Peterbilt Y53-6008 User's Manual

Peterbilt Y53-6008 User's Manual
OPERATOR’S
M ANUAL
Y53-6008 11/06 PRINTED IN U.S.A. PETERBILT MOTORS COMPANY • P.O.BOX 90208 • DENTON, TEXAS 76202 • A DIVISION OF
C l a s s
P a y s
Medium Duty Models
1
7
13
18
44
56
57
113
221
222
227
Introduction
INTRODUCTION
How to Use This Manual
This Operator's Manual contains useful information for the
safe and efficient operation of your Medium Duty vehicle. It
also provides information on maintaining your vehicle in the
best condition, with an outline for performing safety checks
and basic preventive maintenance inspections.
We have tried to present the information you'll need to learn
about your vehicle's functions, controls, and operation as
clearly as possible. We hope you'll find this manual easy to
use. There will be times when you need to take this manual
out of your Peterbilt vehicle. When you do, please be sure to
return it to the cab when you are finished using it. That way it
will be there when you need it the next time or when you pass
the vehicle on to the next user.
Your Medium Duty may not have all the features or options
mentioned in this manual. Therefore, you should pay careful
attention to the instructions that pertain to just your vehicle. In
Medium Duty (R10/06)
addition, if your vehicle is equipped with special equipment or
options not discussed in this manual, consult your dealer or
the manufacturer of the equipment.
All information contained in this manual is based on the latest
production information available at the time of publication.
Peterbilt Motors Company reserves the right to make
changes at any time without notice.
Safety Signals
A number of alerting messages are in this manual. Please
read and follow them. They are there for your protection and
information. These messages can help you avoid injury to
yourself and your passengers, and can help prevent costly
damage to the vehicle.
Key symbols and “signal words” are used to indicate what
kind of message is going to follow. Pay special attention to
instructions prefaced by symbols and the signal words
“WARNING”, “CAUTION”, and “NOTE”. Please do not ignore
any of these alerts.
Y53-6008
–1–
Introduction
WARNING
NOTE
When you see this word, the message that follows is
especially vital. It signals a potentially hazardous
situation which, if not avoided, could result in an
injury or death. This message will tell you what the
hazard is, what can happen if you don't heed the
warning, and how to avoid it.
Provides general information: for example, the note
could warn you on how to avoid damaging your vehicle or how to drive the vehicle more efficiently.
Example:
NOTE: Pumping the accelerator will not assist in
starting the engine.
Example:
WARNING! Never carry additional fuel containers in the vehicle. Such containers, full or empty,
may leak, explode or cause a fire in the event of
a collision.
Please take the time to read these messages when
you see them, and remember:
WARNING!
Something that could seriously injure you.
CAUTION
Signals a potentially hazardous situation which, if
not avoided, could result in property or vehicle damage.
CAUTION:
Something that could cause property or vehicle damage.
NOTE:
Useful information.
Example:
CAUTION: Continuing to operate your vehicle
with insufficient oil pressure will cause serious
engine damage.
–2–
Y53-6008
Medium Duty (R10/06)
Introduction
Vehicle Safety
Make sure your Medium Duty is in top working condition
before heading out on the road—it is the responsible driver's
duty to do so. Inspect the vehicle according to the “Driver's
Check List”, page 13.
WARNING! Do not drink and drive. Your reflexes,
perceptions, and judgment can be affected by
even a small amount of alcohol. You could have
a serious—or even fatal accident—if you drive
after drinking. Please do not drink and drive or
ride with a driver who has been drinking.
Please remember, this manual is not a training manual. It
cannot tell you everything you need to know about driving
your Peterbilt vehicle. For that you need a good training program or truck driving school. If you have not been trained, get
the proper training before you drive. Only qualified drivers
should drive this vehicle.
Every new Peterbilt vehicle is designed to conform to all Federal Motor Vehicle Safety Standards applicable at the time of
manufacture. However, even with these safety features, continued safe and reliable operation depends greatly upon regular vehicle maintenance. The vehicle must be operated
within the range of its mechanical capabilities and the limits
Medium Duty (R10/06)
of its load ratings. (See the tire and rim weight ratings information on the Vehicle Certification Label on the driver's door
frame.) This vehicle is not approved for off-road operation.
How to Find What You Want
There are several tools built into this manual to help you find
what you need quickly and easily. First is the Contents.
Located at the front of the manual, this lists the main subjects
covered and gives page numbers where you can find these
subjects. Use the Contents to find information on a large subject like “Operating the Transmission.”
Cross-references also help you get the information you need.
If some other part of the manual contains further information
on the subject you are reading about, a cross-reference will
refer you to another page, for example: “See page 46, for
more information on Safety Restraint Belts.”
Finally, you will find a helpful Index at the back of the manual,
listing subjects alphabetically. For example, if you want information on brakes, just look under “Brakes” in the Index. You
will find the pages where brakes or related topics are discussed.
Y53-6008
–3–
Introduction
A Special Word About Repairs
Shop Manuals
This is not a repair or workshop manual. Your Peterbilt
Dealer's Service Center is the best place to have your
Medium Duty repaired. You can find Peterbilt dealers all over
the country with the equipment and trained personnel to
quickly get you back on the road—and to keep you there.
If you do decide to do complex repair work, you will need the
Medium Duty Maintenance Manual. It contains service procedures, parts information, and supporting material on major
components in your vehicle, such as Suspensions, Drivelines, Axles, and the Heater/Air Conditioner.
Your Medium Duty is a complex machine. Anyone attempting
repairs on it needs good mechanical training, proper specifications, and proper tools. If you are sure you meet these
qualifications, then you can probably perform some repairs
yourself. But if you are not an experienced mechanic, or do
not have the right equipment or training, please leave the
repairs to an authorized service facility. They are the ones
equipped to do the job safely and correctly.
Listed below are manuals available from your Peterbilt
Dealer. (There is a charge for these manuals.) Please provide the Chassis Serial Number when ordering, to be sure
you get the correct manuals for your vehicle.
WARNING! Do not attempt repair work without
sufficient training, service manuals, and the
proper tools. You could be injured, or you could
make your vehicle unsafe. Do only those tasks
you are fully qualified to do.
–4–
Medium Duty Maintenance Manual. This manual includes
detailed service procedures specifically compiled for the
components on your vehicle, including: electrical information,
maintenance, disassembly, assembly, repairs, overhaul, and
troubleshooting procedures. The information contained in
this manual is the same used by Peterbilt dealers.
Medium Duty Master Parts Catalog. Contains illustrated
parts lists with drawings and exploded views for Medium
Duty series vehicles.
Y53-6008
Medium Duty (R10/06)
Introduction
Medium Duty Body Builders' Manual. Contains general
guidelines on mechanical and electrical modifications
required by your dealer to add bodies, accessories, and special equipment to straight-truck configurations.
WARNING! Modifying your vehicle can make it
unsafe. Some modifications can affect your
vehicle's electrical system, stability, or other
important functions. Before modifying your
vehicle, check with your dealer to make sure it
can be done safely.
Preventive Maintenance Section
The Preventive Maintenance section (pages 116 – 226) in
this manual contains general service information for the operator, such as: lubrication points, making adjustments, and
other helpful service information. This is summary information only, used for general maintenance of major components
installed on your Medium Duty. For detailed service information see your Medium Duty Maintenance Manual.
When it comes time for major service work, your Peterbilt
Dealer or Authorized Service Center will need vehicle and
component information. To help you gather this vehicle infor-
Medium Duty (R10/06)
mation, see “Consumer Information and Vehicle Identification” on page 226. This section explains vehicle identification
and provides space to record model and serial numbers of
major components installed on your vehicle.
Additional Sources of Information
Installed Equipment — Operator's Manuals
Major component suppliers to Peterbilt also supply operation
manuals specific to their products. Additional manuals and
other pieces of literature are included in the glove compartment literature set. Look for information on products such as
the engine, driver’s seat, transmission, axles, tires, and radio.
If you are missing these pieces of literature, ask your Peterbilt
Dealer for copies.
Truck Driver's Handbook
Your set of glove compartment literature also contains a copy
of the Truck Driver's Handbook, published by the American
Trucking Association (ATA). Refer to it for important information on driving your Medium Duty.
Y53-6008
–5–
Introduction
Other Sources
Another place to learn more about trucking is from local truck
driving schools. Contact one near you to learn about courses
they offer.
–6–
Federal and state agencies such as the department of licensing also have information you can ask for. The Interstate
Commerce Commission can give you information about regulations governing transportation across state lines. Regulations that differ from state to state can be found at various
agencies in state governments.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Start–Up
OPERATING INSTRUCTIONS
START–UP
WARNING! To help lessen the chance and/or
severity of personal injury in case of an accident, always lock the doors while driving. Along
with using the lap shoulder belts properly, locking the doors helps prevent occupants from
being thrown from the vehicle.
Introduction
The following section covers start-up procedures for getting
your Medium Duty ready for the road.
• Insert the key in the door lock.
• Turn the key toward the rear door frame to lock; forward
to unlock.
Door Lock and Keys
Doors can be locked from the inside by using the lock button.
Close the door then push the button down to lock. Doors
automatically unlock when you open them from inside, and
can be locked from the outside with the key only.
As standard equipment, two keys are provided for the doors
and ignition. When necessary, additional locks and keys are
provided for storage compartments.
Medium Duty (R10/06)
To lock or unlock the doors from outside the cab:
Cab and Frame Access
The following cab and frame entry/exit procedure recommendations were prepared with personal safety foremost in mind.
Y53-6008
WARNING! Do not jump out of the cab or get into
the cab without proper caution. You could slip or
fall, possibly suffering a serious injury. You
could slip and fall if the steps are wet or icy, or if
you step in fuel, oil, or grease.
–7–
Start–Up
Operating Instructions
To help avoid personal injury due to a slip or fall:
• Use three points of contact (two feet, one hand or one
foot, two hands) to grip the steps or handholds whenever
possible and look where you are going.
WARNING! Do not step on vehicle components
without antiskid surfaces or use components
not designed for entry-and-exit use. You could
fall and injure yourself if you step onto a slippery
surface. For example:
•Do not step onto the surface of a fuel tank. A
fuel tank is not a step. The tank surface can get
very slippery, and you might not be able to prevent a fall. Use only the steps and handholds
provided, not chain hooks, quarter fenders, etc.
•Do not climb onto and off the deck plate—use
steps and grab handle provided. If there is no
deck plate, or if proper steps and grab handles
are not provided, do not climb onto the area
behind the cab.
•Keep steps clean. Clean any fuel, oil, or grease
off the steps before entering the cab or accessing the deck plate.
02611
• Use even more care when steps and handholds (or footwear) are wet, coated with ice, snow, mud, oil, fuel, or
grease.
–8–
Y53-6008
WARNING! Always reinstall the battery compartment cover (step) before entering the cab. Without the battery cover you could slip and fall,
resulting in possible injury to yourself.
Medium Duty (R10/06)
Operating Instructions
Start–Up
NOTE: Any alteration (adding bulkheads, headache
racks, tool boxes, etc.) behind the cab that affects
the utilization of grab handles, deck plates, or frame
access steps installed by Peterbilt should comply
with Federal Motor Carrier Safety Regulation 399.
To open the hood, unlatch both of the hood hold downs.
Hood Hold Downs and Tilt
The hood is locked in its closed position by an external latch
on each side. These latches serve as hold downs and keep
the hood from opening unexpectedly.
CAUTION: If you do not latch the hood securely,
it could open during operation and cause vehicle damage. Be sure to latch the hood securely
before moving the vehicle.
WARNING! A pivoting hood could hurt someone
or be damaged itself. Before opening or closing
the hood, be sure there are no people or objects
in the way.
Medium Duty (R10/06)
Y53-6008
UNLATCHED
–9–
Start–Up
Operating Instructions
Put one hand on the hood handle (just above the Peterbilt
emblem), one foot on the bumper, and one foot on the
ground. Tilt the hood forward until you hear it “lock”.
To close the hood, you must first release the hood safety
lock.
WARNING! Before closing the hood, be sure the
area is clear—no people or objects are in the
way.
CAUTION: To avoid hood damage when closing
the hood, firmly squeeze the handle to release
the hold-open lock.
HOOD HOLD-OPEN
RELEASE HANDLE
02609-1, -2
WARNING! If the hood falls, anyone under it
could be injured. Always make sure the lock is
engaged to keep your hood open any time anyone gets under the hood for any reason. Never
work under the hood unless the hood safety lock
is engaged.
– 10 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Start–Up
After lowering the hood, latch the hood closed with the hold
downs.
WARNING! If the hood is not latched securely, it
could open during operation and cause an accident. Be sure the hood is latched securely
before moving the vehicle.
Safe Vehicle Operation
For your safety, as well as those around you, be a responsible driver:
• If you drink, do not drive.
• Do not drive if you are tired, ill, or under emotional stress.
Much has gone into the manufacturing of your Medium Duty,
including advanced engineering techniques, rigid quality control, and demanding inspections. These manufacturing processes will be enhanced by you—the safe driver—who:
• knows and understands how to operate the vehicle and
all its controls
• maintains the vehicle properly
• uses driving skills wisely
LATCHED
Medium Duty (R10/06)
For more information, refer to Department of Transportation
Regulation 392.7, which states that interstate commercial
motor vehicles are not to be driven unless the driver is sure
that certain parts and accessories are in working order.
Y53-6008
– 11 –
Start–Up
Operating Instructions
WARNING! Do not drink and drive. Your reflexes,
perceptions, and judgment can be affected by
even a small amount of alcohol. You could have
a serious—even fatal—accident if you drive after
drinking. Please do not drink and drive or ride
with a driver who’s been drinking.
WARNING! Do not exceed the specified load rating. Overloading can result in loss of vehicle
control and serious personal injury, either by
causing component failures or by affecting vehicle handling. Exceeding load ratings can also
shorten the service life of the vehicle.
•The use of alcohol, drugs, and certain medications will seriously impair perception, reactions,
and driving ability. These circumstances can
substantially increase the risk of an accident
and serious personal injury.
•The components of your vehicle are designed
to provide satisfactory service if the vehicle is
not loaded in excess of either the gross vehicle
weight rating (GVWR), or the maximum front and
rear gross axle weight ratings (GAWRs). (Axle
weight ratings are listed on the driver's door
edge.)
Vehicle Loading
Here are some definitions of weight you should know:
Compare your vehicle's load capacity with the total load you
are carrying. If adjustments need to be made, make them—
do not drive an overloaded vehicle. If you are overloaded or
your load has shifted, your vehicle may be unsafe to drive.
GVWR: is the Gross Vehicle Weight Rating. This is the
MAXIMUM WEIGHT your vehicle is allowed to carry, including the weight of the empty vehicle, loading platform, occupants, fuel, and any load. Never exceed the GVWR of your
vehicle.
GCW: is the actual combined weight, or Gross Combination
Weight (GCW), of your vehicle and its load: tractor, plus
trailer(s), plus cargo.
– 12 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Start–Up
GAWR: is the Gross Axle Weight Rating. This is the total
weight that one axle is designed to transmit to the ground.
You will find this number listed on the driver's door edge.
Load Distribution: be sure any load you carry is distributed
so that no axle has to support more than its GAWR.
WARNING! An unevenly distributed load or a
load too heavy over one axle can affect the braking and handling of your vehicle, which could
result in an accident. Even if your load is under
the legal limits, be sure it is distributed evenly.
Emergency Equipment
It is good practice to carry an emergency equipment kit in
your vehicle. One day, if you have a roadside emergency, you
will be glad the following items are with you:
•
•
•
•
•
•
•
window scraper
snow brush
container or bag of sand or salt
emergency light
small shovel
first aid kit
fire extinguisher
Medium Duty (R10/06)
Driver's Check List
To keep your Medium Duty in top shape and maintain a high
level of safety for you, your passengers, and your load, make
a thorough inspection every day before you drive. You will
save maintenance time later, and the safety checks could
help prevent a serious accident. Please remember, too, that
the Federal law requires a pre-trip inspection and so do commercial trucking companies.
You are not expected to become a professional mechanic.
The purpose of your inspections is to find anything that might
interfere with the safe and efficient transportation of yourself,
any passengers, and your load. If you do find something
wrong and cannot fix it yourself, have an Authorized Service
Center or qualified mechanic repair your vehicle right away.
The following operations are to be performed by the driver.
Performing these checks and following the maintenance procedures in this manual will help keep your Medium Duty running properly.
Approaching Your Vehicle
• Check the overall appearance and condition. Are windows, mirrors, and lights clean and unobstructed?
Y53-6008
– 13 –
Start–Up
Operating Instructions
• Check beneath the vehicle. Are there signs of fuel, oil, or
water leaks?
• Check for damaged, loose, or missing parts. Are there
parts showing signs of excessive wear or lack of lubrication? Have a qualified mechanic examine any questionable items and repair them without delay.
• Check your load. Is it secured properly?
Daily Checks
NOTE: The following items (Engine Compartment, Chassis and Cab, and Prestart Checks)
should be checked daily, as a minimum. They
are in addition to, not in place of, federal motor
Carrier Safety Regulations. These regulations
may be purchased by writing to:
Superintendent of Documents
U.S. Government Printing Office
Washington, DC 20402
Engine Compartment Checks — Daily
1. Engine Fluid Levels—add more if necessary.
• Engine oil
• Coolant (check while engine is cold)
– 14 –
• Power steering fluid level
• If your truck has hydraulic brakes, check the fluid
level in the master cylinder reservoir. See page 154
for more information.
2. Engine Belt—check tension and condition of belts. This
is important to ensure proper air compressor and engine
operation.
• Measure the belt tension at the longest span of the
belt. See page 142 for further information on checking belt tension.
NOTE: Deflection should be one belt thickness for each foot distance between the
pulley centers.
• If breaks or tears are found, the belt should be
replaced before operating the vehicle.
3. Fuel Filter/Water Separator Draining—check and drain.
Depending on the fuel storage facility, more frequent
draining may be required.
4. Windshield washer reservoir fluid level—fill if necessary.
5. Hood closed before entering cab. Is it latched properly?
Chassis and Cab Checks — Daily
Before entering the cab and operating the vehicle, check the
following equipment for proper maintenance:
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Start–Up
1. Lights—do headlights, turn signals, emergency flashers,
and exterior lamps function and are they clean and
adjusted properly?
2. Windows and Mirrors—are they clean and adjusted
properly?
3. Tires and Wheels—are they inflated properly? Are all
wheel cap nuts in place and torqued properly—tighten if
necessary. Check front wheel bearing oil levels. Inspect
all tires and wheels for damage—correct if found.
4. Suspension—check for loose or missing fasteners.
Check damage to springs or other suspension parts.
5. Brake Components—check lines, linkages, chambers,
and brake operation.
6. If your truck has hydraulic brakes, check:
• the brake system for leaks
• hydraulic lines for cracks or kinks
• calipers for leaks
7. Air System—are there leaks?
• Air Tanks—drain water from all air tanks. Make sure
the drain cocks are closed. This procedure is also
required for air suspension tanks equipped with
automatic drain valves.
• See page 72 for further details on “Using the Brake
System.”
Medium Duty (R10/06)
8. Steps and Handholds—check for worn surfaces and
loose or missing fasteners.
9. Fluid Tanks—check underneath the vehicle for signs of
fluid leaks. If any are found, correct before operating the
vehicle.
10. Fuel Tank Caps—are they secure?
WARNING! Diesel fuel in the presence of an ignition source (such as a cigarette) could cause an
explosion. You could be seriously injured. A
mixture of gasoline or alcohol with diesel fuel
increases this risk of explosion.
•Do not remove a fuel tank cap near an open
flame.
•Use only the fuel and/or additives recommended for your engine.
• See page 114 for more information.
11. Trailer Connections (Tractor)—are they secure and the
lines clear? If they are not being used, are they stored
properly?
• Is the trailer spare wheel secure and inflated?
• Is the landing gear up and the handle secured?
12. Check the fifth wheel. Is the kingpin locked?
• Is the sliding fifth wheel locked?
Y53-6008
– 15 –
Start–Up
Operating Instructions
Prestart — Daily
Weekly Operations
1. Seat—adjust the seat for easy reach of controls.
2. If your vehicle is equipped with an adjustable steering
column, adjust the steering wheel to a comfortable position.
3. Mirrors—check and readjust mirrors if necessary.
4. Lights—turn ignition key to the IGN & ACC position and
check for warning lights and buzzer. Check operation of
turn signals and emergency lights.
5. Instruments—check all instruments.
6. Windshield—check operation of windshield wipers and
washers.
7. Horn—check operation of horn.
8. Check fire extinguisher charge and road emergency kit.
9. Fuel—check fuel. Is there enough fuel?
10. Seat Belts—fasten and adjust safety restraint belts
– 16 –
1. Battery—check battery and terminals.
2. Wheel Cap Nuts—are they all in place and torqued properly—tighten if necessary. See “Wheel Cap Nut Torque,”
Page 173.
3. Other Controls and Wiring—check for condition and
adjustment.
4. Steering Components—check pitman arm, draglink, and
power steering hoses, etc., for loose, broken, or missing
parts.
5. Other Engine Compartment Checks
Y53-6008
• Check condition and fastening of engine belt, hoses,
clamps, and radiator.
• Check the air cleaner, muffler, and exhaust pipes.
Are they tight and secure?
• After Engine Warm-up
– Automatic Transmission—check fluid level in the
automatic transmission oil (if equipped).
Medium Duty (R10/06)
Operating Instructions
Start–Up
14
5
8
7
6
2
15
4
1
9
10
11
12
13
3
02599A
02595-1A
a
DASH INSTRUMENT PANEL
1
2
3
4
5
Headlight
Clearance Lights
Windshield Washer/Wiper
Panel Lights
Tachometer
Medium Duty (R10/06)
6
7
8
9
10
Oil Pressure
Water Temperature
Speedometer
Air Cleaner Restriction/Filter (option)
Fuel
Y53-6008
11
12
13
14
15
Voltmeter (option)
Air Pressure
Transmission Temperature (option)
Warning Lamp Cluster
Ignition Switch
– 17 –
Instruments and Controls
Operating Instructions
INSTRUMENTS AND CONTROLS
Instrument Index
Table 1
Index of Gauges
Introduction
GAUGE
Tachometer
Your Medium Duty dashboard is shown on the opposite
page.
The dash includes standard gauges and switches. Your vehicle may come with all or some of the switches and gauges
discussed here. The location of switches on the dash will
vary depending on the options ordered and how your vehicle
was configured.
For your convenience, all gauges and their corresponding
page numbers are listed here, see “Index of Gauges”. Refer
to the page listed to learn what each gauge does and how it
should be used.
REFERENCE PAGE
22
Engine Oil Pressure
25
Engine Coolant Temperature
23
Speedometer
21
Air Cleaner Restriction (option)
30
Fuel Level
28
Voltmeter (option)
29
Air System Pressure
26
Transmission Temperature (option)
29
Warning Lights and Buzzer
Many vehicle systems are linked to the instruments on your
instrument panel. Warning lights (in each instrument) may
indicate something is wrong with one of the many vehicle
systems. Check the lights frequently, and respond properly
as soon as a light or buzzer comes on.
– 18 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Instruments and Controls
WARNING LAMP MODULE
MIRROR
HEAT
ABS
OIL
BRAKE
AIR
ENGINE
FAN
LOW
WATER
WATER
LOAD
LIGHT
HIGH
BEAM
FIFTH
WHEEL
CRUISE
SPOT
CONTROL LIGHT
STOP
ENGINE
DIFF
LOCK
WAIT
TO
START
CHECK
ENGINE
VEHICLE WITH AIR BRAKES
MIRROR
HEAT
OIL
!
BRAKE
ENGINE
FAN
LOW
WATER
WATER
LOAD
LIGHT
HIGH
BEAM
FIFTH
WHEEL
CRUISE
SPOT
CONTROL LIGHT
STOP
ENGINE
RANGE
INHIBIT
CHECK
TRANS
P
PARK
CHECK
ENGINE
VEHICLE WITH HYDRAULIC BRAKES
Medium Duty (R10/06)
Y53-6008
– 19 –
Instruments and Controls
Operating Instructions
Self Test
The buzzer will sound continuously as long as:
When you turn on your ignition, the following warning lights
will turn on for 3 - 5 seconds, as a test to let you know they
are working.
Diff Lock
Trailer ABS
Water Temp
Left Turn
Mirror Heat
Load Light
Brake Air (or Brake *)
High Beam
Fifth Wheel
Right Turn
Oil Pressure
Engine Fan
ABS
Park *
• Engine temperature is above the specified range
• Air pressure to the service brakes is low
• Engine oil pressure is low
• There is a problem in the hydraulic brake system
If the buzzer sounds while driving, or if a light comes on, do
the following:
1. Slow down carefully.
2. Move a safe distance off the road and stop.
3. Set the parking brake. (See Pages 68 and 74 for transmission shifting and parking brake information.)
4. If the engine is overheating do not turn it off, see page
23; otherwise, for other conditions turn the engine OFF.
5. Turn on the emergency flasher and use other warning
devices to alert other motorists.
* Vehicle with hydraulic brakes only
WARNING! Do not ignore a warning light or
buzzer. These signals tell you something is
wrong with your vehicle. It could be a failure in an
important system, such as the brakes, which
could lead to an accident. Have the appropriate
system checked immediately.
– 20 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Instruments and Controls
WARNING! Do not operate the vehicle if the
BRAKE warning lamp illuminates or the buzzer
sounds. The vehicle should not be operated until
the system is repaired. Failure to respond to a
brake warning (lamp or buzzer) could result in an
accident and/or severe injury.
Speedometer and Odometer
The speedometer indicates the vehicle speed in miles per
hour (MPH) and in kilometers per hour (km/h).
The odometer records the distance traveled by the vehicle,
either in miles or kilometers, depending on which unit is
installed in the vehicle.
02587
Speedometer (MPH-km/h)
Medium Duty (R10/06)
Y53-6008
– 21 –
Instruments and Controls
Operating Instructions
Tachometer
The vehicle's tachometer measures the engine speed in revolutions–per–minute (rpm). Watching the tachometer is
important to driving efficiently. It will let you match driving
speed and gear selection to the operating range of your
engine. If the engine speed gets too high, you can select a
higher gear to lower the rpm's. If the engine speed drops too
low, you can select a lower gear to raise the rpms. See page
99 for further instructions on driving techniques and using the
tachometer.
HOURMETER
(OPTION)
02586
Tachometer
• To avoid engine damage, do not let the pointer exceed
maximum governed speed.
• When driving downhill, shift to a lower gear and use the
service brake, keeping the engine speed below the maximum governed speed.
The hour meter (option) records the time in hours the engine
is operating.
– 22 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Instruments and Controls
Coolant (Water) Temperature Gauge
Engine Overheating
The water temperature gauge shows the temperature of the
engine coolant. Under normal operating conditions the water
temperature gauge should register between 165 and 205°F
(74 and 90°C). Under certain conditions, somewhat higher
temperatures may be acceptable. The maximum allowable
temperature is 210°F (99°C) with the cooling system pressurized, except for certain special engines. Check the engine
manual to be sure.
The cooling system may overheat if the coolant level is below
normal or if there is sudden loss of coolant, such as a split
hose. The system may also temporarily overheat during
severe operating conditions such as:
• Climbing a long hill on a hot day
• Stopping after high–speed driving
If the Engine Coolant Temperature (“WATER”) warning light
comes on and the audible alarm sounds showing an overheat condition, or if you have any other reason to suspect the
engine may be overheating, DON'T TURN OFF THE
ENGINE unless the “LOW WATER” warning light also comes
on, indicating a loss of coolant. Instead, follow these steps:
A. Reduce engine speed or stop. When stopped, place the
transmission in Neutral and set the parking brake. See
Pages 68 and 74 for transmission shifting and parking
brake information.
02580
Water Temperature Gauge
Medium Duty (R10/06)
B. Check to ensure that the oil pressure gauge reads normal.
C. Increase the engine speed to about one–half of full operating speed, or 1100 to 1200 rpm, maximum.
Y53-6008
– 23 –
Instruments and Controls
Operating Instructions
D. Return the engine speed to normal idle after two or three
minutes.
E. Monitor the engine temperature. After the temperature
returns to normal, allow the engine to idle 3 to 5 minutes
before shutting it off. This allows the engine to cool gradually and uniformly.
F. Check the level of coolant in the coolant expansion tank
(engine compartment, right side.)
• If the overheating came from severe operating conditions, the temperature should have cooled by this
time.
•Scalding steam and fluid under pressure may
escape and cause serious personal injuries.
•Wait until the coolant temperature is below
122°F (50°C).
•Protect your face, hands, and arms by covering
the cap with a large, thick rag to protect against
escaping fluid and steam.
WARNING! Removing the radiator fill cap while
the engine is hot can be dangerous. Never
remove the caps of the expansion tank while the
engine is still hot; you could be badly burned.
FILL
WARNING! Carefully and slowly turn cap one
turn to allow excess pressure to escape, then
push down and turn for final removal.
G. See page 143 for instructions on checking and filling the
coolant expansion tank.
02604
Coolant Expansion Tank
– 24 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Instruments and Controls
WARNING! To reduce the chance of personal
injury and/or vehicle damage due to engine
overheating, never leave the engine idling without an alert driver present. If the engine should
overheat, as indicated by the engine coolant
temperature light, immediate action is required
to correct the condition. Continued unattended
operation of the engine, even for a short time,
may result in serious engine damage or a fire.
For further details on engine operation, see the Engine Operation and Maintenance Manual in the glove compartment of
your vehicle.
02585
Engine Oil Pressure Gauge
CAUTION: Continuing to operate your vehicle
with insufficient oil pressure will cause serious
engine damage.
Engine Oil Pressure Gauge
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
Warning Lamp will come ON.
For further information on engine oil and normal operating
pressures, see the Engine Operation and Maintenance Manual.
Medium Duty (R10/06)
• If the oil pressure fails to rise within 10 seconds after the
engine starts, stop the engine and determine the cause.
• Check the engine manufacturer's manual for the correct
oil pressure ranges for your vehicle's engine.
• If the oil pressure suddenly drops, or the audible alarm
and engine oil pressure warning light come on while driving, do the following:
Y53-6008
1. Slow down carefully.
2. Move a safe distance off the road and stop.
– 25 –
Instruments and Controls
Operating Instructions
3. Place the transmission in park and set the parking
brake. (See Pages 68 and 74 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
page 139 for details on checking oil level.)
7. Add oil if necessary. If the problem persists, contact an Authorized Service Center.
FRONT
SECONDARY
SERVICE
CIRCUIT
(WHITE)
For further information on operating your engine properly,
see page 58.
REAR
PRIMARY
SERVICE
CIRCUIT
(ORANGE)
02581
Dual Air Pressure Gauge (Air Reservoir)
Dual Air Pressure Gauge (Air Reservoir)
The dual air pressure gauge indicates the amount of air pressure in the brake system in pounds per square inch (psi). The
WHITE pointer shows the front (secondary service) reservoir
air pressure, and the ORANGE pointer indicates pressure in
the rear (primary service) reservoir.
– 26 –
If the pressure in either or both circuits is too low for normal
brake operation (below 64 psi), a warning light in the panel
will glow and the audible alarm will sound.
Y53-6008
WARNING! If the light and alarm do not turn off
at start-up, do not try to drive the vehicle until
the problem is found and fixed.
Medium Duty (R10/06)
Operating Instructions
Instruments and Controls
WARNING! If the air pressure falls below 60 psi
(414 kPa) the spring brakes may stop the vehicle
abruptly, which could result in an accident and/
or injuries. Observe the warning light in the
panel. If it comes on, do not continue to drive the
vehicle until it has been properly repaired or serviced.
WARNING! The air pressure warning light and
the audible alarm indicate a dangerous situation: there is not enough air pressure in the reservoirs for repeated braking and the brake
system has failed. Without the use of your service brakes, your spring brakes could suddenly
apply. This could cause a wheel lock-up, loss of
control, or over-take by following vehicles. You
could be in an accident and severely injured.
Air Loss Emergency Procedure
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 Pages 68 and 74 for transmission shifting and parking brake information.)
4. Turn OFF the engine.
5. Turn ON the emergency flasher (See “Emergency
Flasher Switch” on page 55) and use other warning
devices to alert other motorists.
•Bring the vehicle to a safe stop right away, while
you still have control of the vehicle.
Medium Duty (R10/06)
Y53-6008
– 27 –
Instruments and Controls
Operating Instructions
Fuel Gauge
The fuel gauge shows the approximate amount of fuel in the
fuel tanks. Besides empty and full, the gauge also indicates
1/4, 1/2 and 3/4 of total fuel capacity.
Your truck has one main fuel tank and up to four optional
tanks. The fuel gauge shows the total amount of fuel. It is a
good idea to keep fuel tanks at least half–full; otherwise,
water that condenses in an empty tank will contaminate the
fuel and could damage the engine.
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.
WARNING! Do not remove a fuel tank cap near
an open flame. Hot fuel vapors are combustible
and can cause an explosion or fire resulting in
injury or death.
02584
See page 114 for more information.
Fuel Gauge
– 28 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Instruments and Controls
Voltmeter (option)
Transmission Temperature Gauge (option)
The voltmeter shows the voltage your vehicle's electrical system is putting out. Normally, it should show 10 to 16 volts. If
voltage drops, have the electrical system checked.
Your vehicle may be equipped with a transmission temperature gauge. It indicates the temperature of the oil in your
transmission. Watch this gauge to know when your transmission is overheating. If it is, have it checked by an Authorized
Service Center.
02582
02579
Voltmeter
Transmission Temperature Gauge
CAUTION: Maximum allowable transmission
temperature may vary, depending upon your
transmission and type of lubricant. Check your
transmission Owner's Manual.
Medium Duty (R10/06)
Y53-6008
– 29 –
Instruments and Controls
Operating Instructions
CAUTION: Do not continue to operate with the
Air Filter Restriction Gauge reading 25 in. (start
of red area). It could lead to damage to the
engine. Inspect the filter and replace if necessary.
RED
CAUTION
AREA
Holes in the paper element render an air cleaner useless and
may cause the Air Filter Restriction Gauge to give a false
reading, even if the element is clogged. Replace the element
if it is damaged. See page 167 for information on Air Filter
Replacement.
02583
Headlight Switch
Air Filter Restriction Indicator
The headlights are controlled by a toggle
switch on the left instrument panel. See
page 17. When the headlights are ON, the
dash lights, side, and tail lamps are also
on.
Air Filter Restriction Indicator (option)
This gauge indicates the condition of the engine air cleaner
and is measured by inches of water. A clean filter should register 7 in. of water and a filter whose life is over will register
approximately 25 in.
– 30 –
For High Beam operation see page 54.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Instruments and Controls
Daytime Running Lights (option)
Panel Lights
On vehicles equipped with the Daytime Running Light (DRL)
system, the low beam headlights are turned ON automatically at reduced brightness (to conserve headlamp life).
Three controls (or conditions) will affect whether the system
is ON or OFF:
• headlight switch
To Operate the Panel Lights:
Turn on either the headlights, clearance lights, or fog/driving
lights.
• engine on
• parking brake
If the headlight switch is turned OFF, the DRL system
engages automatically after the engine starts and you
release the parking brake. If the headlight switch is ON, the
DRL system is overridden, and headlights operate normally.
WARNING! Do not use daytime running lights
(DRL) during periods of darkness or reduced
visibility. Do not use DRL as a substitute for
headlights or other lights during operations that
require lighting of your vehicle. Doing so could
lead to an injury accident.
Medium Duty (R10/06)
The Panel Lights knob lets you vary the
brightness of your instrument panel lights.
The knob is located on the left instrument
panel. See page 17.
To brighten the instrument panel lights, turn the knob clockwise (to the right).
To dim the instrument lights or to turn them off, turn the knob
counterclockwise (to the left).
ID and Clearance Lights
A toggle switch controls the amber lights on
top of your cab, plus any additional lights that
were installed on the front, sides, and rear of
your vehicle. The switch is located on the left instrument
panel, and is labeled CL LPS. See page 17.
Y53-6008
– 31 –
Instruments and Controls
Operating Instructions
Windshield Wipers/Washer
NOTE: The ignition key must be turned to ACC or
IGN & ACC for the wiper/washer switch to operate.
0
1
A five-position windshield wiper switch controls the wipers
and washer. To turn ON the wipers, turn the knob clockwise.
2
• For intermittent operation turn to the 1st and 2nd positions; for continuous operation advance to the 3rd and
4th positions.
• The final option activates the washer cycle. To wash the
windshield, push knob IN and release. Hold knob IN to
extend washing cycle. After one to three wipes (depending on how long you hold the switch in) the wipers will
shut off automatically.
The windshield washer tank is located inside the engine
compar tment below the radiator expansion tank. See
“Washer Reservoir” on page 201. Check the windshield
washing fluid level weekly. If necessary, fill to top.
CAUTION: If the electric pump is operated for a
long period (more than 15 seconds) with a dry
reservoir, the pump rotor may be damaged.
– 32 –
Y53-6008
3
4
PUSH IN
FOR
WASHER
Windshield wipers/washer switch
POSITION
MODE
0
OFF
1
Intermittent Range: long delay
2
Intermittent Range: Short delay
3
Low Speed
4
High Speed
Wiper/washer (push in)
Medium Duty (R10/06)
Operating Instructions
Instruments and Controls
WARNING! Do not drive with worn or dirty wiper
blades. They can reduce visibility, making driving hazardous. Clean the blades regularly to
remove road film and wax build-up. Use an alcohol-based cleaning solution and a lint-free cloth,
and wipe along the blades.
Ignition Key Switch
The engine ignition key switch (located to the left of the steering column) has four positions: ACC (Accessories), OFF, IGN
& ACC, and IGN & START.
OFF: In this position all accessories are OFF (except those
listed below) and you can remove the key.
• The following lights and accessories have power when
the key is in the OFF position:
- brake lights
- marker lamps
- cigarette lighter
- headlights
- tail lights
- radio station memory
- horn
- instrument lights
- emergency hazard flasher
- dome and courtesy lamps (on doors)
- auxiliary Power/Body or Trailer
WINDSHIELD
WASHER FLUID
TANK
02391
NOTE: In the OFF position, fuel is cut off by a solenoid valve located on the left side of the engine,
near the ejection pump.
Windshield Washer Fluid Tank
Clean all inside and outside windows regularly. Use an alcohol-based cleaning solution and wipe dry with either a lintfree or a chamois cloth. Avoid running the wiper blades over
a dry windshield to prevent scratching the glass. Spray on
washer fluid first. A scratched windshield will reduce visibility.
Medium Duty (R10/06)
ACC (Accessory): With the key in this position you can play
the radio, defrost mirrors (if equipped with mirror heat) or use
other accessories.
Y53-6008
– 33 –
Instruments and Controls
Operating Instructions
IGN & ACC: In this position, all circuits are energized. Panel
warning lights will light and the buzzer will sound until (1) the
engine is started, (2) normal oil operating pressure is
reached, and (3) air brake system pressure is above 64 psi
(441 kPa). In this position, the ignition key cannot be
removed.
1. Apply all parking brakes. Pull out the Yellow Parking
Brake Control knob (1) located on the dash. In tractors,
the Red (octagon-shaped) Trailer Air Supply Control
knob (2) will automatically pop out.
IGN & START: Turn the key to this position to start your
engine: it energizes the starter and retracts the solenoid
valve to allow fuel supply to the engine. See page 59 for
details on starting the engine.
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72 $33/<
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386+ 72
5(/($6(
Parking Brake
02391-1
Before you leave the cab, apply all parking brakes.
