Model 220 Owner`s Manual

Model 220 Owner`s Manual
Table of contents
Why this handbook is so important! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warnings and Safety Regulations . . . . . . . . . . . 11
Safety alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Warnings and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Emergency equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Technical items of special importance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Jump starting vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cab, Instruments and Controls . . . . . . . . . . . . . 31
Entering and leaving the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Electrically operated windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Heated Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Electrical mirror adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Windshield wiper blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Roof console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Sun visors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Stepwell lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
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Table of contents
Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Warning indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Control panel of heating/ventilation system. . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Air conditioning switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fan speed selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Temperature adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Air distribution selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Center console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Left-hand steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Right-hand steering column switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Steering wheel switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Adjustable steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Important points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
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Table of contents
Master Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Layout of master display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Start-up phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Menu selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Menu overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Warning symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Inspections and Maintenance. . . . . . . . . . . . . . . 91
Overview of daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Opening the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Engine oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Topping up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Special coolant fill instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Windshield washer reservoir fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Air filter indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Wheels and tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Lighting and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Driver's seat and mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
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Table of contents
Overview of weekly checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Power steering fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Brake system air drier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Draining the water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Cab maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Preventative maintenance before the winter season. . . . . . . . . . . . . . . . . . . 107
Diesel fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Cab heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Windshield washer reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Maintenance after the winter season. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
PDC & Voltage Converter . . . . . . . . . . . . . . . . . .109
Power distribution center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Steering lock/contact/starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
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Glow system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table of contents
Starting procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Engine speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Vehicle speed limitation for special applications . . . . . . . . . . . . . . . . . . . . . . 122
Driving style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
ABS brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Parking brake and service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Automatic Gearbox . . . . . . . . . . . . . . . . . . . . . . 129
Allison 2100 series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Emergency Repairs . . . . . . . . . . . . . . . . . . . . . . 133
Tilting the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Replacing the poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Replacing the fuel fine filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Draining the water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Releasing the parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Jacking up the front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
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Table of contents
Jacking up the rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Changing the wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Tire inflating connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Replacing bulbs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Technical Data and Identification . . . . . . . . . . .157
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
tire pressure table (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Lubricant-, engine coolant- and fuel specifications. . . . . . . . . . . . . . . . . . . . 162
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Steering gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Cab tilting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Chassis number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Paint identification plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Vehicle identification label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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Table of contents
Consumer Information . . . . . . . . . . . . . . . . . . . 171
Federal safety standard certification label . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Alphabetical index . . . . . . . . . . . . . . . . . . . . . . . 177
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Table of contents
8
WHY THIS HANDBOOK IS SO IMPORTANT!
This handbook contains the information which you, the driver, will need for optimum
efficiency, safety and comfort when operating this vehicle.
Besides giving instructions about operation and use, it also pays attention to
maintenance and minor repairs which you may be able to carry out yourself.
NOTE
This handbook is based on the chassis with its fittings as it originally left
the factory.
Depending upon the required body and equipment, the bodybuilder may have made
fundamental changes to various parts or systems, such as the instrument panel, the
lighting or the electric wiring.
The vehicles covered by this handbook consist of various types and models.
Certain descriptions or illustrations in this handbook may not correspond entirely to
the situation on your own vehicle. However, this has practically no influence on its
operation or maintenance.
Every new vehicle is designed to conform to all Federal Motor Vehicle Safety
Standards applicable at the time of manufacture. Even with these safety features,
continued safe and reliable operation depends greatly upon regular vehicle
maintenance. Follow the maintenance recommendations found in Preventive
Maintenance on page 107. This will help preserve your investment
9
Important
Make sure this handbook is in the vehicle at all times.
Read it carefully before making your first journey, especially the "Warnings and
safety precautions", "Cab, instruments and controls", "Inspections" and
"Driving" sections.
10
Warnings and Safety Regulations
11
Warnings and Safety Regulations
SAFETY ALERTS
Please read and follow all of the safety alerts contained in this manual. They are
there for your protection and information. These alerts can help you avoid injury to
yourself, your passengers, and it can also help prevent costly damage to the
vehicle. Safety alerts are highlighted by safety alert symbols and signal words such
as "WARNING", "CAUTION", or "NOTE". Please do not ignore any of these alerts.
Warnings
The safety message following this symbol and signal word provides a warning
against operating procedures which could cause injury or even death. They could
also cause equipment or property damage. The alert will identify the hazard, how to
avoid it, and the probable consequence of not avoiding the hazard.
Example:
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. Failure to comply may result in death or personal injury.
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Warnings and Safety Regulations
Cautions
The safety alert following this symbol and signal word provides a caution against
operating procedures which could cause equipment or property damage. The alert
will identify the hazard, how to avoid it, and the probable consequence of not
avoiding the hazard.
Example:
CAUTION
Continuing to operate your vehicle with insufficient oil pressure will
cause serious engine damage. Failure to comply may result in
equipment or property damage
Notes
The alert following this symbol and signal word provides important information that
is not safety related but should be followed. The alert will highlight things that may
not be obvious and is useful to your efficient operation of the vehicle.
Example:
NOTE
Pumping the accelerator will not assist in starting the engine.
13
Warnings and Safety Regulations
WARNINGS AND SAFETY REGULATIONS
WARNING
To prevent damage to the vehicle and in order not to jeopardize
your health and/or safety, or that of other people, the following
warning and safety regulations must be strictly observed.
First read the instructions and warnings on the labels and stickers on the various
components and comply with them!
They have been put there for your health and safety, so do not ignore them!
Modifications to 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 dealer to make sure it can be done safely.
Improper modifications can cause death or personal injury.
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Warnings and Safety Regulations
Environmental Protection
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.
Components
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 one is near the fan.
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Warnings and Safety Regulations
Cooling system filler cap
WARNING
Do not remove the radiator fill cap while the engine is hot. Scalding
steam and fluid under pressure may escape. You could be badly
burned. Failure to comply may result in death or personal injury.
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:
-
16
Window scraper
Snow brush
Container or bag of sand or salt
Emergency light
Warning triangles
Small shovel
First aid kit
Fire extinguisher
Vehicle recovery hitches
(see Towing on page 147 for details).
Warnings and Safety Regulations
Fire extinguisher
Ensure that you are always in possession of a fire extinguisher It should be well
secured under the seat, within the driver's reach and easily accessible, also for
rescue workers and others providing assistance. Have the fire extinguisher checked
for operational readiness each year. If it has been used, have it refilled at the
earliest opportunity.
In the event of fire:
In the event of a fire, certain plastic seals can produce gases which together with
water form a corrosive acid. Do not touch any fire extinguisher fluid on the vehicle
without protective gloves.
Cab
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. Carry any heavy objects such as luggage in the exterior
storage compartment and close it securely.
First aid kit
Ensure that you are always in possession of a first aid kit and replace first aid items
as soon as possible after use to have the kit always ready.
17
Warnings and Safety Regulations
Tire chains
If you need tire chains, install them on both sides of each driving axle.
CAUTION
Chains on the tires of only one tandem axle can damage the
driveline U-joints and the interaxle differential. Your repairs could
be costly and time-consuming.
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?
Oils and lubricants
Various kinds of oil and other lubricants used on the vehicle may constitute a health
hazard if they come into contact with the skin. This also applies to engine coolant,
windshield washer fluid, refrigerant in air conditioning systems, battery acid and
diesel fuel. So avoid direct contact as much as possible.
The engine and the surrounding area must be free of inflammable materials to avoid
the risk of fire.
Exercise caution when changing hot oil; it can cause serious bodily injury.
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Warnings and Safety Regulations
WARNING
Air conditioning refrigerant can be hazardous to your health. Do not
expose yourself to leaking refrigerant for prolonged periods near
excessive heat, open flames, or without proper ventilation. Failure
to do so may result in death or personal injury.
Maintenance activities
When carrying out maintenance work under the cab, make sure the cab is fully tilted
and locked to prevent it from falling back accidentally.
Following a collision, only tilt the cab in an emergency situation. The tilting
mechanism may be damaged. (The end stop may no longer be on the lifting
cylinder.)
WARNING
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.
Maintenance of air conditioning system
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.
Failure to comply may result in personal injury, death, equipment or
property damage.
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Warnings and Safety Regulations
WARNING
Air conditioning refrigerant can be hazardous to your health. Do not
expose yourself to leaking refrigerant for prolonged periods near
excessive heat, open flames, or without proper ventilation. Failure
to do so may result in death or personal injury or death.
WARNING
The air conditioning system is under pressure. If not handled
properly during servicing, it could explode. Any servicing that
requires depressurizing and recharging the air conditioning system
must be conducted by a qualified technician with the right facilities
to do the job. Failure to comply may result in personal injury, death,
equipment or property damage.
Environment
Pollution constitutes a serious threat to the environment. To keep pollution to a
minimum, the following rules should be observed:
-
-
20
Do not dump used oil, fuel, lubricants, hydraulic fluid or coolants in drains,
sewers, in landfills or on the ground. This is illegal. These fluids should be
returned to the designated authority or appropriate chemical waste collection
company for recycling or destruction. All used fluids should be stored separately.
Make sure that the vehicle is serviced regularly according to the instructions and
recommendations. A properly serviced vehicle helps optimize fuel economy and
reduce the level of harmful constituents in the exhaust gases.
Warnings and Safety Regulations
TECHNICAL ITEMS OF SPECIAL IMPORTANCE
To prevent damage to the vehicle, the following instructions must be strictly
observed.
Running-in
During the running-in period it is best not to subject the new vehicle to excessive
loads. This also applies when an overhauled engine, transmission or differential has
been installed. Therefore, for the first 1,500 km (932 miles): drive carefully and
avoid accelerating sharply.
The following technical items of special importance apply to both the runningin period and to the period thereafter.
After a cold start continue to drive in a low gear and at a moderate engine speed
until the engine coolant temperature is out of the blue zone.
While driving, check the instrument panel regularly and take appropriate action if
you notice anything unusual, such as strange engine or transmission noises,
smoke, or poor performance. Do not let the engine idle for longer than necessary.
This is harmful to the engine and also causes unnecessary pollution of the
environment.
Be aware that engine stalling while driving will lead to power steering failure.
Consequently, the vehicle will be more difficult to steer.
The engine cooling system is thermostatically controlled.
Removing the thermostat when the coolant temperature is (too) high serves no
useful purpose and is strongly advised against, since this will only cause the engine
temperature to rise to an even higher level.
The turbocharger is a precision component. You should therefore immediately
report any abnormal noise that seems to be coming from this component.
21
Warnings and Safety Regulations
Air leakage
If the pressure in the air reservoirs drops rapidly with the engine switched off, this
indicates a leak. Since this affects the safety of the brake system, the leak must be
traced and repaired as quickly as possible.
System voltage
The cab system of this vehicle are on 24-Volt while other areas remain 12-Volt.
When replacing or fitting electrical or electronic components, always verify that they
are suitable for this system voltage.
Batteries
WARNING
Never disconnect the battery leads while the engine is running!
Always disconnect the battery negative (ground) lead before carrying out repairs or
service on the electrical system.
WARNING
Before attempting any work on the batteries or electrical system,
remove all jewelry. If metal jewelry or other metal comes in contact
with electrical circuits, a short circuit may occur causing you to be
injured, as well as causing electrical system failure and damage.
22
Warnings and Safety Regulations
Charging
WARNING
Thaw out frozen batteries before charging them. Remove all the
filler caps before charging.
WARNING
Charger cables must be connected positive to positive (+ to +) and
negative to negative (- to -). If connected improperly, batteries could
explode. Failure to comply may result in personal injury, death,
equipment or property damage.
WARNING
Always make sure the battery charger is OFF before connecting or
disconnecting the cable clamps. To reduce the danger of
explosions and resulting death or personal injury, do not connect
or disconnect charger cables while the charger is operating.
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.
23
Warnings and Safety Regulations
-
Battery terminals should not be coated with improper grease. Use petroleum
jelly or commercially available, noncorrosive, nonconductive terminal coatings.
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.
Battery capacity
Using electrical components, such as the cab heater or refrigerator when the engine
is not running, power will be drawn from the batteries.
Approximately half the battery capacity is required to start the engine.
If this is the case over a protracted period, particularly during low temperatures, the
result may be that the electrical components have used so much power that there is
not enough to start the engine.
If the high current draw electrical components, such as the cab heater, refrigerator,
coffee percolator, microwave oven or tail-lift are used, it is recommended that you
obtain batteries of an adequate higher capacity in consultation with your dealer.
Welding
For welding on the vehicle and/or superstructure, see the "Bodybuilders Manual".
Not following the welding instructions can cause damage to the electronic
components.
24
Warnings and Safety Regulations
JUMP STARTING VEHICLES
Introduction
Jump starting a vehicle is not a recommended practice due to the various battery
installations and electrical options. 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.
WARNING
Batteries contain acid that can burn and gasses that can explode.
Ignoring safety procedures may result in death, personal injury,
equipment or property damage.
WARNING
Never jump start a battery near fire, flames, or electrical sparks.
Batteries generate explosive gases that could explode. Keep
sparks, flame, and lighted cigarettes away from batteries. Failure to
comply may result in death, personal injury, equipment or property
damage.
WARNING
Never remove or tamper with battery caps. Ignoring this could allow
battery acid to come in contact with the eyes, skin, fabrics, or
painted surfaces. Failure to comply may result in death, personal
injury, equipment or property damage. 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.
25
Warnings and Safety Regulations
To Jump Start Your Vehicle
WARNING
When jump starting using a booster battery, it is best to jump start
with an equivalently powered vehicle. Verify that the booster battery
has the same volt and CCA specifications as the dead battery
before attempting to jump start. Failure to comply may cause an
explosion resulting in death, personal injury, equipment or property
damage.
CAUTION
Applying a higher voltage booster battery will cause expensive
damage to sensitive electronic components such as relays, and the
radio. Failure to comply may result in equipment damage. Improper
hook-up of jumper cables or not following these procedures can
damage the alternator or cause serious damage to both vehicles.
WARNING
Heed all warnings and instructions of the jumper cable
manufacturer. Failure to comply may result in personal injury, death
and equipment or property damage.
26
Warnings and Safety Regulations
Preparing the vehicles:
1
Remove any jewelry that may come in contact with the battery terminals.
2
Select a jumper cable that is long enough to attach to both vehicles in a way that
ensures neither vehicle touches each other.
