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Peterbilt 220, Operator'S Manual

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Peterbilt 220 Operator'S Manual Download Page 103

in either or both systems is too low for
normal brake operation, i.e., one gauge
falls below 65 psi (448 kPa), a ‘BRAKE
AIR’ warning on the main display will be
shown and the audible alarm will sound.

NOTE

Park  brakes  lock  up  at  60  psi  (414
kPa),  the  audible  alarm  will  sound  at
65 psi (448 kPa).

Follow the procedure below to check the
compressed air system for leaks:

1. Periodically, or after maintenance or

replacement of air system
components:

2. Build up air pressure in the system to

the governor cutout point or until 120
psi (827 kPa) is reached.

3. Stop the engine and release the

service brakes.

4. Without applying the brake pedal,

observe the rate of air pressure drop.
This rate should not exceed 2.0 psi
(14 kPa) per minute.

5. Start the engine and build up the air

pressure again.

6. Stop the engine, and apply the brakes

fully. Apply the brake pedal and hold it
down for five minutes. The pressure
drop should not exceed 3.0 psi (21
kPa) per minute.

7. If you detect excessive leakage (air

pressure loss greater than 3.0 psi (21
kPa) after two minutes of brake
application), a leakage test should be
made at the air line connections and
at all air brake control units. These
tests should determine where air is
escaping.

Air Compressor

Operation

All compressors, regardless of make or
model, run continuously while the engine is
running. System pressure is controlled by

the governor. The governor acts in
conjunction with the unloading mechanism
in the compressor cylinder block to start
and stop compression of air. The
compressor is unloaded when the system
pressure reaches 120 psi (827 kPa) and
compression is reestablished when system
pressure falls to 100 psi (690 kPa).

Overview of Daily Checks

Overview of the driver's daily checks:

•

engine oil level

•

coolant level, fill cap secure

•

fluid level in windshield washer
reservoir

•

air filter indicator

•

tires and rims

•

lighting and instruments

•

driver's seat and mirrors

Visual check before starting the trip:

•

check that no situation can occur
(such as loose objects, improperly
attached load etc.) that may put
other road users at risk.

MAINTENANCE - Air Compressor

Y53-6078-1B1 (12/18/18)

101

5

Summary of Contents for 220

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Page 5: ...Safety 1 Emergency 2 Controls 3 Driving 4 Maintenance 5 Information 6 Contents ...

Page 6: ... on this vehicle Please disregard any illustrations or descriptions relating to features or equipment which are not on this vehicle PACCAR reserves the right to discontinue change specifications or change the design of its vehicles at any time without notice and without incurring any obligation The information contained in this manual is proprietary to PACCAR Reproduction in whole or in part by an...

Page 7: ...AFETY WHY THIS HANDBOOK IS SO IMPORTANT 6 Safety Alerts 6 Warnings and Safety Regulations 7 Emergency Equipment 9 Technical Items of Special Importance 12 Jump Starting Vehicles 14 SAFETY Y53 6078 1B1 12 18 18 5 1 ...

Page 8: ... Make sure this handbook is in the vehicle at all times Read it carefully before making your first journey especially the Warnings and safety precautions Cab instruments and controls Inspections and Driving sections Safety Alerts Please read and follow all of the safety alerts contained in this manual They are there for your protection and information These alerts can help you avoid injury to your...

Page 9: ...ehicle Example NOTE Pumping the accelerator will not assist in starting the engine Warnings and Safety Regulations WARNING To prevent damage to the vehicle and in order not to jeopardize your health and or safety or that of other people the following warning and safety regu lations must be strictly observed First read the instructions and warnings on the labels and stickers on the various componen...

Page 10: ...n be done safely Improper modifications can cause death or personal injury CAUTION The installation of electronic devices to the On Board Diagnostics OBD con nector the vehicle Controller Area Net work CAN or their associated wiring is not permitted Doing so can ad versely affect vehicle performance and or cause fault codes to be record ed The OBD connector is provided for temporary connection of ...

Page 11: ...or fill cap while the engine is hot Scalding steam and fluid under pressure may escape You could be badly burned Failure to comply may result in death or personal injury Emergency Equipment It is good practice to carry an emergency equipment kit in your vehicle One day if you have a roadside emergency you will be glad the following items are with you Window scraper Snow brush Container or bag of s...

Page 12: ... Check beneath the vehicle Are there signs of fuel oil or water leaks Check for damaged loose or missing parts Are there parts showing signs of excessive wear or lack of lubrication Have a qualified mechanic examine any questionable items and repair them without delay Check your load Is it secured properly Oils and Lubricants Various kinds of oil and other lubricants used on the vehicle may consti...