Full Truck Parking Brake Valve
- for vehicles with air brakes:
WARNING! Do not leave the cab without applying the parking brake. The truck could roll and
cause an injury accident. Always apply the parking brake before you leave the cab.
– 34 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
(2) Trailer Air Supply
Control (Red)
Instruments and Controls
See “Using the Brake System” on page 72 for more information.
(1) Parking Brake Control
(Yellow)
- for vehicles with hydraulic brakes:
02394
Combination (Tractor/Trailer) Parking Brake Control Valves
2. Shift the transmission into its PARK position. (See Pages
68 and 74 for transmission shifting and parking brake
information.)
3. Turn the key to OFF.
4. Remove the key.
The parking brake consists of a driveline drum brake actuated by a lever and cable. The hand lever, mounted on the
vehicle's cab floor, pulls or releases the cable controlling the
brake. Pulling upward on the parking brake lever pulls the
cable and expands the driveline brake shoes outward against
the driveline brake drum.
The driveline brake is disengaged by pushing the handle
downward to its lowest position.
WARNING! Do not pull out the parking brake
valve while the vehicle is moving. Stopping with
the parking brake controls can cause a sudden
wheel lock-up, loss of control, or over-take by
following vehicles. You could be severely
injured.
Medium Duty (R10/06)
Y53-6008
NOTE: Failure to fully release the parking brake can
cause the brakes to overheat.
CAUTION: Unless it is an emergency, do not pull
upward on the parking brake lever while the
vehicle is moving. Attempting to stop with the
parking brake could cause damage to the driveline, transmission, or the parking brake mechanism itself.
– 35 –
Instruments and Controls
Operating Instructions
Using the Parking Brake
2. Apply the parking brake. Pull upward on the parking
brake lever until it reaches an over (top) center position. (The PARK light on the dash will come on.)
1. Come to a complete stop.
NOTE: Ensure the lever is over center. The light will
come on prior to brake being fully applied.
CRUISE
CONTROL
ENGAGE
STOP
ENGINE
SPOT
LIGHT
P
PARK
CHECK
ENGINE
DISENGAGE
PARKING BRAKE INDICATOR
PARKING BRAKE LEVER
– 36 –
3.
4.
5.
6.
Y53-6008
Shift the transmission into NEUTRAL position:
Turn the key OFF.
Remove the key.
If you are parked on a grade, always block the
wheels.
Medium Duty (R10/06)
Operating Instructions
Instruments and Controls
Cruise Control Switch
Hand Throttle Control
Your vehicle may be equipped with a hand throttle. It is
located on the floor, to the left of the driver's seat. It can be
especially helpful in cold weather to keep your engine running above idle speed when you leave the vehicle briefly. See
page 64 for more information on idling your engine safely.
02901
WARNING! Do not operate the cruise control
when operating on road surfaces with poor
traction (wet, icy, or snow covered roads) or in
heavy traffic. Accelerations caused by the normal operation of the cruise control could cause
you to lose control of the vehicle resulting in an
injury accident.
WARNING! Do not use the hand throttle control
for cruise control or to control your road speed.
It could cause an accident and you could be
seriously injured. Always disengage the hand
throttle before driving the vehicle.
The master switch turns the cruise control ON or OFF.
The second switch allows you to SET the desired speed
or RESUME the desired speed after the cruise control
function has been interrupted.
See page 65 for instructions on how to use the cruise control.
Medium Duty (R10/06)
Y53-6008
– 37 –
Heating and Air Conditioning
Operating Instructions
HEATING AND AIR CONDITIONING
C
B
A
Introduction
WARNING! Do not drive with your visibility
reduced by fog, condensation, or frost on the
windshield. Your view may be obscured, which
could result in an injury accident. For clear visibility and safe driving it is extremely important
for you to follow the instructions on the use of
the ventilation/heating and defogging/defrosting
system. If in doubt, consult your dealer. Maximum heating output and fast defrosting can be
obtained only after the engine has reached operating temperature.
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D
E
02593
Heater and Air Conditioner Controls
Internal air circulation control is provided by three sets of
outlets:
• Front outlets on the dashboard panel, with directional
louvers
• Floor outlets under the dashboard
• Window defrost vents on the dashboard
– 38 –
21
Y53-6008
WARNING! Excessive heat may cause the pressurized components of the air conditioning system to explode. Never weld, solder, steam clean,
or use a blow torch near any part of the air conditioning system.
•If a refrigerant leak develops in the presence of
excessive heat or an open flame, hazardous
gases may be generated. These gases may
cause unconsciousness or death. If you become
Medium Duty (R10/06)
Operating Instructions
Heating and Air Conditioning
aware of a refrigerant leak on your vehicle, have your
system serviced immediately and observe the following precautions:
– Stay away from the hot engine until the exhaust
manifold has cooled.
– Do not permit any open flame in the area. Even a
match or a cigarette lighter may generate a hazardous quantity of poisonous gas.
– Do not smoke in the area. Inhaling gaseous
refrigerant through a cigarette may cause violent
illness.
NOTE: Keep the engine exhaust system and the
vehicle’s cab ventilation system properly maintained. It is recommended that the vehicle’s
exhaust system and cab be inspected:
• By a competent technician every 15,000 miles.
• Whenever a change is noticed in the sound of the
exhaust system.
• Whenever the exhaust system, underbody, cab or
sleeper is damaged.
NOTE: To allow for proper operations of the vehicle
ventilation system, keep the inlet grille at the base
of the windshield clear of snow, ice, leaves, and
other obstructions at all times.
WARNING! Never idle your vehicle for prolonged
periods of time if you sense that exhaust fumes
are entering the cab. Investigate the cause of the
fumes and correct it as soon as possible. If the
vehicle must be driven under these conditions,
drive only with the windows slightly open. Failure to repair the source of the exhaust fumes
may lead to personal harm.
WARNING! Do not stay in the vehicle with the
engine running or idling for more than 10 minutes with the vehicle’s Heater and A/C ventilation system in RECIRC or at LOW FAN SPEED.
Even with the ventilation system ON, running
the engine while parked or stopped for prolonged periods of time is not recommended.
Controls
The heater and air conditioning control unit is mounted in the
center dash console, below the radio. The standard control
unit has four controls to regulate air flow and temperature in
Medium Duty (R10/06)
Y53-6008
– 39 –
Heating and Air Conditioning
Operating Instructions
the cab: fan speed switch (A), air directional control switch
(B), air temperature switch (C), and air circulating mode
switch (D). With optional air conditioning, a fifth switch (E) is
used.
Temperature Control
The temperature rotary switch (C) allows you to adjust and
maintain a comfortable internal cab temperature.
Air Circulation Control
Fan Speed Control
The fan speed rotary switch (A) allows you to select one of
four blower speeds (1-4).
The air circulation rocker switch (D) allows you to select
FRESH air from outside the cab or recirculate (RECIRC) air
from within the cab.
Air Direction Control
The air direction rotary switch (B) controls the air movement
within the cab. Five modes direct the air flow to the three sets
of air outlets: front panel, floor, and window defrost:
1.Front Panel only
2.Panel and Floor (Bi-level)
3.Floor only
4.Defrost and Floor (Bi-level)
5.Defrost only
– 40 –
Air Conditioner Control
The optional air conditioner is engaged with this rocker
switch (E).
Heating
To heat the cab: select the desired air direction and circulating mode (B and D) and set the temperature knob (C) to hot
(red position on the control). Adjust the fan speed (A) as
desired.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Heating and Air Conditioning
CAUTION: During extreme cold weather, do not
blow hot air onto cold windshields. This could
crack the glass. Turn the air direction lever to
Defrost and adjust the fan speed accordingly
while the engine warms. If the engine is already
warm, move the temperature selector to Cool,
then gradually increase the temperature when
you see that the windshield is starting to warm
up.
Defogging
NOTE: The air conditioning system is active when
the Defrost mode is selected.
To defog the windshield: select air direction mode 4 or 5 and
turn the fan speed switch (A) to high. Set the temperature
knob (C) to hot (red position on the control). The air conditioner (if equipped) is automatically activated to remove moisture from the cab. After the windshield is clear, adjust the
controls as desired.
HEATING A/C CONTROL
CONTROLS
HEATING
MAX
Fan Speed (A)
Air Direction
Mode (B)
NML
COOLING
MAX
NML
High (4) Adjust High (4) Adjust
DEFOGGING
MAX
NML
High (4)
Adjust
Panel
(1)
Panel
or BiLevel
(2)
Adjust
Adjust
Defrost
(5)
Defrost
or BiLevel (4)
Temperature (C)
Warm
Adjust
Cool
Adjust
Warm
Adjust
Air Circulation
Mode (D)
Recirc
Fresh
Record
Fresh
Recirc
Fresh
OFF
OFF
ON
ON
—
—
Air Conditioner AC (E)
Cooling
To cool the cab: turn on the air conditioner (if equipped)
(switch E), set the temperature knob (C) to cool (blue side),
and the fan (A) to high until the cab becomes cool—adjust as
desired.
For Efficient Cooling:
1. Ensure all heater/air conditioner controls are off.
2. Start the engine. Allow time for warm–up.
Medium Duty (R10/06)
Y53-6008
– 41 –
Heating and Air Conditioning
Operating Instructions
NOTE: A cold compressor can cause refrigerant to
liquefy and warp the valve plates or cause a hydraulic lock. Warm the engine before starting the air conditioner.
3. Set the air conditioner for maximum cooling.
4. Close all windows.
5. Idle the engine between 1000 and 1500 rpm and turn the
fan switch to High.
If the air conditioner does not cool the air, have the
unit checked at an Authorized Service Center.
NOTE: When the air conditioner isn't in regular use,
operate it for at least 15 minutes at least once a
month or every 5,000 miles (8,000 km), whichever
comes first. This will lubricate the seals in the air
conditioning system.
6. After the cab temperature cools to a comfortable level,
adjust the fan speed and other controls to keep the
desired condition.
– 42 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Accessories
ACCESSORIES
WARNING! Do not exceed the voltage/amperage
capacity of the cigarette lighter. It could result in
a fire. Follow all warnings and instructions in the
operator's manual for the appliance you are
using.
Radio
As an option, your vehicle has either an AM/FM Stereo
Receiver or an AM/FM Stereo/Cassette Player.
For instructions on how to operate your particular radio, see
the manufacturer's Radio Operating Instructions in the glove
compartment.
Ashtray
To open, pull on the upper side of the panel. To close, push
against the panel.
WARNING! Do not place paper or other combustible substances in an ashtray. It could cause a
fire. Keep all burnable materials besides smoking materials, out of the ashtray.
Cigarette Lighter
NOTE: The cigarette lighter will operate with the
ignition key in either the OFF, ACC (accessory), or
IGN/ACC position.
To operate, push in on the knob end of the lighter. After a few
moments, the lighter will automatically pop out, glowing hot
and ready to use. After use, insert the lighter back into the
socket without pushing all the way in.
Air Operated Horn (Option)
Your Medium Duty may be equipped with an air horn. To
operate, pull on the lanyard extending from the overhead
header panel. Your vehicle also has an electric horn. See
page 56.
The socket of the cigarette lighter may be used to operate 12
volt, 15 ampere appliances, such as a hand spotlight or small
vacuum cleaner.
Medium Duty (R10/06)
Y53-6008
– 43 –
Accessories
Operating Instructions
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.
Glove Compartment
A glove compartment is provided to store important documents, the vehicle literature set (including this Operator's
Manual) and other related materials. You can open it by
pushing the knob on the front.
• To close, push the cover up and press to latch it.
• You can lock and unlock the glove compartment door
with your ignition key; turn it clockwise to lock and counterclockwise to unlock.
WARNING! Do not drive with the glove compartment open, it can be dangerous. In an accident
or sudden stop, you or a passenger could be
thrown against the cover and be injured. To
reduce the risk of personal injury during an accident or sudden stop, keep the glove compartment closed when the vehicle is in motion.
– 44 –
Dome Light
The dome light is automatically activated when you open the
door. To turn the dome light on when you are inside the cab,
turn the headlight switch counter–clockwise until it clicks and
the light comes on.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Seats
SEATS
Driver's Seat with Air Suspension (Option)
WARNING! Before driving or riding in the vehicle, be sure that there is adequate head clearance at maximum upward travel of seat. Serious
injury may occur if head clearance is not adequate.
Introduction
This section covers the operation and safe use of your
Medium Duty seats. For further information on features and
adjustment of the seat, see the manufacturer's literature
included with the vehicle.
Seat Adjustment
WARNING! Do not adjust the driver's seat while
the vehicle is moving. A sudden or unexpected
seat movement can cause the driver to lose control of the vehicle. Make all adjustments to the
seat while the vehicle is stopped.
CHUGGER-SNUBBER
LOCK-OUT FEATURE
Move handle down to
unlock
• After adjusting the seat and before driving off,
always check to be sure that the seat is firmly
latched in position.
FRONT CUSHION
HEIGHT
Lift and pull forward
to raise position
Standard Driver's Seat
The standard driver's seat can be adjusted forward and rearward. These movements are each controlled by levers
located on the FRONT of the seat.
Medium Duty (R10/06)
BACKREST TILT
Rotate knob for
infinite selection of
settings
FORE & AFT ISOLATOR
Move to left and slide
seat to desired position
SEAT RIDE HEIGHT
LUMBAR ADJUSTMENT
Push switch up to inflate
Push down to deflate
03017
Peterbilt Ultraride II Highback Air Seat
Y53-6008
– 45 –
Seats
Operating Instructions
Safety Restraint Belts
WARNING! Do not drive vehicle without your
seat belt and your riders’ belts fastened. Riding
without a safety belt which is properly fastened
can lead to increased injury or death in an accident. Unbelted riders could be thrown into the
windshield or other parts of the cab or could be
thrown out of the cab. They could strike another
person. Injuries can be much worse when riders
are unbelted. Always fasten your seat belt and
be sure anyone riding with you does the same.
The right and left seats are equipped with 3-point lap/shoulder belts; the center seat has a 2-point seat belt. Safety belts
have proven to be the single most effective means available
for reducing the potential for either serious injury or death in
motor vehicle accidents. Therefore, read and follow these
instructions and always observe user warnings pertaining to
safety belts.
Lap/Shoulder Belt
The combination lap-shoulder belt is equipped with a locking
mechanism. The system adjusts automatically to a person's
size and movements as long as the pull on the belt is slow.
Hard braking or a collision locks the belt. The belt will also
lock when driving up or down a steep hill or in a sharp curve.
To fasten the belt:
0917A
Unbelted Person in Crash
– 46 –
1. Grasp the belt tongue.
2. Pull the belt in a continuous slow motion across your
chest and lap.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Seats
• Belts should fit snugly across the pelvis and chest.
Make sure any slack is wound up on the retractor.
To unfasten the belt:
Push in the release button on the buckle. The belt will spring
out of the buckle.
• To release a locked belt, lean back to take the body pressure off of the belt.
• To store a lap-shoulder belt, allow the belt to wind up on
the retractor by guiding the belt tongue until the belt
comes to a stop.
01888
Proper Safety Belt Adjustment
3. Insert the belt tongue into the buckle on the inboard side
of the seat.
4. Push down until the tongue locks securely (with an audible click). Pull on the belt to check for proper fastening.
• Pull the shoulder section to make sure the belt fits
snugly across the chest.
• The shoulder belt must be positioned over the shoulder—it must never rest against the neck.
Medium Duty (R10/06)
Your combination lap-shoulder belt may need adjustment.
Adjust safety belts properly.
• The lap belt should be worn as low and tight on the hips
as possible. Make sure any slack is taken up by the belt
mechanism.
• The shoulder belt should fit snugly across your body. It
should be positioned midway over the shoulder (nearer
to the door); it should never rest against your neck.
Y53-6008
– 47 –
Seats
Operating Instructions
Lap Belt
Shoulder Belt
Too High
on Hips
Correct
Incorrect
Correct (over arm)
Incorrect (under arm) Incorrect (twisted)
Safety Restraint Belts
• Be sure, also, that your belt is not too loose. A loose belt
could allow you to slide under it in an accident, and that
could bring the belt up around your abdomen.
• Do not twist the belt in the process of putting it on. A
twisted belt will not work as well to protect you.
WARNING! Always wear your seat belt low over
your pelvic bones.
– 48 –
• You can be seriously injured if your belt is buckled
too high. In a crash, it would apply force to your
abdomen, not your pelvic bones. This can result in
serious internal injuries.
• Do not drive with your seat belt loose. A seat belt
that is too loose can allow you to fall too far forward,
possibly causing head and neck injuries. You could
strike the wheel or the windshield. Adjust your belt
so that there is no more than 1 in. (25mm) of slack.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Seats
WARNING! Do not wear the shoulder belt under
your arm or otherwise out of position. In a crash
your body would move too far forward, increasing the chance of head and neck injury. Also, the
belt would apply too much force to the ribs,
which are not as strong as your shoulder bones,
and could cause you to suffer internal injuries.
Wear the shoulder belt over your shoulder (see
“Safety Restraint Belts” on page 46).
WARNING! Do not twist the belt in the process of
putting it on. A twisted belt will not work as well
to protect you. In a crash, the full width of the
belt would not be protecting you. A twisted belt
could cut into your body and cause serious injuries. Straighten the belt before buckling it. If you
are unable to wear it without twisting it, have
your dealer or service person repair it as soon
as possible.
Safety Restraint Tips
NOTE: Per FMCSR 392.60 - Unauthorized Persons
Not to be Transported. Federal law prohibits the
transportation of persons in commercial vehicles
unless they are specifically authorized in writing by
the motor carrier. See the cited FMCSR for a complete description of the regulation and exemptions.
Medium Duty (R10/06)
• Any authorized person riding in your vehicle should wear
a seat belt. A responsible operator sees to it that everyone in the vehicle rides safely—and that means with a
seat belt.
• Do not strap in more than one person with each belt.
• Do not wear a belt over rigid or breakable objects in or on
your clothing, such as eye glasses, pens, keys, etc., as
these may cause injury in an accident.
• Several layers of heavy clothing may interfere with
proper positioning of belts and reduce the overall effectiveness of the system.
• Keep belt buckles free of any obstruction that may prevent secure locking.
• Damaged or worn belts, subjected to excessive stretch
forces from crashes, cuts or tears, or normal wear, must
be replaced—they may not protect you if you have an
accident.
• If belts show damage to any part of assembly, such as
webbing, bindings, buckles or retractors, they must be
replaced.
• Do not allow safety belts to become damaged by getting
caught in door or seat hardware, or rubbing against
sharp objects.
Y53-6008
– 49 –
Seats
Operating Instructions
• The belts must be kept clean or the retractors may not
work properly.
• Never bleach or dye seat belts: chemicals can weaken
them. Do, however, keep them clean by following the
care label on the belts. Let them dry completely before
allowing them to retract.
• Make sure the belt of the unoccupied passenger seat is
fully wound up on its retractor, so that the belt tongue is
in its stowed position. This reduces the possibility of the
tongue becoming a striking object in case of a sudden
stop.
• Do not modify or disassemble the seat belts in your vehicle. They will not be available to keep you and your passengers safe.
• If any seat belt is not working properly, see an Authorized
Service Center for repair or replacement.
Tether Belts
Tether belts are installed on suspension seats. They help
secure the seat to the floor to restrain it in case of a sudden
stop or an accident.
Fixed Tethers
If your Medium Duty has been equipped with fixed length
tethers, no manual adjustment is required. The same inspection and replacement guidelines should be used as stated on
page 197.
WARNING! Before driving or riding in a vehicle,
ensure that there is adequate head clearance at
maximum upward travel of seat. Shorten the
tether belt as necessary to provide adequate
head clearance. Serious injury may occur if head
clearance is not adequate.
– 50 –
Y53-6008
WARNING! Do not remove, modify, or replace
the tether belt system with a different tether system. A failed or missing tether belt could allow
the seat base to fully extend in the event of an
accident leading to greater injuries or death.
WARNING! Failure to adjust tether belts properly
can cause excessive movement of the seat in an
accident. This could lead to greater injuries to
you. Tether belts should be adjusted so that they
are taut when the seat is in its most upward and
forward position.
Medium Duty (R10/06)
Operating Instructions
Seats
Komfort–Lok® Latch
Tether Adjustment
• Make sure that the tether belt is attached to the cab floor
and seat frame. It should be routed through the buckle
on each side.
• Often the attachments are made using a split-type hook.
Make sure both halves of the hook are around the
anchor bracket.
• To lengthen the tether, turn the buckle to a right angle to
the webbing. Then pull the buckle. To shorten the tether,
pull on the strap.
Medium Duty (R10/06)
Your Peterbilt contains a feature designed to eliminate cinching and provide improved safety and comfort. Cinching is the
condition where a belt becomes continually tighter around
you during a rough, bouncy ride. The need for this feature
increases with rough road conditions, particularly over long
distances. To eliminate cinching, simply activate the Komfort–Lok® feature at the appropriate time:
1. Fasten the seatbelt according to the directions in the previous “Safety Belt Restraint” section.
2. You are now ready to activate the Komfort–Lok. Lean forward to pull a little slack in the belt (maximum of one
inch, measured from the belt to your chest). Be sure to
allow only a small amount of slack.
3. When the slack is right, flip the latch cover up, cinching it
into place.
4. To release the Komfort–Lok latch, reach up and pull the
latch cover open (down), or simply pull down on the
shoulder belt.
5. When you want to get out of the cab, release the latch,
then just push the button on the buckle.
Y53-6008
– 51 –
Seats
Operating Instructions
During Pregnancy
Pregnant women should always wear combination lap/shoulder belts. The lap belt portion must be worn snugly and as
low as possible across the pelvis. To avoid pressure on the
abdomen, the belt must never pass over the waist. Sometimes pregnant women worry that in a crash the seat belt
could hurt the baby. But if a woman wears her belt properly—
low over her pelvis, below her abdomen—the belt will not
harm the baby, even in a crash. And remember—the best
way to keep an unborn baby safe is to keep the mother safe.
LATCH COVER
UP
LATCH COVER
DOWN
02395
The Komfort–Lok latch
Passengers
Anyone riding in your vehicle should wear a seat belt. A
responsible operator sees to it that everyone in the vehicle
rides safely—and that means with a seat belt.
Belt Damage and Repair
Damaged belts in the cab must be replaced. Belts that have
been stretched, cut, or worn out may not protect you in an
accident.
– 52 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Seats
If any seat belt is not working properly, see an Authorized
Service Center for repair or replacement.
For further information on seat belts and seat belt maintenance, see “Safety Restraint System — Inspection,” Page
197.
Pregnant Woman with Belt Properly Worn
Medium Duty (R10/06)
Y53-6008
– 53 –
Steering Column and Mirrors
Operating Instructions
STEERING COLUMN AND MIRRORS
TRAILER
BRAKE VALVE
Introduction
This section covers the standard steering column controls
and mirror operation. Depending on how your Medium Duty
is configured, some or all of these features are installed on
your vehicle.
TURN
SIGNAL/HIGH
BEAM SWITCH
EMERGENCY FLASHER
Steering Column Controls
Turn Signal/High Beam Switch
NOTE: The ignition key must be turned to IGN &
ACC for the signal/switch to operate.
The lever-action turn signal/high beam switch is located on
the left side of the steering column.
Turn Signals
• To signal a right turn, push the lever up (clockwise).
• To signal a left turn, push the lever down (counterclockwise).
– 54 –
02596
High Beam
NOTE: The headlights must be “ON” for the high
beam switch to operate.
• To switch your headlights to lower or higher beam, push
and release the button on the end of the turn signal stalk.
The blue indicator light in the instrument panel will be ON
when the high beam is being used.
• To return to previous beam: push and release the button
again.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Steering Column and Mirrors
Emergency Flasher Switch
WARNING! Use your Hazard Flasher Warning
System any time you have to stop off the road or
on the side of the road, day or night. A hard-tosee vehicle can result in an injury accident.
Another vehicle could run into you if you do not
set your flashers. Always move the vehicle a
safe distance off the road when stalled or
stopped for repairs.
The four-way Emergency Flasher switch is on the turn signal
body, just below the turn signal lever. The emergency flasher
makes all four turn signals (front and rear) flash simultaneously. The flasher works independently of the ignition
switch. You should always use the flasher if the vehicle is disabled or parked under emergency conditions.
•Your disabled vehicle can be dangerous for you
and others. The hot exhaust system could ignite
dry grass, brush, spilled fuel, or other material
that can cause fires. Do not park or operate your
vehicle in areas where the hot exhaust system
could cause a fire.
• To operate the emergency flasher, pull the lever out.
• The flasher is self-cancelling. To turn it off, activate the
left or right turn signal.
Trailer Brake Hand Valve
This hand valve, mounted on the steering wheel column of
tractor/trailer vehicles, provides air pressure to apply the
trailer brakes only. It operates independently of the foot treadle valve. See page 83 for more instructions on proper use of
the Trailer Brake Hand Valve.
Medium Duty (R10/06)
Y53-6008
– 55 –
Steering Column and Mirrors
Operating Instructions
Adjustable Steering Column (option)
Horn
Some vehicles are equipped with an optional tilt-telescoping
steering column. The tilt feature allows forward and rearward
movement of the wheel. The telescoping feature allows you
to move the wheel up and down.
To sound the electric horn, press the button in the center of
the steering wheel.
WARNING! Do not adjust the Tilt-Telescoping
Steering Wheel while the vehicle is in motion, it
could cause loss of control. You would not be
able to steer properly and could have an accident. Make all adjustments to the steering column while the vehicle is stopped.
The Tilt-Telescoping Lever is located on the left side of the
steering column.
Mirrors
Your vehicle comes equipped with two outside rear view mirrors that enable you to see to the sides and behind your vehicle. Be sure both mirrors are adjusted properly before you
begin driving.
• To provide good visibility, adjust each mirror so the side
of your vehicle appears in the inboard part of the mirror.
To tilt the wheel:
• PULL the lever up, toward yourself. Move the steering
wheel to the desired angle, then release the lever to lock
the wheel in the correct position.
To raise or lower the wheel:
• Push or pull the steering wheel to the desired height,
then release the lever to lock the wheel at that position.
– 56 –
Y53-6008
WARNING! Convex mirrors can distort images
and make objects appear smaller and farther
away than they really are. You could have an
accident if you are too close to another vehicle
or other object. Keep plenty of space between
your vehicle and others when you turn or
change lanes. Remember that other objects are
closer than they may appear.
Medium Duty (R10/06)
Operating Instructions
Steering Column and Mirrors
Power Mirror (Option)
Heated Mirrors (Option)
Your Medium Duty may have motorized side mirrors. A switch
for each, located on the dash, controls the adjustment.
Your vehicle also may have heated mirrors. To defrost mirrors
in cold weather, turn the mirror heat switch to ON.
To adjust the mirror:
You can keep the mirror heat on to ensure that the mirrors
stay free of ice or condensation. They automatically adjust to
the temperature outside, providing the right amount of heat to
keep them clear.
• Push the arrow that points toward the direction you want
to move the mirror.
NOTE: The power mirror switch does not control
the adjustment of the convex mirrors.
Medium Duty (R10/06)
Y53-6008
– 57 –
Operating the Engine
Operating Instructions
OPERATING THE ENGINE
WARNING! Do not start or let the engine run in
an enclosed, unventilated area. Exhaust fumes
from the engine contain carbon monoxide, a colorless and odorless gas. Carbon monoxide can
be fatal if inhaled.
Introduction
For detailed information on starting and operating the engine,
refer to the Engine Operation and Maintenance Manual provided with your Medium Duty.
Because each vehicle is custom-equipped, all engine operation instructions presented in this section are general. You
will want to consult the engine manual to find out details
about your vehicle's specific engine requirements. You may
need to use a slightly different procedure from the one outlined here.
Also, read the American Trucking Association's (ATA) Truck
Driver's Handbook. It will give you tips on starting, shifting,
and driving your vehicle.
WARNING! Do not use ether or other starting fluids as a cold-starting aid in your Medium Duty.
Your engine uses either an electrical grid or an
open flame inside the manifold, to heat the air/
fuel mixture for cold weather starting. If ether or
another starting fluid is used, the air/fuel will
ignite inside the manifold, which could cause an
explosion and severe injury.
– 58 –
Y53-6008
•Do not park or operate the vehicle in areas
where the hot exhaust system may come in contact with dry grass, brush, spilled fuel or other
material that can cause a fire.
CAUTION: The use of a winterfront can result in
excessive engine coolant, oil, and charge air
(intake) temperatures, which can lead to overheating and possible engine damage. If you
must use a winterfront
•
Refer to the “Engine Operation and Maintenance Manual” for operating restrictions
and recommendations.
• Use only a winterfront available from your
Peterbilt dealer that is compatible with a
2002 EPA-compliant engine cooling system.
These winterfronts are specifically designed
for use with new grill snap patterns.
Medium Duty (R10/06)
Operating Instructions
Operating the Engine
Starting Procedure — Normal Temperature
Use the following procedure to start your Medium Duty when
outside temperatures are at or ABOVE normal starting temperatures. Check the Engine Operation and Maintenance
Manual for starting temperatures.
1. Set the parking brake.
NOTE: When any one of the following is true, oil
should be applied to the turbocharger oil inlet
port: (1) if the engine has not been started for
more than 25 days; or (2), the outside temperature is very cold; or (3), the oil filter has been
changed.
•With an oil can, squirt approximately one-half
cup (120 ml) of clean, specified engine oil into
the turbocharger oil inlet port. This will keep the
turbocharger bearings lubricated until the
engine oil pressure gets up to normal.
2. Insert key into the ignition switch.
3. Disable (or turn OFF) the following systems prior to starting the engine: the exhaust brake, the dual-speed rear
axle (put in LOW), and block heater (if equipped).
4. Disengage the transmission: place the shift lever in the
Neutral position.
Medium Duty (R10/06)
5. Disengage (depress) the clutch (with manual transmission).
6. Turn the ignition switch to the IGN & ACC position. For
normal temperatures, no accelerator advance is necessary. See “Use of Accelerator” below. If the “WAIT TO
START” indicator lamp turns ON, wait until the indicator
lamp goes OFF (approximately 60 seconds) before
attempting to start the engine. (For each engine and
ambient temperatures, warm-up cycles will vary.)
7. Turn the ignition switch to the IGN & START position to
engage the starter. Crank the engine until it starts. If the
engine does not start within 30 seconds, release the key.
Use of Accelerator
• For mild to warm temperatures above 60°F (16°C) keep
your foot OFF the accelerator pedal while cranking. If the
engine does not start after 5 seconds, apply full throttle
while cranking.
• For below normal starting temperatures fully depress the
accelerator (throttle) pedal after engaging the starter.
Y53-6008
NOTE: Pumping the accelerator will not assist in
starting the engine.
– 59 –
Operating the Engine
Operating Instructions
CAUTION: Never operate the starter motor while
the engine is running. The starter and flywheel
gears could clash or jam, severely damaging
them.
CAUTION: To help avoid overtaxing the starter
motor or batteries, or causing engine damage,
follow the recommendations listed below:
• Do not engage starter for more than 30 seconds at a
time.
• Wait two minutes between each attempt to start the
engine. This allows the starter motor to cool and time for
the batteries to regain power.
• If the engine fails to start after a couple of tries, there
could be a malfunction with the engine or other related
system. Make any adjustments or repairs necessary
before trying to start the engine again.
• Wait until normal engine oil pressure registers on the
gauge before idling or accelerating the engine beyond
1000 rpm.
• Watch the air pressure gauge. Wait until both pointers
register at least 100 psi (689 kPa) before releasing the
spring brake and moving the vehicle. Also, check the
alarm system for any type of faults and correct them
before moving the vehicle.
When the engine starts:
• Watch the oil pressure gauge. Oil pressure should rise
within 15 seconds after the engine starts. If the oil pressure does not rise, stop the engine. Find what is wrong
before restarting. Check the Engine Operation and Maintenance Manual for the right oil pressure for your vehicle's engine. In most engines, idle pressure should be
about 15 psi.
– 60 –
Y53-6008
CAUTION: Do not try to put the vehicle in motion
before pressure in the air system reaches 100
psi (689 kPa) because the wheels will still be
locked by the spring brake action.
•Unnecessary stress and possible brake malfunction could occur if the vehicle is forced to
move before the air system reaches 100 psi (689
kPa).
Medium Duty (R10/06)
Operating Instructions
Operating the Engine
Starting Procedure — Cold Weather
Engine Block Heater (Option)
In addition to the previous “Normal Starting Procedures,” use
these Cold Weather Starting guidelines when the air temperature falls below a certain temperature. Check your Engine
Operation and Maintenance Manual for further details on
when cold weather starting aids are needed.
To preheat the engine before starting, plug the optional
engine block heater into a properly grounded AC electrical
source. Do not start the engine with the heater plugged in.
WARNING! Engine block heaters can cause fires
resulting in serious personal injury and/or property damage if not properly maintained and
operated. Regularly inspect the engine block
heater wiring and connector for damaged or
frayed wires. Do not use the heater if there are
any signs of problems. Contact your Authorized
Service Center or the manufacturer of the heater
if you are in need of repairs or information.
Using special cold-starting equipment will help the engine
start easier. And in cold weather, fast engine starting helps
relieve the loads on the electrical system and cranking motor.
If you follow these few simple guidelines, you will extend the
service life of your vehicle's engine:
• Keep the electrical system in top condition.
• Use the best quality and recommended grade of fuel
(see Engine Operation and Maintenance Manual).
• Use the recommended engine lubricating oil.
• As stated in the Normal Starting Procedures, when temperatures are below normal, fully depress the accelerator pedal after engaging the starter.
Medium Duty (R10/06)
CAUTION: Always unplug the heater before
starting the engine. Damage to the cooling system could occur if the heater is not turned OFF
(unplugged).
When the temperature falls below 0°F (–18°F) for Caterpillar
engines, or –10°F (–24°C) for Cummins engines, the block
heater is required.
Y53-6008
– 61 –
Operating the Engine
Operating Instructions
• Use a solution of half ethylene glycol antifreeze and half
water for best heater performance. Do not exceed 60
percent concentration of antifreeze, as it can shorten
heater life. See page 146 for more information.
• After servicing the cooling system, operate the vehicle
for a day or two before using the heater. Trapped air
inside the engine needs time to escape.
Cold Weather Starting—Air Intake Heater
Do not use ether or any other starting fluid as a cold starting
aid in your Medium Duty. Engine conditions are automatically
monitored and in cold weather the fuel/air mixture is preheated in the manifold.
WARNING! Do not use ether or other starting fluids as a cold-starting aid in your Medium Duty.
Your engine uses either an electrical grid or an
open flame inside the manifold, to heat the air/
fuel mixture for cold weather starting. If ether or
another starting fluid is used, the air/fuel will
ignite inside the manifold, which could cause an
explosion and severe injury.
– 62 –
With each engine make, the air intake heating system works
differently. To understand fully how your engine's heating system operates, see the engine Operation and Maintenance
Manual for details.
On most systems the engine block temperature is monitored
at startup; other systems monitor the engine oil pressure,
coolant temperature, and time, as well. When the pre-set
conditions are met, the heater automatically engages.
Air Intake Heater
The air intake heater system will alert you when the engine
requires preheat. On the dash is a “WAIT TO START” warning light (See page 20). This light alerts you to wait before
starting the engine.
Turn the key to IGN & ACC: the WAIT TO START light will
light up for bulb check.
Wait until the WAIT TO START light goes off before you start
the engine.
When the WAIT TO START light goes off, the preheat cycle is
complete and you can start the engine normally.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Operating the Engine
After the engine starts and until operating conditions reach a
certain point, the system will continue to operate to eliminate
white-smoke exhaust.
NOTE: In colder climates where the temperatures are often below freezing, sufficient warmup for turbocharged engines is especially important. Chilled external oil lines leading to the turbocharger will slow the oil flow until the oil
warms, reducing oil available for the bearings.
Watch the engine oil pressure gauge for a
warming trend before increasing engine idle
speed (rpm).
Engine Warm–Up and Idling
The purpose of engine warm-up is to allow an oil film to be
established between pistons, shafts, and bearings while your
engine gradually reaches operating temperature.
Warm–Up Procedure
1. After you have started the engine, idle the engine at
approximately 600 rpm while you check vital engine systems:
– oil pressure
– air pressure
– alternator output (with the optional voltmeter)
2. Before placing engine under a load, continue warm-up
with the engine at 900 to 1000 rpm for 3 to 5 minutes.
• When a cold engine is started, increase the engine
speed (rpm) slowly to be sure adequate lubrication
is available to the bearings and to allow the oil pressure to stabilize. In extremely cold temperatures,
you may have to increase idle speed.
Medium Duty (R10/06)
3. Continue the engine warm-up until the coolant temperature reaches at least 130°F (54°C). At this temperature,
you can use partial throttle. Wait until the coolant temperature is at least 160°F (71°C) before operating at full
throttle. See “Operating Manual Transmissions” on page
67.
Y53-6008
WARNING! Exhaust fumes from the engine contain carbon monoxide, a colorless and odorless
gas. A poorly maintained, damaged, or corroded
exhaust system can allow carbon monoxide to
enter the cab or sleeper. Failure to properly
maintain your vehicle could cause carbon monoxide to enter the cab and cause serious illnesses.
– 63 –
Operating the Engine
Operating Instructions
WARNING! Never idle your vehicle for prolonged
periods of time if you sense that exhaust fumes
are entering the cab. Investigate the cause of the
fumes and correct it as soon as possible. If the
vehicle must be driven under these conditions,
drive only with the windows slightly open. Failure to repair the source of the exhaust fumes
may lead to personal harm.
damage from lack of lubrication. The normal torsional
vibrations generated can also cause transmission wear.
• During the time it takes you to drink a cup of coffee, your
engine can cool as much as 60° F (33° C) below normal
operating temperature. To keep the engine warm during
a short break, turn it off. Do not allow your engine to idle
longer than five minutes.
Idling the Engine
Engine Fan Switch (Option)
Under most circumstances, continuous idling of your engine
merely wastes fuel. In severe Arctic weather conditions, however, you may need longer idling to be sure all parts of your
engine are fully lubricated.
Your Medium Duty may have an engine fan switch installed
as an option. The switch, which is mounted on the accessory
switch panel, allows you to control the engine fan manually or
automatically.
CAUTION: Do not allow your engine to idle, at
low rpm (400–600 rpm), longer than five minutes.
Long periods of idling after the engine has
reached operating temperatures can decrease
engine temperature and cause gummed piston
rings, clogged injectors, and possible engine
• With the ignition key switch ON and the fan switch in the
ON position, the engine fan will be on regardless of
engine temperature.
• With the engine fan switch in the AUTOMATIC position,
the engine fan will automatically turn on when the engine
coolant reaches a temperature of about 200°F (93°C)
– 64 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Operating the Engine
WARNING! Do not work on or near the fan with
the engine running. Anyone near the engine fan
when it turns on could be seriously injured. If it
is set at MANUAL, the fan will turn on any time
the ignition key switch is turned to the ON position. In AUTO, it could engage suddenly without
warning. Before turning on the ignition or
switching from AUTO to MANUAL, be sure no
workers are near the fan.
Cruise Control (Option)
This feature improves fuel mileage and reduces driver
fatigue by maintaining a constant vehicle speed. The
cruise control will only operate above a programmed minimum vehicle speed, 15 mph for the CAT 3126B engine,
30 mph for the Cummins ISC engine.
Engaging the Cruise Control
CAUTION: The fan or equipment near it could be
damaged if the fan turns on suddenly when you
do not expect it. Keep all tools and equipment
away from the fan.
