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Paccar Peterbilt 320, Operator'S Manual

The Paccar Peterbilt 320 Operator's Manual is crucial for anyone operating this powerful vehicle. This comprehensive manual provides in-depth instructions and valuable insights to ensure a smooth and safe experience. Download the manual for free from manualshive.com and unlock a wealth of knowledge to optimize your use of this exceptional product.

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Other Publications

Order either of the two publications shown below through your Peterbilt dealer.
There is a charge for each. Allow four weeks for delivery.

02956A

Custom Maintenance Manual

This manual contains both proprietary and supplier ser-
vice information speci

fi

cally compiled for the compo-

nents on your vehicle.

The material in this manual is the same as that used by
Peterbilt dealers. It includes inspection, maintenance,
overhaul, and troubleshooting procedures.

02956B

Owner’s Custom Parts Book

This book is a complete, unillustrated, computer-gen-
erated list of the parts used to custom-build your Peter-
bilt vehicle. Please provide your Chassis Serial Num-
ber when ordering.

Summary of Contents for Peterbilt 320

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Page 3: ...N 199 PART 11 SUBJECT INDEX 202 Other Publications 206 California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Other chemicals in this vehicle are also known to the State of California to cause cancer birth defects or other reproductive harm Battery posts terminals and relate...

Page 4: ......

Page 5: ...tion if your vehicle is equipped with special equipment or options not discussed in this manual consult your dealer or the manufacturer of the equipment All information contained in this manual is based on the lat est production information available at the time of publica tion Peterbilt Motors Company reserves the right to make changes at any time without notice How To Find What You Want There ar...

Page 6: ...ning service manuals and the proper tools can be dangerous You could be injured or you could make your truck unsafe Do only those tasks you are fully qualified to do Maintenance Manuals If you do decide to do any com plex repair work you ll need the Peterbilt Maintenance manuals Order them from your authorized dealer Please provide your Chassis Serial Number when you order to be sure you get the c...

Page 7: ...urself and your passengers as well as to prevent costly damage to your vehicle We ve used certain sym bols and signal words to indicate what kind of message is going to follow When you see these symbols words you know that you need to pay special attention Please don t ignore any of these signals WARNING When you see this symbol word the message that fol lows is especially vital This signals somet...

Page 8: ...T WARNING Do not drink and drive Your re flexes perceptions and judgment can be af fected by even a small amount of alcohol You could have a serious or even fatal accident if you drive after drinking Please do not drink and drive or ride with a driver who has been drinking WARNING The use of alcohol drugs and cer tain medications will seriously impair percep tion reactions and driving ability Thes...

Page 9: ...ontinued safe and reliable operation depends greatly upon regular vehicle maintenance The vehicle must be operated within the range of its mechanical capa bilities and the limits of its load ratings See the axle and tire load rating information located on the driver s door jamb R 08 07 Y53 6015 5 ...

Page 10: ...b without proper caution is danger ous You could slip and fall possibly suffering a serious injury Keep steps clean Clean any fuel oil or grease off of the steps before en tering the cab Use the steps and grab handles provided and always keep at least three points of contact between your hands and feet and the truck Look where you are going The following pictures show the best way to enter and exi...

Page 11: ... Three points of contact as you step in or out Door Lock and Keys Doors can be locked from the inside by using the lock but ton Close the door then push the button down to lock Doors automatically unlock when you open them from the inside and can be locked from the outside with a key only R 08 07 Y53 6015 7 ...

Page 12: ...deck plate You can slip and fall especially if the surfaces are wet or icy or if you step in oil fuel or grease Keep steps clean Always maintain at least three points of contact between your hands and feet and the steps and deck plate Do not climb onto and off the deck plate use steps and grab handle provided If there is no deck plate or if proper steps and grab handles aren t provided don t climb...

Page 13: ... order to remove debris from above the cab 0001 WARNING Do not climb on the cab roof The cab roof is not a slip resistant surface and is not equipped with handholds A slip and fall could cause serious injury Do not step or stand on the top rung of the ladder This is not a step it is meant to used only as a handhold You could slip or fall and injure yourself if you use it as a step R 08 07 Y53 6015...

Page 14: ... the safety latch is engaged when you or anyone else works under the cab Perform work only when the cab is in the me chanically locked position or in the full tilt po sition When your cab s hydraulic system needs service or repair Have maintenance and repair done only by someone qualified in hydraulic systems Be sure no one tries to bleed the system with the cab raised This will defeat the safety ...

Page 15: ...ve heavy items such as tire chains and tools Remove or stow securely any loose items And shut the doors tightly Straighten the front wheels before tilting the cab or cab tire damage could occur The following cab tilting instructions are labelled and in stalled on the base of the companion seat 1 Park the vehicle on a level surface 2 Apply the parking brake 3 Make sure the shift lever is in Neutral...

Page 16: ...ll release automatically when pump is actuated Pump until the locking bar can be positioned on the anchor mounted below the right hand cab support as shown in the next illustration 02875 Locking Bar in Anchored Position 8 Place the control valve handle in the Lower position and allow the cab to settle down slightly on the locking bar 12 Y53 6015 R 08 07 ...

Page 17: ...876 Handle in Lower Position 02877 Cab in Full Tilt Position Lowering the Cab 1 Place the control valve handle in the Raise position and pump until the locking bar can be removed from the anchor and fastened in its stored position R 08 07 Y53 6015 13 ...

Page 18: ...osition The cab should settle down on the rear mounts 02879 Upper and Lower Rear Cab Mount 3 Allow at least 20 seconds after the cab touches down for the full spring force to develop in the latch hooks in the rear mounts 4 Remove the pump handle and store in the cab 5 Visually inspect the cab latch hooks to ensure they are closed 6 Ensure that the control valve handle is in the Lower position when...

Page 19: ...our Instrument Panel Please remember that each Peterbilt is custom made Your instrument panel may not look exactly like the one in the illustrations on the pages that follow We have tried to describe all the most common features and controls available so your vehicle may not have some of the ones that appear in this section You can pick out the parts that apply to you and read them to be fully inf...

Page 20: ... Reset Switch 9 Headlight Switch 10 Voltmeter 11 Engine Oil Pressure 12 Engine Coolant Temperature 13 Tachometer 14 LED Warning Light Bar 15 Panel Light Knob 16 Speedometer w Message Center SMC 17 Primary Air Pressure 18 Fuel 19 Transmission Oil Temp 20 Secondary Air Pressure 21 Gearshift or Shift Selector 22 Heater Control Panel 23 Cigar Lighter 24 Interaxle Differential Lock 25 Parking Brake Val...

Page 21: ... Lights 8 Headlight Switch 9 Secondary Air Pressure 10 Starter Switch 11 Stop Switch 12 Primary Air Pressure 13 Engine Oil Pressure 14 Safety Chain 15 Brake Pedal 16 Accelerator Pedal Warning Alarms A warning alarm occurs when some condition in the vehicle requires attention A warning alarm cannot be turned off or manually reset Once triggered an alarm will continue to exist until the unacceptable...

Page 22: ...ght NOTE Warning messages from system alarms with an audible alarm can be temporarily overridden by pressing the Reset switch You can then press the Select switch to scroll through other functions but the message will reappear in 60 seconds The audible alarm will always be on Warning messages from system alarms without an audible alarm can be dismissed by pressing the Reset switch To view dismisse...

Page 23: ...ge LED Buzz Deactivation Display H2O TMP Coolant temp is high Engine Water Temperature yes H2OT OK IM CAL System Fault None no None IM CFG System Fault None no None Display Activation Condition Gauge LED Buzz Deactivation Display IM DIAG System Fault None no None IM LIN System Fault None no None IM SLFT System Fault None no None LOW AIR1 Low air pressure in air tank 1 Primary air pressure yes AIR1...

Page 24: ...il temperature is high Main Transmission Oil Temperature yes TRAN OK Steering Column Mounted Controls Turn Signal and Indicator Lights 02882 Turn Signal The turn signal body is mounted on the left side of the steer ing column below the steering wheel At a right hand drive station the turn signal body is mounted on a stub shaft under the dash behind the steering wheel 20 Y53 6015 R 08 07 ...

Page 25: ...n the side of the road day or night A hard to see vehicle can result in an injury accident An other vehicle could run into you if you do not set your flashers Always move the vehicle a safe distance off the road when stalled or stopped for repairs Of course in normal stopping in traffic such as at a stop light you do not use your flashers WARNING Your disabled vehicle can be dan gerous for you and...

Page 26: ...If your vehicle is a tractor it will be equipped with a trailer brake hand valve This hand valve provides air pressure to apply the trailer brakes only It operates independently of the foot treadle valve To operate the trailer brake hand valve Pull down on the lever on the right side of the steering column below the steering wheel 22 Y53 6015 R 08 07 ...

Page 27: ...quently instead of using the foot brake will wear out the trailer brake sooner See Parking Brakes and Their Use for more complete information on when and how to use your trailer brake Or see the Index under Brake Electric Horn Your vehicle has an electric horn To sound the horn press on the button in the center of the steering wheel At a right hand stand up drive station the horn button is located...

Page 28: ... In this position to the left of center you can play the radio or use other accessories but your engine won t start ON In this position to the right of center all circuits except the cranking circuit are energized The warn ing light bar and the multiplex instrument system will begin its start up self test procedure In this switch position the key cannot be removed START When the key is turned and ...