3
Position the two vehicles together, but do not allow them to touch.
4
Turn OFF all lights, heater, radio, and any other accessory on both vehicles.
5
Set the parking brakes: pull out the Yellow button located on the dash.
6
Shift the transmission into park position or neutral for manual transmissions.
(See “Shifting Gears” on page 130 and “PARKING BRAKE AND SERVICE
BRAKE” on page 125, for transmission shifting and parking brake information.)
7
If either vehicle is equipped with battery disconnects ensure they are in the
"OFF" position prior to connecting the two vehicles.
27
Warnings and Safety Regulations
Connect the batteries:
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 not bolted to the
engine block.
IMPORTANT: Always connect positive (+) to positive (+) and negative (-) to
negative (-).
28
5
If either vehicle is equipped with battery disconnects, ensure that they are in the
"ON" position.
6
Start the vehicle that has the good battery first. Let it run for 5 minutes.
7
Start the vehicle that has the discharged (dead) battery. If the engine fails to
start, do not continue to crank the starter and contact the nearest authorized
dealer
Warnings and Safety Regulations
Remove jumper cables:
WARNING
When disconnecting jumper cables, make sure they do not get
caught in any moving parts in the engine compartment. Failure to
comply may result in death, personal injury, equipment or property
damage.
Reverse the above procedure exactly when removing the jumper
cables. With the 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.
NOTE
Review the warranty policy before performing any maintenance
procedures. An extended warranty may be voided if unauthorized
maintenance is performed during this period.
CAUTION
Do not modify or improperly repair the vehicles electrical system or
power distribution center. All electrical repairs should be performed
by an authorized dealer. Improper repair or modifications will void
your warranty and/or cause serious damage to your vehicle.
29
Warnings and Safety Regulations
Disconnect Switch
This vehicle has a disconnect switch. Ensure that your vehicle ignition has been
turned off for at least 40 seconds before switching the disconnect switch to the OFF
position
NOTE
Wait 2 minutes after key-off before disconnecting battery power.
Disconnecting battery power sooner can result in damage to vehicle
DEF.
D0 02 014
Wait 2 minutes after
key-off before
disconnecting battery power.
Disconnecting battery power
sooner can result in damage
to vehicle DEF system.
P53-6080-000
30
Cab, Instruments and Controls
31
Cab, Instruments and Controls
ENTERING AND LEAVING THE VEHICLE
WARNING
Always reinstall steps before entering the cab or accessing the
deck plate. Without steps you could slip and fall. Be careful
whenever you get into or out of your vehicle's cab. Always maintain
at least three points of contact with your hands on the grab handles
and your feet on the steps. Failure to comply may result in personal
injury or death.
D0 00 632
WARNING
Jumping out of the cab or getting into the cab without proper
caution is dangerous. You could slip and fall, which could lead to
personal injury or death. Keep steps clean. Clean any fuel, oil, or
grease off of the steps before entering the cab. Use the steps and
grab handles provided, and always keep at least three points of
contact between your hands and feet and the truck. Look where you
are going.
The picture shows the best way to enter and exit a Cab-Over Engine Cab.
32
Cab, Instruments and Controls
DOORS
WARNING
To help lessen the chance and/or severity of death or 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 doors from inadvertently opening and occupants
from being ejected from the vehicle.
Opening the door
Pull the handle to open the door from the inside.
D0 00 604
Locking the door from the inside
Press the door handle downwards.
D0 00 611
Standard version
Both doors can be locked and unlocked from the outside using the key.
33
Cab, Instruments and Controls
Central door locking
Unlocking
To open the doors of a vehicle with central door locking, use the same procedure
described before.
The door on the co-driver's side can be locked/unlocked using the switch on the
center console.
Locking
- Both doors are locked when one of the doors is closed with the key.
- Avoid locking yourself out!
ELECTRICALLY OPERATED WINDOWS
The switches only work when the ignition is switched on.
The driver's and co-driver's windows can be opened and closed with the switches in
the driver's door. The switch in the co-driver's door can only open and close the codriver's window.
HEATED MIRRORS
D0 00 585-1
34
With the switch for mirror/windscreen heating , the exterior mirrors (excluding curb
mirror) and the windscreen heating, if fitted, can be heated. When you press the
switch again, the mirror heating is switched off the windshield heating remains
active for about 12 minutes. If you press the switch again within 12 minutes, the
windscreen heating is switched off and the mirror heating is switched on again.
Operate the switch once more to switch everything off.
Cab, Instruments and Controls
MIRRORS
The mirror housing and mounting bracket is fixed to the cab. Only the face of the
mirror is adjustable within the mirror housing.
The mirror bracket can be folded back against the cab and will return to its original
position once the bracket is swung out again.
All models have Flat glass mirror.
ELECTRICAL MIRROR ADJUSTMENT
The electric mirrors can be adjusted by means of the switch in the driver's door.
0
Select the right or left mirror by turning the button either to the right or left position.
Move the switch forwards, backwards, left or right, to adjust the mirror.
WINDSHIELD WIPER BLADES
D0 00 612
To prevent damage to the wiper blades during operation in winter conditions,
always check that the blades are not frozen to the windshield. This can be
prevented by placing something between wiper blades and windshield. Switch off
the windshield wipers before turning off the ignition.
WARNING
Clean blades regularly with a damp cloth to remove road film and
wax build-up. Do not drive with worn or dirty wiper blades. They can
reduce visibility, making driving hazardous which may lead to an
injury accident resulting in personal injury or death.
35
Cab, Instruments and Controls
ROOF CONSOLE
WARNING
Overhead compartments are not intended for personnel use or for
items exceeding their designed weight limits. Exceeding the weight
limits may cause the shelf to collapse and or items may fall out in a
sudden stop which may lead to personal injury or death.
D0 02 001
SUN VISORS
As a protection against sun glare, the sun visors can be folded down. The sun visor
on the driver's side can also serve as a side window shade.
STEPWELL LIGHTING
In both doors, a lamp is fitted at the bottom to light the stepwell. This will light up as
soon as the door is opened.
36
Cab, Instruments and Controls
INTERIOR LIGHTING
The interior lighting operates independently of the position of the contact key. The
interior light comes on when the door is opened. When the doors are open for more
than 15 minutes, the interior lamps will be extinguished. The lamp stays lit by
operating the switch on the lamp.
D0 01 197
37
Cab, Instruments and Controls
DASHBOARD
1
!
23
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
!
22 21 20 19 18 17
D001183
38
Cab, Instruments and Controls
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Instrument panel
Dimmer, dashboard lighting
(unused)
(unused)
Front fog lamps
Menu selection switch
Ashtray with 12V auxiliary socket
Hazard warning lights
(unused)
(unused)
(unused)
(unused)
(unused)
(unused)
PTO operation
(unused)
Air conditioning
12V connection
Heater, fan speed selector switch in fresh air position or re-circulation
position
Heater, temperature control
Heater, air distribution selector switch
(unused)
Lighting switch
39
Cab, Instruments and Controls
INSTRUMENT PANEL
B
A
23
8050
C
D
100
60
70
120
60 40
80
STOP
6
L
ABS
15
10
20
20 10
DIESEL
EXHAUST
FLUID
0
60
AM
145
+
PM
CF
35
mph
F
G
I
H
J
20
25
90
30
40
E
30
K
D001198-1
40
Cab, Instruments and Controls
A
B
C
D
E
F
G
H
I
J
K
Speedometer
Fuel gauge
Master display
Coolant temperature gauge
Tachometer
Reset button, trip odometer
Odometer and trip meter
Warning indicators
Diesel exhaust fluid
Circuit 1
Outside temperature and clock
41
Cab, Instruments and Controls
A. SPEEDOMETER
This vehicle’s speedometer is equipped with double scale divisions. Either major
divisions in mph and minor divisions in kph or major divisions in kph and minor
divisions in mph.
B. FUEL GAUGE
The fuel gauge only operates when the contact is on.
Factor in the delay on the gauge when the contact is turned on.
C. MASTER DISPLAY
See "MASTER DISPLAY".
D. COOLANT TEMPERATURE GAUGE
The engine should not be operated under full load if the temperature is in the blue
field.
The engine is at operating temperature when the temperature gauge is vertical, or
slightly further.
If the coolant temperature suddenly rises and/or the pointer is in the red field, the
following points should be checked:
42
-
coolant level (caution – danger of scalding; see "Topping up coolant" in
"INSPECTIONS AND MAINTENANCE");
-
poly V-belt and water hoses;
-
fan clutch.
Cab, Instruments and Controls
E. REV COUNTER
Green area: economical
White: less economical
Blue area: only permitted when driving downhill and for optimal use of the engine
brake
Red area: not permitted
F. TRIP METER RESET BUTTON
The trip meter is set to zero with the reset button.
G. ODOMETER AND TRIP METER
The total distance is displayed in "km" or "mls" in the top section of the display.
H. WARNING INDICATORS
See section concerned.
I. DIESEL EXHAUST FLUID GAUGE
The Diesel Emission Fluid gauge indicates the total (approximate) amount of DEF in
the tank. In addition to indicating empty and full, the gauge also indicates the DEF
level in graduated increments. When the DEF level in the tank reaches 10% full, a
red warning light in the gauge illuminates. When the DEF level in the tank reaches
5%, Refer to your PACCAR Engine After-Treatment Control Operator's Manual for
more information.
43
Cab, Instruments and Controls
J. AIR PRESSURE GAUGE, CIRCUITS 1
The air pressure gauge indicates the air pressure in the reservoirs of one of the
service brake circuits. If the pressure in one of the circuits drops below 65 psi
(448.15 kPa), an audible alarm is generated and the warning symbol "Air system
pressure too low" will illuminate in the master display. When the pressure is higher
than 66.5 psi (458.5 kPa), the brakes can be released with the parking brake lever.
The audible alarm and warning symbol are only generated when the ignition key is
on. The gauge also operates when the ignition key is off.
The vehicle must not be driven when the audible alarm sounds or when the
pressure in one of the circuits is lower than approx. 65 psi (448.15 kPa).
NOTE
The air pressure warning will be activated when primary or secondary air
systems drops below 65 psi.
K. OUTSIDE TEMPERATURE AND CLOCK
The display is activated when the contact is on.
The clock is shown in the top section of the display.
The outside temperature is displayed in the bottom section in degrees C or
degrees F.
44
Cab, Instruments and Controls
WARNING INDICATORS
4
5
1
1
2
3
B
STOP
A
3
2
ABS
1
6
H
5
1
2
3
E
J
1
4
D0 00 786-1
45
Cab, Instruments and Controls
46
A1
Tachograph
A2
Front fog lights
A3
Parking brake
A4
Water in fuel
A5
Work lamp/loadspace lighting
A6
ABS symbol
B1
Fuel level low
E1
Engine warning
E2
Pre-Heating
E3
PTO engaged
E4
DEF level
H1
Left direction indicator, truck or tractor
H2
Main beam
H3
Central "STOP" warning indicator
H4
Right direction indicator, truck or tractor
J
Brake air
Cab, Instruments and Controls
A1. Tachograph fault
See messages in Tachograph operation manual.
A2. Front fog lights
This warning indicator lights up if the front fog lights are switched on.
A3. (unused)
A4. Parking brake
This warning indicator lights up if the parking brake is applied, or when the pressure
in the air system is too low to enable the parking brake to be released.
A5. Water In Fuel
A6. Work lamp/loadspace lighting
The warning indicator lights up when the work lamp/loadspace lighting is switched
on.
47
Cab, Instruments and Controls
A7. ABS
ABS
The yellow warning symbol "ABS truck fault" is activated if a fault in the ABS system
of the truck or tractor.
B1. Fuel level low
This warning indicator lights up when the reserve fuel level is reached. The fuel
reserve then is about 10% of the tank capacity. Refuel as soon as possible.
E1. (unused)
E2. Engine warning
This warning will be activated when the system requires attention, general danger
spot or failure of emission system.
E3. Pre-Heating
If the ignition key is on, the engine ECU automatically determines the necessary
preglowing and afterglowing times.
The necessary preglowing and afterglowing times depend on the temperature that
is measured by the engine management system.
If the preglowing or afterglowing function is activated by the engine ECU, this
warning indicator lights up.
48
Cab, Instruments and Controls
E4. (unused)
E5. PTO engaged
This warning indicator lights up when the PTO is switched on.
E6. DEF level
This warning will be activated if DEF level is lower than 10%.
H1. Left direction indicator, truck or tractor
This warning indicator flashes together with the direction indicators on the truck or
tractor.
H2. (unused)
H3. Main beam
This warning indicator lights up if the main beam is switched on or the headlight
flash is operated.
49
Cab, Instruments and Controls
H4. Central "STOP" warning indicator
STOP
The central "STOP" warning lights up when there is a serious fault in one of the
vehicle functions. The master display shows which vehicle function has triggered
the warning.
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 involving personal injury or death.
H5. (unused)
H6. (unused)
H7. Right direction indicator, truck or tractor
This warning indicator flashes together with the direction indicators on the truck or
tractor.
J. Brake air
This warning is printed on the gauge. It will not be activated, since it lights up with
the gauge light.
50
Cab, Instruments and Controls
CONTROL PANEL
2
!!
23
3
4
5
6
!!
21
20 19 18 17
D0 00 705-1
51
Cab, Instruments and Controls
2
3
4
5
6
17
18
19
20
21
23
52
Dimmer, dashboard lighting
(unused)
(unused)
Front fog lights
Master display menu selection switch
Air conditioning
12-V connection
Heater, fan speed selector switch in fresh air position or re-circulation
position
Heater, temperature control
Heater, air distribution selector switch
Lighting switch
Cab, Instruments and Controls
2. DIMMER, DASHBOARD LIGHTING
When the lighting is switched on, the dashboard lighting will also illuminate. The
setting wheel enables dimming of the lighting.
3. SWITCH FOR CROSS-AXLE DIFFERENTIAL LOCK
The cross-axle differential lock can be activated with this switch.
NOTE
This switch has a lock.
The differential lock should be engaged:
-
with the vehicle stationary or moving very slowly;
-
with the clutch pedal depressed.
NOTE
For vehicles with automatic gearbox, the vehicle must be stationary and
the gearbox in Neutral (N).
See also "DRIVING"
53
Cab, Instruments and Controls
5. FOG LAMPS, FRONT
There is a two position switch to operate the rear fog lamps.