NOTE: Do not operate the engine fan in the MANUAL position for extended periods of time. The fan
hub was designed for intermittent operation. Sustained operation will shorten the fan hub's service
life as well as reduce fuel economy.
02901
NOTE: Ensure that the vehicle speed is above the
minimum cruise control speed and the engine
speed is above 1100 rpm.
1. Move the ON/OFF switch to the ON position.
NOTE: Toggling the SET/RESUME switch to the
RESUME position at this point will select the previously set cruise speed.
2. Accelerate the vehicle to the desired cruise speed.
Medium Duty (R10/06)
Y53-6008
– 65 –
Operating the Engine
Operating Instructions
• Move the ON/OFF switch to the OFF
position.
3. Toggle the SET/RESUME switch lever to the SET position to set the cruise speed. This toggle switch has additional functions that are set by the manufacturer. The two
functions are:
or
02901off
• Depress the brake pedal.
• To decrease the cruise set speed,
hold the SET/RESUME switch in the
RESUME position and coast to a
lower speed.
• To increase the cruise set speed,
hold the SET/RESUME switch in the
SET position; this will accelerate the
vehicle to a higher speed.
Disengaging the Cruise Control
or
• Depress the clutch pedal.
02901b
Reengaging the Cruise Control
1. Move the ON/OFF switch to the ON position.
02901a
or
2. Toggle the SET/RESUME lever to the RESUME position.
Do one of these steps to disengage the cruise control:
– 66 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Operating the Transmission
OPERATING THE TRANSMISSION
Operating Manual Transmissions
If your truck has an automatic transmission, go to page 71.
Introduction
6, 9, 10, and 11–Speed Manual
Your Medium Duty is equipped with either a manual or automatic transmission with special features and gearing to meet
your particular needs. It is important for you, the driver, to
understand how your particular transmission is operated. To
do this, you have two sources of information: this Operator's
Manual and the transmission manufacturer's Driver/Operator's Instruction Manual. Because of the variety of different
transmissions installed in Medium Duty vehicles, operating
procedures for your particular transmission are not included
in this manual; therefore, you should read and understand
both manuals. Read the general guidelines and instructions
that follow and read the specific instructions contained in the
transmission manufacturer's manual that is included with
your vehicle.
NOTE: You will find a shift pattern diagram in the
cab. Check to be sure you know the correct
sequence for your particular transmission.
Medium Duty (R10/06)
The 6–speed synchronized manual transmission has 6 forward speeds and 1 reverse. The 9–speed transmission has 9
forward and 2 reverse speeds, consisting of a 5–speed low
range section and a 4–speed high range section.
For specific instructions on operating one of the optional 10or 11-speed transmissions, consult the transmission manufacturer’s Driver/Operator Instruction Manual.
Transmission Warm–Up
In cold weather [below 32°F (0°C)], you may find shifting
sluggish when you first start up. Transmission warm-up is
especially important at this time, but it is always a good idea
to warm your transmission oil before starting out on the road.
To warm the transmission lubricating oil during engine warmup:
Y53-6008
– 67 –
Operating the Transmission
Operating Instructions
1. Put the transmission in Neutral.
2. Release the clutch pedal and let the transmission operate in Neutral for three to five minutes prior to shifting into
either a forward or reverse range.
Putting the Vehicle in Motion
After making sure the vehicle's oil and air pressure are correct and all other parts and systems are in proper working
condition:
1. If your truck is equipped with a hand throttle, disengage
the hand throttle before driving the vehicle.
2. Fully depress the clutch pedal until the clutch brake
makes contact (see page 69). The contact will occur at
about 1 inch or less from the floorboard.
• The total stroke of the clutch pedal is about 10
inches. The first 1½ inches is free travel. After the
free travel comes the release stroke, which is the
part that fully releases the clutch. The last inch
engages the clutch brake.
• Always start out in a low gear. Starting in a higher
gear, even with a light load, will cause a very jumpy
start and excessive wear.
– 68 –
CAUTION: Always use first gear or a low speed
range to start the vehicle in motion. The use of a
higher gear or speed range forces undue strain
on the engine, clutch, other transmission components, and may cause damage.
3. Evaluate the road surface conditions and terrain your
vehicle is on. Select a gear low enough to let your vehicle
start forward with the throttle at idle.
4. Push the parking brake valve handle (Yellow) against the
dash panel to release the brakes.
5. Release the clutch pedal, then gradually accelerate to
permit smooth starting,
6. Do not allow your vehicle to roll (even a little) in the opposite direction during clutch engagement. If you need to
start up on an incline, apply your service brakes before
you release the parking brake. Then release your service
brakes as you engage the clutch and apply throttle.
For further instructions on operating your transmission, see
the transmission manufacturer's manual that is included with
your vehicle.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Operating the Transmission
If you have a misaligned gear condition in your vehicle's
transmission and cannot start, gradually release the clutch,
allowing the drive gear teeth to line up properly. Then the
drive gear can roll enough to allow the teeth to line up properly and complete the shift.
The best engine performance and maximum economy is
obtained if gears are properly selected. This efficiency is
achieved by always selecting gears within optimum engine
rpm, which is where maximum torque and power are
obtained. For further information, see “More Driving Tips and
Techniques” on page 98.
Shifting Gears in a New Vehicle
Shift carefully in a new vehicle. The transmission may be a little stiff at first. Avoid gear clashing by closely following these
procedures.
When you are operating a new vehicle or one that has been
exposed to cold weather, you want the transmission lubricant
(fluid) to circulate and coat the contacting surfaces of the
gears. Metal contacting metal in moving parts may seriously
damage your transmission—do not drive in one gear for long
periods of time until the transmission lubricant has a chance
Medium Duty (R10/06)
to coat all contacting surfaces. Carefully observe the free
travel in the clutch for the first few hundred miles. As the
clutch lining wears and high spots get worn smooth, you will
get less free travel.
Clutch Brake and Travel (9–, 10–, and 11–Speed
Transmissions only)
These transmissions utilize a clutch brake, rather than synchronizers. The clutch brake works by stopping all of the
gears in the transmission, allowing you to easily shift into first
gear or reverse without grinding gears. The total stroke of the
clutch pedal is about 10 inches. The first part is the release
stroke: the part that fully releases the clutch. The last inch
engages the clutch brake.
During hard-shifting with vehicle not moving
• To apply the clutch brake (while the vehicle is stopped)
fully depress the clutch pedal to the floorboard to stop
the gears. With the throttle at idle, select first gear then
release the clutch pedal to let the vehicle start forward,
until the clutch is fully engaged. See the transmission
manufacturer's manual that is included with your vehicle
for further details.
Y53-6008
– 69 –
Operating the Transmission
Operating Instructions
To double clutch:
During Normal Driving
If you want to shift directly into any gear other than first or
reverse, depress the clutch pedal only far enough to release
the clutch. Pushing the clutch to the floor applies the clutch
brake and could cause gear hang-up.
CAUTION: Be careful not to apply the clutch
brake while the vehicle is moving. The purpose
of the clutch brake is to stop the transmission so
that you can shift into a starting gear without
grinding gears. Applying the clutch brake when
the vehicle is moving causes a braking effect on
the drivetrain and shortens the service life of the
clutch brake.
1. Push the clutch pedal down to disengage the clutch.
2. Move the gear shift lever to Neutral.
3. Release the pedal to engage the clutch. This lets you
control the rpm of the mainshaft gears, allowing you to
match the rpm of the mainshaft gears to those of the output shaft.
• Upshifts: let the engine and gears slow down to the
rpm required for the next gear.
• Downshifts: press accelerator, increase engine and
gear speed to the rpm required in the lower gear.
4. Now quickly press the pedal to disengage the clutch and
move the gear shift lever to the next gear speed position.
5. Release the pedal to engage the clutch.
Double Clutching
Whether you are upshifting or down shifting, it is best to double clutch. Double clutching is easier on the transmission and
on the engine, helping your vehicle match engine speed with
driveline speed and achieving clash-free shifts.
More Transmission Tips
“Riding” the Clutch
The clutch is not a footrest. Do not drive with your foot resting
on the clutch pedal. It will allow your clutch to slip, causing
excessive heat and wear—damage could result.
– 70 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Operating the Transmission
Release Bearing Wear
When you must idle your engine for any period of time, shift
your transmission to Neutral and disengage the clutch (take
your foot OFF of the pedal). This helps prevent unnecessary
wear to your clutch release bearing, and it is less tiring for
you, too.
Operating Automatic Transmissions
Clutch Adjustment
Inspect manual clutches according to the manufacturer's recommendations. Regular maintenance should be followed to
maintain correct clutch adjustment. Have your dealer's Service Department perform any adjustment necessary.
Tips
• Always use the clutch when making upshifts or downshifts.
• Always select a starting gear that will provide sufficient
gear reduction for the load and terrain.
• Never downshift when the vehicle is moving too fast.
Medium Duty (R10/06)
• Never slam or jerk the shift lever to complete gear
engagement.
• Never coast with the transmission in Neutral and the
clutch disengaged.
• To provide smooth gear engagements while shifting, use
proper coordination between shift lever and clutch.
An automatic transmission makes shifting much easier,
however it is important to understand how to operate the
transmission efficiently. Please read the transmission
manufacturer’s operation manual supplied with your vehicle.
There may not be a “park” position with your automatic
transmission. Always be sure you apply the parking brake
before leaving the cab.
Y53-6008
WARNING! Do not leave the cab of your vehicle
without applying the parking brake. The truck
could roll and cause an injury accident. Always
apply the parking brake before you leave the cab.
– 71 –
Using the Brake System
Operating Instructions
USING THE BRAKE SYSTEM
NOTE: Today’s diesel engines have significant
torque and startability power at low RPMs. Combinations of engine speed and available torque may
overpower the vehicle’s parking brakes.
WARNING! Never drive your vehicle with the
parking brakes applied. Always release the parking brakes prior to moving the vehicle. Failure to
disengage the parking brakes prior to moving
your vehicle could result in excessive heat buildup of the brakes and start a fire.
NOTE: If your truck is equipped with hydraulic
brakes, go to page 88.
This air brake system is a multiple circuit type: it has a circuit
for the front wheels, a separate circuit for the rear wheels,
and one for the trailer (tractors only). The system is supplied
by a compressor driven by the engine. The vehicle's compressor takes outside air and compresses it, usually to 100–
130 psi (690–896 kPa). This compressed air then goes to the
reservoirs to be stored until needed.
When you operate your air brakes, the stored compressed air
flows into the chambers where it is used to apply your truck
and trailer brakes. That is why, when you push down on the
brake pedal, you do not feel the same amount of pressure on
the pedal that you do when you apply the brakes on your car.
All you are doing on your truck is opening an air valve to allow
air to flow into the brake chambers.
Introduction
The operation of the vehicle's braking system and many vehicle accessories depends upon the storage and application of
a high-pressure air supply.
– 72 –
Y53-6008
WARNING! The brake system is a critical vehicle
safety system. For the safety of you and others
around you, have the vehicle submitted for periodic preventive maintenance checks as well as
having any suspected problems immediately
checked by an Authorized Service Center. Failure to properly maintain your brake system can
lead to serious injury accidents.
Medium Duty (R10/06)
Operating Instructions
Using the Brake System
Brake Operation
WARNING! Do not drive through water deep
enough to wet brake components, as it may
cause the brakes to work less efficiently than
normal. The vehicle's stopping distance may be
longer than expected, and the vehicle may pull
to the left or right when brakes are applied,
which could contribute to an accident.
If you think your brakes have become wet, check the rear and
both sides of the vehicle for clear traffic, then gently apply the
brakes, releasing and gently reapplying until the brakes dry
out—restoring normal operation. Always check your brakes
after driving through deep water to help reduce the possibility
of personal injury or an accident.
Front Brake System
When the brake pedal is depressed, the front circuit portion
of the treadle valve delivers air from the front service reservoir to the front axle brake chambers via a quick-release
valve.
Medium Duty (R10/06)
Simultaneously (on full truck configurations), air is also supplied to the modulating valve control port. In the event of a
rear service circuit failure, the modulating valve will exhaust
air from the spring brake chambers, applying the spring
brakes in proportion to the front circuit application.
Rear Brake System
When the brake pedal is depressed, the rear circuit portion of
the treadle valve delivers air from the rear service reservoir to
the service brake relay valve control port. The relay valve
then delivers air directly from the rear service reservoir to the
rear brake chambers in proportion to the treadle pressure.
On tractors without ABS, the relay valve is part of the BP-R1
brake valve, which automatically proportions the drive axle
brake application pressure when driving bobtail (without a
trailer connected). The proportioning BP-R1 brake valve
allows full use of the steer axle (front) brakes and reduces
the chance that the drive axle brakes will lockup. The bobtail
brake proportioning system is automatically turned off when
a trailer is connected.
Y53-6008
– 73 –
Using the Brake System
Operating Instructions
Using the Parking Brake
Before you leave the cab:
The yellow diamond-shaped knob on the dash controls the
truck/tractor parking brakes. These are spring brakes that
you activate by releasing air pressure from their chambers.
When they are not in use, air pressure compresses the
springs and releases the brakes. Pulling the knob OUT
applies the parking brake, which exhausts air from the chambers and allows the springs to extend and apply the brakes.
WARNING! Do not pull out the parking brake
valve while the vehicle is moving. Stopping with
the parking brake controls can cause a sudden
wheel lock-up, loss of control, or over-take by
following vehicles. You could be severely
injured.
1. Apply all parking brakes. Pull out the Yellow Parking
Brake Control knob located on the dash. The Red (octagon-shaped) Trailer Air Supply Control knob on tractors
will automatically pop out. (An optional dash warning
light will indicate when the brake is ON.)
2. Shift the transmission into PARK position:
• manual transmission, select First or Reverse gear
• automatic transmission, select Neutral.
3. Turn the key to OFF.
4. Remove the key.
WARNING! Do not leave the cab without applying the parking brake. The truck could roll and
cause an injury accident. Always apply the parking brake before you leave the cab.
38//
72 $33/<
3$5.,1*
%5$.(
386+ 72
5(/($6(
02394-1
Full Truck Parking Brake Control Knob
– 74 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Using the Brake System
To release the trailer brakes ONLY:
(2) Trailer Air Supply
Control (Red)
(1) Parking Brake Control
(Yellow)
• Push IN the Red knob on the dash. The truck or tractor
will remain parked.
To release the full combination of brakes:
02394
• Push IN BOTH knobs on the dash.
• In the event that air pressure is reduced below a safe
level: the low air warning light will come on first; if air
pressure continues to drop, the parking brake valve will
pop OUT, automatically applying the spring brakes.
Combination (Tractor/Trailer) Parking Brake Control Valves
The parking brakes act on the rear wheels only. They are
spring-applied, with air pressure used to release them.
Release air is supplied by both the front and rear circuit reservoirs through a double check valve.
To release the truck or tractor parking brakes ONLY:
• Push IN the Yellow knob on the dash. Your trailer will
remain parked.
Below 60 psi (414 kPa) the Yellow parking brake valve
remains OUT (ON position). If air pressure is not
restored above 60 psi (414 kPa), the knob will automatically return to the OUT position if you attempt to push it
in. See page 26 for more information.
Medium Duty (R10/06)
Y53-6008
CAUTION: Do not try to put the vehicle in
motion before pressure in the system reaches
100 psi (689 kPa) because the wheels are
locked by the spring brake action.
• Unnecessary stress and possible brake malfunction could occur if the vehicle is forced to
move before the air system reaches 100 psi (689
kPa).
• Below 60 psi (414 kPa) the parking brake valve
button remains in the applied (ON) position. If air
pressure is not restored, the button will automatically return to its initial position.
– 75 –
Using the Brake System
Operating Instructions
WARNING! If the air pressure falls below 60 psi
(414 kPa) the spring brakes may stop the vehicle abruptly, which could result in an accident
and/or injuries. Observe the red warning lamps
on the gauges. If one comes on, do not continue to drive the vehicle until it has been properly repaired or serviced.
WARNING! Do not use the trailer hand brake or
service brakes to park and hold an unattended
vehicle—use the parking brakes. Because service brakes work with air pressure, these
brakes could slowly release. Your vehicle could
roll, causing a serious accident. Someone
could be hurt or killed. Never rely on the service
brakes to hold a parked vehicle.
1. Allow the tractor air system pressure to build up to operating level.
2. When system pressure reaches 50 psi (345 kPa) the
Red knob may be pushed IN.
3. Hold the Red knob IN by hand until the trailer air pressure builds to a pre-set level, about 45 psi. At this point it
will remain in, charging the trailer system and releasing
only the trailer brakes.
4. The Yellow knob will remain OUT (tractor brakes ON).
Normal Run Position
• The Yellow knob (system park) may now be pushed IN,
which will supply air to the tractor spring brakes, releasing them.
Tractor and Trailer Air Supply Valve
Initial Charge
The red octagon knob controls the air supply to the trailer.
With the system completely discharged, both the Red (trailer
air supply) and the Yellow (parking brake) knobs are OUT;
thus, tractor and the trailer parking (spring) brakes are
applied.
– 76 –
To supply air to the trailer system and release the trailer parking brakes:
• With both knobs pushed IN, air is now being supplied to
both the trailer and the tractor spring brakes; all brakes
are released.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Using the Brake System
The parking brakes act on the rear wheels only. They are
spring-applied, with air pressure used to release them.
Release air is supplied by both the front and rear circuit reservoirs through a double check valve.
NORMAL OPERATING
POSITION
TRAILER
AIR
SUPPLY
PARKING
BRAKE
RED
YELLOW
PARK TRAILER WITH
TRACTOR RELEASED OR
BOBTAIL TRACTOR
TRAILER
AIR
SUPPLY
PARKING
BRAKE
SYSTEM PARK OR
CHARGE TRAILER
WITH TRACTOR PARKED
TRAILER
AIR
SUPPLY
RED
PARKING
BRAKE
YELLOW
YELLOW
RED
02393
Trailer Park or Emergency Brake Application Only
To apply the trailer brakes only:
If you ever have a failure or disconnect the air supply hose to
the trailer, the trailer parking brakes will set. The Red knob
will automatically pop OUT and seal off the tractor air reservoirs to protect the tractor air system pressure.
Pull OUT the Red knob. This will exhaust air from the trailer
supply line, causing the tractor protection valve to close and
the trailer spring brakes to apply. The trailer is now in “emergency” or “park.” This mode would be used to uncouple from
the trailer and during bobtail operation (running without a
trailer connected).
Medium Duty (R10/06)
Y53-6008
– 77 –
Using the Brake System
Operating Instructions
WARNING! Do not use the trailer hand brake or
service brakes to park and hold an unattended
vehicle—use the parking brakes. Because service brakes work with air pressure, these brakes
could slowly release. Your vehicle could roll,
causing a serious accident. Someone could be
hurt or killed. Never rely on the service brakes to
hold a parked vehicle.
Trailer Charge
• If both knobs are OUT (combination vehicle is parked),
and it is desired to recharge the trailer, the Red knob
may be pushed IN to repressurize the trailer supply line.
The tractor will remain parked. For more information on
air supply pressure requirements, see page 76.
Parking Tractor and Trailer
• With both knobs pushed in for normal operating modes,
the parking brakes of both the tractor and the trailer may
be applied by pulling the Yellow knob OUT. This will
exhaust the air from the tractor spring brakes, and simultaneously cause the Red knob to pop OUT, which will
apply the trailer brakes. This complies with the FMVSS
121 requirement that one control should apply all the
parking brakes on the vehicle.
– 78 –
Brake Safety and Emergency
Y53-6008
WARNING! Do not operate the vehicle in the
event of a malfunction in any air circuit. The
vehicle should not be operated until the system
is repaired and both braking circuits, including
all pneumatic and mechanical components, are
working properly. Loss of system air can cause
the service brakes to not function resulting in
the sudden application of the spring brakes
causing wheel lock-up, loss of control, or overtake by following vehicles. You could be in an
accident and severely injured.
Medium Duty (R10/06)
Operating Instructions
Using the Brake System
Front Brakes — Truck
The following applies to full truck configurations:
If air pressure is lost in the front circuit, the vehicle front
brakes will not operate. Check valves isolate the rear circuit,
so the rear service brakes and parking brakes are unaffected. The spring brakes will not automatically apply as long
as rear service pressure is maintained.
WARNING! If the remaining system pressure
drops below 60 psi (414 kPa) due to repeated
brake applications, the spring brakes will automatically apply—stopping the vehicle abruptly,
potentially causing serious injury. Observe the
warning light (BRAKE AIR) in the panel. If it
comes on, do not continue to drive the vehicle
until it has been properly repaired or serviced.
Rear Brakes — Truck
The following applies to full truck configurations:
If air is lost in the rear brake circuit, check valves isolate the
front circuit, and front brake operation is unaffected. Because
this is a dual air system, spring brakes will not automatically
apply as long as pressure is maintained in the front circuit.
Medium Duty (R10/06)
When the brake pedal is depressed, the modulating valve
detects the reduction or absence of rear service delivery pressure, and exhausts air from the spring chambers, applying the
spring brakes in proportion to the front brake application.
When releasing the brake pedal, the modulating valve delivers front service air to the spring brake chambers, releasing
the spring brakes in proportion to the front brake application.
Thus, if there is a rear service failure, the remaining front axle
braking is supplemented by modulated spring brake action
on the rear axle.
WARNING! Efficiency of emergency braking
depends on the amount of air available in the
front circuit reservoir, which is sufficient for a
limited number of brake applications and
releases.
• REMEMBER: when the remaining system pressure
drops below 60 psi (414 kPa), the spring brake is
automatically applied, stopping the vehicle abruptly,
potentially causing serious injury. Observe the warning light (BRAKE AIR) in the panel, it will come on
before the spring brakes are applied. If it comes on,
do not continue to drive the vehicle until it has been
properly repaired or serviced.
Y53-6008
– 79 –
Using the Brake System
Operating Instructions
Brakes — Tractor/Trailer
The following applies to tractor/trailer configurations:
If pressure is lost in the tractor front or rear circuit, the “check”
valves isolate the unaffected circuit, allowing this circuit to
continue normal operation. The trailer brakes are still functional.
• If air pressure is lost in the trailer supply/park circuit, and
the pressure drops below 60 psi (414 kPa), the trailer
spring brakes are automatically applied, and the tractor
air pressure circuits are unaffected.
• If air pressure is lost in the trailer brake service circuit,
and the pressure in the tractor front and rear circuits
drops below 60 psi (414 kPa), the tractor and trailer
spring brakes are automatically applied.
Emergency Braking
WARNING! Unless you have an anti-lock braking system, always avoid completely depressing the service brake pedal, if possible, even
during emergency braking. Depressing the
brake pedal too aggressively can cause the
wheels to lock, which can lead to an uncontrolled skid and can result in an accident.
– 80 –
For Non-ABS Vehicles: To stop your vehicle in an emergency, vary the service brake application pressure to provide
maximum braking force without locking the wheels. Use
engine compression to assist the service brakes by not
depressing the clutch pedal until the engine reaches idle
speed.
Overheated Brakes
Under normal braking conditions, the energy generated will
bring the internal brake drum temperature to about 500°F
(260°C). This is well within the safe zone: the maximum safe
temperature of lining for drum type brakes is usually about
800°F (427°C).
But if service brakes are used for emergency braking, used
improperly, or for prolonged periods, internal brake drum
temperatures may exceed 800°F (427°C). Such brake overheating may be detected by a burning smell or smoke coming
from a drum. If this occurs, you should immediately stop and
check for cracked brake drums or lining fires. If neither exists,
get back behind the wheel and resume a slow speed as soon
as possible to cool the brakes. If the vehicle was to remain
stopped, the heat transfer could destroy the linings and distort the brake drum.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Using the Brake System
To prevent drums from distortion while they cool down:
• Park the vehicle on level surface and block the wheels.
• Release the parking brake and allow the brakes to cool
down. See page 74.
ABS lamp will remain on until a speed of no more than 9 mph
has been reached and the speed sensors have been
checked for correct output. The lamp should remain off after
this point unless a failure in the system is detected. The
truck/tractor ABS lamp is located in the warning lamp cluster.
Anti-Lock Braking System
This vehicle may be equipped with an anti-lock braking system (ABS). This ABS reduces the possibility of wheel lockup. If a wheel is about to lock during braking, the ABS will
automatically adjust air pressure to the brake chambers on
the appropriate wheel(s) to prevent wheel lock-up. The ABS
is automatically turned on when the ignition switch is turned
on.
ABS Warning Lamps
CAUTION: If the truck/tractor ABS warning light
does not illuminate when the ignition is first
turned on, there is a problem with the bulb or
wiring. You should have this checked as soon as
possible.
Truck/Tractor ABS Warning Lamp
A truck/tractor ABS warning lamp illuminates when the ignition switch is first turned on and will remain on until the system self-test has been completed successfully. Normally, the
Medium Duty (R10/06)
Y53-6008
– 81 –
Using the Brake System
Operating Instructions
Trailer ABS Warning Lamp
Trucks, tractors, and trailers built on and after March 1, 2001
are equipped with power line communication (PLC) per U.S.
FMVSS 121, including a trailer ABS warning lamp in the cab.
A trailer ABS warning lamp will illuminate for a bulb check
when the ignition switch is first turned on - whether or not a
trailer is connected to the vehicle. If the bulb check is satisfactory, the lamp will next do either of the following:
1. If no trailer is connected, or if a non-ABS-equipped trailer
is connected, the trailer ABS lamp will go off after a few
seconds.
ABS
NOTE: A “properly connected” ABS-equipped trailer
is
• a trailer with PLC hooked up to the J560 connector.
CAUTION: If the trailer ABS warning lamp does
not illuminate when the ignition is first turned
on, there is a problem with the bulb or wiring.
The driver should have this checked as soon as
possible.
NOTE: A successsful warning lamp illumination and
bulb check at ignition on does not indicate that the
trailer you may be connected to has trailer ABS. You
should personally inspect every trailer to determine
its braking system.
• a trailer without PLC that is hooked up to an
optional ISO 3731 connector.
NOTE: For doubles or triples: PLC does not distinguish between trailers. An ABS problem in any
trailer will activate the trailer ABS warning lamp.
2. If an ABS-equipped trailer is properly connected, the
trailer ABS warning lamp will remain illuminated for a few
more seconds while the trailer ABS is tested.
• If no trailer ABS problems are detected, the
lamp will go off.
– 82 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Using the Brake System
• If a trailer ABS problem is detected, the lamp
will remain on. The driver should have the
trailer’s ABS problem corrected before the vehicle is driven with that trailer attached.
WARNING! Do not rely on an anti-lock brake system that is functioning improperly. You could
lose control of the vehicle resulting in a severe
accident and serious personal injury. If your
ABS lamp goes on while you are driving or stays
on after the self-check, your anti-lock system
might not be working. The ABS may not function
in an emergency. You will still have conventional
brakes, but not anti-lock brakes. If the lamp indicates a problem, have the ABS checked.
Wheel Spin Control Warning Lamp
Your ABS may have an acceleration slip regulation (ASR) or
automatic traction control (ATC) feature. Either of these features is monitored by a wheel spin control warning lamp. This
lamp is located in the warning lamp cluster.
The Wheel Spin
and then go out
The Wheel Spin
ever the ASR or
Control warning lamp will briefly illuminate
when the ignition switch is first turned on.
Control warning lamp will illuminate whenATC system detects drive wheel spin. The
Medium Duty (R10/06)
lamp will remain illuminated as long as wheel spin is detected
and the ASR or ATC system is applying the drive wheel
brakes or reducing engine torque. Do not allow the Wheel
Spin Control lamp to remain on continuously for an extended
length of time. Extended, continuous use of the ASR / ATC
can cause overheating of the drive wheel brakes. Engine
torque or vehicle speed should be reduced to eliminate
wheel spin and prevent excessive application of the ASR /
ATC system.
Except for checking for proper illumination of the ABS and
Wheel Spin Control warning lamps when first starting the
truck and for monitoring these lamps while driving, no special
operating procedures are required. For detailed system
description, see service literature for your specific ABS that
was provided with your vehicle.
Trailer Brake Hand Valve
Tractor/trailer vehicles are equipped with a trailer brake hand
valve mounted on the right side of the steering wheel column.
This hand valve provides air pressure to apply the trailer
brakes only. It operates independently of the foot treadle
valve.
Y53-6008
– 83 –
Using the Brake System
Operating Instructions
To operate the trailer brake hand valve:
Do not use the engine retarder (such as an exhaust brake) to
slow the vehicle down when you are bobtailing or pulling an
empty trailer.
• Pull down on the lever.
• The valve is self-returning. When pressure is removed
from the valve lever, it will return to the OFF position.
WARNING! Do not use an engine retarder when
you are driving bobtail or with an unloaded
trailer. Using engine retarders while bobtailing
or with an unloaded trailer can cause a wheel
lockup resulting in less control and/or jackknife.
The trailer may not load the rear tractor tires
enough to provide necessary traction. When you
are bobtail or unloaded, you can have a serious
accident if your wheels lock suddenly during
braking—you could be severely injured.
NOTE: The trailer brake is not to be used as a substitute for the service brakes. Using this brake frequently, instead of using the foot brake, will cause
the trailer brakes to wear out sooner.
WARNING! Do not use the trailer hand brake or
service brakes to park and hold an unattended
vehicle—use the parking brakes. Because service brakes work with air pressure, these brakes
could slowly release. Your vehicle could roll,
causing a serious accident. Someone could be
hurt or killed. Never rely on the service brakes to
hold a parked vehicle.
Driving Bobtail or With an Unloaded Trailer
NOTE: The following information is applicable only
to tractor configurations.
– 84 –
Bobtail Brake Proportioning System
When a trailer is not connected, the drive axle brake application pressure will automatically be limited by the proportioning system.
The brake proportioning system regulates the application
pressure to the rear drive axle. To provide equivalent braking
power, tractors (driven bobtail) will require greater brake
pedal application than other types of vehicles not equipped
with a proportioning system.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Using the Brake System
WARNING! The service brakes must be used in
an emergency. The engine or retarder alone
might not stop you fast enough to prevent an
accident. You could be badly hurt if you relied
only on the engine retarder.
On tractors that do not have anti-lock brake systems (ABS) a
bobtail brake proportioning system is installed. When a trailer
is not connected (bobtail mode), the brake application pressure (on the rear drive axle) will automatically be limited by
the proportioning system.
Engine Retarder (option)
An engine retarder or exhaust brake may be installed (as an
option) to create a braking effect on the drive wheels. This
device uses your engine's power to slow your vehicle down.
Because it can help keep your vehicle's brakes from overheating, it can save wear and tear on the service brakes.
However, the retarder is not an emergency brake.
Ideally (on normal road surfaces), you should slow your vehicle with the retarder (where permitted by law) and use the
service brakes only for stopping completely. Operating this
way will greatly prolong the life of the brakes.
Medium Duty (R10/06)
• The engine retarder is NOT intended as the primary
brake for the vehicle, nor is it an emergency brake.
The engine retarder only helps the service brakes by
using pressure to slow the drivetrain. Use the service brakes for quick stops.
Exhaust Brake
With the exhaust brake switch ON, the brake automatically
creates its braking effect when you remove your foot from the
accelerator pedal.
The brake switch is located on the accessory dash panel. It
controls whether the brake is ON (ready to slow the vehicle
down) or OFF (no braking action).
• Do not use the engine retarder (such as an exhaust
brake) to slow the vehicle down when you are bobtailing
or pulling an empty trailer.
• Make sure the brake is OFF before starting the engine.
Y53-6008
– 85 –
Using the Brake System
Operating Instructions
• After the engine is started, warmed up, and you are
ready to get under way, turn the exhaust brake switch
ON for added braking effect.
WARNING! Do not use the engine retarder when
operating on road surfaces with poor traction
(such as wet, icy, or snow covered roads or
gravel). Retarders can cause the wheels to skid
on a slippery surface. You could lose control of
the vehicle and/or jackknife if the wheels begin
to skid, resulting in an accident.
However, if your vehicle is equipped with Rockwell/WABCO
anti-lock brakes (ABS), the operation of the exhaust brake (if
turned ON) will be controlled by the ABS. For more ABS
information, see “Anti-Lock Braking System” on page 81.
For more information on when and how to use the engine
retarder in your vehicle, see the owner’s manual for the
engine brake that is included with your vehicle.
Brake Components
The following is a brief description of the air/brake system. It
is intended to supply you with general information on how the
system works. For complete information see the Medium
Duty Maintenance Manual.
Compressor: supplies air to the system. System pressure is
controlled by the governor.
Governor: controls the air pressure in the system by actuating the compressor discharge mechanism. Its cut-out pressure is 115 to 125 psi (793 to 862 kPa). Its preset cut-in
pressure is set to between 13 to 25 psi (90 to 172 kPa) below
the cut-out pressure setting (cut-out and cut-in interval is not
adjustable).
Safety Valve: installed on the supply reservoir outlet. It
should “vent off ” at 150 psi (1034 kPa) permitting air to
escape.
Air Dryer (Option): collects and removes moisture and contaminants from the air as it travels from the compressor to the
wet tank (reservoir).
– 86 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Using the Brake System
Compressed Air Tanks: The wet (supply) and dry (service)
tanks are located behind the battery box and on the frame
rail; the supply tank is below the front service tank. See “Air
Tanks” on page 162.
• Modulates spring brake application in proportion to front
service application in the event of a rear service failure.
• Prevents compounding of service and spring applications.
The wet tank receives air from the air dryer and cools it
somewhat, allowing moisture to condense for draining. Relatively dry air is then supplied to the two service tanks for distribution to their respective brake circuits. The service tanks
are isolated from each other by check valves.
Relay valve (full truck): speeds up the application of the
rear service brake. It also incorporates a quick–release feature.
Dual Service Brake Treadle Valve: delivers air to the two
service brake circuits.
Double Check Valve: directs the higher air pressure from
either the rear (primary) or front (secondary) service tank to
the modulating valve.
Modulating Valve (SR–1): used only on full trucks, not tractors. It performs four functions:
• Limits spring brake hold-off air pressure delivered to the
spring brake chambers.
• Provides a quick release of air pressure from the spring
brake chambers to speed spring brake application.
Brake Proportioning (BP-R1) valve (tractor): t h i s v a l v e
delivers air to the tractor's service brake chambers. It automatically proportions the drive axle brake app
lication pressure when driving bobtail (without a trailer connected). Proportioning the brakes allows full use of the steer
axle brakes and reduces lockup of the drive axle brakes. The
bobtail brake proportioning system is automatically turned off
when a trailer is connected.
Quick–Release Valve: speeds the release of air from the
brake chambers. When air is released, the air in the brake
chambers is exhausted at the quick-release valve, rather
than exhausting back through the treadle valve.
Single Check Valve: allows air flow in one direction only.
Medium Duty (R10/06)
Y53-6008
– 87 –
Using the Brake System
Operating Instructions
Parking Brake Valve: yellow diamond-shaped knob. It controls the application and release of the parking (spring)
brakes of truck or tractor-trailer combinations or of the tractor
alone. If the air system is being charged from zero pressure,
the parking brake valve will not hold in the release position
until the system pressure exceeds 60 psi (414 kPa), which is
the pressure required to override the load of this valve's
plunger return spring.
Trailer Supply Valve (tractor): The Red octagonal-shaped
knob protects the tractor system; it functions in conjunction
with the parking brake valve (yellow). The trailer supply valve
is responsible for synchronizing the tractor and trailer parking
and emergency brakes. If the air system is being charged
from zero pressure, the trailer supply valve will not hold in the
applied position until the system pressure exceeds 50 psi
(345 kPa). It automatically pops out and exhausts air if supply
air pressure drops below 60 psi (414 kPa).
Tractor Protection Valve: The functions of this valve are to
(1) receive all pneumatic signals pertinent to the operation of
the trailer brake system, (2) transmit these signals to the
trailer, and (3) protect the tractor air supply in case of separation of the air lines connecting the tractor to the trailer.
– 88 –
Hydraulic Brakes
WARNING! Do not operate the vehicle in the
event of a malfunction in any air or hydraulic circuit. Such a malfunction may prevent the brake
system from operating properly, and could
result in an injury accident. The vehicle should
not be operated until the system is repaired and
both braking circuits, including all pneumatic,
hydraulic, and mechanical components are
working properly.
Introduction
The operation of the vehicle's braking system is based on the
principle of hydraulics. Hydraulic action begins when force is
applied to the brake pedal. This force creates hydraulic pressure in the master cylinder and is amplified with assistance of
a power booster. The supplemental boost in force is developed when pressurized power steering fluid from the steering
pump presses on the master cylinder piston. As a safety precaution, the pressurized fluid from the master cylinder has
two mutually independent circuits. The primary circuit supplies the front wheels while the secondary circuit supplies the
rear wheels. The displaced fluid from the master cylinder
travels through brake pipes terminating at the wheel cylin-
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Using the Brake System
ders which actuate the brake pad mechanisms. Actuation of
these mechanisms force the brake pads against the rotors to
stop the wheels.
A reserve electric motor pump provides a redundant power
source for the hydraulic booster in the event normal flow from
the power steering pump is interrupted. Manual braking is
also available in the event both the power and reserve systems are inoperative.
WARNING! Never drive your vehicle with the
parking brakes applied. Always release the parking brakes prior to moving the vehicle. Failure to
disengage the parking brakes prior to moving
your vehicle could result in excessive heat buildup of the brakes and start a fire.
NOTE: Today’s diesel electronic engines have significant torque and startability power at low RPM.
Combinations of engine speed and available torque
may over-power the vehicle’s parking brakes.
WARNING! The brake system is a critical vehicle
safety system. For the safety of you and others
around you, have the vehicle submitted for periodic preventive maintenance checks as well as
having any suspected problems immediately
checked by an Authorized Service Center. Failure to properly maintain your brake system can
lead to serious injury accidents.
Brake Components
The following is a brief description of the hydraulic brake system. It is intended to supply you with general information on
how the system works. For complete information see the
Peterbilt Medium Duty Maintenance Manual.
Anti-Lock Brake System (ABS) Modulator Valve Body:
adjusts brake fluid flow between the master cylinder and the
wheel calipers to avoid wheel lockup.
ABS Warning Lamp: lights when the ABS controller detects
wheel lock-up while driving and activates the ABS. Lights
also when a fault in the ABS is detected.
Brake Fluid Reservoir: stores brake fluid and offers a place
to replenish when needed.
Medium Duty (R10/06)
Y53-6008
– 89 –
Using the Brake System
Operating Instructions
Brake Master Cylinder: translates brake pedal force into
hydraulic fluid pressure in the primary and secondary circuits.
Hydraulic Booster: The hydraulic booster applies additional
hydraulic force from the power steering gear to the master
cylinder piston when the brake pedal is applied.
Brake Pedal: applies actuation force from operator's foot to
the master cylinder pistons.
Parking Brake Lamp: illuminates when the parking brake is
engaged (the lever is in the up position.)
Brake Warning Lamp: illuminates when either power steering fluid flow is interrupted or when a pressure differential is
present in the primary and secondary brake fluid pressure.
Either case adversely affects braking operation.
Parking Brake Lever: the hand lever located in the cab
which engages or disengages the driveline drum brake.
Differential Switch: measures the hydraulic fluid pressure
difference between the primary and secondary circuits.
Electrohydraulic Pump: The Electrohydraulic (EH) pump is
used as a backup boost pump. The EH pump turns on and
provides fluid pressure to the hydraulic booster in the event
power steering fluid stops flowing through the booster head.
Front and Rear Wheel Calipers: translate hydraulic fluid
pressure into force applied at each wheel-end brake rotor to
retard wheel motion.
– 90 –
Power Steering Flow Switch: senses flow of power steering
fluid.