Page 29: ... drive station Stop Button 02888 Pushing this button at the right hand drive station stops the engine Manual Override for Engine Shutdown 03020 On vehicles with an engine shutdown you will have to hold the manual throw switch in the UP position until normal engine pressures are reached If you have one of these systems a label on the control panel will say so For detailed starting procedures see th...

Page 30: ...ytime running lights DRL the high beam headlamps go on auto matically at reduced brightness if the engine is run ning and the headlamp switch is turned off The daytime running lights are turned off automatically while the parking brake is engaged If the headlamp switch is turned on the DRL system is overridden headlamps operate normally Panel Light Knob 02891 The Panel Light Knob lets you vary the...

Page 31: ...wn above Fog Driving Lights Switch 03021 If your vehicle has fog lights turn them ON or OFF with the control panel switch shown above NOTE State requirements vary as to when high beams and fog lights can and cannot be used to gether Further some states allow only four lights to be used together some allow more Whether you have dual or composite lights will affect how many lights you can have on at...

Page 32: ...ated the speed of the wiper increases To turn off the wiper rotate the knob counterclockwise Washer To use the washer push the button on the control panel showing this symbol 02896 WARNING Do not drive with worn or dirty wiper blades They can reduce visibility making driv ing hazardous Clean blades regularly to re move road film and wax build up Use an alco hol based cleaning solution and a lint f...

Page 33: ... this feature is to allow you to lower your tractor to get under a trailer You will notice a guard over the switch This prevents you from accidentally deflating the suspension WARNING Operating the Air Suspension De flate Switch Dump Valve while driving can lead to an accident Sudden deflation while your ve hicle is moving can affect handling and control Use this switch only when your vehicle is n...

Page 34: ... Anyone near the engine fan when it turns on could be badly injured If it is set at ON it will turn on any time the ignition key switch is turned to the ON position In AUTO MATIC it could engage suddenly without warn ing Before turning on the ignition or switching from AUTOMATIC to ON be sure no one is near the fan CAUTION The fan or equipment near it could be damaged if the fan turns on suddenly ...

Page 35: ...cident if you are too close to another vehi cle or other object Keep plenty of space be tween your vehicle and others when you turn or change lanes Remember that other objects are closer than they may appear NOTE The Power Mirror Switch does not control the adjustment of the convex mirrors Mirror Heat Switch 03022 Mirror heat is controlled by the control panel switch shown above If the vehicle is ...

Page 36: ... control when operating on road surfaces with poor traction wet icy or snow covered roads or in heavy traffic Accelerations caused by the nor mal operation of the cruise control could cause you to lose control of the vehicle resulting in an injury accident NOTE Cruise control functions and features may vary depending upon which engine you have For specific explanation of your cruise control see th...

Page 37: ...ond two mode switch is incorporated in the instrument panel With this system you can select either LOW or HIGH retarding For more information on when and how to use the engine brake in your vehicle see the owner s manual for the en gine brake that is included with your vehicle WARNING Using the engine brake when oper ating on surfaces with poor traction such as wet or icy slippery roads or gravel ...

Page 38: ... rear axle you can select the axle range by the dash mounted switch shown above The low range provides maximum torque for operating off highway The high range is a faster ratio for highway speeds There is a guard over this switch to prevent you from accidentally changing speeds For information on how to operate your two speed rear axle properly and safely see PART 7 STARTING OPERAT ING THE VEHICLE...

Page 39: ...an cause a serious accident Your load could shift suddenly causing you to lose control of the ve hicle Never operate the vehicle with the switch in the unlock position Always inspect the fifth wheel after you lock the switch to be sure the fifth wheel is engaged Parking Brake Valve and Trailer Air Supply Valve 02908 Single Valve Your parking brake valve is a yellow diamond shaped knob located on t...

Page 40: ... in both the yellow and the red knobs For full information on parking brakes see the Index under Brake WARNING Stopping with the parking brake controls can cause a sudden wheel lock up loss of control or can cause you to be over taken by following vehicles You could be severely injured Never pull out the parking brake valve while the vehicle is moving Heating And Air Conditioning Controls WARNING ...

Page 41: ...proper operation of the vehi cle ventilation system keep the inlet grille at the base of the windshield clear of snow ice leaves and other obstructions at all times NOTE Do not stay in the vehicle with the engine running or idling for more than 10 minutes with the vehicle s Heater AC ventilation system in RECIRC or at LOW FAN SPEED Even with the ventilation system On running the engine while parke...

Page 42: ...of the blowers The system s controls are mounted in the header in front of the driver They include the following see illustration below A rotary knob to operate the modulating water valve for air temperature control located in the heater con trol head A rotary switch to select blower speed located in the heater control head 02981A Next to the rotary knobs two switches are available for the followi...

Page 43: ...s If the en gine is already warm move the temperature se lector to Cool then gradually increase the tem perature when you see that the windshield is starting to warm up CAUTION A cold compressor can cause refrigerant to liquefy and warp the valve plates or cause a hydraulic lock Warm the engine before start ing the air conditioner To avoid damage to the compressor blower motors turn off all contro...

Page 44: ...blower are located in side the heater unit under the passenger dashboard Con trols for this system are located in a modified heater control head 02981A To cool the cab turn on the air conditioning system then adjust the air temperature and blower speed until comfort able The amount of cooling is controlled by the temperature of the evaporator core the speed of the blower that forces air through th...

Page 45: ...e air conditioner isn t in regular use operate it for at least 15 minutes once a month This will lubricate the seals in the system For More Efficient Heating and Cooling For immediate heating of a cold cab operate the heat ing system with the Fresh Recirc switch in the Re circ position Switch to the Fresh position when the cab has reached a comfortable temperature For immediate cooling of a hot ca...

Page 46: ...ll warnings and instruc tions in the operator s manual for the appliance you are using The lighter receptacle may be used to power auxiliary equipment that does not draw more than 20 amperes maximum Gauges And Displays On the pages that follow you will find descriptions of some of the gauges on your instrument panel For more informa tion about using them in driving see PART 7 STARTING OPERATING TH...

Page 47: ...e displayed sepa rately on the instrument panel They are described further in PART 7 STARTING OPERATING THE VEHICLE of this manual Speedometer Message Center SMC 11243 The speedometer message center SMC is a combination of a speedometer and a message center The speedome ter indicates your vehicle s speed in both miles and kilome ters per hour The message center contains a 7 charac ter segmented LC...

Page 48: ...34A or P The clock alarm reads in hours minutes with A M or P M indicated as shown e g AL12 34A or P To set or reset a function follow the procedures below NOTE Neither the odometer nor the hourmeter can be reset 1 Turn the ignition switch to ON 2 Choose the desired function 3 Set or reset the function Trip Odometers Press and hold the Reset switch until the mileage is reset to zero this will take...

Page 49: ... the minutes digits will stop flashing The alarm is now set and activated the symbol will show in the clock display to indicate this To turn the alarm OFF or ON press hold the Select switch for 3 seconds while viewing any display To deactivate the buzzer when the alarm sounds press release the Select switch Note The alarm will automatically deactivate after 60 seconds NOTE When the ignition is OFF...

Page 50: ... let you match driving speed and gear selection to the operating range of your engine If your engine speed gets too high you can select a higher gear to lower the RPM If your engine speed drops too low you can select a lower gear to raise the RPM Air Application Gauge 11458 This gauge will show you how much air pressure is being applied from your foot brake valve or trailer brake hand valve 46 Y53...

Page 51: ...ndary Air Pressure Gauges Air Reservoir These air pressure gauges indicate the amount of air pres sure in the brake system in pounds per square inch psi The primary gauge shows the front reservoir air pressure 11465 The secondary gauge indicates pressure in the rear reser voir 11464 R 08 07 Y53 6015 47 ...

Page 52: ...be overtaken by following ve hicles You could be in an accident and severely injured If these alarms come on while you are driving bring your vehicle to a safe stop right away If the light and alarm do not turn off at start up do not try to drive the vehicle until the problem is found and fixed Engine Oil Pressure Gauge 11241A It is important to maintain oil pressure within acceptable limits Your ...

Page 53: ... the oil level Add oil if necessary If the problem persists contact an authorized service cen ter Check the engine manufacturer s manual for the correct oil pressure ranges for your engine Water Temperature Gauge 11242A The water temperature gauge shows the temperature of the engine coolant Under normal operating conditions the water temperature gauge should register between 165 205 F 74 and 90 C ...

Page 54: ...p care fully and slowly turn the cap part way to allow excess pres sure to escape Then push down and turn for final removal The cooling system may overheat if the coolant level is below normal or if there is a sudden loss of coolant such as a worn hose splitting It may also temporarily overheat during severe operating conditions such as climbing a long hill on a hot day or stopping after high spee...

Page 55: ...xplosion or fire resulting in injury or death The fuel gauge shows the approximate amount of fuel in the fuel tanks You will want to keep your fuel tanks at least half full to reduce condensation of moisture in the tanks This moisture can damage your engine WARNING Carrying additional fuel containers in your vehicle is dangerous Full or empty they may leak explode and cause or feed a fire Don t ca...

Page 56: ... in your transmission Watch this gauge to know when your transmission is overheating If it is have it checked by an authorized service representative Maxi mum transmission temperature may vary depending upon the transmission and type of lubricant It is typically 250 F 121 C check your transmission s owner s manual Front Drive Axle or Rear Drive Axle Temperature Gauge 11425 52 Y53 6015 R 08 07 ...