6. MASTER DISPLAY MENU SELECTION SWITCH
See "MASTER DISPLAY".
17. AIR CONDITIONING
See "CONTROL PANEL OF HEATING/VENTILATION SYSTEM"
18. 12V CONNECTION
There are two auxiliary connections for a 12-V accessory. Accessories connecting
to these auxiliary connections should not exceed a combined load of 180 Watts.
19, 20, 21. HEATER CONTROLS
See "CONTROL PANEL OF HEATING/VENTILATION SYSTEM
54
Cab, Instruments and Controls
23. LIGHTING SWITCH
The vehicle lighting switch is a rotary switch with three positions:
position "0": lighting switched off
position "1": parking and marker lights on
position "2": headlamps, parking and marker lights on
55
Cab, Instruments and Controls
CONTROL PANEL OF HEATING/VENTILATION SYSTEM
21
20
19
17
D0 00 672
17
19
20
21
Air conditioning
Fan speed selector switch in fresh air or re-circulation position
Temperature adjustment
Air distribution
17. AIR CONDITIONING
See "AIR CONDITIONING SWITCH"
19. FAN SPEED
See "FAN SPEED SELECTOR SWITCH"
20. TEMPERATURE CONTROL
See "TEMPERATURE CONTROL"
21. AIR DISTRIBUTION
SEE "AIR DISTRIBUTION SELECTOR SWITCH"
56
Cab, Instruments and Controls
AIR CONDITIONING SWITCH
The cab air can be heated, cooled or dehumidified using the air conditioning unit.
The air conditioning unit only functions if:
D0 00 566
-
the engine is running
-
the fan is running.
Use of the air conditioning
1. When the air conditioning is in use, the windows must remain closed.
2. To reduce the temperature quickly, first use maximum air speed. Later, the air
speed can be reduced.
3. Avoid direct cold draught on your body.
4. Make sure that the temperature difference between the inside and outside of the
cab does not exceed 40°F (5°C) when you leave the cab. You are therefore
advised to switch off the air conditioning towards the end of your journey.
5. Air conditioning consumes extra power and increases the fuel consumption.
6. On extreme angles (slopes, ruts and difficult terrain) switch off the air
conditioning, to protect the compressor pump against unlubricated operation.
7. Regularly (once a month) switch on the air conditioning briefly, even if cooling is
not required (e.g. in winter). This will help prevent serious damage to the system
(including compressor blockage).
57
Cab, Instruments and Controls
Cooling
1. Switch the air conditioning on.
2. Switch the recirculation to position 1, 2 or 3.
3. Turn the temperature control switch to the desired position. For maximum
cooling set the knob to the far left position in the blue area.
4. Open the side and center vents.
While heating, it is possible to use the air conditioning to remove moisture from the
air in the cab. This has the advantage that demisting of the window glass will be
quicker.
Dehumidification
1. Switch the air conditioning on.
2. Turn the Fan Speed Switch to the Fresh Air setting.
3. Open the vents on the center console and side windows and set them as
desired.
4. Control the temperature as desired.
5. Adjust the volume of air using the fan speed selector switch.
NOTE
The air conditioning system is switched off when the engine coolant
temperature becomes too high. This will protect the engine.
58
Cab, Instruments and Controls
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.
Failure to comply may result in personal injury, death, equipment or
property damage.
WARNING
Air conditioning refrigerant can be hazardous to your health. Do not
expose yourself to leaking refrigerant for prolonged periods near
excessive heat, open flames, or without proper ventilation. Failure
to do so may result in death or personal injury.
NOTE
If the air conditioning system fails to work properly, it must be repaired by
qualified personnel as soon as possible, to avoid further damage to the
system.
59
Cab, Instruments and Controls
FAN SPEED SELECTOR SWITCH
FRESH AIR POSITION OR RE-CIRCULATION POSITION
The fan has two speeds: one applies to re-circulation the other to fresh air. The recirculation position is suited to quickly de-mist or cool the cab with the air
conditioning, quickly heat the cab, de-frost the windows with the heater and keep
out undesirable odors.
D0 00 644
NOTE
You are advised to switch on the re-circulation without air conditioning for
short periods only to prevent the air quality inside the cab from degrading
and moisture from increasing.
Fan speeds with fresh outside air ventilation valve open
Fan speeds with re-circulation valve closed, hardly any supply of
fresh outside air
TEMPERATURE ADJUSTMENT
The supply of heat can be smoothly set from 0% (blue) to 100% (red).
D0 00 614
60
To achieve faster heating when the temperature outside is low, switch on the recirculation. In damp weather conditions it is recommended to reopen the recirculation flap after heating to prevent the windows from misting.
Cab, Instruments and Controls
AIR DISTRIBUTION SELECTOR SWITCH
Dashboard
D0 00 640
D0 00 639
D0 00 638
D0 00 643
D0 00 637
Dashboard vents and footwell
Footwell vent
Footwell and windshield vents
Defrost
61
Cab, Instruments and Controls
CENTER CONSOLE
7
8
9 10
11 12 13
14 15 16
D000706-3
62
Cab, Instruments and Controls
7
Ashtray with 12V auxiliary connection
8
Hazard warning lights
9
(unused)
10
(unused)
11
(unused)
12
(unused)
13
(unused)
14
(unused)
15
PTO operation
16
(unused)
63
Cab, Instruments and Controls
7. ASHTRAY
In the center console there is an ashtray with auxiliary connection for the driver and
co-driver.
Do not connect any accessories above 180 Watt or any combination of accessories
that would require a combined amount greater than 180 Watts.
To remove the ashtray, there are two springs on the top of the tray which should be
pressed in, after which the tray can be removed.
8. HAZARD WARNING LIGHTS
When this switch is pressed, all the direction indicator lights flash simultaneously.
The hazard warning lights are switched off by depressing the switch again. The
warning light in the switch indicates that the hazard warning is switched on.
9. (unused)
11. (unused)
13. (unused)
15. PTO OPERATION
With this switch, the Power Take Off can be engaged, if necessary in combination
with the variable speed engine control. Engage the PTO only when the programmed
engaging conditions are met.
64
Cab, Instruments and Controls
LEFT-HAND STEERING COLUMN SWITCH
C
A
B
C
D
A
B
D
D0 00 600
Horn
Main beam
Direction indicator, right
Direction indicator, left
A. HORN
The horn is operated with button A.
B. MAIN BEAM
Position B: The main beam is activated when the lights are on. The main beam
indicator on the instrument panel will also light up. To switch off the main beam, the
switch must be turned back through the "click" position towards the steering wheel.
If the lights are off, or if the switch has not been pushed through the "click" position,
it can be used to give signals.
C. DIRECTION INDICATOR, RIGHT
Position C: Right turn signal: on the instrument panel, the right direction indicator
will flash and there will also be an audible signal. To briefly operate the direction
indicators (changing lanes, etc.), the switch can be pushed slightly against the
spring pressure. It will spring back when released.
D. DIRECTION INDICATOR, LEFT
Position D: Left turn signal: on the instrument panel, the left direction indicator will
flash and there will also be an audible signal. To briefly operate the direction
indicators (changing lanes, etc.), the switch can be pushed slightly against the
spring pressure. It will spring back when released.
65
Cab, Instruments and Controls
RIGHT-HAND STEERING COLUMN SWITCH
The right-hand steering column switch has the following functions:
1
2
3
4
D001199
66
1
2
3
4
Position 1: Intermittent wipe.
Position 2: Wipe speed (low).
Position 3: Wipe speed (high).
Position A: Wipe/wash.
Cab, Instruments and Controls
STEERING WHEEL SWITCHES
C D
Depending on the vehicle version, the steering wheel either has or does not have
steering wheel switches.
A B
E F
Left-hand switches
D0 01 190-3
A (unused)
B (unused)
C Engine brake
Right-hand switches
D Variable speed limiter
E Cruise control, resume, off
F Cruise control setting/engine speed control
67
Cab, Instruments and Controls
ADJUSTABLE STEERING COLUMN
The position of the steering column is adjustable. To adjust, pull the handle towards
you and simultaneously move the steering column to the desired position. The
steering column is locked by releasing the handle. A pneumatically adjustable
steering column is available as an option.
D0 00 616
68
WARNING
Make all adjustments to the steering mechanism while the vehicle is
stopped. 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 resulting in
personal injury or death.
Seats
69
Seats
IMPORTANT POINTS
WARNING
Make all adjustments to the steering mechanism while the vehicle is
stopped. 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 resulting in death
or personal injury.
-
70
-You must read this section thoroughly and acquaint yourself with the seat
controls.
The vehicle air pressure must be a minimum of 100 PSI 7 bar.
Never operate several controls at once.
The armrest should be folded away before entering/leaving the vehicle.
The co-driver's seat is not suitable for a child's seat.
The seat and its component parts must be checked for wear from time to time.
The seat may only be repaired by trained personnel.
Seats
Driver's seat
Operation:
6
1
1
2
2 3 4 5
D0 00 694-1
3
4
5
Seat fore/aft adjustment
Shock absorber setting: The suspension characteristics of the seat (in
terms of comfort) can be optimized by means of the infinitely adjustable
shock absorber (from "hard" to "soft") for each driving situation.
-
Position switch up: minimum damping ("soft" comfort)
-
Position switch down: maximum damping ("hard" comfort)
NOTE
The shock absorber must always be set tight enough to
withstand conditions on a poor road surface.
Seat squab angle adjustment
Seat height adjustment
Entry/exit aid
-
6
Knob down (seat in driving position): seat drops to its lowest position
(= entry/exit aid)
- Knob up (with lowered seat): seat returns to the last set height
Backrest angle adjustment.
71
Seats
SEAT BELTS
Safety Restraint System - Inspection
The seat belt system, including webbing, buckles, latches, and mounting hardware,
endures heavy use in heavy-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.
WARNING
Failure to properly inspect and maintain restraint systems can lead
to 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.
D000534
Factors contributing to reduced seat belt life:
-
-
-
72
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
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.
Seats
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.
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. Failure
to comply may result in personal injury or death.
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. Failure to comply
may result in personal injury or death.
73
Seats
1. Check the web wear in the system. The webbing must be closely examined to
determine if it is coming into contact with any sharp or rough surfaces on the
seat or other parts of the cab interior. These areas are 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 Comfort Clip for cracks or possible damage and check for proper
operation.
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.
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.
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.
74
Seats
Seat Belt Inspection Points
1. Web cut or frayed or extremely worn at latch area.
2. Web cut or frayed at D-loop web guide.
3. Comfort Clip cracked or damaged.
4. Buckle casting broken.
5. Retractor Web Storage for damage. (located behind trim panel)
6. Tethers for web wear and proper tightness of mounting hardware.
7. Mounting hardware for corrosion, proper tightness of bolts and nuts.
8. Web for deterioration, due to exposure to the sun.
WARNING
Failure to adjust tether belts properly can cause excessive
movement of the seat in an accident. Tether belts should be
adjusted so that they are taut when the seat is in its most upward
and forward position. Failure to comply may result in personal
injury or death. 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 are
torqued to specification. This will maintain the design integrity of
the mounting points for the seat belt assembly. Contact your dealer
if you have any questions concerning seat belt replacement.
75
Seats
Wearing seat belts
-
The belt must be tight against the body and not distorted.
-
With a three-point type belt, the shoulder section must be across center of the
shoulder, not against the neck. The pelvis section should be as low as possible
across the pelvis, not across the abdomen.
-
Do not put any hard, sharp or fragile objects such as pens, glasses or phones
between your body and the seat belt.
Checking the seat belts
-
Give a short pull on the seat-belt to test the locking mechanism.
-
Repeat this check regularly, for example when putting on the seat belt, in order
to check the mechanism.
During this test, the belt must lock. This means that it must not be possible to
pull the seat belt out of the retracting unit after locking.
The locking mechanism should be immediately replaced and/or repaired if it is
defective.
-
76
Inspect the belts regularly for wear. Have the complete assembly replaced at
once if the belt is worn or damaged.
Master Display
77
Master Display
GENERAL
In the master display a menu can be displayed to show the driver all the information
regarding the function and operation of the various systems in as useful a way as
possible.
The master display is a part of the Central Warning System. In addition, the system
contains a menu selection switch, a buzzer and a central "STOP" warning lamp
under the master display.
The master display consists of three different fields; an indication bar, an
information screen (yellow or red) and an information screen (yellow).
78
Master Display
LAYOUT OF MASTER DISPLAY
D001192-3
A
B
C
1
2
3
4
5
6
7
Indication bar
Information screen (yellow and red)
Information screen (yellow)
Number of active red warnings
Number of active yellow warnings
Alarm function engaged
Gear engaged, AS Tronic Lite or automatic gearbox (AGC-A)
Speed set
Vehicle speed setting functions (review)
(unused)
79
Master Display
START-UP PHASE
If the ignition has been switched on and the engine is not yet running, the start-up
screen is shown in the master display.
The following warning symbols, if present, are then displayed:
-
Oil pressure (red)
-
Alternator voltage (red)
-
Steering circuit 1 output (red)
-
ABS of prime mover (yellow)
NOTE
When starting a vehicle equipped with an Allison automatic gearbox, the
transmission fault warning symbol appears in the main display; this
symbol disappears once the engine is started.
During the start-up phase, the "STOP" warning lamp and the acoustic signal are
inactive.
Approximately 3 seconds after switching on the ignition, the yellow warning symbols
will disappear. During these 3 seconds, no other warnings can be displayed.
The red warning symbols should disappear from the screen approximately
2.5 seconds after the engine has been started.
If the oil pressure, charging voltage or steering circuit 1 output is still too low after
these 2.5 seconds, the warning screen will become active, in which the relevant red
warning symbol appears with the accompanying text. The "STOP" warning lamp
and audible alarm will also be activated.
80
Master Display
If there is a less serious fault, the respective yellow symbol with the accompanying
text will appear on the screen and an acoustic signal will be heard for a certain time.
If the indication bar mentions several red and/or yellow warnings, the other
warnings can be called up by turning the menu selector switch one step further each
time. This takes place in order of priority. This means that the most important
warning will be displayed first.
A red warning cannot be removed from the screen when the engine is running.
The red warning symbol can be turned off when the engine is not running. This is so
that it is possible to use other menu options (if you return to the main screen, the
warnings will re-appear).
Yellow warnings can be switched off at any time.
The message detailing the number of warnings present remains active at all times.
A continuous audible alarm tone accompanies a red warning.
