Kenworth T410 Driver'S Handbook Manual Download Page 257 | Manualshive

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CAT: 8612 November 2019

Page 231

PREVENTIVE MAINTENANCE

BRAKE SYSTEM

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. Tyres are also a very important

part of the whole system. How fast you can stop depends on how much

friction there is between the road and your tyres.
The following areas are interrelated and must conform to original

specifications:

•  tyre size
•  cam radius
•  slack adjusters
•  drum radius
•  brake linings
•  brake chambers

Once a brake system is set to specifications, changing any of its components

may cause system degradation. All parts have to work together to perform

as they should. Because your brake system is air-operated, see Air Supply

System on page on 237 for more information on checking your brakes. Any

replacement components in the brake system should be the same or better

than the original components. Any changes from the original specifications

can affect the performance of the entire system.

Do not work on the brake system without the parking brake set and
wheels chocked securely. If the vehicle is not secured to prevent
uncontrolled vehicle movement, it could roll and cause serious
personal injury or damage to the vehicle.

• Use wood blocks (100mm × 100mm or larger) against the front

and rear surfaces of the tyres. Be sure the vehicle cannot move.

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Summary of Contents for T410

Page 1: ...ictoria 3153 Kenworth has built an extensive truck dealer network across Australia New Zealand and Papua New Guinea that is renowned for its professionalism and excellence in the heavy duty truck industry For more information contact your local Kenworth Dealer or go to www kenworth com au DRIVER S HANDBOOK ...

Page 2: ...d to the body Refer to page 260 for locations Registered Tare Weight GVM Gross Vehicle Mass GCM Gross Combination Mass Date of Acquisition Date Stamp Signature of Selling Dealer The above information fully identifies your vehicle It will furnish all of the necessary information in the event that warranty repairs are required Be certain it is completely and properly filled out and signed by your se...

Page 3: ...here inAustralia New Zealand and Papua New Guinea support for your investment is only as far away as a phone call to your nearest Kenworth Dealer Australian Kenworth or DAF owners in need of emergency roadside assistance can simply call 1800 4 PACCAR 1800 4 722227 Trained operators are available 24 7 to connect you with your nearest PACCAR dealer for support Please take the time to read this handb...

Page 4: ......

Page 5: ...dered on this vehicle Please disregard any illustrations or descriptions relating to features or equipment which are not on this vehicle PACCAR reserves the right to discontinue change specifications or change the design of its vehicles at any time without notice and without incurring any obligation The information contained in this handbook is proprietary to PACCAR Reproduction in whole or in par...

Page 6: ......

Page 7: ...xxi SECTION ONE OPERATING INSTRUCTIONS GENERAL INFORMATION 1 VEHICLE ACCESS 1 Door Lock and Keys 1 IGNITION KEY SWITCH 1 Remote Keyless Entry RKE 2 Remote Verification 3 KEYPAD TRANSMITTER 4 Programming 4 CAB AND FRAME ACCESS 5 Safety 5 Climbing onto the Deck Plate 6 ENGINE ACCESS 8 Hood Hold downs 8 Tilting the Hood 9 Hood Safety Latch 10 SAFE VEHICLE OPERATION 11 VEHICLE LOADING 11 EMERGENCY EQU...

Page 8: ...8 Cruise Control 79 Horn 79 DOOR MOUNTED CONTROLS 80 CURB SIDE MIRROR 83 CAB HVAC CONTROLS 84 Buttons and Dials 89 Operating Tips 91 Cab Air Distribution 93 RADIO OPTION 94 INTERIOR STORAGE COMPARTMENTS 94 Toolboxes 94 IGNITION KEY SWITCH 95 VEHICLE TELEMATIC SYSTEM 96 SEATS 98 Seat Adjustment 98 SAFETY RESTRAINT BELTS 99 Lap Shoulder Belt 100 Sleeper Bunks and Restraints 101 OPERATING THE ENGINE ...

Page 9: ...TON AUTOMATED TRANSMISSION 121 PACCAR TRANSMISSIONS 123 Start Up and Power Down 124 PACCAR Transmission Modes 125 PACCAR Transmission Features 128 EATON TRANSMISSIONS 131 UltraShift PLUS Transmissions 131 Start Up and Power Down 133 Eaton Transmission Modes 134 UltraShift PLUS Features 140 Driver Diagnosis UltraShift 143 Retrieving Fault Codes 143 Fault Codes 144 USING THE BRAKE SYSTEM 146 AIR SUP...

Page 10: ...Alert 166 Stationary Vehicle Braking 167 Lane Departure Warning 168 Potential False Alerts 170 How Your Actions Impact the Fusion System 173 System Maintenance and Troubleshooting 174 What to Expect When Using the Fusion System 176 TRAILER BRAKE HAND VALVE 179 DRIVING BOBTAIL OR WITH AN UNLOADED TRAILER 180 ENGINE BRAKES 180 OPERATING THE REAR DRIVE AXLE 181 Driver Controlled Differential Lock DCD...

Page 11: ... IDLE TIMER 208 REFUELLING 209 Fuel Specification 210 Location of Fuel Shut Off Valves 210 SECTION TWO PREVENTIVE MAINTENANCE INTRODUCTION 214 Environmental Protection and Material Hazards 214 SAFETY PRECAUTIONS 215 LUBRICATION SPECIFICATIONS ENGINE 216 FUEL SYSTEM 221 Fuel Specifications 221 Fuel System Priming 221 Fuel Tank Strap Tension 223 AIR CLEANER SYSTEMS 224 Air Cleaners and Filter Replac...

Page 12: ... 247 Wheel Mounting and Fastening 247 VEHICLE JACKING 248 20 Tonne Hydraulic Bottle Jack 248 JACK OPERATING INSTRUCTIONS 249 Storage of the Vehicle Jack 251 Vehicle Jacking points 251 BATTERIES 252 Battery Charging 253 Maintenance Free Batteries 256 Electrical Systems 12 Volt 257 Jump Starting Vehicles 257 WELDING PRECAUTIONS 260 CHASSIS AND CAB FINISH APPEARANCE AND CLEANING 261 Chassis and Cab 2...

Page 13: ...BLE STEERING COLUMN 281 FRONT AXLE AND SUSPENSION 282 Axle Lubrication 282 Kingpin Lubrication 282 Suspension Lubrication 282 Visual Inspection 283 U BOLT TENSION FOR FRONT AND REAR AXLES 283 WHEEL ALIGNMENT 285 Front Wheel Alignment 284 Wheel Bearing Adjustment 284 REAR AXLE AND SUSPENSION 286 General Maintenance 286 Rear Suspension Fasteners 286 Visual Inspection 287 REAR AXLE LUBRICATION 288 Da...

Page 14: ... OWNERSHIP 309 WARRANTY QUESTIONS 310 KENWORTH DEALER NETWORK 314 MAINTENANCE SERVICES ARE THE OWNER S RESPONSIBILITY 314 LUBRICATION SCHEDULES 315 T410 MX Engine Service Schedule 316 First Service 318 A Service Intervals 320 B Service Intervals 322 C Service Intervals 324 VEHICLE LUBRICATION POINTS DIAGRAM 326 Vehicle Lubrication Points Legend 328 MASTER LUBRICATION CHART 331 LUBRICATION FLUID CA...

Page 15: ...d Laden Tyre Pressures 243 Maximum Vehicle Load Rating 245 Wheel Nut Torques 247 Hydrometer Readings 256 Spring Suspension U Bolts Grade 8 284 Front Wheel Alignment Specifications 285 Rear Wheel Alignment 289 Torque Requirements Frame Fasteners 290 Grade 5 Fastener Torques 297 Grade 8 Fastener Torques 298 T410 MX Engine Service Schedule 316 First Service 318 A Service Intervals 320 B Service Inter...

Page 16: ...Page xiv CAT 8612 November 2019 CONTENTS ...

Page 17: ...s that relate to your vehicle In addition if your vehicle is equipped with special equipment or options not discussed in this handbook consult your dealer or the manufacturer of the equipment All information contained in this handbook is based on the latest production information available at the time of publication Kenworth Trucks reserves the right to make changes at any time without notice Your...

Page 18: ...000km service to be recorded In addition a Driver s Check List is included for your convenience on pages 12 We strongly recommend any system covered by State or Federal Regulations be inspected and serviced by an authorised Kenworth dealer or the component manufacturer s service facility This would apply particularly to safety emission lighting and noise control systems Kenworth trucks are built t...

Page 19: ...nd cause or feed a fire Do not carry extra fuel containers Even empty ones are dangerous Failure to comply may result in death or personal injury CAUTIONS The safety alert following this symbol and word provides a caution against operating procedures which could cause equipment or property damage The alert will identify the hazard how to avoid it and the probable consequence of not avoiding the ha...

Page 20: ...enance Follow the maintenance recommendations found in Preventive Maintenance on page 214 This will help preserve your investment Keep in mind that even a well maintained vehicle must be operated within the range of its mechanical capabilities and the limits of its load ratings See the Weight Ratings label on the driver s door edge Safe driving is only possible with the proper concentration on the...

Page 21: ...Maintenance Manuals supplied in the Driver Information Pack Please provide your Chassis Serial Number last 6 digits of the VIN see page 301 when you order to be sure you get the correct manuals for your vehicle Allow about four weeks for delivery There will be a charge for these manuals Final Chassis Bill of Material A complete non illustrated computer printout listing of the parts used to custom ...

Page 22: ... and easy use These are specified at the time of purchase of your new vehicle ELECTRONICCUSTOMISEDPARTSCATALOGUE ECPC A complete listing of the parts used to custom build your Kenworth truck This can be ordered through the dealer network This same information is available electronically to all authorised Kenworth dealers through the PACCAR Parts Electronic Catalogue ECAT system Your Customised Par...

Page 23: ...horised Kenworth dealers for its First Service at 10 000km or 30 days This service includes free labour and inspection you only pay for the lubricants and filters used It is the owner s responsibility to maintain the vehicle and have the recommended services carried out at the intervals specified in the Maintenance Manual Should you have any difficulty obtaining service or require further details ...

Page 24: ...Page xxii CAT 8612 November 2019 CONTENTS ...

Page 25: ...SECTION ONE OPERATING INSTRUCTIONS ...

Page 26: ......

Page 27: ... with tool compartments two separate toolbox keys have a red bow To lock or unlock the doors from outside the cab insert the key in the door lock turn the key toward the truck s rear to lock and forward to unlock press the LOCK or UNLOCK button on remote control module IGNITION KEY SWITCH The ignition key switch has four positions ACC Accessories OFF ON and START OFF In this position all accessori...

Page 28: ...sition to start your engine It energises the starter and retracts the solenoid valve to allow fuel supply to the engine Release the key after the engine has started For complete engine starting procedures see Operating the Engine on page 102 REMOTE KEYLESS ENTRY RKE Kenworth Remote Keyless Entry system gives you added security and convenience for your Kenworth truck This system will lock or unlock...

Page 29: ...amps turn ON for 40 seconds Door Closed 3 To Lock Both Doors a Press the LOCK button once b Both doors lock c Door and dome lights turn ON for 2 seconds d If Remote Verification is enabled press the LOCK button again within 5 seconds to sound the horn Repeated pressing of the LOCK button within a 5 second period causes the horn to sound and the interior lights to stay ON for a further 2 seconds 4 ...

Page 30: ...s This will be reduced if it is operated close to other RF sources such as TV Radio transmitters and cell towers Unlock Lock Pre Trip Test Lamp PROGRAMMING The system is pre programmed but may need to be reprogrammed if a key transmitter or receiver has been replaced The programming procedure is in the Electronic Customised Maintenance Manual ...

Page 31: ... entry exit procedure recommendations were prepared with personal safety foremost in mind Do not jump out of the cab or get into the cab without proper caution You could slip or fall possibly suffering a serious injury To help avoid personal injury due to a slip or fall Always face the vehicle when accessing or leaving the cab or frame access area Use three points of contact two feet one hand or o...

Page 32: ...dles and your feet on the steps Always face toward the vehicle when entering or exiting the cab and look where you are going Failure to comply may result in death or personal injury When stepping onto a surface to enter the cab or access the deck plate only use the steps and grab handles installed and designed for that purpose Failure to use the proper steps and grab handles could cause a fall whi...

Page 33: ...t at all times Using the external cab access grab rails and steps to climb up into a conventional cabin Use the external grab rail and internal access handle to aid ingress and egress to the cabin DO NOT use the steering wheel door handle or arm rest to pull yourself up into the cabin ...

Page 34: ...OLD DOWNS Hood hold downs keep a hood from opening unexpectedly Hood Latch in the Closed Position A hood not latched securely could open during operation and cause vehicle damage Be sure to latch the hood securely Pull Latch Backwards to Unlock Pull Back to Separate and Open ...

Page 35: ...loses A pivoting hood could hurt someone or be damaged itself Before opening or closing the hood be sure there are no people or objects in the way Failure to stand in a position of safety can cause death or personal injury Before opening or closing the hood make sure your footing is secure and stable Failure to do so may cause the hood to close uncontrollably which may result in death or personal ...

Page 36: ... open the safety latch will automatically engage and will need to be disengaged by the operator Hood Assist Ram Safety Clip Red Hood Safety Latch shown in the safe position The release lever for the hood safety latch is located near the front hinge of the hood Press the lever in to disengage the hood hold open device If the red clip is engaged to the Hood Assist Ram it is not safety locked in posi...

Page 37: ... Mass GVM is the maximum allowable total mass of a fully loaded motor vehicle consisting of the tare mass mass of the vehicle plus the load including occupants and fuel Gross Combination Mass GCM is when a vehicle is towing one or more trailers the GCM is the total mass of the motor vehicle plus any and all trailers including load occupants and fuel Do not exceed the specified load rating Overload...

Page 38: ...before you drive You will save maintenance time later and the safety checks could help prevent a serious accident You are not expected to become a professional technician The purpose of your inspections is to find anything that might interfere with the safe and efficient transportation of yourself any passengers and your load If you do find something wrong and cannot fix it yourself have an author...

Page 39: ...icants must be drained and the units refilled at the first 10 000km or 30 days service whichever comes first APPROACHING YOUR VEHICLE Check the overall appearance and condition Are windows mirrors and lights clean and unobstructed Check beneath the vehicle Are there signs of fuel oil or water leaks Check for damaged loose or missing parts Are there parts showing signs of excessive wear or lack of ...

Page 40: ...ab Is it latched correctly CHASSIS AND CAB Before entering the cab and operating the vehicle check the following equipment for proper maintenance 1 Lights Check headlights turn signals emergency flashers and exterior lamps function and are clean and adjusted correctly 2 Windows and Mirrors Are they clean and adjusted correctly 3 Tyres and Wheels Are tyres inflated properly Are all wheel nuts in pl...

Page 41: ...teners 8 Fluid Tanks Check under the vehicle for signs of leaks If any are found correct them before operating the vehicle 9 Fuel Tank Caps Are they secure Diesel fuel in the presence of an ignition source such as a cigarette can cause an explosion You could be seriously injured Do not remove a fuel tank cap near an open flame Use only the fuel and or additives recommended for your engine See Refu...

Page 42: ...ring Column Adjust for easy reach 7 Mirrors Check and readjust mirrors if necessary 8 Lights Turn ignition key to the ON position and check for warning lights and chimes Check operation of turn signals and emergency lights 9 Instruments Check all instruments 10 Windscreen Check operation of windscreen wipers and washers 11 Horn Check operation of horn 12 Sleeper and Luggage Compartment Loose items...

Page 43: ...the air cleaner muffler and exhaust pipes Are they tight and secure After Engine Warm up Looking listening check for leaks all fluids air system air intake piping exhaust for leaks Automatic Transmission Check fluid level if equipped Care must be taken not to touch hot or moving parts AIR LOSS EMERGENCY PROCEDURE Slow down carefully Move a safe distance off the road and stop Place the transmission...

Page 44: ...e paragraphs that follow Remember that each vehicle is custom built Your instrument panel may not look exactly like the one in the pictures that follow We have tried to describe the most common features and controls available You can pick out the parts that apply to you and read them to be fully informed on how your particular vehicle operates TYPICAL DASH LAYOUT LIGHTS P 16 19 22 25 28 AUTO MAX 1...

Page 45: ...ation Optional 7 Menu Control Switch MCS 8 Sunvisors Driver s Side Shown Down 9 Driver Performance Centre Display 10 Headlight Switch 11 Ignition Switch 12 Interior Lights Dimmer Switch 13 Diagnostic Port above accelerator pedal 14 Engine Idle Timer Override Switch 15 Main Instrument Cluster 16 Parking Brake Controls 17 Engine ABS Diagnostic Switches below cupholder 18 Cup Holder 19 Power Socket a...

Page 46: ...COOLANT C DEF F E D I E S EL EXHAUST F L U I D FUEL F E U L T RA LOW SUL F U R D I E SEL FUEL O N L Y P P PARK PARK ABS ABS BRAKE BRAKE BRAKE AIR BRAKE AIR ABS ABS ABS ABS STOP STOP PTO PTO 3 3 Primary Air Pressure Low Primary Air Pressure Low Let Compressor Run Inspect for Leaks Let Compressor Run Inspect for Leaks 1 of 3 1 of 3 1 1 2 2 Set Clock 12 345 6 14 C 10 5 6 7 8 9 1 Speedometer p21 2 Tac...

Page 47: ... engine primary secondary air and driver door open warnings Optional Icons Additional icons may be operational depending on individual vehicle specifications These will be included in the instrument system self test Some optional lights may illuminate even though your vehicle is not equipped with that particular feature Check Messages Check messages are provided to give the operator additional inf...

