Quick Table of Contents

Quick Table of Contents
Y53-6032.book Page 2 Monday, May 24, 2010 3:37 PM
Quick Table of Contents
Introduction . . . . . . . . . . . . . . . . . . 1
Cab And Frame Access . . . . . . . . . . . . 6
Getting To Your Engine . . . . . . . . . . . . . . 11
Controls And Displays. . . . . . . . . . . . . . . . . . . 14
Seat And Restraint Systems . . . . . . . . . . . . . . . . . 75
Driver’s Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Starting And Operating The Vehicle . . . . . . . . . . . . . . . . . . 93
Maintenance and Service
. . . . . . . . . . . . . . . . . . . . . . . . . . 143
Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Consumer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Subject Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
© 2010 PACCAR INC - All Rights Reserved
This manual illustrates and describes the operation of features or equipment which may be either standard or optional on this vehicle. This
manual may also include a description of features and equipment which are no longer available or were not ordered on this vehicle. Please
disregard any illustrations or descriptions relating to the features or equipment which are not on this vehicle.
Peterbilt reserves the right to discontinue, change specifications, or change the desing of its vehicles at any time without notice and without
incurring any obligation.
The information contained in this manual is proprietaary to Peterbilt. Reproduction, in whole or in part, by any means is strictly prohibited
without prio written authorication from PACCAR Inc.
Y53-6032.book Page 1 Monday, May 24, 2010 3:37 PM
PART 1: INTRODUCTION
HOW TO FIND WHAT YOU WANT
PART 1: INTRODUCTION
This manual contains useful information for the safe and
efficient operation of your Peterbilt Model 587. 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—and to present it as clearly as possible. We hope
you’ll find this manual easy to use.
Please remember, though—this manual is not a training
manual. It can’t tell you everything you need to know
about driving your Peterbilt vehicle. For that you need a
good training program or truck driving school. If you have
not been trained, get the proper training before you drive.
Only qualified drivers should drive this vehicle.
There will be times when you need to take this manual out
of your Peterbilt. When you do, please be sure to return it
to the cab when you are finished using it. That way it will
be there when you need it the next time or when you pass
the vehicle on to the next user.
(R05/10)
How To Find What You Want
There are several tools built into this manual to help you
find what you need quickly and easily.
First is the Quick Table of Contents. Located at the front
of the manual, this lists the main subjects covered and
gives page numbers where you can find these subjects.
Use the Quick Table of Contents to find information on a
large subject like “Maintenance.”
Cross-referenced citations also help you get the information you need. If some other part of the manual contains
further information on the subject you are reading about,
we’ll indicate that in a cross-reference like this: (See
“PART 6: DRIVER’S CHECKLIST”). You won’t have to go
searching for more information.
Finally you’ll find a helpful Subject Index. It’s in the back
of the manual and alphabetically lists the subjects covered. So if you want information on brakes, for example,
just look under Brake in the Subject Index. You’ll find all
the pages listed where brakes or braking are discussed.
Y53-6032
–1–
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A SPECIAL WORD ABOUT REPAIRS
PART 1: INTRODUCTION
A Special Word About Repairs
Your Peterbilt dealer’s service center is the best place to
have your vehicle repaired. You can find Peterbilt dealers all
over the country with the equipment and trained personnel
to get you back on the road quickly—and keep you there.
Your vehicle is a complex machine. Anyone attempting
repairs on it needs good mechanical training and the
proper tools. If you are sure you have these requirements,
then you can probably perform some repairs yourself.
However, all warranty repairs must be performed by an
authorized Peterbilt service facility. If you aren’t an experienced mechanic, or don’t have the right equipment,
please leave all repairs to an authorized service facility.
They are the ones equipped to do the job safely and correctly.
WARNING! Attempting repair work without sufficient training, service manuals, and the proper
tools can be dangerous for yourself and others.
You could be injured or you could make your
truck unsafe and cause death or serious injury.
Do only those tasks you are fully qualified to do.
–2–
Maintenance Manuals. If you do decide to do any complex repair work, you’ll need the Peterbilt Maintenance
manuals. Order them from your authorized dealer. Please
provide your Chassis Serial Number when you order, to
be sure you get the correct manuals for your vehicle. Allow
about four weeks for delivery. There will be a charge for
these manuals.
Final Chassis Bill of Material. A complete, nonillustrated
computer printout listing of the parts used to custom-build
your Peterbilt vehicle is available through the Peterbilt
dealer from whom your purchased your vehicle.
WARNING! Modifying your vehicle can make it
unsafe. Some modifications can affect your
truck’s electrical system, stability, or other
important functions. Before modifying your
vehicle, check with your dealer to make sure it
can be done safely.
Additional Sources of Information
Operator’s manuals are also supplied by the manufacturers of components such as the engine, seats, transmission, and radio in your Peterbilt. If you are missing any of
these manuals, ask your Peterbilt dealer to supply them.
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PART 1: INTRODUCTION
SAFETY SIGNALS
Another place to learn more about trucking is a local truck
driving school. Contact one near you to find out what
kinds of instruction it offers.
WARNING
When you see this word, the message that follows is especially vital. It signals a potentially
hazardous situation which, if not avoided, could
result in an injury or death. This message will tell
you what the hazard is, what can happen if you
don't heed the warning, and how to avoid it.
Federal agencies such as The National Highway Traffic
Safety Administration and the Federal Motor Carrier
Safety Administration also have information and various
agencies in state governments are sources for regulations
that differ from state to state.
Example:
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 others, as well as prevent costly
damages to the vehicle.
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.
CAUTION
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.
Signals a potentially hazardous situation
which, if not avoided, could result in property or
vehicle damage.
Example:
CAUTION: Continuing to operate your vehicle
with insufficient oil pressure will cause serious engine damage.
(R05/10)
Y53-6032
–3–
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VEHICLE SAFETY
PART 1: INTRODUCTION
Vehicle Safety
NOTE
Provides general information: for example, the
note may suggest how to operate the vehicle
more efficiently.
Example:
Make sure your Peterbilt is in top working condition before
heading out on the road—it is the responsible driver's duty
to do so. Inspect the vehicle according to “PART 6:
DRIVER’S CHECKLIST”.
WARNING! Do not drink and drive. Your
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.
NOTE: Pumping the accelerator will not assist in
starting the engine.
Please take the time to read these messages when
you see them, and remember:
WARNING!
WARNING! 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 death or personal
injury.
Something that could seriously injure or kill you or others.
CAUTION:
Something that could cause property or vehicle damage.
NOTE:
Useful information.
–4–
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
Y53-6032
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PART 1: INTRODUCTION
VEHICLE SAFETY
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.
Safe driving is only possible with the proper concentration
on the driving task. Keep distraction to a minimum to
improve your concentration. Examples of distractions
may include radio controls, GPS navigation controls, cellular telephone calls, cellular text messages, reading or
reaching for something on the floor. Minimizing your distractions will improve safe driving and will help avoid an
accident involving death or personal injury.
(R05/10)
Be aware of local regulations that may prohibit the use of
cellular telephones while driving. In addition to being an
unsafe practice, it may be against local ordinances to use
cellular devices while operating the 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 of its load ratings. (See the Tire and
Rim Weight Ratings label on the driver's door edge.)
Y53-6032
–5–
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PART 2: GETTING INTO & OUT OF THE CAB AND FRAME ACCESS
PART 2: GETTING INTO & OUT OF THE CAB AND FRAME ACCESS
Be careful whenever you get into or out of your vehicle’s
cab. Always maintain at least three points of contact with
your hands on the grab handles and your feet on the
steps.
WARNING! Do not jump out of the cab or get
into the cab without proper caution. You could
slip or fall, possibly suffering death or serious
injury. You could slip and fall if the steps are
wet or icy, or if you step in fuel, oil, grease,
snow or mud.
The illustrations that follow show the best ways to enter
and exit a cab.
02958-A
Vehicle With External Grab Handle
–6–
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PART 2: GETTING INTO & OUT OF THE CAB AND FRAME ACCESS
DOOR LOCK AND KEYS
WARNING! To help lessen the chance and/or
severity of death or personal injury in case of
an accident, always lock the doors while driving. Along with using the lap shoulder belts
properly, locking the doors helps prevent
doors from inadvertently opening and occupants from being ejected from the vehicle.
Remote Keyless Entry (optional)
This vehicle may be equipped with a Remote Keyless
Entry (RKE) system that adds security and convenience
to your vehicle. The system will lock or unlock the driver’s
door and passenger’s door with the key fob and alert you
with parking lights when the selected door’s are locked or
unlocked. The system includes two key fobs that provide
secure rolling code technology that prevents someone
from recording the entry signal.
02958-B
Vehicle Without External Grab Handle
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. To lock or unlock the doors from outside the cab,
insert the key in the lock. Turn the key toward the rear to
lock; forward to unlock.
(R05/10)
Operation
To unlock the driver’s door, press the UNLOCK button
once. The driver's door will unlock and the parking lights
will come on for 40 seconds.
To unlock the passenger’s door press the UNLOCK button
once and press again within 5 seconds.
Y53-6032
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DOOR LOCK AND KEYS
PART 2: GETTING INTO & OUT OF THE CAB AND FRAME ACCESS
To lock both doors press the LOCK button. The doors will
lock and the parking lights will come on for 2 seconds. If
the doors are open they will not lock. The range of the
RKE system should be approximately 30 ft. This will be
reduced if it is operated close to other RF sources such as
TV/radio transmitters and cell towers.
The key fob may need to be synchronized to the truck
when the battery is replaced or when the key fob has not
been used for an extended period time.
To Synchronize A Key Fob
1. Hold the key fob near the receiver.
Batteries
The key fob uses one CR2032, 3V battery. Batteries
should last approximately three years, depending on use.
Consistently reduced range is an indicator that the battery
needs replacement. Batteries are available at most discount, hardware and drug stores.
The battery is located under the back cover of the key fob.
Be sure to synchonize the key fob every time you replace
the batteries.
–8–
Synchronization
NOTE: The receiver is located behind the
Speedometer/Tachometer cluster assembly.
2. Press and hold both the Lock and Unlock buttons at
the same time for approximately 7 seconds.
3. When the key fob is resynchronized, the doors will
lock then immediately unlock.
4. If the fob fails to synchronize, it could be programmed
to a different truck or could have failed. Contact your
dealer to re-program your key fob.
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PART 2: GETTING INTO & OUT OF THE CAB AND FRAME ACCESS
FCC ID: L2C0031T IC: 3432A-0031T
FCC ID: L2C0032R IC: 3432A-0032R
This device complies with Part 15 of the FCC Rules and with RSS-210
of Industry Canada. Operation is subject to the following two conditions:
1. This device may not cause harmful interference, and
2. This device must accept any interference received, including
interference that may cause undesired operation.
WARNING: Changes or modifications not expressively
approved by the party responsible for compliance could
void the user's authority to operate the equipment. The
term “IC:” before the radio certification number only signifies that Industry Canada technical specifications were
met.
Climbing Onto the Deck Plate
When you are climbing onto and off the deck plate, maintain at least three points of contact with your hands on the
grab handles and your feet on the steps.
NOTE: Any alteration (adding bulkheads, headache racks, tool boxes, etc.) behind the cab or
sleeper that affects the utilization of grab handles,
deck plates, or frame access steps installed by
Peterbilt must comply with FMCSR 399.
(R05/10)
Y53-6032
CLIMBING ONTO THE DECK PLATE
WARNING! Do not step on vehicle components without antiskid surfaces or use components not designed for entry-and-exit use.
You could fall and kill or 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.
• Do not climb onto or stand on the frame
rails. The frame rails are very slippery and
could cause you to fall, resulting in death or
personal injury.
• Always reinstall steps before entering the
cab or accessing the deck plate. Without
steps, you could slip and fall, resulting in
possible injury to yourself.
–9–
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CLIMBING ONTO THE DECK PLATE
– 10 –
PART 2: GETTING INTO & OUT OF THE CAB AND FRAME ACCESS
Hold handles as you step up
Three points of contact as you reach the deck area
Three points of contact
Three points of contact as you step to the deckplate
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PART 3: GETTING TO YOUR ENGINE
HOOD HOLD DOWNS
PART 3: GETTING TO YOUR ENGINE
Hood Hold Downs
Hood hold downs keep a hood from opening unexpectedly.
CAUTION: A hood not latched securely could
open during operation and cause vehicle
damage. Be sure to latch the hood securely.
Hood Tilt
Follow this procedure to tilt the hood.
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. Failure to stand in a
position of safety can cause death or personal
injury.
1. To open your hood, unlock the hood hold downs by
unlatching them. Put one hand on the top of the hood
front, one foot on the bumper, and one foot on the
ground. Tilt the hood forward.
(R05/10)
Y53-6032
LATCHED
UNLATCHED
– 11 –
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HOOD TILT
PART 3: GETTING TO YOUR ENGINE
2. Locate the hood anti-blowdown device mounted to the
driver side hood dampener.
WARNING! The hood uses two struts to control movement during opening and closing.
Do not tilt the hood with one or both struts
disconnected. Replace damaged, worn, or
leaking struts as soon as possible. Tilting a
hood with either strut disconnected or defective may cause the hood to tilt too rapidly.
You could be killed or injured and the hood
could be damaged.
3. Verify that the device was previously reset during the
last hood closing event. This is done by pulling the
collar in the downward direction.
WARNING! Always verify that the hood antiblowdown device has been reset when opening the hood. The device is reset either by
fully closing the hood or by manually pulling
the device down. Failure to reset the antiblowdown device may lead to a hood closing unintentially which can cause death or personal
injury to anyone under the hood.
PULL DOWN TO
RESET DEVICE
Hood antiblowdown device
– 12 –
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PART 3: GETTING TO YOUR ENGINE
HOOD TILT
4. To close the hood, disengage the hood antiblowdown
device by pushing it in the upward direction. The
device will move about 1/4” up the shaft. You may feel
a click when the device disengages.
6. Secure the hood latches on both sides of the vehicle
to hold the hood in the closed position.
PUSH UP TO
DISENGAGE
DEVICE
WARNING! If the hood is not latched securely,
it could open during operation and cause an
accident involving death or injury. Be sure the
hood is latched securely before moving the
vehicle.
CAUTION: Attempting to close a hood without
disengaging the hood antiblowdown device
may cause equipment or vehicle damage.
5. Firmly push upward and rearward on the hood ornament to start the hood tilting backwards. Continue to
push until the hood comes is fully closed.
(R05/10)
Y53-6032
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YOUR INSTRUMENT PANEL
PART 4: CONTROLS AND DISPLAYS
PART 4: CONTROLS AND DISPLAYS
This part explains the location of the various features on
your vehicle and describes their function. For information
on using these features in driving, see the paragraphs
below.
Your Instrument Panel
Please remember that each vehicle is custom-made. Your
instrument panel may not look exactly like the one in the
pictures that follow.
WARNING! Use extreme caution when using
devices while driving (such as cellular telephones) that distracts you from safe driving
practices. Failure to properly concentrate on
the driving task can result in an accident
involving death or personal injury. Limit the
use of such devices to when it is safe to do
so; not while operating the vehicle.
We have tried to describe the most common features and
controls available, so your vehicle may not have some of
the ones that appear in this section. You can pick out the
parts that apply to you and read them to be fully informed
on how your particular vehicle operates.
– 14 –
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PART 4: CONTROLS AND DISPLAYS
YOUR INSTRUMENT PANEL
Typical Cab Instruments and Controls
6
7
8
9
10 11
12
5
13
4
14
15
3
2
(R05/10)
16
1
18
LEFT SIDE
1. Hazard Switch
10. Oil Pressure
2. Ignition Switch
11. Primary Air Pressure
3. Headlight Light Switch
12. Secondary Air Pressure
4. ID/Clearance Lamps Switch
13. Fuel
5. Voltmeter
14. Cigarette Lighter
6. Engine Coolant Temp
15. Menu Control Switch
7. Tachometer
16. Rear A/C Switch
8. Driver Information Display
17. Dome Light Switch
9. Speedometer
18. Panel Dimmer
17
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YOUR INSTRUMENT PANEL
PART 4: CONTROLS AND DISPLAYS
RIGHT SIDE
10
11 12 13 14
15
16 17
9
8
18
7
19
6
1. Parking Brake Valve
12. Optional
2. Trailer Air Supply Valve
13. Engine Brake
3. Heater/AC Control Panel
14. Engine Brake Sel
4. Engine Fan Switch
15. Interaxle Differential Lock
Switch
5. Floor Light Switch
16. 5th Wheel Lock Switch
6. Regeneration Switch
17. Air Suspension Switch
7. Load Light Switch
18. Radio
8. Fog Lights Switch
19. CB Radio
9. Cruise Control Switch
20. Traction Control Switch
10. Transmission Temperature
21. Mirror Heater Switch
20
21
5
4
11. Cruise Control Sel Switch
2
1
3
– 16 –
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PART 4: CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
Instruments And Controls
Standard Warning Lights and Audible Alarm
Menu Control Switch (MCS)
The warning lights and audible alarm may indicate a system malfunction. Check the lights frequently, and respond
properly as soon as you see one go on. These lights could
save you from a serious accident.
The MCS is used to navigate the Driver Information Display unit. The Menu Control Switch is located on the D Panel
as shown in the illustration below.
WARNING! Do not ignore a warning light or
audbile alarm. These signals tell you something is wrong with your vehicle. It could be a
failure in an important system, such as the
brakes, which could lead to an accident
involving death or personal injury. Have the
appropriate system checked immediately.
3
2
The MCS has the following functions:
1
• Rotating the MCS
– Selecting display
– Setting values
1. Driver Information Display
2. Status Indicator
3. Light Bar
• Pushing the MCS
– Confirming desired selection
(R05/10)
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INSTRUMENTS AND CONTROLS
PART 4: CONTROLS AND DISPLAYS
Warning lights and indicator symbols will be shown in both
areas 1 and 2. Area 3 includes the turn and high beam
indicator symbols.
A red warning is active.
1. Driver Information Display:
An amber warning is active.
The display can show up to six warning lights. Warnings
do not have fixed positions and are displayed in order of
criticality. The most critical warning will be displayed on
the top row and to the left. If more than six warnings are
active, the menu control switch (MCS) can be used to
scroll through the additional warnings.
Refer to “Warning Light / Indicator Symbols” on page 20
for information on each symbol.
2. Status Indicator:
Instrument System Self Test:
Additional lights and indicator symbols are displayed in
the Status Indicator. They are limited to:
a. Park Brake
b. Transmission Gear (Automatic transmissions
only)
c. Warnings:
When the ignition switch is turned on the instrumentation
system will undergo a Self Test. This test will verify the
operation of the gauges and warnings.
Number of active warnings.
– 18 –
d. Cruise Control - active
e. Clock alarm bell
During the Instrumentation System Self Test, three
screens will sequentially display warning icons (approximately 3 seconds each screen) on the Information Display. These are:
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PART 4: CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
include but are not limited to headlight on, fifth wheel, stop
engine, primary/secondary air, and driver door open
warnings.
First
Optional Lights:
Second
Additional lights may be operational depending on individual vehicle specifications. These will be included in the
Instrument System Self Test.
Third
NOTE: Some optional lights may illuminate even
though your vehicle is not equipped with that particular feature.
Refer to “Warning Light / Indicator Symbols” on page 20
for information on each symbol.
Completing this sequence will indicate a successful Self
Test. Have your instrumentation system checked by a
qualitfied service technician if does not successfully complete.
Audible Alarm:
The audible alarm will sound during the Instrumentation
System Self Test. The audible alarm will also sound in
conjunction with most warning lights. These events
(R05/10)
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INSTRUMENTS AND CONTROLS
PART 4: CONTROLS AND DISPLAYS
Warning Light / Indicator Symbols
Warning Light / Indicator Symbols
The following is a list of Warning Light / Indicator Symbols.
Reading left to right, the table header identifies
• the Symbol Name
• the appearance of the Symbol
Symbol Name
1. Active Warnings, Exclamation
Point
Symbol
Color Std
Opt Page
Red
23
Yellow
23
Yellow
23
Red
23
5. Anti-Lock Brake System
(ABS)
Yellow
23
6. Anti-Lock Brake System
(ABS), Trailer
Yellow
24
7. Axle, Inter-Axle Differential
Locked (Tandem Axles)
Yellow
24
Yellow
24
Yellow
24
2. Active Warnings, Number
• the Symbol Color when it is illuminated
• whether the symbol is standard (Std) or optional (Opt)
• the Page Number reference for additional information
3. Active Warnings, Triangle
4. Alternator
Symbols are listed by major component sections.
Example: Engine, and then in alphabetical order.
8. Clock, Alarm Bell
9. Cruise Control, Active
– 20 –
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PART 4: CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
Warning Light / Indicator Symbols
Symbol Name
Symbol
Warning Light / Indicator Symbols
Color Std
Opt Page
10. Dump Truck, Body Up
Symbol
Color Std
Opt Page
19. Engine, Low Coolant Level
Yellow
24
Yellow
25
12. Emissions, Diesel Particulate Filter (DPF)
Yellow
25
13. Emissions, High Exhaust
System Temperture (HEST)
Yellow
25
14. Emissions, Malfunction Indicator Lamp
Yellow
26
Yellow
26
Red
27
Green
27
Red
27
Yellow
27
Red
27
Red
27
Blue
28
Green
28
20. Engine, Overspeed
11. Dump Truck, Trailer Body Up
15. Emission, Diesel Exhaust
Fluid Lamp
Symbol Name
21. Engine, Retarder (Brake)
22. Engine, Stop Engine
23. Engine, Wait To Start
24. Fifth Wheel, King Pin Lock
Yellow
26
25. Fifth Wheel, Slide Unlocked
16. Engine, Check Engine
Yellow
26
26. Lights, High Beam
17. Engine, Ether Start
Green
26
27. Message Waiting
18. Engine, Heater
Yellow
(R05/10)
26
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INSTRUMENTS AND CONTROLS
PART 4: CONTROLS AND DISPLAYS
Warning Light / Indicator Symbols
Symbol Name
Symbol
Warning Light / Indicator Symbols
Color Std
Opt Page
28. Park Brake
Symbol
Color Std
Opt Page
37. Transmission, Do Not Shift
Red
28
Green
28
Green
28
Green
28
Red
28
Yellow
28
Yellow
29
Yellow
29
Red
29
29. Power Take-off (PTO)
30. Power Take-off (PTO), Pump
Mode
Symbol Name
Red
29
Yellow
29
Yellow
29
Green
29
Green
29
38. Transmission, Oil Filter
31. Refrigerator
32. Seat Belt, Fasten
33. Suspension Dump
39. Transmission, Oil Temperature High
40. Turn Signal, Left
41. Turn Signal, Right
34. Tire Inflation
35. Transmission, Auxiliary
36. Transmission, Check
– 22 –
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PART 4: CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
4. Alternator
Warning Light/Indicator Symbol Descriptions
1. Active Warnings, Exclamation Point
Illuminates when a red warning is active. Use
the MCS knob to view the warnings that are
active. Refer to the preceeding Figure ,
“Warning Light / Indicator Symbols,” on
page 20 for warning color classification.
2. Active Warnings, Number
Illuminates the total number of red and yellow
active warnings. Use the MCS to view the
active warnings if the display shows a > symbol.
3. Active Warnings, Triangle
Illuminates when an yellow warning is active.
Use the MCS knob to view the warnings that
are active. Refer to the preceeding Figure ,
“Warning Light / Indicator Symbols,” on
page 20 for warning color classification.
(R05/10)
Y53-6032
Illuminates if the alternator is not charging.
(For alternators with warning lamp output
signal.)
5. Anti-Lock Brake System (ABS)
Illuminates during the Instrumentation System Self Test. Have the ABS system checked
by a Peterbilt dealer if the ABS Warning
Lamp stays on for more than 3 seconds.
Illuminates during normal operating conditions to indicate a problem with the ABS System. See “ABS Warning Lamps” on page 109
for more information.
Illuminates when a problem exists with the
optional Wheel Spin Control feature. See
“Advanced ABS with Stability Control” on
page 106 more information.
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INSTRUMENTS AND CONTROLS
PART 4: CONTROLS AND DISPLAYS
6. Anti-Lock Brake System (ABS), Trailer
Illuminates during the Instrumentation System Self Test and the tractor/truck is connected with a ABS equipped trailer.
Illuminates during normal operating conditions to indicate a problem with the Trailer
ABS System. This should be checked by a
Peterbilt dealer as soon as possible. See
“Truck/Tractor ABS Warning Lamp” on
page 109 for more information.
NOTE: Tractors/Trucks and trailers built after 3/1/
01 must be able to turn on an In-Cab Trailer ABS
Warning Lamp (per U.S. FMVSS121). The industry chose Power Line Communication (PLC) as
the standard method to turn it on. See “Trailer ABS
Warning Lamp” on page 110 for more information.
On trailers built prior to 3/1/01 verify trailer ABS
system status via the required external warning
lamp mounted on the trailer. The indicator lamp
on the trailer should be yellow and identified with
the letters "ABS".
7. Axle, Inter-Axle Differential Locked
(Tandem Axles)
Illuminates when the inter-axle differential
switch is ON thus locking the inter-axle differential. This powers the forward rear and the
rear rear differentials equally. When the
switch is turned off (inter-axle differential
unlocked) the engine power is allowed to flow
to any of the 4 drive tires based on the differential effect (mostly to the forward rear differential). (This feature is standard on all
tandem axles).
8.Clock, Alarm Bell
Illuminates when the alarm is set. It will flash
when the clock alarm is active.
9. Cruise Control, Active
Illuminates when cruise control is active.
10.Dump Truck, Body Up
Illuminates when Truck Dump Body is up.
– 24 –
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PART 4: CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
11.Dump Truck, Trailer Body Up
Illuminates when Trailer Dump Body is up.
12.Emissions, Diesel Particulate Filter
(DPF)
Illuminates when diesel particulate trap is
plugged. This warning will also illuminate
when regeneration operation is disabled.
NOTE: Refer to “Exhaust After-Treatment System” on page 126 for more information regarding this warning icon.
13.Emissions, High Exhaust System Temperture (HEST)
Illuminates when the exhaust gas temperature and exhaust components become
extremely hot.
Refer to “Exhaust After-Treatment System” on
page 126 for more information regarding this warning icon.
(R05/10)
Y53-6032
WARNING!Temperatures of the exhaust
pipes and at the outlets of the exhaust system during and shortly after a regeneration
event will be extremely hot. If the High
Exhaust System Temperature (HEST) warning lamp is on:
•Do not park in an area of combustible vapors
or materials. You must keep combustibles at
least five (5) feet away from the side and top
of the vehicle while the HEST light is illuminated. Always park your vehicle outside. Failure to do so could ignite an explosion or harm
bystanders which could result in death or
serious injury.
•Do not park in an area where people are
close by. You must keep bystanders at least
five (5) feet away from the exhaust outlet
while the HEST light is illuminated. Failure to
do so could result in death or serious injury.
•The exhaust piping, diesel particular filter
(DPF) or tail pipe become extremely hot during engine operation or any regeneration
event and can cause death or serious burns
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INSTRUMENTS AND CONTROLS
PART 4: CONTROLS AND DISPLAYS
to the skin. Allow adequate cooling time before
working on or near any part of the exhaust system.
14.Emissions, Malfunction Indicator Lamp
Illuminates when an engine emissions failure
has occurred. The vehicle can be safely
driven but should be serviced to correct the
problem. The situation should not be considered an emergency. In some cases, the Malfunction Indicator Lamp will activate in
conjunction with the High Exhaust Temperature, Diesel Particulate Filter (DPF) and Diesel Emission Fluid (DEF) Warning Lights.
15. Emission, Diesel Exhaust Fluid Lamp
Illuminates when the Diesel Exhaust Fluid
(DEF) tank level is low. The vehicle can be
safely driven but the DEF tank should be filled
at the next opportunity. The situation should
not be considered an emergency.
– 26 –
Y53-6032
16.Engine, Check Engine
Illuminates when a problem exists, but the
vehicle can still be safely driven. Vehicle
should be serviced to correct the problem
but the situation should not be considered
an emergency.
17.Engine, Ether Start
Illuminates when ether start switch is on.
18. Engine, Heater
Illuminates when Engine Heater switch is on.
19. Engine, Low Coolant Level
Illuminates with an audible alarm indicating
critically low coolant level. The vehicle must
be serviced to correct the problem but the situation should not be considered an emergency.
(R05/10)
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PART 4: CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
20. Engine, Overspeed
23. Engine, Wait To Start
Illuminates when engine RPM is exceeded.
Illuminates when engine grid heater is on
(Cummins ISB and ISC engines).
21. Engine, Retarder (Brake)
Illuminates when the engine retarder (compression brake or exhaust brake) switch is
turned on. (Engine retarders are an option.)
Illuminates when air actuated fifth wheel King
Pin is unlocked.
25. Fifth Wheel, Slide Unlocked
22. Engine, Stop Engine
Illuminates and an audible alarm tone will
sound when a major engine system problem
exists.
WARNING! This should be considered
an emergency. You should stop the vehicle as safely as possible and turn OFF
the ignition. The vehicle must be serviced and the problem corrected before
driving again. Failure to do so may cause
severe engine damage or cause an accident involving death or personal injury.
(R05/10)
24. Fifth Wheel, King Pin Lock
Y53-6032
Illuminates and an audible warning tone will
sound when the air operated sliding fifth
wheel switch is on, thus unlocking the sliding
fifth wheel. The light and an audible warning
tone should NOT be considered an emergency but simply as a reminder to turn off the
switch to lock the sliding fifth wheel before
driving. This switch should not be operated
while driving. (Sliding fifth wheels are an
option).
– 27 –
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INSTRUMENTS AND CONTROLS
PART 4: CONTROLS AND DISPLAYS
26. Lights, High Beam
29.Power Take-off (PTO)
Illuminates when the high beams are on.
This icon will flash with audible alarm if the
headlamps are left on when the door is open.
In addition, this icon will flash, but without an
audible alarm, if there is a problem with the
low beam headlights or the low beam headlight wiring. In such event, the high beam
headlights will turn on at 50% normal brightness.
Illuminates when the PTO is engaged.
NOTE: Do not drive vehicle with PTO
engaged.
30.Power Take-off (PTO), Pump Mode
Illuminates with remote throttle application.
Indicates pump mode is active.
31. Refrigerator
27. Message Waiting
Illuminates with telematic equipped messaging.
Illuminates to indicate that the refrigerator is
on and ignition is off.
32. Seat Belt, Fasten
28. Park Brake
Illuminates in the status indicator when parking brakes are applied and the vehicle is stationary. This symbol will also illuminate in the
Driver Information Display if the parking
brakes are applied and the vehicle is in
motion.
– 28 –
Y53-6032
Illuminates when the ignition key is turned on
as a reminder to fasten your seat belt.
33.Suspension Dump
Illuminates when suspension air bags are
deflated.
(R05/10)
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PART 4: CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
34. Tire Inflation
38. Transmission, Oil Filter
Illuminates when tire pressures need to be
checked. (Tire Pressure Monitoring System
is an option)
Illuminates when service is required (Allison
transmissions only).
39. Transmission, Oil Temperature High
35. Transmission, Auxiliary
Illuminates to indicate auxiliary transmission
is in neutral.
36. Transmission, Check
Illuminates when transmission has recorded
a fault code. This icon may also appear in the
Transmission Display menu of the Driver
Information Display unit (see item G; page
33). If the user is in this display menu, the
icon does not indicate a fault code.
37. Transmission, Do Not Shift
Illuminates with automatic transmissions
equipped with “Don’t Shift” output.
(R05/10)
Y53-6032
Illuminates when transmission lubricant temperature is too high.
CAUTION: This should be considered an
emergency. You should stop the vehicle as
safely as possible and turn OFF the ignition.
The vehicle must be serviced and the problem corrected before driving again. Failure to
do so may cause severe transmission damage.
40. Turn Signal, Left
Blinks when the left turn signal or the hazard
light function is operating.
41. Turn Signal, Right
Blinks when the right turn signal or the hazard light function is operating.
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DRIVER INFORMATION DISPLAY
PART 4: CONTROLS AND DISPLAYS
Driver Information Display
• MCS button is pushed (independent of ignition key
switch position)
• clock alarm sounds
• driver or passenger door is opened
• hazard warning lamp switch is on
WARNING! Do not look at the Driver Information Display for prolonged periods while the
vehicle is moving. Only glance at the monitor
briefly while driving. Failure to focus to the
vehicle’s road position could lead to an accident involving death, possible personal injury
or equipment damage.
The various functions may be accessed by navigating
through Menu Screens using the MCS. Refer to “Menu
Control Switch (MCS)” on page 17 for more detail for the
MCS.
The bullets in the Menu Bar allow access to each item by
pushing the MCS when the desired bullet is highlighted.
The Driver Information Display, located at the top of the
instrument cluster, displays important vehicle information
through a constant monitoring of systems when any of the
following conditions are met:
• ignition key in ON or ACC positions
• ignition timer is active
– 30 –
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PART 4: CONTROLS AND DISPLAYS
DRIVER INFORMATION DISPLAY
In addition to a blank screen, the following are menu items
and the information available within each menu selections.
B. RPM Detail (Accessible while parked or driving)
NOTE: Some Driver Information Display functions are
only accessible when the vehicle is parked. Other
functions are accessible while the vehicle is moving
or when parked. Each function is identified in the following descriptions.
RPM reading of actual engine RPM. Engine RPM
within the bar graph indicates the engine is operating in the most efficient RPM range. The display
color will change if you are operating outside of this
range.
C. Ignition Timer (Accessible while parked only)
A. Fuel Economy (Accessible while parked or
driving)
1. Current fuel economy - Indicates instantaneous
fuel economy.
2. Trip fuel economy - Indicates trip fuel economy.
Ignition timer is set from this menu. The ignition
timer may be set for up to 30 minutes.
(R05/10)
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DRIVER INFORMATION DISPLAY
PART 4: CONTROLS AND DISPLAYS
D. Trip Information
– PTO Hours
NOTE: When accessing the trip information
menu, push the MCS on this menu (bullet).
To exit, push the MCS again. To reset the trip
values, press the Trip Odometer Reset Button on the main gauge instrument cluster.
– PTO Trip Hours
– PTO Trip Percentage (%)
To reset the Trip Values, press the Trip Odometer
Reset Button on the main gauge instrument cluster.
E. Truck Information (Accessible only while parked)
NOTE: When accessing the truck information menu, push the MCS on this menu (bullet). To exit, push the MCS again.