A pulsating audible alarm tone accompanies a yellow warning and sounds four
times.
81
Master Display
MENU SELECTOR SWITCH
By pressing the menu selector switch, the main menu will be selected and the
selector bar will become visible.
Turning the menu selector switch will switch between screens in the main menu.
The triangle on the right-hand side of the display shows the direction in which you
can proceed.
D000711
By pressing the menu selector switch, the function/information chosen will be
selected, after which sub-menu 1 will appear, if present. If there is no sub-menu 1,
the menu function will be turned off.
By turning the menu selector switch you will browse through sub-menu 1.
The triangle on the right-hand side of the display shows the direction in which you
can proceed.
By pressing in the menu selector switch, the function/information chosen will be
selected, after which sub-menu 2 will appear, if present. If there is no sub-menu 2,
the menu function will be switched off.
D000555
82
Master Display
By turning the menu selector switch, sub-menu 2 can be accessed.
The triangle on the right-hand side of the display shows the direction in which you
can proceed.
By pressing the menu selector switch, the menu function will be switched off.
D000556
83
Master Display
MENU OVERVIEW
Main menu
Sub-menu 1
Sub-menu 2
Vehicle information
Fuel consumption
-
Current
-
Average
-
Average trip
-
Date
-
Distance
-
PTO 1 counter
-
PTO consumption
Turbocharger pressure
Oil level
Service inspection
PTO counter
Chassis number
Back
Faults
All faults
Back
84
Master Display
Main menu
Sub-menu 1
Sub-menu 2
Trip info
Trip info
-
Distance
-
Time
-
Average speed
-
Average consumption
-
Fuel consumption
-
Setting alarm: hours
-
Setting alarm: minutes
-
Alarm time
Trip reset
Close
Settings
Language 1 or 2
Alarm on/off
Setting alarm
Time, local/home
Set local time
Clock AM/PM/24H
Display miles/km
Close
Close
85
Master Display
FAULTS
Serious fault
A red warning symbol is activated when there is a serious fault.
When a red warning symbol is activated, the "STOP" warning lamp and an audible
alarm are activated at the same time.
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 or DPF damage, or cause
an accident which may result in personal injury or death.
Less serious fault
A yellow warning symbol is activated if there is a less serious fault.
When yellow warnings appear you may continue driving but action must be taken at
the first opportunity to remedy the fault. Have an authorized Service dealer correct
the problem as soon as possible.
WARNING
As the vehicle may behave differently from normal, the vehicle must
be driven with extra caution.
86
Master Display
WARNING SYMBOLS
Red warnings
Oil pressure low
If the oil pressure suddenly drops, or the audible alarm and engine oil pressure
warning light come on while driving, do the following:
1. Slow down carefully.
2. Move a safe distance off the road and stop.
3. Place the transmission in park and set the parking brake. (See Stopping on
page 112 and Automatic Gearbox on page 128-134, for transmission shifting
and parking brake information.)
4. Turn OFF the engine.
5. Turn ON the emergency flasher and use other warning devices to alert other
motorists.
6. Wait a few minutes to allow oil to drain into the engine oil pan, and then check
the oil level. (See "ENGINE OIL LEVEL" in "INSPECTIONS AND
MAINTENANCE" on page 93, for details on checking oil level.)
7. Add oil if necessary. If the problem persists, contact an authorized dealer as
soon as possible.
CAUTION
Continuing to operate your vehicle with insufficient oil pressure
may cause severe engine damage or cause an accident which may
result in equipment or property damage. It is important to maintain
oil pressure within acceptable limits. If oil pressure drops below the
minimum psi a Red Warning Lamp on the oil pressure gauge and
the Stop Engine Lamp will come ON.
87
Master Display
Cab lock open
See "Cab tilting" in "EMERGENCY REPAIRS".
Air pressure low
This warning symbol is active when the pressure in one of the service brake circuits
is lower than 65 psi or 4.48 bar.
Coolant Level Low
This warning symbol will come on when the coolant level is below the minimum
permissible level. Check the coolant level (caution – danger of scalding; see
"Topping up coolant" in "INSPECTIONS AND MAINTENANCE")
Coolant temperature high
This warning symbol will come on when the coolant temperature exceeds the
maxi-mum permissible value. Check the following points:
the coolant level (caution – danger of scalding; see "Topping up coolant" in
"INSPECTIONS AND MAINTENANCE");
the poly V-belt and water hoses; the fan clutch.
Engine fault
Serious fault in the electronic unit.
Transmission fault
If the vehicle is equipped with an automatic gearbox, see "Faults" in "AUTOMATIC
GEARBOX".
88
Master Display
Yellow warnings
Truck ABS fault
ABS
This symbol is activated when:
there is a fault in the ABS of the prime mover;
Engine fault
Depending on the fault, the engine can switch over to emergency control.
PTO fault
Engine speed control does not meet the conditions. See "Engine speed control" in
"DRIVING".
Oil pressure low
Check the engine oil level See also "Daily inspections" in "INSPECTIONS AND
MAINTENANCE".
Water separator fuel filter
Check the fuel prefilter/water separator. See "Weekly inspections" in
"INSPECTIONS AND MAINTENANCE".
89
Master Display
No warning
Coolant level sensor
This symbol will light up if the coolant level sensor is not latched into it
proper position. The sensor is part of the filler cap.
Key to abbreviations
90
ABS
Anti-lock Braking System
PTO
Power Take Off
VIC
Vehicle Intelligence Center
Inspections and Maintenance
91
Inspections and Maintenance
OVERVIEW OF DAILY CHECKS
Overview of the driver's daily checks:
-
engine oil level
-
coolant level, fill cap secure
-
fluid level in windshield washer reservoir
-
air filter indicator
-
tires and rims
-
lighting and instruments
-
driver's seat and mirrors
-
trailer
Visual check before starting the trip:
-
check that no situation can occur (such as loose objects, improperly attached
load etc.) that may put other road users at risk.
NOTE
Cleaning rags, flammable materials, accumulated dirt etc. in the vicinity
of the exhaust system must be removed as these create a fire hazard.
OPENING THE FRONT PANEL
Open the front panel by gripping it at the bottom and lifting it up. The front panel will
tilt upwards and is held in place by two gas struts.
92
Inspections and Maintenance
ENGINE OIL LEVEL
1. Ensure that the vehicle is standing on a flat and level surface.
2. Open the front panel.
3. Pull the dipstick (2) out of the holder.
4. Wipe the dipstick clean with a lint-free cloth.
5. Re-place the dipstick in its holder. Withdraw the dipstick again and check the oil
level.
2
1
D0 00 721
NOTE
It takes approx. 20 minutes for all the oil to run into the sump when the
engine is "warm". If the dipstick is checked immediately after switching
the engine off or immediately after oil has been added, the level shown
on the dipstick will be too low.
6. Fill oil through the filler opening (1) until the oil level reaches the maximum mark.
Only use engine oil that meets specifications. See "TECHNICAL DATA".
NOTE
For the difference between the minimum and maximum engine oil level,
see "TECHNICAL DATA".
93
Inspections and Maintenance
TOPPING UP COOLANT
WARNING
When the coolant is hot, there is an overpressure in the cooling
system. If circumstances dictate that it is necessary to top up the
coolant when the engine is warm, unscrew the filler cap carefully
one turn to relieve the overpressure. Take adequate precautions
against burning by, for example, placing a cloth over the cap.
Coolant is a toxic fluid. Contact with the skin should therefore be
avoided. Also see "Lubricant, engine coolant and fuel
specifications" in "TECHNICAL DATA"
WARNING
To prevent damage to the engine block, topping up with cold
coolant when the engine is hot must be done slowly and with the
engine running.
WARNING
Do not loosen the filler cap of the cooling system when the cab is
tilted. The filler cap houses the coolant level sensor. Take
necessary precautions to protect the sensor from damage when
removing it.
94
Inspections and Maintenance
1. Turn the rotary knob for the heating temperature control to "maximum hot".
2. Open the front panel.
3. Remove the black filler cap from the cooling system reservoir.
4. Run the engine for several minutes.
5. Stop the engine and check the coolant level.
6. If necessary, top up to the bottom of the filler opening.
Always use coolants which meet specifications. See "TECHNICAL DATA".
D0 02 003
NOTE
Take care not to damage the coolant level sensor when removing and
replacing the reservoir filler cap.
95
Inspections and Maintenance
SPECIAL COOLANT FILL INSTRUCTIONS
CAUTION
RADIATOR FILL PROCEDURE REQUIRED FOR THIS VEHICLE
1. Remove the surge tank pressure cap (do not remove the surge tank coolant
level sensor cap).
2. Fill system with premixed coolant to “MAX” level on surge tank and allow coolant
level to settle.
3. Repeat step 2 until coolant level stays at “MAX” level.
4. Start the engine and idle at low RPM for 2 minutes.
1
5. Top off surge tank to “MAX” level while engine is at low idle.
6. Run engine at high idle until operating temperature is reached (~ 200° F).
2
7. Return engine to low idle and top off surge tank to “MAX” level if needed.
8. Run engine at high idle for 10 minutes.
D0 02 017
9. Return engine to low idle and top off surge tank to “MAX” level.
10. Allow engine to cool and top off surge tank to “MAX” level if necessary.
11. Replace the surge tank pressure cap.
CAUTION
Failure to follow this procedure and maintain proper coolant level
can cause engine damage.
It is OK for a hot system to have coolant above the “MAX” level, but a cold system
should not have coolant above the “MAX” level.
96
Inspections and Maintenance
WINDSHIELD WASHER RESERVOIR FLUID LEVEL
1. Open the front panel.
2. Check the fluid level in the screen washer reservoir.
3. Top up, if necessary, via the filler opening.
NOTE
When topping up, it is recommended to add a windshield cleaner to the
water in the windshield washer reservoir.
D0 00 608
During the winter period, add windshield wash antifreeze.
AIR FILTER INDICATOR
The air filter indicator is behind the grille at the front of the cab. If the indicator is in
the red area (showing the text "service"), the air filter is seriously fouled and must be
replaced. Consult an authorized Service dealer. Clogged air filters lead to
increased fuel consumption and loss of power.
RESET
CHANGE
FILTER WHEN RED
AIR FILTE
R INDICATOR
D0 02 004
97
Inspections and Maintenance
WHEELS AND TIRES
-
Remove any stones, etc. from the tread and from between the tires (if twin
wheels are fitted).
-
Check for evidence of wear and damage and for nails or other foreign objects
caught in the tires.
-
Check the attachment of the wheels.
-
Check the tire pressures (do not forget the spare wheel). The tire pressures
should be checked and corrected while the tires are cold. See chapter on
"Technical data" or the back page of this book for the correct tire pressures.
NOTE
If a worn tire is underinflated by 30 psi, the ABS control will be
inoperative under extreme conditions! Also see "Changing the wheel" in
the "EMERGENCY REPAIRS" section of this manual.
LIGHTING AND INSTRUMENTS
98
-
Check the vehicle lighting, brake lights and instruments for correct operation.
-
Also check the operation of the horn, windshield wipers and washers.
Inspections and Maintenance
DRIVER'S SEAT AND MIRRORS
A
Set the seat and mirrors to the correct positions.
Mirrors with field of vision projected on the ground
E
B
A
B
C
D
E
C
D
Side window
Dead angle mirror
Wide view mirror
Main mirror
Pavement mirror
D0 01 062
OVERVIEW OF WEEKLY CHECKS
Overview of the driver's weekly checks:
-
clutch fluid level
-
Power steering fluid level
-
Brake system air drier
-
Draining the fuel system water separator
-
Batteries
99
Inspections and Maintenance
POWER STEERING FLUID LEVEL
1. Tilt the cab.
2. Clean the dipstick and its immediate surroundings to prevent any dirt from
entering the reservoir.
3. Check the fluid level in the reservoir using the dipstick.
4. The fluid level must be between the two marks.
5. Top up oil, if necessary, via the filler opening. Oil type: see "TECHNICAL
DATA".
D0 00 581-1
6. If the level is below the minimum mark, this is a sign of leakage. Contact an
authorized Service dealer as soon as possible.
BRAKE SYSTEM AIR DRIER
The air drier can be checked for correct operation by inspecting the air reservoirs for
condensed water.
1. Check the air reservoirs for condensed water by pulling on the rings of the drain
valves.
2. If repeatedly more than the normal amount of water is drained off, the air drier
element will have to be replaced. Consult your Service dealer.
D0 00 592-1
100
Inspections and Maintenance
DRAINING THE WATER SEPARATOR
B
A
WARNING
When draining the water separator, an amount of fuel will escape.
Collect the fuel and avoid the risk of fire.
Water in the fuel system may lead to significant damage.
1. Place a container beneath the water separator.
2. Remove the connector.
D0 00 620
3. Unscrew the ring-shaped drain cock (B) on the bottom of the water separator in
anti-clockwise direction.
4. Drain the filter until pure diesel fuel comes out of the drain cock (A).
5. Turn the drain cock (B) if it abuts, another 1/8 - 1/4 turn.
6. Check the drain cock (B) for leakage.
7. To prevent pollution, the drained water/diesel fuel mixture should be passed to
the relevant authorities for reprocessing.
101
Inspections and Maintenance
BATTERIES
WARNING
Avoid sparks and open flames in the vicinity of batteries.
Battery acid is an aggressive fluid.
In the event of contact with the skin: rinse the skin profusely with
plenty of water.
Consult a doctor in the event of persistent redness or pain.
Remove polluted clothing and rinse in water.
In the event of contact with the eyes: rinse with plenty of water for
at least 15 minutes and consult a doctor.
If swallowed: do NOT induce vomiting. Rinse the mouth, drink two
glasses of water and consult a doctor.
In the event of inhalation: get fresh air, rest and consult a doctor.
D0 00 627-1
102
-
Check the electrolyte level; this should be approx. 10 mm above the plates or up
to the level indicator, if present. If necessary, top up the batteries with distilled
water.
-
Check that the battery poles and terminals are clean and greased. If necessary,
coat the posts with an acid-free petroleum jelly.
Inspections and Maintenance
GENERAL MAINTENANCE
The durability, safety, trade-in value and reliability of your vehicle largely depend on
the care you give it. This includes regular service in accordance with the
maintenance schedules specified.
The driving style of the person at the wheel and the care given to the vehicle will
have a direct influence on the condition of the vehicle. The driver can often provide
the dealer with information which is very important for correct maintenance.
