OPERATOR’S M ANUAL Y53-6008 11/06 PRINTED IN U.S.A. PETERBILT MOTORS COMPANY • P.O.
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Introduction INTRODUCTION How to Use This Manual This Operator's Manual contains useful information for the safe and efficient operation of your Medium Duty vehicle. It also provides information on maintaining your vehicle in the best condition, with an outline for performing safety checks and basic preventive maintenance inspections. We have tried to present the information you'll need to learn about your vehicle's functions, controls, and operation as clearly as possible.
Introduction WARNING NOTE When you see this word, the message that follows is especially vital. It signals a potentially hazardous situation which, if not avoided, could result in an injury or death. This message will tell you what the hazard is, what can happen if you don't heed the warning, and how to avoid it. Provides general information: for example, the note could warn you on how to avoid damaging your vehicle or how to drive the vehicle more efficiently.
Introduction Vehicle Safety Make sure your Medium Duty is in top working condition before heading out on the road—it is the responsible driver's duty to do so. Inspect the vehicle according to the “Driver's Check List”, page 13. WARNING! Do not drink and drive. Your reflexes, perceptions, and judgment can be affected by even a small amount of alcohol. You could have a serious—or even fatal accident—if you drive after drinking. Please do not drink and drive or ride with a driver who has been drinking.
Introduction A Special Word About Repairs Shop Manuals This is not a repair or workshop manual. Your Peterbilt Dealer's Service Center is the best place to have your Medium Duty repaired. You can find Peterbilt dealers all over the country with the equipment and trained personnel to quickly get you back on the road—and to keep you there. If you do decide to do complex repair work, you will need the Medium Duty Maintenance Manual.
Introduction Medium Duty Body Builders' Manual. Contains general guidelines on mechanical and electrical modifications required by your dealer to add bodies, accessories, and special equipment to straight-truck configurations. WARNING! Modifying your vehicle can make it unsafe. Some modifications can affect your vehicle's electrical system, stability, or other important functions. Before modifying your vehicle, check with your dealer to make sure it can be done safely.
Introduction Other Sources Another place to learn more about trucking is from local truck driving schools. Contact one near you to learn about courses they offer. –6– Federal and state agencies such as the department of licensing also have information you can ask for. The Interstate Commerce Commission can give you information about regulations governing transportation across state lines. Regulations that differ from state to state can be found at various agencies in state governments.
Operating Instructions Start–Up OPERATING INSTRUCTIONS START–UP WARNING! To help lessen the chance and/or severity of personal injury in case of an accident, always lock the doors while driving. Along with using the lap shoulder belts properly, locking the doors helps prevent occupants from being thrown from the vehicle. Introduction The following section covers start-up procedures for getting your Medium Duty ready for the road. • Insert the key in the door lock.
Start–Up Operating Instructions To help avoid personal injury due to a slip or fall: • Use three points of contact (two feet, one hand or one foot, two hands) to grip the steps or handholds whenever possible and look where you are going. WARNING! Do not step on vehicle components without antiskid surfaces or use components not designed for entry-and-exit use. You could fall and injure yourself if you step onto a slippery surface. For example: •Do not step onto the surface of a fuel tank.
Operating Instructions Start–Up NOTE: Any alteration (adding bulkheads, headache racks, tool boxes, etc.) behind the cab that affects the utilization of grab handles, deck plates, or frame access steps installed by Peterbilt should comply with Federal Motor Carrier Safety Regulation 399. To open the hood, unlatch both of the hood hold downs. Hood Hold Downs and Tilt The hood is locked in its closed position by an external latch on each side.
Start–Up Operating Instructions Put one hand on the hood handle (just above the Peterbilt emblem), one foot on the bumper, and one foot on the ground. Tilt the hood forward until you hear it “lock”. To close the hood, you must first release the hood safety lock. WARNING! Before closing the hood, be sure the area is clear—no people or objects are in the way. CAUTION: To avoid hood damage when closing the hood, firmly squeeze the handle to release the hold-open lock.
Operating Instructions Start–Up After lowering the hood, latch the hood closed with the hold downs. WARNING! If the hood is not latched securely, it could open during operation and cause an accident. Be sure the hood is latched securely before moving the vehicle. Safe Vehicle Operation For your safety, as well as those around you, be a responsible driver: • If you drink, do not drive. • Do not drive if you are tired, ill, or under emotional stress.
Start–Up Operating Instructions WARNING! Do not drink and drive. Your reflexes, perceptions, and judgment can be affected by even a small amount of alcohol. You could have a serious—even fatal—accident if you drive after drinking. Please do not drink and drive or ride with a driver who’s been drinking. WARNING! Do not exceed the specified load rating. Overloading can result in loss of vehicle control and serious personal injury, either by causing component failures or by affecting vehicle handling.
Operating Instructions Start–Up GAWR: is the Gross Axle Weight Rating. This is the total weight that one axle is designed to transmit to the ground. You will find this number listed on the driver's door edge. Load Distribution: be sure any load you carry is distributed so that no axle has to support more than its GAWR. WARNING! An unevenly distributed load or a load too heavy over one axle can affect the braking and handling of your vehicle, which could result in an accident.
Start–Up Operating Instructions • Check beneath the vehicle. Are there signs of fuel, oil, or water leaks? • Check for damaged, loose, or missing parts. Are there parts showing signs of excessive wear or lack of lubrication? Have a qualified mechanic examine any questionable items and repair them without delay. • Check your load. Is it secured properly? Daily Checks NOTE: The following items (Engine Compartment, Chassis and Cab, and Prestart Checks) should be checked daily, as a minimum.
Operating Instructions Start–Up 1. Lights—do headlights, turn signals, emergency flashers, and exterior lamps function and are they clean and adjusted properly? 2. Windows and Mirrors—are they clean and adjusted properly? 3. Tires and Wheels—are they inflated properly? Are all wheel cap nuts in place and torqued properly—tighten if necessary. Check front wheel bearing oil levels. Inspect all tires and wheels for damage—correct if found. 4. Suspension—check for loose or missing fasteners.
Start–Up Operating Instructions Prestart — Daily Weekly Operations 1. Seat—adjust the seat for easy reach of controls. 2. If your vehicle is equipped with an adjustable steering column, adjust the steering wheel to a comfortable position. 3. Mirrors—check and readjust mirrors if necessary. 4. Lights—turn ignition key to the IGN & ACC position and check for warning lights and buzzer. Check operation of turn signals and emergency lights. 5. Instruments—check all instruments. 6.
Operating Instructions Start–Up 14 5 8 7 6 2 15 4 1 9 10 11 12 13 3 02599A 02595-1A a DASH INSTRUMENT PANEL 1 2 3 4 5 Headlight Clearance Lights Windshield Washer/Wiper Panel Lights Tachometer Medium Duty (R10/06) 6 7 8 9 10 Oil Pressure Water Temperature Speedometer Air Cleaner Restriction/Filter (option) Fuel Y53-6008 11 12 13 14 15 Voltmeter (option) Air Pressure Transmission Temperature (option) Warning Lamp Cluster Ignition Switch – 17 –
Instruments and Controls Operating Instructions INSTRUMENTS AND CONTROLS Instrument Index Table 1 Index of Gauges Introduction GAUGE Tachometer Your Medium Duty dashboard is shown on the opposite page. The dash includes standard gauges and switches. Your vehicle may come with all or some of the switches and gauges discussed here. The location of switches on the dash will vary depending on the options ordered and how your vehicle was configured.
Operating Instructions Instruments and Controls WARNING LAMP MODULE MIRROR HEAT ABS OIL BRAKE AIR ENGINE FAN LOW WATER WATER LOAD LIGHT HIGH BEAM FIFTH WHEEL CRUISE SPOT CONTROL LIGHT STOP ENGINE DIFF LOCK WAIT TO START CHECK ENGINE VEHICLE WITH AIR BRAKES MIRROR HEAT OIL ! BRAKE ENGINE FAN LOW WATER WATER LOAD LIGHT HIGH BEAM FIFTH WHEEL CRUISE SPOT CONTROL LIGHT STOP ENGINE RANGE INHIBIT CHECK TRANS P PARK CHECK ENGINE VEHICLE WITH HYDRAULIC BRAKES Medium Duty (R10/06)
Instruments and Controls Operating Instructions Self Test The buzzer will sound continuously as long as: When you turn on your ignition, the following warning lights will turn on for 3 - 5 seconds, as a test to let you know they are working.
Operating Instructions Instruments and Controls WARNING! Do not operate the vehicle if the BRAKE warning lamp illuminates or the buzzer sounds. The vehicle should not be operated until the system is repaired. Failure to respond to a brake warning (lamp or buzzer) could result in an accident and/or severe injury. Speedometer and Odometer The speedometer indicates the vehicle speed in miles per hour (MPH) and in kilometers per hour (km/h).
Instruments and Controls Operating Instructions Tachometer The vehicle's tachometer measures the engine speed in revolutions–per–minute (rpm). Watching the tachometer is important to driving efficiently. It will let you match driving speed and gear selection to the operating range of your engine. If the engine speed gets too high, you can select a higher gear to lower the rpm's. If the engine speed drops too low, you can select a lower gear to raise the rpms.
Operating Instructions Instruments and Controls Coolant (Water) Temperature Gauge Engine Overheating The water temperature gauge shows the temperature of the engine coolant. Under normal operating conditions the water temperature gauge should register between 165 and 205°F (74 and 90°C). Under certain conditions, somewhat higher temperatures may be acceptable. The maximum allowable temperature is 210°F (99°C) with the cooling system pressurized, except for certain special engines.
Instruments and Controls Operating Instructions D. Return the engine speed to normal idle after two or three minutes. E. Monitor the engine temperature. After the temperature returns to normal, allow the engine to idle 3 to 5 minutes before shutting it off. This allows the engine to cool gradually and uniformly. F. Check the level of coolant in the coolant expansion tank (engine compartment, right side.
Operating Instructions Instruments and Controls WARNING! To reduce the chance of personal injury and/or vehicle damage due to engine overheating, never leave the engine idling without an alert driver present. If the engine should overheat, as indicated by the engine coolant temperature light, immediate action is required to correct the condition. Continued unattended operation of the engine, even for a short time, may result in serious engine damage or a fire.
Instruments and Controls Operating Instructions 3. Place the transmission in park and set the parking brake. (See Pages 68 and 74 for transmission shifting and parking brake information.) 4. Turn OFF the engine. 5. Turn ON the emergency flasher and use other warning devices to alert other motorists. 6. Wait a few minutes to allow oil to drain into the engine oil pan, and then check the oil level. (See page 139 for details on checking oil level.) 7. Add oil if necessary.
Operating Instructions Instruments and Controls WARNING! If the air pressure falls below 60 psi (414 kPa) the spring brakes may stop the vehicle abruptly, which could result in an accident and/ or injuries. Observe the warning light in the panel. If it comes on, do not continue to drive the vehicle until it has been properly repaired or serviced.
Instruments and Controls Operating Instructions Fuel Gauge The fuel gauge shows the approximate amount of fuel in the fuel tanks. Besides empty and full, the gauge also indicates 1/4, 1/2 and 3/4 of total fuel capacity. Your truck has one main fuel tank and up to four optional tanks. The fuel gauge shows the total amount of fuel. It is a good idea to keep fuel tanks at least half–full; otherwise, water that condenses in an empty tank will contaminate the fuel and could damage the engine.
Operating Instructions Instruments and Controls Voltmeter (option) Transmission Temperature Gauge (option) The voltmeter shows the voltage your vehicle's electrical system is putting out. Normally, it should show 10 to 16 volts. If voltage drops, have the electrical system checked. Your vehicle may be equipped with a transmission temperature gauge. It indicates the temperature of the oil in your transmission. Watch this gauge to know when your transmission is overheating.