Power Steering Fluid Reservoir: stores power steering fluid
and offers a place to replenish when needed.
Power Steering Gear: assists the steering operation and
sends pressurized power steering fluid to the brake booster.
Power Steering Pump: draws power steering fluid from the
reservoir and sends it to the power steering gear.
Warning Buzzer: sounds when either power steering fluid
flow is interrupted or when a pressure differential is present
between the primary and secondary brake fluid pressure.
Either case adversely affects braking operation.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Using the Brake System
Brake Warning Lamp
When the brake warning lamp comes on, it indicates a malfunction in the brake system. Possible malfunctions include
loss of hydraulic pressure from the power steering circuit or a
pressure differential between the primary and secondary
brake circuits.
MIRROR
HEAT
0
OIL
WARNING! Do not operate the vehicle if the
brake light or buzzer comes on. The light or
buzzer indicates a failure in one of the brake
components/system. Drive your vehicle to the
side of the road immediately. Failure to do this
may lead to an accident and severe injury.
!
LOW
WATER
WATER
BRAKE
SERVICE BRAKE WARNING INDICATOR
If the buzzer sounds while driving, or if the BRAKE light
comes on, do the following:
1. Slow down carefully.
Here are some things you can do to assist in slowing
the vehicle:
• Downshift - Putting the transmission into a lower
gear will help slow the vehicle.
Medium Duty (R10/06)
Y53-6008
– 91 –
Using the Brake System
Operating Instructions
• Pump the brakes - Pumping the brake pedal may
generate enough hydraulic pressure to stop the
vehicle.
• Use the parking brake - The parking or emergency
brake is separate from the hydraulic system. Therefore it can be used to slow the vehicle.
2. Move a safe distance off the road and stop.
3. Set the parking brake. (See page 36.)
4. Turn on the emergency flasher and use other warning
devices to alert other motorists.
• Place transmission in lower gear.
• Gently press on the brake pedal.
• Increase engine speed while keeping light pressure
on the brake pedal for a short distance to dry out the
brake linings.
• Overheated Brakes
Wet or Overheated Brakes
• Wet Brakes
If you have been driving in heavy rain or deep standing water, your brakes will get wet. Water in the
brakes can cause them to be weak, to apply
unevenly, or to grab. These conditions can cause a
lack of braking power, wheel lockups, or pulling of the
vehicle to one side or the other.
Avoid driving through deep puddles or flowing water if
possible. If not possible, you should to the following:
• Slow down.
– 92 –
Y53-6008
While traveling down steep hills, gravity will tend to
speed you up. You must go slow enough that your
brakes can hold you back without getting too hot. If
you ride the brake pedal and the brakes get too hot,
they may “fade”, causing you to press even harder in
an attempt to maintain your desired stopping power.
The brakes may even fade so much that you won’t be
able to slow down or stop at all.
Using lower transmission gears will help keep the
vehicle from going too fast. Using lower gears allows
engine compression and friction to help slow the
vehicle. Be sure to be in the right gear before you
start down a hill, especially if you have a manual
transmission. You could get hung up in NEUTRAL
and lose the benefit of engine braking. “Coasting” is
illegal, and also VERY dangerous.
Medium Duty (R10/06)
Operating Instructions
Using the Brake System
Anti-Lock Braking System
This vehicle is equipped with an Anti-Lock Braking System
(ABS). ABS reduces the likelihood of a wheel locking. If a
wheel is about to lock during braking, the ABS will automatically adjust hydraulic pressure to the brake calipers on the
appropriate wheel(s) to prevent wheel lock-up. The ABS is
automatically activated when the ignition switch is turned on.
CAUTION: The center pin of the 7-way trailer light
line may be constantly powered for ABS. Make
sure it will not accidently turn on trailer equipment.
ABS Warning Lamp
The ABS warning lamp will come on briefly, then go off, when
the key switch is first turned on. If the lamp remains ON until
a speed of 4 mph (6 km/h) is reached, then goes OFF, there
may be a stored fault code. If the lamp remains ON when a
speed in excess of 4 mph (6 km/h) is reached, there may be
an active fault in the ABS system.
CAUTION: If the ABS warning light does not illuminate when the ignition is first turned on, there
is a problem with the bulb or wiring. You should
have this checked as soon as possible.
Medium Duty (R10/06)
Y53-6008
MIRROR
HEAT
0
OIL
!
LOW
WATER
WATER
BRAKE
ABS WARNING INDICATOR
WARNING! No indication will be given via the
dashboard warning lights or buzzer if tires of the
wrong size are installed on your vehicle. The
Anti-Lock Brake System (ABS) is calibrated for
the specific tire revolutions per mile. Use of a tire
and/or wheel size different from that originally
installed on your vehicle may cause the ABS system to not function during a hard braking event.
This could cause an accident or serious personal injury. Consult with your Peterbilt dealer
before using a different tire and/or wheel size
than was originally installed on your vehicle.
– 93 –
Using the Brake System
Operating Instructions
Parking Brake Burnishing
This procedure is recommended for new vehicles where less
lever actuation force is required. This procedure is mandatory whenever the driveline brake shoes or brake drum are
replaced.
WARNING! If a new drum or new brake shoes
are installed, the driveline brake must be burnished. Failure to properly burnish the parking
brake before putting it in service could result in
an inoperative parking brake, possible vehicle
rollaway, and serious personal injury or damage to the vehicle.
– 94 –
Y53-6008
1. Drive the vehicle at 15 mph (24 km/h) in a low gear
(first or second) on a dry, hard road surface.
2. Apply the parking brake lever with a moderate force
(approximately 40 pounds) until the vehicle is
brought to a stop. Do not allow the wheels to lock up.
3. After stopping, release the parking brake lever and
drive the vehicle at 20 mph (32 km/h) in a low gear
for approximately 2.5 miles, to allow the brake drum
to cool.
4. Repeat steps 1, 2, and 3 above until a total of 10
stops have been completed.
5. Adjust the parking brake lever. See the Medium Duty
Maintenance Manual.
Medium Duty (R10/06)
Operating Instructions
Operating the Rear/Drive Axle
OPERATING THE REAR/DRIVE AXLE
When operating normally on paved, dry surfaces, keep your
truck's interaxle differential in the UNLOCK position.
Introduction
GUARD
This section covers the operation of your Rear/Drive Axle.
These instructions apply to the most common features of
drive axles. Refer to the manufacturer’s instructions for further information on the operation of your axle.
If your vehicle is equipped with a Rockwell Tractech™ Nospin single rear axle, the wheel differential lock feature automatically engages and disengages. When one wheel starts
to spin on a slippery surface, this rear axle feature engages
to improve traction.
Interaxle Differential Lock Switch in normal (unlocked)
position
Interaxle Differential Lock
On vehicles with tandem rear axles, the interaxle differential
allows each axle to turn independently. Differential action
between the tandems relieves stress on the rear axles and
reduces tire wear. The interaxle differential lock switch allows
the operator to LOCK or UNLOCK the differential, depending
on road surface conditions.
Medium Duty (R10/06)
Y53-6008
Interaxle Differential Lock Switch in locked position
– 95 –
Operating the Rear/Drive Axle
Operating Instructions
In the LOCK position, an air operated clutch positively locks
both sets of axles together, providing greater traction on slippery road surfaces; however, steering around corners and on
dry pavement is more difficult. Continuous operation on a
paved, dry surface stresses the tandem axles, possibly causing internal damage.
Use this feature only when driving on surfaces with poor traction, such as wet slippery roads, heavy mud or snow, or loose
gravel. And do not use it when going downhill or at speeds
greater than 25 mph (40 km/h).
• Look ahead for wet, muddy, or icy patches on the road,
stop your vehicle and switch to LOCK ahead of time.
WARNING! Do not operate the vehicle on dry
pavement with the differential locked. This could
lead to an injury accident. On dry pavement, you
will not be able to steer well with the differential
locked. Lock the differential only when operating
on surfaces with poor traction, such as wet, slippery roads or loose gravel.
Inter–Axle Differential Lock Operation
WARNING! Do not use the inter-axle differential
lock when travelling downhill or at speeds above
25 mph (40 km/h). When it is engaged under
these conditions, your vehicle will exhibit
“understeer” handling characteristics. This
“understeer” condition will cause your vehicle
to turn less quickly and more steering effort will
be required, which can cause an injury accident.
Lock the inter-axle differential when you encounter road conditions such as these:
• Ice or snow — with or without tire chains.
• Dirt roads.
• Loose sand, mud, or other rough road conditions.
WARNING! Do not put the differential lock in the
LOCK position while the wheels are spinning
freely (slipping), you could lose control of the
vehicle or cause axle damage—you could be
injured. Switch to LOCK only when the wheels
are not spinning.
– 96 –
To LOCK the inter-axle differential:
1. Anticipate when you might need increased traction, slow
down to a steady speed under 25 mph (40 km/h) or stop
the vehicle. Do not lock the inter-axle differential while
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Operating the Rear/Drive Axle
going down steep grades or traveling faster than 25 mph,
or while wheels are spinning or traction is minimal; lock it
before you encounter these conditions.
3. If you LOCK or UNLOCK the inter-axle differential while
moving, let up momentarily on the accelerator pedal to
relieve torque on the gearing and allow full engagement
of the clutch (the mechanism that locks the wheels).
NOTE: If your vehicle has an automatic transmission, it may be necessary to shift the transmission to the Neutral position momentarily to
allow the main inter-axle differential lock splines
to fully engage or disengage.
Turning Radius When
Unlocked (Disengaged)
Turning Radius When
Locked (Engaged)
4. Drive the vehicle through the poor traction area, keeping
your speed under 25 mph (40 km/h).
To UNLOCK the inter-axle differential:
02871
Understeer Condition
2. Put the inter-axle differential lock switch, labeled MAIN
DIFFERENTIAL LOCK, in the LOCK position. A light
(DIFF LOCK) in the warning module on the dash will turn
on, indicating that the differential is locked (engaged).
Medium Duty (R10/06)
1. When you reach dry pavement or better road conditions
where the differential lock is not needed, switch the differential lock to UNLOCK.
2. Let up momentarily on the accelerator pedal to relieve
torque and allow the clutch to disengage.
3. When you unlock the differential, normal vehicle handling will resume and the light on the warning module will
turn off.
Y53-6008
– 97 –
More Driving Tips and Techniques
Operating Instructions
MORE DRIVING TIPS AND
TECHNIQUES
Coasting
WARNING! Do not coast with the transmission in neutral or with the clutch pedal
depressed—it is a dangerous practice. Without the use of the retarding power of the drivetrain, your vehicle can reach dangerous
speeds. At very high speeds you may not be
able to put the transmission in any gear. At
high speeds you could seriously damage your
vehicle or cause an accident when you put the
transmission in gear. The engine speed could
exceed the maximum governed speed and
cause a serious accident due to mechanical
failures.
WARNING! Low air pressure could make the
brakes unsafe for driving. Before driving the
vehicle, make sure the pressure does pump
up to over 100 psi for normal brake operation.
If the air pressure does not pump up to at
least 100 psi, don’t try to move the vehicle.
CAUTION: Operating a vehicle with air suspension bags either overinflated or underinf l a t e d m ay c a u s e d a m a g e t o d r i v e l i n e
components. If a vehicle must be operated
under such conditions, do not exceed 5 mph.
Driving Tips And Techniques
This section covers additional driving tips and techniques
on how to drive your vehicle more efficiently. For further
information, read the American Trucking Association's
(ATA) Truck Driver's Handbook. It will give you more tips
on starting, shifting, and driving your vehicle.
– 98 –
Do not coast with the transmission in neutral or with the
clutch pedal depressed. Besides being illegal and dangerous, coasting is also expensive. It causes premature failure or damage to the clutch and transmission and
overloads the brake system.
Coasting with the transmission in neutral also prevents
proper transmission component lubrication. During coasting the transmission is driven by the rear wheels, and the
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Driving Tips And Techniques
NOTE: Often these recommendations are secondary to maintaining an adequate and safe
speed relative to the surrounding traffic and road
conditions.
countershaft gear (which lubricates the transmission components by oil splash) will only be turning at idle speed.
Descending a Grade
WARNING! Do not hold the brake pedal down
too long or too often while going down a steep
or long grade. This could cause the brakes to
overheat and reduce their effectiveness. As a
result, the vehicle will not slow down at the
usual rate. To reduce the risk of personal injury
and/or an accident, before going down a steep
or long grade, reduce speed and shift the transmission into a lower gear to help control your
vehicle speed. Failure to follow procedures for
proper downhill operation could result in loss of
vehicle control.
Engine Overspeed
CAUTION: To avoid engine damage, do not let
the engine rpm go beyond the maximum governed rpm—valve damage could result if overspeed conditions occur.
Medium Duty (R10/06)
Operate the engine within the optimum engine rpm range
and do not allow the rpm's to exceed the maximum governed speed. See your Engine Operation and Maintenance manual for information regarding engine rpm.
When the engine is used as a brake to control vehicle
speed (e.g., while driving down a grade), do not allow the
engine rpm to exceed maximum governed speed.
Under normal load and road conditions operate the
engine in the lower end of the range.
Use of Tachometer
The tachometer is an instrument that aids in obtaining the
best performance of the engine and manual transmission,
serving as a guide for shifting gears.
Refer to the Engine Operation and Maintenance manual
for optimum engine rpm.
Y53-6008
– 99 –
Driving Tips And Techniques
Operating Instructions
• If the engine rpm moves beyond the maximum governed speed, indicating an overspeed condition,
apply the service brake or shift to a higher gear to
bring engine rpm within the optimum speed range.
• Shift into higher or lower gears (or apply the service
brake) to keep engine rpm near the lower end of the
optimum operating range.
• Avoid rapid acceleration and braking.
• When driving downhill: shift to a lower gear, use the
engine brake (if so equipped), and use the service
brake, keeping the engine speed below 2,100 rpm.
When the engine speed reaches its maximum governed
speed, the injection pump governor cuts off fuel to the
engine. However, the governor has no control over the
engine rpm when it is being driven by the vehicle's transmission, for example, on steep downgrades. Apply service
brakes or shift to a higher gear.
Fuel economy and engine performance are also directly
related to driving habits:
• The best results in trip time and fuel economy are
obtained while driving the vehicle at a steady speed.
– 100 –
Y53-6008
WARNING! Do not exceed the specified load rating. Overloading can result in loss of vehicle
control and serious personal injury, either by
causing component failures or by affecting vehicle handling. Exceeding load ratings can also
shorten the service life of the vehicle.
•The components of your vehicle are designed
to provide satisfactory service if the vehicle is
not loaded in excess of either the gross vehicle
weight rating (GVWR), or the maximum front and
rear gross axle weight ratings (GAWRs). (Axle
weight ratings are listed on the driver's door
edge.)
NOTE: For your safety and the safety of others, follow routine and periodic maintenance schedules for
all components on your vehicle. See Table 3, “Maintenance Schedule,” Page 123
Medium Duty (R10/06)
Operating Instructions
Driving Tips And Techniques
Air Suspension Height/Air Pressure
Your vehicle may have an air suspension. A deflation switch
on the dash allows you to exhaust the air in the suspension,
which allows you to lower the height of your vehicle for loading. On tractors, the deflate switch allows you to lower the
fifth wheel to slide under a trailer.
DEFLATE
AIR
A guard on the switch prevents you from accidentally deflating the suspension.
WARNING! Do not operate the Air Suspension
Deflate Switch (Dump Valve) while driving. Sudden deflation while your vehicle is moving can
affect handling and control and could lead to an
accident. Use this switch only when your vehicle
is not moving.
CAUTION: Operating a vehicle with air suspension bags either overinflated or underinflated
may cause damage to driveline components. If a
vehicle must be operated under such conditions, do not exceed 5 mph (8 km/h).
Medium Duty (R10/06)
NORMAL
SPSN
Air Suspension Deflate Switch
Setting Ride Height
Vehicles equipped with rear air suspensions have their ride
height and axle (pinion) angle(s) preset at the factory. These
are precision settings and should not be altered. Incorrectly
adjusted ride height may result in improper interaxle U-joint
working angles. This can result in pre-mature driveline wear
and driveline vibration. If your vehicle is equipped with a
Peterbilt rear air suspension, and if it becomes necessary to
reset the ride height, you may temporarily set it by following
the next procedure. Proper ride height measurement and values are shown in the illustration and table below.
Y53-6008
– 101 –
Driving Tips And Techniques
Operating Instructions
WARNING! To prevent possible injury and
damage to property, ensure that a vehicle is
parked and the wheels chocked before beginning this procedure.
CAUTION: Completing this procedure will
enable you to safely reach the nearest authorized Peterbilt repair facility to have ride
height and pinion angle reset using the proper
equipment and technique. Do this as soon as
possible to avoid potential driveline damage.
NOTE: Suitable wheel chocks are at a minimum
an 18-inch (46 cm) long 4x4.
Ride Height Measurement (Location for Tandem Axles Shown)
1. Ensure that the air supply and delivery plumbing of the
height control valve is consistent with the illustration.
Ride Height [inches (mm)]*
Proprietary Rear
Air Suspension
Single Drive
Tandem Drive
Air Trac
Low Air Leaf
11.00 (279)
6.50 (165)
11.00 (279)
8.50 (216)
NOTE: At least one of the mounting holes in the
height control valve bracket will be slotted to permit
rotating the valve.
NOTE: On dual-valve systems, begin with the LH
valve on the next step.
*These values are for a fully laden vehicle
Follow this procedure to temporarily set ride height.
– 102 –
2. Loosen the fasteners mounting a height control valve to
its bracket.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Driving Tips And Techniques
WARNING! Be extremely careful when deflating
the air springs. The rear of the vehicle will drop
about 3-1/2 inches (88 mm) when the air springs
are deflated. Make sure that no persons or
objects that could be injured or damaged are
under the vehicle.
To minimize the risk of damage or injury, do not
use the dump valve to deflate the air springs.
Operate the height control valve(s) manually to
ensure positive control of air spring deflation.
ALIGNMENT PIN OR DOWEL CONTROL ARM
LINK BOLT
FROM DUMP VALVE SWITCH
1.To minimize risk of injury, keep away from air
springs as they are being inflated.
FORWARD
02941A
Typical Height Control Valve (Top View)
Medium Duty (R10/06)
Y53-6008
– 103 –
Driving Tips And Techniques
Operating Instructions
Rotate the valve either clockwise or counterclockwise
until air pressure in the air springs provides the ride
height specified for that suspension. Measure the ride
height from the bottom of the frame rail to the approximate centerline of the rearmost drive axle hub:
DELIVERY TO RH AIR BAG(S)
SUPPLY FROM FORWARD
AIR TANK
MOUNTING NUTS
• For tandem axles, make the vertical measurement
at the centerline of the suspension (see illustration
on page 102).
• For a single axle, make the measurement in front of
the axle, in the area forward of the tires but not past
the suspension bracket.
EXHAUST
DELIVERY TO LH AIR BAG(S)
AIR BAG
LINK ROD
02941B
Typical Height Control Valve
(Rear View Looking Forward)
– 104 –
2. When at the correct ride height, ensure that the height
control valve lever is in the neutral position, then
install either the built-in alignment pin or a 1/8-inch (3
mm) dowel (see page 102).
3. Torque the mounting fasteners to 55 — 75 lb. in.
(6.2 — 8.5 N.m.).
4. Remove the alignment pin or dowel.
5. Repeat Steps 2 through 6 above for the RH valve on
vehicles with a dual-valve system.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Driving Tips And Techniques
Driving with Deflated Air Springs
Vehicles with the air suspension (option): If an air spring ruptures, there will be enough air pressure to drive the vehicle to
a safe stop off the highway to investigate the problem.
WARNING! Do not continue to drive with ruptured air springs. The air loss can cause the
spring brakes to apply allowing your brakes to
drag and burn up the linings, which could lead to
an injury accident. Do not continue to operate
the vehicle in this condition.
pumps up to over 100 psi for normal brake operation. If it
does not reach 100 psi, do not try to move the vehicle.
CAUTION: Do not operate a vehicle with air suspension bags either over- or under-inflated.
This could cause damage to driveline components. If you must drive under such conditions,
do not exceed 5 mph (8 km/h).
Fifth Wheel
The following applies to tractor configurations:
To get to a repair facility, do the following:
WARNING! Ensure that all fifth wheel maintenance, adjustments, and rebuilding are done
only by a qualified mechanic. An improperly
maintained fifth wheel can cause a trailer to separate from a tractor. This could lead to an injury
accident and damage to property.
1. Remove the height control link connected to the axle and
to the suspension air valve control arm. This will cause
the air valve control arm to center in the closed position.
2. The air system can then be pumped up to normal pressure for continued operation.
WARNING! Low air pressure could make brakes
unsafe for driving by not providing sufficient air
brake application pressure in an emergency,
which could lead to an injury accident. Before
driving the vehicle, make sure the air pressure
Medium Duty (R10/06)
Your Medium Duty may be equipped with either a fixed or an
air-controlled sliding fifth wheel. Either type should self-lock
when a trailer king pin trips the locking dogs as the tractor is
backed under a trailer.
Y53-6008
– 105 –
Driving Tips And Techniques
Operating Instructions
Fifth Wheel Jaw Lock
Air–Controlled Sliding Fifth Wheel
To unlock the fifth wheel lock:
Vehicles having an air-controlled sliding fifth wheel have a
fifth wheel slider lock controlled by a switch on the accessory
switch panel. To operate this type of lock, move the switch to
the appropriate position. By placing the switch in the
UNLOCK position, you can slide the fifth wheel to various
positions to adjust weight distribution. There is a guard on
this switch to protect you against accidentally activating or
releasing the lock.
• Pull out on the lever (usually located on the left-hand
side of the fifth wheel) until it remains in an overcenter
position.
Hook–Up:
• After connecting your tractor to the trailer, always inspect
the jaws to be sure they have locked on the kingpin
before driving.
WARNING! Do not move of the fifth wheel while
the tractor-trailer is in motion. Your load could
shift suddenly, causing you to lose control of the
vehicle, which can result in a serious accident.
Never operate the vehicle with the switch in the
UNLOCK position. Always inspect the fifth wheel
after you lock the switch to be sure the fifth
wheel lock is engaged.
Fifth Wheel Slide Switch
– 106 –
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Driving Tips And Techniques
CAUTION: Both the fifth wheel plate and the
slide tracks (if a slider) should be cleaned and
lubricated periodically to ensure smooth turning
and sliding action. Failure to keep these surfaces lubricated can lead to frame or driveline
damage.
Fifth Wheel Lubrication
• Frequently operate and lubricate movable or sliding fifth
wheels to prevent corrosion.
See page 219 for maintenance information.
Medium Duty (R10/06)
Y53-6008
– 107 –
Vehicle Recovery and Spring Brakes
Operating Instructions
VEHICLE RECOVERY AND SPRING
BRAKES
Introduction
Your Medium Duty is equipped with built-in recovery provisions, designed for short distance use only. If your vehicle
must be recovered, disconnect the driveline at the rear U–
joint, and remove or support the rearmost section of the driveline. This is necessary because if the transmission is driven
by the driveshaft (rear wheels on the ground), no lubricant
will reach the gears and bearings, causing damage to the
transmission.
the engine is stopped. You could seriously damage your
vehicle by towing it with the driveline connected and the
drive wheels on the ground.
Worse, when vehicles are towed, either by wrecker or piggyback, the lubricant in the top front of the drive axle will drain
to the rear. This will leave the top components dry. The resulting friction may seriously damage them. Always remove the
main driveshaft and axle shafts before towing your vehicle.
CAUTION: Remove the driveline and axle shafts
or lift the driving wheels off the ground before
towing the vehicle. See “More Driving Tips and
Techniques” on page 98. All lubricating and
clutch application oil pressure is provided by an
engine-driven pump, which will not work when
– 108 –
Y53-6008
NOTE: For additional information concerning heavyduty truck recovery, see Truck Maintenance Council
Recommended Practice #602–A — “Front Towing
Devices For Trucks and Tractors,” and #626 —
“Heavy Duty Truck Towing Procedures.” Copies of
these can be obtained from the following address:
The Maintenance Council
American Trucking Association Inc.
2200 Mill Rd.
Alexandria, VA 22314
(703) 838-1763
Medium Duty (R10/06)
Operating Instructions
Vehicle Recovery and Spring Brakes
Vehicle Recovery Guidelines
Recovery Rigging
Refer to the guidelines below when towing to prevent possible damage:
To connect to the Medium Duty, attach the towing chain or
cable to the tow hook through the access hole in the bumper.
• Use proper towing equipment to prevent damage to the
vehicle.
CAUTION: Connect only to the towing provisions, as described on the following pages.
Connections to other structural parts could
da mag e th e v e hicle . Do no t a t ta ch to
bumpers or bumper brackets. Use only
equipment designed for this purpose.
• Use a safety chain system.
• Disconnect driveline.
• Follow state/provincial and local laws that apply to vehicles in tow.
• Do not tow vehicles at speeds in excess of 55 mph
(90 km/h).
• The front tow hook has a maximum working load limit of
26,000 lb. (11,700 kg).
TOW HOOK
Front Tow Hook
Returning Vehicle to Service
You will have to add lubricant to prevent damage after your
vehicle has been towed.
Medium Duty (R10/06)
Y53-6008
– 109 –
Vehicle Recovery and Spring Brakes
Operating Instructions
1. Into the pinion cage, add 1 pint (.47 liter) of lubricant.
2. Into the inter-axle differential, add 2 pints (.94 liter) of
approved lubricant.
• See “Recommended Lubrication Types,” Page 136.
3. After adding the specified type and amount of lubricant,
drive the vehicle. It should be unloaded. Drive 1 to 2
miles (1.5 to 3 km) at a speed lower than 25 mph (40 km/
h). This will thoroughly circulate the lubricant through the
assembly.
Spring Brakes — Manual Release
In order to tow a vehicle, if there is insufficient air to release
the parking brake, the spring brakes can be manually
released.
WARNING! Do not drive vehicle with malfunctioning brakes. If one of the brake circuits
should become inoperative, braking distances
will increase substantially and handling characteristics while braking will be affected. You could
lose control of your vehicle, be severely injured,
or cause an accident. Have it towed to the nearest dealer or qualified workshop for repair.
– 110 –
You may sometimes have to release your vehicle's spring
brakes by hand. This could happen if the system air pressure
does not reach operating pressure because your engine or
compressor is not working properly. You will have to release
the spring brakes at the spring brake chambers.
WARNING! Do not disassemble a spring brake
chamber. These chambers contain a powerful
spring that is compressed. Sudden release of
this spring can cause you to be severely injured.
• Do not operate a vehicle when the spring brakes
have been manually released. Driving a vehicle after
its spring brakes are manually released is extremely
dangerous. You will probably have no brakes at all.
You could have a serious or fatal accident.
• Releasing the spring brakes on an unsecured vehicle could lead to an accident. The vehicle could roll,
causing severe injury. Always secure the vehicle
with wheel chocks, chains, or other safe means to
prevent rolling before manually releasing the spring
brakes.
To move a vehicle immobilized by the spring brakes due to
loss of air pressure in the brake system, perform the following
procedure:
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Vehicle Recovery and Spring Brakes
1. Remove the cap from the
spring chamber.
2. Remove the release stud
assembly from the side pocket,
and remove the release nut and
washer from the release stud.
4. Insert the release stud through
the opening in the spring chamber where the cap was removed.
Insert it into the pressure plate.
Turn the release stud 1/4 turn
clockwise in the pressure plate.
This secures the cross pin into
the cross pin area of the pressure
plate and locks it into the manual
release position.
5. Assemble the release stud
washer and nut on the release
stud.
3. Slide out the release stud.
6. With a wrench, turn the
release stud assembly nut until
the compression spring is 90–95
percent caged. While doing this,
check to make sure the push rod
(adapter push rod or ser vice
Medium Duty (R10/06)
Y53-6008
– 111 –
Vehicle Recovery and Spring Brakes
Operating Instructions
push rod) is retracting. Do not over-torque the release
stud assembly. (S–Cam type maximum: 50 ft-lb, Wedge
type maximum: 30 ft-lb.) The spring brake is now
mechanically released.
• Apply light pressure on the accelerator pedal while the
transmission is in gear.
• Remove your foot from the accelerator while shifting.
• Do not race the engine.
• For best traction and safety, avoid spinning the wheels.
Comply with the following instructions to avoid transmission
damage:
Freeing the Vehicle from Sand,
Mud, Snow and Ice
WARNING! Do not spin the wheels faster
than 35 mph (55 km/h). Spinning a tire at
speedometer readings above this can be
dangerous—tires can explode from spinning
too fast. Under some conditions, a tire may
be spinning at a speed twice that shown on
the speedometer. Any resulting tire explosion could cause severe injury or death to a
bystander or passenger, as well as extensive vehicle damage: including tire, transmission and/or rear axle malfunction.
If the vehicle gets stuck in sand, mud, snow, or ice:
• Always start the vehicle in motion with the shift lever in
first gear.
• Be sure that the transmission is fully engaged in gear
before releasing the clutch pedal (manual only).
• Do not shift into reverse while the vehicle is moving.
• Do not permit the vehicle to be towed for long distances
without removing the driveshaft.
Tire Chains
If you need tire chains, install them on both sides of the driving axle.
• Move the gearshift lever or selector from First to
Reverse.
– 112 –
Y53-6008
CAUTION: Chains on the tires of only one tandem axle can damage the driveline U–joints and
the interaxle differential. Repairs could be costly
and time-consuming.
Medium Duty (R10/06)
Operating Instructions
Shut–Down
SHUT–DOWN
Always use your parking brakes!
WARNING! Do not use the trailer hand brake or
service brakes to park and hold an unattended
vehicle—use the parking brakes. Because service brakes work with air pressure, these brakes
could slowly release. Your vehicle could roll,
causing a serious accident. Someone could be
hurt or killed. Never rely on the service brakes to
hold a parked vehicle.
Introduction
After you have parked in a safe place, check your vehicle to
make sure it will be ready for the next trip. To make sure your
vehicle is ready to go after a long stop (such as overnight),
please follow the suggestions below. Your vehicle will be easier to get going when you are ready, and it will be safer for
everyone who might be around it.
2. If you must park on a steep grade, always block the
wheels.
Please remember, too, that in some states it is illegal to leave
the engine running and the vehicle unattended.
Final Stopping Procedures
1. Set the parking brake before leaving the driver's seat.
To hold your vehicle while it is parked, DO NOT rely on
the following:
• air brakes
• hand control valve for trailer brakes
• engine compression
Medium Duty (R10/06)
02440
Blocked Wheels
Y53-6008
– 113 –
Shut–Down
Operating Instructions
3. Drain water from the air reservoirs.
Turbocharger
• While the engine and air supply system are still
warm, drain moisture from the air reservoirs. Open
the reservoir drains just enough to drain the moisture. Do not deplete the entire air supply. Be sure to
close the drains before leaving the vehicle.
4. Secure the vehicle, close all the windows, and lock all
doors.
This cooling-down practice is especially important for a turbocharged engine. The turbocharger on your vehicle contains
bearings and seals that are subjected to hot exhaust gases.
While the engine is operating, heat is carried away by circulating oil. If you stop the engine suddenly after a hard run, the
temperature of the turbocharger could rise to as much as
100°F (55°C) above the temperature reached during operation. A sudden rise in temperature like this could cause the
bearings to seize or the oil seals to loosen.
Before Stopping the Engine
Do not shut off the engine immediately. A hot engine stores a
great amount of heat and it does not cool down immediately
after you shut if off. Always cool the engine down before shutting it off. You will greatly increase its service life.
Idle the engine at 1000 rpm for five minutes. Then low idle for
thirty seconds before shutdown. This will allow circulating
coolant and lubricating oil to carry away heat from the cylinder head, valves, pistons, cylinder liners, turbocharger, and
bearings. This way you can prevent engine damage that may
result from uneven cooling.
– 114 –
Refueling
Air inside the fuel tanks allows water to condense in the tank.
To prevent this condensation while the vehicle is parked for
extended periods of time, fill the tanks to 95 percent of
capacity. Never fill to more than 95 percent capacity as this
provides room for expansion resulting from temperature
extremes. When refueling, add approximately the same
amount to each fuel tank on vehicles with more than one
tank.
Y53-6008
Medium Duty (R10/06)
Operating Instructions
Shut–Down
WARNING! Do not carry additional fuel containers in your vehicle. Fuel containers, either full or
empty, may leak, explode, and cause or feed a
fire. Do not carry extra fuel containers, even
empty ones are dangerous.
Specification: Use only Diesel Fuel, Grade 2–D, as recommended by engine manufacturers. If you need further information on Grade 2–D fuel specifications, consult the Engine
Operation and Maintenance Manual.
WARNING! Diesel fuel in the presence of an ignition source (such as a cigarette) could cause an
explosion. You could be seriously injured. A
mixture of gasoline or alcohol with diesel fuel
increases this risk of explosion.
Location of Fuel Shut–Off Valves
•Do not remove a fuel tank cap near an open
flame.
•Use only the fuel and/or additives recommended for your engine.
Medium Duty (R10/06)
If your vehicle is equipped with shut-off valves for the take-off
and return lines, they are located on the fuel lines entering
the top of the fuel tank. Fuel shut-off valves for the fuel crossover line are on the bottom of the fuel tank, at the crossover
line connection.
Y53-6008
– 115 –
Introduction
Preventive Maintenance
PREVENTIVE MAINTENANCE
INTRODUCTION
Safety Precautions
This section will help you keep your Medium Duty in good
running condition. There are a number of checks you can do,
and you may be able to do some of the service work yourself.
But please, let your Peterbilt Dealer or Authorized Service
Center do any work you do not have the tools or skill to perform. Authorized service mechanics are trained in the proper
technical and safety procedures to maintain your Medium
Duty correctly.
Good driving practices, daily and weekly driver maintenance
inspections, and periodic service inspections by an Authorized Service Center, will help keep your Medium Duty in
good working order and provide many years of dependable
service.
WARNING! It is dangerous to work on a vehicle
without the right know-how and proper tools.
You could be seriously injured, cause damage to
the vehicle, or make your vehicle unsafe to
drive. Do only work you know you are fully able
to do, and for which you have the right tools.
– 116 –
• Before attempting any procedures in the engine
compartment, stop the engine and let it cool down.
Hot components can burn skin on contact.
• Be alert and cautious around the engine at all times
while the engine is running.
• If work has to be done with the engine running,
always (1) set the parking brake, (2) chock the
wheels, and (3) ensure that the shift lever or selector
is in Neutral.
• Exercise extreme caution to prevent neckties, jewelry, long hair, or loose clothing from getting caught
in the fan blades or any other moving engine parts.
• Disconnect the battery ground strap whenever you
work on the fuel system or the electrical system.
When you work around fuel, do not smoke or work
near heaters or other fire hazard. Keep an approved
fire extinguisher handy.
• Always support the vehicle with appropriate safety
stands if it is necessary to work underneath the vehicle. A jack is not adequate for this purpose.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Introduction
• When working underneath the vehicle without
appropriate safety stands but with the wheels on the
ground (not supported), make sure that (1) the vehicle is on hard level ground, (2) the parking brake is
applied, (3) all wheels are chocked (front and rear)
and (4) the engine cannot be started. Remove the
ignition key.
• Never start or let the engine run in an enclosed,
unventilated area. Exhaust fumes from the engine
contain carbon monoxide, a colorless and odorless
gas. Carbon monoxide can be fatal if inhaled.
WARNING! Wear protective clothing when
handling hydraulic fluid. It is mildly toxic and
can cause skin and eye irritation.
CAUTION: Hydraulic brake fluid may damage
painted surfaces of the vehicle.
Modifying your vehicle can make it unsafe. Some modifications can affect your vehicle's electrical system, stability, or
other important functions. Before modifying your vehicle,
check with your Peterbilt Dealer to make sure it can be done
safely and correctly.
Environmental Protection and Material
Hazards
Some of the ingredients in engine oil, hydraulic oil, transmission and axle oil, engine coolant, diesel fuel, air conditioning
refrigerant (R–134a and PAG oil), batteries, etc., may contaminate the environment if spilled or not disposed of properly. Non-compliance with environmental regulations can
result in fines and/or jail terms. Contact your local government agency for information concerning proper disposal.
Incomplete or improper servicing may cause problems in the
operation of the vehicle. If in doubt about any servicing, have
it done by your Authorized Service Center. Improper maintenance during the warranty period may also affect the warranty coverage.
Medium Duty (R10/06)
Y53-6008
WARNING! Diesel engine exhaust and some of
its constituents are known to the State of California to cause cancer, birth defects, and other
reproductive harm. Other chemicals in this vehicle are also known to the State of California to
cause cancer, birth defects, and other reproduc-
– 117 –
Introduction
Preventive Maintenance
tive harm. This warning requirement is mandated by California law (Proposition 65) and does not result from any
change in the manner in which Peterbilt Motors Company trucks are manufactured.
and the Peterbilt Electronic Parts Catalog (ECAT). When
ordering replacement parts, please provide the Medium Duty
Chassis Serial Number. See Page 228.
WARNING! Handle lubricants carefully. Vehicle
lubricants (oil and grease) can be poisonous
and cause sickness.
Operator's Parts Catalog a complete, non-illustrated listing
of the Final Chassis Bill of Material. It includes all parts used
to custom-build your Medium Duty.
How to Order Parts
Replacement parts can be ordered through your local Peterbilt Dealer. For service parts information, two parts catalogs
are also available, the Medium Duty Operator's Parts Catalog
– 118 –
Electronic Parts Catalog a complete illustrated parts listing
for your specific vehicle, with drawings and exploded views,
available only in electronic CD–ROM format.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Maintenance Schedule and Lubrication
MAINTENANCE SCHEDULE AND
LUBRICATION
Introduction
The following section summarizes preventive maintenance
and lubrication requirements for the maintenance of your
Medium Duty. For specific maintenance procedures and
complete lubrication instructions of specific components consult the Medium Duty Maintenance Manual and manufacturer's service manuals. These manuals are available for a
minimal charge from your Peterbilt Dealer or direct from the
component manufacturer. In addition, supporting manuals
and literature are included in the glove compartment of your
Medium Duty.
Preventive Maintenance Intervals and
Schedule
Your preventive maintenance program begins with daily
checks you perform. See “Driver's Check List” on page 13. If
your Medium Duty is serviced regularly, you can avoid many
large, expensive, and time-consuming repairs, as well as
Medium Duty (R10/06)
ensuring many years of safe and smooth operation. Also, be
advised that neglect of recommended service may in some
cases void your vehicle's warranty. So, for your safety and life
of your vehicle, please follow Table 3, “Maintenance Schedule,” Page 123. But remember, there may be maintenance
operations that demands skills and equipment you do not
have. If so, please take your Medium Duty to an expert
mechanic, for your safety and your vehicle's performance.
WARNING! It can be dangerous to attempt maintenance work without sufficient training, service
manuals, and the proper tools. You could be
injured, or you could make your vehicle unsafe.
Do only those tasks you are fully trained and
equipped to do.
In severe operating conditions such as mining, logging, or
earth moving, you will need to perform maintenance checks
and services more frequently. Other “severe operating conditions” to be aware of are: rough, extreme temperature environments; conditions where heavy loads are being hauled;
contaminated environments, or steep grades. Consult the
component manufacturer's maintenance manuals for further
information on maintenance procedures specific to these
conditions.
Y53-6008
– 119 –
Maintenance Schedule and Lubrication
Preventive Maintenance
Maintenance Intervals
Table 2, ”Recommended Maintenance Intervals”, shows service intervals for normal and heavy-duty operations.