Prior to the service intervals and the related activities, contact your authorized
Service dealer.
CAB MAINTENANCE
In order to keep this quality as high as possible, during vehicle use, regular
maintenance should be carried out on the cab surfaces.
To prevent the formation of rust in box sections and other cavities, the cab is
protected with corrosion-inhibiting products (ML) in production.
Due to the setting of the structure, minor bare spots may develop in this
additional protective coating. For this reason, the manufacturer considers it
necessary to have further treatment carried out within a specific period
(consult the warranty manual) after the vehicle has been taken into service.
If this does not happen, the warranty will become invalid.
The relevant warranty conditions are listed in the warranty manual.
103
Inspections and Maintenance
CLEANING
Cleaning the vehicle
Before the vehicle is cleaned, check for leaks in the engine, axles, gearbox, etc.
This is no longer possible after cleaning the vehicle and carrying out maintenance
work.
When a high-pressure cleaner is used, take special note of the following points:
104
-
Make sure that the doors, windows and roof hatch are properly closed.
-
Never spray directly on seals. There is a danger of them being forced open so
that water can penetrate or grease packed behind them is flushed away. This
may happen, for example, with the universal joint on the steering box. As a
result, the spider may seize so that the steering will jam.
-
Do not spray directly onto steering ball joints.
-
The power steering fluid reservoir is fitted with a vent. Water may enter the
reservoir via this vent, which will cause damage to the steering gear.
-
When cleaning the radiator/intercooler, take care not to damage the fins.
-
Do not direct the high-pressure cleaner/steam cleaner jet too long at the
air-conditioning system condenser. As a result of the high temperature, the
pressure in the system will rise too high, which may cause damage to the
system. Parts of the air-conditioning must not be cleaned with the aid of a
high-pressure/steam cleaner as this can cause damage to the seals.
-
Make sure that no water can enter the differential and gearbox via the vents.
-
Make sure that no water can enter via the reservoir bleed screws of the clutch,
brakes, trailing axle, etc.
Inspections and Maintenance
-
The engine and engine compartments can be cleaned with a high-pressure/
steam cleaner. Avoid spraying directly onto electrical components such as the
fuel system pump units, electronic units the starter motor, alternator,
air-conditioning compressor, headlights, etc.
-
Carefully clean the engine encapsulation and its fittings. Remove any spilled oil
and diesel oil to avoid the risk of fire.
-
Do not aim the jet of water directly at electrical connections such as connectors,
cable plugs in the vehicle lighting system, etc. Also do not aim the jet at the gear
lever unit.
-
When cleaning the vehicle, make sure that no water can enter the air inlet
system via the air intake or its flexible seals.
-
When the vehicle has been cleaned, it must be lubricated again with a grease
gun or via the automatic lubrication system. This is important because it
prevents the penetration of moisture and dirt at the various pivot points.
Cleaning the cab
Depending on the vehicle's operating conditions, the external paintwork of the cab is
subject to attack by corrosive substances, for example road salt, grit and polluted
air. For instance, road salt and air pollution.
The paintwork must therefore be cleaned regularly.
When cleaning the cab, make sure that:
-
no caustic cleaners are used
-
no hard brushes are used
-
all seams, gaps and door shut-lines are thoroughly cleaned.
105
Inspections and Maintenance
Waxing the cab
The paintwork of new vehicles is waxed to protect it against the elements.
After a time this wax coating will gradually wear away as a result of cleaning and
other external influences.
To give corrosive substances less chance of attacking the paint, it is advisable to
protect the paintwork with a new wax coating at least twice a year.
It is advisable to use wax for this.
Your authorized Service dealer can advise you about additional anti-rust treatment
and maintenance of the paintwork when the vehicle is in service.
Cleaning the interior
The day cab can be fitted with fabric or plastic trimming.
The sleeper cab is only available with fabric trimming.
The plastic can be cleaned with a household cleaning agent and warm water.
The fabric trimming should be cleaned with a non-aggressive dry-cleaning agent, or
an equivalent product.
NOTE
The appearance of your vehicle is your company's face to the world!
106
Inspections and Maintenance
PREVENTATIVE MAINTENANCE BEFORE THE WINTER SEASON
Your authorized Service dealer can always give you good advice to prepare
your vehicle for winter.
DIESEL FUEL
If outside temperatures are persistently low, only fill up with winter diesel oil
produced by a reputable oil company.
During the winter months the oil companies often use additives, to prevent
blockages caused by the precipitation of paraffin crystals (wax deposits).
It is not permitted to use your own fuel additives.
NOTE
Additives which are used to prevent precipitation of paraffin crystals have
a purely preventative effect. They can not dissolve the paraffin crystals
once they have been precipitated.
Always carry a spare fuel fine filter in the vehicle so that you can replace
it quickly if it becomes blocked in any way (for example, by paraffin
crystals).
Always preferably fill up in the evenings to prevent condensation
(especially in winter).
107
Inspections and Maintenance
CAB HEATER
If necessary, install a separate fuel tank for the cab heater.
If the tank has been filled up with winter diesel oil because of a cold weather period
or a trip to a colder country, allow the cab heater to run on the new fuel for half an
hour to ensure that all the old fuel has been used up.
The above recommendations apply for both air and water heating and for all vehicle
types.
WINDSHIELD WASHER RESERVOIR
-
When topping-up, it is advisable to add a cleaner to the water in the windshield
washer reservoir.
-
During the winter period, add windshield wash antifreeze.
MAINTENANCE AFTER THE WINTER SEASON
Your authorized Service dealer can always give you good advice to prepare
your vehicle for summer.
COOLING SYSTEM
The coolant may be left in the cooling system during the summer.
108
PDC & Voltage Converter
109
PDC & Voltage Converter
POWER DISTRIBUTION CENTER
Power Distribution Center (PDC)
The PDC provides a fused 24V/12v to the cab and controls 12V to chassis systems,
inside of the box and relays 12V to chassis and cab systems.
PDC box has the following Specifications:
D0 02 012
110
-
400 amps max output
64 I/O pins (color coded)
4 power input terminals
Customer configurable
PACCAR branded
Component labeling
PDC & Voltage Converter
Voltage converter.
The Voltage converter provides 24V to cab systems. It is located in the battery box.
Below to the PDC support. The Voltage converter has the following Specifications:
-
12V input - 24V output
Input current: 90 amps
Output current: 45 amps
Temperature range: -40C to+85C
D0 02 013
111
PDC & Voltage Converter
112
Driving
113
Driving
GENERAL
Before setting out on a journey, always check:
-
vehicle for possible water or oil leaks
-
engine oil level
-
fluid level in the screen washer reservoir
-
air filter indicator
-
coolant level
-
drawn vehicle coupling for correct attachment and correct operation
-
connection and operation of the drawn vehicle lighting and brakes
-
wheel attachment and tire pressures
-
tread depth of tires
-
tread of each tire for even distribution of wear pattern
-
correct setting of seat and mirrors
-
correct operation of lights and instruments
-
fuel level
After each journey check that:
114
-
doors of the vehicle are locked
-
load is still properly secured
Driving
STEERING LOCK/CONTACT/STARTER SWITCH
WARNING
NEVER turn the ignition key to the rest position (0) or remove it
while the vehicle is in motion. This may cause the steering wheel
lock to engage.
S
D
0
Position 0: rest position
When the key is removed in this position the steering wheel can be locked.
A
D000970
If the steering wheel is turned slightly the steering wheel will lock.
Position A: accessories position
Steering wheel unlocked. The key cannot be removed. Accessories, such as a
radio, can be switched on.
Position D: ignition turned on
All power consumers can be switched on.
Position S: starting
When the key is released, it automatically returns to position D.
If the engine is running, the start lock is switched on.
GLOW SYSTEM
If the ignition is on, the electronic unit determines the necessary pre and after glow
time.
The necessary pre- and after glow time depends on the temperature that is
measured by the electronic unit of the engine management system.
If the pre- or after glow time is activated by the electronic unit, a warning lamp on the
instrument panel lights up.
115
Driving
STARTING PROCEDURE
WARNING
If you start the engine inside a building, open the doors fully to
ensure adequate ventilation. Exhaust gases contain carbon
monoxide, an invisible, odorless, but highly toxic gas. Inhalation of
these gases may cause unconsciousness and death.
1. Check that the parking brake is engaged.
2. Depress the clutch pedal and put the gear lever in neutral.
3. Switch the ignition to position D.
4. Check that the warning indicator of the parking brake lights up.
5. Check that the oil pressure warning symbol in the master display is lit.
6. Check the operation of the fuel gauge and the coolant temperature gauge.
7. Check that the glow system warning lamp is off.
8. Without pressing the accelerator pedal down, turn the ignition to position S. If
the engine does not start; the key must be released after 10 seconds. Then wait
10 seconds and try again.
NOTE
The vehicle is equipped with start protection. The gear lever must be in
neutral otherwise the start protection device will not allow the starter
motor to activate.
If the engine is running, the engine speed may not be increased before
the oil pressure warning symbol has extinguished.
116
Driving
NOTE
Depending on the coolant temperature measured by the electronic unit, it
is possible that, in extremely cold conditions, the maximum engine speed
is limited for a specific period of time.
In case of an optional engine speed control, one of various engine speeds can be
selected with the right-hand steering column switch, if so desired.
Before driving away, check that the central "STOP" warning light is not illuminated.
ENGINE SPEED CONTROL
The minimum and maximum engine speeds that can be set are limited by a
programmed value in the electronic unit. This value may be below the idling speed.
In this case it will, however, not fall below idling speed.
3 2 1
The programmed engine speeds and conditions for activation or deactivation of the
engine speed control can be modified by a Authorized Dealership on request.
Activating the engine speed control
D001135-4
Press the 'SET+' or 'SET –' button (1) to immediately increase the engine speed
to the set speed value. This value may have been or can be changed within
specific limits by a Authorized Dealership to meet the customer's requirements.
Hold down the 'SET+'- or 'SET–' button on the steering wheel switch (1) to
gradually increase or decrease the engine speed.
117
Driving
NOTE
If the engine speed control is active, the engine brake is deactivated.
NOTE
Depending on how the electronic unit is programmed, the accelerator
pedal is active or not. When speed is increased via the accelerator pedal,
the speed reduces to the set speed value once the accelerator pedal is
released.
Deactivating the engine speed control
Press the RES/OFF switch (2) to the 'OFF' position.
Interruption of engine speed control
3 2 1
When the vehicle brake is operated.
When the parking brake is disengaged.
When the clutch is operated.
D001135-4
When the RES/OFF switch (2) is pressed to the 'OFF' position.
When the engine speed control is active via the superstructure.
WARNING
Check whether the stated conditions for deactivation of the engine
speed control apply to the vehicle.
118
Driving
CRUISE CONTROL
Cruise control is a facility that can be used to have the vehicle maintain a constant
vehicle speed. The desired driving speed is set, and the electronics maintain this
speed. The driver can overrule the cruise control at any time by pushing the
accelerator pedal.
The cruise control can be activated at a programmed minimum vehicle speed. This
speed is 35 km/h as standard.
The programmed standard speed and the conditions for activation and deactivation
of the cruise control can be modified by an authorized dealer apon request.
WARNING
Check whether the stated conditions for activation and deactivation
of the cruise control apply to the vehicle.
Engaging Conditions
Cruise control can be activated when:
- The vehicle speed exceeds 36 km/h.
- no braking functions are active.
3 2 1
- there is no current engine management fault.
- the clutch is not operated.
- adjustable vehicle speed limiting is not active.
D001135-4
- vehicle speed limiting for special applications below 35 km/h is not active.
119
Driving
Disengaging conditions
When the cruise control has been engaged, there are various conditions on which it
disengages. Cruise control is deactivated when:
- vehicle speed is outside the programmed limit values.
3 2 1
- parking brake is operated.
- clutch is operated.
- foot brake is operated.
D001135-4
- position 'OFF' on the steering wheel switch (2) is operated or the adjustable
vehicle speed limiting 'SET' is activated using the steering wheel switch (3).
- ABS/ASR system is activated.
Engaging cruise control
Activate cruise control by toggling the steering wheel switch (1) once briefly to the
'SET+' position or to the 'SET–' position when the required control speed is reached.
Cruise control can be activated when the vehicle speed is 36 km/h or more (or
another value programmed by the Authorized Dealership).
Modifying cruise control speed
When cruise control is activated, the speed can be increased by pressing 'SET+' or
be decreased by pressing 'SET–' on the steering wheel switch (1). Briefly operate
the switch to increase or decrease speed in small increments of 0.5 km/h.
Keep the switch down to gradually increase or decrease speed.
This limits the minimum and maximum adjustable speeds by values programmed in
the electronic unit. These values can be modified within specific limits by an
authorized Service dealer.
120
Driving
Accelerator pedal function during cruise control
When cruise control is active, the vehicle speed can be increased above the control
speed using the accelerator pedal. When the accelerator pedal is released, the
vehicle speed will return to the last valid control speed.
3 2 1
D001135-4
Disengaging cruise control
Press the 'OFF' switch (2) on the steering wheel to deactivate cruise control.
Re-engaging cruise control (Resume)
When it has been deactivated, cruise control can be resumed, provided the above
conditions are met, by pressing the 'RES' button (2) on the steering wheel. This reengages cruise control at the last set speed. If the current vehicle speed is lower
than this speed, cruise control accelerates to the programmed speed.
121
Driving
VEHICLE SPEED LIMITATION FOR SPECIAL APPLICATIONS
Speed limitation for special applications consists of a switch which is fitted on the
vehicle superstructure. With this switch, the vehicle speed can be limited to a preprogrammed value. The programmed value can be modified by an authorized
Service dealer on request.
DRIVING STYLE
The following recommendations result in improved economy without adversely
affecting the vehicle speed (i.e. slowing down). In other words: an efficient driving
style. Anticipate traffic and other conditions; release the accelerator pedal in time
(zero fuel consumption) and do not press down on the accelerator when it is not
necessary
NOTE
In the event of extreme acceleration to 30 to 40 km/h (19 to 25 mph) ,
and depending on the vehicle and engine type, the engine management
system will intervene in the control of the engine to prevent excessive
engine noise at high revs and low speeds.
122
Driving
STEERING
The steering gear is hydraulically assisted. As excessive pressure may damage the
hydraulic pump, stop turning the steering wheel when the wheels are at full lock or
are blocked by an obstacle. The steering gear may be damaged, if this is ignored.