Instruments and Controls Operating Instructions CAUTION: Do not continue to operate with the Air Filter Restriction Gauge reading 25 in. (start of red area). It could lead to damage to the engine. Inspect the filter and replace if necessary. RED CAUTION AREA Holes in the paper element render an air cleaner useless and may cause the Air Filter Restriction Gauge to give a false reading, even if the element is clogged. Replace the element if it is damaged.
Operating Instructions Instruments and Controls Daytime Running Lights (option) Panel Lights On vehicles equipped with the Daytime Running Light (DRL) system, the low beam headlights are turned ON automatically at reduced brightness (to conserve headlamp life). Three controls (or conditions) will affect whether the system is ON or OFF: • headlight switch To Operate the Panel Lights: Turn on either the headlights, clearance lights, or fog/driving lights.
Instruments and Controls Operating Instructions Windshield Wipers/Washer NOTE: The ignition key must be turned to ACC or IGN & ACC for the wiper/washer switch to operate. 0 1 A five-position windshield wiper switch controls the wipers and washer. To turn ON the wipers, turn the knob clockwise. 2 • For intermittent operation turn to the 1st and 2nd positions; for continuous operation advance to the 3rd and 4th positions. • The final option activates the washer cycle.
Operating Instructions Instruments and Controls WARNING! Do not drive with worn or dirty wiper blades. They can reduce visibility, making driving hazardous. Clean the blades regularly to remove road film and wax build-up. Use an alcohol-based cleaning solution and a lint-free cloth, and wipe along the blades. Ignition Key Switch The engine ignition key switch (located to the left of the steering column) has four positions: ACC (Accessories), OFF, IGN & ACC, and IGN & START.
Instruments and Controls Operating Instructions IGN & ACC: In this position, all circuits are energized. Panel warning lights will light and the buzzer will sound until (1) the engine is started, (2) normal oil operating pressure is reached, and (3) air brake system pressure is above 64 psi (441 kPa). In this position, the ignition key cannot be removed. 1. Apply all parking brakes. Pull out the Yellow Parking Brake Control knob (1) located on the dash.
Operating Instructions (2) Trailer Air Supply Control (Red) Instruments and Controls See “Using the Brake System” on page 72 for more information. (1) Parking Brake Control (Yellow) - for vehicles with hydraulic brakes: 02394 Combination (Tractor/Trailer) Parking Brake Control Valves 2. Shift the transmission into its PARK position. (See Pages 68 and 74 for transmission shifting and parking brake information.) 3. Turn the key to OFF. 4. Remove the key.
Instruments and Controls Operating Instructions Using the Parking Brake 2. Apply the parking brake. Pull upward on the parking brake lever until it reaches an over (top) center position. (The PARK light on the dash will come on.) 1. Come to a complete stop. NOTE: Ensure the lever is over center. The light will come on prior to brake being fully applied. CRUISE CONTROL ENGAGE STOP ENGINE SPOT LIGHT P PARK CHECK ENGINE DISENGAGE PARKING BRAKE INDICATOR PARKING BRAKE LEVER – 36 – 3. 4. 5. 6.
Operating Instructions Instruments and Controls Cruise Control Switch Hand Throttle Control Your vehicle may be equipped with a hand throttle. It is located on the floor, to the left of the driver's seat. It can be especially helpful in cold weather to keep your engine running above idle speed when you leave the vehicle briefly. See page 64 for more information on idling your engine safely.
Heating and Air Conditioning Operating Instructions HEATING AND AIR CONDITIONING C B A Introduction WARNING! Do not drive with your visibility reduced by fog, condensation, or frost on the windshield. Your view may be obscured, which could result in an injury accident. For clear visibility and safe driving it is extremely important for you to follow the instructions on the use of the ventilation/heating and defogging/defrosting system. If in doubt, consult your dealer.
Operating Instructions Heating and Air Conditioning aware of a refrigerant leak on your vehicle, have your system serviced immediately and observe the following precautions: – Stay away from the hot engine until the exhaust manifold has cooled. – Do not permit any open flame in the area. Even a match or a cigarette lighter may generate a hazardous quantity of poisonous gas. – Do not smoke in the area. Inhaling gaseous refrigerant through a cigarette may cause violent illness.
Heating and Air Conditioning Operating Instructions the cab: fan speed switch (A), air directional control switch (B), air temperature switch (C), and air circulating mode switch (D). With optional air conditioning, a fifth switch (E) is used. Temperature Control The temperature rotary switch (C) allows you to adjust and maintain a comfortable internal cab temperature. Air Circulation Control Fan Speed Control The fan speed rotary switch (A) allows you to select one of four blower speeds (1-4).
Operating Instructions Heating and Air Conditioning CAUTION: During extreme cold weather, do not blow hot air onto cold windshields. This could crack the glass. Turn the air direction lever to Defrost and adjust the fan speed accordingly while the engine warms. If the engine is already warm, move the temperature selector to Cool, then gradually increase the temperature when you see that the windshield is starting to warm up.
Heating and Air Conditioning Operating Instructions NOTE: A cold compressor can cause refrigerant to liquefy and warp the valve plates or cause a hydraulic lock. Warm the engine before starting the air conditioner. 3. Set the air conditioner for maximum cooling. 4. Close all windows. 5. Idle the engine between 1000 and 1500 rpm and turn the fan switch to High. If the air conditioner does not cool the air, have the unit checked at an Authorized Service Center.
Operating Instructions Accessories ACCESSORIES WARNING! Do not exceed the voltage/amperage capacity of the cigarette lighter. It could result in a fire. Follow all warnings and instructions in the operator's manual for the appliance you are using. Radio As an option, your vehicle has either an AM/FM Stereo Receiver or an AM/FM Stereo/Cassette Player. For instructions on how to operate your particular radio, see the manufacturer's Radio Operating Instructions in the glove compartment.
Accessories Operating Instructions WARNING! Do not carry loose objects in your cab, it can be dangerous. In a sudden stop, or even going over a bump in the road, they could fly through the air and strike you or a passenger. You could be injured or even killed. Secure all loose objects in the cab before moving the vehicle. Glove Compartment A glove compartment is provided to store important documents, the vehicle literature set (including this Operator's Manual) and other related materials.
Operating Instructions Seats SEATS Driver's Seat with Air Suspension (Option) WARNING! Before driving or riding in the vehicle, be sure that there is adequate head clearance at maximum upward travel of seat. Serious injury may occur if head clearance is not adequate. Introduction This section covers the operation and safe use of your Medium Duty seats. For further information on features and adjustment of the seat, see the manufacturer's literature included with the vehicle.
Seats Operating Instructions Safety Restraint Belts WARNING! Do not drive vehicle without your seat belt and your riders’ belts fastened. Riding without a safety belt which is properly fastened can lead to increased injury or death in an accident. Unbelted riders could be thrown into the windshield or other parts of the cab or could be thrown out of the cab. They could strike another person. Injuries can be much worse when riders are unbelted.
Operating Instructions Seats • Belts should fit snugly across the pelvis and chest. Make sure any slack is wound up on the retractor. To unfasten the belt: Push in the release button on the buckle. The belt will spring out of the buckle. • To release a locked belt, lean back to take the body pressure off of the belt. • To store a lap-shoulder belt, allow the belt to wind up on the retractor by guiding the belt tongue until the belt comes to a stop. 01888 Proper Safety Belt Adjustment 3.
Seats Operating Instructions Lap Belt Shoulder Belt Too High on Hips Correct Incorrect Correct (over arm) Incorrect (under arm) Incorrect (twisted) Safety Restraint Belts • Be sure, also, that your belt is not too loose. A loose belt could allow you to slide under it in an accident, and that could bring the belt up around your abdomen. • Do not twist the belt in the process of putting it on. A twisted belt will not work as well to protect you.
Operating Instructions Seats WARNING! Do not wear the shoulder belt under your arm or otherwise out of position. In a crash your body would move too far forward, increasing the chance of head and neck injury. Also, the belt would apply too much force to the ribs, which are not as strong as your shoulder bones, and could cause you to suffer internal injuries. Wear the shoulder belt over your shoulder (see “Safety Restraint Belts” on page 46). WARNING! Do not twist the belt in the process of putting it on.
Seats Operating Instructions • The belts must be kept clean or the retractors may not work properly. • Never bleach or dye seat belts: chemicals can weaken them. Do, however, keep them clean by following the care label on the belts. Let them dry completely before allowing them to retract. • Make sure the belt of the unoccupied passenger seat is fully wound up on its retractor, so that the belt tongue is in its stowed position.
Operating Instructions Seats Komfort–Lok® Latch Tether Adjustment • Make sure that the tether belt is attached to the cab floor and seat frame. It should be routed through the buckle on each side. • Often the attachments are made using a split-type hook. Make sure both halves of the hook are around the anchor bracket. • To lengthen the tether, turn the buckle to a right angle to the webbing. Then pull the buckle. To shorten the tether, pull on the strap.
Seats Operating Instructions During Pregnancy Pregnant women should always wear combination lap/shoulder belts. The lap belt portion must be worn snugly and as low as possible across the pelvis. To avoid pressure on the abdomen, the belt must never pass over the waist. Sometimes pregnant women worry that in a crash the seat belt could hurt the baby. But if a woman wears her belt properly— low over her pelvis, below her abdomen—the belt will not harm the baby, even in a crash.
Operating Instructions Seats If any seat belt is not working properly, see an Authorized Service Center for repair or replacement. For further information on seat belts and seat belt maintenance, see “Safety Restraint System — Inspection,” Page 197.
Steering Column and Mirrors Operating Instructions STEERING COLUMN AND MIRRORS TRAILER BRAKE VALVE Introduction This section covers the standard steering column controls and mirror operation. Depending on how your Medium Duty is configured, some or all of these features are installed on your vehicle. TURN SIGNAL/HIGH BEAM SWITCH EMERGENCY FLASHER Steering Column Controls Turn Signal/High Beam Switch NOTE: The ignition key must be turned to IGN & ACC for the signal/switch to operate.
Operating Instructions Steering Column and Mirrors Emergency Flasher Switch WARNING! Use your Hazard Flasher Warning System any time you have to stop off the road or on the side of the road, day or night. A hard-tosee vehicle can result in an injury accident. Another vehicle could run into you if you do not set your flashers. Always move the vehicle a safe distance off the road when stalled or stopped for repairs.
Steering Column and Mirrors Operating Instructions Adjustable Steering Column (option) Horn Some vehicles are equipped with an optional tilt-telescoping steering column. The tilt feature allows forward and rearward movement of the wheel. The telescoping feature allows you to move the wheel up and down. To sound the electric horn, press the button in the center of the steering wheel.
Operating Instructions Steering Column and Mirrors Power Mirror (Option) Heated Mirrors (Option) Your Medium Duty may have motorized side mirrors. A switch for each, located on the dash, controls the adjustment. Your vehicle also may have heated mirrors. To defrost mirrors in cold weather, turn the mirror heat switch to ON. To adjust the mirror: You can keep the mirror heat on to ensure that the mirrors stay free of ice or condensation.
Operating the Engine Operating Instructions OPERATING THE ENGINE WARNING! Do not start or let the engine run in an enclosed, unventilated area. Exhaust fumes from the engine contain carbon monoxide, a colorless and odorless gas. Carbon monoxide can be fatal if inhaled. Introduction For detailed information on starting and operating the engine, refer to the Engine Operation and Maintenance Manual provided with your Medium Duty.
Operating Instructions Operating the Engine Starting Procedure — Normal Temperature Use the following procedure to start your Medium Duty when outside temperatures are at or ABOVE normal starting temperatures. Check the Engine Operation and Maintenance Manual for starting temperatures. 1. Set the parking brake.
