you do this will depend on the method of attaching the noise insula tors on the engine and around the oil pan bolts snap fasteners or straps Tighten loose fasteners repair or replace any worn or damaged fasteners Insulators Check insulators around fasteners and stress points especially where they may be affected by engine vibration Repair any cracked or damaged mounting points Use suitable reinforcing plates to ensure that the insulators will remain in position Inner Fender Shields and Cab Skirts Fasteners Check all fasteners for security especially the self tap ping hex head screws Remove and replace any loose rivets Shields and Skirts 212 Y53 6004 PART 8 MAINTENANCE AND SERVICE Check shields and skirts for cracks at mounting and stress points Check fender shields for tire marks worn spots or damage from objects thrown from tire treads
203. t 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 203 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 stores 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 It is the chemical reaction between the carbon steel of the wool and the alum solution that cleans the stainless not the scrubbing or abrasive action of application 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 of different materials including fabrics carpet polyure thane and painted plastic surfaces These cleaning pro 204 PART 8 MAINTENANCE AND SERVICE cedures wil
204. t window Check the center plug mounting flange X and fill plug for leaks and for proper installation Replace broken or damaged parts Check the lubricant level and add as required 139 Y53 6004 08 06 PART 8 MAINTENANCE AND SERVICE PREVENTIVE MAINTENANCE SCHEDULE Recommended SYSTEM COMPONENT MAINTENANCE TASK cae I A B C DIE Main amp Main amp auxiliary Inspect for visible damage signs of overheating and leaks X X auxiliary transmission and transfer Check the drain plugs for tightness x transmission case Mounting Brackets and Check the condition of the fasteners and their torque Tighten to X Fasteners the specified torque value as required Oil cooler Clean the fins air to oil type and body Check the hose X condition and for leaks replace as required Main amp Main amp aux transmission Check the oil level refill as required X auxiliary Main amp auxiliary Drain lubricant while warm Flush each unit with clean flushing 500 000 miles transmission transmission ON oil 800 000 km except HIGHWAY Freedomline Main amp auxiliary Drain lubricant while warm Flush each unit with clean flushing X X transmission OFF oil HIGHWAY Main Freedomline Transmission Change the oil see page 159 500 000 miles transmission 800 000 km 08 06 Y53 6004 140 PREVENTIVE MAINTENANCE SCHEDULE PART 8 MAINTEN
205. tallation instructions Tethers must also be inspected for web wear just as with the seat belt systems 08 06 PART 5 SEAT AND RESTRAINT SYSTEMS 7 Mounting hardware should be evaluated for corrosion and for tightness of bolts and nuts 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 WARNING Replace the entire belt system AN 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 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 08 06 Y53 6004 INSPECTION OF THE RESTRAINT SYSTEM the original components that were removed This
206. tch it 69 CAB FEATURES The glove compartment can be locked Turn your glove box key clockwise right to lock and counterclockwise left to unlock WARNING An open glove compartment can AN 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 Shift Pattern Display The correct shift pattern for your vehicle appears on your control panel or windshield or on a medallion in the shift knob Itis 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 Cab Features Mirrors 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 70 Y53 6004 PART 4 CONTROLS AND DISPLAYS mirror so you can just see the side of your vehicle in the inboard part of the mirror WARNING Optional convex outside rear view 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 Luggage Compartment s An
207. tches 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 Assembly NS 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 e Temporarily release the parking brakes e Grab the caliper and move it This movement is Run ning Clearance 08 06 PART 8 MAINTENANCE AND SERVICE BRAKE ADJUSTMENT e Proper Running Clearance is 0 08 2 mm of move e A correctly installed and functioning auto slack ment of the brake caliper approximately the thickness adjuster will produce the following strokes of a nickel in the inboard outboard direction e Have a qualified mechanic provide further inspection Chamber Type Stroke if the caliper does not move or appears to move more 36 rear brakes Vie 24a 8 57 mm than the specified clearance 30 rear brakes 11 2 2 38 51 mm Drum Brakes 16 20 amp 24 front brakes 1 13 4 25 4 44 4 mm Have brake drum linings and disc brake pads inspected by a qualified mechanic for wear at regular intervals accord ing to the mainten
208. ter core is leaking take the vehicle to a Peterbilt dealer for proper heater service or repair Check the heater core for debris blocking the air flow If the blower is functioning properly yet the heater is not operating properly the heater core may be clogged Clean the heater core if necessary If the condition persists take the vehicle to a Peterbilt dealer for proper heater service or repair Y53 6004 CAB HEATER AIR CONDITIONER Air Conditioner j WARNING The air conditioning system is under pressure If not handled properly it could explode causing injury to you and your vehicle Any servicing that requires depres surizing and recharging the air conditioning system must be conducted by a qualified technician with the right facilities to do the job H NOTE Engines equipped with poly vee belts are equipped with tensioners No belt adjustments can be made Replace a poly vee belt when the indicator on the tensioner is no longer within the recommended green range e Check the compressor belt for condition and proper tension Adjust 105 125 pounds e Check the compressor and drive clutch for noise and vibration If you find problems have the system checked thoroughly A malfunctioning clutch usually indicates trouble elsewhere in the system 201 CAB HEATER AIR CONDITIONER e Check the evaporator core and condenser core for debris restricting air flow Clean if necessary Small particles may be remo
