BENDIX BP-R1 BOBTAIL PROP RELAY VALVE Specifications

Quick Table of Contents
•Introduction. . . . . . . . . . . . . . . . . . 3
•Cab And Frame Access . . . . . . . . . . . 9
•Getting To Your Engine . . . . . . . . . . . . . . 11
•Controls And Displays . . . . . . . . . . . . . . . . . . 14
•Seat And Restraint Systems . . . . . . . . . . . . . . . . 72
•Driver’s Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
•Starting And Operating The Vehicle . . . . . . . . . . . . . . . . . 87
•Maintenance and Service
. . . . . . . . . . . . . . . . . . . . . . . . . . 146
•Consumer Information and Vehicle Identification . . . . . . . . . . . . . 257
•Subject Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
© 2008 PACCAR Inc - All Rights Reserved
This manual illustrates and describes the operation of features or equipment which may be either standard or optional on this
vehicle. This manual may also include a description of features and equipment which are no longer available or were not ordered
on this vehicle. Please disregard any illustrations or descriptions relating to featuures or equipment which are not on this vehicle.
Peterbilt reserves the right to discontinue, change specifications, or change the design of its vehicles at any time without notice
and without incurring any obligation.
The information contained in this manual is proprietary to Peterbilt. Reproduction, in whole or in part, by any means is strictly prohibited without prior written authorization from PACCAR Inc.
INTRODUCTION
Introduction
How to Use This Manual
This Operator's Manual contains useful information for the
safe and efficient operation of your Medium Duty vehicle.
It also provides information on maintaining your vehicle in
the best condition, with an outline for performing safety
checks and basic preventive maintenance inspections.
We have tried to present the information you'll need to
learn about your vehicle's functions, controls, and operation as clearly as possible. We hope you'll find this manual
easy to use. There will be times when you need to take
this manual out of your Peterbilt vehicle. 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.
Your Medium Duty may not have all the features or options
mentioned in this manual. Therefore, you should pay careful attention to the instructions that pertain to just your
Medium Duty (R05/09)
vehicle. In addition, if your vehicle is equipped with special
equipment or options not discussed in this manual, consult your dealer or the manufacturer of the equipment.
All information contained in this manual is based on the
latest production information available at the time of publication. Peterbilt Motors Company reserves the right to
make changes at any time without notice.
Safety Signals
A number of alerting messages are in this manual. Please
read and follow them. They are there for your protection
and information. These messages can help you avoid
injury to yourself and your passengers, and can help prevent costly damage to the vehicle.
Key symbols and “signal words” are used to indicate what
kind of message is going to follow. Pay special attention to
instructions prefaced by symbols and the signal words
“WARNING”, “CAUTION”, and “NOTE”. Please do not
ignore any of these alerts.
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INTRODUCTION
NOTE
WARNING
When you see this word, the message that follows is especially vital. It signals a potentially
hazardous situation which, if not avoided, could
result in an injury or death. This message will tell
you what the hazard is, what can happen if you
don't heed the warning, and how to avoid it.
Provides general information: for example, the
note could warn you on how to avoid damaging
your vehicle or how to drive the vehicle more efficiently.
Example:
NOTE: Pumping the accelerator will not assist in
starting the engine.
Example:
WARNING! Never carry additional fuel containers in the vehicle. Such containers, full or
empty, may leak, explode or cause a fire in the
event of a collision.
Please take the time to read these messages when
you see them, and remember:
WARNING!
CAUTION
Something that could seriously injure you.
Signals a potentially hazardous situation
which, if not avoided, could result in property or
vehicle damage.
CAUTION:
Something that could cause property or vehicle damage.
Example:
NOTE:
CAUTION: Continuing to operate your vehicle
with insufficient oil pressure will cause serious engine damage.
–4–
Useful information.
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Medium Duty (R05/09)
INTRODUCTION
Vehicle Safety
Make sure your Medium Duty is in top working condition
before heading out on the road—it is the responsible
driver's duty to do so. Inspect the vehicle according to the
“Driver's Check List”, page 81.
WARNING! Do not drink and drive . Your
reflexes, perceptions, and judgment can be
affected by even a small amount of alcohol.
You could have a serious—or even fatal accident—if you drive after drinking. Please do
not drink and drive or ride with a driver who
has been drinking.
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 features, continued safe and reliable operation depends
greatly upon regular vehicle maintenance. The vehicle
Medium Duty (R05/09)
must be operated within the range of its mechanical capabilities and the limits of its load ratings. (See the tire and
rim weight ratings information on the Vehicle Certification
Label on the driver's door frame.) This vehicle is not
approved for off-road operation.
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 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 Contents to find information
on a large subject like “Operating the Transmission.”
Cross-references also help you get the information you
need. If some other part of the manual contains further
information on the subject you are reading about, a crossreference will refer you to another page, for example: “See
page 73, for more information on Safety Restraint Belts.”
Finally, you will find a helpful Index at the back of the manual, listing subjects alphabetically. For example, if you
want information on brakes, just look under “Brakes” in the
Index. You will find the pages where brakes or related topics are discussed.
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INTRODUCTION
A Special Word About Repairs
Shop Manuals
This is not a repair or workshop manual. Your Peterbilt
Dealer's Service Center is the best place to have your
Medium Duty repaired. You can find Peterbilt dealers all
over the country with the equipment and trained personnel to quickly get you back on the road—and to keep you
there.
If you do decide to do complex repair work, you will need
the Medium Duty Maintenance Manual. It contains service procedures, parts information, and supporting material on major components in your vehicle, such as
Suspensions, Drivelines, Axles, and the Heater/Air Conditioner.
Your Medium Duty is a complex machine. Anyone
attempting repairs on it needs good mechanical training,
proper specifications, and proper tools. If you are sure you
meet these qualifications, then you can probably perform
some repairs yourself. But if you are not an experienced
mechanic, or do not have the right equipment or training,
please leave the repairs to an authorized service facility.
They are the ones equipped to do the job safely and correctly.
Listed below are manuals available from your Peterbilt
Dealer. (There is a charge for these manuals.) Please provide the Chassis Serial Number when ordering, to be sure
you get the correct manuals for your vehicle.
WARNING! Do not attempt repair work without
sufficient training, service manuals, and the
proper tools. You could be injured, or you
could make your vehicle unsafe. Do only
those tasks you are fully qualified to do.
–6–
Medium Duty Maintenance Manual. T h i s
manual
includes detailed service procedures specifically compiled
for the components on your vehicle, including: electrical
information, maintenance, disassembly, assembly,
repairs, overhaul, and troubleshooting procedures. The
information contained in this manual is the same used by
Peterbilt dealers.
Medium Duty Master Parts Catalog. Contains illustrated
parts lists with drawings and exploded views for Medium
Duty series vehicles.
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Medium Duty (R05/09)
INTRODUCTION
Medium Duty Body Builders' Manual. Contains general
guidelines on mechanical and electrical modifications
required by your dealer to add bodies, accessories, and
special equipment to straight-truck configurations.
WARNING! Modifying your vehicle can make it
unsafe. Some modifications can affect your
vehicle's electrical system, stability, or other
important functions. Before modifying your
vehicle, check with your dealer to make sure it
can be done safely.
Preventive Maintenance Section
The Preventive Maintenance section (pages 116 – 226) in
this manual contains general service information for the
operator, such as: lubrication points, making adjustments,
and other helpful service information. This is summary
information only, used for general maintenance of major
components installed on your Medium Duty. For detailed
service information see your Medium Duty Maintenance
Manual.
When it comes time for major service work, your Peterbilt
Dealer or Authorized Service Center will need vehicle and
component information. To help you gather this vehicle
Medium Duty (R05/09)
information, see “Consumer Information and Vehicle Identification” on page 226. This section explains vehicle identification and provides space to record model and serial
numbers of major components installed on your vehicle.
Additional Sources of Information
Installed Equipment — Operator's Manuals
Major component suppliers to Peterbilt also supply operation manuals specific to their products. Additional manuals
and other pieces of literature are included in the glove
compartment literature set. Look for information on products such as the engine, driver’s seat, transmission, axles,
tires, and radio. If you are missing these pieces of literature, ask your Peterbilt Dealer for copies.
Truck Driver's Handbook
Your set of glove compartment literature also contains a
copy of the Truck Driver's Handbook, published by the
American Trucking Association (ATA). Refer to it for important information on driving your Medium Duty.
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INTRODUCTION
Other Sources
Another place to learn more about trucking is from local
truck driving schools. Contact one near you to learn about
courses they offer.
–8–
Federal and state agencies such as the department of
licensing also have information you can ask for. The Interstate Commerce Commission can give you information
about regulations governing transportation across state
lines. Regulations that differ from state to state can be
found at various agencies in state governments.
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Medium Duty (R05/09)
CAB AND FRAME ACCESS
Cab and Frame Access
Introduction
To lock or unlock the doors from outside the cab:
The following section covers procedures for accessing the
cab and the frame.
Door Lock and Keys
• Insert the key in the door lock.
• Turn the key toward the rear door frame to lock; forward to unlock.
Cab and Frame Access
Doors can be locked from the inside by using the lock button. Close the door then push the button down to lock.
Doors automatically unlock when you open them from
inside, and can be locked from the outside with the key
only.
The following cab and frame entry/exit procedure recommendations were prepared with personal safety foremost
in mind.
WARNING! Do not jump out of the cab or get
into the cab without proper caution. You could
slip or fall, possibly suffering a serious injury.
You could slip and fall if the steps are wet or
icy, or if you step in fuel, oil, or grease.
As standard equipment, two keys are provided for the
doors and ignition. When necessary, additional locks and
keys are provided for storage compartments.
WARNING! To help lessen the chance and/or
severity 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.
Medium Duty (R05/09)
To help avoid personal injury due to a slip or fall:
• Use three points of contact (two feet, one hand or one
foot, two hands) to grip the steps or handholds whenever possible and look where you are going.
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CAB AND FRAME ACCESS
WARNING! Do not step on vehicle components without antiskid surfaces or use components not designed for entry-and-exit use.
You could fall and injure yourself if you step
onto a slippery surface. For example:
• Do not step onto the surface of a fuel tank.
A fuel tank is not a step. The tank surface
can get very slippery, and you might not be
able to prevent a fall. Use only the steps and
handholds provided, not chain hooks, quarter fenders, etc.
02611
• Use even more care when steps and handholds (or
footwear) are wet, coated with ice, snow, mud, oil,
fuel, or grease.
WARNING! Always reinstall the battery compartment cover (step) before entering the cab.
Without the battery cover you could slip and
fall, resulting in possible injury to yourself.
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• Do not climb onto and off the deck plate—
use steps and grab handle provided. If there
is no deck plate, or if proper steps and grab
handles are not provided, do not climb onto
the area behind the cab.
• Keep steps clean. Clean any fuel, oil, or
grease off the steps before entering the cab
or accessing the deck plate.
NOTE: Any alteration (adding bulkheads, headache racks, tool boxes, etc.) behind the cab that
affects the utilization of grab handles, deck plates,
or frame access steps installed by Peterbilt
should comply with Federal Motor Carrier Safety
Regulation 399.
Medium Duty (R05/09)
ENGINE ACCESS
HOOD HOLD DOWNS AND TILT
Engine Access
Hood Hold Downs and Tilt
The hood is locked in its closed position by an external
latch on each side. These latches serve as hold downs
and keep the hood from opening unexpectedly.
CAUTION: If you do not latch the hood
securely, it could open during operation and
cause vehicle damage. Be sure to latch the
hood securely before moving the vehicle.
WARNING! A pivoting hood could hurt someone or be damaged itself. Before opening or
closing the hood, be sure there are no people
or objects in the way.
To open the hood, unlatch both of the hood hold downs.
UNLATCHED
Medium Duty (R05/09)
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HOOD HOLD DOWNS AND TILT
ENGINE ACCESS
Put one hand on the hood handle (just above the Peterbilt
emblem), one foot on the bumper, and one foot on the
ground. Tilt the hood forward until you hear it “lock”.
WARNING! If the hood falls, anyone under it
could be injured. Always make sure the lock is
engaged to keep your hood open any time
anyone gets under the hood for any reason.
Never work under the hood unless the hood
safety lock is engaged.
To close the hood, you must first release the hood safety
lock.
WARNING! Before closing the hood, be sure
the area is clear—no people or objects are in
the way.
CAUTION: To avoid hood damage when closing the hood, firmly pull the cable to release
the hold-open lock.
Locate the hood lock release cable as shown in the illustration below. The cable is located on the Drivers side
bumper, visable when the hood is in the open position.
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Medium Duty (R05/09)
ENGINE ACCESS
HOOD HOLD DOWNS AND TILT
After lowering the hood, latch the hood closed with the
hold downs.
WARNING! If the hood is not latched securely,
it could open during operation and cause an
accident. Be sure the hood is latched securely
before moving the vehicle.
LATCHED
Medium Duty (R05/09)
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INSTRUMENTS AND CONTROLS
CONTROLS AND DISPLAYS
Controls and Displays
Instruments and Controls
Introduction
Your Medium Duty dashboard is shown on the opposite
page.
– 14 –
The dash includes standard gauges and switches. Your
vehicle may come with all or some of the switches and
gauges discussed here. The location of switches on the
dash will vary depending on the options ordered and how
your vehicle was configured.
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Medium Duty (R05/09)
CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
LEFT SIDE
1
2
3
4
5
6
7 8
9
16
17
18
15
10
11
12 13 14
20
Medium Duty (R05/09)
19
1
Engine Oil Pressure
2
DEF Gauge
3
Fuel Level
4
Tachometer
5
Driver Information Display
6
Speedometer
7
Primary Air Pressure
8
Secondary Air Pressure
9
Water Temperature
10
Headllights
11
Load Lights
12
Hazard Switch
13
Optional
14
Optional
15
Panel Lights
16
Optional
17
Cruise Control On/Off
18
Cruise Control Select
19
Menu Control Switch
20
Ignition
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INSTRUMENTS AND CONTROLS
CONTROLS AND DISPLAYS
RIGHT SIDE
1
Radio
2
Navigation
3
HVAC Controls
4
Emission Controls
5
Engine Brake (on/off)
6
Engine Brake (Select)
10
7
Optional Switch*
11
8
Optional Switch*
12
9
Optional Switch*
13
14
15
16
10
Park Brake Controls
11
Transmission Display (Automatic)
12
Optional Switch
13
Optional Switch
1
2
3
4
14
Optional Switch
15
Optional USB Port
16
Optional Switch
5 6
*These switches are not shown. These switch locations are
available only if the automatic transmission selector is not
mounted (item 11).
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Medium Duty (R05/09)
CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
Menu Control Switch (MCS)
The MCS has the following functions:
The MCS is used to navigate the Driver Information Display unit. The Menu Control Switch is located on the D
Panel as shown in the illustration below.
• Rotating the MSC
– Selecting display
– Setting values
• Pushing the MSC
– Confirming desired selection
Standard Warning Lights and Audible Alarm
The warning lights and audible alarm may indicate a system malfunction. Check the lights frequently, and respond
properly as soon as you see one go on. These lights could
save you from a serious accident.
Rotate knob to scroll
WARNING! Do not ignore a warning light or
audbile alarm. These signals tell you something is wrong with your vehicle. It could be a
failure in an important system, such as the
brakes, which could lead to an accident. Have
the appropriate system checked immediately.
Push knob to select (Enter)
Medium Duty (R05/09)
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INSTRUMENTS AND CONTROLS
CONTROLS AND DISPLAYS
criticality. The most critical warning will be displayed on
the top row and to the left. If more than six warnings are
active, the menu control switch (MCS) can be used to
scroll through the additional warnings.
3
2. Status Indicator:
2
1
1. Driver Information Display
Additional lights and indicator symbols are displayed in
the Status Indicator. They are limited to:
a. Park Brake
b. Transmission Gear (Automatic transmissions
only)
c. Warnings:
2. Status Indicator
Number of active warnings.
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
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Medium Duty (R05/09)
CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
A red warning is active.
First
An amber warning is active.
Second
d. Cruise Control - active
e. Clock alarm bell
Third
Refer to “Warning Light / Indicator Symbols” on page 20
for information on each symbol.
Refer to “Warning Light / Indicator Symbols” on page 20
for information on each symbol.
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 (approximately 3 seconds each screen) on the Information Display. These are:
Medium Duty (R05/09)
Completing this sequence will indicate a successful Self
Test. Have your instrumentation system checked by a
qualitfied service technician if does not successfully complete.
Audible Alarm:
The audible alarm will sound during the Instrumentation
System Self Test. The audible alarm will also sound in
conjunction with some warning lights. These events
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INSTRUMENTS AND CONTROLS
CONTROLS AND DISPLAYS
include but are not limited to headlight on, fifth wheel, stop
engine, primary/secondary air, and driver door open
warnings.
Example: Engine, and then in alphabetical order.
Warning Light / Indicator Symbols
Symbol Name
Optional Lights:
Additional lights may be operational depending on individual vehicle specifications. These will be included in the
Instrument System Self Test.
NOTE: Some optional lights may illuminate even
though your vehicle is not equipped with that particular feature.
Symbol
1. Active Warnings, Exclamation Point
Color
Std
Opt Page
Red
22
Yellow
23
Yellow
23
Red
23
Yellow
23
2. Active Warnings, Number
3. Active Warnings, Triangle
4. Alternator
Warning Light / Indicator Symbols
The following is a list of Warning Light / Indicator Symbols.
Reading left to right, the table header identifies
5. Anti-Lock Brake System
(ABS)
6. Anti-Lock Brake System
(ABS), Trailer
• the Symbol Name
• the appearance of the Symbol
Yellow
7. Axle, Inter-Axle Differential
Locked (Tandem Axles)
• the Symbol Color when it is illuminated
• whether the symbol is standard (Std) or optional (Opt)
• the Page Number reference for additional information
8. Brake System
Yellow
!
23
24
24
BRAKE
9. Clock, Alarm Bell
Yellow
24
Symbols are listed by major component sections.
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Medium Duty (R05/09)
CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
Warning Light / Indicator Symbols
Symbol Name
Symbol
Warning Light / Indicator Symbols
Color
Std
Opt Page
10. Cruise Control, Active
Symbol Name
Symbol
Color
Std
Opt Page
19. Engine, Overspeed
Yellow
25
Yellow
25
12. Dump Truck, Trailer Body
Up
Yellow
25
13. Emissions, Diesel Particulate Filter (DPF)
Yellow
25
14. Emissions, High Exhaust
System Temperture (HEST)
Yellow
25
11. Dump Truck, Body Up
Red
26
Green
26
Red
26
Yellow
26
Red
26
Red
26
20. Engine, Retarder (Brake)
21. Engine, Stop Engine
22. Engine, Wait To Start
15. Engine, Check Engine
23. Fifth Wheel, King Pin Lock
25
24. Fifth Wheel, Slide
Unlocked
Green
25
25. Lights, High Beam
Yellow
25
Yellow
16. Engine, Ether Start
Blue
27
26. Message Waiting
17. Engine, Heater
Green
27
27. Park Brake
Red
18. Engine, Low Coolant Level
Yellow
Medium Duty (R05/09)
25
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27
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INSTRUMENTS AND CONTROLS
CONTROLS AND DISPLAYS
Warning Light / Indicator Symbols
Symbol Name
Symbol
Warning Light / Indicator Symbols
Color
Std
Opt Page
28. Power Take-off (PTO)
29. Power Take-off (PTO),
Pump Mode
Symbol Name
Symbol
Color
Std
Opt Page
37. Transmission, Oil Filter
Green
27
Green
27
38. Transmission, Oil Temperature High
Green
27
39. Turn Signal, Left
27
40. Turn Signal, Right
27
41. Voltage
Yellow
28
Yellow
28
Green
28
Green
29
30. Refrigerator
31. Seat Belt, Fasten
Red
32. Suspension Dump
Yellow
Orange
29
33. Tire Inflation
Yellow
28
Yellow
28
Warning Light/Indicator Symbol Descriptions
34. Transmission, Auxiliary
1. Active Warnings, Exclamation Point
35. Transmission, Check
36. Transmission, Range
Inhibit
– 22 –
Red
28
Red
28
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Illuminates when a red warning is active. Use
the MCS knob to view the warnings that are
active.RefertothepreceedingFigure “Warning
,
Light/
IndicatorSymbols,”onpage 20forwarningcolorclassification.
Medium Duty (R05/09)
CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
2. Active Warnings, Number
5. Anti-Lock Brake System (ABS)
Illuminates the total number of red and yellow
active warnings. Use the MCS to view the
active warnings if the display shows a > symbol.
Illuminates during the Instrumentation System Self Test. Have the ABS system checked
by a Peterbilt dealer if the ABS Warning
Lamp stays on for more than 3 seconds.
3. Active Warnings, Triangle
Illuminates when an yellow warning is active.
Use the MCS knob to view the warnings that
are active. Refer to the preceeding Figure ,
“Warning Light / Indicator Symbols,” on
page 20 for warning color classification.
Illuminates during normal operating conditions to indicate a problem with the ABS System. See “ABS Warning Lamps” on page 104
for more information.
Illuminates when a problem exists with the
optional Wheel Spin Control feature. See
“Advanced ABS with Stability Control” on
page 106 more information.
4. Alternator
Illuminates if the alternator is not charging.
(For alternators with warning lamp output
signal.)
Medium Duty (R05/09)
Y53-6008A
6. Anti-Lock Brake System (ABS), Trailer
Illuminates during the Instrumentation System Self Test and the tractor/truck is connected with a ABS equipped trailer.
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INSTRUMENTS AND CONTROLS
CONTROLS AND DISPLAYS
7. Axle, Inter-Axle Differential Locked
(Tandem Axles)
Illuminates during normal operating conditions to indicate a problem with the Trailer
ABS System. This should be checked by a
Peterbilt dealer as soon as possible. See
“ABS Warning Lamps” on page 104 for more
information.
Illuminates when the inter-axle differential
switch is ON thus locking the inter-axle differential. This powers the forward rear and the
rear rear differentials equally. When the
switch is turned off (inter-axle differential
unlocked) the engine power is allowed to flow
to any of the 4 drive tires based on the differential effect (mostly to the forward rear differential). (This feature is standard on all
tandem axles).
NOTE:
•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
•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".
8.Brake System
!
BRAKE
Illuminates to indicate a malfunction in the
hydraulic brake system (when equipped with
Hybraulic brakes).
9.Clock, Alarm Bell
Illuminates when the alarm is set. It will flash
when the clock alarm is active.
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Medium Duty (R05/09)
CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
10.Cruise Control, Active
15.Engine, Check Engine
Illuminates when cruise control is active.
Illuminates when a problem exists, but the
vehicle can still be safely driven. Vehicle
should be serviced to correct the problem
but the situation should not be considered
an emergency.
11.Dump Truck, Body Up
Illuminates when Truck Dump Body is up.
12.Dump Truck, Trailer Body Up
16.Engine, Ether Start
Illuminates when Trailer Dump Body is up.
13.Emissions, Diesel Particulate Filter
(DPF)
Illuminates when diesel particulate trap is
plugged. This warning will also illuminate
when regeneration operation is disabled.
14.Emissions, High Exhaust System Temperture (HEST)
Illuminates when the exhaust gas temperature and exhaust components become
extremely hot.
Medium Duty (R05/09)
Y53-6008A
Illuminates when ether start switch is on.
17. Engine, Heater
Illuminates when Engine Heater switch is on.
18. Engine, Low Coolant Level
Illuminates with an audible alarm indicating
critically low coolant level. The vehicle must
be serviced to correct the problem but the situation should not be considered an emergency.
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INSTRUMENTS AND CONTROLS
CONTROLS AND DISPLAYS
19. Engine, Overspeed
22. Engine, Wait To Start
Illuminates when engine RPM is exceeded.
Illuminates when engine grid heater is on
(PACCAR PX-6 and PX-8).
20. Engine, Retarder (Brake)
Illuminates when the engine retarder (compression brake or exhaust brake) switch is
turned on. (Engine retarders are an option.)
Illuminates when air actuated fifth wheel King
Pin is unlocked.
24. Fifth Wheel, Slide Unlocked
21. Engine, Stop Engine
Illuminates 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 vehicle as safely as possible and turn OFF
the ignition. The vehicle must be serviced and the problem corrected before
driving again. Failure to do so may cause
severe engine damage or cause an accident.
– 26 –
23. Fifth Wheel, King Pin Lock
Y53-6008A
Illuminates and an audible warning tone will
sound when the air operated sliding fifth
wheel switch is on, thus unlocking the sliding
fifth wheel. The light and an audible warning
tone should NOT be considered an emergency 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).
Medium Duty (R05/09)
CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
25. Lights, High Beam
28.Power Take-off (PTO)
Illuminates when the high beams are on.
This icon will flash with audible alarm if the
headlamps are left on when the door is open.
In addition, this icon will flash, but without an
audible alarm, if there is a problem with the
low beam headlights or the low beam headlight wiring. In such event, the high beam
headlights will turn on at 50% normal brightness.
Illuminates when the PTO is engaged.
NOTE: Do not drive vehicle with PTO
engaged.
29.Power Take-off (PTO), Pump Mode
Illuminates with remote throttle application.
Indicates pump mode is active.
30. Refrigerator
26. Message Waiting
Illuminates with telematic equipped messaging.
Illuminates to indicate that the refrigerator is
on and ignition is off.
31. Seat Belt, Fasten
27. Park Brake
Illuminates in the status indicator when parking brakes are applied and the vehicle is stationary. This symbol will also illuminate in the
Driver Information Display if the parking
brakes are applied and the vehicle is in
motion.
Medium Duty (R05/09)
Y53-6008A
Illuminates when the ignition key is turned on
as a reminder to fasten your seat belt.
32.Suspension Dump
Illuminates when suspension air bags are
deflated.
– 27 –
INSTRUMENTS AND CONTROLS
CONTROLS AND DISPLAYS
33. Tire Inflation
37. Transmission, Oil Filter
Illuminates when tire pressures need to be
checked. (Tire Pressure Monitoring System
is an option)
Illuminates when service is required (Allison
transmissions only).
38. Transmission, Oil Temperature High
34. Transmission, Auxiliary
Illuminates to indicate auxiliary transmission
is in neutral.
35. Transmission, Check
Illuminates 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
33). If the user is in this display menu, the
icon does not indicate a fault code.
36. Transmission, Range Inhibit
Illuminates with Allison 1000/2000 series
transmissions with “Range Inhibit” output.
Illuminates when transmission lubricant temperature is too high.The information display
will provide the current oil temperature when
the icon is illuminated.
Trans. Temp.
302 F
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 problem corrected before driving again. Failure to
do so may cause severe transmission damage.
39. Turn Signal, Left
Blinks when the left turn signal or the hazard
light function is operating.
– 28 –
Y53-6008A
Medium Duty (R05/09)
CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
Driver Information Display
40. Turn Signal, Right
Blinks when the right turn signal or the hazard light function is operating.
41. Voltage
Illuminates when transmission lubricant temperature is too high.The information display
will provide the current oil temperature when
the icon is illuminated.
WARNING! Do not look at the Driver Information Display for prolonged periods while the
vehicle is moving. Only glance at the monitor
briefly while driving. 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.
Voltage
12.6 Volts
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:
• ignition key in ON or ACC positions
• ignition timer is active
Medium Duty (R05/09)
Y53-6008A
– 29 –
INSTRUMENTS AND CONTROLS
CONTROLS AND DISPLAYS
• MCS button is pushed (independent of ignition key
switch position)
• clock alarm sounds
In addition to a blank screen, the following are menu items
and the information available within each menu selections.
• driver or passenger door is opened
• 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 17 for more detail for the
MCS.
NOTE: Some Driver Information Display functions
are only accessible when the vehicle is parked.
Other functions are accessible while the vehicle is
moving or when parked. Each function is identified
in the following descriptions.
A.Fuel Economy (Accessible while parked or
driving)
The bullets in the Menu Bar allow access to each item by
pushing the MCS when the desired bullet is highlighted.
1. Current fuel economy - Indicates instantaneous fuel economy.
2. Trip fuel economy - Indicates trip fuel economy.
– 30 –
Y53-6008A
Medium Duty (R05/09)
CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
B. RPM Detail (Accessible while parked or driving)
D. Trip Information
NOTE: When accessing the trip information
menu, push the MCS on this menu (bullet).
To exit, push the MCS again. To reset the trip
values, press the Trip Odometer Reset Button on the main gauge instrument cluster.
RPM reading of actual engine RPM. Engine RPM
within the bar graph indicates the engine is operating in the most efficient RPM range. The display
color will change if you are operating outside of this
range.
C. Ignition Timer (Accessible while parked only)
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
Ignition timer is set from this menu. The ignition
timer may be set for up to 30 minutes.
– Trip Engine Hours
– Trip Idle Hours
– Trip Idle Percentage (%)
Medium Duty (R05/09)
Y53-6008A
– 31 –
INSTRUMENTS AND CONTROLS
CONTROLS AND DISPLAYS
– PTO Hours
6. Transmission Model
– PTO Trip Hours
7. Transmission SW Version
– PTO Trip Percentage (%)
8. ABS (Antilock Braking System) Make
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 information menu, push the MCS on this menu (bullet). To exit, push the MCS again.
9. ABS Model
10. ABS SW Version
11. CECU (Cab Electronic Control Unit) Software
Version
12. CECU Hardware Version
F. Diagnostic Display (Accessible only while parked)
NOTE: “Faults Found” will only be active if a
red or yellow warning lamp is illuminated.
1. Chassis Number
2. Engine Make
3. Engine Model
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
4. Engine SW Version
5. Transmission Make
– 32 –
Y53-6008A
Medium Duty (R05/09)
CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
Found" or "Faults Found". If "Faults Found" is active,
pushing the MCS will display new menus for more
information.
G. Transmission Display (Automated Transmissions
only - Accessible while parked or driving)
NOTE: Refer to the Automated Transmission
Operator’s Manual for additional information.
• Display Format 12 Hour (AM/PM) or 24 Hour
(military)
• Home/Local Time
• Alarm ON/OFF
• Alarm Time
• Units of measure
• Language (English, Spanish or French)
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.)
H. Settings Menu (Accessible only while parked)
The Settings menu screen allows the driver to view
and/or change the following menu items:
Medium Duty (R05/09)
Y53-6008A
To Set Clock Display Format:
1. When in the Settings Menu, scroll through the
list of menu items to "Format".
2. Press the MCS to display either 12 hour (AM/
PM) or 24 hour (military) time.
– 33 –
INSTRUMENTS AND CONTROLS
CONTROLS AND DISPLAYS
1. When in the Settings Menu, scroll through the
list of menu items. Press the MCS to select
the item to change.
2.
To Set Home, Local or Alarm Time:
3. Rotate the MCS knob to change the hour.
Press the MCS.
– 34 –
Y53-6008A
Medium Duty (R05/09)
CONTROLS AND DISPLAY
STANDARD GAUGES
Standard Gauges
On the pages that follow you will find descriptions of some
of the gauges on your instrument panel. For more information about using them in driving, see “Starting and
Operating the Vehicle” Also check the Index under the
name of the gauge or function you want to know more
about.
WARNING! Do not ignore a warning light or
audbile alarm. These signals tell you something is wrong with your vehicle. 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.
Trip Reset
Button
Odometer / Trip Meter
Odometer
Trip
Meter
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 exceeded.
Speedometer
The speedometer indicates the vehicle speed in miles per
hour (mph) and in kilometers per hour (km/h). The speedometer also includes an odometer, trip meter, and trip
reset button.
Medium Duty (R05/09)
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
Y53-6008A
– 35 –
STANDARD GAUGES
CONTROLS AND DISPLAY
Tachometer
distance that can be shown on the odometer is
“1 999 999” before it rolls over to zero.
The trip odometer displays how far the vehicle has gone
on a particular trip. The trip odometer will display in miles
on an English speedometer or in kilometers on a metric
speedometer, in one tenth divisions. The maximum distance that can be shown on the trip odometer is “9999.9”
before it rolls over to zero.
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 37.)
NOTE: The Odometer/Trip Meter comes on when
the door is opened or the key is in the accessory
or ignition 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 odometer without ignition switch being turned on.
– 36 –
Your tachometer measures the engine speed in revolutions-per-minute (RPM). The tachometer also includes an
engine hour meter and outside air temperature display.
Watching your tachometer is important to driving efficiently. It will let you match driving speed and gear selection to the operating range of your engine. If your engine
speed gets too high, you can select a higher gear to lower
the RPM. If your engine speed drops too low, you can
select a lower gear to raise the RPM.
Y53-6008A
Medium Duty (R05/09)
CONTROLS AND DISPLAY
STANDARD GAUGES
Engine Hours / Outside Air Temperature
Hour Meter
Snowflake
Symbol
the first 3 seconds, then stay on until the temperature
goes above 37°F or 28°C.
Outside
Air
Temperature
The LCD display in the lower part of the tachometer contains the engine hour meter and the outside air temperature display.
The temperature can display using Standard or Metric
units. Press the trip reset button on the Speedometer 4
times within 4 seconds. This will also change the units
shown by the Driver Information Display.
Refer to “Units of measure” on page 33 for another
method to change units.
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 temperature outside the vehicle. The temperature can be displayed from -40° to 158° in Fahrenheit or -40° to 70°
Celsius.The display will also alert the driver when the outside temperate approaches freezing (32°F or 0°C) by displaying a snowflake symbol. The symbol will turn on when
the temperature drops below 34°F or 11°C and flash for
Medium Duty (R05/09)
Y53-6008A
NOTE: The OAT will come on when the door is
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
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
mirror heat, will increase the outside air temperature displayed while the vehicle is stationary.
– 37 –
STANDARD GAUGES
CONTROLS AND DISPLAY
Engine Oil Pressure Gauge
• If your oil pressure suddenly drops while you are driving, bring the vehicle to a stop as soon as possible in
a safe location off the road and turn off the engine.
Wait a few minutes to allow oil to drain into the oil pan,
and then check the oil level. Add oil if necessary. If the
problem persists, contact an authorized service center.
Check the engine manufacturer’s manual for the correct
oil pressure ranges for your engine.
Water Temperature Gauge
It is important to maintain oil pressure within acceptable
limits. Your engine manual will give normal operating pressures for your engine.
CAUTION: Continuing to operate your vehicle
with insufficient oil pressure will cause serious
engine damage.
• If your oil pressure fails to rise within 10 seconds after
your engine starts, stop the engine and determine the
cause.
The water temperature gauge shows the temperature of
the engine coolant. Under normal operating conditions the
– 38 –
Y53-6008A
Medium Duty (R05/09)
CONTROLS AND DISPLAY
STANDARD GAUGES
water temperature gauge should register between 165°
and 205°F (74° and 90°C). Under certain conditions,
somewhat higher temperatures may be acceptable. But
the maximum allowable temperature is 210°F (99°C) with
the cooling system pressurized, except for certain special
engines. Check your engine manual to be sure.
Engine Overheating
WARNING! Do not remove the radiator fill cap
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 is below
122°F (50°C).
• Protect face, hands, and arms by covering
the cap with a large, thick rag to protect
against escaping fluid and steam.
• Carefully and slowly turn the cap one-quarter of a turn or until it reaches the first stop—
allowing excess pressure to escape—push
down and turn for final removal.
Medium Duty (R05/09)
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, carefully 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:
• Stop the vehicle, but DO NOT TURN OFF THE
ENGINE unless a low water warning device indicates
a loss of coolant.
• With the transmission in neutral, check to be certain
the oil pressure gauge reads normal. Increase the
engine speed to about 1100 - 1200 RPM, maximum.
Return the idle speed to normal after 2 or 3 minutes. If
Y53-6008A
– 39 –
STANDARD GAUGES
CONTROLS AND DISPLAY
the warning light does not go off or the temperature
gauge does not begin to drop, then turn the engine
off.
CAUTION: Use Ultra Low Sulfur Diesel fuel only.
Failure to do so may damage components of the
Diesel Particulate Filter (DPF).
• If the overheating came from severe operating conditions, the temperature should have cooled by this
time. If it has not, stop the engine and let it cool before
checking to see if the coolant is low.
The fuel gauge shows the approximate amount of fuel in
the fuel tanks. Besides empty and full, the gauge also indicates 1/4, 1/2, and 3/4 of total capacity. You will want to
keep your fuel tanks at least half full to reduce condensation of moisture in the tanks. This moisture can damage
your engine.
Fuel Gauge
Diesel Exhaust Fluid (DEF) Gauge
WARNING! Do not remove a fuel tank cap near
an open flame. Hot fuel vapors are combustible and can cause an explosion or fire resulting in injury or death.
– 40 –
The deisel exhaust fluid gauge shows the approximate
amount of DEF fluid in the DEF tank. Besides empty and
full, the gauge also indicates 1/4, 1/2, and 3/4 of total
Y53-6008A
Medium Duty (R05/09)
CONTROLS AND DISPLAY
STANDARD GAUGES
capacity. DEF fluid is required to meet certain emission
requirements. Do not allow your DEF tank to remain
empty. Please refer to your emission supplemental manual for more details about DEF fluid.
CAUTION: Use Diesel Exhaust Fluid only. Failure
to do so may damage components of the Diesel
Particulate Filter (DPF).
Primary (Secondary) Air Pressure Gauge
(Air Reservoir)
The air pressure gauge indicates the amount of air pressure in the brake system in pounds per square inch (psi).
• The primary gauge shows front reservoir air pressure.
• The secondary gauge shows pressure in the rear reservoir.
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 operation, the warning light will glow and the audible alarm will
sound.
Medium Duty (R05/09)
Y53-6008A
– 41 –
OPTIONAL GAUGES
CONTROLS AND DISPLAY
WARNING! The air pressure warning light and
the audible alarm indicate a dangerous situation. There is not enough air pressure in the
reservoirs for repeated braking and the brake
system has failed. If air pressure falls below
60 psi (414 kPa) the spring brakes could suddenly apply, causing a wheel lockup, loss of
control, or your vehicle to be overtaken by following vehicles. You could be in an accident
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.
Forward Drive Axle Temperature Gauge
Rear Drive Axle Temperature Gauge
These gauges indicate the temperature of the lubricant in
your vehicle’s axle(s). These temperatures will vary with
the kind of load you are carrying and the driving conditions you encounter. Maximum axle temperature may
vary, depending upon the axle and type of lubricant. Very
high temperatures signal a need to have your axle(s) lubrication checked.
Optional Gauges
Maximum transmission temperature may vary, depending
upon the transmission and type of lubricant. Check your
transmission’s owner’s manual.
– 42 –
Y53-6008A
Medium Duty (R05/09)
CONTROLS AND DISPLAY
OPTIONAL GAUGES
tional indicator 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.
CAUTION: Driving with very hot temperatures in
your rear drive axles can cause serious damage
to axle bearings and seals. Have your axle lubrication checked if you notice a sign of overheating.
Steering Column-Mounted Controls
Turn Signal and Indicator Lights
NOTE: The ignition key must be turned to ON for
the signal/switch to operate.
Your turn signal lever is mounted on the left side of the
steering column below the steering wheel. Green direc-
Medium Duty (R05/09)
Y53-6008A
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.
– 43 –
OPTIONAL GAUGES
CONTROLS AND DISPLAY
High Beam Headlamps
ID And Clearance Lights Flash
NOTE: The headlamps must be “ON” for the high
beam switch to operate.
• 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.
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 Wiper Mode
• To return to previous beam: pull the lever towards the
steering wheel again.
Press Button For ID and Clearance Lights Flash
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.
• 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.
If your ID and clearance lights are on, they will flash off.
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 windshield 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
ACC for the wiper/washer switches to operate.
– 44 –
Y53-6008A
Medium Duty (R05/09)
CONTROLS AND DISPLAY
OPTIONAL GAUGES
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 intermittent delay times.
Wiper Switch Settings
WARNING! Do not drive with worn or dirty
wiper blades. They can reduce visibility, making driving hazardous. Clean blades regularly
to remove road film and wax build-up. Use an
alcohol-based cleaning solution and a lintfree cloth, and wipe along the blades.
CAUTION:
• Do not use antifreeze or engine coolant in
the windshield washer reservoir—damage to
seals and other components will result.
If the electric pump is operated for a long
period (more than 15 seconds) with a dry reservoir, the pump motor may be damaged.
Medium Duty (R05/09)
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
Y53-6008A
– 45 –
OPTIONAL GAUGES
CONTROLS AND DISPLAY
To Wash The Windshield
Electric Horn
Push the rotary wash/wipe knob in (towards steering column), hold for more than 0.8 seconds and then release.