Page 57: ...ind of load you are carrying and the driving conditions you encounter Maximum axle temperature may vary de pending upon the axle and type of lubricant Very high tem peratures signal a need to have your axle s lubrication checked Manifold Pressure Gauge 11453 1 Your manifold pressure gauge indicates the power your en gine is putting out by showing the amount of turbo boost If the pressure indicated...

Page 58: ...2V during en gine cranking If voltage drops below 12V and stays there have the electrical system checked Air Filter Restriction Indicator Gauge 11495 This gauge indicates the condition of the engine air cleaner and is measured by inches of water H2O A clean filter should register 7 H2O may vary with system design a filter whose life is over will register approximately 20 H2O for Cummins engines or...

Page 59: ...ignore a warning signal Have the appropriate system checked right away The warning lights and buzzer may indicate something is wrong with one of the vital systems on your vehicle Check the lights frequently and respond properly as soon as you see one go on see ABS Warning Lamps These lights could save you from a serious accident 07802 Warning Light Bar When you turn on your ignition the warning li...

Page 60: ... of space be tween your vehicle and others when you turn or change lanes Remember that other objects are closer than they seem Your vehicle is equipped with outside mirrors to enable you to see to the sides and behind your vehicle Be sure they are adjusted properly before you drive off You will have the best field of view to the side if you adjust each mirror so you can just see the side of your v...

Page 61: ...pped Af ter adjusting the seat and before driving off ensure that the seat is firmly latched in posi tion Seat Belts And Their Proper Use Seat or safety belts have proven to be the single most effective means available for reducing the risk of serious injury and death in motor vehicle accidents It s not just an opinion it s a fact Seat belts save lives WARNING Do not drive vehicle without your sea...

Page 62: ...nd pull the belt in a continuous slow motion across your chest and lap 2 Insert the belt tongue into the buckle on the inboard side of the seat 3 Push down until the tongue locks securely with an au dible click Pull on the belt to check for proper fasten ing Pull the shoulder section to make sure the belt fits snugly across the chest The shoulder belt must be positioned over the shoulder it must n...

Page 63: ...elt should be worn as low and tight on the hips as possible Make sure any slack is taken up by the belt mechanism The shoulder belt should fit snugly across your body It should be positioned midway over the shoulder nearer to the door it should never rest against your neck It you put the belt under your arm it can t protect you properly Be sure also that your belt is not too loose A loose belt cou...

Page 64: ...ed too high In a crash it would ap ply force to your abdomen not your pelvic bones This can result in serious internal in juries Do not drive with your seat belt loose A seat belt that is too loose can allow you to fall too far forward possibly causing head and neck injuries You could strike the wheel or the windshield Adjust your belt so that there is no more than 1 in 25mm of slack 60 Y53 6015 R...

Page 65: ...to wear it without twisting it have your dealer or service per son repair it as soon as possible Komfort Lok Feature Your Peterbilt contains a feature designed to eliminate cinching and provide improved safety and comfort Cinch ing is the condition where a belt becomes continually tighter around you during a rough bouncy ride The need for this feature increases with rough road conditions particula...

Page 66: ...ase the latch then just push the button on the buckle Pregnant Women Sometimes pregnant women worry that in a crash the seat belt could hurt the baby But if a woman wears her belt properly low over her pelvis below her abdomen the belt won t harm the baby even in a crash And remember the best way to keep an unborn baby safe is to keep the mother safe PREGNT Pregnant Woman With Belt Properly Worn 6...

Page 67: ...Don t modify or disassemble the seat belts in your ve hicle They won t be available to keep you and your passengers safe Never bleach or dye seat belts chemicals can weaken them Do however keep them clean by following the care label on the belts Let them dry completely before allowing them to retract If any seat belt is not working properly see an autho rized Peterbilt dealer for repair or replace...

Page 68: ...riding in a vehicle ensure that there is adequate head clearance at max imum upward travel of seat Serious injury may occur if head clearance is not adequate Shorten the tether belt as necessary to pro vide adequate head clearance sk28514_Page_1 Illustration of a Tether Make sure the tether belt is attached to the cab deck and seat frame It should be routed through the buckle on each side To lengt...

Page 69: ...s off the belt In trucks however there is almost constant movement of the belt through hardware due to ride characteristics and seats which are designed to move in order to enhance driver comfort There can even be movement of the webbing in the seat belt system when the belt in not being used Relative movement between the seat and the cab which nor mally occurs whenever the truck is in operation c...

Page 70: ...ement of the belt actually means the webbing is experiencing wear as it travels in and out of the retractor through the pillar loop web guide and through the various pieces of hardware associated with the belt The following guidelines detail how to inspect for cuts fraying extreme or unusual wear of the webbing etc and damage to the buckle retractor hardware or other factors which indicate that be...

Page 71: ... also be inspected for web wear just as with the seat belt systems 7 Mounting hardware should be evaluated for corrosion and for tightness of bolts and nuts 8 Check web in areas exposed to ultraviolet rays from the sun If the color of the web in these areas is gray to light brown the physical strength of this web may have deteriorated due to exposure to the sun s ultraviolet rays replace the syste...

Page 72: ... seat belt has been determined be certain that it is only replaced with the rec ommended replacement seat belt The occupant restraint system has been developed and tested specifically for this vehicle If the vehicle was originally equipped with a lap belt it cannot be replaced with a three point shoulder har ness system because the cab mounting points are not structurally designed for a three poin...

Page 73: ...nd accessories are in work ing order You aren t expected to become a professional mechanic The purpose of your inspections is to find anything that might interfere with the safe and efficient transportation of yourself and your load If you do find something wrong and can t fix it yourself please have a qualified mechanic fix it right away For your safety as well as those around you be a respon sib...

Page 74: ...nce and condition Are win dows mirrors and lights clean and unobstructed 2 Check beneath the vehicle Are there signs of fuel oil or water leaks 3 Check for damaged loose or missing parts Are there parts showing signs of excessive wear or lack of lubri cation Have a qualified mechanic examine any ques tionable items and repair them without delay Checking Under the Hood or Cab With the engine stoppe...

Page 75: ...wheel bearing lube level 4 Check parking spring brakes as to the condition and tightness of air lines breathers clamp rings bolts mounting studs and release bolts 5 Check turn signal operation 6 Check emergency flashers and exterior lamps 7 Check the fuel tanks Is there enough fuel Are the tank caps secure 8 Visually inspect the fuel tank mounting hardware Are the tank straps tight Is the webbing ...

Page 76: ...points of contact as you enter or exit a cab See PART 2 CAB AND FRAME ACCESS of this manual for more information 1 Adjust the seats 2 Fasten and adjust safety restraint belts See PART 5 SEAT AND RESTRAINT SYSTEMS or the Index under Restraint Systems 3 Safety Restraints Check and inspect condition See PART 5 SEAT AND RESTRAINT SYSTEMS or the Index under Restraint Systems 4 Check mirror adjustment 5...

Page 77: ...t your main transmission in Neutral 3 Disengage depress the clutch with manual transmis sion 4 Turn the key switch to ON The vehicle s system will conduct a test of all gauges and warning lights NOTE If the instrument panel displays other messages or if other alarms activate after the key is turned ON see the Instruments and Con trols section to understand what you should do CAUTION Never operate ...

Page 78: ...em operations service manual for more information 7 Slowly engage release the clutch after the engine has started 8 Wait until normal engine oil pressure registers on the gauge before idling or accelerating the engine beyond 1000 RPM Cold Temperature Starting Procedure In cold weather fast engine starting helps relieve the loads on the electrical system and cranking motor Using the special cold st...

Page 79: ...r ature reaches at least 130 F 54 C At this tempera ture you can use partial throttle Wait until the coolant temperature is at least 160 F 71 C before operating at full throttle WARNING Exhaust fumes from the engine con tain carbon monoxide a colorless and odorless gas Do not breathe the engine exhaust gas A poorly maintained damaged or corroded ex haust system can allow carbon monoxide to en ter ...

Page 80: ...ehicle with the engine run ning or idling for more than 10 minutes with the vehicle s Heater and A C ventilation system in RECIRC or at LOW FAN SPEED Even with the ventilation system On running the engine while parked or stopped for prolonged periods of time is not recommended If other vehicles are parked next to you idling move your vehicle or do not stay in your vehicle for prolonged periods of ...

Page 81: ... the clutch pedal If you have a two transmission combination Put the main transmission in gear Put the auxiliary transmission in Neutral This will allow the transmission countershaft to turn agitating the oil and warming it Idling the Engine Under most circumstances idling your engine for long pe riods merely wastes fuel In severe arctic weather condi tions however you may need longer idling to be...

Page 82: ... a sudden stop or even going over a bump in the road they could fly through the air and strike you or a passen ger You could be injured or even killed Secure all loose objects in the cab before moving the vehicle Shifting The Transmission You will find a shift pattern either on a decal in your cab or on a medallion in the shift knob Check to be sure you know the correct sequence for your particula...

Page 83: ...se stroke the part that fully releases the clutch The last 1 2 to 1 inch engages the clutch brake If your vehicle is new watch the free travel in your clutch carefully for the first few hundred miles As your clutch lining wears and high spots get worn smooth you will get less free travel Always start out in a low gear with a ceramic faced clutch Starting in higher gears even with a light load will...

Page 84: ...the vehicle is moving The purpose of the clutch brake is to stop the transmission so that you can shift into a starting gear with out grinding Applying the clutch brake when the vehicle is moving causes a braking effect on the entire vehicle This wear naturally short ens the service life of your clutch brake Double Clutching Whether you are upshifting or down shifting it is best to double clutch D...

