Paccar Peterbilt 587 Owner'S Manual Download Page 198 | Manualshive

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ELECTRICAL

PART 8: MAINTENANCE AND SERVICE

– 196 –

Y53-6032

(R05/10)

Recharging Batteries

Except for using small trickle chargers to maintain battery
condition, you should have your vehicle’s batteries
charged by a qualified service facility. To help reduce the
risk of personal injuries, follow these guidelines carefully
when recharging a battery:

WARNING!

Batteries can kill or injure you

severely. They contain acid, produce poisonous
and explosive gases, and supply levels of elec-
tric current high enough to cause burns. A spark
or flame near a battery on charge may cause it to
explode with great force.

• Allow no sparks or open flame anywhere near the

charging area.

• Charge a battery only in a well-ventilated area, such

as outdoors or in a fully open garage which contains
no pilot lights or other flames.

• Always make sure the battery charger is OFF before

connecting or disconnecting the cable clamps.

WARNING!

Always shield your eyes, your skin

and painted surfaces to from contact with batt-
tery fluid. Batteries contain a corrosive fluid
which can cause death or severe personal
injury.

• Use protective eyewear.

CAUTION: Never use a metallic funnel to add
distilled water. It could come in contact with a
terminal, creating a short circuit, resulting in
severe injury or damage to your vehicle.

• Maintain the full level of electrolyte in the batteries.

This reduces the volume of gas in the cells. The elec-
trolyte level should always be between 0.4–0.6 in.
(10–15mm) above plates.

Fill with distilled water

only.

After distilled water has been added, wait at

least a half hour to measure solution density (specific
gravity). The specific gravity should be between
1.258–1.265 or the electrolyte level within “MIN” and
“MAX” marks.

Y53-6032.book Page 196 Monday, May 24, 2010 3:37 PM

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Summary of Contents for Peterbilt 587

Page 1: ......

Page 2: ...he features or equipment which are not on this vehicle Peterbilt reserves the right to discontinue change specifications or change the desing of its vehicles at any time without notice and without incurring any obligation Quick Table of Contents Introduction 1 Cab And Frame Access 6 Getting To Your Engine 11 Controls And Displays 14 Seat And Restraint Systems 75 Driver s Checklists 88 Starting And...

Page 3: ...of your Peterbilt When you do please be sure to return it to the cab when you are finished using it That way it will be there when you need it the next time or when you pass How To Find What You Want There are several tools built into this manual to help you find what you need quickly and easily First is the Quick Table of Contents Located at the front of the manual this lists the main subjects co...

Page 4: ...ed or you could make your truck unsafe and cause death or serious injury 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 correct manuals for your vehicle Allow about...

Page 5: ...are used to indicate what kind of message is going to follow Pay special attention to instructions prefaced by symbols and the signal words WARNING CAUTION and NOTE Please do not ignore any of these alerts WARNING When you see this word the message that fol lows is especially vital It signals a potentially hazardous situation which if not avoided could result in an injury or death This message wil...

Page 6: ... acci dent 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 These circumstances can substantially increase the risk of an accident and death or personal injury Please remember this manual is not a training manual It cannot te...

Page 7: ...lp avoid an accident involving death or personal injury Be aware of local regulations that may prohibit the use of cellular telephones while driving In addition to being an unsafe practice it may be against local ordinances to use cellular devices while operating the vehicle Every new Peterbilt vehicle is designed to conform to all Federal Motor Vehicle Safety Standards applicable at the time of m...

Page 8: ...ab handles and your feet on the steps WARNING Do not jump out of the cab or get into the cab without proper caution You could slip or fall possibly suffering death or serious injury You could slip and fall if the steps are wet or icy or if you step in fuel oil grease snow or mud The illustrations that follow show the best ways to enter and exit a cab Vehicle With External Grab Handle 02958 A Y53 6...

Page 9: ...s properly locking the doors helps prevent doors from inadvertently opening and occu pants from being ejected from the vehicle Remote Keyless Entry optional This vehicle may be equipped with a Remote Keyless Entry RKE system that adds security and convenience to your vehicle The system will lock or unlock the driver s door and passenger s door with the key fob and alert you with parking lights whe...

Page 10: ...ardware and drug stores The battery is located under the back cover of the key fob Be sure to synchonize the key fob every time you replace the batteries Synchronization The key fob may need to be synchronized to the truck when the battery is replaced or when the key fob has not been used for an extended period time To Synchronize A Key Fob 1 Hold the key fob near the receiver NOTE The receiver is...

Page 11: ...b onto and off the deck plate use steps and grab handle provided If there is no deck plate or if proper steps and grab handles are not provided do not climb onto the area behind the cab Do not climb onto or stand on the frame rails The frame rails are very slippery and could cause you to fall resulting in death or personal injury Always reinstall steps before entering the cab or accessing the deck...

Page 12: ...MBING ONTO THE DECK PLATE PART 2 GETTING INTO OUT OF THE CAB AND FRAME ACCESS Hold handles as you step up Three points of contact as you reach the deck area Y53 6032 book Page 10 Monday May 24 2010 3 37 PM ...

Page 13: ...ocedure to tilt the hood WARNING A pivoting hood could hurt some one or be damaged itself Before opening or closing the hood be sure there are no people or objects in the way Failure to stand in a position of safety can cause death or personal injury 1 To open your hood unlock the hood hold downs by unlatching them Put one hand on the top of the hood front one foot on the bumper and one foot on th...

Page 14: ...y You could be killed or injured and the hood could be damaged 3 Verify that the device was previously reset during the last hood closing event This is done by pulling the collar in the downward direction WARNING Always verify that the hood anti blowdown device has been reset when open ing the hood The device is reset either by fully closing the hood or by manually pulling the device down Failure ...

Page 15: ...ipment or vehicle damage 5 Firmly push upward and rearward on the hood orna ment to start the hood tilting backwards Continue to push until the hood comes is fully closed 6 Secure the hood latches on both sides of the vehicle to hold the hood in the closed position WARNING If the hood is not latched securely it could open during operation and cause an accident involving death or injury Be sure the...

Page 16: ...ribe the most common features and controls available so your vehicle may not have some of the ones that appear in this section You can pick out the parts that apply to you and read them to be fully informed on how your particular vehicle operates WARNING Use extreme caution when using devices while driving such as cellular tele phones that distracts you from safe driving practices Failure to prope...

Page 17: ...e 3 Headlight Light Switch 12 Secondary Air Pressure 4 ID Clearance Lamps Switch 13 Fuel 5 Voltmeter 14 Cigarette Lighter 6 Engine Coolant Temp 15 Menu Control Switch 7 Tachometer 16 Rear A C Switch 8 Driver Information Display 17 Dome Light Switch 9 Speedometer 18 Panel Dimmer 18 17 16 15 14 13 12 11 10 8 7 6 5 4 3 9 2 1 Y53 6032 book Page 15 Monday May 24 2010 3 37 PM ...

Page 18: ...le Differential Lock Switch 5 Floor Light Switch 16 5th Wheel Lock Switch 6 Regeneration Switch 17 Air Suspension Switch 7 Load Light Switch 18 Radio 8 Fog Lights Switch 19 CB Radio 9 Cruise Control Switch 20 Traction Control Switch 10 Transmission Temperature 21 Mirror Heater Switch 11 Cruise Control Sel Switch 19 18 20 21 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Y53 6032 book Page 16 Monday May...

Page 19: ...rning lights and audible alarm may indicate a sys tem malfunction Check the lights frequently and respond properly as soon as you see one go on These lights could save you from a serious accident WARNING Do not ignore a warning light or audbile alarm These signals tell you some thing is wrong with your vehicle It could be a failure in an important system such as the brakes which could lead to an a...

Page 20: ...ights and indicator symbols are displayed in the Status Indicator They are limited to a Park Brake b Transmission Gear Automatic transmissions only c Warnings d Cruise Control active e Clock alarm bell Refer to Warning Light Indicator Symbols on page 20 for information on each symbol Instrument System Self Test When the ignition switch is turned on the instrumentation system will undergo a Self Te...

Page 21: ...l sound during the Instrumentation System Self Test The audible alarm will also sound in include but are not limited to headlight on fifth wheel stop engine primary secondary air and driver door open warnings Optional Lights Additional lights may be operational depending on individ ual vehicle specifications These will be included in the Instrument System Self Test NOTE Some optional lights may il...

Page 22: ...al information Symbols are listed by major component sections Example Engine and then in alphabetical order Warning Light Indicator Symbols Symbol Name Symbol Color Std Opt Page 1 Active Warnings Exclamation Point Red 23 2 Active Warnings Number Yellow 23 3 Active Warnings Triangle Yellow 23 4 Alternator Red 23 5 Anti Lock Brake System ABS Yellow 23 6 Anti Lock Brake System ABS Trailer Yellow 24 7...

Page 23: ... Engine Yellow 26 17 Engine Ether Start Green 26 18 Engine Heater Yellow 26 Warning Light Indicator Symbols Symbol Name Symbol Color Std Opt Page 19 Engine Low Coolant Level Yellow 26 20 Engine Overspeed Red 27 21 Engine Retarder Brake Green 27 22 Engine Stop Engine Red 27 23 Engine Wait To Start Yellow 27 24 Fifth Wheel King Pin Lock Red 27 25 Fifth Wheel Slide Unlocked Red 27 26 Lights High Beam...

Page 24: ...n Yellow 29 35 Transmission Auxiliary Yellow 29 36 Transmission Check Red 29 Warning Light Indicator Symbols Symbol Name Symbol Color Std Opt Page 37 Transmission Do Not Shift Red 29 38 Transmission Oil Filter Yellow 29 39 Transmission Oil Tempera ture High Yellow 29 40 Turn Signal Left Green 29 41 Turn Signal Right Green 29 Warning Light Indicator Symbols Symbol Name Symbol Color Std Opt Page Y53...

Page 25: ...to view the warnings that are active Refer to the preceeding Figure Warning Light Indicator Symbols on page 20 for warning color classification 4 Alternator Illuminates if the alternator is not charging For alternators with warning lamp output signal 5 Anti Lock Brake System ABS Illuminates during the Instrumentation Sys tem Self Test Have the ABS system checked by a Peterbilt dealer if the ABS Wa...