Certain Trip Information functions area accessible
when driving or when parked:
– Trip Economy
– Trip Average Speed
1. Chassis Number
Other Trip Information functions are accessible only
when parked:
– Trip Distance
3. Engine Model
4. Engine SW Version
– Trip Engine Hours
5. Transmission Make
– Trip Idle Hours
6. Transmission Model
– Trip Idle Percentage (%)
– 32 –
2. Engine Make
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PART 4: CONTROLS AND DISPLAYS
DRIVER INFORMATION DISPLAY
Found" or "Faults Found". If "Faults Found" is active,
pushing the MCS will display new menus for more
information.
G. Transmission Display (Automated Transmissions
only - Accessible while parked or driving)
7. Transmission SW Version
8. ABS (Antilock Braking System) Make
9. ABS Model
10. ABS SW Version
11. CECU (Cab Electronic Control Unit) Software
Version
NOTE: Refer to the Automated Transmission
Operator’s Manual for additional information.
12. CECU Hardware Version
F. Diagnostic Display (Accessible only while parked)
NOTE: “Faults Found” will only be active if a
red or yellow warning lamp is illuminated.
The diagnostic display menu (bullet) will indicate a
fault that is generated by the vehicle's Engine, ABS
and/or Transmission systems. While on this menu
item the display will either indicate "No Faults
(R05/10)
Y53-6032
This menu will show gear number that coincides with
the current transmission gear selected. The menu
also displays the transmission icon to let the user
know what screen they are in. (Does not indicate a
fault code.)
H. Settings Menu (Accessible only while parked)
The Settings menu screen allows the driver to view
and/or change the following menu items:
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DRIVER INFORMATION DISPLAY
PART 4: CONTROLS AND DISPLAYS
• Display Format 12 Hour (AM/PM) or 24 Hour
(military)
• Home/Local Time
• Alarm ON/OFF
• Alarm Time
To Set Home, Local or Alarm Time:
• Units of measure
1. When in the Settings Menu, scroll through the
list of menu items. Press the MCS to select the
item to change.
• Language (English, Spanish or French)
2.
To Set Clock Display Format:
1. When in the Settings Menu, scroll through the
list of menu items to "Format".
3. Rotate the MCS knob to change the hour. Press
the MCS.
2. Press the MCS to display either 12 hour (AM/
PM) or 24 hour (military) time.
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PART 4: CONTROLS AND DISPLAYS
STEERING COLUMN-MOUNTED CONTROLS
To Set Language:
1. When in the Settings Menu, scroll through the
list of menu items to "Language". Press the
MCS.
4. Rotate the MCS knob to change the minutes.
Press the MCS.
5. Rotate the MCS to toggle AM/PM. Press the
MCS
2. Rotate the MCS to display either English, Spanish or French. Press the MCS knob to select the
desired language.
Steering Column-Mounted Controls
Turn Signal and Indicator Lights
NOTE: The ignition key must be turned to ON for
the signal/switch to operate.
6. Rotate the MCS to select Exit. Press the MCS to
exit the settings function.
To Turn Alarm ON/OFF:
1. When in the Settings Menu, scroll through the
list of menu items to "Alarm". Press the MCS.
2. Press the MCS to turn the alarm ON or OFF.
To Set Units of Measure:
Your turn signal lever is mounted on the left side of the steering column below the steering wheel. Green directional indicator lights appear on the instrument panel. To operate the
signal, move the lever in the direction of the turn. Each time
the turn indicator is activated the audbile alarm emits a short
beep.
1. When in the Settings Menu, scroll through the
list of menu items to "Units". Press the MCS.
2. Press the MCS to display either Standard or
Metric units.
(R05/10)
Y53-6032
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Y53-6032.book Page 36 Monday, May 24, 2010 3:37 PM
STEERING COLUMN-MOUNTED CONTROLS
PART 4: CONTROLS AND DISPLAYS
Headlamp Flash
To activate headlamp flash, gently push the turn signal
lever away from the steering wheel until you hear and feel
the switch click. Release lever to deactivate.
• If your headlamps are off, low beams will flash on.
• If your headlamps are on, they will dim. Maximum
duration of dimming is 3 seconds. When the function
ends, your headlamps will return to low beams.
ID And Clearance Lights Flash
To flash, press the button on the end of the turn signal
lever and hold. To cancel the flash, release the button.
High Beam Headlamps
NOTE: The headlamps must be “ON” for the high
beam switch to operate.
Press In For Washer Pump
Rotate To Change Wiper Mode
To switch your headlamps to lower or higher beam, gently
pull the turn signal lever towards the steering wheel, until
you hear the switch click and the beam changes. The blue
indicator light in the instrument panel will be ON when the
high beam is being used.
To return to previous beam: pull the lever towards the
steering wheel again.
– 36 –
Press Button For ID and Clearance Lights Flash
If your ID and clearance lights are on, they will flash off.
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PART 4: CONTROLS AND DISPLAYS
STEERING COLUMN-MOUNTED CONTROLS
Windshield Wipers/Washer
Wiper Switch Settings
Your vehicle is equipped with a two-speed, intermittent
windshield wiper system. A seven-position rotary wiper
switch (located on the turn signal lever) operates the windshield wipers and washer (see next illustration). Rotate
the end of the turn signal lever to change the wiper mode.
NOTE: The ignition key must be turned to ON or
ACC for the wiper/washer switches to operate.
The first position after OFF is the intermittent #1 cycle.
The next positions are intermittent #2, #3, and #4. The last
two positions are wiper low speed and wiper high speed.
See the wiper switch settings table that follows for intermittent delay times.
Wiper Switch Position
Wiper Speed
Off
Off
Intermittent #1
20 Second Delay
Intermittent #2
17 Second Delay
Intermittent #3
7 Second Delay
Intermittent #4
4 Second Delay
Low
Low Speed
High
High Speed
To Wash The Windshield
Push the rotary wash/wipe knob in (towards steering column), hold for more than 0.8 seconds and then release.
Hold the knob in to extend the washing cycle. After the
(R05/10)
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STEERING COLUMN-MOUNTED CONTROLS
PART 4: CONTROLS AND DISPLAYS
lever is released, the wipers will shut off automatically or
resume the wiper’s setting speed.
Check the windshield washing fluid level daily. If necessary, fill to top.
To activate the wipers for one swipe without activating the
washer (“mist” function), push the turn signal lever in
(towards the steering column) and release in less than 0.5
seconds. The wipers will perform a single swipe and then
resume the wiper’s setting speed.
Clean all inside and outside windows regularly. Use an
alcohol-based cleaning solution and wipe dry with either a
lint-free or a chamois cloth. Avoid running the wiper
blades over a dry windshield to prevent scratching the
glass. Spray on washer fluid first. A scratched windshield
will reduce visibility.
WARNING! Clean blades regularly with a
damp cloth to remove road film and wax buildup. Do not drive with worn or dirty wiper
blades. They can reduce visibility, making
driving hazardous which may lead to an injury
accident resulting in death or personal injury.
CAUTION:
• Do not use antifreeze or engine coolant in
the windshield washer reservoir—damage to
seals and other components will result.
• If the electric pump is operated for a long
period (more than 15 seconds) with a dry reservoir, the pump motor may be damaged.
– 38 –
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PART 4: CONTROLS AND DISPLAYS
STEERING COLUMN-MOUNTED CONTROLS
Hazard Flasher
WARNING! Use your Hazard Flasher Warning
System any time you have to stop the vehicle
on or off the road, day or night. A hard-to-see
vehicle can result in an accident causing
death or personal injury. Another vehicle
could run into you if you do not set your flashers and follow the placement of emergency
signals per FMCSR 392.22. Always move the
vehicle a safe distance off the road when
stalled or stopped for repairs. A disabled vehicle can be dangerous for you and others.
Of course, in normal stopping in traffic, such as at a stop
light, you do not use your flashers.
The four-way Hazard Flasher switch is on the turn signal
body, just underneath the turn signal lever. It will operate
with the key switch in the ON or OFF position. Use your
hazard flasher whenever you are off the road or on the
side of the road, or in a potentially hazardous situation.
Pull it out to activate the system. All turn signals will flash
at once. To turn it off, move the turn signal lever up or
down.
(R05/10)
Y53-6032
WARNING! Your disabled vehicle can be dangerous for you and others. The hot exhaust
system could ignite dry grass, spilled fuel, or
other substances. Do not park or operate your
vehicle where the exhaust system could contact dry grass, brush, spilled fuel, or any other
material that could cause a fire resulting in
death or personal injury.
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STEERING COLUMN-MOUNTED CONTROLS
PART 4: CONTROLS AND DISPLAYS
Electric Horn
Trailer Brake Hand Valve
Your Peterbilt has an electric horn. To sound the horn,
press on the bar in the center of the steering wheel
Electric Horn Bar
02975A
Air Horn
Your vehicle has an air horn in addition to an electric horn.
Control the air horn by pulling on the lanyard extending
from the overhead header panel.
This hand valve provides air pressure to apply the trailer
brakes only. It operates independently of the foot treadle
valve.
NOTE: The trailer brake is not to be used as the
main means of braking. To use this brake frequently instead of using the foot brake will wear
out the trailer brake sooner.
To operate the trailer brake hand valve: pull down on
the lever under the right side of the steering wheel.
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PART 4: CONTROLS AND DISPLAYS
TILT-TELESCOPING STEERING COLUMN
See the Index, under Brake Safety and Emergency for
more complete information on when and how to use your
trailer brake
The telescoping feature of the steering wheel allows forward and rearward movement of the wheel. The tilting feature allows you to move the wheel up and down.
WARNING! It is dangerous to use air-applied
trailer brakes for parking or holding a vehicle.
Air system pressure can bleed down and
release the brakes. You could have a vehicle
roll-away resulting in an accident involving
death or personal injury. Always apply the
parking brakes for parking or holding your
vehicle on grade.
WARNING! Make all adjustments to the steering mechanism while the vehicle is stopped.
Adjusting the Tilt-Telescoping Steering Wheel
while the vehicle is in motion could cause
loss of control. You wouldn’t be able to steer
properly and could have an accident resulting
in death or personal injury.
Tilt-Telescoping Steering Column
To position the wheel: Locate the Tilt-Telescope Lever
on the floor, to the left of the steering column. Push this
lever toward the floor. Move the steering wheel to the
desired angle and height. Release the lever to lock in the
correct position.
Dash-Mounted Features
Keys and Locks
The same key fits your ignition, doors, and sleeper luggage compartment. Frame-mounted tool box locks, locking fuel tank caps, and glove boxes each have individual
keys.
Tilt-Telescope Lever
(R05/10)
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DASH-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
Ignition Switch
Headlamps
The headlamps are controlled by the control panel switch
showing the next symbol. When the headlights are ON,
the dash lights, side, and tail lamps are also on.
02977B
Your ignition switch has four positions:
• ACC (Accessory): With your key in this position you
can play the radio or use other accessories, but your
engine won’t start.
WARNING! Do not use daytime running lights
(DRL) during periods of darkness or reduced
visibility. Do not use DRL as a substitute for
headlamps or other lights during operations
that require lighting of your vehicle. Doing so
could lead to an accident involving death or
personal injury.
• OFF: In this position all systems are off, and you can
remove your key.
• IGN & ACC: This position allows you to turn on the
engine and all accessory power.
• START: Starter activation to start engine.
– 42 –
On vehicles equipped with daytime running lights (DRL), the
high-beam headlamps go on automatically at reduced
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PART 4: CONTROLS AND DISPLAYS
DASH-MOUNTED FEATURES
brightness if the engine is running and the headlamp switch
is turned off. The daytime running lights are turned off automatically while the parking brake is engaged. If the headlamp switch is turned on, the DRL system is overridden &
headlamps operate normally
Panel Light Knob
ID and Clearance Lights Switches
These are the amber lights on top of your cab, the lights on
the front and sides of the trailer and the red lights on the
rear of a truck or trailer. They may be turned on and off by
the switch located on the lower left control panel labeled
CL LPS and showing the symbol below.
The Panel Light Knob lets you vary the brightness of your
instrument panel lights.
To Operate Your Panel Light Knob:
02892
1. Turn on either the headlights or clearance lights.
2. To brighten the instrument lights, rotate the thumbwheel up.
3. To dim the instrument lights, rotate the thumbwheel
down.
(R05/10)
When your clearance lights are turned on, you may blink
or flash them by operating the flash switch located on the
right side of the dash showing the symbol below. Press
and release this rocker switch to flash your clearance
lights.
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PART 4: CONTROLS AND DISPLAYS
NOTE: State requirements vary as to when high
beams and fog lights can and cannot be used
together. Further, some states allow only four
lights to be used together; some allow more.
Whether you have dual or composite lights will
affect how many lights you can have on at one
time. Always comply with the state requirements
where you are driving.
Dome Light Switch
03912-1
I
Fog/ Driving Lights Switch
O
02894A
03021
If your vehicle has fog/driving lights, turn them ON or OFF
with the control panel switch shown above.
– 44 –
A momentary switch controls the main dome light:
• OFF (O) Position: Light is off.
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PART 4: CONTROLS AND DISPLAYS
DASH-MOUNTED FEATURES
will notice a guard over the switch. This prevents you from
accidentally deflating the suspension.
• ON (I) Position:
– Press once: Light will turn on at high intensity.
– Press again: Light will shift to low intensity.
– Press a third time: Light will turn off.
Air Suspension Deflate Switch (Dump Valve)
WARNING! Operating the Air Suspension
Deflate Switch (Dump Valve) while driving can
lead to an accident causing death or personal
injury. Sudden deflation while your vehicle is
moving can affect handling and control. 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.
03035
This vehicle may have an air suspension deflation switch
that allows the air in the suspension to be exhausted from
a switch on the dash. The purpose of this feature is to
allow you to lower your tractor to get under a trailer. You
(R05/10)
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DASH-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
Engine Fan Switch
WARNING! Do not work on the fan with the
engine running. Anyone near the engine fan
when it turns on could be killed or seriously
injured. If it is set at ON, it will turn on any
time the ignition key switch is turned to the
ON position. In AUTOMATIC, it could engage
suddenly without warning. Before turning on
the ignition or switching from AUTOMATIC to
ON, be sure no one is near the fan.
I
CAUTION: The fan or equipment near it could be
damaged if the fan turns on suddenly when you
don’t expect it. Keep all tools and equipment
such as rags away from the fan, and take care no
one turns on the ignition when someone is
working near the fan.
0
03023
The engine fan switch allows you to control the engine fan
manually or automatically. With the ignition key switch ON
and the fan switch in the ON position, the engine fan will
be on regardless of engine temperature. With the engine
fan switch in the AUTOMATIC position, the engine fan will
automatically turn on when the engine coolant reaches a
temperature of about 200°F.
– 46 –
Y53-6032
CAUTION: Do not operate the engine fan in the
manual (ON) 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.
(R05/10)
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PART 4: CONTROLS AND DISPLAYS
DASH-MOUNTED FEATURES
Mirror Heat Switch
Power Mirror Switch
I
The power mirror control controls the adjustment of the
right or left outside mirrors, depending on the option
selected. It is located in the driver side armrest.
O
03022
Mirror heat is controlled by the control panel switch shown
above. If the vehicle is equipped with this switch, mirror
heat can be switched on to help remove frost and ice from
the mirror glass.
(R05/10)
Y53-6032
NOTE: The Power Mirror Switch does not control
the adjustment of the convex mirrors.
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DASH-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
WARNING! Convex mirrors can distort images
and make objects appear smaller and farther
away than they really are. You could have an
accident resulting in death or personal injury 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.
or RESET the desired speed after the cruise control has
been interrupted.
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 accident causing death or personal
injury.
Cruise Control Switch
NOTE: Cruise control functions and features may
vary depending upon which engine you have. For
specific explanation of your cruise control, see
the cruise control or engine manual included with
your vehicle.
The master switch turns the cruise control ON or OFF.
The second switch allows you to SET the desired speed
– 48 –
This vehilcle’s electronic system will perform a ‘rationality
check’ every time the vehicle is started. This check is to
ensure that the service brakes are working before allowing cruise control to function. This safety feature is
designed to ensure that a driver is able to cancel the
cruise set speed by using the service brake pedal. The
system will not allow cruise control operation if it does not
pass the ‘rationality check’. The Driver Information Display
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PART 4: CONTROLS AND DISPLAYS
DASH-MOUNTED FEATURES
will prompt you to press the service brake pedal if it has
not been pressed since the vehicle has been started.
When an engine brake is energized, the power-producing
diesel engine is converted into a power-absorbing air
compressor to retard the vehicle.
• The brake is energized whenever the driver’s foot is
completely removed from the accelerator pedal.
• The brake is deenergized during driving by pressure
on the accelerator pedal, and during shifting by
depressing the clutch pedal.
The ON/OFF toggle switch turns the system ON or OFF.
Engine Brake
• In PACCAR, Caterpillar- and Cummins-powered vehicles equipped with a Jacobs Engine Brake, a second
two- or three-mode switch is incorporated in the
instrument panel. With this system, you can select
either LOW or HIGH or LOW/MEDIUM/HIGH retarding.
For more information on when and how to use the engine
brake in your vehicle, see the Engine owner’s manual for
the engine brake.
(R05/10)
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DASH-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
WARNING! Using the engine brake when
operating on surfaces with poor traction
(such as wet or icy, slippery roads or gravel)
could cause an accident involving death or
personal injury.
Interaxle Differential Lock Switch
Two-Speed Rear Axle (Range) Switch
SHIFT AT ANY SPEED EXCEPT
IF A WHEEL IS SPINNING
2
03029
03030
If your vehicle is equipped with a two-speed rear axle, you
can select the axle range by the dash mounted switch
shown above.
• The low range provides maximum torque for operating
off-highway.
The interaxle differential allows differential action between
the forward rear and the rear rear driving axles. The interaxle differential lock switch allows the operator to LOCK or
UNLOCK the differential. The guard over this switch prevents you from accidentally activating the lock. See “Interaxle Differential” on page 101 for more information on
using your interaxle differential.
• The high range is a faster ratio for highway speeds.
For information on how to operate your two-speed rear
axle properly and safely, see “PART 7: STARTING &
OPERATING THE VEHICLE”.
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DASH-MOUNTED FEATURES
WARNING! Do not engage the differential lock
if the vehicle is moving or if the tires are slipping. Otherwise, the vehicle may move in an
unexpected direction, and could cause an
accident involving death or personal injury.
This may also lead to equipment damage.
Bring the vehicle to a complete stop and
ensure that all wheels are not spinning before
engaging the differential lock switch.
START
Depressing the button in the START direction for 4 to 8
seconds will initiate a parked regeneration. Be sure to
release the button to ensure that the system will begin
the regerenation cycle.
CENTER (three position switch only)
Center is the normal position of the switch.
The center position will allow an automatic regeneration to occur.
Regeneration Switch
In order to meet EPA engine emission requirements, vehicles will have a either a two or three position switch to help
control and maintain the exhaust Diesel Particulate Filter.
Please refer to “Exhaust After-Treatment System” on
page 126 for more information about the emission control
system and how it affects normal operating procedures.
Two Position
(R05/10)
STOP (three position switch only)
When STOP is pressed the system will not regenerate
under any conditions.
CAUTION: Do not leave the three position switch
in the STOP position unless you need to cancel
or stop regeneration. Leaving the switch in the
STOP position for extended periods of time will
result in increased soot levels in the DPF.
Three Position
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DASH-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
Fifth Wheel Lock (Slider Adjustment) Switch
03031
Vehicles having an air slide fifth wheel have a fifth wheel
slider lock controlled by a switch on the instrument panel.
By placing the switch in the unlock position, you can slide
the fifth wheel to various positions to adjust weight distribution. There is a guard over this switch to protect you
against accidentally activating or releasing the lock.
– 52 –
Y53-6032
WARNING! Do not move the fifth wheel while
the tractor-trailer is in motion. Movement of
the fifth wheel while a tractor-trailer is moving
can cause a serious accident involving death
or personal injury. Your load could shift suddenly, causing you to lose control of the vehicle. Never operate the vehicle with the switch
in the unlock position. Always inspect the fifth
wheel after you lock the switch to be sure the
fifth wheel is engaged.
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.
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PART 4: CONTROLS AND DISPLAYS
DASH-MOUNTED FEATURES
Parking Brake Valve and Trailer Air Supply
Valve
Your parking brake valve is a yellow diamond-shaped
knob located below the right instrument panel. It controls
the parking brakes.
To apply all parking brakes, pull the yellow, or parking
brake, knob out. The truck or tractor parking brakes will
set, and the Trailer Air Supply Valve (red octagon knob)
will automatically trip (“pop out”) and set the trailer parking
brakes. To release both truck/tractor and trailer parking
brakes, push in BOTH yellow and red knobs. For full information on using parking brakes, see section titled “Parking Brakes and Their Use” on page 118 for more
information.
(R05/10)
Y53-6032
WARNING!
• Do not leave the cab without applying the
parking brake. The truck could roll and cause
an accident involving death or personal injury.
Always apply the parking brake before you
leave the cab
• 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 possibly resulting in an
accident involving death or personal injury
• 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.
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DASH-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
WARNING! Before operating your vehicle after
it has been parked, do not forget to push in
the parking brake valve to release the parking
brakes. Failure to release your parking brakes
before putting the vehicle into motion can
cause fire or loss of control of the vehicle,
which can result in death or personal injury.
Heater-Air Conditioning Controls
Your heat and air conditioning controls are mounted in the
right hand instrument panel. Additionally, the sleeper compartment may also contain a separate heating and cooling
system with separate controls.
WARNING! Exhaust fumes from the engine
contain carbon monoxide, a colorless and
odorless gas. Do not breathe the engine
exhaust gas. A poorly maintained, damaged
or corroded exhaust system can allow carbon
monoxide to enter the cab. Entry of carbon
monoxide into the cab is also possible from
other vehicles nearby. Failure to properly
maintain your vehicle could cause carbon
monoxide to enter the cab/sleeper and cause
death or serious illness.
– 54 –
Y53-6032
WARNING! ever idle your vehicle for prolonged periods of time if you sense that
exhaust fumes are entering the cab or sleeper.
Investigate the cause of the fumes and correct
it as soon as possible. If the vehicle must be
driven under these conditions, drive only with
the windows open. Failure to repair the
source of the exhaust fumes may lead to
death, injury or personal harm.
NOTES:Keep the engine exhaust system and the
vehicle’s 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
•when a change is noticed in the sound of the
exhaust system
•if the exhaust system, underbody, or cab is damaged
NOTE: To allow for proper operation of the vehicle
ventilation system, keep the inlet grille at the base
of the windshield clear of snow, ice, leaves and
other obstructions at all times.
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PART 4: CONTROLS AND DISPLAYS
DASH-MOUNTED FEATURES
NOTE: Do not stay in the vehicle with the engine
running or idling for more than 10 minutes with
the vehicle’s Heater / AC ventilation system in
RECIRC or at LOW FAN SPEED. Even with the
ventilation system On, running the engine while
parked or stopped for prolonged periods of time is
not recommended.
NOTE: If you are required to idle your vehicle for
long periods of time, install an auxiliary heater or
automatic idle control. These auxiliary devices
can reduce fuel consumption and save you
money.
To Set the Heater-Air Conditioning Controls
The cab’s control panel may have up to six controls (see
illustration below):
• A rotary knob (A) in the upper left portion controlling
the blower speed with four settings.
• A rotary knob (B) in the upper center portion controlling the movement of air within the cab. This control is
continuously variable through five modes (clockwise
from left):
– Panel
NOTES:When idling for short periods of time
– Panel/Floor
•Set the heating or cooling system to Heat or
A/C
– Floor
– Defrost/Floor
•Set the fan to Medium or High speed
– Defrost
•Set the controls to FRESH AIR
NOTE: If other vehicles are parked next to you
idling, move your vehicle or do not stay in your
vehicle for prolonged periods of time.
(R05/10)
• A rotary knob (C) in the upper right portion controlling
the air temperature.
• A rocker switch (D) in the lower left portion to engage
the air conditioner compressor.
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DASH-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
• A rocker switch (E) on the lower center portion to send
power to the “bunk” or sleeper control panel.
• A rotary knob in the right portion controlling the air
temperature.
• A rocker switch (F) in the lower right portion to select
either fresh or recirculated air mode.
B
A
02981B
C
1
2
3
4
1
2
3
4
The cab “bunk” control rocker switch must be ON for the
sleeper controls to function.
D
E
F
• To heat the cab, select the desired air mode and set
the temperature knob to hot (the red position on the
control) and the blower to whatever speed makes you
most comfortable.
02980B
The sleeper control panel will have two controls (see next
illustration):
• A rotary knob in the left portion controlling the blower
speed with four settings.
– 56 –
Y53-6032
WARNING! Do not drive with visibility reduced
by fog, condensation, or frost on the windshield. Your view may be obscured, which
could result in an accident involving causing
death or personal injury. For clear visibility
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PART 4: CONTROLS AND DISPLAYS
DASH-MOUNTED FEATURES
and safe driving, it is extremely important for
you to follow the instructions pertaining to
the function and use of the ventilation/heating
and defogging/defrosting system. If in doubt,
consult your dealer. Maximum heating output
and fast defrosting can be obtained only after
the engine has reached operating temperature.
• To cool the cab, turn on the A/C switch, set the temperature knob to cool (the blue position on the control), and the blower to high until the cab becomes
cool. Then you can turn down the blower if you wish.
For Efficient Cooling:
1. Be sure all heater - air conditioner controls are off.
2. Start the engine. Allow time for warm-up.
CAUTION: During extreme cold weather, do not
blow hot defroster air onto cold windshields.
This could crack the glass. Turn the air flow control lever to Defrost and adjust the fan speed
accordingly while the engine warms. If the
engine is already warm, move the temperature
selector to Cool, then gradually increase the
temperature when you see that the windshield is
starting to warm up.
• To defog the windshield, select the Defrost mode
and turn the blower speed to high. Set the temperature knob to hot (the red position on the control). The
air conditioner is automatically activated to remove
moisture from the cab. After the windshield is clear,
adjust the mode, blower speed, and temperature to
your comfort.
(R05/10)
CAUTION:
• A cold compressor can cause refrigerant to
liquefy and warp the valve plates or cause a
hydraulic lock. Warm the engine before starting the air conditioner.
3.
4.
5.
6.
Y53-6032
• Turn off all controls when the system is not
in use. Doing so will avoid damage to the air
conditioning system components.
Set the air control in the RECIRC mode.
Close all windows.
Idle the engine between 1000 and 1500 RPM and
turn the blower speed control to high.
After the cab temperature cools to a comfortable level,
adjust the blower speed and controls to keep the
desired condition.
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DASH-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
NOTE: When the air conditioner isn’t in regular
use, operate it for at least 15 minutes at least
once a month or every 5,000 miles(8,000 Km),
whichever comes first. This will lubricate the seals
in the air conditioning system. The air conditioning system is active when the Defrost mode is
selected.
tion. If this fuse needs replacement, check to ensure that
the lighter is not stuck before replacing the fuse.
WARNING! Do not exceed the voltage/amperage capacity of the cigarette lighter. It could
result in a fire causing death or personal
injury. Follow all warnings and instructions in
the operator's manual for the appliance you
are using.
Cigarette Lighter
The lighter receptacle may be used to power auxiliary
equipment that does not draw more than 10 amperes
maximum.
Ashtray
02912
Lighter
To operate your lighter, push the knob in. After a few
moments the lighter will automatically pop out, ready to
use. After use, insert the knob, but don’t push it in. The
lighter circuit is protected by a 10-ampere polyswitch to
prevent damage should the lighter get stuck in the IN posi-
– 58 –
Y53-6032
WARNING! Paper or other combustible substances in an ashtray could cause a fire
resulting in death or personal injury. Keep all
burnable materials besides smoking materials
out of the ashtray.
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PART 4: CONTROLS AND DISPLAYS
GAUGES
Glove Compartment
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
killed or injured. To reduce the risk of death or
personal injury during an accident or sudden
stop, keep the glove compartment closed
when the vehicle is in motion.
Gauges
To open your glove compartment, pull the latch. To close
it, push the cover up and press to latch it.
On the pages that follow you will find descriptions of some
of the gauges on your instrument panel. For more information about using them in driving, see “PART 7: STARTING & OPERATING THE VEHICLE”. Also check the Index
under the name of the gauge or function you want to know
more about.
The glove compartment can be locked. Turn your glove
box key clockwise (right) to lock and counterclockwise
(left) to unlock.
(R05/10)
Y53-6032
WARNING! Do not ignore a warning light or
audbile alarm. These signals tell you something is wrong with your vehicle. It could be a
failure in an important system, such as the
brakes, which could lead to an accident
involving death or personal injury. Have the
appropriate system checked immediately.
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GAUGES
PART 4: CONTROLS AND DISPLAYS
NOTE: All of the warning lights and alarms for
functions monitored by the multiplex instrumentation system instrument system are contained
within the individual gauges of the system. The
alarms for other controls or systems that you may
have will be displayed separately on the instrument panel. They are described further in “PART
7: STARTING & OPERATING THE VEHICLE” of
this manual.
ometer also includes an odometer, trip meter, and trip
reset button.
Trip Reset
Button
Speedometer
Odometer / Trip Meter
Odometer
Trip
Meter
The LCD display in the lower part of the speedometer
contains the odometer and trip meter.
11243
The speedometer indicates the vehicle speed in miles per
hour (mph) and in kilometers per hour (km/h). The speed– 60 –
The odometer displays the total distance your vehicle has
traveled. It will display in miles on an English speedometer
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PART 4: CONTROLS AND DISPLAYS
GAUGES
or in kilometers on a metric speedometer. The maximum
distance that can be shown on the odometer is
“1 999 999” before it rolls over to zero.
Tachometer
The trip odometer displays how far the vehicle has gone
on a particular trip. The trip odometer will display in miles
on an English speedometer or in kilometers on a metric
speedometer, in one tenth divisions. The maximum distance that can be shown on the trip odometer is “9999.9”
before it rolls over to zero.
To reset the trip odometer, press and hold the trip reset
button on the speedometer. The numbers will reset to 0
and begin to count new miles/km traveled. This also
resets the trip values in the Driver Information Display.
The trip reset button also toggles all displays between
English and Metric. (See page 62.)
NOTE: The Odometer/Trip Meter comes on when
the door is opened or the key is in the accessory
or ignition position. The Odometer/Trip Meter will
remain on for 3 seconds after the door is closed
or the ignition switch is turned off. This allows
driver and service personnel to read the odometer without ignition switch being turned on.
(R05/10)
11244
Your tachometer measures the engine speed in revolutions-per-minute (RPM). The tachometer also includes an
engine hour meter and outside air temperature display.
Watching your tachometer is important to driving efficiently. It will let you match driving speed and gear selection to the operating range of your engine. If your engine
speed gets too high, you can select a higher gear to lower
the RPM. If your engine speed drops too low, you can
select a lower gear to raise the RPM.
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GAUGES
PART 4: CONTROLS AND DISPLAYS
Engine Hours / Outside Air Temperature
Hour Meter
Snowflake
Symbol
Outside
Air
Temperature
The temperature can display using Standard or Metric
units. Press the trip reset button on the Speedometer 4
times within 4 seconds. This will also change the units
shown by the Driver Information Display.
Refer to “To Set Units of Measure:” on page 35 for another
method to change units.
The LCD display in the lower part of the tachometer contains the engine hour meter and the outside air temperature display.
The engine hour meter will display the total number of
hours the engine has been running. The maximum hours
that can be shown are “99999.9” before the meter rolls
over to zero.
The outside air temperature (OAT) will display the temperature outside the vehicle. The temperature can be displayed from -40° to 158° in Fahrenheit or -40° to 70°
Celsius.The display will also alert the driver when the outside temperate approaches freezing (32°F or 0°C) by displaying a snowflake symbol. The symbol will turn on when
the temperature drops below 34°F or 11°C and flash for
the first 3 seconds, then stay on until the temperature
goes above 37°F or 28°C.
– 62 –
Y53-6032
NOTE: The OAT will come on when the door is
open and the key switch is in the accessory or
ignition position. The OAT display will turn off
when the ignition switch is turned off.
NOTE: The OAT uses a sensor (located at the
bottom of the driver’s side mirror assembly) to
measure outside air temperature only. It is not
capable of displaying the temperature of the road
surface on either the temperature display or the
snowflake icon.
NOTE: The effects of direct sunlight, or the use of
mirror heat, will increase the outside air temperature displayed while the vehicle is stationary.
(R05/10)
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PART 4: CONTROLS AND DISPLAYS
GAUGES
Air Application Gauge
Ensure the air pressure registers more than 100 psi in
both service systems before you move the vehicle. If the
pressure in either circuit is too low for normal brake operation, the warning light will glow and the audible alarm will
sound.
This gauge will show you how much air pressure is being
applied from your foot brake valve or trailer brake hand
valve.
Primary (Secondary) Air Pressure Gauge
(Air Reservoir)
The air pressure gauge indicates the amount of air pressure in the brake system in pounds per square inch (psi).
• The primary gauge shows front reservoir air pressure.
• The secondary gauge shows pressure in the rear reservoir.
(R05/10)
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GAUGES
PART 4: CONTROLS AND DISPLAYS
Engine Oil Pressure Gauge
WARNING! The air pressure warning light and
the audible alarm indicate a dangerous situation. There is not enough air pressure in the
reservoirs for repeated braking and the brake
system has failed. If air pressure falls below
60 psi (414 kPa) the spring brakes could suddenly apply, causing a wheel lockup, loss of
control, or your vehicle to be overtaken by following vehicles. You could be in an accident
and severely injured or killed. If these alarms
come on while you are driving, bring your
vehicle to a safe stop right away. If the light
and alarm do not turn off at start-up, do not
try to drive the vehicle until the problem is
found and fixed.
– 64 –
It is important to maintain oil pressure within acceptable
limits. Your engine manual will give you normal operating
pressures for your particular engine.
CAUTION: Continuing to operate your vehicle
with in-sufficient oil pressure will cause serious
engine damage.
• If your oil pressure fails to rise within 10 seconds after
your engine starts, stop the engine and determine the
cause.
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PART 4: CONTROLS AND DISPLAYS
GAUGES
• If your oil pressure suddenly drops while you are driving, bring the vehicle to a stop as soon as possible in
a safe location off the road and turn off the engine.
Wait a few minutes to allow oil to drain into the oil pan,
and then check the oil level. Add oil if necessary. If the
problem persists, contact an authorized service center.
the maximum allowable temperature is 210°F (99°C) with
the cooling system pressurized, except for certain special
engines. Check your engine manual to be sure.
Engine Overheating
WARNING! Do not remove the radiator fill cap
while the engine is hot. Scalding steam and
fluid under pressure may escape and cause
death or personal injuries.
Water Temperature Gauge
• Wait until the coolant temperature is below
122°F (50°C).