Operating the Engine Operating Instructions CAUTION: Never operate the starter motor while the engine is running. The starter and flywheel gears could clash or jam, severely damaging them. CAUTION: To help avoid overtaxing the starter motor or batteries, or causing engine damage, follow the recommendations listed below: • Do not engage starter for more than 30 seconds at a time. • Wait two minutes between each attempt to start the engine.
Operating Instructions Operating the Engine Starting Procedure — Cold Weather Engine Block Heater (Option) In addition to the previous “Normal Starting Procedures,” use these Cold Weather Starting guidelines when the air temperature falls below a certain temperature. Check your Engine Operation and Maintenance Manual for further details on when cold weather starting aids are needed.
Operating the Engine Operating Instructions • Use a solution of half ethylene glycol antifreeze and half water for best heater performance. Do not exceed 60 percent concentration of antifreeze, as it can shorten heater life. See page 146 for more information. • After servicing the cooling system, operate the vehicle for a day or two before using the heater. Trapped air inside the engine needs time to escape.
Operating Instructions Operating the Engine After the engine starts and until operating conditions reach a certain point, the system will continue to operate to eliminate white-smoke exhaust. NOTE: In colder climates where the temperatures are often below freezing, sufficient warmup for turbocharged engines is especially important. Chilled external oil lines leading to the turbocharger will slow the oil flow until the oil warms, reducing oil available for the bearings.
Operating the Engine Operating Instructions WARNING! Never idle your vehicle for prolonged periods of time if you sense that exhaust fumes are entering the cab. Investigate the cause of the fumes and correct it as soon as possible. If the vehicle must be driven under these conditions, drive only with the windows slightly open. Failure to repair the source of the exhaust fumes may lead to personal harm. damage from lack of lubrication.
Operating Instructions Operating the Engine WARNING! Do not work on or near the fan with the engine running. Anyone near the engine fan when it turns on could be seriously injured. If it is set at MANUAL, the fan will turn on any time the ignition key switch is turned to the ON position. In AUTO, it could engage suddenly without warning. Before turning on the ignition or switching from AUTO to MANUAL, be sure no workers are near the fan.
Operating the Engine Operating Instructions • Move the ON/OFF switch to the OFF position. 3. Toggle the SET/RESUME switch lever to the SET position to set the cruise speed. This toggle switch has additional functions that are set by the manufacturer. The two functions are: or 02901off • Depress the brake pedal. • To decrease the cruise set speed, hold the SET/RESUME switch in the RESUME position and coast to a lower speed.
Operating Instructions Operating the Transmission OPERATING THE TRANSMISSION Operating Manual Transmissions If your truck has an automatic transmission, go to page 71. Introduction 6, 9, 10, and 11–Speed Manual Your Medium Duty is equipped with either a manual or automatic transmission with special features and gearing to meet your particular needs. It is important for you, the driver, to understand how your particular transmission is operated.
Operating the Transmission Operating Instructions 1. Put the transmission in Neutral. 2. Release the clutch pedal and let the transmission operate in Neutral for three to five minutes prior to shifting into either a forward or reverse range. Putting the Vehicle in Motion After making sure the vehicle's oil and air pressure are correct and all other parts and systems are in proper working condition: 1. If your truck is equipped with a hand throttle, disengage the hand throttle before driving the vehicle.
Operating Instructions Operating the Transmission If you have a misaligned gear condition in your vehicle's transmission and cannot start, gradually release the clutch, allowing the drive gear teeth to line up properly. Then the drive gear can roll enough to allow the teeth to line up properly and complete the shift. The best engine performance and maximum economy is obtained if gears are properly selected.
Operating the Transmission Operating Instructions To double clutch: During Normal Driving If you want to shift directly into any gear other than first or reverse, depress the clutch pedal only far enough to release the clutch. Pushing the clutch to the floor applies the clutch brake and could cause gear hang-up. CAUTION: Be careful not to apply the clutch brake while the vehicle is moving.
Operating Instructions Operating the Transmission Release Bearing Wear When you must idle your engine for any period of time, shift your transmission to Neutral and disengage the clutch (take your foot OFF of the pedal). This helps prevent unnecessary wear to your clutch release bearing, and it is less tiring for you, too. Operating Automatic Transmissions Clutch Adjustment Inspect manual clutches according to the manufacturer's recommendations.
Using the Brake System Operating Instructions USING THE BRAKE SYSTEM NOTE: Today’s diesel engines have significant torque and startability power at low RPMs. Combinations of engine speed and available torque may overpower the vehicle’s parking brakes. WARNING! Never drive your vehicle with the parking brakes applied. Always release the parking brakes prior to moving the vehicle.
Operating Instructions Using the Brake System Brake Operation WARNING! Do not drive through water deep enough to wet brake components, as it may cause the brakes to work less efficiently than normal. The vehicle's stopping distance may be longer than expected, and the vehicle may pull to the left or right when brakes are applied, which could contribute to an accident.
Using the Brake System Operating Instructions Using the Parking Brake Before you leave the cab: The yellow diamond-shaped knob on the dash controls the truck/tractor parking brakes. These are spring brakes that you activate by releasing air pressure from their chambers. When they are not in use, air pressure compresses the springs and releases the brakes. Pulling the knob OUT applies the parking brake, which exhausts air from the chambers and allows the springs to extend and apply the brakes.
Operating Instructions Using the Brake System To release the trailer brakes ONLY: (2) Trailer Air Supply Control (Red) (1) Parking Brake Control (Yellow) • Push IN the Red knob on the dash. The truck or tractor will remain parked. To release the full combination of brakes: 02394 • Push IN BOTH knobs on the dash.
Using the Brake System Operating Instructions WARNING! If the air pressure falls below 60 psi (414 kPa) the spring brakes may stop the vehicle abruptly, which could result in an accident and/or injuries. Observe the red warning lamps on the gauges. If one comes on, do not continue to drive the vehicle until it has been properly repaired or serviced. WARNING! Do not use the trailer hand brake or service brakes to park and hold an unattended vehicle—use the parking brakes.
Operating Instructions Using the Brake System The parking brakes act on the rear wheels only. They are spring-applied, with air pressure used to release them. Release air is supplied by both the front and rear circuit reservoirs through a double check valve.
Using the Brake System Operating Instructions WARNING! Do not use the trailer hand brake or service brakes to park and hold an unattended vehicle—use the parking brakes. Because service brakes work with air pressure, these brakes could slowly release. Your vehicle could roll, causing a serious accident. Someone could be hurt or killed. Never rely on the service brakes to hold a parked vehicle.
Operating Instructions Using the Brake System Front Brakes — Truck The following applies to full truck configurations: If air pressure is lost in the front circuit, the vehicle front brakes will not operate. Check valves isolate the rear circuit, so the rear service brakes and parking brakes are unaffected. The spring brakes will not automatically apply as long as rear service pressure is maintained.
Using the Brake System Operating Instructions Brakes — Tractor/Trailer The following applies to tractor/trailer configurations: If pressure is lost in the tractor front or rear circuit, the “check” valves isolate the unaffected circuit, allowing this circuit to continue normal operation. The trailer brakes are still functional.
Operating Instructions Using the Brake System To prevent drums from distortion while they cool down: • Park the vehicle on level surface and block the wheels. • Release the parking brake and allow the brakes to cool down. See page 74. ABS lamp will remain on until a speed of no more than 9 mph has been reached and the speed sensors have been checked for correct output. The lamp should remain off after this point unless a failure in the system is detected.
Using the Brake System Operating Instructions Trailer ABS Warning Lamp Trucks, tractors, and trailers built on and after March 1, 2001 are equipped with power line communication (PLC) per U.S. FMVSS 121, including a trailer ABS warning lamp in the cab. A trailer ABS warning lamp will illuminate for a bulb check when the ignition switch is first turned on - whether or not a trailer is connected to the vehicle. If the bulb check is satisfactory, the lamp will next do either of the following: 1.
Operating Instructions Using the Brake System • If a trailer ABS problem is detected, the lamp will remain on. The driver should have the trailer’s ABS problem corrected before the vehicle is driven with that trailer attached. WARNING! Do not rely on an anti-lock brake system that is functioning improperly. You could lose control of the vehicle resulting in a severe accident and serious personal injury.
Using the Brake System Operating Instructions To operate the trailer brake hand valve: Do not use the engine retarder (such as an exhaust brake) to slow the vehicle down when you are bobtailing or pulling an empty trailer. • Pull down on the lever. • The valve is self-returning. When pressure is removed from the valve lever, it will return to the OFF position. WARNING! Do not use an engine retarder when you are driving bobtail or with an unloaded trailer.
Operating Instructions Using the Brake System WARNING! The service brakes must be used in an emergency. The engine or retarder alone might not stop you fast enough to prevent an accident. You could be badly hurt if you relied only on the engine retarder. On tractors that do not have anti-lock brake systems (ABS) a bobtail brake proportioning system is installed.
Using the Brake System Operating Instructions • After the engine is started, warmed up, and you are ready to get under way, turn the exhaust brake switch ON for added braking effect. WARNING! Do not use the engine retarder when operating on road surfaces with poor traction (such as wet, icy, or snow covered roads or gravel). Retarders can cause the wheels to skid on a slippery surface. You could lose control of the vehicle and/or jackknife if the wheels begin to skid, resulting in an accident.
Operating Instructions Using the Brake System Compressed Air Tanks: The wet (supply) and dry (service) tanks are located behind the battery box and on the frame rail; the supply tank is below the front service tank. See “Air Tanks” on page 162. • Modulates spring brake application in proportion to front service application in the event of a rear service failure. • Prevents compounding of service and spring applications.
Using the Brake System Operating Instructions Parking Brake Valve: yellow diamond-shaped knob. It controls the application and release of the parking (spring) brakes of truck or tractor-trailer combinations or of the tractor alone. If the air system is being charged from zero pressure, the parking brake valve will not hold in the release position until the system pressure exceeds 60 psi (414 kPa), which is the pressure required to override the load of this valve's plunger return spring.
Operating Instructions Using the Brake System ders which actuate the brake pad mechanisms. Actuation of these mechanisms force the brake pads against the rotors to stop the wheels. A reserve electric motor pump provides a redundant power source for the hydraulic booster in the event normal flow from the power steering pump is interrupted. Manual braking is also available in the event both the power and reserve systems are inoperative. WARNING! Never drive your vehicle with the parking brakes applied.
Using the Brake System Operating Instructions Brake Master Cylinder: translates brake pedal force into hydraulic fluid pressure in the primary and secondary circuits. Hydraulic Booster: The hydraulic booster applies additional hydraulic force from the power steering gear to the master cylinder piston when the brake pedal is applied. Brake Pedal: applies actuation force from operator's foot to the master cylinder pistons.
Operating Instructions Using the Brake System Brake Warning Lamp When the brake warning lamp comes on, it indicates a malfunction in the brake system. Possible malfunctions include loss of hydraulic pressure from the power steering circuit or a pressure differential between the primary and secondary brake circuits. MIRROR HEAT 0 OIL WARNING! Do not operate the vehicle if the brake light or buzzer comes on. The light or buzzer indicates a failure in one of the brake components/system.
Using the Brake System Operating Instructions • Pump the brakes - Pumping the brake pedal may generate enough hydraulic pressure to stop the vehicle. • Use the parking brake - The parking or emergency brake is separate from the hydraulic system. Therefore it can be used to slow the vehicle. 2. Move a safe distance off the road and stop. 3. Set the parking brake. (See page 36.) 4. Turn on the emergency flasher and use other warning devices to alert other motorists. • Place transmission in lower gear.