Page 48: ...aximum governed speed The tachometer will illuminate a small green light just below the numbers of the gauge This is to indicate the engine speed for optimal fuel economy 3 Fuel Level The fuel gauge indicates the total approximate amount of fuel in the fuel tank In addition to indicating empty and full the gauge also indicates the fuel level in graduated increments When the fuel level for the tank...

Page 49: ...e tank to remain empty 5 Engine Coolant Temperature The engine coolant temperature gauge shows the temperature of the engine coolant Under normal operating conditions the engine coolant temperature gauge should register between 75 C and 90 C Under certain conditions somewhat higher temperatures may be acceptable 6 Driver Performance Centre The display can show multiple warning lights Warning infor...

Page 50: ...s stop the engine and determine the cause Check the table on page 26 for the correct oil pressure ranges for your vehicle s engine If the oil pressure suddenly drops or the audible alarm and engine oil pressure warning light come on while driving follow the procedure below 1 Slow down carefully 2 Move a safe distance off the road and stop 3 Place the transmission in neutral and set the parking bra...

Page 51: ...r the spring brakes may stop the vehicle abruptly which could cause an accident resulting in death or personal injury 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 If the light and alarm do not turn off at start up do not try to drive the vehicle until the problem is found and fixed The air pressure ...

Page 52: ...ures the oil must be changed more frequently Do not continuously operate with oil temperature exceeding 121 C At these temperatures oil oxidation is accelerated OPERATING PRESSURES Engine Oil 10W40 Minimum oil pressure at idle speed Pressure at 1000 rpm Pressure at 1900 rpm 150 kPA Approx 300 kPa Approx 450 kPa Engine Oil 10W30 Minimum oil pressure at idle speed Pressure at 1000 rpm Pressure at 19...

Page 53: ... minimise in the screen Reviewing the warnings can be done by navigating the menu via the Menu Control Switch Driver Information Display 1 Menu Control Switch Cue p28 2 Automated Transmission and Shift Indicator Area p29 3 Outside Air Temperature p29 4 Cruise Control Indicator p29 5 Odometer Trip Odometer p30 6 Clock p30 7 Active Warnings p31 8 Main Content Window p31 9 Header p31 ...

Page 54: ...tch position clock alarm sounds driver or passenger door is opened hazard warning lamp switch is on service brake switch is on prime mover marker lamp switch is on trailer marker lamp switch is on low Voltage Display not active and the screen has not been put into Display Off Mode In addition to a blank screen the following are menu items and the information available within each of the menu selec...

Page 55: ...tside air temperature display will come on when the door is open and when the ignition key is in the ACC or ON position and turn off when the ignition switch is turned off The outside air temperature display uses a sensor located at the bottom of the driver s side mirror assembly to measure outside air temperature only It is not capable of displaying the temperature of the road surface on either t...

Page 56: ...o 0 and begin to count new km travelled Press the trip button on the instrument panel any time you wish to view the odometer reading Press the trip button again to scroll through the other odometers available in the cluster 6 Clock The clock presents the home time when the clock is set If the clock is not set the words SET CLOCK will appear when the ignition is turned ON If the clock does not get ...

Page 57: ... there are multiple warnings the display will show how many are active The numbers may change without user interaction if individual warnings are intermittent time based self correcting or the situation is rectified 8 Main Content Window There are 5 functions allowed when driving and 7 when the vehicle is parked Some functions are available in both modes but have different content available depend...

Page 58: ...en spun and enter your settings when pushed The indicator image on the left lets you know whether spin or push is available The back button is always available even if there is no indicator image being displayed In addition to the prompts for spin and push this area will show the current menu item as a larger icon and the available menus before and after as smaller icons The MCS button has a BACK ...

Page 59: ... to view vehicle fault codes and messages Settings Use these menus to change preferences Fuel Economy Use this display to view the fuel economy performance of the vehicle available in driving mode Navigation of the system is organised into 3 levels of functions The first level of organisation is identified as Trunk level functions The second level is identified as Branch level functions The third ...

Page 60: ...o what is termed the Branch level of the software Navigation at Trunk Level Branch Level In the branch level of functions the MCS knob rotation controls a cursor highlight When something is highlighted an MCS push will select that item or toggle its contents Toggle fields typically use a darker coloured text to distinguish them from fields that take the user to the Leaf level Display of a Branch L...

Page 61: ... to choose from The MCS can be used to scroll through various information and the back button can be used to revert up to the branch 1 push or the trunk 2 pushes levels of the system Display of a Leaf Level Description of Menu Screens Blank Screen This screen is available in both parked and driving modes ...

Page 62: ...ode where the entire display shuts off The blank screen mode is selected through the rotary MCS The Display OFF Mode is selected by pressing the button to the right of the MCS for more than 2 seconds Digital Gauges The Digital Gauges function is selected through the rotary MCS and is available in both parked and driving modes Digital gauges provide dynamic information about the vehicle s performan...

Page 63: ... available when driving Average fuel economy is computed by the fuel consumed during the trip see the next section for Trip information The fuel economy for a trip will be reset when that trip odometer is reset Trip Information This function allows you to keep trip information data on up to 4 separate trips labeled A B C and D Trips are also selectable as Active or Inactive so you can use the data...

Page 64: ... used sweetspot hours cruise control hours average engine load drive hours PTO hours PTO hours PTO fuel used PTO fuel used PTO economy The cluster mounted trip reset button is used to zero and clear accumulated trip data Short presses toggle between the odometer view and the 4 trips Holding the button when on a particular trip will zero the stored data and also automatically set the cleared trip t...

Page 65: ...on This information is available when the vehicle is parked 1 Chassis Information a Chassis Number b Fleet ID Number c CECU Software Version Number 2 Engine Information a Engine Make b Engine Model c Engine Software Version d Governed Speed Limit e Engine Power Hours 3 Transmission Information a Transmission Make b Transmission Model c Transmission Software Version Number ...

Page 66: ... on the truck These alert messages are called pop ups because they take over the screen Some messages are low enough priority that they can be suppressed which is done by pushing the MCS There will be a screen indicator showing which messages are suppressible If multiple pop ups are present at the same time they are viewed in a stack format and a spin of the MCS will allow you to see the different...

Page 67: ...when parked but the fault details are visible only when parked The menu selection shown in the image on page 40 will not be displayed when the truck is driving though the warnings and telltale indicators on the cluster will still be available as indicators if the problem is serious Fault detail screens include 1 How many faults shown in a scrollable stack format 2 Which ECU the fault is being gene...

Page 68: ...nction is available only when the vehicle is parked Various settings may be changed using this function The operator can change the time format 12hr 24hr the time of day units of measure for the display mile kilometer and the language being displayed Changing settings functions are typically done one of two ways Items can be toggled straight from the highlighted selection at the branch level these...

Page 69: ...3 Rotate the MCS to change the hour Press the MCS 4 Rotate the MCS to change the minutes Press the MCS 5 Rotate the MCS to toggle AM PM if 12 hour clock selected Press the MCS 6 Press the button beside the MCS to exit Display Mode Press Back and hold MCS 2 seconds The Display Off mode is available at any time in menu navigation but the screen minimise mode can only be done when on this screen Ther...

Page 70: ... the brakes which could lead to an accident causing death or injury Have the appropriate system checked immediately Check messages are provided to give the operator additional information regarding systems that require attention due to a system malfunction and or operating conditions that may hinder safe and proper performance for the vehicle The system will emit a chime to alert the operator that...

Page 71: ...ABS Yellow STD 49 3 Brakes Low Air BRAKE AIR Red STD 50 4 Brake Parking brake P P PARK PARK Red STD 50 5 Brake Service Brakes Trailer Low Air BRAKE BRAKE Red OPT 50 6 Brake Wear Disc Brakes ONLY BRAKE BRAKE WEAR WEAR Red OPT 50 7 Brakes Trailer Anti Lock Brake System ABS ABS ABS Yellow STD 50 8 Differential Inter Axle Diff Lock Yellow OPT 50 9 Tipper Truck Body Up Red OPT 51 ...

Page 72: ...1 Tipper Truck Trailer Body Up Red AFTER MARKET 51 12 Emissions Malfunction Indicator Lamp MIL Yellow STD 51 13 Engine Check Engine Yellow STD 51 14 Engine Engine Fan Green STD 51 15 Engine Low Coolant Level Yellow STD 51 16 Engine Retarder Brake Green STD 51 17 Engine Stop Engine Red OPT 52 18 Engine Wait To Start WAIT Yellow OPT 52 ...

Page 73: ...ellow OPT 52 20 Lane Departure Warning LDW Yellow OPT 52 21 Lights High Beam Blue STD 52 22 Power Take off PTO PTO PTO Yellow OPT 52 23 Power Take off PTO Pump Mode PUMP MODE Green AFTER MARKET 53 24 Refrigerator Green OPT 53 25 Seat Belt Fasten Red STD 53 26 Suspension Dump Yellow STD 53 27 Tyre Inflation Yellow OPT 53 ...

Page 74: ...T Page 28 Transmission Auxiliary AUX AUX Yellow OPT 53 29 Transmission Check Red OPT 53 30 Transmission Retarder includes Brakesaver when applicable Yellow OPT 53 31 Transmission Service Transmission Allison Yellow OPT 53 32 Turn Signal Left Green OPT 54 33 Turn Signal Right Green OPT 54 ...

Page 75: ...n the Driver Information Pack If this chassis is equipped with an ESP and is modified e g adding or removing an axle converting from a truck to a prime mover converting from a prime mover to a truck changing the body lengthening of the wheelbase and or frame relocating frame components or modifying pneumatic or electricalABS ESPharnesses the ESPmust be disabled by a qualified technician If you hav...

Page 76: ... mover is connected with an ABS equipped trailer Illuminates during normal operating conditions to indicate a problem with the trailer ABS System This should be checked by an authorised dealer as soon as possible See ABS Warning Lamps on page 154 for more information 8 Differential Inter Axle Diff Lock Illuminates when the inter axle differential switch is ON thus locking the inter axle differenti...

Page 77: ...ot be considered an emergency 13 Engine Check Engine Illuminates when a non emissions related problem exists but the vehicle can still be safely driven Vehicle should be serviced to correct the problem but the situation should not be considered an emergency 14 Engine Engine Fan Illuminates when fan is active 15 Engine Low Coolant Level Illuminates with an audible alarm indicating critically low co...

Page 78: ...WIF Illuminates when water has been detected in the fuel 20 Lane Departure Warning LDW Illuminates when optional LDW system is not able to track the vehicle s position within the lane For vehicles equipped with Lane Departure Warning refer to Lane Departure Warning Driver s Instructions on page 168 21 Lights High Beam Illuminates when the high beams are on This icon will flash with audible alarm i...

Page 79: ...ehicle 27 Tyre Inflation Illuminates when tyre pressures need to be checked Tyre Pressure Monitoring System is an option 28 Transmission Auxiliary Illuminates to indicate auxiliary transmission is in neutral 29 Transmission Check Illuminates when transmission has recorded a fault code This icon may also appear in the Transmission Display menu of the Driver Performance Center If the user is in this...

Page 80: ...tion could vary according to the type or make of engine Consult the engine manufacturer s manual or engine dealer for fuel restriction specifications Air Filter Restriction Indicator or Gauge This gauge indicates the condition of the engine air cleaner and is measured by inches of water H2 O A clean filter should register 7in H2 O may vary with system design and a filter whose life is over will re...

Page 81: ...ssure indicated by your manifold pressure gauge goes down there may be something wrong with your engine Have it checked by an authorised service technician Fuel Pressure Gauge Your vehicle may also have a fuel pressure gauge Transmission Temperature Gauge Your Transmission Temperature Gauge indicates the temperature of the oil in your transmission Watch this gauge to know when your transmission is...

Page 82: ...ls Have your axle lubrication checked if you notice a sign of overheating Suspension Load Air Pressure No s 1 2 The Suspension Load Air Pressure gauge indicates the amount of air pressure in the air suspension air bags When the vehicle is equipped with dual leveling valves the No 1 gauge indicates the air pressure in the left hand side passenger s side air bags The No 2 gauge indicates the air pre...

Page 83: ...recommended by the manufacturer See the Transmission Operation and Maintenance Manual for details Transmission Retarder Oil Temperature The Transmission Retarder Oil Temperature gauge indicates the temperature of the oil in the transmission retarder Watch this gauge to know when the transmission is overheating Do not exceed maximum oil temperature recommended by the manufacturer See the Transmissi...

Page 84: ... ON position for switch to maintain control via air pressure If the switch requires ignition power it will allow that air circuit to lose pressure deactivate once the ignition is turned OFF To activate that function again the ignition needs to be turned to the ACC or ON position and the switch needs to be re engaged Some of the switches that control air functions will not disengage when the vehicl...

Page 85: ...r OPT 63 7 Axle Two Speed Green OPT 63 8 Reversing Alarm Mute Amber OPT 63 9 Batteries Low Voltage Disconnect LVD None STD 64 10 Brakes ABS Off Road ABS ABS OFF ROAD OFF ROAD Amber OPT 64 11 Brakes Parking Brake Valve Yellow Button PULL TO APPLY PARKING BRAKE PUSH TO RELEASE PULL TO APPLY PARKING BRAKE PUSH TO RELEASE Red STD 64 12 Brakes Trailer Air Supply Valve Red Button Red STD 64 149 13 Brake...

Page 86: ...r Green OPT 65 17 Engine Cruise Control On Off OFF OFF ON ON Green STD 65 18 Engine Cruise Control Set Resume RESUME RESUME SET SET None STD 65 19 Engine Fan Override Green OPT 66 20 Engine Remote Throttle PUMP MODE Amber OPT 66 21 Alternator Isolation Switch Green OPT 66 22 Generic Air Accessory Green OPT 66 23 Generic Spare SPARE Green OPT 67 24 Lights Auxiliary AUX Green OPT 67 ...

Page 87: ...27 Lights Exterior Lights Self Test None STD 67 28 Lights Flood Amber OPT 67 29 Lights Flood ISO 3732 Spare Amber OPT 67 30 Lights Fog Green OPT 67 31 Lights Hazard Red STD 68 32 Lights Headlight Parking Lights P None STD 68 33 Lights Marker ID Clearance None STD 68 34 Lights Marker Clearance Cab None OPT 68 35 Lights Marker Clearance Trailer None OPT 69 ...

Page 88: ...RUCTIONS Symbol Name Symbol Colour STD OPT Page 36 Lights Spot Green OPT 69 37 Power Take off PTO PTO PTO Amber OPT 69 38 Suspension Dump Amber OPT 69 39 Transmission Transfer Case Amber OPT 70 40 Transmission Transfer Case 2 Speed 2 Amber OPT 70 ...

Page 89: ...n switch on to engage Single Rear Axle Diff Lock 6 Axle Inter Axle Differential Locked Tandem Turn switch on to engage Inter Axle on to Differential Lock 7 Axle Two Speed If equipped the two speed axle switch allows you to select axle high and low ranges The low range Off provides maximum torque for operating off highway The high range On is a faster ratio for highway speeds This switch does not r...

Page 90: ...arking brakes See Parking Brake Valve on page 148 12 Brakes Trailer Air Supply Valve The red octagonal knob controls the air supply to the trailer With both knobs pushed IN air is now being supplied to both the trailer and the truck spring brakes all brakes are released 13 Brakes Trailer Hand This dash mounted switch provides air pressure to apply the trailer brakes only It operates independently ...

Page 91: ...vailable if the vehicle needs to be turned off before the timer reaches 3 minutes 17 Engine Cruise Control On Off Turn switch on to activate Cruise Control System 18 Engine Cruise Control Set Resume The Cruise Control Set Resume switch allows you to SET the desired speed or RESUME the desired speed after the cruise control function has been interrupted Do not operate the cruise control when operat...

Page 92: ...ep all tools and equipment away from the fan Do not operate the engine fan in the MANUAL position for extended periods of time The fan hub was designed for intermittent operation Sustained operation will shorten the fan hub s service life as well as reduce fuel economy 20 Engine Remote Throttle Turn switch on to activate Remote Throttle Control 21 Alternator Isolation Switch Used in fuel haul appl...

Page 93: ...t In addition the dome lights can be switched on or off with the dash mounted control labelled DOMELIGHT 27 Lights Exterior Lights Self Test This switch will engage a program which will illuminate exterior lights for the operator to verify functionality Refer to Exterior Lights Self Test on page 82 for more detail on how to use the program 28 Lights Flood Turn switch on for cab mounted Flood Light...

Page 94: ...side and tail lamps are also on This switch also controls the park lights If you have confirmed there is a problem in the low beam wiring circuit proceed with caution to the next available exit turnoff and safely pull your vehicle completely off the road and call for assistance Driving your vehicle with the headlights on high beam at reduced intensity for a prolonged period could lead to an injury...

Page 95: ...immediately even though PTO disengagement may not have occurred Actual PTO engagement disengagement may be delayed momentarily since it is controlled by the air system and mechanical movement Increasing engine RPM before the PTO is actually engaged could prevent the PTO from engaging and or cause PTO damage 38 Suspension Dump Turn switch on to deflate Suspension Air Bags This switch does not requi...

Page 96: ... CAT 8612 November 2019 OPERATING INSTRUCTIONS 39 Transmission Transfer Case Turn switch on to shift the Transfer Case 40 Transmission Transfer Case 2 Speed Turn switch on to shift the 2 Speed Transfer Case 2 ...

Page 97: ...gnition key must be turned to ON for the signal switch to operate TILT TELESCOPING STEERING COLUMN Your truck is fitted with an adjustable Tilt Telescoping steering column the tilt feature allows forward and rearward movement of the wheel the telescoping feature allows you to adjust the height by moving the wheel up and down To activate these features locate the Tilt Telescoping lever Make all adj...