ABS BRAKES
The ABS system is an Anti-lock Braking System.
The ABS ensures good brake stability and good steering in a critical braking
situation.
By preventing the wheels from locking, the steering characteristics of the vehicle are
retained.
Bear in mind that when the prime mover is equipped with ABS but not the drawn
vehicle, or vice versa, the directional stability and steering characteristics will not be
as good as when both units are equipped with ABS.
WARNING
The ABS does not release the driver from his obligation to adapt his
driving style to the traffic and road surface conditions.
The anti-lock protection cannot offset the results of driving too
close to the vehicle in front or taking a bend at too high a speed.
123
Driving
WARNING
Do not adapt your driving style to the ABS system!
Above all, do not brake later and then harder.
This only causes unnecessary tire wear. It may also be hazardous
for other road users.
NOTE
Occasionally, but not always, your braking distance will be shorter with
ABS.
WARNING
If the yellow warning symbol "ABS truck fault" is activated, there is
a fault in the ABS system of the prime mover.
ABS warning symbol in master display
If the ABS warning symbol in the master display remains illuminated while driving,
the ABS system is partly or completely deactivated and the brake system will work
as if no ABS is present. The wheels may then lock upon braking.
D0 00 587-1
124
Driving
PARKING BRAKE AND SERVICE BRAKE
WARNING
Always apply the parking brake when parking the vehicle. Do not
release the parking brake while the steering lock is still engaged.
The vehicle cannot be steered if the steering lock is still engaged.
The service brake is operated by the foot pedal. If the service brake fails to operate
owing to insufficient air pressure, the parking brake can be used as an emergency
brake. Moving the parking brake lever slowly backwards as far as the stop will
gradually brake the vehicle or combination in a controlled manner. The parking
brake is engaged by moving the parking lever back past the locking cam. On a
vehicle with a drawn vehicle connection, the parking brake has a test position. See
"Stopping". The parking brake is disengaged by lifting the locking ring up against the
spring pressure and letting the parking brake lever move forwards.
125
Driving
ENGINE BRAKE
The engine brake is primarily intended for prolonged braking, for example when
decelerating from high speed on a level road or when driving downhill. This reduces
service brake wear.
The engine brake is activated by operating steering wheel switch (C).
C D
NOTE
-The engine cannot be switched off with the engine brake.
A B
-To save the service brakes and to prevent the engine brake valve from
becoming stuck, it is wise to regularly use the engine brake.
E F
The braking effect decreases as the engine speed falls.
D0 01 190-3
The most appropriate area of use for the engine brake is in the blue area of the
revolution counter. The engine brake delivers the highest braking effect in this area.
When using the engine brake, adjust the gear selection so that the engine speed
remains in the most favourable range. In case of an AS Tronic Lite gearbox, gear
selection is automatic.
The engine brake is automatically switched off when:
126
-
the engine speed drops below 1000 rpm.
-
the ABS/ASR system has established a tendency for the wheels to lock.
-
the accelerator pedal is depressed.
-
the vehicle speed control or engine speed control has been activated.
Driving
WARNING
If the ABS/ASR control is activated, the engine brake will be
switched off as long as the control is in operation. On vehicles
where the ABS/ASR control fails to function or on vehicles not
equipped with ABS/ASR, use of the engine brake may lead to the
risk of skidding on slippery surfaces.
STOPPING
Parking
-
Move the parking brake lever (from position A) backwards past the locking cam
(position B). The parking brake is now engaged.
-
When driving a tractor-trailer, check whether the parking brake lever can be
moved even further backwards from position B against the pressure of the
spring. Press in the parking brake lever and pull it further back (to position C).
This is the test position, the drawn vehicle's brakes are not applied in this
position. Check that the tractor-trailer remains in place.
-
Let the parking brake spring back to position B.
-
Place chocks in front of and behind the wheels.
-
Angle the front wheels so that the vehicle will not move into the traffic stream if it
is accidentally set in motion.
127
Driving
C
B
If the tractor-trailer does not remain in place in the test position, find a flatter place to
park the vehicle. Always carry out this test if the vehicle is parked in unfavourable
circumstances (gradient, slippery road surface, etc.). In this way, the tractor-trailer
will remain safely parked, even if air leakage should make the drawn vehicle brakes
ineffective.
A
Switch off the engine.
Put the gear lever in neutral when the vehicle is stationary.
D0 00 645-1
Before switching off the engine after a long trip or when the engine has been
subjected to high loading, let it idle for at least 5 minutes. It is important to let the
engine run for a while in order to prevent the coolant temperature becoming too high
and to allow the turbocharger to cool down.
Switch the engine off by turning the ignition key to 0 position (rest position).
128
Automatic Gearbox
129
Automatic Gearbox
ALLISON 2100 SERIES
General
The automatic gearbox is fully electronically controlled. The automatic gearbox has
5 forward gears and 1 reverse gear.
The automatic gearbox is operated by a selector lever. The selector lever is located
next to the driver's seat.
Shifting gears
The various gears are selected with the selector lever.
Neutral position
No gears are activated in the "N" position. The vehicle is not locked in this position
and can therefore roll.
Use the parking brake to lock the vehicle.
D0 00 789
Automatic forward drive
If the "D" position is selected, the vehicle will immediately begin to move (if the
brake system is pressurized and the vehicle is not on the parking brake). It is
therefore advisable to depress the brake pedal before selecting position "D". In this
position the gearbox will automatically shift up and down in all forward gears. In the
"1", "2" and "3" positions the gearbox shifts up to the selected gear. These positions
are used to keep the engine within the proper speed range or to obtain the
maximum engine brake performance.
Reverse
If position "R" is chosen the vehicle will also be immediately set in motion. In this
case, too, first depress the brake pedal and then select "R" position.
130
Automatic Gearbox
Faults
If the transmission fault warning symbol lights up in the master display, a fault has
been detected in the gearbox.
Read the following recommendations first or consult an authorized dealer if
necessary.
Gearbox
The ECU will block the functions of the selector lever and ensure that the gearbox
will select a "safe gear". It is important to drive the vehicle to a safe place as soon as
possible and switch the ignition off. It will no longer be possible to shift the gearbox
to neutral. The ECU will prevent this.
After approximately 30 seconds, try starting the engine again and engaging a gear.
If the fault is one whereby the gearbox must in no circumstances be shifted, the
ECU will no longer shift the gearbox. Driving is therefore no longer possible!
131
Automatic Gearbox
Gearbox
The ECU will block the functions of the selector and the gearbox will select a "safe
gear" for the gearbox. It is important to drive the vehicle to a safe place as soon as
possible and turn the contact off. It will no longer be possible to shift the gearbox to
neutral. The ECU will prevent this.
After approximately 30 seconds, try starting the engine again and engaging a gear.
If the fault is one whereby the gearbox must in no circumstances be shifted, the
ECU will no longer shift the gearbox. Driving is therefore no longer possible!
If the fault is one whereby the gearbox may still be shifted, the warning in the main
display will disappear. The ECU will have recorded the fault as an inactive fault.
It is now possible to drive the vehicle again, though the fault will still need to be
remedied.
In this situation, however, it is no longer possible to shift gears.
Gearbox oil temperature
If the transmission fault warning symbol in the master display comes on during
driving, this could be an indication that the gearbox oil has reached its maximum
temperature.
In this situation, the ECU limits gearbox shifting to the first four gears.
It is important to drive to a safe place as soon as possible and let the engine idle in
neutral at an increased idling speed.
As a result, the cooling system of the engine will try to cool the gearbox oil.
If after approximately two minutes the warning in the master display has not
disappeared, the engine must be turned off and contact made with the nearest
authorized Service dealer.
132
Emergency Repairs
133
Emergency Repairs
TILTING THE CAB
General
WARNING
Make sure that the filler caps of the cooling system, the hydraulic
clutch and the windshield washer reservoir are tightened. Do not
loosen the filler caps when the cab is tilted.
WARNING
Only tilt the cab when the engine has stopped.
WARNING
Make sure there is sufficient clearance around the cab.
WARNING
You can stop tilting the cab forward at any time by turning the valve
to position .
WARNING
If the vehicle has been involved in a collision, the cab must under
no circumstances be tilted without due precautions. The internal
mechanism of the lifting cylinder may have been damaged to such
an extent that the cylinder is no longer locked by the internal stop
washer. In that case there is a danger of the cab no longer being
held back and falling forward to the ground. Have your authorized
Service dealer check the tilting mechanism.
134
Emergency Repairs
WARNING
Make sure that there is no one in the cab. Also make sure there are
no loose objects inside the cab; this includes objects in the
refrigerator. Make sure there are no people immediately in front of
the cab.
WARNING
Never work under the cab if the cab has not been tilted fully
forward.
NOTE
If a cooler box/refrigerator has been fitted, it should be switched off and if
necessary unplugged before tilting (depending on the type). The cooler
box/refrigerator should remain switched off at least 30 minutes after the
cab has been tilted back.
The cab is tilted hydraulically using a hand pump. This pump is located at the
co-driver's side, behind the cab. The pump has a cock which can be moved to two
positions:
position  to tilt the cab forwards.
position  to tilt the cab backwards; this is also the driving position.
D0 00 623
135
Emergency Repairs
Tilting forward
-
Apply the parking brake.
-
Put the gear lever in "neutral" position.
-
Close the doors.
-
Turn the lever fully to the right, against the spring pressure, until it is locked in
position ; use the jack rod.
-
Operate the pump so that the cab tilts forward. The cab locking mechanism
automatically releases. As soon as the cab passes its natural point of balance,
the force of gravity will gradually tilt the cab further forward without additional
pumping.
Tilting back
-
Turn the lever to position .
-
Tilt the cab back by operating the pump with the jack rod. The last part of
tilting-back is effected by the cab's own weight. When the catch engages, the
cab is automatically locked.
-
Leave the lever in position .
-
Push the gear lever in 1st gear to lock the gearbox control.
-
Put the gear lever in neutral.
Checking the cab locking
When the cab is back in its normal position, the cab lock warning lamp in the master
display should be extinguished.
136
Emergency Repairs
REPLACING THE POLY-V BELT
Important
Always fit the same type of poly-V-belt as the one being replaced.
B
1. Disconnect the earth lead from the battery.
C
2. Place a ratchet (A) with a 3/8" socket in the arm of the automatic belt tensioner
(B).
3. Slacken the poly-V-belt (C) (see arrow in illustration), so that it can be removed
from the pulleys.
4. Carefully allow the automatic belt tensioner to spring back to the stop.
5. Push the poly-V-belt between the fan and the wind tunnel collar and remove the
poly-V-belt.
6. Check all pulleys over which the poly-V-belt runs for dirt, rust and damage.
A
D0 00 633-1
7. Fit a new poly-V-belt between the fan and wind tunnel collar. Place the poly-Vbelt over as many pulleys as possible.
8. Tension the automatic belt tensioner and place the poly-V-belt over the
remaining pulleys. Carefully allow the automatic belt tensioner to spring back
against the new poly-V-belt.
9. Check that the poly-V-belt is in all pulley grooves.
10. Connect the earth lead to the battery.
137
Emergency Repairs
REPLACING THE FUEL FINE FILTER
WARNING
When removing the fuel fine filter, a quantity of fuel will escape.
Collect the fuel and avoid the risk of fire.
Dirt in the fuel system can lead to significant damage to the fuel
system.
Diesel fuel is toxic and can therefore have a damaging effect on
your health. Any direct or indirect physical contact should therefore
be avoided.
In the event of contact with the skin: remove with paper or a cloth,
wash with soap and water. If irritation persists, consult a doctor.
If swallowed: do NOT induce vomiting. Rinse the mouth, drink two
glasses of water and see a doctor.
In the event of inhalation: get some fresh air and rest.
Removing the fuel filter
1. Place a receptacle under the filter.
D0 02 002
2. Remove the filter by turning it anti-clockwise.
NOTE
The fuel fine filter is a disposable filter and, therefore, may not be cleaned
and reused.
138
Emergency Repairs
Fitting the fuel filter
1. Lightly lubricate the sealing ring (see arrow in illustration) with clean engine oil
(not diesel fuel).
2. Fit the filter unfilled until the sealing ring abuts and manually rotate it a ½ to ¾
turn further.
3. Bleed the fuel system. See "BLEEDING THE FUEL SYSTEM".
4. Start the engine and check for leaks. If necessary, retighten the filter by hand.
DRAINING THE WATER SEPARATOR
B
A
WARNING
When draining the water separator, an amount of fuel will escape.
Collect the fuel and avoid the risk of fire.
Water in the fuel system may lead to significant damage.
1. Place a container beneath the water separator.
2. Remove the connector.
D0 00 620
3. Unscrew the ring-shaped drain cock (B) on the bottom of the water separator in
anti-clockwise direction.
4. Drain the filter until pure diesel fuel comes out of the drain cock (A).
5. Turn the drain cock (B) if it abuts, another 1/8 - 1/4 turn.
6. Check the drain cock (B) for leakage.
7. To prevent pollution, the drained water/diesel fuel mixture should be passed to
the relevant authorities for reprocessing.
139
Emergency Repairs
RELEASING THE PARKING BRAKE
WARNING
Never release the parking brake on an incline.
1. Place wheel chocks in front of and behind the wheels.
2. Turn the release bolt counter-clockwise as far as the stop using a ring spanner.
3. This operation should be carried out for each spring brake cylinder.
D0 00 606
4. Bring the parking brake back in operating order as soon as possible by turning
the bolts clockwise as far as possible and tightening them to a torque of 70 Nm
(51.6 lb-ft).
JACKING UP THE FRONT AXLE
When jacking up the front axle, the jack must be positioned under the jacking point
near the shock absorber.
WARNING
Always use stands to support the chassis when carrying out repairs
or service under a vehicle which is resting on a jack.
D0 00 626
140
Emergency Repairs
JACKING UP THE REAR AXLE
When jacking up the rear axle, the jack should always be positioned under the
jacking point at the bottom of the spring bracket.
WARNING
Always use stands to support the chassis when carrying out repairs
or service under a vehicle which is resting on a jack.
To prevent deformation of the axle housing, the jack must under no
circumstances be located directly under the axle housing or the
differential casing.
D0 00 719
141
Emergency Repairs
CHANGING THE WHEEL
NOTE
After changing a wheel/tire, the difference between the diameters of the
various tires on the vehicle may have become too large (for example, as
a result of differences in tread depth and/or tire pressure).