Operating Instructions Using the Brake System Anti-Lock Braking System This vehicle is equipped with an Anti-Lock Braking System (ABS). ABS reduces the likelihood of a wheel locking. If a wheel is about to lock during braking, the ABS will automatically adjust hydraulic pressure to the brake calipers on the appropriate wheel(s) to prevent wheel lock-up. The ABS is automatically activated when the ignition switch is turned on.
Using the Brake System Operating Instructions Parking Brake Burnishing This procedure is recommended for new vehicles where less lever actuation force is required. This procedure is mandatory whenever the driveline brake shoes or brake drum are replaced. WARNING! If a new drum or new brake shoes are installed, the driveline brake must be burnished.
Operating Instructions Operating the Rear/Drive Axle OPERATING THE REAR/DRIVE AXLE When operating normally on paved, dry surfaces, keep your truck's interaxle differential in the UNLOCK position. Introduction GUARD This section covers the operation of your Rear/Drive Axle. These instructions apply to the most common features of drive axles. Refer to the manufacturer’s instructions for further information on the operation of your axle.
Operating the Rear/Drive Axle Operating Instructions In the LOCK position, an air operated clutch positively locks both sets of axles together, providing greater traction on slippery road surfaces; however, steering around corners and on dry pavement is more difficult. Continuous operation on a paved, dry surface stresses the tandem axles, possibly causing internal damage. Use this feature only when driving on surfaces with poor traction, such as wet slippery roads, heavy mud or snow, or loose gravel.
Operating Instructions Operating the Rear/Drive Axle going down steep grades or traveling faster than 25 mph, or while wheels are spinning or traction is minimal; lock it before you encounter these conditions. 3. If you LOCK or UNLOCK the inter-axle differential while moving, let up momentarily on the accelerator pedal to relieve torque on the gearing and allow full engagement of the clutch (the mechanism that locks the wheels).
More Driving Tips and Techniques Operating Instructions MORE DRIVING TIPS AND TECHNIQUES Coasting WARNING! Do not coast with the transmission in neutral or with the clutch pedal depressed—it is a dangerous practice. Without the use of the retarding power of the drivetrain, your vehicle can reach dangerous speeds. At very high speeds you may not be able to put the transmission in any gear. At high speeds you could seriously damage your vehicle or cause an accident when you put the transmission in gear.
Operating Instructions Driving Tips And Techniques NOTE: Often these recommendations are secondary to maintaining an adequate and safe speed relative to the surrounding traffic and road conditions. countershaft gear (which lubricates the transmission components by oil splash) will only be turning at idle speed. Descending a Grade WARNING! Do not hold the brake pedal down too long or too often while going down a steep or long grade. This could cause the brakes to overheat and reduce their effectiveness.
Driving Tips And Techniques Operating Instructions • If the engine rpm moves beyond the maximum governed speed, indicating an overspeed condition, apply the service brake or shift to a higher gear to bring engine rpm within the optimum speed range. • Shift into higher or lower gears (or apply the service brake) to keep engine rpm near the lower end of the optimum operating range. • Avoid rapid acceleration and braking.
Operating Instructions Driving Tips And Techniques Air Suspension Height/Air Pressure Your vehicle may have an air suspension. A deflation switch on the dash allows you to exhaust the air in the suspension, which allows you to lower the height of your vehicle for loading. On tractors, the deflate switch allows you to lower the fifth wheel to slide under a trailer. DEFLATE AIR A guard on the switch prevents you from accidentally deflating the suspension.
Driving Tips And Techniques Operating Instructions WARNING! To prevent possible injury and damage to property, ensure that a vehicle is parked and the wheels chocked before beginning this procedure. CAUTION: Completing this procedure will enable you to safely reach the nearest authorized Peterbilt repair facility to have ride height and pinion angle reset using the proper equipment and technique. Do this as soon as possible to avoid potential driveline damage.
Operating Instructions Driving Tips And Techniques WARNING! Be extremely careful when deflating the air springs. The rear of the vehicle will drop about 3-1/2 inches (88 mm) when the air springs are deflated. Make sure that no persons or objects that could be injured or damaged are under the vehicle. To minimize the risk of damage or injury, do not use the dump valve to deflate the air springs. Operate the height control valve(s) manually to ensure positive control of air spring deflation.
Driving Tips And Techniques Operating Instructions Rotate the valve either clockwise or counterclockwise until air pressure in the air springs provides the ride height specified for that suspension. Measure the ride height from the bottom of the frame rail to the approximate centerline of the rearmost drive axle hub: DELIVERY TO RH AIR BAG(S) SUPPLY FROM FORWARD AIR TANK MOUNTING NUTS • For tandem axles, make the vertical measurement at the centerline of the suspension (see illustration on page 102).
Operating Instructions Driving Tips And Techniques Driving with Deflated Air Springs Vehicles with the air suspension (option): If an air spring ruptures, there will be enough air pressure to drive the vehicle to a safe stop off the highway to investigate the problem. WARNING! Do not continue to drive with ruptured air springs. The air loss can cause the spring brakes to apply allowing your brakes to drag and burn up the linings, which could lead to an injury accident.
Driving Tips And Techniques Operating Instructions Fifth Wheel Jaw Lock Air–Controlled Sliding Fifth Wheel To unlock the fifth wheel lock: Vehicles having an air-controlled sliding fifth wheel have a fifth wheel slider lock controlled by a switch on the accessory switch panel. To operate this type of lock, move the switch to the appropriate position. By placing the switch in the UNLOCK position, you can slide the fifth wheel to various positions to adjust weight distribution.
Operating Instructions Driving Tips And Techniques CAUTION: Both the fifth wheel plate and the slide tracks (if a slider) should be cleaned and lubricated periodically to ensure smooth turning and sliding action. Failure to keep these surfaces lubricated can lead to frame or driveline damage. Fifth Wheel Lubrication • Frequently operate and lubricate movable or sliding fifth wheels to prevent corrosion. See page 219 for maintenance information.
Vehicle Recovery and Spring Brakes Operating Instructions VEHICLE RECOVERY AND SPRING BRAKES Introduction Your Medium Duty is equipped with built-in recovery provisions, designed for short distance use only. If your vehicle must be recovered, disconnect the driveline at the rear U– joint, and remove or support the rearmost section of the driveline.
Operating Instructions Vehicle Recovery and Spring Brakes Vehicle Recovery Guidelines Recovery Rigging Refer to the guidelines below when towing to prevent possible damage: To connect to the Medium Duty, attach the towing chain or cable to the tow hook through the access hole in the bumper. • Use proper towing equipment to prevent damage to the vehicle. CAUTION: Connect only to the towing provisions, as described on the following pages.
Vehicle Recovery and Spring Brakes Operating Instructions 1. Into the pinion cage, add 1 pint (.47 liter) of lubricant. 2. Into the inter-axle differential, add 2 pints (.94 liter) of approved lubricant. • See “Recommended Lubrication Types,” Page 136. 3. After adding the specified type and amount of lubricant, drive the vehicle. It should be unloaded. Drive 1 to 2 miles (1.5 to 3 km) at a speed lower than 25 mph (40 km/ h). This will thoroughly circulate the lubricant through the assembly.
Operating Instructions Vehicle Recovery and Spring Brakes 1. Remove the cap from the spring chamber. 2. Remove the release stud assembly from the side pocket, and remove the release nut and washer from the release stud. 4. Insert the release stud through the opening in the spring chamber where the cap was removed. Insert it into the pressure plate. Turn the release stud 1/4 turn clockwise in the pressure plate.
Vehicle Recovery and Spring Brakes Operating Instructions push rod) is retracting. Do not over-torque the release stud assembly. (S–Cam type maximum: 50 ft-lb, Wedge type maximum: 30 ft-lb.) The spring brake is now mechanically released. • Apply light pressure on the accelerator pedal while the transmission is in gear. • Remove your foot from the accelerator while shifting. • Do not race the engine. • For best traction and safety, avoid spinning the wheels.
Operating Instructions Shut–Down SHUT–DOWN Always use your parking brakes! WARNING! Do not use the trailer hand brake or service brakes to park and hold an unattended vehicle—use the parking brakes. Because service brakes work with air pressure, these brakes could slowly release. Your vehicle could roll, causing a serious accident. Someone could be hurt or killed. Never rely on the service brakes to hold a parked vehicle.
Shut–Down Operating Instructions 3. Drain water from the air reservoirs. Turbocharger • While the engine and air supply system are still warm, drain moisture from the air reservoirs. Open the reservoir drains just enough to drain the moisture. Do not deplete the entire air supply. Be sure to close the drains before leaving the vehicle. 4. Secure the vehicle, close all the windows, and lock all doors. This cooling-down practice is especially important for a turbocharged engine.
Operating Instructions Shut–Down WARNING! Do not carry additional fuel containers in your vehicle. Fuel containers, either full or empty, may leak, explode, and cause or feed a fire. Do not carry extra fuel containers, even empty ones are dangerous. Specification: Use only Diesel Fuel, Grade 2–D, as recommended by engine manufacturers. If you need further information on Grade 2–D fuel specifications, consult the Engine Operation and Maintenance Manual.
Introduction Preventive Maintenance PREVENTIVE MAINTENANCE INTRODUCTION Safety Precautions This section will help you keep your Medium Duty in good running condition. There are a number of checks you can do, and you may be able to do some of the service work yourself. But please, let your Peterbilt Dealer or Authorized Service Center do any work you do not have the tools or skill to perform.
Preventive Maintenance Introduction • When working underneath the vehicle without appropriate safety stands but with the wheels on the ground (not supported), make sure that (1) the vehicle is on hard level ground, (2) the parking brake is applied, (3) all wheels are chocked (front and rear) and (4) the engine cannot be started. Remove the ignition key. • Never start or let the engine run in an enclosed, unventilated area.
Introduction Preventive Maintenance tive harm. This warning requirement is mandated by California law (Proposition 65) and does not result from any change in the manner in which Peterbilt Motors Company trucks are manufactured. and the Peterbilt Electronic Parts Catalog (ECAT). When ordering replacement parts, please provide the Medium Duty Chassis Serial Number. See Page 228. WARNING! Handle lubricants carefully. Vehicle lubricants (oil and grease) can be poisonous and cause sickness.
Preventive Maintenance Maintenance Schedule and Lubrication MAINTENANCE SCHEDULE AND LUBRICATION Introduction The following section summarizes preventive maintenance and lubrication requirements for the maintenance of your Medium Duty. For specific maintenance procedures and complete lubrication instructions of specific components consult the Medium Duty Maintenance Manual and manufacturer's service manuals.
Maintenance Schedule and Lubrication Preventive Maintenance Maintenance Intervals Table 2, ”Recommended Maintenance Intervals”, shows service intervals for normal and heavy-duty operations. Table 2 For additional “Engine Cooling System” information see Page 143. For additional “Air System” information see Page 161. NOTE: Different lubricants or service intervals than those listed below may be required.
Preventive Maintenance Table 2 Maintenance Schedule and Lubrication Recommended Maintenance Intervals ITEM Rear Wheel Bearings INTERVAL 100,000 COMMENTS With LMS Wheel End Package Rear Brake Camshafts 10,000–15,000 Synthetic Grease With Special Fittings Fifth Wheel 10,000–15,000 40 to 60K For Adjustment Spring Pins 10,000–15,000 With Rubber Bushed Pins – No Service Front & Rear Slack Adjusters 10,000–15,000 Synthetic Grease With Special Fittings King Pins 10,000–15,000 Front Wheel Bearin
Maintenance Schedule and Lubrication Table 2 Preventive Maintenance Recommended Maintenance Intervals ITEM INTERVAL COMMENTS Hydraulic Brakes Brake Pad Lining Inspection 7,500 mile Rotor Inspection 15,000 miles or 15 mos Park Brake Inspection 15,000 miles or 15 mos Minimum 3/16 in.