Table 2
For additional “Engine Cooling System” information see Page
143. For additional “Air System” information see Page 161.
NOTE: Different lubricants or service intervals than
those listed below may be required.
Recommended Maintenance Intervals
ITEM
Hood Pivot
INTERVAL
COMMENTS
None
Front Brake Camshaft
10,000–15,000
Tie–Rod Ends
10,000–15,000
Synthetic Grease With Special Fittings
Power Steering Reservoir
– Check Fluid Level
– Change Fluid & Filter
Drag Link
10,000–15,000
60,000
Steering Gear Box
None
Steering U–joints
10,000–15,000
Steering Slip Joint
10,000–15,000
Brake Treadle
10,000–15,000
Clutch Pedal Shaft
2 Times/Year (After Summer & Winter)
10,000–15,000
t
None
Transmission
– Check
10,000–15,000
– Drain and Refill - Manual
50,000
– Drain and Refill - Automatic
25,000
Rear Axle
– Check Fluid Level
– (Rear Axle) Drain, Flush, Refill
– 120 –
10,000–15,000
500,000
Y53-6008
Synthetic Lube
Medium Duty (R10/06)
Preventive Maintenance
Table 2
Maintenance Schedule and Lubrication
Recommended Maintenance Intervals
ITEM
Rear Wheel Bearings
INTERVAL
100,000
COMMENTS
With LMS Wheel End Package
Rear Brake Camshafts
10,000–15,000
Synthetic Grease With Special Fittings
Fifth Wheel
10,000–15,000
40 to 60K For Adjustment
Spring Pins
10,000–15,000
With Rubber Bushed Pins – No Service
Front & Rear Slack Adjusters
10,000–15,000
Synthetic Grease With Special Fittings
King Pins
10,000–15,000
Front Wheel Bearings
Accelerator Linkage
100,000
Eaton LMS
None
Engine Lubricating Oil
– Check Fluid Level
Daily Trip Check
– Change Oil
10,000–15,000
Must Meet Engine Company Specifications
Spring Shackle Pins
10,000–15,000
No Service With Rubber Bushed Spring Pins
Clutch Linkage
10,000–15,000
Clutch Release Bearing
10,000–15,000
Extended Grease Fittings
Clutch Cross Shaft
10,000–15,000
Extended Grease Fittings
Door Weatherstrip
As Required
Lock Cylinders
As Required
Door Hinges
As Required
Door Latches and Striker Plate
As Required
Teflon Bushing
Driveshaft
– U-Joints
10,000–15,000
SPL Driveline, Up To 100,000 Miles
– Slip Joints
10,000–15,000
SPL Driveline
Center Bearing
Suspension
Medium Duty (R10/06)
None
Per Specifications
Y53-6008
AG200 – Synthetic Grease With Special Fitting
– 121 –
Maintenance Schedule and Lubrication
Table 2
Preventive Maintenance
Recommended Maintenance Intervals
ITEM
INTERVAL
COMMENTS
Hydraulic Brakes
Brake Pad Lining Inspection
7,500 mile
Rotor Inspection
15,000 miles or 15 mos
Park Brake Inspection
15,000 miles or 15 mos
Minimum 3/16 in. thickness
Brake Fluid Reservoir
Check Fluid Level
Change Fluid
7,500 miles
Use DOT 3 brake fluid only
Every 2 years
Use DOT 3 brake fluid only
Power Steering Fluid Reservoir
Check Fluid Level
Change Fluid
– 122 –
7,500 miles
Use Automatic Transmission Fluid (ATF)
60,000 miles or twice per
year
Use Automatic Transmission Fluid (ATF)
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Maintenance Schedule and Lubrication
Maintenance Schedule
TABLE KEY
NOTE: If a scheduled service interval is shaded, skip to the
next interval. The frequency of each service operation is
identified by open (non-shaded areas).
Use Table 3, ”Maintenance Schedule,” as a guide to plan service work. Be sure and follow the frequency recommendations for your vehicle.
Table 3
C2
Federal Annual Inspection 120,000 miles/192,000 km only.
C4
Federal Annual Inspection 240,000 miles/384,000 km only.
E2
50,000 Mile Service Interval
G2
Synthetic Lube Required – 500,000 Drain
Maintenance Schedule
OPERATION \ FREQUENCY
15,000 mi
24,000 km
60,000 mi
96,000 km
COMMENTS
7,500 mi
12,000 km
INTERVAL
INITIAL DRIVE–IN
A
B
C
Clutch Brake
Clutch Pedal Free Travel _____ inches
Glass for Cracks or Chips
Door Window Operation
Radio
Interior Lights
Interior Appearance:
Seats
Floor Mats
Door Panels
Headliner
Sleeper
Dash
Covers
Wiper Operation
Medium Duty (R10/06)
Y53-6008
– 123 –
Maintenance Schedule and Lubrication
Table 3
Preventive Maintenance
Maintenance Schedule
15,000 mi
24,000 km
60,000 mi
96,000 km
OPERATION \ FREQUENCY
COMMENTS
7,500 mi
12,000 km
INTERVAL
A
B
C
A
B
C
Wiper Blade Condition
Horns (Electric and Air)
Mirrors
SAFETY EQUIPMENT
Drain Water from Air Tanks
Air Tank Check Valve
Emergency Operation of Spring Brakes
Air Press. Build–up time: _______ min.
Governed Air Pressure: _______ psi
Air Press. Drop–Brakes not Applied: ___
Air Press. Drop–Brakes Applied: ___
Fire Extinguisher Charge
Flare Kit / Reflectors
CIRCLE INSPECTION
Physical Damage:
Exterior Sheet Metal
Grille and Radiator
Trailer Light Cord and Connectors
Air Lines and Gladhands
5th Wheel Mounting and Condition
Pintle – Hook/Eye Condition
Headlights – High and Low Beams
Road Lights
Marker Lights
Turn Signals
– 124 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Table 3
Maintenance Schedule and Lubrication
Maintenance Schedule
Emergency Flasher
Brake Lights
Backup/Loading Lights
License Plates: Permits and Mounting
Mud Flaps / Serviceable
Fuel Tank Mounting
Exhaust System–Condition and Mounting Bolts
Frame Fastener Torque: does NOT apply to Le
Jeune frame fasteners.
Lubricate:
Door Hinges and Latches
Body Mounts (Straight Truck Only)
Body Sides and Roof Panels (Straight trucks)
Cab:
Hold–down Latches
Mounts
Front Pivot Assembly
Jack Operation and Leaks
Safety Lock, Tip–Over Stop
ENGINE SERVICE
Cooling:
COMMENTS
60,000 mi
96,000 km
15,000 mi
24,000 km
OPERATION \ FREQUENCY
7,500 mi
12,000 km
INTERVAL
C2
A
B
C
Extended Life Coolant maintenance/
is located on page 148 of this manual
Coolant Level
Pressure Test
New Release At 100–120K – Per Engine
Filter Manufacturer Recommendations
Replace Water Filter
Radiator Mounting
Medium Duty (R10/06)
Y53-6008
– 125 –
Maintenance Schedule and Lubrication
Table 3
Preventive Maintenance
Maintenance Schedule
COMMENTS
60,000 mi
96,000 km
15,000 mi
24,000 km
OPERATION \ FREQUENCY
7,500 mi
12,000 km
INTERVAL
Fan Shroud
Fan Assembly and Idler Pulley
Check Water Pump for Leaks / Play
Radiator – Exterior Condition
No Service Required
Replace Engine Coolant
C4
Fill as Required – Extended Drain Per
Manufacturer Specifications.
Air Cleaner:
Contaminant Accumulation
Air Cleaner Restriction ___
(replace if greater than 20)
Vacuator Valve–Operation & Condition
Mounting Bolts
Leaks
Interference
Engine Oil Level
Power Steering – Reservoir Level
Daily Inspection Required
Service 2XPer Year – 60,000 Mile
Intervals
Power Steering Fluid – Replace
C2
Power Steering Filter – Replace
Drive Belt Condition and Adjustment
Air Conditioner Compressor Mounting
Cold Start Aids
Governor and Pump Security Seals OK
High Idle: ________ rpm
Emergency Shutdown
Vibration Damper Condition
– 126 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Table 3
Maintenance Schedule and Lubrication
Maintenance Schedule
COMMENTS
60,000 mi
96,000 km
15,000 mi
24,000 km
OPERATION \ FREQUENCY
7,500 mi
12,000 km
INTERVAL
Drain Water from Fuel System
25,000 Mile Change Interval – Must Meet
Engine Co. Requirements
Engine Oil – Change
Oil Filters – Replace
Fuel Filters – Replace
Engine Tune–up
Cranking System:
Visual Inspect./Loose Connections
Starter Draw: _________ volts
Alternator/Charging System:
Visual Inspection/Loose Connections
Output Voltage: _________ volts
UNDER VEHICLE
C2
A
B
C
Steering Components – Condition:
Steering Gear
Steering Shaft Splines and Joint(s)
Pitman Arm
Drag Link
Steering Arms
Tie Rod Arms
Tie Rod Ends
Radius Rods / Torque Arms
Chassis Frame – Cracks or Breaks
Spring Shackles and Hanger Brackets
Spring Pins
Medium Duty (R10/06)
No Service Required
No Service Required
Y53-6008
– 127 –
Maintenance Schedule and Lubrication
Table 3
Preventive Maintenance
Maintenance Schedule
COMMENTS
60,000 mi
96,000 km
15,000 mi
24,000 km
OPERATION \ FREQUENCY
7,500 mi
12,000 km
INTERVAL
King Pin Wear
Steer Axle Wheel Bearing - End Play Adjustment
and Inspection
Front Hub Lubricant Level
Spring Leaves
350,000 Miles With LMS Outer Ends
• No Leak – No Service
Tighten U-bolts after the first 500 miles
(800 km). Rear suspension fasteners:
retorque after first 2,000 miles (3218 km).
U–Bolt and Suspension Fastener Torque
Leaks:
Coolant
Engine Oil
Power Steering
Fuel
Transmission
Axles
Inner and Outer Hub Seals
Engine and Transmission Mounts
Drivelines – U–joints and Slip Yokes
Rear Axle Lubricant Level
Rear Axle Lubricant Flush & Refill
Rear Axle Breathers – Clear
Tractor Protection Valve Breakaway Test
Brake Chamber Mounting Bolt Torque
Brake Hoses for Cracks and Chafing
Adjust Brakes
– 128 –
C4
Y53-6008
At 250,000 Miles
Medium Duty (R10/06)
Preventive Maintenance
Table 3
Maintenance Schedule and Lubrication
Maintenance Schedule
COMMENTS
60,000 mi
96,000 km
15,000 mi
24,000 km
OPERATION \ FREQUENCY
7,500 mi
12,000 km
INTERVAL
Synthetic Grease Required – Special
Fitting
No Service Required
Front & Rear Brake Camshaft Tube Lubrication
Clutch Pedal Shaft
Clutch Linkage
Suspension Fittings
Clutch Release Bearing
Driveline Center Bearing
Automatic Slack Adjusters
Brakes: Lining Remaining (replace as required)
RF ______ RRF ______ RRR ______
LF ______ LRF ______ LRR ______
Drum Condition:
RF ______ RRF ______ RRR ______
LF ______ LRF ______
AG 200 – 250,000 Mile Service
Required Extended Fittings
No Service Required
Synthetic Lube Required – Special Fittings
LRR ______
Chassis Lubrication
Transmission Lubricant Level
Transmission Lubricant and Filter Change
Rear Axle Lubricant Change
Front Hub Lubricant Change
BATTERIES
C2
C2
C2
A
B
Synthetic Lube Required – 500,000 Drain
Synthetic Lube Required – 500,000 Drain
Synthetic Lube Required – 500,000 Drain
C
Signs of Over–Charging
Remove Corrosion and Seal Terminals
Hold-down and Box – Mounting Bolts
Load Test Batteries
Sealed Type – Condition:
Medium Duty (R10/06)
Y53-6008
– 129 –
Maintenance Schedule and Lubrication
Table 3
Preventive Maintenance
Maintenance Schedule
15,000 mi
24,000 km
60,000 mi
96,000 km
OPERATION \ FREQUENCY
COMMENTS
7,500 mi
12,000 km
INTERVAL
A
B
C
(Color of charge indicator for each battery)
1 ______ 2 ______ 3 ______ 4 ______
TIRES AND WHEELS
Missing Valve Caps and Stem Locks
Cracks or Loose Wheel lugs
Tandem Mating
Irregular Wear
Tire Pressure (Record below)
Remaining Tread (Record below)
Tires & Wheels Inspection
Right
– 130 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Table 3
Maintenance Schedule and Lubrication
Maintenance Schedule
15,000 mi
24,000 km
60,000 mi
96,000 km
OPERATION \ FREQUENCY
COMMENTS
7,500 mi
12,000 km
INTERVAL
A
B
C
A
B
Left
Air Pressure Adjusted to: _____________
ALIGNMENT
Toe–in: ______________ in (mm)
Caster: L ________ R ________
Rear Axle Alignment
ROAD TEST
C2
C
Steering / Steering Play
Shifting
Brakes
Engine Operation (noises, surging, black smoke)
Throttle Linkage
Jake Brake Operation
Seat Belts
Air Seat Operation
Cab Heater
Medium Duty (R10/06)
Y53-6008
– 131 –
Maintenance Schedule and Lubrication
Table 3
Preventive Maintenance
Maintenance Schedule
15,000 mi
24,000 km
60,000 mi
96,000 km
OPERATION \ FREQUENCY
COMMENTS
7,500 mi
12,000 km
INTERVAL
A
B
C
A
B
C
Air Conditioner
Instruments and Gauges:
Speedometer/odometer
Tachometer
Oil Pressure
Engine Temperature
Illumination
BODY
Interior Liner Damage
Door Operation
Roll–up Door Tracks – Lubricate
Lift–gate Operation
OTHER
Hood Pivots
Fifth Wheel Components
Brake Treadle Hinge and Roller
Lock Cylinders
Door Hinges
Door Latches and Striker Plate
Door Weatherstrip
40 – 60K For Adjustment
Drain Tanks, Replace Desiccant as
Required
Air Dryer
– 132 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Maintenance Schedule and Lubrication
Lubrication Specifications
You will find a complete Engine Lubrication Service Guide in
the Engine Operation and Maintenance Manual. There, the
engine manufacturer explains more fully all the maintenance
operations you and a qualified service mechanic will need.
And please remember: one key to keeping your Medium Duty
running at top economy and in prolonging its life is proper
lubrication servicing. Neglecting this essential aspect of vehicle care can cost time and money in the long run.
Below you will find basic information needed to perform routine vehicle lubrication. Of course you will want to schedule
service more frequently if you are operating under severe
conditions such as extreme heat or cold, with very heavy
loads, rough roads, etc. For any special service require-
Medium Duty (R10/06)
ments, consult your service manuals and your lubricant supplier. The component manufacturer's specification and
requirements take precedence over other specifications.
WARNING! Handle lubricants carefully. Vehicle
lubricants (oil and grease) can be poisonous
and cause sickness. They can also damage the
paint on the vehicle.
CAUTION: Do not mix different types of lubricants. Mixing lubricants (oil and grease) of different brands or types could damage vehicle
components; therefore, drain (or remove) old
lubricants from the unit before refilling it.
• When switching between types of lubricants, thoroughly drain all areas of the component.
Y53-6008
– 133 –
Maintenance Schedule and Lubrication
Preventive Maintenance
Lubrication Types
APPLICATION
Use Table 4 on page 136 and the list of lubricants below to
identify the type of lubricant to use on your Medium Duty. For
a quick summary of each lubrication point, see Table 2 on
page 120.
Universal Joints
LUBRICANT
EP
Drive Shaft Splines
CL
Wheel Bearings (driven hubs)
HD
Wheel Bearings (nondriven hubs)
CD50
ATF: DEXRON® III/MERCON®-approved automatic transmission fluid
Steering Column
CL
BB: Ball Bearing grease
Alternator Bearing
BB*
CB: Engine oil for mild to moderate requirements
Fan Hub
BB*
CC/CD: Engine oil for severe requirements (MIL–L–2104B /
MIL–L–45199B w/ 1.85% max sulfated ash content)
Power Steering Reservoir
ATF
Steering Drag Link
CL
CD: Engine oil meeting API “Five engine test sequence”
Steering Knuckles
CL
CD50: SAE 50W synthetic transmission fluid
Spring Pins
CL
CE: Engine oil meeting severe duty service requirements for
direct—injection turbocharged engines.
Clutch Release Bearings
BB
Brake Shoe Anchor Pins
HT
CL: Multipurpose chassis grease
Brake Cam Bearings
HT
EP: Extreme Pressure lubricant
Slack Adjusters
CL
GL: Straight mineral gear lubricant
Starter Bearings
CC
HD: Hypoid Gear Oil, A.P.I. — GL–5/SAE 80W–90
Turbocharger Aneroid
CC
HT: High Temperature grease (Timken Specification 0–616)
Water Pump
BB*
MP: Multipurpose gear lubricant (MIL–L–2105B)
*Consult manufacturer or lubricant supplier for special details.
SD: Engine oils with increased protection against temperature deposits,
rust, wear, and corrosion.
WB: Wheel Bearing grease (Timken Specification 0–610)
– 134 –
Y53-6008
NOTE: The responsibility for meeting these specifications, the quality of the product, and its performance in service rests with the lubricant supplier.
Medium Duty (R10/06)
Preventive Maintenance
Maintenance Schedule and Lubrication
Oil Reservoirs
For oil reservoirs with side filler plugs (transmissions, axles,
steering gear boxes, transfer cases, etc.), the oil must be
level with the filler opening.
NOTE: Use care when checking the oil level with a
finger. Just because you can reach the oil level with
a finger, does not mean the oil level is correct.
Lubrication Chart
The following lubrication specifications (see Table 4 on
page 136) are for an ambient operating temperature range of
–15 to 100°F (–26 to 38°C). For extreme temperature operations, consult the component manufacturer's manuals.
Medium Duty (R10/06)
Y53-6008
– 135 –
Maintenance Schedule and Lubrication
Table 4
Preventive Maintenance
Recommended Lubrication Types
COMPONENTS
RECOMMENDED LUBRICANT
Power Steering Gear
Automatic Transmission Fluid (ATF)
Driveline U-Joints
Slip-Joint Splines
Hood Pivots
Fan Drive
Fifth Wheel Components
Clutch Pedal Shaft
Clutch Linkage
Other chassis grease fittings not covered
below.
EP chassis grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2.
Wheel Bearing-Non Driving Axles
OIL LUBICATED: SAE 80W-90 EP gear oil, MIL-L-2105D, API GL5; or SAE 75W-90 synthetic
oil
GREASE LUBRICATED: EP chassis grease, lithium 12-hydroxystearate or lithium complex
base, NLGI 2.
Threaded Pins & Bushings (e.g., spring pins &
bushings)
EP grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2, with 3% molybdenum
additive: Mobil Grease Special (Mobil), Molygrease EP (Chevron), or equal.
Suspension Fittings (other than threaded pins
& bushings)
EP chassis grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2.
Steering Axle: Grease Fittings on Steering
Arm; Tie Rod Ends; Drag Link; King Pins
EP chassis grease, lithium 12-hydroxystearate base, NLGI 2.
Clutch Release Bearing (remove inspection
plate for access); Driveshaft Center Bearing
High temperature ball bearing grease. Chevron SRI Mobil Grease HP, Texaco Multifax 2, or
equivalent.
Automatic Slack Adjusters; Wedge Brake
Components; Disc Brake Caliper
High temperature EP grease; Texaco Thermotex EP-1, Shell Darina EP-1, Mobilith AW-1,
Rockwell 0-616A, or equivalent.
Deviations from the above list of lubricants should be based on specifications published in the component manufacturer's manuals or otherwise
approved by the manufacturer.
– 136 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Table 4
Maintenance Schedule and Lubrication
Recommended Lubrication Types
COMPONENTS
RECOMMENDED LUBRICANT
Cam Brake Camshaft Splines; Disc Brake
Shaft Splines and Slide Pin Retainers; Brake
Clevis Pins
Antiseize type grease, Rockwell specification 0-637.
Brake Camshaft Bushings
EP Chassis grease, lithium 12-hydroxystearate base, NLGI 2.
CAUTION: Do not contaminate brake linings with grease.
Steering Shaft Grease Fittings
EP chassis grease, lithium 12-hydroxystearate base, NLGI 2.
Brake Treadle Hinge and Roller
Engine oil
Lock Cylinders
Lock lubricant.
Door Hinges
Not required — Teflon bushings
Door Latches & Striker Plates.
Polyethylene grease stick.
Door Weatherstrip
Silicone lubricant.
Other Items
Use manufacturer’s manuals.
Deviations from the above list of lubricants should be based on specifications published in the component manufacturer's manuals or otherwise
approved by the manufacturer.
WARNING! Exhaust fumes from the engine contain carbon monoxide, a colorless and odorless
gas. A poorly maintained, damaged, or corroded
exhaust system can allow carbon monoxide to
enter the cab or sleeper. Failure to properly
maintain your vehicle could cause carbon monoxide to enter the cab and cause serious illnesses.
Medium Duty (R10/06)
Y53-6008
WARNING! Never idle your vehicle for prolonged
periods of time if you sense that exhaust fumes
are entering the cab. Investigate the cause of the
fumes and correct it as soon as possible. If the
vehicle must be driven under these conditions,
drive only with the windows slightly open. Failure to repair the source of the exhaust fumes
may lead to personal harm.
– 137 –
Maintenance Schedule and Lubrication
Preventive Maintenance
NOTE: Keep the engine exhaust system and the
vehicle’s cab ventilation system properly maintained. It is recommended that the vehicle’s
exhaust system and cab be inspected:
• By a competent technician every 15,000 miles.
• Whenever a change is noticed in the sound of the
exhaust system.
• Whenever the exhaust system, underbody, cab or
sleeper is damaged.
– 138 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Engine Maintenance
ENGINE MAINTENANCE
WARNING! Hot engine oil can be dangerous. You
could be seriously burned. Let the engine oil
cool down before changing it.
Engine Lubrication
Proper engine lubrication depends on ambient temperature
and where the vehicle will be operated. Use the recommended oil for the weather conditions outside.
NOTE: For engine oil specifications, oil change
intervals, engine filter requirements or general
engine maintenance procedures, refer to the Engine
Operation Manual included with your vehicle or the
engine manufacturer’s service manual.
Service Intervals
• Check engine oil daily.
Oil Draining:
• Refer to the engine manufacturer's Engine Operation
and Maintenance Manual supplied with your vehicle for
information about draining and refilling engine oil, engine
crankcase capacity, engine oil type, and changing oil filters, etc.
Medium Duty (R10/06)
• Drain the oil into a container designed for this purpose.
• When draining the oil, remove the plug with the proper
size wrench and keep as far away as possible. Always
keep your forearm parallel to the ground to help prevent
hot oil from running down your arm.
• The oil filler cap must be secured to avoid oil spill causing a potential fire hazard.
Oil Level Check
• To check the engine oil level, park the vehicle on level
ground and wait 5 minutes after shutting the engine OFF.
This allows time for the oil to drain to the oil pan.
• Remove the dipstick and wipe it off with a clean, lint-free
rag.
• Reinsert the dipstick all the way in and pull it out again to
check oil level. Correct oil level is between the low (L)
and high (H) marks on the dipstick.
For further information regarding oil level, see the engine
manufacturer's Engine Operation and Maintenance Manual
supplied with the vehicle.
Y53-6008
– 139 –
Engine Maintenance
Preventive Maintenance
Fuel System
Specification: Use only Diesel Fuel, Grade 2-D, as recommended by engine manufacturers. If you need further information on Grade 2-D fuel specifications, consult the Engine
Operation Manual in the glove compartment.
Please follow these recommendations when you are changing your fuel filters or strainer elements. Your vehicle's engine
will run better and last longer if you do. See the engine manufacturer's recommendations for proper water and micron
requirements.
WARNING! Diesel fuel in the presence of an ignition source (such as a cigarette) could cause an
explosion. You could be seriously injured. A
mixture of gasoline or alcohol with diesel fuel
increases this risk of explosion.
Installing Fuel Filters
CAUTION: If anyone ever pours gasoline into
your fuel tank, drain the entire system. Otherwise, the pump and engine will be damaged.
Don't try to dilute the gasoline by adding diesel
fuel (see Warning above).
When installing spin–on (throwaway) filters:
When removing filters, cover any electrical equipment and
wiring that might get soaked with fuel. Diesel fuel may permanently damage electrical insulation.
1. Prefill filter with fuel.
2. Moisten gasket with diesel fuel.
3. Hand tighten them only 1/2 to 2/3 turn after gasket contact. Mechanical tightening of these filters may distort or
crack the filter head.
• When replacing a fuel filter element, do not use a substitute. Install only filter elements designed for fuel filtration.
First clean and inspect the shell. Then insert the new
element and fill the container at least 2/3 full of clean fuel
before installing the shell
– 140 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Engine Maintenance
NOTE: To expel air from density-type strainer
elements, soak them in clean fuel before installing them.
• Throw away old gaskets. Replace them with new ones to
ensure a positive seal.
• Position the shell and gasket properly. Then tighten the
cover nut or bolt just enough to prevent fuel leakage.
• After starting the engine, check for leaks around the filter.
A. Close valve and run engine until smooth idle is
established, then repeat drain procedures, or
B. Remove filter from mounting head, completely drain
all fluid, and reassemble filter assembly. Be sure to
follow new filter assembly instructions.
2. Close drain valve by turning valve screw clockwise
approximately 1 1/2 to 2 turns.
CAUTION: Do not overtighten the valve. Overtightening can damage the threads.
Fuel Tanks
Filter Draining
Check fuel filter/water separator daily. Check with engine
OFF. Depending on the fuel storage facility, more frequent
draining may be required.
1. Open drain valve (by hand only): turn valve screw
counter-clockwise approximately 1 1/2 to 2 turns until
draining occurs. Drain filter sump of water until clear fuel
is visible.
1. Inspect fuel tanks, fuel hoses, and fittings to ensure
proper positioning and fastening; check for leaks.
2. Inspect mounting brackets, straps, and pins to ensure
proper positioning & fastening every 15,000 miles/
24,000 km (see label on fuel tank and data below):
If entrapped water exceeds sump volume, you can
either:
Medium Duty (R10/06)
Y53-6008
Type of Tank
Tank Strap T-Bolt Nut Torque
Aluminum
30 Lb. ft. (41 Nm)
Cylindrical Steel
8 Lb. ft. (11 Nm)
– 141 –
Engine Maintenance
Preventive Maintenance
Engine Accesories: Accessory Drive Belts
You can extend the reliability and service life of your vehicle's
drive belts with proper attention to installation, and maintenance. Neglect could cause belt failure. The result could be
the loss of the electrical or air system as well as possible
engine damage from overheating. So it’s a very good idea to
check your belts frequently and replace them as soon as you
detect trouble.
Follow this procedure to install an accessory drive belt:
1. Rotate the new belt around the pulleys, and then rotate
the automatic tensioner so that the idler pulley swings
toward the belt routing. Figure 1 shows an example of
the rotation direction to release the tensioner.
2. Slip the belt around the idler pulley attached to the automatic tensioner.
3. Release the automatic tensioner.
4. Check the belt alignment on each pulley. The belt must
fall between the flanges of each pulley.
– 142 –
Engine Fan
Thermatic (Clutch) — Type Fan
Y53-6008
WARNING! Do not work on the fan with the
engine running. The engine fan can engage at
any time without warning. Anyone near the fan
when it turns on could be seriously injured.
Before turning on the ignition, be sure that no
one is near the fan.
Medium Duty (R10/06)
Preventive Maintenance
Engine Cooling System
To Check the Fan:
• Check the fan assembly mounting bolts for tightness.
Inspect the blades for damage.
• Check the clutch operation by starting the engine when it
is cold. Then idle it at about 800 RPM. Listen for air
leaks.
• Check that the fan is not working while the engine is
warming. When the clutch engages, note the reading on
the vehicle's panel—mounted coolant temperature
gauge. If the fan clutch engages at low engine temperature or cycles on and off more frequently than it should
(receives “false signals”), have the problem corrected at
an Authorized Service Center.
• The leading edge of any fan blade must be 1 in. (25 mm)
from the inside edge of the shroud.
Exhaust System
The exhaust system is part of the noise control system. Periodically check the exhaust for wear and loose or missing
parts. For details, see “Noise and Emission Control” on
page 220.
WARNING! The exhaust piping, muffler, converter muffler or independent converter become
extremely hot during engine operation and can
cause serious burns to the skin. Allow adequate
cooling time before working on or near any part
of the exhaust system.
Fan Drive and Blade
Fan Blade Clearance: Around the fan shroud, the recommended distance is 1 in. (25 mm) from front edge of any fan
blade-to-radiator side member. Minimum clearance is 3/4 in.
(19 mm).
• Rear edge of any blade must be no closer than 3/8 in.
(9 mm) to the nearest engine component. If this cannot
be obtained, the fan spacer or fan is not correct.
Medium Duty (R10/06)
Engine Cooling System
Your engine’s cooling system is standard with Extended
Life Coolant (ELC). ELC consists of a mixture of ethylene
glycol, water, and organic acid technology chemical inhibitors. ELC prevents corrosion and scale formation as well
as provides freezing and boiling point protection.
Y53-6008
– 143 –
Engine Cooling System
Preventive Maintenance
CAUTION: The engine cooling system has very
specific maintenance and inspection requirements. Failure to follow requirements can damage the engine. Engine damage can include but
is not limited to:
• Freezing
• Boiling
• Corrosion
• Pitted cylinder liners
This information is found in the engine manufacturers owner’s manual. It is the owner’s responsibility to follow all requirements listed in the
engine manufacturers owner’s manual.
What To Check In An ELC-filled Cooling System
ELC Concentration
Check the level of freeze/boilover protection, which is
determined by the ELC concentration. Use a glycol refractometer to determine glycol level. Add ELC to obtain the
ELC to water ratio required to provide the protection you
need. Use the chart below to help determine how much
ELC you need to add.
NOTE: Maximum recommended ELC concentration is 60% ELC and 40% water by volume (a 60/
40 coolant mixture). The minimum recommended
concentration is 40%.
In an ELC-filled cooling system, the freeze point should be
maintained between -30° F and -45° F (-34° C and -43° C)
– 144 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Engine Cooling System
Desired ELC/
Water ratio:
0%
10%
15%
20%
25%
30%
35%
40%
Freeze point
°F (°C)
+32
(0)
+25
(-4)
+20
(-7)
+15
(-9)
+10
+5
-5
-12
-23
-34
-50
-65
-75
-84
-70
-55
-43
-30
-5
(-12) (-15) (-21) (-24) (-31) (-37) (-46) (-54) (-59) (-64) (-57) (-48) (-42) (-34) (-21)
ELC Condition (Contamination and Inhibitor Concentration)
Perform a visual inspection of the ELC. It should have no
cloudiness or floating debris. Determine the chemical
inhibitor concentration level by using an ELC-specific test
kit or test strips. Inhibitor concentration level determines
corrosion protection. If you are concerned about possible
coolant quality, contamination, or mechanical problems,
submit a coolant sample for analysis. Improper maintenance may cause coolant degradation and could result in
damage to the cooling system and engine components.
Consult your dealer or the ELC manufacturer’s representative for recommended ELC test kits, test strips, and laboratory sample procedures.
Medium Duty (R10/06)
45%
50%
55%
60%
65%
70%
75%
80%
85%
90% 100%
ELC Extender
Add ELC extender if necessary at the maintenance interval under “Cooling” on page 148.
Topping Off
Y53-6008
WARNING! Removing the fill cap on a hot
engine can cause scalding coolant to spray
out and burn you badly. If the engine has been
in operation within the previous 30 minutes,
be very careful in removing the fill cap. Protect face, hands, and arms against escaping
fluid and steam by covering the cap with a
large, thick rag. Do not try to remove it until
the surge tank cools down if you see any
steam or coolant escaping. In any situation,
remove the cap very slowly and carefully. Be
ready to back off if any steam or coolant
begins to escape.
– 145 –
Engine Cooling System
Preventive Maintenance
NOTE: If frequent topping off is necessary and
there are no visible signs of coolant leaks when
the engine is cold, check for leaks with the engine
operating at normal temperature.
Proper Coolant Level
NOTE: Do not overfill a cooling system. Excess
coolant may result in overflow, loss of antifreeze,
and reduced corrosion protection.
WARNING! Handle coolant and antifreeze carefully. Ethylene glycol antifreeze is poisonous.
Store in original fluid container only and always
keep out of reach of children.
FILL
COOLANT
EXPANSION
TANK
Check the coolant level after each trip. Add coolant as
necessary. You may find your coolant level is not up to the
correct level soon after you have filled the radiator. This
may be because all the trapped air in the system has not
yet been purged. It takes a little time for all the air to leave
the system after you fill your radiator.
Refilling Your Radiator
1.
2.
3.
4.
Cooling System Expansion Tank
– 146 –
Be sure the radiator and engine block drains are closed.
Move the heater control to maximum heat position.
Remove the surge tank pressure cap
Through the surge tank, fill the system with premixed
coolant. Pour it in a steady flow until the radiator is full.
5. Start the engine.
6. Idle at low RPM.
7. Complete the filling. Do it as quickly as possible.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Engine Cooling System
8. Idle the engine until it reaches normal operating temperature.
9. Fill the radiator as necessary to raise the coolant level to
the proper reading. Replace the surge tank pressure
cap.
Engine (Block) Heater (option)
WARNING! Do not use the heater if there are any
signs of problems. Engine block heaters can
cause fires resulting in serious personal injury
and/or property damage if not properly maintained and operated. Regularly inspect the
engine block heater wiring and connector for
damaged or frayed wires. Contact your Authorized Service Center or the manufacturer of the
heater if you are in need of repairs or information.
Medium Duty (R10/06)
CAUTION: Always unplug the block heater
before starting your engine. Damage to the cooling system could occur if not turned OFF
(unplugged).
Use a solution of half ethylene glycol antifreeze and half
water for best heater performance. Do not use more than 65
percent concentration of antifreeze, as a shortened heater
life will result.
After servicing the cooling system, operate the vehicle for a
day or two before using the heater. Trapped air inside the
engine needs time to escape.
Y53-6008
– 147 –
Engine Cooling System
Preventive Maintenance
PREVENTIVE MAINTENANCE (PM) INTERVALS
A
I
B
C
At the first 15,000 mi./ 15,000 mi./24,000 km/ 30,000 mi./48,000 km
24,000 km or at the first Monthly
PM
SYSTEM
COMPONENT
60,000 mi./96,000 km/
6 months
D
E
120,000 mi./
192,000km / Annually
240,000 mi./384,000 km
Recommended
PM Interval
MAINTENANCE TASK
I
Cooling
A
B
Hoses
Check the radiator and heater hoses for leaks.
X
Extended Life Coolant (ELC)
Check the freeze point (see page 143).
X
Check for contamination using test strips (see page 145).
X
C
D
E
X
Replace blank water filter if applicable.
X
Perform lab analysis (see page 145).
X
If lab analysis shows coolant is unsuitable for continued use
Flush, drain, and refill (see page 143).
Add ELC Extender (see page 145).
X
Flush, drain, and refill with new coolant (see page 143).
– 148 –
Fan clutch housing
Check for air leaks.
X
Surge Tank Fill Cap
Check fill cap seal at each oil change.
X
Y53-6008
X
X
X
X
X
Medium Duty (R10/06)
X
Preventive Maintenance
Brake System
BRAKE SYSTEM
All of the following areas are interrelated and must conform to original specifications:
If your truck has an air brake system, see the pages below.
•
•
•
•
If your truck has a hydraulic brake system, please go to
“Hydraulic Brake System” on page 153.
Introduction
To operate your vehicle safely, you need some understanding
of its brake systems. Brake adjustment and brake balance
must be set carefully to allow equal stopping forces at all
wheels. Tires are also a very important part of the whole system. How fast you can stop depends on how much friction
there is between the road and your tires.
CAUTION: The air brake system of this vehicle
was configured for ONE of the following operations: tractor or truck, and complies with the
respective portions of FMVSS 121. A tractor
shall not be operated or configured as a truck,
nor shall a truck be operated or configured as a
tractor, without significant modifications to the
air brake system in order to retain compliance
with FMVSS 121. Contact your Peterbilt dealer
for instructions.
Medium Duty (R10/06)
tire size
wedge angle
brake linings
slack adjusters
• cam radius
• drum radius
• brake chambers
Once a brake system is set to specifications, changing any
one of its components or any combination of components
may degrade the system. All parts have to work together to
perform as they should.
Because your brake system is air operated, see the following
section “Air System” on page 160 for more information on
checking your brakes.
Any replacement components in the brake system should be
the same or better than the original components. Any
changes from the original specifications can affect the performance of the entire system.
Y53-6008
– 149 –
Brake System
Preventive Maintenance
WARNING! Do not use any replacement part in
the brake system unless it conforms exactly to
original specifications. A nonconforming part in
your vehicle's brake system could cause a malfunction resulting in an injury accident. Sizes
and types are so related to one another that a
seemingly unimportant change in one may
result in a change in how well the brakes work
for you on the road. If parts do not work together
properly, you could lose control of your vehicle,
which could cause a serious accident.
WARNING! Do not work on the brake system
without the parking brake set and wheels
chocked securely. If the vehicle is not secured to
prevent uncontrolled vehicle movement, it could
roll and cause serious personal injury or damage to the vehicle.
•Use wood blocks (4 in. X 4 in. or larger) against
the front and rear surfaces of the tires. Be sure
the vehicle cannot move.
Lubrication
Cam-actuated brake components such as anchor pins and
brake camshafts are subjected to high temperatures, and
must be lubricated with nonmelting, water resistant brake
grease meeting R–S Specification 0–616 (NLGI–Grade 1).
• Lubricate according to Table 2, “Recommended Maintenance Intervals,” Page 120.
WARNING! Do not apply too much lubricant to
brake components—lubricate sparingly. Excessive amounts of lubricant could contaminate
brake linings, which could reduce brake effectiveness and cause an accident.
Brake and Slack Adjuster Lubrication
According to the interval, pressure lubricate the slack
adjuster and brake camshaft (bracket/tube). Two grease fittings are provided for both the slack adjuster and camshaft
bracket/tube.
• Use standard chassis lubricant (meeting No. 1 grade
high temperature, water proof specifications).
• Do not use moly-disulfide loaded grease or oil (they may
shorten the service life of the slack adjuster).
– 150 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Brake System
• Do not use pressure-release grease fittings when lubricating the slack adjuster.
Checks and Adjustments
All vehicle operators should check the brakes regularly.
Always adjust the brakes when they are cool.
• Park the vehicle on a level surface and block the wheels
before attempting any brake checks or adjustments.
Brake Linings
WARNING! Do not use brake linings with a thickness below the specified minimum. Such linings
will have lining rivets exposed that can damage
the brake drum and reduce brake efficiency,
which could cause an injury accident or system
failure.
• Brake linings should be inspected for wear by a qualified
mechanic at an Authorized Service Center. See Table 3,
“Maintenance Schedule,” Page 123. In severe service
applications inspect the linings more frequently.
Medium Duty (R10/06)
Automatic Slack Adjusters
Your Medium Duty is equipped with automatic brake (slack)
adjusters.
Periodically, brake adjustment should be checked using
the following procedure:
1. Check brakes when the temperature of the service brake
linings are cool and the system air pressure is at 100 psi
(690 kPa) minimum.
2. Release the parking brakes to allow the slack adjusters
to retract.