Page 85: ...stress on the rear axles and tires and provides better performance When operat ing normally on paved dry surfaces keep your truck s in teraxle differential in the UNLOCK position 0004 Switch In Unlock Position In the LOCK position continuous operation on a paved dry surface stresses the tandem axles possibly causing internal damage to them Shift into the LOCK position to operate on slippery sur fa...

Page 86: ... at speeds above 25 mph 40 km h When it is engaged under these con ditions your vehicle will exhibit understeer handling characteristics This understeer condition will cause your vehicle to not turn as quickly and more steering effort will be re quired which can cause an injury accident To reduce load on the drive train ease up on the throttle pedal whenever you shift into LOCK or UNLOCK Dual Rang...

Page 87: ...tial is UNLOCKED B Keep the accelerator down and move the Range Selector lever to HIGH C Keep driving with the accelerator down until you want the axle to shift D Then release the accelerator until the axle has shifted E You are now in the HIGH axle range on the high way Shift the transmission normally to reach your desired cruising speed 5 If you need to downshift the axle for more power A Keep t...

Page 88: ...UTION If you shift the axle range with the interaxle differential in LOCK you could do serious damage to your axles Never shift the axle range with the differential locked Park the truck with the Range Selector in LOW Automatic and Automated Transmissions An automatic or automated transmission makes shifting much easier It remains important to completely under stand how to operate the transmission...

Page 89: ...n auxiliary transmission see your transmis sion manufacturer s manual for its proper operation If Your Vehicle Must Be Towed Follow these directions to ensure your vehicle is not dam aged when towing is required 1 Lift driving wheels off the ground or remove the drive line and axle shafts before towing the vehicle CAUTION Failure to lift the driving wheels off the ground or remove the driveline an...

Page 90: ...les with driver controlled main differential lock install the caging bolt before removing the axle shafts for towing A Remove the air line and firmly cap 0007 Illustration of Driver Controlled Main Differential Lock B Remove the caging bolt from its storage hole C Screw the caging bolt into the air line hole When fully engaged a 0 25 0 5 in 6 1 2 mm space will remain between the air cylinder and t...

Page 91: ...recovered vehi cle s brakes ensure that the vehicles air system is connected to that of the recovery vehicle Also ensure that any air line that has been removed from a driver controlled main differential lock is firmly capped to prevent loss of air pressure from the recovery vehicle If you don t desire to use the recov ered vehicle s brakes ensure that you cage the spring brakes before attempting ...

Page 92: ...heel is about to lock during braking the ABS will automatically adjust air pressure to the brake chambers on the appropriate wheel s to prevent wheel lock up The ABS is automatically turned on when the ignition switch is turned on WARNING The brake system is a critical vehicle safety system For the safety of you and others around you have the vehicle submitted for periodic preventive maintenance c...

Page 93: ...nd will remain on until the sys tem self test has been completed successfully Normally this ABS lamp will remain on until a speed of no more than 9 mph has been reached and the speed sensors have been checked for correct output The lamp should remain off af ter this point unless a failure in the system is detected The truck tractor ABS lamp is located in the warning lamp clus ter see Warning Light...

Page 94: ...atisfactory the lamp will next do either of the following 1 If no trailer is connected or if a non ABS equipped trailer is connected the trailer ABS lamp will go off after one second NOTE A properly connected ABS equipped trailer is a trailer with PLC hooked up to the J560 connector a trailer without PLC that is hooked up to an optional ISO 3731 connector For doubles or triples PLC does not distin...

Page 95: ... tected and the ASR or ATC system is applying the drive wheel brakes or reducing engine torque Do not allow the Wheel Spin Control lamp to remain on continuously for an extended length of time Extended continuous use of the ASR ATC can cause overheating of the drive wheel brakes Engine torque or vehicle speed should be reduced to eliminate wheel spin and prevent excessive application of the ASR AT...

Page 96: ...pplication pressure to provide maximum braking force without locking the wheels Use engine compression to assist the service brakes i e don t depress the clutch pedal until the engine reaches idle speed WARNING Do not operate the vehicle in the event of a malfunction in any air circuit The vehicle should not be operated until the system is repaired and both braking circuits including all pneumatic...

Page 97: ... springs and releases the brakes But putting the valve in the Park position exhausts air from the chambers and allows the springs to extend and apply the brakes Also if your system air drops below the safe operating level the spring brakes will apply automatically bringing your vehicle to a stop 02909 Red Yellow Controls WARNING On trailers built before March 1975 you may not have parking brakes i...

Page 98: ...es prior to moving the vehicle Failure to disengage the parking brakes prior to mov ing your vehicle could result in excessive heat build up in the brake system resulting in a fire NOTE Today s diesel electronic engines have sig nificant torque and startability power at low RPM Combinations of engine speed and available torque may over power the vehicle s parking brakes To apply all your parking b...

Page 99: ...r air system pres sure When operating the tractor bobtail The red knob must remain out to protect the tractor air system pressure Manually Releasing Spring Brakes There may be an occasion when you need to tow the vehi cle but the air system does not produce enough operating pressure to release the parking brakes For these situa tions the spring brakes may be manually released to allow the vehicle ...

Page 100: ...release stud assembly from the side pocket and remove the release nut and washer from the release stud 01896 3 Slide out the release stud 01897 4 Insert the release stud through the opening in the spring chamber where the cap was removed Insert it into the pressure plate Turn the release stud 1 4 turn clockwise in the pressure plate This secures the cross pin into the cross pin area of the pressur...

Page 101: ...us and could cause serious injury These chambers contain a powerful spring that is compressed Sudden release of this spring could cause you to be badly injured Do not disassemble a spring brake chamber Retarders Various retarders are available which function against the engine driveline or transmission These are devices that use your engine s power to slow down your vehicle They save wear and tear...

Page 102: ...ou could lose control of the vehicle if the wheels begin to skid resulting in an accident Driving Bobtail or with an Unloaded Trailer We recommend that you do not use your engine retarder to slow down when you are bobtailing or pulling an empty trailer WARNING Using an engine retarder can cause a wheel lockup The trailer is not loading the tires enough to give the traction you may need When you ar...

Page 103: ...pped fill your tanks to 95 of capacity Final Stop To make sure your vehicle is ready to go after a long stop such as over night please follow the suggestions below Your vehicle will be easier to get going when you are ready and it will be safer for anyone who might be around it Please remember too that in some states it is illegal to leave the engine running and the vehicle unattended Final Stoppi...

Page 104: ...e sure to close the drains before leaving the vehicle 02939 Opening Drains 4 Secure the vehicle Close all the windows and lock all the doors Setting Ride Height Vehicles equipped with rear air suspensions have their ride height and axle pinion angle s preset at the factory These are precision settings and should not be altered Incorrectly adjusted ride height may result in improper interaxle U joi...

Page 105: ...f 6 50 165 8 50 216 Low Low Air Leaf N A 6 50 165 FLEX Air N A 8 50 216 These values are for a fully laden vehicle Follow this procedure to temporarily set ride height WARNING To prevent possible injury and dam age to property ensure that a vehicle is parked and the wheels chocked before beginning this procedure CAUTION Completing this procedure will en able you to safely reach the nearest authori...

Page 106: ... Height Control Valve Rear View Looking Forward At least one of the mounting holes in the height con trol valve bracket will be slotted to permit rotating the valve On dual valve systems begin with the LH valve on the next step 2 Loosen the fasteners mounting a height control valve to its bracket 102 Y53 6015 R 08 07 ...

Page 107: ...t from the bottom of the frame rail to the approx imate centerline of the rearmost drive axle hub For tandem axles make the vertical measurement at the centerline of the suspension see illustration in Setting Ride Height For a single axle make the measurement in front of the axle in the area forward of the tires but not past the suspension bracket 4 When at the correct ride height ensure that the ...

Page 108: ... up to normal pres sure for continued operation WARNING Low air pressure could make the brakes unsafe for driving Before driving the vehicle make sure the pressure does pump up to over 100 psi for normal brake operation If the air pressure does not pump up to at least 100 psi don t try to move the vehicle CAUTION Operating a vehicle with air suspen sion bags either overinflated or underinflated ma...

Page 109: ...e system Coasting with the transmission in neutral also prevents proper transmission component lubrication During coast ing the transmission is driven by the rear wheels and the countershaft gear which lubricates the transmission com ponents by oil splash will only be turning at idle speed Descending a Grade WARNING Do not hold the brake pedal down too long or too often while going down a steep or...

Page 110: ...ond the maximum gov erned speed indicating an overspeed condition apply the service brake or shift to a higher gear to bring en gine rpm within the optimum speed range When driving downhill shift to a lower gear use the engine brake if so equipped and use the service brake keeping the engine speed below 2 100 rpm When the engine speed reaches its maximum governed speed the injection pump governor ...

Page 111: ...on shift selector lever either forward or rearward then hold it in the extreme for ward rearward position until the shift is complete A completed shift is signalled by the illumination of the indicator light for a selected range 4 Upon reaching the desired transmission range re lease the foot brake pedal and depress the accelerator pedal Switching from Streetside LH to Curbside RH Operation 1 Brin...

Page 112: ...ot brake pedal 2 Push in the parking brake valve knob to release the brake NOTE A shift shock eliminator will not allow a shift from neutral to either a forward or reverse gear when the engine speed is over 900 rpm When shifting between transmission ranges keep the push button depressed until the indicator light for the selected range comes on indicating the shift is complete 3 Press in and hold d...