Page 13: ...without proper ventila tion Failure to do so may result in death or personal injury WARNING The air conditioning system is under pressure If not handled properly dur ing servicing it could explode Any servicing that requires depressurizing and recharging the air conditioning system must be conducted by a quali fied technician with the right facilities to do the job Failure to comply may result in ...

Page 14: ...while driving will lead to power steering failure Consequently the vehicle will be more difficult to steer The engine cooling system is thermostatically controlled Removing the thermostat when the coolant temperature is too high serves no useful purpose and is strongly advised against since this will only cause the engine temperature to rise to an even higher level The turbocharger is a precision ...

Page 15: ...le the charger is operating Charging Reminders Use protective eyewear Keep all batteries away from children Never reverse battery poles Never attempt to place the vehicle in motion or run the engine with batteries disconnected Keep the battery clean and dry Look for any signs of damage Battery terminals should not be coated with improper grease Use petroleum jelly or commercially available noncorr...

Page 16: ... or property damage WARNING Never jump start a battery near fire flames or electrical sparks Batteries generate explosive gases that could explode Keep sparks flame and lighted cigarettes away from batteries Failure to comply may result in death personal injury equipment or property damage WARNING Never remove or tamper with battery caps Ignoring this could allow battery acid to contact eyes skin ...

Page 17: ... vehicle 6 Shift the transmission into park position or neutral for manual transmissions 7 If either vehicle is equipped with battery disconnects ensure they are in the OFF position prior to connecting the two vehicles 8 Attach one end of a jumper cable to the positive terminal of the discharged dead battery This will have a large red or P on the battery case post or clamp 9 Attach the other end o...

Page 18: ...oth vehicles in the exact reverse order making sure to first remove the negative cable from the vehicle with the discharged battery Disconnect Switch This vehicle has a disconnect switch Ensure that your vehicle ignition has been turned off for at least 40 seconds before switching the disconnect switch to the OFF position CAUTION Wait 2 minutes after key off before dis connecting battery power Dis...

Page 19: ...cing the Fuel Line Filter 20 Draining the Water Separator 21 Releasing the Parking Brake 21 Jacking Up the Front Axle 22 Jacking Up the Rear Axle 22 Changing the Wheel 22 Tire Inflating Connection 24 Towing 25 Replacing Bulbs 26 Fuses 28 EMERGENCY Y53 6078 1B1 12 18 18 17 2 ...

Page 20: ...ing held back and falling forward to the ground Have your authorized Service dealer check the tilting mechanism WARNING Make sure that there is no one in the cab Also make sure there are no loose objects inside the cab this in cludes objects in the refrigerator Make sure there are no people immediately in front of the cab WARNING Never work under the cab if the cab has not been tilted fully forwar...

Page 21: ...ever in position Push the gear lever in 1st gear to lock the gearbox control Put the gear lever in neutral Checking the Cab Locking When the cab is back in its normal position the cab lock warning lamp in the master display should be extinguished Replacing the Poly V Belt Important Always fit the same type of poly V belt as the one being replaced 1 Disconnect the earth lead from the battery 2 Plac...

Page 22: ...system can lead to signifi cant damage to the fuel system Diesel fuel is toxic and can therefore have a damaging effect on your health Any direct or indirect physical contact should therefore be avoided In the event of contact with the skin re move with paper or a cloth wash with soap and water If irritation persists con sult a doctor If swallowed do NOT induce vomiting Rinse the mouth drink two g...

Page 23: ... the ring shaped drain cock B on the bottom of the water separator in anti clockwise direction 4 Drain the filter until pure diesel fuel comes out of the drain cock A 5 Turn the drain cock B if it abuts another 1 8 1 4 turn 6 Check the drain cock B for leakage 7 To prevent pollution the drained water diesel fuel mixture should be passed to the relevant authorities for reprocessing Releasing the Pa...

Page 24: ...be positioned under the jacking point at the bottom of the spring bracket WARNING Always use stands to support the chas sis when carrying out repairs or service under a vehicle which is resting on a jack To prevent deformation of the axle hous ing the jack must under no circumstan ces be located directly under the axle housing or the differential casing Changing the Wheel NOTE After changing a whe...

Page 25: ...valve in view of possible tensions in the wheel rim General Only use the original tire wheel rims specified for the vehicle concerned Make sure that tires of the same type are fitted on both sides of the axle Insufficient cleaning of the mating surfaces and or uneven tightening of the wheel nuts may cause vibrations during driving or braking NOTE If a wheel stud is renewed the other wheel studs on...

Page 26: ...n For the specified tightening torque see Wheel Nut Tightening torques on page 113 NOTE Wheel nuts should always be tightened and retightened in cold condition However tightening wheel studs in extreme cold should be avoided 8 Check the tire pressure 9 Retorque the wheel nuts after 62 miles 100 km If new wheel studs are fitted they need additional retorquing after 310 miles 500 km NOTE When a whee...