Hold the knob in to extend the washing cycle. After the
lever is released, the wipers will shut off automatically or
resume the wiper’s setting speed.
Your Peterbilt has an electric horn. To operate, press on
the horn symbol near the center of the steering wheel.
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.
Check the windshield washing fluid level daily. If necessary, fill to top.
Clean all inside and outside windows regularly. Use an
alcohol-based cleaning solution and wipe dry with either a
lint-free or a chamois cloth. 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.
– 46 –
Air Operated Horn (Option)
Your Medium Duty may be equipped with an air horn. To
operate, pull on the lanyard extending 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.
Y53-6008A
Medium Duty (R05/09)
CONTROLS AND DISPLAY
OPTIONAL GAUGES
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
NOTE: The trailer brake is not to be used as the
main means of braking. To use this brake frequently instead of using the foot brake will wear
out the trailer brake sooner.
WARNING! It is dangerous to use air-applied
trailer brakes for parking or holding a vehicle.
Air system pressure can bleed down and
release the brakes. You could have a vehicle
roll-away resulting in an accident. You or others could be badly injured. Always apply the
parking brakes for parking or holding your
vehicle on grade.
To operate the trailer brake hand valve: Pull down on
the lever under the right side of the steering wheel.
WARNING! Activating the trailer hand brake
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 58).
Medium Duty (R05/09)
Tilt- Telescoping Steering Column
Depending on your vehicle’s configuration, you may have
either a Tilt or a Tilt/Telescoping steering column.
• The tilt feature allows forward and rearward movement of the wheel.
• The telescoping feature allows you to move the wheel
up and down.
Y53-6008A
– 47 –
DASH- AND DOOR-MOUNTED FEATURES
CONTROLS AND DISPLAY
To activate these features, locate the Tilt/Telescoping handle on the left side of the steering column.
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 & ACC
START
WARNING! Adjusting the Tilt-Telescoping
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 accident. Make all adjustments to the steering
mechanism while the vehicle is stopped.
– 48 –
• ACC (Accessory): With your key in this position you
can play the radio or use other accessories, but your
engine won’t start.
• OFF:In this position all systems are off, and you can
remove your key.
Y53-6008A
Medium Duty (R05/09)
CONTROLS AND DISPLAY
DASH- AND DOOR-MOUNTED FEATURES
• IGN & ACC:This position allows you to turn on the
engine and all accessory power.
• 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.
Medium Duty (R05/09)
Y53-6008A
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-tosee 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.
– 49 –
DASH- AND DOOR-MOUNTED FEATURES
CONTROLS AND DISPLAY
release the parking brake. If the headlight switch is ON,
the DRL system is overridden, and headlights operate
normally.
WARNING! Do not use daytime running lights
(DRL) during periods of darkness or reduced
visibility. Do not use DRL as a substitute for
headlights or other lights during operations
that require lighting of your vehicle. Doing so
could lead to an injury accident.
Daytime Running Lights
On vehicles equipped with the Daytime Running Light
(DRL) system, the low beam headlights are turned ON
automatically at reduced brightness (to conserve headlamp life).
If the headlight switch is turned OFF, the DRL system
engages automatically after the engine starts and you
– 50 –
Y53-6008A
CAUTION: On vehicles equipped with daytime
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 & headlamps operate
normally.
Medium Duty (R05/09)
CONTROLS AND DISPLAY
DASH- AND DOOR-MOUNTED FEATURES
Panel Light Dimmer
ID and Clearance Lights Switch
The Panel Light Dimmer lets you vary the brightness of
your instrument panel lights.
To Operate Your Panel Light Dimmer:
1. Turn on either the headlights or clearance lights.
2. To brighten the instrument lights, rotate the thumbwheel up.
3. To dim the instrument lights, rotate the thumbwheel
down.
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.
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.
Medium Duty (R05/09)
Y53-6008A
– 51 –
DASH- AND DOOR-MOUNTED FEATURES
CONTROLS AND DISPLAY
Fog Lights Switch
Air Suspension Deflate Switch (Dump Valve)
AIR SUSPENSION
If your vehicle has fog lights, turn them ON or OFF with
the control panel switch with the symbol shown above.
NOTE: Across the U.S.A. and Canada, State/Provincial requirements vary as to when high beams
and fog lights can and cannot be used together.
Some states allow only four lights to be used
together, while some allow more. How your lights
are arranged will affect whether you can operate
headlights and fog lights concurrently—always comply
with the state or provincial requirements where you are
driving.
– 52 –
Your Peterbilt vehicle may have an air suspension deflation 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 prevents you from accidentally deflating the suspension.
Y53-6008A
WARNING! Operating the Air Suspension
Deflate Switch (Dump Valve) while driving can
lead to an accident. Sudden deflation while
your vehicle is moving can affect handling
and control. Use this switch only when your
vehicle is not moving.
Medium Duty (R05/09)
CONTROLS AND DISPLAY
DASH- AND DOOR-MOUNTED FEATURES
CAUTION: Operating a vehicle with air suspension bags either overinflated or underinflated
may cause damage to driveline components. If a
vehicle must be operated under such conditions, do not exceed 5 mph.
WARNING! Do not operate the cruise control
when operating on road surfaces with poor
traction (wet, icy, or snow covered roads) or in
heavy traffic. Accelerations caused by the
normal operation of the cruise control could
cause you to lose control of the vehicle resulting in an injury accident.
Cruise Control Switch
NOTE: Cruise control functions and features may
vary depending upon which engine you have. For
specific explanation of your cruise control, see
the cruise control or engine manual included with
your vehicle.
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.
Medium Duty (R05/09)
This vehilcle’s electronic system will perform a ‘rationality
check’ every time the vehicle is started. This check is to
ensure that the service brakes are working before allowing cruise control to function. This safety feature is
designed to ensure that a driver is able to cancel the
Y53-6008A
– 53 –
DASH- AND DOOR-MOUNTED FEATURES
CONTROLS AND DISPLAY
cruise set speed by using the service brake pedal. The
system will not allow cruise control operation if it does not
pass the ‘rationality check’. The Driver Information Display
will prompt you to press the service brake pedal if it has
not been pressed since the vehicle has been started.
START
START
Regeneration Switch
In order to meet 2007 EPA engine emission requirements,
vehicles will have a either a two or three position switch to
help control and maintain the exhaust Diesel Particulate
Filter. Please refer to “Exhaust After-Treatment System”
on page 128 for more information about the emission control system and how it affects normal operating procedures.
STOP
Two Position
CENTER (three position switch only)
Center is the normal position of the switch.
The center position will allow an automatic regeneration to occur.
START
Depressing the button in the START direction for 4 to 8
seconds will initiate a parked regeneration. Be sure to
release the button to ensure that the system will begin the
regerenation cycle.
– 54 –
Three Position
STOP (three position switch only)
Y53-6008A
When STOP is pressed the system will not regenerate
under any conditions.
Medium Duty (R05/09)
CONTROLS AND DISPLAY
DASH- AND DOOR-MOUNTED FEATURES
CAUTION: Do not leave the three position
switch in the STOP position unless you need
to cancel or stop regeneration. Leaving the
switch in the STOP position for extended periods of time will result in increased soot levels
in the DPF.
Power Mirror Switch
If your vehicle is equipped with power mirrors, the mirror
controls will be located on the driver side door pad. Aerodynamic-style mirrors are controlled for 4-way adjustable
movement, while Moto mirrors are controlled for 2-way
adjustable movement.
Mirror Directional
Control Pad
Mirror Selector
Switch
WARNING! Convex mirrors can distort images
and make objects appear smaller and farther
away than they really are. You could have an
accident if you are too close to another vehicle
or other object. 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.
NOTE: The Power Mirror Switch does not control
the adjustment of the convex mirrors.
Medium Duty (R05/09)
Y53-6008A
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DASH- AND DOOR-MOUNTED FEATURES
CONTROLS AND DISPLAY
Mirror Heat Switch
To Adjust Moto Mirrors
1. Move the mirror selector switch to the right or left from
the neutral center position to select the desired mirror
for adjustment.
NOTE: If the mirror is fixed (non-motorized) on
the left side, then the mirror selector switch will
ONLY allow selection of the neutral and right mirror switch positions.
Mirror Heat
Switch Button
Mirror Heat
Indicator Light
2. Depress the mirror directional control pad towards the
arrows pointing left or right to adjust the mirror in/out.
NOTE: After mirror adjustments have been completed, return the mirror selector switch back to
the center (neutral) position, to prevent unintentional adjustments to the mirrors.
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 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 function has been activated. Pressing and releasing the button
again turns the mirror heat and the indicator light Off.
– 56 –
Y53-6008A
Medium Duty (R05/09)
CONTROLS AND DISPLAY
DASH- AND DOOR-MOUNTED FEATURES
NOTE: The effects of direct sunlight, or the use of
mirror heat, will increase the outside air temperature displayed while the vehicle is stationary.
Power Window Switch
Driver Window
Switch
Power Door Lock Switch
Passenger
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-
Medium Duty (R05/09)
tively, in the window symbol on the switch face. Release the
switch to stop window movement.
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.
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DASH- AND DOOR-MOUNTED FEATURES
CONTROLS AND DISPLAY
Manual Control Lever
Manual and Automatic Control Switch
This hand-operated control lever provides modulated
application of the BrakeSaver in the manual or ON mode
(see next illustration). How much braking you get depends
on how much you move the lever.
With the switch in the AUTOMATIC position, the BrakeSaver will be fully applied automatically when the operator
has the vehicle in gear and takes 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.
– 58 –
A Control Air Pressure gauge and an Engine Oil Temperature gauge are provided with the BrakeSaver.
Y53-6008A
Medium Duty (R05/09)
CONTROLS AND DISPLAY
DASH- AND DOOR-MOUNTED FEATURES
Jacobs Engine Brake or Cummins “C” Brake
Switch
The ON/OFF switch turns the system ON or OFF. The
second switch performs the progressive braking function
that controls the amount of retarding.
• If you have the two-mode system, you can select
HIGH or LOW.
• If you have the three-mode system, you can select
low, medium, or high retarding.
Interaxle Differential Lock Switch
The interaxle differential allows differential action between
the forward rear and the rear rear driving axles. The interaxle differential lock switch allows the operator to LOCK or
UNLOCK the differential. The guard over this switch prevents you from accidentally activating the lock.
SHIFT AT ANY SPEED EXCEPT
IF A WHEEL IS SPINNING
2-Mode and 3-Mode Systems
Medium Duty (R05/09)
Y53-6008A
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DASH- AND DOOR-MOUNTED FEATURES
CONTROLS AND DISPLAY
WARNING! Placing the differential lock in the
“LOCK” position while your wheels are spinning could cause loss of control or axle damage. You could be hurt. Switch to “LOCK”
only when your wheels are not spinning.
See “Interaxle Differential” on page 95 for more information on using your interaxle differential.
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
.
Two-Speed Rear Axle (Range) Switch
.
FIFTH WHEEL
RANGE SELECTOR
If your vehicle is equipped with a two-speed rear axle, you
can select the axle range by the dash mounted switch
shown above. The low range provides maximum torque
for operating off-highway. The high range is a faster ratio
for highway speeds.
– 60 –
Y53-6008A
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.
Medium Duty (R05/09)
CONTROLS AND DISPLAY
DASH- AND DOOR-MOUNTED FEATURES
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 distribution. There is a guard over this switch to protect you
against accidentally activating or releasing the lock.
PULL
TO APPLY
PARKING
BRAKE
PUSH TO
RELEASE
Parking Brake Valve and Trailer Air Supply
Valve
02391-1
Before you leave the cab, apply all parking brakes.
Full Truck Parking Brake Valve
- for vehicles with air brakes:
1. Apply all parking brakes. Pull out the Yellow Parking
Brake Control knob (1) located on the dash. In tractors, the Red (octagon-shaped) Trailer Air Supply
Control knob (2) will automatically pop out.
Medium Duty (R05/09)
Y53-6008A
WARNING! Do not leave the cab without
applying the parking brake. The truck could
roll and cause an injury accident. Always
apply the parking brake before you leave the
cab.
– 61 –
DASH- AND DOOR-MOUNTED FEATURES
(2) Trailer Air Supply
Control (Red)
CONTROLS AND DISPLAY
See “Using the Brake System” on page 101 for more information.
(1) Parking Brake Control
(Yellow)
- for vehicles with hydraulic brakes:
02394
Combination (Tractor/Trailer) Parking Brake Control Valves
2. Shift the transmission into its PARK position. (See
Pages 98 and 143 for transmission shifting and parking brake information.)
3. Turn the key to OFF.
4. Remove the key.
WARNING! Do not pull out the parking brake
valve while the vehicle is moving. Stopping
with the parking brake controls can cause a
sudden wheel lock-up, loss of control, or
over-take by following vehicles. You could be
severely injured.
The parking brake consists of a driveline drum brake actuated by a lever and cable. The hand lever, mounted on the
vehicle's cab floor, pulls or releases the cable controlling
the brake. Pulling upward on the parking brake lever pulls
the cable and expands the driveline brake shoes outward
against the driveline brake drum.
The driveline brake is disengaged by pushing the handle
downward to its lowest position.
NOTE: Failure to fully release the parking brake
can cause the brakes to overheat.
CAUTION: Unless it is an emergency, do not pull
upward on the parking brake lever while the
vehicle is moving. Attempting to stop with the
parking brake could cause damage to the driveline, transmission, or the parking brake mechanism itself.
Using the Parking Brake
1. Come to a complete stop.
– 62 –
Y53-6008A
Medium Duty (R05/09)
CONTROLS AND DISPLAY
DASH- AND DOOR-MOUNTED FEATURES
2. Apply the parking brake. Pull upward on the parking
brake lever until it reaches an over (top) center position. (The PARK light on the dash will come on.)
NOTE: Ensure the lever is over center. The light
will come on prior to brake being fully applied.
PARKING BRAKE LEVER
Medium Duty (R05/09)
Y53-6008A
– 63 –
HEATER-AIR CONDITIONING CONTROLS
CONTROLS AND DISPLAY
Heater-Air Conditioning Controls
NOTES:
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.
•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:
WARNING! Exhaust fumes from the engine
contain carbon monoxide, a colorless and
odorless gas. Do not breathe the engine
exhaust gas. A poorly maintained, damaged, or
corroded exhaust system can allow carbon
monoxide to enter the cab 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.
Never idle your vehicle for prolonged 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.
– 64 –
Y53-6008A
– By a competent technician every 15,000 miles
– Whenever a change is noticed in the sound of
the exhaust system
– Whenever the exhaust system, underbody, cab
or sleeper is damaged
•To allow for proper operation of the vehicle ventilation system, keep the inlet grille at the base of
the windshield clear of snow, ice, leaves and
other obstructions at all times.
•Do not stay in the vehicle with the engine running
or idling for more than 10 minutes with the vehicle’s Heater and A/C ventilation system in
RECIRC or at LOW FAN SPEED. Even with the
ventilation system On, running the engine while
parked or stopped for prolonged periods of time is
not recommended.
Medium Duty (R05/09)
CONTROLS AND DISPLAY
HEATER-AIR CONDITIONING CONTROLS
•If you are required to idle your vehicle for
long periods of time, install an auxiliary
heater or automatic idle control. These auxiliary devices can reduce fuel consumption
and save you money.
•If other vehicles are parked next to you
idling, move your vehicle or do not stay in
your vehicle for prolonged periods of time.
•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
• A rotary knob (A) in the left portion controlling the
blower speed with five settings (including OFF).
• A rotary knob (B) in the center portion controlling the
movement of air within the cab. This control is continuously variable through five modes (clockwise from
left):
– Panel
– Panel/Floor
– Floor
– Defrost/Floor
– Defrost
• A rotary knob (C) in the right portion controlling the air
temperature.
• A push button switch (D) in the center left portion to
engage the air conditioner compressor (only vehicles
with air conditioning).
• A push button switch (E) in the center right portion to
select either fresh- or recirculated-air mode.
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):
Medium Duty (R05/09)
Y53-6008A
– 65 –
HEATER-AIR CONDITIONING CONTROLS
•
CONTROLS AND DISPLAY
.
B
A
C
02980A
D
E
F
NOTE: For vehicles equipped with the Peterbilt
Comfort Control (PCC) option: The PCC option
lets the temperature knob function as a thermostat that regulates duct temperatures based on
the knob settings. When active, the “COMFORT
CONTROL” icon (F) will be illuminated under the
temperature knob (C).
• To heat the cab, select the desired air mode and set
the temperature knob to hot (the red position on the
control) and the blower to whatever speed makes you
most comfortable.
• To defog the windshield, select the Defrost mode
and turn the blower speed to high. Set the temperature knob to hot (the red position on the control). The
air conditioner is automatically activated to remove
moisture from the cab. After the windshield is clear,
adjust the mode, blower speed, and temperature to
your comfort.
Conventional Cab Control Panel (vehicle with air conditioner and PCC)
– 66 –
Y53-6008A
WARNING! Do not drive with visibility reduced
by fog, condensation, or frost on the windshield. Your view may be obscured, which
could result in an injury accident. For clear
visibility 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.
Medium Duty (R05/09)
CONTROLS AND DISPLAY
CIGARETTE LIGHTER
CAUTION: During extreme cold weather, do not
blow hot defroster air onto cold windshields.
This could crack the glass. Turn the air flow control lever to Defrost and adjust the fan speed
accordingly while the engine warms. If the
engine is already warm, move the temperature
selector to Cool, then gradually increase the
temperature when you see that the windshield is
starting to warm up.
4. Close all windows.
5. Idle the engine between 1000 and 1500 RPM and
turn the blower speed control to High.
6. After the cab temperature cools to a comfortable level,
adjust the blower speed and controls to keep the
desired condition.
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 conditioning system is active when the Defrost mode is
selected.
• To cool the cab, turn on the A/C switch, set the temperature knob to cool (the blue position on the control), and the blower to high until the cab becomes
cool. Then you can turn down the blower if you wish.
For Efficient Cooling:
Cigarette Lighter
1. Be sure all heater - air conditioner controls are off.
2. Start the engine. Allow time for warm-up.
CAUTION: 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.
CAUTION: To avoid damage to the compressor & blower motors, turn off all controls
when a system is not in use.
3. Set the air control in the RECIRC mode.
Medium Duty (R05/09)
02912A
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
in. The lighter circuit is protected by a 10-ampere fuse to
Y53-6008A
– 67 –
CUPHOLDERS/ASHTRAY
CONTROLS AND DISPLAY
prevent damage should the lighter get stuck in the IN position. If this fuse needs replacement, check to ensure that
the lighter is not stuck before replacing the fuse.
WARNING! Do not exceed the voltage/amperage capacity of the cigarette lighter. It could
result in a fire . 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 15 amperes maximum.
While there are two receptacles at the top of the
dashboard, there is one more on the base of the cup
holders.
Cupholders/Ashtray
Your vehicle comes standard with two cupholders located
in the center of the cab, below the dashboard. This vehicle
may have an optional ashtray which is designed to fit into
one cupholder.
WARNING! Paper or other combustible substances in an ashtray could cause a fire. Keep
all burnable materials besides smoking materials out of the ashtray.
– 68 –
Y53-6008A
Medium Duty (R05/09)
CONTROLS AND DISPLAY
SHIFT PATTERN DISPLAY
Shift Pattern Display
The correct shift pattern for your vehicle appears on your
control panel or windshield or on a medallion in the shift
knob. It is important that you know more about your transmission than just the shift pattern. Please read the manufacturer’s manual that is included with your vehicle.
CUPHOLDER
Medium Duty (R05/09)
Y53-6008A
– 69 –
ACCESSORIES
CONTROLS AND DISPLAY
Accessories
Peterbilt Navigation System
Your vehicle may be equipped with a Peterbilt Navigation
System. This system is a Global Positioning Satellite
(GPS)-linked computer. It receives input from multiple
sources to locate your vehicle. Read and understand the
Supplemental Navigation System Owner’s Manual and
observe the Warnings, Cautions, and Notes that follow
before using the system.
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. Failure to verify weight restrictions could result in
a traffic infraction.
WARNING! Only glance at the Navigation
System monitor while driving. Prolonged periods of viewing while driving could result in an
accident and possible personal injury.
– 70 –
Y53-6008A
WARNING! Do not program the Navigation
System while driving. Always stop your vehicle when programming or changing the settings 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.
NOTE: Regardless of how and where the navigation 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.
Medium Duty (R05/09)
CONTROLS AND DISPLAY
ACCESSORIES
NOTE: The map database is the most current
available at the time of production. The database
is designed to provide you with route suggestions
and does not take into account the relative safety
of a suggested route or of factors that may affect
the time required to reach your destination. See
the Supplemental Navigation System Owner’s
Manual for more information.
• To close, push the cover up and press to latch it.
• You can lock and unlock the glove compartment door
with your ignition key; turn it clockwise to lock and
counterclockwise to unlock.
Radio
As an option, your vehicle has either an AM/FM Stereo
Receiver or an AM/FM Stereo/Cassette Player.
For instructions on how to operate your particular radio,
see the manufacturer's Radio Operating Instructions in
the glove compartment.
Glove Compartment
A glove compartment is provided to store important documents, the vehicle literature set (including this Operator's
Manual) and other related materials. You can open it by
pushing the knob on the front.
Medium Duty (R05/09)
Y53-6008A
WARNING! Do not drive with the glove compartment open, it can be dangerous. In an
accident or sudden stop, you or a passenger
could be thrown against the cover and be
injured. To reduce the risk of personal injury
during an accident or sudden stop, keep the
glove compartment closed when the vehicle is
in motion.
WARNING! Do not carry loose objects in your
cab, it can be dangerous. In a sudden stop, or
even going over a bump in the road, they
could fly through the air and strike you or a
passenger. You could be injured or even
killed. Secure all loose objects in the cab
before moving the vehicle.
– 71 –
SEATS
Seats
Introduction
Standard Driver's Seat
This section covers the operation and safe use of your
Medium Duty seats. For further information on features
and adjustment of the seat, see the manufacturer's literature included with the vehicle.
The standard driver's seat can be adjusted forward and
rearward. These movements are each controlled by levers
located on the FRONT of the seat.
Driver's Seat with Air Suspension (Option)
Seat Adjustment
WARNING! Do not adjust the driver's seat
while the vehicle is moving. A sudden or
unexpected seat movement can cause the
driver to lose control of the vehicle. Make all
adjustments to the seat while the vehicle is
stopped.
WARNING! Before driving or riding in the
vehicle, be sure that there is adequate head
clearance at maximum upward travel of seat.
Serious injury may occur if head clearance is
not adequate.
• After adjusting the seat and before driving
off, always check to be sure that the seat is
firmly latched in position.
– 72 –
Y53-6008A
Medium Duty (R05/09)
SEATS
Safety Restraint Belts
CHUGGER-SNUBBER
LOCK-OUT FEATURE
Move handle down to
unlock
BACKREST TILT
Rotate knob for
infinite selection of
settings
The right and left seats are equipped with 3-point lap/
shoulder belts; the center seat has a 2-point seat belt.
Safety belts have proven to be the single most effective
means available for reducing the potential for either serious injury or death in motor vehicle accidents. Therefore,
read and follow these instructions and always observe
user warnings pertaining to safety belts.
FRONT CUSHION
HEIGHT
Lift and pull forward
to raise position
FORE & AFT ISOLATOR
Move to left and slide
seat to desired position
SEAT RIDE HEIGHT
LUMBAR ADJUSTMENT
Push switch up to inflate
Push down to deflate
03017
Peterbilt Ultraride II Highback Air Seat
0917A
Unbelted Person in Crash
Medium Duty (R05/09)
Y53-6008A
– 73 –
SEATS
WARNING! Do not drive vehicle without your
seat belt and your riders’ belts fastened.
Riding without a safety belt which is properly
fastened can lead to increased injury or death
in an accident. Unbelted riders could be
thrown into the windshield or other parts of
the cab or could be thrown out of the cab.
They could strike another person. Injuries can
be much worse when riders are unbelted.
Always fasten your seat belt and be sure anyone riding with you does the same.
2. Pull the belt in a continuous slow motion across your
chest and lap.
Lap/Shoulder Belt
The combination lap-shoulder belt is equipped with a locking mechanism. The system adjusts automatically to a
person's size and movements as long as the pull on the
belt is slow.
Hard braking or a collision locks the belt. The belt will also
lock when driving up or down a steep hill or in a sharp
curve.
To fasten the belt:
1. Grasp the belt tongue.
– 74 –
01888
3. Insert the belt tongue into the buckle on the inboard
side of the seat.
4. Push down until the tongue locks securely (with an
audible click). Pull on the belt to check for proper fastening.
• Pull the shoulder section to make sure the belt fits
snugly across the chest.
• The shoulder belt must be positioned over the shoulder—it must never rest against the neck.
Y53-6008A
Medium Duty (R05/09)
SEATS
• Belts should fit snugly across the pelvis and chest.
Make sure any slack is wound up on the retractor.
To unfasten the belt:
Push in the release button on the buckle. The belt will
spring out of the buckle.
• To release a locked belt, lean back to take the body
pressure off of the belt.
• To store a lap-shoulder belt, allow the belt to wind up
on the retractor by guiding the belt tongue until the
belt comes to a stop.
Proper Safety Belt Adjustment
Your combination lap-shoulder belt may need adjustment.
Adjust safety belts properly.
• The lap belt should be worn as low and tight on the
hips as possible. Make sure any slack is taken up by
the belt mechanism.
• The shoulder belt should fit snugly across your body.
It should be positioned midway over the shoulder
(nearer to the door); it should never rest against your
neck.
Lap Belt
Shoulder Belt
Too High
on Hips
Correct
Incorrect
Correct (over arm)
Incorrect (under arm) Incorrect (twisted)
Safety Restraint Belts
Medium Duty (R05/09)
Y53-6008A
– 75 –
SEATS
• Be sure, also, that your belt is not too loose. A loose
belt could allow you to slide under it in an accident,
and that could bring the belt up around your abdomen.
• Do not twist the belt in the process of putting it on. A
twisted belt will not work as well to protect you.
WARNING! Always wear your seat belt low
over your pelvic bones.
• You can be 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.
• 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.
– 76 –
Y53-6008A
WARNING! Do not wear the shoulder belt
under your arm or otherwise out of position.
In a crash your body would move too far forward, increasing 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 (see “Safety Restraint Belts”
on page 73).
WARNING! Do not twist the belt in the process
of putting 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.
Medium Duty (R05/09)
SEATS
Safety Restraint Tips
NOTE: Per FMCSR 392.60 - Unauthorized Persons Not to be Transported. Federal law prohibits the transportation of persons in commercial
vehicles unless they are specifically authorized
in writing by the motor carrier. See the cited
FMCSR for a complete description of the regulation and exemptions.
• Any authorized person riding in your vehicle should
wear a seat belt. A responsible operator sees to it that
everyone in the vehicle rides safely—and that means
with a seat belt.
• Do not strap in more than one person with each belt.
• Do not wear a belt over rigid or breakable objects in or
on your clothing, such as eye glasses, pens, keys,
etc., as these may cause injury in an accident.
• Several layers of heavy clothing may interfere with
proper positioning of belts and reduce the overall
effectiveness of the system.
• Keep belt buckles free of any obstruction that may
prevent secure locking.
Medium Duty (R05/09)
• Damaged or worn belts, subjected to excessive
stretch forces from crashes, cuts or tears, or normal
wear, must be replaced—they may not protect you if
you have an accident.
• If belts show damage to any part of assembly, such as
webbing, bindings, buckles or retractors, they must be
replaced.
• Do not allow safety belts to become damaged by getting caught in door or seat hardware, or rubbing
against sharp objects.
• The belts must be kept clean or the retractors may not
work properly.
• Never bleach or dye seat belts: chemicals can
weaken them. Do, however, keep them clean by following the care label on the belts. Let them dry completely before allowing them to retract.
• Make sure the belt of the unoccupied passenger seat
is fully wound up on its retractor, so that the belt
tongue is in its stowed position. This reduces the possibility of the tongue becoming a striking object in
case of a sudden stop.
• Do not modify or disassemble the seat belts in your
vehicle. They will not be available to keep you and
your passengers safe.
Y53-6008A
– 77 –
SEATS
WARNING! Do not remove, modify, or replace
the tether belt system with a different tether
system. A failed or missing tether belt could
allow the seat base to fully extend in the event
of an accident leading to greater injuries or
death.
• If any seat belt is not working properly, see an Authorized Service Center for repair or replacement.
WARNING! Before driving or riding in a vehicle, ensure that there is adequate head clearance at maximum upward travel of seat.
Shorten the tether belt as necessary to provide adequate head clearance. Serious injury
may occur if head clearance is not adequate.
WARNING! Failure to adjust tether belts properly can cause excessive movement of the
seat in an accident. This could lead to greater
injuries to you. Te ther belts should be
adjusted so that they are taut when the seat is
in its most upward and forward position.
Tether Belts
Tether belts are installed on suspension seats. They help
secure the seat to the floor to restrain it in case of a sudden stop or an accident.
Fixed Tethers
If your Medium Duty has been equipped with fixed length
tethers, no manual adjustment is required. The same
inspection and replacement guidelines should be used as
stated on page 197.
– 78 –
Tether Adjustment
• Make sure that the tether belt is attached to the cab
floor and seat frame. It should be routed through the
buckle on each side.
• Often the attachments are made using a split-type
hook. Make sure both halves of the hook are around
the anchor bracket.
• 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.
Y53-6008A
Medium Duty (R05/09)
SEATS
Komfort–Lok® Latch
Your Peterbilt contains a feature designed to eliminate
cinching and provide improved safety and comfort. Cinching is the condition where a belt becomes continually
tighter around you during a rough, bouncy ride. The need
for this feature increases with rough road conditions, particularly over long distances. To eliminate cinching, simply
activate the Komfort–Lok® feature at the appropriate time:
4. 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.
1. Fasten the seatbelt according to the directions in the
previous “Safety Belt Restraint” section.
LATCH COVER
UP
2. You are now ready to activate the Komfort–Lok. Lean
forward to pull a little slack in the belt (maximum of
one inch, measured from the belt to your chest). Be
sure to allow only a small amount of slack.
3. When the slack is right, flip the latch cover up, cinching it into place.
LATCH COVER
DOWN
02395
The Komfort–Lok latch
Medium Duty (R05/09)
Y53-6008A
– 79 –
SEATS
During Pregnancy
Pregnant women should always wear combination lap/
shoulder belts. The lap belt portion must be worn snugly
and as low as possible across the pelvis. To avoid pressure on the abdomen, the belt must never pass over the
waist. Sometimes pregnant women worry that in a crash
the seat belt could hurt the baby. But if a woman wears
her belt properly—low over her pelvis, below her abdomen—the belt will not harm the baby, even in a crash. And
remember—the best way to keep an unborn baby safe is
to keep the mother safe.
Passengers
Anyone riding in your vehicle should wear a seat belt. A
responsible operator sees to it that everyone in the vehicle
rides safely—and that means with a seat belt.
Pregnant Woman with Belt Properly Worn
Belt Damage and Repair
If any seat belt is not working properly, see an Authorized
Service Center for repair or replacement.
Damaged belts in the cab must be replaced. Belts that
have been stretched, cut, or worn out may not protect you
in an accident.
For further information on seat belts and seat belt maintenance, see “Safety Restraint System — Inspection,” Page
197.
– 80 –
Y53-6008A
Medium Duty (R05/09)
DRIVER'S CHECK LIST
Driver's Check List
Safe Vehicle Operation
To keep your Medium Duty in top shape and maintain a
high level of safety for you, your passengers, and your
load, make a thorough inspection every day before you
drive. You will save maintenance time later, and the safety
checks could help prevent a serious accident. Please
remember, too, that the Federal law requires a pre-trip
inspection and so do commercial trucking companies.
You are not expected to become a professional mechanic.
The purpose of your inspections is to find anything that
might interfere with the safe and efficient transportation of
yourself, any passengers, and your load. If you do find
something wrong and cannot fix it yourself, have an
Authorized Service Center or qualified mechanic repair
your vehicle right away.
The following operations are to be performed by the
driver. Performing these checks and following the maintenance procedures in this manual will help keep your
Medium Duty running properly.
Medium Duty (R05/09)
For your safety, as well as those around you, be a responsible driver:
• If you drink, do not drive.
• Do not drive if you are tired, ill, or under emotional
stress.
Much has gone into the manufacturing of your Medium
Duty, including advanced engineering techniques, rigid
quality control, and demanding inspections. These manufacturing processes will be enhanced by you—the safe
driver—who:
• knows and understands how to operate the vehicle
and all its controls
• maintains the vehicle properly
• uses driving skills wisely
For more information, refer to Department of Transportation Regulation 392.7, which states that interstate commercial motor vehicles are not to be driven unless the
driver is sure that certain parts and accessories are in
working order.
Y53-6008A
– 81 –
DRIVER'S CHECK LIST
WARNING! Do not exceed the specified load
rating. Overloading can result in loss of vehicle control and serious personal injury, either
by causing component failures or by affecting
vehicle handling. Exceeding load ratings can
also shorten the service life of the vehicle.
WARNING! Do not drink and drive . Your
reflexes, perceptions, and judgment can be
affected by even a small amount of alcohol.
You could have a serious—even fatal—accident if you drive after drinking. Please do not
drink and drive or ride with a driver who’s
been drinking.
• The components of your vehicle are
designed to provide satisfactory service if
the vehicle is not loaded in excess of either
the gross vehicle weight rating (GVWR), or
the maximum front and rear gross axle
weight ratings (GAWRs). (Axle weight ratings are listed on the driver's door edge.)
• The use of alcohol, drugs, and certain medications will seriously impair perception,
reactions, and driving ability. These circumstances can substantially increase the risk
of an accident and serious personal injury.
Vehicle Loading
Here are some definitions of weight you should know:
Compare your vehicle's load capacity with the total load
you are carrying. If adjustments need to be made, make
them—do not drive an overloaded vehicle. If you are overloaded or your load has shifted, your vehicle may be
unsafe to drive.
GVWR: is the Gross Vehicle Weight Rating. This is the
MAXIMUM WEIGHT your vehicle is allowed to carry,
including the weight of the empty vehicle, loading platform, occupants, fuel, and any load. Never exceed the
GVWR of your vehicle.
GCW: is the actual combined weight, or Gross Combina-
tion Weight (GCW), of your vehicle and its load: tractor,
plus trailer(s), plus cargo.
– 82 –
Y53-6008A
Medium Duty (R05/09)
DRIVER'S CHECK LIST
GAWR: is the Gross Axle Weight Rating. This is the total
weight that one axle is designed to transmit to the ground.
You will find this number listed on the driver's door edge.
Load Distribution: be sure any load you carry is distributed so that no axle has to support more than its GAWR.
WARNING! An unevenly distributed load or a
load too heavy over one axle can affect the
braking and handling of your vehicle, which
could result in an accident. Even if your load
is under the legal limits, be sure it is distributed evenly.
Approaching Your Vehicle
• Check the overall appearance and condition. Are windows, mirrors, and lights clean and unobstructed?
• Check beneath the vehicle. Are there signs of fuel, oil,
or water leaks?
• Check for damaged, loose, or missing parts. Are there
parts showing signs of excessive wear or lack of lubrication? Have a qualified mechanic examine any questionable items and repair them without delay.
• Check your load. Is it secured properly?
Daily Checks
Emergency Equipment
It is good practice to carry an emergency equipment kit in
your vehicle. One day, if you have a roadside emergency,
you will be glad the following items are with you:
•
•
•
•
•
•
•
window scraper
snow brush
container or bag of sand or salt
emergency light
small shovel
first aid kit
fire extinguisher
Medium Duty (R05/09)
NOTE: The following items (Engine Compartment, Chassis and Cab, and Prestart Checks)
should be checked daily, as a minimum. They
are in addition to, not in place of, federal motor
Carrier Safety Regulations. These regulations
may be purchased by writing to:
Superintendent of Documents
U.S. Government Printing Office
Washington, DC 20402
Y53-6008A
– 83 –
DRIVER'S CHECK LIST
Engine Compartment Checks — Daily
1. Engine Fluid Levels—add more if necessary.
• Engine oil
• Coolant (check while engine is cold)
• Power steering fluid level
• If your truck has hydraulic brakes, check the fluid
level in the master cylinder reservoir. See page 154
for more information.
2. Engine Belt—check tension and condition of belts.
This is important to ensure proper air compressor and
engine operation.
• Measure the belt tension at the longest span of the
belt. See page 142 for further information on checking belt tension.
NOTE: Deflection should be one belt thickness for each foot distance between the
pulley centers.
• If breaks or tears are found, the belt should be
replaced before operating the vehicle.
3. Fuel Filter/Water Separator Draining—check and
drain. Depending on the fuel storage facility, more frequent draining may be required.
4. Windshield washer reservoir fluid level—fill if necessary.
5. Hood closed before entering cab. Is it latched properly?
Chassis and Cab Checks — Daily
Before entering the cab and operating the vehicle, check
the following equipment for proper maintenance:
1. Lights—do headlights, turn signals, emergency flashers, and exterior lamps function and are they clean
and adjusted properly?
2. Windows and Mirrors—are they clean and adjusted
properly?
3. Tires and Wheels—are they inflated properly? Are all
wheel cap nuts in place and torqued properly—tighten
if necessary. Check front wheel bearing oil levels.
Inspect all tires and wheels for damage—correct if
found.
4. Suspension—check for loose or missing fasteners.
Check damage to springs or other suspension parts.
5. Brake Components—check lines, linkages, chambers, and brake operation.
– 84 –
Y53-6008A
Medium Duty (R05/09)
DRIVER'S CHECK LIST
WARNING! Diesel fuel in the presence of an
ignition source (such as a cigarette) could
cause an explosion. You could be seriously
injured. A mixture of gasoline or alcohol with
diesel fuel increases this risk of explosion.
•Do not remove a fuel tank cap near an open
flame.
•Use only the fuel and/or additives recommended for your engine.
6. If your truck has hydraulic brakes, check:
• the brake system for leaks
• hydraulic lines for cracks or kinks
• calipers for leaks
7. Air System—are there leaks?
• Air Tanks—drain water from all air tanks. Make sure
the drain cocks are closed. This procedure is also
required for air suspension tanks equipped with
automatic drain valves.
• See page 101 for further details on “Using the Brake
System.”
8. Steps and Handholds—check for worn surfaces and
loose or missing fasteners.
9. Fluid Tanks—check underneath the vehicle for signs
of fluid leaks. If any are found, correct before operating the vehicle.
10. Fuel Tank Caps—are they secure?
•See page 144 for more information.
11. Trailer Connections (Tractor)—are they secure and
the lines clear? If they are not being used, are they
stored properly?
• Is the trailer spare wheel secure and inflated?
• Is the landing gear up and the handle secured?
12. Check the fifth wheel. Is the kingpin locked?
• Is the sliding fifth wheel locked?
Prestart — Daily
1. Seat—adjust the seat for easy reach of controls.
2. If your vehicle is equipped with an adjustable steering
column, adjust the steering wheel to a comfortable
position.
Medium Duty (R05/09)
Y53-6008A
– 85 –
DRIVER'S CHECK LIST
3. Mirrors—check and readjust mirrors if necessary.
4. Lights—turn ignition key to the IGN & ACC position
and check for warning lights and buzzer. Check operation of turn signals and emergency lights.
5. Instruments—check all instruments.
6. Windshield—check operation of windshield wipers
and washers.
7. Horn—check operation of horn.
2. Wheel Cap Nuts—are they all in place and torqued
properly—tighten if necessary. See “Wheel Cap Nut
Torque,” Page 173.
3. Other Controls and Wiring—check for condition and
adjustment.
4. Steering Components—check pitman arm, draglink,
and power steering hoses, etc., for loose, broken, or
missing parts.
5. Other Engine Compartment Checks
8. Check fire extinguisher charge and road emergency
kit.
9. Fuel—check fuel. Is there enough fuel?
10. Seat Belts—fasten and adjust safety restraint belts
Weekly Operations
• Check condition and fastening of engine belt, hoses,
clamps, and radiator.
• Check the air cleaner, muffler, and exhaust pipes.
Are they tight and secure?
• After Engine Warm-up
– Automatic Transmission—check fluid level in the
automatic transmission oil (if equipped).