• Protect face, hands, and arms by covering
the cap with a large, thick rag to protect
against escaping fluid and steam.
• Carefully and slowly turn the cap one-quarter of a turn or until it reaches the first stop
(allowing excess pressure to escape) push
down and turn for final removal.
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. But
(R05/10)
Wait until the coolant temperature is below 122° F (50° C).
Protect your face, hands, and arms by covering the cap
with a large, thick rag to protect you against escaping fluid
and steam. Before you completely remove the cap, carefully and slowly turn the cap part way to allow excess
Y53-6032
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GAUGES
PART 4: CONTROLS AND DISPLAYS
pressure to escape. Then push down and turn for final
removal.
not, stop the engine and let it cool before checking to see
if the coolant is low.
The cooling system may overheat if the coolant level is
below normal or if there is a sudden loss of coolant (such
as a worn hose splitting). It may also temporarily overheat
during severe operating conditions such as climbing a
long hill on a hot day or stopping after high-speed driving.
Fuel Gauge
If the “Engine Coolant Temperature” warning light comes
on, or you have any other reason to suspect the engine
may be overheating:
• Stop the vehicle, but DON’T TURN OFF THE
ENGINE unless a low water warning device indicates
a loss of coolant.
• With the transmission in neutral, check to be certain
the oil pressure gauge reads normal. Increase the
engine speed to about 1100 - 1200 RPM, maximum.
Return the idle speed to normal after 2 or 3 minutes. If
the warning light doesn’t go off or the temperature
gauge doesn’t begin to drop, then turn the engine off.
WARNING! Do not remove a fuel tank cap near
an open flame. Fuel vapors are combustible
and can cause an explosion or fire resulting in
injury or death.
WARNING! Do not breathe diesel fumes as
exposure to diesel fumes may cause respiratory illness, personal injury or death.
If the overheating came from severe operating conditions,
the temperature should have cooled by this time. If it has
– 66 –
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PART 4: CONTROLS AND DISPLAYS
GAUGES
CAUTION: Use Ultra Low Sulfur Diesel fuel only.
Failure to do so may damage the engine and
components of the Diesel Particulate Filter
(DPF).
Diesel Exhaust Fluid (DEF) 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 capacity. You will want to
keep your fuel tanks at least half full to reduce condensation of moisture in the tanks. This moisture can damage
your engine.
WARNING! Carrying additional fuel containers
in your vehicle is dangerous. Full or empty,
they may leak, explode, or cause or fuel a fire
which may lead to death or personal injury.
Don’t carry extra fuel containers - even empty
ones.
The deisel exhaust fluid gauge shows the approximate
amount of DEF fluid in the DEF tank. Besides empty and
full, the gauge also indicates 1/4, 1/2, and 3/4 of total
capacity. DEF fluid is required to meet certain emission
requirements. Do not allow your DEF tank to remain
empty. Please refer to your emission supplemental manual for more details about DEF fluid.
Use Diesel Exhaust Fluid only. Failure to do so
may damage components of the Diesel Particulate Filter (DPF).
(R05/10)
Y53-6032
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GAUGES
PART 4: CONTROLS AND DISPLAYS
Transmission Temperature Gauge
Front Drive Axle or Rear Drive Axle
Temperature Gauge
Your Transmission Temperature Gauge 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 representative.
Maximum transmission temperature may vary, depending
upon the transmission and type of lubricant. Check your
transmission’s owner’s manual.
– 68 –
Y53-6032
11425
CAUTION: Driving with very hot temperatures in
your rear drive axles can cause serious damage
to axle bearings and seals. Check axle lubrication if a driver temperature alarm sounds.
(R05/10)
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PART 4: CONTROLS AND DISPLAYS
GAUGES
Manifold Pressure Gauge
11425a
These gauges indicate the temperature of the lubricant in
your vehicle’s axle(s). These temperatures will vary with
the kind of load you are carrying and the driving conditions you encounter. Maximum axle temperature may
vary, depending upon the axle and type of lubricant. Very
high temperatures signal a need to have your axle(s)’
lubrication checked.
(R05/10)
Your manifold pressure gauge indicates the power your
engine is putting out by showing the amount of turbo
boost. If the pressure indicated by your manifold pressure
gauge goes down, there may be something wrong with
your engine. Have it checked by a qualified service person.
Y53-6032
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GAUGES
PART 4: CONTROLS AND DISPLAYS
Voltmeter
Air Filter Restriction Indicator Gauge
The voltmeter displays the voltage at which your batteries
are being charged while the engine is operating.
This gauge indicates the condition of the engine air
cleaner and is measured by inches of water (H2 O). A
clean filter should register 7 in. H2O (may vary with system design) and a filter whose life is over will register
approximately 25 in. H2O.
NOTE: Even with a healthy charge/start system,
the voltmeter may fall well below 12V during
engine cranking. If voltage drops below 12V and
stays there, have the electrical system checked.
– 70 –
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PART 4: CONTROLS AND DISPLAYS
GAUGES
CAUTION: Continued operation with the Air Filter Re-striction Gauge reading 25” H 2 O may
cause damage to the engine. Inspect the filter
and replace if necessary. Holes in the paper element render an air cleaner useless and may
cause the Air Filter Restriction Gauge to give a
false reading, even if the element is clogged.
Replace the element if it is damaged.
Shift Pattern Display
The correct shift pattern for your vehicle appears on your
control panel, windshield or on a medallion in the shift
knob. It is important that you know more about your transmission than just the shift pattern. Please read the manufacturer’s manual that is included with your vehicle.
Your vehicle is equipped with outside mirrors to enable
you to see to the sides and behind your vehicle. Be sure
they are adjusted properly before you drive off. You will
have the best field of view to the side if you adjust each
mirror so you can just see the side of your vehicle in the
inboard part of the mirror.
Luggage Compartment(s)
An interior luggage compartment is under the bunk in the
sleeper. The exterior compartment is beneath the bunk,
opening from the driver’s side, on the outside of the cab.
Mirrors
WARNING! Convex mirrors can distort images
and make objects appear smaller and farther
away than they really are. You could have an
accident resulting in death or personal injury 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.
(R05/10)
Y53-6032
WARNING! Carrying objects loose in your cab
or sleeper can be dangerous. In a sudden
stop, or even going over a bump, th object
could fly forward and strike you or a passenger, possibly causing death or serious injury.
Secure lo ose o bjects. Ca rry an y heav y
objects in the exterior luggage compartment
and close it securely.
WARNING! Do not store combustible materials in the luggage compartment. They may
leak and, if ignited, cause or fuel a fire which
may lead to death or personal injury.
– 71 –
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GAUGES
PART 4: CONTROLS AND DISPLAYS
Appliances in the Cab
NOTES:
•For additional information about the refrigerator,
refer to the refrigerator owner’s manual that came
with this appliance.
You may decide to equip your vehicle with a radio, a refrigerator, or other appliances and conveniences. Be sure
they are compatible with your truck’s electrical system.
Secure them in the cab so they can’t fly loose in a sudden
stop.
WARNING! In a sudden stop or collision a
heavy object in your cab could strike you or
anyone with you. You could be injured or
killed. Secure any appliance (such as a refrigerator or radio) you add to your cab.
Refrigerator
Follow the procedure below to operate the refrigerator.
CAUTION: Leaving your refrigerator on when the
vehicle’s engine is not running will rapidly run
down your vehicle’s batteries. This may cause
premature battery failure.
•Refrigerator cooling ability decreases as sleeper
temperature increases.
The main power supply to the refrigerator and cooling fan
(located behind the refrigerator) is controlled by a switch
labeled "REFRIG/FAN" located on the sleeper control
panel.
• To turn the refrigerator and cooling fan on, move the
REFRIG/FAN switch to ON, then turn the thermostat
dial (located inside the refrigerator) clockwise from
the OFF setting.
• To turn the refrigerator and cooling fan off, turn the
thermostat dial inside the refrigerator counterclockwise to the OFF setting, then move the REFRIG/FAN
switch to OFF.
• To turn only the refrigerator off, turn the thermostat
dial counterclockwise to OFF.
– 72 –
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PART 4: CONTROLS AND DISPLAYS
GAUGES
Peterbilt Navigation System
Your vehicle may be equipped with a Peterbilt Navigation
System. This system is a Global Positioning Satellite
(GPS)-linked computer. It receives input from multiple
sources to locate your vehicle. Read and understand the
Supplemental Navigation System Owner’s Manual and
observe the Warnings, Cautions, and Notes that follow
before using the system.
WARNING! Verify legal weight and height
restrictions for the route suggested by the
Navigation System. Failure to verify height
restrictions could lead to death or personal
injury. Failure to verify weight restrictions
could also result in a traffic infraction.
WARNING! Only glance at the Navigation
System monitor while driving. Prolonged periods of viewing while driving could result in an
accident and death or possible personal
injury.
(R05/10)
Y53-6032
WARNING! Do not program the Navigation
System while driving. Always stop your vehicle when programming or changing the settings on the Navigation System. Programming
the system while driving can cause you to
take your eyes off the road, which could result
in an accident. Failure to do so could lead to
death, serious injury or equipment damage.
CAUTION: Do not rely on the Navigation System
to route you to the closest emergency services.
Not all emergency services are in the database.
NOTE: Regardless of how and where the navigation system directs you, it is your responsibility to
operate the vehicle in a safe and legal manner.
NOTE: Ensure the volume level of all audio
devices is set to a level that still allows you to hear
outside traffic and emergency vehicles.
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GAUGES
PART 4: CONTROLS AND DISPLAYS
NOTE: The map database is the most current
available at the time of production. The database
is designed to provide you with route suggestions
and does not take into account the relative safety
of a suggested route or of factors that may affect
the time required to reach your destination. See
the Supplemental Navigation System Owner’s
Manual for more information.
– 74 –
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PART 5: SEAT AND RESTRAINT SYSTEMS
SEAT
PART 5: SEAT AND RESTRAINT SYSTEMS
Seat
Seat Belts And Their Proper Use
For information on the features and adjustment of the
seat, see the seat manufacturer’s literature included with
the vehicle.
Seat (or safety) belts have proven to be the single most
effective means available for reducing the risk of serious
injury and death in motor vehicle accidents. It’s not just an
opinion -- it’s a fact: Seat belts save lives.
WARNING! Do not drive or ride with your seat
back in the reclined position. You could be
injured or killed by sliding under the seat
belts in a collision.
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 causing
death or personal injury. Make all adjustments
to the seat while the vehicle is stopped.
• After adjusting the seat and before driving
off, always check to be sure that the seat is
firmly latched in position.
(R05/10)
Y53-6032
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 death or injury
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.
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SEAT BELTS AND THEIR PROPER USE
PART 5: SEAT AND RESTRAINT SYSTEMS
• The lap portion should be worn as low on the hips as
possible
02998
Person In Crash, Unbelted
Shoulder Belt
Your combination shoulder-lap belt needs proper adjustment:
Properly worn belt
– 76 –
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PART 5: SEAT AND RESTRAINT SYSTEMS
SEAT BELTS AND THEIR PROPER USE
WARNING! Always wear your seat belt low
over your pelvic bones.
• You can be killed or 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 death or serious internal injuries.
.
Improperly worn belt
The shoulder portion should fit snugly across your body. It
should always be worn over the shoulder next to the door.
It you put the belt under your arm, it can’t protect you
properly
Correct (over arm)
(R05/10)
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SEAT BELTS AND THEIR PROPER USE
PART 5: SEAT AND RESTRAINT SYSTEMS
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.
.
WARNING! 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, resulting in death or
personal injury. You could strike the wheel or
the windshield. Adjust your belt so that there
is no more than 1 in. (25mm) of slack.
Watch that you don’t twist the belt in the process of putting
it on. A twisted belt won’t work as well to protect you.
Incorrect (under arm)
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 death or 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.
02930
Twisted Belt
– 78 –
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PART 5: SEAT AND RESTRAINT SYSTEMS
SEAT BELTS AND THEIR PROPER USE
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 death or 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
To eliminate cinching simply activate the comfort feature
at the appropriate time:
To connect your shoulder-lap belt: Grasp the belt
tongue and pull in a smooth, slow motion across your
chest and lap. Insert the tongue into the buckle on the
inboard side of the seat. Push down until you hear a click.
Pull on the belt to make sure it is buckled. Check that it is
positioned correctly on your body.
3. When the slack is right, slide the comfort feature up
When the slack is right, flip the latch cover up, cinching it into place. This locks the Komfort-Lok.
Komfort-Lok® Feature
5. When you want to get out of the cab, release the
latch, then just push the button on the buckle.
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.
(R05/10)
1. Fasten your seat belt according to the directions.
2. You are now ready to activate the Komfort-Lok. Lean
forward to pull a little slack (about 1 inch) in the belt.
Be sure to allow only a small amount of slack. See the
Warning on a loose belt, on the previous page.
4. To release the Komfort-Lok latch, reach up and pull
the latch cover open (down), or simply pull down on
the shoulder belt.
Pregnant Women: Sometimes pregnant women worry
that in a crash the seat belt could hurt the baby. But if a
woman wears her belt properly - low over her pelvis,
below her abdomen - the belt won’t harm the baby, even in
a crash. And remember - the best way to keep an unborn
baby safe is to keep the mother safe.
Y53-6032
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SEAT BELTS AND THEIR PROPER USE
PART 5: SEAT AND RESTRAINT SYSTEMS
CAUTION: To avoid damage when lifting a
bunk, remove all items from the top of the
bunk mattress, and arrange bedding so that
items will not slide down the mattress and fall
behind the bunk.
.
The bunk restraint is attached to the sleeper in six locations (see illustration below):
1. Two buckles at the upper rear wall
2. Two buckles at the side walls
3. Bolts in two places at the lower rear wall
There is also a buckle at the driver’s side front of the bunk
for easy entry/exit of the sleeper with the bunk restraint in
use.
Pregnant Woman With Belt Properly Worn
Sleeper Bunk Restraints
If your cab is equipped with a sleeper, be sure to use the
restraint device. You may have belts which either are over
the bunk or cover the opening. Of course, you do not need
to use a restraint if you sleep in a parked vehicle. But anyone using the sleeper while the truck is in motion should
be restrained in a safety device.
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PART 5: SEAT AND RESTRAINT SYSTEMS
SEAT BELTS AND THEIR PROPER USE
• The lower rear wall: The restraint is attached to the
lower rear wall by bolts that do not require removal for
use or stowage of the bunk restraint.
You will notice that if your Peterbilt has an upper bunk, it
has no restraint device. This is because no one should
ever be in an upper bunk when the vehicle is moving.
WARNING!
• In an accident an unrestrained person lying in
a sleeper bunk could be killed or seriously
injured. He or she could be thrown from the
bunk. Be su re anyone occupying the
sleeper is restrained while a vehicle is moving.
• The upper rear wall: Access to the bunk is easiest
when these connections are buckled and the front
buckle is detached.
• The side walls: The tenting straps are attached to the
side wall sills with easy-to-use buckles.
(R05/10)
• Be sure that no one ever rides in the upper
bunk while the vehicle is in motion. That
person would be thrown out in an accident
and could be killed or seriously injured.
Passengers
Anyone riding in your vehicle should wear a seat belt. The
responsible operator sees to it that everyone in the vehicle
rides safely - and that means with a seat belt.
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SEAT BELTS AND THEIR PROPER USE
PART 5: SEAT AND RESTRAINT SYSTEMS
Some Other Safety Restraint Tips:
• Don’t wear belts over rigid or breakable objects in or
on your clothing. Such things might be eyeglasses,
pens, keys, etc. These could cause injury in an accident.
• Damaged belts in the cab or sleeper must be
replaced. Belts that have been stretched, cut, or worn
out may not protect you in an accident.
• Avoid catching belts in the doors or seat hardware.
They could be damaged.
• 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.
• If any seat belt is not working properly, see an authorized Peterbilt dealer for repair or replacement.
Tether Belts
Tether belts are installed on suspension seats. They help
secure the seat to the floor to restrain it in case of a sudden stop or an accident.
• Don’t modify or disassemble the seat belts in your
vehicle. They won’t be available to keep you and your
passengers safe.
– 82 –
Y53-6032
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.
(R05/10)
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PART 5: SEAT AND RESTRAINT SYSTEMS
INSPECTION OF THE RESTRAINT SYSTEM
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. Death or serious injury may occur if head clearance is not
adequate.
Make sure the tether belt is attached to the cab deck and
seat frame. It should be routed through the buckle on each
side.
To lengthen the tether, turn the buckle to a right angle to
the webbing. Then pull the buckle. To shorten the tether,
pull on the strap.
Inspection of the Restraint System
Tether Adjustment
WARNING! Failure to adjust tether belts properly can cause excessive movement of the
seat in an accident. This could lead to death
or 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.
(R05/10)
Y53-6032
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.
– 83 –
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INSPECTION OF THE RESTRAINT SYSTEM
PART 5: SEAT AND RESTRAINT SYSTEMS
The typical three-point seat systems in passenger cars
may seem very similar to the three-point seat belt system
in heavy duty vehicles, but there are some key differences
that all users of this system should be aware of:
• In typical passenger vehicle automotive seat belt
applications, the normal life of the vehicles is usually 8
to 10 years and the total mileage frequently does not
exceed 125,000 miles (200,000 km). Heavy duty vehicles often see this type of mileage in a very short
period of time, and accumulation of mileage in excess
of 500,000 miles (800,000 km) during the vehicle lifetime is not unusual.
• A significant difference in the two systems is the
amount of movement of webbing in the system. In an
automotive application, there is little movement of the
seat belt system, except when the user puts on or
takes off the belt. In trucks, however, there is almost
constant movement of the belt through hardware due
to ride characteristics and seats which are designed
to move, in order to enhance driver comfort. There
can even be movement of the webbing in the seat belt
system when the belt in not being used. Relative
– 84 –
movement between the seat and the cab, which normally occurs whenever the truck is in operation, can
cause wear of the seat belt webbing.
• Environmental conditions represent another major difference in the systems in automobiles and heavy duty
and specialty vehicles. Unlike the automotive environment, heavy duty and specialty vehicles may be very
dirty, and have more exposure to the sun’s damaging
ultraviolet rays, thus resulting in a reduction of the life
of the seat belt system.
The high mileage associated with heavy duty vehicles and
possible wear of the 3-point seat belt system, the continual relative movement of the system, the possible contact
with the vehicle seat or other parts of the cab structure,
and the potential exposure of this system to severe environmental conditions make it crucial to inspect the threepoint seat belt systems regularly.
It is recommended that the seat belt system in a vehicle
be inspected every 20,000 miles (32,000 km) or more
often if the vehicle is exposed to severe environmental
conditions. Any seat belt system that shows cuts, fraying,
extreme or unusual wear, significant discoloration due to
UV exposure, abrasion to the seat belt webbing, or dam-
Y53-6032
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PART 5: SEAT AND RESTRAINT SYSTEMS
INSPECTION OF THE RESTRAINT SYSTEM
age to the buckle, latch plate, retractor hardware or any
other obvious problem should be replaced immediately,
regardless of mileage.
WARNING! It is important to remember that
any time a vehicle is involved in an accident,
the entire seat belt system must be replaced.
Unexposed damage caused by the stress of
an accident could prevent the system from
functioning properly the next time it is
needed, which could result in severe injury or
even death.
One of the most critical areas to be inspected is the seat
belt webbing. Constant movement of the belt actually
means the webbing is experiencing wear as it travels in
and out of the retractor, through the pillar loop web guide
and through the various pieces of hardware associated
with the belt. The following guidelines detail how to
inspect for cuts, fraying, extreme or unusual wear of the
webbing, etc. and damage to the buckle, retractor, hardware, or other factors which indicate that belt replacement
is necessary.
(R05/10)
Y53-6032
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INSPECTION OF THE RESTRAINT SYSTEM
PART 5: SEAT AND RESTRAINT SYSTEMS
even unintentionally. Check retractor web storage
device operation to ensure that it is not locked up and
that it spools out and retracts webbing properly.
1. Check the web wear in the system. The webbing must
be closely examined to determine if it is coming into
contact with any sharp or rough surfaces on the seat
or other parts of the cab interior. These areas are typical places where the web will experience cutting or
abrasion. Cuts, fraying, or excessive wear would indicate the need for replacement of the seat belt system.
2. The D-loop web guide is the area where almost constant movement of the seat belt webbing occurs
because of relative movement between the seat and
the cab.
3. Check the comfort feature for cracks or possible damage and that it works properly.
4. Check the buckle and latch for proper operation and
to determine if the latch plate is worn, deformed, or
damaged.
5. Inspect the retractor web storage device, that is
mounted on the floor or B-pillar of the vehicle for damage. The retractor is the heart of the occupant
restraint system and can often be damaged if abused,
– 86 –
WARNING! Failure to adjust tether belts properly can cause excessive movement of the
seat in an accident. This could lead to death
or serious injury. Tether belts should be
adjusted so that they are taut when the seat is
in its most upward and forward position.
6. If adjustable tethers are being used, be sure they are
adjusted in accordance with installation instructions.
Tethers must also be inspected for web wear, just as
with the seat belt systems.
7. Mounting hardware should be evaluated for corrosion,
and for tightness of bolts and nuts.
8. Check web in areas exposed to ultraviolet rays from
the sun. If the color of the web in these areas is gray
to light brown, the physical strength of this web may
have deteriorated due to exposure to the sun’s ultraviolet rays; replace the system.
Y53-6032
(R05/10)
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PART 5: SEAT AND RESTRAINT SYSTEMS
INSPECTION OF THE RESTRAINT SYSTEM
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.
If the inspection indicates that any part of the seat belt
system requires replacement, the entire system must be
replaced, both retractor and buckle side. An installation
guide is attached to every replacement belt. This set of
instructions is entitled “THREE-POINT SEAT BELT
INSTALLATION GUIDE.” There are separate seat belt
instruction guides for suspension and fixed bench seats.
Use the proper guide for your type of seat, and follow the
(R05/10)
instructions very closely. It is vitally important that all components must be remounted back in the same position as
the original components that were removed. This will
maintain the design integrity of the mounting points for the
seat belt assembly.
Once the need for replacement of the seat belt has been
determined, be certain that it is only replaced with the recommended replacement seat belt. The occupant restraint
system has been developed and tested specifically for this
vehicle. If the vehicle was originally equipped with a lap
belt, it cannot be replaced with a three-point shoulder harness system, because the cab mounting points are not
structurally designed for a three-point seat belt.
Y53-6032
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SAFE VEHICLE OPERATION
PART 6: DRIVER’S CHECKLIST
PART 6: DRIVER’S CHECKLIST
Safe Vehicle Operation
To keep your vehicle in top shape, and to maintain its high
level of safety for you, your passengers, and your load,
make a thorough inspection every day before you drive.
You’ll save maintenance time later -- and the safety
checks could help prevent a serious accident. Please
remember, too, that Federal law requires a pre-trip inspection and so do commercial trucking companies.
For more information, you can refer to Federal Motor Carrier Safety Regulation 392.7 which tells you that interstate
commercial motor vehicles are not to be driven unless the
driver is sure that certain parts and accessories are in
working order.
You aren’t expected to become a professional mechanic.
The purpose of your inspections is to find anything that
might interfere with the safe and efficient transportation of
yourself and your load. If you do find something wrong
and can’t fix it yourself, please have a qualified mechanic
fix it right away.
For your safety, as well as those around you, be a 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 Peterbilt,
including advanced engineering techniques, rigid quality
control, and demanding inspections. These manufacturing processes will be enhanced by you—the safe driver—
who observes the following:
• knows & understands how to operate a vehicle and all
its controls
• maintains the vehicle properly
• uses driving skills wisely
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PART 6: DRIVER’S CHECKLIST
SAFE VEHICLE OPERATION
WARNING! Do not drink and drive. Your
reflexes, perceptions, and judgment can be
affected by even a small amount of alcohol.
You could have a serious—even fatal—accident if you drive after drinking. Please do not
drink and drive or ride with a driver who’s
been drinking.
• The 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 death or serious personal injury.
The daily checks listed below are the foundation of your
overall preventive maintenance program. See “PART 8:
MAINTENANCE AND SERVICE” for the complete preventive maintenance schedule for your vehicle.
Checking Under the Hood or Cab
With the engine stopped:
1. Check the engine oil level; top up as necessary. Refer to
your engine’s operating manual for the type of oil to use.
2. Check the engine coolant level while the engine is
cold. Top up as necessary with premixed coolant.
Refer to the instructions on page 193 for adding coolant to the proper level.
3. Check the engine belts. Refer to the instructions on
page 210 to check belt condition and adjust tension.
4. Check brake lines and hoses.
Approaching the Vehicle
1. Check the overall appearance and condition. Are windows, mirrors, and lights clean and unobstructed?
2. Check beneath the vehicle. Are there signs of fuel, oil,
or water leaks?
(R05/10)
3. 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.
5. Check all other accessories, controls, belts, hoses,
and wiring for condition and adjustment.
6. Check the windshield washer fluid level; top up as
necessary.
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SAFE VEHICLE OPERATION
PART 6: DRIVER’S CHECKLIST
7. Check the power steering fluid reservoir; top up as
necessary.
4. Check parking (spring) brakes as to the condition and
tightness of air lines, breathers, clamp rings & bolts,
mounting studs, and release bolts.
8. Check the steering components (pitman arm, draglink, power steering hoses, etc.)
5. Check turn signal operation.
9. Drain the fuel/water separator.
6. Check emergency flashers and exterior lamps.
Checking the Luggage Compartment
7. Check the fuel tanks. Is there enough fuel? Are the
tank caps secure?
1. Check the fire extinguisher charge.
WARNING!
2. Check the road emergency kit. Is it complete?
WARNING! Do not store combustible materials in the luggage compartment. They may
leak and, if ignited, cause or fuel a fire which
may lead to death or personal injury.
Checking Outside the Vehicle
1. Be sure all wheel studs and cap nuts are secure.
Check wheel cap nut torque weekly; refer to the
instructions on page 185.
2. Check tires for condition and proper inflation.
• Fuel vapors are combustible and can cause
an explosion or fire resulting in injury or
death. Do not remove a fuel tank cap near
an open flame.
• Do not breathe diesel fumes as exposure to
diesel fumes may cause respiratory illness,
personal injury or death.
3. Check the front wheel bearing lube level.
– 90 –
• Diesel fuel in the presence of an ignition
source (such as a cigarette) could cause an
explosion. You could be killed or seriously
injured. A mixture of gasoline or alcohol
with diesel fuel increases this risk of explosion. Use only the fuel recommended for
your engine.
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PART 6: DRIVER’S CHECKLIST
SAFE VEHICLE OPERATION
8. Visually inspect the fuel tank mounting hardware. Are
the tank straps tight? Is the webbing in place?
9. Check the air cleaner and exhaust system. Are they
tight and secure?
10. Check the trailer connections. Are they secure and
the lines clear? If they are not being used, are they
stored properly?
18. Drain excess moisture from all air supply tanks. Make
sure the drain valves are closed. This procedure is
also required for air supply tanks equipped with automatic drain valves.
In-Cab Checklist
WARNING! To avoid death or injury while
entering or leaving the cab, keep your feet in
contact with the steps and your hands on the
handhold. Always have three points of contact as you enter or exit a cab. See “PART 2:
GETTING INTO & OUT OF THE CAB AND
FRAME ACCESS” of this manual for more
information.
11. Is the trailer spare wheel secure? Inflated?
12. Is the landing gear up and the handle secured?
13. Check the 5th wheel. Is the kingpin locked?
14. Is the sliding 5th wheel locked?
15. Check for loose or missing suspension fasteners.
1. Adjust the seats.
16. Check springs or other suspension parts for damage
such as cracks, gouges, distortions, bulges, or chafing.
2. Fasten and adjust safety restraint belts. See “PART 5:
SEAT AND RESTRAINT SYSTEMS”, or the Index,
under Restraint Systems.
17. Check the air system. Are there leaks?
3. Sleeper Restraints: Check and inspect condition. See
“PART 5: SEAT AND RESTRAINT SYSTEMS”, or the
Index, under Restraint Systems.
4. Adjust the steering column.
(R05/10)
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SAFE VEHICLE OPERATION
PART 6: DRIVER’S CHECKLIST
5. Check mirror adjustment.
Superintendent of Documents
6. Operate air-powered devices to circulate lubricants.
U.S. Government Printing Office
NOTE: The above items should be checked daily,
as a minimum. They are in addition to, not in
place of Federal Motor Carrier Safety Regulations. These may be purchased by writing to:
– 92 –
Y53-6032
Washington, DC 20402
(R05/10)
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PART 7: STARTING & OPERATING THE VEHICLE
NORMAL TEMPERATURE STARTING PROCEDURE
PART 7: STARTING & OPERATING THE VEHICLE
Since each vehicle is custom-equipped, all engine operation instructions in this manual are general. You will want
to consult the manual for your engine to find out details
about your specific engine’s needs. You may need to use
a slightly different procedure from the one outlined here.
Below are instructions for both normal-temperature starting and cold-weather starting.
4. Turn the key switch to ON.
• The driver information display will proceed through
the instrumentation self test (refer to page 18 for a
description of the instrumentation self test).
NOTE: Refer to “Warning Light/Indicator Symbol
Descriptions,” Page 23 if the Driver Information
Display other messages or if other alarms activate after the key is turned ON.
Normal Temperature Starting Procedure
When the outside temperature is above 50° F (10° C), you
can use the following procedure.
5. Turn the key to start.
CAUTION: Never operate the starter motor
while the engine is running. The starter and
flywheel gears could clash or jam, severely
damaging them.
1. Set the parking brake.
2. Put your main transmission in Neutral.
NOTE: Some starters are equipped with overcrank
protection. Check the “Engine Operation and Maintenance Manual” for details.
3. Disengage (depress) the clutch (with manual transmission).
If the engine does not start within 30 seconds, release the
starter button. To avoid overtaxing the starter motor or the
batteries, don’t use the starter for more than 30 seconds.
Let the starter motor cool and the batteries recover for 2
(05/10)
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COLD TEMPERATURE STARTING PROCEDURE
PART 7: STARTING & OPERATING THE VEHICLE
minutes before trying again. If the engine still won’t start
after a couple of tries, check the manual override shutdown valve and fuel lines for possible fuel starvation or air
leaks. Starting failure may mean fuel isn’t reaching the
injectors.
1. As soon as the engine starts, begin to watch the oil
pressure gauge. Check your engine manufacturer’s
manual for the right pressure for your engine. If the oil
pressure doesn’t rise within a few seconds, stop the
engine. Find out what is wrong before restarting the
engine.
Cold Temperature Starting Procedure
In cold weather, fast engine starting helps relieve the
loads on the electrical system and cranking motor. Using
the special cold starting equipment will help starting. If
you follow a few simple guidelines, you will extend the service life of your engine.
• Keep the electrical system in top condition.
• Use the best quality fuel of the recommended grade.
• Use recommended engine lubricating oil.
2. Slowly engage (release) the clutch after the engine
has started.
3. Wait until normal engine oil pressure registers on the
gauge before idling or accelerating the engine beyond
1000 RPM.
– 94 –
Y53-6032
WARNING! Do not use ether or starting fluid in
conjunction with flame-start air intake heating
systems. Flame-start systems use an open
flame inside the manifold to heat the air/fuel mixture for cold weather starting. If ether is also
used with flame-start, the air/fuel will ignite
inside the manifold, which could cause an explosion, death or severe injury.
(05/10)
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PART 7: STARTING & OPERATING THE VEHICLE
ENGINE WARMUP
Engine Warmup
freely while pistons, liners, shafts, and bearings
expand slowly and evenly. In extremely cold temperatures, you may have to increase idle speed.
The purpose of engine warmup is to allow oil film to be
established between pistons and liners, shafts and bearings while your engine gradually reaches operating temperature.
NOTE: In colder climates where the temperature
is often below freezing, the 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
temperature or pressure gauge for a warming
trend before increasing engine idle speed (RPM).
Warmup Procedure
1. After you’ve started your engine, idle it at approximately 600 RPM while you check
• oil pressure
• air pressure
• alternator output
WARNING! Do not start or let the engine run
in an enclosed, unventilated area. Exhaust
fumes from the engine contain carbon monoxide, a colorless and odorless gas. Carbon
monoxide can be fatal or can cause serious
respiratory illness if inhaled.
3. Continue the engine warmup 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.
2. After a few minutes of idling at 600 RPM, increase
your idle speed to 900 or 1000 RPM. Continue your
warmup. This procedure allows oil to warm and flow
(05/10)
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ENGINE WARMUP
PART 7: STARTING & OPERATING THE VEHICLE
WARNING! Exhaust fumes from the engine
contain carbon monoxide, a colorless and
odorless gas. Do not breathe the engine
exhaust gas. A poorly maintained, damaged or
corroded exhaust system can allow carbon
monoxide to enter the cab or sleeper. Entry of
carbon monoxide into the cab is also possible
from other vehicles nearby. Failure to properly
maintain your vehicle could cause carbon
monoxide to enter the cab/sleeper and causes
death or serious illness.
WARNING! Never idle your vehicle for prolonged periods of time if you sense that
exhaust fumes are entering the cab or sleeper.
Investigate the cause of the fumes and correct
it as soon as possible. If the vehicle must be
driven under these conditions, drive only with
the windows slightly open. Failure to repair
the source of the exhaust fumes may lead to
death or personal harm.
– 96 –
Y53-6032
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
EPA-compliant engine cooling system.
These winterfronts are specifically
designed for use with new grill snap patterns.
(05/10)
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PART 7: STARTING & OPERATING THE VEHICLE
TRANSMISSION WARMUP
Transmission Warmup
NOTES:
• Keep the engine exhaust system and the vehicle’s cab/sleeper ventilation system properly
maintained. It is recommended that the vehicle’s exhaust system and cab/sleeper be
inspected
– 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
(05/10)
In cold weather you may find shifting sluggish when you
first start the engine. Transmission warmup is especially
important at this time, but it is always a good idea to warm
up your transmission before starting out on the road. To
warm up the transmission lubricating oil during engine
warmup, with a single transmission:
• Check that the transmission is in Neutral.
• Release the clutch pedal.
• 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.
If you have a two-transmission combination:
• If other vehicles are parked next to you idling,
move your vehicle or do not stay in your vehicle
for prolonged periods of time.
Under most circumstances, idling your engine for long
periods 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.
• Put the main transmission in gear.
• Put the auxiliary transmission in Neutral. This will
allow the transmission countershaft to turn, agitating
the oil and warming it.