209. 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 95 PUTTING THE VEHICLE IN MOTION SHIFT AT ANY SPEED EXCEPT IF A WHEEL IS SPINNING 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 96 Y53 6004 a aay fy p ex PART 7 STARTING amp OPERATING THE VEHICLE WARNING e Do not put the differential lock in the LOCK position while the wheels are spinning freely slipping you could lose control of the vehi cle or cause axle damage you could be injured Switch to LOCK only when the wheels are not spinning e 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 differential locked Lock the differential only when operat ing on surfaces with poor traction such as wet sl
210. ther the gross vehicle weight rating GVWR or the maximum front and rear gross axle weight rat ings GAWRs Axle weight ratings are listed on the driver s door edge Supervise all load ing to ensure that 1 the Gross Vehicle Weight Rating GVWR is not exceeded and 2 the load is distributed correctly so that the weight distribution is within the limits of the front and rear axle load ratings Severe dam age to your vehicle difficult handling or an accident could occur if your vehicle is not loaded properly 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 VEHICLE LOADING 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 door frame Load Distribution Be sure any load you carry is distrib uted so that no axle has to support more than its load limit EXAMPLE NOTE Weight Mass in pounds kilograms 7 880 3574 q ____ Axle Weight 7 640 3 420 4 120 1 869 Payload Distribution _ 24 385 11061
211. tion 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 08 06 PART 10 CONSUMER INFORMATION Administration NHTSA in addition to notifying Peterbilt Motors Company If NHTSA receives similar complaints it may open an inves tigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign How ever NHTSA cannot get involved in individual problems between you your dealer and Peterbilt Motors Company 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 Canadian 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 08 06 Y53 6004 ENVIRONMENTAL PROTECTION For additional road safe
212. tion position The Odometer Trip Meter will remain on for 3 seconds after the door is closed or the ignition switch is turned off This allows driver and service personnel to read the odome ter without ignition switch being turned on 08 06 Y53 6004 STANDARD GAUGES Tachometer Your tachometer measures the engine speed in revolu tions per minute RPM The tachometer also includes an engine hour meter and outside air temperature display Watching your tachometer is important to driving effi ciently It will let you match driving speed and gear selec tion 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 35 STANDARD GAUGES Engine Hours Outside Air Temperature HESABA wes ar Hour Meter Snowflake Symbol Temperature AgBs Ee The LCD display in the lower part of the tachometer con tains the engine hour meter and the outside air tempera ture display The engine hour meter will display the total number of hours the engine has been running The maximum hours that can be shown are 99999 9 before the meter rolls over to zero The outside air temperature OAT will display the temper ature outside the vehicle The temperature can be dis played from 40 to 158 in Fahrenheit or 40 to 70 Celsius The display will also alert t
213. to the level indicated as MIN on the surge tank The surge tank is transluscent which allows the coolant level to be 08 06 PART 8 MAINTENANCE AND SERVICE seen Add coolant through the surge tank fill cap Do not remove the pressure cap to fill the cooling system Fill Cap Service point Pressure Cap Never to be removed ENGINE COOLING SYSTEM e The minimum fluid level is determined by the line on the surge tank indicated by the letters MIN This indi cator is located below the fill cap e The cooling system will need fluid if the surge tank level does not rise to the MIN line regardless if the system is hot or cold ee 2 5 3 Refilling Your Radiator Fill Line 3 Surge Tank NOTE Do not use the pressure cap to fill the 4 surge tank with fluid 5 il Proper Coolant Level H coolant may result in overflow loss of antifreeze and reduced corrosion protection 7 08 06 Y53 6004 1 2 NOTE Do not overfill a cooling system Excess 6 Be sure the radiator and engine block drains are closed Remove the surge tank fill cap Do not remove the surge tank pressure cap Fill the system with premixed coolant through the surge tank fill cap Pour coolant at a steady flow rate until the surge tank is full Start the engine and idle at low RPM As air is purged from the cooling system continue to fill the system until the coolant level remains above the MIN l
214. 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 78 Y53 6004 PART 5 SEAT AND RESTRAINT SYSTEMS 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 e In an accident an unrestrained 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 an accident and could be very seriously injured Passengers 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 Some Other Safety Restraint Tips 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 accident 08 06 PART 5 SEAT AND RESTRAINT SYSTEMS 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 The
215. trols to keep the desired condition il NOTE When the air conditioner is not 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 02912A Lighter To operate your lighter push the center of the knob in After a few moments the lighter will automatically pop out ready to use After use insert the knob but do not push it 08 06 Y53 6004 DASH AND DOOR MOUNTED FEATURES in The lighter circuit is protected by a 10 ampere fuse 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 not drawing 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 Glove Compartment To open your glove compartment lift the latch To close it push the cover up and press to la
216. ts in your brake system should be exactly equal to the original components Any changes from the original specifications can affect the whole sys 08 06 PART 8 MAINTENANCE AND SERVICE tem All of the following areas are interrelated and must conform to original specifications e Tire Size Drum brakes mmoOO WO gt Cam Radius Wedge Angle Drum Radius Brake Linings Brake Chambers Slack Adjusters Disc Brakes A A 08 06 Disc Rotors WARNING A nonconforming part in your 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 a together properly you could lose control of your vehicle Be sure any replacement parts in your brake system conform exactly to origi nal specifications Y53 6004 BRAKE ADJUSTMENT All vehicle operators should check their brakes regularly Always adjust your brakes when they are cool A WARNING Brake linings and pads with a 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