Page 98: ... To adjust the steering wheel PUSH and HOLD the lever down fully Adjust the steering wheel by pulling or pushing the wheel to the desired height and angle then return the lever back into the locked position Steering Column Locked Steering Column Unlocked ...

Page 99: ...ng emits a short click If the vehicle turn signals and turn signal indicators in the dash gauge cluster ever begin flashing at an accelerated rate 115 cycles per minute when the turn signal lever is in the OFF center position or when a Right Left turn has been selected the problem may be related to a failed turn signal switch or turn signal module In either case the problem is not a failed bulb Co...

Page 100: ...wards the steering wheel again The high beams can be momentarily flashed with or without the headlights being on To flash the high beams gently push the headlight lever away from the steering wheel to momentarily turn on the lights Continued pressing of the high beam flash will not keep the high beams on Flash to Pass on Steering Column The flash to pass functionality of the headlight switch is no...

Page 101: ...e headlights on and then off again and the low beams will turn off A seven position rotary wiper switch located on the turn signal lever operates the windscreen wipers and washer Rotate the end of the turn signal lever to change the wiper mode The ignition key must be turned to ON orACC for the wiper washer switches to operate Wiper Washer on Steering Column The first position after OFF is the int...

Page 102: ...king driving hazardous which may lead to an injury or accident resulting in death or personal injury Do not use antifreeze or engine coolant in the windscreen washer reservoir damage to seals and other components will result If the electric pump is operated for a long period more than 15 seconds with a dry reservoir the pump motor may be damaged The washer bottle filler is located on the passenger...

Page 103: ...ipped with a PACCAR Transmission or Eaton UltraShift Plus Transmission The lever on the right hand side of the steering column will operate the transmission functions in addition to operating the engine brake For detailed instruction see Engine Brake Operations on pages 111 112 and Transmission Controls on pages 121 122 2 3 4 1 1 Transmission D N R Function 2 Up and Down Shift and Low Mode 3 Engin...

Page 104: ...g driveline or steering gear Tampering with these components may result in an inoperable multiplex system This vehicle may be equipped with an optional steering wheel with audio and cruise control button mounted on the spokes of the steering wheel 1 Left Switch Pad 2 Horn Pad 3 Right Switch Pad System Description The steering wheel contains controls for commonly used functions so the operator does...

Page 105: ...2 Audio Seek 2 Cruise Control Set Resume 3 Audio Mute Mode 3 Cruise Control Accelerate Coast Do not operate the cruise control when operating on road surfaces with poor traction wet icy or snow covered roads or in heavy traffic Acceleration caused by the normal operation of the cruise control could cause you to lose control of the vehicle resulting in an injury or accident HORN To use the electric...

Page 106: ...he mirrors while driving could cause you to take your eyes off the road which can result in an accident Failure to do so could lead to serious injury or equipment damage To provide good visibility adjust the mirror so the side of your vehicle appears in the inboard part of the mirror Convex mirrors can distort images and make objects appear smaller and further away than they really are You could h...

Page 107: ...have been completed return the mirror selector switch back 3 to the center neutral position to prevent unintentional adjustments to the mirrors 3 Mirror Selector Switch If the mirrors require adjustment use this switch to select either right or left hand mirror 4 Power Window Switch Power window rocker switches are located on the door pads Depress the switch to open the window or pull up on the sw...

Page 108: ...ights The light test will eventually stop on its own The operator may interrupt the test by turning the vehicle off or pressing the switch a second time while the test is running The operator can verify the functionality of the lights by visibly watching the lights from outside the vehicle during the test or can read the instrument cluster for any faults displayed that are lighting related To star...

Page 109: ...UCTIONS CURB SIDE MIRROR General information on using the curb side mirror A mirror is located above the passenger door that provides a quick view of the blind spot created by the passenger door Rotate the mirror up or down to get the desired view ...

Page 110: ...ton Introduction Your vehicle s heating and air conditioning system operates in three distinct modes manual automatic and maximum defrost Each mode provides the driver with the greatest level of comfort and convenience while maintaining the flexibility of traditional systems The recommended mode for all conditions that do not require windscreen defrosting is the automatic mode as detailed on page ...

Page 111: ...l injury 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 open Failure to repair the source of the exhaust fumes may result in death personal injury equipment or property damage Keep the engi...

Page 112: ...e dials on the controller Adjusting the settings Step 1 To adjust the fan speed turn the fan control dial clockwise to increase speed or counter clockwise to decrease speed Setting the fan dial to 0 turns the HVAC system off Step 2 To adjust the temperature setting turn the temperature control dial to the desired temperature The system automatically adjusts the outlet air temperature to achieve th...

Page 113: ...s possible Using the automatic mode Step 1 Turn on HVAC by rotating fan speed control clockwise Step 2 To engage automatic mode press the AUTO button Step 3 To adjust cab temperature rotate the temperature dial to the desired temperature The system automatically adjusts to achieve the desired cab temperature The system will achieve the comfort level associated with the selected temperature on the ...

Page 114: ... Function An economy function is also available in partial automatic mode In this mode the system will operate in AUTO mode without the use of the A C compressor The operator may select economy by initiating AUTO mode and then pressing the A C button to disengage the compressor The indicators for A C compressor and AUTO mode do not illuminate while operating in economy mode MAX Defrost Mode The he...

Page 115: ... air using the button inside the fan speed control dial Outside air mode is automatically selected when any of the defrost modes are selected Outside Air Recirculation Air Button Air Distribution Dial The mode of air distribution inside the cab is set using the air distribution dial Five icons on the dial indicate the primary mode options The driver may also select a secondary mode in between the ...

Page 116: ...e Control Dial The cab temperature is set using the temperature control dial The operating range is 16 C to 28 C Adjustments of 1 increments 22 22 Temperature Control Set Point The button inside the temperature control dial engages theA C compressor When activated the indicator on the button will illuminate During AUTO mode the A C button indicator will remain illuminated at all times even though ...

Page 117: ...Manual Windscreen Defrosting Defogging The manual defrost defogging mode differs from the MAX defrost mode by allowing the driver to select an air temperature other than full heat This allows the driver to maintain a constant cab temperature while defrosting the windscreen Note however that performance may be reduced Step 1 Adjust the fan speed to high by rotating the fan control dial clockwise St...

Page 118: ...ise Step 2 Set the air distribution dial to the floor setting Step 3 Adjust the air temperature to maximum heat by rotating the temperature dial clockwise The engine must be at operating temperature for maximum heating If operating in AUTO mode heating airflow is not allowed until the engine warms sufficiently to provide required coolant temperatures Air Dehumidification The HVAC system can be use...

Page 119: ...n obtaining the desired cabin temperature if the temperature setting is repeatedly changed Outside Air Recirculation Air Selecting air recirculation mode completely isolates the cab interior from the outside air This mode is helpful in preventing dust pollen and odours from entering the cab Additionally recirculation mode can reduce the amount of time needed to cool down the vehicle while in maxim...

Page 120: ...lies or small tools overhead storage compartments sleeper storage compartments centre console map pocket records holder on front of rider s seat base door in passenger seat base rear wall storage pocket Appliances If your vehicle is equipped with a television or other appliance be sure they are compatible with your vehicle s electrical system Secure them in the cab so they cannot come loose in a s...

Page 121: ...asher dome and courtesy lamps on doors electric horn cigarette lighter tail lights marker lamps headlights radio station memory instrument lights auxiliary power instrument panel memory settings ON In the ON position all circuits are energised 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 pr...

Page 122: ...programming or changing the settings on the telematic system Programming the system while driving can cause you to take your eyes off the road which could result in an accident involving death personal injury or equipment damage Regardless of how and where the navigation system directs you it is your responsibility to operate the vehicle in a safe and legal manner Failure to comply may result in d...

Page 123: ...ate on your driving Distractions could cause an accident resulting in injuries to you or others Disclaimer Map data may be inaccurate and navigation routes may not be available for larger size vehicles Regardless of how and where the navigation system directs you it is your responsibility to operate the vehicle in a safe and legal manner Note Before using this system read the Owner s Manual and le...

Page 124: ...t can be adjusted forward and backward as well as up and down The seat back angle can also be adjusted These three movements are each controlled by levers located either beneath or at the sides of the seat Driver s Seat with Air Suspension Before driving or riding in the vehicle ensure there is adequate head clearance at maximum upward seat travel You could seriously injure your head or neck by bu...

Page 125: ...y have been designed A slack belt will greatly reduce the protection afforded to the wearer Care should be taken to avoid contamination of the webbing with polishes oils and chemicals and particularly battery acid Cleaning may safely be carried out using mild soap and water The belt should be replaced if webbing becomes frayed contaminated or damaged It is essential to replace the entire assembly ...

Page 126: ...a belt over rigid or breakable objects in or on your clothing for example eye glasses pens keys as these may cause injury in an accident Several layers of heavy clothing may interfere with proper positioning of belts and reduce the overall effectiveness of the system Keep belt buckles free of any obstruction that may prevent secure locking Cab or sleeper belts which have been damaged or worn becau...

Page 127: ...tbelts in your vehicle If any seatbelt is not working properly see your authorised Kenworth service dealer for repair or replacement SLEEPER BUNKS AND RESTRAINTS For Kenworth cabs equipped with a sleeper be sure to use the fitted restraint devices Your vehicle may have belts and or a net restraint system which are over the bunk or cover the opening Be sure to stow away all loose belongings before ...

Page 128: ...ht turns off The engine must have adequate oil pressure within 15 seconds after starting If the warning light indicating low oil pressure has not gone out or there is no oil pressure indicated on the gauge within 15 seconds shut OFF the engine immediately to reduce the possibility of engine damage As soon as the engine starts watch the oil pressure gauge Refer to your engine manufacturer s handboo...

Page 129: ... damage Confirm the correct oil level in the engine sump Once the engine has warmed sufficiently to exit cold mode the engine should be operated at low rpm and low load until normal operating temperature is reached Operating the engine in this way will warm it faster than if the engine is operated at high rpm and low load Slow oil flow to the turbocharger reduces oil available for bearings Watch e...

Page 130: ...orly maintained damaged or corroded exhaust system can allow carbon monoxide to enter the cab or sleeper Entry of carbon monoxide into the cab is also possible from other vehicles nearby Failure to properly maintain your vehicle could cause carbon monoxide to enter the cab sleeper and cause serious illness Never idle your vehicle for prolonged periods of time if you sense that exhaust fumes are en...

Page 131: ...ric and air operation 4 Check position of the inter axle differential control 5 Turn emergency flashers OFF 6 Check air suspension is inflated 7 Load test trailer hitch for security 8 Check service brake operation and air pressure gauge Engine Oil Temperature Gauge The Engine Oil Temperature gauge indicates engine oil temperature Do not exceed the maximum engine oil temperature recommended by the ...

Page 132: ...e applied 2 Ensure transmission is in Neutral 3 Engage PTO per the manufacturer s operating instructions 4 Move the ON OFF switch to the ON position 5 Toggle the SET RESUME switch to obtain the desired engine rpm Cancel the PTO operation by canceling the engine rpm set speed This can be done by tapping the brake or clutch pedal or by using the cruise control switches After starting the engine idle...

Page 133: ...AUST F L U I D Warning light 12 Close to Empty approx 12 remaining AdBlue warning light will illuminate on the AdBlue Gauge ADBLUE LOW LEVEL WARNING AND INDUCEMENT The low AdBlue warning light will illuminate when the AdBlue level is at 12 to warn the operator to refill the SCR system at 6 the light will start to blink and the engine will derate The derate would take affect when the vehicle speed ...

Page 134: ...f the engine system detects failures that may be the result of tampering with the SCR system the Check Engine light will come on the engine will derate and if equipped the Malfunction Indicator Lamp MIL will be on AdBlue Level If the engine detects that AdBlue level is below acceptable levels 12 the AdBlue warning light will flash when the level is below 6 the Check Engine light will come on and t...

Page 135: ... up the AdBlue tank Avoid diesel mixing with AdBlue in the AdBlue tank always use 100 clean canisters and funnels that have not been used for any other liquids such as coolant oil diesel or petrol SAFETY Avoid physical contact with AdBlue Eye Contact If this product comes in contact with the eyes Wash out immediately with fresh running water Ensure complete irrigation of the eye by keeping eyelids...

Page 136: ... AdBlue filler cap as soon as filling of the AdBlue tank is completed do not allow foreign matter to enter the AdBlue tank ADBLUE FILLING When filling the AdBlue tank the filler neck is welded at a specific location to enable part of it to be inserted within the tank this physically prevents the tank being filled over 90 due to theAdBlue reaching the bottom of the neck and causing a head of air wh...

Page 137: ...unt of engine brake by moving the lever further clockwise Each position has a corresponding level of engine brake Position Engine Brake Level Off OFF 1 LOW 2 HIGH Engine Brake Operation for T410 with Automated Transmission Moving the lever clockwise will engage the engine brake Increase the amount of engine brake by moving the lever further clockwise Each position has a corresponding level of engi...

Page 138: ...tion not every day driving Deactivating Max Mode Vehicles with automated transmissions will have the engine brake function integrated with the transmission controls Follow these steps to deactivate MAX engine brake mode 1 Accelerate with the throttle pedal 2 Upshift see Up or Down Shifting on page 122 3 Wait for the transmission coast down gear to engage 4 Reduce engine brake level see Engine Brak...

Page 139: ...ow the correct sequence for your particular transmission Adecal with the shift pattern and operating instructions is normally located on the sunvisor 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 Fully depress the clutch pedal for manual transmission until the clutch brake makes conta...

Page 140: ... This efficiency is achieved by always selecting gears within optimum engine rpm which is where maximum torque and power are obtained For further information see ULTRASHIFT PLUS FEATURES page 140 For further instructions on operating your transmission see the transmission manufacturer s Driver Operator s Instruction Manual SHIFTING GEARS IN A NEW VEHICLE Shift gears carefully in a new vehicle The ...

Page 141: ...Then the drive gear can roll enough to allow the teeth to line up properly and complete the shift 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 will cause gear hang up Be careful not to apply the clutch brake while the vehicle i...

Page 142: ...utch 2 Move the gear shift lever to neutral 3 Release the pedal to engage the clutch This lets you control the rpm of the main shaft gears allowing you to match the rpm of the main shaft gears to those of the output shaft Upshifts let the engine and gears slow down to the rpm required for the next gear Downshifts press accelerator and increase engine and gear speed to the rpm required in the lower...

Page 143: ...ake The clutch brake provides a means of stopping the transmission so that the shift into a starting gear may be accomplished with raking Once the vehicle is in motion use of the clutch brake will try to stop the vehicle resulting in very short service life of the clutch brake Release Bearing Wear Whenever the engine is idling for any period of time shift transmission to neutral and disengage the ...

Page 144: ...gear reduction for the load and terrain Never downshift when the vehicle is moving too fast Never slam or jerk the shift lever to complete gear engagement Never coast with the transmission in neutral and the clutch disengaged To provide smooth gear engagements while shifting use proper coordination between shift lever and clutch TRANSMISSION OIL TEMPERATURE GAUGE The Transmission Oil Temperature G...

Page 145: ...D DIR H L H L Eaton 18 Speed Transmission RTLO Shift Lever Patterns and Shifting Controls PACCAR RIGHT HAND STALK CONTROLS CAUTION READ OWNERS MANUAL PRIOR TO OPERATION MINIMUM RECOMMENDED OPERATING PRESSURE TO BE 90 PSI 621KPa DO NOT OPERATE VEHICLE IF ALTERNATOR LIGHT OR LOW VOLTAGE INDICATOR IS ILLUMINATED NEUTRAL MUST BE SELECTED TO START ENGINE AVOID CLUCTH DAMAGE DEPRESS BRAKE PEDAL WHEN STO...

Page 146: ...selector in Neutral and apply the parking brake to hold the vehicle when it is unattended If your vehicle has an automated transmission be aware that it can roll backwards when stopped on a hill or grade or when starting from a stop on a hill or grade Failure to comply may result in death personal injury equipment or property damage Observe the following guidelines 1 When stopped on a hill or grad...

Page 147: ...d Transmission controls are located on the right hand side of the steering column refer page 77 for functions Drive Neutral Reverse Selector Transmission mode is selected by rotating the lever s outer knob There is a detent for Drive Neutral and Reverse The instrument cluster will display the corresponding mode 10 10 D N R N N D N R R R2 2 D N R The transmission selector must be in N Neutral to st...

Page 148: ...ton The instrument cluster will display the corresponding selection Up or Down Shifting When in the Manual mode the transmission gears can be manually selected by pushing or pulling on the lever Pushing the lever forward away from the steering wheel will downshift the transmission Pushing and holding the lever forward will engage the LOW mode Pulling the lever towards the steering wheel or driver ...

Page 149: ... display may momentarily flash the target gear position Current Gear Gear Shift Transition Successful Gear Shift 4 4 5 5 5 5 SOLID FLASHING SOLID The DASH indicates the transmission may be torque locked in gear and unable to confirm neutral CA will appear in the gear display if a clutch abuse event is occurring CA CA AN will appear in the gear display if the transmission goes into Auto Neutral AN ...

Page 150: ...he transmission requires a minimum system pressure of 90psi or Trans Air Low error message will display and the transmission will not be able to select gears 5 Apply service brake If the service brake is not applied while selecting a starting gear the initial start gear will not be engaged and the driver will have to reselect Neutral and press the brake while re selecting the desired mode 6 Select...

Page 151: ...ould cause unintended vehicle movement resulting in death serious injury or damage to property When attempting to start the engine and the engine does not crank confirm Neutral is selected vehicle parking brake is applied and service brake is depressed Drive Mode Intelligent Start Gear Selection will automatically select the start gear depending on inputs such as load grade and axle transmission r...