1. Battery—check battery and terminals.
– 86 –
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
Starting and Operating the Vehicle
Introduction
For detailed information on starting and operating the
engine, refer to the Engine Operation and Maintenance
Manual provided with your Medium Duty.
Because each vehicle is custom-equipped, all engine
operation instructions presented in this section are general. You will want to consult the engine manual to find out
details about your vehicle's specific engine requirements.
You may need to use a slightly different procedure from
the one outlined here.
Also, read the American Trucking Association's (ATA)
Truck Driver's Handbook. It will give you tips on starting,
shifting, and driving your vehicle.
Medium Duty (R05/09)
Y53-6008A
WARNING! Do not use ether or other starting
fluids as a cold-starting aid in your Medium
Duty. Your engine uses either an electrical
grid or an open flame inside the manifold, to
heat the air/fuel mixture for cold weather starting. If ether or another starting fluid is used,
the air/fuel will ignite inside the manifold,
which could cause an explosion and severe
injury.
WARNING! Do not 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.
• Do not park or operate the vehicle in areas
where the hot exhaust system may come in
contact with dry grass, brush, spilled fuel or
other material that can cause a fire.
– 87 –
STARTING AND OPERATING THE VEHICLE
NOTE: When any one of the following is true, oil
should be applied to the turbocharger oil inlet
port: (1) if the engine has not been started for
more than 25 days; or (2), the outside temperature is very cold; or (3), the oil filter has been
changed.
•With an oil can, squirt approximately one-half
cup (120 ml) of clean, specified engine oil into
the turbocharger oil inlet port. This will keep the
turbocharger bearings lubricated until the
engine oil pressure gets up to normal.
CAUTION: The use of a winterfront can result
in excessive engine coolant, oil, and charge
air (intake) temperatures, which can lead to
overheating and possible engine damage. If
you must use a winterfront
•
Refer to the “Engine Operation and Maintenance Manual” for operating restrictions
and recommendations.
• 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.
Starting Procedure — Normal Temperatures
Use the following procedure to start your Medium Duty
when outside temperatures are at or ABOVE normal starting temperatures. Check the Engine Operation and Maintenance Manual for starting temperatures.
1. Set the parking brake.
– 88 –
2. Insert key into the ignition switch.
3. Disable (or turn OFF) the following systems prior to
starting the engine: the exhaust brake, the dual-speed
rear axle (put in LOW), and block heater (if equipped).
4. Disengage the transmission: place the shift lever in
the Neutral position.
5. Disengage (depress) the clutch (with manual transmission).
6. Turn the ignition switch to the IGN & ACC position. For
normal temperatures, no accelerator advance is necessary. See “Use of Accelerator” below. If the “WAIT
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
TO START” indicator lamp turns ON, wait until the
indicator lamp goes OFF (approximately 60 seconds)
before attempting to start the engine. (For each
engine and ambient temperatures, warm-up cycles
will vary.)
7. Turn the ignition switch to the IGN & START position
to engage the starter. Crank the engine until it starts.
If the engine does not start within 30 seconds, release
the key.
Use of Accelerator
• For mild to warm temperatures above 60°F (16°C)
keep your foot OFF the accelerator pedal while cranking. If the engine does not start after 5 seconds, apply
full throttle while cranking.
• For below normal starting temperatures fully depress
the accelerator (throttle) pedal after engaging the
starter.
NOTE: Pumping the accelerator will not assist in
starting the engine.
Medium Duty (R05/09)
CAUTION: To help avoid overtaxing the starter
motor or batteries, or causing engine damage,
follow the recommendations listed below:
• Do not engage starter for more than 30 seconds at a
time.
• Wait two minutes between each attempt to start the
engine. This allows the starter motor to cool and time
for the batteries to regain power.
• If the engine fails to start after a couple of tries, there
could be a malfunction with the engine or other
related system. Make any adjustments or repairs necessary before trying to start the engine again.
When the engine starts:
• Watch the oil pressure gauge. Oil pressure should
rise within 15 seconds after the engine starts. If the oil
pressure does not rise, stop the engine. Find what is
wrong before restarting. Check the Engine Operation
and Maintenance Manual for the right oil pressure for
your vehicle's engine. In most engines, idle pressure
should be about 15 psi.
Y53-6008A
– 89 –
STARTING AND OPERATING THE VEHICLE
CAUTION: Never operate the starter motor
while the engine is running. The starter and
flywheel gears could clash or jam, severely
damaging them.
• Wait until normal engine oil pressure registers on the
gauge before idling or accelerating the engine beyond
1000 rpm.
• Watch the air pressure gauge. Wait until both pointers
register at least 100 psi (689 kPa) before releasing the
spring brake and moving the vehicle. Also, check the
alarm system for any type of faults and correct them
before moving the vehicle.
CAUTION: Do not try to put the vehicle in
motion before pressure in the air system
reaches 100 psi (689 kPa) because the wheels
will still be locked by the spring brake action.
• Unnecessary stress and possible brake
malfunction could occur if the vehicle is
forced to move before the air system
reaches 100 psi (689 kPa).
– 90 –
Starting Procedure — Cold Temperatures
In addition to the previous “Normal Starting Procedures,”
use these Cold Weather Starting guidelines when the air
temperature falls below a certain temperature. Check your
Engine Operation and Maintenance Manual for further
details on when cold weather starting aids are needed.
Using special cold-starting equipment will help the engine
start easier. And in cold weather, fast engine starting
helps relieve the loads on the electrical system and cranking motor. If you follow these few simple guidelines, you
will extend the service life of your vehicle's engine:
• Keep the electrical system in top condition.
• Use the best quality and recommended grade of fuel
(see Engine Operation and Maintenance Manual).
• Use the recommended engine lubricating oil.
• As stated in the Normal Starting Procedures, when
temperatures are below normal, fully depress the
accelerator pedal after engaging the starter.
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
Engine Block Heater (Option)
To preheat the engine before starting, plug the optional
engine block heater into a properly grounded AC electrical
source. Do not start the engine with the heater plugged in.
WARNING! Engine block heaters can cause
fires resulting in serious personal injury and/
or property damage if not properly maintained
and operated. Regularly inspect the engine
block heater wiring and connector for damaged or frayed wires. Do not use the heater if
there are any signs of problems. Contact your
Authorized Service Center or the manufacturer of the heater if you are in need of repairs
or information.
• Use a solution of half ethylene glycol antifreeze and
half water for best heater performance. Do not exceed
60 percent concentration of antifreeze, as it can
shorten heater life. See page 146 for more information.
• After servicing the cooling system, operate the vehicle
for a day or two before using the heater. Trapped air
inside the engine needs time to escape.
Cold Weather Starting—Air Intake Heater
Do not use ether or any other starting fluid as a cold starting aid in your Medium Duty. Engine conditions are automatically monitored and in cold weather the fuel/air
mixture is preheated in the manifold.
CAUTION: Always unplug the heater before
starting the engine. Damage to the cooling
system could occur if the heater is not turned
OFF (unplugged).
When the temperature falls below 0°F (–18°F) for Caterpillar engines, or –10°F (–24°C) for Cummins engines, the
block heater is required.
Medium Duty (R05/09)
Y53-6008A
WARNING! Do not use ether or other starting
fluids as a cold-starting aid in your Medium
Duty. Your engine uses either an electrical
grid or an open flame inside the manifold, to
heat the air/fuel mixture for cold weather starting. If ether or another starting fluid is used,
the air/fuel will ignite inside the manifold,
which could cause an explosion and severe
injury.
– 91 –
STARTING AND OPERATING THE VEHICLE
With each engine make, the air intake heating system
works differently. To understand fully how your engine's
heating system operates, see the engine Operation and
Maintenance Manual for details.
On most systems the engine block temperature is monitored at startup; other systems monitor the engine oil
pressure, coolant temperature, and time, as well. When
the pre-set conditions are met, the heater automatically
engages.
Air Intake Heater
The air intake heater system will alert you when the
engine requires preheat. On the dash is a “WAIT TO
START” warning light (See page 26). This light alerts you
to wait before starting the engine.
Turn the key to IGN & ACC: the WAIT TO START light will
light up for bulb check.
Wait until the WAIT TO START light goes off before you
start the engine.
When the WAIT TO START light goes off, the preheat
cycle is complete and you can start the engine normally.
– 92 –
After the engine starts and until operating conditions
reach a certain point, the system will continue to operate
to eliminate white-smoke exhaust.
Engine Warm–Up and Idling
The purpose of engine warm-up is to allow an oil film to be
established between pistons, shafts, and bearings while
your engine gradually reaches operating temperature.
Warm–Up Procedure
1. After you have started the engine, idle the engine at
approximately 600 rpm while you check vital engine
systems:
– oil pressure
– air pressure
– alternator output (with the optional voltmeter)
2. Before placing engine under a load, continue warmup with the engine at 900 to 1000 rpm for 3 to 5 minutes.
• When a cold engine is started, increase the engine
speed (rpm) slowly to be sure adequate lubrication
is available to the bearings and to allow the oil pressure to stabilize. In extremely cold temperatures,
you may have to increase idle speed.
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
NOTE: In colder climates where the temperatures are often below freezing, sufficient warmup for turbocharged engines is especially important. Chilled external oil lines leading to the turbocharger will slow the oil flow until the oil
warms, reducing oil available for the bearings.
Watch the engine oil pressure gauge for a
warming trend before increasing engine idle
speed (rpm).
WARNING! Never idle your vehicle for prolonged periods of time if you sense that
exhaust fumes are entering the cab. 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.
Idling the Engine
3. Continue the engine warm-up until the coolant temperature reaches at least 130°F (54°C). At this temperature, you can use partial throttle. Wait until the
coolant temperature is at least 160°F (71°C) before
operating at full throttle. See “Operating Manual
Transmissions” on page 96.
Under most circumstances, continuous idling of your
engine merely wastes fuel. In severe Arctic weather conditions, however, you may need longer idling to be sure all
parts of your engine are fully lubricated.
WARNING! Exhaust fumes from the engine
contain carbon monoxide, a colorless and
odorless gas. A poorly maintained, damaged,
or corroded exhaust system can allow carbon
monoxide to enter the cab or sleeper. Failure
to properly maintain your vehicle could cause
carbon monoxide to enter the cab and cause
serious illnesses.
Medium Duty (R05/09)
Y53-6008A
CAUTION: Do not allow your engine to idle, at
low rpm (400–600 rpm), longer than five minutes. 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 lubrication. The normal torsional vibrations generated can also cause transmission wear.
– 93 –
STARTING AND OPERATING THE VEHICLE
WARNING! Do not work on or near the fan
with the engine running. Anyone near the
engine fan when it turns on could be seriously
injured. If it is set at MANUAL, the fan will turn
on any time the ignition key switch is turned
to the ON position. In AUTO, it could engage
suddenly without warning. Before turning on
the ignition or switching from AUTO to MANUAL, be sure no workers are near the fan.
• During the time it takes you to drink a cup of coffee,
your engine can cool as much as 60° F (33° C) below
normal operating temperature. To keep the engine
warm during a short break, turn it off. Do not allow
your engine to idle longer than five minutes.
Engine Fan Switch (Option)
Your Medium Duty may have an engine fan switch
installed as an option. The switch, which is mounted on
the accessory switch panel, 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 fan switch in the AUTOMATIC position, the engine fan will automatically turn on when
the engine coolant reaches a temperature of about
200°F (93°C)
CAUTION: The fan or equipment near it could
be damaged if the fan turns on suddenly when
you do not expect it. Keep all tools and equipment away from the fan.
NOTE: Do not operate the engine fan in the MANUAL position for extended 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.
Cruise Control (Option)
This feature improves fuel mileage and reduces driver
fatigue by maintaining a constant vehicle speed. The
cruise control will only operate above a programmed minimum vehicle speed, 15 mph for the CAT 3126B engine,
30 mph for the Cummins ISC engine.
– 94 –
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
• To decrease the cruise set speed, hold the SET/
RESUME switch in the RESUME position and coast
to a lower speed.
Engaging the Cruise Control
• To increase the cruise set speed, hold the SET/
RESUME switch in the SET position; this will accelerate the vehicle to a higher speed.
Disengaging the Cruise Control
Do one of these steps to disengage the cruise control:
NOTE: Ensure that the vehicle speed is above
the minimum cruise control speed and the
engine speed is above 1100 rpm.
• Move the ON/OFF switch to the OFF position.
or
1. Move the ON/OFF switch to the ON position.
• Depress the brake pedal.
NOTE: Toggling the SET/RESUME switch to the
RESUME position at this point will select the previously set cruise speed.
2. Accelerate the vehicle to the desired cruise speed.
3. Toggle the SET/RESUME switch lever to the SET
position to set the cruise speed. This toggle switch
has additional functions that are set by the manufacturer. The two functions are:
Medium Duty (R05/09)
or
• Depress the clutch pedal.
Reengaging the Cruise Control
1. Move the ON/OFF switch to the ON position.
or
2. Toggle the SET/RESUME lever to the RESUME position.
Y53-6008A
– 95 –
OPERATING THE TRANSMISSION
STARTING AND OPERATING THE VEHICLE
Operating the Transmission
6, 9, 10, and 11–Speed Manual
Introduction
The 6–speed synchronized manual transmission has 6
forward speeds and 1 reverse. The 9–speed transmission
has 9 forward and 2 reverse speeds, consisting of a 5–
speed low range section and a 4–speed high range section.
Your Medium Duty is equipped with either a manual or
automatic transmission with special features and gearing
to meet your particular needs. It is important for you, the
driver, to understand how your particular transmission is
operated. To do this, you have two sources of information:
this Operator's Manual and the transmission manufacturer's Driver/Operator's Instruction Manual. Because of
the variety of different transmissions installed in Medium
Duty vehicles, operating procedures for your particular
transmission are not included in this manual; therefore,
you should read and understand both manuals. Read the
general guidelines and instructions that follow and read
the specific instructions contained in the transmission
manufacturer's manual that is included with your vehicle.
NOTE: You will find a shift pattern diagram in the
cab. Check to be sure you know the correct
sequence for your particular transmission.
Operating Manual Transmissions
If your truck has an automatic transmission, go to page
100.
– 96 –
For specific instructions on operating one of the optional
10- or 11-speed transmissions, consult the transmission
manufacturer’s Driver/Operator Instruction Manual.
Transmission Warm–Up
In cold weather [below 32°F (0°C)], you may find shifting
sluggish when you first start up. Transmission warm-up is
especially important at this time, but it is always a good
idea to warm your transmission oil before starting out on
the road.
To warm the transmission lubricating oil during engine
warm-up:
1. Put the transmission in Neutral.
2. Release the clutch pedal and let the transmission
operate in Neutral for three to five minutes prior to
shifting into either a forward or reverse range.
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
OPERATING THE TRANSMISSION
Putting the Vehicle in Motion
After making sure the vehicle's oil and air pressure are
correct and all other parts and systems are in proper
working condition:
1. If your truck is equipped with a hand throttle, disengage the hand throttle before driving the vehicle.
2. Fully depress the clutch pedal until the clutch brake
makes contact (see page 98). The contact will occur
at about 1 inch or less from the floorboard.
• The total stroke of the clutch pedal is about 10
inches. The first 1½ inches is free travel. After the
free travel comes the release stroke, which is the
part that fully releases the clutch. The last inch
engages the clutch brake.
• Always start out in a low gear. Starting in a higher
gear, even with a light load, will cause a very jumpy
start and excessive wear.
CAUTION: Always use first gear or a low
speed range to start the vehicle in motion.
The use of a higher gear or speed range
forces undue strain on the engine, clutch,
other transmission components, and may
cause damage.
Medium Duty (R05/09)
3. Evaluate the road surface conditions and terrain your
vehicle is on. Select a gear low enough to let your
vehicle start forward with the throttle at idle.
4. Push the parking brake valve handle (Yellow) against
the dash panel to release the brakes.
5. Release the clutch pedal, then gradually accelerate to
permit smooth starting,
6. Do not allow your vehicle to roll (even a little) in the
opposite direction during clutch engagement. If you
need to start up on an incline, apply your service
brakes before you release the parking brake. Then
release your service brakes as you engage the clutch
and apply throttle.
For further instructions on operating your transmission, see
the transmission manufacturer's manual that is included with
your vehicle.
If you have a misaligned gear condition in your vehicle's
transmission and cannot start, gradually release the
clutch, allowing the drive gear teeth to line up properly.
Then the drive gear can roll enough to allow the teeth to
line up properly and complete the shift.
Y53-6008A
– 97 –
OPERATING THE TRANSMISSION
STARTING AND OPERATING THE VEHICLE
The best engine performance and maximum economy is
obtained if gears are properly selected. This efficiency is
achieved by always selecting gears within optimum
engine rpm, which is where maximum torque and power
are obtained. For further information, see “More Driving
Tips and Techniques” on page 127.
Shifting Gears in a New Vehicle
Shift carefully in a new vehicle. The transmission may be
a little stiff at first. Avoid gear clashing by closely following
these procedures.
When you are operating a new vehicle or one that has
been exposed to cold weather, you want the transmission
lubricant (fluid) to circulate and coat the contacting surfaces of the gears. Metal contacting metal in moving parts
may seriously damage your transmission—do not drive in
one gear for long periods of time until the transmission
lubricant has a chance to coat all contacting surfaces.
Carefully observe the free travel in the clutch for the first
few hundred miles. As the clutch lining wears and high
spots get worn smooth, you will get less free travel.
– 98 –
Clutch Brake and Travel (9–, 10–, and 11–Speed
Transmissions only)
These transmissions utilize a clutch brake, rather than
synchronizers. The clutch brake works by stopping all of
the gears in the transmission, allowing you to easily shift
into first gear or reverse without grinding gears. The total
stroke of the clutch pedal is about 10 inches. The first part
is the release stroke: the part that fully releases the clutch.
The last inch engages the clutch brake.
During hard-shifting with vehicle not moving
• To apply the clutch brake (while the vehicle is
stopped) fully depress the clutch pedal to the floorboard to stop the gears. With the throttle at idle, select
first gear then release the clutch pedal to let the vehicle start forward, until the clutch is fully engaged. See
the transmission manufacturer's manual that is
included with your vehicle for further details.
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
OPERATING THE TRANSMISSION
During Normal Driving
To double clutch:
If you want to shift directly into any gear other than
first or reverse, depress the clutch pedal only far
enough to release the clutch. Pushing the clutch to
the floor applies the clutch brake and could cause gear
hang-up.
CAUTION: Be careful not to apply the clutch
brake while the vehicle is moving. The purpose of the clutch brake is to stop the transmission so that you can shift into a starting
gear without grinding gears. Applying the
clutch brake when the vehicle is moving
causes a braking effect on the drivetrain and
shortens the service life of the clutch brake.
Double Clutching
Whether you are upshifting or down shifting, it is best to
double clutch. Double clutching is easier on the transmission and on the engine, helping your vehicle match engine
speed with driveline speed and achieving clash-free
shifts.
1. Push the clutch pedal down 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, allowing you to
match the rpm of the mainshaft gears to those of the
output shaft.
• Upshifts: let the engine and gears slow down to the
rpm required for the next gear.
• Downshifts: press accelerator, increase engine and
gear speed to the rpm required in the lower gear.
4. Now quickly press the pedal to disengage the clutch
and move the gear shift lever to the next gear speed
position.
5. Release the pedal to engage the clutch.
More Transmission Tips
“Riding” the Clutch
The clutch is not a footrest. Do not drive with your foot
resting on the clutch pedal. It will allow your clutch to slip,
causing excessive heat and wear—damage could result.
Medium Duty (R05/09)
Y53-6008A
– 99 –
OPERATING THE TRANSMISSION
STARTING AND OPERATING THE VEHICLE
Release Bearing Wear
When you must idle your engine for any period of time,
shift your transmission to Neutral and disengage the
clutch (take your foot OFF of the pedal). This helps prevent unnecessary wear to your clutch release bearing,
and it is less tiring for you, too.
Clutch Adjustment
Operating Automatic Transmissions
Inspect manual clutches according to the manufacturer's
recommendations. Regular maintenance should be followed to maintain correct clutch adjustment. Have your
dealer's Service Department perform any adjustment necessary.
Tips
• Always use the clutch when making upshifts or downshifts.
• Always select a starting gear that will provide sufficient gear reduction for the load and terrain.
• Never downshift when the vehicle is moving too fast.
– 100 –
• Never slam or jerk the shift lever to complete gear
engagement.
• Never coast with the transmission in Neutral and the
clutch disengaged.
• To provide smooth gear engagements while shifting,
use proper coordination between shift lever and
clutch.
An automatic transmission makes shifting much easier,
however it is important to understand how to operate the
transmission efficiently. Please read the transmission
manufacturer’s operation manual supplied with your vehicle.
There may not be a “park” position with your automatic
transmission. Always be sure you apply the parking brake
before leaving the cab.
Y53-6008A
WARNING! Do not leave the cab of your vehicle
without applying the parking brake. The truck
could roll and cause an injury accident. Always
apply the parking brake before you leave the cab.
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
USING THE BRAKE SYSTEM
Using the Brake System
NOTE: Today’s diesel engines have significant
torque and startability power at low RPMs. Combinations of engine speed and available torque
may overpower the vehicle’s parking brakes.
WARNING! Never drive your vehicle with the
parking brakes applied. Always release the
parking brakes prior to moving the vehicle.
Failure to disengage the parking brakes prior
to moving your vehicle could result in excessive heat build-up of the brakes and start a
fire.
is supplied by a compressor driven by the engine. The
vehicle's compressor takes outside air and compresses it,
usually to 100–130 psi (690–896 kPa). This 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
truck and trailer brakes. That is why, when you push down
on the brake pedal, you do not 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.
NOTE: If your truck is equipped with hydraulic
brakes, go to page 118.
The operation of the vehicle's braking system and many
vehicle accessories depends upon the storage and application of a high-pressure air supply.
This air brake system is a multiple circuit type: it has a circuit for the front wheels, a separate circuit for the rear
wheels, and one for the trailer (tractors only). The system
Medium Duty (R05/09)
Y53-6008A
WARNING! 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
immediately checked by an Authorized Service Center. Failure to properly maintain your
brake system can lead to serious injury accidents.
– 101 –
USING THE BRAKE SYSTEM
STARTING AND OPERATING THE VEHICLE
Brake Operation
WARNING! Do not drive through water deep
enough to wet brake components, as it may
cause the brakes to work less efficiently than
normal. The vehicle's stopping distance may
be longer than expected, and the vehicle may
pull to the left or right when brakes are
applied, which could contribute to an accident.
If you think your brakes have become wet, check the rear
and both sides of the vehicle for clear traffic, then gently
apply the brakes, releasing and gently reapplying until the
brakes dry out—restoring normal operation. Always check
your brakes after driving through deep water to help
reduce the possibility of personal injury or an accident.
Front Brake System
When the brake pedal is depressed, the front circuit portion of the treadle valve delivers air from the front service
reservoir to the front axle brake chambers via a quickrelease valve.
– 102 –
Simultaneously (on full truck configurations), air is also
supplied to the modulating valve control port. In the event
of a rear service circuit failure, the modulating valve will
exhaust air from the spring brake chambers, applying the
spring brakes in proportion to the front circuit application.
Rear Brake System
When the brake pedal is depressed, the rear circuit portion of the treadle valve delivers air from the rear service
reservoir to the service brake relay valve control port. The
relay valve then delivers air directly from the rear service
reservoir to the rear brake chambers in proportion to the
treadle pressure.
On tractors without ABS, the relay valve is part of the BPR1 brake valve, which automatically proportions the drive
axle brake application pressure when driving bobtail (without a trailer connected). The proportioning BP-R1 brake
valve allows full use of the steer axle (front) brakes and
reduces the chance that the drive axle brakes will lockup.
The bobtail brake proportioning system is automatically
turned off when a trailer is connected.
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
USING THE BRAKE SYSTEM
Using the Parking Brake
Before you leave the cab:
The yellow diamond-shaped knob on the dash controls
the truck/tractor parking brakes. These are spring brakes
that you activate by releasing air pressure from their
chambers. When they are not in use, air pressure compresses the springs and releases the brakes. Pulling the
knob OUT applies the parking brake, which exhausts air
from the chambers and allows the springs to extend and
apply the brakes.
WARNING! Do not pull out the parking brake
valve while the vehicle is moving. Stopping
with the parking brake controls can cause a
sudden wheel lock-up, loss of control, or
over-take by following vehicles. You could be
severely injured.
1. Apply all parking brakes. Pull out the Yellow Parking
Brake Control knob located on the dash. The Red
(octagon-shaped) Trailer Air Supply Control knob on
tractors will automatically pop out. (An optional dash
warning light will indicate when the brake is ON.)
2. Shift the transmission into PARK position:
• manual transmission, select First or Reverse gear
• automatic transmission, select Neutral.
3. Turn the key to OFF.
4. Remove the key.
WARNING! Do not leave the cab without
applying the parking brake. The truck could
roll and cause an injury accident. Always
apply the parking brake before you leave the
cab.
PULL
TO APPLY
PARKING
BRAKE
PUSH TO
RELEASE
02394-1
Full Truck Parking Brake Control Knob
Medium Duty (R05/09)
Y53-6008A
– 103 –
USING THE BRAKE SYSTEM
STARTING AND OPERATING THE VEHICLE
To release the trailer brakes ONLY:
(2) Trailer Air Supply
Control (Red)
(1) Parking Brake Control
(Yellow)
• Push IN the Red knob on the dash. The truck or tractor will remain parked.
To release the full combination of brakes:
02394
Combination (Tractor/Trailer) Parking Brake Control Valves
• Push IN BOTH knobs on the dash.
• In the event that air pressure is reduced below a safe
level: the low air warning light will come on first; if air
pressure continues to drop, the parking brake valve
will pop OUT, automatically applying the spring
brakes.
The parking brakes act on the rear wheels only. They are
spring-applied, with air pressure used to release them.
Release air is supplied by both the front and rear circuit
reservoirs through a double check valve.
To release the truck or tractor parking brakes ONLY:
• Push IN the Yellow knob on the dash. Your trailer will
remain parked.
Below 60 psi (414 kPa) the Yellow parking brake valve
remains OUT (ON position). If air pressure is not
restored above 60 psi (414 kPa), the knob will automatically return to the OUT position if you attempt to
push it in. See page 41 for more information.
– 104 –
Y53-6008A
CAUTION: Do not try to put the vehicle in
m o t i o n b e fo r e p r e s s u r e i n t h e s y s t e m
reaches 100 psi (689 kPa) because the
wheels are locked by the spring brake action.
•Unnecessary stress and possible brake malfunction could occur if the vehicle is forced to
move before the air system reaches 100 psi
(689 kPa).
•Below 60 psi (414 kPa) the parking brake valve
button remains in the applied (ON) position. If
air pressure is not restored, the button will
automatically return to its initial position.
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
USING THE BRAKE SYSTEM
WARNING! If the air pressure falls below 60
psi (414 kPa) the spring brakes may stop the
vehicle abruptly, which could result in an
accident and/or injuries. Observe the red
warning lamps on the gauges. If one comes
on, do not continue to drive the vehicle until
it has been properly repaired or serviced.
WARNING! Do not use the trailer hand brake
or service brakes to park and hold an unattended vehicle—use the parking brakes.
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.
1. Allow the tractor air system pressure to build up to
operating level.
2. When system pressure reaches 50 psi (345 kPa) the
Red knob may be pushed IN.
3. Hold the Red knob IN by hand until the trailer air pressure builds to a pre-set level, about 45 psi. At this
point it will remain in, charging the trailer system and
releasing only the trailer brakes.
4. The Yellow knob will remain OUT (tractor brakes ON).
Normal Run Position
• The Yellow knob (system park) may now be pushed
IN, which will supply air to the tractor spring brakes,
releasing them.
Tractor and Trailer Air Supply Valve
Initial Charge
The red octagon knob controls the air supply to the trailer.
With the system completely discharged, both the Red
(trailer air supply) and the Yellow (parking brake) knobs
are OUT; thus, tractor and the trailer parking (spring)
brakes are applied.
Medium Duty (R05/09)
To supply air to the trailer system and release the trailer
parking brakes:
• With both knobs pushed IN, air is now being supplied
to both the trailer and the tractor spring brakes; all
brakes are released.
Y53-6008A
– 105 –
USING THE BRAKE SYSTEM
STARTING AND OPERATING THE VEHICLE
The parking brakes act on the rear wheels only. They are
spring-applied, with air pressure used to release them.
Release air is supplied by both the front and rear circuit
reservoirs through a double check valve.
NORMAL OPERATING
POSITION
TRAILER
AIR
SUPPLY
PARKING
BRAKE
RED
YELLOW
PARK TRAILER WITH
TRACTOR RELEASED OR
BOBTAIL TRACTOR
TRAILER
AIR
SUPPLY
PARKING
BRAKE
SYSTEM PARK OR
CHARGE TRAILER
WITH TRACTOR PARKED
TRAILER
AIR
SUPPLY
RED
PARKING
BRAKE
YELLOW
YELLOW
RED
02393
Trailer Park or Emergency Brake Application Only
To apply the trailer brakes only:
If you ever have a failure or disconnect the air supply hose
to the trailer, the trailer parking brakes will set. The Red
knob will automatically pop OUT and seal off the tractor
air reservoirs to protect the tractor air system pressure.
Pull OUT the Red knob. This will exhaust air from the
trailer supply line, causing the tractor protection valve to
close and the trailer spring brakes to apply. The trailer is
now in “emergency” or “park.” This mode would be used to
uncouple from the trailer and during bobtail operation
(running without a trailer connected).
– 106 –
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
USING THE BRAKE SYSTEM
WARNING! Do not use the trailer hand brake
or service brakes to park and hold an unattended vehicle—use the parking brakes.
Because service brakes work with air pressure, these brakes could slowly release. Your
vehicle could roll, causing a serious accident.
Someone could be hurt or killed. Never rely on
the service brakes to hold a parked vehicle.
Trailer Charge
• If both knobs are OUT (combination vehicle is
parked), and it is desired to recharge the trailer, the
Red knob may be pushed IN to repressurize the trailer
supply line. The tractor will remain parked. For more
information on air supply pressure requirements, see
page 105.
Parking Tractor and Trailer
• With both knobs pushed in for normal operating
modes, the parking brakes of both the tractor and the
trailer may be applied by pulling the Yellow knob OUT.
This will exhaust the air from the tractor spring brakes,
and simultaneously cause the Red knob to pop OUT,
which will apply the trailer brakes. This complies with
the FMVSS 121 requirement that one control should
apply all the parking brakes on the vehicle.
Medium Duty (R05/09)
Brake Safety and Emergency
Y53-6008A
WARNING! 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 to not
function resulting in the sudden application of
the spring brakes causing wheel lock-up, loss
of control, or over-take by following vehicles.
You could be in an accident and severely
injured.
– 107 –
USING THE BRAKE SYSTEM
STARTING AND OPERATING THE VEHICLE
Front Brakes — Truck
Rear Brakes — Truck
The following applies to full truck configurations:
The following applies to full truck configurations:
If air pressure is lost in the front circuit, the vehicle front
brakes will not operate. Check valves isolate the rear circuit, so the rear service brakes and parking brakes are
unaffected. The spring brakes will not automatically apply
as long as rear service pressure is maintained.
If air is lost in the rear brake circuit, check valves isolate
the front circuit, and front brake operation is unaffected.
Because this is a dual air system, spring brakes will not
automatically apply as long as pressure is maintained in
the front circuit.
WARNING! If the remaining system pressure
drops below 60 psi (414 kPa) due to repeated
brake applications, the spring brakes will
automatically apply—stopping the vehicle
abruptly, potentially causing serious injury.
Observe the warning light (BRAKE AIR) in the
panel. If it comes on, do not continue to drive
the vehicle until it has been properly repaired
or serviced.
When the brake pedal is depressed, the modulating valve
detects the reduction or absence of rear service delivery
pressure, and exhausts air from the spring chambers,
applying the spring brakes in proportion to the front brake
application.
When releasing the brake pedal, the modulating valve
delivers front service air to the spring brake chambers,
releasing the spring brakes in proportion to the front brake
application.
Thus, if there is a rear service failure, the remaining front
axle braking is supplemented by modulated spring brake
action on the rear axle.
– 108 –
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
USING THE BRAKE SYSTEM
WARNING! Efficiency of emergency braking
depends on the amount of air available in the
front circuit reservoir, which is sufficient for a
limited number of brake applications and
releases.
• REMEMBER: when the remaining system
pressure drops below 60 psi (414 kPa), the
spring brake is automatically applied, stopping the vehicle abruptly, potentially causing serious injury. Observe the warning
light (BRAKE AIR) in the panel, it will come
on before the spring brakes are applied. If it
comes on, do not continue to drive the vehicle until it has been properly repaired or
serviced.
• If air pressure is lost in the trailer supply/park circuit,
and the pressure drops below 60 psi (414 kPa), the
trailer spring brakes are automatically applied, and
the tractor air pressure circuits are unaffected.
• If air pressure is lost in the trailer brake service circuit,
and the pressure in the tractor front and rear circuits
drops below 60 psi (414 kPa), the tractor and trailer
spring brakes are automatically applied.
Emergency Braking
WARNING! Unless you have an anti-lock
braking system, always avoid completely
depressing the service brake pedal, if possibl e , ev e n d u r i n g e m e rg e n c y b r a k i n g .
Depressing the brake pedal too aggressively
can cause the wheels to lock, which can lead
to an uncontrolled skid and can result in an
accident.
Brakes — Tractor/Trailer
The following applies to tractor/trailer configurations:
If pressure is lost in the tractor front or rear circuit, the
“check” valves isolate the unaffected circuit, allowing this
circuit to continue normal operation. The trailer brakes are
still functional.
Medium Duty (R05/09)
For Non-ABS Vehicles: To stop your vehicle in an emer-
gency, vary the service brake application pressure to provide maximum braking force without locking the wheels.
Y53-6008A
– 109 –
USING THE BRAKE SYSTEM
STARTING AND OPERATING THE VEHICLE
Use engine compression to assist the service brakes by
not depressing the clutch pedal until the engine reaches
idle speed.
Overheated Brakes
Under normal braking conditions, the energy generated
will bring the internal brake drum temperature to about
500°F (260°C). This is well within the safe zone: the maximum safe temperature of lining for drum type brakes is
usually about 800°F (427°C).
But if service brakes are used for emergency braking,
used improperly, or for prolonged periods, internal brake
drum temperatures may exceed 800°F (427°C). Such
brake overheating may be detected by a burning smell or
smoke coming from a drum. If this occurs, you should
immediately stop and check for cracked brake drums or
lining fires. If neither exists, get back behind the wheel and
resume a slow speed as soon as possible to cool the
brakes. If the vehicle was to remain stopped, the heat
transfer could destroy the linings and distort the brake
drum.
– 110 –
To prevent drums from distortion while they cool down:
• Park the vehicle on level surface and block the
wheels.
• Release the parking brake and allow the brakes to
cool down. See page 103.
Anti-Lock Braking System
This vehicle may be equipped with an anti-lock braking
system (ABS). This ABS reduces the possibility of wheel
lock-up. If a wheel is about to lock during braking, the ABS
will automatically adjust air pressure to the brake chambers on the appropriate wheel(s) to prevent wheel lock-up.
The ABS is automatically turned on when the ignition
switch is turned on.
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. Normally, the ABS lamp will remain on until a speed of no
more than 9 mph has been reached and the speed sensors have been checked for correct output. The lamp
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
USING THE BRAKE SYSTEM
should remain off after this point unless a failure in the
system is detected. The truck/tractor ABS lamp is located
in the warning lamp cluster.
ABS
CAUTION: If the trailer ABS warning lamp
does not illuminate when the ignition is first
turned on, there is a problem with the bulb or
wiring. The driver should have this checked
as soon as possible.
CAUTION: If the truck/tractor ABS warning
light does not illuminate when the ignition is
first turned on, there is a problem with the
bulb or wiring. You should have this checked
as soon as possible.
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.
Medium Duty (R05/09)
NOTE: A successsful warning lamp illumination
and bulb check at ignition on does not indicate
that the trailer you may be connected to has
trailer ABS. You should personally inspect every
trailer to determine its braking system.
A trailer ABS warning lamp will illuminate for a bulb check
when the ignition switch is first turned on - whether or not
a trailer is connected to the vehicle. If the bulb check is
satisfactory, the lamp will next do either of the following:
1. If no trailer is connected, or if a non-ABS-equipped
trailer is connected, the trailer ABS lamp will go off
after a few seconds.
Y53-6008A
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USING THE BRAKE SYSTEM
STARTING AND OPERATING THE VEHICLE
NOTE: A “properly connected” ABS-equipped
trailer is
WARNING! Do not rely on an anti-lock brake
system that is functioning improperly. You
could lose control of the vehicle resulting in a
severe accident and serious personal injury. If
your ABS lamp goes on while you are driving
or stays on after the self-check, your anti-lock
system might not be working. The ABS may
not function in an emergency. You will still
have conventional brakes, but not anti-lock
brakes. If the lamp indicates a problem, have
the ABS checked.
• a trailer with PLC hooked up to the J560 connector.
• a trailer without PLC that is hooked up to an
optional ISO 3731 connector.
NOTE: For doubles or triples: PLC does not distinguish between trailers. An ABS problem in any
trailer will activate the trailer ABS warning lamp.
2. If an ABS-equipped trailer is properly connected, the
trailer ABS warning lamp will remain illuminated for a
few more seconds while the trailer ABS is tested.
• 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
trailer’s ABS problem corrected before the vehicle is driven with that trailer attached.
– 112 –
Wheel Spin Control Warning Lamp
Your ABS may have an acceleration slip regulation (ASR)
or automatic traction control (ATC) feature. Either of these
features is monitored by a wheel spin control warning
lamp. This lamp is located in the warning lamp cluster.
The Wheel Spin Control warning lamp will briefly illuminate and then go out when the ignition switch is first
turned on. The Wheel Spin Control warning lamp will illuminate 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
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
USING THE BRAKE SYSTEM
torque. Do not allow the Wheel Spin Control lamp to
remain on continuously for an extended length of time.
Extended, continuous use of the ASR / ATC can cause
overheating of the drive wheel brakes. Engine torque or
vehicle speed should be reduced to eliminate wheel spin
and prevent excessive application of the ASR / ATC system.
To operate the trailer brake hand valve:
• Pull down on the lever.
• The valve is self-returning. When pressure is removed
from the valve lever, it will return to the OFF position.
NOTE: The trailer brake is not to be used as a
substitute for the service brakes. Using this brake
frequently, instead of using the foot brake, will
cause the trailer brakes to wear out sooner.
Except for checking for proper illumination of the ABS and
Wheel Spin Control warning lamps when first starting the
truck 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.
WARNING! Do not use the trailer hand brake
or service brakes to park and hold an unattended vehicle—use the parking brakes.
Because service brakes work with air pressure, these brakes could slowly release. Your
vehicle could roll, causing a serious accident.
Someone could be hurt or killed. Never rely on
the service brakes to hold a parked vehicle.
Trailer Brake Hand Valve
Tractor/trailer vehicles are equipped with a trailer brake
hand valve mounted on the right side of the steering
wheel column. This hand valve provides air pressure to
apply the trailer brakes only. It operates independently of
the foot treadle valve.
Medium Duty (R05/09)
Driving Bobtail or With an Unloaded Trailer
NOTE: The following information is applicable
only to tractor configurations.
Do not use the engine retarder (such as an
exhaust brake) to slow the vehicle down when you are
bobtailing or pulling an empty trailer.
Y53-6008A
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USING THE BRAKE SYSTEM
STARTING AND OPERATING THE VEHICLE
WARNING! Do not use an engine retarder
when you are driving bobtail or with an
unloaded trailer. Using engine retarders while
bobtailing or with an unloaded trailer can
cause a wheel lockup resulting in less control
and/or jackknife. The trailer may not load the
rear tractor tires enough to provide necessary
traction. When you are bobtail or unloaded,
you can have a serious accident if your
wheels lock suddenly during braking—you
could be severely injured.
Bobtail Brake Proportioning System
When a trailer is not connected, the drive axle brake application pressure will automatically be limited by the proportioning system.
The brake proportioning system regulates the application
pressure to the rear drive axle. To provide equivalent braking power, tractors (driven bobtail) will require greater
brake pedal application than other types of vehicles not
equipped with a proportioning system.
– 114 –
On tractors that do not have anti-lock brake systems
(ABS) a bobtail brake proportioning system is installed.