Page 26: ...n On trailers built prior to 3 1 01 verify trailer ABS system status via the required external warning lamp mounted on the trailer The indicator lamp on the trailer should be yellow and identified with the letters ABS 7 Axle Inter Axle Differential Locked Tandem Axles Illuminates when the inter axle differential switch is ON thus locking the inter axle differ ential This powers the forward rear an...

Page 27: ...e exhaust sys tem during and shortly after a regeneration event will be extremely hot If the High Exhaust System Temperature HEST warn ing lamp is on Do not park in an area of combustible vapors or materials You must keep combustibles at least five 5 feet away from the side and top of the vehicle while the HEST light is illumi nated Always park your vehicle outside Fail ure to do so could ignite a...

Page 28: ...Lamp Illuminates when the Diesel Exhaust Fluid DEF tank level is low The vehicle can be safely driven but the DEF tank should be filled at the next opportunity The situation should not be considered an emergency 16 Engine Check Engine Illuminates when a problem exists but the vehicle can still be safely driven Vehicle should be serviced to correct the problem but the situation should not be consid...

Page 29: ...ain Failure to do so may cause severe engine damage or cause an acci dent involving death or personal injury 23 Engine Wait To Start Illuminates when engine grid heater is on Cummins ISB and ISC engines 24 Fifth Wheel King Pin Lock Illuminates when air actuated fifth wheel King Pin is unlocked 25 Fifth Wheel Slide Unlocked Illuminates and an audible warning tone will sound when the air operated sl...

Page 30: ...in the status indicator when park ing brakes are applied and the vehicle is sta tionary This symbol will also illuminate in the Driver Information Display if the parking brakes are applied and the vehicle is in 29 Power Take off PTO Illuminates when the PTO is engaged NOTE Do not drive vehicle with PTO engaged 30 Power Take off PTO Pump Mode Illuminates with remote throttle application Indicates p...

Page 31: ...Do Not Shift Illuminates with automatic transmissions equipped with Don t Shift output 38 Transmission Oil Filter Illuminates when service is required Allison transmissions only 39 Transmission Oil Temperature High Illuminates when transmission lubricant tem perature is too high CAUTION This should be considered an emergency You should stop the vehicle as safely as possible and turn OFF the igniti...

Page 32: ...plays important vehicle information through a constant monitoring of systems when any of the following conditions are met ignition key in ON or ACC positions ignition timer is active MCS button is pushed independent of ignition key switch position clock alarm sounds driver or passenger door is opened hazard warning lamp switch is on The various functions may be accessed by navigating through Menu ...

Page 33: ...ions A Fuel Economy Accessible while parked or driving 1 Current fuel economy Indicates instantaneous fuel economy 2 Trip fuel economy Indicates trip fuel economy B RPM Detail Accessible while parked or driving RPM reading of actual engine RPM Engine RPM within the bar graph indicates the engine is operat ing in the most efficient RPM range The display color will change if you are operating outsid...

Page 34: ...my Trip Average Speed Other Trip Information functions are accessible only when parked Trip Distance Trip Engine Hours Trip Idle Hours PTO Hours PTO Trip Hours PTO Trip Percentage To reset the Trip Values press the Trip Odometer Reset Button on the main gauge instrument cluster E Truck Information Accessible only while parked NOTE When accessing the truck informa tion menu push the MCS on this men...

Page 35: ...he display will either indicate No Faults Found or Faults Found If Faults Found is active pushing the MCS will display new menus for more information G Transmission Display Automated Transmissions only Accessible while parked or driving NOTE Refer to the Automated Transmission Operator s Manual for additional information This menu will show gear number that coincides with the current transmission ...

Page 36: ... Display Format 1 When in the Settings Menu scroll through the list of menu items to Format 2 Press the MCS to display either 12 hour AM PM or 24 hour military time To Set Home Local or Alarm Time 1 When in the Settings Menu scroll through the list of menu items Press the MCS to select the item to change 2 3 Rotate the MCS knob to change the hour Press the MCS Y53 6032 book Page 34 Monday May 24 2...

Page 37: ...ither Standard or To Set Language 1 When in the Settings Menu scroll through the list of menu items to Language Press the MCS 2 Rotate the MCS to display either English Span ish or French Press the MCS knob to select the desired language Steering Column Mounted Controls Turn Signal and Indicator Lights NOTE The ignition key must be turned to ON for the signal switch to operate Your turn signal lev...

Page 38: ...e Headlamp Flash To activate headlamp flash gently push the turn signal lever away from the steering wheel until you hear and feel the switch click Release lever to deactivate If your headlamps are off low beams will flash on If your headlamps are on they will dim Maximum duration of dimming is 3 seconds When the function ends your headlamps will return to low beams ID And Clearance Lights Flash T...

Page 39: ... operate The first position after OFF is the intermittent 1 cycle The next positions are intermittent 2 3 and 4 The last two positions are wiper low speed and wiper high speed See the wiper switch settings table that follows for inter mittent delay times To Wash The Windshield Push the rotary wash wipe knob in towards steering col umn hold for more than 0 8 seconds and then release Wiper Switch Se...

Page 40: ...ing driving hazardous which may lead to an injury accident resulting in death or personal injury CAUTION Do not use antifreeze or engine coolant in the windshield washer reservoir damage to seals and other components will result If the electric pump is operated for a long period more than 15 seconds with a dry res ervoir the pump motor may be damaged Check the windshield washing fluid level daily ...

Page 41: ...ehicle can result in an accident causing death or personal injury Another vehicle could run into you if you do not set your flash ers and follow the placement of emergency signals per FMCSR 392 22 Always move the vehicle a safe distance off the road when stalled or stopped for repairs A disabled vehi cle can be dangerous for you and others Of course in normal stopping in traffic such as at a stop ...

Page 42: ...by pulling on the lanyard extending from the overhead header panel Trailer Brake Hand Valve This hand valve provides air pressure to apply the trailer brakes only It operates independently of the foot treadle valve NOTE The trailer brake is not to be used as the main means of braking To use this brake fre quently instead of using the foot brake will wear out the trailer brake sooner To operate the...

Page 43: ...ilting fea ture allows you to move the wheel up and down WARNING Make all adjustments to the steer ing mechanism while the vehicle is stopped Adjusting the Tilt Telescoping Steering Wheel while the vehicle is in motion could cause loss of control You wouldn t be able to steer properly and could have an accident resulting in death or personal injury To position the wheel Locate the Tilt Telescope L...

Page 44: ...r activation to start engine Headlamps The headlamps are controlled by the control panel switch showing the next symbol When the headlights are ON the dash lights side and tail lamps are also on WARNING Do not use daytime running lights DRL during periods of darkness or reduced visibility Do not use DRL as a substitute for headlamps or other lights during operations that require lighting of your v...

Page 45: ...brighten the instrument lights rotate the thumb wheel up 3 To dim the instrument lights rotate the thumbwheel down ID and Clearance Lights Switches These are the amber lights on top of your cab the lights on the front and sides of the trailer and the red lights on the rear of a truck or trailer They may be turned on and off by the switch located on the lower left control panel labeled CL LPS and s...

Page 46: ...and cannot be used together Further some states allow only four lights to be used together some allow more Whether you have dual or composite lights will affect how many lights you can have on at one time Always comply with the state requirements where you are driving Dome Light Switch A momentary switch controls the main dome light 03912 1 03021 02894A I O Y53 6032 book Page 44 Monday May 24 2010...

Page 47: ...notice a guard over the switch This prevents you from accidentally deflating the suspension WARNING Operating the Air Suspension Deflate Switch Dump Valve while driving can lead to an accident causing death or personal injury Sudden deflation while your vehicle is moving can affect handling and control Use this switch only when your vehicle is not mov ing CAUTION Operating a vehicle with air suspe...

Page 48: ...is set at ON it will turn on any time the ignition key switch is turned to the ON position In AUTOMATIC it could engage suddenly without warning Before turning on the ignition or switching from AUTOMATIC to ON be sure no one is near the fan CAUTION The fan or equipment near it could be damaged if the fan turns on suddenly when you don t expect it Keep all tools and equipment such as rags away from...

Page 49: ... can be switched on to help remove frost and ice from the mirror glass Power Mirror Switch The power mirror control controls the adjustment of the right or left outside mirrors depending on the option selected It is located in the driver side armrest NOTE The Power Mirror Switch does not control the adjustment of the convex mirrors I 03022 O Y53 6032 book Page 47 Monday May 24 2010 3 37 PM ...

Page 50: ...tions caused by the normal operation of the cruise control could cause you to lose control of the vehicle result ing in an accident causing death or personal injury NOTE Cruise control functions and features may vary depending upon which engine you have For specific explanation of your cruise control see the cruise control or engine manual included with your vehicle This vehilcle s electronic syst...

Page 51: ...or pedal The brake is deenergized during driving by pressure on the accelerator pedal and during shifting by depressing the clutch pedal The ON OFF toggle switch turns the system ON or OFF In PACCAR Caterpillar and Cummins powered vehi cles equipped with a Jacobs Engine Brake a second two or three mode switch is incorporated in the instrument panel With this system you can select either LOW or HIG...

Page 52: ...e is a faster ratio for highway speeds For information on how to operate your two speed rear axle properly and safely see PART 7 STARTING Interaxle Differential Lock Switch The interaxle differential allows differential action between the forward rear and the rear rear driving axles The inter axle differential lock switch allows the operator to LOCK or UNLOCK the differential The guard over this s...

Page 53: ...System on page 126 for more information about the emission control system and how it affects normal operating procedures START Depressing the button in the START direction for 4 to 8 seconds will initiate a parked regeneration Be sure to release the button to ensure that the system will begin the regerenation cycle CENTER three position switch only Center is the normal position of the switch The c...

Page 54: ...he tractor trailer is in motion Movement of the fifth wheel while a tractor trailer is moving can cause a serious accident involving death or personal injury Your load could shift sud denly causing you to lose control of the vehi cle 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 CAUTIO...

Page 55: ...118 for more WARNING Do not leave the cab without applying the parking brake The truck could roll and cause an accident involving death or personal injury Always apply the parking brake before you leave the cab Do not pull out the parking brake valve while the vehicle is moving Stopping with the parking brake controls can cause a sudden wheel lock up loss of control or over take by following vehic...