Page 152: ...efault Reverse gear is engaged LOW Mode LOW mode should be used any time you want to maximize engine braking and minimize the use of the brake pedal For example when driving down long grades or when coming to a stop Selects lowest available gear for start gear see Note page 126 The starting gear cannot be changed in LOW mode If LOW is selected while moving the transmission will not upshift except ...

Page 153: ...icle is being back driven and the engine is approaching a higher than normal level the transmission system will override the MANUAL position and perform and upshift If the start gear is changed and it causes the engine to lug at takeoff the transmission system will override the MANUAL position and select the best available gear The PACCAR Transmission initiates upshifts from MANUAL and LOW for eng...

Page 154: ...wnshift request however if the selection requested could cause damage or engine lugging the request will be denied and an audible tone will sound Skip Shifting The PACCAR Automated Transmission will shift multiple gears at one time skip shift with moderate to high accelerator pedal input while in Drive mode up to 8th gear Clutch Protection The PACCAR Automated Transmission clutch can still overhea...

Page 155: ...ated Below are some examples of situations which may initiate clutch abuse along with some helpful hints on how to avoid them Example How to Avoid Starting on hills using the throttle rather than the brake Use the service brakes to hold on a hill To start moving apply the throttle and release the brakes as you feel the truck start to pull Moving trailer tandems Be sure to always start off in 1st g...

Page 156: ...s to relearn these inputs for the first few shifts to make the proper adjustments Coast Mode When coasting to a stop in Drive mode on level terrain the transmission system may not downshift into the lower gears This allows the transmission to coast to a stop Auto Neutral The transmission system will automatically shift to neutral if the vehicle is left in Drive and the parking brakes are set AN wi...

Page 157: ...for further information relating to operation service and maintenance of your UltraShift PLUS transmission Gear Display The Gear Display indicates the current gear position of the transmission During an upshift or downshift the gear display may momentarily flash the target gear position Current Gear Gear Shift Transition Successful Gear Shift 4 4 5 5 5 5 SOLID FLASHING SOLID The DASH indicates the...

Page 158: ... gear display The driver must select Neutral and then select the desired forward or reverse mode with the service brake applied AN AN In heavy duty UltraShift PLUS models GI may briefly appear in the gear display after the engine is started This indicates the clutch release bearing will need to be greased soon see Optional Automated Lube Schedule section in UltraShift PLUS Automated Transmission D...

Page 159: ...o re select Neutral and press the brake while re selecting the desired mode 4 Select the desired mode and starting gear on the shift console The transmission will override inappropriate start gear selections to avoid damaging the transmission 5 Release the vehicle parking brakes 6 Release service brake and apply accelerator Power Down 1 Select Neutral on the shift control If gear display does not ...

Page 160: ...ansmission cannot range shift while moving but the driver can split shift while moving if the vehicle is equipped with a multi speed auxiliary section R4 is only available on the UltraShift PLUS Multipurpose Extreme Performance MXP and UltraShift PLUS Vocational Extreme Performance VXP models If you attempt to select a non neutral mode without depressing the service brakes the transmission will no...

Page 161: ... by up or down shifting when the transmission is near the shift point The transmission may also deny a shift while ascending or descending grades if the load of the vehicle and grade of the terrain in combination with the drivetrain ratio and engine torque will fall outside of the acceptable range to perform a shift If the shift is denied it will sound a tone Multiple gear upshifts and downshifts ...

Page 162: ...nditions noted below Multiple gear upshifts and downshifts may be allowed when the up downshift request procedure is performed multiple times Each request equals one gear change request For optimal vehicle performance it is recommended the vehicle be operated in Drive mode UltraShift PLUS initiates upshifts from MANUAL and LOW for engine overspeed protection Transmission MANUAL Override If the veh...

Page 163: ...shift except for the Transmission Override conditions noted below The transmission system will downshift at the earliest opportunity to provide maximum engine braking Transmission LOW Override If the vehicle is being back driven and the engine is approaching a higher than normal level the transmission system will override the MANUAL position and perform and upshift UltraShift PLUS initiates upshif...

Page 164: ... engaged and the driver releases the service brake the clutch will close automatically providing vehicle movement The clutch will remain closed allowing the vehicle to creep at constant engine idle after the service brake is released The clutch will also open if the engine lugs 150 rpm below the governed low engine idle speed Launching 1 Engage the desired gear 2 Release service brake vehicle will...

Page 165: ...ed after the accelerator is released allowing the vehicle to creep at constant engine idle The clutch will also open if the engine lugs 150 rpm below the governed low engine idle speed due to load conditions Launching 1 Engage the desired gear 2 Release service brake 3 Apply the throttle pedal to accelerate the vehicle until the clutch is closed engaged 4 Release the throttle pedal vehicle will cr...

Page 166: ...select the lowest possible start gear for the application If moving slowly is require select 1st or R1 DO use Creep mode when appropriate DO use the Service Brakes and let Hill Start Aid assist when launching on an incline DO minimize the time it takes to engage the clutch from rest Do NOT use the throttle to hold the vehicle on an incline Use Service Brakes Do NOT use the throttle to stop roll ba...

Page 167: ...R1 on gear display Use light brake pedal pressure to reduce the jerking of the vehicle Engine Over Speed Protection The transmission system will upshift if necessary to prevent engine over speed in Drive MANUAL and LOW modes UltraShift PLUS initiates upshifts from Low and Manual for engine overspeed protection above governed speed Optimal Engine Braking The LOW Mode can be selected while moving Th...

Page 168: ...d a gear instead of upshifting Simply upshift using the Upshift request procedure to start the upshift It may take three or four shifts for the transmission system to learn the new conditions After that it will handle upshifts and downshift automatically Depending on conditions UltraShift can activate the engine brake in order to bring the engine down faster for an upshift This can happen even if ...

Page 169: ...et the parking brake 3 Turn the ignition key on but do not start the engine If the engine is already running you may still retrieve codes However do not engage the starter if engine stalls 4 To Retrieve Active Codes Start with the key in the ON position Turn the key off and on two times within five seconds ending with the key in the ON position After five seconds the service lamp begins flashing t...

Page 170: ...2 ABS CAN message 23 Urge to Move Brake Switch Signal 25 No Faults Found 26 Clutch Slip 27 Clutch Disengagement 29 Remote Throttle Enable 33 Low Voltage Supply 34 Weak Battery Voltage Supply 35 J1939 Communication Link 36 J1939 Engine Message 37 Power Supply 41 Range Failed to Engage 43 Range Solenoid Valve 45 Inertia Brake Performance 51 Rail Position Sensor 52 Gear Position Sensor 56 Input Shaft...

Page 171: ...to Disengage Gear 72 Failed to Select Rail 73 Failed to Engage Gear 74 Engine Speed Response Fault Engine Torque Response Fault Shift Quality 75 Power Down in Gear 81 Gear Engagement Detected 83 Shift Lever Missing 84 Shift Controller Device not Configured 85 Shift Control Device Incompatible 99 Direction Mismatch An 88 code may appear in gear display which indicates self testing ...

Page 172: ... feeling of a firm brake pedal You will not feel this in a pneumatic brake system as used in trucks because the operator is simply operating a valve The brake system is a critical vehicle safety system For the safety of yourself and others around you have the vehicle submitted for scheduled preventive maintenance checks as well as having any suspected problems immediately checked by an authorised ...

Page 173: ... front service reservoir to the front axle brake chambers via the front relay ATR 6 valve and ABS pressure modulation valves Simultaneously on full truck configurations air is also supplied to the modulating valve control port In the event of a rear service circuit failure the modulating valve will exhaust air from the spring brake chambers applying the spring brakes in proportion to the front cir...

Page 174: ...ed Trailer Air Supply Control valve will automatically apply 2 Shift the transmission into PARK position Manual transmission select Neutral Automated and Automatic transmission select Neutral 3 Turn the key to the OFF position and remove the key 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 an...

Page 175: ...s on do not continue to drive the vehicle until it has been properly repaired or serviced TRUCK TRAILER AIR SUPPLY VALVE Initial Charge The red octagonal knob controls the air supply to the trailer With the system completely discharged both the red trailer air supply and the yellow parking brake knobs are OUT thus truck and trailer parking spring brakes are applied Allow the truck air system press...

Page 176: ... ADR 35 03 requirements The trailer brakes can only be released after all the parking brakes have activated and stabilised The engine must be running for the system to operate engine oil pressure switch controlled and not moving The basic operation of the trailer is that the tipping motion drags the trailer forwards toward the truck due to the effective shortening of the drawbar as the tip angle i...

Page 177: ...unction in any air circuit The vehicle should not be operated until the system is repaired and both braking circuits including all pneumatic and mechanical components are working correctly Loss of system air can cause the service brakes to not function resulting in the sudden application of the spring brakes causing wheel lock up loss of control or collision by following vehicles Loss of air syste...

Page 178: ...um type brakes is usually about 427 C If service brakes are used improperly for prolonged periods or for emergency braking internal brake drum temperatures may exceed 427 C Such brake overheating may be detected by a burning smell or smoke coming from a drum If this occurs you should immediately stop and check for cracked brake drums or lining fires If neither exists get back behind the wheel and ...

Page 179: ... saddle The clamping force generated by the primary actuation is applied to the inner pad which forces it into contact with the rotor A reactive force through the caliper body applies equal clamping force to the outer pad applying a balanced clamping force to the rotor The slide pins also allow the caliper to freely position itself on the saddle to compensate for the reduction in lining pad thickn...

Page 180: ...al brakes but not anti lock brakes If the lamp indicates a problem have the ABS checked If the ABS warning light does not illuminate when the ignition is first turned on there is a problem with the bulb or wiring You should have this checked as soon as possible The ABS warning lamp will come on momentarily when the key switch is first turned The lamp will go out and stay off unless the system dete...

Page 181: ...s to acceleration by holding acceleration slip within acceptable levels to prevent wheel spin The ATC system communicates with the engine ECU via the J1939 data bus In the event of a wheel slip incident both engine and ATC systems operate simultaneously to reduce engine torque RPM and apply or release pressure in the service brake system to prevent wheel slip or spin The ATC system sensitivity can...

Page 182: ...s function is NOT to be used for on highway driving but is intended to be used to improve stopping performance in off highway conditions e g loose gravel and mud The ABS off road function is accomplished by not allowing a wedge of material to build up in front of momentarily locked wheels Features and Benefits Changes the ABS control limits to allow for a more aggressive ABS function while off roa...

Page 183: ...e retarder disable output is turned off That is the engine retarders are left to function without ABS intervention For more information explaining individual EBSS elements see your Electronic Customised Maintenance Manual USB Section 5 Air System For vehicles with EBSS read either BW2428 or BW2429 as specified HILL START ASSIST HSA Vehicles fitted with Eaton UltraShift Plus transmissions or PACCAR...

Page 184: ...ion system do not replace the need for you to remain alert react appropriately and in a timely manner and use safe driving practices You are always responsible for the control and safe operation of the vehicle at all times The Fusion system does not replace the need for a skilled alert professional driver reacting appropriately and in a timely manner and using safe driving practices System Compone...

Page 185: ... Due to the inherent limitations of image recognition technology camera based safety technology on rare occasions may not be able to detect or may misinterpret lane markings At these times alerts may not occur or erroneous alerts may occur System Overview Integrating camera radar and brakes the Fusion Active Safety System provides the following alerts and actions 1 Active Cruise with Braking ACB 2...

Page 186: ...needed Active Cruise with Braking Think of the Active Cruise with Braking ACB feature as an additional upgrade to ordinary cruise control When using cruise control your vehicle not only will maintain the set speed but the system will also intervene as needed to help maintain a set following distance behind the vehicle in front of you Whenever the cruise control is set the Active Cruise with Brakin...

Page 187: ...ate back to the original cruise control set speed and again maintain a set following distance behind any vehicles ahead of you Because the Fusion system operates along with normal cruise control all the typical features built into cruise control work as usual For example limits imposed by factory set road speed governors etc are fully supported by the Fusion system Where the Driver Interface Unit ...

Page 188: ...vehicle automatically manages foundation braking priorities among the various vehicle systems that use the foundation brakes such as Fusion ESP Electronic Stability Program ATC Automatic Traction Control and the ABS Antilock Braking System Applying the Brakes Before the System Does If you determine that a hazard or unsafe condition exists you should take all necessary actions immediately Never wai...

Page 189: ...ether or not you are using cruise control Any audible and or visual alert by the system means that your vehicle is too close to the vehicle ahead or your vehicle is outside the intended lane of travel You must immediately act to potentially avoid or lessen the severity of a collision and to maintain control of the vehicle to the intended lane Pedestrians Animals Non metallic or Limited metallic Ob...

Page 190: ...and audible alerts when it is braking The IA CMB is ready to alert you the driver whenever the vehicle is moving above 24km h When activated the IA CMB will sound and a visual message icon typically appears on the dash screen or Driver Interface Unit DIU display The IA CMB is typically accompanied by automatic brake interventions if a collision with the forward detected vehicle is likely to occur ...

Page 191: ...e and the vehicle ahead is at least one and a half 1 5 seconds and getting closer Once the audible alert is given you should increase the distance between your vehicle and the vehicle ahead until the audible alert stops The FDAis ready to alert you whenever the vehicle is moving above 8km h If the following distance continues to decrease you will hear more rapid audible alerts When the FDA reaches...

Page 192: ...ationary Object Alert System may alert in response to stationary objects not in the vehicle lane of travel These objects may include bridges signs parked vehicles and traffic lights Braking or throttle intervention will not occur in response to stationary objects As the driver you remain responsible for safely controlling the vehicle at all times by appropriately applying the brakes steering or th...

Page 193: ...oes not take action to address the potential impact that caused the alert the Fusion system can automatically engage the brakes to assist the driver in reducing the severity of or potentially avoiding a collision with that stationary vehicle If the system cannot definitively identify the stationary object as a vehicle for example if the vehicle is not a licensed motorized vehicle or certain types ...

Page 194: ...Lane Red LEDs Illuminated indicates direction of departure DIU Showing Lane Departure Warning a rumble strip tone will typically also sound on the side where the vehicle has departed from the lane of travel Temporarily Disable the Lane Departure Warning LDW To avoid erroneous LDW warnings in areas such as construction zones where the non standard or overlapping road markings present might cause fa...

Page 195: ...ontrol for at least 20 minutes This gives the brakes time to cool down If you choose to reset cruise control during that 20 minute period Fusion system interventions will be limited to de throttling and engine retarder only The system will automatically disable all Fusion system foundation brake applications for at least 20 minutes If the system does not detect a driver intervention within 15 seco...

Page 196: ...ct moving vehicles or stationary vehicles in your vehicle s lane of travel Alerts warnings or brake interventions may not occur Due to the inherent limitations of radar and camera technology the enhanced Collision Mitigation Technology on rare occasions may react to moving vehicles not in your vehicle s lane of travel Alerts warnings or brake interventions may occur Potentially Challenging Situati...

Page 197: ...g distance recorded You should be especially attentive to the Fusion system behavior through curves In some cases when traveling around a curve the Fusion system may lose the vehicle ahead and attempt to accelerate when resuming the set speed It is also possible for the Fusion system to begin tracking vehicles in other lanes when traveling around curves In cases where the Fusion system perceives t...

Page 198: ... set if you decide to change lanes or pass a vehicle by applying the throttle the vehicle being passed will no longer be detected by the radar and camera NOT TO SCALE Lane changes and dynamic steering input Example 4 Lane changes Alert only Normal response Alert only NOT TO SCALE Example 5 Stationary objects ...

Page 199: ...l Nothing The Active Cruise with Braking feature will not engage until the driver sets the cruise control speed Switch off the cruise control The Active Cruise with Braking feature will turn off the collision mitigation feature remains active and ready to intervene You the driver will continue to hear all alerts as needed Set the cruise control speed The Active Cruise with Braking feature is autom...

Page 200: ...depending on the vehicle manufacturer typically there will be a message on the dashboard display Depending on the type of problem detected the system will determine if the vehicle may continue normal cruise control functions without the benefits of Fusion or whether all cruise control functions should be disabled until service is performed The system should be serviced as soon as possible to resto...

Page 201: ...aintenance free The key items to keep the system functioning properly include 1 Keep the radar and camera lens clean and free of obstructions 2 Visually inspect for any damage to the bumper or the Fusion cover bracket or radar to ensure that the alignment has not been compromised Never use the radar unit as a step 3 Periodically have the radar alignment checked by an authorised PACCAR dealer 4 Per...

Page 202: ...above 16km h a Stationary Vehicle Alert SVA may be issued up to three and a half 3 5 seconds prior to impact Warning You must immediately act to potentially avoid or lessen the severity of a collision If a collision is likely to occur the Fusion system can provide a warning and or apply the vehicle brakes Moving objects vehicles ahead in your lane of travel Your vehicle comes up fast behind a slow...

Page 203: ...bove 60km h your vehicle departs your lane of travel without the corresponding turn signal activated A rumble strip audible vibration visual alert is initiated None You must respond as needed Use the turn signal when changing lanes and or keep your vehicle within the lane markings Part Two Cruise is ON and speed is SET What to Expect Situation Typical System Indication Alerts Typical System Action...

Page 204: ...sound and a visual message icon typically appears on the dash screen or DIU display The Following Distance Alert may also be heard You must respond as needed If the system intervenes the vehicle throttle will be reduced the engine retarder engaged and the foundation brakes applied in that order Note When the foundation brakes are applied cruise control is cancelled A detected forward vehicle cuts ...

Page 205: ... Brakes independent of the truck brakes For trucks delivered in Australia this valve is NOT self returning When pressure is removed from the valve lever it will remain in the ON position until manually pushed up to the OFF position For trucks delivered to New Zealand this valve is self returning When pressure is removed from the valve lever it will return to the OFF position The trailer brake is n...