217. ty 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 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 08 06 Y53 6004 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 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 i
218. ty information please visit the Road Safety website at http www tc gc ca roadsafety menu htm Environmental Protection WARNING Diesel engine exhaust and some of AN its constituents are known to the State of Cali fornia to cause cancer birth defects and other reproductive harm Other chemicals in this vehi cle are also known to the State of California to cause cancer birth defects or other reproduc tive harm This warning requirement is man dated by California law Proposition 65 and does not result from any change in the manner in which Peterbilt trucks are manufactured Some of the ingredients in engine oil hydraulic 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 217 STATE OF CALIFORNIA PART 10 CONSUMER INFORMATION 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 associate
219. ved with compressed air blown through the core in the opposite direction of normal air flow pressed air could injure your eyes Wear eye WARNING Small particles blown by com protection any time you blow compressed air e Check all hoses for kinks deterioration chafing and leaks Adjust kinked or chafing hoses to eliminate restrictions and prevent further wear On tilt cab vehicles verify that hoses are routed around the pivot point so that lifting the cab does not strain them 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 leak Have a qualified technician correct the problem cannot be repaired it must be replaced PART 8 MAINTENANCE AND SERVICE e Have the air conditioning system fully inspected annu ally by your dealer Special Precautions 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 j WARNING Excessive heat may cause your air e Stay away from the hot engine until the exhaust manifold has cooled e Don t permit any open flame in the area Even a match or a cigarette lighter may gener ate a hazardou
220. will start faster and the starter motor will work more easily if ether is injected into the engine cylinder while the engine is being cranked Automatic System When you turn the ignition switch to the START position the cranking motor and the ether system are engaged When needed starting fluid is released from a pressur ized cylinder flows through a valve and tubing and sprays from a nozzle in you engine s air intake system For more helpful starting information refer to the engine manual that came with your 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 90 Y53 6004 PART 7 STARTING amp OPERATING THE VEHICLE Warmup Procedure 1 After you ve started your engine idle it at approxi mately 600 RPM while you check e oil pressure air pressure e alternator output 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 NOTE In colder climates where the temperature il is often below freezing the warmup for turbo charged engines is especially important Chilled external oil lines leading to the turbocharg
221. y Fob 1 Hold the key fob near the receiver NOTE The receiver is located behind the Soeedometer 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 pro grammed to a different truck or could have failed Contact your dealer to re program your key fob 08 06 PART 2 CAB AND FRAME ACCESS 08 06 PART 2 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 A 08 06 WARNING 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 there is no deck plate or if proper steps and grab han dles 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 A il Y53 6004 CLIMBING ONTO THE DECK PLATE WARNING Do n
222. y be necessary to shift it to the Neutral position momentarily to allow the main differential lock splines to fully engage or disengage 98 PART 7 STARTING amp OPERATING THE VEHICLE 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 PRESS TO UNLOCK s SHIFT AT ANY SPEED EXCEPT IF A WHEEL IS SPINNING Y53 6004 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 e Always UNLOCK the interaxle differential before shift ing the axle speed range 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 the Range Selector in LOW CAUTION If you shift the axle range with the 08 06 PART 7 STARTING amp OPERATING THE VEHICLE Automatic and Automated Transmissions j 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 There is no park position So you will need to apply the parking brake before leaving the cab ing the parking brake The truck could roll and cause an injury
223. y 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 lowing 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 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 the tether belt system with a different tether sys f WARNING Do not remove modify or replace 08 06 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 Y53 6004 SEAT BELTS AND THEIR PROPER USE Tether Adjustment WARNING AN 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 e Before driving or riding in a vehicle ensure that there is adequate head clearance at maxi mum upward travel of seat Serious injury may occur if head clearance is not adequate Shorten the tether belt as necessary to pro vide adequate head clearance Make sure the tether belt is attached to the cab deck and seat frame It should be r
224. ys ensure the steer axle brakes are func tioning and properly adjusted Failure to do so can lead to decreased braking ability longer stopping distances loss of vehicle control and can cause an accident 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 112 Y53 6004 PART 7 STARTING amp OPERATING THE VEHICLE 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 including all pneumatic and mechanical components are working properly Loss of system air can cause the 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 e Unless you have an anti lock braking sys tem always avoid completely depressing the service brake pedal even during emergency braking This action can cause the wheels to lock which can lead to an uncontrolled skid and could cause an accident Overheated Brakes Overheated brakes may be detected by a burning smell or smoke coming from a brake assembly If this occurs you

Peterbilt Conventional Trucks Operator`s Manual after 1-07

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