Page 56: ...from other vehicles nearby Failure to properly maintain your vehicle could cause carbon monoxide to enter the cab sleeper and cause death or serious illness WARNING ever idle your vehicle for pro longed periods of time if you sense that exhaust fumes are entering the cab or sleeper Investigate the cause of the fumes and correct it as soon as possible If the vehicle must be driven under these condi...

Page 57: ...A C Set the fan to Medium or High speed Set the controls to FRESH AIR NOTE If other vehicles are parked next to you idling move your vehicle or do not stay in your vehicle for prolonged periods of time To Set the Heater Air Conditioning Controls The cab s control panel may have up to six controls see illustration below A rotary knob A in the upper left portion controlling the blower speed with fou...

Page 58: ...wer speed with four settings A rotary knob in the right portion controlling the air temperature The cab bunk control rocker switch must be ON for the sleeper controls to function To heat the cab select the desired air mode and set the temperature knob to hot the red position on the control and the blower to whatever speed makes you most comfortable WARNING Do not drive with visibility reduced by f...

Page 59: ... the control The air conditioner is automatically activated to remove moisture from the cab After the windshield is clear adjust the mode blower speed and temperature to your comfort To cool the cab turn on the A C switch set the tem perature knob to cool the blue position on the con trol and the blower to high until the cab becomes cool Then you can turn down the blower if you wish For Efficient ...

Page 60: ...e polyswitch to prevent damage should the lighter get stuck in the IN posi tion If this fuse needs replacement check to ensure that the lighter is not stuck before replacing the fuse WARNING Do not exceed the voltage amper age capacity of the cigarette lighter It could result in a fire causing death or personal injury Follow all warnings and instructions in the operator s manual for the appliance ...

Page 61: ...ident or sudden stop keep the glove compartment closed when the vehicle is in motion Gauges On the pages that follow you will find descriptions of some of the gauges on your instrument panel For more infor mation about using them in driving see PART 7 START ING OPERATING THE VEHICLE Also check the Index under the name of the gauge or function you want to know more about WARNING Do not ignore a war...

Page 62: ...y on the instru ment panel They are described further in PART 7 STARTING OPERATING THE VEHICLE of this manual Speedometer The speedometer indicates the vehicle speed in miles per ometer also includes an odometer trip meter and trip reset button Odometer Trip Meter The LCD display in the lower part of the speedometer contains the odometer and trip meter The odometer displays the total distance your...

Page 63: ...set button also toggles all displays between English and Metric See page 62 NOTE The Odometer Trip Meter comes on when the door is opened or the key is in the accessory or ignition position The Odometer Trip Meter will remain on for 3 seconds after the door is closed or the ignition switch is turned off This allows driver and service personnel to read the odome ter without ignition switch being tu...

Page 64: ...y on until the temperature The temperature can display using Standard or Metric units Press the trip reset button on the Speedometer 4 times within 4 seconds This will also change the units shown by the Driver Information Display Refer to To Set Units of Measure on page 35 for another method to change units NOTE The OAT will come on when the door is open and the key switch is in the accessory or i...

Page 65: ...ount of air pres sure in the brake system in pounds per square inch psi The primary gauge shows front reservoir air pressure The secondary gauge shows pressure in the rear res ervoir Ensure the air pressure registers more than 100 psi in both service systems before you move the vehicle If the pressure in either circuit is too low for normal brake oper ation the warning light will glow and the audi...

Page 66: ...nt and severely injured or killed If these alarms come on while you are driving bring your vehicle to a safe stop right away If the light and alarm do not turn off at start up do not Engine Oil Pressure Gauge It is important to maintain oil pressure within acceptable limits Your engine manual will give you normal operating pressures for your particular engine CAUTION Continuing to operate your veh...

Page 67: ...pt for certain special engines Check your engine manual to be sure Engine Overheating WARNING Do not remove the radiator fill cap while the engine is hot Scalding steam and fluid under pressure may escape and cause death or personal injuries Wait until the coolant temperature is below 122 F 50 C Protect face hands and arms by covering the cap with a large thick rag to protect against escaping flui...

Page 68: ...the transmission in neutral check to be certain the oil pressure gauge reads normal Increase the engine speed to about 1100 1200 RPM maximum Return the idle speed to normal after 2 or 3 minutes If the warning light doesn t go off or the temperature gauge doesn t begin to drop then turn the engine off If the overheating came from severe operating conditions the temperature should have cooled by thi...

Page 69: ...r vehicle is dangerous Full or empty they may leak explode or cause or fuel a fire which may lead to death or personal injury Don t carry extra fuel containers even empty ones Diesel Exhaust Fluid DEF Gauge The deisel exhaust fluid gauge shows the approximate amount of DEF fluid in the DEF tank Besides empty and full the gauge also indicates 1 4 1 2 and 3 4 of total capacity DEF fluid is required ...

Page 70: ...uthorized service representative Maximum transmission temperature may vary depending upon the transmission and type of lubricant Check your transmission s owner s manual Front Drive Axle or Rear Drive Axle Temperature Gauge CAUTION Driving with very hot temperatures in your rear drive axles can cause serious damage to axle bearings and seals Check axle lubrica tion if a driver temperature alarm so...

Page 71: ...ng upon the axle and type of lubricant Very high temperatures signal a need to have your axle s lubrication checked Manifold Pressure Gauge Your manifold pressure gauge indicates the power your engine is putting out by showing the amount of turbo boost If the pressure indicated by your manifold pressure gauge goes down there may be something wrong with your engine Have it checked by a qualified se...

Page 72: ... 12V during engine cranking If voltage drops below 12V and stays there have the electrical system checked Air Filter Restriction Indicator Gauge This gauge indicates the condition of the engine air cleaner and is measured by inches of water H2O A clean filter should register 7 in H2O may vary with sys tem design and a filter whose life is over will register approximately 25 in H2O Y53 6032 book Pa...

Page 73: ... other object Keep plenty of space between your vehicle and others when you turn or change Your vehicle is equipped with outside mirrors to enable you to see to the sides and behind your vehicle Be sure they are adjusted properly before you drive off You will have the best field of view to the side if you adjust each mirror so you can just see the side of your vehicle in the inboard part of the mi...

Page 74: ...es This may cause premature battery failure NOTES For additional information about the refrigerator refer to the refrigerator owner s manual that came with this appliance Refrigerator cooling ability decreases as sleeper temperature increases The main power supply to the refrigerator and cooling fan located behind the refrigerator is controlled by a switch labeled REFRIG FAN located on the sleeper...

Page 75: ...riving Prolonged peri ods of viewing while driving could result in an accident and death or possible personal injury WARNING Do not program the Navigation System while driving Always stop your vehi cle when programming or changing the set tings on the Navigation System Programming the system while driving can cause you to take your eyes off the road which could result in an accident Failure to do ...

Page 76: ...base is designed to provide you with route suggestions and does not take into account the relative safety of a suggested route or of factors that may affect the time required to reach your destination See the Supplemental Navigation System Owner s Manual for more information Y53 6032 book Page 74 Monday May 24 2010 3 37 PM ...

Page 77: ...riving off always check to be sure that the seat is firmly latched in position 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 seat belt and your riders belt...

Page 78: ...ESTRAINT SYSTEMS Person In Crash Unbelted Shoulder Belt Your combination shoulder lap belt needs proper adjust ment The lap portion should be worn as low on the hips as possible Properly worn belt 02998 Y53 6032 book Page 76 Monday May 24 2010 3 37 PM ...

Page 79: ...e door It you put the belt under your arm it can t protect you properly WARNING Always wear your seat belt low over your pelvic bones You can be killed or seriously injured if your belt is buckled too high In a crash it would apply force to your abdomen not your pel vic bones This can result in death or seri ous internal injuries Correct over arm Y53 6032 book Page 77 Monday May 24 2010 3 37 PM ...

Page 80: ...your shoulder Be sure also that your belt is not too loose A loose belt could allow you to slide under it in an accident and that could bring the belt up around your abdomen WARNING Do not drive with your seat belt loose A seat belt that is too loose can allow you to fall too far forward possibly causing head and neck injuries resulting in death or personal injury You could strike the wheel or the...

Page 81: ...ly tighter around you during a rough bouncy ride The need for this feature increases with rough road conditions par ticularly over long distances To eliminate cinching simply activate the comfort feature at the appropriate time 1 Fasten your seat belt according to the directions 2 You are now ready to activate the Komfort Lok Lean forward to pull a little slack about 1 inch in the belt Be sure to ...

Page 82: ...e truck is in motion should CAUTION To avoid damage when lifting a bunk remove all items from the top of the bunk mattress and arrange bedding so that items will not slide down the mattress and fall behind the bunk The bunk restraint is attached to the sleeper in six loca tions see illustration below 1 Two buckles at the upper rear wall 2 Two buckles at the side walls 3 Bolts in two places at the ...

Page 83: ...device This is because no one should ever be in an upper bunk when the vehicle is moving WARNING In an accident an unrestrained person lying in a sleeper bunk could be killed or seriously injured He or she could be thrown from the bunk Be sure anyone occupying the sleeper is restrained while a vehicle is mov ing Be sure that no one ever rides in the upper bunk while the vehicle is in motion That p...

Page 84: ...eep you and your passengers safe Never bleach or dye seat belts chemicals can weaken them Do however keep them clean by fol lowing the care label on the belts Let them dry com pletely before allowing them to retract If any seat belt is not working properly see an autho rized Peterbilt dealer for repair or replacement Tether Belts Tether belts are installed on suspension seats They help secure the ...

Page 85: ... necessary to pro vide adequate head clearance Death or seri ous injury may occur if head clearance is not adequate Make sure the tether belt is attached to the cab deck and seat frame It should be routed through the buckle on each side To lengthen the tether turn the buckle to a right angle to the webbing Then pull the buckle To shorten the tether pull on the strap Inspection of the Restraint Sys...

Page 86: ...o 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 can cause wear of the seat belt webbing Environmental conditions represent another major dif ference in the systems in automobiles and heavy duty and specialty vehicles Unl...

Page 87: ...the next time it is needed which could result in severe injury or even death One of the most critical areas to be inspected is the seat belt webbing Constant movement of the belt actually means the webbing is experiencing wear as it travels in and out of the retractor through the pillar loop web guide and through the various pieces of hardware associated with the belt The following guidelines deta...