Page 206: ...ere permitted by law and use the service brakes only for stopping completely Operating this way will greatly prolong the life of the brakes The engine brake is NOT intended as the primary brake for the vehicle nor is it an emergency brake The engine brake only helps the service brakes by using pressure to slow the drivetrain Use the service brakes for quick stops Engine brakes create a braking eff...

Page 207: ...er than 40km Lock the differential when you encounter dirt roads loose sand mud or other off road conditions Do not put the differential lock in the LOCK position while the wheels are spinning freely slipping You could lose control of the vehicle causing an accident or injury to yourself and or others Switch to LOCK only when the wheels are not spinning Look ahead for wet muddy or icy patches on t...

Page 208: ...CK OPERATION To LOCK the inter axle differential 1 Anticipate when you might need increased traction slow down to a steady speed under 40km or stop the vehicle Do not lock the differential while going down steep grades or travelling faster than 40km or while wheels are spinning or traction is minimal Lock the differential before you encounter these conditions 2 Put the inter axle differential lock...

Page 209: ...nter axle differential 1 When you reach normal road surfaces or better road conditions where the differential lock is not needed switch the differential lock to UNLOCK 2 Let up momentarily on the accelerator pedal to relieve torque and allow the clutch to disengage 3 When you unlock the differential normal vehicle handling will resume and the light on the warning cluster will turn off TRIDEM DRIVE...

Page 210: ...t from its storage hole 3 Screw the caging bolt all the way into the air line hole This locks the differential by pushing a piston into the lock position DUAL RANGE TWO SPEED REAR AXLE Your vehicle may be equipped with a two speed or dual range axle option You can select two rear axle ratios for operating under heavy loads or rough terrain as well as for over the road hauling The Low Range provide...

Page 211: ...fferential locked STARTING UP 1 Unlock the interaxle differential before starting 2 Put the Range Selector in the LOW range Shift the transmission to start the vehicle moving 3 When you are driving on rough terrain and secondary roads or under a very heavy load keep the axle in the LOW range Shift the transmission to maintain correct road speed Never shift the axle when moving down hill Engine dri...

Page 212: ...ain your vehicle speed accelerator depressed and move the Range Selector lever to HIGH 3 Keep driving with the accelerator depressed until you want the axle to shift 4 To make the axle shift release the accelerator until the axle shifts You are now in the HIGH axle range for highway speeds Shift the transmission normally to reach your desired cruising speed HIGH to LOW Rough Terrain If you need to...

Page 213: ...ures indicated will vary with the kind of load you are carrying and the driving conditions you encounter Very high temperatures signal a need to have the axle lubrication checked Maximum axle temperature may vary depending on the axle type and lubricant used For information on axle temperature ranges see the Drive Axle Operation Manual Driving with very hot temperatures in the rear drive axles can...

Page 214: ...lures Besides being illegal and dangerous coasting is also expensive It causes premature failure of or damage to the clutch and transmission and overloads the brake system Coasting with the transmission in neutral also prevents proper transmission component lubrication During coasting the transmission is driven by the rear wheels and the countershaft gear which lubricates the transmission componen...

Page 215: ...he same gear used to climb it If engine rpm approaches the top limit apply brakes or shift up to a higher gear Use regular moderate brake application to bring speed to about 10km below desired speed and release the brakes to allow the truck to speed up again This procedure allows all brakes to contribute to brake performance whereas a light continuous application can cause one axle to do all the b...

Page 216: ...peratures Turning off the engine while there are high pyrometer temperatures may damage turbo bearings Accelerating The practice of rapidly accelerating a loaded vehicle from a standstill can cause severe damage to the drive shaft transmission and rear axle Normal service life of these components can be greatly extended by gradual and smooth acceleration If the driver were to unnecessarily acceler...

Page 217: ...NT JACKKNIFING Most truck and semi trailer jackknifes occur when the roads are wet and the semi trailer is unladen This is because the drive tyres will skid much more easily when there is water between the tread and the road surface Also when the semi trailer is unladen 50 of the time with tankers and tippers there is less weight on the drive tyres so less brake pedal travel is required to lock th...

Page 218: ...ropriate to allow all brakes to apply as near as possible to simultaneously 5 Semi trailer suspension roll stiffness should be equal to or greater than that of the truck to minimise degradation of brake balance by minimising side to side weight transfer when cornering 6 Semi tankers should never be operated with less load on each individual drive axle than on each individual semi tanker axle i e i...

Page 219: ... maintaining an adequate and safe speed relative to the surrounding traffic and road conditions Use of Tachourmeter The tachourmeter is an instrument that helps you obtain the best performance of the engine and manual transmission serving as a guide for shifting gears Refer to the Engine Operation and Maintenance Manual for optimum engine rpm If the engine rpm moves beyond the maximum governed spe...

Page 220: ... fuel consumption is connected to three important factors maintenance driving habits and general condition of the road including traffic conditions and vehicle load Maintenance Factors Affecting Fuel Consumption Correct maintenance will keep the vehicle running like new even after long periods of use The driver must perform daily and weekly checks of the vehicle for engine valves out of adjustment...

Page 221: ...sible to choose the best road but it must be kept in mind that the ideal road is the one that allows a steady speed in high gear without requiring frequent braking and acceleration The following general conditions can affect fuel consumption overload unbalanced load very high load poorly maintained roads traffic conditions SAFE DRIVING The following recommendations are merely informative and do no...

Page 222: ...ct the same gear used to climb the hill Use the brakes properly do not ride them Do not exceed maximum governed speed as specified in the Engine Operation and Maintenance Manual Do not exceed the specified load rating Overloading can result in loss of vehicle control and personal injury either by causing component failures or by affecting vehicle handling Exceeding load ratings can also shorten th...

Page 223: ...a vehicle must be operated under such conditions do not exceed 8km h Driving with Deflated Air Springs 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 Do not drive with ruptured air springs The air loss can cause the spring brakes to apply This allows your brakes to drag and may burn up the linings which cou...

Page 224: ...ntil it remains in an overcentre position HOOK UP After connecting your truck to the trailer always inspect the jaws to be sure they have locked on the kingpin before you drive the vehicle Use the trailer hand piece to check that trailer kingpin and 5th wheel jaws are fully engaged AIR ACTIVATED 5TH WHEEL RELEASE PROCEDURE 5th Wheels 1 Apply Parking brake 2 Switch the 5th Wheel release switch to t...

Page 225: ... The tow hitch is only designed to tow an unladen prime mover DO NOT ATTEMPT TO TOW A FULLY LADEN VEHICLE USING A TOW HITCH The tow hitch could snap causing damage to either or both vehicles resulting in an accident or injury to yourself and or others plus property damage TOWING All lubricating and transmission application oil pressure is provided by an engine driven pump This pump cannot be motor...

Page 226: ...ge your vehicle by towing it with the driveline connected and the drive wheels on the ground Worse when vehicles are towed either by wrecker or piggyback the lubricant in the top front of the drive axle will drain to the rear This will leave the top components dry The resulting friction may damage them Always remove the main drive axle shafts before towing your vehicle Remove the drive axle shafts...

Page 227: ...ng damage to the transmission 4 Install the recovery rigging using a safety chain system see Recovery Rigging on page 204 5 Make sure the recovered vehicle s parking brakes are released 6 If you need to use the recovered vehicle s brakes ensure that the vehicle s air system is connected to that of the recovery vehicle Ensure that any air line that has been removed from a driver controlled main dif...

Page 228: ...signed hitches are required to recover your vehicle The recovery hitches attach to the frame see Recovery Hitch Assembly on page 203 Two hitch assemblies are recommended for the proper recovery of your vehicle see Recovery Hitch Assembly on page 203 Do not use parts from other trucks or materials from other sources to repair a hitch or to replace a missing hitch The parts provided for recovery are...

Page 229: ...on 1 Check square sockets behind lower bumper for obstructions clear if necessary 2 With lock pins removed insert hitches through bumper and into the square hitch socket 3 Align the hole in the tow hitch with the square hitch socket hole 4 Insert the lock pin into the square hitch socket hole and through the hole in the tow hitch until the lock tab is within the square hitch socket 5 Rotate the lo...

Page 230: ...lly to both hitches See illustration below 1 Use a spreader or equaliser bar to distribute the load on both hitches 2 If no spreader bar is available connect the main tow chain or cable no closer than 2 metres from the vehicle 3 Never loop a single chain or cable through both hitches 1 Spreader Bar or Equaliser 2 Minimum 2m Preferred Acceptable 3 NEVER USE SINGLE CHAIN OR CABLE LOOPED THROUGH TOW ...

Page 231: ... not working properly You will have to release the spring brakes at the spring brake chambers Do not disassemble a spring brake chamber These chambers contain a powerful spring that is compressed Sudden release of this spring can cause severe injury Do not operate a vehicle when the spring brakes have been manually released Driving a vehicle after its spring brakes are manually released is extreme...

Page 232: ...g was removed inserting it into the pressure plate 4 Turn the release bolt 1 4 turn clockwise in the pressure plate This secures the cross pin into the cross pin area of the pressure plate and locks it into the manual release position 5 Assemble the release bolt washer and nut on the release stud 6 With a spanner turn the release bolt assembly nut until the compression spring is 90 95 percent cage...

Page 233: ... can be dangerous Tyres can explode from spinning too fast Under some conditions a tyre may be spinning at a speed twice that shown on the speedometer Any resulting tyre explosion could cause severe injury or death to a bystander or passenger as well as extensive vehicle damage including tyre transmission and or rear axle malfunction Comply with the following instructions to avoid transmission dam...

Page 234: ...ulating coolant and lubricating oil to carry away heat from the cylinder head valves pistons cylinder liners turbocharger and bearings This way you can prevent engine damage that may result from uneven cooling ENGINE IDLE TIMER If an engine idle timer is fitted to the vehicle please follow this procedure to activate the system 1 Vehicle must be stationary and park brake applied 2 Turn ignition key...

Page 235: ...ows and lock all doors REFUELLING Air inside the fuel tanks allows water to condense in the tank To prevent this condensation while the vehicle is parked for extended periods do not overfill the tanks above 95 percent of capacity 95 percent is to the lower edge of the filler neck so the air gap is still visible as this provides room for expansion resulting from temperature extremes When refuelling...

Page 236: ...se an explosion or fire Failure to comply may result in death personal injury equipment or property damage Never refuel while engine is idling Shut down a vehicle before refuelling this can allow air to enter the fuel system resulting in a possible shutdown Do not remove a fuel tank cap near an open flame Use only the fuel and or additives recommended for your engine FUEL SPECIFICATION Use only di...

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Page 238: ...SECTION TWO PREVENTIVE MAINTENANCE ...

Page 239: ......

Page 240: ...nworth in good working order and provide many years of dependable service It is dangerous to work on a vehicle without the proper training and proper tools People could be seriously injured damage can be done to the vehicle or your vehicle could become unsafe to drive Perform only work you know you are fully able to do and for which you have the right tools ENVIRONMENTAL PROTECTION AND MATERIAL HA...

Page 241: ...ork near heaters or other fire hazards Keep an approved fire extinguisher handy 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 ...

Page 242: ...oisonous and cause sickness They can also damage the paint on the vehicle LUBRICATION SYSTEM Lubricating oil can cause skin irritation or skin injury To prevent skin injury avoid unnecessary contact with the lubricating oil Wear protective clothing eyewear and gloves Clean the area before performing maintenance Dirt in the oil system can lead to significant damage to the engine Avoid dirt in the o...

Page 243: ...rifugal oil filter element 4 Remove the O ring from the screw cap 5 Fit the new O ring 1 onto the screw cap 2 6 Mount the centrifugal oil filter 3 with its top side in the bearing of the screw cap 2 7 Check if the centrifugal oil filter 3 can rotate freely 8 Lightly lubricate the O ring 1 with some engine oil 9 Position the screw cap carefully onto the oil module 10 Tighten the screw cap 1 by hand...

Page 244: ...cap damage loosen the cap Fig 5 3 Unscrew the cap a few turns to drain the filter housing 4 Allow to drain for 60 seconds 5 Remove the screw cap 4 with the oil filter element from the filter housing 6 Carefully remove the oil filter element avoiding any damage to the screw cap thorn Fig 6 7 Remove the O ring from the screw cap 4 8 Install a new O ring onto the screw cap 4 9 Lightly oil the new O r...

Page 245: ...f the oil module making sure the lock slides all the way down and catches the screw cap 4 If the lock 3 collides with a rib tighten the screw cap a little further to allow it to pass Lubricating System Check oil lines housing and connections for leaks damage or deterioration Leaks could be the result of damaged oil lines or seals Oil Draining Hot engine oil can be dangerous You could be seriously ...

Page 246: ... be level with the filler opening Hub reduction axles may require specific oil volumes to ensure correct levels Refer to Electronic Customised Maintenance Manual rear axle section Use care when checking the oil level with your finger Just because you can reach the oil level with a finger does not mean the oil level is correct Oil Sampling Analysis of your major components oil is crucial in keeping...

Page 247: ...g to standard EN590 are used Using a fuel with a biodiesel blend will a more regular service schedule discuss with an authorised Kenworth dealer To prevent condensation while the vehicle is parked for extended periods do not overfill the tanks above 95 percent of capacity 95 percent is to the lower edge of the filler neck so that air gap is clearly visible as this provides room for expansion resul...

Page 248: ...1 Bleed Screw Fuel System Priming Procedure 1 Make sure vehicle has enough fuel for priming 2 Loosen the bleed screw on the primary fuel filter 1 3 Pump the primer button 2 until all air is expelled from the bleed screw 1 4 Tighten bleed screw 1 5 Loosen bleed screw on the main fuel filter 3 6 Pump the primer button 2 until all air is expelled from the bleed screw 3 7 Tighten bleed screw 3 ...

Page 249: ...nly Once engine starts it will self bleed all air from the system 11 If engine does not start repeat steps 9 10 12 Push main primer 4 in and rotate knob clockwise to lock WHEN DUAL FUEL TANK PICK UPS AND RETURNS ARE FITTED Maintain adequate fuel in both pick up tanks when using tank isolating valves FUEL TANK STRAP TENSION Ø625mm tank tension for strap 26 34ft lb 35 46Nm Rectangular fuel tank stra...

Page 250: ...ce life 3 Service the air cleaner periodically If the vehicle operates in areas with heavy dust maintenance should be more frequent 4 Air cleaner elements should be replaced when service indicator pops AIR INTAKE SYSTEM Engine heat vibration and age combine to loosen air intake connections and cause cracks in the tubing and elbows Leaks in the intake system allow abrasive dust to enter the engine ...

Page 251: ...es ribs while still continuing to function normally Many vehicles now have serpentine drive belts this eliminates the need for multiple V belts Aspring loaded pulley maintains tension on the serpentine belt This eliminates the need to re tension the belt when it is replaced PACCAR MX 13 has two serpentine belts which eliminate the need for multiple V belts A spring loaded pulley on each serpentine...

Page 252: ...oaded Tensioner Pulley x 2 4 A C Compressor 5 Alternator 6 Crankshaft Harmonic Balancer 7 Idler Pulleys x 2 BELTS A Fan Coolant Pump 9PK Belt B Alternator A C Compressor 7PK Belt 1 2 3 4 5 3 6 1 2 3 4 5 3 6 7 7 7 7 A B A B Fan Coolant Pump 9PK Serpentine Belt Alternator A C Compressor 7PK Serpentine Belt To Release the Belt Tension To Release the Belt Tension Replacing Poly V belt 7PK Alternator a...

Page 253: ...oly V belt 9PK Engine Fan and Coolant Pump 1 Pull the poly V belt over the coolant pump and fan drive pulleys and route it correctly 2 Move the tensioner against the spring tension and remove the locking pin 3 Position the tensioner against the belt Check that the mark 2 on the tensioner arm is within range A Mark 1 represents the nominal V belt tension deviating 2 mm Outside range A a belt is eit...

Page 254: ...ant The coolant must be clean and free of corrosive and scale forming chemicals Drinking water is not suitable use only coolant approved to DAF MAT 74002 Approved coolant helps neutralise harmful effects on the cooling system No additives are approved for use in the cooling system UNDER NO CIRCUMSTANCES should you use the ALLCOOL coolant with your PACCAR MX 13 engines Use extreme caution when remo...

Page 255: ...eration at normal operating temperature The system may be leaking when pressurised Never use 100 antifreeze to top up coolant UNDER NO CIRCUMSTANCES REMOVE THE PRESSURE CAP Do not add stop leak to the cooling system Stop leak collects around turbulators in the radiator interfering with proper cooling Standard System Refill 1 Verify that the radiator and engine block drains are closed 2 Move the he...

Page 256: ...line allows air to bleed from the running engine when the engine thermostat is closed It also allows air to bleed from the engine when filling the cooling system The anti cavitation line 1 heater hose connects into the suction side of the coolant pump This line supplies non agitated coolant to the pump to prevent cavitation Both the anti cavitation line and the air bleed line should take a continu...

Page 257: ...tions changing any of its components may cause system degradation All parts have to work together to perform as they should Because your brake system is air operated see Air Supply System on page on 237 for more information on checking your brakes Any replacement components in the brake system should be the same or better than the original components Any changes from the original specifications ca...

Page 258: ...to the interval pressure lubricate the slack adjuster and brake camshaft bracket tube Two grease fittings are provided for both the slack adjuster and camshaft bracket tube Use standard chassis lubricant which meets No 2 grade high temperature waterproof specifications Do not use moly sulphide loaded grease or oil as it may shorten the service life of the slack adjuster Checks and Adjustments Brak...