When a trailer is not connected (bobtail mode), the brake
application pressure (on the rear drive axle) will automatically be limited by the proportioning system.
Engine Retarder (option)
An engine retarder or exhaust brake may be installed (as
an option) to create a braking effect on the drive wheels.
This device uses your engine's power to slow your vehicle
down. Because it can help keep your vehicle's brakes
from overheating, it can save wear and tear on the service
brakes. However, the retarder is not an emergency brake.
Ideally (on normal road surfaces), you should slow your
vehicle with the retarder (where permitted by law) and use
the service brakes only for stopping completely. Operating
this way will greatly prolong the life of the brakes.
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
USING THE BRAKE SYSTEM
WARNING! The service brakes must be used
in an emergency. The engine or retarder alone
might not stop you fast enough to prevent an
accident. You could be badly hurt if you relied
only on the engine retarder.
• Make sure the brake is OFF before starting the
engine.
• After the engine is started, warmed up, and you are
ready to get under way, turn the exhaust brake switch
ON for added braking effect.
• The engine retarder is NOT intended as the
primary brake for the vehicle, nor is it an
emergency brake. The engine retarder only
helps the service brakes by using pressure
to slow the drivetrain. Use the service
brakes for quick stops.
WARNING! Do not use the engine retarder
when operating on road surfaces with poor
traction (such as wet, icy, or snow covered
roads or gravel). Retarders can cause the
wheels to skid on a slippery surface. You
could lose control of the vehicle and/or jackknife if the wheels begin to skid, resulting in
an accident.
Exhaust Brake
With the exhaust brake switch ON, the brake automatically creates its braking effect when you remove your foot
from the accelerator pedal.
The brake switch is located on the accessory dash panel.
It controls whether the brake is ON (ready to slow the
vehicle down) or OFF (no braking action).
• Do not use the engine retarder (such as an exhaust
brake) to slow the vehicle down when you are bobtailing or pulling an empty trailer.
Medium Duty (R05/09)
However, if your vehicle is equipped with Rockwell/
WABCO anti-lock brakes (ABS), the operation of the
exhaust brake (if turned ON) will be controlled by the ABS.
For more ABS information, see “Anti-Lock Braking System” on page 110.
For more information on when and how to use the engine
retarder in your vehicle, see the owner’s manual for the
engine brake that is included with your vehicle.
Y53-6008A
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USING THE BRAKE SYSTEM
STARTING AND OPERATING THE VEHICLE
Compressed Air Tanks: The wet (supply) and dry (ser-
Brake Components
The following is a brief description of the air/brake system.
It is intended to supply you with general information on
how the system works. For complete information see the
Medium Duty Maintenance Manual.
Compressor: supplies air to the system. System pressure
is controlled by the governor.
Governor: controls the air pressure in the system by
vice) tanks are located behind the battery box and on the
frame rail; the supply tank is below the front service tank.
See “Air Tanks” on page 162.
The wet tank receives air from the air dryer and cools it
somewhat, allowing moisture to condense for draining.
Relatively dry air is then supplied to the two service tanks
for distribution to their respective brake circuits. The service tanks are isolated from each other by check valves.
actuating the compressor discharge mechanism. Its cutout pressure is 115 to 125 psi (793 to 862 kPa). Its preset
cut-in pressure is set to between 13 to 25 psi (90 to 172
kPa) below the cut-out pressure setting (cut-out and cut-in
interval is not adjustable).
Dual Service Brake Treadle Valve: delivers air to the two
Safety Valve: installed on the supply reservoir outlet. It
should “vent off” at 150 psi (1034 kPa) permitting air to
escape.
Modulating Valve (SR–1): used only on full trucks, not
tractors. It performs four functions:
Air Dryer (Option): collects and removes moisture and
contaminants from the air as it travels from the compressor to the wet tank (reservoir).
– 116 –
service brake circuits.
Double Check Valve: directs the higher air pressure from
either the rear (primary) or front (secondary) service tank
to the modulating valve.
• Limits spring brake hold-off air pressure delivered to
the spring brake chambers.
• Provides a quick release of air pressure from the
spring brake chambers to speed spring brake application.
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
USING THE BRAKE SYSTEM
• Modulates spring brake application in proportion to
front service application in the event of a rear service
failure.
• Prevents compounding of service and spring applications.
Relay valve (full truck): speeds up the application of the
rear service brake. It also incorporates a quick–release
feature.
Brake Proportioning (BP-R1) valve (tractor): t h i s v a l v e
delivers air to the tractor's service brake chambers. It
automatically proportions the drive axle brake app
lication pressure when driving bobtail (without a trailer
connected). Proportioning the brakes allows full use of the
steer axle brakes and reduces lockup of the drive axle
brakes. The bobtail brake proportioning system is automatically turned off when a trailer is connected.
Quick–Release Valve: speeds the release of air from the
brake chambers. When air is released, the air in the brake
chambers is exhausted at the quick-release valve, rather
than exhausting back through the treadle valve.
Medium Duty (R05/09)
Single Check Valve: allows air flow in one direction only.
Parking Brake Valve: yellow diamond-shaped knob. It
controls the application and release of the parking
(spring) brakes of truck or tractor-trailer combinations or of
the tractor alone. If the air system is being charged from
zero pressure, the parking brake valve will not hold in the
release position until the system pressure exceeds 60 psi
(414 kPa), which is the pressure required to override the
load of this valve's plunger return spring.
Trailer Supply Valve (tractor): T h e R e d o c t a g o n a l -
shaped knob protects the tractor system; it functions in
conjunction with the parking brake valve (yellow). The
trailer supply valve is responsible for synchronizing the
tractor and trailer parking and emergency brakes. If the air
system is being charged from zero pressure, the trailer
supply valve will not hold in the applied position until the
system pressure exceeds 50 psi (345 kPa). It automatically pops out and exhausts air if supply air pressure
drops below 60 psi (414 kPa).
Tractor Protection Valve: The functions of this valve are
to (1) receive all pneumatic signals pertinent to the operation of the trailer brake system, (2) transmit these signals
Y53-6008A
– 117 –
USING THE BRAKE SYSTEM
STARTING AND OPERATING THE VEHICLE
to the trailer, and (3) protect the tractor air supply in case
of separation of the air lines connecting the tractor to the
trailer.
Hydraulic Brakes
WARNING! Do not operate the vehicle in the
event of a malfunction in any air or hydraulic
circuit. Such a malfunction may prevent the
brake system from operating properly, and
could result in an injury accident. The vehicle
should not be operated until the system is
repaired and both braking circuits, including
all pneumatic, hydraulic, and mechanical
components are working properly.
The operation of the vehicle's braking system is based on
the principle of hydraulics. Hydraulic action begins when
force is applied to the brake pedal. This force creates
hydraulic pressure in the master cylinder and is amplified
with assistance of a power booster. The supplemental
boost in force is developed when pressurized power steering fluid from the steering pump presses on the master
cylinder piston. As a safety precaution, the pressurized
fluid from the master cylinder has two mutually independent circuits. The primary circuit supplies the front wheels
– 118 –
while the secondary circuit supplies the rear wheels. The
displaced fluid from the master cylinder travels through
brake pipes terminating at the wheel cylinders which actuate the brake pad mechanisms. Actuation of these mechanisms force the brake pads against the rotors to stop the
wheels.
A reserve electric motor pump provides a redundant
power source for the hydraulic booster in the event normal
flow from the power steering pump is interrupted. Manual
braking is also available in the event both the power and
reserve systems are inoperative.
WARNING! Never drive your vehicle with the
parking brakes applied. Always release the
parking brakes prior to moving the vehicle.
Failure to disengage the parking brakes prior
to moving your vehicle could result in excessive heat build-up of the brakes and start a
fire.
NOTE: Today’s diesel electronic engines have
significant torque and startability power at low
RPM. Combinations of engine speed and available torque may over-power the vehicle’s parking
brakes.
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
USING THE BRAKE SYSTEM
WARNING! 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
immediately checked by an Authorized Service Center. Failure to properly maintain your
brake system can lead to serious injury accidents.
Brake Components
The following is a brief description of the hydraulic brake
system. It is intended to supply you with general information on how the system works. For complete information
see the Peterbilt Medium Duty Maintenance Manual.
Anti-Lock Brake System (ABS) Modulator Valve Body:
adjusts brake fluid flow between the master cylinder and
the wheel calipers to avoid wheel lockup.
ABS Warning Lamp: lights when the ABS controller
detects wheel lock-up while driving and activates the ABS.
Lights also when a fault in the ABS is detected.
Brake Fluid Reservoir: stores brake fluid and offers a
place to replenish when needed.
Medium Duty (R05/09)
Brake Master Cylinder: translates brake pedal force into
hydraulic fluid pressure in the primary and secondary circuits.
Brake Pedal: applies actuation force from operator's foot
to the master cylinder pistons.
Brake Warning Lamp: illuminates when either power
steering fluid flow is interrupted or when a pressure differential is present in the primary and secondary brake fluid
pressure. Either case adversely affects braking operation.
Differential Switch: measures the hydraulic fluid pressure difference between the primary and secondary circuits.
Electrohydraulic Pump: The Electrohydraulic (EH)
pump is used as a backup boost pump. The EH pump
turns on and provides fluid pressure to the hydraulic
booster in the event power steering fluid stops flowing
through the booster head.
Front and Rear Wheel Calipers: translate hydraulic fluid
pressure into force applied at each wheel-end brake rotor
to retard wheel motion.
Y53-6008A
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USING THE BRAKE SYSTEM
STARTING AND OPERATING THE VEHICLE
Hydraulic Booster: The hydraulic booster applies additional hydraulic force from the power steering gear to the
master cylinder piston when the brake pedal is applied.
Parking Brake Lamp: illuminates when the parking brake
is engaged (the lever is in the up position.)
Parking Brake Lever: the hand lever located in the cab
which engages or disengages the driveline drum brake.
Brake Warning Lamp
When the brake warning lamp comes on, it indicates a
malfunction in the brake system. Possible malfunctions
include loss of hydraulic pressure from the power steering
circuit or a pressure differential between the primary and
secondary brake circuits.
WARNING! Do not operate the vehicle if the
brake light or buzzer comes on. The light or
buzzer indicates a failure in one of the brake
components/system. Drive your vehicle to the
side of the road immediately. Failure to do this
may lead to an accident and severe injury.
Power Steering Flow Switch: senses flow of power
steering fluid.
Power Steering Fluid Reservoir: stores power steering
fluid and offers a place to replenish when needed.
Power Steering Gear: assists the steering operation and
sends pressurized power steering fluid to the brake
booster.
Power Steering Pump: draws power steering fluid from
the reservoir and sends it to the power steering gear.
Warning Buzzer: sounds when either power steering
fluid flow is interrupted or when a pressure differential is
present between the primary and secondary brake fluid
pressure. Either case adversely affects braking operation.
– 120 –
!
SERVICE BRAKE WARNING INDICATOR
BRAKE
If the buzzer sounds while driving, or if the BRAKE light
comes on, do the following:
1. Slow down carefully.
Y53-6008A
Here are some things you can do to assist in slowing
the vehicle:
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
USING THE BRAKE SYSTEM
• Downshift - Putting the transmission into a lower
gear will help slow the vehicle.
Avoid driving through deep puddles or flowing water if
possible. If not possible, you should to the following:
• Pump the brakes - Pumping the brake pedal may
generate enough hydraulic pressure to stop the
vehicle.
• Slow down.
• Use the parking brake - The parking or emergency
brake is separate from the hydraulic system. Therefore it can be used to slow the vehicle.
• Gently press on the brake pedal.
• Place transmission in lower gear.
• Increase engine speed while keeping light pressure
on the brake pedal for a short distance to dry out the
brake linings.
2. Move a safe distance off the road and stop.
• Overheated Brakes
3. Set the parking brake. (See page 103.)
4. Turn on the emergency flasher and use other warning
devices to alert other motorists.
Wet or Overheated Brakes
• Wet Brakes
If you have been driving in heavy rain or deep standing water, your brakes will get wet. Water in the brakes
can cause them to be weak, to apply unevenly, or to
grab. These conditions can cause a lack of braking
power, wheel lockups, or pulling of the vehicle to one
side or the other.
Medium Duty (R05/09)
Y53-6008A
While traveling down steep hills, gravity will tend to
speed you up. You must go slow enough that your
brakes can hold you back without getting too hot. If
you ride the brake pedal and the brakes get too hot,
they may “fade”, causing you to press even harder in
an attempt to maintain your desired stopping power.
The brakes may even fade so much that you won’t be
able to slow down or stop at all.
Using lower transmission gears will help keep the
vehicle from going too fast. Using lower gears allows
engine compression and friction to help slow the vehicle. Be sure to be in the right gear before you start
down a hill, especially if you have a manual transmis-
– 121 –
USING THE BRAKE SYSTEM
STARTING AND OPERATING THE VEHICLE
sion. You could get hung up in NEUTRAL and lose the
benefit of engine braking. “Coasting” is illegal, and
also VERY dangerous.
OFF, there may be a stored fault code. If the lamp
remains ON when a speed in excess of 4 mph (6 km/h) is
reached, there may be an active fault in the ABS system.
Anti-Lock Braking System
This vehicle is equipped with an Anti-Lock Braking System (ABS). ABS reduces the likelihood of a wheel locking.
If a wheel is about to lock during braking, the ABS will
automatically adjust hydraulic pressure to the brake calipers on the appropriate wheel(s) to prevent wheel lock-up.
The ABS is automatically activated when the ignition
switch is turned on.
CAUTION: The center pin of the 7-way trailer
light line may be constantly powered for ABS.
Make sure it will not accidently turn on trailer
equipment.
ABS Warning Lamp
The ABS warning lamp will come on briefly, then go off,
when the key switch is first turned on. If the lamp remains
ON until a speed of 4 mph (6 km/h) is reached, then goes
– 122 –
Y53-6008A
CAUTION: If the ABS warning light does not
illuminate when the ignition is first turned on,
there is a problem with the bulb or wiring. You
should have this checked as soon as possible.
WARNING! No indication will be given via the
dashboard warning lights or buzzer if tires of
the wrong size are installed on your vehicle.
The Anti-Lock Brake System (ABS) is calibrated for the specific tire revolutions per
mile. Use of a tire and/or wheel size different
from that originally installed on your vehicle
may cause the ABS system to not function
during a hard braking event. This could cause
an accident or serious personal injury. Consult with your Peterbilt dealer before using a
different tire and/or wheel size than was originally installed on your vehicle.
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
USING THE BRAKE SYSTEM
Parking Brake Burnishing
This procedure is recommended for new vehicles where
less lever actuation force is required. This procedure is
mandatory whenever the driveline brake shoes or brake
drum are replaced.
WARNING! If a new drum or new brake shoes
are installed, the driveline brake must be burnished. Failure to properly burnish the parking brake before putting it in service could
result in an inoperative parking brake, possible vehicle rollaway, and serious personal
injury or damage to the vehicle.
Medium Duty (R05/09)
Y53-6008A
1. Drive the vehicle at 15 mph (24 km/h) in a low gear
(first or second) on a dry, hard road surface.
2. Apply the parking brake lever with a moderate force
(approximately 40 pounds) until the vehicle is
brought to a stop. Do not allow the wheels to lock up.
3. After stopping, release the parking brake lever and
drive the vehicle at 20 mph (32 km/h) in a low gear
for approximately 2.5 miles, to allow the brake drum
to cool.
4. Repeat steps 1, 2, and 3 above until a total of 10
stops have been completed.
5. Adjust the parking brake lever. See the Medium Duty
Maintenance Manual.
– 123 –
OPERATING THE REAR/DRIVE AXLE
STARTING AND OPERATING THE VEHICLE
Operating the Rear/Drive Axle
Introduction
This section covers the operation of your Rear/Drive Axle.
These instructions apply to the most common features of
drive axles. Refer to the manufacturer’s instructions for
further information on the operation of your axle.
If your vehicle is equipped with a Rockwell Tractech™ Nospin single rear axle, the wheel differential lock feature
automatically engages and disengages. When one wheel
starts to spin on a slippery surface, this rear axle feature
engages to improve traction.
Interaxle Differential Lock
On vehicles with tandem rear axles, the interaxle differential allows each axle to turn independently. Differential
action between the tandems relieves stress on the rear
axles and reduces tire wear. The interaxle differential lock
switch allows the operator to LOCK or UNLOCK the differential, depending on road surface conditions.
When operating normally on paved, dry surfaces, keep
your truck's interaxle differential in the UNLOCK position.
– 124 –
SHIFT AT ANY SPEED EXCEPT
IF A WHEEL IS SPINNING
In the LOCK position, an air operated clutch positively
locks both sets of axles together, providing greater traction on slippery road surfaces; however, steering around
corners and on dry pavement is more difficult. Continuous
operation on a paved, dry surface stresses the tandem
axles, possibly causing internal damage.
Use this feature only when driving on surfaces with poor
traction, such as wet slippery roads, heavy mud or snow,
or loose gravel. And do not use it when going downhill or
at speeds greater than 25 mph (40 km/h).
Lock the inter-axle differential when you encounter road
conditions such as these:
• Ice or snow — with or without tire chains.
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
OPERATING THE REAR/DRIVE AXLE
• Dirt roads.
• Loose sand, mud, or other rough road conditions.
Inter–Axle Differential Lock Operation
WARNING! Do not use the inter-axle differential lock when travelling downhill or at speeds
above 25 mph (40 km/h). When it is engaged
under these conditions, your vehicle will
exhibit “understeer” handling characteristics. This “understeer” condition will cause
your vehicle to turn less quickly and more
steering effort will be required, which can
cause an injury accident.
WARNING! Do not put the differential lock in
the LOCK position while the wheels are spinning freely (slipping), you could lose control
of the vehicle or cause axle damage—you
could be injured. Switch to LOCK only when
the wheels are not spinning.
• Look ahead for wet, muddy, or icy patches on the
road, stop your vehicle and switch to LOCK ahead of
time.
WARNING! Do not operate the vehicle on dry
pavement with the differential locked. This
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 operating on surfaces with poor
traction, such as wet, slippery roads or loose
gravel.
Medium Duty (R05/09)
To LOCK the inter-axle differential:
1. Anticipate when you might need increased traction,
slow down to a steady speed under 25 mph (40 km/h)
or stop the vehicle. Do not lock the inter-axle differential while going down steep grades or traveling faster
than 25 mph, or while wheels are spinning or traction
is minimal; lock it before you encounter these conditions.
Y53-6008A
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OPERATING THE REAR/DRIVE AXLE
STARTING AND OPERATING THE VEHICLE
NOTE: If your vehicle has an automatic transmission, it may be necessary to shift the transmission to the Neutral position momentarily to
allow the main inter-axle differential lock splines
to fully engage or disengage.
Turning Radius When
Unlocked (Disengaged)
4. Drive the vehicle through the poor traction area, keeping your speed under 25 mph (40 km/h).
Turning Radius When
Locked (Engaged)
To UNLOCK the inter-axle differential:
02871
Understeer Condition
2. Put the inter-axle differential lock switch, labeled
MAIN DIFFERENTIAL LOCK, in the LOCK position. A
light (DIFF LOCK) in the warning module on the dash
will turn on, indicating that the differential is locked
(engaged).
1. When you reach dry pavement or better road conditions where the differential lock is not needed, switch
the differential lock to UNLOCK.
2. Let up momentarily on the accelerator pedal to relieve
torque and allow the clutch to disengage.
3. When you unlock the differential, normal vehicle handling will resume and the light on the warning module
will turn off.
3. If you LOCK or UNLOCK the inter-axle differential
while moving, let up momentarily on the accelerator
pedal to relieve torque on the gearing and allow full
engagement of the clutch (the mechanism that locks
the wheels).
– 126 –
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
MORE DRIVING TIPS AND TECHNIQUES
More Driving Tips and Techniques
Use of Driver Information Display
WARNING! Low air pressure could make the
brakes unsafe for driving. Before driving the
vehicle, make sure the pressure does pump
up to over 100 psi for normal brake operation.
If the air pressure does not pump up to at
least 100 psi, don’t try to move the vehicle.
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.
Coasting
CAUTION: Operating a vehicle with air suspension bags either overinflated or underinf l a t e d m ay c a u s e d a m a g e t o d r i v e l i n e
components. If a vehicle must be operated
under such conditions, do not exceed 5 mph.
WARNING! Do not coast with the transmission in neutral or with the clutch pedal
depressed—it is a dangerous practice. Without the use of the retarding power of the drivetrain, your vehicle can reach dangerous
speeds. At very high speeds you may not be
able to put the transmission in any gear. 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.
Driving Tips And Techniques
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.
Do not coast with the transmission in neutral or with the
clutch pedal depressed. Besides being illegal and dangerous, coasting is also expensive. It causes premature failMedium Duty (R05/09)
Y53-6008A
– 127 –
DRIVING TIPS AND TECHNIQUES
STARTING AND OPERATING THE VEHICLE
ure or damage to the clutch and transmission and
overloads the brake system.
Engine Overspeed
CAUTION: To avoid engine damage, do not let
the engine rpm go beyond the maximum governed rpm—valve damage could result if overspeed conditions occur.
Coasting with the transmission in neutral also prevents
proper transmission component lubrication. During coasting the transmission is driven by the rear wheels, and the
countershaft gear (which lubricates the transmission components by oil splash) will only be turning at idle speed.
NOTE: Often these recommendations are secondary to maintaining an adequate and safe
speed relative to the surrounding traffic and road
conditions.
Descending a Grade
WARNING! Do not hold the brake pedal down
too long or too often while going down a steep
or long grade. This could cause the brakes to
overheat and reduce their effectiveness. As a
result, the vehicle will not slow down at the
usual rate. To reduce the risk of personal injury
and/or an accident, before going down a steep
or long grade, reduce speed and shift the transmission 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.
Operate the engine within the optimum engine rpm range
and do not allow the rpm's to exceed the maximum governed speed. See your Engine Operation and Maintenance 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.
– 128 –
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
DRIVING TIPS AND TECHNIQUES
Refer to the Engine Operation and Maintenance manual
for optimum engine rpm.
• If the engine rpm moves beyond the maximum governed speed, indicating an overspeed condition,
apply the service brake or shift to a higher gear to
bring engine rpm within the optimum speed range.
• Shift into higher or lower gears (or apply the service
brake) to keep engine rpm near the lower end of the
optimum operating range.
• Avoid rapid acceleration and braking.
• 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 transmission, for example, on steep downgrades. Apply service
brakes or shift to a higher gear.
Fuel economy and engine performance are also directly
related to driving habits:
• The best results in trip time and fuel economy are
obtained while driving the vehicle at a steady speed.
Medium Duty (R05/09)
Y53-6008A
WARNING! Do not exceed the specified load
rating. Overloading can result in loss of vehicle control and serious personal injury, either
by causing component failures or by affecting
vehicle handling. Exceeding load ratings can
also shorten the service life of the vehicle.
• The components of your vehicle are
designed to provide satisfactory service if
the vehicle is not loaded in excess of either
the gross vehicle weight rating (GVWR), or
the maximum front and rear gross axle
weight ratings (GAWRs). (Axle weight ratings are listed on the driver's door edge.)
NOTE: For your safety and the safety of others,
follow routine and periodic maintenance schedules for all components on your vehicle. See Table 3,
“Maintenance Schedule,” Page 123
– 129 –
DRIVING TIPS AND TECHNIQUES
STARTING AND OPERATING THE VEHICLE
Air Suspension Height/Air Pressure
Your vehicle may have an air suspension. A deflation
switch on the dash allows you to exhaust the air in the
suspension, which allows you to lower the height of your
vehicle for loading. On tractors, the deflate switch allows
you to lower the fifth wheel to slide under a trailer.
A guard on the switch prevents you from accidentally
deflating the suspension.
WARNING! Do not operate the Air Suspension
Deflate Switch (Dump Valve) while driving.
Sudden deflation while your vehicle is moving
can affect handling and control and could
lead to an accident. Use this switch only when
your vehicle is not moving.
CAUTION: Operating a vehicle with air suspension bags either overinflated or underinf l a t e d m ay c a u s e d a m a g e t o d r i v e l i n e
components. If a vehicle must be operated
under such conditions, do not exceed 5 mph
(8 km/h).
– 130 –
AIR SUSPENSION
Air Suspension Deflate Switch
Setting Ride Height
Vehicles equipped with rear air suspensions have their
ride height and axle (pinion) angle(s) preset at the factory.
These are precision settings and should not be altered.
Incorrectly adjusted ride height may result in improper
interaxle U-joint working angles. This can result in premature driveline wear and driveline vibration. If your vehicle is equipped with a Peterbilt rear air suspension, and if
it becomes necessary to reset the ride height, you may
temporarily set it by following the next procedure. Proper
ride height measurement and values are shown in the
illustration and table below.
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
DRIVING TIPS AND TECHNIQUES
WARNING! To prevent possible injury and damage to
property, ensure that a vehicle is parked and the
wheels chocked before beginning this procedure.
CAUTION: Completing this procedure will
enable you to safely reach the nearest authorized Peterbilt repair facility to have ride
height and pinion angle reset using the proper
equipment and technique. Do this as soon as
possible to avoid potential driveline damage.
NOTE: Suitable wheel chocks are at a minimum
an 18-inch (46 cm) long 4x4.
Ride Height Measurement (Location for Tandem Axles Shown)
Proprietary Rear
Air Suspension
Air Trac
Low Air Leaf
1. Ensure that the air supply and delivery plumbing of
the height control valve is consistent with the illustration.
Ride Height [inches (mm)]*
Single Drive
11.00 (279)
6.50 (165)
NOTE: At least one of the mounting holes in the
height control valve bracket will be slotted to permit rotating the valve.
Tandem Drive
11.00 (279)
8.50 (216)
NOTE: On dual-valve systems, begin with the LH
valve on the next step.
*These values are for a fully laden vehicle
Follow this procedure to temporarily set ride height.
2. Loosen the fasteners mounting a height control valve to
its bracket.
Medium Duty (R05/09)
Y53-6008A
– 131 –
DRIVING TIPS AND TECHNIQUES
STARTING AND OPERATING THE VEHICLE
WARNING! Be extremely careful when deflating the air springs. The rear of the vehicle will
drop about 3-1/2 inches (88 mm) when the air
springs are deflated. Make sure that no persons or objects that could be injured or damaged are under the vehicle.
To minimize the risk of damage or injury, do
not use the dump valve to deflate the air
springs. Operate the height control valve(s)
manually to ensure positive control of air
spring deflation.
ALIGNMENT PIN OR DOWEL CONTROL ARM
LINK BOLT
FROM DUMP VALVE SWITCH
To minimize risk of injury, keep away from air
springs as they are being inflated.
FORWARD
02941A
Typical Height Control Valve (Top View)
– 132 –
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
DELIVERY TO RH AIR BAG(S)
SUPPLY FROM FORWARD
AIR TANK
MOUNTING NUTS
DRIVING TIPS AND TECHNIQUES
3. Rotate the valve either clockwise or counterclockwise
until air pressure in the air springs provides the ride
height specified for that suspension. Measure the ride
height from the bottom of the frame rail to the approximate centerline of the rearmost drive axle hub:
• For tandem axles, make the vertical measurement
at the centerline of the suspension (see illustration
on page 131).
• 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.
EXHAUST
DELIVERY TO LH AIR BAG(S)
AIR BAG
LINK ROD
02941B
Typical Height Control Valve
(Rear View Looking Forward)
4. 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 131).
5. Torque the mounting fasteners to 55 — 75 lb. in.
(6.2 — 8.5 N.m.).
6. Remove the alignment pin or dowel.
7. Repeat Steps 2 through 6 above for the RH valve on
vehicles with a dual-valve system.
Medium Duty (R05/09)
Y53-6008A
– 133 –
DRIVING TIPS AND TECHNIQUES
STARTING AND OPERATING THE VEHICLE
Driving with Deflated Air Springs
WARNING! Low air pressure could make
brakes unsafe for driving by not providing
sufficient air brake application pressure in an
emergency, which could lead to an injury accident. Before driving the vehicle, make sure
the air pressure pumps up to over 100 psi for
normal brake operation. If it does not reach
100 psi, do not try to move the vehicle.
Vehicles with the air suspension (option): If an air spring
ruptures, there will be enough air pressure to drive the
vehicle to a safe stop off the highway to investigate the
problem.
WARNING! Do not continue to drive with ruptured air springs. The air loss can cause the
spring brakes to apply allowing your brakes to
drag and burn up the linings, which could lead
to an injury accident. Do not continue to operate the vehicle in this condition.
CAUTION: Do not operate a vehicle with air
suspension bags either over- or underinflated. This could cause damage to driveline components. If you must drive under
such conditions, do not exceed 5 mph (8 km/
h).
To get to a repair facility, 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.
Fifth Wheel
The following applies to tractor configurations:
2. The air system can then be pumped up to normal
pressure for continued operation.
– 134 –
Y53-6008A
WARNING! Ensure that all fifth wheel maintenance, adjustments, and rebuilding are done
only by a qualified mechanic. An improperly
maintained fifth wheel can cause a trailer to
separate from a tractor. This could lead to an
injury accident and damage to property.
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
DRIVING TIPS AND TECHNIQUES
Your Medium Duty may be equipped with either a fixed or
an air-controlled sliding fifth wheel. Either type should
self-lock when a trailer king pin trips the locking dogs as
the tractor is backed under a trailer.
Fifth Wheel Jaw Lock
To unlock the fifth wheel lock:
FIFTH WHEEL
• Pull out on the lever (usually located on the left-hand
side of the fifth wheel) until it remains in an overcenter
position.
Hook–Up:
Air–Controlled Sliding Fifth Wheel
• After connecting your tractor to the trailer, always
inspect the jaws to be sure they have locked on the
kingpin before driving.
Medium Duty (R05/09)
Fifth Wheel Slide Switch
Vehicles having an air-controlled sliding fifth wheel have a
fifth wheel slider lock controlled by a switch on the accessory switch panel. To operate this type of lock, move the
switch to the appropriate position. By placing the switch in
the UNLOCK position, you can slide the fifth wheel to various positions to adjust weight distribution. There is a
guard on this switch to protect you against accidentally
activating or releasing the lock.
Y53-6008A
– 135 –
DRIVING TIPS AND TECHNIQUES
STARTING AND OPERATING THE VEHICLE
WARNING! Do not move of the fifth wheel
while the tractor-trailer is in motion. Your load
could shift suddenly, causing you to lose control of the vehicle, which can result in a serious accident. Never operate the vehicle with
the switch in the UNLOCK position. Always
inspect the fifth wheel after you lock the
switch to be sure the fifth wheel lock is
engaged.
Fifth Wheel Lubrication
• Frequently operate and lubricate movable or sliding
fifth wheels to prevent corrosion.
CAUTION: Both the fifth wheel plate and the
slide tracks (if a slider) should be cleaned and
lubricated periodically to ensure smooth turning and sliding action. Failure to keep these
surfaces lubricated can lead to frame or driveline damage.
See page 219 for maintenance information.
– 136 –
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
VEHICLE RECOVERY AND SPRING BRAKES
Vehicle Recovery and Spring Brakes
Introduction
Your Medium Duty is equipped with built-in recovery provisions, designed for short distance use only. If your vehicle
must be recovered, disconnect the driveline at the rear U–
joint, and remove or support the rearmost section of the
driveline. This is necessary because if the transmission is
driven by the driveshaft (rear wheels on the ground), no
lubricant will reach the gears and bearings, causing damage to the transmission.
Worse, when vehicles are towed, either by wrecker or
piggy-back, the lubricant in the top front of the drive axle
will drain to the rear. This will leave the top components
dry. The resulting friction may seriously damage them.
Always remove the main driveshaft and axle shafts before
towing your vehicle.
CAUTION: Remove the driveline and axle
shafts or lift the driving wheels off the ground
before towing the vehicle. See “More Driving
Tips and Techniques” on page 127. All lubricating and clutch application oil pressure is provided by an engine-driven pump, which will
not work when the engine is stopped. You
could seriously damage your vehicle by towing it with the driveline connected and the
drive wheels on the ground.
Medium Duty (R05/09)
Y53-6008A
NOTE: For additional information concerning
heavy-duty truck recovery, see Truck Maintenance Council Recommended Practice #602–A
— “Front Towing Devices For Trucks and Tractors,” and #626 — “Heavy Duty Truck Towing Procedures.” Copies of these can be obtained from
the following address:
The Maintenance Council
American Trucking Association Inc.
2200 Mill Rd.
Alexandria, VA 22314
(703) 838-1763
– 137 –
VEHICLE RECOVERY AND SPRING BRAKES
STARTING AND OPERATING THE VEHICLE
Vehicle Recovery Guidelines
Recovery Rigging
Refer to the guidelines below when towing to prevent possible damage:
To connect to the Medium Duty, attach the towing chain or
cable and the hitches to the (2) tow recievers through the
center access hole in the bumper.
• Use proper towing equipment to prevent damage to
the vehicle.
CAUTION: Connect only to the towing provisions, as described on the following pages.
Connections to other structural parts could
damag e the vehicle . Do no t at tach to
bumpers or bumper brackets. Use only
equipment designed for this purpose.
• Use a safety chain system and the vehicle’s (2)
hitches. Be sure to use both hitches together to
recover a vehicle.
• Disconnect driveline.
• Follow state/provincial and local laws that apply to
vehicles in tow.
• Do not tow vehicles at speeds in excess of 55 mph
(90 km/h).
Front Tow Hook Recievers
Returning 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.
– 138 –
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
VEHICLE RECOVERY AND SPRING BRAKES
2. Into the inter-axle differential, add 2 pints (.94 liter) of
approved lubricant.
• See “Recommended Lubrication Types,” Page
136.
3. After adding the specified type and amount of lubricant, drive the vehicle. It should be unloaded. Drive 1
to 2 miles (1.5 to 3 km) at a speed lower than 25 mph
(40 km/h). This will thoroughly circulate the lubricant
through the assembly.
You may sometimes have to release your vehicle's spring
brakes by hand. This could happen if the system air pressure does not reach operating pressure because your
engine or compressor is not working properly. You will
have to release the spring brakes at the spring brake
chambers.
Spring Brakes — Manual Release
In order to tow a vehicle, if there is insufficient air to
release the parking brake, the spring brakes can be manually released.
WARNING! Do not drive vehicle with malfunctioning brakes. If one of the brake circuits
should become inoperative, braking distances will increase substantially and handling characteristics while braking will be
affected. You could lose control of your vehicle, be severely injured, or cause an accident.
Have it towed to the nearest dealer or qualified workshop for repair.
Medium Duty (R05/09)
Y53-6008A
WARNING! Do not disassemble a spring brake
chamber. These chambers contain a powerful
spring that is compressed. Sudden release of
this spring can cause you to be severely
injured.
• Do not operate a vehicle when the spring
brakes have been manually released. Driving a vehicle after its spring brakes are
manually released is extremely dangerous.
You will probably have no brakes at all. You
could have a serious or fatal accident.
• Releasing the spring brakes on an unsecured vehicle could lead to an accident. The
vehicle could roll, causing severe injury.
Always secure the vehicle with wheel
chocks, chains, or other safe means to prevent rolling before manually releasing the
spring brakes.
– 139 –
VEHICLE RECOVERY AND SPRING BRAKES
STARTING AND OPERATING THE VEHICLE
To move a vehicle immobilized by the spring brakes due to
loss of air pressure in the brake system, perform the following procedure:
1. Remove the cap from the
spring chamber.
2. Remove the release stud
assembly from the side pocket,
and remove the release nut and
washer from the release stud.
4. Insert the release stud
through the opening in the
spring chamber where the cap
was removed. Insert it into the
pressure plate. 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.
5. Assemble the release stud
washer and nut on the release
stud.
3. Slide out the release stud.
– 140 –
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
VEHICLE RECOVERY AND SPRING BRAKES
6. With a wrench, turn the
release stud assembly nut until
the compression spring is 90–
95 percent caged. While doing
this, check to make sure the
push rod (adapter push rod or
service push rod) is retracting.
Do not over-torque the release
stud assembly. (S–Cam type
maximum: 50 ft-lb, Wedge type
maximum: 30 ft-lb.) The spring
brake is now m echan ically
released.
Freeing the Vehicle from Sand,
Mud, Snow and Ice
WARNING! Do not spin the wheels faster
than 35 mph (55 km/h). Spinning a tire at
speedometer readings above this can be
dangerous—tires can explode from spinning
too fast. Under some conditions, a tire may
be spinning at a speed twice that shown on
the speedometer. Any resulting tire explosion could cause severe injury or death to a
bystander or passenger, as well as extensive vehicle damage: including tire, transmission and/or rear axle malfunction.
If the vehicle gets stuck in sand, mud, snow, or ice:
• Move the gearshift lever or selector from First to
Reverse.
• Apply light pressure on the accelerator pedal while
the transmission is in gear.
• Remove your foot from the accelerator while shifting.
• Do not race the engine.
• For best traction and safety, avoid spinning the
wheels.
Medium Duty (R05/09)
Y53-6008A
– 141 –
VEHICLE RECOVERY AND SPRING BRAKES
STARTING AND OPERATING THE VEHICLE
Comply with the following instructions to avoid transmission damage:
• Always start the vehicle in motion with the shift lever in
first gear.
• Be sure that the transmission is fully engaged in gear
before releasing the clutch pedal (manual only).
• Do not shift into reverse while the vehicle is moving.
• Do not permit the vehicle to be towed for long distances without removing the driveshaft.
– 142 –
Tire Chains
If you need tire chains, install them on both sides of the
driving axle.
Y53-6008A
CAUTION: Chains on the tires of only one tandem axle can damage the driveline U–joints
and the interaxle differential. Repairs could be
costly and time-consuming.
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
SHUT–DOWN
Shut–Down
WARNING! Do not use the trailer hand brake
or service brakes to park and hold an unattended vehicle—use the parking brakes.
Because service brakes work with air pressure, these brakes could slowly release. Your
vehicle could roll, causing a serious accident.
Someone could be hurt or killed. Never rely on
the service brakes to hold a parked vehicle.
Introduction
After you have parked in a safe place, check your vehicle
to make sure it will be ready for the next trip. To make sure
your vehicle is ready to go after a long stop (such as overnight), please follow the suggestions below. Your vehicle
will be easier to get going when you are ready, and it will
be safer for everyone who might be around it.
Please remember, too, that in some states it is illegal to
leave the engine running and the vehicle unattended.
2. If you must park on a steep grade, always block the
wheels.
Final Stopping Procedures
1. Set the parking brake before leaving the driver's seat.
To hold your vehicle while it is parked, DO NOT rely on
the following:
• air brakes
• hand control valve for trailer brakes
• engine compression
02440
Blocked Wheels
Always use your parking brakes!
Medium Duty (R05/09)
Y53-6008A
– 143 –
SHUT–DOWN
STARTING AND OPERATING THE VEHICLE
Turbocharger
3. Drain water from the air reservoirs.
• While the engine and air supply system are still
warm, drain moisture from the air reservoirs. Open
the reservoir drains just enough to drain the moisture. Do not deplete the entire air supply. Be sure to
close the drains before leaving the vehicle.
4. Secure the vehicle, close all the windows, and lock all
doors.
Before Stopping the Engine
Do not shut off the engine immediately. A hot engine
stores a great amount of heat and it does not cool down
immediately after you shut if off. Always cool the 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 circulating coolant and lubricating oil to carry away heat from the
cylinder head, valves, pistons, cylinder liners, turbocharger, and bearings. This way you can prevent engine
damage that may result from uneven cooling.
– 144 –
This cooling-down practice is especially important for a
turbocharged engine. The turbocharger on your vehicle
contains bearings and seals that are subjected to hot
exhaust gases. While the engine is operating, heat is carried away by circulating oil. If you stop the engine suddenly after a hard run, the temperature of the
turbocharger could rise to as much as 100°F (55°C)
above the temperature reached during operation. A sudden rise in temperature like this could cause the bearings
to seize or the oil seals to loosen.
Refueling
Air inside the fuel tanks allows water to condense in the
tank. To prevent this condensation while the vehicle is
parked for extended periods of time, fill the tanks to 95
percent of capacity. Never fill to more than 95 percent
capacity as this provides room for expansion resulting
from temperature extremes. When refueling, add approximately the same amount to each fuel tank on vehicles
with more than one tank.
Y53-6008A
Medium Duty (R05/09)
STARTING AND OPERATING THE VEHICLE
SHUT–DOWN
WARNING! Do not carry additional fuel containers in your vehicle. Fuel containers, either
full or empty, may leak, explode, and cause or
feed a fire. Do not carry extra fuel containers,
even empty ones are dangerous.