Idling the Engine
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PUTTING THE VEHICLE IN MOTION
PART 7: STARTING & OPERATING THE VEHICLE
WARNING! To reduce the chance of personal
injury and/or vehicle damage from overheated
engines, which can result in a fire, never leave
the engine idling without an alert driver
present. If the engine should overheat, as
indicated by the engine coolant temperature
light, immediate action is required to correct
the condition. Continued unattended operation of the engine, even for a short time, may
result in serious engine damage or a fire.
Putting The Vehicle In Motion
This section discusses the clutch and transmission operation to get your Peterbilt underway.
CAUTION: Do not allow your engine to idle, at
low rpm's (400–600 rpm), longer than five minutes. Long periods of idling after the engine
has reached operating temperatures can
decrease engine temperature and cause
gummed piston rings, clogged injectors, and
possible engine damage from lack of lubrication. The normal torsional vibrations generated can also cause transmission wear.
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.
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).
During the time it takes you to drink a cup of coffee, your
engine can cool as much as 60° F (33° C) below normal
operating temperature. To keep the engine warm during a
short break, turn it off. And don’t allow your engine to idle
longer than five minutes.
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PART 7: STARTING & OPERATING THE VEHICLE
PUTTING THE VEHICLE IN MOTION
Shifting The Transmission
Operating the Clutch
You will find a shift pattern either on a decal in your cab or
on a medallion in the shift knob. Check to be sure you
know the correct sequence for your particular transmission. Refer to the transmission manual included with your
vehicle for complete instructions in the operation of your
transmission.
“Riding” the Clutch
Shifting Gears in a New Vehicle
Clutch Travel
The clutch pedal is not a footrest. Driving with your foot on
the clutch pedal will allow your clutch to slip, causing
excessive heat and wear. You can damage your vehicle
this way.
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.
Shift carefully in a new vehicle. The transmission may be
a little stiff at first. So be careful to avoid gear clashing.
When you are operating a new vehicle or one that has
been exposed to cold weather, you want the transmission
lubricant to circulate and coat the contacting surfaces of
the gears. Metal contacting metal in moving parts may
seriously damage your transmission. So don’t drive in one
gear for long until the transmission lubricant has had a
chance to coat those contacting surfaces.
(05/10)
To put your vehicle into motion, push down on the clutch
pedal until the clutch brake makes contact. This contact
will occur at about 1/2 inch to 1 inch from the end of pedal
stroke. Select a gear low enough to let your vehicle start
forward with the throttle at idle until the clutch is fully
engaged.
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PUTTING THE VEHICLE IN MOTION
PART 7: STARTING & OPERATING THE VEHICLE
The total stroke of the clutch pedal is about 10 inches. The
first 1 3/4 to 2 inches is free travel. After that is the release
stroke, the part that fully releases the clutch. The last 1/2
to 1 inch engages the clutch brake. If your vehicle is new,
watch the free travel in your clutch carefully for the first few
hundred miles. As your clutch lining wears and high spots
get worn smooth, you will get less free travel.
Always start out in a low gear with a ceramic-faced clutch.
Starting in higher gears, even with a light load, will cause
a very jumpy start and excessive wear.
And don’t allow your vehicle to roll in the opposite direction at all during clutch engagement. If you need to start
up on an incline, apply your service brakes before you
release the parking brake. Then release your service
brakes as you engage the clutch and apply throttle.
Release Bearing Wear
When you must idle your engine for any period of time,
shift your transmission to neutral and engage the clutch
(take your foot off the pedal). This helps prevent unnecessary wear of your clutch release bearing. And it is less tiring for you, too.
– 100 –
Clutch Adjustment
Inspect manual and self-adjusting clutches regularly to
maintain correct clutch adjustment. Have your dealer’s
service department perform any adjustments necessary.
Do not adjust your clutch by adjusting the external linkage
without first checking (and correcting if necessary) the
internal clutch adjustment. Using only the external linkage
adjustment could damage the clutch.
Clutch Brake
Your clutch brake is used for stopping gear rotation to let
you shift into 1st gear or reverse when your vehicle is at a
standstill.
About the last 1/2 to 1 inch of clutch pedal travel activates
your clutch brake. So if you are stopped and want to shift
directly into 1st or reverse, depress the clutch pedal until
contact with the clutch brake is made to stop transmission
gear rotation.
If you have a butt-tooth condition and can’t shift the transmission, gradually release the clutch. Then the drive gear
can roll enough to allow the teeth to line up properly and
complete the shift.
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PART 7: STARTING & OPERATING THE VEHICLE
PUTTING THE VEHICLE IN MOTION
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. Applying the clutch
brake when the vehicle is moving causes a
braking effect on the entire vehicle. This wear
naturally shortens the service life of your
clutch brake.
Double Clutching
Whether you are upshifting or down shifting, it is best to
double clutch. Double clutching is easier on your transmission and on your engine, helping your vehicle match
engine speed with driveline speed and achieving clashfree shifts. To double clutch:
1. Push down the clutch pedal to disengage the clutch.
2. Move the gear shift lever to neutral.
3. Release the pedal to engage the clutch. This lets you
control the RPM of the mainshaft gears. Thus you can
match the RPM of the mainshaft gears to those of the
output shaft.
(05/10)
• Upshifts - Let the engine and gears slowdown to
the RPM required for the next gear. Use the tachometer to determine optimum RPM for gear engagement.
• Downshifts - Press accelerator to increase engine
and gear speed to the RPM required in the lower
gear. Use the tachometer to determine optimum
RPM for gear engagement.
4. Now quickly press the pedal to disengage the clutch.
Move the gear shift lever to the next gear speed position.
5. Release the pedal to engage the clutch.
Interaxle Differential
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 tires and provides better performance. When
operating normally on paved, dry surfaces, keep your
truck’s interaxle differential in the UNLOCK position.
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PUTTING THE VEHICLE IN MOTION
PART 7: STARTING & OPERATING THE VEHICLE
In the LOCK position, continuous operation on a paved,
dry surface stresses the tandem axles, possibly causing
internal damage to them.
• Shift into the LOCK position to operate on slippery
surfaces like
– Ice or snow - with or without tire chains
– Dirt roads
– Loose sand, mud, or other off-road conditions
• Switch into LOCK when checking performance on a
chassis dynamometer.
SHIFT AT ANY SPEED EXCEPT
IF A WHEEL IS SPINNING
03029
Switch In Unlock Position
WARNING! Do not engage the differential lock
while operating on dry pavement; it could
lead to an accident involving death or personal injury. You will not be able to safely
steer the vehicle while using the differential
lock and driving on dry pavement. Only
engage the switch for short periods of time to
move the vehicle in a straight motion.
WARNING! Do not engage the differential lock
if the vehicle is moving or if the tires are slipping. Otherwise, the vehicle may move in an
unexpected direction, and could cause an
accident involving death or personal injury.
This may also lead to equipment damage.
Bring the vehicle to a complete stop and
ensure that all wheels are not spinning before
engaging the differential lock switch.
To lock the differential, ease up on the throttle. Be sure to
stop any spinning wheels. Then push the switch to the
LOCK position. It may be neccessary to use light throttle
to help engage the differential lock.
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(05/10)
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PART 7: STARTING & OPERATING THE VEHICLE
PUTTING THE VEHICLE IN MOTION
WARNING! Do not use the differential lock at
speeds greater than 25 mph (40 kph); it could
lead to an accident involving death or personal injury. A vehicle with the differentials
locked will be difficult to steer. At higher
speeds, you may loose control of the vehicle.
Only engage the differentials to maneuver
through areas of poor traction. Do not keep
driving with the switch in the LOCK position.
Dual Range (Two Speed) Axles
2
03030
Range Selector
Using Your Dual Range Axle
WARNING! Never shift the axle when moving
downhill. Engine driveline disengagement
may occur, eliminating engine retardation and
allowing the wheels to spin faster than the
current speed of the engine. This may require
severe braking to slow the vehicle down and
can result in an accident involving death or
personal injury.
If you have this option, dual range axles provide two rear
axle ratios for operating under heavy loads or off-highway
as well as for over the road trucking. The Low range provides maximum torque for off-road work. The High range
is a faster ratio for highway speeds and conditions. A
switch on your instrument panel controls this function. You
will notice that it has a guard to protect you from activating
it accidentally.
1. Unlock the interaxle differential before starting.
2. Put the Range Selector in the LOW range. Shift the
transmission to start the truck moving.
(05/10)
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PUTTING THE VEHICLE IN MOTION
PART 7: STARTING & OPERATING THE VEHICLE
3. Off-Highway: When you are driving on rough terrain
and secondary roads, or under a very heavy load,
keep the axle in the LOW range. Shift your transmission to maintain the road speed you want.
4. When you go from off-highway to highway driving,
shift the axle to the HIGH range this way:
a. Be sure the differential is UNLOCKED.
b. Keep the accelerator down and move the Range
Selector lever to HIGH.
c. Keep driving with the accelerator down until you
want the axle to shift.
d. Then release the accelerator until the axle has
shifted.
e. You are now in the HIGH axle range on the highway.
Shift the transmission normally to reach your
desired cruising speed.
d. The axle will shift to the LOW range.
Important Tips on Operating Your Dual Range Axle
NOTE: If your vehicle has an automatic transmission, it may be necessary to shift it to the Neutral
position momentarily to allow the main differential
lock splines to fully engage or disengage.
To avoid damaging your vehicle, shift the axle at a slower
speed until you are used to driving with the dual range
axle.
When driving on a surface with good traction, keep the
interaxle differential unlocked. You can drive with the axle
in LOW or HIGH range.
5. If you need to downshift the axle for more power
a. Keep the accelerator down & move the Range
Selector lever to LOW.
b. Keep driving with the accelerator down until you
want to downshift the axle.
c. Then release and depress the accelerator pedal
quickly to increase the engine RPM.
– 104 –
Y53-6032
SHIFT AT ANY SPEED EXCEPT
IF A WHEEL IS SPINNING
03029
Interaxle In Unlock
(05/10)
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PART 7: STARTING & OPERATING THE VEHICLE
PUTTING THE VEHICLE IN MOTION
When you are driving with poor traction, lock the differential. When you have the differential locked, drive with the
axle in LOW range only.
Automatic and Automated Transmission
An automatic or automated transmission makes shifting
much easier. It remains important to completely understand how to operate the transmission to optimize its efficiency. Please read the manual for your automatic or
automated transmission included with your vehicle.
WARNING! If your vehicle has a Freedomline™ transmission, be aware that it can roll
backwards when stopped on a hill or grade, or
when starting from a stop on a hill or grade.
This could cause serious damage, death or
personal injury. Observe the following guidelines:
SHIFT AT ANY SPEED EXCEPT
IF A WHEEL IS SPINNING
03029A
Interaxle In Lock
Always UNLOCK the interaxle differential before shifting
the axle speed range.
• When stopped on a hill or grade, press the
brake pedal.
CAUTION: If you shift the axle range with the
interaxle differential in LOCK, you could do
serious damage to your axles. Never shift the
axle range with the differential locked.
• Park the truck with the Range Selector in LOW.
• When starting from a stop on a hill or grade,
quickly remove your foot from the brake
pedal and firmly press on the accelerator
pedal.
Auxiliary Transmission
If you have an auxiliary transmission, see your transmission manufacturer’s manual for its proper operation.
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PUTTING THE VEHICLE IN MOTION
PART 7: STARTING & OPERATING THE VEHICLE
If Your Vehicle Must Be Towed
CAUTION: Water, dirt and other material can
enter an open hub or axle. This can contaminate the axle fluid and cause possible damage
to components. Ensure that the hubs are covered with plastic whenever a drive axle shaft
is removed.
Follow these directions to ensure your vehicle is not damaged when towing is required.
1. Lift driving wheels off the ground or remove the driveline and axle shafts before towing the vehicle.
CAUTION: Failure to lift the driving wheels off
the ground or remove the driveline and axle
shafts before towing the vehicle could seriously damage your vehicle. All lubricating
and clutch application oil pressure is provided by an engine-driven pump, which does
not work when the engine is stopped. When
vehicles are towed either by wrecker or piggyback, lubricant in the top front of the drive
axle will drain to the rear. This will leave the
top components dry, resulting in friction that
will seriously damage these components.
3. For vehicles with driver-controlled main differential
lock, install the caging bolt before removing the axle
shafts for towing.
CAUTION: To avoid damaging your vehicle
shift the axle at slower travel speeds until you
are used to driving with a dual range axle.
2. Cover open hubs when removing drive axle shafts.
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PART 7: STARTING & OPERATING THE VEHICLE
PUTTING THE VEHICLE IN MOTION
a. Remove the air line and firmly cap
Air Line - Remove to Install
Caging Bolt
CAUTION: Failure to install the caging bolt
when towing vehicles with driver-control main
differential lock can result in damage by failing to lock internal components in position.
WARNING! Ensure there are no open air lines
on the recovered vehicle if the recovery vehicle and recovered vehicle brake systems are
connected. An open air line on the recovered
vehicle will cause a leak in the air brake system of the recovery vehicle possibly causing
an accident and death or personal injury.
Caging Bolt Storage Location
Illustration of Driver-Controlled Main Differential Lock
b. Remove the caging bolt from its storage hole.
c. Screw the caging bolt into the air line hole. When
fully engaged, a 0.25 - 0.5 in. (6-1/2 mm) space will
remain between the air cylinder and the bolt head.
This action will lock the differential by pushing a piston into a “lock” position.
(05/10)
Y53-6032
CAUTION: A recovered vehicle will have no
operational brake system. Additionally, the
rear axle spring brakes will probably be
applied.
• If you desire to use the recovered vehicle’s
brakes, ensure that the vehicles air system
is connected to that of the recovery vehicle.
Also ensure that any air line that has been
removed from a driver-controlled main differential lock is firmly capped to prevent
loss of air pressure from the recovery vehicle.
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ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
• If you don’t desire to use the recovered
vehicle’s brakes, ensure that you cage the
spring brakes before attempting to move
the vehicle.
4. Install recovery hitches and rigging.
CAUTION: Connect recovery rigging only to
hitches intended for that purpose. Do not
attach to bumpers or brackets. Connections
to other structural parts could damage the
vehicle.
5. Follow all state/provincial and local laws that apply to
vehicles in tow.
6. Do not tow vehicles at speeds in excess of 55 mph
(90 kph).
Returning a Towed Vehicle to Service
You will have to add lubricant to prevent damage after
your vehicle has been towed.
– 108 –
PART 7: STARTING & OPERATING THE VEHICLE
1. Into the pinion cage, add 1 pint (.47 liter) of lubricant,
OR
Into the inter-axle differential, add 2 pints (.94 liter) of
lubricant. See the Index, under Lubricant Specifications, for the lubricant required by each axle.
2. 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.
Anti-Lock Braking System Operating
Information
A Model 587 is equipped with an anti-lock braking system
(ABS). This ABS reduces the possibility of wheel lock-up.
If a wheel is about to lock during braking, the ABS will
automatically adjust air pressure to the brake chambers
on the appropriate wheel(s) to prevent wheel lock-up. The
ABS is automatically turned on when the ignition switch is
turned on.
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PART 7: STARTING & OPERATING THE VEHICLE
ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
ABS may not function in an emergency. You
will still have conventional brakes, but not
anti-lock brakes. If any warning lamp indicates a problem, have that ABS checked.
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 death or personal injury accidents.
• Do not drive through water deep enough to
wet brake components, as it may cause the
brakes to work less efficiently than normal.
The vehicle's stopping distance may be
longer than expected, and the vehicle may
pull to the left or right when brakes are
applied, which could contribute to an accident involving death or personal injury.
• Do not rely on an anti-lock brake system
that is functioning improperly. You could
lose control of the vehicle resulting in an
accident involving death or personal injury.
If any ABS lamp goes on while you are driving or stays on after the self-check, that
anti-lock system might not be working. That
(05/10)
ABS Warning Lamps
Truck/Tractor ABS Warning Lamp
A truck/tractor ABS warning lamp illuminates when the
ignition switch is first turned on and will remain on until the
system self-test has been completed successfully. Normally, this 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.
CAUTION: If the truck/tractor 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.
The truck/tractor ABS lamp is located in the warning lamp
cluster. (See illustration on page 17.).
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ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
PART 7: STARTING & OPERATING THE VEHICLE
CAUTION: If the trailer ABS warning lamp
does not illuminate when the ignition is first
turned on, there is a problem with the bulb or
wiring. The driver should have this checked
as soon as possible.
NOTE: A successful warning lamp illumination
and bulb check 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.
Trailer ABS Warning Lamp
Trucks, tractors, and trailers built on and after March 1,
2001 are equipped with power line communication (PLC)
per U.S. FMVSS 121, including a PLC Trailer ABS warning lamp in the cab (see page 17):
– 110 –
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.
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PART 7: STARTING & OPERATING THE VEHICLE
ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
CAUTION:
• The center pin of the 7-way trailer light line
may be constantly powered for ABS. Make
sure it will not accidently turn on trailer
equipment.
• Do not splice into the non-switchable “Auxiliary” circuit on the primary 7-way trailer
light line. Doing so may cause the trailer
ABS to malfunction. This circuit is dedicated for trailer ABS power. To add a switchable “auxiliary” circuit, contact a Peterbilt
Authorized Dealership.
NOTES:
• A “properly connected” ABS-equipped trailer is
– a trailer with PLC hooked up to the J560 connector
2. If an ABS-equipped trailer is properly connected, the
trailer ABS warning lamp will remain illuminated for a
few more seconds while the trailer ABS is tested.
• If no trailer ABS problems are detected, the lamp will
go off.
• If a trailer ABS problem is detected, the lamp will
remain on. The driver should have the trailer’s ABS
problem corrected before the vehicle is driven with
that trailer attached.
Advanced ABS with Stability Control
This vehicle may be equipped with an optional Electronic
Stability Program (ESP). ESP is a feature for ABSequipped vehicles that reduces the risk of rollovers, jackknifing and other loss of control. ESP features include Roll
Stability Program (RSP) and Yaw Control.
– a trailer without PLC that is hooked up to an
optional ISO 3731 connector
• For doubles or triples: PLC does not distinguish
between trailers. An ABS problem in any trailer
will activate the trailer ABS warning lamp.
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WARNING! While ESP may reduce the risk of
loosing control of the vehicle, it does not prevent an event where the vehicle is not under
control. The driver must excercise extreme
caution to prevent a rollover or other loss of
control events. Failure to do so may result in
an accident involving death or personal injury.
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ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
During operation, the ECU of the Bendix Advanced ABS
system constantly compares performance models to the
vehicle’s actual movement, using the wheel speed sensors of the ABS system, as well as lateral, yaw, and steering angle sensors. If the vehicle shows a tendency to
leave an appropriate travel path, or if critical threshold values are approached, the system will intervene to assist
the driver.
PART 7: STARTING & OPERATING THE VEHICLE
A Real World Example
Of How The RSP
System Operates:
Excessive speed for road
conditions creates forces
that exceed the threshold at
which a vehicle is likely to
rollover on a higher-friction
surface.
Roll Stability Program
Bendix RSP, an element of the overall ESP system,
addresses rollover conditions. In the case of a potential
roll event, the ECU will override the throttle and quickly
apply brake pressure various wheel ends to slow the vehicle combination. The level of braking application during an
RSP event will be proportional to roll risk.
The system automatically
reduces engine torque and
ap pl ie s t he s e r v ic e b r ak e s
(based on the projected rollover
r i s k ) t o r e d u c e t h e v e h ic le
speed, thereby reducing the
tendency to roll over.
RSP Example
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PART 7: STARTING & OPERATING THE VEHICLE
ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
Yaw Stability
Yaw stability counteracts the tendency of a vehicle to spin
about its vertical axis. During operation, if the friction
between the road surface and the tires is not sufficient to
oppose lateral (side) forces, one or more of the tires can
slide, causing the truck/tractor to spin.
vehicle (in addition to potentially applying the trailer
brakes), thus applying a counter-force to better align the
vehicle with an appropriate path of travel. For example, in
an over-steer situation, the system applies the “outside”
front brake; while in an under-steer condition, the “inside”
rear brake is applied.
These yaw events are referred to as either “under-steer”
(where there is a lack of vehicle response to steering input
due to tire slide on the steer axle) or “over-steer” (where
the tractor's rear end slides out due to tire slide on the rear
axle) situation. Generally, shorter wheelbase vehicles
(tractors, for instance) have less natural yaw stability,
while longer wheelbase vehicles (straight trucks, for
instance) have greater natural yaw stability. Factors that
influence yaw stability are: wheelbase, suspension, steering geometry, weight distribution front to rear, and vehicle
track width.
Yaw Control
Yaw Control responds to a wide range of low- to high-friction surface scenarios including rollover, jackknife and
loss of control. In the case of vehicle slide (over-steer or
understeer situations), the system will reduce the throttle
and then brake one or more of the “four corners” of the
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ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
PART 7: STARTING & OPERATING THE VEHICLE
IMPORTANT SAFETY INFORMATION ABOUT
THE STABILITY SYSTEM
ESP May Reduce The Vehicle Speed Automatically
To minimize unexpected deceleration and reduce the risk
of a collision the operator must:
• Avoid aggressive driving maneuvers, such as sharp
turns or abrupt lane changes at high speeds, which
might trigger the stability system.
• Always operate the vehicle safely, drive defensively,
anticipate obstacles and pay attention to road,
weather and traffic conditions. ABS, ATC and ESP
stability systems are no substitute for prudent, careful
driving.
A Real World Example
Of How Yaw Control Operates:
Excessive speed exceeds the threshold, creating a
situation where a vehicle is likely to spin and jackknife.
Towing Doubles Or Triples May Reduce The Effectiveness Of Stability Systems
The Bendix® Yaw Control system reduces engine throttle
and selectively applies brakes to reduce the vehicle
speed, thereby reducing the tendency to jackknife.
Yaw Control Example
– 114 –
ESP is designed and optimized for trucks and for tractors
that tow single trailers. If a tractor equipped with ESP is
used to power multiple trailer combinations (known as
“doubles” or “triples”) the effectiveness of the ESP system
may be greatly reduced.
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PART 7: STARTING & OPERATING THE VEHICLE
ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
WARNING! Exercise extreme care when towing doubles or triples with a vehicle equipped
with Electronic Stability Program. Excessive
speed and aggressive maneuvers, such as
sharp turns, sudden steering inputs or abrupt
lane changes should be avoided because
these maneuvers could cause loss of vehicle
control possibly resulting death or severe personal injury.
Limitations Of Stability Systems
The ESP stability system’s effectiveness may be greatly
reduced if:
• The load shifts due to improper retention, accident
damage or the inherently mobile nature of some loads
(for example, hanging meat, live animals or partially
laden tankers),
• The vehicle has an unusually high or off-set center of
gravity (CG),
• One side of the vehicle drops off the pavement at an
angle that is too large to be counteracted by a reduction in speed,
• The vehicle is used to haul double or triple trailer combinations,
(05/10)
• If very rapidly winding steering inputs are inputted at
high speeds,
• There are mechanical problems with suspension leveling of the tractor or trailer resulting in uneven loads,
• The vehicle is maneuvering on a high banked road
creating either additional side forces due to the weight
(mass) of the vehicle or a deviation between expected
& actual yaw rates,
• Gusty winds are strong enough to cause significant
side forces on the vehicle and any towed vehicles.
To Maximize The Effectiveness Of ESP:
• Loads must be properly secured and evenly distributed at all times.
• Drivers need to exercise extreme caution at all times,
and avoid sharp turns, sudden steering inputs or
abrupt lane changes at high speeds, particularly if:
Y53-6032
– the vehicle hauls loads that could shift,
– the vehicle or load has a high or off-set center of
gravity (CG) when loaded, or
– the vehicle tows doubles or triples.
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ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
Truck Chassis Modifications
The ESP system was specifically calibrated and validated
only for your vehicle’s original factory-built configuration. If
your vehicle’s chassis components are altered (for example; a wheelbase extension or reduction, tag axle addition
or removal, tractor to truck conversion or steering system
component change) the ESP system must be disabled
immediately by a qualified mechanic.
WARNING! Failure to disable ESP “Electronic
Stability Program” when modifying a vehicle
could result in a loss of vehicle control possibly resulting in death or severe personal
injury.
WARNING! For vehicles equipped with ESP
“Electronic Stability Program” do not replace
the vehicle’s steering wheel. Using a different
steering wheel could cause ESP to malfunction causing a loss of vehicle control possibly
resulting in death or severe personal injury.
PART 7: STARTING & OPERATING THE VEHICLE
wheel track, or if the steering angle sensor is replaced or
the steering wheel is changed or re-centered, the Steering Angle Sensor must be re-calibrated.
WARNING! If the Steering Angle Sensor is not
re-calibrated, the Yaw Control system will not
function properly, which could result in a loss
of control of your vehicle, death or personal
injury.
Wheel Spin Control Warning Lamp
Your truck/tractor ABS may have an acceleration slip regulation (ASR) or automatic traction control (ATC) feature.
This feature is controlled by a switch as shown in the next
illustration. Either of these features is monitored by a
warning lamp located on the main dash.
.
I
ATC
Steering Angle Sensor Re-Calibration
Whenever maintenance or repair work is performed to the
steering mechanism, linkage, gear, adjustment of the
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PART 7: STARTING & OPERATING THE VEHICLE
BRAKE SAFETY AND EMERGENCY
The Wheel Spin Control warning lamp will briefly illuminate and then go out when the ignition switch is first
turned on. The Wheel Spin Control warning lamp will illuminate whenever the ASR or ATC system detects drive
wheel spin. The lamp will remain illuminated as long as
wheel spin is detected and the ASR or ATC system is
applying the drive wheel brakes or reducing engine
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.
Brake Safety and Emergency
To stop your vehicle in an emergency, vary the service
brake application pressure to provide maximum braking
force without locking the wheels. Use engine compression
to assist the service brakes; i.e., don’t depress the clutch
pedal until the engine reaches idle speed.
Except for checking for proper illumination of the ABS and
Wheel Spin Control warning lamps when first starting the
vehicle, and for monitoring these lamps while driving, no
special operating procedures are required. For detailed
system description, see service literature for your specific
ABS that was provided with your vehicle.
(05/10)
Y53-6032
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 not to
function resulting in the sudden application
of the spring brakes causing wheel lock-up,
loss of control, or overtake by following
vehicles. You could be in an accident, be
killed or severely injured.
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BRAKE SAFETY AND EMERGENCY
PART 7: STARTING & OPERATING THE VEHICLE
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 could cause an accident
involving death or personal injury.
Overheated Brakes
Under normal braking conditions, the energy generated
will bring the internal brake drum temperature to about
500° F (260° C). This is well within the safe zone: The
maximum safe temperature of linings for drum type brakes
is usually about 800° F (427° C).
Parking Brakes and Their Use
The yellow diamond-shaped knob on your instrument
panel controls your parking brakes. These are spring
brakes which you activate by releasing air pressure from
their chambers. When they are not in use, air pressure
compresses the springs and releases the brakes. But putting the valve in the Park position exhausts air from the
chambers and allows the springs to extend and apply the
brakes. Also, if your system air drops below the safe operating level, the spring brakes will apply automatically,
bringing your vehicle to a stop.
But if service brakes are used improperly or for prolonged
periods, internal brake drum temperatures may commonly
exceed 800° F (427° C). Such brake overheating may be
detected by a burning smell or smoke coming from a
drum. If this occurs, you should immediately stop and
check for cracked brake drums or lining fires. If neither
exists, get back behind the wheel and resume a slow
speed as soon as possible to cool the brakes.
– 118 –
Y53-6032
WARNING! On trailers built before March 1975
you may not have parking brakes if the trailer
reservoir pressure leaks down. If you depend
on them to hold your vehicle, they could
release, causing a serious accident involving
death or personal injury. These older trailers
have emergency brakes not designed for
parking. They will apply only if there is
enough trailer reservoir pressure. Don’t use
your trailer emergency brakes for parking.
Apply your tractor parking valve too.
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PART 7: STARTING & OPERATING THE VEHICLE
BRAKE SAFETY AND EMERGENCY
WARNING!
• Do not leave the cab without applying the
parking brake. The truck could roll and cause
an accident involving death or personal injury.
Always apply the parking brake before you
leave the cab.
02909
Red / Yellow Controls
• Stopping with the parking brake controls can
cause a sudden wheel lock-up, loss of control,
or can cause you to be overtaken by following
vehicles. You could be killed or severely
injured. Never pull out the parking brake valve
while the vehicle is moving.
• Do not use the trailer hand brake or service
brakes to park and hold an unattended vehicle—use the parking brakes. Because service
brakes work with air pressure, these brakes
could slowly release. Your vehicle could roll,
causing an accident involving death or personal injury. Someone could be hurt or killed.
Never rely on the service brakes to hold a
parked vehicle.
• Never drive your vehicle with the parking
brake applied. Always release the parking
brakes prior to moving the vehicle. Failure to
disengage the parking brakes prior to moving
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BRAKE SAFETY AND EMERGENCY
PART 7: STARTING & OPERATING THE VEHICLE
your vehicle could result in excessive heat
build-up in the brake system, resulting in a
fire.
NOTE: Today’s diesel electronic engines have
significant torque and startability power at low
RPM. Combinations of engine speed and available torque may over-power the vehicle’s parking
brakes.
To apply all your parking brakes, pull the yellow knob
Out. The parking brakes will set. And the trailer air supply
valve (red octagon knob) will automatically pop out,
releasing air pressure and setting the trailer brakes.
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).
To release your truck or tractor brakes ONLY, push in
the yellow knob. Your trailer will remain parked.
• To release the trailer brakes ONLY, push in the red
knob. The truck or tractor will remain parked.
– 120 –
• To release the full combination of brakes, push in
BOTH yellow and red knobs.
Trailer Air Supply Valve
The red octagon knob controls the air supply to the trailer.
To supply air to the trailer system and release the trailer
parking brakes:
• Allow the tractor air system pressure to build up to
operating level.
• Push the red knob in.
• 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.
The yellow knob will remain out; the tractor will remain
parked. If you ever have a failure or disconnect of the air
supply hose to the trailer, the trailer parking brakes will
set. The red knob will automatically pop out and seal off
the tractor air reservoirs to protect the tractor air system
pressure. When operating the tractor “bobtail”: The red
knob must remain out to protect the tractor air system
pressure.
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PART 7: STARTING & OPERATING THE VEHICLE
BRAKE SAFETY AND EMERGENCY
Manually Releasing Spring Brakes
There may be an occasion when you need to tow the vehicle but the air system does not produce enough operating
pressure to release the parking brakes. For these situations, the spring brakes may be manually released to
allow the vehicle to be towed. This section details how to
release a drum or an air disc brake.
WARNING!
• Disassembling the spring brake chamber is
dangerous and could cause death or serious injury. These chambers contain a powerful spring that is compressed. Sudden
release of this spring could cause you to be
badly injured. Do not disassemble a spring
brake chamber.
NOTE: The primary purpose of the manual
release feature is to permit the vehicle to be
towed to a repair facility.
• Do not operate a vehicle when the spring
brakes have been released manually. Driving a vehicle that has had its spring brakes
manually released is extremely dangerous.
You would probably have no brakes at all,
which could cause death or serious injury.
• Releasing the spring brakes on an unsecured vehicle could lead to an accident. The
truck could roll, causing death or severe
injury. Always secure the truck with wheel
chocks, chains, or other safe means to prevent rolling before manually releasing the
spring brakes.
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BRAKE SAFETY AND EMERGENCY
PART 7: STARTING & OPERATING THE VEHICLE
To release spring brakes manually
:
1. Remove the cap from the spring chamber.
02936A
2. Remove the release stud assembly from the side
pocket; remove the release nut and washer from the
release stud.
02936B
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PART 7: STARTING & OPERATING THE VEHICLE
BRAKE SAFETY AND EMERGENCY
3. Slide out the release stud
02936C
4. Insert the release stud through the opening in the
spring chamber where the cap was removed. Insert it
into the pressure plate. Turn the release stud 1/4-turn
clockwise in the pressure plate. This secures the
cross pin into the cross pin area of the pressure plate
and locks it into the manual release position.
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02937A
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BRAKE SAFETY AND EMERGENCY
PART 7: STARTING & OPERATING THE VEHICLE
5. Assemble the release stud washer and nut on the
release stud.
:
02937B
6. With a wrench, turn the release stud assembly nut
until the compression spring is 90% - 95% caged.
While doing this, check to make sure the push rod
(adapter push rod or service push rod) is retracting.
Do not overtorque the release stud assembly. (S-Cam
type maximum 50 ft.-lb., Wedge type maximum 30 ft.lb.) The spring brake is now mechanically released.
02937C
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PART 7: STARTING & OPERATING THE VEHICLE
BRAKE SAFETY AND EMERGENCY
Retarders
Various retarders are available which function against the
engine, driveline, or transmission. These are devices that
use your engine’s power to slow down your vehicle. They
save wear and tear on your service brakes and can be a
safety feature, too, because they can keep your brakes
from overheating.
Ideally, you should always slow your vehicle with your
retarder (where permitted by law) and use your service
brakes only for stopping completely. Operating this way
will greatly prolong the life of your brakes.
WARNING!
• The retarder is NOT intended as the primary
brake for the vehicle, nor is it an emergency
brake. The retarder only helps the service
brakes by using pressure to slow the drivetrain. Use the service brakes for quick
stops.
• Do not use the retarder when operating on
road surfaces with poor traction (such as
wet, icy, or snow covered roads or gravel).
Retarders can cause the wheels to skid on a
slippery surface. You could lose control of
the vehicle if the wheels begin to skid,
resulting in an accident involving death or
personal injury.
• In an emergency, the retarder might not
stop you fast enough to prevent an accident. You could be killed or severely injured
if you relied only on your retarder. Use the
service brakes for quick stops. The retarder
is not an emergency brake.
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EXHAUST AFTER-TREATMENT SYSTEM
PART 7: STARTING & OPERATING THE VEHICLE
Driving Bobtail or with an Unloaded Trailer
We recommend that you do not use your engine retarder
to slow down when you are bobtailing or pulling an empty
trailer.
WARNING! Using an engine retarder can
cause a wheel lockup. The trailer is not loading the tires enough to give the traction you
may need. When you are bobtail or unloaded,
you can have a serious accident if your
wheels lock suddenly during braking. You
could be killed or injured. Don’t use your
retarder when you are driving bobtail or with
an unloaded trailer.
Exhaust After-Treatment System
NOTE: The emission warning lamps and emission
switch functions described below supersede those
listed in the Engine manufacturer's Operator and
Maintenance manual. For additional Emissions
Aftertreatment information specific to your engine,
see the Engine manufacturer's Operation and
Maintenance Manual supplied in your vehicle. All
other lamp and switch functionality described in
the manual are still valid.