Page 259: ...ke Y Minus X Drum brake free stroke must be 12 7 15 9 mm 1 2 5 8 in X Y Disengage a pull pawl or remove a conventional pawl 2 Release the parking brakes to allow the slack adjusters to retract 3 Measure the retracted pushrod length from the face of the brake chamber to the centre of the pushrod pin 4 Have another person apply and hold the brakes one full application measure the same distance 5 The...

Page 260: ... the brake If adjustment is necessary and the slack adjuster is working the adjusting hex nut will rotate during the chamber return stroke Installing a spanner on the hex nut will make this easier to see On each stroke after the first the amount of adjustment and chamber travel will be less Constant manual adjustment of automatic slack adjusters can shorten the life of your internal clutch If the ...

Page 261: ...no testing or any time the ignition is ON with part of the ABS disconnected a failure code will be recorded Consult your authorised Kenworth dealer for information on clearing the failure code If one wheel on any driven axle continues to slip or spin for approximately 4 seconds this will cause the anti lock controller for that axle to go into the fail safe mode and the warning light will give a sh...

Page 262: ... Do not attempt to recycle the ABS system by turning the keyswitch OFF and ON until the vehicle has been brought to a full stop and the parking brakes set Failure to do so could adversely affect steering and braking control and may result in loss of vehicle control causing an accident Do not operate the vehicle in the event of a malfunction in any air circuit Such a malfunction may prevent the bra...

Page 263: ... contain powerful springs and injury or death can result if they are not properly disassembled Use only proper tools and observe all precautions pertaining to the use of those tools Do not release the parking brake or attempt to move the vehicle until air pressure in both circuits is at least 690kPa the level required for normal brake operation Do not use the control to hold vehicle while parked T...

Page 264: ...e air devices daily to drain moisture within the unit Manual drain valves are located on each tank operated by a pull action on the appropriate cable Periodically Clean filter screens ahead of the valves by removing the screens and soaking them in solvent Blow them dry with pressurised air before reinstalling them If the supply and service tanks are not drained at the recommended frequency water c...

Page 265: ... service checks are provided for your information only and should be performed by a certified technician Contact your authorised Kenworth dealer or consult the Kenworth Maintenance Manual and the engine manufacturer s Maintenance Manual for further information on servicing air compressors After completing any repairs to the air system always test for air leaks and check the brakes for safe operati...

Page 266: ... systems is too low for normal brake operation i e the pointer of one gauge falls below 414kPa 60psi a warning light on the gauge will glow and the audible alarm will sound Follow the procedure below to check the compressed air system for leaks periodically or after maintenance or replacement of air system components 1 Build up air pressure in the system to the governor cut out point or until 827k...

Page 267: ...ne operating check for leaking manifold or flange gaskets High Frequency Vibration Vibration may indicate turbo rotor imbalance Have your authorised Kenworth dealer investigate this immediately Delay could lead to severe and expensive damage to your vehicle Do not operate engine with turbocharger intake piping disconnected A suction is created when the engine is running This suction could draw you...

Page 268: ... braking Refer these conditions to an authorised tyre service centre for repair or replacement Never drive on a tyre if such conditions appear If the tyre looks underinflated stand off to the side and check for damage to the wheel assembly This can be done by visually comparing the wheel in question to other wheels on the vehicle For dual wheel assemblies check between the wheels for damage If any...

Page 269: ...d will give you an inaccurate reading Never deflate a warm tyre to the specified pressure Underinflated tyres will adversely affect the operation of the vehicle and tyres making steering difficult causing extra strain on the tyre sidewalls reducing the tread life of tyres due to the high temperatures generated from excess flexing of the tyre Recommended maximum vehicle operating speed 100km h Reco...

Page 270: ...to impact and other road hazard damage Proper Inflation The correct profile for full contact with the road Underinflation Causes abnormal tyre deflection which builds up excessive heat running the risk of failure It also causes irregular wear Overinflation Reduces the tread contact area with the road surface concentrating all of the vehicle weight on the centre of the tread This causes premature w...

Page 271: ...t if necessary Tyre Loading Do not exceed the load rating of your tyres moulded on the sidewall of your tyre or the maximum vehicle load rating whichever is less Overloading could result in premature tyre failure causing you to lose control of your vehicle resulting in injury and or accident The Gross Combined Mass GCM load rating is found on the tyre placard decal located on the vehicle Overloadi...

Page 272: ...depth in any major tread groove at three locations around the tyre spaced 120 apart Tyres on drive axles or trailer must be replaced when less than 1 5mm of tread depth remains in any major groove as checked at 120 locations around tyre Regrooved tyres or tyres with reinforcement repairs should never be used on steering axles MATCHING TYRES In addition to having tyres balanced and having their rad...

Page 273: ... tightening sequence applies to all wheels except Gunite rims Wheel nuts must be tightened in three stages in the sequence shown below for the particular wheel type using a suitable calibrated torque wrench making sure not to rotate captive washers Tightening sequence must be strictly adhered to or misalignment may occur Never tighten nut fully while others are loose WHEEL MOUNTING AND FASTENING 6...

Page 274: ...GROUND WHEREVER POSSIBLE NO PERSON SHOULD PLACE ANY PORTION OF THEIR BODY UNDER A VEHICLE THAT IS SUPPORTED BY A JACK USE VEHICLE SUPPORT STANDS WHEELS NOT BEING JACKED SHOULD BE CHOCKED NO PERSON SHOULD REMAIN IN A VEHICLE THAT IS BEING JACKED INCORRECT USE MAY RESULT IN POSSIBLE LOSS OF LOAD DAMAGE AND PERSONAL INJURY When the jack leaves the factory the oil chamber contains the correct amount o...

Page 275: ... or turn OFF the electrical master switch 4 No person should remain in a vehicle that is to be jacked 5 Position the jack beneath the axle to be lifted A 20 tonne jack will be required when changing a road wheel Do not use road springs as a jacking point Position the jack under the axle of and as close as practicable to the wheel to be changed 6 The jack must be seated on a level flat hard surface...

Page 276: ...under the load 7 Slowly turn the release valve counterclockwise just sufficiently to allow a gradual decent of the load onto the support stands To lower the load 1 Close the release valve Operate the jack to raise the ram to the correct position under the vehicle Raise the load until the support stands are free Remove the stands clear of the load 2 Slowly turn the release valve counter clockwise u...

Page 277: ...eful not to let dirt or foreign matter enter the system STORAGE OF THE VEHICLE JACK The vehicle jack must be stored upright and securely clamped in the location provided The main cause of Air in the Hydraulic System and Oil Level too Low are both due to poor maintenance or jacks being stored incorrectly i e laid on their side VEHICLE JACKING POINTS Primary Jacking Points Position the jack under th...

Page 278: ...witch is installed Field isolated alternator must be used when replacing alternator in service Batteries If a hydrometer check indicates that a battery is less than 80 charged the battery should be recharged to full capacity See table on page 256 Hydrometer Readings Overcharge Improper voltage regulator setting results in overheating warped plates and boiling off of electrolyte Undercharge Afaulty...

Page 279: ...uidelines carefully when recharging a battery Before attempting any service in the electrical installation disconnect the battery negative cable Allow no sparks or open flame anywhere near the charging area Charge a battery only in a well ventilated area such as outdoors or in a fully open garage which contains no pilot lights or other flames Gases generated during the charging process must be all...

Page 280: ...le Always shield your eyes and avoid leaning over the battery whenever possible Electrolyte in batteries could splash up into your eyes causing severe burns and or serious personal injury Battery terminals should not be coated with improper grease Use petroleum jelly or commercially available non corrosive non conductive terminal coatings Battery acid that may spill during charging should be washe...

Page 281: ... and MAX marks If the fluid level is below the mark correct the condition 3 Disconnect the battery cables 4 Connect charger cables 5 Start charging the battery at a rate not over 6 amps Normally a battery should be charged at no more than 10 percent of its rated capacity 6 After charging is complete switch off charger and disconnect charger cables from the batteries Fast Battery Charging If the ba...

Page 282: ...ble LAST when battery is installed MAINTENANCE FREE BATTERIES Use applicable procedures as for standard batteries but observe the following precautions 1 Do not attempt a jump start if the charge indicator lamp is yellow Yellow colour indicates battery requires replacement 2 If charge indicator is dark and a green dot is visible in the centre check the starter motor and wiring This colour conditio...

Page 283: ...faces Failure to comply may result in death personal injury equipment or property damage Be careful that metal tools or any metal objects do not contact the positive battery terminal and any other metal on the vehicle at the same time Remove metal jewellery and avoid leaning over the battery To Jump Start Your Vehicle When jump starting it is best to jump start with an equivalently powered vehicle...

Page 284: ...dash 6 Shift the transmission into park position or neutral for manual transmissions 7 If either vehicle is equipped with a battery isolation switch ensure they are in the OFF position prior to connecting the two vehicles Connect the batteries 1 Attach one end of a jumper cable to the positive terminal of the discharged battery This will have a large red or P on the battery case post or clamp 2 At...

Page 285: ...in the vehicle with the discharged battery starts running switch on as many power consumers as possible for example headlights fog lamps heater fan and so on in both vehicles before disconnecting jumper cables Remove jumper cables When disconnecting jumper cables make sure they do not get caught in any moving parts in the engine compartment Failure to comply may result in death personal injury equ...

Page 286: ...ty Observe these recommended procedures to protect electronic systems during welding operations If ABS system is installed disconnect ECU Servicing Systems and Units refer to Electronic Customised Maintenance Manual Section 4 Braking Bendix Manuals BW2428 or SD 13 4983 1 With the engine turned OFF disconnect all electronic connections to the vehicle batteries 2 Remove battery power cable and insul...

Page 287: ...y cured finishes Do not use a high pressure lance any closer than 450 mm or 18 inches from the paint surface Do not use a commercial car wash Stiff brushes or coarse sponges could mar the finish and damage the surface Wash the vehicle by hand with cool water and a very mild car wash solution Be sure to use a soft cloth or soft sponge Wash the vehicle in the shade never in the sun Do not dry wipe t...

Page 288: ... Chrome Surfaces Aluminium wheels and bumpers can be cleaned with warm water Tar remover will take off heavy deposits of road grime For added appearance wipe aluminium surfaces dry after washing to prevent spotting Under corrosive conditions such as driving on salted roads clean aluminium pans with steam or high pressure water from a hose A mild soap solution will help Rinse thoroughly Chrome surf...

Page 289: ...ts should be applied with a soft cloth as soon as possible to remove the stain Paint Cautious use of turpentine will remove fresh paint Immediately rinse with a soap and water solution Oil Grease Petroleum based products will stain all vinyls if allowed to stand too long Clean as soon as possible using a soft cloth and eucalyptus oil to wipe clean Rinse with a soap and water mixture Blood Rub out ...

Page 290: ...l module or wiring harnesses Moisture can enter the harness connectors resulting in poor electrical contact and subsequent electronic failures SMART STEERING WHEEL CARE MAINTENANCE Special care and attention must be taken to prolong the life of your steering wheel Do not use the steering wheel as a means of support for entering the cab do not wear oily greasy gloves whilst driving and be aware of ...

Page 291: ...oper operation of the vehicle ventilation system Keep the inlet grille clear of leaves and other debris at all times Inspect and clean fresh air inlet filter and recirculation filter to HVAC unit at 10 000 kilometre intervals This inspection is dependant on the vehicle s service application and may need to occur more often if operating in dusty conditions Keep the exhaust pipe area clear to help r...

Page 292: ...ention to the following items will help ensure its reliable operation Take special note of the safety precautions Heater Check all heater controls for full range operation Check hoses connections and heater core for condition and leaks Check heater core for debris blocking airflow and clean if necessary If heater is not operating properly and the blower and air controls function normally probable ...

Page 293: ...rculations filter is located behind the hinged fuse and relay panel in the cabin Check all hoses for kinks deterioration chafing and leaks Kinked hoses must be replaced with new hoses and the cause of kinking eliminated Check all components and connections for refrigerant leaks Do not attempt to tighten a connection if a leak exists This usually indicates other problems and tightening a fitting co...

Page 294: ...uently will not exceed 200 000 kilometres Seat and cab movement In trucks there is almost constant movement of the belt due to ride characteristics and seat design The constant movement of the belt inside the restraint hardware and the potential for the belt to come in contact with the cab and other vehicle parts contribute to the wear of the entire system Environmental conditions such as dirt and...

Page 295: ...nts refer to the illustration on page 270 Check the web wear in the system The webbing must be closely examined to determine if it is coming into contact with any sharp or rough surfaces on the seat or other parts of the cab interior These areas are typical places where the web will experience cutting or abrasion Cuts fraying or excessive wear would indicate the need for replacement of the seat be...

Page 296: ... for proper operation and to determine if latch plate is worn deformed or damaged Check web in areas exposed to ultraviolet rays from the sun If the colour of the web in these areas is grey to light brown the physical strength of the web may have deteriorated due to exposure to the sun s ultraviolet rays If signs of deterioration are detected replace the system ...

Page 297: ...eplaced An installation guide is attached to every replacement belt Utilise the proper guide for your type of seat and follow the instructions very closely It is vitally important that all components be reinstalled in the same position as the original components that were removed and the fasteners are torqued to specification This will maintain the design integrity of the mounting points for the s...

Page 298: ...ambient outside air temperatures When adding oil types and brands of oil should not be mixed because of possible incompatibility which could decrease the effectiveness of the lubrication or cause component failure Manual and Automated Transmission Oil Level The vehicle must be parked on level ground See the Transmission Operator s Manual for information on checking the transmission oil level Manua...

Page 299: ...sure to the hydraulic fluid The fluid pressure applies force to an air servo in addition to applying force to the clutch fork actuator in the clutch servo mounted to the transmission When the air servo is opened compressed air is allowed to assist the hydraulic pressure and move the clutch fork actuator When the clutch pedal is released the air servo will close and compressed air will exhaust out ...

Page 300: ...ith harder pressure the release yoke moves the release bearing away from the engine This causes the clutch plate to release from the driven discs in the clutch This is called release travel And finally as the pedal is pushed to the last 25mm to 40mm of travel the release bearing contacts and engages the clutch brake This is called clutch brake squeeze When the clutch wears the release bearing grad...

Page 301: ...tion Pack supplied with your vehicle for the correct adjustment procedures Clutch brake travel 25 40 mm 1 11 2 in Pedal free travel 13 mm 1 2 in See the clutch manufacturer s Service Manual in the Electronic Customised Maintenance Manual for the correct adjustment procedures This procedure is all that is required for normal clutch adjustment Adjustment of any other components is not required ...

Page 302: ...t the end of the clutch release yoke These bearings are permanently lubed and do not require maintenance Release Bearing Wear Pads Where the release fork contacts the bearing housing there are small hardened steel pads Apply a small amount of grease to the wear pads where the clutch release fork contacts Clutch Brake The clutch brake friction material is designed to operate with lubricant While lu...

Page 303: ...ge 277 PREVENTIVE MAINTENANCE MAX MIN Master Cylinder The fluid reservoir for the hydraulic clutch system is located on the engine side of the firewall adjacent to the dual brake foot valve and below the windscreen wiper motor ...

Page 304: ...e problem have the problem diagnosed and corrected by an authorised Kenworth dealer While operating the vehicle the driver should avoid deep ruts or obstructions which cause a binding condition on front wheels If the front wheels are in a rut or against a curb the vehicle should be driven out under its own power rather than lifted out by turning the wheels while the vehicle is stopped UNDERSTEER A...

Page 305: ...le alignment it is recommended that axle stops and steering gear poppets are checked for proper relief on turns HYDRAULIC POWER STEERING FILTER SERVICE AND PARTS RESERVOIR ASSEMBLY The original filter element should be replaced after a maximum of 50 hours of operation Thereafter the element and cover gasket should be replaced after every 40 000km 1 000 hours of operation or more often depending up...

Page 306: ...icated periodically Use a good quality lithium soap base or equivalent extreme pressure E P grease NLGI Grade 2 For towing guidelines and returning a towed vehicle to service see page 163 U JOINTS The slip joints and universal joints of the drive shaft should be lubricated according to Recommended Maintenance Schedules pages 315 342 Use a good quality lithium soap base or equivalent extreme pressu...

Page 307: ... by the easy access lever on the lower left hand side of the column housing Locked Position Unlocked Position Height and Tilt Adjustment Push down on the lever on left side of steering column Adjust column tilt angle fore and aft when holding lever Adjust column height by pushing down or pulling up at the same time Raise lever to its fully locked position assuring proper locking Use of excessive f...

Page 308: ... and hard steering Lubrication schedule may be shortened if necessary The grease fitting for the front drive pins faces inboard to prevent interference with the drag link SUSPENSION LUBRICATION Each standard spring anchor pin has a grease fitting Pressure lubricate spring pins as specified See Recommended Maintenance Schedules page 315 342 At regular service intervals the spring leaves may be lubr...

Page 309: ... faster 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 Kenworth New springs can settle in after service relieving the tension on the U bolts Loose U bolts can cause leaf spring breakage axle misalignment hard steering and abnormal tyre wear Do not operate the vehicle if the...

Page 310: ...of operation Then check weekly Load the vehicle to its normal gross weight before tightening U bolts Loading the vehicle ensures proper adjustment of the U bolt and spring assembly To ensure an accurate torque reading use properly maintained and calibrated torque wrenches Clean the nut and bolt No dirt grit or rust should be present Do not replace U bolts and nuts with common U bolts or standard n...

Page 311: ...th aligning wheels on Kenworth vehicles Consult the table below for alignment specifications for each type of axle Camber Camber figures shown are at unladen chassis weight Front Wheel Alignment Kenworth Australia Specifications Axle Model Caster Degrees Positive Camber Toe in MFS66 122 MFS 73 E 1462 I All Models 3 5 1 All Models Left 1 4 3 8 Right 1 3 8 All Models 0 1 5 mm m WHEEL BEARING ADJUSTM...