Specification: Use only Diesel Fuel, Grade 2–D, as rec-
WARNING! Diesel fuel in the presence of an
ignition source (such as a cigarette) could
cause an explosion. You could be seriously
injured. A mixture of gasoline or alcohol with
diesel fuel increases this risk of explosion.
Location of Fuel Shut–Off Valves
• Do not remove a fuel tank cap near an open
flame.
ommended by engine manufacturers. If you need further
information on Grade 2–D fuel specifications, consult the
Engine Operation and Maintenance Manual.
If your vehicle is equipped with shut-off valves for the takeoff and return lines, they are located on the fuel lines
entering the top of the fuel tank. Fuel shut-off valves for
the fuel crossover line are on the bottom of the fuel tank,
at the crossover line connection.
• Use only the fuel and/or additives recommended for your engine.
Medium Duty (R05/09)
Y53-6008A
– 145 –
Introduction
Preventive Maintenance
PREVENTIVE MAINTENANCE
INTRODUCTION
Safety Precautions
This section will help you keep your Medium Duty in good
running condition. There are a number of checks you can do,
and you may be able to do some of the service work yourself.
But please, let your Peterbilt Dealer or Authorized Service
Center do any work you do not have the tools or skill to perform. Authorized service mechanics are trained in the proper
technical and safety procedures to maintain your Medium
Duty correctly.
Good driving practices, daily and weekly driver maintenance
inspections, and periodic service inspections by an Authorized Service Center, will help keep your Medium Duty in
good working order and provide many years of dependable
service.
WARNING! It is dangerous to work on a vehicle
without the right know-how and proper tools.
You could be seriously injured, cause damage to
the vehicle, or make your vehicle unsafe to
drive. Do only work you know you are fully able
to do, and for which you have the right tools.
– 146 –
• Before attempting any procedures in the engine
compartment, stop the engine and let it cool down.
Hot components can burn skin on contact.
• Be alert and cautious around the engine at all times
while the engine is running.
• If work has to be done with the engine running,
always (1) set the parking brake, (2) chock the
wheels, and (3) ensure that the shift lever or selector
is in Neutral.
• Exercise extreme caution to prevent neckties, jewelry, long hair, or loose clothing from getting caught
in the fan blades or any other moving engine parts.
• Disconnect the battery ground strap whenever you
work on the fuel system or the electrical system.
When you work around fuel, do not smoke or work
near heaters or other fire hazard. Keep an approved
fire extinguisher handy.
• Always support the vehicle with appropriate safety
stands if it is necessary to work underneath the vehicle. A jack is not adequate for this purpose.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Introduction
• 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 are 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.
WARNING! Wear protective clothing when
handling hydraulic fluid. It is mildly toxic and
can cause skin and eye irritation.
CAUTION: Hydraulic brake fluid may damage
painted surfaces of the vehicle.
Modifying your vehicle can make it unsafe. Some modifications can affect your vehicle's electrical system, stability, or
other important functions. Before modifying your vehicle,
check with your Peterbilt Dealer to make sure it can be done
safely and correctly.
Environmental Protection and Material
Hazards
Some of the ingredients in engine oil, hydraulic oil, transmission and axle oil, engine coolant, diesel fuel, air conditioning
refrigerant (R–134a and PAG oil), batteries, etc., may contaminate the environment if spilled or not disposed of properly. Non-compliance with environmental regulations can
result in fines and/or jail terms. Contact your local government agency for information concerning proper disposal.
Incomplete or improper servicing may cause problems in the
operation of the vehicle. If in doubt about any servicing, have
it done by your Authorized Service Center. Improper maintenance during the warranty period may also affect the warranty coverage.
Medium Duty (R05/09)
Y53-6008A
WARNING! Diesel engine exhaust and some of
its constituents are known to the State of California to cause cancer, birth defects, and other
reproductive harm. Other chemicals in this vehicle are also known to the State of California to
cause cancer, birth defects, and other reproduc-
– 147 –
Introduction
Preventive Maintenance
tive harm. This warning requirement is mandated by California law (Proposition 65) and does not result from any
change in the manner in which Peterbilt Motors Company trucks are manufactured.
and the Peterbilt Electronic Parts Catalog (ECAT). When
ordering replacement parts, please provide the Medium Duty
Chassis Serial Number. See Page 259.
WARNING! Handle lubricants carefully. Vehicle
lubricants (oil and grease) can be poisonous
and cause sickness.
Operator's Parts Catalog a complete, non-illustrated listing
of the Final Chassis Bill of Material. It includes all parts used
to custom-build your Medium Duty.
How to Order Parts
Replacement parts can be ordered through your local Peterbilt Dealer. For service parts information, two parts catalogs
are also available, the Medium Duty Operator's Parts Catalog
– 148 –
Electronic Parts Catalog a complete illustrated parts listing
for your specific vehicle, with drawings and exploded views,
available only in electronic CD–ROM format.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Maintenance Schedule and Lubrication
MAINTENANCE SCHEDULE AND
LUBRICATION
Introduction
The following section summarizes preventive maintenance
and lubrication requirements for the maintenance of your
Medium Duty. For specific maintenance procedures and
complete lubrication instructions of specific components consult the Medium Duty Maintenance Manual and manufacturer's service manuals. These manuals are available for a
minimal charge from your Peterbilt Dealer or direct from the
component manufacturer. In addition, supporting manuals
and literature are included in the glove compartment of your
Medium Duty.
Preventive Maintenance Intervals and
Schedule
Your preventive maintenance program begins with daily
checks you perform. See “Driver's Check List” on page 13.
If your Medium Duty is serviced regularly, you can avoid
many large, expensive, and time-consuming repairs, as well
Medium Duty (R05/09)
as ensuring many years of safe and smooth operation. Also,
be advised that neglect of recommended service may in
some cases void your vehicle's warranty. So, for your safety
and life of your vehicle, please follow Table 2, “Maintenance
Schedule,” Page 153. But remember, there may be maintenance operations that demands skills and equipment you do
not have. If so, please take your Medium Duty to an expert
mechanic, for your safety and your vehicle's performance.
WARNING! It can be dangerous to attempt maintenance work without sufficient training, service
manuals, and the proper tools. You could be
injured, or you could make your vehicle unsafe.
Do only those tasks you are fully trained and
equipped to do.
In severe operating conditions such as mining, logging, or
earth moving, you will need to perform maintenance checks
and services more frequently. Other “severe operating conditions” to be aware of are: rough, extreme temperature environments; conditions where heavy loads are being hauled;
contaminated environments, or steep grades. Consult the
component manufacturer's maintenance manuals for further
information on maintenance procedures specific to these
conditions.
Y53-6008A
– 149 –
Maintenance Schedule and Lubrication
Preventive Maintenance
Maintenance Intervals
Table 1, ”Recommended Maintenance Intervals”, shows
service intervals for normal and heavy-duty operations.
For additional “Engine Cooling System” information see
Table 1
Page 174. For additional “Air System” information see Page
192.
NOTE: Different lubricants or service intervals than
those listed below may be required.
Recommended Maintenance Intervals
ITEM
Hood Pivot
INTERVAL
COMMENTS
None
Front Brake Camshaft
10,000–15,000
Tie–Rod Ends
10,000–15,000
Synthetic Grease With Special Fittings
Power Steering Reservoir
– Check Fluid Level
– Change Fluid & Filter
Drag Link
10,000–15,000
60,000
Steering Gear Box
None
Steering U–joints
10,000–15,000
Steering Slip Joint
10,000–15,000
Brake Treadle
10,000–15,000
Clutch Pedal Shaft
2 Times/Year (After Summer & Winter)
10,000–15,000
t
None
Transmission
– Check
10,000–15,000
– Drain and Refill - Manual
50,000
– Drain and Refill - Automatic
25,000
Rear Axle
– Check Fluid Level
– (Rear Axle) Drain, Flush, Refill
– 150 –
10,000–15,000
500,000
Y53-6008A
Synthetic Lube
Medium Duty (R05/09)
Preventive Maintenance
Table 1
Maintenance Schedule and Lubrication
Recommended Maintenance Intervals
ITEM
Rear Wheel Bearings
INTERVAL
100,000
COMMENTS
With LMS Wheel End Package
Rear Brake Camshafts
10,000–15,000
Synthetic Grease With Special Fittings
Fifth Wheel
10,000–15,000
40 to 60K For Adjustment
Spring Pins
10,000–15,000
With Rubber Bushed Pins – No Service
Front & Rear Slack Adjusters
10,000–15,000
Synthetic Grease With Special Fittings
King Pins
10,000–15,000
Front Wheel Bearings
Accelerator Linkage
100,000
Eaton LMS
None
Engine Lubricating Oil
– Check Fluid Level
Daily Trip Check
– Change Oil
10,000–15,000
Must Meet Engine Company Specifications
Spring Shackle Pins
10,000–15,000
No Service With Rubber Bushed Spring Pins
Clutch Linkage
10,000–15,000
Clutch Release Bearing
10,000–15,000
Extended Grease Fittings
Clutch Cross Shaft
10,000–15,000
Extended Grease Fittings
Door Weatherstrip
As Required
Lock Cylinders
As Required
Door Hinges
As Required
Door Latches and Striker Plate
As Required
Teflon Bushing
Driveshaft
– U-Joints
10,000–15,000
SPL Driveline, Up To 100,000 Miles
– Slip Joints
10,000–15,000
SPL Driveline
Center Bearing
Suspension
Medium Duty (R05/09)
None
Per Specifications
Y53-6008A
AG200 – Synthetic Grease With Special Fitting
– 151 –
Maintenance Schedule and Lubrication
Table 1
Preventive Maintenance
Recommended Maintenance Intervals
ITEM
INTERVAL
COMMENTS
Hydraulic Brakes
Brake Pad Lining Inspection
7,500 mile
Rotor Inspection
15,000 miles or 15 mos
Park Brake Inspection
15,000 miles or 15 mos
Minimum 3/16 in. thickness
Brake Fluid Reservoir
Check Fluid Level
Change Fluid
7,500 miles
Use DOT 3 brake fluid only
Every 2 years
Use DOT 3 brake fluid only
Power Steering Fluid Reservoir
Check Fluid Level
Change Fluid
– 152 –
7,500 miles
Use Automatic Transmission Fluid (ATF)
60,000 miles or twice per
year
Use Automatic Transmission Fluid (ATF)
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Maintenance Schedule and Lubrication
Maintenance Schedule
TABLE KEY
NOTE: If a scheduled service interval is shaded, skip to the
next interval. The frequency of each service operation is
identified by open (non-shaded areas).
Use Table 2, ”Maintenance Schedule,” as a guide to plan
service work. Be sure and follow the frequency recommendations for your vehicle.
Table 2
C2
Federal Annual Inspection 120,000 miles/192,000 km only.
C4
Federal Annual Inspection 240,000 miles/384,000 km only.
E2
50,000 Mile Service Interval
G2
Synthetic Lube Required – 500,000 Drain
Maintenance Schedule
OPERATION \ FREQUENCY
15,000 mi
24,000 km
60,000 mi
96,000 km
COMMENTS
7,500 mi
12,000 km
INTERVAL
INITIAL DRIVE–IN
A
B
C
Clutch Brake
Clutch Pedal Free Travel _____ inches
Glass for Cracks or Chips
Door Window Operation
Radio
Interior Lights
Interior Appearance:
Seats
Floor Mats
Door Panels
Headliner
Sleeper
Dash
Covers
Wiper Operation
Medium Duty (R05/09)
Y53-6008A
– 153 –
Maintenance Schedule and Lubrication
Table 2
Preventive Maintenance
Maintenance Schedule
15,000 mi
24,000 km
60,000 mi
96,000 km
OPERATION \ FREQUENCY
COMMENTS
7,500 mi
12,000 km
INTERVAL
A
B
C
A
B
C
Wiper Blade Condition
Horns (Electric and Air)
Mirrors
SAFETY EQUIPMENT
Drain Water from Air Tanks
Air Tank Check Valve
Emergency Operation of Spring Brakes
Air Press. Build–up time: _______ min.
Governed Air Pressure: _______ psi
Air Press. Drop–Brakes not Applied: ___
Air Press. Drop–Brakes Applied: ___
Fire Extinguisher Charge
Flare Kit / Reflectors
CIRCLE INSPECTION
Physical Damage:
Exterior Sheet Metal
Grille and Radiator
Trailer Light Cord and Connectors
Air Lines and Gladhands
5th Wheel Mounting and Condition
Pintle – Hook/Eye Condition
Headlights – High and Low Beams
Road Lights
Marker Lights
Turn Signals
– 154 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Table 2
Maintenance Schedule and Lubrication
Maintenance Schedule
Emergency Flasher
Brake Lights
Backup/Loading Lights
License Plates: Permits and Mounting
Mud Flaps / Serviceable
Fuel Tank Mounting
Exhaust System–Condition and Mounting Bolts
Frame Fastener Torque: does NOT apply to Le
Jeune frame fasteners.
Lubricate:
Door Hinges and Latches
Body Mounts (Straight Truck Only)
Body Sides and Roof Panels (Straight trucks)
Cab:
Hold–down Latches
Mounts
Front Pivot Assembly
Jack Operation and Leaks
Safety Lock, Tip–Over Stop
ENGINE SERVICE
Cooling:
COMMENTS
60,000 mi
96,000 km
15,000 mi
24,000 km
OPERATION \ FREQUENCY
7,500 mi
12,000 km
INTERVAL
C2
A
B
C
Extended Life Coolant maintenance/
is located on page 179 of this manual
Coolant Level
Pressure Test
New Release At 100–120K – Per Engine
Filter Manufacturer Recommendations
Replace Water Filter
Radiator Mounting
Medium Duty (R05/09)
Y53-6008A
– 155 –
Maintenance Schedule and Lubrication
Table 2
Preventive Maintenance
Maintenance Schedule
COMMENTS
60,000 mi
96,000 km
15,000 mi
24,000 km
OPERATION \ FREQUENCY
7,500 mi
12,000 km
INTERVAL
Fan Shroud
Fan Assembly and Idler Pulley
Check Water Pump for Leaks / Play
Radiator – Exterior Condition
No Service Required
Replace Engine Coolant
C4
Fill as Required – Extended Drain Per
Manufacturer Specifications.
Air Cleaner:
Contaminant Accumulation
Air Cleaner Restriction ___
(replace if greater than 20)
Vacuator Valve–Operation & Condition
Mounting Bolts
Leaks
Interference
Engine Oil Level
Power Steering – Reservoir Level
Daily Inspection Required
Service 2XPer Year – 60,000 Mile
Intervals
Power Steering Fluid – Replace
C2
Power Steering Filter – Replace
Drive Belt Condition and Adjustment
Air Conditioner Compressor Mounting
Cold Start Aids
Governor and Pump Security Seals OK
High Idle: ________ rpm
Emergency Shutdown
Vibration Damper Condition
– 156 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Table 2
Maintenance Schedule and Lubrication
Maintenance Schedule
COMMENTS
60,000 mi
96,000 km
15,000 mi
24,000 km
OPERATION \ FREQUENCY
7,500 mi
12,000 km
INTERVAL
Drain Water from Fuel System
25,000 Mile Change Interval – Must Meet
Engine Co. Requirements
Engine Oil – Change
Oil Filters – Replace
Fuel Filters – Replace
Engine Tune–up
Cranking System:
Visual Inspect./Loose Connections
Starter Draw: _________ volts
Alternator/Charging System:
Visual Inspection/Loose Connections
Output Voltage: _________ volts
UNDER VEHICLE
C2
A
B
C
Steering Components – Condition:
Steering Gear
Steering Shaft Splines and Joint(s)
Pitman Arm
Drag Link
Steering Arms
Tie Rod Arms
Tie Rod Ends
Radius Rods / Torque Arms
Chassis Frame – Cracks or Breaks
Spring Shackles and Hanger Brackets
Spring Pins
Medium Duty (R05/09)
No Service Required
No Service Required
Y53-6008A
– 157 –
Maintenance Schedule and Lubrication
Table 2
Preventive Maintenance
Maintenance Schedule
COMMENTS
60,000 mi
96,000 km
15,000 mi
24,000 km
OPERATION \ FREQUENCY
7,500 mi
12,000 km
INTERVAL
King Pin Wear
Steer Axle Wheel Bearing - End Play Adjustment
and Inspection
Front Hub Lubricant Level
Spring Leaves
350,000 Miles With LMS Outer Ends
• No Leak – No Service
Tighten U-bolts after the first 500 miles
(800 km). Rear suspension fasteners:
retorque after first 2,000 miles (3218 km).
U–Bolt and Suspension Fastener Torque
Leaks:
Coolant
Engine Oil
Power Steering
Fuel
Transmission
Axles
Inner and Outer Hub Seals
Engine and Transmission Mounts
Drivelines – U–joints and Slip Yokes
Rear Axle Lubricant Level
Rear Axle Lubricant Flush & Refill
Rear Axle Breathers – Clear
Tractor Protection Valve Breakaway Test
Brake Chamber Mounting Bolt Torque
Brake Hoses for Cracks and Chafing
Adjust Brakes
– 158 –
C4
Y53-6008A
At 250,000 Miles
Medium Duty (R05/09)
Preventive Maintenance
Table 2
Maintenance Schedule and Lubrication
Maintenance Schedule
COMMENTS
60,000 mi
96,000 km
15,000 mi
24,000 km
OPERATION \ FREQUENCY
7,500 mi
12,000 km
INTERVAL
Synthetic Grease Required – Special
Fitting
No Service Required
Front & Rear Brake Camshaft Tube Lubrication
Clutch Pedal Shaft
Clutch Linkage
Suspension Fittings
Clutch Release Bearing
Driveline Center Bearing
Automatic Slack Adjusters
Brakes: Lining Remaining (replace as required)
RF ______ RRF ______ RRR ______
LF ______ LRF ______ LRR ______
Drum Condition:
RF ______ RRF ______ RRR ______
LF ______ LRF ______
AG 200 – 250,000 Mile Service
Required Extended Fittings
No Service Required
Synthetic Lube Required – Special Fittings
LRR ______
Chassis Lubrication
Transmission Lubricant Level
Transmission Lubricant and Filter Change
Rear Axle Lubricant Change
Front Hub Lubricant Change
BATTERIES
C2
C2
C2
A
B
Synthetic Lube Required – 500,000 Drain
Synthetic Lube Required – 500,000 Drain
Synthetic Lube Required – 500,000 Drain
C
Signs of Over–Charging
Remove Corrosion and Seal Terminals
Hold-down and Box – Mounting Bolts
Load Test Batteries
Sealed Type – Condition:
Medium Duty (R05/09)
Y53-6008A
– 159 –
Maintenance Schedule and Lubrication
Table 2
Preventive Maintenance
Maintenance Schedule
15,000 mi
24,000 km
60,000 mi
96,000 km
OPERATION \ FREQUENCY
COMMENTS
7,500 mi
12,000 km
INTERVAL
A
B
C
(Color of charge indicator for each battery)
1 ______ 2 ______ 3 ______ 4 ______
TIRES AND WHEELS
Missing Valve Caps and Stem Locks
Cracks or Loose Wheel lugs
Tandem Mating
Irregular Wear
Tire Pressure (Record below)
Remaining Tread (Record below)
Tires & Wheels Inspection
Right
– 160 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Table 2
Maintenance Schedule and Lubrication
Maintenance Schedule
15,000 mi
24,000 km
60,000 mi
96,000 km
OPERATION \ FREQUENCY
COMMENTS
7,500 mi
12,000 km
INTERVAL
A
B
C
A
B
Left
Air Pressure Adjusted to: _____________
ALIGNMENT
Toe–in: ______________ in (mm)
Caster: L ________ R ________
Rear Axle Alignment
ROAD TEST
C2
C
Steering / Steering Play
Shifting
Brakes
Engine Operation (noises, surging, black smoke)
Throttle Linkage
Jake Brake Operation
Seat Belts
Air Seat Operation
Cab Heater
Medium Duty (R05/09)
Y53-6008A
– 161 –
Maintenance Schedule and Lubrication
Table 2
Preventive Maintenance
Maintenance Schedule
15,000 mi
24,000 km
60,000 mi
96,000 km
OPERATION \ FREQUENCY
COMMENTS
7,500 mi
12,000 km
INTERVAL
A
B
C
A
B
C
Air Conditioner
Instruments and Gauges:
Speedometer/odometer
Tachometer
Oil Pressure
Engine Temperature
Illumination
BODY
Interior Liner Damage
Door Operation
Roll–up Door Tracks – Lubricate
Lift–gate Operation
OTHER
Hood Pivots
Fifth Wheel Components
Brake Treadle Hinge and Roller
Lock Cylinders
Door Hinges
Door Latches and Striker Plate
Door Weatherstrip
40 – 60K For Adjustment
Drain Tanks, Replace Desiccant as
Required
Air Dryer
– 162 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Maintenance Schedule and Lubrication
Lubrication Specifications
You will find a complete Engine Lubrication Service Guide in
the Engine Operation and Maintenance Manual. There, the
engine manufacturer explains more fully all the maintenance
operations you and a qualified service mechanic will need.
And please remember: one key to keeping your Medium Duty
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.
Below you will find basic information needed to perform routine vehicle lubrication. 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, rough roads, etc. For any special service require-
Medium Duty (R05/09)
ments, consult your service manuals and your lubricant supplier. The component manufacturer's specification and
requirements take precedence over other specifications.
WARNING! Handle lubricants carefully. Vehicle
lubricants (oil and grease) can be poisonous
and cause sickness. They can also damage the
paint on the vehicle.
CAUTION: Do not mix different types of lubricants. Mixing lubricants (oil and grease) of different brands or types could damage vehicle
components; therefore, drain (or remove) old
lubricants from the unit before refilling it.
• When switching between types of lubricants, thoroughly drain all areas of the component.
Y53-6008A
– 163 –
Maintenance Schedule and Lubrication
Preventive Maintenance
Lubrication Types
APPLICATION
Use Table 3 on page 166 and the list of lubricants below to
identify the type of lubricant to use on your Medium Duty. For
a quick summary of each lubrication point, see Table 1 on
page 150.
ATF: DEXRON® III/MERCON®-approved automatic transmission fluid
BB: Ball Bearing grease
CB: Engine oil for mild to moderate requirements
CC/CD: Engine oil for severe requirements (MIL–L–2104B /
MIL–L–45199B w/ 1.85% max sulfated ash content)
Universal Joints
LUBRICANT
EP
Drive Shaft Splines
CL
Wheel Bearings (driven hubs)
HD
Wheel Bearings (nondriven hubs)
CD50
Steering Column
CL
Alternator Bearing
BB*
Fan Hub
BB*
Power Steering Reservoir
ATF
Steering Drag Link
CL
CD: Engine oil meeting API “Five engine test sequence”
Steering Knuckles
CL
CD50: SAE 50W synthetic transmission fluid
Spring Pins
CL
CE: Engine oil meeting severe duty service requirements for
direct—injection turbocharged engines.
Clutch Release Bearings
BB
Brake Shoe Anchor Pins
HT
CL: Multipurpose chassis grease
Brake Cam Bearings
HT
EP: Extreme Pressure lubricant
Slack Adjusters
CL
GL: Straight mineral gear lubricant
Starter Bearings
CC
HD: Hypoid Gear Oil, A.P.I. — GL–5/SAE 80W–90
Turbocharger Aneroid
CC
HT: High Temperature grease (Timken Specification 0–616)
Water Pump
BB*
MP: Multipurpose gear lubricant (MIL–L–2105B)
*Consult manufacturer or lubricant supplier for special details.
SD: Engine oils with increased protection against temperature deposits,
rust, wear, and corrosion.
WB: Wheel Bearing grease (Timken Specification 0–610)
– 164 –
Y53-6008A
NOTE: The responsibility for meeting these specifications, the quality of the product, and its performance in service rests with the lubricant supplier.
Medium Duty (R05/09)
Preventive Maintenance
Maintenance Schedule and Lubrication
Oil Reservoirs
For oil reservoirs with side filler plugs (transmissions, axles,
steering gear boxes, transfer cases, etc.), the oil must be
level with the filler opening.
NOTE: Use care when checking the oil level with a
finger. Just because you can reach the oil level with
a finger, does not mean the oil level is correct.
Lubrication Chart
The following lubrication specifications (see Table 3 on
page 166) are for an ambient operating temperature range
of –15 to 100°F (–26 to 38°C). For extreme temperature
operations, consult the component manufacturer's manuals.
Medium Duty (R05/09)
Y53-6008A
– 165 –
Maintenance Schedule and Lubrication
Table 3
Preventive Maintenance
Recommended Lubrication Types
COMPONENTS
RECOMMENDED LUBRICANT
Power Steering Gear
Automatic Transmission Fluid (ATF)
Driveline U-Joints
Slip-Joint Splines
Hood Pivots
Fan Drive
Fifth Wheel Components
Clutch Pedal Shaft
Clutch Linkage
Other chassis grease fittings not covered
below.
EP chassis grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2.
Wheel Bearing-Non Driving Axles
OIL LUBICATED: SAE 80W-90 EP gear oil, MIL-L-2105D, API GL5; or SAE 75W-90 synthetic
oil
GREASE LUBRICATED: EP chassis grease, lithium 12-hydroxystearate or lithium complex
base, NLGI 2.
Threaded Pins & Bushings (e.g., spring pins &
bushings)
EP grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2, with 3% molybdenum
additive: Mobil Grease Special (Mobil), Molygrease EP (Chevron), or equal.
Suspension Fittings (other than threaded pins
& bushings)
EP chassis grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2.
Steering Axle: Grease Fittings on Steering
Arm; Tie Rod Ends; Drag Link; King Pins
EP chassis grease, lithium 12-hydroxystearate base, NLGI 2.
Clutch Release Bearing (remove inspection
plate for access); Driveshaft Center Bearing
High temperature ball bearing grease. Chevron SRI Mobil Grease HP, Texaco Multifax 2, or
equivalent.
Automatic Slack Adjusters; Wedge Brake
Components; Disc Brake Caliper
High temperature EP grease; Texaco Thermotex EP-1, Shell Darina EP-1, Mobilith AW-1,
Rockwell 0-616A, or equivalent.
Deviations from the above list of lubricants should be based on specifications published in the component manufacturer's manuals or otherwise
approved by the manufacturer.
– 166 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Table 3
Maintenance Schedule and Lubrication
Recommended Lubrication Types
COMPONENTS
RECOMMENDED LUBRICANT
Cam Brake Camshaft Splines; Disc Brake
Shaft Splines and Slide Pin Retainers; Brake
Clevis Pins
Antiseize type grease, Rockwell specification 0-637.
Brake Camshaft Bushings
EP Chassis grease, lithium 12-hydroxystearate base, NLGI 2.
CAUTION: Do not contaminate brake linings with grease.
Steering Shaft Grease Fittings
EP chassis grease, lithium 12-hydroxystearate base, NLGI 2.
Brake Treadle Hinge and Roller
Engine oil
Lock Cylinders
Lock lubricant.
Door Hinges
Not required — Teflon bushings
Door Latches & Striker Plates.
Polyethylene grease stick.
Door Weatherstrip
Silicone lubricant.
Other Items
Use manufacturer’s manuals.
Deviations from the above list of lubricants should be based on specifications published in the component manufacturer's manuals or otherwise
approved by the manufacturer.
WARNING! Exhaust fumes from the engine contain carbon monoxide, a colorless and odorless
gas. A poorly maintained, damaged, or corroded
exhaust system can allow carbon monoxide to
enter the cab or sleeper. Failure to properly
maintain your vehicle could cause carbon monoxide to enter the cab and cause serious illnesses.
Medium Duty (R05/09)
Y53-6008A
WARNING! Never idle your vehicle for prolonged
periods of time if you sense that exhaust fumes
are entering the cab. 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.
– 167 –
Maintenance Schedule and Lubrication
Preventive Maintenance
NOTE: Keep the engine exhaust system and the
vehicle’s cab ventilation system properly maintained. It is recommended that the vehicle’s
exhaust system and cab be inspected:
• By a competent technician every 15,000 miles.
• Whenever a change is noticed in the sound of the
exhaust system.
• Whenever the exhaust system, underbody, cab or
sleeper is damaged.
– 168 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Engine Maintenance
ENGINE MAINTENANCE
WARNING! Hot engine oil can be dangerous. You
could be seriously burned. Let the engine oil
cool down before changing it.
Engine Lubrication
Proper engine lubrication depends on ambient temperature
and where the vehicle will be operated. Use the recommended oil for the weather conditions outside.
NOTE: For engine oil specifications, oil change
intervals, engine filter requirements or general
engine maintenance procedures, refer to the Engine
Operation Manual included with your vehicle or the
engine manufacturer’s service manual.
Service Intervals
• Check engine oil daily.
Oil Draining:
• Refer to the engine manufacturer's Engine Operation
and Maintenance Manual supplied with your vehicle for
information about draining and refilling engine oil, engine
crankcase capacity, engine oil type, and changing oil filters, etc.
Medium Duty (R05/09)
• Drain the oil into a container designed for this purpose.
• When draining the oil, remove the plug with the proper
size wrench and keep as far away as possible. Always
keep your forearm parallel to the ground to help prevent
hot oil from running down your arm.
• The oil filler cap must be secured to avoid oil spill causing a potential fire hazard.
Oil Level Check
• To check the engine oil level, park the vehicle on level
ground and wait 5 minutes after shutting the engine OFF.
This allows time for the oil to drain to the oil pan.
• Remove the dipstick and wipe it off with a clean, lint-free
rag.
• Reinsert the dipstick all the way in and pull it out again to
check oil level. Correct oil level is between the low (L)
and high (H) marks on the dipstick.
For further information regarding oil level, see the engine
manufacturer's Engine Operation and Maintenance Manual
supplied with the vehicle.
Y53-6008A
– 169 –
Engine Maintenance
Preventive Maintenance
Fuel System
Specification: Use only Diesel Fuel, Grade 2-D, as recommended by engine manufacturers. If you need further information on Grade 2-D fuel specifications, consult the Engine
Operation Manual in the glove compartment.
Please follow these recommendations when you are changing your fuel filters or strainer elements. Your vehicle's engine
will run better and last longer if you do. See the engine manufacturer's recommendations for proper water and micron
requirements.
WARNING! Diesel fuel in the presence of an ignition source (such as a cigarette) could cause an
explosion. You could be seriously injured. A
mixture of gasoline or alcohol with diesel fuel
increases this risk of explosion.
Installing Fuel Filters
CAUTION: If anyone ever pours gasoline into
your fuel tank, drain the entire system. Otherwise, the pump and engine will be damaged.
Don't try to dilute the gasoline by adding diesel
fuel (see Warning above).
When installing spin–on (throwaway) filters:
When removing filters, cover any electrical equipment and
wiring that might get soaked with fuel. Diesel fuel may permanently damage electrical insulation.
1. Prefill filter with fuel.
2. Moisten gasket with diesel fuel.
3. Hand tighten them only 1/2 to 2/3 turn after gasket contact. Mechanical tightening of these filters may distort or
crack the filter head.
• When replacing a fuel filter element, do not use a substitute. Install only filter elements designed for fuel filtration.
First clean and inspect the shell. Then insert the new
element and fill the container at least 2/3 full of clean fuel
before installing the shell
– 170 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Engine Maintenance
NOTE: To expel air from density-type strainer
elements, soak them in clean fuel before installing them.
• Throw away old gaskets. Replace them with new ones to
ensure a positive seal.
• Position the shell and gasket properly. Then tighten the
cover nut or bolt just enough to prevent fuel leakage.
• After starting the engine, check for leaks around the filter.
A. Close valve and run engine until smooth idle is
established, then repeat drain procedures, or
B. Remove filter from mounting head, completely drain
all fluid, and reassemble filter assembly. Be sure to
follow new filter assembly instructions.
2. Close drain valve by turning valve screw clockwise
approximately 1 1/2 to 2 turns.
CAUTION: Do not overtighten the valve. Overtightening can damage the threads.
Fuel Tanks
Filter Draining
Check fuel filter/water separator daily. Check with engine
OFF. Depending on the fuel storage facility, more frequent
draining may be required.
1. Open drain valve (by hand only): turn valve screw
counter-clockwise approximately 1 1/2 to 2 turns until
draining occurs. Drain filter sump of water until clear fuel
is visible.
1. Inspect fuel tanks, fuel hoses, and fittings to ensure
proper positioning and fastening; check for leaks.
2. Inspect mounting brackets, straps, and pins to ensure
proper positioning & fastening every 15,000 miles/
24,000 km (see label on fuel tank and data below):
If entrapped water exceeds sump volume, you can
either:
Medium Duty (R05/09)
Y53-6008A
Type of Tank
Tank Strap T-Bolt Nut Torque
Aluminum
30 Lb. ft. (41 Nm)
Cylindrical Steel
8 Lb. ft. (11 Nm)
– 171 –
Engine Maintenance
Preventive Maintenance
Emission Components
Engine Accesories: Accessory Drive Belts
Deisel Exhaust Fluid Tank
You can extend the reliability and service life of your vehicle's
drive belts with proper attention to installation, and maintenance. Neglect could cause belt failure. The result could be
the loss of the electrical or air system as well as possible
engine damage from overheating. So it’s a very good idea to
check your belts frequently and replace them as soon as you
detect trouble.
Follow this procedure to install an accessory drive belt:
Vehicles that comply with 2010 EPA emission requirements
will have a Deisel Exhaust Fluid (DEF) tank mounted to the
vehicle frame. During normal operating situations, your vehicle may consume 1 gallon of DEF for every 2 gallons of
deisel fuel. Be sure to maintain sufficient fluid in the DEF tank
for proper vehicle performance.
– 172 –
1. Rotate the new belt around the pulleys, and then rotate
the automatic tensioner so that the idler pulley swings
toward the belt routing. Figure 1 shows an example of
the rotation direction to release the tensioner.
2. Slip the belt around the idler pulley attached to the automatic tensioner.
3. Release the automatic tensioner.
4. Check the belt alignment on each pulley. The belt must
fall between the flanges of each pulley.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Engine Maintenance
To Check the Fan:
• Check the fan assembly mounting bolts for tightness.
Inspect the blades for damage.
• Check the clutch operation by starting the engine when it
is cold. Then idle it at about 800 RPM. Listen for air
leaks.
• Check that the fan is not working while the engine is
warming. When the clutch engages, note the reading on
the vehicle's panel—mounted coolant temperature
gauge. 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
an Authorized Service Center.
Fan Drive and Blade
Engine Fan
Thermatic (Clutch) — Type Fan
WARNING! Do not work on the fan with the
engine running. The engine fan can engage at
any time without warning. Anyone near the fan
when it turns on could be seriously injured.
Before turning on the ignition, be sure that no
one is near the fan.
Medium Duty (R05/09)
Fan Blade Clearance: Around the fan shroud, the recommended distance is 1 in. (25 mm) from front edge of any fan
blade-to-radiator side member. Minimum clearance is 3/4 in.
(19 mm).
• Rear edge of any blade must be no closer than 3/8 in.
(9 mm) to the nearest engine component. If this cannot
be obtained, the fan spacer or fan is not correct.
Y53-6008A
– 173 –
Engine Cooling System
Preventive Maintenance
• The leading edge of any fan blade must be 1 in. (25 mm)
from the inside edge of the shroud.
itors. ELC prevents corrosion and scale formation as well
as provides freezing and boiling point protection.
Exhaust System
The exhaust system is part of the noise control system. Periodically check the exhaust for wear and loose or missing
parts. For details, see “Noise and Emission Control” on
page 251.
WARNING! The exhaust piping, muffler, converter muffler or independent converter become
extremely hot during engine operation and can
cause serious burns to the skin. Allow adequate
cooling time before working on or near any part
of the exhaust system.
CAUTION: The engine cooling system has very
specific maintenance and inspection requirements. Failure to follow requirements can damage the engine. Engine damage can include but
is not limited to:
• Freezing
• Boiling
• Corrosion
• Pitted cylinder liners
This information is found in the engine manufacturers owner’s manual. It is the owner’s responsibility to follow all requirements listed in the
engine manufacturers owner’s manual.
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-
– 174 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Engine Cooling System
What To Check In An ELC-filled Cooling System
NOTE: Maximum recommended ELC concentration is 60% ELC and 40% water by volume (a 60/
40 coolant mixture). The minimum recommended
concentration is 40%.
ELC Concentration
Check the level of freeze/boilover protection, which is
determined by the ELC concentration. Use a glycol refractometer to determine glycol level. Add ELC to obtain the
ELC to water ratio required to provide the protection you
need. Use the chart below to help determine how much
ELC you need to add.
30%
35%
40%
In an ELC-filled cooling system, the freeze point should be
maintained between -30° F and -45° F (-34° C and -43° C)
Desired ELC/
Water ratio:
0%
10%
15%
20%
25%
Freeze point
°F (°C)
+32
(0)
+25
(-4)
+20
(-7)
+15
(-9)
+10
+5
-5
-12
-23
-34
-50
-65
-75
-84
-70
-55
-43
-30
-5
(-12) (-15) (-21) (-24) (-31) (-37) (-46) (-54) (-59) (-64) (-57) (-48) (-42) (-34) (-21)
ELC Condition (Contamination and Inhibitor Concentration)
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 maintenance may cause coolant degradation and could result in
Medium Duty (R05/09)
45%
50%
55%
60%
65%
70%
75%
80%
85%
90% 100%
damage to the cooling system and engine components.
Consult your dealer or the ELC manufacturer’s representative for recommended ELC test kits, test strips, and laboratory sample procedures.
ELC Extender
Add ELC extender if necessary at the maintenance interval under “Cooling” on page 179.
Y53-6008A
– 175 –
Engine Cooling System
Preventive Maintenance
Topping Off
WARNING! Removing the fill cap on a hot
engine can cause scalding coolant to spray
out and burn you badly. If the engine has been
in operation within the previous 30 minutes,
be very careful in removing the fill cap. Protect face, hands, and arms against escaping
fluid and steam by covering the cap with a
large, thick rag. Do not try to remove it until
the surge tank cools down 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.
FILL
COOLANT
EXPANSION
TANK
Cooling System Expansion Tank
Proper Coolant Level
NOTE: Do not overfill a cooling system. Excess
coolant may result in overflow, loss of antifreeze,
and reduced corrosion protection.
WARNING! Handle coolant and antifreeze carefully. Ethylene glycol antifreeze is poisonous.
Store in original fluid container only and always
keep out of reach of children.
Check the coolant level after each trip. Add coolant as
necessary. You may find your coolant level is not up to the
– 176 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Engine Cooling System
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.
Engine (Block) Heater (option)
Refilling Your Radiator
1.
2.
3.
4.
5.
6.
7.
8.
9.
Be sure the radiator and engine block drains are closed.
Move the heater control to maximum heat position.
Remove the surge tank pressure cap
Through the surge tank, fill the system with premixed
coolant. Pour it in a steady flow until the radiator is full.
Start the engine.
Idle at low RPM.
Complete the filling. Do it as quickly as possible.
Idle the engine until it reaches normal operating temperature.
Fill the radiator as necessary to raise the coolant level to
the proper reading. Replace the surge tank pressure
cap.
Medium Duty (R05/09)
Y53-6008A
WARNING! Do not use the heater if there are any
signs of problems. Engine block heaters can
cause fires resulting in serious personal injury
and/or property damage if not properly maintained and operated. Regularly inspect the
engine block heater wiring and connector for
damaged or frayed wires. Contact your Authorized Service Center or the manufacturer of the
heater if you are in need of repairs or information.
CAUTION: Always unplug the block heater
before starting your engine. Damage to the cooling system could occur if not turned OFF
(unplugged).
– 177 –
Engine Cooling System
Preventive Maintenance
Use a solution of half ethylene glycol antifreeze and half
water for best heater performance. Do not use more than 65
percent concentration of antifreeze, as a shortened heater
life will result.
After servicing the cooling system, operate the vehicle for a
day or two before using the heater. Trapped air inside the
engine needs time to escape.
PREVENTIVE MAINTENANCE (PM) INTERVALS
I
A
B
C
At the first 15,000 mi./ 15,000 mi./24,000 km/ 30,000 mi./48,000 km
24,000 km or at the first Monthly
PM
SYSTEM
COMPONENT
60,000 mi./96,000 km/
6 months
D
120,000 mi./
192,000km / Annually
E
240,000 mi./384,000 km
Recommended
PM Interval
MAINTENANCE TASK
I
– 178 –
Y53-6008A
A
B
C
D
Medium Duty (R05/09)
E
Preventive Maintenance
Cooling
Engine Cooling System
Hoses
Check the radiator and heater hoses for leaks.