– 126 –
In order to meet EPA engine emission requirements, vehicles will have an exhaust After-Treatment System (ATS)
which includes a Diesel Particulate Filter (DPF), Regeneration Switch and warning lights. The DPF will trap soot
from the engine exhaust gases. The ATS will periodically
regenerate the DPF.
The Regeneration Switch is mounted on the dash and can
override the ATS. Various situations may require the
operator to use the functions of this switch. Refer to
“Regeneration Switch” on page 51 to view the regeneration switch and its use. In addition, refer to “Parked
Regeneration” on page 131 and “Stop an Automatic or
Parked Regeneration” on page 133 for more operating
information.
ATS specific warning lights and indicator symbols will
reside in the driver information display unit.
Functionality / Notification
Information
The ATS will regenerate the DPF by using hot exhaust
gases normally generated by the engine. This typically
occurs during highway operation. This is referred to as a
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PART 7: STARTING & OPERATING THE VEHICLE
EXHAUST AFTER-TREATMENT SYSTEM
"Passive" Regeneration and is transparent to the operation of the vehicle.
Occasionally, the exhaust gases are too cool for passive
regeneration. When this occurs, the ATS will regenerate
the DPF by increasing the exhaust temperature. This is
referred to as an "Automatic" Regeneration and is also
transparent to the operation of vehicle. An Automatic
Regeneration event typically lasts 30 minutes. During and
shortly after the event, the exhaust gases from the DPF
may reach temperatures in excess of 650 C (1200 F). See
the information in the table below on probable causes and
recommended actions related to the warning lights and
indicator symbols of the ATS.
The ATS may not be able to regenerate the DPF when the
vehicle is driven at extended low speeds or with frequent
start and stops. In such cases, warning lights and indicator symbols will alert the operator to take action. The operator should be aware of whether the lights are on alone or
in combination with others. The following table will
describe each warning light(s) and what actions are
needed from the operator.
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EXHAUST AFTER-TREATMENT SYSTEM
PART 7: STARTING & OPERATING THE VEHICLE
Notification of High Exhaust System Temperature:
Indicator
On-Steady
Information
What to do
The High Exhaust Temperature (HEST) warning
lamp will illuminate, regardless of ATS status, as
the vehicle's exhaust outlet temperature
becomes extremely hot (at least 450 deg C /
842 deg F) and subsequently the vehicle speed
slows to below 5 mph / 8 kph.
Follow all warnings listed below. Use the STOP function of the
Regeneration Switch if the situation requires. Follow the instructions
described “Stop an Automatic or Parked Regeneration” on page 133
This will typically occur when:
An Automatic or Parked Regeneration is in process
or
During normal vehicle operation when engine is
under high or heavy loading
WARNING! Temperatures of the exhaust pipes and at
the outlets of the exhaust system during and shortly
after a regeneration event will be extremely hot. If the
High Exhaust System Temperature (HEST) warning
lamp is on:
• Do not park in an area of combustible vapors or materials. You must keep combustibles at least five (5) feet
away from the side and top of the vehicle while the
HEST light is illuminated. Always park your vehicle
outside. Failure to do so could ignite an explosion
which could result in serious injury or death.
• Do not park in an area where people are close by. You
must keep bystanders at least five (5) feet away from
the exhaust outlet while the HEST light is illuminated.
Failure to do so could result in serious injury or death.
• The exhaust piping, diesel particular filter (DPF) or tail
pipe become extremely hot during engine operation
or any regeneration event and can cause serious
burns to the skin. Allow adequate cooling time before
working on or near any part of the exhaust system.
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PART 7: STARTING & OPERATING THE VEHICLE
EXHAUST AFTER-TREATMENT SYSTEM
Notification That Regeneration Is Required:
Indicator
On Steady
Blink once
every second
Blinking
On Steady
Information
What to do
The DPF status indicator symbol will illuminate when the soot level in the DPF is
above the desired level and it needs
regenerating.
The DPF needs regenerating soon. Follow the instructions described
“DPF Regeneration” on page 131
The DPF status indicator symbol will blink
when the soot level in the DPF continues
to stay above the desired level and it
needs regenerating.
Regenerate the DPF as soon as safely possible. Follow the instructions
described “DPF Regeneration” on page 131
The DPF status indicator symbol will blink
when the soot level in the DPF continues
to stay above the desired level and it
MUST be regenerated.
Regenerate the DPF immediately. Follow the instructions described “DPF
Regeneration” on page 131.
NOTE: If you ignore the warning lamp and do not initiate
regeneration at the soonest, safest possible time, the DPF
will become increasingly clogged with soot and can lead to
engine shutdown.
CAUTION: If you do not initiate regeneration after the DPF
Indicator lamp is blinking, you only have a short time before
the check engine light will illuminate and the engine will go
into protection mode and de-rate power.
The engine will de-rate power.
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CAUTION: If you do not initiate regeneration after the DPF
Indicator lamp is blinking and the check engine light is illuminated, you only have a short time before the stop engine
light will illuminate and the engine will automatically begin
to shutdown.
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EXHAUST AFTER-TREATMENT SYSTEM
Indicator
PART 7: STARTING & OPERATING THE VEHICLE
Information
What to do
Blinking
(Caterpillar Engine)
At this point, you CANNOT regenerate the DPF and the engine will begin a
shutdown sequence.
On Steady
The DPF status indicator symbol will blink
when the soot level in the DPF continues
to stay above the desired level
On Steady
WARNING! If the Stop Engine warning lamp illuminates, it
means you have a serious engine system problem. This
should be considered an emergency. You should stop the
vehicle as safely as possible and turn OFF the ignition. The
vehicle must be serviced and the problem corrected before
driving again. Failure to do so may cause severe engine,
DPF damage, death or personal injury.
The soot level in the DPF is now at full
capacity.
NOTE: The engine shutdown sequence is engine specific;
therefore to learn how this works on your vehicle, refer to the
Engine Manufacturer's Operation and Maintenance Manual
supplied with your vehicle.
On Steady
(Cummins and PACCAR Engines)
At this point, you CANNOT regenerate the DPF and the engine will begin a
shutdown sequence.
The Stop Engine light is illuminated when
the soot level in the DPF continues to stay
above the desired level
The soot level in the DPF is now at full
capacity.
WARNING! If the Stop Engine warning lamp illuminates, it
means you have a serious engine system problem. This
should be considered an emergency. You should stop the
vehicle as safely as possible and turn OFF the ignition. The
vehicle must be serviced and the problem corrected before
driving again. Failure to do so may cause severe engine,
DPF damage, death or personal injury.
NOTE: The engine shutdown sequence is engine specific;
therefore to learn how this works on your vehicle, refer to the
Engine Manufacturer's Operation and Maintenance Manual
supplied with your vehicle.
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PART 7: STARTING & OPERATING THE VEHICLE
EXHAUST AFTER-TREATMENT SYSTEM
DPF Regeneration
Parked Regeneration
Carefully read the following instructions to regenerate the
DPF. If you have any problems or difficulties contact your
nearest Peterbilt authorized dealer for assistance.
The After-Treatment System (ATS) needs conditions typically found in highway driving to regenerate the DPF. If
your DPF Indicator lamp is illuminated, the easiest option
is to help the ATS by proceeding to the nearest highway.
In very limited applications or operations the DPF must be
regenerated by initiating a Parked Regeneration. Follow
these six steps to initiate a Parked Regeneration:
1. Pull the vehicle over to a safe location
2. Ensure no one is in the immediate vicinity to the tail
pipe
3. Maintain a minimum of 5 feet of clearance to any combustible materials from the edge and top of the vehicle
• For the three position switch only, make sure the
Regeneration Switch is in the CENTER position.
• Select a highway that has a posted legal speed of
more than 40 mph.
• Drive your vehicle until the DPF light goes off. This
may take 30 - 45 minutes of speeds greater than 20
mph (32 kph) for a Caterpillar engine or 40 mph (64
kph) for a PACCAR or Cummins engine.
If your operation or planned route in the immediate future
limits your ability to reach highway speeds, proceed to the
next section titled Parked Regeneration.
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WARNING! Parking the vehicle too close to
any combustible materials or vapors may
start a fire, ignite an explosion or burn someone standing close by. Before pushing the
Regeneration switch on the dash, walk
around your vehicle and ensure you have at
least five (5) feet clearance from the sides and
top of your vehicle to any combustibles.
Ensure no one is in the immediate vicinity to
the tailpipe. Failure to do so could cause a
fire or lead to death or serious injury to you
and/or bystanders.
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EXHAUST AFTER-TREATMENT SYSTEM
PART 7: STARTING & OPERATING THE VEHICLE
WARNING! Never initiate an regeneration in a
closed building or enclosure. Always park
your vehicle outside and ensure no one is in
the immediate vicinity. Failure to do so could
ignite an explosion or harm bystanders which
could result in death or serious injury.
4. Verify that the following conditions are met before proceeding. A Parked Regeneration will not initiate if any
of these conditions are not met.
• Parking brake is applied / set
• Engine is at low idle
NOTES:Typical operation areas or materials that
can contain explosive vapors, flammable materials or people in close proximity of the vehicle are
• No throttle, brake or clutch applied
• PTO is disengaged
• Transmission is in neutral
5. Get out and walk all around vehicle to ensure that the
vehicle is at least 5 feet away from all combustible
materials and no one is in the immediate vicinity.
6. Climb back into the vehicle
7. Push the Regeneration (START) Switch located on
the dash for at least 4 -8 seconds and release the button to initiate a Parked Regeneration.
• Fuel depots
• Grain elevators
• Dry grass, leaves or trees
• Transfer refuse stations/dumps
• Parking lots
• Load/unload terminals
NOTE: While the list above may appear comprehensive, it is your responsibility to take the necessary precautions and be aware of your
surroundings and ensure that no combustibles
(materials or vapors) or bystanders are close by
before initiating a regeneration.
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PART 7: STARTING & OPERATING THE VEHICLE
EXHAUST AFTER-TREATMENT SYSTEM
NOTE: Acknowledgment that a Parked Regeneration has initiated will vary by engine. The most
predominant acknowledgement to you will be an
increase in engine RPM and overall engine
noise.
NOTE: The time delay between when the regeneration switch has been pushed and released
and when the system starts regenerating may
vary by engine. A Parked Regeneration may take
30 or more seconds to initiate as the ATS system
conducts various self-checks to verify all the system requirements have been met.
NOTE: A Parked Regeneration will initiate only if
the DPF status light is illuminated or blinking.
If you are unable to initiate a Parked regeneration and the
DPF status light is illuminated, contact your nearest Peterbilt authorized dealer for assistance.
Stop an Automatic or Parked
Regeneration
the regeneration switch is a two position switch, then the
operator will not have the ability to stop a regeneration
and this section will not apply.
WARNING! If the vehicle’s regeneration
switch does not have a STOP position, never
allow the vehicle to remain inside a building
such as a service bay, shop or building of
any kind during an Automatic regeneration.
Failure to do so could ignite an explosion
which could result in death or serious injury
to you and/or bystanders.
Vehicles with a three position switch provides the operator
with the ability to STOP an Automatic or Parked Regeneration. Since Automatic Regenerations can occur at any
time with this engine, you must depress the STOP portion
of the Regeneration Switch ANYTIME you plan to drive
your vehicle into a building, enclosure or area where the
activation of a regeneration is not allowed. If the regeneration does not stop, turn the vehicle ignition OFF.
A three position switch with a START, Center, and STOP
position will allow the operator to stop a regeneration. If
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Y53-6032.book Page 134 Monday, May 24, 2010 3:37 PM
STOPPING THE ENGINE
PART 7: STARTING & OPERATING THE VEHICLE
WARNING! Never allow an Automatic regeneration to automatically start while inside a
building such as a service bay, shop or building of any kind. Any time you are parking
your vehicle inside a building or enclosure,
ALWAYS press the Regeneration (STOP)
switch prior to entering the building. Failure
to do so could ignite an explosion which
could result in death or serious injury to you
and/or bystanders.
WARNING! Never initiate a Parked Regeneration in a closed building or enclosure.
Always park your vehicle outside. Failure to
do so could ignite an explosion which could
result in death or serious injury to you and/or
bystanders.
CAUTION: Do not leave the switch in the
STOP position unless you need to cancel or
stop regeneration. Leaving the switch in
the STOP position for extended periods of
time will result in increased soot levels in
the DPF.
– 134 –
Stopping The Engine
Before Stopping The Engine
A hot engine stores a great amount of heat. And it doesn’t
cool down immediately after you shut it off. Always cool
your engine down before shutting it off. You will greatly
increase its service life.
Idle the engine at 1000 RPM for five minutes. Then low
idle for thirty seconds before shutdown. This will allow 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 serious
engine damage that may result from uneven cooling.
Turbochargers
This cooling-down practice is especially important on a
turbocharged engine. The turbocharger contains bearings
and seals that are subjected to hot exhaust gases. While
the engine is operating, heat is carried away by circulating
oil. If you stop the engine suddenly after a hard run, the
temperature of the turbocharger could rise as much as
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PART 7: STARTING & OPERATING THE VEHICLE
STOPPING THE ENGINE
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.
Refuel Before the Final Stop
Air space in your fuel tanks allows water to condense
there. To prevent this condensation while you are stopped,
fill your tanks to 95% of capacity.
WARNING! Do not carry additional fuel con-
tainers in your vehicle. Fuel containers, either
full or empty, may leak, explode, and cause or
feed a fire. Do not carry extra fuel containers,
even empty ones are dangerous.
Final Stop
To make sure your vehicle is ready to go after a long stop
(such as over night), please follow the suggestions below.
Your vehicle will be easier to get going when you are
ready, and it will be safer for anyone who might be around
it. Please remember, too, that in some states it is illegal to
leave the engine running and the vehicle unattended.
Final Stopping Procedures
1. Set the parking brake before leaving the driver’s seat.
To hold your vehicle while it is parked, don’t rely on
• Diesel fuel in the presence of an ignition
source (such as a cigarette) could cause an
explosion. You could be killed or 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.
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Y53-6032
• Air Brakes
• Hand Control Valve for Trailer Brakes
• Engine Compression
WARNING! Using the trailer hand brake or air
brakes to hold a parked vehicle is dangerous.
Because they work with air pressure, these
brakes could come loose. Your vehicle could
roll, causing an accident involving death or
personal injury. Always set the parking
brakes. Never rely on the trailer hand brake or
truck air brakes to hold a parked vehicle.
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SETTING RIDE HEIGHT
PART 7: STARTING & OPERATING THE VEHICLE
2. If you are parked on a steep grade, block the wheels
.
.
02939
02938
Opening Drains
Blocked Wheels
3. Drain water from the air reservoirs. While the engine
and air supply system are still warm, drain moisture
from the air reservoirs. Open the reservoir drains just
enough to drain the moisture. Don’t deplete the entire
air supply. Be sure to close the drains before leaving
the vehicle.
– 136 –
4. Secure the vehicle. Close all the windows and lock all
the doors.
Setting Ride Height
Vehicles equipped with rear air suspensions have their
ride height and axle (pinion) angle(s) preset at the factory.
These are precision settings and should not be altered.
Incorrectly adjusted ride height may result in improper
interaxle U-joint working angles. This can result in premature driveline wear and driveline vibration. If your vehicle
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PART 7: STARTING & OPERATING THE VEHICLE
SETTING RIDE HEIGHT
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.
Proprietary Rear Air
Suspension
Air Leaf
Ride Height [inches (mm)]*
Single Drive
N/A
Tandem Drive
11.70 (297)
Air Trac
11.00 (279)
11.00 (279)
Low Air Leaf
6.50 (165)
8.50 (216)
Low Low Air Leaf
N/A
6.50 (165)
FLEX Air
N/A
8.50 (216)
*These values are for a fully laden vehicle
Follow this procedure to temporarily set ride height.
WARNING! To prevent possible death, 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.
Ride Height Measurement (Tandem Axles Location)
NOTE: Suitable wheel chocks are at a minimum
an 18-inch (46 cm) long 4x4.
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SETTING RIDE HEIGHT
PART 7: STARTING & OPERATING THE VEHICLE
1. Ensure the air supply and delivery plumbing of the
height control valve is consistent with the following
illustrations:
SUPPLY FROM FORWARD AIR TANK
DELIVERY TO RIGHT HAND AIR BAG
MOUNTING BOLTS
LINK BOLT
EXHAUST
ALIGNMENT PIN OR DOWEL
FROM DUMP VALVE SWITCH
DELIVERY TO LEFT HAND AIR BAG
CONTROL ARM
Typical Height Control Valve (Rear View Looking Forward)
NOTES:
• At least one of the mounting holes in the height
control valve bracket will be slotted to permit
rotating the valve.
• On dual-valve systems, begin with the LH
valve on the next step.
Typical Height Control Valve (Top View)
– 138 –
2. Loosen the fasteners mounting a height control valve
to its bracket.
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PART 7: STARTING & OPERATING THE VEHICLE
SETTING RIDE HEIGHT
WARNING! The rear of a vehicle will drop
about 3 1/2 inches (88 mm) when the air
springs are deflated. Ensure that no persons
or objects that could be killed, injured or
damaged are under the vehicle before deflating the air springs.
WARNING! To minimize risk of damage or
death or injury, do not use a dump valve to
deflate the air springs. Rotate the height
control valve(s) manually to ensure positive
control of air spring deflation.
3. Rotate the valve either clockwise or counterclockwise
until air pressure in the air springs provides the ride
height specified for that suspension. Measure the ride
height from the bottom of the frame rail to the approximate centerline of the rearmost drive axle hub:
WARNING! Do not allow the air springs to
overinflate. Overinflating the air springs may
cause them to burst which can lead to death
or personal injury from debris or the frame.
• For tandem axles, make the vertical measurement
at the centerline of the suspension (see illustration
on page 137).
(05/10)
• 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.
4. When at the correct ride height, ensure that the height
control valve lever is in the neutral position, then
install either the built-in alignment pin or a 1/8-inch (3
mm) dowel (see page 138).
5. Torque the mounting fasteners to 55–75 Lb. in. (6.2–
8.5 N.m.).
6. Remove the alignment pin or dowel.
7. Repeat Steps 2 through 6 above for the RH valve on
vehicles with a dual-valve system.
Driving With Deflated Air Springs
If an air spring is ruptured, there will be enough air pressure to drive the vehicle to a safe stop off the highway to
investigate the problem.
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DRIVING TIPS AND TECHNIQUES
PART 7: STARTING & OPERATING THE VEHICLE
WARNING! Your brakes could fail if you continue driving with deflated air springs. Air
escaping from the system will lower the air
pressure, which could cause a spring brake to
engage. The spring brake may cause your
brakes to drag and burn up the linings. If you t
continue to operate in this condition, a fire
may result which will result in equipment
damage, death or personal injury.
You can get to a repair facility if you do the following:
1. Remove the height control link connected to the axle
and to the suspension air valve control arm. This will
cause the air valve control arm to center in the closed
position.
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.
Driving Tips And Techniques
This section covers additional driving tips and techniques
on how to drive your Peterbilt more efficiently.
Coasting
2. The air system can then be pumped up to normal
pressure for continued operation.
WARNING! Low air pressure could make the
brakes unsafe for driving which can lead to
death or personal injury. 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.
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Y53-6032
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
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PART 7: STARTING & OPERATING THE VEHICLE
DRIVING TIPS AND TECHNIQUES
cause a serious accident due to mechanical failures
which could cause death or personal injury.
Engine Overspeed
CAUTION: To avoid engine damage, do not let
the engine rpm go beyond the maximum governed rpm—valve damage could result if overspeed conditions occur.
Coasting with the transmission in neutral 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
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 death or personal injury in 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.
(05/10)
NOTE: Often these recommendations are secondary to maintaining an adequate and safe
speed relative to the surrounding traffic and road
conditions.
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.
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DRIVING TIPS AND TECHNIQUES
PART 7: STARTING & OPERATING THE VEHICLE
Refer to the Engine Operation and Maintenance manual
for optimum engine rpm.
• The best results in trip time and fuel economy are
obtained while driving the vehicle at a steady speed.
• If the engine rpm exceeds the maximum governed
speed, apply the service brake or shift to a higher
gear to lower engine rpm.
• Shift into higher or lower gears (or apply the service
brake) to keep engine rpm near the lower end of the
optimum operating range.
• 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.
• Avoid rapid acceleration and braking.
NOTE: Vehicles with an Eaton Ultrashift®
Transmission mated to a Caterpillar or Cummins Engine will automatically shift to a higher
gear (even in manual mode) if an engine overspeed condition exists.
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:
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PART 8: MAINTENANCE AND SERVICE
PREVENTIVE MAINTENANCE SCHEDULE
PART 8: MAINTENANCE AND SERVICE
Preventive Maintenance Schedule
Your preventive maintenance program begins with the
daily checks you perform. See “PART 6: DRIVER’S
CHECKLIST” for these. If you check your Peterbilt vehicle
regularly, you can avoid many large, expensive, and timeconsuming repairs. Your vehicle will operate better, be
safer, and last longer. Neglect of recommended maintenance may in some cases void your vehicle’s warranty. So
for your safety and the life of your vehicle, please follow
the Maintenance Schedule. Remember - there may be
maintenance operations that demand skills and equipment you don’t have. If so, please take your vehicle to an
expert mechanic, for your safety and your vehicle’s safety.
WARNING! It can be dangerous to attempt
maintenance work without sufficient training,
service manuals, and the proper tools. You
could be killed, injured or you could make
your vehicle unsafe. Do only those tasks you
are fully trained and equipped to do.
• Before attempting any procedures in the
engine compartment, stop the engine and
let it cool down. Hot components can burn
skin on contact.
• Be alert and cautious around the engine at
all times while the engine is running
• If work has to be done with the engine 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.
(R05/10)
Y53-6032
– 143 –
Y53-6032.book Page 144 Monday, May 24, 2010 3:37 PM
PREVENTIVE MAINTENANCE SCHEDULE
PART 8: MAINTENANCE AND SERVICE
• Never start or let the engine run in an
enclosed, unventilated area. Exhaust fumes
from the engine contain carbon monoxide,
a colorless and odorless gas. Carbon monoxide can be fatal if inhaled.
• 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.
NOTE: Suitable wheel chocks are at a minimum
an 18-inch (46 cm) long 4x4.
• 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.
• 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.
– 144 –
Table 1
Preventative Maintenance (PM) Intervals
I
A
B
C
D
E
At the first
15,000 mi./
24,000 km
or at the
first PM
15,000
mi./
24,000
km/
Monthly
30,000
mi./48,000
km
60,000
mi./
96,000
km/6
months
120,000
mi./
192,000
km/Annually
240,000
mi./
384,000
km
Y53-6032
(R05/10)
Y53-6032.book Page 145 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
PREVENTIVE MAINTENANCE SCHEDULE
NOTES:
• Where questions or discrepancies develop
between these recommendations and component supplier recommendations, consult the
supplier for specific recommendations.
vices more frequently. The charts on the following pages
show the maintenance intervals for recommended maintenance practices.
• Maintenance requirements of specific vocational configurations will dictate whether the
intervals used are determined based on mileage, time in service, hours operating, etc.
• These maintenance practices and intervals are
intended as additional requirements and are
not to replace, in whole or in part, the pretrip
inspection requirements of the Commercial
Driver’s License (CDL) as established in the
Federal Commercial Motor Vehicle Safety Act
of 1986.
If you operate your vehicle off-highway or in very heavyduty applications such as mining, logging, or earth moving, you will need to perform maintenance checks and ser-
(R05/10)
Y53-6032
NOTES:
• Engine lubricating oil change intervals aren’t
listed here. Refer to your engine’s operating
manual for recommendations. For specific
information on maintenance procedures, consult your vehicle maintenance manual.
• The initial fill of drive axle lubricant must be
changed before the end of the first scheduled
maintenance interval. Refer to the information
on page 169 before you put a new vehicle into
service.
• The initial fill of lubricant in manual transmissions must be changed before the end of the
first maintenance interval. See page 165 for
specific information.
– 145 –
Y53-6032.book Page 146 Monday, May 24, 2010 3:37 PM
PREVENTIVE MAINTENANCE SCHEDULE
Table 2
PART 8: MAINTENANCE AND SERVICE
Preventative Maintenance Schedule
SYSTEM
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Frame
Front Axle
Front
Suspension
– 146 –
A
B
C
D
Fifth Wheel
Check the kingpin lock and plate for wear and function; lubricate (NLGI #2
grease).
Frame Fasteners
Check for tightness; tighten to the specified torque value as required (see
page 208).
X
Crossmembers and Mounting
Brackets
Inspect for cracks and loose fasteners. Replace or tighten to the specified
torque value as required (see page 208).
X
Steering knuckles, thrust
bearings, kingpins, drawkeys,
tie rod ends, steering stops, &
bushings
Inspect for wear and damage and for endplay. Shim or replace as required
(see page 207).
X
Kingpin bushings & tie rod
ball ends
Lubricate with approved grease.
Total Vehicle Alignment
Check and adjust as required.
X
Drawkeys
Tighten nuts
X
E
X
X
X
X
Front Spring
Inspect for cracked leaves, worn bushings, & excessive corrosion.
X
Spring Pins & Shackles
Inspect for worn parts and excessive joint clearance. Shim or replace as
required.
X
Spring Pins
Lubricate.
X
Y53-6032
(R05/10)
Y53-6032.book Page 147 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
Table 2
PREVENTIVE MAINTENANCE SCHEDULE
Preventative Maintenance Schedule (Continued)
SYSTEM
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Front
Suspension
Drive Axle
Shock Absorbers
Inspect for leaking, body damage, and damaged or worn bushings.
Replace as required.
B
C
Check for proper function.
U-bolts (ON HIGHWAY)
Check the general condition and the tightness of the nuts. Tighten the nuts
to the specified torque value as required (see page 207 ).
U-bolts (OFF HIGHWAY)
Check the general condition and the tightness of the nuts. Tighten the nuts
to the specified torque value as required (see page 207 ).
Axle Housing
Visually inspect for damage or leaks.
X
Check oil level. Check “cold.” Torque the drain plug.
X
Drain the lubricant while warm. Flush each unit with clean flushing oil.
Change the lubricant.
Air Shift Unit
Check the lubricant level.
D
X
X
X
X
See information on page
170
X
Remove the housing cover and drain the lubricant. Wash the parts thoroughly and dry in air.
X
Breather
Clean or replace.
X
Lube Pump (ON HIGHWAY)
Remove the magnetic strainer and inspect for wear particles. Wash in solvent and dry in air.
X
Lube Pump (OFF HIGHWAY)
Remove the magnetic strainer and inspect for wear particles. Wash in solvent and dry in air.
Y53-6032
E
X
Shock Absorbers
(Dana)
(R05/10)
A
X
– 147 –
Y53-6032.book Page 148 Monday, May 24, 2010 3:37 PM
PREVENTIVE MAINTENANCE SCHEDULE
Table 2
PART 8: MAINTENANCE AND SERVICE
Preventative Maintenance Schedule (Continued)
SYSTEM
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Drive Axle
(Dana)
Drive Axle
Lube Filter (ON HIGHWAY)
Change.
Lube Filter (OFF HIGHWAY)
Change.
Magnetic drain plug and
breather (ON HIGHWAY)
Clean or replace.
Magnetic drain plug and
breather (OFF HIGHWAY)
Clean or replace.
Axle Housing
Check the “cold” fill level at the differential carrier plug for a pinion angle of
less than 7 degrees, or at the axle bowl plug for a pinion angle of greater
than 7 degrees. Tighten the plug to 35 - 50 Lb. ft. (47 - 68 N.m.)
(Meritor)
– 148 –
A
B
C
D
E
X
X
X
X
Axle Housing
Visually inspect for damage or leaks.
Axle Housing
Drain and replace the lubricant.
Lubricant filter
Change the filter.
X
X
See information on page
169
X
Breather
Check the operation. If the cap doesn’t rotate freely, replace.
Input shaft & pinion shaft
Check and adjust the endplay.
X
Axle shaft
Tighten the rear axle flange nuts to the specified torque value.
X
Interaxle differential
Check the operation.
X
Y53-6032
X
(R05/10)
Y53-6032.book Page 149 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
Table 2
PREVENTIVE MAINTENANCE SCHEDULE
Preventative Maintenance Schedule (Continued)
SYSTEM
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Rear
Suspension
Drum
Brakes
(All)
B
C
U-bolts
Check the torque. Tighten to specified torque value as required (see page
207).
Frame & crossmember bolts
Check the torque. Tighten to specified torque value as required (see page
208).
Mounting brackets and fasteners
Check the condition and the fastener torque. Tighten to the specified
torque value as required (see page 208).
Slack adjusters
Check the push rod travel and check the control arm for cracks. Adjust at
reline (see page 173).
X
Lubricate (NLGI #2 grease).
X
Brake camshaft bearing
Lubricate (NLGI #2 grease).
X
Check for excessive cam shaft play in the axial and radial directions. Max
allowable play is 0.003”.
X
Clean the area around the treadle, boot, and mounting plate. Check the
pivot and mounting plate for integrity. Check the plunger boot for cracks.
Lubricate roller pin, pivot pin, and plunger (NLGI #2 grease).
X
Brake treadle valve
(R05/10)
A
Brake air system
Check air lines and fittings for leaks (see page 173). Adjust routing as
required to reduce chafing. Check tank mounting and condition.
Brake air system
Clean or replace the inline filters.
Brake lining
Inspect; replace as required.
Y53-6032
X
D
E
X
X
X
X
X
X
X
– 149 –
Y53-6032.book Page 150 Monday, May 24, 2010 3:37 PM
PREVENTIVE MAINTENANCE SCHEDULE
Table 2
PART 8: MAINTENANCE AND SERVICE
Preventative Maintenance Schedule (Continued)
SYSTEM
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Disc Brakes
(All)
Hub, Drum,
& Hubcap
A
B
C
Brake pads
Inspect; replace as required.
X
Brake disc/rotor
Inspect for visible cracks, heat checking, galling, or scoring of surface.
Check thickness minimum of 1.46” (37 mm).
X
Caliper sliding function
Ensure caliper slides freely with no obstructions or excessive play (see
manufacturer’s service literature for “Checking Running Clearance”).
X
Caliper function
Inspect bearings, seals, tappet and boots of the guide pins for damage or
cracking.
X
Adjuster
Check operation; inspect as per manufacturer’s service literature.
X
Hubs (non-LMS)
Check the bearing endplay and adjust as required (see page 185).
Hubs (non-LMS) with outrunner seals
Clean the components and check for excessive wear or damage. Change
the oil and seal (see page 185).
Hubs (non-LMS) with standard seals
Clean the components and check for excessive wear or damage. Change
the oil and seal (see page 185).
Hub seals (all)
Check for leaks; replace as required.
LMS Hubs (Dana)
Check the bearing endplay and adjust as required (see page 185).
LMS Hubs (Dana) with
Clean the components and check for excessive wear or damage. Change
the oil and seal (see page 185).
D
E
X
X
X
X
X
500,000 miles/
800,000 km
Synthetic Lubricant
– 150 –
Y53-6032
(R05/10)
Y53-6032.book Page 151 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
Table 2
PREVENTIVE MAINTENANCE SCHEDULE
Preventative Maintenance Schedule (Continued)
SYSTEM
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Hub, Drum,
& Hubcap
LMS Hubs (Dana) with
Clean the components and check for excessive wear or damage. Change
the oil and seal (see page 185).
A
B
C
D
E
360,000 miles/
576,000 km
Mineral Lubricant
Brake drums
Hubcaps
Main & auxiliary transmission
Main & auxiliary transmission
(Dana)
(R05/10)
Inspect for visible cracks, heat checking, galling or scoring of the braking
surface, and for severe corrosion on the outside surface. Check for out-ofround or oversize condition [0.080 in. (2 mm) more than the original diameter]. Replace as required.
X
Clean the sight window. Check the center plug, mounting flange, and fill
plug for leaks and for proper installation. Replace broken or damaged
parts. Check the lubricant level and add as required.
Main & auxiliary transmission
and transfer case
Inspect for visible damage, signs of overheating, and leaks.
Main & auxiliary transmission
and transfer case
Check the drain plugs for tightness.
Oil cooler
Clean the fins (air-to-oil type) and body. Check the hose condition and for
leaks; replace as required.
Main & auxiliary transmission
Check the oil level; refill as required (see page 165 and page 167).
Main & auxiliary transmission
(ON HIGHWAY)
Drain the lubricant while warm. Flush each unit with clean flushing oil.
Main & auxiliary transmission
(OFF HIGHWAY)
Drain the lubricant while warm. Flush each unit with clean flushing oil.
Y53-6032
X
X
X
X
X
X
500,000 miles/
800,000 km
X
X
– 151 –
Y53-6032.book Page 152 Monday, May 24, 2010 3:37 PM
PREVENTIVE MAINTENANCE SCHEDULE
Table 2
PART 8: MAINTENANCE AND SERVICE
Preventative Maintenance Schedule (Continued)
SYSTEM
COMPONENT
Main & auxiliary transmission
(Meritor)
Transfer Case
Air Intake
Air intake piping, mounting,
and charge air cooler
Check the system for broken pipes, leaks, joint integrity, cleanliness, and
proper support (see page 212).
Engine air intake tubing
Disassemble, clean, check for cracks, leaks, and joint integrity.
Clutch
Cooling
– 152 –
Recommended
PM Interval
MAINTENANCE TASK
Check the oil level; refill as required (see page 169).
I
A
X
X
B
C
D
E
Drain lubricant while warm. Flush each unit with clean flushing oil.
X
X
X
X
Cold starting aids
Check for leaks and proper operation (see page 94).
Air cleaner
Replace the element as indicated (see page 212).
Clutch pedal shaft
Check for excessive looseness and lubricate (NLGI #2 grease).
X
Clutch pedal
Check for proper pedal free travel (see page 203).
X
Clutch release linkage
Check for excessive looseness and lubricate (NLGI #2 grease).
X
Clutch release bearing
Lubricate.
X
Clutch release shaft
Lubricate.
X
When required by the air
restriction indicator
Components
Check the radiator and heater hoses for leaks.
X
Radiator Pressure Cap
Check radiator pressure cap
X
Y53-6032
X
X
X
X
X
X
(R05/10)
Y53-6032.book Page 153 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
Table 2
PREVENTIVE MAINTENANCE SCHEDULE
Preventative Maintenance Schedule (Continued)
SYSTEM
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Cooling
System (ELC)
A
B
Check the freeze point (see page 191).
X
Check for contamination using test strips (see page 192).
X
C
Replace blank water filter if applicable.
X
Perform lab analysis of coolant to determine suitability for continued use
(see page 192).
X
Flush, drain, and refill with new coolant if lab analysis shows coolant is
unsuitable for continued use(see page 194).
X
Add ELC Extender if lab analysis shows coolant is suitable for continued
use (see page 192).