Page 312: ... system failure possibly resulting in an accident Improperly tightened loose suspension U bolts can lead to unsafe vehicle conditions including hard steering axle misalignment spring breakage or abnormal tyre wear See the Fastener Torque Tables pages 284 for proper torque specifications REAR SUSPENSION FASTENERS To maintain the performance of the air suspension check fastener torque values after t...

Page 313: ...our Kenworth After the first 1 000km of operation inspect the suspension periodically as noted below Visually check for loose or missing fasteners cracks in hanger or axle connection brackets Check springs are centred in hangers and in good condition Check for cracks wear marks splits or other defects on the surface of the spring Replace defective parts Because repaired springs cannot be fully res...

Page 314: ...Maintenance Manual and the axle manufacturer s Service Manual for further information on servicing drive axles Initial Change See Recommended Maintenance Schedules pages 315 342 for standard rear axle service schedules Change mineral based lubricant in other Dana axle assemblies new or rebuilt within the first 10 000km For petroleum based axles use lubricants meeting MIL L 2105 C D grade specifica...

Page 315: ... Loose suspension fasteners loose is defined as any torque below the recommended torque value Elongated holes in a suspension component Bushing replacement Excessive or abnormal tyre wear Rear Axle Alignment Kenworth Australia Specifications SINGLE REAR AXLE Item Specification Toe 0 3mm m Off Track 0 2mm m to the left TANDEM REAR AXLE Item Specification Toe 0 3mm m Off Track Forward Rear 0 2mm m t...

Page 316: ...hen the U Bolt and nut threads are clean and have been lubricated with an SAE 20 or SAE 30 oil Never re use a self locking nut TORQUE REQUIREMENTS FRAME FASTENERS Bolt Size Imperial Grade 8 Nylon Insert Nuts Nm ft lb 3 8 41 54 30 40 7 16 75 88 55 65 109 122 80 90 9 16 156 190 115 140 5 8 224 265 165 195 394 462 290 340 7 8 517 626 380 460 1 925 1129 700 830 1 1 8 1346 1591 990 1170 1 1822 2217 138...

Page 317: ...an Design Rules or the Noise Control Regulations are covered by this warranty TAMPERING WITH NOISE CONTROL SYSTEM IS PROHIBITED Australian Design Rules prohibit the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise c...

Page 318: ...System are fitted with silencers These silencers need to be inspected on a regular basis with particular attention being paid to theAir Dryer Purge Tank if fitted This can block internally due to the air supply coming from the engine intake side As a routine check it is good practice to apply heavy braking when stationary at the start of the day when the truck has warmed up and before entering pub...

Page 319: ...ipes and clamps which could allow exhaust to escape Piping Check exhaust piping for rust corrosion and damage Replace deteriorated piping before holes appear If piping is perforated at any point temporary patching or lagging is acceptable until permanent repairs can be made On turbocharged engines check joints at flanges and mounting brackets for tightness Mufflers Check muffler clamps and mountin...

Page 320: ...mmediately This condition not only causes excessive noise it can result in serious damage to the engine Engine Fan and Shroud Do not work on the fan with the engine running The engine fan can engage at any time without warning Anyone near the fan when it turns ON could be seriously injured Before turning on the ignition be sure that no one is near the fan Check all fasteners for tightness Check fo...

Page 321: ...Skirts Check all fasteners for security particularly the self tapping hex head screws Remove and replace any loose rivets Check shields and skirts for cracks of mounting stress points Check fender shields for tyre marks worn spots or damage from objects thrown from tyre treads Cracked or damaged fibreglass fender shields can be repaired with fibreglass and resin If damage is found at a fastening p...

Page 322: ...arandprematurefailureofengine components gears and bearings The oil drain plug is a good place to catch theseparticlesandshouldbecleanedoffeverytimeanoilchangeisperformed The magnets can lose their effectiveness as material collects on the poles and shorts the magnetic field Check the effectivness of your drain plugs and change plugs before this occurs It may be necessary to change plugs one or mo...

Page 323: ...nuts plain cadmium plated Grade 5 bolts or studs with cadmium or zinc chromate plated hardened washers SAE GRADE 5 FASTENERS NON LUBRICATED FASTENER TORQUE Size Thread N m ft lb 28 UNF 20 UNC 12 14 9 11 9 10 7 8 5 16 24 UNF 18 UNC 24 26 22 23 18 19 16 17 3 8 24 UNF 16 UNC 45 47 38 41 33 35 28 30 7 16 20 UNF 14 UNC 68 75 61 68 50 55 45 50 20 UNF 13 UNC 115 122 95 102 85 90 70 75 ...

Page 324: ...ricated with cadmium or zinc chromate plated hardened washers SAE GRADE 8 FASTENER TORQUE REQUIREMENTS FASTENER SIZE TORQUE N m ft lb 5 16 22 30 16 22 3 8 41 54 30 40 7 16 75 88 55 65 109 122 80 90 9 16 156 190 115 140 5 8 224 265 165 195 394 462 290 340 7 8 517 626 380 460 1 952 1129 700 830 1 1 8 1346 1591 990 1170 1 1877 2217 1380 1630 The torque values apply to both UNF and UNC threads of corr...

Page 325: ...Australia will have a certification label fixed to the cab as required by Australian Motor Vehicle Certification The compliance plate is located inside the driver s side door frame below the latch mechanism The vehicle identification placard is located inside the passenger s side door rebate below the latch mechanism See next page for detailed view ...

Page 326: ...GCM APPROVED FOR DATE OF MANUFACTURE k g k g k g OVERLOADING OR OVERSPEEDING WILL VOID YOUR WARRANTY CAUTION ALL INFORMATION VALID AT TIME OF MANUFACTURE P53 1267 Turbo VIN Number Vehicle Identification Placard A Vehicle Identification Number VIN or chassis number is stamped on the top flange of the right hand side chassis rail all models approximately one metre from the front of the rail in the v...

Page 327: ...character N N N N N N N N N N N N N N Numeric character WMI World Manufacturer Index A A A A A A I I I Manufacturer e g Kenworth I I Country e g Australia I Geographic Region e g Oceania VDS Vehicle Descriptor Section A A A A A A N N N N N N Use of VDS is optional but generally it is used to describe manufacturer specified vehicle attributes VIS Vehicle Indicator Section A A N N N N N N N N N N I ...

Page 328: ...wd Carrier Serial No Centre Rear Axle Serial No Centre Carrier Serial No Rear Rear Axle Serial No Rear Carrier Serial No Rear Axle Capacity Fwd Rear Electrical System 12 Volt Negative Ground Total Fuel Capacity Litres Engine Crankcase Capacity Litres Radiator Coolant Capacity Litres Transmission Capacity Unit Litres Aux Litres Rear Axle Capacity Wheel Size Front Rear Fan Belt Part No Alternator Be...

Page 329: ...CCAR 1800 472 222 Trained operators are available 24 7 to connect you with your nearest PACCAR dealer for support Have your chassis serial number ready when calling this service Your chassis number should be recorded inside the front cover of this Driver s Handbook Insert the last 5 digits from your VIN number this is your individual Chassis Number 1800 4 PACCAR 4 ROADSIDE ASSISTANCE 1800 4 PACCAR...

Page 330: ......

Page 331: ...SECTION THREE MAINTENANCE LUBRICATION SCHEDULES ...

Page 332: ...via drains sewers or onto the soil Such practices are not only illegal but also contribute considerably to environmental pollution Used oils coolants and hydraulic fluids should be returned to the appointed organisation for re use Ensure all used liquids are separated Ensure your vehicle is regularly maintained A correctly maintained vehicle contributes to maximum fuel saving and reduces pollutant...

Page 333: ...subsequently sell this vehicle please complete and return this form to the address on the reverse This notification is important even after the original vehicle warranty in case Kenworth need to contact you NOTICE OF NAME ADDRESS OWNERSHIP DETAILS Name Address Change New Owner Date Ownership Changed Delete not applicable Business Name ABN Title Mr Mrs Ms Owner s Name Address Town State Postcode Ph...

Page 334: ...omer Service Kenworth Trucks Reply Paid 64847 BAYSWATER VIC 3153 Delivery Address 64 Canterbury Road BASYSWATER VIC 3153 No stamp required if posted in Australia Delivery Address 64 Canterbury Road BAYSWATER VIC 3153 ...

Page 335: ...sponsibility 314 Lubrication Schedules 315 T410 MX Engine Service Schedule 316 First Service 318 A Service Intervals 320 B Service Intervals 322 C Service Intervals 324 Chassis Lubrication Points 326 Master Lubrication Chart 331 Lubrication and Fluid Capacities 333 Service Intervals 334 Maintenance Service Records 344 First Service Inspection Record 345 Service Inspection Records 347 CHANGE OF ADD...

Page 336: ...or you to take your vehicle to the selling dealer you may take your vehicle to any other authorised Kenworth dealer The owner and vehicle identification details recorded on the inside front cover of this handbook are required by the authorised Kenworth servicing dealer in connection with the provision of warranty service Therefore you should present this handbook to the authorised Kenworth service...

Page 337: ...arranty service A All parts and labour used and supplied in carrying out warranty service at the premises of an authorised Kenworth servicing dealer are free of charge except consumables such as oil and filters Whenever warranty service is to be carried out by an authorised Kenworth service dealer it is your responsibility to deliver your vehicle to the service dealer s premises If as a result of ...

Page 338: ...an authorised Kenworth service dealer the cost of labour will also be covered for a period of 12 months from the date of installation Warranty on parts fitted as part of a warranty repair expires 12 months from the vehicle s date in service 10 Q Will I have to pay maintenance costs during the warranty period A Maintenance costs since they do not arise from defects in materials or workmanship are n...

Page 339: ... engine transmission differential or power steering systems after 10 000 kilometres Adding to or replacing lubricants Adjustments to drive belts transmission clutch parking brake etc Replacing wiper blade rubber elements Wheel balancing after 10 000 kilometres Wheel alignment front and rear De dusting or de glazing of brake linings or pads after 10 000 kilometres Brake lining wear or damage Batter...

Page 340: ...TY It is the owner s responsibility to ensure that all scheduled maintenance services specified on the vouchers in this book are carried out at the recommended intervals The owner should also retain evidence that these services have been performed It is important to note that any claims made during the warranty period will not qualify under the terms of the New Vehicle Warranty if resulting from f...

Page 341: ...hanged the cooling system must be drained and flushed prior to refill For special service requirements consult your lubricant supplier In all cases the lubricant supplier assumes full responsibility for the performance of the product and for product and patent liability The Preventive Maintenance Program really starts with the daily checks that you perform These checks are itemised in Section 1 in...

Page 342: ...90 000 km Maximum OR Every 1500 hrs OR Yearly Which ever comes first Group II Every 10 000 kms Maximum OR Every Fortnight Which ever comes first Change transmission and rear axle oil at first service Every 40 000 kms Maximum OR Every 500 hrs Which ever comes first Every 90 000 km Maximum OR Every 1500 hrs OR Yearly Which ever comes first Group III Every 10 000 kms Maximum OR Every Fortnight Which ...

Page 343: ...first Dana Use only Dana approved oils 250 000 kms OR 3 Years Maximum Which ever comes first Mineral Oil 90 000 km Maximum Synthetic Oil 360 000 km Maximum Meritor Mineral Oil 120 000 kms Maximum OR Yearly Which ever comes first Synthetic Oil 360 000 kms Maximum OR 3 Years Which ever comes first Dana Use only Dana approved oils 250 000 kms OR 3 Years Maximum Which ever comes first Mineral Oil 100 ...

Page 344: ...heck and lubricate where applicable spring shackle and hanger brackets spring pins shackle pins and bushes spring leaves king pins bushings thrust bearings and spindles u bolt torque steering and tierod arms joints steering stops and general inspection for wear 11 REAR AXLES Meritor With Mineral Oil Drain and refill with mineral oil With Synthetic Oil Drain and refill with synthetic oil Change oil...

Page 345: ...ition and tightness Check cab and sleeper panels joints Check interior trim for condition Check operation of wipers washers horns air and electric mirrors all warning lights and gauges Fill washers Lubricate door locks hinges latches and striker plates sparingly Check low air pressure warning devices 17 ROAD TEST Check operation of steering gear shifting service brakes engine throttle air seat HVA...

Page 346: ...f electrcial harnesses and connections 8 EMERGENCY SHUT DOWN Check operation of ISO switch remote switches and rollover devices 9 COOLING SYSTEM Check radiator CAC and A C condensor for fouling or damage Pressure test cooling system and check for leaks Check coolant level and top up where necessary Use only PACCAR Genuine ELC30 Coolant 10 CLUTCH Check and adjust where applicable Lubricate release ...

Page 347: ...m condition Check air pressure build up time and maximum pressure Record maximum pressure and adjust governor if required Check air pressure drop service brakes applied and service brakes not applied 19 WHEELS AND TYRES Check torque of all wheel nuts Check for missing valve caps and stem locks cracked or loose wheel lugs cleats and tyre pressures Check for uneven tyre wear 20 CAB Check glass for s...

Page 348: ...ing surfaces as applicable and general pipe clearances to other components Check mounting bolts for tightness 8 AD BLUE SYSTEM Check for leaks air and ad blue 9 EMERGENCY SHUT DOWN Check operation of ISO switch remote switches and rollover devices 10 ELECTRICAL CONNECTIONS Check integrity and mounting of electrcial harnesses and connections 11 STARTER MOTOR AND ALTERNATOR Check operation and outpu...

Page 349: ...essary Drain water from fuel water seperator if present 21 BRAKES FRONT AND REAR Check brake adjustment wheel seals for leaks operation of spring brakes brake pedal free play and hoses and fittings for leaks condition and attachment support Lubricate camshafts and slack adjusters sparingly Check drum condition Check air pressure build up time and maximum pressure Record maximum pressure and adjust...

Page 350: ...learances to other components Check mounting bolts for tightness Check exhaust system for leaks 8 AD BLUE SYSTEM Check for leaks air and ad blue Change in tank filter and air filter 9 EMERGENCY SHUT DOWN Check operation of ISO switch remote switches and rollover devices 10 ELECTRICAL CONNECTIONS Check integrity and mounting of electrcial harnesses and connections 11 STARTER MOTOR AND ALTERNATOR Ch...

Page 351: ...r tank check valves Change air dryer filter s Check hood alignment and clearance Check and drain water from air and fuel tanks where applicable Check and lubricate 5th wheel Check all air valve silencers and clean replace as necessary Drain water from fuel water seperator if present 21 BRAKES FRONT AND REAR Check brake adjustment wheel seals for leaks operation of spring brakes brake pedal free pl...

Page 352: ...Page 326 CAT 8612 November 2019 CHASSIS LUBRICATION POINTS 2 3 4 5 26 8 25 27 12 13 14 20 19 1 22 23 24 28 9 10 6 7 11 ...

Page 353: ...CAT 8612 November 2019 Page 327 CHASSIS LUBRICATION POINTS VEHICLE LUBRICATION POINTS Legend on page 328 10 15 17 10 30 30 16 16 29 18 21 31 ...

Page 354: ... coolant EC 3 STEERING U JOINTS one fitting each end CL 4 DRAG LINK one fitting each end CL 5 STEERING SLIP JOINT CL 6 FRONT BRAKE CAMSHAFT lubricate sparingly one fitting each side BG 7 CLUTCH Master cylinder hydraulic fluid reservoir BF 8 TIE ROD ENDS one fitting each side CL 9 MAIN and AUX TRANSMISSION MANUAL TRANSMISSIONS Check EO Drain and refill except synthetic EO PACCAR and ULTRASHIFT PLUS...

Page 355: ...CL 20 FAN DRIVE inspect and drain 21 FRONT SLACK ADJUSTERS lube sparingly BG 22 FRONT WHEEL BEARINGS Oil lubricated GO 23 KING PIN two fittings each side CL 24 ENGINE LUBRICATING OIL Check oil level EO Change oil fuel and coolant filters EO Refer to engine manual for intervals 25 DOOR LOCK CYLINDERS LL 26 DOOR HINGES EO 27 DOOR LATCHES and STRIKER PLATES PG 28 SPRING SHACKLE PINS two fittings each...

Page 356: ... Lube Specs CL Chassis Grease NLGI 2 EC PACCAR Genuine ELC30 Coolant EO Castrol Vecton 15W 40 CK 4 E9 GO Drive Axles Gear Oil MO Mineral Oil SO Synthetic Oil Requires Periodic Sampling Major Components Require Different Specific Oils ATF Automatic Transmission Fluid Hydraulic fluid STF Synthetic Transmission Fluid Requires oil sampling SL Silicone Lubricant LL Lock Lubricant PG Polyethylene Grease...

Page 357: ...VICE INTERVAL PACCAR Clutch CASTROL BRAKE FLUID DOT 3 Daily DRAIN REPLACE ON HIGHWAY every 2 years DRIVING AXLES LUBRICATION CHECK NORMAL SERVICE INTERVAL Dana Castrol Axle AP 85W 140 Mineral Oil 40 000km FACTORY FILLED WITH AP 85W 140 MINERAL OIL 80 000km or every 1 year whichever comes first Castrol Dynadrive 80W 90 Semi Synthetic Oil DYNADRIVE80W 90SEMI SYNTHETIC 200 000km or every 1 year which...

Page 358: ...ort Pads Castrol Red Rubber Grease 10 000km Door Latches Castrol Spheerol PH Grease 10 000km Front Wheel Bearings Castrol Axle AP 85W 140 Mineral Oil 40 000km 10 000km KENWORTH TRUCKS recommends the use of the lubricants specified in these charts Schedule service intervals more frequently for severe operational conditions For special service requirements consult your lubricant supplier In all case...