X
X
Extended Life Coolant (ELC)
Check the freeze point (see page 174).
X
Check for contamination using test strips (see page 175).
X
Replace blank water filter if applicable.
X
Perform lab analysis (see page 175).
X
If lab analysis shows coolant is unsuitable for continued use
Flush, drain, and refill (see page 174).
Add ELC Extender (see page 175).
Flush, drain, and refill with new coolant (see page 174).
X
Fan clutch housing
Check for air leaks.
X
Surge Tank Fill Cap
Check fill cap seal at each oil change.
X
Medium Duty (R05/09)
Y53-6008A
X
X
X
X
X
– 179 –
X
Brake System
Preventive Maintenance
BRAKE SYSTEM
All of the following areas are interrelated and must conform to original specifications:
If your truck has an air brake system, see the pages below.
•
•
•
•
If your truck has a hydraulic brake system, please go to
“Hydraulic Brake System” on page 184.
Introduction
To operate your vehicle safely, you need some understanding
of its brake systems. Brake adjustment and brake balance
must be set carefully to allow equal stopping forces at all
wheels. Tires are also a very important part of the whole system. How fast you can stop depends on how much friction
there is between the road and your tires.
CAUTION: The air brake system of this vehicle
was configured for ONE of the following operations: 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.
– 180 –
tire size
wedge angle
brake linings
slack adjusters
• cam radius
• drum radius
• brake chambers
Once a brake system is set to specifications, changing any
one of its components or any combination of components
may degrade the system. All parts have to work together to
perform as they should.
Because your brake system is air operated, see the following
section “Air System” on page 191 for more information on
checking your brakes.
Any replacement components in the brake system should be
the same or better than the original components. Any
changes from the original specifications can affect the performance of the entire system.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Brake System
WARNING! Do not use any replacement part in
the brake system unless it conforms exactly to
original specifications. A nonconforming part in
your vehicle's brake system could cause a malfunction resulting in an injury 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 the brakes work
for you on the road. If parts do not work together
properly, you could lose control of your vehicle,
which could cause a serious accident.
WARNING! Do not work on the brake system
without the parking brake set and wheels
chocked securely. If the vehicle is not secured to
prevent uncontrolled vehicle movement, it could
roll and cause serious personal injury or damage to the vehicle.
•Use wood blocks (4 in. X 4 in. or larger) against
the front and rear surfaces of the tires. Be sure
the vehicle cannot move.
Lubrication
Cam-actuated brake components such as anchor pins and
brake camshafts are subjected to high temperatures, and
must be lubricated with nonmelting, water resistant brake
grease meeting R–S Specification 0–616 (NLGI–Grade 1).
• Lubricate according to Table 1, “Recommended Maintenance Intervals,” Page 150.
WARNING! Do not apply too much lubricant to
brake components—lubricate sparingly. Excessive amounts of lubricant could contaminate
brake linings, which could reduce brake effectiveness and cause an accident.
Brake and Slack Adjuster Lubrication
According to the interval, pressure lubricate the slack
adjuster and brake camshaft (bracket/tube). Two grease fittings are provided for both the slack adjuster and camshaft
bracket/tube.
• Use standard chassis lubricant (meeting No. 1 grade
high temperature, water proof specifications).
• Do not use moly-disulfide loaded grease or oil (they may
shorten the service life of the slack adjuster).
Medium Duty (R05/09)
Y53-6008A
– 181 –
Brake System
Preventive Maintenance
• Do not use pressure-release grease fittings when lubricating the slack adjuster.
Checks and Adjustments
All vehicle operators should check the brakes regularly.
Always adjust the brakes when they are cool.
• Park the vehicle on a level surface and block the wheels
before attempting any brake checks or adjustments.
Brake Linings
WARNING! Do not use brake linings with a thickness below the specified minimum. Such linings
will have lining rivets exposed that can damage
the brake drum and reduce brake efficiency,
which could cause an injury accident or system
failure.
• Brake linings should be inspected for wear by a qualified
mechanic at an Authorized Service Center. See Table 2,
“Maintenance Schedule,” Page 153. In severe service
applications inspect the linings more frequently.
– 182 –
Automatic Slack Adjusters
Your Medium Duty is equipped with automatic brake (slack)
adjusters.
Periodically, brake adjustment should be checked using
the following procedure:
1. Check brakes when the temperature of the service brake
linings are cool and the system air pressure is at 100 psi
(690 kPa) minimum.
2. Release the parking brakes to allow the slack adjusters
to retract.
3. Measure the retracted pushrod length from the face of
the brake chamber to the center of the pushrod pin.
4. Apply 80 to 90 psi brake application and measure the
same distance.
5. The difference is the pushrod travel distance (applied
stroke).
Verify that the result is within the correct range (see Table 4,
”Brake Adjuster Stroke”). Correctly installed and functioning
brakes (auto slack) will produce the strokes listed for each
chamber type.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Brake System
WARNING! Manual adjustment of automatic
slack adjusters is a dangerous practice that
could have serious consequences. It gives
the operator a false sense of security about
the effectiveness of the brakes. Contact the
Service Department at your dealership if the
stroke exceeds the above specifications. A
stroke exceeding these values may indicate a
problem with the slack adjuster or the brake
foundation.
BRAKE
CHAMBER
SLACK
ADJUSTER
PUSHROD
“APPLIED STROKE”
01830
Measuring Pushrod Travel
Table 4
Brake Adjuster Stroke
80–90 PSI (552 – 621 KPA) BRAKE APPLICATION
PUSHROD TRAVEL
(Applied Stroke)
AIR CHAMBER
TYPE (Size)
BRAKE
20
Front
1 to 1–3/4 in. (25–44mm)
30
Rear
1–1/4 to 2 in. (32–51mm)
Medium Duty (R05/09)
• If the pushrod travel reaches the above specifications,
check the slack adjuster installation. Inspect brake
adjuster and anchor bracket for damage. The anchor
bracket should be tight.
• With the air system at 100 psi (690 kPa) or more, apply
the brake.
If adjustment is necessary and the slack adjuster is working,
the adjusting hex nut will rotate during the chamber return
stroke. Installing a wrench on the hex nut will make this easier to see. On each stroke after the first, the amount of adjustment and chamber travel will be less.
Y53-6008A
– 183 –
Brake System
Preventive Maintenance
Constant manual adjustment of automatic slack adjusters
can shorten the life of the internal clutch. If the installation
appears to be free of damage, but the applied stroke range
could not be achieved, the slack adjuster must be replaced.
NOTE: The brake adjuster alone does not ensure
proper brake operation. Inspect all brake components. All brake components work together and
must be checked periodically to ensure the brake
system works properly. See the “Medium Duty
Maintenance Manual” for more information on
brake maintenance.
Hydraulic Brake System
Introduction
To operate your vehicle safely, you need some understanding
of its brake systems. Brake adjustment and brake balance
must be set carefully to allow equal stopping forces at all
wheels. Tires are also a very important part of the whole system. How fast you can stop depends on how much friction
there is between the road and your tires.
– 184 –
All of the following areas are interrelated and must conform to original specifications:
•
•
•
•
wheel size
tire size
brake pads
brake rotors
• front wheel bearings
• front end alignment
• parking brake drum
radius
Once a brake system is set to specifications, changing any
one of its components or any combination of components
may degrade the system. All parts have to work together to
perform as they should.
Your brake system is hydraulically operated. Refer to the section titled “Service Brake Component Inspection” on
page 186 for more information on inspecting the brakes.
Any replacement components in the brake system must meet
the specifications of the original components. Any changes
from the original specifications can affect the performance of
the entire system.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Brake System
WARNING! Do not use any replacement part in
the brake system unless it conforms exactly to
original specifications. A nonconforming part in
your vehicle's brake system could cause a malfunction resulting in an injury accident. Consult
you local dealer for suitable replacement parts.
Brake Fluid Check and Refill
WARNING! Do not work on the brake system
without the parking brake set, the keys removed
from the vehicle, and wheels chocked securely.
If the vehicle is not properly secured to prevent
inadvertent vehicle movement, it could roll and
cause serious personal injury or damage to the
vehicle.
• Use wood blocks (4 in. X 4 in. X 6 in. or
larger) against the front and rear surfaces of
the tires. Be sure the vehicle cannot move.
WARNING! Wear protective clothing when handling hydraulic fluid. It is mildly toxic and can
cause skin and eye irritation.
WARNING! Use only the type of hydraulic fluid
specified. Do not use or mix different types of
hydraulic fluid. The wrong hydraulic fluid will
damage the rubber parts of the brake system
which may lead to loss of braking and possibly
cause serious personal injury.
CAUTION: Hydraulic brake systems use two distinct and incompatible fluids. Power steering
fluid is used in the hydraulic brake booster system. Brake fluid is used in the master cylinder
and brake pipes. Do not mix these fluids when
replenishing the system or seal damage can
result.
CAUTION: Hydraulic brake fluid may damage
painted surfaces of the vehicle.
Medium Duty (R05/09)
Y53-6008A
– 185 –
Brake System
Preventive Maintenance
WARNING! If the brake fluid reservoir requires an
excessive amount of hydraulic fluid, the complete system must be inspected for leaks and
repaired if necessary (consult your nearest
Peterbilt dealer). Failure to keep the brake system in good repair may lead to loss of braking
and possibly cause serious personal injury.
Make sure that the fluid level registers on or above the fluid
level mark molded on the reservoir - add more if necessary,
as follows:
1. Remove each reservoir cap and extract the rubber diaphragm from each reservoir.
2. Fill each reservoir with clean hydraulic fluid of the
approved specification (DOT 3 brake fluid).
3. Insert the rubber diaphragms into the reservoirs.
Service Brake Component Inspection
Remove each wheel to inspect the brake components.
REFILL CAPS
CAUTION: When replacing disc brake pads, be
sure to use the same lining material on both
axles. Mixing lining types can result in unbalanced braking, increased pad wear, or degraded
stopping performance. Consult your nearest
Peterbilt dealer.
Disc brake pads - Visually inspect all brake pad linings.
Brake pads should be replaced when the
remaining lining reaches 3⁄16 inch thickness or
less.
BOOSTER AND MASTER CYLINDER ASSEMBLY
4. To prevent leakage from the reservoirs, ensure that the
seal in each reservoir cap is in good condition before
refitting the cap.
– 186 –
Y53-6008A
It is recommended that all disc brake pads be
replaced at the same time since this will maintain balanced braking. At a minimum, replace all
disc brake pads on one axle, both ends, at the
same time.
Medium Duty (R05/09)
Preventive Maintenance
Brake System
BRAKE PADS
ANCHOR
PLATES
BRAKE PADS
CALIPERS
CALIPERS
ROTORS
FRONT
REAR
SYSTEM COMPONENTS
Calipers - Visually inspect calipers for brake fluid leakage,
damaged or defective pistons or piston boots. If
there is evidence of leakage, damage, or other
defects the caliper should be replaced or
repaired.
Disc brake rotors - Visually inspect rotors for scoring, warping, cracks, bluing or heat spots or other damage
or defects. If signs of damage or defects are
found, the rotor(s) should be resurfaced or
replaced in accordance with the vehicle manufacturer's recommended service procedure.
Anchor plates - Visually inspect anchor plates for worn or
damaged slippers, damaged or dislodged guide
pin boots or other defects. If signs of wear, damage or defects are found, the anchor plate(s)
should be repaired or replaced.
Parking Brake Component Inspection
NOTE: If you are not properly trained to perform
brake inspections or service, take your vehicle to
your nearest Peterbilt dealer.
Medium Duty (R05/09)
Y53-6008A
– 187 –
Brake System
Preventive Maintenance
Visually inspect brake shoe lining for wear, cracks, or breakage. If linings are worn down to 2.5 mm (0.10 in), they must
be replaced. Inspect brake drum for deep scores, heat spots,
cracks, or damage. Replace if needed.
BRAKE
SHOE
LININGS
Anti–Lock Braking System (ABS)
Your Medium Duty is equipped with an anti-lock braking system. For detailed service information, see the Peterbilt
Medium Duty Maintenance Manual. All service work
should be performed by a qualified technician at an Authorized Service Center. The foundation brake system must be
in proper working order to ensure the best ABS performance.
CAUTION: Do not weld anywhere on the vehicle
before detaching the ABS Electronic Control Unit
(ECU) connector and all other electronic control
units. Welding equipment can send an energy
surge through electronic equipment and cause
damage. Disconnect all ECUs before attaching
welding equipment.
CAUTION: Never detach the ECU connector with
the ignition turned on. The connectors could arc
and damage electronic equipment. Turn off the
ignition before disconnecting any electronic
equipment.
PARKING BRAKE COMPONENTS
Other precautions
• Check ABS wiring harnesses periodically for chafing or
other problems. No regular maintenance is required on
the ABS components.
– 188 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Brake System
• During wheel balancing, dyno testing, or any time the
ignition is on with part of the ABS disconnected, a failure
code will be recorded. Consult with your Peterbilt Dealer
or Authorized Service Center for information on clearing
the failure code.
If, due to operating conditions, a brake application causes
either wheel on the same axle to begin skidding, wheel
speed sensors immediately signal the anti-lock controller in
the modulator assembly. The controller responds instantly by
signaling the solenoids in the modulator which activate the air
valves, reducing application pressure as needed to prevent
the wheels from locking up. If this over-riding correction is
effective, application pressure is allowed to build up to the
original input.
Any malfunction of the anti-lock system on one or more axles
will cause the system to fail-safe, and the panel-mounted
amber warning light will come on, indicating both a malfunction, and automatic shut-down of the system. If the foundation brake system is intact, the service brakes will continue to
function normally, but without benefit of the anti-lock feature.
Medium Duty (R05/09)
Y53-6008A
NOTE: If one wheel on any driven axle continues to
slip or spin for approximately 4 seconds, this will
cause the anti-lock controller for that axle to go into
the fail-safe mode, and the warning light will give a
shutdown signal.
•In this case, the anti-lock system can be turned
back on, and the warning light extinguished, by turning the key switch OFF and ON, after the vehicle has
been brought to a full stop. When the key switch is
turned back on, the warning light will illuminate and
remain on for 3 to 5 seconds. This is a built-in function test of the warning light.
WARNING! Do not attempt to recycle the antilock system by turning the keyswitch OFF and
ON until the vehicle has been brought to a full
stop and the parking brakes set. Failure to do so
could adversely affect steering and braking control, and may result in loss of vehicle control and
an injury accident.
– 189 –
Brake System
Preventive Maintenance
WARNING! Do not operate the vehicle in the
event of a malfunction in any air or hydraulic circuit. Such a malfunction may prevent the brake
system from operating properly, and could
result in an injury accident. The vehicle should
not be operated until the system is repaired and
both braking circuits, including all pneumatic,
hydraulic, and mechanical components are
working properly.
– 190 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Air System
AIR SYSTEM
Introduction
WARNING! Prior to the removal of any air system
component, always block and hold the vehicle
by a secure means other than the vehicle's own
brakes. Depleting air system pressure may
cause the vehicle to roll unexpectedly resulting
in an accident and/or injuries. Keep hands away
from chamber push rods and slack adjusters,
they may apply as system pressure drops.
•Never connect or disconnect a hose or line containing air pressure. It may whip as air escapes.
Never remove a component or pipe plug unless
you are certain all system pressure has been
depleted.
•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.
•Never attempt to disassemble a component
until you have read and understood recommended procedures. Some components contain
powerful springs and injury or death can result if
not properly disassembled. Use only proper
tools and observe all precautions pertaining to
the use of those tools.
Medium Duty (R05/09)
• Completely bypassing a Bendix AD-IS air dryer will
bypass the system’s 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 manuf a c t u r er’s p ro c ed u r e if it i s n ec es s ar y in an
emergency to temporarily bypass an AD-IS-series air
dryer.
WARNING! Do not release the parking brake or
attempt to move the vehicle until air pressure in
both circuits is at least 100 psi (690 kPa), the
level required for normal brake operation.
•Do not use the trailer hand brake control to hold
vehicle while parked. This control utilizes air
pressure for brake application. Because acceptable air leakage levels cause all truck air systems to gradually lose pressu re , vehicle
rollaway could occur, resulting in an accident
and/or injuries.
•Always apply the tractor and trailer parking
brakes when the vehicle is unattended.
Contamination of the air supply system is the major cause of
problems in air-operated components such as brake valves,
wiper motors, and suspension height control valves. To keep
contaminants to the lowest possible level, follow these maintenance procedures.
Y53-6008A
– 191 –
Air System
Preventive Maintenance
Scheduled Maintenance
Table 5
Use Table 5, ”Air System Scheduled Maintenance,” to
schedule service operations and air system tests.
Air System Scheduled Maintenance
MAXIMUM INTERVALS
EACH MONTH
TEST
Air Compressor
Air Governor
System Leakage
Dual Air Brake Treadle Valve
Hand–Operated Trailer Brake Valve
Tractor Parking Valve
Parking Brake Valve
Trailer Air Supply
Tractor Protection Valves
Relay Valve
Spring Brake Inversion Valve
Automatic Limiting Valve
Single Check Valves
Double Check Valves
Stop Light Switch
Low–Pressure Wig Wag
Low–Pressure Switch
Automatic Drain Valve
Safety Valve
Quick Release Valve
Manual Drain Valve
– 192 –
EACH WEEK
THREE MONTHS
SIX MONTHS
ANNUALLY
(10,000 mi) (16,000 (25,000 mi) (40,000 (50,000 mi) (80,000
km)
km)
km)
(100,000 mi)
(160,000 km)
•
•
•
•
•
•
•
•
–
–
or
or
–
–
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Air System
WARNING! If the supply and service tanks are
not drained at the recommended frequency,
water could enter the air lines and valves. This
could cause corrosion or blockage, which could
compromise the brake system safety and potentially cause an injury accident.
Air System Function Test
Scheduled maintenance should be performed on the Medium
Duty air system, as outlined in the Medium Duty Maintenance Manual and Table 5. In addition, perform an Air System Function Test at least every 3 months or if there is any
indication of a potential problem.
REAR PRIMARY
(SERVICE) TANK
FRONT
SECONDARY
(SERVICE) TANK
Air Tanks
The front (secondary) service tank is underneath the cab, on
the driver's side; the wet (supply) tank is underneath the front
service tank, behind the battery box; and the rear (primary)
service tank is attached to the left frame, just behind the cab.
DRAIN VALVE
WET (SUPPLY)
TANK UNDER
FRONT SERVICE
TANK
The supply tank (or “wet” tank), must be drained on a daily
basis. Drain the supply tank by pulling the drain valve lanyard. Hold it open until the escaping air is free of water.
02602
The two service tanks (or “dry” tanks), must be drained on a
weekly basis. Drain the two service tanks by opening the
drain valves. Turn valve handles counter-clockwise, and
leave open until the escaping air is free of water.
Medium Duty (R05/09)
Location of Air Tanks
Periodically: 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.
Y53-6008A
– 193 –
Air System
Preventive Maintenance
CAUTION: Do not use penetrating oil, brake
fluid, or wax-based oils in the air system. These
fluids may cause severe damage to air system
components.
WARNING! Do not operate the vehicle if leakage
in the air system is detected. Conduct the following procedure and contact an Authorized Service Center (or any other properly equipped
• Maintain the air compressor to prevent excessive oil bypass. See the Medium Duty Maintenance Manual for
maintenance details.
• Replace worn seals in valves and air motors as they are
needed. Your Peterbilt Dealer carries rebuild kits for most
units.
service center) if a leak is detected. Failure to
check the brakes or follow these procedures
could cause a system failure, increasing the risk
of an injury accident.
Dual Air Gauge and Air Leaks
Your Medium Duty comes with a primary and secondary air
pressure guage. The gauge indicates the amount of air pressure in pounds per square inch (psi). See “Primary (Sec-
ondary) Air Pressure Gauge (Air Reservoir)” on page 41.
If the pressure in either or both systems is too low for normal
brake operation, i.e., either pointer falls below 60 psi (414
kPa), a warning light on the gauge will glow and the audible
alarm will sound. If the light and alarm do not turn off at startup, do not try to drive the vehicle until the problem is found
and fixed.
– 194 –
Follow the procedure below to check the compressed air
system for leaks:
1. Periodically, or after maintenance or replacement of air
system components:
2. Build up air pressure in the system to the governor cutout point or until 120 psi (827 kPa) is reached.
3. Stop the engine and release the service brakes.
4. Without applying the brake pedal, observe the rate of air
pressure drop. This rate should not exceed 2.0 psi (14
kPa) per minute.
5. Start the engine and build up the air pressure again.
6. Stop the engine, and apply the brakes fully. Apply the
brake pedal and hold it down for five minutes. The pressure drop should not exceed 3.0 psi (21 kPa) per minute.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Air System
7. If you detect excessive leakage (air pressure loss greater
than 3.0 psi after five minutes of brake application), a
leakage test should be made at the air line connections
and at all air brake control units. These tests should
determine where air is escaping.
Air Compressor
Operation
All compressors, regardless of make or model, run continuously while the engine is running. System pressure is controlled by the governor. The governor acts in conjunction with
the unloading mechanism in the compressor cylinder block to
star t and stop compression of air. The compressor is
unloaded when the system pressure reaches 120 psi (827
kPa) and compression is re-established when system pressure falls to 100 psi (690 kPa).
Preventive Maintenance
The following service checks are provided for your information only and should be performed by a certified mechanic.
Contact your Peterbilt Dealer or consult the Medium Duty
Medium Duty (R05/09)
Maintenance Manual and the engine manufacturer's Maintenance Manual for further information on servicing air compressors. After completing any repairs to the air system,
always test for air leaks, and check the brakes for safe operation before putting the vehicle in service.
According to Table 5, “Air System Scheduled Maintenance,” Page 192:
• Inspect compressor air filter element, if so equipped, and
replace element if clogged. Check compressor mounting
and drive for alignment and belt tension. Adjust if necessary.
• Remove compressor discharge valve cap nuts and
check for presence of excessive carbon. If excessive carbon is found, clean or replace the compressor cylinder
head. Also, check compressor discharge line for carbon,
and clean or replace the discharge line if necessary.
• Disassemble compressor and thoroughly clean and
inspect all parts. Repair or replace all worn or damaged
parts, or replace compressor with a factory exchange
unit.
Y53-6008A
– 195 –
Air System
Preventive Maintenance
CAUTION: When draining the engine cooling
system is required, to prevent damage from
freezing, the compressor must also be drained
at the cylinder head and block. Engine damage
could occur if the cooling system is not periodically drained and maintained. See “Engine Cooling System,” Page 174 , and the Medium Duty
Maintenance Manual for further information.
Air Dryer
WARNING! Use of incorrect air dryer could
cause air system failure, leading to loss of
vehicle control and serious personal injury or
death. If your vehicle is equipped with a Bendix 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
valve in the tank inlet. The check valves prevent a complete loss of air in the event of an air system failure (tank
or hose failure). This ensures a controlled stop (with
– 196 –
reduced braking capability). Other vehicles use a Bendix
AD-IS air dryer which eliminates the need for a wet tank
and check valves in the dry tanks.
NOTE: A small amount of oil in the system may be
normal and should not, by itself, be considered
reason to replace a desiccant cartridge; oil-stained
desiccant can function adequately.
Every 900 operating hours or 25,000 miles/40,000 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 reservoir would
point to the need for a desiccant cartridge change. However,
the following should be considered first:
• Air usage is exceptionally high/abnormal for a highway
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 normal fashion or it
may be due to excessive leaks in the air system.
• 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
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Air System
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.
Turbocharger
When servicing the air intake and exhaust systems on a turbocharged engine, check the items listed below.
Air Intake System
Engine heat, vibration, and age combine to loosen air intake
connections and cause cracks in the tubing and elbows.
Leaks in the intake system allow abrasive dust to enter the
engine and quickly cause expensive damage. During your
daily walk-around inspection, carefully check all tubing,
elbows, clamps supports and fasteners for condition and
tightness.
• Under normal operating conditions, Peterbilt recommends complete disassembly and cleaning of the air
intake system at each 25,000 mile (40,000 km). Under
severe operating conditions, the disassembly and cleaning should be more frequent. Replace any defective
parts. With the possible exception of mounting brackets,
do not repair defective parts.
Medium Duty (R05/09)
• Check the Charge-Air-Cooler for air leaks annually. The
air leaks can be caused by cracked tubes or header. For
service see your Peterbilt Dealer or Authorized Service
Center.
WARNING! Do not operate engine with the turbocharger intake piping disconnected. A suction is
created 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 connected when you will be running the engine.
Lubricating System: Check the oil lines, housing, and connections. Look for leaks, damage, or deterioration. Leaks
could mean you have damaged oil lines or oil seals.
Manifold: With the engine operating, check for leaking manifold or flange gaskets.
Y53-6008A
– 197 –
Air System
Preventive Maintenance
High Frequency Vibration: Vibration may indicate turbo
rotor imbalance. Have your Peterbilt Dealer or Authorized
Service Center investigate this immediately. If you detect any
deficiencies, take the vehicle to an Authorized Service Center for servicing. Delay could lead to severe and expensive
damage to your vehicle.
Service the air cleaner periodically. If the vehicle operates in
areas with heavy dust, maintenance should be more frequent. Follow the instructions below to remove the air filter.
AIR INTAKE
ASSEMBLY
Air Filter Replacement
Service the filter elements when the Air Cleaner Restriction
gauge (option) locks in the extreme High position. Have the
element serviced at a Peterbilt Dealer or Authorized Service
Center. Paper elements require care and proper handling,
because they are critical to engine service life.
02603
Air Intake Assembly
– 198 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Air System
3. Remove the filter element.
4. Clean out the inside of the air cleaner body and outlet
tube with a dry rag.
COVER
To install air cleaner element:
1. Slide air cleaner element into housing.
2. Install air cleaner end cap.
3. Install thumbscrews around air cleaner housing end cap.
00455B
NOTE: The air cleaner is internally sealed by a
radial seal around Inlet tube of air cleaner element.
For further information on servicing the air cleaner,
see the Medium Duty Maintenance Manual.
FILTER ELEMENT
Air Cleaner - Filter Element
To remove the air filter:
1. Remove the two thumb screws.
2. Remove air cleaner service cover.
Medium Duty (R05/09)
Y53-6008A
– 199 –
Tires and Wheels
Preventive Maintenance
TIRES AND WHEELS
Introduction
Keeping the tires in good condition is essential to the safe,
efficient operation of your Medium Duty. Regular, frequent
inspection and the right care will give you the assurance of
safe and reliable tire operation.
General Safety Requirements
WARNING! Use only original equipment manufactured (OEM) components. Use of non-original
equipment could cause wheel breakage and
wheel separation from vehicle, which could
result in an injury accident. Each mounting system is engineered only for use with its correct
mating part. Be sure that properly matched components are used for each type of mounting. The
comparison chart on Page 208 illustrates the
differences between parts used in hub-piloted
mount and ball seat mount applications. Only
OEM supplied hub-piloted or ball-seat mounted
wheels may be used on this vehicle.
– 200 –
• If you are not fully qualified and not equipped with
the proper tools and equipment, do not attempt to
raise the vehicle or remove or install the damaged
tire and wheel assembly. Obtain expert help. A person can be seriously injured and/or damage can
result from using the wrong service methods. Truck
tires and wheels should be serviced only by trained
personnel using proper equipment. Do not reinflate
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.
• Follow OSHA regulations per section 1910.177.
• Do not exceed the speed rating of tires. Exceeding
the speed rating may result in sudden tire failure and
loss of vehicle control.
• Follow all warnings and cautions contained within
the tire and wheel manufacturers literature.
• Only properly trained personnel should service tire
and rim assemblies.
• See page 210 for specific safety requirements for
trucks with hydraulic brakes.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Tires and Wheels
Speed Restricted Tires
WARNING! This vehicle may be equipped with
speed restricted tires. Check each tire’s sidewall for maximum rated speed. Vehicle should
not be operated at sustained speed in excess
of maximum rated speed. Failure to comply
with these speed restrictions could cause
sudden tire failure which can result in property damage or personal injury.
Tire Inspection and Replacement
vehicle. For dual wheel assemblies, check between the
wheels for damage. If any damage is found, or you suspect
damage, do not attempt further repair. Call for expert tire service.
Tire Inflation and Loading
Low pressure is a tire's worst enemy. Underinflation allows
tires to flex improperly, causing high temperatures to build up.
Heat causes early tire damage such as flex break, radial
cracks, and ply separation. And low pressure may affect control of your vehicle, especially at the front wheels.
Visually inspect your tires frequently for any abnormal conditions such as scrapes, bulges, and uneven wear. This must
be done immediately after known or suspected contact with
an object in the road, with a pothole, road irregularity or after
severe braking. Refer these conditions to an Authorized Tire
Service Center for repair or replacement. Never drive on a
tire if such conditions appear.
WARNING! Do not operate vehicle with underinflated tires. The extra heat caused by underinflation can cause sudden tire failure such as a tire
fire or blow out. Low pressure may affect control
at the front wheels, which could result in an accident and serious injury. Keep your tires inflated
to the manufacturer's recommended air pressure.
If the tire looks underinflated, stand off to the side and check
for damage to the wheel assembly. This can be done by visually comparing the wheel in question to other wheels on the
Medium Duty (R05/09)
Y53-6008A
– 201 –
Tires and Wheels
Preventive Maintenance
Tire Inflation
Most tire wear problems are caused by underinflation as the
result of slow leaks. So you will want to check tire pressure
regularly. Give the tires a visual test every day, and check
inflation with a gauge every week.
When checking tire pressure, inspect each tire for damage to
sidewalls, cuts, cracks, uneven wear, rocks between dual
wheels (tires), etc. If a tire appears underinflated, check for
damage to the wheel assembly. Do not forget to check
between dual wheels. If you find wheel damage, have an
expert tire service repair it.
WARNING! Do not repair damaged tires unless
you are fully qualified and equipped to do so.
Wheel and tire assemblies cannot be worked on
without proper tools and equipment, such as:
safety cages or restraining devices. Have all tire
repairs performed by an expert. And stand away
from the tire assembly while the expert is working.
CAUTION: Pressure should be checked when
the tires are cool. Warm or hot tires cause pressure buildup and will give you an inaccurate
reading. So never deflate a warm tire to the
specified pressure.
– 202 –
Underinflated tires will adversely affect the operation of
the vehicle and tires:
• making steering difficult
• causing extra strain on the tire sidewalls
• reducing the tread life of tires due to the high temperatures generated from excess flexing of the tire
• Inflate tires to the manufacturer's cold air pressure specification molded into the tire side wall.
Lower tire pressure does not give you more traction on ice or
snow. Underinflation actually reduces traction and steering
control. See the tire manufacturer's Drivers Handbook for
more information on proper operation and use of tires.
00137a
Proper Inflation: t h e c o r r e c t
profile for full contact with the
road.
TREAD CONTACT
WITH ROAD
00138a
Y53-6008A
TREAD
CONTACT WITH ROAD
Underinflation: causes abnormal tire deflection, which builds
up excessive heat, running the
risk of failure. It also causes
irregular wear.
Medium Duty (R05/09)
Preventive Maintenance
Tires and Wheels
Overinflation: r e d u c e s t h e
tread contact area with the road
surface, concentrating all of the
vehicle weight on the center of
TREAD CONTACT
the tread. This causes premaWITH ROAD
ture wear of the tire.
• Too much air pressure reduces the tire tread contact
area and results in rapid wear in the center of the tire. It
also causes tires to run hard and makes them more vulnerable to impact and other road hazard damage.
00139a
WARNING! Overinflated tires can cause accidents. They wear more quickly than properly
inflated tires and are more subject to punctures,
cracks, and other damage. They could fail and
cause you to lose control of your vehicle resulting in an injury accident. Be sure all tires are
inflated correctly according to the manufacturer's recommendations.
Table 6
If overinflation is noted during travel, do not deflate tires. The
increased pressure is caused by temperature build-up during
operation. This condition has been taken into account during
manufacturing of the tires. Allow tires to cool, then recheck
and adjust if necessary.
Tire Loading
WARNING! Do not exceed the load rating of your
tires (molded on the side wall of your tire) or the
maximum vehicle load rating, whichever is less.
Overloading could result in premature tire failure causing you to loose control of your vehicle
and result in an injury accident. The maximum
vehicle load rating (GVWR) is found on the Tire
and Rim Data label on the driver's door.
Overloading your vehicle is as damaging to the tires as
underinflation. It significantly affects the expected life (total
mileage of a tire). The following chart shows how neglect or
deliberate abuse can affect the life of your vehicle's tires.
Effect of Load Pressure on Tire Life
Vehicle Load
Normal
20% Over
40% Over
60% Over
80% Over
100% Over
Tire Pressure
Normal
20% Low
30% Low
35% Low
45% Low
55% Low
70%
50%
40%
30%
25%
Expected Total Tire
Mileage
Medium Duty (R05/09)
Normal
Y53-6008A
– 203 –
Tires and Wheels
Preventive Maintenance
Wheel Mounting and Fastening
Wheel Bearing Adjustment
After the vehicle travels about 50 to 100 miles (80 to 160 km),
wheel mountings “seat in” and will lose some initial torque.
Check hub/wheel mountings after this initial period and
retighten.
Wheel Cap Nut Torque
At the first scheduled lube interval, have all wheel cap nuts
torqued to their specified value. See Table 7, “Wheel Cap
Nut Torque,” Page 205 After that, check wheel cap nuts at
least once a week. Contact an Authorized Service Center 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 if you do not have the right equipment.
For safe, reliable operation and adequate service life, your
wheel bearings must be checked and adjusted properly at
the recommended intervals. See Table 2, “Maintenance
Schedule,” Page 113, and Table 2, “Maintenance Schedule,” Page 153. The person best equipped to do this is your
Authorized Service Center's mechanic.
Proper Torque and Sequence
Proper wheel torque can best be obtained on level ground.
Install lug nuts and finger-tighten in the numerical sequence
as shown below, see “Crisscross Tightening Sequence” on
page 207. This procedure will ensure that the wheel is drawn
evenly against the hub. Torque each nut to the torque value
listed in Table 7 on page 205.
WARNING! Never use oil or grease on studs or
nuts; improper torque readings will result, which
could cause improper wheel clamping and could
lead to a wheel failure resulting in an injury accident.
– 204 –
Y53-6008A
WARNING! Tighten wheel cap nuts properly. If
they are not tightened properly, wheel nuts
could eventually cause the wheel to become
loose, to fail, and/or to come off while the vehicle is moving, possibly causing loss of control
and/or serious personal injury or damage to the
vehicle.
Medium Duty (R05/09)
Preventive Maintenance
Table 7
Tires and Wheels
Wheel Cap Nut Torque
WHEEL & NUT
CONFIGURATION
Steel Disc-Type Wheel; Double Cap Nut Mounting; Standard
7/8” Radius Ball Seat or Flanged Nuts:
Alum. Disc-Type Wheel; Double Cap Nut Mounting; Standard
7/8” Radius Ball Seat or Flanged Nuts:
Heavy-Duty Steel Disc-Type Wheel; Double Cap Nut Mounting; 13/16” Radius Ball Seat:
Hub-Piloted Disc-Type Wheel w/Two Piece Flanged Cap Nuts:
Budd Nut w/Teflon Coating:
Motor Wheel Nut:
Stud Backnuts (when used)
Heavy-Duty Cast Wheel w/Demountable Rim:
Rockwell or Clark Demountable Rims on Planetary Axles
Medium Duty (R05/09)
STUD SIZE
DYNAMIC TORQUE FOR
INNER & OUTER CAP
NUTS & RIM CLAMP NUTS
N.m
Lb–Ft
3/4-16
545–630
400–465
1-1/8-16
545–630
400–465
3/4-16
530–625
390–460
1-1/8-16
530–625
390–460
15/16-12
1020–1090
750–800
1-1/8-16
885–950
650–700
1-15/16-12
1020–1090
750–800
Steel Wheel
505–590
370–435
Alum. Wheel
475–580
350–425
Steel Wheel
545–630
400–465
Alum. Wheel
530–625
390–460
3/4-16
240–270
175–200
1-14
240–410
175–300
1-8
585–640
430–470
1-12
585–640
430–470
1-14
585–640
430–470
3/4-10
270–305
200–225
Y53-6008A
– 205 –
Tires and Wheels
Table 7
Preventive Maintenance
Wheel Cap Nut Torque
WHEEL & NUT
CONFIGURATION
STUD SIZE
Dayton:
5/8-11 Front & Rear
DYNAMIC TORQUE FOR
INNER & OUTER CAP
NUTS & RIM CLAMP NUTS
N.m
Lb–Ft
220–240
160–175
3/4-10, Cad Plated Studs Front
306–340
225–250
Rear
272–340
220–250
3/4-10, PHOS & Oil Coated Studs,
Front & Rear
238–258
175–190
Gunite: 5/8-11 Front & Rear
220–250
160–185
3/4-10 Front/Over
14,000 Lb GAWR
325–359
240–265
Other Front & Rear
271–305
200–225
Cast Wheel with Demountable Rim:
Cast Wheel with Demountable Rim:
Disc Wheels
WARNING! Use the correct components and
tools when working on wheels. Grooves in the
wheel disc or other damage to the disc can
weaken the wheel and cause it to eventually
come off. This could cause you to lose control of
your vehicle, and may result in an injury accident.
– 206 –
The end of the wheel wrench must be smooth. Burrs on the
end of the wrench can tear grooves in the disc. These
grooves may lead to cracks in the disc, and can cause it to
fail.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Tires and Wheels
Demounted Rims
WARNING! Improperly mounting and demounting tire and rim assemblies is dangerous. Failure
to observe proper precautions could cause the
tire-rim assembly to burst explosively, causing
serious injury or death. See the wheel manufacturer's literature for the proper way to mount and
demount your tires and rims. Follow their precautions exactly.
To check the torque on demountable rims, follow the crisscross sequence shown below. See Table 7, “Wheel Cap Nut
Torque,” Page 205 for proper torque specifications.
00118
DISK WHEEL
Comparing Hub Piloted and Ball Seat Parts
WARNING! Do not mismatch wheel components.
Equipment that does not exactly match original
specifications or that is mismatched could
cause the wheels to break and separate from the
vehicle. The resulting accident could be very
serious. Each mounting system is engineered
for use only with its correct mating part. Be sure
properly matched components are used for each
type of mounting.
DEMOUNTED RIMS
02951
The following comparison ( Table 8, ”Comparing Hubpiloted and Ball-seat Wheels” ), shows the difference
between parts used in hub pilot mount and ball seat mount
applications.
Crisscross Tightening Sequence
Medium Duty (R05/09)
Y53-6008A
– 207 –
Tires and Wheels
Table 8
Preventive Maintenance
Comparing Hub-piloted and Ball-seat Wheels
BALL–SEAT MOUNT
HUB–PILOTED MOUNT
00187
00203
Hub, Drum, and Stud Assembly
Hub-piloted mountings use M22 x 1.5 metric threads (about 7/8 in.
diameter). The stud stands out at least 1.94 in. beyond the brake drum.
All studs are right-hand threads. Pilot bosses (machined surfaces) on
the hub, fit tightly to the wheel center bore.
Ball-seat (stud-piloted) mountings use 3/4x16 or 1-1/8x16 threads. The
dual mounting studs provide 1.30 in. –1.44 in. standout. Right-hand
and left-hand threads are required. Inner and outer wheel nuts center
the wheels by seating against wheel ball seats.
Wheels
Hub-piloted wheels have stud holes reamed straight through (no ball
seats). Center bore diameter is 8-21/32 in.
Ball-seat wheels have spherical chamfers machined on each stud hole.
Center bore diameter is 8-23/32 in.
Wheel Nuts
Hub-piloted wheel nuts have a hex body and a flange for clamping
against wheel face. Hex size is 1-5/16 in. (33 mm).
– 208 –
Ball-seat inner and outer wheel nuts mate with spherical chamfers on
wheels. The inner nut has 13/16 in. square end. The outer nut has a
1-1/2 in. hex.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Tires and Wheels
Tire Replacement
NOTE: To prolong the tires' life and make them
safer, have their radial and lateral run-out checked at
your Peterbilt Dealer. And of course have the tires
balanced any time you change a tire.