3. Measure the retracted pushrod length from the face of
the brake chamber to the center of the pushrod pin.
4. Apply 80 to 90 psi brake application and measure the
same distance.
5. The difference is the pushrod travel distance (applied
stroke).
Verify that the result is within the correct range (see Table 5,
”Brake Adjuster Stroke”). Correctly installed and functioning
brakes (auto slack) will produce the strokes listed for each
chamber type.
Y53-6008
– 151 –
Brake System
Preventive Maintenance
WARNING! Manual adjustment of automatic
slack adjusters is a dangerous practice that
could have serious consequences. It gives
the operator a false sense of security about
the effectiveness of the brakes. Contact the
Service Department at your dealership if the
stroke exceeds the above specifications. A
stroke exceeding these values may indicate a
problem with the slack adjuster or the brake
foundation.
BRAKE
CHAMBER
SLACK
ADJUSTER
PUSHROD
“APPLIED STROKE”
01830
Measuring Pushrod Travel
Table 5
Brake Adjuster Stroke
80–90 PSI (552 – 621 KPA) BRAKE APPLICATION
PUSHROD TRAVEL
(Applied Stroke)
AIR CHAMBER
TYPE (Size)
BRAKE
20
Front
1 to 1–3/4 in. (25–44mm)
30
Rear
1–1/4 to 2 in. (32–51mm)
– 152 –
• If the pushrod travel reaches the above specifications,
check the slack adjuster installation. Inspect brake
adjuster and anchor bracket for damage. The anchor
bracket should be tight.
• With the air system at 100 psi (690 kPa) or more, apply
the brake.
If adjustment is necessary and the slack adjuster is working,
the adjusting hex nut will rotate during the chamber return
stroke. Installing a wrench on the hex nut will make this easier to see. On each stroke after the first, the amount of adjustment and chamber travel will be less.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Brake System
Constant manual adjustment of automatic slack adjusters
can shorten the life of the internal clutch. If the installation
appears to be free of damage, but the applied stroke range
could not be achieved, the slack adjuster must be replaced.
NOTE: The brake adjuster alone does not ensure
proper brake operation. Inspect all brake components. All brake components work together and
must be checked periodically to ensure the brake
system works properly. See the “Medium Duty
Maintenance Manual” for more information on
brake maintenance.
Hydraulic Brake System
Introduction
To operate your vehicle safely, you need some understanding
of its brake systems. Brake adjustment and brake balance
must be set carefully to allow equal stopping forces at all
wheels. Tires are also a very important part of the whole system. How fast you can stop depends on how much friction
there is between the road and your tires.
Medium Duty (R10/06)
All of the following areas are interrelated and must conform to original specifications:
•
•
•
•
wheel size
tire size
brake pads
brake rotors
• front wheel bearings
• front end alignment
• parking brake drum
radius
Once a brake system is set to specifications, changing any
one of its components or any combination of components
may degrade the system. All parts have to work together to
perform as they should.
Your brake system is hydraulically operated. Refer to the section titled “Ser vice Brake Component Inspection” on
page 155 for more information on inspecting the brakes.
Any replacement components in the brake system must meet
the specifications of the original components. Any changes
from the original specifications can affect the performance of
the entire system.
Y53-6008
– 153 –
Brake System
Preventive Maintenance
WARNING! Do not use any replacement part in
the brake system unless it conforms exactly to
original specifications. A nonconforming part in
your vehicle's brake system could cause a malfunction resulting in an injury accident. Consult
you local dealer for suitable replacement parts.
Brake Fluid Check and Refill
WARNING! Do not work on the brake system
without the parking brake set, the keys removed
from the vehicle, and wheels chocked securely.
If the vehicle is not properly secured to prevent
inadvertent vehicle movement, it could roll and
cause serious personal injury or damage to the
vehicle.
• Use wood blocks (4 in. X 4 in. X 6 in. or
larger) against the front and rear surfaces of
the tires. Be sure the vehicle cannot move.
WARNING! Wear protective clothing when handling hydraulic fluid. It is mildly toxic and can
cause skin and eye irritation.
WARNING! Use only the type of hydraulic fluid
specified. Do not use or mix different types of
hydraulic fluid. The wrong hydraulic fluid will
damage the rubber parts of the brake system
which may lead to loss of braking and possibly
cause serious personal injury.
CAUTION: Hydraulic brake systems use two distinct and incompatible fluids. Power steering
fluid is used in the hydraulic brake booster system. Brake fluid is used in the master cylinder
and brake pipes. Do not mix these fluids when
replenishing the system or seal damage can
result.
CAUTION: Hydraulic brake fluid may damage
painted surfaces of the vehicle.
– 154 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Brake System
WARNING! If the brake fluid reservoir requires an
excessive amount of hydraulic fluid, the complete system must be inspected for leaks and
repaired if necessary (consult your nearest
Peterbilt dealer). Failure to keep the brake system in good repair may lead to loss of braking
and possibly cause serious personal injury.
Make sure that the fluid level registers on or above the fluid
level mark molded on the reservoir - add more if necessary,
as follows:
1. Remove each reservoir cap and extract the rubber diaphragm from each reservoir.
2. Fill each reservoir with clean hydraulic fluid of the
approved specification (DOT 3 brake fluid).
3. Insert the rubber diaphragms into the reservoirs.
Service Brake Component Inspection
Remove each wheel to inspect the brake components.
REFILL CAPS
CAUTION: When replacing disc brake pads, be
sure to use the same lining material on both
axles. Mixing lining types can result in unbalanced braking, increased pad wear, or degraded
stopping performance. Consult your nearest
Peterbilt dealer.
Disc brake pads - Visually inspect all brake pad linings.
Brake pads should be replaced when the
remaining lining reaches 3⁄16 inch thickness or
less.
BOOSTER AND MASTER CYLINDER ASSEMBLY
4. To prevent leakage from the reservoirs, ensure that the
seal in each reservoir cap is in good condition before
refitting the cap.
Medium Duty (R10/06)
Y53-6008
It is recommended that all disc brake pads be
replaced at the same time since this will maintain balanced braking. At a minimum, replace all
disc brake pads on one axle, both ends, at the
same time.
– 155 –
Brake System
Preventive Maintenance
BRAKE PADS
ANCHOR
PLATES
BRAKE PADS
CALIPERS
CALIPERS
ROTORS
FRONT
REAR
SYSTEM COMPONENTS
Calipers - Visually inspect calipers for brake fluid leakage,
damaged or defective pistons or piston boots. If
there is evidence of leakage, damage, or other
defects the caliper should be replaced or
repaired.
Disc brake rotors - Visually inspect rotors for scoring, warping, cracks, bluing or heat spots or other damage
or defects. If signs of damage or defects are
found, the rotor(s) should be resurfaced or
replaced in accordance with the vehicle manufacturer's recommended service procedure.
Anchor plates - Visually inspect anchor plates for worn or
damaged slippers, damaged or dislodged guide
pin boots or other defects. If signs of wear, damage or defects are found, the anchor plate(s)
should be repaired or replaced.
Parking Brake Component Inspection
NOTE: If you are not properly trained to perform
brake inspections or service, take your vehicle to
your nearest Peterbilt dealer.
– 156 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Brake System
Visually inspect brake shoe lining for wear, cracks, or breakage. If linings are worn down to 2.5 mm (0.10 in), they must
be replaced. Inspect brake drum for deep scores, heat spots,
cracks, or damage. Replace if needed.
BRAKE
SHOE
LININGS
Anti–Lock Braking System (ABS)
Your Medium Duty is equipped with an anti-lock braking system. For detailed service information, see the Peterbilt
Medium Duty Maintenance Manual. All service work
should be performed by a qualified technician at an Authorized Service Center. The foundation brake system must be
in proper working order to ensure the best ABS performance.
CAUTION: Do not weld anywhere on the vehicle
before detaching the ABS Electronic Control Unit
(ECU) connector and all other electronic control
units. Welding equipment can send an energy
surge through electronic equipment and cause
damage. Disconnect all ECUs before attaching
welding equipment.
CAUTION: Never detach the ECU connector with
the ignition turned on. The connectors could arc
and damage electronic equipment. Turn off the
ignition before disconnecting any electronic
equipment.
PARKING BRAKE COMPONENTS
Other precautions
• Check ABS wiring harnesses periodically for chafing or
other problems. No regular maintenance is required on
the ABS components.
Medium Duty (R10/06)
Y53-6008
– 157 –
Brake System
Preventive Maintenance
• During wheel balancing, dyno testing, or any time the
ignition is on with part of the ABS disconnected, a failure
code will be recorded. Consult with your Peterbilt Dealer
or Authorized Service Center for information on clearing
the failure code.
If, due to operating conditions, a brake application causes
either wheel on the same axle to begin skidding, wheel
speed sensors immediately signal the anti-lock controller in
the modulator assembly. The controller responds instantly by
signaling the solenoids in the modulator which activate the air
valves, reducing application pressure as needed to prevent
the wheels from locking up. If this over-riding correction is
effective, application pressure is allowed to build up to the
original input.
Any malfunction of the anti-lock system on one or more axles
will cause the system to fail-safe, and the panel-mounted
amber warning light will come on, indicating both a malfunction, and automatic shut-down of the system. If the foundation brake system is intact, the service brakes will continue to
function normally, but without benefit of the anti-lock feature.
– 158 –
Y53-6008
NOTE: If one wheel on any driven axle continues to
slip or spin for approximately 4 seconds, this will
cause the anti-lock controller for that axle to go into
the fail-safe mode, and the warning light will give a
shutdown signal.
•In this case, the anti-lock system can be turned
back on, and the warning light extinguished, by turning the key switch OFF and ON, after the vehicle has
been brought to a full stop. When the key switch is
turned back on, the warning light will illuminate and
remain on for 3 to 5 seconds. This is a built-in function test of the warning light.
WARNING! Do not attempt to recycle the antilock system by turning the keyswitch OFF and
ON until the vehicle has been brought to a full
stop and the parking brakes set. Failure to do so
could adversely affect steering and braking control, and may result in loss of vehicle control and
an injury accident.
Medium Duty (R10/06)
Preventive Maintenance
Brake System
WARNING! Do not operate the vehicle in the
event of a malfunction in any air or hydraulic circuit. Such a malfunction may prevent the brake
system from operating properly, and could
result in an injury accident. The vehicle should
not be operated until the system is repaired and
both braking circuits, including all pneumatic,
hydraulic, and mechanical components are
working properly.
Medium Duty (R10/06)
Y53-6008
– 159 –
Air System
Preventive Maintenance
AIR SYSTEM
Introduction
WARNING! Prior to the removal of any air system
component, always block and hold the vehicle
by a secure means other than the vehicle's own
brakes. Depleting air system pressure may
cause the vehicle to roll unexpectedly resulting
in an accident and/or injuries. Keep hands away
from chamber push rods and slack adjusters,
they may apply as system pressure drops.
•Never connect or disconnect a hose or line containing air pressure. It may whip as air escapes.
Never remove a component or pipe plug unless
you are certain all system pressure has been
depleted.
•Never exceed recommended air pressure and
always wear safety glasses when working with
air pressure. Never look into air jets or direct
them at anyone.
•Never attempt to disassemble a component
until you have read and understood recommended procedures. Some components contain
powerful springs and injury or death can result if
not properly disassembled. Use only proper
tools and observe all precautions pertaining to
the use of those tools.
– 160 –
• Completely bypassing a Bendix AD-IS air dryer will
bypass the system’s pressure protection valves.
This could lead to loss of air pressure or damage to
the vehicle’s air system, which could cause an accident or personal injury. Always adhere to the manufa c tu r e r ’s p ro c edu r e if it i s n ec es s ar y in an
emergency to temporarily bypass an AD-IS-series air
dryer.
WARNING! Do not release the parking brake or
attempt to move the vehicle until air pressure in
both circuits is at least 100 psi (690 kPa), the
level required for normal brake operation.
•Do not use the trailer hand brake control to hold
vehicle while parked. This control utilizes air
pressure for brake application. Because acceptable air leakage levels cause all truck air systems to gradually los e pres sur e , ve hicle
rollaway could occur, resulting in an accident
and/or injuries.
•Always apply the tractor and trailer parking
brakes when the vehicle is unattended.
Contamination of the air supply system is the major cause of
problems in air-operated components such as brake valves,
wiper motors, and suspension height control valves. To keep
contaminants to the lowest possible level, follow these maintenance procedures.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Air System
Scheduled Maintenance
Table 6
Use Table 6, ”Air System Scheduled Maintenance,” to schedule service operations and air system tests.
Air System Scheduled Maintenance
MAXIMUM INTERVALS
EACH MONTH
TEST
Air Compressor
Air Governor
System Leakage
Dual Air Brake Treadle Valve
Hand–Operated Trailer Brake Valve
Tractor Parking Valve
Parking Brake Valve
Trailer Air Supply
Tractor Protection Valves
Relay Valve
Spring Brake Inversion Valve
Automatic Limiting Valve
Single Check Valves
Double Check Valves
Stop Light Switch
Low–Pressure Wig Wag
Low–Pressure Switch
Automatic Drain Valve
Safety Valve
Quick Release Valve
Manual Drain Valve
Medium Duty (R10/06)
EACH WEEK
THREE MONTHS
SIX MONTHS
(10,000 mi) (16,000 (25,000 mi) (40,000 (50,000 mi) (80,000
km)
km)
km)
ANNUALLY
(100,000 mi)
(160,000 km)
•
•
•
•
•
•
•
•
–
–
or
or
–
–
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Y53-6008
– 161 –
Air System
Preventive Maintenance
WARNING! If the supply and service tanks are
not drained at the recommended frequency,
water could enter the air lines and valves. This
could cause corrosion or blockage, which could
compromise the brake system safety and potentially cause an injury accident.
Air System Function Test
Scheduled maintenance should be performed on the Medium
Duty air system, as outlined in the Medium Duty Maintenance Manual and Table 6. In addition, perform an Air System Function Test at least every 3 months or if there is any
indication of a potential problem.
REAR PRIMARY
(SERVICE) TANK
FRONT
SECONDARY
(SERVICE) TANK
Air Tanks
The front (secondary) service tank is underneath the cab, on
the driver's side; the wet (supply) tank is underneath the front
service tank, behind the battery box; and the rear (primary)
service tank is attached to the left frame, just behind the cab.
DRAIN VALVE
WET (SUPPLY)
TANK UNDER
FRONT SERVICE
TANK
The supply tank (or “wet” tank), must be drained on a daily
basis. Drain the supply tank by pulling the drain valve lanyard. Hold it open until the escaping air is free of water.
02602
The two service tanks (or “dry” tanks), must be drained on a
weekly basis. Drain the two service tanks by opening the
drain valves. Turn valve handles counter-clockwise, and
leave open until the escaping air is free of water.
– 162 –
Location of Air Tanks
Periodically: Clean filter screens ahead of the valves by
removing the screens and soaking them in solvent. Blow
them dry with pressurized air before reinstalling them.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Air System
CAUTION: Do not use penetrating oil, brake
fluid, or wax-based oils in the air system. These
fluids may cause severe damage to air system
components.
service center) if a leak is detected. Failure to check the
brakes or follow these procedures could cause a system
failure, increasing the risk of an injury accident.
FRONT
SECONDARY
SERVICE
CIRCUIT
(WHITE)
• Maintain the air compressor to prevent excessive oil bypass. See the Medium Duty Maintenance Manual for
maintenance details.
• Replace worn seals in valves and air motors as they are
needed. Your Peterbilt Dealer carries rebuild kits for most
units.
Dual Air Gauge and Air Leaks
Your Medium Duty comes with a dual-circuit air pressure
gauge for two separate systems, Primary and Secondary:
the WHITE pointer indicates pressure in the front (Secondary) braking circuit; the ORANGE pointer indicates pressure
in the rear (Primary) braking circuit. The gauge indicates the
amount of air pressure in pounds per square inch (psi).
WARNING! Do not operate the vehicle if leakage
in the air system is detected. Conduct the following procedure and contact an Authorized Service Center (or any other properly equipped
Medium Duty (R10/06)
02581
REAR
PRIMARY
SERVICE
CIRCUIT
(ORANGE)
Dual Air Pressure Gauge (Air Reservoir)
If the pressure in either or both systems is too low for normal
brake operation, i.e., either pointer falls below 60 psi (414
kPa), a warning light on the gauge will glow and the audible
alarm will sound. If the light and alarm do not turn off at startup, do not try to drive the vehicle until the problem is found
and fixed.
Y53-6008
– 163 –
Air System
Preventive Maintenance
Follow the procedure below to check the compressed air
system for leaks:
1. Periodically, or after maintenance or replacement of air
system components:
2. Build up air pressure in the system to the governor cutout point or until 120 psi (827 kPa) is reached.
3. Stop the engine and release the service brakes.
4. Without applying the brake pedal, observe the rate of air
pressure drop. This rate should not exceed 2.0 psi (14
kPa) per minute.
5. Start the engine and build up the air pressure again.
6. Stop the engine, and apply the brakes fully. Apply the
brake pedal and hold it down for five minutes. The pressure drop should not exceed 3.0 psi (21 kPa) per minute.
7. If you detect excessive leakage (air pressure loss greater
than 3.0 psi after five minutes of brake application), a
leakage test should be made at the air line connections
and at all air brake control units. These tests should
determine where air is escaping.
Air Compressor
Operation
All compressors, regardless of make or model, run continuously while the engine is running. System pressure is controlled by the governor. The governor acts in conjunction with
– 164 –
the unloading mechanism in the compressor cylinder block to
star t and stop compression of air. The compressor is
unloaded when the system pressure reaches 120 psi (827
kPa) and compression is re-established when system pressure falls to 100 psi (690 kPa).
Preventive Maintenance
The following service checks are provided for your information only and should be performed by a certified mechanic.
Contact your Peterbilt Dealer or consult the Medium Duty
Maintenance Manual and the engine manufacturer's Maintenance Manual for further information on servicing air compressors. After completing any repairs to the air system,
always test for air leaks, and check the brakes for safe operation before putting the vehicle in service.
According to Table 6, “Air System Scheduled Maintenance,”
Page 161:
• Inspect compressor air filter element, if so equipped, and
replace element if clogged. Check compressor mounting
and drive for alignment and belt tension. Adjust if necessary.
• Remove compressor discharge valve cap nuts and
check for presence of excessive carbon. If excessive carbon is found, clean or replace the compressor cylinder
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Air System
head. Also, check compressor discharge line for carbon,
and clean or replace the discharge line if necessary.
• Disassemble compressor and thoroughly clean and
inspect all parts. Repair or replace all worn or damaged
parts, or replace compressor with a factory exchange
unit.
CAUTION: When draining the engine cooling
system is required, to prevent damage from
freezing, the compressor must also be drained
at the cylinder head and block. Engine damage
could occur if the cooling system is not periodically drained and maintained. See “Engine Cooling System,” Page 143, and the Medium Duty
Maintenance Manual for further information.
Air Dryer
WARNING! Use of incorrect air dryer could
cause air system failure, leading to loss of
vehicle control and serious personal injury or
death. If your vehicle is equipped with a Bendix AD-IS air dryer, it is important that future
replacements be identical or similar in design.
Any deviation from the Bendix AD-IS type air dryer would
require changes to the vehicle air system. Some vehicles
use a dual air system consisting of a wet tank, forward dry
Medium Duty (R10/06)
tank, and rear dry tank. The dry tanks have a single-check
valve in the tank inlet. The check valves prevent a complete loss of air in the event of an air system failure (tank
or hose failure). This ensures a controlled stop (with
reduced braking capability). Other vehicles use a Bendix
AD-IS air dryer which eliminates the need for a wet tank
and check valves in the dry tanks.
NOTE: A small amount of oil in the system may be
normal and should not, by itself, be considered
reason to replace a desiccant cartridge; oil-stained
desiccant can function adequately.
Every 900 operating hours or 25,000 miles/40,000 km or 3
months, check for moisture in the air brake system by opening reservoirs, drain cocks, or valves and checking for the
presence of water. A tablespoon of water in a reservoir would
point to the need for a desiccant cartridge change. However,
the following should be considered first:
• Air usage is exceptionally high/abnormal for a highway
vehicle. This may be due to accessory air demands or
some other unusual air requirement that doesn’t allow
the compressor to load/unload in a normal fashion or it
may be due to excessive leaks in the air system.
Y53-6008
– 165 –
Air System
Preventive Maintenance
• When more than a 30-degree F. (17-degree C) range of
temperature occurs in one day, small amounts of water
can accumulate in the air brake system due to condensation. Under these conditions, the presence of small
amounts of moisture is normal and should not be considered as an indication that the dryer is not performing
properly.
• An outside air source may have been used to charge the
air system, in which case this air did not pass through
the drying bed.
ing should be more frequent. Replace any defective
parts. With the possible exception of mounting brackets,
do not repair defective parts.
• Check the Charge-Air-Cooler for air leaks annually. The
air leaks can be caused by cracked tubes or header. For
service see your Peterbilt Dealer or Authorized Service
Center.
Turbocharger
When servicing the air intake and exhaust systems on a turbocharged engine, check the items listed below.
Air Intake System
Engine heat, vibration, and age combine to loosen air intake
connections and cause cracks in the tubing and elbows.
Leaks in the intake system allow abrasive dust to enter the
engine and quickly cause expensive damage. During your
daily walk-around inspection, carefully check all tubing,
elbows, clamps supports and fasteners for condition and
tightness.
• Under normal operating conditions, Peterbilt recommends complete disassembly and cleaning of the air
intake system at each 25,000 mile (40,000 km). Under
severe operating conditions, the disassembly and clean-
– 166 –
WARNING! Do not operate engine with the turbocharger intake piping disconnected. A suction is
created when the engine is running. This suction
could draw your hand or anything else near it
into the impeller fan. You could be seriously
injured. Always keep the intake piping connected when you will be running the engine.
Lubricating System: Check the oil lines, housing, and connections. Look for leaks, damage, or deterioration. Leaks
could mean you have damaged oil lines or oil seals.
Manifold: With the engine operating, check for leaking manifold or flange gaskets.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Air System
High Frequency Vibration: Vibration may indicate turbo
rotor imbalance. Have your Peterbilt Dealer or Authorized
Service Center investigate this immediately. If you detect any
deficiencies, take the vehicle to an Authorized Service Center for servicing. Delay could lead to severe and expensive
damage to your vehicle.
Service the air cleaner periodically. If the vehicle operates in
areas with heavy dust, maintenance should be more frequent. Follow the instructions below to remove the air filter.
AIR INTAKE
ASSEMBLY
Air Filter Replacement
Service the filter elements when the Air Cleaner Restriction
gauge (option) locks in the extreme High position. Have the
element serviced at a Peterbilt Dealer or Authorized Service
Center. Paper elements require care and proper handling,
because they are critical to engine service life.
02603
Air Intake Assembly
Medium Duty (R10/06)
Y53-6008
– 167 –
Air System
Preventive Maintenance
3. Remove the filter element.
4. Clean out the inside of the air cleaner body and outlet
tube with a dry rag.
COVER
To install air cleaner element:
1. Slide air cleaner element into housing.
2. Install air cleaner end cap.
3. Install thumbscrews around air cleaner housing end cap.
00455B
NOTE: The air cleaner is internally sealed by a
radial seal around Inlet tube of air cleaner element.
For further information on servicing the air cleaner,
see the Medium Duty Maintenance Manual.
FILTER ELEMENT
Air Cleaner - Filter Element
To remove the air filter:
1. Remove the two thumb screws.
2. Remove air cleaner service cover.
– 168 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Tires and Wheels
TIRES AND WHEELS
Introduction
Keeping the tires in good condition is essential to the safe,
efficient operation of your Medium Duty. Regular, frequent
inspection and the right care will give you the assurance of
safe and reliable tire operation.
General Safety Requirements
WARNING! Use only original equipment manufactured (OEM) components. Use of non-original
equipment could cause wheel breakage and
wheel separation from vehicle, which could
result in an injury accident. Each mounting system is engineered only for use with its correct
mating part. Be sure that properly matched components are used for each type of mounting. The
comparison chart on Page 177 illustrates the differences between parts used in hub-piloted
mount and ball seat mount applications. Only
OEM supplied hub-piloted or ball-seat mounted
wheels may be used on this vehicle.
Medium Duty (R10/06)
• If you are not fully qualified and not equipped with
the proper tools and equipment, do not attempt to
raise the vehicle or remove or install the damaged
tire and wheel assembly. Obtain expert help. A person can be seriously injured and/or damage can
result from using the wrong service methods. Truck
tires and wheels should be serviced only by trained
personnel using proper equipment. Do not reinflate
a tire that has been run flat or is seriously low on air
without first removing the tire from the rim and
inspecting for damage.
• Follow OSHA regulations per section 1910.177.
• Do not exceed the speed rating of tires. Exceeding
the speed rating may result in sudden tire failure and
loss of vehicle control.
• Follow all warnings and cautions contained within
the tire and wheel manufacturers literature.
• Only properly trained personnel should service tire
and rim assemblies.
• See page 179 for specific safety requirements for
trucks with hydraulic brakes.
Y53-6008
– 169 –
Tires and Wheels
Preventive Maintenance
Speed Restricted Tires
WARNING! This vehicle may be equipped with
speed restricted tires. Check each tire’s sidewall for maximum rated speed. Vehicle should
not be operated at sustained speed in excess
of maximum rated speed. Failure to comply
with these speed restrictions could cause
sudden tire failure which can result in property damage or personal injury.
Tire Inspection and Replacement
vehicle. For dual wheel assemblies, check between the
wheels for damage. If any damage is found, or you suspect
damage, do not attempt further repair. Call for expert tire service.
Tire Inflation and Loading
Low pressure is a tire's worst enemy. Underinflation allows
tires to flex improperly, causing high temperatures to build up.
Heat causes early tire damage such as flex break, radial
cracks, and ply separation. And low pressure may affect control of your vehicle, especially at the front wheels.
Visually inspect your tires frequently for any abnormal conditions such as scrapes, bulges, and uneven wear. This must
be done immediately after known or suspected contact with
an object in the road, with a pothole, road irregularity or after
severe braking. Refer these conditions to an Authorized Tire
Service Center for repair or replacement. Never drive on a
tire if such conditions appear.
WARNING! Do not operate vehicle with underinflated tires. The extra heat caused by underinflation can cause sudden tire failure such as a tire
fire or blow out. Low pressure may affect control
at the front wheels, which could result in an accident and serious injury. Keep your tires inflated
to the manufacturer's recommended air pressure.
If the tire looks underinflated, stand off to the side and check
for damage to the wheel assembly. This can be done by visually comparing the wheel in question to other wheels on the
– 170 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Tires and Wheels
Tire Inflation
Most tire wear problems are caused by underinflation as the
result of slow leaks. So you will want to check tire pressure
regularly. Give the tires a visual test every day, and check
inflation with a gauge every week.
When checking tire pressure, inspect each tire for damage to
sidewalls, cuts, cracks, uneven wear, rocks between dual
wheels (tires), etc. If a tire appears underinflated, check for
damage to the wheel assembly. Do not forget to check
between dual wheels. If you find wheel damage, have an
expert tire service repair it.
WARNING! Do not repair damaged tires unless
you are fully qualified and equipped to do so.
Wheel and tire assemblies cannot be worked on
without proper tools and equipment, such as:
safety cages or restraining devices. Have all tire
repairs performed by an expert. And stand away
from the tire assembly while the expert is working.
CAUTION: Pressure should be checked when
the tires are cool. Warm or hot tires cause pressure buildup and will give you an inaccurate
reading. So never deflate a warm tire to the
specified pressure.
Medium Duty (R10/06)
Underinflated tires will adversely affect the operation of
the vehicle and tires:
• making steering difficult
• causing extra strain on the tire sidewalls
• reducing the tread life of tires due to the high temperatures generated from excess flexing of the tire
• Inflate tires to the manufacturer's cold air pressure specification molded into the tire side wall.
Lower tire pressure does not give you more traction on ice or
snow. Underinflation actually reduces traction and steering
control. See the tire manufacturer's Drivers Handbook for
more information on proper operation and use of tires.
00137a
Proper Inflation: t h e c o r r e c t
profile for full contact with the
road.
TREAD CONTACT
WITH ROAD
00138a
Y53-6008
TREAD
CONTACT WITH ROAD
Underinflation: causes abnormal tire deflection, which builds
up excessive heat, running the
risk of failure. It also causes
irregular wear.
– 171 –
Tires and Wheels
Preventive Maintenance
Overinflation: r e d u c e s t h e
tread contact area with the road
surface, concentrating all of the
vehicle weight on the center of
TREAD CONTACT
the tread. This causes premaWITH ROAD
ture wear of the tire.
• Too much air pressure reduces the tire tread contact
area and results in rapid wear in the center of the tire. It
also causes tires to run hard and makes them more vulnerable to impact and other road hazard damage.
00139a
WARNING! Overinflated tires can cause accidents. They wear more quickly than properly
inflated tires and are more subject to punctures,
cracks, and other damage. They could fail and
cause you to lose control of your vehicle resulting in an injury accident. Be sure all tires are
inflated correctly according to the manufacturer's recommendations.
Table 7
Tire Loading
WARNING! Do not exceed the load rating of your
tires (molded on the side wall of your tire) or the
maximum vehicle load rating, whichever is less.
Overloading could result in premature tire failure causing you to loose control of your vehicle
and result in an injury accident. The maximum
vehicle load rating (GVWR) is found on the Tire
and Rim Data label on the driver's door.
Overloading your vehicle is as damaging to the tires as
underinflation. It significantly affects the expected life (total
mileage of a tire). The following chart shows how neglect or
deliberate abuse can affect the life of your vehicle's tires.
Effect of Load Pressure on Tire Life
Vehicle Load
Normal
20% Over
40% Over
60% Over
80% Over
100% Over
Tire Pressure
Normal
20% Low
30% Low
35% Low
45% Low
55% Low
70%
50%
40%
30%
25%
Expected Total Tire
Mileage
– 172 –
If overinflation is noted during travel, do not deflate tires. The
increased pressure is caused by temperature build-up during
operation. This condition has been taken into account during
manufacturing of the tires. Allow tires to cool, then recheck
and adjust if necessary.
Normal
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Tires and Wheels
Wheel Mounting and Fastening
Wheel Bearing Adjustment
After the vehicle travels about 50 to 100 miles (80 to 160 km),
wheel mountings “seat in” and will lose some initial torque.
Check hub/wheel mountings after this initial period and
retighten.
Wheel Cap Nut Torque
At the first scheduled lube interval, have all wheel cap nuts
torqued to their specified value. See Table 8, “Wheel Cap Nut
Torque,” Page 174 After that, check wheel cap nuts at least
once a week. Contact an Authorized Service Center for information on the proper installation procedure for the wheels on
your truck. This is a job you may not be able to do yourself if
you do not have the right equipment.
For safe, reliable operation and adequate service life, your
wheel bearings must be checked and adjusted properly at
the recommended intervals. See Table 2, “Maintenance
Schedule,” Page 113, and Table 3, “Maintenance Schedule,”
Page 123. The person best equipped to do this is your Authorized Service Center's mechanic.
Proper Torque and Sequence
Proper wheel torque can best be obtained on level ground.
Install lug nuts and finger-tighten in the numerical sequence
as shown below, see “Crisscross Tightening Sequence” on
page 176. This procedure will ensure that the wheel is drawn
evenly against the hub. Torque each nut to the torque value
listed in Table 8 on page 174.
WARNING! Never use oil or grease on studs or
nuts; improper torque readings will result, which
could cause improper wheel clamping and could
lead to a wheel failure resulting in an injury accident.
Medium Duty (R10/06)
Y53-6008
WARNING! Tighten wheel cap nuts properly. If
they are not tightened properly, wheel nuts
could eventually cause the wheel to become
loose, to fail, and/or to come off while the vehicle is moving, possibly causing loss of control
and/or serious personal injury or damage to the
vehicle.
– 173 –
Tires and Wheels
Table 8
Preventive Maintenance
Wheel Cap Nut Torque
WHEEL & NUT
CONFIGURATION
Steel Disc-Type Wheel; Double Cap Nut Mounting; Standard
7/8” Radius Ball Seat or Flanged Nuts:
Alum. Disc-Type Wheel; Double Cap Nut Mounting; Standard
7/8” Radius Ball Seat or Flanged Nuts:
Heavy-Duty Steel Disc-Type Wheel; Double Cap Nut Mounting; 13/16” Radius Ball Seat:
Hub-Piloted Disc-Type Wheel w/Two Piece Flanged Cap Nuts:
Budd Nut w/Teflon Coating:
Motor Wheel Nut:
Stud Backnuts (when used)
Heavy-Duty Cast Wheel w/Demountable Rim:
Rockwell or Clark Demountable Rims on Planetary Axles
– 174 –
STUD SIZE
DYNAMIC TORQUE FOR
INNER & OUTER CAP
NUTS & RIM CLAMP NUTS
N.m
Lb–Ft
3/4-16
545–630
400–465
1-1/8-16
545–630
400–465
3/4-16
530–625
390–460
1-1/8-16
530–625
390–460
15/16-12
1020–1090
750–800
1-1/8-16
885–950
650–700
1-15/16-12
1020–1090
750–800
Steel Wheel
505–590
370–435
Alum. Wheel
475–580
350–425
Steel Wheel
545–630
400–465
Alum. Wheel
530–625
390–460
3/4-16
240–270
175–200
1-14
240–410
175–300
1-8
585–640
430–470
1-12
585–640
430–470
1-14
585–640
430–470
3/4-10
270–305
200–225
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Table 8
Tires and Wheels
Wheel Cap Nut Torque
WHEEL & NUT
CONFIGURATION
STUD SIZE
Dayton:
5/8-11 Front & Rear
DYNAMIC TORQUE FOR
INNER & OUTER CAP
NUTS & RIM CLAMP NUTS
N.m
Lb–Ft
220–240
160–175
3/4-10, Cad Plated Studs Front
306–340
225–250
Rear
272–340
220–250
3/4-10, PHOS & Oil Coated Studs,
Front & Rear
238–258
175–190
Gunite: 5/8-11 Front & Rear
220–250
160–185
3/4-10 Front/Over
14,000 Lb GAWR
325–359
240–265
Other Front & Rear
271–305
200–225
Cast Wheel with Demountable Rim:
Cast Wheel with Demountable Rim:
Disc Wheels
WARNING! Use the correct components and
tools when working on wheels. Grooves in the
wheel disc or other damage to the disc can
weaken the wheel and cause it to eventually
come off. This could cause you to lose control of
your vehicle, and may result in an injury accident.
Medium Duty (R10/06)
The end of the wheel wrench must be smooth. Burrs on the
end of the wrench can tear grooves in the disc. These
grooves may lead to cracks in the disc, and can cause it to
fail.
Y53-6008
– 175 –
Tires and Wheels
Preventive Maintenance
Demounted Rims
WARNING! Improperly mounting and demounting tire and rim assemblies is dangerous. Failure
to observe proper precautions could cause the
tire-rim assembly to burst explosively, causing
serious injury or death. See the wheel manufacturer's literature for the proper way to mount and
demount your tires and rims. Follow their precautions exactly.
To check the torque on demountable rims, follow the crisscross sequence shown below. See Table 8, “Wheel Cap Nut
Torque,” Page 174 for proper torque specifications.
00118
DISK WHEEL
Comparing Hub Piloted and Ball Seat Parts
WARNING! Do not mismatch wheel components.
Equipment that does not exactly match original
specifications or that is mismatched could
cause the wheels to break and separate from the
vehicle. The resulting accident could be very
serious. Each mounting system is engineered
for use only with its correct mating part. Be sure
properly matched components are used for each
type of mounting.
The following comparison (Table 9, ”Comparing Hub-piloted
and Ball-seat Wheels”), shows the difference between parts
used in hub pilot mount and ball seat mount applications.
DEMOUNTED RIMS
02951
Crisscross Tightening Sequence
– 176 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Table 9
Tires and Wheels
Comparing Hub-piloted and Ball-seat Wheels
BALL–SEAT MOUNT
HUB–PILOTED MOUNT
00187
00203
Hub, Drum, and Stud Assembly
Hub-piloted mountings use M22 x 1.5 metric threads (about 7/8 in.
diameter). The stud stands out at least 1.94 in. beyond the brake drum.
All studs are right-hand threads. Pilot bosses (machined surfaces) on
the hub, fit tightly to the wheel center bore.
Ball-seat (stud-piloted) mountings use 3/4x16 or 1-1/8x16 threads. The
dual mounting studs provide 1.30 in. –1.44 in. standout. Right-hand
and left-hand threads are required. Inner and outer wheel nuts center
the wheels by seating against wheel ball seats.
Wheels
Hub-piloted wheels have stud holes reamed straight through (no ball
seats). Center bore diameter is 8-21/32 in.
Ball-seat wheels have spherical chamfers machined on each stud hole.
Center bore diameter is 8-23/32 in.
Wheel Nuts
Hub-piloted wheel nuts have a hex body and a flange for clamping
against wheel face. Hex size is 1-5/16 in. (33 mm).
Medium Duty (R10/06)
Ball-seat inner and outer wheel nuts mate with spherical chamfers on
wheels. The inner nut has 13/16 in. square end. The outer nut has a
1-1/2 in. hex.
Y53-6008
– 177 –
Tires and Wheels
Preventive Maintenance
Tire Replacement
NOTE: To prolong the tires' life and make them
safer, have their radial and lateral run-out checked at
your Peterbilt Dealer. And of course have the tires
balanced any time you change a tire.
Front: replace front tires when less than 4/32 in. of tread
depth remains. Check depth at three places equally spaced
around the tire.
Matching Tires
Drive Axles or Trailers: replace tires on drive axles when
less than 2/32 in. of tread depth remains in any major groove.
Check depth at three places equally spaced around the tire.
WARNING! Do not install regrooved or reinforcement-repaired tires on steering axles. They
could fail unexpectedly and cause you to lose
control of your vehicle resulting in an injury
accident.
WARNING! Do not replace original equipment
tires with load ratings less than the original
tires. Doing so could lead to unintentional overloading of the tire, which could cause a failure
resulting in loss of vehicle control and an injury
accident.
– 178 –
Be sure to buy matched tires for your vehicle, especially on
the rear axles. Mismatched tires can cause stress between
axles and cause the temperature of the axle lubricant to get
too hot. Matched tires will help the driveline last longer and
will give you better tire mileage.
WARNING! Do not mismatch tires, it can be dangerous. Never mix tires of different design such
as steel belted radials and bias ply tires, etc.
Mixing tire types and sizes will adversely affect
the road-holding ability of both types of tires and
can lead to loss of vehicle control and serious
personal injury.
Make sure, too, that you use the right size tires on each
wheel. Some trucks require different sizes on front and rear
wheels. For safety, always use the recommended size and
type of tires.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Tires and Wheels
Wheel and Tire Replacement
WARNING! The Anti-Lock Brake System (ABS) is
calibrated for the specific tire revolutions per
mile. Use of a tire and/or wheel size different
from that originally installed on your vehicle may
cause the ABS system to not function during a
hard braking event. This could cause an accident
or serious personal injury. Consult with your
Peterbilt dealer before using a different tire and/
or wheel size than was originally installed on
your vehicle.
Medium Duty (R10/06)
Y53-6008
CAUTION: No indication will be given via the
dashboard warning lights or buzzer if tires of the
wrong size are installed on your vehicle. See the
warning above for consequences of tires of the
wrong size.
– 179 –
Heater and Air Conditioner
Preventive Maintenance
HEATER AND AIR CONDITIONER
– Stay away from the hot engine until the exhaust
manifold has cooled.