WARNING
The ABS system cannot cope with too great a difference in tire
diameter and the system will automatically be disengaged.
Consequently, the ABS warning symbol will be shown in the master
display.
Depending on the tire types on the front and rear axle, this phenomenon may
already with a worn tire that is underinflated by 2 bar. So first check the tire pressure
if the warning indicator is on after a tire has been replaced.
WARNING
Hence, there will be no ABS control under extreme conditions!
This is the reason why the maximum permitted difference in tire diameter for new
tires is 14%.
(This may occur when different tire sizes are fitted on the front or rear axles.)
WARNING
When removing a wheel with a cracked or damaged wheel rim,
always deflate the tire (remove the tire valve) in view of possible
tensions in the wheel rim.
142
Emergency Repairs
General
-
Only use the original tire wheel rims specified for the vehicle concerned.
-
Make sure that tires of the same type are fitted on both sides of the axle.
-
Insufficient cleaning of the mating surfaces and/or uneven tightening of the
wheel nuts may cause vibrations during driving or braking.
NOTE
If a wheel stud is renewed, the other wheel studs on the relevant wheel
must also be renewed.
Removing the wheel
1. Chock the wheels to prevent the vehicle moving off.
2. Clean the screw thread of the wheel studs using a wire brush.
3. Oil the wheel studs sparingly.
4. Unscrew the wheel nuts.
5. Fit a jack under the jacking point at the wheel to be replaced.
6. Jack up the vehicle and place a support under the axle.
7. Remove the wheel nuts and take the wheel off the hub.
Installing the wheel
1. Clean the fitting edge of the wheel hub by scraping off dirt and corrosion with a
scraper.
D000495
143
Emergency Repairs
2. Apply a thin layer of grease to the fitting edge of the wheel hub.
3. Also apply a thin layer of grease to the fitting edge of the wheel rim. This grease
layer should prevent the wheel rim and the wheel hub from becoming "rustbound".
4. Check whether the contact surfaces of the wheel rim and the drum brake are
clean. Clean if necessary.
D000496
5. Clean the wheel nuts and then apply a drop of oil between the thrust washer and
the nut.
6. Also apply a drop of oil to the first turn of the wheel-stud screw threads.
D000520
6
1
1
8
9
3
4
10
3
4
5
6
7
8
5
4
7
2
5
2
7. Fit the wheel nuts and tighten them evenly according to the sequence in the
illustration.
1
6
3
2
D0 00 615
144
For the specified tightening torque, see "TECHNICAL DATA".
Emergency Repairs
NOTE
Wheel nuts should always be tightened and retightened in cold condition.
However, tightening wheel studs in extreme cold should be avoided.
8. Check the tire pressure.
9. Retorque the wheel nuts after 100 km (62 miles).
If new wheel studs are fitted, they need additional retorquing after 500 km (31
miles).
NOTE
When a wheel had to be replaced, have the wheel nuts torqued to the
correct tightening torque by a dealer.
145
Emergency Repairs
TIRE INFLATING CONNECTION
Next to the brake system air dryer to the left rear of the cab there is a tire inflating
connection.
1. Remove the rubber protective cap from the tire inflating connection.
2. Connect the tire inflating hose.
3. Pump up the tire. Inflate the tires while the engine is running and with maximum
pressure in the air reservoirs.
4. Refit the protective rubber cap to the tire inflating connection after the tire has
been inflated and store the hose.
Check as soon as possible that the tires have the correct pressure using a pressure
gauge. See the tire pressure table under "TECHNICAL DATA".
NOTE
The entire air pressure system of the vehicle can be filled with air from an
outside source using the tire inflating connection. When doing this, check
that the system pressure is correct using the air pressure gauge.
146
Emergency Repairs
TOWING
It is possible to install a towing eye behind the grille.
Always use a towing bar when towing. Departure from this rule is only allowed in
emergencies.
When towing, the fault message "Engine management fault" may appear in the
master display when the ignition is turned on.
D0 00 723
NOTE
The maximum permissible vehicle speed, weight and distance vary per
country.
Tractors may be fitted with a small towing hook at the rear end of the chassis. This
towing hook must only be used for light shunting work.
WARNING
Do not tow the vehicle when fully loaded or with a drawn vehicle
attached.
Being towed by another vehicle
When the engine is not running, there is no power steering and no
air is supplied to the braking system.
If the service brake is applied or in the case of air leakage, the
parking brake might be applied.
147
Emergency Repairs
WARNING
The towed vehicle can be located asymmetrically (left or right)
behind the tractor. Towing may not take place at an angle larger
than 20ð with the vehicle centerline.
-
To clear the towing eyes, the black grid must be removed from the lower grille by
turning the attachment screws a quarter turn.
-
Always fix the tow rod with its original attachment pin (part of the vehicle tool kit)
in the towing eyes.
-
Turn the ignition key so that the steering wheel is released (unless the vehicle is
in a hoist, see below).
-
To prevent damage to the gearbox, the propeller shaft must always be
disconnected from the differential.
-
If there is insufficient pressure in the air reservoirs, release the parking brake.
See "Releasing the parking brake".
D0 00 722
If the differential is damaged:
-
Hoist the vehicle at the rear and lock the steering wheel in the straight-ahead
position.
Tow starting
If the vehicle has to be towed to start the engine, the ignition key must first be turned
clockwise to position D of the starter/ignition switch (ignition on).
Long-distance towing
If the vehicle is to be moved over a larger distance, this must be done by a recovery
vehicle that lifts the vehicle to be towed under its front axle.
148
Emergency Repairs
REPLACING BULBS
-
Do not touch the glass of the halogen lamps with bare fingers. If necessary, this
glass can be cleaned with a cloth, which has been dampened with industrial
alcohol (methylated spirits).
-
When fitting a new bulb, make sure that the lugs on the bulb holder engage in
the slots of the reflector.
Dipped beam
1. Tilt the cab forwards.
2. Detach the rubber cover (2) from the rear of the headlamp unit.
3. Detach the spring clamp and pull the bulb away from the reflector.
4. Detach the double plug from the rear of the bulb.
1
2
Parking light
3
D0 00 594
1. Tilt the cab forwards.
2. Detach the rubber cover (2) from the rear of the headlamp unit.
3. Pull the holder of the parking light from the headlamp unit.
4. Pull the bulb out of the bulb holder.
Main beam
1. Tilt the cab forwards.
2. Detach the rubber cover (1) from the rear of the headlamp unit.
3. Detach the spring clamp and pull the bulb away from the reflector.
4. Detach the spring clamp and pull the bulb away from the reflector.
149
Emergency Repairs
Direction indicator
1. Tilt the cab forwards.
2. Detach the plug from the rear of the bulb holder (3).
3. Screw the bulb holder anti-clockwise out of the headlamp unit.
4. Pull the bulb carefully out of the bulb holder.
5
4
3
2
Rear lights
1
1. Unscrew the four Philips screws and remove the lens cap.
D0 02 016
1.
2.
3.
4.
5.
Fog light
Reversing light
Rear light
Stop light
Direction indicator
Direction indicators
1. Detach the plug on the inside bumperend cap/step moulding.
2. Remove the two screws and detach the lamp unit of the direction indicator.
3. Unscrew the bulb holder anti-clockwise out of the indicator lamp unit.
4. Pull the bulb carefully out of the bulb holder.
150
Emergency Repairs
Stepwell lighting
1. Remove the stepwell lighting housing from the bottom of the door by inserting a
screwdriver in the notch.
2. If necessary, remove the plug.
3. Unscrew the bulb holder anti-clockwise out of the stepwell lighting housing.
4. Pull the bulb carefully out of the bulb holder.\
D0 00 590
Roof light
The transparent covers of the roof lights have a slot allowing the lens to be tilted out
of the housing using a screwdriver.
1. Remove the transparent cover of the roof light carefully from the roof upholstery.
2. Pull the bulb carefully out of the bulb holder.
D0 00 571
151
Emergency Repairs
FUSES AND RELAYS
WARNING
To prevent overload and the risk of fire you must NEVER replace a
burnt-out fuse with a fuse with a higher rating than specified. If a
specific fuse repeatedly blows, this means there is a fault in the
circuit, which MUST be inspected and remedied.
NEVER replace or remove a fuse if:
-the contact is on.
-the engine is running.
-a consumer is switched on.
The fuses are behind a cover in the dashboard on the co-driver's side.
Attached to the inside of the cover is a sticker with an overview of the fuses.
For replacing fuses there is a special fuse clamp on the fuse board.
Each fuse is color-coded to show the rating:
D0 00 617
152
Orange
5A
Red
10 A
Blue
15 A
Yellow
20 A
Transparent
25 A
Green
30 A
Emergency Repairs
Fuses
E004
Fuse, driver’s side dipped beam
E005
Fuse, co-driver’s side dipped beam
E006
Fuse, driver’s side main beam
E009
Fuse, rear fog lights
E013
Fuse, stop lights
E016
Fuse, reversing lights and cross-axle lock control
E018
Fuse, G.O reverse lamp
E019
Fuse, horn
E023
Fuse, tachograph timer
E025
Fuse, wiper wash
E026
Fuse, cigar lighter/door switches/electronic unit, converter 24/12 V with
power supply for radio memory
E027
Fuse, converter 24/12
E028
Fuse, interior lighting/central door locking
E031
Fuse, heater and air conditioner
E035
Fuse, ECU engine ignition
E039
Fuse, seat heating
E044
Fuse, mirror heating/electrical mirror adjustment/electrical window
operation/sun roof
E051
(unused)
E052
Fuse, body light
153
Emergency Repairs
Fuses
154
E053
Fuse, diagnostic connector/ECAS
E058
(unused)
E062
Fuse, ECAS remote
E091
Fuse, Mechanical clutch/air Orer
E108
Fuse, VIC
E114
Fuse, cab heater
E142
Fuse, accessories unswitched power
E143
Fuse, option / various/ ABS
E144
Fuse, automatic gearbox AGC
E145
Fuse, gear box
E153
(unused)
E156
Fuse, accessories
E160
Fuse, engine ECU
E163
(unused)
E164
Fuse, fuel heater
E165
Fuse, fuel heater FPH-E, switched power
E190
Fuse, ABS-E / ASR
E198
Fuse, central door lock
E277
Fuse, VIC
E279
(unused)
E280
Fuse, VIC
Emergency Repairs
Fuses
E282
(unused)
E283
Fuse, side lights
E284
Width marker light
E285
Fuse, fog lights switch
E286
(unused)
E290
Fuse, customer adaptation cab
E297
Fuse, airbag and seat belt tensioner system
E299
(unused)
E310
Fuse, instrument panel, DIP-4
E330
(unused)
E349
(unused)
E350
Fuse, remote bat ISO
E354
(unused)
E357
Fuse, dosing unit
E390
Fuse, body builder module
E409
Fuse, dosing module
E434
Fuse, Nox unit
155
Emergency Repairs
156
Technical Data and Identification
157
Technical Data and Identification
ENGINE
Type
Model: KW: K270, K370 or PB:210, 220, PX6-2010
Engine
Engine type
Model
Number of cylinders
Bore x stroke
Total capacity
Capacity of lubrication system,
including filter and oil cooler
Sump capacity, maximum level
Sump capacity, minimum level
Capacity of cooling system,
including heater
B ENGINE
EPA 10, water-cooled, four-stroke diesel
engine with electronically controlled fuel
injection system, 4 valves per cylinder and
turbo-intercooling.
6 In Line
107 x 124 mm
6.7 litres
liters TBD
liters 18L (w/OP9517 Option)
liters 16L (w/OP9517 Option)
liters TBD
Output and torque
Type
PX-6 220hp
PX-6 240hp
PX-6 250hp
158
Maximum
output
P (kW/hp)
164/220
179/240
186/250
Engine speed
at max. output np
(rpm)
1600
1600
1600
Maximum
torque
M (Nm)/(lb ft)
705 / 520
759.2 / 560
894.8 / 660
Engine speed
at max. torque nm
(rpm)
215-2600
235-2600
245-2600
Technical Data and Identification
ELECTRICAL SYSTEM
Voltage
Alternator
Batteries
Starter motor
12/24 V
160 A / 14 V
700 / 1000 CCA
3.3 Kw / 12 V
Bulbs
Dipped beam Left/right
Main beam Left/right
Auxiliary high beam
Fog lights
Tail light Left/right
Cab interior lighting
Stepwell lighting
Marker lights
Side repeater lights
Roof lights
12V/55W
12V/55W
12V/55W
12V/55W
12V/45W
24V/15W
24V/5W
12V/5W
12V/21W
24V/5W
159
Technical Data and Identification
WHEELS
Whenever the wheel nuts have been slackened or removed, they must be retorqued
with a torque wrench after 100 km (62 miles).
WARNING
If a wheel stud is renewed, the other wheel studs on the relevant
wheel must also be renewed. If new wheel studs are fitted, the nuts
must be retorqued after 500 km (310 miles).
Wheel nut tightening torques
Model K270 / K370, 210 / 220
Version with 8 M20 wheel nuts
Version with 10 M22 wheel nuts
160
485 Nm (357.7 lb ft)
644 Nm (475 lb ft)
Technical Data and Identification
TIRE PRESSURE TABLE (METRIC)
Recommended pressure (bar) at various loads (kg) E= single fitting D= twin fitting
Tires
2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000
size
245/70
R19.5
285/70
R19.5
D
4.2
4.7
5.2
D
5.7
6.2
6.7
7.2
4.6
5.2
5.6
6.0
8500
9000
6.5
7.3
10000
11000
12000
13000
Max.
axle
load
(kg)
7248
Pressure
at
maximum
axle load
7.5
9513
7
TIRE PRESSURE TABLE (IMPERIAL)
Recommended pressure (psi) at various loads (lb) E= single fitting D= twin fitting
Tires
4400 5500 6600 7700 8800 9900 11000 12100 13200 14300 15400 16500 17600
size
245/70
R19.5
285/70
R19.5
D
D
60.9
68.15
75.4
82.65
89.9
97.15
104.4
66.7
75.4
81.2
87
18700 19800
94.25
105.85
22000 24200 24600 28600
Max.
axle
load
(lb)
9592
Pressure
at
maximum
axle load
120.35
12320 101.5
161
Technical Data and Identification
Checking the tire pressures
Tire pressures depend on axle load and tire size.