Front: replace front tires when less than 4/32 in. of tread
depth remains. Check depth at three places equally spaced
around the tire.
Matching Tires
Drive Axles or Trailers: replace tires on drive axles when
less than 2/32 in. of tread depth remains in any major groove.
Check depth at three places equally spaced around the tire.
WARNING! Do not install regrooved or reinforcement-repaired tires on steering axles. They
could fail unexpectedly and cause you to lose
control of your vehicle resulting in an injury
accident.
WARNING! Do not replace original equipment
tires with load ratings less than the original
tires. Doing so could lead to unintentional overloading of the tire, which could cause a failure
resulting in loss of vehicle control and an injury
accident.
Medium Duty (R05/09)
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 the axle lubricant to get
too hot. Matched tires will help the driveline last longer and
will give you better tire mileage.
WARNING! Do not mismatch tires, it can be dangerous. Never mix tires of different design such
as steel belted radials and bias ply tires, etc.
Mixing tire types and sizes will adversely affect
the road-holding ability of both types of tires and
can lead to loss of vehicle control and serious
personal injury.
Make sure, too, that you use the right size tires on each
wheel. Some trucks require different sizes on front and rear
wheels. For safety, always use the recommended size and
type of tires.
Y53-6008A
– 209 –
Tires and Wheels
Preventive Maintenance
Wheel and Tire Replacement
WARNING! The Anti-Lock Brake System (ABS) is
calibrated for the specific tire revolutions per
mile. Use of a tire and/or wheel size different
from that originally installed on your vehicle may
cause the ABS system to not function during a
hard braking event. This could cause an accident
or serious personal injury. Consult with your
Peterbilt dealer before using a different tire and/
or wheel size than was originally installed on
your vehicle.
– 210 –
Y53-6008A
CAUTION: No indication will be given via the
dashboard warning lights or buzzer if tires of the
wrong size are installed on your vehicle. See the
warning above for consequences of tires of the
wrong size.
Medium Duty (R05/09)
Preventive Maintenance
Heater and Air Conditioner
HEATER AND AIR CONDITIONER
– Stay away from the hot engine until the exhaust
manifold has cooled.
– Do not permit any open flame in the area. Even a
match or a cigarette lighter may generate a hazardous quantity of poisonous gas.
– Do not smoke in the area. Inhaling gaseous
refrigerant through a cigarette may cause violent
illness.
Introduction
The combination heater-air conditioner provides comfort for
those in the cab through accurate control of the cab environment in all weather conditions. Regular attention to the items
below will help you keep the heater-air conditioner unit running well.
Special Precautions
WARNING! Excessive heat may cause the pressurized components of the air conditioning system to explode. Never weld, solder, steam clean,
or use a blow torch near any part of the air conditioning system.
• If a refrigerant leak develops in the presence of
excessive heat or an open flame, hazardous gases
may be generated. These gases may cause unconsciousness or death. If you become aware of a refrigerant leak on your vehicle have your system service
immediately and observe the following precautions:
Medium Duty (R05/09)
Heater
• Check all heater controls for full-range operation.
• Check hoses, connections, and heater core for condition
and leaks.
• Check the drain pan of the fresh air vent for trapped
water before assuming that there is a leak in the heating
system. If the heater core is leaking, a reliable radiator
shop should be able to repair it.
• Check the heater core for debris blocking the air flow. If
the blower and air controls are functioning properly, yet
the heater is not operating properly, the heater core or
the hot water valves may be clogged or closed. Clean
the heater core if necessary. If the condition persists,
take the vehicle to a Peterbilt Dealer for proper heater
service or repair.
Y53-6008A
– 211 –
Heater and Air Conditioner
Preventive Maintenance
CAUTION: During extreme cold weather, do not
blow hot air onto cold windshields. This could
crack the glass. Turn the air direction lever to
Defrost and reduce the fan speed while the
engine warms. If the engine is already warm,
move the temperature selector to Cool, then
gradually increase the temperature when you
see that the windshield is starting to warm-up.
Air Conditioner
WARNING! The air conditioning system is under
pressure. If not handled properly during servicing, it could explode, causing injury to you and
damag e your vehicle . Any ser vicin g that
requires depressurizing and recharging the air
conditioning system must be conducted by a
qualified technician with the right facilities to do
the job.
• 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.
• Check the evaporator core and condenser core for
debris restricting air flow. Clean if necessary. Small parti-
– 212 –
cles may be removed with compressed air blown through
the core in the opposite direction of normal air flow.
WARNING! Wear eye protection any time
you blow compressed air. Small particles
blown by compressed air could injure your
eyes.
• Check the compressor belt for condition and proper tension.
• Check all hoses for kinks, deterioration, chafing, and
leaks. Adjust kinked or chafing hoses to eliminate restrictions and prevent further wear.
• Check all components and connections for refrigerant
leaks. If you discover a leak, do not try to tighten a connection. Tightening a connection may cause a worse
leak. Have a qualified technician correct the problem.
NOTE: A leaking evaporator or condenser core
cannot be repaired; it must be replaced.
Have the air conditioning system fully serviced annually by
your Peterbilt Dealer or Authorized Service Center. Qualified
service technicians will have to evacuate and recharge the
system.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Electrical System
ELECTRICAL SYSTEM
CAUTION: Do not modify or improperly repair
the vehicle’s electrical system or power distribution box. All electrical repairs should be performed by an authoriz ed Peterbilt dealer.
Improper repair or modifications will void your
warranty and/or cause serious damage to your
vehicle.
Location Of Fuses
Fuses are located inside the cab, left side, next to the driver’s
door.
CAUTION: Never patch fuses with tin foil or wire.
This may cause serious damage elsewhere in
the electrical circuit, and it may cause a fire.
CAUTION: If a circuit keeps blowing fuses, have
the electrical system inspected for a short circuit or overload by an authorized Peterbilt dealer
as soon as possible. Failure to do so could
cause serious damage to the electrical system
and/or vehicle.
NOTE: If a fuse of the same rating is not available, a
fuse of a lower rating may be temporarily substituted. You can also use a fuse from a circuit you can
temporarily do without (for example, an accessory
circuit or radio).
Fuse Inspection and Replacement
WARNING! Do not replace a fuse with one of a
higher rating. Doing so may damage the electrical system and cause a fire.
CAUTION: Before replacing a fuse, turn OFF all
lights and accessories and remove the ignition
key to avoid damaging the electrical system.
Medium Duty (R05/09)
Y53-6008A
BLOWN
– 213 –
Electrical System
Preventive Maintenance
All the electrical circuits have fuses to protect them from a
short circuit or overload. If something electrical on your chassis stops working, the first thing you should check for is a
blown fuse.
1. Turn OFF all lights and accessories and remove the ignition key to avoid damaging the electrical system..
2. Determine from the chart on the fuse panel which fuse
controls that component.
3. Remove that fuse and see if it is blown.
4. If it is blown, replace it with a fuse of the same rating.
Truck-Body Connection
Your vehicle includes a junction box mounted to the frame for
wiring the vehicle body to the main chassis harness.
Refer to the Body Builder's Manual for further information on
using the Truck and Body Connection.
Batteries
WARNING! Battery posts, terminals, and related
accessories contain lead and lead compounds,
chemicals known to the State of California to
cause cancer and reproductive harm. Wash
hands after handling.
Adding Electrical Options
WARNING! Do not add a fuse with a rating
higher than 30 amps. Doing so may damage the
electrical system and cause a fire.
CAUTION: Follow all manufacturers’ circuit protection recommendations for the components
and wires being added.
Spare circuits are located throughout the wiring for the dash.
For proper electrical system performance, refer to a wiring
diagram for your chassis before adding electrical options.
– 214 –
Battery Access
The vehicle is originally equipped with two batteries.
Replacement batteries must meet the following specifications: maintenance-free, group 31 size, threaded stud, 12V/
650 cold cranking ampere (CCA), and 160 minutes of
reserve capacity. The battery compartment has space to
install an optional third battery.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Electrical System
The battery compartment is located on the left side of the
vehicle, under the cab access steps.
WARNING! Before attempting any work on the
batteries or electrical system, remove all jewelry.
If metal jewelry or other metal comes in contact
with electrical circuits, a short circuit may occur
causing you to be injured, as well as electrical
system failure and damage.
The cover is held in place by two latches one on each side.
WARNING! Always reinstall the battery compartment cover (step) before entering the cab. Without the step you could slip and fall, resulting in
possible injury to yourself.
Removing and Installing Batteries:
1.
2.
3.
4.
BATTERY COVER
LATCH
(BOTH SIDES)
Be sure all switches on the vehicle are turned OFF.
Disconnect negative ground cable.
Disconnect positive cable.
Unscrew bolt of holding plate with open end wrench.
To reinstall batteries:
1. Place batteries in vehicle and tighten bolt of holding
plate.
2. Reconnect positive cable.
3. Reconnect negative ground cable.
Battery Care
02601
Battery Compartment
Medium Duty (R05/09)
Regular attention to the charging system will help prolong the
service life of the batteries. Here are some common causes
of battery failure:
Y53-6008A
– 215 –
Electrical System
Preventive Maintenance
Overcharge: this condition results from improper voltage
regulator adjustment. It results in overheating of the battery,
warped plates, and evaporation of electrolyte.
Undercharge: the voltage regulator is malfunctioning or is
improperly adjusted, the drive belt is slipping, or your vehicle
has undergone long periods of standing idle or short distance
driving. These conditions result in battery plates becoming
covered with a hard coating.
Vibration: loose battery hold-downs may cause battery
plate failure.
Jump Starting Vehicles
Because of the various battery installations and optional
electrical systems, Peterbilt does not recommend that you
attempt to jump start your vehicle. If you have a battery problem, it is best to contact a Peterbilt Dealer or a reputable towing service.
However, if your battery is discharged (dead), you may be
able to start it by using energy from a good battery in another
vehicle. This is termed “jump starting.” Be sure to follow the
precautions and instructions below.
Short Circuits: these discharge the battery by draining
electricity.
Dirty or Loose Connections: improper connections may
stop the flow of electrical power to and from the battery.
– 216 –
Y53-6008A
WARNING! Batteries contain acid that can burn
and gases that can explode. Ignoring safety procedures can cause you or others to be badly
hurt.
WARNING! Never jump start a battery near fire,
flames, or electrical sparks. Batteries generate
explosive gases that could explode causing
serious personal injury. Keep sparks, flame, and
lighted cigarettes away from batteries.
Medium Duty (R05/09)
Preventive Maintenance
Electrical System
WARNING! 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, immediately rinse
with cold water for several minutes and call a
doctor.
• Be careful that metal tools (or any metal in contact
with the positive terminal) do not contact the positive battery terminal and any other metal on the vehicle at the same time. Remove metal jewelry and
avoid leaning over the battery.
• If metal jewelry or other metal comes in contact with
electrical circuits, a short circuit may occur causing
you to be injured, as well as electrical system failure
and damage to the vehicle.
• Do not try to jump start or charge a frozen battery.
(Even a battery with ice particles on the electrolyte
surface is dangerous.) Allow it to thaw out first. And
always allow the battery to thaw gradually—do not
apply direct heat. Gas trapped in the ice may cause
an explosion.
Medium Duty (R05/09)
To Jump Start Your Vehicle
WARNING! The voltage of the booster battery
must have a 12–volt rating. And the capacity of
the booster battery should not be lower than
that of the discharged battery. Use of batteries of
different voltage or substantially different capacity rating may cause an explosion and serious
personal injury.
CAUTION: Applying a higher voltage booster
battery will cause expensive damage to sensitive electronic components, such as relays, and
the radio.
• Improper hook-up of jumper cables or not following
these procedures can damage the alternator or
cause serious damage to both vehicles.
WARNING! To avoid serious personal injury and
damage to the vehicle, heed all warnings and
instructions of the jumper cable manufacturer.
• The jumper cables must be long enough so that the
vehicles do not touch.
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
Y53-6008A
– 217 –
Electrical System
Preventive Maintenance
before proceeding. If no water is available, remove the caps
and cover the filler openings with a cloth. After jump starting
the vehicle, dispose of the cloth.
WARNING! If you do not cover the filler openings
on the battery, electrolyte could boil out of the
openings and hurt someone or damage the vehicle. Replace caps securely if the battery has the
full level of electrolyte. If the electrolyte is low
and no water is available, cover with a cloth.
Preparing the vehicles:
1. Position the two vehicles together, but do not let them to
touch.
2. Turn OFF all lights, heater, radio, and any other accessory.
3. Set the parking brakes: pull out the Yellow button
located on the dash.
4. Shift the transmission into park position. (See Pages 67
and 34 for transmission shifting and parking brake information.)
5. Turn engine OFF (booster vehicle).
6. Disconnect ground cable on booster battery.
– 218 –
Connect the batteries:
WARNING! When connecting jumper cables,
make sure they can not get caught in any moving parts in the engine compartment. You could
be seriously injured.
1. Attach one end of a jumper cable to the positive terminal
of the discharged (dead) battery. This will have a large
red “+” or “P” on the battery case, post, or clamp.
2. Attach the other end of the same cable to the positive (+)
terminal of the good (booster) battery.
3. Attach the remaining jumper cable FIRST to the negative
terminal (black “–” or “N”) of the good battery.
4. Attach the other end of the negative cable to a bare
metal part bolted to the engine block or clamp directly to
the engine block if possible.
IMPORTANT: Always connect positive (+) to positive (+)
and negative (–) to negative (–).
5. Start the engines:
Y53-6008A
• Start the vehicle that has the good battery first. Let it
run for a few minutes.
• Then start the vehicle that has the discharged
(dead) battery.
Medium Duty (R05/09)
Preventive Maintenance
Electrical System
WARNING! Batteries can injure you severely.
They contain acid, produce poisonous and
explosive gases, and supply levels of electric
current high enough to cause burns. A spark or
flame near a battery on charge may cause it to
explode with great force.
If the engine fails to start, do not continue to crank the
starter but contact the nearest Authorized Service
Center.
Remove jumper cables:
WARNING! When disconnecting jumper cables,
make sure they do not get caught in any moving
parts in the engine compartment. You could be
seriously injured.
Reverse the above procedure exactly when removing the
jumper cables. With engine running, disconnect jumper
cables from both vehicles in the exact reverse order (Steps 4
– 1), making sure to first remove the negative cable from the
vehicle with the discharged battery.
Battery Charging
Except for using small trickle charges (as explained on Page
221) to maintain battery condition, you should have your
vehicle's batteries charged by a qualified service facility.
Medium Duty (R05/09)
To help reduce the risk of personal injuries, follow these
guidelines carefully when recharging a battery:
• Before attempting any service in the electrical installation, disconnect the battery negative cable.
• Allow no sparks or open flame anywhere near the charging area.
• Charge a battery only in a well-ventilated area, such as
outdoors or in a fully open garage which contains no pilot
lights or other flames. Gases generated during the
charging process must be allowed to escape.
• Maintain the full level of electrolyte in the batteries. This
reduces the volume of gas in the cells. The electrolyte
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.
Y53-6008A
– 219 –
Electrical System
Preventive Maintenance
• When fast charging, remove the battery caps so pressure does not accumulate.
• Always make sure the battery charger is OFF before
connecting or disconnecting the cable clamps.
• To avoid short circuits and damage to yourself or the
vehicle, never place metal tools or jumper cables on the
battery or nearby. Metal that accidentally comes in contact with the positive battery terminal or any other metal
on the vehicle (that is in contact with the positive terminal), could cause a short circuit or an explosion.
Charging Reminders
•
•
•
•
Use protective eyewear.
Keep all batteries away from children.
Never reverse battery poles.
Never attempt to place the vehicle in motion, or run the
engine with batteries disconnected.
• Keep the battery clean and dry.
• Look for any signs of damage.
WARNING! Never use a metallic funnel to add
distilled water. It could come in contact with a
terminal, creating a short circuit, resulting in
severe personal injury or damage to your vehicle.
– 220 –
WARNING! Always shield your eyes and avoid
leaning over the battery whenever possible.
Electrolyte in batteries could splash up into your
eyes causing severe burns and/or serious personal injury.
• Battery terminals should not be coated with improper
grease. Use petroleum jelly or commercially available,
noncorrosive, nonconductive terminal coatings.
• Battery acid that may spill during charging should be
washed off with a solution of warm water and baking
soda to neutralize the acid. If you accidentally get acid in
your eyes or on your skin, immediately rinse with cold
water for several minutes and call a doctor.
• Do not charge a frozen battery; allow it to thaw out first.
And always allow the battery to thaw gradually—do not
apply direct heat. Gas trapped in the ice may cause an
explosion.
• Never use a fast charger as a booster to start the engine.
This can seriously damage sensitive electronic components such as relays, radio, etc., as well as the battery
charger. Fast charging a battery is dangerous and
should only be attempted by a competent mechanic with
the proper equipment.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Electrical System
Bulb Replacement
Slow Battery Charging
NOTE: Follow the instructions that come with your
battery charger.
• It is not necessary to remove the battery from the compartment.
WARNING! Charger cables must be connected
positive to positive (+ to +) and negative to negative (– to –). If connected improperly, batteries
could explode causing serious personal injury.
• Always make sure the battery charger is OFF before
connecting or disconnecting the cable clamps. To
reduce the danger of explosions and resulting serious personal injury, do not connect or disconnect
charger cables while the charger is operating.
1. Make sure the electrolyte level in each cell is between
the “MIN” and “MAX” marks. If the fluid level is below the
“MIN” mark, correct the condition.
2. Disconnect the battery cables.
3. Connect charger cables.
4. Start charging the battery at a rate not over 6 amperes.
Normally, a battery should be charged at no more than
10 percent of its rated capacity.
5. After charging, turn OFF charger and disconnect charger
cables.
Medium Duty (R05/09)
Tail Lights
To replace the tail lamps, remove lens. The bulbs are all of
the bayonet type.
1. To remove the bulbs, turn bayonet counter clockwise and
pull out.
2. To install, fit the bulb in the socket, push in and turn bayonet clockwise.
Replacement Bulbs
DESCRIPTION
PART NO.
Headlights
9007BULB
Front turn signal
3157K LL BULB
Marker
1895BULB
Stop/tail turn
1157BULB
Backup
1156BULB
Hood marker
4157NAK LL BULB
Roof marker
194BULB
Dome
1141BULB
Warning lamp module
#37 or 73 (T1 3/4 wedge
base
Y53-6008A
– 221 –
Electrical System
Preventive Maintenance
Electrical and Alternator Precautions
Take the following precautions to avoid burning out
alternator diodes:
• Do not start the engine with alternator disconnected
(connections removed) from the circuit.
• Before welding, disconnect all electronic connections to
the vehicle batteries.
• Remove battery power cable and insulate it from the
vehicle. See “Welding” on page 249 for more information.
• Do not run the engine with the batteries disconnected.
– 222 –
• Do not disconnect the battery cables or alternator connection cables with the engine running.
• Never turn the ignition switch to the IGN & START position with the engine running.
• When charging the battery (installed in the vehicle) disconnect the battery cables.
• Do not reverse the cables of the alternator, starter motor,
or battery.
• Do not polarize the alternator. The alternator should not
be polarized like a generator. To ensure correct polarity,
use a test lamp or a voltmeter.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Cab Maintenance
CAB MAINTENANCE
Exterior Maintenance
Painted Surfaces
Wash painted surfaces frequently to remove grime and caustic deposits which may stain the finish. See “Cleaning, Protection and Weather–Stripping” on page 224.
Chrome and Aluminum Surfaces
To prevent rust, keep chromed parts clean and protected with
wax at all times, especially in winter conditions where the
roads are salted.
• If necessary, use a commercial chrome cleaner to
remove light rust.
• Chrome surfaces are best cleaned with fresh water.
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 preventive lubricant
around bolts or other fasteners.
Medium Duty (R05/09)
• Clean aluminum wheels and bumpers with warm water.
Tar remover will get rid of heavy deposits of road grime.
To prevent spotting, wipe aluminum surfaces dry after
washing.
• Under corrosive conditions, such as driving on salted
roads, clean aluminum parts with steam or high pressure
water from a hose. A mild soap solution will help. Rinse
thoroughly.
Stainless Steel
Even high quality stainless steel parts can rust under prolonged exposure to salt water, especially when the salt-laden
moisture is held against the metal surface by road grime. It is,
therefore, important to frequently clean salty moisture and
grime from stainless steel surfaces.
• If surface rust is encountered, wash the surface and use
a commercial polishing compound to clean off the rust,
followed by a coating of wax (do not apply wax to hot
parts, such as exhaust pipes).
• Never use steel wool when cleaning stainless steel
because minute particles of the steel wool can embed in
the surface of the stainless steel and cause rust staining.
Y53-6008A
– 223 –
Cab Maintenance
Preventive Maintenance
Cleaning, Protection and Weather–Stripping
Frequent washings of the vehicle are required to remove
grime and contaminants that can stain and oxidize paint and
accelerate corrosion of plated and polished metal surfaces.
Waxing offers added protection against staining and oxidation. But to allow enough time for your truck's finish to cure,
wait about 30 days after the date of manufacture before waxing. Do not apply wax in the hot sun and do not friction burn
the paint with a buffing machine.
Occasionally spray weather-stripping on doors and windows
with silicone compound to help preserve resiliency. This is
especially useful in freezing weather to prevent doors and
windows from sticking shut with ice.
Vehicle Cleaning
Precautions
WARNING! Handle cleaning agents carefully.
Cleaning agents may be poisonous. Keep them
out of the reach of children.
• Observe all caution labels.
– 224 –
• Always read directions on the container before using any
product.
• Do not use any solution that can damage the body paint.
• Most chemical cleaners are concentrates which require
dilution.
• Use spot removing fluids only in well ventilated areas.
• Do not use gasoline, kerosene, naphtha, nail polish
remover or other volatile cleaning fluids. They may be
toxic, flammable or hazardous in other ways.
• Do not clean the underside of chassis, fenders wheel
covers, etc. without protecting your hands and arms. You
may cut yourself on sharp-edged metal parts.
• Moisture, ice, and road salt on brakes may affect braking
efficiency. Test the brakes carefully after each vehicle
wash.
Any vehicle is subject to deterioration from industrial fumes,
ice, snow, corrosive road salt, etc., to name just a few
causes. A well-cared-for vehicle can look like new many
years later. Regular and correct care will contribute to maintaining the beauty and the value of your vehicle.
Your Peterbilt Dealer has a number of vehicle-care products
and can advise you on which ones to use for cleaning the
exterior and interior of your vehicle.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Cab Maintenance
CAUTION: Do not aim the water jet directly at
door locks or latch. Tape the key holes to prevent water from seeping into the lock cylinders.
Water in lock cylinders should be removed with
compressed air. To prevent locks from freezing
in the winter, squirt glycerin or lock deicer into
the lock cylinders.
4. Wipe everything dry with a chamois to avoid water spots.
• To prevent water spotting, dry off the cosmetic surfaces with a clean cloth or chamois.
5. Remove road tar with an automotive type tar remover or
mineral spirits.
6. After cleaning and drying, apply a quality automotive
wax.
Washing the Exterior
1. Begin by spraying water over the dry surface to remove
all loose dirt before applying the car wash and wax solution.
• Do not wash the vehicle in direct sunshine.
• Do not spray water directly into any vents.
2. Using soapy water, wash the vehicle with a clean soft
cloth or a soft brush made for automotive cleaning.
• Use cool or warm water and a mild, household type
soap. Strong industrial detergents and cleaning
agents are not recommended.
• Do not use stiff brushes, paper towels, steel wool, or
abrasive cleaning compounds because they will
scratch painted, plated, and polished metal surfaces.
3. Rinse surfaces frequently while washing to flush away
dirt that might scratch the finishes during the washing
operation.
Medium Duty (R05/09)
NOTE: To allow enough time for your truck's finish to
cure, wait at least thirty days after the date of manufacture before waxing.
• Do not apply wax in the hot sun
• Never dust off dry surfaces with a cloth because it will
scratch the finishes.
Cleaning the Chassis
• Hose dirt and grime from the entire chassis. Then, if an
oil leak develops, you will be able to detect it easier.
• Corrosive materials used for ice and snow removal and
dust control can collect on the underbody. If these materials are not removed, accelerated corrosion (rust) can
occur on underbody parts such as fuel lines, frames,
floor pan, and exhaust system—even though they have
been provided with corrosion protection.
Y53-6008A
– 225 –
Cab Maintenance
Preventive Maintenance
At least every spring, flush these materials from the under
body with plain water. Be sure to clean any area where mud
and other debris can collect. Sediment packed in closed
areas of the frame should be loosened before being flushed.
If desired, your Peterbilt Dealer or Authorized Service Center
can do this service for you.
General Cleaning Guidelines
Cleaning Cab Interiors
Peterbilt cab and sleeper interiors are built using a variety
of different materials including fabrics, carpet, polyurethane, and painted plastic surfaces. These cleaning procedures will ensure that interior components remain in
good condition for the life of the vehicle.
– 226 –
Y53-6008A
WARNING!
•Cleaning agents may contain hazardous
agents. Thoroughly read, understand and follow the manufacturer’s instructions when
using a cleaning agent to avoid possible personal injury and property damage.
• Handle cleaning agents carefully. Keep
them out of the reach of children. Commercial
cleaning agents may be poisonous.
CAUTION: To avoid possible property damage
• 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.
Medium Duty (R05/09)
Preventive Maintenance
Cab Maintenance
• Always test a commercial cleaning agent on
an inconspicuous area of the surface to be
cleaned before using it.
• Never clean interior components
chemicals or solvents such as
– Gasoline
– Naphtha
– Acetone
– Turpentine
– Benzene
– Carbon Tetrachloride
– Lacquer Thinner
– Nail Polish Remover
– Ammonia-based Products
Interior Trim, Dash Shell, and Instrument Panels
CAUTION: To avoid possible damage to these
components, do not use abrasive cleaners,
brushes, chemical solvents or strong detergents.
with
• Use a clean, lint-free cloth.
• Clean with the cloth dampened with a mild soap-andwater solution.
• Remove soap with a clean, damp rag.
• 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.
• Avoid application of conditioning products
containing silicones or waxes to the top surface of the dash panel. This may cause glare
that can be a driver distraction.
• 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
CAUTION: Do not apply water directly to carpet.
Excess water may damage the carpet. Keep
carpet as dry as possible.
• Use a clean, lint-free cloth or clean, soft-fiber brush.
• Clean with the cloth or brush dampened with a mild
soap-and-water solution.
Medium Duty (R05/09)
Y53-6008A
– 227 –
Cab Maintenance
Preventive Maintenance
• Remove soap with a clean, damp rag.
Safety Restraint System — Inspection
• If a stronger cleaning solution is required, use a foamtype carpet shampoo.
The seat belt system, including webbing, buckles, latches,
and mounting hardware, endures heavy use in medium-duty
vehicles—much more than seat belt systems in passenger
cars. All users should be aware of the factors contributing to
this heavy use and reduced belt life.
Vinyl and Fabric Upholstery
CAUTION: To avoid possible damage to the
upholstery, do not use chemical solvents or
WARNING! Failure to properly inspect and maintain restraint systems can lead to serious injury
or loss of life. Without periodic inspection and
maintenance to detect unsafe conditions, seat
restraint components can wear out or not protect you in an accident.
strong detergents on these components.
• Use a clean, lint-free cloth.
• Clean with the cloth dampened with a mild soap-andwater solution.
• Remove soap with a clean, damp rag.
Factors contributing to reduced seat belt life:
• For difficult stains, use a commercial fabric or vinyl
cleaner.
– 228 –
• High mileage—heavy trucks often accumulate mileage
in excess of 500,000 total miles (800,000 km) during the
vehicle lifetime. This is much greater than a typical passenger car, which frequently will not exceed 125,000
total miles (200,000 km).
• Seat and cab movement—in trucks, there is almost constant movement of the belt due to ride characteristics
and seat design. The constant movement of the belt
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Cab Maintenance
WARNING! It is important to remember that any
time a vehicle is involved in an accident, the
entire seat belt system must be replaced. Unexposed damage caused by the stress of an accident could prevent the system from functioning
properly the next time it is needed, which could
result in severe injury or even death.
inside the restraint hardware and the potential for the belt
to come in contact with the cab and other vehicle parts,
contributes to the wear of the entire system.
• Environmental conditions, such as dirt and ultraviolet
rays from the sun, will reduce the life of the seat belt system.
Due to these factors, the three-point safety belt system
installed in your vehicle requires thorough inspection every
20,000 miles (32,000 km). If the vehicle is exposed to severe
environmental or working conditions, more frequent inspections may be necessary.
Any seat belt system that shows cuts, fraying, extreme or
unusual wear, significant discoloration due to UV (ultraviolet)
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.
Inspection Guidelines
Follow these guidelines when inspecting for “cuts, fraying,
extreme or unusual wear of the webbing, and damage to the
buckle, retractor, hardware, or other factors.” Damage to
these areas indicates that belt system replacement is necessary.
WARNING! Replace the entire belt system
(retractor and buckle side) if replacement of any
one part is necessary. Unexposed damage to
one or more components could prevent the system from functioning properly the next time it is
needed, which could result in severe injury or
even death.
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
Medium Duty (R05/09)
Y53-6008A
– 229 –
Cab Maintenance
Preventive Maintenance
parts of the cab interior. These areas are typical places
where the web will experience cutting or abrasion. Cuts,
fraying, or excessive wear would indicate the need for
replacement of the seat belt system.
2. The pillar web guide (D-loop) is the area where almost
constant movement of the seat belt webbing occurs
because of relative movement between the seat and
cab.
3. Check the Komfort-Lok Latch for cracks or possible damage and check for proper operation.
03004
Seat Belt Inspection Points
– 230 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Cab Maintenance
4. Check buckle and latch for proper operation and to determine if latch plate is worn, deformed, or damaged.
5. Inspect the retractor web storage device, which is
mounted on the floor of the vehicle, for damage. The
retractor is the heart of the occupant restraint system
and can often be damaged if abused, even unintentionally. Check operation to ensure that it is not locked up
and that it spools out and retracts webbing properly.
WARNING! 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.
6. If tethers are used, be sure they are properly attached to
the seat and, if adjustable, that they are adjusted in
accordance with installation instructions. Tethers must
also be inspected for web wear and proper tightness of
mounting hardware.
Medium Duty (R05/09)
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 the web may have deteriorated due to exposure to the sun's ultraviolet rays.
Replace the system.
Once the need for replacement of the seat belt has been
determined, be certain it is only replaced with an authorized
PACCAR Parts replacement seat belt.
If the inspection indicates that any part of the seat belt system requires replacement, the entire system must be
replaced. An installation guide is attached to every replacement belt. Utilize the proper guide for your type of seat, and
follow the instructions very closely. It is vitally important that
all components be reinstalled in the same position as the
original components that were removed and that the fasteners be torqued to specification. This will maintain the design
integrity of the mounting points for the seat belt assembly.
Contact your Authorized Peterbilt Dealer if you have any
questions concerning seat belt replacement.
Y53-6008A
– 231 –
Cab Maintenance
Preventive Maintenance
Windshield Wipers/Washer
Check wiper blades annually or every 60,000 miles (96,000
km). Anco 18-inch (450mm) wiper blades are recommended.
The windshield washer tank is located inside the engine
compar tment below the radiator expansion tank. See
“Washer Reservoir” on page 201. Check the windshield
washing fluid level weekly. If necessary, fill to top.
WINDSHIELD
WASHER FLUID
TANK
CAUTION: If the electric pump is operated for a
long period (more than 15 seconds) with a dry
reservoir, the pump rotor may be damaged.
02391
Clean all inside and outside windows regularly. Use an alcohol-based cleaning solution and wipe dry with either a lintfree 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.
Windshield Washer Fluid Tank
Washer Reservoir
CAUTION: Do not use antifreeze or engine coolant in the windshield washer reservoir—damage
to seals and other components will result.
Weekly: check reservoir water level, located in the engine
compartment under the coolant expansion tank. If necessary,
fill to the proper level.
– 232 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Transmission and Clutch
TRANSMISSION AND CLUTCH
Transmission Lubricants
CAUTION: When adding oil, types and brands of
oil should not be intermixed because of possible
incompatibility, which could decrease the effectiveness of the lubrication or cause component
failure.
Introduction
Follow these steps to ensure parts are properly lubricated:
•
•
•
•
Maintain oil level, check it regularly
Change oil regularly
Use the correct grade and type of oil
Buy oil from a reputable dealer
Manual Transmissions
Manual transmissions are designed so that the internal parts
operate in a bath of oil circulated by the motion of gears and
shafts.
All Transmissions
Oil Change: Drain and replace according to Table 1, “Recommended Maintenance Intervals,” Page 150 and the
Transmission Service Manual. Use the recommended types
of oil as specified in the Operation and Service Manual
(included with vehicle). Select the appropriate lubricant for
the expected ambient (outside air) temperatures.
Medium Duty (R05/09)
Service Intervals
For recommended types and brands of all lubricants, see the
transmission manufacturer's Service Manual and Table 1,
“Recommended Maintenance Intervals,” Page 150.
Y53-6008A
– 233 –
Transmission and Clutch
Table 9
Preventive Maintenance
Transmission Lubrication — Manual transmissions
Eaton-Fuller
AMBIENT
TEMPERATURE RANGE
RECOMMENDED
LUBRICANT (See Note)
MODEL
VISCOSITY (SAE)
DEG. C
DEG. F
HD engine oil: API CE or CF-4.
Above -12
Above +10
50
Synthetic oil: Chevron RPM
Synthetic Transmission Fluid, or equal,
meeting MIL-L-2104D and Eaton PS-081
specifications.
Above -40
Above -40
50
NOTE: Do not use multi-viscosity or EP (extreme pressure) gear oil (e.g., axle oils) in transmissions. Multi-viscosity or EP oils may damage components.
Clutch System Introduction
Standard Transmission Oil Level
NOTE: The vehicle must be parked on level ground.
• Maintain the oil level and check it regularly. Oil should be
up to bottom of filler plug hole.
– 234 –
Free pedal is the distance the clutch pedal moves by applying
only slight pressure. During free pedal the release yoke in the
transmission moves until its bearing pads contact the release
bearing. This movement of the release yoke is called free
travel. Thus, free pedal and free travel are directly related to
each other.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Transmission and Clutch
As the clutch pedal is depressed further, with harder pressure, the release yoke moves the release bearing away from
the engine. This causes the clutch plate to release from the
driven disks in the clutch. This is called release travel. And
finally, on 9-, 10-, and 11-speed transmissions, as the pedal
is pushed to the last 1/2 to 1 inch of travel, the release bearing contacts and engages the clutch brake. This is called
clutch brake squeeze. When the clutch wears, the release
bearing gradually moves toward the engine, decreasing free
pedal and free travel. When all free pedal and free travel are
gone, the clutch requires adjustment.
The clutch is adjusted by turning an adjustment ring that is
built into the clutch. When the ring is turned, the release
bearing moves back toward the transmission, restoring free
pedal and clutch free travel. Under normal clutch wear this is
the only adjustment needed. Do not attempt to change any
other component. See the Medium Duty Maintenance Manual for details.
Medium Duty (R05/09)
Clutch Adjustment — Normal Wear
Clutch pedal free travel is usually 1 3/4 in. to 2 in. (34 to 51
mm). This should be your guide for determining whether your
truck needs clutch adjustment. Also, if it becomes increasingly difficult to shift into gears, or the truck creeps with the
clutch pedal depressed, your clutch needs adjustment. See
the Medium Duty Maintenance Manual for the proper
adjustment procedures.
Some vehicles have automatic clutch adjustment. If yours
doesn't have this feature, adjustment will have to be done by
a trained certified mechanic. Have the adjustment done
before clutch pedal free travel is reduced to the minimum
allowable 1/2 in. (13mm).
Clutch Linkage
The Medium Duty is equipped with a rod and lever mechanical clutch linkage. Lubricate each pivot point on the clutch
linkage.
Y53-6008A
– 235 –
Transmission and Clutch
Preventive Maintenance
Automatic Transmissions
Automatic Transmission Oil Level
NOTE: The vehicle must be parked on level ground.
Service Intervals
Check daily with engine idling. See Table 1, “Recommended Maintenance Intervals,” Page 150 for service
intervals.
Maintain the oil level and check it daily. Oil should be up to
the “HOT” mark on the dipstick when (1) the engine is running, (2) the transmission is at operating temperature, and (3)
the transmission is in Neutral. See the Transmission Operator's Manual in the glove compartment for more information
on checking the transmission oil level.
Table 10 Transmission Lubrication — Automatic transmissions
MODEL
ALLISON
– 236 –
RECOMMENDED
LUBRICANTS
TranSynd (Castrol)
Y53-6008A
AMBIENT
TEMPERATURE RANGE
DEG. C
DEG. F
Above -23
Above -10
VISCOSITY (SAE)
10W
Medium Duty (R05/09)
Preventive Maintenance
Steering and Driveline
STEERING AND DRIVELINE
If you cannot correct the problem, check with an Authorized
Service Center.
Power Steering
Oil (under low pressure) provides the power to operate the
steering gear. It also serves to lubricate moving parts and
remove heat. A loss of steering efficiency will occur if too
much heat builds up in the system.
WARNING! Do not operate the vehicle if the
steering system is not working properly. You
could lose control of your vehicle if the steering
system is not in good working condition, which
could result in a serious injury accident. For
driving safety, visually check the steering gear
and components. Frequent checks are important for driving safety, especially after traveling
over rough roads.
NOTE: If the steering feels unbalanced from side-toside while turning, check for the following possible
causes:
• unequal tire pressures
• vehicle overloaded or unevenly distributed load
• wheels out of alignment
• wheel bearings improperly adjusted
Medium Duty (R05/09)
The Medium Duty is equipped with integral power steering.
The system includes an engine-driven fluid pump, a fluid reservoir, the steering gear, and connecting hoses. Because of
the hydraulic power assist, little effort is required to turn the
steering wheel. When no input is applied through the steering wheel, the steering gear will return to the neutral position.
If, for any reason, the power assist system goes out, steering
the vehicle is still possible—yet it will require much greater
effort.
Visually check the following parts:
• Crosstube: Is it straight?
• Draglink tube clamp: Check for looseness or interference.
• Ball joints and steering U–joints: Check for looseness.
• Steering wheel for excessive free-play. Check the simplest probable causes first:
– unequal tire pressures
– loose cap nuts
– bent crosstube
– lack of lubrication
Y53-6008A
– 237 –
Steering and Driveline
Preventive Maintenance
If these checks do not reveal the problem, or if you correct
them and still have a steering problem, take your truck to an
authorized Peterbilt Dealer for evaluation.
RESERVOIR
Fluid Level and Refill
Have the power steering fluid and filters changed at an
Authorized Service Center.
• Check and completely change the fluid level according to
Table 1, “Recommended Maintenance Intervals,”
Page 150. Use the following procedure:
02603
NOTE: Before removing reservoir cover, wipe
outside of cover so that no dirt can fall into the
reservoir.
The power steering fluid reservoir is attached to an underhood bracket on the LH side of the engine.
• Maximum / Minimum level is marked on the reservoir.
These same levels are also marked by lines on the dipstick in the reservoir.
• There are two ways to check whether the power steering
fluid is at its proper level. Both checks are with the
engine NOT running.
– 238 –
Power Steering Fluid Reservoir
1. If you check the fluid with the engine and steering system COLD the fluid level should be at/or above the Minimum indicator level and should generally not exceed the
middle point between Maximum and Minimum level indicators.
2. If you check the fluid with the engine and steering system WARM the fluid should NOT exceed the Maximum
level indicator and should generally not drop below the
middle point between the Maximum and Minimum level
indicators.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Steering and Driveline
Fluid Refill
Use Automatic Transmission Fluid (ATF) Type E or F or
Dexron® II. For other approved brands and types of fluid, see
the Medium Duty Maintenance Manual.
SLIP JOINT
Steering Driveline
• Torque on U–joint pinch bolt and nut 45–55 lb. ft. (61-75
N.m.), lubricated.
• Torque on Pitman arm clamp bolt and nut: 180-210 lb. ft.
(244-285 N.m.), lubricated.
UNIVERSAL JOINT
01904
Driveshaft Lubrication
Driveshaft and U-Joints
The slip joints and universal joints of the drive shaft should be
lubricated according to Table 1, “Recommended Maintenance Intervals,” Page 150.
• Use a good quality lithium-soap-base or equivalent
extreme pressure (E.P.) grease: NLGI Grade 2.