Page 88: ...le for dam age The retractor is the heart of the occupant restraint system and can often be damaged if abused even unintentionally Check retractor web storage device operation to ensure that it is not locked up and that it spools out and retracts webbing properly WARNING Failure to adjust tether belts prop erly can cause excessive movement of the seat in an accident This could lead to death or ser...

Page 89: ...belt instruction guides for suspension and fixed bench seats Use the proper guide for your type of seat and follow the instructions very closely It is vitally important that all com ponents must be remounted back in the same position as the original components that were removed This will maintain the design integrity of the mounting points for the seat belt assembly Once the need for replacement o...

Page 90: ... are in working order You aren t expected to become a professional mechanic The purpose of your inspections is to find anything that might interfere with the safe and efficient transportation of yourself and your load If you do find something wrong and can t fix it yourself please have a qualified mechanic fix it right away For your safety as well as those around you be a respon sible driver If yo...

Page 91: ...on Are win dows mirrors and lights clean and unobstructed 2 Check beneath the vehicle Are there signs of fuel oil 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 stopped 1 Check the engine oil level...

Page 92: ...oper inflation 3 Check the front 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 WARNING Diesel fuel in the presence of an ignition source s...

Page 93: ...g 17 Check the air system Are there leaks 18 Drain excess moisture from all air supply tanks Make sure the drain valves are closed This procedure is also required for air supply tanks equipped with auto matic drain valves In Cab Checklist WARNING To avoid death or injury while entering or leaving the cab keep your feet in contact with the steps and your hands on the handhold Always have three poin...

Page 94: ...e lubricants NOTE The above items should be checked daily as a minimum They are in addition to not in place of Federal Motor Carrier Safety Regula tions These may be purchased by writing to Superintendent of Documents U S Government Printing Office Washington DC 20402 Y53 6032 book Page 92 Monday May 24 2010 3 37 PM ...

Page 95: ...he clutch with manual trans mission 4 Turn the key switch to ON The driver information display will proceed through the instrumentation self test refer to page 18 for a description of the instrumentation self test NOTE Refer to Warning Light Indicator Symbol Descriptions Page 23 if the Driver Information Display other messages or if other alarms acti vate after the key is turned ON 5 Turn the key ...

Page 96: ...rs 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 starting equipment will help starting If you follow a few simple guidelines you will extend the ser vice life of your engine Keep the electrical system in top cond...

Page 97: ...e speed to 900 or 1000 RPM Continue your warmup This procedure allows oil to warm and flow freely while pistons liners shafts and bearings expand slowly and evenly In extremely cold tempera tures you may have to increase idle speed NOTE In colder climates where the temperature is often below freezing the warmup for turbo charged engines is especially important Chilled external oil lines leading to...

Page 98: ...cab or sleeper Investigate the cause of the fumes and correct it as soon as possible If the vehicle must be driven under these conditions drive only with the windows slightly open Failure to repair the source of the exhaust fumes may lead to death or personal harm CAUTION The use of a winterfront can result in excessive engine coolant oil and charge air intake temperatures which can lead to overhe...

Page 99: ... move your vehicle or do not stay in your vehicle for prolonged periods of time Transmission Warmup In cold weather you may find shifting sluggish when you first start the engine Transmission warmup is especially important at this time but it is always a good idea to warm up your transmission before starting out on the road To warm up the transmission lubricating oil during engine warmup with a si...

Page 100: ...ations gener ated can also cause transmission wear During the time it takes you to drink a cup of coffee your engine can cool as much as 60 F 33 C below normal operating temperature To keep the engine warm during a short break turn it off And don t allow your engine to idle Putting The Vehicle In Motion This section discusses the clutch and transmission opera tion to get your Peterbilt underway WA...

Page 101: ...parts may seriously damage your transmission So don t drive in one gear for long until the transmission lubricant has had a chance to coat those contacting surfaces Operating the Clutch Riding the Clutch The clutch pedal is not a footrest Driving with your foot on the clutch pedal will allow your clutch to slip causing excessive heat and wear You can damage your vehicle this way Clutch Travel CAUT...

Page 102: ...r transmission to neutral and engage the clutch take your foot off the pedal This helps prevent unneces sary wear of your clutch release bearing And it is less tir ing for you too Clutch Adjustment Inspect manual and self adjusting clutches regularly to maintain correct clutch adjustment Have your dealer s service department perform any adjustments necessary Do not adjust your clutch by adjusting ...

Page 103: ...engage the clutch This lets you control the RPM of the mainshaft gears Thus you can match the RPM of the mainshaft gears to those of the output shaft Upshifts Let the engine and gears slowdown to the RPM required for the next gear Use the tachom eter to determine optimum RPM for gear engage ment Downshifts Press accelerator to increase engine and gear speed to the RPM required in the lower gear Us...

Page 104: ...the LOCK position continuous operation on a paved dry surface stresses the tandem axles possibly causing internal damage to them Shift into the LOCK position to operate on slippery surfaces like Ice or snow with or without tire chains Dirt roads Loose sand mud or other off road conditions Switch into LOCK when checking performance on a chassis dynamometer WARNING Do not engage the differential loc...

Page 105: ... trucking The Low range pro vides maximum torque for off road work The High range is a faster ratio for highway speeds and conditions A switch on your instrument panel controls this function You will notice that it has a guard to protect you from activating it accidentally Range Selector Using Your Dual Range Axle WARNING Never shift the axle when moving downhill Engine driveline disengagement may...

Page 106: ... cruising speed 5 If you need to downshift the axle for more power a Keep the accelerator down move the Range Selector lever to LOW b Keep driving with the accelerator down until you want to downshift the axle c Then release and depress the accelerator pedal d The axle will shift to the LOW range Important Tips on Operating Your Dual Range Axle NOTE If your vehicle has an automatic transmis sion i...

Page 107: ...es shifting much easier It remains important to completely under stand how to operate the transmission to optimize its effi ciency Please read the manual for your automatic or automated transmission included with your vehicle WARNING If your vehicle has a Freedom line 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 Th...

Page 108: ...re towed either by wrecker or piggy back lubricant in the top front of the drive axle will drain to the rear This will leave the top components dry resulting in friction that will seriously damage these components 2 Cover open hubs when removing drive axle shafts CAUTION Water dirt and other material can enter an open hub or axle This can contami nate the axle fluid and cause possible damage to co...

Page 109: ... no open air lines on the recovered vehicle if the recovery vehi cle and recovered vehicle brake systems are connected An open air line on the recovered vehicle will cause a leak in the air brake sys tem of the recovery vehicle possibly causing an accident and death or personal injury CAUTION A recovered vehicle will have no operational brake system Additionally the rear axle spring brakes will pr...

Page 110: ...owed 1 Into the pinion cage add 1 pint 47 liter of lubricant OR Into the inter axle differential add 2 pints 94 liter of lubricant See the Index under Lubricant Specifica tions for the lubricant required by each axle 2 After adding the specified type and amount of lubri cant drive the vehicle It should be unloaded Drive 1 to 2 miles 1 5 to 3 km at a speed lower than 25 mph 40 km h This will thorou...

Page 111: ...the vehicle resulting in an accident involving death or personal injury If any ABS lamp goes on while you are driv ABS may not function in an emergency You will still have conventional brakes but not anti lock brakes If any warning lamp indi cates a problem have that ABS checked ABS Warning Lamps Truck Tractor ABS Warning Lamp A truck tractor ABS warning lamp illuminates when the ignition switch i...

Page 112: ...s checked as soon as possible NOTE A successful warning lamp illumination and bulb check at ignition on does not indicate that the trailer you may be connected to has trailer ABS You should personally inspect every trailer to determine its braking system A trailer ABS warning lamp will illuminate for a bulb check when the ignition switch is first turned on whether or not a trailer is connected to ...

Page 113: ...quipped trailer is properly connected the trailer ABS warning lamp will remain illuminated for a few more seconds while the trailer ABS is tested If no trailer ABS problems are detected the lamp will go off If a trailer ABS problem is detected the lamp will remain on The driver should have the trailer s ABS problem corrected before the vehicle is driven with that trailer attached Advanced ABS with...

Page 114: ...e overall ESP system addresses rollover conditions In the case of a potential roll event the ECU will override the throttle and quickly apply brake pressure various wheel ends to slow the vehi cle combination The level of braking application during an RSP event will be proportional to roll risk A Real World Example Of How The RSP System Operates Excessive speed for road conditions creates forces t...

Page 115: ...eelbase vehicles tractors for instance have less natural yaw stability while longer wheelbase vehicles straight trucks for instance have greater natural yaw stability Factors that influence yaw stability are wheelbase suspension steer ing geometry weight distribution front to rear and vehicle track width Yaw Control Yaw Control responds to a wide range of low to high fric tion surface scenarios in...

Page 116: ...ABS ATC and ESP stability systems are no substitute for prudent careful driving Towing Doubles Or Triples May Reduce The Effective ness Of Stability Systems ESP is designed and optimized for trucks and for tractors that tow single trailers If a tractor equipped with ESP is used to power multiple trailer combinations known as doubles or triples the effectiveness of the ESP system The Bendix Yaw Con...

Page 117: ...avement at an angle that is too large to be counteracted by a reduc tion in speed The vehicle is used to haul double or triple trailer com If very rapidly winding steering inputs are inputted at high speeds There are mechanical problems with suspension lev eling of the tractor or trailer resulting in uneven loads The vehicle is maneuvering on a high banked road creating either additional side forc...

Page 118: ...cle s steering wheel Using a different steering wheel could cause ESP to malfunc tion causing a loss of vehicle control possibly resulting in death or severe personal injury Steering Angle Sensor Re Calibration Whenever maintenance or repair work is performed to the wheel track or if the steering angle sensor is replaced or the steering wheel is changed or re centered the Steer ing Angle Sensor mu...

Page 119: ...st starting the vehicle and for monitoring these lamps while driving no special operating procedures are required For detailed system description see service literature for your specific ABS that was provided with your vehicle Brake Safety and Emergency To stop your vehicle in an emergency vary the service brake application pressure to provide maximum braking force without locking the wheels Use e...