Page 113: ...active Using The Work Brake WARNING To avoid injury damage never apply the work brake when the vehicle is in motion Do not use the work brake instead of the service brake to stop the vehicle The work brake fully applies the brakes and if used while the vehicle is moving could result in a sudden stop skid or loss of control leading to an accident and possible serious personal injury 1 Apply the wor...

Page 114: ...unsafe Do only those maintenance items you are fully trained and equipped to do Before attempting any procedures in the en gine compartment stop the engine and let it cool down Hot components can burn skin on contact Be alert and cautious around the engine at all times while the engine is running If work has to be done with the engine run ning always 1 set the parking brake 2 chock the wheels and ...

Page 115: ...ed Remove the ignition key Never start or let the engine run in an en closed unventilated area Exhaust fumes from the engine contain carbon monoxide a colorless and odorless gas Carbon monox ide can be fatal if inhaled NOTE Suitable wheel chocks are at a minimum an 18 inch 46 cm long 4x4 PREVENTIVE MAINTENANCE PM INTERVALS I A B C D E At the first 15 000 mi 24 000 km or at the first PM 15 000 mi 2...

Page 116: ... logging or earth moving you will need to perform maintenance checks and services more frequently The charts on the following pages show the maintenance intervals for recommended maintenance practices NOTE Engine lubricating oil change intervals aren t listed here Refer to your engine s operating manual for recommendations For specific in formation on maintenance procedures consult your vehicle ma...

Page 117: ...me Crossmembers and Mounting Brackets Inspect for cracks and loose fasteners Replace or tighten to the specified torque value as required see Frame Fastener Torque Specifications X Total Vehicle Alignment Check and adjust as required X X Steering knuckle spindles thrust bearings kingpins drawkeys tie rod ends steering stops bushings Inspect for wear and damage and endplay Shim or replace as requir...

Page 118: ...st bearings tie rod ball ends OFF HIGHWAY AND VOCATIONAL Lubricate with approved grease X Steering knuckle spindles thrust bearings kingpins drawkeys tie rod ends steering stops bushings ON HIGHWAY Inspect for wear and damage and for endplay Shim or replace as required X Front Axle Dana Steering knuckle spindles thrust bearings kingpins drawkeys tie rod ends steering stops bushings OFF HIGHWAY AND...

Page 119: ...mage and damaged or worn bushings Replace as required Check the shock mounting stud torque X Shock Absorbers Check for proper function X U bolts ON HIGHWAY Check the general condition and the tightness of the nuts Tighten the nuts to the specified torque value as required see U Bolt Tension for Front and Rear Axles X X Front Suspension U bolts OFF HIGHWAY Check the general condition and the tightn...

Page 120: ...move the housing cover and drain the lubricant Wash the parts thoroughly and dry in air X Breather Clean or replace X Lube Pump ON HIGHWAY Remove the magnetic strainer and inspect for wear particles Wash in solvent and dry in air X Lube Pump OFF HIGHWAY Remove the magnetic strainer and inspect for wear particles Wash in solvent and dry in air X Lube Filter ON HIGHWAY Change X Lube Filter OFF HIGHW...

Page 121: ...ees Tighten the plug to 35 50 Lb ft 47 68 N m X Visually inspect for damage or leaks X Axle Housing Drain and replace the lubricant See information on Meritor Axle Lubrication Lubricant filter Change the filter X Breather Check the operation If the cap doesn t rotate freely replace X Input shaft pinion shaft Check and adjust the endplay X Axle shaft Tighten the rear axle flange nuts to the specifi...

Page 122: ...X Lube Filter Clean the suction filter for the optional pressure lubrication system X Drive Axle SISU S cam brakes Overhaul the brakes degrease all moving parts check the bushings and seals for wear X U bolts Check the torque Tighten to specified torque value as required see U Bolt Tension for Front and Rear Axles X X Frame crossmember bolts Check the torque Tighten to specified torque value as re...

Page 123: ... the treadle boot and mounting plate Check the pivot and mounting plate for integrity Check the plunger boot for cracks Lubricate roller pin pivot pin and plunger NLGI 2 grease X Brake treadle valve Rebuild through an authorized Peterbilt service facility X Brake air system Check air lines and fittings for leaks see Brake Adjustment Adjust routing as required to reduce chafing Check tank mounting ...

Page 124: ...or scoring of surface Check thickness minimum of 1 46 37 mm X Caliper sliding function Ensure caliper slides freely with no obstructions or excessive play see manufacturer s service literature for Checking Running Clearance X Caliper function Inspect bearings seals tappet and boots of the guide pins for damage or cracking X Disc Brakes Bendix Adjuster Check operation inspect as per manufacturer s ...

Page 125: ...Wheel Bearing Adjustment X LMS Hubs Dana with Synthetic Lubricant Clean the components and check for excessive wear or damage Change the oil and seal see Wheel Bearing Adjustment 500 000 miles 800 000 km LMS Hubs Dana with Mineral Lubricant Clean the components and check for excessive wear or damage Change the oil and seal see Wheel Bearing Adjustment 350 000 miles 560 000 km Brake drums Inspect f...

Page 126: ...ed X Main auxiliary transmission Oil cooler Clean the fins air to oil type and body Check the hose condition and for leaks replace as required X Main aux transmission Check the oil level refill as required X Main auxiliary transmission ON HIGHWAY Drain lubricant while warm Flush each unit with clean flushing oil 500 000 miles 800 000 km Main auxiliary transmission except Freedom line Main auxiliar...

Page 127: ...ct Check oil level inspect for leaks and any visible damage X Initial oil change Drain oil while warm flush case with gear oilcompatible fluid clean magnetic drain plug refill Do not flush the case with any solvent X Fabco Transfer Case TC142 TC143 TC170 TC270 Change oil X Inspect Check oil level inspect for leaks and any visible damage X Initial oil change Drain oil while warm flush case with gea...

Page 128: ...r leaks and proper operation see Cold Temperature Starting Procedure X Air Intake Air cleaner Replace the engine intake air cleaner element see Air Cleaners When required by air restriction indicator Clutch pedal shaft Check for excessive looseness and lubricate NLGI 2 grease X Clutch pedal Check for proper free pedal see Clutch Adjustment X Clutch release linkage Check for excessive looseness and...

Page 129: ...bitor Concentration X Replace blank water filter if applicable X Perform lab analysis see page 152 If lab analysis shows coolant is unsuitable for continued use Flush drain and refill see Refilling Your Radiator Add ELC Extender see ELC Condition Contamination and Inhibitor Concentration X Extended Life Coolant ELC Flush drain and refill with new coolant see Refilling Your Radiator X Fan clutch ho...

Page 130: ...ies Inspect the rim edge and bead seat area for damage Replace any damaged wheels DO NOT ATTEMPT TO REPAIR X Demountable rims Inspect the mounting ring rim gutter side ring and lock ring for damage replace as required X Wheel nuts and studs Check the tightness of the fasteners and tighten the fasteners to the specified torque as required see Wheel Cap Nut Torque X Tires Wheels Wheel nuts and studs...

Page 131: ...X Steering gear Grease the input shaft seal EP NLGI 2 lithium based moly filled HD grease X Power assist cylinder Lubricate the ball joints Inspect for leaking rod seals damaged ball joint boots and damage to cylinder rod or barrel X Hoses and tubes Check for leaks and chafing X Steering linkage Check all joints for excessive lash replace as required see Guidelines For Checking A Steering System X...

Page 132: ...63 C to 23 C range X X Steering intermediate shaft U joints OFF HIGHWAY or CITY DELIVERY Lubricate EP NLGI 2 HD grease 325 F to 10 F 163 C to 23 C range X X Draglink and tie rod arm ball sockets ON HIGHWAY Lubricate EP NLGI 2 lithium based moly filled HD grease X X Power Steering Draglink and tie rod arm ball sockets OFF HIGHWAY or CITY DELIVERY Lubricate EP NLGI 2 lithium based moly filled HD gre...

Page 133: ...eathers Check for proper function clean the drain hoses X Fuel tank straps Check the strap tightness tighten to proper torque value as required Aluminum tank 30 Lb ft 41 N m Cylindrical Steel tank 8 Lb ft 11 N m X X Fuel Tanks Fuel tank steps Check for snug fit of side plates against tank and tank straps Check for damaged or broken steps missing bolts and missing grommet between tank and side plat...

Page 134: ...ricate X X Model SPL 100 slip member U joints Lubricate X Models SPL 140 140HD 170 170HD 250 250HD slip members U joints Lubricate X Models SPL 140XL 170XL 250XL slip members and Ujoints ON HIGHWAY LINE HAUL Lubricate 350 000 miles 560 000 km every 3 years Driveshafts Models SPL 140XL 170XL 250XL slip members and U joints OFF HIGHWAY CITY Lubricate X 130 Y53 6015 R 08 07 ...

Page 135: ...s or excessive wear see Battery Care X Batteries ON HIGHWAY LINE HAUL Check for cracks and damage electrolyte level condition of terminals and tightness of holddowns see Battery Care X Batteries VOCATIONAL SEVERE SERVICE Check for cracks and damage electrolyte level condition of terminals and tightness of holddowns see Battery Care X Battery box and tray ON HIGHWAY LINE HAUL Check the box integrit...