X
Tires &
Wheels
(R05/10)
E
X
Flush, drain, and refill with new coolant (see page 194).
Fan clutch
D
Check for leaks.
X
X
Check the fan drive bearings (turn the sheavein both directions to check for
worn hub bearings).
X
X
Solenoid Valve
Check the fan drive for proper engagement and disengagement.
X
X
Tires
Check inflation pressure (see page 178).
Weekly “cold” using calibrated gauge
Tires
Inspect for cuts, irregular wear, missing lugs, sidewall damage, etc.
Y53-6032
X
– 153 –
Y53-6032.book Page 154 Monday, May 24, 2010 3:37 PM
PREVENTIVE MAINTENANCE SCHEDULE
Table 2
PART 8: MAINTENANCE AND SERVICE
Preventative Maintenance Schedule (Continued)
SYSTEM
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Tires &
Wheels
Power
Steering
– 154 –
Disc wheels
A
Inspect the wheel disc for any cracks or surface irregularities. Inspect the
rim edge and bead seat area for damage. Replace any damaged wheels DO NOT ATTEMPT TO REPAIR.
X
Demountable rims
Inspect the mounting ring, rim gutter, side ring, and lock ring for damage;
replace as required.
X
Wheel nuts and studs
Check the tightness of the fasteners and tighten the fasteners to the specified torque as required (see page 185).
X
Wheel nuts and studs
Inspect for damaged hex corners, stripped or damaged threads, and
excessive corrosion; clean or replace as required.
X
B
C
Reservoir
Check the fluid level (see page 171).
Reservoir (ON HIGHWAY)
Drain, replace the filter, and refill (see page 171).
X
Reservoir (OFF HIGHWAY)
Drain, replace the filter, and refill (see page 171).
X
Steering gear
Check the lash of the sector shaft; adjust as required.
X
Steering gear
Grease the trunnion bearing (EP NLGI #2 lithium-based, moly-filled, HD
grease).
X
Steering gear
Grease the input shaft seal (EP NLGI #2 lithium-based, moly-filled, HD
grease).
X
Power assist cylinder
Lubricate the ball joints. Inspect for leaking rod seals, damaged ball joint
boots, and damage to cylinder rod or barrel.
Hoses and tubes
Check for leaks and chafing.
Y53-6032
D
E
X
X
X
X
X
(R05/10)
Y53-6032.book Page 155 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
Table 2
PREVENTIVE MAINTENANCE SCHEDULE
Preventative Maintenance Schedule (Continued)
SYSTEM
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Power
Steering
Fuel &
Tanks
(R05/10)
Steering linkage
Check all joints for excessive lash; replace as required (see page 207).
Draglink tube clamp and ball
socket
Check the torque; tighten to specified torque value as required.
Pitman arm clamp bolt and
nut
Check the torque; tighten to specified torque value as required.
Steering intermediate shaft
A
B
C
E
X
X
X
X
X
Check the torque on the pinch bolt and nut.
X
X
Steering intermediate shaft
U-joints (ON HIGHWAY)
Lubricate [EP NLGI #2 HD grease, +325° F to -10° F (+163° C to
-23° C) range].
X
X
Steering intermediate shaft
U-joints (OFF HIGHWAY or
CITY DELIVERY)
Lubricate [EP NLGI #2 HD grease, +325° F to -10° F (+163° C to
-23° C) range].
Draglink and tie rod arm ball
sockets (ON HIGHWAY)
Lubricate (EP NLGI #2 lithium-based, moly-filled, HD grease).
Steering intermediate shaft
U-joints (OFF HIGHWAY or
CITY DELIVERY)
Lubricate (EP NLGI #2 lithium-based, moly-filled, HD grease).
Fuel tanks
Inspect tanks, brackets, hoses, and fittings for correct location, tightness,
abrasion damage, and leaks; repair or replace as required.
Fuel tank breathers
Check for proper function; clean the drain hoses.
X
X
X
X
X
Y53-6032
D
X
X
X
– 155 –
Y53-6032.book Page 156 Monday, May 24, 2010 3:37 PM
PREVENTIVE MAINTENANCE SCHEDULE
Table 2
PART 8: MAINTENANCE AND SERVICE
Preventative Maintenance Schedule (Continued)
SYSTEM
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Fuel &
Tanks
Driveshafts
Battery
Fuel tank straps
X
X
Models 1610-1810 & SPL-90
Lubricate slip member & U-joints
Model SPL-100
Lubricate slip member & U-joints
Models SPL-140/140HD/170/
170HD/250/250HD
Lubricate slip member & U-joints
Models SPL-140XL/170XL/
250XL (ON HIGHWAY &
LINE HAUL)
Lubricate slip member & U-joints
Models SPL-140XL/170XL/
250XL (OFF HIGHWAY &
CITY)
Lubricate slip member & U-joints
Battery cables
Check the condition of the cables, cushion clamps, and routing. Replace a
cushion clamp if the rubber has deteriorated. Repair or tighten terminals,
and secure cables to prevent chafing. Replace damaged cables (cuts,
cracks, or excessive wear) (see page 195).
Batteries
– 156 –
Tighten to proper torque value of 45 - 70 Lb. ft. (61 - 95 N.m.); *check annually once strap tension reaches a steady state; i.e., after 2 - 3 retorquings,
the measured torque is the same as previous reading.
A
B
C
X
D
E
*
X
X
X
360,000 miles/
576,000 km/
every 3 years
X
Check for cracks and damage, electrolyte level, condition of terminals, and
tightness of holddowns (see page 195).
Y53-6032
X
X
X
(R05/10)
Y53-6032.book Page 157 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
Table 2
PREVENTIVE MAINTENANCE SCHEDULE
Preventative Maintenance Schedule (Continued)
SYSTEM
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
A
B
C
Battery
Battery box and tray
Check the box integrity. Clean the drain tube and check for acid leaks.
Check condition of all equipment mounted under the box.
X
Electrical &
lights
Headlamps
Check the aim and adjust as required.
X
Warning lights in light bar
Check at the ignition start position to verify bulbs and Driver Information
Display function.
(R05/10)
E
X
Turn signal
Visual check.
X
Stop lights
Visual check.
X
Reverse lights
Visual check.
X
Alternator
Check operation and output.
X
Check tightness of the pulley nut.
X
Check the tension of the drive belt (see page 210).
X
Check tightness of the terminal hex nuts.
X
Starter
Check torque on hex nuts.
X
ECM connector
Check the tightness of the ECM connector.
X
Wheel sensors
Check for damaged sensors and connectors, and worn or frayed wires.
X
Fuel and Diesel Exhaust Fluid
tank sending unit
Check the mounting screws and electrical connections for worn or damaged wires and connectors.
Y53-6032
D
X
X
– 157 –
Y53-6032.book Page 158 Monday, May 24, 2010 3:37 PM
PREVENTIVE MAINTENANCE SCHEDULE
Table 2
PART 8: MAINTENANCE AND SERVICE
Preventative Maintenance Schedule (Continued)
SYSTEM
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Electrical &
lights
Cab structure, doors,
& hoods
Heating &
Air Conditioning
A
B
C
Power supply harnesses
(engine, transmission, etc.)
Check for worn or damaged insulation, corroded terminals, frayed wires,
and oil or fluid leaks on the connectors or wiring.
Power supply harnesses
(engine, transmission, etc.)
Wash to remove excess grease.
Hood
Lubricate the lower hood pivot (only if lube fittings are present).
X
Hinges and latch
Lubricate with silicone spray.
X
Body & cab holddown bolts
Check the condition and tightness.
Air conditioner
Operate the system. (NOTE: The air conditioning system is active when the
Defrost/Defog mode is selected.)
Heater & air conditioner
Perform the checks listed on page 215.
Cab air filter
Clean; replace after a maximum of three cleanings.
X
Condenser
Clear any debris from the front of the condenser.
X
System
Check for leaks and proper support (see page 213).
Flexible pipe
Replace the main and anciliary exhaust flexible pipe.
– 158 –
Y53-6032
E
X
X
X
X
X
Full operational and diagnostic check.
Aftertreatment System
D
X
X
150,000 mi/241,401 Km
(R05/10)
Y53-6032.book Page 159 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
Table 2
PREVENTIVE MAINTENANCE SCHEDULE
Preventative Maintenance Schedule (Continued)
SYSTEM
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Aftertreatment System
Air
(R05/10)
A
B
C
D
E
Refer to the engine
maintenance manual
Diesel Particulate Filter
Clean Filter.
Diesel Exhaust Fluid Tank
Check fittings for abrasion damage, leaks, tightness and fully engaged connectors
Diesel Exhaust Fluid Supply
Module
Replace Filter (See page page 205)
X
X
Air compressor governor
Replace air strainer.
X
Air lines
Check condition and routing to prevent chafing.
X
System
Lubricate (see page 188).
X
Inline filters
Replace elements or clean with solvent.
X
Air dryer
Perform the checks listed on page 190.
Air dryer (ON HIGHWAY)
Overhaul.
Air dryer (OFF HIGHWAY)
Overhaul.
X
360,000 miles/
576,000 km
X
Y53-6032
– 159 –
Y53-6032.book Page 160 Monday, May 24, 2010 3:37 PM
PREVENTIVE MAINTENANCE SCHEDULE
Table 2
PART 8: MAINTENANCE AND SERVICE
Preventative Maintenance Schedule (Continued)
SYSTEM
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Engine
– 160 –
Basic Engine
A
B
C
D
E
The maintenance and service interval recommendations for the specific
engine are the maintenance requirements specified in the engine manufacturer’s Operations and Maintenance Manual included with the vehicle.
Strict adherence to these recommendations is required to maintain warranty coverage. The maintenance and service interval recommendations
for the engines vary significantly, depending on the manufacturer and the
model of the engine. As a minimum, perform the operations listed below:
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PART 8: MAINTENANCE AND SERVICE
PREVENTIVE MAINTENANCE SCHEDULE
Lubricant Specifications
Engine
WARNING! Handle lubricants carefully. Vehicle
lubricants (oil and grease) can be poisonous and
cause death, injury or sickness. They can also
damage the paint on the vehicle.
NOTE: The engine in this vehicle may comply with
EPA emission standards. Consult the engine manufacturer’s manual for changed lubrication and maintenance requirements.
In this section you will find the basic information you need to
do the routine lubrication your vehicle requires. Of course you
will want to schedule service more frequently if you are operating under severe conditions such as extreme heat or cold,
with very heavy loads, off-road, etc. For any special service
requirements, consult your service manuals and your lubricant supplier. And please remember: one key to keeping your
truck running at top economy and in prolonging its life is
proper lubrication servicing. Neglecting this essential aspect
of vehicle care can cost time and money in the long run.
Proper engine lubrication depends on the outside temperatures where you will be driving. Use the oil recommended for
the conditions you are most likely to be facing. You will find a
complete engine lubrication service guide in the Engine
Operation Manual that came with your vehicle. There, the
engine manufacturer explains more fully all the maintenance
operations that you and a qualified service mechanic need to
perform on your engine.
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.
(R05/10)
Y53-6032
WARNING! Exhaust fumes from the engine contain carbon monoxide, a colorless and odorless
gas. Do not breathe the engine exhaust gas. A
poorly maintained, damaged or corroded exhaust
system can allow carbon monoxide to enter the
cab or sleeper. Entry of carbon monoxide into the
cab is also possible from other vehicles nearby.
Failure to properly maintain your vehicle could
cause carbon monoxide to enter the cab/sleeper
and cause death or serious illness.
– 161 –
Y53-6032.book Page 162 Monday, May 24, 2010 3:37 PM
PREVENTIVE MAINTENANCE SCHEDULE
PART 8: MAINTENANCE AND SERVICE
WARNING! Never idle your vehicle for prolonged
periods of time if you sense that exhaust fumes
are entering the cab or sleeper. Investigate the
cause of the fumes and correct it as soon as possible. If the vehicle must be driven under these
conditions, drive only with the windows slightly
open. Failure to repair the source of the exhaust
fumes may lead to death or personal injury.
NOTES:Keep the engine exhaust system and the
vehicle’s cab/sleeper ventilation system properly
maintained. It is recommended that the vehicle’s
exhaust system and cab/sleeper be inspected
NOTE: Use only exact replacement components in
exhaust systems. Certain components contain integral catalytic converters essential for compliance with
EPA emission standards. Using noncompliant components as a replacement could violate these standards and also void the emission system’s warranty.
WARNING! Hot engine oil can be dangerous. You
could be seriously burned. Let the engine oil cool
down before changing it.
• By a competent technician every 15,000 miles/
24,000 km.
• Whenever a change is noticed in the sound of the
exhaust system.
• Whenever the exhaust system, underbody, cab or
sleeper is damaged.
– 162 –
Y53-6032
(R05/10)
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PART 8: MAINTENANCE AND SERVICE
PREVENTIVE MAINTENANCE SCHEDULE
Master Lubrication Index
Table 3
Lubricant Symbol Key
ATF
Dextron III/Mercon approved Automatic Transmission
Fluid
BB
Ball Bearing grease
CB
Engine oil for mild to moderate requirements
CC/CD
Engine oil for severe requirements (MIL-L-2104B /MIL-L45199B w/ 1.85% max. sulfated ash content)
CD
Engine oil meeting API “Five engine test sequence”
CD50
SAE50W synthetic transmission fluid
CE
Engine oil meeting severe duty service requirements for
direct-injection turbocharged engines
CJ-4
Engine oil
(R05/10)
Y53-6032
Table 3
Lubricant Symbol Key
CL
Multipurpose chassis grease
C4
Type C4 transmission fluid (torque fluid)
EP
Extreme Pressure Lubricant
GL
Straight mineral gear lubricant
HD
Hypoid Gear Oil, A.P.I. - GL-5, SAE 80W-90
HT
High Temperature grease (Timken Spec. 0-616)
MP
Multipurpose gear lubricant (MIL-L-2105B)
WB
Wheel Bearing grease (Timken Spec. 0-610)
NOTE: The responsibility for meeting these specifications, the quality of the product, and its performance in service rests with the lubricant supplier.
– 163 –
Y53-6032.book Page 164 Monday, May 24, 2010 3:37 PM
PREVENTIVE MAINTENANCE SCHEDULE
Table 4
PART 8: MAINTENANCE AND SERVICE
Table 4
Component Lubrication Index
Component Lubrication Index (Continued)
Universal Joints
EP
Clutch Release Bearings
BB
Drive Shaft Splines
CL
Brake Shoe Anchor Pins
HT
Wheel Bearings (driven hubs)
HD
Brake Cam Bearings
HT
Wheel Bearings (nondriven hubs)
CD50
Slack Adjusters
CL
Wheel Bearings (all grease-lubricated hubs)
WB
Water Pump
BB*
Steering Column
CL
Cab Tilt Hydraulic Reservoir
Alternator Bearing
BB*
Fan Hub
BB*
Hydraulic
Jack Oil,
MIL-L5056B
Power Steering Reservoir
ATF
Speedometer Cables
Steering Drag Link
CL
Lubriplate
Aero or
equivalent
Steering Knuckles
CL
Spring Pins
CL
– 164 –
*Consult manufacturer or lubricant supplier for special details
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PART 8: MAINTENANCE AND SERVICE
PREVENTIVE MAINTENANCE SCHEDULE
2. Change oil regularly.
3. Use the correct grade and type of oil.
4. Buy oil from a reputable dealer.
Lubrication Change and Inspection
Off-Highway Use
Refer to the Eaton Fuller transmission manual for servicing information.
02942
Highway Use
Fuller Transmission Lubrication
Fuller transmissions are designed so that the internal parts
operate in a bath of oil circulated by the motion of gears
and shafts. Grey iron parts have built-in channels where
needed to help lubricate bearings and shafts. All parts will
be amply lubricated if these procedures are closely followed:
• Refer to the Eaton Fuller transmission manual for servicing information.
• Refer to the oil change vs. temperature chart that follows for special oil change information. The “intermittent peak temperature” is the maximum temperature
observed for a short time in a fully loaded vehicle performing normally.
1. Maintain oil level; check it regularly.
(R05/10)
Y53-6032
– 165 –
Y53-6032.book Page 166 Monday, May 24, 2010 3:37 PM
PREVENTIVE MAINTENANCE SCHEDULE
PART 8: MAINTENANCE AND SERVICE
Recommended Lubricants
Table 5
Recommended Lubricants
Type
Grade (SAE)
Ambient Temperature
Heavy Duty Engine
Oil MIL-L-2104B, C,
or D;
50
Above 10° F (-12° C)
API - SF, or API-CD
(Previous API designations are
acceptable)
40
Above 10° F (-12° C
30
Below 10° F (-12° C)
90
Above 10° F (-12° C)
80W
Below 10° F (-12° C)
50
All
Mineral gear oil
with rust and oxidation inhibitor APIGL-1
CAUTION: Exceeding the recommended oil
change intervals may be harmful to the life of
the transmission and the transmission oil
cooler.
– 166 –
Synthetic Lubricant*
* See your Peterbilt dealer for approved brands.
Y53-6032
(R05/10)
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PART 8: MAINTENANCE AND SERVICE
PREVENTIVE MAINTENANCE SCHEDULE
Spicer Transmission Lubrication
It is extremely important to use the proper lubricants and
maintain the correct oil levels in Spicer units. This will
ensure proper lubrication and operating temperatures in
these units.
Recommended Lubricants
The lubricants listed below are recommended, in order of
preference, for use in all Spicer mechanical transmissions, auxiliaries, and transfer cases. Do not use extreme
pressure additives such as those found in multipurpose or
rear axle-type lubricants. These additives are not required
in Spicer transmissions, and may in some cases create
transmission problems. Multipurpose oils, as a group,
have relatively poor oxidation stability, a high rate of
sludge formation, and a greater tendency to react with or
corrode the steel and bronze parts.
Table 6
Recommended Lubricants
Grade (SAE)
Ambient
Temperature
30, 40, or 50
Above 0° F
(-18° C)
30
Below 0° F
(-18° C)
90
Above 0° F
(-18° C)
80
Below 0° F
(-18° C)
Synthetic Engine Oil meeting MILL-2104D or MIL-L-46152B, APISF or API-CD
CD50
CD30
All
*Synthetic Gear Oil Meeting MIL2105C or API-GL5
EP75W90
EP75W140
All
Type
Heavy Duty Engine Oil MIL-L2104D or MIL-L-46152B, API-SF
or API-CD (MIL-L-2104B or C or
MIL-L-46152 designations are
acceptable)
Mineral gear oil
(R & O type) API-GL-1
*EP Gear Oils are not recommended when lubricant operating temperatures are above 230° F (110° C).
(R05/10)
Y53-6032
– 167 –
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PREVENTIVE MAINTENANCE SCHEDULE
PART 8: MAINTENANCE AND SERVICE
Refilling
Oil Changes
CAUTION: When adding oil, types and brands
of oil should not be intermixed because of
p o s s i b l e i n c o m p a t i b i l i t y, w h i c h c o u l d
decrease the effectiveness of the lubrication
or cause component failure.
An initial oil change and flush should be performed after
the transmission has been placed in actual service. This
change should be made any time after 3000 miles (4800
km) but never longer than 5000 miles (8000 km) of overthe-road service. In off-highway use, the change should
be made after 24 hours but before 100 hours of service
have elapsed.
– 168 –
Remove all dirt around filler plug. Refill with new oil of the
grade recommended for the existing season and prevailing service. Fill to the bottom of the level testing plug positioned on the side of the transmission. Do not overfill the
transmission. Overfilling usually results in oil breakdown
due to excessive heat and aeration from the churning
action of the gears. Early breakdown of the oil will result in
heavy varnish and sludge deposits that plug up oil ports
and build up on the splines and bearings. Overflow of oil
can also escape onto clutch or parking brakes. When adding oil, do not mix different types of oil.
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PART 8: MAINTENANCE AND SERVICE
PREVENTIVE MAINTENANCE SCHEDULE
Meritor Axle Lubrication
NOTE: Axles utilized in 100% off-highway use are
not eligible for Meritor’s Advanced Lube Rear
Drive Axle program.
Under Meritor’s Advanced Lube Rear Drive Axle program,
the axles listed below are exempt from an initial lubricant
change:
Table 7
• Refer to the following chart for lubricant change intervals:
Table 8
Application
Linehaul
Available Advanced Lube Axles
RS-17-145
RS-23-180
RT-40-145
RT-44-145P
RS-19-145
RS-26-180
RT-40-145P
RT-46-160
RS-21-145
RS-30-180
SQ-100A
RT-46-160P
RS-23-160
RT-34-145
SQ-100AP
RT-52-160
RS-23-161
RT-34-145P
RT-44-145
RT-52-160P
Meritor rear axles that do not appear on the list above will
continue to require an initial drain at 3000-5000 miles
(4800-8000 km).
City Delivery
Vocational
• Refer to the Meritor Field Maintenance Manual for a
particular axle for lubricant specifications.
• See your Peterbilt dealer for Meritor-approved lubricant brands.
(R05/10)
Lubricant Change Intervals
Y53-6032
Type Of Lubricant
Mileage Interval
Synthetic
240,000 mi. (384,000
km)
Synthetic with Pump
and Filter
500,000 mi. (800,000
km)
Mineral Base
120,000 mi. (192,000
km)
Synthetic
120,000 mi. (192,000
km)
Synthetic with Pump
and Filter
240,000 mi. (384,000
km)
Mineral Base
120,000 mi. (192,000
km)
Synthetic
120,000 mi. (192,000
km)
Synthetic with Pump
and Filter
120,000 mi.(192,000
km)
Mineral Base
120,000 mi. (192,000
km)
– 169 –
Y53-6032.book Page 170 Monday, May 24, 2010 3:37 PM
PREVENTIVE MAINTENANCE SCHEDULE
PART 8: MAINTENANCE AND SERVICE
• Change the lubricant filter every 120,000 miles
(192,000 km). Top off the lubricant level with a similar
lubricant.
Table 9
Type of
Lubricant
Eaton/Dana Axle Lubrication
• The original mineral-based lubricant must be drained
within 3000-5000 miles (4800-8000 km) on all Eaton
axles. This initial change is very important because it
flushes out break-in contaminants that might otherwise cause premature wear.
• No initial drain is required on Eaton axles that are factory filled with an Eaton-approved synthetic lubricant.
• Mineral-based lubes must be drained within the first
5000 miles (8000 km) if converting to an Eatonapproved synthetic lube.
• Change the lubricant within the first 5000 miles (8000
km) of operation after a carrier head replacement,
regardless of the lubricant type.
• Refer to the Eaton Field Maintenance Manual for a
particular axle for lubricant specifications.
• See your Peterbilt dealer for Eaton-approved lubricant
brands.
• Refer to the chart below for lubricant change interval.
– 170 –
Eaton/Dana Axle Lubricant Change Intervals
Mineral-Based
On/Off
Highway
Severe Service Mi.(km)
On-High- Maximum
Change
way
Interval
Mi.(km)
120,000 Yearly
(192,000)
Eaton-Approved 240,000 2 Years
Synthetic
(384,000)
Maximum
Change
Interval
60,000
(96,000)
Yearly
120,000
(192,000)
Yearly
Eaton-Approved 360,000
(576,000)
Synthetic in
axle with
extended drain
interval option
Wheel Bearing Lubrication
Oil-lubricated Driven Hubs
Use hypoid oil, A.P.I.-GL-5 SAE 80W-90 or equivalent. A
minimum of 1 quart (921 ml) of oil is required for proper
lubrication of each drive hub. Add oil through the filler hole
in the hub; if none, add oil through the differential filler
hole. (Note: Remember to replace vent plug or threaded
filler plug when done.) Allow time for the oil to seep
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PART 8: MAINTENANCE AND SERVICE
PREVENTIVE MAINTENANCE SCHEDULE
through the bearings when initially filling a hub. Maintain
the differential oil level by adding oil until its surface is
even with the bottom of the filler hole (see page 165).
Universal Joint Lubrication
Oil-lubricated Nondriven Hubs
Steering Gear Lubrication
Refer to the Spicer Universal Joints and Driveshafts service manual and lubrication specifications.
Use CD50 synthetic transmission fluid SAE 50W or equivalent. A minimum of 9 oz. (270 ml) of lubricant is required
for proper lubrication of an LMS™ hub; 10 - 13 oz. (295 400 ml) is required for a non-LMS hub, depending on
wheel design. Allow time for the fluid to seep through the
bearings when initially filling a hub. When properly filled,
the fluid level will lie between the fluid level line and 1/4”
above the line. (Note: Remember to replace vent plug
when done.)
Grease-Lubricated Hubs
Repack the hub bearing with clean wheel bearing grease
after disassembling, cleaning, and inspecting.
(R05/10)
Y53-6032
CAUTION: When adding fluid, be sure to use
fluid of the same type. While many fluids have
the same description and intended purpose,
they should not be mixed due to incompatible
additives. If incompatible (insoluble) fluids
are mixed in a power steering system, air bubbles can be produced at the interface of the
two fluids. This can cause cavitation, which
reduces the lubrication between moving parts
in the gear. This could result in worn components. The mixture of two different fluids,
although harmless to individual internal components, may initiate a chemical reaction that
produces a new compound that will attack
seals and other internal components. Do not
mix different fluids.
– 171 –
Y53-6032.book Page 172 Monday, May 24, 2010 3:37 PM
PREVENTIVE MAINTENANCE SCHEDULE
PART 8: MAINTENANCE AND SERVICE
Replacement
Inspection
NOTE: Before removing reservoir cover, wipe outside of cover so that no dirt can fall into the reservoir.
1. Replace fluid per the chart below.
2. Bleed the system if necessary
.
Table 10 Fluid and Filter Replacement Schedule
Steering
Gear
TRW
Sheppard
Inspect
[mi.(km)]
Replace
[mi. (km)/
months]
ATF
Every 15,000
(24,000)
Every 240,000
(384,000)/24
ATF
Every 15,000
(24,000)
Every 240,000
(384,000)/24
Fluid * @
1. Check the fluid level; add fluid if required.
2. Check fluid for contamination, discoloration, or burnt
smell; correct source of such problems before replacing fluid & filter.
*Extremely low temperatures may require lower viscosity fluids; consult your Peterbilt dealer for recommendations
@See TRW or Sheppard Service Manuals for additional fluid listings
– 172 –
Y53-6032
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PART 8: MAINTENANCE AND SERVICE
SERVICING SPECIFIC SYSTEMS AND UNITS
Servicing Specific Systems And Units
This section will help you keep your Peterbilt vehicle in
good running condition. There are a number of checks
you can do, and you may be able to do some of the service work yourself. But please: let your dealer’s service
department do any work you don’t have the tools or skill to
perform. Authorized service mechanics are trained in the
proper technical and safety procedures to fix your Peterbilt
vehicle right.
To operate your vehicle safely and profitably, you need
some understanding of its brake systems. For more on
brakes, see the Index, under Brakes.
Brake adjustment and brake balance must be set carefully
to (1) make the most efficient use of the forces available
for braking and (2) allow equal stopping forces at all
wheels.
CAUTION: The air brake system of this vehicle
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.
WARNING! It is dangerous to work on a vehicle without the right know-how and proper
tools. You could be killed or badly injured, and
you could damage the vehicle. Do only work
you know you are fully capable of doing, and
for which you have the right tools.
Brake Adjustment
WARNING! To prevent uncontrolled vehicle
movement and reduce risk of death or personal injury, park the vehicle on a hard level
surface, apply the parking brake, and chock
all wheels securely.
(R05/10)
Once a brake system is set to specifications, changing
any one of its components or any combination of components may cause the system to not work as well. All parts
have to work together to perform as they should. Any
replacement components in your brake system should be
exactly equal to the original components. Any changes
from the original specifications can affect the whole sys-
Y53-6032
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Y53-6032.book Page 174 Monday, May 24, 2010 3:37 PM
BRAKE ADJUSTMENT
PART 8: MAINTENANCE AND SERVICE
tem. All of the following areas are interrelated and must
conform to original specifications:
• Tire Size
• Drum brakes
A.
B.
C.
D.
E.
F.
Cam Radius
Wedge Angle
Drum Radius
Brake Linings
Brake Chambers
Slack Adjusters
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 death , personal
injury or system failure
Air System
• Build up air pressure in the system to the governor
cut-out point.
• Disc Brakes
A. Disc Rotors
• Stop the engine.
WARNING! A nonconforming part in your
brake system could cause an accident involving death or personal injury. Sizes and types
are so related to one another that a seemingly
unimportant change in one may result in a
change in how well your brakes work for you
on the road. If parts don’t work together properly, you could lose control of your vehicle. Be
sure any replacement parts in your brake system conform exactly to original specifications.
– 174 –
All vehicle operators should check their brakes regularly.
Always adjust your brakes when they are cool.
• Release the parking brakes (push in the yellow knob).
• Watch the rate of air pressure drop. The rate of drop
should not be more than 2 psi (14 kPa) per minute.
• Now start the engine and build up the air pressure
again.
• Stop the engine. Ensure that the parking brakes are
still released (i.e., the yellow knob is pushed in).
• Fully apply the service brakes.
Y53-6032
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PART 8: MAINTENANCE AND SERVICE
BRAKE ADJUSTMENT
• Watch the rate of air pressure drop registered by the
air gauge. The rate of drop should not be more than 3
psi (21 kPa) per minute.
• If you find excessive leakage, a leakage test should
be made at the air line connections and at all air brake
control units. To perform a leakage test, refer to the
detailed instructions in the Peterbilt Maintenance
Manual, or take your vehicle to an authorized Peterbilt
dealer.
• Have a qualified mechanic perform a detailed inspection if the notches are not found. The pads and rotors
should be measured and compared against the manufacturers specifications located in the brake manufacturer’s service manual.
Air Disc Brakes
Have brake pads inspected by a qualified mechanic for
wear at regular intervals according to the “Preventive
Maintenance Schedule” on page 143. In severe service or
off-highway applications inspect the linings more frequently.
Regularly inspect for pad/rotor wear:
• Park on level ground and chock the wheels.
• Temporarily release the parking brakes.
• Compare the relative position of two notches; one
located on the caliper and the other on the carrier.
See the illustration below to determine if the brakes
require a detailed inspection by a qualified mechanic.
(R05/10)
Regularly inspect caliper for Running Clearance:
• Stop the vehicle on level ground and let the brakes
cool down. Hot brake calipers can burn skin on contact.
• Chock the wheels.
• Temporarily release the parking brakes.
• Grab the caliper and move it. This movement is Running Clearance.
Y53-6032
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Y53-6032.book Page 176 Monday, May 24, 2010 3:37 PM
BRAKE ADJUSTMENT
PART 8: MAINTENANCE AND SERVICE
• Proper Running Clearance is 0.08” (2 mm) of movement of the brake caliper (approximately the thickness
of a nickel) in the inboard/outboard direction.
• Have a qualified mechanic provide further inspection
if the caliper does not move or appears to move more
than the specified clearance.
• A correctly installed and functioning auto slack
adjuster will produce the following strokes:
Drum Brakes
Have brake drum linings and disc brake pads inspected by
a qualified mechanic for wear at regular intervals according to the maintenance schedule. In severe service or offhighway applications inspect the linings more frequently.
Chamber Type
Stroke
36 (rear brakes)
11/2” - 21/4” (38 - 57 mm)
30 (rear brakes)
11/2” - 2” (38 - 51 mm)
16, 20, & 24 (front brakes)
1” - 13/4” (25.4 - 44.4 mm)
Automatic Slack Adjusters
Periodically check the Brake Chamber Stroke. Replace
the slack adjuster if proper stroke cannot be maintained.
Operational checks of automatic slack adjusters
• Measure brake chamber stroke with the spring brake
released and the air pressure no less than 100 psi
(690 kPa).
• Brake Chamber Stroke is the difference between the
applied and the retracted position of the air chamber
pushrod.
– 176 –
Y53-6032
02945a
Brake Chamber Stroke
(R05/10)
Y53-6032.book Page 177 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
TIRES, WHEELS, AND RIMS
WARNING! Manual adjustment of automatic
slack adjusters is a dangerous practice that
could result in an accident involving death or
injury. 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.
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.
• 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 killed or 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.
Tires, Wheels, And Rims
Tires
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 accident causing death or personal
injury. 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 184 illustrates the differences between
(R05/10)
• Follow OSHA regulations per section 1910.177.
• Follow all warnings and cautions contained
within the tire and wheel manufacturers literature.
• Only properly trained personnel should service
tire and rim assemblies.
Your tires are a very important part of your vehicle’s whole
braking system. How fast you can stop depends on how
much friction you get between the road and your tires. In
Y53-6032
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Y53-6032.book Page 178 Monday, May 24, 2010 3:37 PM
TIRES, WHEELS, AND RIMS
PART 8: MAINTENANCE AND SERVICE
addition, keeping your tires in good condition is essential
to the safe, efficient operation of your vehicle. Regular, frequent inspection and the right care will give you the assurance of safe and reliable tire operation. Here are some
tips on maintaining your tires.
Checking Inflation Pressure
Give your tires a visual test every day, and check inflation
with a gauge every week:
• When checking tire pressure, inspect each tire for
damage to sidewalls, cuts, cracks, uneven wear, rocks
between duals, etc. If a tire appears underinflated,
check for damage to the wheel assembly. Don’t forget
to check between dual wheels. If you find wheel damage, have an expert tire service repair it.
• Maximum tire pressure will be indicated on the sidewall of a tire.
• Check pressure only when the tires are cool. Warm or
hot tires cause pressure buildup and will give you an
inaccurate reading. So never deflate a warm tire to
the specified pressure.
– 178 –
• Lower tire pressure does not give you more traction
on ice or snow. This is an old myth that refuses to die.
Underinflation actually reduces traction, steering control and tire load capacity.
Underinflated Tires
Low pressure is a tire’s worst enemy. Underinflation allows
tires to flex improperly, causing high temperatures to build
up. Heat causes early tire damage such as flex break,
radial cracks, and ply separation. Low pressure may affect
control of your vehicle, especially at the front wheels. Most
tire wear problems are caused by underinflation as the
result of slow leaks, so you’ll want to check tire pressure
regularly.
Y53-6032
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 which can cause an accident
resulting in death or personal injury. 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.
(R05/10)
Y53-6032.book Page 179 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
TIRES, WHEELS, AND RIMS
Overloaded tires
Overinflated tires
Overloading your truck is as damaging to your tires as
underinflation. The following chart shows how neglect or
deliberate abuse can affect the life of your tires.
Too much air pressure reduces the tire tread contact area
and results in rapid wear in the center of the tread.
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 accident causing death
or personal injury. The maximum vehicle load
rating (GVWR) is found on the Tire and Rim Data
label on the driver's door.