Preventive Maintenance Maintenance Schedule and Lubrication Maintenance Schedule TABLE KEY NOTE: If a scheduled service interval is shaded, skip to the next interval. The frequency of each service operation is identified by open (non-shaded areas). Use Table 3, ”Maintenance Schedule,” as a guide to plan service work. Be sure and follow the frequency recommendations for your vehicle. Table 3 C2 Federal Annual Inspection 120,000 miles/192,000 km only.
Maintenance Schedule and Lubrication Table 3 Preventive Maintenance Maintenance Schedule 15,000 mi 24,000 km 60,000 mi 96,000 km OPERATION \ FREQUENCY COMMENTS 7,500 mi 12,000 km INTERVAL A B C A B C Wiper Blade Condition Horns (Electric and Air) Mirrors SAFETY EQUIPMENT Drain Water from Air Tanks Air Tank Check Valve Emergency Operation of Spring Brakes Air Press. Build–up time: _______ min. Governed Air Pressure: _______ psi Air Press. Drop–Brakes not Applied: ___ Air Press.
Preventive Maintenance Table 3 Maintenance Schedule and Lubrication Maintenance Schedule Emergency Flasher Brake Lights Backup/Loading Lights License Plates: Permits and Mounting Mud Flaps / Serviceable Fuel Tank Mounting Exhaust System–Condition and Mounting Bolts Frame Fastener Torque: does NOT apply to Le Jeune frame fasteners.
Maintenance Schedule and Lubrication Table 3 Preventive Maintenance Maintenance Schedule COMMENTS 60,000 mi 96,000 km 15,000 mi 24,000 km OPERATION \ FREQUENCY 7,500 mi 12,000 km INTERVAL Fan Shroud Fan Assembly and Idler Pulley Check Water Pump for Leaks / Play Radiator – Exterior Condition No Service Required Replace Engine Coolant C4 Fill as Required – Extended Drain Per Manufacturer Specifications.
Preventive Maintenance Table 3 Maintenance Schedule and Lubrication Maintenance Schedule COMMENTS 60,000 mi 96,000 km 15,000 mi 24,000 km OPERATION \ FREQUENCY 7,500 mi 12,000 km INTERVAL Drain Water from Fuel System 25,000 Mile Change Interval – Must Meet Engine Co. Requirements Engine Oil – Change Oil Filters – Replace Fuel Filters – Replace Engine Tune–up Cranking System: Visual Inspect.
Maintenance Schedule and Lubrication Table 3 Preventive Maintenance Maintenance Schedule COMMENTS 60,000 mi 96,000 km 15,000 mi 24,000 km OPERATION \ FREQUENCY 7,500 mi 12,000 km INTERVAL King Pin Wear Steer Axle Wheel Bearing - End Play Adjustment and Inspection Front Hub Lubricant Level Spring Leaves 350,000 Miles With LMS Outer Ends • No Leak – No Service Tighten U-bolts after the first 500 miles (800 km). Rear suspension fasteners: retorque after first 2,000 miles (3218 km).
Preventive Maintenance Table 3 Maintenance Schedule and Lubrication Maintenance Schedule COMMENTS 60,000 mi 96,000 km 15,000 mi 24,000 km OPERATION \ FREQUENCY 7,500 mi 12,000 km INTERVAL Synthetic Grease Required – Special Fitting No Service Required Front & Rear Brake Camshaft Tube Lubrication Clutch Pedal Shaft Clutch Linkage Suspension Fittings Clutch Release Bearing Driveline Center Bearing Automatic Slack Adjusters Brakes: Lining Remaining (replace as required) RF ______ RRF ______ RRR ______
Maintenance Schedule and Lubrication Table 3 Preventive Maintenance Maintenance Schedule 15,000 mi 24,000 km 60,000 mi 96,000 km OPERATION \ FREQUENCY COMMENTS 7,500 mi 12,000 km INTERVAL A B C (Color of charge indicator for each battery) 1 ______ 2 ______ 3 ______ 4 ______ TIRES AND WHEELS Missing Valve Caps and Stem Locks Cracks or Loose Wheel lugs Tandem Mating Irregular Wear Tire Pressure (Record below) Remaining Tread (Record below) Tires & Wheels Inspection Right – 130 – Y53-6008 Medium
Preventive Maintenance Table 3 Maintenance Schedule and Lubrication Maintenance Schedule 15,000 mi 24,000 km 60,000 mi 96,000 km OPERATION \ FREQUENCY COMMENTS 7,500 mi 12,000 km INTERVAL A B C A B Left Air Pressure Adjusted to: _____________ ALIGNMENT Toe–in: ______________ in (mm) Caster: L ________ R ________ Rear Axle Alignment ROAD TEST C2 C Steering / Steering Play Shifting Brakes Engine Operation (noises, surging, black smoke) Throttle Linkage Jake Brake Operation Seat Belts Air Sea
Maintenance Schedule and Lubrication Table 3 Preventive Maintenance Maintenance Schedule 15,000 mi 24,000 km 60,000 mi 96,000 km OPERATION \ FREQUENCY COMMENTS 7,500 mi 12,000 km INTERVAL A B C A B C Air Conditioner Instruments and Gauges: Speedometer/odometer Tachometer Oil Pressure Engine Temperature Illumination BODY Interior Liner Damage Door Operation Roll–up Door Tracks – Lubricate Lift–gate Operation OTHER Hood Pivots Fifth Wheel Components Brake Treadle Hinge and Roller Lock Cylinder
Preventive Maintenance Maintenance Schedule and Lubrication Lubrication Specifications You will find a complete Engine Lubrication Service Guide in the Engine Operation and Maintenance Manual. There, the engine manufacturer explains more fully all the maintenance operations you and a qualified service mechanic will need. And please remember: one key to keeping your Medium Duty running at top economy and in prolonging its life is proper lubrication servicing.
Maintenance Schedule and Lubrication Preventive Maintenance Lubrication Types APPLICATION Use Table 4 on page 136 and the list of lubricants below to identify the type of lubricant to use on your Medium Duty. For a quick summary of each lubrication point, see Table 2 on page 120.
Preventive Maintenance Maintenance Schedule and Lubrication Oil Reservoirs For oil reservoirs with side filler plugs (transmissions, axles, steering gear boxes, transfer cases, etc.), the oil must be level with the filler opening. NOTE: Use care when checking the oil level with a finger. Just because you can reach the oil level with a finger, does not mean the oil level is correct.
Maintenance Schedule and Lubrication Table 4 Preventive Maintenance Recommended Lubrication Types COMPONENTS RECOMMENDED LUBRICANT Power Steering Gear Automatic Transmission Fluid (ATF) Driveline U-Joints Slip-Joint Splines Hood Pivots Fan Drive Fifth Wheel Components Clutch Pedal Shaft Clutch Linkage Other chassis grease fittings not covered below. EP chassis grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2.
Preventive Maintenance Table 4 Maintenance Schedule and Lubrication Recommended Lubrication Types COMPONENTS RECOMMENDED LUBRICANT Cam Brake Camshaft Splines; Disc Brake Shaft Splines and Slide Pin Retainers; Brake Clevis Pins Antiseize type grease, Rockwell specification 0-637. Brake Camshaft Bushings EP Chassis grease, lithium 12-hydroxystearate base, NLGI 2. CAUTION: Do not contaminate brake linings with grease.
Maintenance Schedule and Lubrication Preventive Maintenance NOTE: Keep the engine exhaust system and the vehicle’s cab ventilation system properly maintained. It is recommended that the vehicle’s exhaust system and cab be inspected: • By a competent technician every 15,000 miles. • Whenever a change is noticed in the sound of the exhaust system. • Whenever the exhaust system, underbody, cab or sleeper is damaged.
Preventive Maintenance Engine Maintenance ENGINE MAINTENANCE WARNING! Hot engine oil can be dangerous. You could be seriously burned. Let the engine oil cool down before changing it. Engine Lubrication Proper engine lubrication depends on ambient temperature and where the vehicle will be operated. Use the recommended oil for the weather conditions outside.
Engine Maintenance Preventive Maintenance Fuel System Specification: Use only Diesel Fuel, Grade 2-D, as recommended by engine manufacturers. If you need further information on Grade 2-D fuel specifications, consult the Engine Operation Manual in the glove compartment. Please follow these recommendations when you are changing your fuel filters or strainer elements. Your vehicle's engine will run better and last longer if you do.
Preventive Maintenance Engine Maintenance NOTE: To expel air from density-type strainer elements, soak them in clean fuel before installing them. • Throw away old gaskets. Replace them with new ones to ensure a positive seal. • Position the shell and gasket properly. Then tighten the cover nut or bolt just enough to prevent fuel leakage. • After starting the engine, check for leaks around the filter. A. Close valve and run engine until smooth idle is established, then repeat drain procedures, or B.
Engine Maintenance Preventive Maintenance Engine Accesories: Accessory Drive Belts You can extend the reliability and service life of your vehicle's drive belts with proper attention to installation, and maintenance. Neglect could cause belt failure. The result could be the loss of the electrical or air system as well as possible engine damage from overheating. So it’s a very good idea to check your belts frequently and replace them as soon as you detect trouble.
Preventive Maintenance Engine Cooling System To Check the Fan: • Check the fan assembly mounting bolts for tightness. Inspect the blades for damage. • Check the clutch operation by starting the engine when it is cold. Then idle it at about 800 RPM. Listen for air leaks. • Check that the fan is not working while the engine is warming. When the clutch engages, note the reading on the vehicle's panel—mounted coolant temperature gauge.
Engine Cooling System Preventive Maintenance CAUTION: The engine cooling system has very specific maintenance and inspection requirements. Failure to follow requirements can damage the engine. Engine damage can include but is not limited to: • Freezing • Boiling • Corrosion • Pitted cylinder liners This information is found in the engine manufacturers owner’s manual. It is the owner’s responsibility to follow all requirements listed in the engine manufacturers owner’s manual.
Preventive Maintenance Engine Cooling System Desired ELC/ Water ratio: 0% 10% 15% 20% 25% 30% 35% 40% Freeze point °F (°C) +32 (0) +25 (-4) +20 (-7) +15 (-9) +10 +5 -5 -12 -23 -34 -50 -65 -75 -84 -70 -55 -43 -30 -5 (-12) (-15) (-21) (-24) (-31) (-37) (-46) (-54) (-59) (-64) (-57) (-48) (-42) (-34) (-21) ELC Condition (Contamination and Inhibitor Concentration) Perform a visual inspection of the ELC. It should have no cloudiness or floating debris.
Engine Cooling System Preventive Maintenance NOTE: If frequent topping off is necessary and there are no visible signs of coolant leaks when the engine is cold, check for leaks with the engine operating at normal temperature. Proper Coolant Level NOTE: Do not overfill a cooling system. Excess coolant may result in overflow, loss of antifreeze, and reduced corrosion protection. WARNING! Handle coolant and antifreeze carefully. Ethylene glycol antifreeze is poisonous.
Preventive Maintenance Engine Cooling System 8. Idle the engine until it reaches normal operating temperature. 9. Fill the radiator as necessary to raise the coolant level to the proper reading. Replace the surge tank pressure cap. Engine (Block) Heater (option) WARNING! Do not use the heater if there are any signs of problems. Engine block heaters can cause fires resulting in serious personal injury and/or property damage if not properly maintained and operated.