Page 136: ...of the drive belt see Accessory Drive Belts X Alternator Check tightness of the terminal hex nuts X Starter Check torque on hex nuts X ECM connector Check the tightness of the ECM connector X Wheel sensors Check for damaged sensors and connectors and worn or frayed wires X Fuel tank sending unit Check the mounting screws and electrical connections for worn or damaged wires and connectors X X Check...

Page 137: ...and tightness X Tilt pump Check the oil level refill as required X Cab structure doors hoods Cab tilt system Check for hydraulic leaks X Air conditioner Operate the system X Heater air conditioner Perform the checks listed on Cab Heater Air Conditioner X Cab air filter Clean replace after a maximum of three cleanings X Heating Air Conditioning Heater air conditioner Full operational and diagnostic...

Page 138: ...Perform the checks listed on Air System X Air dryer ON HIGHWAY Overhaul 360 000 miles 576 000 km Air Air dryer OFF HIGHWAY Overhaul X Engine Basic Engine Maintenance and service interval recommendations are detailed in the engine manufacturer s Operations and Maintenance Manual included with the vehicle The engine manufacturer s recommendations vary depending engine model Information is also avail...

Page 139: ...g this essential aspect of vehicle care can cost time and money in the long run CAUTION Do not mix different types of lubri cants Mixing lubricants oil and grease of dif ferent brands or types could damage vehicle components therefore drain or remove old lubricants from the unit before refilling it Engine NOTE The engine in this vehicle complies with 2007 EPA emission standards Consult the engine ...

Page 140: ...e must be driven under these con ditions drive only with the windows slightly open Failure to repair the source of the ex haust fumes may lead to personal harm NOTE Keep the engine exhaust system and the vehicle s cab ventilation system properly main tained It is recommended that the vehicle s exhaust system and cab be inspected By a competent technician every 15 000 miles 24 000 km Whenever a cha...

Page 141: ...ricant GL Straight mineral gear lubricant HD Hypoid Gear Oil A P I GL 5 SAE 80W 90 HT High Temperature grease Timken Spec 0 616 Lubricant Symbol Key MP Multipurpose gear lubricant MIL L 2105B MB Wheel Bearing grease Timken Spec 0 610 NOTE The responsibility for meeting these speci fications the quality of the product and its perfor mance in service rests with the lubricant supplier Component Lubri...

Page 142: ...briplate Aero or equivalent Consult manufacturer or lubricant supplier for special details 02942 Fuller Transmission Lubrication Fuller transmissions are designed so that the internal parts operate in a bath of oil circulated by the motion of gears and shafts Grey iron parts have built in channels where needed to help lubricate bearings and shafts All parts will be amply lubricated if these proced...

Page 143: ...ission manual for ser vicing information Refer to the oil change vs temperature chart that fol lows for special oil change information The intermit tent peak temperature is the maximum temperature observed for a short time in a fully loaded vehicle per forming normally 02944 CAUTION Exceeding the recommended oil change intervals may be harmful to the life of the transmission and the transmission o...

Page 144: ... extremely important to use the proper lubricants and maintain the correct oil levels in Spicer units This will en sure proper lubrication and operating temperatures in these units Recommended Lubricants The lubricants listed below are recommended in order of preference for use in all Spicer mechanical transmissions auxiliaries and transfer cases Do not use extreme pres sure additives such as thos...

Page 145: ...which could decrease the effectiveness of the lubrication or cause com ponent failure An initial oil change and flush should be performed after the transmission has been placed in actual service This change should be made any time after 3000 miles 4800 km but never longer than 5000 miles 8000 km of over the road service In off highway use the change should be made after 24 hours but before 100 hou...

Page 146: ...pt from an initial lubricant change AVAILABLE ADVANCED LUBE AXLES RS 17 145 RS 23 180 RT 40 145 RT 44 145P AVAILABLE ADVANCED LUBE AXLES RS 19 145 RS 26 180 RT 40 145P RT 46 160 RS 21 145 RS 30 180 SQ 100A RT 46 160P RS 23 160 RT 34 145 SQ 100AP RT 52 160 RS 23 161 RT 34 145P RT 44 145 RT 52 160P Meritor rear axles that do not appear on the list above will continue to require an initial drain at 3...

Page 147: ...se it flushes out break in contaminants that might otherwise cause premature wear No initial drain is required on Eaton axles that are fac tory filled with an Eaton approved synthetic lubricant Mineral based lubes must be drained within the first 5000 miles 8000 km if converting to an Eaton ap proved synthetic lube Change the lubricant within the first 5000 miles 8000 km of operation after a carri...

Page 148: ...d filler plug when done Allow time for the oil to seep through the bearings when initially filling a hub Maintain the differential oil level by adding oil until its surface is even with the bottom of the filler hole see Master Lubrication Index Oil lubricated Nondriven Hubs Use CD50 synthetic transmission fluid SAE 50W or equiva lent A minimum of 9 oz 270 ml of lubricant is required for proper lub...

Page 149: ...ditives If incompatible insoluble fluids are mixed in a power steering system air bubbles can be produced at the inter face of the two fluids This can cause cavitation which reduces the lubrication between moving parts in the gear This could result in worn components The mixture of two different fluids al though harmless to individual internal components may initiate a chemical reaction that produ...

Page 150: ...anics are trained in the proper technical and safety procedures to fix your Peterbilt vehicle right WARNING It is dangerous to work on a vehicle without the right know how and proper tools You could be badly injured and you could dam age the vehicle Do only work you know you are fully capable of doing and for which you have the right tools Brake Adjustment WARNING To prevent uncontrolled vehicle m...

Page 151: ...iginal specifications can affect the whole system All of the fol lowing areas are interrelated and must conform to original specifications Tire Size Drum brakes A Cam Radius B Wedge Angle C Drum Radius D Brake Linings E Brake Chambers F Slack Adjusters WARNING A nonconforming part in your brake system could cause an accident Sizes and types are so related to one another that a seem ingly unimporta...

Page 152: ...rol units To perform a leakage test refer to the detailed instructions in the Peterbilt Maintenance Man ual or take your vehicle to an authorized Peterbilt dealer Drum Brakes Have brake drum linings and disc brake pads inspected by a qualified mechanic for wear at regular intervals according to the maintenance schedule In severe service or offhigh way applications inspect the linings more frequent...

Page 153: ...th the slack adjuster or the brake foundation Tires Wheels And Rims Tires WARNING You can be badly injured trying to fix tires Don t mount or dismount a tire yourself have any wheel service performed by an expert And stand away from the tire assembly while the expert is working Your tires are a very important part of your vehicle s whole braking system How fast you can stop depends in large measur...

Page 154: ... actually reduces traction steering control and tire load capacity Underinflated Tires Low pressure is a tire s worst enemy Underinflation allows tires to flex improperly causing high temperatures to build up Heat causes early tire damage such as flex break ra dial cracks and ply separation Low pressure may affect control of your vehicle especially at the front wheels Most tire wear problems are c...

Page 155: ...y could fail and cause you to lose control of your vehicle Be sure all tires are inflated correctly according to the manufacturer s recommendations The chart on Tire Load and Inflation Tables gives you the right load and inflation rates for different tire sizes Please follow it for the safest and most economical use of your tires Consult the tire manufacturer for proper pressure settings with tire...

Page 156: ...type of tires Regrooved tires or tires with reinforcement repairs can be dangerous on steering axles They could cause you to lose control of your vehicle Do not install regrooved or rein forcement repaired tires on your steering axles Replacing Tires Front Replace front tires when less than 4 32 in of tread remains Check at three places equally spaced around the tire Drive Axles or Trailers Replac...

Page 157: ...of each driving axle CAUTION Chains on the tires of only one tan dem axle can damage the driveline U joints and the interaxle differential Your repairs could be costly time consuming Speed Restricted Tires WARNING This vehicle may be equipped with speed restricted tires Check each tire s side wall for maximum rated speed Vehicle should not be operated at sustained speed in excess of maximum rated ...

Page 158: ...1R24 5 H 4820 5070 5310 5550 5840 6095 6350 6610 6790 6970 7160 275 70R22 5 H 4850 5050 5250 5480 5705 5945 6195 6450 6720 7000 295 75R22 5 G 4500 4725 4940 5155 5370 5510 5780 5980 6175 285 75R24 5 G 4545 4770 4940 5210 5420 5675 5835 6040 6175 DUAL RADIAL TIRES FOR VEHICLES IN HIGHWAY SERVICE 11R22 5 G 4380 4580 4760 4950 5205 5415 5625 5840 11R22 5 H 4380 4580 4760 4950 5205 5415 5625 5840 5895...

Page 159: ... 5005 5210 5430 5660 5890 6135 295 75R22 5 G 4095 4300 4540 4690 4885 5070 5260 5440 5675 285 75R24 5 G 4135 4340 4540 4740 4930 5205 5310 5495 5675 NOTES 1 Pressure listed is the minimum for the load 2 All tire load figures are in pounds 3 Figures in Bold faceindicate maximum recommended load Source Bridgestone Tire 2 02 R 08 07 Y53 6015 155 ...

Page 160: ...TIRES FOR VEHICLES IN HIGHWAY SERVICE Tire Load Limits At Various Cold Inflation Pressures psi Tire Size Load Range 80 85 90 95 100 105 110 115 120 125 130 L 5675 5840 6070 6395 6545 6770 6940 7210 7610 7850 8255 315 80R22 5 Except R296 J 5675 5840 6070 6395 6545 6770 6940 7210 7610 L 5675 5840 6070 6395 6545 6770 6940 7210 7610 7850 9090 315 80R22 5 for R296 J 5675 5840 6070 6395 6545 6770 6940 7...