Page 120: ...either exists get back behind the wheel and resume a slow speed as soon as possible to cool the brakes Parking Brakes and Their Use The yellow diamond shaped knob on your instrument panel controls your parking brakes These are spring brakes which you activate by releasing air pressure from their chambers When they are not in use air pressure compresses the springs and releases the brakes But put t...

Page 121: ...killed or severely injured Never pull out the parking brake valve while the vehicle is moving Do not use the trailer hand brake or service brakes to park and hold an unattended vehi cle use the parking brakes Because service brakes work with air pressure these brakes could slowly release Your vehicle could roll causing an accident involving death or per sonal injury Someone could be hurt or killed...

Page 122: ...em reaches 100 psi 689 kPa To release your truck or tractor brakes ONLY push in the yellow knob Your trailer will remain parked To release the full combination of brakes push in BOTH yellow and red knobs Trailer Air Supply Valve The red octagon knob controls the air supply to the trailer To supply air to the trailer system and release the trailer parking brakes Allow the tractor air system pressur...

Page 123: ...ngerous You would probably have no brakes at all which could cause death or serious injury Releasing the spring brakes on an unse cured vehicle could lead to an accident The truck could roll causing death or severe injury Always secure the truck with wheel chocks chains or other safe means to pre vent rolling before manually releasing the spring brakes Disassembling the spring brake chamber is dan...

Page 124: ...THE VEHICLE To release spring brakes manually 1 Remove the cap from the spring chamber 2 Remove the release stud assembly from the side pocket remove the release nut and washer from the release stud 02936A Y53 6032 book Page 122 Monday May 24 2010 3 37 PM ...

Page 125: ...pening in the spring chamber where the cap was removed Insert it into the pressure plate Turn the release stud 1 4 turn clockwise in the pressure plate This secures the cross pin into the cross pin area of the pressure plate and locks it into the manual release position 02936C 02937A Y53 6032 book Page 123 Monday May 24 2010 3 37 PM ...

Page 126: ...tud assembly nut until the compression spring is 90 95 caged While doing this check to make sure the push rod adapter push rod or service push rod is retracting Do not overtorque the release stud assembly S Cam type maximum 50 ft lb Wedge type maximum 30 ft lb The spring brake is now mechanically released 02937B Y53 6032 book Page 124 Monday May 24 2010 3 37 PM ...

Page 127: ... the retarder might not stop you fast enough to prevent an acci dent You could be killed or severely injured if you relied only on your retarder Use the service brakes for quick stops The retarder is not an emergency brake The retarder is NOT intended as the primary brake for the vehicle nor is it an emergency brake The retarder only helps the service brakes by using pressure to slow the driv etra...

Page 128: ...on and Maintenance Manual supplied in your vehicle All other lamp and switch functionality described in the manual are still valid In order to meet EPA engine emission requirements vehi cles will have an exhaust After Treatment System ATS which includes a Diesel Particulate Filter DPF Regener ation Switch and warning lights The DPF will trap soot from the engine exhaust gases The ATS will periodic...

Page 129: ...t the exhaust gases from the DPF may reach temperatures in excess of 650 C 1200 F See the information in the table below on probable causes and recommended actions related to the warning lights and indicator symbols of the ATS The ATS may not be able to regenerate the DPF when the vehicle is driven at extended low speeds or with frequent start and stops In such cases warning lights and indica tor ...

Page 130: ... and at the outlets of the exhaust system during and shortly after a regeneration event will be extremely hot If the High Exhaust System Temperature HEST warning lamp is on Do not park in an area of combustible vapors or mate rials You must keep combustibles at least five 5 feet away from the side and top of the vehicle while the HEST light is illuminated Always park your vehicle outside Failure t...

Page 131: ...generating Regenerate the DPF as soon as safely possible Follow the instructions described DPF Regeneration on page 131 CAUTION If you do not initiate regeneration after the DPF Indicator lamp is blinking you only have a short time before the check engine light will illuminate and the engine will go into protection mode and de rate power Blinking On Steady The DPF status indicator symbol will blin...

Page 132: ...vehicle refer to the Engine Manufacturer s Operation and Maintenance Manual supplied with your vehicle On Steady Cummins and PACCAR Engines The Stop Engine light is illuminated when the soot level in the DPF continues to stay above the desired level The soot level in the DPF is now at full capacity At this point you CANNOT regenerate the DPF and the engine will begin a shutdown sequence WARNING If...

Page 133: ...in the immediate future limits your ability to reach highway speeds proceed to the next section titled Parked Regeneration Parked Regeneration In very limited applications or operations the DPF must be regenerated by initiating a Parked Regeneration Follow these six steps to initiate a Parked Regeneration 1 Pull the vehicle over to a safe location 2 Ensure no one is in the immediate vicinity to th...

Page 134: ...e hensive it is your responsibility to take the neces sary precautions and be aware of your surroundings and ensure that no combustibles materials or vapors or bystanders are close by 4 Verify that the following conditions are met before pro ceeding A Parked Regeneration will not initiate if any of these conditions are not met Parking brake is applied set Engine is at low idle No throttle brake or...

Page 135: ...Parked Regeneration A three position switch with a START Center and STOP the regeneration switch is a two position switch then the operator will not have the ability to stop a regeneration and this section will not apply WARNING If the vehicle s regeneration switch does not have a STOP position never allow the vehicle to remain inside a building such as a service bay shop or building of any kind d...

Page 136: ...eriods of time will result in increased soot levels in the DPF Stopping The Engine Before Stopping The Engine A hot engine stores a great amount of heat And it doesn t cool down immediately after you shut it off Always cool your engine down before shutting it off You will greatly increase its service life Idle the engine at 1000 RPM for five minutes Then low idle for thirty seconds before shutdown...

Page 137: ... explo sion Do not remove a fuel tank cap near an open flame Use only the fuel and or additives recom 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 l...

Page 138: ...plete the entire air supply Be sure to close the drains before leaving the vehicle 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 i...

Page 139: ...rked and the wheels chocked before beginning this procedure CAUTION Completing this procedure will enable you to safely reach the nearest autho rized Peterbilt repair facility to have ride height and pinion angle reset using the proper equipment and technique Do this as soon as possible to avoid potential driveline damage NOTE Suitable wheel chocks are at a minimum an 18 inch 46 cm long 4x4 Propri...

Page 140: ...At least one of the mounting holes in the height control valve bracket will be slotted to permit rotating the valve On dual valve systems begin with the LH valve on the next step 2 Loosen the fasteners mounting a height control valve to its bracket ALIGNMENT PIN OR DOWEL CONTROL ARM FROM DUMP VALVE SWITCH LINK BOLT DELIVERY TO LEFT HAND AIR BAG EXHAUST SUPPLY FROM FORWARD AIR TANK DELIVERY TO RIGH...

Page 141: ... springs to overinflate Overinflating the air springs may cause them to burst which can lead to death or personal injury from debris or the frame For tandem axles make the vertical measurement at the centerline of the suspension see illustration on page 137 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...

Page 142: ...to death or personal injury Before driving the vehicle make sure the pressure does pump up to over 100 psi for normal brake operation If the air pressure does not pump up to at CAUTION Operating a vehicle with air sus pension bags either overinflated or underin flated may cause damage to driveline components If a vehicle must be operated under such conditions do not exceed 5 mph Driving Tips And T...

Page 143: ...down a steep or long grade reduce speed and shift the transmission into a lower gear to help control your vehicle speed Failure to follow procedures for proper downhill operation could result in Engine Overspeed CAUTION To avoid engine damage do not let the engine rpm go beyond the maximum gov erned rpm valve damage could result if over speed conditions occur NOTE Often these recommendations are s...

Page 144: ... gear even in manual mode if an engine over speed condition exists When the engine speed reaches its maximum governed speed the injection pump governor cuts off fuel to the engine However the governor has no control over the engine rpm when it is being driven by the vehicle s trans mission for example on steep downgrades Apply service brakes or shift to a higher gear Fuel economy and engine perfor...

Page 145: ...vehicle to an expert mechanic for your safety and your vehicle s safety WARNING It can be dangerous to attempt maintenance work without sufficient training service manuals and the proper tools You could be killed injured or you could make your vehicle unsafe Do only those tasks you are fully trained and equipped to do Before attempting any procedures in the engine compartment stop the engine and l...

Page 146: ...supported make sure that 1 the vehicle is on hard level ground 2 the parking brake is applied 3 all wheels are chocked front and rear and 4 the engine cannot be started Remove the ignition key Never start or let the engine run in an enclosed unventilated area Exhaust fumes from the engine contain carbon monoxide a colorless and odorless gas Carbon mon oxide can be fatal if inhaled NOTE Suitable wh...

Page 147: ...ur vehicle off highway or in very heavy duty applications such as mining logging or earth mov ing you will need to perform maintenance checks and ser vices more frequently The charts on the following pages show the maintenance intervals for recommended main tenance practices NOTES Engine lubricating oil change intervals aren t listed here Refer to your engine s operating manual for recommendations...

Page 148: ...n to the specified torque value as required see page 208 X Front Axle Steering knuckles thrust bearings kingpins drawkeys tie rod ends steering stops bushings Inspect for wear and damage and for endplay Shim or replace as required see page 207 X Kingpin bushings tie rod ball ends Lubricate with approved grease X Total Vehicle Alignment Check and adjust as required X X Drawkeys Tighten nuts X X Fro...

Page 149: ... Visually inspect for damage or leaks X Check oil level Check cold Torque the drain plug X Drain the lubricant while warm Flush each unit with clean flushing oil Change the lubricant See information on page 170 Air Shift Unit Check the lubricant level X Remove the housing cover and drain the lubricant Wash the parts thor oughly and dry in air X Breather Clean or replace X Lube Pump ON HIGHWAY Remo...

Page 150: ... greater than 7 degrees Tighten the plug to 35 50 Lb ft 47 68 N m X Axle Housing Visually inspect for damage or leaks X Axle Housing Drain and replace the lubricant See information on page 169 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 nu...

Page 151: ...haft bearing Lubricate NLGI 2 grease X Check for excessive cam shaft play in the axial and radial directions Max allowable play is 0 003 X Brake treadle valve Clean the area around the treadle boot and mounting plate Check the pivot and mounting plate for integrity Check the plunger boot for cracks Lubricate roller pin pivot pin and plunger NLGI 2 grease X Brake air system Check air lines and fitt...