Engine Cooling System Preventive Maintenance PREVENTIVE MAINTENANCE (PM) INTERVALS A I B C At the first 15,000 mi./ 15,000 mi./24,000 km/ 30,000 mi./48,000 km 24,000 km or at the first Monthly PM SYSTEM COMPONENT 60,000 mi./96,000 km/ 6 months D E 120,000 mi./ 192,000km / Annually 240,000 mi./384,000 km Recommended PM Interval MAINTENANCE TASK I Cooling A B Hoses Check the radiator and heater hoses for leaks. X Extended Life Coolant (ELC) Check the freeze point (see page 143).
Preventive Maintenance Brake System BRAKE SYSTEM All of the following areas are interrelated and must conform to original specifications: If your truck has an air brake system, see the pages below. • • • • If your truck has a hydraulic brake system, please go to “Hydraulic Brake System” on page 153. Introduction To operate your vehicle safely, you need some understanding of its brake systems. Brake adjustment and brake balance must be set carefully to allow equal stopping forces at all wheels.
Brake System Preventive Maintenance WARNING! Do not use any replacement part in the brake system unless it conforms exactly to original specifications. A nonconforming part in your vehicle's brake system could cause a malfunction resulting in an injury accident. Sizes and types are so related to one another that a seemingly unimportant change in one may result in a change in how well the brakes work for you on the road.
Preventive Maintenance Brake System • Do not use pressure-release grease fittings when lubricating the slack adjuster. Checks and Adjustments All vehicle operators should check the brakes regularly. Always adjust the brakes when they are cool. • Park the vehicle on a level surface and block the wheels before attempting any brake checks or adjustments. Brake Linings WARNING! Do not use brake linings with a thickness below the specified minimum.
Brake System Preventive Maintenance WARNING! Manual adjustment of automatic slack adjusters is a dangerous practice that could have serious consequences. It gives the operator a false sense of security about the effectiveness of the brakes. Contact the Service Department at your dealership if the stroke exceeds the above specifications. A stroke exceeding these values may indicate a problem with the slack adjuster or the brake foundation.
Preventive Maintenance Brake System Constant manual adjustment of automatic slack adjusters can shorten the life of the internal clutch. If the installation appears to be free of damage, but the applied stroke range could not be achieved, the slack adjuster must be replaced. NOTE: The brake adjuster alone does not ensure proper brake operation. Inspect all brake components. All brake components work together and must be checked periodically to ensure the brake system works properly.
Brake System Preventive Maintenance WARNING! Do not use any replacement part in the brake system unless it conforms exactly to original specifications. A nonconforming part in your vehicle's brake system could cause a malfunction resulting in an injury accident. Consult you local dealer for suitable replacement parts. Brake Fluid Check and Refill WARNING! Do not work on the brake system without the parking brake set, the keys removed from the vehicle, and wheels chocked securely.
Preventive Maintenance Brake System WARNING! If the brake fluid reservoir requires an excessive amount of hydraulic fluid, the complete system must be inspected for leaks and repaired if necessary (consult your nearest Peterbilt dealer). Failure to keep the brake system in good repair may lead to loss of braking and possibly cause serious personal injury. Make sure that the fluid level registers on or above the fluid level mark molded on the reservoir - add more if necessary, as follows: 1.
Brake System Preventive Maintenance BRAKE PADS ANCHOR PLATES BRAKE PADS CALIPERS CALIPERS ROTORS FRONT REAR SYSTEM COMPONENTS Calipers - Visually inspect calipers for brake fluid leakage, damaged or defective pistons or piston boots. If there is evidence of leakage, damage, or other defects the caliper should be replaced or repaired. Disc brake rotors - Visually inspect rotors for scoring, warping, cracks, bluing or heat spots or other damage or defects.
Preventive Maintenance Brake System Visually inspect brake shoe lining for wear, cracks, or breakage. If linings are worn down to 2.5 mm (0.10 in), they must be replaced. Inspect brake drum for deep scores, heat spots, cracks, or damage. Replace if needed. BRAKE SHOE LININGS Anti–Lock Braking System (ABS) Your Medium Duty is equipped with an anti-lock braking system. For detailed service information, see the Peterbilt Medium Duty Maintenance Manual.
Brake System Preventive Maintenance • During wheel balancing, dyno testing, or any time the ignition is on with part of the ABS disconnected, a failure code will be recorded. Consult with your Peterbilt Dealer or Authorized Service Center for information on clearing the failure code. If, due to operating conditions, a brake application causes either wheel on the same axle to begin skidding, wheel speed sensors immediately signal the anti-lock controller in the modulator assembly.
Preventive Maintenance Brake System WARNING! Do not operate the vehicle in the event of a malfunction in any air or hydraulic circuit. Such a malfunction may prevent the brake system from operating properly, and could result in an injury accident. The vehicle should not be operated until the system is repaired and both braking circuits, including all pneumatic, hydraulic, and mechanical components are working properly.
Air System Preventive Maintenance AIR SYSTEM Introduction WARNING! Prior to the removal of any air system component, always block and hold the vehicle by a secure means other than the vehicle's own brakes. Depleting air system pressure may cause the vehicle to roll unexpectedly resulting in an accident and/or injuries. Keep hands away from chamber push rods and slack adjusters, they may apply as system pressure drops. •Never connect or disconnect a hose or line containing air pressure.
Preventive Maintenance Air System Scheduled Maintenance Table 6 Use Table 6, ”Air System Scheduled Maintenance,” to schedule service operations and air system tests.
Air System Preventive Maintenance WARNING! If the supply and service tanks are not drained at the recommended frequency, water could enter the air lines and valves. This could cause corrosion or blockage, which could compromise the brake system safety and potentially cause an injury accident. Air System Function Test Scheduled maintenance should be performed on the Medium Duty air system, as outlined in the Medium Duty Maintenance Manual and Table 6.
Preventive Maintenance Air System CAUTION: Do not use penetrating oil, brake fluid, or wax-based oils in the air system. These fluids may cause severe damage to air system components. service center) if a leak is detected. Failure to check the brakes or follow these procedures could cause a system failure, increasing the risk of an injury accident. FRONT SECONDARY SERVICE CIRCUIT (WHITE) • Maintain the air compressor to prevent excessive oil bypass.
Air System Preventive Maintenance Follow the procedure below to check the compressed air system for leaks: 1. Periodically, or after maintenance or replacement of air system components: 2. Build up air pressure in the system to the governor cutout point or until 120 psi (827 kPa) is reached. 3. Stop the engine and release the service brakes. 4. Without applying the brake pedal, observe the rate of air pressure drop. This rate should not exceed 2.0 psi (14 kPa) per minute. 5.
Preventive Maintenance Air System head. Also, check compressor discharge line for carbon, and clean or replace the discharge line if necessary. • Disassemble compressor and thoroughly clean and inspect all parts. Repair or replace all worn or damaged parts, or replace compressor with a factory exchange unit. CAUTION: When draining the engine cooling system is required, to prevent damage from freezing, the compressor must also be drained at the cylinder head and block.
Air System Preventive Maintenance • When more than a 30-degree F. (17-degree C) range of temperature occurs in one day, small amounts of water can accumulate in the air brake system due to condensation. Under these conditions, the presence of small amounts of moisture is normal and should not be considered as an indication that the dryer is not performing properly. • An outside air source may have been used to charge the air system, in which case this air did not pass through the drying bed.
Preventive Maintenance Air System High Frequency Vibration: Vibration may indicate turbo rotor imbalance. Have your Peterbilt Dealer or Authorized Service Center investigate this immediately. If you detect any deficiencies, take the vehicle to an Authorized Service Center for servicing. Delay could lead to severe and expensive damage to your vehicle. Service the air cleaner periodically. If the vehicle operates in areas with heavy dust, maintenance should be more frequent.
Air System Preventive Maintenance 3. Remove the filter element. 4. Clean out the inside of the air cleaner body and outlet tube with a dry rag. COVER To install air cleaner element: 1. Slide air cleaner element into housing. 2. Install air cleaner end cap. 3. Install thumbscrews around air cleaner housing end cap. 00455B NOTE: The air cleaner is internally sealed by a radial seal around Inlet tube of air cleaner element.
Preventive Maintenance Tires and Wheels TIRES AND WHEELS Introduction Keeping the tires in good condition is essential to the safe, efficient operation of your Medium Duty. Regular, frequent inspection and the right care will give you the assurance of safe and reliable tire operation. General Safety Requirements WARNING! Use only original equipment manufactured (OEM) components.
Tires and Wheels Preventive Maintenance Speed Restricted Tires WARNING! This vehicle may be equipped with speed restricted tires. Check each tire’s sidewall for maximum rated speed. Vehicle should not be operated at sustained speed in excess of maximum rated speed. Failure to comply with these speed restrictions could cause sudden tire failure which can result in property damage or personal injury. Tire Inspection and Replacement vehicle. For dual wheel assemblies, check between the wheels for damage.
Preventive Maintenance Tires and Wheels Tire Inflation Most tire wear problems are caused by underinflation as the result of slow leaks. So you will want to check tire pressure regularly. Give the tires a visual test every day, and check inflation with a gauge every week. When checking tire pressure, inspect each tire for damage to sidewalls, cuts, cracks, uneven wear, rocks between dual wheels (tires), etc. If a tire appears underinflated, check for damage to the wheel assembly.
Tires and Wheels Preventive Maintenance Overinflation: r e d u c e s t h e tread contact area with the road surface, concentrating all of the vehicle weight on the center of TREAD CONTACT the tread. This causes premaWITH ROAD ture wear of the tire. • Too much air pressure reduces the tire tread contact area and results in rapid wear in the center of the tire. It also causes tires to run hard and makes them more vulnerable to impact and other road hazard damage.
Preventive Maintenance Tires and Wheels Wheel Mounting and Fastening Wheel Bearing Adjustment After the vehicle travels about 50 to 100 miles (80 to 160 km), wheel mountings “seat in” and will lose some initial torque. Check hub/wheel mountings after this initial period and retighten. Wheel Cap Nut Torque At the first scheduled lube interval, have all wheel cap nuts torqued to their specified value. See Table 8, “Wheel Cap Nut Torque,” Page 174 After that, check wheel cap nuts at least once a week.
Tires and Wheels Table 8 Preventive Maintenance Wheel Cap Nut Torque WHEEL & NUT CONFIGURATION Steel Disc-Type Wheel; Double Cap Nut Mounting; Standard 7/8” Radius Ball Seat or Flanged Nuts: Alum.
Preventive Maintenance Table 8 Tires and Wheels Wheel Cap Nut Torque WHEEL & NUT CONFIGURATION STUD SIZE Dayton: 5/8-11 Front & Rear DYNAMIC TORQUE FOR INNER & OUTER CAP NUTS & RIM CLAMP NUTS N.
Tires and Wheels Preventive Maintenance Demounted Rims WARNING! Improperly mounting and demounting tire and rim assemblies is dangerous. Failure to observe proper precautions could cause the tire-rim assembly to burst explosively, causing serious injury or death. See the wheel manufacturer's literature for the proper way to mount and demount your tires and rims. Follow their precautions exactly. To check the torque on demountable rims, follow the crisscross sequence shown below.
Preventive Maintenance Table 9 Tires and Wheels Comparing Hub-piloted and Ball-seat Wheels BALL–SEAT MOUNT HUB–PILOTED MOUNT 00187 00203 Hub, Drum, and Stud Assembly Hub-piloted mountings use M22 x 1.5 metric threads (about 7/8 in. diameter). The stud stands out at least 1.94 in. beyond the brake drum. All studs are right-hand threads. Pilot bosses (machined surfaces) on the hub, fit tightly to the wheel center bore. Ball-seat (stud-piloted) mountings use 3/4x16 or 1-1/8x16 threads.