Table 11 Effect of Load Pressure on Tire Life
Vehicle
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
Expected
Total Tire
Mileage
Normal
70%
50%
40%
30%
25%
(R05/10)
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 accident causing death or personal
injury. Be sure all tires are inflated correctly
according to the manufacturer's recommendations.
The chart on page 182 gives you the right load and inflation rates for different tire sizes. Please follow it for the safest and most economical use of your tires. (Consult the
tire manufacturer for proper pressure settings with tires
not listed in this table.)
Matching tires
Be sure to buy matched tires for your vehicle, especially
on the rear axles. Mismatched tires can cause stress
between axles and cause the temperature of your axle
lubricant to get too hot. Matched tires will help your driveline last longer and will give you better tire mileage.
Y53-6032
– 179 –
Y53-6032.book Page 180 Monday, May 24, 2010 3:37 PM
TIRES, WHEELS, AND RIMS
PART 8: MAINTENANCE AND SERVICE
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 causing death or personal
injury. 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.
Front: Replace front tires when less than 4/32 in. of tread
remains. Check at three places equally spaced around the
tire.
Drive Axles or Trailers: Replace tires on drive axles or
trailers when less than 2/32 in. of tread depth remains in
any major groove. Check at three places equally spaced
around the tire. See the next illustration for recommended
measuring points for tread depth.
Replacing Tires
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
accident causing death or personal injury.
– 180 –
Y53-6032
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 accident causing death or personal injury.
(R05/10)
Y53-6032.book Page 181 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
TIRES, WHEELS, AND RIMS
NOTE: To prolong your tires’ life and make them
safer, have their radial and lateral run-out
checked at your dealer. And of course you should
have your tires balanced any time you change a
tire.
Tire chains
If you need tire chains, install them on both sides of each
driving axle.
CAUTION: Chains on the tires of only one tandem axle can damage the driveline U-joints
and the interaxle differential. Your repairs
could be costly & time-consuming.
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 death,
personal injury or property damage.
02946
Steer Tire Points in Upper View, Drive Tire in Lower View
(R05/10)
Y53-6032
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Y53-6032.book Page 182 Monday, May 24, 2010 3:37 PM
TIRE LOAD AND INFLATION TABLES
PART 8: MAINTENANCE AND SERVICE
Tire Load and Inflation Tables
Table 12 Load Range Letters and Corresponding Ply Rating
Tire
Size
11R22.5
11R22.5
11R24.5
11R24.5
275 / 70R22.5
295 / 75R22.5
285 / 75R24.5
Load
Range
G
H
G
H
H
G
G
70
4530
4530
4820
4820
4500
4545
( G = 14 ply; H = 16 ply)
SINGLE RADIAL TIRES FOR VEHICLES IN HIGHWAY SERVICE
Tire Load Limits At Various Cold Inflation Pressures (psi)
75
80
85
90
95
100
105
110
4770
4990
5220
5510
5730
5950
6175
4770
4990
5220
5510
5730
5950
6175
6320
5070
5310
5550
5840
6095
6350
6610
5070
5310
5550
5840
6095
6350
6610
6790
4850
5050
5250
5480
5705
5945
6195
6450
4725
4940
5155
5370
5510
5780
5980
6175
4770
4940
5210
5420
5675
5835
6040
6175
DUAL RADIAL TIRES FOR VEHICLES IN HIGHWAY SERVICE
4580
4760
4950
5205
5415
5625
5840
4580
4760
4950
5205
5415
5625
5840
5895
4870
5070
5260
5510
5675
5840
6005
4870
5070
5260
5510
5675
5840
6005
6205
4430
4610
4795
5005
5210
5430
5660
5890
4300
4540
4690
4885
5070
5260
5440
5675
4340
4540
4740
4930
5205
5310
5495
5675
11R22.5
G
4380
11R22.5
H
4380
11R24.5
G
4660
11R24.5
H
4660
275 / 70R22.5
H
295 / 75R22.5
G
4095
285 / 75R24.5
G
4135
NOTES:
• Pressure listed is the minimum for the load.
• All tire load figures are in pounds.
• Figures in Bold face indicate maximum recommended load.
115
120
6465
6610
6970
6720
7160
7000
5950
6005
6405
6135
6610
6395
Source: Bridgestone Tire 2/02
– 182 –
Y53-6032
(R05/10)
Y53-6032.book Page 183 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
VEHICLE LOADING
Vehicle Loading
WARNING! Do not exceed the specified load rating. Overloading can result in loss of vehicle
control, death or 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. Supervise all loading to ensure that
(1) the Gross Vehicle Weight Rating (GVWR) is
not exceeded and (2) the load is distributed
correctly so that the weight distribution is
within the limits of the front and rear axle load
ratings. Severe damage to your vehicle, difficult handling, or an accident could occur if
your vehicle is not loaded properly.
(R05/10)
Y53-6032
• An unevenly distributed load or a load too
heavy over one axle can affect the braking and
handling of your vehicle and cause an accident. Even if your load is under the legal limits,
be sure it is distributed evenly.
GVW: GVW is the Gross Vehicle Weight. This is the TOTAL
WEIGHT your vehicle is designed to carry. Never carry so
heavy a load that you exceed the GVW rating of your Peterbilt
vehicle.
Axle Weight: Your front and rear axles are rated according to
the load they are designed to carry. You will find this number
listed on the driver’s door frame.
– 183 –
Y53-6032.book Page 184 Monday, May 24, 2010 3:37 PM
VEHICLE LOADING
PART 8: MAINTENANCE AND SERVICE
Load Distribution: Be sure any load you carry is distributed
so that no axle has to support more than its load limit.
Wheels And Rims
02949
Hub, Drum, and Stud Assembly
• The hub pilot mounting system uses M22x1.5 metric
threads (about 7/8 in. dia.). The stud stands out at least
1.9 in. beyond the brake drum. All studs are right hand
threads. Pilot bosses machined on the hub fit tightly to
the wheel center bore.
• The ball seat mounting system uses 3/4 x 16 or
1-1/8 x 16 threads. The dual mounting studs provide 1.3 1.44 in. standout. Right hand and left hand threads are
required. Inner and outer cap nuts center the wheels by
seating against wheel ball seats.
Wheels
Hub Pilot Mount System
• Pilot mount wheels have stud holes that are reamed
straight through (no ball seats). Center bore diameter is
8-21/32 in. Budd Uni-Mount - 10 wheels have UNIMOUNT stamped on the disc.
Ball Seat Mount System
• Ball seat wheels have spherical chamfers machined on
each stud hole. Center bore diameter is 8-23/32 in.
– 184 –
Y53-6032
(R05/10)
Y53-6032.book Page 185 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
VEHICLE LOADING
Wheel Nuts
• Hub pilot nut has a hex body and a flange for clamping against wheel face. Hex size is 33 mm (same as 15/16 in.).
procedure for the wheels on your truck. This is a job you
may not be able to do yourself. You need the right torquing
equipment to do it.
WARNING!
• 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
accident causing death or personal injury.
• Inner and outer cap nuts mate with spherical chamfers on wheels. Inner nut has 13/16 in. square end.
Outer nut has 1-1/2 in. hex.
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 causing death or personal
injury. Each mounting system is engineered for
use only with its correct mating part. Be sure
properly matched components are used for each
type of mounting.
Wheel Bearing Adjustment
Wheel Cap Nut Torque
At the first 100 miles, have all wheel cap nuts torqued to
their specified value. After that, check wheel cap nuts at
least once a week. Contact the Service Department at
your dealership for information on the proper installation
(R05/10)
• 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 if the
vehicle and death, serious personal injury or
damage to the vehicle.
For safe, reliable operation and adequate service life, your
wheel bearings must be checked and adjusted properly.
The person best equipped to do this is your authorized
dealer’s service mechanic.
Y53-6032
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Y53-6032.book Page 186 Monday, May 24, 2010 3:37 PM
VEHICLE LOADING
PART 8: MAINTENANCE AND SERVICE
Disc Wheels
Crisscross Sequence For Disc Wheels
To check the torque on disc wheels, follow the crisscross
sequence shown. See the Specifications chart for proper
torque specification.
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 accident causing death or personal injury.
Demountable Rims
To check the torque on demountable rims, follow the crisscross sequence shown. See the Specifications chart for
proper torque specification.
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.
02950
– 186 –
Y53-6032
(R05/10)
Y53-6032.book Page 187 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
VEHICLE LOADING
Table 13 Cap Nut Torque Specifications (R12/01)
WHEEL AND NUT
CONFIGURATION
STUD SIZE
TORQUES FOR INNER &
OUTER CAP NUTS
Lb. Ft.
N.m
Stud-Piloted Disc
Wheels
3/4”-16 Inner
1 1/8”-16 Outer
450-500
610-680
Heavy Duty StudPiloted Disc Wheels
15/16”-12 Inner
1 5/16”-12
Outer
750-900
1025-1225
M22 x 1.5-6H
450-500
610-680
PHP-10; Budd UniMount-10; WHD-8
Rim Clamp Nut Torque
02951
Crisscross Sequence For Demountable Rims
(R05/10)
Cast Spoke Wheel
Assembly
Y53-6032
1/2” Dia.
5/8” Dia.
3/4” Dia.
80-90
110-120
160-185
220-250
225-245
305-335
– 187 –
Y53-6032.book Page 188 Monday, May 24, 2010 3:37 PM
YOUR VEHICLE’S AIR SYSTEM
PART 8: MAINTENANCE AND SERVICE
Your Vehicle’s Air System
• Never attempt to disassemble a component
until you have read and understood recommended procedures. Some components
contain powerful springs and injury can
result if not properly disassembled. Use
only proper tools and observe all precautions pertaining to use of those tools.
• 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 manufacturer’s procedure if it is necessary in an
emergency to temporarily bypass an AD-ISseries air dryer.
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 vehicle to roll which may
result in an accident involving death or personal injury. Keep hands away from chamber
push rods and slack adjusters, they may
apply as system pressure drops.
• 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.
– 188 –
• 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.
The operation of the vehicle’s braking system and many
vehicle accessories depends upon the storage and application of a high-pressure air supply.
• 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.
Your vehicle’s compressor takes outside air and compresses it, usually to 100-120 psi. The compressed air
then goes to the reservoirs to be stored until needed.
When you operate your air brakes, the stored compressed
air flows into the chambers where it is used to apply your
Y53-6032
(R05/10)
Y53-6032.book Page 189 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
YOUR VEHICLE’S AIR SYSTEM
WARNING! If the supply and service tanks are
not drained at the recommended frequency,
water could be sent to all air lines and valves.
This could cause corrosion, which could compromise the brake system safety and potentially
cause an accident involving death or personal
injury.
truck and trailer brakes. That is why, when you push down
on your brake pedal, you don’t feel the same amount of
pressure on the pedal that you do when you apply the
brakes on your car. All you are doing on your truck is
opening an air valve to allow air to flow into the brake
chambers.
Air Supply System
Daily
WARNING! Do not operate the vehicle if leakage in the air system is detected. Conduct the
following procedure and contact an authorized Peterbilt Dealer (or any other properly
equipped service center) if a leak is detected.
Failure to check the brakes or follow these
procedures could cause a system failure,
increasing the risk of an accident involving
death or personal injury.
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.
(R05/10)
• Drain moisture from the supply and service air tanks.
• Operate air devices to circulate lubricants within the
unit.
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.
Twice a Year
• Add approximately 1/4 oz. (7.5 ml) of light viscosity
lubricant to the air line leading to the wiper motor.
Acceptable lubricants are Dow Corning 200 fluid, 200
CS viscosity, and Sprague Wiper Lube. If you have
alcohol dryers installed in the air system, the alcohol
can wash away lubricants from the wiper motors.
Y53-6032
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Y53-6032.book Page 190 Monday, May 24, 2010 3:37 PM
YOUR VEHICLE’S AIR SYSTEM
PART 8: MAINTENANCE AND SERVICE
CAUTION: Don’t use penetrating oil, brake fluid,
or wax-based oils in the air system. These fluids
may cause severe damage to air system components.
trolled 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.
• Maintain the air compressor to prevent excessive oil
by-pass. See your shop manual for maintenance
details.
• Replace worn seals in valves and air motors as they
are needed.
Air Dryer
WARNING! Use of incorrect air dryer could
cause air system failure, leading to loss of vehicle control and serious personal injury or death.
If your vehicle is equipped with a Bendix AD-IS
air dryer, it is important that future replacements
be identical or similar in design.
Any deviation from the Bendix AD-IS type air
dryer would require changes to the vehicle air system.
Some vehicles use a dual air system consisting of a wet
tank, forward dry tank, and rear dry tank. The dry tanks
have a single-check valve in the tank inlet. The check
valves prevent a complete loss of air in the event of an air
system failure (tank or hose failure). This ensures a con– 190 –
Every 900 operating hours or 30,000 miles/48,000 km or 3
months, check for moisture in the air brake system by
opening reservoirs, drain valves, or valves and checking
for the presence of water. A tablespoon of water in a reservoir would point to the need for a desiccant cartridge
change. However, the following should be considered first:
• Air usage is exceptionally high/abnormal for a highway vehicle. This may be due to accessory air
demands or some other unusual air requirement that
doesn’t allow the compressor to load/unload in a normal fashion or it may be due to excessive leaks in the
air system.
• When more than a 30-degree F (17-degree C) range
of temperature occurs in one day, small amounts of
water can accumulate in the air brake system due to
condensation. Under these conditions, the presence
Y53-6032
(R05/10)
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PART 8: MAINTENANCE AND SERVICE
ENGINE COOLING SYSTEM
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.
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.
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.
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
(R05/10)
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. In an ELC-filled cooling system, the
freeze point should be maintained between -30° F and 45° F (-34° C and -43° C)
Y53-6032
NOTE: Maximum recommended ELC concentration is 60% ELC and 40% water by volume (a 60/
40 coolant mixture). The minimum recommended
concentration is 40%.
– 191 –
Y53-6032.book Page 192 Monday, May 24, 2010 3:37 PM
ENGINE COOLING SYSTEM
PART 8: MAINTENANCE AND SERVICE
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.
– 192 –
45%
50%
55%
60%
65%
70%
75%
80%
85%
90% 100%
Consult your dealer or the ELC manufacturer’s representative for recommended ELC test kits, test strips, and laboratory sample procedures.
ELC Extender
Add ELC extender if necessary at the maintenance interval under “Cooling” on page 152.
Coolant Filter
If your vehicle came with a non-chemical filter (“blank filter”), replace it only with a blank filter at the interval specified in the “Preventive Maintenance Schedule” on
page 143. Never use filters that contain SCAs in an ELCfilled system.
Y53-6032
(R05/10)
Y53-6032.book Page 193 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
ENGINE COOLING SYSTEM
Topping Off
WARNING! Removing the fill cap on a hot
engine can cause scalding coolant to spray
out and burn you badly. If the engine has been
in operation within the previous 30 minutes,
be very careful in removing the fill cap. Protect face, hands, and arms against escaping
fluid and steam by covering the cap with a
large, thick rag. Do not try to remove it until
the surge tank cools down if you see any
steam or coolant escaping. In any situation,
remove the cap very slowly and carefully. Be
ready to back off if any steam or coolant
begins to escape.
Check the coolant level after each trip. Add coolant as
necessary. You may find your coolant level is not up to the
correct level soon after you have filled the radiator. This
may be because all the trapped air in the system has not
yet been purged. It takes a little time for all the air to leave
the system after you fill your radiator.
With the engine cold, top up with premixed coolant of the
desired freeze protection concentration. Add coolant
through the pressure cap neck of the surge tank.
.
NOTE: If frequent topping off is necessary and
there are no visible signs of coolant leaks when
the engine is cold, check for leaks with the engine
operating at normal temperature.
WARNING! Handle coolant and antifreeze carefully. Ethylene glycol antifreeze is poisonous
and can cause death or personal injury. Store in
original fluid container only and always keep out
of reach of children.
Surge Tank
*Pressure Cap = 15 psi
(R05/10)
Y53-6032
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Y53-6032.book Page 194 Monday, May 24, 2010 3:37 PM
ENGINE COOLING SYSTEM
PART 8: MAINTENANCE AND SERVICE
WARNING! Do not ingest ethylene glycol
based antifreeze, it is poisonous. It can be
harmful or fatal, especially to children. Store
in its original container only and keep it out of
reach of children.
Proper Coolant Level
NOTE: Do not overfill a cooling system. Excess
coolant may result in overflow, loss of antifreeze,
and reduced corrosion protection.
• The proper coolant level for a cold engine is at the
base of the filler neck extension tube.
• The proper coolant level for an engine at normal operating temperature is even with the pressure cap seal.
Refilling Your Radiator
1. If your cooling system is built with petcocks in the
upper engine coolant pipe, open them before filling
the surge tank.
2. Be sure the radiator and engine block drains are
closed.
3. Remove the surge tank pressure cap
4. Through the surge tank, fill the system with premixed
coolant. Pour it in a steady flow until the surge tank is
full. It may be necessary to pause for 1 minute and
then re-fill if the fluid level dropped.
– 194 –
5. If the system has petcocks, close them.
6. Start the engine and idle at a low RPM.
7. During low rpm idle, air will purge from the cooling
system which will lower the coolant level in the surge
tank. Continue to fill the surge tank until the level
remains at the base of the fill neck. This may take up
to 2 minutes.
8. Operate the engine throttle unitl the operating temperature stabilizes (when the thermostat opens).
9. Fill the surge tank as necessary to raise the coolant
level to the proper reading.
10. Operate the engine at high idle for another 10 minutes
and add coolant to raise the level back up to the base
of the fill neck.
11. Replace the surge tank pressure cap.
Y53-6032
(R05/10)
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PART 8: MAINTENANCE AND SERVICE
ELECTRICAL
Check the coolant level after each trip when the engine
has cooled. Add coolant as necessary. You may find your
coolant level is not up to the correct level soon after you
have filled the radiator. This may be because all the
trapped air in the system has not yet been purged. It takes
a little time for all the air to leave the system after you fill
your radiator.
Electrical
CAUTION: Do not modify or improperly repair
the vehicle’s electrical system or power distribution box. All electrical repairs should be
performed by a qualified service technician.
Improper repair or modifications will void
your warranty and/or cause serious damage
to your vehicle.
Battery Care
Regular attention to the charging system will help prolong
the service life of your batteries. Here are some common
causes of battery failure:
(R05/10)
• Overcharge: This condition may result from improper
voltage regulator adjustment. It results in overheating
of the battery, warped plates, and evaporation of electrolyte.
• Undercharge: Your voltage regulator may be 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.
• Short Circuits: These discharge a battery by draining electricity.
• Dirty or Loose Connections: Bad connections may
stop the flow of electrical power to and from the battery.
Y53-6032
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Y53-6032.book Page 196 Monday, May 24, 2010 3:37 PM
ELECTRICAL
PART 8: MAINTENANCE AND SERVICE
WARNING! Always shield your eyes, your skin
and painted surfaces to from contact with batttery fluid. Batteries contain a corrosive fluid
which can cause death or severe personal
injury.
Recharging Batteries
Except for using small trickle chargers to maintain battery
condition, you should have your vehicle’s batteries
charged by a qualified service facility. To help reduce the
risk of personal injuries, follow these guidelines carefully
when recharging a battery:
WARNING! Batteries can kill or 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.
• 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.
• Always make sure the battery charger is OFF before
connecting or disconnecting the cable clamps.
– 196 –
• Use protective eyewear.
CAUTION: Never use a metallic funnel to add
distilled water. It could come in contact with a
terminal, creating a short circuit, resulting in
severe injury or damage to your vehicle.
• 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.
Y53-6032
(R05/10)
Y53-6032.book Page 197 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
ELECTRICAL
• 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—
plus electrical system failure and damage.
• To avoid short circuits and damage to yourself or the
vehicle, never place metal tools or jumper cables on
the battery or nearby. Metal that accidentally comes in
contact with the positive battery terminal or any other
metal on the vehicle (that is in contact with the positive terminal), could cause a short circuit or an explosion.
personal injury, do not connect or disconnect charger cables while the charger is
operating.
• Never reverse battery polarity.
• Battery terminals should not be coated with improper
grease. Use petroleum jelly or commercially available,
noncorrosive, nonconducting terminal coatings.
• Keep the battery clean and dry.
• Look for any signs of damage.
WARNING! Examine the battery and alternator
cables for signs of damage or chaffing. A
chaffed or damaged cable, in which wiring is
exposed, can arch against metal components
and cause a fire which can lead to death, personal injury or damage to equipment.
• Keep all batteries away from children.
WARNING! Charger cables must be connected
positive to positive (+ to +) and negative to negative (– to –). If connected improperly, batteries
could explode causing death or 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 death or serious
(R05/10)
• Battery acid that may spill during charging should be
washed off with a solution of warm water and baking
soda to neutralize the acid. If you accidentally get acid
in your eyes or on your skin, immediately rinse with
cold water for several minutes and call a doctor.
Y53-6032
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Y53-6032.book Page 198 Monday, May 24, 2010 3:37 PM
ELECTRICAL
PART 8: MAINTENANCE AND SERVICE
• Do not charge a frozen battery; allow it to thaw out
first. And always allow the battery to thaw gradually—
do not apply direct heat. Gas trapped in the ice may
cause an explosion.
• Never attempt to place the vehicle in motion, or run
the engine with batteries disconnected.
• When fast charging, remove the battery caps so pressure doesn’t accumulate.
• 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.
Slow Battery Charging
NOTE: Follow the instructions that come with
your battery charger. It is not necessary to
remove the battery from the compartment.
2. Disconnect the battery cables.
3. Connect charger cables.
4. Start charging the battery at a rate not over 6
amperes. Normally, a battery should be charged at no
more than 10 percent of its rated capacity.
5. After charging, turn OFF charger and disconnect
charger cables.
Jump Starting Batteries
If your battery is discharged (dead), you may be able to
start it by using energy from a good battery in another
vehicle. This is termed “jump starting.” Because of the various battery installations in optional electrical systems,
Peterbilt does not recommend that you attempt to jump
start your vehicle. If you have a battery problem, contact a
Peterbilt Dealer or a reputable towing service. But if you
are unable to do this, and must jump-start your vehicle,
then ensure that you follow the precautions and instructions below.
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.
– 198 –
Y53-6032
(R05/10)
Y53-6032.book Page 199 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
ELECTRICAL
WARNING! Batteries contain acid that can
burn and gasses that can explode. Ignoring
safety procedures can possible cause death
or severe personal injury.
• Never jump start a battery near fire, flames,
or electrical sparks. Batteries generate
explosive gases. Keep sparks, flame, and
lighted cigarettes away from batteries.
• Do not allow battery fluid to contact eyes,
skin, fabrics, or painted surfaces. Always
wear eye protection. Battery acid that may
spill during charging should be washed off
with a solution of warm water and baking
soda to neutralize the acid. If you 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; avoid leaning
over a battery. If metal jewelry or other
metal comes in contact with electrical cir(R05/10)
Y53-6032
cuits, a short circuit may occur causing you
to be killed or injured—plus electrical system failure and damage to the vehicle.
• Do not try to jump start or charge a frozen
battery. (Even a battery with ice particles on
the electrolyte surface is dangerous.) Allow
it to thaw out first. And always allow battery
to thaw gradually—do not apply direct heat.
Gas trapped in the ice may cause an explosion.
• Do not try to jump start a vehicle if the electrolyte level in the battery of either vehicle is
low. Maintain the full level of electrolyte in
the batteries. This reduces the volume of
gas in the cells.
• The voltage of the booster battery must
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. To avoid serious personal injury
and damage to the vehicle, heed all warnings and instructions of the jumper cable
– 199 –
Y53-6032.book Page 200 Monday, May 24, 2010 3:37 PM
ELECTRICAL
PART 8: MAINTENANCE AND SERVICE
manufacturer. The jumper cables must be
long enough so that the vehicles do not
touch.
• Applying a higher voltage booster battery
will cause expensive damage to sensitive
electronic components, such as relays, and
the radio. Improper hook–up of jumper
cables or not following these procedures
can cause death, personal injury or damage
to equipement.
• 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.
• To avoid serious personal injury and damage to the vehicle, heed all warnings and
instructions of the jumper cable manufacturer.
To Jump Start Your Vehicle:
1. Wear eye protection and remove rings, metal watch
bands, and any other metal jewelry.
2. Set the parking brakes. Place the transmissions of
both vehicles in Neutral. Do not let the vehicles touch
one another. Turn the ignition key to Off in the vehicle
with the discharged battery. Also turn off lights,
heater, and any other unnecessary electrical load.
3. If either battery has vent caps, remove them and
check the fluid level. If it is OK, replace the caps
before going further. If the level is low, add distilled
water, and replace the caps before proceeding. If no
water is available, remove the caps and cover the filler
openings with a cloth before proceeding. After jump
starting the vehicle, dispose of the cloth.
CAUTION: Departures from these procedures
could also cause serious damage to both
vehicles. Improper use of a booster battery to
start a vehicle may cause an explosion.
– 200 –
Y53-6032
WARNING! If you do not cover the filler openings on the battery, electrolyte could boil out
of the openings and cause death, serious
injury or equipement damage. Replace caps
securely if there is enough fluid in the battery,
or cover with a cloth if no water is available
and your fluid is low.
(R05/10)
Y53-6032.book Page 201 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
ELECTRICAL
4. Attach one end of a jumper cable to the dead battery’s
positive terminal. This will have a large red “+” or “P”
on the battery case, post, or clamp. Attach the other
end of the same cable to the positive terminal of the
good battery.
Removing and Installing Batteries
5. Attach the remaining jumper cable FIRST to the negative battery terminal (black “-” or “N”) of the good battery, and then to the chassis or ground of the vehicle
being jump started.
Whenever you have to install a battery or remove one, follow these guidelines for the safety of yourself and the battery.
6. Start the engine in the vehicle with the good battery.
Let it run a few minutes. Then start the engine in the
vehicle with the dead battery. If the engine fails to start,
do not continue to crank the starter but contact the nearest Authorized Service Center.
WARNING! When disconnecting jumper cables,
make sure they do not get caught in any moving
parts in the engine compartment. Failure to
comply may result in death or personal injury.
7. Reverse the above sequence exactly when removing
the jumper cables. Take care that your first step is to
remove the cable from the chassis or ground of the
vehicle that was jump-started.
(R05/10)
WARNING! Always reinstall the battery compartment cover (step) before entering the cab.
Without the battery cover you could slip and
fall, resulting in death or personal injury.
• Ensure all switches on the vehicle are turned Off.
• Disconnect the ground cable first when removing a
battery.
• Connect the ground cable last when installing a battery.
Headlamp Adjustment
Follow the procedure below to adjust a headlamp. Vertical
adjustment is controlled via an access hole on the backside of the headlamp assembly and a 10mm socket.
Access to this adjuster knob is gained from inside the
fender well. The headlights have vertical adjustment only.
Y53-6032
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Y53-6032.book Page 202 Monday, May 24, 2010 3:37 PM
ELECTRICAL
PART 8: MAINTENANCE AND SERVICE
1. Ensure that the hood is properly adjusted.
2. Ensure that the hood is closed and completely
latched.
3. Ensure that the tires are inflated to an on-highway setting.
4. Ensure that the headlamp surfaces are clean and dry.
5. Park the vehicle on a flat, level surface at least 25 ft
from a suitable aiming surface.
6. Establish a horizontal line, no more than 1 in. (2.5 cm)
wide, on a suitable aiming surface at the same height
above a level surface as the optical center of the
headlamp. The optical center is identified on the cover
lens by a small dot. If a dot is not present, the optical
center is the center of the beam that is being aimed.
7. Determine the headlamp identifier from the cover lens
of the headlamp. Look for either the letters ‘VOL’ or
‘VOR’.
8. Determine the H-H line value from the table below.
– 202 –
Y53-6032
(R05/10)
Y53-6032.book Page 203 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
TRANSMISSION AND DRIVE TRAIN
Transmission And Drive Train
H-H Line
X
X
VOR (mm)
VOL(mm)
560-900
0
53
900-1200
50
103
1200-1372
64
117
Distance from
floor (mm)
Clutch Adjustment
9. Establish a second horizonal line, no more than 1 in.
(2.5 cm) wide, below the H-H line. This is the A-A line.
10. Using a 10 mm socket, turn the headlamp’s adjuster
until the aim zone visible in the beam pattern is level
with the A-A line on the aiming surface; the lamp is
now properly adjusted.
11. Repeat for opposite headlamp.
Low beams and high beams are integrated; only low
beams need adjustment. The high beams should be level
wht the H-H line once the low beams are adjusted the the
A-A line.
(R05/10)
Clutch pedal free travel is usually 1 3/4 in. to 2 in. (34 to 51
mm). This should be your guide for determining whether
your truck needs clutch adjustment. Some vehicles have
automatic clutch adjustment. If yours doesn’t have this
feature, adjustment will have to be done by a trained certified mechanic. Have the adjustment done before clutch
pedal free travel is reduced to the minimum allowable 1/2
in. (13 mm).
Fuel System
Location of Fuel Shut-off Valves
Fuel shut-off valves for the fuel crossover line are on the
bottom of the secondary fuel tank, at the crossover line
connection. They are optional on the primary fuel tank.
Specification
Use only diesel fuel as recommended by engine manufacturers.
Y53-6032
– 203 –
Y53-6032.book Page 204 Monday, May 24, 2010 3:37 PM
FUEL SYSTEM
PART 8: MAINTENANCE AND SERVICE
WARNING! A mixture of gasoline or alcohol
with diesel fuel in the presence of an ignition
source (such as a cigarette) could cause an
explosion. You could be killed or seriously
injured. Use only the recommended diesel
fuel.
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).
CAUTION: Use Ultra Low Sulfur Diesel fuel
only. Failure to do so may damage the engine
and components of the Diesel Particulate Filter (DPF).
Fuel Filters
Please follow these recommendations when you are
changing your fuel filters or strainer elements. Your engine
will run better and last longer if you do. See the engine
manufacturer’s recommendations for proper water and
micron requirements.
– 204 –
CAUTION: When removing filters, cover any
electrical equipment and wiring that might get
soaked with fuel. Diesel fuel may permanently
damage electrical insulation.
• When installing spin-on (throwaway) filters, hand
tighten them only to 1/2 to 2/3 turn after gasket contact. Mechanical tightening of these filters may distort
or crack the filter head.
NOTE: To expel air from density-type strainer elements, soak them in clean fuel before installing
them.
• When replacing a fuel filter element, don’t 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.
• 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.
Y53-6032
(R05/10)
Y53-6032.book Page 205 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
FUEL SYSTEM
CAUTION: Do not overtighten the valve. Overtightening can damage the threads.
• After starting the engine, check for leaks around the
filter.
Emission Components
Vehicles that comply with 2010 EPA emission requirements
will have a Deisel Exhaust Fluid (DEF) tank mounted to the
vehicle frame. During normal operating situations, your vehicle may consume DEF at a rate of 3% per gallon of diesel
consumed. The DEF tank has been designed to hold a minimum of 6% of the diesel fuel your vehicle is designed to
carry.
DEF filter
Deisel Exhaust Fluid Tank
The DEF system has a supply pump filter and this filter
should be serviced according to the preventive maintenance
schedule. Follow these steps to replace the DEF supply
pump filter:
1. Turn off the vehicle and allow the vehicle to cool
down. Take special precaution with hot exhaust piping.
WARNING! The exhaust piping can become
extremely hot during engine operation and
can cause personal injury including serious
burns to the skin. Allow adequate cooling
time before working near any part of the
exhaust system.
(R05/10)
Y53-6032
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Y53-6032.book Page 206 Monday, May 24, 2010 3:37 PM
FUEL SYSTEM
PART 8: MAINTENANCE AND SERVICE
2. Remove the pump protective plate mounted on the
bottom of the DEF tank.
3. Using a 27 mm socket wrench (DIN3124), remove the
filter cap that is screwed to the DEF Supply pump.
4. Replace filter and reassemble the cap. Tighten the
cap to 11.4 - 18.5 lb-ft (15 - 25 Nm).
5. Replace the pump protective plate.
– 206 –
Y53-6032
(R05/10)
Y53-6032.book Page 207 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
FUEL SYSTEM
Steering
Guidelines For Checking A Steering System
WARNING! A steering system that is not working properly can cause an accident involving
death or personal injury. You could lose control of your vehicle if the steering is not in
good order. For driving safety, give your steering gear and components the following visual
checks frequently. Check them especially
after trips over rough roads.
• Check tie rod for straightness
If these checks do not reveal the problem, or if you correct
them and still have a steering problem, take your vehicle
to an authorized dealer for evaluation.
Front End Alignment
For driving safety and comfort, and to prolong the life of
your vehicle, it is important to have proper front end alignment. Check tire wear frequently. Uneven tire wear is a
sign that your front end or rear axles may be misaligned.
If you see uneven wear, take your vehicle to a service center familiar with aligning front ends on Peterbilt vehicles.
• Check draglink clamp for looseness or interference
Rear Axle Alignment
• Check ball joints and steering U-joints for looseness
Continual road shock and load stresses may force your
rear axles out of alignment. If you detect rapid tire wear on
the rear axles, you may have misaligned axles. If you suspect you do, have your rear axle alignment checked and
adjusted by an authorized dealership.
• Check steering wheel for excessive freeplay. Check
the simplest probable causes first:
– Unequal tire pressures
– Loose cap nuts
– Bent tie rod
– Loose wheel bearing
(R05/10)
U-Bolt Tension for Front and Rear Axles
It is important that U-bolts remain tight. Off-highway use of
your vehicle will cause them to loosen faster. But all vehicles need to have their U-bolts checked and tightened
Y53-6032
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Y53-6032.book Page 208 Monday, May 24, 2010 3:37 PM
FASTENERS
PART 8: MAINTENANCE AND SERVICE
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
an accident involving death or personal injury.
Use only U–bolts and nuts of SAE Grade 8
specification or better.
regularly. Be sure someone with the proper training and
the right tools checks and tightens the U-bolts on your
Peterbilt. The proper torque requirements are specified in
the Peterbilt Maintenance Manual for your vehicle.
WARNING! 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 accident resulting in death or injury.
Loose U–bolts can also cause uneven tire wear
and poor alignment.
Fasteners
Frame Fastener Torque Specifications
Table 14 Frame Fastener Torque Specifications
WARNING! Failure to maintain the specified
torque values or to replace worn parts can cause
component system failure, possibly resulting in
an accident causing death or injury. 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.
– 208 –
Fastener
Type
Bolt / Locknut /
Hardened Washer
Y53-6032
Torque
Fastener
Size
Lb. ft.
N.m.