Page 161: ... 7590 7990 8270 8740 9100 9370 9790 10100 10500 445 50R22 5 L 7370 7740 8100 8460 8820 9170 9515 9860 10200 445 65R19 5 J 7540 7930 8270 8680 9040 9370 9730 10100 10500 445 65R22 5 L 8230 8660 9090 9480 9870 10200 10600 11000 11400 11700 12300 NOTES 1 Letters in parentheses denote Load Range for which bold face loads and inflations are maximum 2 International Load Index numbers are shown after Loa...

Page 162: ...in standout Right hand and left hand threads are required Inner and outer cap nuts center the wheels by seating against wheel ball seats Wheels Pilot mount wheels have stud holes that are reamed straight through no ball seats Center bore diameter is 8 21 32 in Budd Uni Mount 10 wheels have UNI MOUNT stamped on the disc Ball seat wheels have spherical chamfers machined on each stud hole Center bore...

Page 163: ... is a job you may not be able to do yourself You need the right torquing equip ment to do it Wheel Bearing Adjustment For safe reliable operation and adequate service life your wheel bearings must be checked and adjusted properly The person best equipped to do this is your authorized dealer s service mechanic Disc Wheels To check the torque on disc wheels follow the crisscross sequence shown See t...

Page 164: ...ates the differences between parts used in hub piloted mount and ball seat mount appli cations Only PACCAR Parts supplied hub piloted or ball seat mounted wheels may be used on this vehicle If you are not fully qualified and not equipped with the proper tools and equipment do not attempt to raise the vehicle or remove or install the damaged tire and wheel assembly Obtain expert help A person can b...

Page 165: ...rim assemblies 02951 Crisscross Sequence For Demountable Rims CAP NUT TORQUE SPECIFICATIONS R12 01 TORQUES FOR INNER OUTER CAP NUTS WHEEL AND NUT CONFIG URATION STUD SIZE Lb Ft N m Stud Piloted Disc Wheels 3 4 16 Inner 1 1 8 16 Outer 450 500 610 680 Heavy Duty Stud Piloted Disc Wheels 15 16 12 Inner 1 5 16 12 Outer 750 900 1025 1225 PHP 10 Budd Uni Mount 10 WHD 8 M22 x 1 5 6H 450 500 610 680 Rim C...

Page 166: ... of the front and rear axle load ratings Severe damage to your vehicle difficult han dling or an accident could occur if your vehicle is not loaded properly An unevenly distributed load or a load too heavy over one axle can affect the braking and handling of your vehicle and cause an accident Even if your load is under the legal limits be sure it is distributed evenly 02947 02948 GVW GVW is the Gr...

Page 167: ...mmended air pressure and always wear safety glasses when work ing with air pressure Never look into air jets or direct them at anyone Never attempt to disassemble a component until you have read and understood rec ommended procedures Some components contain powerful springs and injury can re sult if not properly disassembled Use only proper tools and observe all precautions pertaining to use of th...

Page 168: ...nks are not drained at the recommended frequency wa ter could be sent to all air lines and valves This could cause corrosion which could compro mise the brake system safety and potentially cause an accident Daily Drain moisture from the supply and service air tanks Operate air devices to circulate lubricants within the unit Periodically Clean filter screens ahead of the valves by removing the scre...

Page 169: ...idge change However the following should be considered first Air usage is exceptionally high abnormal for a highway vehicle This may be due to accessory air demands or some other unusual air requirement that doesn t allow the compressor to load unload in a normal fashion or it may be due to excessive leaks in the air system When more than a 30 degree F 17 degree C range of temperature occurs in on...

Page 170: ...l as provides freezing and boiling point protection CAUTION The engine cooling system has very specific maintenance and inspection re quirements Failure to follow requirements can damage the engine Engine damage can include but is not limited to Freezing Boiling Corrosion Pitted cylinder liners This information is found in the engine manu facturers owner s manual It is the owner s re sponsibility ...

Page 171: ...ume a 60 40 coolant mixture The minimum recommended concentration is 40 In an ELC filled cooling system the freeze point should be maintained between 30 F and 45 F 34 C and 43 C ELC Condition Contamination and Inhibitor Concentration Perform a visual inspection of the ELC It should have no cloudiness or floating debris Determine the chemical in hibitor concentration level by using an ELC specific ...

Page 172: ...g the cap with a large thick rag Do not try to remove it until the surge tank cools down if you see any steam or coolant escaping In any situation remove the cap very slowly and carefully Be ready to back off if any steam or coolant begins to escape NOTE If frequent topping off is necessary and there are no visible signs of coolant leaks when the engine is cold check for leaks with the engine oper...

Page 173: ...ssure cap 4 Through the surge tank fill the system with premixed coolant Pour it in a steady flow until the radiator is full 5 Start the engine 6 Idle at low RPM 7 Complete the filling Do it as quickly as possible 8 Idle the engine until it reaches normal operating tem perature 9 Fill the radiator as necessary to raise the coolant level to the proper reading Replace the surge tank pres sure cap Ch...

Page 174: ... idle or short distance driving These condi tions result in battery plates becoming covered with a hard coating Vibration Loose battery hold downs may cause bat tery plate failure Short Circuits These discharge a battery by draining electricity Dirty or Loose Connections Bad connections may stop the flow of electrical power to and from the bat tery Recharging Batteries Except for using small trick...

Page 175: ...ur to measure solution density spe cific gravity The specific gravity should be between 1 258 1 265 or the electrolyte level within MIN and MAX marks Before attempting any work on the batteries or elec trical system remove all jewelry If metal jewelry or other metal comes in contact with electrical circuits a short circuit may occur causing you to be injured plus electrical system failure and dama...

Page 176: ...ry is danger ous and should only be attempted by a competent me chanic with the proper equipment Slow Battery Charging NOTE Follow the instructions that come with your battery charger It is not necessary to remove the battery from the compartment 1 Make sure the electrolyte level in each cell is between the MIN and MAX marks If the fluid level is below the MIN mark correct the condition 2 Disconne...

Page 177: ...contact the positive battery terminal and any other metal on the vehicle at the same time Remove metal jewelry avoid leaning over a battery If metal jewelry or other metal comes in contact with electrical circuits a short circuit may occur causing you to be injured plus electrical system failure and damage to the vehicle Do not try to jump start or charge a frozen battery Even a battery with ice p...

Page 178: ... jewelry 2 Set the parking brakes Place the transmissions of both vehicles in Neutral Do not let the vehicles touch one another Turn the ignition key to Off in the vehicle with the discharged battery Also turn off lights heater and any other unnecessary electrical load 3 If either battery has vent caps remove them and check the fluid level If it is OK replace the caps before going further If the l...

Page 179: ...p is to remove the cable from the chassis or ground of the vehicle that was jump started Removing and Installing Batteries CAUTION Always reinstall the battery compart ment cover step before entering the cab With out the battery cover you could slip and fall re sulting in possible injury to yourself Whenever you have to install a battery or remove one fol low these guidelines for the safety of you...

Page 180: ... electrical equipment and wiring that might get soaked with fuel Diesel fuel may permanently damage electrical insulation When installing spin on throwaway filters hand tighten them only to 1 2 to 2 3 turn after gasket con tact Mechanical tightening of these filters may distort or crack the filter head NOTE To expel air from density type strainer el ements soak them in clean fuel before installing...

Page 181: ...ect them and still have a steering problem take your vehicle to an authorized dealer for evaluation Front End Alignment For driving safety and comfort and to prolong the life of your vehicle it is important to have proper front end align ment Check tire wear frequently Uneven tire wear is a sign that your front end or rear axles may be misaligned If you see uneven wear take your vehicle to a servi...

Page 182: ... km Then tighten them every 60 000 miles 96 000 km after that For off highway vehicles tighten the U bolts after the first day or two of operation Then tighten them every 15 000 miles 24 000 km after that Failure to maintain the specified torque values or to replace worn parts can cause component system failure possibly result ing in an injury accident Improperly tight ened loose suspension U bolt...

Page 183: ... 149 214 9 16 18 87 124 118 168 123 176 167 239 5 8 11 108 154 147 209 153 218 208 296 SAE Grade Number 5 8 Torque Torque Capscrew Body Size inch esthread Lb ft N m Lb ft N m 5 8 18 122 174 166 236 173 247 235 335 3 4 10 192 273 260 370 271 386 367 523 3 4 16 214 305 290 414 303 431 411 583 7 8 9 309 441 419 598 437 624 593 846 7 8 14 341 486 462 659 482 589 654 799 1 8 464 662 629 898 656 935 889...

Page 184: ... could be the loss of the electrical or air system as well as possible engine damage from overheating So it s a very good idea to check your belts frequently and replace them as soon as you detect trouble Follow this procedure to install an accessory drive belt 1 Route the new belt around the pulleys and then rotate the automatic tensioner so that the idler pulley swings toward the belt routing Fi...

Page 185: ...ine when it is cold When the truck is cold the viscous fan clutch will require more time to disengage This time will depend on the engine RPM Run the engine above idle and you will audibly notice the fan turning off If the fan clutch does not disengage have the problem corrected at your dealership Air Intake System Engine heat vibration and age combine to loosen air in take connections and cause c...

Page 186: ...n is created when the engine is running This suction could draw your hand or anything else near it into the impeller fan You could be se riously injured Always keep the intake piping connected when you will be running the engine Lubricating System Check the oil lines housing and connections Look for leaks damage or deterioration Leaks could mean you have damaged oil lines or oil seals Manifold Wit...