Page 359: ... DSH40P Forward 18 5 ltrs Rear 13 2 ltrs DS RDH40P Forward 18 5 ltrs Rear 13 2 ltrs DD RDH40P Forward 18 5 ltrs Rear 13 2 ltrs D46 170 Forward 19 9 ltrs Rear 18 5 ltrs Wheel Hubs each 1 2 ltrs plus Oil Cooler Approx 0 5 ltr of oil per 3 metre run includ ing oil cooler and standard size 10 hose Meritor Rear Axles MT 20 14XG Forward 14 3 ltrs Rear 12 2 ltrs MT 20 14XGP Forward 14 3 ltrs Rear 12 2 lt...

Page 360: ...r comes first Mounting bolts ü ü Air Intake System ü ü ü Check for leaks and damage Examine all intake components on the clean side Condition and sealing of rubber elbows and hump hoses clamp tensions and orientation material integrity of intake pipes including welds on fabricated parts other sealing and mating surfaces as applicable and general pipe clearances to other components Exhaust System ü...

Page 361: ...g bolts and replace as required Check shroud clearance and adjust as required Pressure test the cooling system Radiator Hoses ü ü ü Inspect hoses for routing chafing and leaks Check all hose fittings for tightness CLUTCH Release Bearing ü ü ü ü Lubricate sparingly Requires extended fittings Clutch ü ü ü ü Check clutch pedal for free play operation and adjustment Check and lubricate cross shaft bus...

Page 362: ...orque Steering Pinch Bolts ü ü ü ü Steering Wheel Free Play and Centralise ü ü ü ü Check and adjust if required Steering Box Bracket and Mounting Bolts ü ü ü ü Check torque of bolts Hoses and Fittings ü ü ü ü Check for leaks and fittings for tightness Check for clearance Operation and Damage ü ü ü ü Check for correct operation and any damage to system Fluid Level ü ü ü ü Change Fluid Drain and rep...

Page 363: ...between tyres and frame components Front End Alignment As required dependent on tyre wear DRIVE SHAFTS U Joints ü ü ü ü Lubricate More frequent under Severe Working Conditions Slip Joint ü ü ü ü Centre Bearing if fitted ü ü ü ü Inspect only as non greaseable sealed unit REAR AXLES Check Oil Level ü ü ü ü Rear axle breathers ü ü ü ü Check to ensure they are clear Meritor With Mineral Oil Change Oil...

Page 364: ...ditions Chassis Bolts Frame Fasteners ü ü ü ü Suspension to Frame Bolts ü ü ü ü Cab and Sleeper Mounting Points ü ü ü ü Engine Mounting Bolts ü ü ü ü Transmission Mounting Bolts ü ü ü ü S u s p e n s i o n U B o l t Torques ü ü ü ü Torque Rod Mounting Bolts ü ü ü ü Hood Pivots Alignment and Clearance ü ü ü ü Air and Electrical Routing ü ü ü ü Air Dryers and Moisture Ejectors ü ü ü ü Air Dryer Filt...

Page 365: ...olyte Level ü ü ü ü C l e a n a n d Ti g h t e n Terminals Connections and Earth ü ü ü ü C h e c k f o r S i g n s o f O v e r c h a r g i n g Undercharging ü Load Test Batteries Check every 6 months Hold Down and Battery Box Mounting Bolts ü ü ü Wiring for Chaffing and Loose Terminals ü ü ü Visual Inspection Loose Connections ü ü ü ü S t a r t e r D r a w Volts Check every service Wiring for Chaf...

Page 366: ...ü Record in kPa Air Pressure Drop Brakes Not Applied ü ü ü Air Pressure Drop Brakes Applied ü ü ü Brake Pedal Free Play ü ü ü ü Hoses Fittings for Damage and Leaks ü ü ü ü Brake Camshafts ü ü ü ü Lubricate sparingly Slack Adjusters ü ü ü ü BRAKE TREADLE Hinge and Roller ü ü ü WHEELS AND TYRES Wheel Nut Torque ü ü ü ü Cracked and Loose Wheel Lugs ü ü ü ü Missing Valve Caps Stem Locks ü ü ü ü W h e ...

Page 367: ...aints Mounting Points ü ü ü ü HVAC System ü ü ü Check no exhaust leaks enter the cab area HVAC Fresh Air Filter ü ü ü More frequently under Severe Working Conditions Floor Mats ü ü ü Door Panels ü ü ü Headlining ü ü ü Sleeper ü ü ü Dash Console ü ü ü Covers ü ü ü Mirrors ü ü ü ü Horns Air and Electric ü ü ü ü Door Weather Stripping ü ü ü ü Door Lock Hinges Latches and Striker Plates ü ü ü ü Lubric...

Page 368: ...d Operation ü ü ü ü Cab HVAC and Sleeper HVAC if fitted ü ü ü ü Radio Antenna CD Player CB Radios ü ü ü ü Headlights Hi Lo Tail S t o p R e v e r s e a n d Indicators ü ü ü ü Speedometer Odometer ü ü ü ü Tachometer Hourmeter ü ü ü ü All Instruments and Gauges ü ü ü ü Instrument Illumination ü ü ü ü Cabin Interior Lights ü ü ü ü ABS Warning Lights ü ü ü ü Low Air Brake Pressure Warning Devices ü ü ...

Page 369: ...SECTION FOUR SERVICE RECORDS ...

Page 370: ...important as it will enhance the value of the vehicle whenever resale is contemplated What the Servicing Dealer has to do Your service dealer must attend to all items listed for the particular service and see that both copies of the validation record are signed Tear out the perforated top copy and keep with dealership file The second copy remains in this handbook All operations listed on the servi...

Page 371: ...if Tyres Rubbing 19 Check Adjust Front and Rear Brakes 20 Lubricate Purge Grease Points Suspension Driveline Strg Components 21 Check Steering inc King Pins 22 Check Tension Chassis Bolts 23 Check Tension Cab Sleeper Mount Bolts 24 Check Hood Bolts Tension Hood Alignment Adjust 25 Check Re Tension U Bolts Refer page of this Drivers Handbook 26 Check Tension Rear Suspension Bolts 27 Check Tension S...

Page 372: ...d All other major components Gearbox Drive axles etc specified with synthetic oil must be drained and filled with synthetic oils at this service interval CHECK AND RECORD BELOW Radiator Coolant Condition Battery Electrolyte Level Tighten Terminals 1 2 3 4 Technician s Notes Use separate sheet of paper if necessary DEALERSHIP STAMP Technician to Sign Date ...

Page 373: ...ion System Compressor Rear Suspension Belts and Pulleys Rear Axles Intake and Exhaust Systems Drivelines AdBlue System Chassis Emengency Shutdown Brakes Front and Rear Electrical Connections Wheels Tyres Starter Motor and Alternator Cab Cooling System Road Test See pages 228 237 in this Driver s Handbook for full description of work to be carried out during these inspec tions For Technician s comm...

Page 374: ...Page 348 CAT 8612 November 2019 SERVICE INSPECTION RECORDS B Service Inspection Record Technician s Notes Use separate sheet of paper if necessary ...

Page 375: ...on Intake and Exhaust Systems Rear Axles System Compressor Drivelines AdBlue System Chassis Electrical Connections Brakes Front and Rear Emengency Shutdown Wheels Tyres Cooling System Cab Clutch Road Test Transmission See pages 228 237 in this Driver s Handbook for full description of work to be carried out during these inspections For Technician s comments please use reverse side Refer to Origina...

Page 376: ...AT 8612 November 2019 SERVICE INSPECTION RECORDS A Service Inspection Record CHECK AND RECORD BELOW Battery Electrolyte Level Tighten Terminals 1 2 3 4 Technician s Notes Use separate sheet of paper if necessary ...

Page 377: ...mpressor Rear Suspension Belts and Pulleys Rear Axles Intake and Exhaust Systems Drivelines AdBlue System Chassis Emengency Shutdown Brakes Front and Rear Electrical Connections Wheels Tyres Starter Motor and Alternator Cab Cooling System Road Test See pages 228 237 in this Driver s Handbook for full description of work to be carried out during these inspections For Technician s comments please us...

Page 378: ...Page 352 CAT 8612 November 2019 SERVICE INSPECTION RECORDS C Service Inspection Record Technician s Notes Use separate sheet of paper if necessary ...

Page 379: ...on Intake and Exhaust Systems Rear Axles System Compressor Drivelines AdBlue System Chassis Electrical Connections Brakes Front and Rear Emengency Shutdown Wheels Tyres Cooling System Cab Clutch Road Test Transmission See pages 228 237 in this Driver s Handbook for full description of work to be carried out during these inspections For Technician s comments please use reverse side Refer to Origina...

Page 380: ...AT 8612 November 2019 SERVICE INSPECTION RECORDS A Service Inspection Record CHECK AND RECORD BELOW Battery Electrolyte Level Tighten Terminals 1 2 3 4 Technician s Notes Use separate sheet of paper if necessary ...

Page 381: ...mpressor Rear Suspension Belts and Pulleys Rear Axles Intake and Exhaust Systems Drivelines AdBlue System Chassis Emengency Shutdown Brakes Front and Rear Electrical Connections Wheels Tyres Starter Motor and Alternator Cab Cooling System Road Test See pages 228 237 in this Driver s Handbook for full description of work to be carried out during these inspections For Technician s comments please us...

Page 382: ...Page 356 CAT 8612 November 2019 SERVICE INSPECTION RECORDS B Service Inspection Record Technician s Notes Use separate sheet of paper if necessary ...

Page 383: ...on Intake and Exhaust Systems Rear Axles System Compressor Drivelines AdBlue System Chassis Electrical Connections Brakes Front and Rear Emengency Shutdown Wheels Tyres Cooling System Cab Clutch Road Test Transmission See pages 228 237 in this Driver s Handbook for full description of work to be carried out during these inspections For Technician s comments please use reverse side Refer to Origina...

Page 384: ...AT 8612 November 2019 SERVICE INSPECTION RECORDS A Service Inspection Record CHECK AND RECORD BELOW Battery Electrolyte Level Tighten Terminals 1 2 3 4 Technician s Notes Use separate sheet of paper if necessary ...

Page 385: ...mpressor Rear Suspension Belts and Pulleys Rear Axles Intake and Exhaust Systems Drivelines AdBlue System Chassis Emengency Shutdown Brakes Front and Rear Electrical Connections Wheels Tyres Starter Motor and Alternator Cab Cooling System Road Test See pages 228 237 in this Driver s Handbook for full description of work to be carried out during these inspections For Technician s comments please us...

Page 386: ...Page 360 CAT 8612 November 2019 SERVICE INSPECTION RECORDS C Service Inspection Record Technician s Notes Use separate sheet of paper if necessary ...

Page 387: ...on Intake and Exhaust Systems Rear Axles System Compressor Drivelines AdBlue System Chassis Electrical Connections Brakes Front and Rear Emengency Shutdown Wheels Tyres Cooling System Cab Clutch Road Test Transmission See pages 228 237 in this Driver s Handbook for full description of work to be carried out during these inspections For Technician s comments please use reverse side Refer to Origina...

Page 388: ...AT 8612 November 2019 SERVICE INSPECTION RECORDS A Service Inspection Record CHECK AND RECORD BELOW Battery Electrolyte Level Tighten Terminals 1 2 3 4 Technician s Notes Use separate sheet of paper if necessary ...

Page 389: ...mpressor Rear Suspension Belts and Pulleys Rear Axles Intake and Exhaust Systems Drivelines AdBlue System Chassis Emengency Shutdown Brakes Front and Rear Electrical Connections Wheels Tyres Starter Motor and Alternator Cab Cooling System Road Test See pages 228 237 in this Driver s Handbook for full description of work to be carried out during these inspections For Technician s comments please us...

Page 390: ...Page 364 CAT 8612 November 2019 SERVICE INSPECTION RECORDS B Service Inspection Record Technician s Notes Use separate sheet of paper if necessary ...

Page 391: ... Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed B Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed C Service Inspection Servicing Dealer Date of Service Odometer Signed...

Page 392: ...rvices Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed C Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed Change In Tank AdBlue Filter A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed BService Inspection Servicing Dealer Date of Service O...

Page 393: ... Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed B Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed C Service Inspection Servicing Dealer Date of Service Odometer Signed...

Page 394: ...Additional Services Performed A Service Inspectionn Servicing Dealer Date of Service Odometer Signed Additional Services Performed C Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed B Service Inspection Servicing Dealer Date of Service Odometer Signed...

Page 395: ...vices Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed B Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed C Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Ser...

Page 396: ... Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed C Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed B Service Inspection Servicing Dealer Date of Service Odometer Signed...

Page 397: ... Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed B Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed C Service Inspection Servicing Dealer Date of Service Odometer Signed...

Page 398: ... Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed C Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed B Service Inspection Servicing Dealer Date of Service Odometer Signed...

Page 399: ...vices Performed Change In Tank AdBlue Filter A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed B Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed C Service Inspection Servicing Dealer Date of Service O...

Page 400: ... Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed C Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed B Service Inspection Servicing Dealer Date of Service Odometer Signed...

Page 401: ... Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed B Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed C Service Inspection Servicing Dealer Date of Service Odometer Signed...

Page 402: ...vices Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed C Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed Change In Tank AdBlue Filter A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed B Service Inspection Servicing Dealer Date of Service O...

Page 403: ... Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed B Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed C Service Inspection Servicing Dealer Date of Service Odometer Signed...

Page 404: ... Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed C Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed B Service Inspection Servicing Dealer Date of Service Odometer Signed...

Page 405: ...vices Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed B Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed A Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Services Performed C Service Inspection Servicing Dealer Date of Service Odometer Signed Additional Ser...

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Page 407: ...235 ABS fault codes 235 warning lamp 154 off road function switch 156 Approaching your vehicle 13 Automatic traction control 154 Automated transmissions 120 indicator 29 operating 120 oil change 272 oil sampling 220 parking brake 120 Automatic slack adjusters 233 free stroke measurement adjusted233 chamber stroke 234 Axle stops 279 Axle cross wheel differential lock 181 Axle inter axle differentia...

Page 408: ...cator 29 Cross shaft bushings 276 Cross wheel diff lock 181 full combination 149 linings 232 lubrication 232 normal run position 149 operation 147 overheated brakes 152 parking brake 148 rear brakes 147 spring brakes manual release 205 system safety and emergency 151 system truck park 151 trailer brake 149 trailer park brake 150 initial charge 149 trailer parking release valve 150 using brake syst...

Page 409: ...es 140 general conditions 195 habits 195 unloaded trailer bobtail 180 with deflated air springs 197 Dual range axle 184 operation 185 starting up 185 low to high 186 high to low 186 Dump valve 69 E Eaton transmissions 131 Shift patterns 119 Economical driving 193 Electronic brake safety system EBSS 154 ABS 154 off road function 156 warning lamp fault codes 154 ATC 154 DTC 155 ESP 156 TRM 156 ACB 1...

Page 410: ...lic power steering 279 Hydrometer readings 256 Hydraulic bottle jack 248 idling 106 idle timer 208 lubrication specifications 216 331 oil pressure gauge 24 oil temperature gauge 105 overspeed 193 shut down 208 Electrical systems 257 batteries 252 battery isolation switch 252 field isolated alternator 252 jump starting 257 Emergency equipment 12 Environmental protection 214 306 Exhaust Aftertreatme...

Page 411: ... 251 operating instructions 249 to raise the load 249 to lower the load 250 20 tonne hydraulic bottle jack 248 storage of the jack 251 Jackknifing prevention 191 Jump starting with booster battery 257 before connecting jumper cables 258 connecting cables 258 disconnecting cables 259 K Keys and locks remote keyless entry 2 remote verification 3 Keypad transmitter 4 programming 4 Kenworth dealer net...

Page 412: ...tion 113 R Radio 94 Rear drive axle 181 alignment 289 cross wheel diff lock 181 general maintenance 286 housing breather vent 288 Meritor rear axle 288 Mirrors 80 Mountain driving 189 Mufflers 293 N New vehicle precautions 13 Noise control system 291 air intake system 291 294 air system silencers 292 engine 291 cooling 291 engine fan shroud 294 exhaust system 292 293 hood insulation blankets 295 i...

Page 413: ...bols xvii restraint belts 99 Safety precautions 215 Seat adjustment 98 Safety restraint system 99 268 belts 99 inspection guidelines 269 lap shoulder 100 seat belt tips 100 sleeper bunk 101 reduced seat belt life 268 Seats 98 adjustment 98 driver s seat with air suspension 98 reclining seats 98 Selective Catalytic Reduction SCR 107 Serial numbers and capacities 302 Service inspection records 343 S...

Page 414: ...pressure 243 inspection 242 matching tyres 246 replacement 246 loading 245 care maintenance 264 cleaning 264 controls 71 filter service and parts 279 oversteer understeer 278 power steering filter 279 Stopping procedures 208 Storage compartment 94 Suspension deflate switch 197 fasteners torque 286 general maintenance 286 lubrication 282 visual inspection 283 Suspension air pressure 197 T Tachomete...

Page 415: ...edure 201 hitch connection 202 hitch installation 203 recovery rigging 204 manual release 205 return to service 200 Vehicle telematics system 96 97 Voltmeter 103 W Warning Alarm 21 check engine 51 stop engine 52 symbols 44 warnings faults 40 description of 49 Warnings cautions notes xvii Warning symbols 44 Warranty questions 310 Weekly operations 17 Welding precautions 260 Bearing adjustment 285 f...

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Page 418: ...ictoria 3153 Kenworth has built an extensive truck dealer network across Australia New Zealand and Papua New Guinea that is renowned for its professionalism and excellence in the heavy duty truck industry For more information contact your local Kenworth Dealer or go to www kenworth com au DRIVER S HANDBOOK ...

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