– Do not permit any open flame in the area. Even a
match or a cigarette lighter may generate a hazardous quantity of poisonous gas.
– Do not smoke in the area. Inhaling gaseous
refrigerant through a cigarette may cause violent
illness.
Introduction
The combination heater-air conditioner provides comfort for
those in the cab through accurate control of the cab environment in all weather conditions. Regular attention to the items
below will help you keep the heater-air conditioner unit running well.
Special Precautions
WARNING! Excessive heat may cause the pressurized components of the air conditioning system to explode. Never weld, solder, steam clean,
or use a blow torch near any part of the air conditioning system.
• If a refrigerant leak develops in the presence of
excessive heat or an open flame, hazardous gases
may be generated. These gases may cause unconsciousness or death. If you become aware of a refrigerant leak on your vehicle have your system service
immediately and observe the following precautions:
– 180 –
Heater
• Check all heater controls for full-range operation.
• Check hoses, connections, and heater core for condition
and leaks.
• Check the drain pan of the fresh air vent for trapped
water before assuming that there is a leak in the heating
system. If the heater core is leaking, a reliable radiator
shop should be able to repair it.
• Check the heater core for debris blocking the air flow. If
the blower and air controls are functioning properly, yet
the heater is not operating properly, the heater core or
the hot water valves may be clogged or closed. Clean
the heater core if necessary. If the condition persists,
take the vehicle to a Peterbilt Dealer for proper heater
service or repair.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Heater and Air Conditioner
CAUTION: During extreme cold weather, do not
blow hot air onto cold windshields. This could
crack the glass. Turn the air direction lever to
Defrost and reduce the fan speed while the
engine warms. If the engine is already warm,
move the temperature selector to Cool, then
gradually increase the temperature when you
see that the windshield is starting to warm-up.
Air Conditioner
WARNING! The air conditioning system is under
pressure. If not handled properly during servicing, it could explode, causing injury to you and
damag e your vehicle . Any ser vicin g that
requires depressurizing and recharging the air
conditioning system must be conducted by a
qualified technician with the right facilities to do
the job.
• Check the compressor and drive clutch for noise and
vibration. If you find problems, have the system checked
thoroughly. A malfunctioning clutch usually indicates
trouble elsewhere in the system.
• Check the evaporator core and condenser core for
debris restricting air flow. Clean if necessary. Small parti-
Medium Duty (R10/06)
cles may be removed with compressed air blown through
the core in the opposite direction of normal air flow.
WARNING! Wear eye protection any time
you blow compressed air. Small particles
blown by compressed air could injure your
eyes.
• Check the compressor belt for condition and proper tension.
• Check all hoses for kinks, deterioration, chafing, and
leaks. Adjust kinked or chafing hoses to eliminate restrictions and prevent further wear.
• Check all components and connections for refrigerant
leaks. If you discover a leak, do not try to tighten a connection. Tightening a connection may cause a worse
leak. Have a qualified technician correct the problem.
NOTE: A leaking evaporator or condenser core
cannot be repaired; it must be replaced.
Have the air conditioning system fully serviced annually by
your Peterbilt Dealer or Authorized Service Center. Qualified
service technicians will have to evacuate and recharge the
system.
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Electrical System
Preventive Maintenance
ELECTRICAL SYSTEM
CAUTION: Do not modify or improperly repair
the vehicle’s electrical system or power distribution box. All electrical repairs should be performed by an authoriz ed Peterbilt dealer.
Improper repair or modifications will void your
warranty and/or cause serious damage to your
vehicle.
Location Of Fuses
Fuses are located inside the cab, left side, next to the driver’s
door.
CAUTION: Never patch fuses with tin foil or wire.
This may cause serious damage elsewhere in
the electrical circuit, and it may cause a fire.
CAUTION: If a circuit keeps blowing fuses, have
the electrical system inspected for a short circuit or overload by an authorized Peterbilt dealer
as soon as possible. Failure to do so could
cause serious damage to the electrical system
and/or vehicle.
NOTE: If a fuse of the same rating is not available, a
fuse of a lower rating may be temporarily substituted. You can also use a fuse from a circuit you can
temporarily do without (for example, an accessory
circuit or radio).
Fuse Inspection and Replacement
WARNING! Do not replace a fuse with one of a
higher rating. Doing so may damage the electrical system and cause a fire.
CAUTION: Before replacing a fuse, turn OFF all
lights and accessories and remove the ignition
key to avoid damaging the electrical system.
– 182 –
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BLOWN
Medium Duty (R10/06)
Preventive Maintenance
Electrical System
All the electrical circuits have fuses to protect them from a
short circuit or overload. If something electrical on your chassis stops working, the first thing you should check for is a
blown fuse.
1. Turn OFF all lights and accessories and remove the ignition key to avoid damaging the electrical system..
2. Determine from the chart on the fuse panel which fuse
controls that component.
3. Remove that fuse and see if it is blown.
4. If it is blown, replace it with a fuse of the same rating.
Truck-Body Connection
Your vehicle includes a junction box mounted to the frame for
wiring the vehicle body to the main chassis harness.
Refer to the Body Builder's Manual for further information on
using the Truck and Body Connection.
Batteries
WARNING! Battery posts, terminals, and related
accessories contain lead and lead compounds,
chemicals known to the State of California to
cause cancer and reproductive harm. Wash
hands after handling.
Adding Electrical Options
WARNING! Do not add a fuse with a rating
higher than 30 amps. Doing so may damage the
electrical system and cause a fire.
CAUTION: Follow all manufacturers’ circuit protection recommendations for the components
and wires being added.
Spare circuits are located throughout the wiring for the dash.
For proper electrical system performance, refer to a wiring
diagram for your chassis before adding electrical options.
Medium Duty (R10/06)
Battery Access
The vehicle is originally equipped with two batteries.
Replacement batteries must meet the following specifications: maintenance-free, group 31 size, threaded stud, 12V/
650 cold cranking ampere (CCA), and 160 minutes of
reserve capacity. The battery compartment has space to
install an optional third battery.
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Electrical System
Preventive Maintenance
The battery compartment is located on the left side of the
vehicle, under the cab access steps.
WARNING! Before attempting any work on the
batteries or electrical system, remove all jewelry.
If metal jewelry or other metal comes in contact
with electrical circuits, a short circuit may occur
causing you to be injured, as well as electrical
system failure and damage.
The cover is held in place by two latches one on each side.
WARNING! Always reinstall the battery compartment cover (step) before entering the cab. Without the step you could slip and fall, resulting in
possible injury to yourself.
Removing and Installing Batteries:
1.
2.
3.
4.
BATTERY COVER
LATCH
(BOTH SIDES)
Be sure all switches on the vehicle are turned OFF.
Disconnect negative ground cable.
Disconnect positive cable.
Unscrew bolt of holding plate with open end wrench.
To reinstall batteries:
1. Place batteries in vehicle and tighten bolt of holding
plate.
2. Reconnect positive cable.
3. Reconnect negative ground cable.
Battery Care
02601
Battery Compartment
– 184 –
Regular attention to the charging system will help prolong the
service life of the batteries. Here are some common causes
of battery failure:
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Medium Duty (R10/06)
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Electrical System
Overcharge: this condition results from improper voltage
regulator adjustment. It results in overheating of the battery,
warped plates, and evaporation of electrolyte.
Undercharge: the voltage regulator is malfunctioning or is
improperly adjusted, the drive belt is slipping, or your vehicle
has undergone long periods of standing idle or short distance
driving. These conditions result in battery plates becoming
covered with a hard coating.
Vibration: loose battery hold-downs may cause battery
plate failure.
Jump Starting Vehicles
Because of the various battery installations and optional
electrical systems, Peterbilt does not recommend that you
attempt to jump start your vehicle. If you have a battery problem, it is best to contact a Peterbilt Dealer or a reputable towing service.
However, if your battery is discharged (dead), you may be
able to start it by using energy from a good battery in another
vehicle. This is termed “jump starting.” Be sure to follow the
precautions and instructions below.
Short Circuits: these discharge the battery by draining
electricity.
Dirty or Loose Connections: improper connections may
stop the flow of electrical power to and from the battery.
Medium Duty (R10/06)
Y53-6008
WARNING! Batteries contain acid that can burn
and gases that can explode. Ignoring safety procedures can cause you or others to be badly
hurt.
WARNING! Never jump start a battery near fire,
flames, or electrical sparks. Batteries generate
explosive gases that could explode causing
serious personal injury. Keep sparks, flame, and
lighted cigarettes away from batteries.
– 185 –
Electrical System
Preventive Maintenance
WARNING! Do not allow battery fluid to contact
eyes, skin, fabrics, or painted surfaces. Always
wear eye protection. Battery acid that may spill
during charging should be washed off with a
solution of warm water and baking soda to neutralize the acid. If you accidentally get acid in
your eyes or on your skin, immediately rinse
with cold water for several minutes and call a
doctor.
• Be careful that metal tools (or any metal in contact
with the positive terminal) do not contact the positive battery terminal and any other metal on the vehicle at the same time. Remove metal jewelry and
avoid leaning over the battery.
• If metal jewelry or other metal comes in contact with
electrical circuits, a short circuit may occur causing
you to be injured, as well as electrical system failure
and damage to the vehicle.
• Do not try to jump start or charge a frozen battery.
(Even a battery with ice particles on the electrolyte
surface is dangerous.) Allow it to thaw out first. And
always allow the battery to thaw gradually—do not
apply direct heat. Gas trapped in the ice may cause
an explosion.
– 186 –
To Jump Start Your Vehicle
WARNING! The voltage of the booster battery
must have a 12–volt rating. And the capacity of
the booster battery should not be lower than that
of the discharged battery. Use of batteries of different voltage or substantially different capacity
rating may cause an explosion and serious personal injury.
CAUTION: Applying a higher voltage booster
battery will cause expensive damage to sensitive electronic components, such as relays, and
the radio.
• Improper hook-up of jumper cables or not following
these procedures can damage the alternator or
cause serious damage to both vehicles.
WARNING! To avoid serious personal injury and
damage to the vehicle, heed all warnings and
instructions of the jumper cable manufacturer.
• The jumper cables must be long enough so that the
vehicles do not touch.
If either battery has vent caps, remove them and check the
fluid level. If it is OK, replace the caps before going further. If
the level is low, add distilled water and replace the caps
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Electrical System
before proceeding. If no water is available, remove the caps
and cover the filler openings with a cloth. After jump starting
the vehicle, dispose of the cloth.
WARNING! If you do not cover the filler openings
on the battery, electrolyte could boil out of the
openings and hurt someone or damage the vehicle. Replace caps securely if the battery has the
full level of electrolyte. If the electrolyte is low
and no water is available, cover with a cloth.
Preparing the vehicles:
1. Position the two vehicles together, but do not let them to
touch.
2. Turn OFF all lights, heater, radio, and any other accessory.
3. Set the parking brakes: pull out the Yellow button
located on the dash.
4. Shift the transmission into park position. (See Pages 67
and 34 for transmission shifting and parking brake information.)
5. Turn engine OFF (booster vehicle).
6. Disconnect ground cable on booster battery.
Medium Duty (R10/06)
Connect the batteries:
WARNING! When connecting jumper cables,
make sure they can not get caught in any moving parts in the engine compartment. You could
be seriously injured.
1. Attach one end of a jumper cable to the positive terminal
of the discharged (dead) battery. This will have a large
red “+” or “P” on the battery case, post, or clamp.
2. Attach the other end of the same cable to the positive (+)
terminal of the good (booster) battery.
3. Attach the remaining jumper cable FIRST to the negative
terminal (black “–” or “N”) of the good battery.
4. Attach the other end of the negative cable to a bare
metal part bolted to the engine block or clamp directly to
the engine block if possible.
IMPORTANT: Always connect positive (+) to positive (+)
and negative (–) to negative (–).
5. Start the engines:
Y53-6008
• Start the vehicle that has the good battery first. Let it
run for a few minutes.
• Then start the vehicle that has the discharged
(dead) battery.
– 187 –
Electrical System
Preventive Maintenance
If the engine fails to start, do not continue to crank the
starter but contact the nearest Authorized Service
Center.
WARNING! Batteries can injure you severely.
They contain acid, produce poisonous and
explosive gases, and supply levels of electric
current high enough to cause burns. A spark or
flame near a battery on charge may cause it to
explode with great force.
Remove jumper cables:
WARNING! When disconnecting jumper cables,
make sure they do not get caught in any moving
parts in the engine compartment. You could be
seriously injured.
Reverse the above procedure exactly when removing the
jumper cables. With engine running, disconnect jumper
cables from both vehicles in the exact reverse order (Steps 4
– 1), making sure to first remove the negative cable from the
vehicle with the discharged battery.
Battery Charging
Except for using small trickle charges (as explained on Page
190) to maintain battery condition, you should have your
vehicle's batteries charged by a qualified service facility.
– 188 –
To help reduce the risk of personal injuries, follow these
guidelines carefully when recharging a battery:
• Before attempting any service in the electrical installation, disconnect the battery negative cable.
• Allow no sparks or open flame anywhere near the charging area.
• Charge a battery only in a well-ventilated area, such as
outdoors or in a fully open garage which contains no pilot
lights or other flames. Gases generated during the
charging process must be allowed to escape.
• Maintain the full level of electrolyte in the batteries. This
reduces the volume of gas in the cells. The electrolyte
level should always be between 0.4–0.6 in. (10–15mm)
above plates. Fill with distilled water only. After distilled water has been added, wait at least a half hour to
measure solution density (specific gravity). The specific
gravity should be between 1.258–1.265 or the electrolyte
level within “MIN” and “MAX” marks.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Electrical System
• When fast charging, remove the battery caps so pressure does not accumulate.
• Always make sure the battery charger is OFF before
connecting or disconnecting the cable clamps.
• To avoid short circuits and damage to yourself or the
vehicle, never place metal tools or jumper cables on the
battery or nearby. Metal that accidentally comes in contact with the positive battery terminal or any other metal
on the vehicle (that is in contact with the positive terminal), could cause a short circuit or an explosion.
Charging Reminders
•
•
•
•
Use protective eyewear.
Keep all batteries away from children.
Never reverse battery poles.
Never attempt to place the vehicle in motion, or run the
engine with batteries disconnected.
• Keep the battery clean and dry.
• Look for any signs of damage.
WARNING! Never use a metallic funnel to add
distilled water. It could come in contact with a
terminal, creating a short circuit, resulting in
severe personal injury or damage to your vehicle.
Medium Duty (R10/06)
WARNING! Always shield your eyes and avoid
leaning over the battery whenever possible.
Electrolyte in batteries could splash up into your
eyes causing severe burns and/or serious personal injury.
• Battery terminals should not be coated with improper
grease. Use petroleum jelly or commercially available,
noncorrosive, nonconductive terminal coatings.
• Battery acid that may spill during charging should be
washed off with a solution of warm water and baking
soda to neutralize the acid. If you accidentally get acid in
your eyes or on your skin, immediately rinse with cold
water for several minutes and call a doctor.
• Do not charge a frozen battery; allow it to thaw out first.
And always allow the battery to thaw gradually—do not
apply direct heat. Gas trapped in the ice may cause an
explosion.
• Never use a fast charger as a booster to start the engine.
This can seriously damage sensitive electronic components such as relays, radio, etc., as well as the battery
charger. Fast charging a battery is dangerous and
should only be attempted by a competent mechanic with
the proper equipment.
Y53-6008
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Electrical System
Preventive Maintenance
Bulb Replacement
Slow Battery Charging
NOTE: Follow the instructions that come with your
battery charger.
• It is not necessary to remove the battery from the compartment.
WARNING! Charger cables must be connected
positive to positive (+ to +) and negative to negative (– to –). If connected improperly, batteries
could explode causing serious personal injury.
• Always make sure the battery charger is OFF before
connecting or disconnecting the cable clamps. To
reduce the danger of explosions and resulting serious personal injury, do not connect or disconnect
charger cables while the charger is operating.
1. Make sure the electrolyte level in each cell is between
the “MIN” and “MAX” marks. If the fluid level is below the
“MIN” mark, correct the condition.
2. Disconnect the battery cables.
3. Connect charger cables.
4. Start charging the battery at a rate not over 6 amperes.
Normally, a battery should be charged at no more than
10 percent of its rated capacity.
5. After charging, turn OFF charger and disconnect charger
cables.
– 190 –
Tail Lights
To replace the tail lamps, remove lens. The bulbs are all of
the bayonet type.
1. To remove the bulbs, turn bayonet counter clockwise and
pull out.
2. To install, fit the bulb in the socket, push in and turn bayonet clockwise.
Replacement Bulbs
DESCRIPTION
PART NO.
Headlights
9007BULB
Front turn signal
3157K LL BULB
Marker
1895BULB
Stop/tail turn
1157BULB
Backup
1156BULB
Hood marker
4157NAK LL BULB
Roof marker
194BULB
Dome
1141BULB
Warning lamp module
#37 or 73 (T1 3/4 wedge
base
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Electrical System
Electrical and Alternator Precautions
Take the following precautions to avoid burning out
alternator diodes:
• Do not start the engine with alternator disconnected
(connections removed) from the circuit.
• Before welding, disconnect all electronic connections to
the vehicle batteries.
• Remove battery power cable and insulate it from the
vehicle. See “Welding” on page 218 for more information.
• Do not run the engine with the batteries disconnected.
Medium Duty (R10/06)
• Do not disconnect the battery cables or alternator connection cables with the engine running.
• Never turn the ignition switch to the IGN & START position with the engine running.
• When charging the battery (installed in the vehicle) disconnect the battery cables.
• Do not reverse the cables of the alternator, starter motor,
or battery.
• Do not polarize the alternator. The alternator should not
be polarized like a generator. To ensure correct polarity,
use a test lamp or a voltmeter.
Y53-6008
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Cab Maintenance
Preventive Maintenance
CAB MAINTENANCE
Exterior Maintenance
Painted Surfaces
Wash painted surfaces frequently to remove grime and caustic deposits which may stain the finish. See “Cleaning, Protection and Weather–Stripping” on page 193.
Chrome and Aluminum Surfaces
To prevent rust, keep chromed parts clean and protected with
wax at all times, especially in winter conditions where the
roads are salted.
• If necessary, use a commercial chrome cleaner to
remove light rust.
• Chrome surfaces are best cleaned with fresh water.
Wipe dry to preserve their luster. A commercial chrome
cleaner will remove light rust. After cleaning, wax flat surfaces and apply a thin coat of rust preventive lubricant
around bolts or other fasteners.
– 192 –
• Clean aluminum wheels and bumpers with warm water.
Tar remover will get rid of heavy deposits of road grime.
To prevent spotting, wipe aluminum surfaces dry after
washing.
• Under corrosive conditions, such as driving on salted
roads, clean aluminum parts with steam or high pressure
water from a hose. A mild soap solution will help. Rinse
thoroughly.
Stainless Steel
Even high quality stainless steel parts can rust under prolonged exposure to salt water, especially when the salt-laden
moisture is held against the metal surface by road grime. It is,
therefore, important to frequently clean salty moisture and
grime from stainless steel surfaces.
• If surface rust is encountered, wash the surface and use
a commercial polishing compound to clean off the rust,
followed by a coating of wax (do not apply wax to hot
parts, such as exhaust pipes).
• Never use steel wool when cleaning stainless steel
because minute particles of the steel wool can embed in
the surface of the stainless steel and cause rust staining.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Cab Maintenance
Cleaning, Protection and Weather–Stripping
Frequent washings of the vehicle are required to remove
grime and contaminants that can stain and oxidize paint and
accelerate corrosion of plated and polished metal surfaces.
Waxing offers added protection against staining and oxidation. But to allow enough time for your truck's finish to cure,
wait about 30 days after the date of manufacture before waxing. Do not apply wax in the hot sun and do not friction burn
the paint with a buffing machine.
Occasionally spray weather-stripping on doors and windows
with silicone compound to help preserve resiliency. This is
especially useful in freezing weather to prevent doors and
windows from sticking shut with ice.
Vehicle Cleaning
Precautions
WARNING! Handle cleaning agents carefully.
Cleaning agents may be poisonous. Keep them
out of the reach of children.
• Observe all caution labels.
Medium Duty (R10/06)
• Always read directions on the container before using any
product.
• Do not use any solution that can damage the body paint.
• Most chemical cleaners are concentrates which require
dilution.
• Use spot removing fluids only in well ventilated areas.
• Do not use gasoline, kerosene, naphtha, nail polish
remover or other volatile cleaning fluids. They may be
toxic, flammable or hazardous in other ways.
• Do not clean the underside of chassis, fenders wheel
covers, etc. without protecting your hands and arms. You
may cut yourself on sharp-edged metal parts.
• Moisture, ice, and road salt on brakes may affect braking
efficiency. Test the brakes carefully after each vehicle
wash.
Any vehicle is subject to deterioration from industrial fumes,
ice, snow, corrosive road salt, etc., to name just a few
causes. A well-cared-for vehicle can look like new many
years later. Regular and correct care will contribute to maintaining the beauty and the value of your vehicle.
Your Peterbilt Dealer has a number of vehicle-care products
and can advise you on which ones to use for cleaning the
exterior and interior of your vehicle.
Y53-6008
– 193 –
Cab Maintenance
Preventive Maintenance
CAUTION: Do not aim the water jet directly at
door locks or latch. Tape the key holes to prevent water from seeping into the lock cylinders.
Water in lock cylinders should be removed with
compressed air. To prevent locks from freezing
in the winter, squirt glycerin or lock deicer into
the lock cylinders.
4. Wipe everything dry with a chamois to avoid water spots.
• To prevent water spotting, dry off the cosmetic surfaces with a clean cloth or chamois.
5. Remove road tar with an automotive type tar remover or
mineral spirits.
6. After cleaning and drying, apply a quality automotive
wax.
Washing the Exterior
1. Begin by spraying water over the dry surface to remove
all loose dirt before applying the car wash and wax solution.
• Do not wash the vehicle in direct sunshine.
• Do not spray water directly into any vents.
2. Using soapy water, wash the vehicle with a clean soft
cloth or a soft brush made for automotive cleaning.
• Use cool or warm water and a mild, household type
soap. Strong industrial detergents and cleaning
agents are not recommended.
• Do not use stiff brushes, paper towels, steel wool, or
abrasive cleaning compounds because they will
scratch painted, plated, and polished metal surfaces.
3. Rinse surfaces frequently while washing to flush away
dirt that might scratch the finishes during the washing
operation.
– 194 –
NOTE: To allow enough time for your truck's finish to
cure, wait at least thirty days after the date of manufacture before waxing.
• Do not apply wax in the hot sun
• Never dust off dry surfaces with a cloth because it will
scratch the finishes.
Cleaning the Chassis
• Hose dirt and grime from the entire chassis. Then, if an
oil leak develops, you will be able to detect it easier.
• Corrosive materials used for ice and snow removal and
dust control can collect on the underbody. If these materials are not removed, accelerated corrosion (rust) can
occur on underbody parts such as fuel lines, frames,
floor pan, and exhaust system—even though they have
been provided with corrosion protection.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Cab Maintenance
At least every spring, flush these materials from the under
body with plain water. Be sure to clean any area where mud
and other debris can collect. Sediment packed in closed
areas of the frame should be loosened before being flushed.
If desired, your Peterbilt Dealer or Authorized Service Center
can do this service for you.
General Cleaning Guidelines
Cleaning Cab Interiors
Peterbilt cab and sleeper interiors are built using a variety
of different materials including fabrics, carpet, polyurethane, and painted plastic surfaces. These cleaning procedures will ensure that interior components remain in
good condition for the life of the vehicle.
Medium Duty (R10/06)
Y53-6008
WARNING!
•Cleaning agents may contain hazardous
agents. Thoroughly read, understand and follow the manufacturer’s instructions when
using a cleaning agent to avoid possible personal injury and property damage.
• Handle cleaning agents carefully. Keep
them out of the reach of children. Commercial
cleaning agents may be poisonous.
CAUTION: To avoid possible property damage
• Do not spray any kind of liquid directly at
instruments or controls. Apply cleaner to a
rag first and then clean instruments and
gauges. Excess fluid may damage the use
and function of instruments and gauges.
– 195 –
Cab Maintenance
Preventive Maintenance
• Always test a commercial cleaning agent on
an inconspicuous area of the surface to be
cleaned before using it.
• Never clean interior components
chemicals or solvents such as
– Gasoline
– Naphtha
– Acetone
– Turpentine
– Benzene
– Carbon Tetrachloride
– Lacquer Thinner
– Nail Polish Remover
– Ammonia-based Products
Interior Trim, Dash Shell, and Instrument Panels
CAUTION: To avoid possible damage to these
components, do not use abrasive cleaners,
brushes, chemical solvents or strong detergents.
with
• Use a clean, lint-free cloth.
• Clean with the cloth dampened with a mild soap-andwater solution.
• Remove soap with a clean, damp rag.
• Clean difficult stains such as oil, grease,
and mustard as soon as possible. The longer
a stain goes untreated, the more difficult it is
to remove.
• Avoid application of conditioning products
containing silicones or waxes to the top surface of the dash panel. This may cause glare
that can be a driver distraction.
• For difficult stains on painted plastic surfaces, such as
the dash shell, use Dupont™ Sontara® cleaner, part
number PS-3909S. The product is available from
Dupont as a presaturated wipe.
Carpet
CAUTION: Do not apply water directly to carpet.
Excess water may damage the carpet. Keep
carpet as dry as possible.
• Use a clean, lint-free cloth or clean, soft-fiber brush.
• Clean with the cloth or brush dampened with a mild
soap-and-water solution.
– 196 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Cab Maintenance
• Remove soap with a clean, damp rag.
Safety Restraint System — Inspection
• If a stronger cleaning solution is required, use a foamtype carpet shampoo.
The seat belt system, including webbing, buckles, latches,
and mounting hardware, endures heavy use in medium-duty
vehicles—much more than seat belt systems in passenger
cars. All users should be aware of the factors contributing to
this heavy use and reduced belt life.
Vinyl and Fabric Upholstery
CAUTION: To avoid possible damage to the
upholstery, do not use chemical solvents or
WARNING! Failure to properly inspect and maintain restraint systems can lead to serious injury
or loss of life. Without periodic inspection and
maintenance to detect unsafe conditions, seat
restraint components can wear out or not protect you in an accident.
strong detergents on these components.
• Use a clean, lint-free cloth.
• Clean with the cloth dampened with a mild soap-andwater solution.
• Remove soap with a clean, damp rag.
Factors contributing to reduced seat belt life:
• For difficult stains, use a commercial fabric or vinyl
cleaner.
Medium Duty (R10/06)
• High mileage—heavy trucks often accumulate mileage
in excess of 500,000 total miles (800,000 km) during the
vehicle lifetime. This is much greater than a typical passenger car, which frequently will not exceed 125,000
total miles (200,000 km).
• Seat and cab movement—in trucks, there is almost constant movement of the belt due to ride characteristics
and seat design. The constant movement of the belt
Y53-6008
– 197 –
Cab Maintenance
Preventive Maintenance
WARNING! It is important to remember that any
time a vehicle is involved in an accident, the
entire seat belt system must be replaced. Unexposed damage caused by the stress of an accident could prevent the system from functioning
properly the next time it is needed, which could
result in severe injury or even death.
inside the restraint hardware and the potential for the belt
to come in contact with the cab and other vehicle parts,
contributes to the wear of the entire system.
• Environmental conditions, such as dirt and ultraviolet
rays from the sun, will reduce the life of the seat belt system.
Due to these factors, the three-point safety belt system
installed in your vehicle requires thorough inspection every
20,000 miles (32,000 km). If the vehicle is exposed to severe
environmental or working conditions, more frequent inspections may be necessary.
Any seat belt system that shows cuts, fraying, extreme or
unusual wear, significant discoloration due to UV (ultraviolet)
exposure, abrasion to the seat belt webbing, or damage to
the buckle, latch plate, retractor hardware or any other obvious problem should be replaced immediately, regardless of
mileage.
Inspection Guidelines
Follow these guidelines when inspecting for “cuts, fraying,
extreme or unusual wear of the webbing, and damage to the
buckle, retractor, hardware, or other factors.” Damage to
these areas indicates that belt system replacement is necessary.
WARNING! Replace the entire belt system
(retractor and buckle side) if replacement of any
one part is necessary. Unexposed damage to
one or more components could prevent the system from functioning properly the next time it is
needed, which could result in severe injury or
even death.
1. Check the web wear in the system. The webbing must be
closely examined to determine if it is coming into contact
with any sharp or rough surfaces on the seat or other
– 198 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Cab Maintenance
parts of the cab interior. These areas are typical places
where the web will experience cutting or abrasion. Cuts,
fraying, or excessive wear would indicate the need for
replacement of the seat belt system.
2. The pillar web guide (D-loop) is the area where almost
constant movement of the seat belt webbing occurs
because of relative movement between the seat and
cab.
3. Check the Komfort-Lok Latch for cracks or possible damage and check for proper operation.
03004
Seat Belt Inspection Points
Medium Duty (R10/06)
Y53-6008
– 199 –
Cab Maintenance
Preventive Maintenance
4. Check buckle and latch for proper operation and to determine if latch plate is worn, deformed, or damaged.
5. Inspect the retractor web storage device, which is
mounted on the floor of the vehicle, for damage. The
retractor is the heart of the occupant restraint system
and can often be damaged if abused, even unintentionally. Check operation to ensure that it is not locked up
and that it spools out and retracts webbing properly.
WARNING! Failure to adjust tether belts
properly can cause excessive movement of
the seat in an accident. This could lead to
greater injuries for you. Tether belts should
be adjusted so that they are taut when the
seat is in its most upward and forward position.
6. If tethers are used, be sure they are properly attached to
the seat and, if adjustable, that they are adjusted in
accordance with installation instructions. Tethers must
also be inspected for web wear and proper tightness of
mounting hardware.
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
– 200 –
brown, the physical strength of the web may have deteriorated due to exposure to the sun's ultraviolet rays.
Replace the system.
Once the need for replacement of the seat belt has been
determined, be certain it is only replaced with an authorized
PACCAR Parts replacement seat belt.
If the inspection indicates that any part of the seat belt system requires replacement, the entire system must be
replaced. An installation guide is attached to every replacement belt. Utilize the proper guide for your type of seat, and
follow the instructions very closely. It is vitally important that
all components be reinstalled in the same position as the
original components that were removed and that the fasteners be torqued to specification. This will maintain the design
integrity of the mounting points for the seat belt assembly.
Contact your Authorized Peterbilt Dealer if you have any
questions concerning seat belt replacement.
Windshield Wiper/Washer
Check wiper blades annually or every 60,000 miles (96,000
km). Anco 18-inch (450mm) wiper blades are recommended.
See “Windshield Wipers/Washer” on page 32 for more information.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Cab Maintenance
Washer Reservoir
CAUTION: Do not use antifreeze or engine coolant in the windshield washer reservoir—damage
to seals and other components will result.
RESERVOIR
Weekly: check reservoir water level, located in the engine
compartment under the coolant expansion tank. If necessary,
fill to the proper level.
02604
Windshield Washer Reservoir
Medium Duty (R10/06)
Y53-6008
– 201 –
Transmission and Clutch
Preventive Maintenance
TRANSMISSION AND CLUTCH
Transmission Lubricants
CAUTION: When adding oil, types and brands of
oil should not be intermixed because of possible
incompatibility, which could decrease the effectiveness of the lubrication or cause component
failure.
Introduction
Follow these steps to ensure parts are properly lubricated:
•
•
•
•
Maintain oil level, check it regularly
Change oil regularly
Use the correct grade and type of oil
Buy oil from a reputable dealer
Manual Transmissions
Manual transmissions are designed so that the internal parts
operate in a bath of oil circulated by the motion of gears and
shafts.
All Transmissions
Oil Change: Drain and replace according to Table 2, “Recommended Maintenance Intervals,” Page 120 and the Transmission Service Manual. Use the recommended types of oil
as specified in the Operation and Service Manual (included
with vehicle). Select the appropriate lubricant for the
expected ambient (outside air) temperatures.
– 202 –
Service Intervals
For recommended types and brands of all lubricants, see the
transmission manufacturer's Service Manual and Table 2,
“Recommended Maintenance Intervals,” Page 120.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Transmission and Clutch
Table 10 Transmission Lubrication — Manual transmissions
Eaton-Fuller
AMBIENT
TEMPERATURE RANGE
RECOMMENDED
LUBRICANT (See Note)
MODEL
VISCOSITY (SAE)
DEG. C
DEG. F
HD engine oil: API CE or CF-4.
Above -12
Above +10
50
Synthetic oil: Chevron RPM
Synthetic Transmission Fluid, or equal,
meeting MIL-L-2104D and Eaton PS-081
specifications.
Above -40
Above -40
50
NOTE: Do not use multi-viscosity or EP (extreme pressure) gear oil (e.g., axle oils) in transmissions. Multi-viscosity or EP oils may damage components.
Clutch System Introduction
Standard Transmission Oil Level
NOTE: The vehicle must be parked on level ground.
• Maintain the oil level and check it regularly. Oil should be
up to bottom of filler plug hole.
Medium Duty (R10/06)
Free pedal is the distance the clutch pedal moves by applying
only slight pressure. During free pedal the release yoke in the
transmission moves until its bearing pads contact the release
bearing. This movement of the release yoke is called free
travel. Thus, free pedal and free travel are directly related to
each other.
Y53-6008
– 203 –
Transmission and Clutch
Preventive Maintenance
As the clutch pedal is depressed further, with harder pressure, the release yoke moves the release bearing away from
the engine. This causes the clutch plate to release from the
driven disks in the clutch. This is called release travel. And
finally, on 9-, 10-, and 11-speed transmissions, as the pedal
is pushed to the last 1/2 to 1 inch of travel, the release bearing contacts and engages the clutch brake. This is called
clutch brake squeeze. When the clutch wears, the release
bearing gradually moves toward the engine, decreasing free
pedal and free travel. When all free pedal and free travel are
gone, the clutch requires adjustment.
The clutch is adjusted by turning an adjustment ring that is
built into the clutch. When the ring is turned, the release
bearing moves back toward the transmission, restoring free
pedal and clutch free travel. Under normal clutch wear this is
the only adjustment needed. Do not attempt to change any
other component. See the Medium Duty Maintenance Manual for details.
– 204 –
Clutch Adjustment — Normal Wear
Clutch pedal free travel is usually 1 3/4 in. to 2 in. (34 to 51
mm). This should be your guide for determining whether your
truck needs clutch adjustment. Also, if it becomes increasingly difficult to shift into gears, or the truck creeps with the
clutch pedal depressed, your clutch needs adjustment. See
the Medium Duty Maintenance Manual for the proper
adjustment procedures.
Some vehicles have automatic clutch adjustment. If yours
doesn't have this feature, adjustment will have to be done by
a trained certified mechanic. Have the adjustment done
before clutch pedal free travel is reduced to the minimum
allowable 1/2 in. (13mm).
Clutch Linkage
The Medium Duty is equipped with a rod and lever mechanical clutch linkage. Lubricate each pivot point on the clutch
linkage.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Transmission and Clutch
Automatic Transmissions
Automatic Transmission Oil Level
NOTE: The vehicle must be parked on level ground.
Service Intervals
Check daily with engine idling. See Table 2, “Recommended
Maintenance Intervals,” Page 120 for service intervals.
Maintain the oil level and check it daily. Oil should be up to
the “HOT” mark on the dipstick when (1) the engine is running, (2) the transmission is at operating temperature, and (3)
the transmission is in Neutral. See the Transmission Operator's Manual in the glove compartment for more information
on checking the transmission oil level.
Table 11 Transmission Lubrication — Automatic transmissions
MODEL
ALLISON
Medium Duty (R10/06)
RECOMMENDED
LUBRICANTS
TranSynd (Castrol)
Y53-6008
AMBIENT
TEMPERATURE RANGE
DEG. C
DEG. F
Above -23
Above -10
VISCOSITY (SAE)
10W
– 205 –
Steering and Driveline
Preventive Maintenance
STEERING AND DRIVELINE
If you cannot correct the problem, check with an Authorized
Service Center.
Power Steering
Oil (under low pressure) provides the power to operate the
steering gear. It also serves to lubricate moving parts and
remove heat. A loss of steering efficiency will occur if too
much heat builds up in the system.
WARNING! Do not operate the vehicle if the
steering system is not working properly. You
could lose control of your vehicle if the steering
system is not in good working condition, which
could result in a serious injury accident. For
driving safety, visually check the steering gear
and components. Frequent checks are important for driving safety, especially after traveling
over rough roads.
NOTE: If the steering feels unbalanced from side-toside while turning, check for the following possible
causes:
• unequal tire pressures
• vehicle overloaded or unevenly distributed load
• wheels out of alignment
• wheel bearings improperly adjusted
– 206 –
The Medium Duty is equipped with integral power steering.
The system includes an engine-driven fluid pump, a fluid reservoir, the steering gear, and connecting hoses. Because of
the hydraulic power assist, little effort is required to turn the
steering wheel. When no input is applied through the steering wheel, the steering gear will return to the neutral position.
If, for any reason, the power assist system goes out, steering
the vehicle is still possible—yet it will require much greater
effort.
Visually check the following parts:
• Crosstube: Is it straight?
• Draglink tube clamp: Check for looseness or interference.
• Ball joints and steering U–joints: Check for looseness.
• Steering wheel for excessive free-play. Check the simplest probable causes first:
– unequal tire pressures
– loose cap nuts
– bent crosstube
– lack of lubrication
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Steering and Driveline
If these checks do not reveal the problem, or if you correct
them and still have a steering problem, take your truck to an
authorized Peterbilt Dealer for evaluation.
RESERVOIR
Fluid Level and Refill
Have the power steering fluid and filters changed at an
Authorized Service Center.
• Check and completely change the fluid level according to
Table 2, “Recommended Maintenance Intervals,” Page
120. Use the following procedure:
02603
NOTE: Before removing reservoir cover, wipe
outside of cover so that no dirt can fall into the
reservoir.
The power steering fluid reservoir is attached to an underhood bracket on the LH side of the engine.
• Maximum / Minimum level is marked on the reservoir.
These same levels are also marked by lines on the dipstick in the reservoir.
• There are two ways to check whether the power steering
fluid is at its proper level. Both checks are with the
engine NOT running.
Medium Duty (R10/06)
Power Steering Fluid Reservoir
1. If you check the fluid with the engine and steering system COLD the fluid level should be at/or above the Minimum indicator level and should generally not exceed the
middle point between Maximum and Minimum level indicators.
2. If you check the fluid with the engine and steering system WARM the fluid should NOT exceed the Maximum
level indicator and should generally not drop below the
middle point between the Maximum and Minimum level
indicators.
Y53-6008
– 207 –
Steering and Driveline
Preventive Maintenance
Fluid Refill
Use Automatic Transmission Fluid (ATF) Type E or F or
Dexron® II. For other approved brands and types of fluid, see
the Medium Duty Maintenance Manual.
SLIP JOINT
Steering Driveline
• Torque on U–joint pinch bolt and nut 45–55 lb. ft. (61-75
N.m.), lubricated.
• Torque on Pitman arm clamp bolt and nut: 180-210 lb. ft.
(244-285 N.m.), lubricated.
UNIVERSAL JOINT
01904
Driveshaft Lubrication
Driveshaft and U-Joints
The slip joints and universal joints of the drive shaft should be
lubricated according to Table 2, “Recommended Maintenance Intervals,” Page 120.
• Use a good quality lithium-soap-base or equivalent
extreme pressure (E.P.) grease: NLGI Grade 2.
For “Towing Guidelines” and “Returning a Towed Vehicle to
Service” see “Vehicle Recovery Guidelines” on page 109.