Page 187: ...in the modulator assembly The controller responds instantly by signaling the solenoids in the modulator which activate the air valves reducing application pressure as needed to prevent the wheels from locking up If this overriding cor rection is effective application pressure is allowed to build up to the original input Any malfunction of the anti lock system on one or more axles will cause the sy...

Page 188: ...s exhaust system and cab be inspected by a competent technician every 15 000 miles whenever a change is noticed in the sound of the exhaust system whenever the exhaust system underbody or cab is damaged Allow for the proper operation of the vehicle ven tilation system Keep the inlet grille at the base of the windshield clear of snow ice leaves and other obstructions at all times Keep the exhaust p...

Page 189: ...r core and condenser core for debris restricting air flow Clean if necessary Small particles may be removed with compressed air blown through the core in the opposite direction of normal air flow WARNING Small particles blown by com pressed air could injure your eyes Wear eye protection any time you blow compressed air Check all hoses for kinks deterioration chafing and leaks Adjust kinked or chaf...

Page 190: ...hrough a cigarette may cause vi olent illness Appearance Painted Surfaces CAUTION Do not aim the water jet directly at door locks or hatch Tape the key holes to pre vent water from seeping into the lock cylinders Water in lock cylinders should be removed with compressed air To prevent locks from freezing in the winter squirt glycerin or lock deicer into the lock cylinders Wash frequently to remove...

Page 191: ... around bolts or other fasteners Stainless Steel Follow this procedure to clean and restore the finish of stainless steel components 1 In a plastic pail mix 4 tsp of alum a powder found in grocery stores or drugstores with 32 oz of wa ter warm water will dissolve alum faster but cool will work 2 Apply the alum water solution with a pad of steel wool 0000 grade or finer GENTLY wipe the component le...

Page 192: ...ments and gauges Always test a commercial cleaning agent on an inconspicuous area of the surface to be cleaned before using it Never clean interior components with chem icals or solvents such as Gasoline Naphtha Acetone Turpentine Benzene Carbon Tetrachloride Lacquer Thinner Nail Polish Remover Ammonia based Products Clean difficult stains such as oil grease and mustard as soon as possible The lon...

Page 193: ...ap with a clean damp rag If a stronger cleaning solution is required use a foam type carpet shampoo Vinyl and Fabric Upholstery CAUTION To avoid possible damage to the upholstery do not use chemical solvents or strong detergents on these components Use a clean lint free cloth Clean with the cloth dampened with a mild soap and water solution Remove soap with a clean damp rag For difficult stains us...

Page 194: ... system at least 15 min utes Drive the vehicle a short distance to allow lubricants to circulate in the transmission and axles Noise Control System Noise Emission Warranty Peterbilt Motors Company warrants to the first person who purchases this vehicle for purposes other than resale and to each subsequent purchaser that this vehicle as manu factured by Peterbilt Motors Company was designed built a...

Page 195: ...rom around the oil pan Cutting holes in or cutting away part of noise insula tors Removing hood mounted noise insulation Engine Electronic Control Unit ECU Modifying ECU parameters Engine Cooling System Removing or rendering inoperative the fan clutch Removing the fan shroud Air Intake System Removing or rendering inoperative the air cleaner silencers or intake piping Exhaust System Removing or re...

Page 196: ...eplace ment DPF in exhaust systems Using a noncom pliant DPF as a replacement could violate these standards and also void the emission system s war ranty Turbo Emission Control Components The vehicle may have emission control components to meet 2007 EPA requirements Refer to the engine man ufacturer s service manual for the maintenance of these components Joints and Clamps Check for leaks and tigh...

Page 197: ...ne is near the fan Do not work on the fan with the engine running Check all fasteners for tightness Check for stress cracks in the shroud Make sure the shroud is adjusted so that it does not touch the fan blades Engine Mounted Noise Insulators Fasteners Check for condition and security How you do this will de pend on the method of attaching the noise insulators on the engine and around the oil pan...

Page 198: ... and repair them as necessary Damaged rubber fender shields or cab skirting cannot be repaired You will need to replace it Your authorized dealership can perform all of these checks and repairs or replacements Air Intake System Do all checks and maintenance chores listed in this man ual under Engine Air Intake System and Air Cleaner See Index Check the induction tubing elbow connections clamps bra...

Page 199: ...N WORK PERFORMED DATE R O NUM BER REPAIR FACILITY LOCATION WORK PERFORMED EXHAUST SYSTEM ROUTING INTEGRITY 25 000 MUFFLER INTERNAL BAFFLES 250 000 SHUTTERS SHROUDS 25 000 ENGINE MOUNTED HOSE INSULATORS FASTENERS 10 000 INNER FENDER SHIELDS 50 000 CAB SKIRT FASTENERS 50 000 AIR INTAKE SYSTEM INTEGRITY ELEMENT 5 000 CLUTCH TYPE FAN DRIVE 10 000 R 08 07 Y53 6015 195 ...

Page 200: ... of Federal Regulations vin VIN Location The VIN is marked on the Incomplete Vehicle Certification Label on trucks or on the Tire Rim and Weight Rating Data Label on tractors Both labels are located on the driver s door frame Chassis Number Locations The chassis serial number is shown in three places Right frame rail top flange about 3 ft from the front end Components and Weights Label on driver s...

Page 201: ...ehicle Identification Number LISTING OF APPLICABLE FEDERAL MOTOR VEHI CLE SAFETY STANDARDS Noise Emission Label The Noise Emission Label is in the map compartment It contains information regarding U S noise emission regu lations and date of manufacture Paint Data Label The Paint Data Label contains the paint colors used by the factory to paint your vehicle It lists frame wheels cab interior and ex...

Page 202: ... Engine Operation and Maintenance Manual Clutch Enclosed in clutch housing Location depends on manufacturer Transmission For both manual and automatic transmis sions the identification number is stamped on a tag affixed to the right rear side of the transmission case Steer Axle The front axle serial number is stamped on a plate located on the center of the axle beam Drive Axles The drive axle numb...

Page 203: ...ed in the owner s manual of motor vehicles manufactured after September 1 1990 If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Ad ministration NHTSA in addition to notifying Peterbilt Mo tors Company If NHTSA receives similar complaints it may open an in vestigation and if it fi...

Page 204: ...ate of Cal ifornia to cause cancer birth defects or other reproductive harm This warning requirement is mandated by California law Proposition 65 and does not result from any change in the manner in which Peterbilt trucks are manufac tured Some of the ingredients in engine oil hydraulic oil trans mission and axle oil engine coolant diesel fuel air con ditioning refrigerant R12 R134a and PAG oil ba...

Page 205: ...1 Disclosure of Recording Device For additional information on your rights associated with the use of this data contact the California Department of Motor Vehicles Licensing Operations Division or http www dmv ca gov pubs vctop d03_6 vc9951 htm R 08 07 Y53 6015 201 ...

Page 206: ...Tilting 10 Cap Nut Torque Specifications 161 Cleaning the vehicle 188 Consumer Information 199 Controls Air Horn 23 Air Suspension Deflate Switch Dump Valve 29 Cigarette Lighter 42 Cruise Control Switch 32 Dome Light Switch 28 Electric Horn 23 Engine Brake 32 Engine Fan Switch 30 Fifth Wheel Lock Slider Adjustment Switch 34 Fog Lights Switch 27 Headlights 26 heating system 38 40 High Beam Headligh...

Page 207: ...conomical driving 104 Electrical system batteries 170 battery charging 170 jumper cables 171 Electrolyte 171 Engine overspeed 105 Engine Warmup 74 Environmental Protection 200 Exhaust fumes 111 F Federal motor vehicle safety standards 4 Federal Safety Standard Certification Label 198 Frame Fastener Torque Specifications 178 Front Cab Guard Ladder 9 G Gauges And Displays 42 Air Application Gauge 46...

Page 208: ...tion Switch 24 L Lubrication Axle 142 143 Coasting 105 Specifications 135 Steering Gear 145 Transmission 138 140 Universal Joint 145 Wheel Bearing 144 Lubrication Index 136 M Maintenance Schedule 110 Mirrors 56 N Noise Control System 190 P Parking Brake use 93 Proper Coolant Level 169 R Restraint System 57 Inspection 65 Komfort Lok 61 Lap Belt 58 Safety Chain 17 Shoulder Belt 58 204 Y53 6015 R 08 ...

Page 209: ...s 179 Starting And Operating 88 Bobtail Brake Proportioning System 91 Cold Temperature Starting Procedure 74 Driving Bobtail or with an Unloaded Trailer 98 Driving With Deflated Air Springs 103 If Your Vehicle Must Be Towed 85 Overheated Brakes 92 Retarders 97 Setting Ride Height 100 Shifting The Transmission 78 Stopping The Engine 98 Trailer Air Supply Valve 95 Warning Alarms 17 T Tachometer 46 T...

Page 210: ...PART 11 SUBJECT INDEX Windshield Washer Reservoir 29 206 Y53 6015 R 08 07 ...

Page 211: ... ser vice information specifically compiled for the compo nents on your vehicle The material in this manual is the same as that used by Peterbilt dealers It includes inspection maintenance overhaul and troubleshooting procedures 02956B Owner s Custom Parts Book This book is a complete unillustrated computer gen erated list of the parts used to custom build your Peter bilt vehicle Please provide yo...

Page 212: ...Peterbilt Motors Company P O Box 90208 Denton Texas 76202 ...

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