Page 152: ...Hubs non LMS Check the bearing endplay and adjust as required see page 185 X Hubs non LMS with outrun ner seals Clean the components and check for excessive wear or damage Change the oil and seal see page 185 X Hubs non LMS with stan dard seals Clean the components and check for excessive wear or damage Change the oil and seal see page 185 X Hub seals all Check for leaks replace as required X LMS ...

Page 153: ...as required X Main aux iliary trans mission Main auxiliary transmission and transfer case Inspect for visible damage signs of overheating and leaks X X Main auxiliary transmission and transfer case Check the drain plugs for tightness X Oil cooler Clean the fins air to oil type and body Check the hose condition and for leaks replace as required X Main aux iliary trans mission Dana Main auxiliary tr...

Page 154: ...g aids Check for leaks and proper operation see page 94 X Air cleaner Replace the element as indicated see page 212 When required by the air restriction indicator Clutch Clutch pedal shaft Check for excessive looseness and lubricate NLGI 2 grease X Clutch pedal Check for proper pedal free travel see page 203 X Clutch release linkage Check for excessive looseness and lubricate NLGI 2 grease X Clutc...

Page 155: ... shows coolant is suitable for continued use see page 192 X Flush drain and refill with new coolant see page 194 X Fan clutch Check for leaks X X Check the fan drive bearings turn the sheavein both directions to check for worn hub bearings X X Solenoid Valve Check the fan drive for proper engagement and disengagement X X Tires Wheels Tires Check inflation pressure see page 178 Weekly cold using ca...

Page 156: ...on clean or replace as required X Power Steering Reservoir Check the fluid level see page 171 X Reservoir ON HIGHWAY Drain replace the filter and refill see page 171 X X Reservoir OFF HIGHWAY Drain replace the filter and refill see page 171 X X Steering gear Check the lash of the sector shaft adjust as required X Steering gear Grease the trunnion bearing EP NLGI 2 lithium based moly filled HD grea...

Page 157: ...eering 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 Steering intermediate shaft U joints OFF HIGHWAY or CITY DELIVERY Lubricate EP NLGI 2 lithium based moly filled HD grease X X Fuel Tanks Fuel tanks Inspect tan...

Page 158: ...NE HAUL Lubricate slip member U joints 360 000 miles 576 000 km every 3 years Models SPL 140XL 170XL 250XL OFF HIGHWAY CITY Lubricate slip member U joints X Battery Battery cables Check the condition of the cables cushion clamps and routing Replace a cushion clamp if the rubber has deteriorated Repair or tighten terminals and secure cables to prevent chafing Replace damaged cables cuts cracks or e...

Page 159: ... Visual check X Alternator Check operation and output X Check tightness of the pulley nut X Check the tension of the drive belt see page 210 X Check tightness of the terminal hex nuts X Starter Check torque on hex nuts X ECM connector Check the tightness of the ECM connector X Wheel sensors Check for damaged sensors and connectors and worn or frayed wires X Fuel and Diesel Exhaust Fluid tank sendi...

Page 160: ...ghtness X Heating Air Condi tioning Air conditioner Operate the system NOTE The air conditioning system is active when the Defrost Defog mode is selected X Heater air conditioner Perform the checks listed on page 215 X Full operational and diagnostic check X Cab air filter Clean replace after a maximum of three cleanings X Condenser Clear any debris from the front of the condenser X Aftertreat men...

Page 161: ...ee page page 205 X Air Air compressor governor Replace air strainer X Air lines Check condition and routing to prevent chafing X System Lubricate see page 188 X Inline filters Replace elements or clean with solvent X Air dryer Perform the checks listed on page 190 X Air dryer ON HIGHWAY Overhaul 360 000 miles 576 000 km Air dryer OFF HIGHWAY Overhaul X Table 2 Preventative Maintenance Schedule Con...

Page 162: ...uded with the vehicle Strict adherence to these recommendations is required to maintain war ranty coverage The maintenance and service interval recommendations for the engines vary significantly depending on the manufacturer and the model of the engine As a minimum perform the operations listed below Table 2 Preventative Maintenance Schedule Continued SYSTEM COMPONENT MAINTENANCE TASK Recommended ...

Page 163: ...ponents therefore drain or remove old lubricants from the unit before refilling it Engine NOTE The engine in this vehicle may comply with EPA emission standards Consult the engine manu facturer s manual for changed lubrication and main tenance requirements Proper engine lubrication depends on the outside tempera tures where you will be driving Use the oil recommended for the conditions you are mos...

Page 164: ...maintained It is recommended that the vehicle s exhaust system and cab sleeper be inspected By a competent technician every 15 000 miles 24 000 km Whenever a change is noticed in the sound of the exhaust system Whenever the exhaust system underbody cab or sleeper is damaged NOTE Use only exact replacement components in exhaust systems Certain components contain inte gral catalytic converters essen...

Page 165: ...L 2104B MIL L 45199B w 1 85 max sulfated ash content CD Engine oil meeting API Five engine test sequence CD50 SAE50W synthetic transmission fluid CE Engine oil meeting severe duty service requirements for direct injection turbocharged engines CJ 4 Engine oil CL Multipurpose chassis grease C4 Type C4 transmission fluid torque fluid EP Extreme Pressure Lubricant GL Straight mineral gear lubricant HD...

Page 166: ...Bearing BB Fan Hub BB Power Steering Reservoir ATF Steering Drag Link CL Steering Knuckles CL Spring Pins CL Clutch Release Bearings BB Brake Shoe Anchor Pins HT Brake Cam Bearings HT Slack Adjusters CL Water Pump BB Cab Tilt Hydraulic Reservoir Hydraulic Jack Oil MIL L 5056B Speedometer Cables Lubriplate Aero or equivalent Consult manufacturer or lubricant supplier for special details Table 4 Com...

Page 167: ...vel check it regularly 2 Change oil regularly 3 Use the correct grade and type of oil 4 Buy oil from a reputable dealer Lubrication Change and Inspection Off Highway Use Refer to the Eaton Fuller transmission manual for servic ing information Highway Use Refer to the Eaton Fuller transmission manual for ser vicing information Refer to the oil change vs temperature chart that fol lows for special o...

Page 168: ...mmended Lubricants Type Grade SAE Ambient Temperature Heavy Duty Engine Oil MIL L 2104B C or D 50 Above 10 F 12 C API SF or API CD Previous API des ignations are acceptable 40 Above 10 F 12 C 30 Below 10 F 12 C Mineral gear oil with rust and oxida tion inhibitor API GL 1 90 Above 10 F 12 C 80W Below 10 F 12 C Synthetic Lubri cant 50 All See your Peterbilt dealer for approved brands Y53 6032 book P...

Page 169: ...me cases create transmission problems Multipurpose oils as a group have relatively poor oxidation stability a high rate of sludge formation and a greater tendency to react with or corrode the steel and bronze parts Table 6 Recommended Lubricants Type Grade SAE Ambient Temperature Heavy Duty Engine Oil MIL L 2104D or MIL L 46152B API SF or API CD MIL L 2104B or C or MIL L 46152 designations are acc...

Page 170: ... made after 24 hours but before 100 hours of service have elapsed Refilling Remove all dirt around filler plug Refill with new oil of the grade recommended for the existing season and prevail ing service Fill to the bottom of the level testing plug posi tioned on the side of the transmission Do not overfill the transmission Overfilling usually results in oil breakdown due to excessive heat and aer...

Page 171: ...lubri Refer to the following chart for lubricant change inter vals Table 7 Available Advanced Lube Axles RS 17 145 RS 23 180 RT 40 145 RT 44 145P RS 19 145 RS 26 180 RT 40 145P RT 46 160 RS 21 145 RS 30 180 SQ 100A RT 46 160P RS 23 160 RT 34 145 SQ 100AP RT 52 160 RS 23 161 RT 34 145P RT 44 145 RT 52 160P Table 8 Lubricant Change Intervals Application Type Of Lubricant Mileage Interval Linehaul Sy...

Page 172: ...after a carrier head replacement regardless of the lubricant type Refer to the Eaton Field Maintenance Manual for a particular axle for lubricant specifications See your Peterbilt dealer for Eaton approved lubricant brands Wheel Bearing Lubrication Oil lubricated Driven Hubs Use hypoid oil A P I GL 5 SAE 80W 90 or equivalent A minimum of 1 quart 921 ml of oil is required for proper lubrication of ...

Page 173: ...ing with clean wheel bearing grease after disassembling cleaning and inspecting Universal Joint Lubrication Refer to the Spicer Universal Joints and Driveshafts ser vice manual and lubrication specifications Steering Gear Lubrication CAUTION When adding fluid be sure to use fluid of the same type While many fluids have the same description and intended purpose they should not be mixed due to incom...

Page 174: ...on discoloration or burnt smell correct source of such problems before replac ing fluid filter Table 10 Fluid and Filter Replacement Schedule Steering Gear Fluid Inspect mi km Replace mi km months TRW ATF Every 15 000 24 000 Every 240 000 384 000 24 Sheppard ATF Every 15 000 24 000 Every 240 000 384 000 24 Extremely low temperatures may require lower viscosity fluids con sult your Peterbilt dealer...

Page 175: ...pply the parking brake and chock all wheels securely To operate your vehicle safely and profitably you need some understanding of its brake systems For more on brakes see the Index under Brakes Brake adjustment and brake balance must be set carefully to 1 make the most efficient use of the forces available for braking and 2 allow equal stopping forces at all wheels CAUTION The air brake system of ...

Page 176: ...ts in your brake sys tem conform exactly to original specifica All vehicle operators should check their brakes regularly Always adjust your brakes when they are cool WARNING Do not use brake linings with a thickness below the specified minimum Such linings will have lining rivets exposed that can damage the brake drum and reduce brake effi ciency which could cause death personal injury or system f...

Page 177: ...ct the linings more fre quently Regularly inspect for pad rotor wear Park on level ground and chock the wheels Temporarily release the parking brakes Compare the relative position of two notches one located on the caliper and the other on the carrier See the illustration below to determine if the brakes Have a qualified mechanic perform a detailed inspec tion if the notches are not found The pads ...