Tire pressure table*
-
The tire pressures shown in the table apply to cold tires.
Unnecessary tire wear is frequently caused by vehicle operation with tire
pressures which do not match the axle load.
When twin wheels are fitted:
Both tires must be inflated to the same pressure;
The tread depth must be practically the same on both tires.
* The axle loads and corresponding tire pressures shown in the table apply to
normal operating conditions. For all other cases, refer to the specifications of the tire
manufacturer.
LUBRICANT-, ENGINE COOLANT- AND FUEL SPECIFICATIONS
To comply with the warranty terms and to guarantee the durability of the
manufacturers products, it is essential that the correct lubricants, engine
coolant and fuel are used and that the oil change intervals are adhered to.
Additives to lubricants, engine coolant and fuel - of whatever type - must not
be used except in those circumstances prescribed by the manufacturer.
Always follow the safety instructions below and the instructions that are
supplied with the product.
Use Ultra Low Sulfur Diesel Fuel only. Failure to do so may cause exhaust
equipment damage.
162
Technical Data and Identification
Ask your lubricant and fuel suppliers whether their products comply with
specifications.
The manufacturer is not liable for damage or problems in the following instances:
-
If oil has been used of a lower grade than specified.
If oil has been used of a different viscosity than specified.
If the specified oil change interval has been exceeded.
If fuel, lubricants or coolants have been used which do not meet the
requirements specified.
WARNING
Avoid physical contact with:
- lubricants
- coolants
- Fuel
- battery acid
In the event of skin contact: remove substance with paper or cloth, wash with
soap and water.
Consult a doctor in the event of persistent irritation.
In the event of contact with the eyes: remove substance with soft cloth and
rinse with water.
Consult a doctor in the event of persistent irritation.
If any is swallowed: DO NOT induce vomiting. Rinse mouth, drink two glasses
of water and consult a doctor.
In the event of inhalation: get some fresh air and rest.
163
Technical Data and Identification
Battery acid:
In the event of skin contact: rinse the skin profusely with plenty of water.
Consult a doctor in the event of persistent redness or pain. Remove polluted
clothing and rinse in water.
In the event of contact with the eyes: rinse with plenty of water for at least
15 minutes and see a doctor.
If any is swallowed: do NOT induce vomiting. Rinse the mouth, drink two
glasses of water and see a doctor.
In the event of inhalation: get some fresh air, rest and consult a doctor.
ENGINE OIL
Specification lists refer to international standards, such as ACEA and API.
Viscosity is also subject to specific requirements.
Additional information:
PX-6 2010:Synthetic oil
Explanation of overview:
V = may be used
164
Technical Data and Identification
COOLANTS
WARNING
Coolant is a toxic fluid. Protect skin and eyes. In case of accidental
contact with skin and/or eyes, see "Lubricant, engine coolant and
fuel specifications".
Coolant is harmful to the environment; after use, it should be
processed as industrial chemical waste.
The cooling system should preferably be filled with a ready-mixed coolant
containing antifreeze and corrosion inhibiting additives.
The coolant present in the cooling system from the factory consists of an ethylene
glycol base: Climatech
Coolant identification
A sticker behind the grille states the information on the coolant used.
D0 02 018
165
Technical Data and Identification
Coolant according to specification 74002
The below table lists the current suppliers that meet specification 74002.
It is not allowed to fill the cooling system with another product than the one specified
in this overview.
166
Brand name
Supplier
Long Life Coolant
N.V.
Havoline XLC/Havoline Extended Life
Antifreeze Coolant
ChevronTexaco
Caltex Extended Life Coolant
Caltex
Total Organifreeze
Total
Maxigel Plus/Ultracooling Plus
Renault Truck Oils
Bevercool Organic
Beverol
BP Procool
BP
Castrol Antifreeze SF Premix
Castrol
Inugel Optimal/Inugel Optimal Ultra
Motul
Yacco LR Organique
Yacco
Valvoline Antifreeze Extreme
Valvoline
Petrol Antifriz Koncentrat
Petrol
Orvema Protex Long Life/Coolmix LL
Orvema
SB-G12
Sotragel
Technical Data and Identification
STEERING GEAR
Hydraulic power steering
ATF DEXRON III with valid approval
number
CAB TILTING MECHANISM
Cab tilting pump
The following may be used:
Oil must meet MIL-H-5606C
ESSO Univis J13
FINA Hydran B5219B
TEXACO Aircraft Hydraulic Oil 5606G
TOTAL Aerohydraulic 520
167
Technical Data and Identification
CHASSIS NUMBER
The chassis number is the last 6 digits of the VIN number. It is stamped on the right
chassis side member close to the front axle.
D0 02 015
D0 00 597-1
ENGINE NUMBER
Cu
mm
ins
Cummins
Engine Company Inc.
Box 3005
Columbus, Indiana
47202-3005
Warning injury may result and warranty is voided
if fuel rate or rpm or altitudes exceed published
maximum values for this model and application.
Date of Mig
Made in Great Britain by
Cummins Engine Co Ltd
C.I.D./L
CPL
Engine Serial No.
Cust. spec.
Family
Engine model
Low idle RPM
Valve lash cold
Firing Order
Rated HP/KW
Int.
Exh. Fuel rate at rated HP
mm3/st
Timing-TDC
at
RPM
D0 00 599
168
The engine number is located on the data plate located on the top cover of the
engine.
Technical Data and Identification
PAINT IDENTIFICATION PLATE
XXXXXXXXXXXXX
XXXXXXXXXXXX
XXXXXXXX
The paint identification plate is attached to the bulkhead behind the front panel.
xxxkxxxx xmxxxkxjxhxhxlx
xxxkxxxx xmx
xxxkxxxx
xxxkxxxx xmxxxkxjxhxhxlx
xxxkxxxx xmxxxx xxx
VEHICLE IDENTIFICATION LABEL
xxxkxxxx xmxxxkxjxhxhxlx
XXXXXXXXXXXXX
XXXXXXXXXXXX
XXXXXXXX
The vehicle identification plate is located on the door jamb.
Each vehicle uses a Vehicle Identification Number (VIN) that contains the model
year designation of your vehicle. The practice is in compliance with 49 CFR 565,
Code of Federal Regulations. The VIN contains 17 digits. The 10th digit is the code
for the model year of your vehicle. The example VIN below from a 1999 model
shows how this code works:
xxxkxxxx xmxxxkxjxhxhxlx
xxxkxxxx xmx
xxxkxxx
xxxkxxxx xmxxxkxjxhxhxlx
xxxkxxx
xxxk
xxxk
xxxkxxxx xmx
xxxk
xxxkxxxx xmxxxkxjxhxhxlx
xxxkxxxx xmxx
xxxkxxxxxx
xxxkxxxx xmxxxkxjxhxh
xxxkxxx
xxxkxxx
xxxkxxxx xmxxxkxjxhxh
xxxkxxxx xm
xxxk
EXAMPLE VIN: 1XP 9D2X9 6 X D 345678
xxxkxxxx xmxxxkxjxhxh
xxxkxxxx xm
xxxk
xxxkxxxx xmxxxkxjxhxh
xxxkxxxx xm
xxxkxxx
Model Year
xxxkxxxx xmxxxkxjxhxh
xxxkxxxx
xxxkxxx
Serial Number
xxxkxxxx xmxxxkxjxhxh
xxxkxxxx
xxxk
xxxkxxxx xmxxxkxjxhxh
xxxkxxxx xmxxxkx
xxxkxxxx xmxxxkx
xxxkxxxx xmxxxkxjxhxh
xxxkxxxx xmxxxkx
xxxkxxxx xmxxxkx
xxxkxxxx
xxxkxxxx xm
D0 00 667-1
169
Technical Data and Identification
170
Consumer Information
171
Consumer Information
FEDERAL SAFETY STANDARD CERTIFICATION LABEL
The National Highway Traffic Safety Administration regulations require a label
certifying compliance with Federal Safety Standards, for United States and U.S.
Territories, be affixed to each motor vehicle and prescribe where such label may be
located. This certification label, which indicates the date of manufacture and other
pertinent information, is located on the left hand cab door post
.
How To Order Parts
When you need replacement parts for your Kenworth / Peterbilt vehicles, contact
your nearest authorized Kenworth / Peterbilt dealer, who may be located from the
"Kenworth / Peterbilt Authorized U.S. and Canadian Dealers" listing (Cat. No. 5212).
When you order, it is IMPORTANT than you have the following information ready:
Your name and address.
Serial number of the truck.
The name of the part you need.
The name and number of the component for which the part is required.
The quantity of parts you need.
How you want your order shipped.
172
Consumer Information
NHTSA Consumer Information
The National Highway Traffic Safety Administration requires that the following
information be included in the owner’s manual of motor vehicles manufactured after
September 1, 1990:
If you believe that your vehicle has a defect which could cause a crash or could
cause injury or death, you should immediately inform the National Highway Traffic
Safety Administration (NHTSA) in addition to notifying KW/PB 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 dealer, and KW/PB Motors Company.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800327-4236 (TTY 1-800-424-9153), email to [email protected] or write to:
Office of Defects Investigations, CRD NVS-216, 1200 New Jersey Ave SE,
Washington, D.C. 20590. You can also get other information about auto safety from
the Hotline.
For additional road safety information, please visit the NHTSA website at
http://www.safercar.gov
173
Consumer Information
Canadian Consumer Information
Canadian customers who wish to report a safety-related defect to Transport
Canada, Defect Investigations and Recalls, may telephone the toll free hotline 1800-333-0510, or contact Transport Canada by mail at
Transport Canada, ASFAD
Place de Ville Tower C
330 Sparks Street
Ottawa ON K1A 0N5.
For additional road safety information, please visit the Road Safety website at
http://www.tc.gc.ca/roadsafety/menu.htm
Environmental Protection
Warning
Diesel engine exhaust and some of 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. This warning requirement is mandated by
California law (Proposition 65) and does not result from any change
in the manner in which KW/PB trucks are manufactured.
Some of the ingredients in engine oil, hydraulic oil, transmission and axle oil, engine
coolant, diesel fuel, air conditioning refrigerant (R12, R134a, and PAG oil),
batteries, etc., may contaminate the environment if spilled or not disposed of
properly. Contact your local government agency for information concerning proper
disposal.
174
Consumer Information
State of California
California Vehicle Code, Section 9951 - Disclosure of Recording Device
Your vehicle may be equipped with one or more recording devices commonly
referred to as “event data recorders (EDR)” or “sensing and diagnostic modules
(SDM)”. If you are involved in an accident, the device(s) may have the ability to
record vehicle data that occurred just prior to and/or during the accident.
For additional information on your rights associated with the use of this data, contact
the California Department of Motor Vehicles - Licensing Operations Division
or
http://www.dmv.ca.gov/pubs/vctop/d03_6/vc9951.htm
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.
175
Consumer Information
176
Alphabetical index
177
A
Adjustable steering column............................................. 68
Air conditioning switch .................................................... 57
Air filter indicator ............................................................. 97
Air pressure gauge, circuits 1 and 2 ............................... 40
Antifreeze...................................................................... 165
B
Batteries........................................................................
Bleeding the fuel system...............................................
Brake system air drier ...................................................
Bulbs .............................................................................
102
139
100
159
C
Cab maintenance.......................................................... 103
Cab tilting mechanism................................................... 167
Center console................................................................ 62
Central door locking ........................................................ 34
Changing the wheel ...................................................... 142
Chassis number ............................................................ 168
Cleaning........................................................................ 104
Consumer Information .................................................. 173
Control panel................................................................... 51
Coolant............................................................................ 94
Coolant temperature gauge ............................................ 40
Coolants........................................................................ 165
Cooling system ............................................................. 108
Cruise control................................................................ 119
D
Dashboard ...................................................................... 38
Diesel fuel ..................................................................... 107
Doors .............................................................................. 33
178
Draining the water separator ................................. 101, 139
Driving style ................................................................... 122
E
Electrical mirror adjustment ............................................. 35
Electrical system............................................................ 159
Electrically operated windows ......................................... 34
Engine ........................................................................... 158
Engine brake ................................................................. 126
Engine number .............................................................. 168
Engine oil....................................................................... 164
Engine oil level ................................................................ 93
Engine Speed Control ................................................... 117
Environmental Protection .............................................. 174
F
Fan opening selector switch ............................................ 61
Fan speed selector switch ............................................... 60
Federal Safety Standard Certification Label.................. 172
Fluid level in screen washer reservoir ............................. 97
Fuses and relays ........................................................... 152
G
Glow system .................................................................. 115
H
Hazard warning lights ...................................................... 62
I
Instrument panel.............................................................. 40
Interior lighting ................................................................. 37
ITS ..................................................................................... 9
J
Jacking
front axle.................................................................. 140
Rear axle ................................................................. 141
L
Lubricant, coolant and fuel specifications ..................... 162
M
Maintenance
general..................................................................... 103
operations after the winter season .......................... 108
operations before the winter season ....................... 106
Master display ................................................................. 79
Menu overview ................................................................ 84
Menu selector switch....................................................... 82
Mirrors ............................................................................. 35
Modifications to the vehicle ............................................. 14
O
Opening the front panel................................................... 92
Overview of daily checks......................................... 92, 110
Overview of weekly checks ............................................. 99
P
Paint identification plate ................................................
Parking brake ................................................................
Parking brake and service brake...................................
Power steering fluid level ..............................................
169
140
125
100
R
Replacing the fuel fine filter ........................................... 138
Replacing the poly V-belt .............................................. 137
Rev counter ..................................................................... 40
Roof console ................................................................... 36
S
Seat belts ........................................................................ 72
Starting procedure ........................................................ 116
Steering ........................................................................ 123
Steering column switch
Engine brake ............................................................. 67
left ............................................................................. 65
right ........................................................................... 66
Steering gear ................................................................ 167
Steering lock/contact/starter switch .............................. 115
Stopping........................................................................ 127
T
Temperature adjustment................................................. 60
Tilting the cab ............................................................... 134
Tire pressure table ........................................................ 161
Towing .......................................................................... 147
Tyre inflating connection ............................................... 146
Tyre pressure table ....................................................... 161
V
Vehicle identification plate ............................................ 169
Vehicle speed limitation for special applications........... 122
W
Warning indicators .......................................................... 45
Warning symbols ............................................................ 87
Wheel winch ................................................................. 140
Wheels .......................................................................... 160
Windscreen washer reservoir ....................................... 108
179
180
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