Tires and Wheels Preventive Maintenance Tire Replacement NOTE: To prolong the tires' life and make them safer, have their radial and lateral run-out checked at your Peterbilt Dealer. And of course have the tires balanced any time you change a tire. Front: replace front tires when less than 4/32 in. of tread depth remains. Check depth at three places equally spaced around the tire. Matching Tires Drive Axles or Trailers: replace tires on drive axles when less than 2/32 in.
Preventive Maintenance Tires and Wheels Wheel and Tire Replacement WARNING! The Anti-Lock Brake System (ABS) is calibrated for the specific tire revolutions per mile. Use of a tire and/or wheel size different from that originally installed on your vehicle may cause the ABS system to not function during a hard braking event. This could cause an accident or serious personal injury.
Heater and Air Conditioner Preventive Maintenance HEATER AND AIR CONDITIONER – Stay away from the hot engine until the exhaust manifold has cooled. – Do not permit any open flame in the area. Even a match or a cigarette lighter may generate a hazardous quantity of poisonous gas. – Do not smoke in the area. Inhaling gaseous refrigerant through a cigarette may cause violent illness.
Preventive Maintenance Heater and Air Conditioner CAUTION: During extreme cold weather, do not blow hot air onto cold windshields. This could crack the glass. Turn the air direction lever to Defrost and reduce the fan speed while the engine warms. If the engine is already warm, move the temperature selector to Cool, then gradually increase the temperature when you see that the windshield is starting to warm-up. Air Conditioner WARNING! The air conditioning system is under pressure.
Electrical System Preventive Maintenance ELECTRICAL SYSTEM CAUTION: Do not modify or improperly repair the vehicle’s electrical system or power distribution box. All electrical repairs should be performed by an authoriz ed Peterbilt dealer. Improper repair or modifications will void your warranty and/or cause serious damage to your vehicle. Location Of Fuses Fuses are located inside the cab, left side, next to the driver’s door. CAUTION: Never patch fuses with tin foil or wire.
Preventive Maintenance Electrical System All the electrical circuits have fuses to protect them from a short circuit or overload. If something electrical on your chassis stops working, the first thing you should check for is a blown fuse. 1. Turn OFF all lights and accessories and remove the ignition key to avoid damaging the electrical system.. 2. Determine from the chart on the fuse panel which fuse controls that component. 3. Remove that fuse and see if it is blown. 4.
Electrical System Preventive Maintenance The battery compartment is located on the left side of the vehicle, under the cab access steps. WARNING! Before attempting any work on the batteries or electrical system, remove all jewelry. If metal jewelry or other metal comes in contact with electrical circuits, a short circuit may occur causing you to be injured, as well as electrical system failure and damage. The cover is held in place by two latches one on each side.
Preventive Maintenance Electrical System Overcharge: this condition results from improper voltage regulator adjustment. It results in overheating of the battery, warped plates, and evaporation of electrolyte. Undercharge: the voltage regulator is malfunctioning or is improperly adjusted, the drive belt is slipping, or your vehicle has undergone long periods of standing idle or short distance driving. These conditions result in battery plates becoming covered with a hard coating.
Electrical System Preventive Maintenance WARNING! Do not allow battery fluid to contact eyes, skin, fabrics, or painted surfaces. Always wear eye protection. Battery acid that may spill during charging should be washed off with a solution of warm water and baking soda to neutralize the acid. If you accidentally get acid in your eyes or on your skin, immediately rinse with cold water for several minutes and call a doctor.
Preventive Maintenance Electrical System before proceeding. If no water is available, remove the caps and cover the filler openings with a cloth. After jump starting the vehicle, dispose of the cloth. WARNING! If you do not cover the filler openings on the battery, electrolyte could boil out of the openings and hurt someone or damage the vehicle. Replace caps securely if the battery has the full level of electrolyte. If the electrolyte is low and no water is available, cover with a cloth.
Electrical System Preventive Maintenance If the engine fails to start, do not continue to crank the starter but contact the nearest Authorized Service Center. WARNING! Batteries can injure you severely. They contain acid, produce poisonous and explosive gases, and supply levels of electric current high enough to cause burns. A spark or flame near a battery on charge may cause it to explode with great force.
Preventive Maintenance Electrical System • When fast charging, remove the battery caps so pressure does not accumulate. • Always make sure the battery charger is OFF before connecting or disconnecting the cable clamps. • To avoid short circuits and damage to yourself or the vehicle, never place metal tools or jumper cables on the battery or nearby.
Electrical System Preventive Maintenance Bulb Replacement Slow Battery Charging NOTE: Follow the instructions that come with your battery charger. • It is not necessary to remove the battery from the compartment. WARNING! Charger cables must be connected positive to positive (+ to +) and negative to negative (– to –). If connected improperly, batteries could explode causing serious personal injury. • Always make sure the battery charger is OFF before connecting or disconnecting the cable clamps.
Preventive Maintenance Electrical System Electrical and Alternator Precautions Take the following precautions to avoid burning out alternator diodes: • Do not start the engine with alternator disconnected (connections removed) from the circuit. • Before welding, disconnect all electronic connections to the vehicle batteries. • Remove battery power cable and insulate it from the vehicle. See “Welding” on page 218 for more information. • Do not run the engine with the batteries disconnected.
Cab Maintenance Preventive Maintenance CAB MAINTENANCE Exterior Maintenance Painted Surfaces Wash painted surfaces frequently to remove grime and caustic deposits which may stain the finish. See “Cleaning, Protection and Weather–Stripping” on page 193. Chrome and Aluminum Surfaces To prevent rust, keep chromed parts clean and protected with wax at all times, especially in winter conditions where the roads are salted. • If necessary, use a commercial chrome cleaner to remove light rust.
Preventive Maintenance Cab Maintenance Cleaning, Protection and Weather–Stripping Frequent washings of the vehicle are required to remove grime and contaminants that can stain and oxidize paint and accelerate corrosion of plated and polished metal surfaces. Waxing offers added protection against staining and oxidation. But to allow enough time for your truck's finish to cure, wait about 30 days after the date of manufacture before waxing.
Cab Maintenance Preventive Maintenance CAUTION: Do not aim the water jet directly at door locks or latch. Tape the key holes to prevent water from seeping into the lock cylinders. Water in lock cylinders should be removed with compressed air. To prevent locks from freezing in the winter, squirt glycerin or lock deicer into the lock cylinders. 4. Wipe everything dry with a chamois to avoid water spots. • To prevent water spotting, dry off the cosmetic surfaces with a clean cloth or chamois. 5.
Preventive Maintenance Cab Maintenance At least every spring, flush these materials from the under body with plain water. Be sure to clean any area where mud and other debris can collect. Sediment packed in closed areas of the frame should be loosened before being flushed. If desired, your Peterbilt Dealer or Authorized Service Center can do this service for you.
Cab Maintenance Preventive Maintenance • Always test a commercial cleaning agent on an inconspicuous area of the surface to be cleaned before using it.
Preventive Maintenance Cab Maintenance • Remove soap with a clean, damp rag. Safety Restraint System — Inspection • If a stronger cleaning solution is required, use a foamtype carpet shampoo. The seat belt system, including webbing, buckles, latches, and mounting hardware, endures heavy use in medium-duty vehicles—much more than seat belt systems in passenger cars. All users should be aware of the factors contributing to this heavy use and reduced belt life.
Cab Maintenance Preventive Maintenance WARNING! It is important to remember that any time a vehicle is involved in an accident, the entire seat belt system must be replaced. Unexposed damage caused by the stress of an accident could prevent the system from functioning properly the next time it is needed, which could result in severe injury or even death.
Preventive Maintenance Cab Maintenance parts of the cab interior. These areas are typical places where the web will experience cutting or abrasion. Cuts, fraying, or excessive wear would indicate the need for replacement of the seat belt system. 2. The pillar web guide (D-loop) is the area where almost constant movement of the seat belt webbing occurs because of relative movement between the seat and cab. 3. Check the Komfort-Lok Latch for cracks or possible damage and check for proper operation.
Cab Maintenance Preventive Maintenance 4. Check buckle and latch for proper operation and to determine if latch plate is worn, deformed, or damaged. 5. Inspect the retractor web storage device, which is mounted on the floor of the vehicle, for damage. The retractor is the heart of the occupant restraint system and can often be damaged if abused, even unintentionally. Check operation to ensure that it is not locked up and that it spools out and retracts webbing properly.
Preventive Maintenance Cab Maintenance Washer Reservoir CAUTION: Do not use antifreeze or engine coolant in the windshield washer reservoir—damage to seals and other components will result. RESERVOIR Weekly: check reservoir water level, located in the engine compartment under the coolant expansion tank. If necessary, fill to the proper level.
Transmission and Clutch Preventive Maintenance TRANSMISSION AND CLUTCH Transmission Lubricants CAUTION: When adding oil, types and brands of oil should not be intermixed because of possible incompatibility, which could decrease the effectiveness of the lubrication or cause component failure.
Preventive Maintenance Transmission and Clutch Table 10 Transmission Lubrication — Manual transmissions Eaton-Fuller AMBIENT TEMPERATURE RANGE RECOMMENDED LUBRICANT (See Note) MODEL VISCOSITY (SAE) DEG. C DEG. F HD engine oil: API CE or CF-4. Above -12 Above +10 50 Synthetic oil: Chevron RPM Synthetic Transmission Fluid, or equal, meeting MIL-L-2104D and Eaton PS-081 specifications. Above -40 Above -40 50 NOTE: Do not use multi-viscosity or EP (extreme pressure) gear oil (e.g.
Transmission and Clutch Preventive Maintenance As the clutch pedal is depressed further, with harder pressure, the release yoke moves the release bearing away from the engine. This causes the clutch plate to release from the driven disks in the clutch. This is called release travel. And finally, on 9-, 10-, and 11-speed transmissions, as the pedal is pushed to the last 1/2 to 1 inch of travel, the release bearing contacts and engages the clutch brake. This is called clutch brake squeeze.
Preventive Maintenance Transmission and Clutch Automatic Transmissions Automatic Transmission Oil Level NOTE: The vehicle must be parked on level ground. Service Intervals Check daily with engine idling. See Table 2, “Recommended Maintenance Intervals,” Page 120 for service intervals. Maintain the oil level and check it daily. Oil should be up to the “HOT” mark on the dipstick when (1) the engine is running, (2) the transmission is at operating temperature, and (3) the transmission is in Neutral.
Steering and Driveline Preventive Maintenance STEERING AND DRIVELINE If you cannot correct the problem, check with an Authorized Service Center. Power Steering Oil (under low pressure) provides the power to operate the steering gear. It also serves to lubricate moving parts and remove heat. A loss of steering efficiency will occur if too much heat builds up in the system. WARNING! Do not operate the vehicle if the steering system is not working properly.
Preventive Maintenance Steering and Driveline If these checks do not reveal the problem, or if you correct them and still have a steering problem, take your truck to an authorized Peterbilt Dealer for evaluation. RESERVOIR Fluid Level and Refill Have the power steering fluid and filters changed at an Authorized Service Center. • Check and completely change the fluid level according to Table 2, “Recommended Maintenance Intervals,” Page 120.
Steering and Driveline Preventive Maintenance Fluid Refill Use Automatic Transmission Fluid (ATF) Type E or F or Dexron® II. For other approved brands and types of fluid, see the Medium Duty Maintenance Manual. SLIP JOINT Steering Driveline • Torque on U–joint pinch bolt and nut 45–55 lb. ft. (61-75 N.m.), lubricated. • Torque on Pitman arm clamp bolt and nut: 180-210 lb. ft. (244-285 N.m.), lubricated.
Preventive Maintenance Front Axle and Suspension FRONT AXLE AND SUSPENSION SPRING AND SHACKLE PINCH BOLTS Inspection For all vehicles, mandatory maintenance procedures include retightening all U–bolts and inspecting the suspension for loose fasteners, abnormal wear, or damage. However, even with proper maintenance, the service life of leaf springs is affected by many factors, such as: fatigue, vehicle gross weight, type of load, road conditions, and vehicle speed.