Page 178: ...s inspect the linings more frequently Automatic Slack Adjusters Periodically check the Brake Chamber Stroke Replace the slack adjuster if proper stroke cannot be maintained Operational checks of automatic slack adjusters Measure brake chamber stroke with the spring brake released and the air pressure no less than 100 psi 690 kPa Brake Chamber Stroke is the difference between the applied and the re...

Page 179: ... Page 184 illustrates the differences between parts used in hub piloted mount and ball seat mount applications Only OEM supplied hub piloted or ball seat mounted wheels may be used on this vehicle 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 perso...

Page 180: ...er deflate a warm tire to the specified pressure Lower tire pressure does not give you more traction on ice or snow This is an old myth that refuses to die Underinflation actually reduces traction steering con trol 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 ti...

Page 181: ...ar more quickly than properly inflated tires and are more subject to punctures cracks and other damage They could fail and cause you to lose control of your vehicle result ing in an accident causing death or personal injury Be sure all tires are inflated correctly according to the manufacturer s recommenda tions The chart on page 182 gives you the right load and infla tion rates for different tire...

Page 182: ...trol of your vehicle resulting in an accident causing death or personal injury Front Replace front tires when less than 4 32 in of tread remains Check at three places equally spaced around the tire Drive Axles or Trailers Replace tires on drive axles or trailers when less than 2 32 in of tread depth remains in any major groove Check at three places equally spaced around the tire See the next illus...

Page 183: ...s 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 speed Failure to comply with these speed restri...

Page 184: ... 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 5950 6005 11R24 5 G 4660 4870 5070 5260 5510 5675 5840 6005 11R24 5 H 4660 4870 5070 5260 5510 5...

Page 185: ...ating GVWR is not exceeded and 2 the load is distributed correctly so that the weight distribution is within the limits of the front and rear axle load ratings Severe damage to your vehicle diffi cult handling 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...

Page 186: ...ned on the hub fit tightly to the wheel center bore The ball seat mounting system uses 3 4 x 16 or 1 1 8 x 16 threads The dual mounting studs provide 1 3 1 44 in standout Right hand and left hand threads are required Inner and outer cap nuts center the wheels by seating against wheel ball seats Wheels Pilot mount wheels have stud holes that are reamed straight through no ball seats Center bore dia...

Page 187: ...a week Contact the Service Department at your dealership for information on the proper installation procedure for the wheels on your truck This is a job you may not be able to do yourself You need the right torquing equipment to do it WARNING Never use oil or grease on studs or nuts improper torque readings will result which could cause improper wheel clamping and could lead to a wheel failure res...

Page 188: ...t in an accident caus ing death or personal injury Crisscross Sequence For Disc Wheels Demountable Rims To check the torque on demountable rims follow the criss cross sequence shown See the Specifications chart for proper torque specification WARNING Improperly mounting and demount ing tire and rim assemblies is dangerous Failure to observe proper precautions could cause the tire rim assembly to b...

Page 189: ...R CAP NUTS Lb Ft N m Stud Piloted Disc Wheels 3 4 16 Inner 1 1 8 16 Outer 450 500 610 680 Heavy Duty 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 Cast Spoke Wheel Assembly 1 2 Dia 5 8 Dia 3 4 Dia Rim Clamp Nut Torque 80 90 110 120 160 185 220 250 225 245 305 335 Y53 6032 book Page 187 Monday May 24 2010 3 37 P...

Page 190: ...ith air pressure Never look into air jets Never attempt to disassemble a component until you have read and understood recom mended procedures Some components contain powerful springs and injury can result if not properly disassembled Use only proper tools and observe all precau tions pertaining to use of those tools Completely bypassing a Bendix AD IS air dryer will bypass the system s pressure pr...

Page 191: ...ir operated components such as brake valves wiper motors and suspension height control valves To keep contaminants to the lowest possible level follow these maintenance procedures WARNING If the supply and service tanks are not drained at the recommended frequency water could be sent to all air lines and valves This could cause corrosion which could com promise the brake system safety and potentia...

Page 192: ...ith reduced braking capability Other vehi cles use a Bendix AD IS air dryer which eliminates the need for a wet tank and check valves in the dry tanks NOTE A small amount of oil in the system may be normal and should not by itself be considered rea son to replace a desiccant cartridge oil stained desiccant can function adequately Every 900 operating hours or 30 000 miles 48 000 km or 3 months chec...

Page 193: ...ne Engine damage can include but is not limited to Freezing Boiling Corrosion Pitted cylinder liners This information is found in the engine manufac turers owner s manual It is the owner s respon sibility to follow all requirements listed in the engine manufacturers owner s manual What To Check In An ELC filled Cooling System ELC Concentration Check the level of freeze boilover protection which is...

Page 194: ...oling system and engine components Consult your dealer or the ELC manufacturer s represen tative for recommended ELC test kits test strips and lab oratory sample procedures ELC Extender Add ELC extender if necessary at the maintenance inter val under Cooling on page 152 Coolant Filter If your vehicle came with a non chemical filter blank fil ter replace it only with a blank filter at the interval ...

Page 195: ...igns of coolant leaks when the engine is cold check for leaks with the engine operating at normal temperature WARNING Handle coolant and antifreeze care fully Ethylene glycol antifreeze is poisonous and can cause death or personal injury Store in original fluid container only and always keep out of reach of children Check the coolant level after each trip Add coolant as necessary You may find your...

Page 196: ...ry to pause for 1 minute and then re fill if the fluid level dropped WARNING Do not ingest ethylene glycol based antifreeze it is poisonous It can be harmful or fatal especially to children Store in its original container only and keep it out of reach of children 5 If the system has petcocks close them 6 Start the engine and idle at a low RPM 7 During low rpm idle air will purge from the cooling s...

Page 197: ...cle Battery Care Regular attention to the charging system will help prolong the service life of your batteries Here are some common causes of battery failure Overcharge This condition may result from improper voltage regulator adjustment It results in overheating of the battery warped plates and evaporation of elec trolyte Undercharge Your voltage regulator may be mal functioning or is improperly ...

Page 198: ...other flames Always make sure the battery charger is OFF before connecting or disconnecting the cable clamps WARNING Always shield your eyes your skin and painted surfaces to from contact with batt tery fluid Batteries contain a corrosive fluid which can cause death or severe personal injury Use protective eyewear CAUTION Never use a metallic funnel to add distilled water It could come in contact ...

Page 199: ... make sure the battery charger is OFF before connecting or disconnecting the cable clamps To reduce the danger of explosions and resulting death or serious personal injury do not connect or discon nect charger cables while the charger is operating Never reverse battery polarity Battery terminals should not be coated with improper grease Use petroleum jelly or commercially available noncorrosive no...

Page 200: ...e 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 2 Disconnect the battery cables 3 Connect charger cables 4 Start charging the battery at a rate not over 6 amperes Normally a battery should be charged at no more than 10 percent of its rated capacity 5 After charging turn OFF charger and disconnect charger cab...

Page 201: ...icle at the same time Remove metal jewelry avoid leaning over a battery If metal jewelry or other cuits a short circuit may occur causing you to be killed or injured plus electrical sys tem failure and damage to the vehicle Do not try to jump start or charge a frozen battery Even a battery with ice particles on the electrolyte surface is dangerous Allow it to thaw out first And always allow batter...

Page 202: ... To Jump Start Your Vehicle 1 Wear eye protection and remove rings metal watch bands and any other metal jewelry 2 Set the parking brakes Place the transmissions of both vehicles in Neutral Do not let the vehicles touch one another Turn the ignition key to Off in the vehicle with the discharged battery Also turn off lights heater and any other unnecessary electrical load 3 If either battery has ve...

Page 203: ...ply may result in death or personal injury 7 Reverse the above sequence exactly when removing the jumper cables Take care that your first step is to remove the cable from the chassis or ground of the Removing and Installing Batteries WARNING Always reinstall the battery com partment cover step before entering the cab Without the battery cover you could slip and fall resulting in death or personal ...

Page 204: ...urface 6 Establish a horizontal line no more than 1 in 2 5 cm wide on a suitable aiming surface at the same height above a level surface as the optical center of the headlamp The optical center is identified on the cover lens by a small dot If a dot is not present the optical center is the center of the beam that is being aimed 7 Determine the headlamp identifier from the cover lens of the headlam...

Page 205: ...avel is usually 1 3 4 in to 2 in 34 to 51 mm This should be your guide for determining whether your truck needs clutch adjustment Some vehicles have automatic clutch adjustment If yours doesn t have this feature adjustment will have to be done by a trained certi fied mechanic Have the adjustment done before clutch pedal free travel is reduced to the minimum allowable 1 2 in 13 mm Fuel System Locat...

Page 206: ...commendations for proper water and micron requirements CAUTION When removing filters cover any electrical equipment and wiring that might get soaked with fuel Diesel fuel may permanently damage electrical insulation When installing spin on throwaway filters hand tighten them only to 1 2 to 2 3 turn after gasket con tact Mechanical tightening of these filters may distort or crack the filter head NO...

Page 207: ...F tank has been designed to hold a mini mum of 6 of the diesel fuel your vehicle is designed to carry DEF filter The DEF system has a supply pump filter and this filter should be serviced according to the preventive maintenance schedule Follow these steps to replace the DEF supply pump filter 1 Turn off the vehicle and allow the vehicle to cool down Take special precaution with hot exhaust pip ing...

Page 208: ...e bottom of the DEF tank 3 Using a 27 mm socket wrench DIN3124 remove the filter cap that is screwed to the DEF Supply pump 4 Replace filter and reassemble the cap Tighten the cap to 11 4 18 5 lb ft 15 25 Nm 5 Replace the pump protective plate Y53 6032 book Page 206 Monday May 24 2010 3 37 PM ...

Page 209: ...eveal the problem or if you correct them and still have a steering problem take your vehicle to an authorized dealer for evaluation Front End Alignment For driving safety and comfort and to prolong the life of your vehicle it is important to have proper front end 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 w...

Page 210: ...e suspension U bolts can lead to unsafe vehicle conditions including hard steering axle misalignment spring breakage or abnormal tire wear See the Fastener Torque Tables for proper torque specifications WARNING Do not replace U bolts and nuts with common U bolts or standard nuts These parts are critical to vehicle safety If the wrong U bolts or nuts are used the axle could loosen or separate from ...