– 208 –
Y53-6008
WARNING! Improper lubrication of U–joints can
cause them to fail prematurely. The driveshaft
could separate from the vehicle and result in an
injury accident and/or vehicle damage. Make
sure lubricant is purged at all four ends of each
U–joint and loosen caps if necessary. Also, regularly inspect U–joints for excessive wear or
movement, and repair or replace as necessary.
Medium Duty (R10/06)
Preventive Maintenance
Front Axle and Suspension
FRONT AXLE AND SUSPENSION
SPRING AND
SHACKLE PINCH
BOLTS
Inspection
For all vehicles, mandatory maintenance procedures include
retightening all U–bolts and inspecting the suspension for
loose fasteners, abnormal wear, or damage. However, even
with proper maintenance, the service life of leaf springs is
affected by many factors, such as: fatigue, vehicle gross
weight, type of load, road conditions, and vehicle speed.
• Check for cracks, wear marks, splits, or other defects on
the surface of the spring. Defective parts must be
replaced. Because repaired springs cannot be fully
restored to their original service life, replace the complete assembly if cracks or other defects are detected.
• Visually inspect shock absorbers and rubber bushings.
See the Medium Duty Maintenance Manual for further
information on servicing the front suspension.
Medium Duty (R10/06)
SPRING
ANCHOR
PINS
SPRING
ANCHOR PIN
U-BOLTS
00439
Front Suspension
Axle Lubrication
• Change bearing lubrication when seals are replaced, or
brakes are relined. See Table 2, “Recommended Maintenance Intervals,” Page 120.
Y53-6008
– 209 –
Front Axle and Suspension
Preventive Maintenance
• Thoroughly clean hubs and bearings with solvent and a
stiff bristle brush, then dry and inspect components for
wear or damage. Re-lubricate with approved axle lubricant.
KINGPIN (TOP)
Kingpin Lubrication
• Lubricate with approved lubricant. Lubricate knuckle
thrust bearings, knuckle pins, and tie rod ends. See
Table 2, “Recommended Maintenance Intervals,” Page
120. Lack of lubrication causes premature wear and
hard steering. Lubrication schedule may be shortened if
necessary.
KINGPIN
(BOTTOM)
00445
Front Axle
Suspension Lubrication
Each spring anchor pin has a grease fitting. Pressure lubricate spring pins according to Table 2, “Recommended Maintenance Intervals,” Page 120, using EP chassis lube with 12Hydroxy Lithium Stearate Base NLGI-2 with 3% molybdenum
additive (e.g. Mobil-grease EP or equal).
– 210 –
• At regular intervals, the spring leaves may be lubricated
with a rust-inhibiting oil applied with a spray gun or
brush.
• Lubricate all spring pins until grease flows out of both
ends of the bushing. Look for signs of rust or water in the
flushed grease. If a pin will not accept grease, it should
be removed, cleaned, and inspected.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Front Axle and Suspension
WARNING! Do not operate the vehicle if the U–
bolts are not properly tightened. Loose U–bolts
do not properly secure the axle to the suspension. This could cause loss of vehicle control
and an injury accident. Loose U–bolts can also
cause uneven tire wear and poor alignment.
CAUTION: Do not spray the suspension with
chemical products or mineral oil; it can cause
damage to the bushings.
Torque
U–Bolts, Spring and Shackle Pinch Bolts
It is important that U–bolts remain tight. Severe use of your
vehicle will cause them to loosen faster. But all vehicles need
to have their U–bolts checked and tightened regularly. See
“Maintenance Schedule” on page 123. Be sure someone
with the proper training and the right tools checks and tightens the U–bolts on your Medium Duty.
New springs can “settle in” after service, relieving the tension
on the U–bolts. Loose U–bolts can cause leaf spring breakage, axle misalignment, hard steering and abnormal tire
wear.
U–bolts are difficult to tighten unless you have the right
equipment. If you cannot tighten them correctly yourself, be
sure to have them checked and tightened regularly by an
authorized mechanic.
WARNING! Do not replace U–bolts and nuts with
common U–bolts or standard nuts. Use only U–
bolts and nuts of SAE Grade 8 specification or
better.These parts are critical to vehicle safety. If
the wrong U–bolts or nuts are used, the axle
could loosen or separate from the vehicle and
cause a serious injury accident.
• At the same time U-bolts are tightened, re-torque the
spring and shackle pinch bolts to 105 lb. ft. (142 N. m.)
• All vehicles should have suspension U–bolts tightened
after the first 500 miles (800 km) of operation. Torque the
front suspension U-bolts to 245-300 lb. ft. (333-408
N.m.)
Medium Duty (R10/06)
Y53-6008
– 211 –
Rear Axle and Suspension
Preventive Maintenance
REAR AXLE AND SUSPENSION
WARNING! Failure to maintain the specified
torque values or to replace worn parts can cause
component system failure, possibly resulting in
an injury accident. Improperly tightened (loose)
suspension U–bolts can lead to unsafe vehicle
conditions, including: hard steering, axle misalignment, spring breakage or abnormal tire
wear. See the Fastener Torque Tables for proper
torque specifications.
General Maintenance
WARNING! Do not work on the vehicle without
the parking brake set and wheels chocked
securely. If the vehicle is not secured to prevent
uncontrolled vehicle movement, it could roll and
cause serious personal injury or damage to the
vehicle.
CAUTION: Do not spray the suspension with
chemical products or mineral oil; it can cause
damage to the bushings.
• Use wood blocks (4 in. X 4 in. or larger) against the
front and rear surfaces of the tires. Be sure the vehicle cannot move.
Your vehicle's suspension, by design, requires a minimal
amount of maintenance. However, suspensions in “over-theroad” operations require periodic inspection to ensure trouble-free performance.
WARNING! Do not operate the vehicle if the U–
bolts are not properly tightened. Loose U–bolts
do not properly secure the axle to the suspension. This could cause loss of vehicle control
and an injury accident. Loose U–bolts can also
cause uneven tire wear and poor alignment.
– 212 –
NOTE: Failure to follow these recommendations
could void warranty. See the “Medium Duty Maintenance Manual” for further information on servicing
the rear suspension.
Visual Inspection
For all vehicles, mandatory maintenance procedures include
retightening of U–bolts and complete inspection. However,
even with proper maintenance, many factors affect the service life of springs and suspension components, such as:
fatigue, vehicle gross weight, type of load, road conditions
and vehicle speed.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Rear Axle and Suspension
It is important that U–bolts remain tight. Severe use of your
vehicle can cause them to loosen faster. But all vehicles need
to have their U–bolts checked and tightened regularly. Be
sure someone with the proper training and the right tools
checks and tightens the U–bolts on your Medium Duty.
Rear Axle Lubrication
• Check oil level with the vehicle parked on level ground
and the fluid warm. The level should be even with the
bottom of the filler hole.
New springs “settle-in” after the vehicle's initial service, causing the U–bolts to become loose. After the first 500 miles
(800 km) of operation, inspect the suspension periodically, as
noted below:
CAUTION: Do not mix lubricants of different
grades; although, mixing different brands of the
same grade lubricant (meeting MIL–L–2105–C),
is acceptable. Lubricants of different grades are
not compatible and could damage the axle.
• Visually check for loose or missing fasteners, cracks in
hanger or axle connection brackets.
• Check that springs are centered in hangers and in good
condition.
• Check for cracks, wear marks, splits, or other defects on
the surface of the spring.
• Replace defective parts. Because repaired springs cannot be fully restored to their original service life, replace
the complete assembly if cracks or other defects are
detected.
• After replacement of any part or discovery of loose components, check the torque of all fasteners.
NOTE: In all cases, the lubricant supplier assumes
full responsibility for the performance of their product, and for product and patent liability.
Medium Duty (R10/06)
Initial Change: Change lubricant in new or rebuilt axle
assemblies within the first 3,000 to 5,000 miles (4800 to 8000
km). For recommended types and brands of lubricants, contact your Peterbilt Dealer or Authorized Service Center. See
the Medium Duty Maintenance Manual and the axle manufacturer's Service Manual for further information on servicing
drive axles.
Y53-6008
– 213 –
Rear Axle and Suspension
Preventive Maintenance
Table 12 Drive Axle Lubrication
MODEL
EATON,
ROCKWELL
RECOMMENDED LUBRICANTS
AMBIENT TEMPERATURE RANGE
°F
EP gear oil, MIL-L-2105D, API GL-5.
-26 to +38
-15 to +100
80W-90
Synthetic Lubricant: Chevron RPM
Synthetic Gear Lubricant, or equal, meeting
MIL-L-2105D and Eaton PS-037 specification.
-40 to +38
-40 to +100
75W-90
• No initial drain is required on Eaton axles that are factory
filled with an Eaton-approved synthetic lubricant.
• Petroleum-based lubricants must be drained within the
first 5,000 miles (8000 km) if converting to an approved
synthetic lubricant.
To change axle lubricant:
1. Park the vehicle on level ground with the axle lubricant at
normal operating temperature.
2. Remove filler (1) and drain plug (2).
3. Completely drain the oil and clean the drain plug.
CAUTION: Do not overfill axles.
See Table 2, “Recommended Maintenance Intervals,” Page
120 for standard rear axle service intervals.
• Use petroleum-based lubricants meeting MIL–L–2105–
C/D grade specifications or approved synthetic lubrication. Do not use oil additives.
– 214 –
VISCOSITY (SAE)
°C
4. Reinstall the drain plug (2) and refill with recommended
oil up to the bottom of filler plug hole.
5. Reinstall filler plug (1).
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Rear Axle and Suspension
Rear Suspension Fasteners
3
Continual road shock and load stresses may force the rear
axles out of alignment. If you detect rapid tire wear on the
rear axles, you may have misaligned axles. Have your rear
axle alignment checked and adjusted by a Peterbilt Dealer or
Authorized Service Center.
1
2
0446A
Rear Axle Filler and Drain Holes and Breather Vent
Axle Housing Breather Vent
• Check and clean the axle housing breather vent (3) at
each oil level check.
Medium Duty (R10/06)
Every 5,000 miles (8000 km) or 180 days, whichever occurs
first and thereafter, retorque all suspension fasteners to recommended specifications. See the Fastener Torque Table for
proper torque specifications.
Load the vehicle to its normal gross weight before tightening
U-bolts. Loading the vehicle ensures proper adjustment of
the U-bolt and spring assembly.
U–bolts are difficult to tighten unless you have the right
equipment. If you cannot tighten them correctly yourself, be
sure to have them checked and tightened regularly by an
authorized mechanic.
Y53-6008
– 215 –
Rear Axle and Suspension
Preventive Maintenance
WARNING! Do not replace U–bolts and nuts with
common U–bolts or standard nuts. These parts
are critical to vehicle safety. If the wrong U–bolts
or nuts are used, the axle could loosen or separate from the vehicle and cause a serious injury
accident. Use only U–bolts and nuts of SAE
Grade 8 specification or better.
Grade 5 Capscrew Torque Specifications
Capscrew Body
Size
(inches-thread)
1/4-20
Torque
Lb. ft.
N.m.
6—9
8—12
-28
7—10
9.5—14
WARNING! Do not operate the vehicle if the U–
bolts are not properly tightened. Loose U–bolts
do not properly secure the axle to the suspension. This could cause loss of vehicle control
and an injury accident. Loose U–bolts can also
cause uneven tire wear and poor alignment.
5/16-18
13—18
18—24
-24
14—20
19—27
3/8-16
22—32
30—43
-20
39—56
53—76
Suspension alignment should be checked when any one of
the following conditions exist:
1/2-13
54—77
73—104
-20
58—87
79—118
• Discovery of loose suspension fasteners (Any
torque below the recommended torque value.).
• Discovery of elongated holes in a suspension component.
• Bushing replacement.
• Excessive or abnormal tire wear.
9/16-12
78—111
105—151
-16
214—305
290—414
NOTE: To ensure an accurate torque reading, use
p r o p e r l y m a i n t a i n e d a n d c a l i b ra t e d t o r q u e
wrenches.
7/8-9
309—441
419—598
462—659
– 216 –
Y53-6008
-24
25—40
34—54
7/16-14
35—50
47—68
-18
87—124
118—168
5/8-11
108—154
147—209
-18
122—174
166—236
3/4-10
192—273
260—370
-14
341—486
1 -8
464—662
629—898
1-12
508—724
689—982
Medium Duty (R10/06)
Preventive Maintenance
Rear Axle and Suspension
Grade 8 Capscrew Torque Specifications
Capscrew Body
Size
(inches-thread)
Torque
Lb. ft.
N.m.
1/4-20
9—12
12—16
-28
10—14
14—19
5/16-18
18—25
24—34
-24
20—28
27—38
3/8-16
31—44
42—60
-24
35—50
47—68
7/16-14
50—71
68—96
-20
56—80
53—108
1/2-13
76—109
103—149
-20
86—123
117—167
9/16-12
110—158
149—214
-18
123—176
167—239
5/8-11
153—218
208—296
-18
173—247
235—335
3/4-10
271—386
367—523
-16
303—431
411—583
7/8-9
437—624
593—846
-14
482—589
654—799
1 -8
656—935
889—1268
1-12
718—1023
973—1386
Medium Duty (R10/06)
The torque values in the previous tables are based on the
use of clean and dry threads.
For standard capscrews:
1. Always use the torque values listed the capscrew table.
2. Reduce torque by 10% when engine oil is used as a
lubricant.
3. Reduce torque by 20% if new plated capscrews are
used.
Y53-6008
– 217 –
Frame and Fifth Wheel
Preventive Maintenance
FRAME AND FIFTH WHEEL
NOTE: Welding to frame rail may void frame rail warranty.
Introduction
WARNING! Do not cut or splice frame rails or
drill through the top or bottom flanges. These
operations could affect frame rail strength leading to a failure resulting in serious personal
injury and/or an accident. Always leave frame
repairs to your Peterbilt Dealer.
Engine Painting
• Do not electrostatically paint electronically controlled
engines or vehicles with these engines.
Welding
• Disconnect all electronic connections to the vehicle batteries.
• Remove battery power cable and insulate it from the
vehicle.
• Disconnect all Electronic Control Module (ECM) connectors (on electronic engines).
• Do not use the ECM or engine ground stud for the
ground of the welding probe.
• Ensure that the ground connection for the welder is as
close to the weld point as possible. This ensures maximum weld current and minimum risk to damage of electrical components on the vehicle.
• Turn engine OFF.
All Anti–Lock Braking Systems (ABS)
• Observe these recommended procedures to protect
electronic systems during welding operations.
Engines
• Before welding anywhere on the vehicle, detach the ABS
Electronic Control Unit (ECU) connector and all other
electronic control units.
Before welding on vehicles equipped with electronic engines,
the following precautions should be observed:
– 218 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Frame and Fifth Wheel
Fifth Wheel Maintenance
Every 6 Months or 50,000 Miles:
Proper preventive maintenance is essential to trouble-free
service and safe operation of the fifth wheel.
Every 2 Months or 25,000 Miles:
• Refer to specific manufacturer's literature for any special
instructions.
• Steam clean the fifth wheel.
• Check lock guard operation using a commercial lock
tester.
• Clean and oil all moving parts.
• Lubricate the following parts with a lithium-base grease.
• Lock mechanism
• All grease fittings (especially those which grease the
top surface of the fifth wheel).
• Check for missing or loose nuts and bolts in the fifth
wheel and mounting brackets. Retighten loose bolts to
correct torque. Replace missing or damaged bolts.
Medium Duty (R10/06)
• Refer to specific manufacturer's literature for any special
instructions.
• Remove fifth wheel from vehicle. Refer to the Medium
Duty Maintenance Manual, “Fifth Wheel Removal.”
• Steam clean the fifth wheel and mounting brackets.
• Check all moving parts for excessive wear or damage.
Replace all worn or broken parts.
• Complete two-month service procedure.
• Install fifth wheel. Refer to the Medium Duty Maintenance Manual, “Fifth Wheel Installation.”
Sliding Fifth Wheel
• Lubricate bearing surface of support bracket through the
grease fittings on the side of the fifth wheel plate. Use a
water resistant lithium-base grease.
Y53-6008
NOTE: The plate must be lifted up slightly to
relieve the weight of the bracket while applying
grease.
– 219 –
Noise and Emission Control
Preventive Maintenance
NOISE AND EMISSION CONTROL
Tampering with Noise Control System
Federal law prohibits the following acts or the causing
thereof:
Noise Emission Warranty
Peterbilt Motors Company warrants to the first person who
purchases this vehicle (for purposes other than resale) and to
each subsequent purchaser: that this vehicle, as manufactured by Peterbilt Motors Company, was designed, built and
equipped to conform, at the time it left Peterbilt's control, with
all applicable U.S. EPA Noise Control Regulations.
This warranty covers this vehicle as designed, built and
equipped by Peterbilt, and is not limited to any particular part,
component or system of the vehicle manufactured by Peterbilt. Defects in design, assembly or in any part, component or
system of the vehicle as manufactured by Peterbilt, which at
the time it left Peterbilt's control caused noise emissions to
exceed Federal standards, are covered by this warranty for
the life of the vehicle.
1. The removal or rendering inoperative by any person
other than for purposes of maintenance, repair, or
replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser
or while it is in use, or
2. The use of the vehicle after such device or element of
design has been removed or rendered inoperative by
any person.
Among those acts presumed to constitute tampering are the
acts listed below:
Air Intake System
• Removing or rendering inoperative the air cleaner/silencers or intake piping.
Engine Cooling System
• Removing or rendering inoperative the fan clutch.
• Removing the fan shroud.
– 220 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Noise and Emission Control
Engine
• Removing or rendering engine speed governor inoperative so as to allow engine speed to exceed manufacturer's specifications.
• Modifying ECU parameters.
• Check the induction tubing, elbow connections, clamps,
brackets, and fasteners for deterioration, cracks, and
security.
• If you find an air leak anywhere between the air cleaner
and the engine, repair that leak immediately.
Exhaust System
• Removing or rendering inoperative exhaust system components.
CAUTION: Air leaks cause excessive noise and
may result in serious damage to the engine. If
you do not repair them the engine damage will
not be covered by your warranty. Repair all air
leaks as soon as you find them.
Inspection and Maintenance Instructions
Exhaust System
The following instructions are based on inspection of the
noise control system at regular intervals.
If, during periodic inspection and maintenance of other systems and components, it is found that parts of the noise control system require attention, we recommend that those parts
be inspected at more frequent intervals to assure adequate
maintenance and performance.
Air Intake System
• Do all checks and maintenance procedures listed in this
manual under Engine Air Intake System and Air Cleaner.
See “Air Intake System” on page 166.
Medium Duty (R10/06)
• Check for exhaust leaks, which would indicate a leaking
manifold gasket; replace gasket if necessary.
• Check cap screws for tightness, including those at the
flanges. Refer to the engine manufacturer's service manual for proper tightening sequence and torque values.
Joints and Clamps
• Check for leaks, and tighten as necessary. Check for
deterioration or dents in pipes and clamps which could
allow exhaust to escape.
Y53-6008
– 221 –
Noise and Emission Control
Preventive Maintenance
Piping
Exhaust Tail Pipe
• Check exhaust piping for rust, corrosion, or damage.
Replace deteriorated piping before holes appear. If piping is perforated at any point, temporary patching or lagging is acceptable until you can have permanent repairs
made. On turbocharged engines, check joints at flanges
and mounting brackets for tightness.
• Check the mounting. Tighten as necessary. The miter
cut at the tip of the pipe must be facing the rear of the
vehicle. Do not modify the end of the pipe in any way.
Engine Fan and Shroud
WARNING! Do not work on the fan with the
engine running. The engine fan can engage at
any time without warning. Anyone near the fan
when it turns on could be seriously injured.
Before turning on the ignition, be sure that no
one is near the fan.
Mufflers
NOTE: Use only an exact replacement muffler in
exhaust systems. Certain mufflers contain integral
catalytic converters essential for compliance with
EPA emission standards. Using a noncompliant muffler as a replacement could violate these standards
and also void the emission system’s warranty.
• Check muffler, clamps, and mounting brackets. Tighten if
necessary. Inspect muffler for signs of rust or corrosion.
• Check internal baffling. You can do this by listening for
rattling sounds while tapping the muffler with a rubber
mallet or revving the engine up and down through its normal operating range.
– 222 –
• Check all fasteners for tightness. Check for stress cracks
in the shroud. Make sure the shroud is adjusted so that it
does not touch the fan blades.
• Check to verify that the fan is disengaged (not turning)
with the engine running at normal operating temperatures (from cold to the point that the fan engages).
• Check fan blade mounting bolts. Inspect fan blades to be
sure they are not cracked or bent. If problems exist, refer
to the Cooling System section in the Medium Duty
Maintenance Manual for detailed maintenance instructions.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Noise and Emission Control
Maintenance Log
Transmission and Driveline
• Substituting a different main transmission or drive line
components, other than design-specified units, may
result in increased vehicle noise emission.
To ensure your Medium Duty's noise control requirements
are maintained, record maintenance checks. Use the following log sheet (see Table 13) and retain copies of documents
regarding maintenance services performed and par ts
replaced on the vehicle.
Table 13 Maintenance Log
Date of Service
Mileage
Medium Duty (R10/06)
Service Performed
Y53-6008
Service Center Name and
Address
– 223 –
Noise and Emission Control
Preventive Maintenance
Table 13 Maintenance Log
– 224 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Noise and Emission Control
Table 13 Maintenance Log
Medium Duty (R10/06)
Y53-6008
– 225 –
Consumer Information and Vehicle Identification
Preventive Maintenance
CONSUMER INFORMATION
AND VEHICLE IDENTIFICATION
Canadian Consumer Information
Reporting Safety Defects
If you believe that your vehicle has a defect which could
cause a crash or could cause injury or death, you should
immediately inform the National Highway Traffic Safety
Administration (NHTSA) in addition to notifying Peterbilt
Motors Company.
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of
vehicles, it may order a recall and remedy campaign. However, NHTSA cannot get involved in individual problems
between you, your Peterbilt Dealer, and Peterbilt Motors
Company.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1–800–424–9393 (366–0123 in Washington,
D.C.) or write to: Administrator, NHTSA, 400 Seventh Street,
S.W., Washington, D.C. 20590. You can also get other information about auto safety from the Hotline.
– 226 –
Canadian customers who wish to report a safety-related
defect to Transport Canada, Defect Investigations and
Recalls, may telephone the toll free hotline 1-680-333-0510,
or cantact Transport Canada by mail at:
Transport Canada, ASFAD
Place de Ville Tower C
330 Sparks Street
Ottawa ON KIA 0N5
For additional road safety information, please visit the Road
Safety website at: http://www.tc.gc.ca/roadsafety/menu.htm
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm. Other chemicals in this
vehicle are also known to the State of California to cause
cancer, birth defects or other reproductive harm. Battery
posts, terminals, and related accessories contain lead and
lead compounds, chemicals known to the State of California
to cause cancer and reproductive harm. Wash hands after
handling.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Consumer Information and Vehicle Identification
Vehicle Identification
All Peterbilt vehicles are identified by a 17–digit Vehicle Identification Number (VIN). This unique numeral and letter combination identifies the manufacturer, the model year it was
built, and other vehicle attributes. The VIN is in compliance
with 49CFR565, Code of Federal Regulations. As an example, the model year and assembly plant are designated by a
letter in the tenth and eleventh character positions (see 4 and
5 below).
• The Chassis/Serial Number refers to the last seven characters of the VIN, including the assembly plant designator (eleventh character position) and a six-digit serial
number. This number will allow your Peterbilt Dealer to
identify your vehicle. You will be asked for this number
when you bring your vehicle in for service.
Table 14 Model Year Letter Designations
SAMPLE VIN
2NP
v
NHD 8 X
w
X
YM 5 6 7 8 9 0
x yz
v Manufacturer Identifier
w Vehicle Attributes
x Check Digit
y Model Year
z Assembly Plant
{ Serial/Chassis Number
{
CODE
YEAR
2
2002
3
2003
4
2004
5
2005
6
2006
VIN Location
The VIN is marked on the Incomplete Vehicle Certification
Label (on trucks) or on the Tire, Rim, and Weight Rating
Data Label (on tractors). Both labels are located on the
driver’s door frame.
Vehicle Identification Number (VIN)
Medium Duty (R10/06)
Y53-6008
– 227 –
Consumer Information and Vehicle Identification
Preventive Maintenance
Chassis Number Locations
A2378
The chassis/serial number is shown in three places:
• Right frame rail, top flange, about 3 ft. from the front end
• Components and Weights Label on driver’s door frame
• Tire and Rim Info Label on driver’s door frame
VIN LOCATION
Driver’s Door Frame
– 228 –
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Consumer Information and Vehicle Identification
Complete Vehicle Certification Label
VEHICLE NAME PLATE
The Complete Vehicle Certification label certifies that the
vehicle complies with all applicable Federal Motor Vehicle
Safety Standards. It is located on the driver's side door frame
and contains the following information:
• Date of manufacture
• GVWR — Gross Vehicle Weight Rating
• GAWR FRONT and REAR — Gross Axle Weight Ratings for Front and Rear Axle
• TIRE/RIM SIZES AND INFLATION PRESSURES —
Tire/Rim Sizes and Cold Pressure Minimums
• VIN — Vehicle Identification Number
0$ 18 )$ &785 ('
%<
3( 7( 5%,/ 7 02 72 56 &2
7,5(
)5
6, =(
68 ,7$%/( 7,5( 5, 0 &+ 2, &(
5, 0 6,=(
36, &2 /'
*$ :5
', 9,6,21 2) 3$ &&$ 5 ,QF 1 ' *$ :5
5 ' *$ :5
'$ 7( 0) '
*9 :5
7 + *$ :5
7+ ,6 9( +, &/ ( &21) 25 06 72 $/ /
$33/ ,&$%/( )( '( 5$ / 02 72 5 9( +,&/ (
6$ )( 7< 67$1 '$ 5' 6 ,1 () )(&7 21 7+ (
'$ 7( 2) 0$ 18 )$ &785 ( 6+ 2: 1 $%29 (
9,1
7<3(9(+
758&.75$&725
/$%(/12
5(9
+
COMPLETE VEHICLE CERTIFICATION LABEL — SAMPLE
Medium Duty (R10/06)
Y53-6008
– 229 –
Consumer Information and Vehicle Identification
Preventive Maintenance
WARNING! Do not exceed the specified load rating. Overloading can result in loss of vehicle
control and serious personal injury, either by
causing component failures or by affecting vehicle handling. Exceeding load ratings can also
shorten the service life of the vehicle.
NOTE: GVW is the TOTAL SCALE WEIGHT the
vehicle is designed to carry. This includes the weight
of the empty vehicle, loading platform, occupants,
fuel, and any load.
The tire size and rim size (and the cold inflation pressure to
match that combination) listed under “Suitable Tire-Rim
Choice” on the Certification Label are only representative
examples for the specified axle ratings. These components
may not be the ones actually installed on the axle, because
there are many other appropriate combinations.
The “PSI Cold” inflation pressure on the Certification Label is
for the tire-rim combination in the example, and may not be
the same as the recommended inflation pressure for the
actual tires on that axle.
Check the manufacturer's product information for the tires
and rims actually on each axle to obtain recommended tire
inflation pressure for specific applications.
– 230 –
Incomplete Vehicle Certification Label
The Incomplete Vehicle Certification Label (for trucks) is
located on the driver’s door frame. It contains the following
information:
• DATE OF MANUFACTURE
• VIN — Vehicle Identification Number
• LISTING OF APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS
Noise Emission Label
The Noise Emission Label is in the map compartment. It contains information regarding U.S. noise emission regulations
and date of manufacture.
Paint Data Label
The Paint Data Label contains the paint colors used by the
factory to paint your vehicle. It lists frame, wheels, cab interior and exterior colors. This label is located in the map compartment.
Y53-6008
Medium Duty (R10/06)
Preventive Maintenance
Consumer Information and Vehicle Identification
Federal Safety Standard Certification Label
The NHTSA regulations require a label certifying compliance
with Federal Safety Standard, for United States and U.S. Territories, be affixed to each motor vehicle and prescribe where
such label may be located. This certification label, which indicates the date of manufacture and other pertinent information, is located on the driver's side door frame.
Component Identification
Each of the major components on your vehicle has an identification label or tag. For easy reference, record component
numbers such as, model, serial, and assembly number. See
the “Vehicle Component Register” (last page of this manual).
Engine: For further information, please refer to the Engine
Operation and Maintenance Manual.
Clutch: Enclosed in clutch housing. Location depends on
manufacturer.
Medium Duty (R10/06)
Transmission: For both manual and automatic transmissions, the identification number is stamped on a tag affixed to
the right rear side of the transmission case.
Steer Axle: The front axle serial number is stamped on a
plate located on the center of the axle beam.
Drive Axles: The drive axle numbering system includes
three labels or stamps:
1. Axle Specification Number, usually stamped on the right
rear side of the axle housing. This number identifies the
complete axle.
2. Axle Housing Number Tag, usually located on the left forward side of the housing arm. This tag identifies the axle
housing.
3. Axle Differential Carrier Identification, usually located on
the top side of the differential carrier. The following information is either stamped, or marked with a metal tag:
Model No., Production Assembly No., Serial No., Gear
Ratio, and Part Number.
Y53-6008
– 231 –
Index
A
Accessories 43
Adjustable Tilt Column 56
Air conditioner 181
refrigerant 117
Air Dryer 165
Air filter 167
Air horns 43
Air intake 166, 220
Air leaks 163
Air loss emergency procedure 27
Air pressure gauge 26, 163
Air suspension
deflated air spring 105
switch, operation 101
Air tanks 15, 87, 114
alteration 9
Alternator precautions 191, 218
Anti-lock brakes 80, 83, 93
Ashtray 43
Automatic transmission 16, 71, 205
fluid 208
oil level 205
Axle weight rating 12, 13, 100, 230
B
Ball bearing grease 134
Ball seat mounted wheels 177
Battery
– 232 –
access 183
care 184
compartment cover 8
electrolyte 188
recharging 188, 189
slow battery charging 190
Belts, seat 46, 48
Block heater 61, 147
Bobtail brake 77, 85
Brake
adjustment 151
air pressure gauge 26, 163
checks and adjustments 150
components 86
compounding 87
emergency braking 80
hand valve, trailer 55, 83
linings 151
lubrication 150
operation 73
overheating 80
parking 74
proportion valve 73
safety - front 79
safety - rear 79
safety - tractor/trailer 80
system - safety and emergency 78,
159
Y53-6008
system - towing and spring brakes 110
system checks 149, 153
system malfunction 110
system park - tractor 78
trailer brake hand valve 84
trailer charge 78
treadle valve 87
Brake Fluid Check 154
Brake Fluid Reservoir 89
Brake Master Cylinder 90
Brake Warning Lamp 91
C
Cab
access 7
heater maintenance 180
heater precautions 38
maintenance 197
Calipers 156
Charge air cooler 166
Chassis
grease 134
number 227, 228
Cigarette lighter 43
Cleaning the vehicle 193
Clutch 67
clutch adjustment 71
clutch brake 69
clutch travel 69
Medium Duty (R10/06)
Index
fan drive 222
operating the clutch 67
riding the clutch 70
Coasting 71
Component lubrication index 134
Compressed air reservoir 15, 87, 162
Compressor 86
Consumer information 226
Cooling system
conventional coolant 146
expansion tank 24
extended life coolant 144
temperature 23, 24
temperature gauge 23
topping up 145
Cruise control
operation 65
switch 37
D
Dome light 44
Door Lock 7
Door lock 194
Double check valve 87
Downshift 71
Driver’s
checklist 13
daily and weekly checks 13, 14, 16
handbook American Trucking Assoc. 5
seat 45
tips 71
Driveshaft 208
lubrication 208
Driving
bobtail 84, 89
vehicle inspection 11
with deflated air springs 105
Dry tank 87
Dual air pressure gauge 26, 60
Daily operations 14
Daytime running lights 31
Defogging/defrosting system 38
Department of transportation regulation
392.7 11
Diesel fuel 115
Dipstick 139
Disc brake pads 155
Disc brake rotors 156
Economical driving 98
Electrical system 183
alternator 191
batteries 183, 184, 188
battery charging 185, 187, 188, 189
jumper cables 186
Electrolyte 188
Emergency
Medium Duty (R10/06)
E
Y53-6008
braking 80
equipment 13
flasher switch 55
Engine
belt tension 14, 185
block heater 61
compression 113
daily checks 14
fan switch 65
heater 147, 179, 182
identification 231
idling 64
lubrication 139
oil draining 139
oil level check 139
oil pressure 25
oil pressure gauge 25
overheating 23
overspeed 99
retarder 84
rpm 114
service notes 139
speed 23
starting procedure 58
stopping the engine 114
temperature 24
vital engine systems 63
warmup procedure 63
– 233 –
Index
water temperature gauge 23
weekly checks 16
winterfronts 58
Environmental protection 117
Ether 58
Exhaust
brake 84, 85
fumes 117
filter 14, 140
filter draining 141
gauge 28
refueling 114
system 115
tanks 28
Fuel Tank Inspection 141
Fuel tanks 141
F
G
Fan blade 222
switch 65
Federal motor regulations 11, 14
Federal motor vehicle safety standards 3
Federal safety label 231
Fifth wheel 105
air controlled 106
fixed 106
lock switch 106
maintenance 219
sliding maintenance 219
Frame precautions 218
Front axle 210
front axle identification 231
Front brake system 73
Front suspension
u-bolts 209
Front Wheel Calipers 90
Fuel
GAWR
defined 13
GAWR - gross axle weight rating 12, 100,
230
GCW - gross combination weight 12
Glove compartment 44
Governor 86
Grease index 134
GVWR
defined 12
GVWR - gross vehicle weight rating 12,
100, 172, 230
– 234 –
H
Hand brake 84, 113
Hazard flasher 20, 26, 27, 55, 92
Headlight switch 31
Heater and air conditioner 38
controls 42
defogging 41
Y53-6008
maintenance 180
High beam 54
Hood Latch and Tilt 9
Hour meter 22
Hub piloted and ball seat parts 177
Hydraulic Booster 90
Hydraulic Brakes 14, 15, 35, 88
Hydraulic Fluid Check 14
Hypoid gear oil 134
I
Idling the engine 64
Ignition switch 33
Incomplete vehicle certification label 230
Instrument index 18
Inter-axle differential 96
J
Jumper cables 186
use of 186
K
Keys 7
Komfort-Lok latch 51
L
Lap - shoulder belt 46
Lap belt 47
Load capacity 12
Load distribution 13
Low air pressure 105
Medium Duty (R10/06)
Index
Lubrication 150, 210
axle 209
brakes 150
chart 135
coasting 99
driveshaft 208
engine 139
front axle 210
front suspension 210
idling 63, 64
power steering 206, 207
rear axle 213, 214, 215
transmission 202, 203
types and brands 133
wheel bearings 210
M
Maintenance
manual 4
schedule 119
Manual transmission 67
lubricants 202
oil level 203
shifting gears 67
master cylinder 88
Mirrors 56
Modifications 117
Modulating valve 87
Muffler 222
Medium Duty (R10/06)
N
NHTSA consumer information 226
Noise and emission control 220
air intake system 220
engine 221
exhaust system 221
fan drive 220
inspection and maintenance instructions 221
O
Off-road operation 3
Oil
draining 139
level 139
pressure gauge 25, 60
Operating instructions 7
Operating the engine 58
Operating the Rear/Drive Axle 95
Operating the transmission 67
Optional equipment 71, 85, 96
Overheated Brakes 92
P
Paint identification label 230
Parking brake 31, 74
adjustment 151
automatic 75
brake system, operation 34, 35, 74,
75, 79, 110
Y53-6008
brake system, tractor/trailer operation
76
use 20, 23, 26, 27, 35, 59, 68, 92,
113, 116, 187
valve 88
Parking Brake Burnishing 94
Parking Brake Component Inspection
156
Parking Brake Indicator 36
Parking Brake Lever 90
Parts catalog 4, 5, 118
Power steering 206
fluid level 207
fluid refill 208
lubrication 206
Q
Quick-release valve 87
R
Radio 43
Rear axle 213
housing breather vent 215
identification 231
lubrication 213, 214, 215
oil change 213
oil level 213
Rear brake system 73
Rear suspension 212
fasteners (standard) 212
– 235 –
Index
Rear Wheel Calipers 90
Recovering vehicles 108
Relay valve 87
Release bearing wear 71
Repairs 4
Retarders
engine 85
rpm 23, 63, 69, 114
S
Safe vehicle operation 11
Safety
belt adjustment 47
passengers 49
restraint belts 46
restraint tips 49, 52
signals 1
stands 117
tether belts 50
Safety precautions, maintenance 116
Seat adjustment 45
Seat belt system
damage and repair 52
guidelines 198
inspection 197
Komfort-Lok latch 51
replacement part 200
tether belts 200
Seats 45
– 236 –
Serial number 228
Service Brake Components 155
Shackle pinch bolts 211
Shift pattern/diagram 67, 69
Shifting gears 22, 59, 67, 68, 69, 70, 71,
99, 100, 112
Shifting gears in a new vehicle 69
Shock absorber 209
Shop manuals 4
Shoulder belt 47
Single check valve 87
Slack adjusters 151
Speedometer 21
Spring brakes - manual release 110
Spring pins 210
Springs 209
Starting procedure - cold weather 61
Starting procedure - normal temperature
59
Steering column controls 54
Steering maintenance 206
Stopping procedures 113
Storage compartment 44
Suspension 212
fasteners 212
fasteners, torque 212
T
Tachometer 22, 99
Y53-6008
Tether belts 50, 200
adjustment 51
Tire
chains 112
inflation pressure 171
inspection 170
replacement, tread depth 178
Towing 110, 112
vehicle recovery precautions 108
Tractor park 78
Tractor protection manifold 88
Trailer
hand brake 55, 83, 84
park 77
spring brakes 80
supply valve, red 88
Trailer ABS 82
Trailer park 76
Transmission
automatic 71
clutch 67
identification 231
lubrication 202, 203, 205
maintenance 203
manual 67
operation 67
service notes 202
Truck/tractor ABS 81
Medium Duty (R10/06)
Index
Turbocharger 114, 166
Turn signal/high beam switch 54
U
U-Bolt torque 211
Underbody maintenance 194
Underinflated tires 171
V
Vehicle
driving 11
loading 12
weight rating 12, 100, 230
Vehicle inspections 11
W
WAIT TO START light 59
Medium Duty (R10/06)
Warning Lamp Module 19
Warning Lamp Self Test 20
Warning lights and buzzer 18
Warranty 117, 119, 212, 218, 220, 221
Weekly operations 16
Weight rating 12, 100
Welding 191, 218
Wet Brakes 92
Wet tank 87
Wheel and Tire Replacement, hydraulic
brakes 179
Wheel bearing
grease 134
lubrication 209
wheel cylinders 88
Y53-6008
Wheels and tires 169
general safety requirements 169
load rating 172
overinflation 172
proper inflation 171
replacement 169, 178
tightening sequence 173
tire inspection 170
tread depth 178
underinflation 171
wheel mounting and fastening 169
wheel nut torque 173
Windshield
washer reservoir 201
wiper/washer switch 32
– 237 –
OPERATOR’S
M ANUAL
Y53-6008 11/06 PRINTED IN U.S.A. PETERBILT MOTORS COMPANY • P.O.BOX 90208 • DENTON, TEXAS 76202 • A DIVISION OF
C l a s s
P a y s
Medium Duty Models
1
7
13
18
44
56
57
113
221
222
227
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