For “Towing Guidelines” and “Returning a Towed Vehicle to
Service” see “Vehicle Recovery Guidelines” on page 109.
Medium Duty (R05/09)
Y53-6008A
WARNING! Improper lubrication of U–joints can
cause them to fail prematurely. The driveshaft
could separate from the vehicle and result in an
injury accident and/or vehicle damage. Make
sure lubricant is purged at all four ends of each
U–joint and loosen caps if necessary. Also, regularly inspect U–joints for excessive wear or
movement, and repair or replace as necessary.
– 239 –
Front Axle and Suspension
Preventive Maintenance
FRONT AXLE AND SUSPENSION
SPRING AND
SHACKLE PINCH
BOLTS
Inspection
For all vehicles, mandatory maintenance procedures include
retightening all U–bolts and inspecting the suspension for
loose fasteners, abnormal wear, or damage. However, even
with proper maintenance, the service life of leaf springs is
affected by many factors, such as: fatigue, vehicle gross
weight, type of load, road conditions, and vehicle speed.
SPRING
ANCHOR
PINS
• Check for cracks, wear marks, splits, or other
• ects on the surface of the spring. Defective parts must be
replaced. Because repaired springs cannot be fully
restored to their original service life, replace the complete assembly if cracks or other defects are detected.
• Visually inspect shock absorbers and rubber bushings.
See the Medium Duty Maintenance Manual for further
information on servicing the front suspension.
– 240 –
SPRING
ANCHOR PIN
U-BOLTS
00439
Front Suspension
Axle Lubrication
• Change bearing lubrication when seals are replaced, or
brakes are relined. See Table 1, “Recommended Maintenance Intervals,” Page 150.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Front Axle and Suspension
• Thoroughly clean hubs and bearings with solvent and a
stiff bristle brush, then dry and inspect components for
wear or damage. Re-lubricate with approved axle lubricant.
KINGPIN (TOP)
Kingpin Lubrication
• Lubricate with approved lubricant. Lubricate knuckle
thrust bearings, knuckle pins, and tie rod ends. See
Table 1, “Recommended Maintenance Intervals,”
Page 150. Lack of lubrication causes premature wear
and hard steering. Lubrication schedule may be shortened if necessary.
KINGPIN
(BOTTOM)
00445
Front Axle
Suspension Lubrication
Each spring anchor pin has a grease fitting. Pressure lubricate spring pins according to Table 1, “Recommended
Maintenance Intervals,” Page 150, using EP chassis lube
with 12-Hydroxy Lithium Stearate Base NLGI-2 with 3%
molybdenum additive (e.g. Mobil-grease EP or equal).
Medium Duty (R05/09)
• At regular intervals, the spring leaves may be lubricated
with a rust-inhibiting oil applied with a spray gun or
brush.
• Lubricate all spring pins until grease flows out of both
ends of the bushing. Look for signs of rust or water in the
flushed grease. If a pin will not accept grease, it should
be removed, cleaned, and inspected.
Y53-6008A
– 241 –
Front Axle and Suspension
Preventive Maintenance
WARNING! Do not operate the vehicle if the U–
bolts are not properly tightened. Loose U–bolts
do not properly secure the axle to the suspension. This could cause loss of vehicle control
and an injury accident. Loose U–bolts can also
cause uneven tire wear and poor alignment.
CAUTION: Do not spray the suspension with
chemical products or mineral oil; it can cause
damage to the bushings.
Torque
U–Bolts, Spring and Shackle Pinch Bolts
It is important that U–bolts remain tight. Severe use of your
vehicle will cause them to loosen faster. But all vehicles need
to have their U–bolts checked and tightened regularly. See
“Maintenance Schedule” on page 153. Be sure someone
with the proper training and the right tools checks and tightens the U–bolts on your Medium Duty.
New springs can “settle in” after service, relieving the tension
on the U–bolts. Loose U–bolts can cause leaf spring breakage, axle misalignment, hard steering and abnormal tire
wear.
U–bolts are difficult to tighten unless you have the right
equipment. If you cannot tighten them correctly yourself, be
sure to have them checked and tightened regularly by an
authorized mechanic.
WARNING! Do not replace U–bolts and nuts with
common U–bolts or standard nuts. Use only U–
bolts and nuts of SAE Grade 8 specification or
better.These parts are critical to vehicle safety. If
the wrong U–bolts or nuts are used, the axle
could loosen or separate from the vehicle and
cause a serious injury accident.
• At the same time U-bolts are tightened, re-torque the
spring and shackle pinch bolts to 105 lb. ft. (142 N. m.)
• All vehicles should have suspension U–bolts tightened
after the first 500 miles (800 km) of operation. Torque the
front suspension U-bolts to 245-300 lb. ft. (333-408
N.m.)
– 242 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Rear Axle and Suspension
REAR AXLE AND SUSPENSION
WARNING! Failure to maintain the specified
torque values or to replace worn parts can cause
component system failure, possibly resulting in
an injury accident. Improperly tightened (loose)
suspension U–bolts can lead to unsafe vehicle
conditions, including: hard steering, axle misalignment, spring breakage or abnormal tire
wear. See the Fastener Torque Tables for proper
torque specifications.
General Maintenance
WARNING! Do not work on the vehicle without
the parking brake set and wheels chocked
securely. If the vehicle is not secured to prevent
uncontrolled vehicle movement, it could roll and
cause serious personal injury or damage to the
vehicle.
CAUTION: Do not spray the suspension with
chemical products or mineral oil; it can cause
damage to the bushings.
• Use wood blocks (4 in. X 4 in. or larger) against the
front and rear surfaces of the tires. Be sure the vehicle cannot move.
Your vehicle's suspension, by design, requires a minimal
amount of maintenance. However, suspensions in “over-theroad” operations require periodic inspection to ensure trouble-free performance.
WARNING! Do not operate the vehicle if the U–
bolts are not properly tightened. Loose U–bolts
do not properly secure the axle to the suspension. This could cause loss of vehicle control
and an injury accident. Loose U–bolts can also
cause uneven tire wear and poor alignment.
Medium Duty (R05/09)
NOTE: Failure to follow these recommendations
could void warranty. See the “Medium Duty Maintenance Manual” for further information on servicing
the rear suspension.
Visual Inspection
For all vehicles, mandatory maintenance procedures include
retightening of U–bolts and complete inspection. However,
even with proper maintenance, many factors affect the service life of springs and suspension components, such as:
fatigue, vehicle gross weight, type of load, road conditions
and vehicle speed.
Y53-6008A
– 243 –
Rear Axle and Suspension
Preventive Maintenance
It is important that U–bolts remain tight. Severe use of your
vehicle can cause them to loosen faster. But all vehicles need
to have their U–bolts checked and tightened regularly. Be
sure someone with the proper training and the right tools
checks and tightens the U–bolts on your Medium Duty.
Rear Axle Lubrication
• Check oil level with the vehicle parked on level ground
and the fluid warm. The level should be even with the
bottom of the filler hole.
New springs “settle-in” after the vehicle's initial service, causing the U–bolts to become loose. After the first 500 miles
(800 km) of operation, inspect the suspension periodically, as
noted below:
CAUTION: Do not mix lubricants of different
grades; although, mixing different brands of the
same grade lubricant (meeting MIL–L–2105–C),
is acceptable. Lubricants of different grades are
not compatible and could damage the axle.
• Visually check for loose or missing fasteners, cracks in
hanger or axle connection brackets.
• Check that springs are centered in hangers and in good
condition.
• Check for cracks, wear marks, splits, or other defects on
the surface of the spring.
• Replace defective parts. Because repaired springs cannot be fully restored to their original service life, replace
the complete assembly if cracks or other defects are
detected.
• After replacement of any part or discovery of loose components, check the torque of all fasteners.
NOTE: In all cases, the lubricant supplier assumes
full responsibility for the performance of their product, and for product and patent liability.
– 244 –
Initial Change: Change lubricant in new or rebuilt axle
assemblies within the first 3,000 to 5,000 miles (4800 to 8000
km). For recommended types and brands of lubricants, contact your Peterbilt Dealer or Authorized Service Center. See
the Medium Duty Maintenance Manual and the axle manufacturer's Service Manual for further information on servicing
drive axles.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Rear Axle and Suspension
Table 11 Drive Axle Lubrication
MODEL
EATON,
ROCKWELL
RECOMMENDED LUBRICANTS
AMBIENT TEMPERATURE RANGE
°F
EP gear oil, MIL-L-2105D, API GL-5.
-26 to +38
-15 to +100
80W-90
Synthetic Lubricant: Chevron RPM
Synthetic Gear Lubricant, or equal, meeting
MIL-L-2105D and Eaton PS-037 specification.
-40 to +38
-40 to +100
75W-90
• No initial drain is required on Eaton axles that are factory
filled with an Eaton-approved synthetic lubricant.
• Petroleum-based lubricants must be drained within the
first 5,000 miles (8000 km) if converting to an approved
synthetic lubricant.
To change axle lubricant:
1. Park the vehicle on level ground with the axle lubricant at
normal operating temperature.
2. Remove filler (1) and drain plug (2).
3. Completely drain the oil and clean the drain plug.
CAUTION: Do not overfill axles.
See Table 1, “Recommended Maintenance Intervals,”
Page 150 for standard rear axle service intervals.
• Use petroleum-based lubricants meeting MIL–L–2105–
C/D grade specifications or approved synthetic lubrication. Do not use oil additives.
Medium Duty (R05/09)
VISCOSITY (SAE)
°C
4. Reinstall the drain plug (2) and refill with recommended
oil up to the bottom of filler plug hole.
5. Reinstall filler plug (1).
Y53-6008A
– 245 –
Rear Axle and Suspension
Preventive Maintenance
Rear Suspension Fasteners
3
Continual road shock and load stresses may force the rear
axles out of alignment. If you detect rapid tire wear on the
rear axles, you may have misaligned axles. Have your rear
axle alignment checked and adjusted by a Peterbilt Dealer or
Authorized Service Center.
1
2
0446A
Rear Axle Filler and Drain Holes and Breather Vent
Axle Housing Breather Vent
• Check and clean the axle housing breather vent (3) at
each oil level check.
– 246 –
Every 5,000 miles (8000 km) or 180 days, whichever occurs
first and thereafter, retorque all suspension fasteners to recommended specifications. See the Fastener Torque Table for
proper torque specifications.
Load the vehicle to its normal gross weight before tightening
U-bolts. Loading the vehicle ensures proper adjustment of
the U-bolt and spring assembly.
U–bolts are difficult to tighten unless you have the right
equipment. If you cannot tighten them correctly yourself, be
sure to have them checked and tightened regularly by an
authorized mechanic.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Rear Axle and Suspension
WARNING! Do not replace U–bolts and nuts with
common U–bolts or standard nuts. These parts
are critical to vehicle safety. If the wrong U–bolts
or nuts are used, the axle could loosen or separate from the vehicle and cause a serious injury
accident. Use only U–bolts and nuts of SAE
Grade 8 specification or better.
Grade 5 Capscrew Torque Specifications
Capscrew Body
Size
(inches-thread)
1/4-20
Torque
Lb. ft.
N.m.
6—9
8—12
9.5—14
-28
7—10
WARNING! Do not operate the vehicle if the U–
bolts are not properly tightened. Loose U–bolts
do not properly secure the axle to the suspension. This could cause loss of vehicle control
and an injury accident. Loose U–bolts can also
cause uneven tire wear and poor alignment.
5/16-18
13—18
18—24
-24
14—20
19—27
3/8-16
22—32
30—43
34—54
-24
25—40
7/16-14
35—50
47—68
-20
39—56
53—76
Suspension alignment should be checked when any one of
the following conditions exist:
1/2-13
54—77
73—104
-20
58—87
79—118
• Discovery of loose suspension fasteners (Any
torque below the recommended torque value.).
• Discovery of elongated holes in a suspension component.
• Bushing replacement.
• Excessive or abnormal tire wear.
9/16-12
78—111
105—151
NOTE: To ensure an accurate torque reading, use
p r o p e r l y m a i n t a i n e d a n d c a l i b ra t e d t o r q u e
wrenches.
Medium Duty (R05/09)
Y53-6008A
-18
87—124
118—168
5/8-11
108—154
147—209
166—236
-18
122—174
3/4-10
192—273
260—370
-16
214—305
290—414
7/8-9
309—441
419—598
462—659
-14
341—486
1 -8
464—662
629—898
1-12
508—724
689—982
– 247 –
Rear Axle and Suspension
Preventive Maintenance
Grade 8 Capscrew Torque Specifications
Capscrew Body
Size
(inches-thread)
– 248 –
Torque
Lb. ft.
N.m.
1/4-20
9—12
12—16
-28
10—14
14—19
5/16-18
18—25
24—34
-24
20—28
27—38
3/8-16
31—44
42—60
-24
35—50
47—68
7/16-14
50—71
68—96
-20
56—80
53—108
1/2-13
76—109
103—149
-20
86—123
117—167
9/16-12
110—158
149—214
-18
123—176
167—239
5/8-11
153—218
208—296
-18
173—247
235—335
3/4-10
271—386
367—523
-16
303—431
411—583
7/8-9
437—624
593—846
-14
482—589
654—799
1 -8
656—935
889—1268
1-12
718—1023
973—1386
The torque values in the previous tables are based on the
use of clean and dry threads.
For standard capscrews:
1. Always use the torque values listed the capscrew table.
2. Reduce torque by 10% when engine oil is used as a
lubricant.
3. Reduce torque by 20% if new plated capscrews are
used.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Frame and Fifth Wheel
FRAME AND FIFTH WHEEL
NOTE: Welding to frame rail may void frame rail warranty.
Introduction
WARNING! Do not cut or splice frame rails or
drill through the top or bottom flanges. These
operations could affect frame rail strength leading to a failure resulting in serious personal
injury and/or an accident. Always leave frame
repairs to your Peterbilt Dealer.
Engine Painting
• Do not electrostatically paint electronically controlled
engines or vehicles with these engines.
Welding
• Disconnect all electronic connections to the vehicle batteries.
• Remove battery power cable and insulate it from the
vehicle.
• Disconnect all Electronic Control Module (ECM) connectors (on electronic engines).
• Do not use the ECM or engine ground stud for the
ground of the welding probe.
• Ensure that the ground connection for the welder is as
close to the weld point as possible. This ensures maximum weld current and minimum risk to damage of electrical components on the vehicle.
• Turn engine OFF.
All Anti–Lock Braking Systems (ABS)
• Observe these recommended procedures to protect
electronic systems during welding operations.
Engines
• Before welding anywhere on the vehicle, detach the ABS
Electronic Control Unit (ECU) connector and all other
electronic control units.
Before welding on vehicles equipped with electronic engines,
the following precautions should be observed:
Medium Duty (R05/09)
Y53-6008A
– 249 –
Frame and Fifth Wheel
Preventive Maintenance
Fifth Wheel Maintenance
Every 6 Months or 50,000 Miles:
Proper preventive maintenance is essential to trouble-free
service and safe operation of the fifth wheel.
Every 2 Months or 25,000 Miles:
• Refer to specific manufacturer's literature for any special
instructions.
• Steam clean the fifth wheel.
• Check lock guard operation using a commercial lock
tester.
• Clean and oil all moving parts.
• Lubricate the following parts with a lithium-base grease.
• Lock mechanism
• All grease fittings (especially those which grease the
top surface of the fifth wheel).
• Check for missing or loose nuts and bolts in the fifth
wheel and mounting brackets. Retighten loose bolts to
correct torque. Replace missing or damaged bolts.
– 250 –
• Refer to specific manufacturer's literature for any special
instructions.
• Remove fifth wheel from vehicle. Refer to the Medium
Duty Maintenance Manual, “Fifth Wheel Removal.”
• Steam clean the fifth wheel and mounting brackets.
• Check all moving parts for excessive wear or damage.
Replace all worn or broken parts.
• Complete two-month service procedure.
• Install fifth wheel. Refer to the Medium Duty Maintenance Manual, “Fifth Wheel Installation.”
Sliding Fifth Wheel
• Lubricate bearing surface of support bracket through the
grease fittings on the side of the fifth wheel plate. Use a
water resistant lithium-base grease.
Y53-6008A
NOTE: The plate must be lifted up slightly to
relieve the weight of the bracket while applying
grease.
Medium Duty (R05/09)
Preventive Maintenance
Noise and Emission Control
NOISE AND EMISSION CONTROL
Tampering with Noise Control System
Federal law prohibits the following acts or the causing
thereof:
Noise Emission Warranty
Peterbilt Motors Company warrants to the first person who
purchases this vehicle (for purposes other than resale) and to
each subsequent purchaser: that this vehicle, as manufactured by Peterbilt Motors Company, was designed, built and
equipped to conform, at the time it left Peterbilt's control, with
all applicable U.S. EPA Noise Control Regulations.
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, component or
system of the vehicle as manufactured by Peterbilt, 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.
1. The removal or rendering inoperative by any person
other than for purposes of 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 use of the vehicle after such device or element of
design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the
acts listed below:
Air Intake System
• Removing or rendering inoperative the air cleaner/silencers or intake piping.
Engine Cooling System
• Removing or rendering inoperative the fan clutch.
• Removing the fan shroud.
Medium Duty (R05/09)
Y53-6008A
– 251 –
Noise and Emission Control
Preventive Maintenance
Engine
• Removing or rendering engine speed governor inoperative so as to allow engine speed to exceed manufacturer's specifications.
• Modifying ECU parameters.
• Check the induction tubing, elbow connections, clamps,
brackets, and fasteners for deterioration, cracks, and
security.
• If you find an air leak anywhere between the air cleaner
and the engine, repair that leak immediately.
Exhaust System
• Removing or rendering inoperative exhaust system components.
CAUTION: Air leaks cause excessive noise and
may result in serious damage to the engine. If
you do not repair them the engine damage will
not be covered by your warranty. Repair all air
leaks as soon as you find them.
Inspection and Maintenance Instructions
Exhaust System
The following instructions are based on inspection of the
noise control system at regular intervals.
If, during periodic inspection and maintenance of other systems and components, it is found that parts of the noise control system require attention, we recommend that those parts
be inspected at more frequent intervals to assure adequate
maintenance and performance.
Air Intake System
• Do all checks and maintenance procedures listed in this
manual under Engine Air Intake System and Air Cleaner.
See “Air Intake System” on page 197.
– 252 –
• Check for exhaust leaks, which would indicate a leaking
manifold gasket; replace gasket if necessary.
• Check cap screws for tightness, including those at the
flanges. Refer to the engine manufacturer's service manual for proper tightening sequence and torque values.
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.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Noise and Emission Control
Piping
Exhaust Tail Pipe
• Check exhaust piping for rust, corrosion, or damage.
Replace deteriorated piping before holes appear. If piping is perforated at any point, temporary patching or lagging is acceptable until you can have permanent repairs
made. On turbocharged engines, check joints at flanges
and mounting brackets for tightness.
• Check the mounting. Tighten as necessary. The miter
cut at the tip of the pipe must be facing the rear of the
vehicle. Do not modify the end of the pipe in any way.
Engine Fan and Shroud
WARNING! Do not work on the fan with the
engine running. The engine fan can engage at
any time without warning. Anyone near the fan
when it turns on could be seriously injured.
Before turning on the ignition, be sure that no
one is near the fan.
Mufflers
NOTE: Use only an exact replacement muffler in
exhaust systems. Certain mufflers contain integral
catalytic converters essential for compliance with
EPA emission standards. Using a noncompliant muffler as a replacement could violate these standards
and also void the emission system’s warranty.
• Check muffler, clamps, and mounting brackets. Tighten if
necessary. Inspect muffler for signs of rust or corrosion.
• Check internal baffling. You can do this by listening for
rattling sounds while tapping the muffler with a rubber
mallet or revving the engine up and down through its normal operating range.
Medium Duty (R05/09)
• 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.
• Check to verify that the fan is disengaged (not turning)
with the engine running at normal operating temperatures (from cold to the point that the fan engages).
• Check fan blade mounting bolts. Inspect fan blades to be
sure they are not cracked or bent. If problems exist, refer
to the Cooling System section in the Medium Duty
Maintenance Manual for detailed maintenance instructions.
Y53-6008A
– 253 –
Noise and Emission Control
Preventive Maintenance
Maintenance Log
Transmission and Driveline
• Substituting a different main transmission or drive line
components, other than design-specified units, may
result in increased vehicle noise emission.
To ensure your Medium Duty's noise control requirements
are maintained, record maintenance checks. Use the following log sheet (see Table 12) and retain copies of documents
regarding maintenance services performed and par ts
replaced on the vehicle.
Table 12 Maintenance Log
Date of Service
– 254 –
Mileage
Service Performed
Y53-6008A
Service Center Name and
Address
Medium Duty (R05/09)
Preventive Maintenance
Noise and Emission Control
Table 12 Maintenance Log
Medium Duty (R05/09)
Y53-6008A
– 255 –
Noise and Emission Control
Preventive Maintenance
Table 12 Maintenance Log
– 256 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Consumer Information and Vehicle Identification
CONSUMER INFORMATION
AND VEHICLE IDENTIFICATION
Canadian Consumer Information
Reporting Safety Defects
If you believe that your vehicle has a defect which could
cause a crash or could cause injury or death, you should
immediately inform the National Highway Traffic Safety
Administration (NHTSA) in addition to notifying Peterbilt
Motors Company.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of
vehicles, it may order a recall and remedy campaign. However, NHTSA cannot get involved in individual problems
between you, your Peterbilt 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 Washington,
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.
Medium Duty (R05/09)
Canadian customers who wish to report a safety-related
defect to Transport Canada, Defect Investigations and
Recalls, may telephone the toll free hotline 1-680-333-0510,
or cantact Transport Canada by mail at:
Transport Canada, ASFAD
Place de Ville Tower C
330 Sparks Street
Ottawa ON KIA 0N5
For additional road safety information, please visit the Road
Safety website at: http://www.tc.gc.ca/roadsafety/menu.htm
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm. Other chemicals in this
vehicle are also known to the State of California to cause
cancer, birth defects or other reproductive harm. Battery
posts, terminals, and related accessories contain lead and
lead compounds, chemicals known to the State of California
to cause cancer and reproductive harm. Wash hands after
handling.
Y53-6008A
– 257 –
Consumer Information and Vehicle Identification
Preventive Maintenance
Vehicle Identification
All Peterbilt vehicles are identified by a 17–digit Vehicle Identification Number (VIN). This unique numeral and letter combination identifies the manufacturer, the model year it was
built, and other vehicle attributes. The VIN is in compliance
with 49CFR565, Code of Federal Regulations. As an example, the model year and assembly plant are designated by a
letter in the tenth and eleventh character positions (see 4 and
5 below).
• The Chassis/Serial Number refers to the last seven characters of the VIN, including the assembly plant designator (eleventh character position) and a six-digit serial
number. This number will allow your Peterbilt Dealer to
identify your vehicle. You will be asked for this number
when you bring your vehicle in for service.
Table 13 Model Year Letter Designations
SAMPLE VIN
2NP
❶
NHD 8 X
❷
X
YM 5 6 7 8 9 0
❸ ❹❺
❶ Manufacturer Identifier
❷ Vehicle Attributes
❸ Check Digit
❹ Model Year
❺ Assembly Plant
❻ Serial/Chassis Number
❻
CODE
YEAR
2
2002
3
2003
4
2004
5
2005
6
2006
VIN Location
The VIN is marked on the Incomplete Vehicle Certification
Label (on trucks) or on the Tire, Rim, and Weight Rating
Data Label (on tractors). Both labels are located on the
driver’s door frame.
Vehicle Identification Number (VIN)
– 258 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Consumer Information and Vehicle Identification
Chassis Number Locations
A2378
The chassis/serial number is shown in three places:
• Right frame rail, top flange, about 3 ft. from the front end
• Components and Weights Label on driver’s door frame
• Tire and Rim Info Label on driver’s door frame
VIN LOCATION
Driver’s Door Frame
Medium Duty (R05/09)
Y53-6008A
– 259 –
Consumer Information and Vehicle Identification
Preventive Maintenance
Complete Vehicle Certification Label
VEHICLE NAME PLATE
The Complete Vehicle Certification label certifies that the
vehicle complies with all applicable Federal Motor Vehicle
Safety Standards. It is located on the driver's side door frame
and contains the following information:
• Date of manufacture
• GVWR — Gross Vehicle Weight Rating
• GAWR FRONT and REAR — Gross Axle Weight Ratings for Front and Rear Axle
• TIRE/RIM SIZES AND INFLATION PRESSURES —
Tire/Rim Sizes and Cold Pressure Minimums
• VIN — Vehicle Identification Number
SUITABLE TIRE–RIM CHOICE
TIRE SIZE
RIM SIZE
PSI COLD
MANUFACTURED BY
PETERBILT MOTORS CO. FR.
GAWR
DIVISION OF PACCAR Inc. 2 ND GAWR
3 RD GAWR
DATE MFD
GVWR
4 TH GAWR
THIS VEHICLE CONFORMS TO ALL
APPLICABLE FEDERAL MOTOR VEHICLE
SAFETY STANDARDS IN EFFECT ON THE
DATE OF MANUFACTURE SHOWN ABOVE
VIN
TYPE VEH. TRUCK TRACTOR
LABEL NO. 22–00709 REV. H
COMPLETE VEHICLE CERTIFICATION LABEL — SAMPLE
– 260 –
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Consumer Information and Vehicle Identification
WARNING! Do not exceed the specified load rating. Overloading can result in loss of vehicle
control and serious personal injury, either by
causing component failures or by affecting vehicle handling. Exceeding load ratings can also
shorten the service life of the vehicle.
NOTE: GVW is the TOTAL SCALE WEIGHT the
vehicle is designed to carry. This includes the weight
of the empty vehicle, loading platform, occupants,
fuel, and any load.
The tire size and rim size (and the cold inflation pressure to
match that combination) listed under “Suitable Tire-Rim
Choice” on the Certification Label are only representative
examples for the specified axle ratings. These components
may not be the ones actually installed on the axle, because
there are many other appropriate combinations.
The “PSI Cold” inflation pressure on the Certification Label is
for the tire-rim combination in the example, and may not be
the same as the recommended inflation pressure for the
actual tires on that axle.
Check the manufacturer's product information for the tires
and rims actually on each axle to obtain recommended tire
inflation pressure for specific applications.
Medium Duty (R05/09)
Incomplete Vehicle Certification Label
The Incomplete Vehicle Certification Label (for trucks) is
located on the driver’s door frame. It contains the following
information:
• DATE OF MANUFACTURE
• VIN — Vehicle Identification Number
• LISTING OF APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS
Noise Emission Label
The Noise Emission Label is in the map compartment. It contains information regarding U.S. noise emission regulations
and date of manufacture.
Paint Data Label
The Paint Data Label contains the paint colors used by the
factory to paint your vehicle. It lists frame, wheels, cab interior and exterior colors. This label is located in the map compartment.
Y53-6008A
– 261 –
Consumer Information and Vehicle Identification
Preventive Maintenance
Federal Safety Standard Certification Label
The NHTSA regulations require a label certifying compliance
with Federal Safety Standard, for United States and U.S. Territories, be affixed to each motor vehicle and prescribe where
such label may be located. This certification label, which indicates the date of manufacture and other pertinent information, is located on the driver's side door frame.
Component Identification
Each of the major components on your vehicle has an identification label or tag. For easy reference, record component
numbers such as, model, serial, and assembly number. See
the “Vehicle Component Register” (last page of this manual).
Engine: For further information, please refer to the Engine
Operation and Maintenance Manual.
Clutch: Enclosed in clutch housing. Location depends on
manufacturer.
– 262 –
Transmission: For both manual and automatic transmissions, the identification number is stamped on a tag affixed to
the right rear side of the transmission case.
Steer Axle: The front axle serial number is stamped on a
plate located on the center of the axle beam.
Drive Axles: The drive axle numbering system includes
three labels or stamps:
1. Axle Specification Number, usually stamped on the right
rear side of the axle housing. This number identifies the
complete axle.
2. Axle Housing Number Tag, usually located on the left forward side of the housing arm. This tag identifies the axle
housing.
3. Axle Differential Carrier Identification, usually located on
the top side of the differential carrier. The following information is either stamped, or marked with a metal tag:
Model No., Production Assembly No., Serial No., Gear
Ratio, and Part Number.
Y53-6008A
Medium Duty (R05/09)
Preventive Maintenance
Medium Duty (R05/09)
Consumer Information and Vehicle Identification
Y53-6008A
– 263 –
INDEX
INDEX
A
Accessories 70
Air conditioner 212
refrigerant 147
Air Dryer 196
Air filter 198
Air horns 46
Air intake 197, 251
Air leaks 194
Air pressure gauge 194
Air suspension
deflated air spring 134
switch, operation 130
Air tanks 85, 116, 144
Alternator precautions 222, 249
Anti-lock brakes 109, 112, 122
Automatic transmission 86, 100, 236
fluid 239
oil level 236
Axle weight rating 82, 83, 129, 261
B
Ball bearing grease 164
Ball seat mounted wheels 208
Battery
access 214
– 264 –
care 215
compartment cover 10
electrolyte 219
recharging 219, 220
slow battery charging 221
Belts, seat 73, 76
Block heater 91, 177
Bobtail brake 106, 114
Brake
adjustment 182
air pressure gauge 194
checks and adjustments 181
components 116
compounding 117
emergency braking 109
hand valve, trailer 113
linings 182
lubrication 181
operation 102
overheating 110
parking 103
proportion valve 102
safety - front 108
safety - rear 108
safety - tractor/trailer 109
system - safety and emergency 107, 190
Y53-6008A
Medium Duty (R05/09)
INDEX
system - towing and spring brakes 139
system checks 180, 184
system malfunction 139
system park - tractor 107
trailer brake hand valve 113
trailer charge 107
treadle valve 116
Brake Fluid Check 185
Brake Fluid Reservoir 119
Brake Master Cylinder 119
Brake Warning Lamp 120
C
Cab
access 9
heater maintenance 211
maintenance 228
Calipers 187
Charge air cooler 197
Chassis
grease 164
number 258, 259
Cleaning the vehicle 224
Clutch 96
clutch adjustment 100
clutch brake 98
clutch travel 98
fan drive 253
operating the clutch 96
Medium Duty (R05/09)
riding the clutch 99
Coasting 100
Component lubrication index 164
Compressed air reservoir 85, 116, 193
Compressor 116
Consumer information 257
Controls
Air Suspension Deflate Switch (Dump Valve) 52
Brakesaver 58
Cruise Control Switch 53
Dome Light Switch 51
Electric Horn 46
Fifth Wheel Lock (Slider Adjustment) Switch 60
Fog Lights Switch 52
Hazard Flasher 49
Heater-Air Conditioning Controls 64
ID and Clearance Lights Switch 51
Interaxle Differential Lock Switch 59
Mirror Heat Switch 56
Panel Light Dimmer 51
Parking Brake Valve and Trailer Air Supply Valve 61
Power Door Lock Switch 57
Power Mirror Switch 55
Power Window Switch 57
Tilt- Telescoping Steering Column 47
Trailer Brake Hand Valve 46
Two-Speed Rear Axle (Range) Switch 60
Windshield Wipers and Washers 44
Y53-6008A
– 265 –
INDEX
Cooling system
conventional coolant 176
extended life coolant 175
temperature 39
topping up 176
Cruise control
operation 94
Cruise Control On/Off 15
Cruise Control Select 15
D
Daily operations 84
dash 14
dashboard 14
Daytime running lights 50
DEF 40, 172
DEF Gauge 15
Defogging/defrosting system 66
Deisel Exhaust Fluid 172
Department of transportation regulation 392.7 81
Diesel fuel 145
Dipstick 169
Disc brake pads 186
Disc brake rotors 187
Door Lock 9
Door lock 57, 225
Double check valve 116
Downshift 100
Driver Information Display 15
– 266 –
Driver’s
checklist 81
daily and weekly checks 83, 84, 86
handbook American Trucking Assoc. 7
seat 72
tips 100
Driveshaft 239
lubrication 239
Driving
bobtail 113, 118
vehicle inspection 81
with deflated air springs 134
DRL 50
Dry tank 116
Dual air pressure gauge 90
E
Economical driving 127
Electrical system 214
alternator 222
batteries 214, 215, 219
battery charging 216, 218, 219, 220
jumper cables 217
Electrolyte 219
Emergency
braking 109
equipment 83
Emission Components 172
Engine
Y53-6008A
Medium Duty (R05/09)
INDEX
belt tension 84, 216
block heater 91
compression 143
daily checks 84
fan switch 94
heater 177, 210, 213
identification 262
idling 93
lubrication 169
oil draining 169
oil level check 169
overspeed 128
retarder 114
rpm 144
service notes 169
starting procedure 87
stopping the engine 144
vital engine systems 92
warmup procedure 92
weekly checks 86
winterfronts 88
Engine Oil Pressure 15
Environmental protection 147
Ether 87
Exhaust
brake 114, 115
fumes 147
Medium Duty (R05/09)
F
Fan blade 253
switch 94
Federal motor regulations 81, 83
Federal motor vehicle safety standards 5
Federal safety label 262
Fifth wheel 134
air controlled 135
fixed 135
lock switch 135
maintenance 250
sliding maintenance 250
Frame precautions 249
Front axle 241
front axle identification 262
Front brake system 102
Front suspension
u-bolts 240
Front Wheel Calipers 119
Fuel
filter 84, 170
filter draining 171
refueling 144
system 145
Fuel Level 15
Fuel Tank Inspection 171
Fuel tanks 171
Y53-6008A
– 267 –
INDEX
G
Gauges and Displays 35
Drive Axle Temperature Gauge 42
Engine Oil Pressure Gauge 38
Fuel Gauge 40
Speedometer / Odometer 29, 35
Tachometer 36
Voltmeter 40
Warning Lights and Buzzers 17
Water Temperature Gauge 38
GAWR
defined 83
GAWR - gross axle weight rating 82, 129, 261
GCW - gross combination weight 82
Glove compartment 71
Governor 116
Grease index 164
GVWR
defined 82
GVWR - gross vehicle weight rating 82, 129, 203, 261
H
Hand brake 113, 143
Hazard flasher 121
Hazard Switch 15
Headllights 15
Heater and air conditioner
maintenance 211
High beam 44
– 268 –
Hood Latch and Tilt 10, 11
hood lock release cable 12
Hub piloted and ball seat parts 208
HVAC 16
Hydraulic Booster 120
Hydraulic Brakes 62, 84, 85, 118
Hydraulic Fluid Check 84
Hypoid gear oil 164
I
Idling the engine 93
Ignition 15
Incomplete vehicle certification label 261
Inter-axle differential 125
J
Jumper cables 217
use of 217
K
Keys 9
Keys and Locks
Ignition Switch 48
Komfort-Lok latch 79
L
Lap - shoulder belt 74
Lap belt 75
Load capacity 82
Load distribution 83
Load Lights 15
Y53-6008A
Medium Duty (R05/09)
INDEX
Low air pressure 134
Lubrication 181, 241
axle 240
brakes 181
chart 165
coasting 128
driveshaft 239
engine 169
front axle 241
front suspension 241
idling 92, 93
power steering 237, 238
rear axle 244, 245, 246
transmission 233, 234
types and brands 163
wheel bearings 241
M
Maintenance
manual 6
schedule 149
Manual transmission 96
lubricants 233
oil level 234
shifting gears 96
master cylinder 118
Menu Control Switch 15
Modifications 147
Modulating valve 116
Medium Duty (R05/09)
Muffler 253
N
NHTSA consumer information 257
Noise and emission control 251
air intake system 251
engine 252
exhaust system 252
fan drive 251
inspection and maintenance instructions 252
O
Off-road operation 5
Oil
draining 169
level 169
pressure gauge 89
Operating the engine 87
Operating the Rear/Drive Axle 124
Operating the transmission 96
Optional equipment 100, 114, 125
Overheated Brakes 121
P
Paint identification label 261
parked regeneration 54
Parking brake 103
adjustment 182
automatic 104
brake system, operation 61, 62, 103, 104, 108, 139
brake system, tractor/trailer operation 105
Y53-6008A
– 269 –
INDEX
use 62, 88, 97, 121, 143, 146, 218
valve 117
Parking Brake Burnishing 123
Parking Brake Component Inspection 187
Parking Brake Indicator 63
Parking Brake Lever 120
Parts catalog 6, 7, 148
Power steering 237
fluid level 238
fluid refill 239
lubrication 237
Primary Air Pressure 15
Q
Quick-release valve 117
R
Radio 16, 71
Rear axle 244
housing breather vent 246
identification 262
lubrication 244, 245, 246
oil change 244
oil level 244
Rear brake system 102
Rear suspension 243
fasteners (standard) 243
Rear Wheel Calipers 119
Recovering vehicles 137
Regeneration Switch 54
– 270 –
Relay valve 117
Release bearing wear 100
Repairs 6
Retarders
engine 114
rpm 92, 98, 144
S
Safe vehicle operation 81
Safety
belt adjustment 75
passengers 77
restraint belts 73
restraint tips 77, 80
signals 3
stands 147
tether belts 78
Safety precautions, maintenance 146
Seat adjustment 72
Seat belt system
damage and repair 80
guidelines 229
inspection 228
Komfort-Lok latch 79
replacement part 231
tether belts 231
Seats 72
Secondary Air Pressure 15
Serial number 259
Y53-6008A
Medium Duty (R05/09)
INDEX
Service Brake Components 186
Shackle pinch bolts 242
Shift pattern/diagram 96, 98
Shifting gears 88, 96, 97, 98, 99, 100, 128, 129, 142
Shifting gears in a new vehicle 98
Shock absorber 240
Shop manuals 6
Shoulder belt 75
Single check valve 117
Slack adjusters 182
Speedometer 15
Spring brakes - manual release 139
Spring pins 241
Springs 240
Starting Procedure
Cold Temperatures 90
Normal Temperatures 88
Steering Column-Mounted Controls 43
Steering maintenance 237
Stopping procedures 143
Storage compartment 71
Suspension 243
fasteners 243
fasteners, torque 243
T
Tachometer 15, 128
Tether belts 78, 231
adjustment 78
Medium Duty (R05/09)
Tire
chains 142
inflation pressure 202
inspection 201
replacement, tread depth 209
Towing 139, 142
vehicle recovery precautions 137
Tractor park 107
Tractor protection manifold 118
Trailer
hand brake 113
park 106
spring brakes 109
supply valve, red 117
Trailer ABS 111
Trailer park 105
Transmission
automatic 100
clutch 96
identification 262
lubrication 233, 234, 236
maintenance 234
manual 96
operation 96
service notes 233
Truck/tractor ABS 110
Turbocharger 144, 197
Y53-6008A
– 271 –
INDEX
U
U-Bolt torque 242
Underbody maintenance 225
Underinflated tires 202
V
Vehicle
driving 81
loading 82
weight rating 82, 129, 261
Vehicle inspections 81
W
WAIT TO START light 89
Warning Light Symbols table 20
Warranty 147, 149, 243, 249, 251, 252
Water Temperature 15
Weekly operations 86
Weight rating 82, 129
Welding 222, 249
Wet Brakes 121
Wet tank 116
– 272 –
Wheel and Tire Replacement, hydraulic brakes 210
Wheel bearing
grease 164
lubrication 240
wheel cylinders 118
Wheels and tires 200
general safety requirements 200
load rating 203
overinflation 203
proper inflation 202
replacement 200, 209
tightening sequence 204
tire inspection 201
tread depth 209
underinflation 202
wheel mounting and fastening 200
wheel nut torque 204
Windshield
washer reservoir 232
Windshield washer reservoir 45
Y53-6008A
Medium Duty (R05/09)
Other Publications
Order either of the two publications shown below through your Peterbilt dealer.
There is a charge for each. Allow four weeks for delivery.
02956A
Custom Maintenance Manual
This manual contains both proprietary and supplier service
information specifically compiled for the components on your
vehicle.
The material in this manual is the same as that used by Peterbilt dealers. It includes inspection, maintenance, overhaul,
and troubleshooting procedures.
02956B
Owner’s Custom Parts Book
This book is a complete, unillustrated, computer-generated
list of the parts used to custom-build your Peterbilt vehicle.
Please provide your Chassis Serial Number when ordering.
Y53-6008A
06/09
Printed in the U.S.A.
Peterbilt Motors Company, A PACCAR Company, P.O. Box 90208, Denton, Texas 76202