Page 211: ...4 25 40 34 54 35 50 47 68 7 16 14 35 50 47 68 50 71 68 96 20 39 56 53 76 56 80 76 108 1 2 13 54 77 73 104 76 109 103 149 20 58 87 79 118 86 123 117 167 9 16 12 78 111 105 151 110 158 149 214 18 87 124 118 168 123 176 167 239 5 8 11 108 154 147 209 153 218 208 296 18 122 174 166 236 173 247 235 335 3 4 10 192 273 260 370 271 386 367 523 16 214 305 290 414 303 431 411 583 7 8 9 309 441 419 598 437 6...

Page 212: ...ive Belts You can extend the reliability and service life of your vehi cle s drive belts with proper attention to installation failure The result could be the loss of the electrical or air system as well as possible engine damage from overheat ing 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 dri...

Page 213: ... is near the fan Your truck may be equipped with an On Off or Viscous Fan Drive Follow these guidelines to check your engine fan Check the fan assembly mounting bolts for tightness Inspect the fan blades for damage On Off Fan Drives Check the clutch operation by starting the engine when it is cold Idle the engine at about 800 RPM Listen for air leaks Check that the fan is not work ing while the en...

Page 214: ...mounting brackets don t repair defec tive parts Air Cleaners The following service information is basic to all air cleaner makes and models Service the air cleaner filter elements as specified in the Preventive Maintenance Schedule If your vehicle is equipped with an optional air inlet restriction indicator ser vice the filter elements when the air inlet restriction indica tor locks in the extreme...

Page 215: ...n the engine is running This suction could draw your hand or anything else near it into the impeller fan You could be killed or seriously injured Always keep the intake pip ing connected when you will be running the engine CAUTION Operating the engine with the tur bocharger intake piping disconnected will allow abrasive dust to enter the engine which can cause equipment damage Lubricating System C...

Page 216: ...no testing or any time the ignition is on with part of the ABS disconnected a fail ure code will be recorded After servicing or testing of the vehicle is completed clear the failure codes If due to operating conditions a brake application causes either wheel on the same axle to begin skidding wheel speed sensors immediately signal the anti lock controller in the modulator assembly The controller r...

Page 217: ...ned back on and the warn ing light extinguished by turning the key switch OFF and ON after the vehicle has been brought to a full stop When the key switch is turned back on the warning light will illuminate and remain on for 3 to 5 seconds This is a built in function test of the warning light Cab Heater Air Conditioner The combination heater air conditioner provides comfort for those in the cab th...

Page 218: ...or repair Check the heater core for debris blocking the air flow If the blower is functioning properly yet the heater is not operating properly the heater core may be clogged Clean the heater core if necessary If the condition persists take the vehicle to a Peterbilt dealer for proper heater service or repair Air Conditioner WARNING The air conditioning system is under pressure If not handled prop...

Page 219: ...rect the problem NOTE A leaking evaporator or condenser core cannot be repaired it must be replaced Have the air conditioning system fully inspected annu ally by your dealer Special Precautions WARNING Excessive heat may cause your air conditioning system to explode which may result in death or personal injury Never weld solder steam clean or use a blow torch near any part of the air conditioning ...

Page 220: ...oved with a special commercial tar remover or mineral spirits Waxing offers added protection against staining and oxidation But to allow enough time for your truck s fin ish to cure wait about ninety days after the date of manufacture before waxing Don t wax in the hot sun Don t friction burn the paint with a buffing machine Aluminum and Chrome Surfaces Clean aluminum wheels and bumpers with warm ...

Page 221: ...ior Cleaning Cab Interiors Peterbilt cab and sleeper interiors are built using a variety thane and painted plastic surfaces These cleaning pro cedures will ensure that interior components remain in good condition for the life of the vehicle General Cleaning Guidelines WARNING Cleaning agents may contain hazardous agents Thoroughly read understand and follow the manufacturer s instructions when usi...

Page 222: ...nel This may cause glare that can be a driver distraction Interior Trim Dash Shell and Instrument Panels CAUTION To avoid possible damage to these components do not use abrasive cleaners brushes chemical solvents or strong deter gents 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 on painted plast...

Page 223: ...these com ponents Clean with the cloth dampened with lukewarm water Dry with a clean cloth For difficult stains use a commercial leather cleaner Weatherstripping Occasionally spray weatherstripping on doors and win dows with silicone compound to help preserve resiliency This is especially useful in freezing weather to prevent doors and windows from sticking shut with ice Chassis Hose dirt and grim...

Page 224: ...nd 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 and equipped to conform at the time it left Peterbilt s con trol with all applicable U S EPA Noise Control Regula tions...

Page 225: ...an shroud Air Intake System Removing or rendering inoperative the air cleaner silenc ers or intake piping Exhaust System Removing or rendering inoperative the exhaust sys tem components Removing shields or skirts Cutting away parts of shields skirts or damaged or loose portions of shields or skirts Fuel System Removing or rendering engine speed governor inop erative allowing engine speed to exceed...

Page 226: ...ause death or personal injury Allow adequate cooling time before working on or near any part of the exhaust system Exhaust System WARNING If your vehicle becomes disabled the hot exhaust system could ignite dry grass brush spilled fuel or other material that can cause fires which can lead to death personal injury and property damage Do not park or operate your vehicle in areas where the hot exhaus...

Page 227: ...g for rattling sounds while tapping the unit with a rubber mallet or revving the engine up and down through its normal operating range Check the DPF for rust and corrosion Exhaust Tail Pipe s Check the mounting security Tighten as necessary The miter cut at the tip of the pipe must be facing the rear of the truck Do not modify the end of the pipe in any way Fan Shroud WARNING Do not work on the fa...

Page 228: ...la tors will remain in position Inner Fender Shields and Cab Skirts Fasteners Check all fasteners for security especially the self tapping hex head screws Remove and replace any loose rivets Shields and Skirts Check shields and skirts for cracks at mounting and stress points Check fender shields for tire marks worn spots or damage from objects thrown from tire treads You can repair cracked or dama...

Page 229: ...s clamps brackets and fasteners for deterioration cracks and security If you find an air leak anywhere between the air cleaner and the engine repair that leak immediately CAUTION Air leaks cause excessive noise and may result in serious damage to the engine If you do not repair them the engine damage won t be covered by your warranty Repair all air leaks as soon as you find them Y53 6032 book Page...

Page 230: ...ERFORMED DATE R O NUMBER REPAIR FACILITY LOCATION WORK PERFORMED Exhaust System Rout ing Integrity 25 000 Shutters Shrouds 25 000 Hood Insulation Blanket 10 000 Engine Mounted Hose Insultators Fasteners 10 000 Inner Fender Shields 50 000 Cab Skirt Fasteners 50 000 Air Intake System Integrity Element 5 000 Clutch Type FanDrive 10 000 Y53 6032 book Page 228 Monday May 24 2010 3 37 PM ...

Page 231: ...ombination identifies the manufacturer the model year it was built and other vehicle attributes The VIN is in compliance with 49CFR565 Code of Federal Regula tions As an example the model year and assembly plant are designated by a letter in the tenth and eleventh char acter positions see 4 and 5 below EXAMPLE VIN 1XP9D2X96XD345678 1XP 9D2X9 6 X D 345678 1 2 3 4 5 6 VIN characteristics 1 Manufactu...

Page 232: ...erbilt dealer who may be located from the Peterbilt Authorized U S and When you order it is IMPORTANT than you have the fol lowing information ready Your name and address Serial number of the truck The name of the part you need The name and number of the component for which the part is required The quantity of parts you need How you want your order shipped NHTSA Consumer Information If you believe...

Page 233: ...ation please visit the Road Safety website at http www tc gc ca roadsafety menu htm Environmental Protection 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 Cal ifornia to cause cancer birth defects or other reproductive harm This ...

Page 234: ...cessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling California Vehicle Code Section 9951 Disclosure of Recording Device Your vehicle may be equipped with one or more recording devices commonly referred to as event data recorders EDR or sensing and diagnostic modules SDM If you are involved in an accide...

Page 235: ...ontrol Switch 48 Dome Light Switch 44 Electric Horn 40 Engine Brake 49 Engine Fan Switch 46 Fifth Wheel Lock Slider Adjustment Switch 52 Fog Lights Switch 44 Hazard Flasher 39 Headlamps 42 Headlights 42 Heater Air Conditioning Controls 54 Interaxle Differential Lock Switch 50 Manual Override 42 Mirror Heat Switch 47 Panel Light Knob 43 Parking Brake Valve and Trailer Air Supply Valve 53 Power Mirr...

Page 236: ...haust fumes 144 F Frame Fastener Torque Specifications 208 G Gauges and Displays 59 Air Application Gauge 63 Air Filter Restriction Indicator or Gauge 70 Engine Oil Pressure Gauge 64 Fuel Gauge 66 Manifold Pressure Gauge 69 Primary And Secondary Air Pressure Gauges 63 Pyrometer 70 Speedometer Odometer 30 Speedometer Message Center 60 Tachometer 61 Voltmeter 70 Warning Lights and Buzzers 17 Water T...

Page 237: ...oise Control System 222 P Parking brake brake system operation 53 119 use 143 R Rear suspension fasteners standard 208 Refrigerator 72 Regeneration Switch 16 51 Restraint Systems 75 Inspection 83 Komfort Lok Feature 79 Shoulder Belt 76 Sleeper Bunk Restraints 80 Tether Belts 82 S Safe vehicle operation 88 Safety stands 144 Seat 75 Seat adjustment 75 Seats 75 Servicing Specific Systems Air Intake S...

Page 238: ...r Vehicle Must Be Towed 105 Interaxle Differential 101 Manually Releasing Spring Brakes 121 Operating the Clutch 99 Overheated Brakes 118 Parking Brakes and Their Use 118 Retarders 125 Setting Ride Height 136 Shifting The Transmission 99 Normal Temperature 93 Stopping The Engine 134 Trailer Air Supply Valve 120 Suspension fasteners torque 208 T Tachometer 142 Tire Load and Inflation Tables 182 tow...

Page 239: ...PART 11 SUBJECT INDEX Numerics 49 CFR 565 Code of Federal Regulations 229 Y53 6032 book Page 237 Monday May 24 2010 3 37 PM ...

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