1/2 Inch
86 - 108
117 - 147
5/8 Inch
130 - 163
176 - 221
M12
65 - 85
89 -115
M16
155 -195
210 - 264
M20
315 - 385
427 - 523
CAUTION: When installing bolts on the frame,
use only metric grade 10.9 bolts of the proper
length.
(R05/10)
Y53-6032.book Page 209 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
FASTENERS
Table 15 Capscrew Torque Specifications (Continued)
Standard Capscrew Torque Specifications
SAE Grade
Number
Table 15 Capscrew Torque Specifications
-20
58 - 87
79 - 118
86 - 123
117 - 167
8
9/16-12
78 - 111
105 - 151
110 - 158
149 - 214
Torque
Torque
-18
87 - 124
118 - 168
123 - 176
167 - 239
5/8-11
108 - 154
147 - 209
153 - 218
208 - 296
-18
122 - 174
166 - 236
173 - 247
235 - 335
3/4-10
192 - 273
260 - 370
271 - 386
367 - 523
-16
214 - 305
290 - 414
303 - 431
411 - 583
7/8-9
309 - 441
419 - 598
437 - 624
593 - 846
-14
341 - 486
462 - 659
482 - 589
654 - 799
1 -8
464 - 662
629 - 898
656 - 935
889 - 1268
1-12
508 - 724
689 - 982
718 - 1023
973 - 1386
Lb. ft.
N.m.
Lb. ft.
N.m.
1/4-20
6-9
8 - 12
9 - 12
12 - 16
-28
7 - 10
9.5 - 14
10 - 14
14 - 19
5/16-18
13 - 18
18 - 24
18 - 25
24 - 34
-24
14 - 20
19 - 27
20 - 28
27 - 38
3/8-16
22 - 32
30 - 43
31 - 44
42 - 60
-24
25 - 40
34 - 54
35 - 50
47 - 68
7/16-14
35 - 50
47 - 68
50 - 71
68 - 96
-20
39 - 56
53 - 76
56 - 80
76 - 108
1/2-13
54 - 77
73 - 104
76 - 109
103 - 149
(R05/10)
8
5
SAE Grade
Number
Capscrew
Body Size
(inchesthread)
5
The torque values in the previous tables are based on the
use of clean and dry threads.
Y53-6032
– 209 –
Y53-6032.book Page 210 Monday, May 24, 2010 3:37 PM
ENGINE ACCESSORIES
PART 8: MAINTENANCE AND SERVICE
Frame Fasteners
• Go around your vehicle as per the Preventive Maintenance Schedule and tighten all frame fasteners with a
torque wrench.
• Always use the torque values listed in frame fastener
table.
• Always torque fasteners from the nut end.
For standard capscrews
• Always use the torque values listed the capscrew
table.
failure. The result could be the loss of the electrical or air
system as well as possible engine damage from overheating. So it’s a very good idea to check your belts frequently
and replace them as soon as you detect trouble.
Follow this procedure to install an accessory drive belt:
1. Route the new belt around the pulleys, and then
rotate the automatic tensioner so that the idler pulley
swings toward the belt routing. Refer to figure below
an example of the rotation direction to release the tensioner.
Belt route for PACCAR MX Engine
• Reduce torque by 10% when engine oil is used as a
lubricant.
• Reduce torque by 20% if new plated capscrews are
used.
Engine Accessories
Accessory Drive Belts
You can extend the reliability and service life of your vehicle’s drive belts with proper attention to installation,
adjustment, and maintenance. Neglect could cause belt
– 210 –
Y53-6032
(R05/10)
Y53-6032.book Page 211 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
ENGINE ACCESSORIES
Fan Clutch / Fan
Belt route for Caterpillar Engine
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 killed or seriously
injured. Before turning on the ignition, be sure
that no one is near the fan.
Your truck may be equipped with an On/Off or Viscous
Fan Drive. Follow these guidelines to check your engine
fan:
• Check the fan assembly mounting bolts for tightness.
Inspect the fan blades for damage.
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.
(R05/10)
On/Off Fan Drives - Check the clutch operation by starting
the engine when it is cold. Idle the engine at about 800
RPM. Listen for air leaks. Check that the fan is not working while the engine is warming up. When the clutch
engages, note the reading on the vehicle's panel-mounted
coolant temperature gauge. If the fan clutch engages at
low engine temperature or cycles on and off more frequently than it should (receives "false signals"), have the
problem corrected at your dealership.
Y53-6032
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Y53-6032.book Page 212 Monday, May 24, 2010 3:37 PM
AIR INTAKE SYSTEM
PART 8: MAINTENANCE AND SERVICE
Air Intake System
Air Cleaners
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.
The following service information is basic to all air cleaner
makes and models.
CAUTION: Improper maintenance of the air
intake system will allow abrasive dust to enter
the engine which can cause equipment damage.
Under normal operating conditions, we recommend complete disassembly and cleaning of the air intake
system annually.
Under severe operating conditions, such as heavy offhighway use, the disassembly and cleaning should be
more frequent. Replace any defective parts. With the possible exception of mounting brackets, don’t repair defective parts.
– 212 –
Service the air cleaner filter elements as specified in the
Preventive Maintenance Schedule. If your vehicle is
equipped with an optional air inlet restriction indicator, service the filter elements when the air inlet restriction indicator locks in the extreme Up position. Paper elements
require care and proper handling because they are critical
to engine service life.
Turbocharger
When servicing the air intake and exhaust systems on a
turbocharged engine, check the items that follow. If you
detect any deficiencies, take the vehicle to an authorized
dealer for servicing. Delay could lead to severe and
expensive damage to your vehicle.
Y53-6032
WARNING! The exhaust piping and Diesel Particulate Filter can become extremely hot during engine operation and can cause death or
personal injury. Allow adequate cooling time
before working on or near any part of the
exhaust system.
(R05/10)
Y53-6032.book Page 213 Monday, May 24, 2010 3:37 PM
PART 8: MAINTENANCE AND SERVICE
EXHAUST SYSTEM
WARNING! If your vehicle becomes disabled,
the hot exhaust system could ignite dry
grass, brush, spilled fuel, or other material
that can cause fires which can lead to death,
personal injury and property damage. Do not
park or operate your vehicle in areas where
the hot exhaust system could cause a fire.
CAUTION: This truck is equipped with a diesel
particulate filter in order to meet both noise
and exhaust emissions requirements.
Removal or tampering with the unit will not
improve engine performance. Also tampering
is against the rules that are established by the
U.S. Code of Federal Regulations. The unit
may only be replaced with an approved part.
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 killed
or seriously injured. Always keep the intake piping connected when you will be running the
engine.
(R05/10)
CAUTION: Operating the engine with the turbocharger intake piping disconnected will
allow abrasive dust to enter the engine which
can cause equipment damage.
• Lubricating System: Check the oil lines, housing, and
connections. Look for leaks, damage, or deterioration.
Leaks could mean you have damaged oil lines or oil
seals.
• Manifold: With the engine operating, check for leaking
manifold or flange gaskets.
• High Frequency Vibration: Vibration may indicate
turbo rotor imbalance. Have your dealer investigate
this immediately.
Exhaust System
Details of inspection and maintenance of your exhaust
system are covered under “Noise Control System” on
page 222.
Anti-lock Braking System (ABS)
For details of use and maintenance of your anti-lock system, see the anti-lock braking system service literature
that came with your truck.
Y53-6032
– 213 –
Y53-6032.book Page 214 Monday, May 24, 2010 3:37 PM
ANTI-LOCK BRAKING SYSTEM (ABS)
PART 8: MAINTENANCE AND SERVICE
Below are some general notes on repairing your anti-lock
braking system:
• The foundation brake system must be in proper working order to ensure the best ABS performance.
• Before welding anywhere on the vehicle, detach the
ABS ECU connector and all other electronic control
units.
• Never detach the ECU connector with the ignition
turned on.
• Do not attempt to repair ABS/ASR/ATC electrical
cables that are outside the vehicle. Replace faulty
cables as an assembly.
• When servicing brakes, hubs, or axle, recoat the ABS
sensors with anti-seize compound. Make sure the
sensor is pushed against the pulse wheel after the
hub is reinstalled. On rear axles, the sensor should be
pushed fully into the mounting block before reinstalling the hub.
• During wheel balancing, dyno testing, or any time the
ignition is on with part of the ABS disconnected, a failure code will be recorded. After servicing or testing of
the vehicle is completed, clear the failure codes.
If, due to operating conditions, a brake application causes
either wheel on the same axle to begin skidding, wheel
speed sensors immediately signal the anti-lock controller
in the modulator assembly. The controller responds
instantly by signaling the solenoids in the modulator which
activate the air valves, reducing application pressure as
needed to prevent the wheels from locking up. If this overriding 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 panelmounted amber warning light will come on, indicating both
a malfunction, and automatic shut-down of the system. If
the air system is intact (indicated by the pressure
gauges), the service brakes will continue to function normally, but without benefit of the anti-lock feature.
• Check ABS wiring harnesses and piping periodically
for chafing or other problems. No regular maintenance is required on the ABS components.
– 214 –
Y53-6032
(R05/10)
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PART 8: MAINTENANCE AND SERVICE
CAB HEATER-AIR CONDITIONER
WARNING! Although the brakes will continue to
operate with a malfunction in either circuit, the
vehicle should not be operated until the system
is repaired, and both braking circuits, including
all pneumatic and mechanical components, are
working properly. Failure to do so may result in
death or personal injury.
Cab Heater-Air Conditioner
The combination heater-air conditioner provides comfort
for those in the cab through accurate control of the cab
environment in all weather conditions. Regular attention
will help you keep your unit running well.
CAUTION: Do not attempt to recycle the antilock system until the veh icle h as been
brought to a full stop.
NOTE: If one wheel on any driven axle continues
to slip or spin for approximately 4 seconds, this
will cause the anti-lock controller for that axle to
go into the fail-safe mode, and the warning light
will give a shutdown signal. In this case, the antilock 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.
(R05/10)
Y53-6032
NOTES:Keep the engine exhaust system and the
vehicle’s cab/sleeper ventilation system properly
maintained. It is recommended that the vehicle’s
exhaust system and cab/sleeper be inspected
• 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
– 215 –
Y53-6032.book Page 216 Monday, May 24, 2010 3:37 PM
CAB HEATER-AIR CONDITIONER
PART 8: MAINTENANCE AND SERVICE
NOTES:Allow for the proper operation of the vehicle ventilation system:
• Keep the inlet grille at the base of the windshield clear of snow, ice, leaves, and other
obstructions at all times.
• Keep the exhaust pipe area clear to help
reduce the buildup of exhaust gases under the
vehicle.
• Check the heater core for debris blocking the air flow.
If the blower is functioning properly, yet the heater is
not operating properly, the heater core may be
clogged. Clean the heater core if necessary. If the
condition persists, take the vehicle to a Peterbilt
dealer for proper heater service or repair.
Air Conditioner
WARNING! The air conditioning system is
under pressure. If not handled properly, it
could explode, causing death or injury to you
and can damage your vehicle. Any servicing
that requires depressurizing and recharging
the air conditioning system must be conducted by a qualified technician with the right
facilities to do the job.
Perform the following checks every 3 months or 30,000
miles / 48,000 km, whichever occurs first:
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, take the vehicle to a
Peterbilt dealer for proper heater service or repair.
– 216 –
• Check the compressor belt condition and proper tension. Adjust 105 - 125 pounds.
• 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.
Y53-6032
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PART 8: MAINTENANCE AND SERVICE
CAB HEATER-AIR CONDITIONER
• Check the evaporator core and condenser core for
debris restricting air flow. Clean if necessary. Small
particles may be removed with compressed air blown
through the core in the opposite direction of normal air
flow.
Special Precautions
WARNING! Wear eye protection any time you
blow compressed air. Small particles blown by
compressed air could injure your eyes.
• 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, don’t 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 inspected annually by your dealer.
(R05/10)
Y53-6032
WARNING! Excessive heat may cause your air
conditioning system to explode which may
result in death or personal injury. 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 illness or death. If the system is leaking
refrigerant
• Stay away from the hot engine until the
exhaust manifold has cooled.
• Don’t permit any open flame in the area.
Even a match or a cigarette lighter may generate a hazardous quantity of phosgene
gas.
• Don’t smoke in the area. Inhaling gaseous
refrigerant through a cigarette may cause
illness.
– 217 –
Y53-6032.book Page 218 Monday, May 24, 2010 3:37 PM
APPEARANCE
PART 8: MAINTENANCE AND SERVICE
Appearance
Painted Surfaces
CAUTION: Do not aim the water jet directly at
door locks or hatch. 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.
• Wash frequently to remove grime and caustic deposits that may stain the finish. Apply cool or lukewarm
water. You may want to use a mild soap.
• Avoid washing your vehicle in bright sunlight.
WARNING! Handle cleaning agents carefully.
Cleaning agents may be poisonous and cause
death or personal injury if swallowed or inhaled.
Keep them out of the reach of children.
• Road tar may be removed with a special commercial
tar remover or mineral spirits.
– 218 –
• Waxing offers added protection against staining and
oxidation. But to allow enough time for your truck’s finish to cure, wait about ninety days after the date of
manufacture before waxing. Don’t wax in the hot sun.
Don’t friction burn the paint with a buffing machine.
Aluminum and Chrome Surfaces
• 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.
• 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.
Y53-6032
(R05/10)
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PART 8: MAINTENANCE AND SERVICE
APPEARANCE
Stainless Steel
Follow this procedure to clean and restore the finish of
stainless steel components:
1. In a plastic pail mix 4 tsp of alum (a powder found in
grocery stores or drugstores), with 32 oz. of water
(warm water will dissolve alum faster, but cool will
work).
thane, and painted plastic surfaces. These cleaning procedures will ensure that interior components remain in
good condition for the life of the vehicle.
General Cleaning Guidelines
2. Apply the alum/water solution with a pad of steel wool
(0000 grade or finer). GENTLY wipe the component
lengthwise; no pressure is necessary.
3. It is the chemical reaction between the carbon steel of
the wool and the alum solution that cleans the stainless, not the scrubbing or abrasive action of application.
4. You may also use any stainless cleaner recommended for cleaning boat parts.
Interior
Cleaning Cab Interiors
WARNING!
• •Cleaning agents may contain hazardous
agents. Thoroughly read, understand and
follow the manufacturer’s instructions when
using a cleaning agent to avoid possible
death, 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.
Peterbilt cab and sleeper interiors are built using a variety
of different materials including fabrics, carpet, polyure(R05/10)
Y53-6032
– 219 –
Y53-6032.book Page 220 Monday, May 24, 2010 3:37 PM
APPEARANCE
PART 8: MAINTENANCE AND SERVICE
• 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
–Diesel Exhaust Fluid
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.
– 220 –
Interior Trim, Dash Shell, and Instrument Panels
• 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.
Y53-6032
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PART 8: MAINTENANCE AND SERVICE
APPEARANCE
• Remove soap with a clean, damp rag.
• Clean with the cloth dampened with lukewarm water.
• If a stronger cleaning solution is required, use a foamtype carpet shampoo.
• Dry with a clean cloth.
• For difficult stains, use a commercial leather cleaner.
Weatherstripping
Vinyl and Fabric Upholstery
CAUTION: To avoid possible damage to the
upholstery, do not use chemical solvents or
strong detergents on these components.
• Use a clean, lint-free cloth.
• Clean with the cloth dampened with a mild soap-andwater solution.
• Remove soap with a clean, damp rag.
Occasionally spray weatherstripping 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.
Chassis
Hose dirt and grime from the entire chassis. Then if an oil
leak develops, you will be able to detect it easier.
CAUTION: Do not spray the suspension with
chemical products or mineral oil; it can cause
damage to the bushings.
• For difficult stains, use a commercial fabric or vinyl
cleaner.
Leather Upholstery
CAUTION: To avoid possible damage to the
upholstery, do not use oils, varnishes, solvents,
abrasive cleaners or shoe polish on these components.
• Use a clean, lint-free cloth.
(R05/10)
Storing and Reintroducing Vehicles Into
Service
To help maintain a vehicle in storage as well as ease its
reintroduction into service, perform the following actions
at least monthly:
Y53-6032
– 221 –
Y53-6032.book Page 222 Monday, May 24, 2010 3:37 PM
NOISE CONTROL SYSTEM
PART 8: MAINTENANCE AND SERVICE
• Wash and protect painted and metal surfaces, and
also weatherstripping, as outlined in the preceding
“Appearance” information.
Noise Control System
• Operate the vehicle to circulate fluids and lubricants
that have settled to the lowest part of a component.
This will provide protection against corrosion on gears
and bearings and keep seals resilient.
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.
Before starting the engine, do the following:
– Check the engine oil level and fill as required.
– Check and maintain batteries as outlined on page
195.
– Drain any condensation from the fuel/water separator, if so equipped.
– Start the engine and bring to normal operating
temperature:
– Operate the air conditioning system at least 10
minutes.
– Drive the vehicle a short distance to allow lubricants to circulate in the transmission and axles.
– 222 –
Noise Emission Warranty
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.
Tampering with Noise Control System
Prohibited
Federal law prohibits the following acts or the causing
thereof:
Y53-6032
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PART 8: MAINTENANCE AND SERVICE
NOISE CONTROL SYSTEM
(1) The removal or rendering inoperative by any person
other than for maintenance, repair, or replacement, of any
device or element of design incorporated into any new
vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use, or
(2) the operation of the vehicle after such device or element of design has been removed or rendered inoperative
by any person.
Among those acts presumed to constitute tampering are
• Removing shields or skirts.
• Cutting away parts of shields, skirts or damaged or
loose portions of shields or skirts.
Fuel System
• Removing or rendering engine speed governor inoperative, allowing engine speed to exceed manufacturer’s specifications.
• Removing air signal attenuator on engines equipped
with this device.
Engine Cooling System
• Removing or rendering inoperative the fan clutch.
Noise Insulating Blankets
• Removing the fan shroud.
• Removing noise insulators from engine block or from
around the oil pan.
Air Intake System
Removing or rendering inoperative the air cleaner / silencers or intake piping.
• Cutting holes in, or cutting away part of, noise insulators.
• Removing hood-mounted noise insulation.
Exhaust System
• Removing or rendering inoperative the exhaust system components.
Engine Electronic Control Unit (ECU)
Modifying ECU parameters.
• Inner Fender Shields and Cab Skirts
(R05/10)
Y53-6032
– 223 –
Y53-6032.book Page 224 Monday, May 24, 2010 3:37 PM
NOISE CONTROL SYSTEM
PART 8: MAINTENANCE AND SERVICE
Inspection & Maintenance Instructions for
Noise Control System
Exhaust System
The following instructions are based on regular inspection
of the noise control system. If, during regular inspection or
maintenance of other systems or components, you find
something wrong with parts of the noise control system,
inspect those parts more frequently to be sure they are
performing up to specification. At the end of this section
you will find the Maintenance Log. This is a schedule of
inspection and maintenance intervals for each component.
WARNING! The exhaust piping and Diesel Particulate Filter can become extremely hot during engine operation and can cause death or
personal injury. Allow adequate cooling time
before working on or near any part of the
exhaust system.
– 224 –
WARNING! If your vehicle becomes disabled,
the hot exhaust system could ignite dry
grass, brush, spilled fuel, or other material
that can cause fires which can lead to death,
personal injury and property damage. Do not
park or operate your vehicle in areas where
the hot exhaust system could cause a fire.
Manifold
Check for exhaust leaks and condition of gaskets.
Replace any blown gaskets. Use a torque wrench to
check all cap-screws, including those at the flanges. Refer
to the engine manufacturer’s service manual for proper
tightening sequence and torque values.
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.
Y53-6032
(R05/10)
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PART 8: MAINTENANCE AND SERVICE
NOISE CONTROL SYSTEM
Piping
Exhaust Tail Pipe(s)
Check for rust, corrosion, and damage. 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 the flanges and
mounting brackets for tightness.
Check the mounting security. Tighten as necessary. The
miter cut at the tip of the pipe must be facing the rear of
the truck. Do not modify the end of the pipe in any way.
Fan 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 killed or seriously
injured. Before turning on the ignition, be sure
that no one is near the fan.
Diesel Particulate Filter (DPF)
NOTE: Use only exact replacement components
in exhaust systems. Certain components contain
integral catalytic converters essential for compliance with EPA emission standards. Using a noncompliant component as a replacement could
violate these standards and also void the emission system’s warranty.
Check clamps and mounting brackets for security. Check
internal baffling for security. You can do this by listening for
rattling sounds while tapping the unit with a rubber mallet
or revving the engine up and down through its normal
operating range. Check the DPF for rust and corrosion.
(R05/10)
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.
Hood Insulation Blanket
Fasteners
Check all fasteners for condition and security. Repair or
replace any broken or defective fasteners.
Y53-6032
– 225 –
Y53-6032.book Page 226 Monday, May 24, 2010 3:37 PM
NOISE CONTROL SYSTEM
PART 8: MAINTENANCE AND SERVICE
Blanket
Inner Fender Shields and Cab Skirts
Check for chafing, tears, etc. Patch it if necessary. Find
the cause of the damage. If any component or accessory
is causing wear or damage and can’t be relocated, put
reinforcing pads on the blanket at the site of wear.
Fasteners
Engine Mounted Noise Insulators
Fasteners
Check for condition and security. How you do this will
depend on the method of attaching the noise insulators on
the engine and around the oil pan (bolts, snap fasteners,
or straps). Tighten loose fasteners; repair or replace any
worn or damaged fasteners.
Insulators
Check insulators around fasteners and stress points,
especially where they may be affected by engine vibration. Repair any cracked or damaged mounting points.
Use suitable reinforcing plates to ensure that the insulators will remain in position.
Check all fasteners for security, especially the self-tapping
hex head screws. Remove and replace any loose rivets.
Shields and Skirts
• Check shields and skirts for cracks at mounting and
stress points. Check fender shields for tire marks,
worn spots, or damage from objects thrown from tire
treads. You can repair cracked or damaged fiberglass
fender shields with fiberglass and resin.
• If you find damage at a fastening point, you can gain
additional strength by installing a suitable reinforcing
plate. This plate should be drilled to accept a rivet and
laminated to the shield with fiberglass and resin.
• Check cab skirts, sills, and brackets for overall condition and repair them as necessary. Damaged rubber
fender shields or cab skirting cannot be repaired. You
will need to replace it.
Your authorized dealership can perform all of these
checks and repairs or replacements.
– 226 –
Y53-6032
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PART 8: MAINTENANCE AND SERVICE
NOISE CONTROL SYSTEM
Air Intake System
• Do all checks and maintenance chores listed in this
manual under Engine Air Intake System and Air
Cleaner (See Index).
CAUTION: Air leaks cause excessive noise
and may result in serious damage to the
engine. If you do not repair them the engine
damage won’t be covered by your warranty.
Repair all air leaks as soon as you find them.
• 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.
(R05/10)
Y53-6032
– 227 –
Y53-6032.book Page 228 Monday, May 24, 2010 3:37 PM
NOISE CONTROL SYSTEM
PART 8: MAINTENANCE AND SERVICE
Table 16 Noise Control System Maintenance Logs
COMPONENT
RECOMMENDED
INTERVAL
(MILES)
DATE &
R.O. NUMBER
REPAIR
FACILITY &
LOCATION
WORK PERFORMED
DATE &
R.O. NUMBER
REPAIR
FACILITY &
LOCATION
WORK PERFORMED
Exhaust System Rout25,000
ing Integrity
Shutters
Shrouds
25,000
Hood Insulation
Blanket
10,000
Engine-Mounted Hose
10,000
Insultators
Fasteners
Inner Fender Shields 50,000
Cab Skirt
Fasteners
50,000
Air Intake System
Integrity Element
5,000
Clutch-Type FanDrive 10,000
– 228 –
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PART 9: VEHICLE IDENTIFICATION NUMBERS
PART 9: VEHICLE IDENTIFICATION NUMBERS
Each vehicle completed by Peterbilt Motors Company
uses a Vehicle Identification Number (VIN) that contains
the model year designation of your Peterbilt. The practice
is in compliance with 49 CFR 565, Code of Federal Regulations.
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).
EXAMPLE VIN: 1XP9D2X96XD345678
(R05/10)
VIN characteristics
1
Manufacturer Identifier
2
Vehicle Attributes
3
Check Digit
4
Model Year
5
Assembly Plant
6
Serial/Chassis number
Model Year Codes
9
2009
A
2010
1XP
9D2X9
6
X
D
345678
B
2011
1
2
3
4
5
6
C
2012
D
2013
0 (ZERO)
Glider Kit
Y53-6032
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Y53-6032.book Page 230 Monday, May 24, 2010 3:37 PM
FEDERAL SAFETY STANDARD CERTIFICATION LABEL
PART 10: CONSUMER INFORMATION
PART 10: CONSUMER INFORMATION
Federal Safety Standard Certification
Label
When you order, it is IMPORTANT than you have the following information ready:
The National Highway Traffic Safety Administration regulations require a label certifying compliance with Federal
Safety Standards, for United States and U.S. Territories,
be affixed to each motor vehicle and prescribe where such
label may be located.
This certification label, which indicates the date of manufacture and other pertinent information, is located on the
left hand cab door post.
02955
How To Order Parts
When you need replacement parts for your Peterbilt vehicles, contact your nearest authorized Peterbilt dealer, who
may be located from the “Peterbilt Authorized U.S. and
Canadian Dealers” listing (Cat. No. 5212).
– 230 –
•
•
•
•
Your name and address.
Serial number of the truck.
The name of the part you need.
The name and number of the component for which
the part is required.
• The quantity of parts you need.
• How you want your order shipped.
NHTSA Consumer Information
If you believe that your vehicle has a defect which could
cause a crash or could cause injury or death, you should
immediately inform the National Highway Traffic Safety
Administration (NHTSA) in addition to notifying Peterbilt
Motors Company.
If NHTSA receives similar complaints, it may open an
investigation, and if it finds that a safety defect exists in a
group of vehicles, it may order a recall and remedy cam-
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PART 10: CONSUMER INFORMATION
CANADIAN CONSUMER INFORMATION
paign. However, NHTSA cannot get involved in individual
problems between you, your dealer, and Peterbilt Motors
Company.
Contacting NHTSA is possible through telephone, wriitten
mail and email. NHTSA also has a website where you can
input you comments directly to them onthe web. Please
use any of the four ways to contact NHTSA:
Transport Canada, ASFAD
Place de Ville Tower C
330 Sparks Street
Ottawa ON K1A 0N5
For additional road safety information, please visit the
Road Safety website at
http://www.tc.gc.ca/roadsafety/menu.htm
Environmental Protection
Toll Free 888-327-4236 (800-4249153 TTY)
8:00 am to 10:00 pm ET Monday-Friday
WARNING! Diesel engine exhaust and some
of its constituents are known to the State of
California to cause cancer, birth defects, and
other reproductive harm. Other chemicals in
this vehicle are also known to the State of California to cause cancer, birth defects or other
reproductive harm. This warning requirement
is mandated by California law (Proposition 65)
and does not result from any change in the
manner in which Peterbilt trucks are manufactured.
Office of Defects Investigations/CRD
NVS-216
1200 New Jersey Ave SE.
Washington, D.C. 20590
www
@
www.safercar.gov
[email protected]
Canadian Consumer Information
Canandian customers, who wish to report a safety-related
defect to Transport Canada, Defect Investigations and
Recalls, may telephone the toll free hotline 1-800-3330510, or contact Transport Canada by mail at:
(R05/10)
Some of the ingredients in engine oil, hydraulic oil, transmission and axle oil, engine coolant, diesel fuel, air conditioning refrigerant (R12, R134a, and PAG oil), batteries,
Y53-6032
– 231 –
Y53-6032.book Page 232 Monday, May 24, 2010 3:37 PM
STATE OF CALIFORNIA
PART 10: CONSUMER INFORMATION
etc., may contaminate the environment if spilled or not disposed of properly. Contact your local government agency
for information concerning proper disposal.
State of California
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.
– 232 –
California Vehicle Code, Section 9951 Disclosure of Recording Device
Your vehicle may be equipped with one or more recording
devices commonly referred to as “event data recorders
(EDR)” or “sensing and diagnostic modules (SDM)”. If you
are involved in an accident, the device(s) may have the
ability to record vehicle data that occurred just prior to
and/or during the accident.
For additional information on your rights associated with
the use of this data, contact
the California Department of Motor Vehicles - Licensing
Operations Division
or
http://www.dmv.ca.gov/pubs/vctop/d03_6/vc9951.htm
Y53-6032
(R05/10)
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PART 11: SUBJECT INDEX
PART 11: SUBJECT INDEX
A
Anti-lock brakes 109, 213
Appearance 218
Appliances in the Cab 72
B
Battery
compartment cover 201
electrolyte 196
recharging 196
slow battery charging 198
Belts, seat 77
Brake
operation 109
Brake system
Electronic Stability Control 111
truck & tractor 109
C
Cap Nut Torque Specifications 187
Cleaning the vehicle 218
Consumer Information 230
Controls
Air Horn 41
Air Suspension Deflate Switch (Dump Valve) 45
Brakesaver 49
Cigarette Lighter 58
(R05/10)
Cruise Control Switch 48
Dome Light Switch 44
Electric Horn 40
Engine Brake 49
Engine Fan Switch 46
Fifth Wheel Lock (Slider Adjustment) Switch 52
Fog Lights Switch 44
Hazard Flasher 39
Headlamps 42
Headlights 42
Heater-Air Conditioning Controls 54
Interaxle Differential Lock Switch 50
Manual Override 42
Mirror Heat Switch 47
Panel Light Knob 43
Parking Brake Valve and Trailer Air Supply Valve 53
Power Mirror Switch 47
Tilt- Telescoping Steering Column 41
Trailer Brake Hand Valve 40
Turn Signal and Indicator Lights 35
Windshield Wipers and Washers 37
Cooling system
coolant level 194
extended life coolant 191, 193
temperature 65
topping up 193
Y53-6032
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Y53-6032.book Page 234 Monday, May 24, 2010 3:37 PM
PART 11: SUBJECT INDEX
D
Dash 14
DEF 67, 205
Defogging/defrosting system 57
Deisel Exhaust Fluid 205
Deisel Exhaust Fluid Tank 205
Door lock 218
Driver Information Display 30
Driver’s Checklist 88
Driving
vehicle inspection 88
E
Electrical system
batteries 197
battery charging 198
jumper cables 199
Electrolyte 196
Emission, Diesel Exhaust Fluid Lamp 26
Emissions, Diesel Particulate Filter (DPF) 25
Emissions, Malfunction Indicator Lamp 26
Engine
overspeed 141
Engine Warmup 95
Environmental Protection 231
Exhaust fumes 144
F
Federal motor vehicle safety standards 5
Federal Safety Standard Certification Label 230
– 234 –
Frame Fastener Torque Specifications 208
G
Gauges and Displays 59
Air Application Gauge 63
Air Filter Restriction Indicator or Gauge 70
Engine Oil Pressure Gauge 64
Fuel Gauge 66
Manifold Pressure Gauge 69
Primary And Secondary Air Pressure Gauges 63
Pyrometer 70
Speedometer / Odometer 30
Speedometer-Message Center 60
Tachometer 61
Voltmeter 70
Warning Lights and Buzzers 17
Water Temperature Gauge 65
Glove Compartment 59
GVWR - gross vehicle weight rating 179, 183
H
Headlamp
adjustment 201
Heater and air conditioner 57
HEST warning lamp 128
High beam 36
High Exhaust System Temperature (HEST) warning lamp 127
hood anti-blowdown device 12
Hood Tilting 11
Y53-6032
(R05/10)
Y53-6032.book Page 235 Monday, May 24, 2010 3:37 PM
PART 11: SUBJECT INDEX
J
Jumper cables 199
K
Keys 7
Keys and Locks
Ignition Switch 41
L
Lubrication
Axle 169–170
coasting 141
Steering Gear 171
Transmission 165–??
types and brands 161
Universal Joint 171
Wheel Bearing 170
Lubrication Index 163
Luggage Compartment(s) 71
M
Maintenance Schedule 143
Menu Control Switch (MCS) 15, 17
Mirrors 71
N
Navigation System 73
Noise Control System 222
P
Parked Regeneration 131
parked regeneration 51
(R05/10)
Parking brake
brake system, operation 53, 119
use 143
R
Rear suspension
fasteners (standard) 208
Refrigerator 72
Regeneration Switch 16, 51
Restraint Systems 75
Inspection 83
Komfort-Lok® Feature 79
Shoulder Belt 76
Sleeper Bunk Restraints 80
Tether Belts 82
S
Safe vehicle operation 88
Safety stands 144
Seat 75
Seat adjustment 75
Seats 75
Servicing Specific Systems
Air Intake System 212
Air System 188
Anti-lock Braking System (ABS) 213
Brake Adjustment 173
Cab Heater-Air Conditioner 215
Electrical 195
Engine Accessories 210
Y53-6032
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Y53-6032.book Page 236 Monday, May 24, 2010 3:37 PM
PART 11: SUBJECT INDEX
Engine Cooling System 191
Fasteners 208
Steering 207
Tires, Wheels, And Rims 177
Transmission And Drive Train 203
Shifting gears 141, 142
Standard Capscrew Torque Specifications 209
Starting and Operating 93
Anti-Lock Braking System 108
Automated Transmission 105
Auxiliary Transmission 105
Bobtail Brake Proportioning System 117
Brake Safety and Emergency 117
Digital Message Center 117
Driving Bobtail or with an Unloaded Trailer 126
Driving With Deflated Air Springs 139
Dual Range (Two Speed) Axles 103
Idling the Engine 97
If Your Vehicle Must Be Towed 105
Interaxle Differential 101
Manually Releasing Spring Brakes 121
Operating the Clutch 99
Overheated Brakes 118
Parking Brakes and Their Use 118
Retarders 125
Setting Ride Height 136
Shifting The Transmission 99
Starting Procedure
Cold Temperature 94
– 236 –
Normal Temperature 93
Stopping The Engine 134
Trailer Air Supply Valve 120
Suspension
fasteners, torque 208
T
Tachometer 142
Tire Load and Inflation Tables 182
towing 106
Transmission
lubrication 165
warmup 97
U
Units of Measure 35
V
Vehicle
driving 88
Vehicle inspections 88
Vehicle weight rating 183
W
Warning Light / Indicator Symbols 20
Warning Light Symbols table 20
Warning Light/Indicator Symbol Descriptions 23
Wheels and tires
load rating 179
replacement 177
Windshield washer reservoir 38
Y53-6032
(R05/10)
Y53-6032.book Page 237 Monday, May 24, 2010 3:37 PM
PART 11: SUBJECT INDEX
Numerics
49 CFR 565, Code of Federal Regulations 229
(R05/10)
Y53-6032
– 237 –
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