Front Axle and Suspension Preventive Maintenance • Thoroughly clean hubs and bearings with solvent and a stiff bristle brush, then dry and inspect components for wear or damage. Re-lubricate with approved axle lubricant. KINGPIN (TOP) Kingpin Lubrication • Lubricate with approved lubricant. Lubricate knuckle thrust bearings, knuckle pins, and tie rod ends. See Table 2, “Recommended Maintenance Intervals,” Page 120. Lack of lubrication causes premature wear and hard steering.
Preventive Maintenance Front Axle and Suspension WARNING! Do not operate the vehicle if the U– bolts are not properly tightened. Loose U–bolts do not properly secure the axle to the suspension. This could cause loss of vehicle control and an injury accident. Loose U–bolts can also cause uneven tire wear and poor alignment. CAUTION: Do not spray the suspension with chemical products or mineral oil; it can cause damage to the bushings.
Rear Axle and Suspension Preventive Maintenance REAR AXLE AND SUSPENSION WARNING! Failure to maintain the specified torque values or to replace worn parts can cause component system failure, possibly resulting in an injury accident. Improperly tightened (loose) suspension U–bolts can lead to unsafe vehicle conditions, including: hard steering, axle misalignment, spring breakage or abnormal tire wear. See the Fastener Torque Tables for proper torque specifications.
Preventive Maintenance Rear Axle and Suspension It is important that U–bolts remain tight. Severe use of your vehicle can cause them to loosen faster. But all vehicles need to have their U–bolts checked and tightened regularly. Be sure someone with the proper training and the right tools checks and tightens the U–bolts on your Medium Duty. Rear Axle Lubrication • Check oil level with the vehicle parked on level ground and the fluid warm. The level should be even with the bottom of the filler hole.
Rear Axle and Suspension Preventive Maintenance Table 12 Drive Axle Lubrication MODEL EATON, ROCKWELL RECOMMENDED LUBRICANTS AMBIENT TEMPERATURE RANGE °F EP gear oil, MIL-L-2105D, API GL-5. -26 to +38 -15 to +100 80W-90 Synthetic Lubricant: Chevron RPM Synthetic Gear Lubricant, or equal, meeting MIL-L-2105D and Eaton PS-037 specification. -40 to +38 -40 to +100 75W-90 • No initial drain is required on Eaton axles that are factory filled with an Eaton-approved synthetic lubricant.
Preventive Maintenance Rear Axle and Suspension Rear Suspension Fasteners 3 Continual road shock and load stresses may force the rear axles out of alignment. If you detect rapid tire wear on the rear axles, you may have misaligned axles. Have your rear axle alignment checked and adjusted by a Peterbilt Dealer or Authorized Service Center.
Rear Axle and Suspension Preventive Maintenance WARNING! Do not replace U–bolts and nuts with common U–bolts or standard nuts. These parts are critical to vehicle safety. If the wrong U–bolts or nuts are used, the axle could loosen or separate from the vehicle and cause a serious injury accident. Use only U–bolts and nuts of SAE Grade 8 specification or better. Grade 5 Capscrew Torque Specifications Capscrew Body Size (inches-thread) 1/4-20 Torque Lb. ft. N.m. 6—9 8—12 -28 7—10 9.
Preventive Maintenance Rear Axle and Suspension Grade 8 Capscrew Torque Specifications Capscrew Body Size (inches-thread) Torque Lb. ft. N.m.
Frame and Fifth Wheel Preventive Maintenance FRAME AND FIFTH WHEEL NOTE: Welding to frame rail may void frame rail warranty. Introduction WARNING! Do not cut or splice frame rails or drill through the top or bottom flanges. These operations could affect frame rail strength leading to a failure resulting in serious personal injury and/or an accident. Always leave frame repairs to your Peterbilt Dealer.
Preventive Maintenance Frame and Fifth Wheel Fifth Wheel Maintenance Every 6 Months or 50,000 Miles: Proper preventive maintenance is essential to trouble-free service and safe operation of the fifth wheel. Every 2 Months or 25,000 Miles: • Refer to specific manufacturer's literature for any special instructions. • Steam clean the fifth wheel. • Check lock guard operation using a commercial lock tester. • Clean and oil all moving parts. • Lubricate the following parts with a lithium-base grease.
Noise and Emission Control Preventive Maintenance NOISE AND EMISSION CONTROL Tampering with Noise Control System Federal law prohibits the following acts or the causing thereof: Noise Emission Warranty Peterbilt Motors Company warrants to the first person who purchases this vehicle (for purposes other than resale) and to each subsequent purchaser: that this vehicle, as manufactured by Peterbilt Motors Company, was designed, built and equipped to conform, at the time it left Peterbilt's control, with all
Preventive Maintenance Noise and Emission Control Engine • Removing or rendering engine speed governor inoperative so as to allow engine speed to exceed manufacturer's specifications. • Modifying ECU parameters. • Check the induction tubing, elbow connections, clamps, brackets, and fasteners for deterioration, cracks, and security. • If you find an air leak anywhere between the air cleaner and the engine, repair that leak immediately.
Noise and Emission Control Preventive Maintenance Piping Exhaust Tail Pipe • Check exhaust piping for rust, corrosion, or damage. Replace deteriorated piping before holes appear. If piping is perforated at any point, temporary patching or lagging is acceptable until you can have permanent repairs made. On turbocharged engines, check joints at flanges and mounting brackets for tightness. • Check the mounting. Tighten as necessary.
Preventive Maintenance Noise and Emission Control Maintenance Log Transmission and Driveline • Substituting a different main transmission or drive line components, other than design-specified units, may result in increased vehicle noise emission. To ensure your Medium Duty's noise control requirements are maintained, record maintenance checks. Use the following log sheet (see Table 13) and retain copies of documents regarding maintenance services performed and par ts replaced on the vehicle.
Noise and Emission Control Preventive Maintenance Table 13 Maintenance Log – 224 – Y53-6008 Medium Duty (R10/06)
Preventive Maintenance Noise and Emission Control Table 13 Maintenance Log Medium Duty (R10/06) Y53-6008 – 225 –
Consumer Information and Vehicle Identification Preventive Maintenance CONSUMER INFORMATION AND VEHICLE IDENTIFICATION Canadian Consumer Information Reporting Safety Defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Peterbilt Motors Company.
Preventive Maintenance Consumer Information and Vehicle Identification Vehicle Identification All Peterbilt vehicles are identified by a 17–digit Vehicle Identification Number (VIN). This unique numeral and letter combination identifies the manufacturer, the model year it was built, and other vehicle attributes. The VIN is in compliance with 49CFR565, Code of Federal Regulations.
Consumer Information and Vehicle Identification Preventive Maintenance Chassis Number Locations A2378 The chassis/serial number is shown in three places: • Right frame rail, top flange, about 3 ft.
Preventive Maintenance Consumer Information and Vehicle Identification Complete Vehicle Certification Label VEHICLE NAME PLATE The Complete Vehicle Certification label certifies that the vehicle complies with all applicable Federal Motor Vehicle Safety Standards.
Consumer Information and Vehicle Identification Preventive Maintenance WARNING! Do not exceed the specified load rating. Overloading can result in loss of vehicle control and serious personal injury, either by causing component failures or by affecting vehicle handling. Exceeding load ratings can also shorten the service life of the vehicle. NOTE: GVW is the TOTAL SCALE WEIGHT the vehicle is designed to carry. This includes the weight of the empty vehicle, loading platform, occupants, fuel, and any load.
Preventive Maintenance Consumer Information and Vehicle Identification Federal Safety Standard Certification Label The NHTSA regulations require a label certifying compliance with Federal Safety Standard, for United States and U.S. Territories, be affixed to each motor vehicle and prescribe where such label may be located. This certification label, which indicates the date of manufacture and other pertinent information, is located on the driver's side door frame.
Index A Accessories 43 Adjustable Tilt Column 56 Air conditioner 181 refrigerant 117 Air Dryer 165 Air filter 167 Air horns 43 Air intake 166, 220 Air leaks 163 Air loss emergency procedure 27 Air pressure gauge 26, 163 Air suspension deflated air spring 105 switch, operation 101 Air tanks 15, 87, 114 alteration 9 Alternator precautions 191, 218 Anti-lock brakes 80, 83, 93 Ashtray 43 Automatic transmission 16, 71, 205 fluid 208 oil level 205 Axle weight rating 12, 13, 100, 230 B Ball bearing grease 134 Ba
Index fan drive 222 operating the clutch 67 riding the clutch 70 Coasting 71 Component lubrication index 134 Compressed air reservoir 15, 87, 162 Compressor 86 Consumer information 226 Cooling system conventional coolant 146 expansion tank 24 extended life coolant 144 temperature 23, 24 temperature gauge 23 topping up 145 Cruise control operation 65 switch 37 D Dome light 44 Door Lock 7 Door lock 194 Double check valve 87 Downshift 71 Driver’s checklist 13 daily and weekly checks 13, 14, 16 handbook Ameri
Index water temperature gauge 23 weekly checks 16 winterfronts 58 Environmental protection 117 Ether 58 Exhaust brake 84, 85 fumes 117 filter 14, 140 filter draining 141 gauge 28 refueling 114 system 115 tanks 28 Fuel Tank Inspection 141 Fuel tanks 141 F G Fan blade 222 switch 65 Federal motor regulations 11, 14 Federal motor vehicle safety standards 3 Federal safety label 231 Fifth wheel 105 air controlled 106 fixed 106 lock switch 106 maintenance 219 sliding maintenance 219 Frame precautions 218 Front
Index Lubrication 150, 210 axle 209 brakes 150 chart 135 coasting 99 driveshaft 208 engine 139 front axle 210 front suspension 210 idling 63, 64 power steering 206, 207 rear axle 213, 214, 215 transmission 202, 203 types and brands 133 wheel bearings 210 M Maintenance manual 4 schedule 119 Manual transmission 67 lubricants 202 oil level 203 shifting gears 67 master cylinder 88 Mirrors 56 Modifications 117 Modulating valve 87 Muffler 222 Medium Duty (R10/06) N NHTSA consumer information 226 Noise and emis
Index Rear Wheel Calipers 90 Recovering vehicles 108 Relay valve 87 Release bearing wear 71 Repairs 4 Retarders engine 85 rpm 23, 63, 69, 114 S Safe vehicle operation 11 Safety belt adjustment 47 passengers 49 restraint belts 46 restraint tips 49, 52 signals 1 stands 117 tether belts 50 Safety precautions, maintenance 116 Seat adjustment 45 Seat belt system damage and repair 52 guidelines 198 inspection 197 Komfort-Lok latch 51 replacement part 200 tether belts 200 Seats 45 – 236 – Serial number 228 Serv
Index Turbocharger 114, 166 Turn signal/high beam switch 54 U U-Bolt torque 211 Underbody maintenance 194 Underinflated tires 171 V Vehicle driving 11 loading 12 weight rating 12, 100, 230 Vehicle inspections 11 W WAIT TO START light 59 Medium Duty (R10/06) Warning Lamp Module 19 Warning Lamp Self Test 20 Warning lights and buzzer 18 Warranty 117, 119, 212, 218, 220, 221 Weekly operations 16 Weight rating 12, 100 Welding 191, 218 Wet Brakes 92 Wet tank 87 Wheel and Tire Replacement, hydraulic brakes 17
OPERATOR’S M ANUAL Y53-6008 11/06 PRINTED IN U.S.A. PETERBILT MOTORS COMPANY • P.O.
1 7 13 18 44 56 57 113 221 222 227