Page 27: ...ssage Engine management fault may appear in the master display when the ignition is turned on NOTE The maximum permissible vehicle speed weight and distance vary per country WARNING Do not tow the vehicle when fully load ed or with a drawn vehicle attached Being Towed by Another Vehicle WARNING When the engine is not running there is no power steering and no air is sup plied to the braking system ...

Page 28: ...Do not touch the glass of the halogen lamps with bare fingers If necessary this glass can be cleaned with a cloth which has been dampened with industrial alcohol methylated spirits When fitting a new bulb make sure that the lugs on the bulb holder engage in the slots of the reflector Dipped Beam 1 Tilt the cab forwards 2 Detach the rubber cover 2 from the rear of the headlamp unit 3 Detach the spr...

Page 29: ...the bulb holder anti clockwise out of the indicator lamp unit 4 Pull the bulb carefully out of the bulb holder Stepwell Lighting 1 Remove the stepwell lighting housing from the bottom of the door by inserting a screwdriver in the notch 2 If necessary remove the plug 3 Unscrew the bulb holder anti clockwise out of the stepwell lighting housing 4 Pull the bulb carefully out of the bulb holder Roof L...

Page 30: ... Each fuse is color coded to show the rating Orange 5 A Red 10 A Blue 15 A Yellow 20 A Transparent 25 A Green 30 A List of Fuses E004 Fuse driver s side dipped beam E005 Fuse co driver s side dipped beam E006 Fuse driver s side main beam E013 Fuse stop lights E016 Fuse reversing lights and cross axle lock control E018 Fuse G O reverse lams E019 Fuse horn E025 Fuse wiper wash E026 Fuse cigar lighte...

Page 31: ...64 Fuse fuel heater E165 Fuse fuel heater FPH E switched power E190 Fuse ABS E ASR E198 Fuse door lock E277 Fuse VIC E279 unused E280 Fuse VIC E283 Fuse side lights E284 Width marker light E285 Fuse fog lights switch E286 unused E290 Fuse customer adaption cab E297 Fuse airbag and seat belt tensioner system E299 unused E310 Fuse instrument panel DIP 4 E330 unused E349 unused E350 Fuse remote bat I...

Page 32: ...EMERGENCY Fuses 30 Y53 6078 1B1 12 18 18 2 ...

Page 33: ...34 Mirrors 34 Electrical Mirror Adjustment 34 Windshield Wiper Blades 35 Roof Console 35 Sun Visors 35 Stepwell Lighting 35 Interior Lighting 35 Dashboard 36 Control Panel 39 Control Panel of Heating Ventilation System 40 Air Conditioning Switch 40 Fan Speed Selector Switch 41 CONTROLS Y53 6078 1B1 12 18 18 31 3 ...

Page 34: ... 43 Left Hand Steering Column Switch 43 Right Hand Steering Column Switch 43 Steering Wheel Switches 44 Adjustable Steering Column 44 Seats 45 Master Display 48 PDC and Voltage Display 72 Power Distribution Center PDC 72 Voltage Converter 72 CONTROLS 32 Y53 6078 1B1 12 18 18 3 ...

Page 35: ...uel oil or grease off of the steps before enter ing the cab Use the steps and grab handles provided and always keep at least three points of contact between your hands and feet and the truck Look where you are going The picture shows the best way to enter and exit a Cab Over Engine Cab Doors WARNING To help lessen the chance and or se verity of death or personal injury in case of an accident alway...

Page 36: ...minutes If you press the switch again within 12 minutes the windscreen heating is switched off and the mirror heating is switched on again Operate the switch once more to switch everything off Mirrors The mirror housing and mounting bracket is fixed to the cab Only the face of the mirror is adjustable within the mirror housing The mirror bracket can be folded back against the cab and will return t...

Page 37: ...use or for items exceeding their designed weight limits Exceeding the weight limits may cause the shelf to collapse and or items may fall out in a sudden stop which may lead to personal injury or death Sun Visors As a protection against sun glare the sun visors can be folded down The sun visor on the driver s side can also serve as a side window shade Stepwell Lighting In both doors a lamp is fitt...

Page 38: ...mmed instrument lighting 16 N A 17 N A 1 Light switch The switch is a rotary switch with a spring loaded position and three static positions Position 0 Lighting switched off Position 1 Parking lights on Position 2 Headlights parking lights on Front fog lights Pull out the light switch one step to switch on the front fog lights The light switch must be in position 1 or 2 to activate When the front ...

Page 39: ... The Fuel gauge indicates the total approximate amount of fuel in the fuel tank In addition to indicating empty and full the gauge s also indicate the fuel level in graduated increments When the fuel level for the tank is below 1 4 full a red warning lamp in the gauge will come on Diesel Exhaust Fluid DEF Gauge The diesel exhaust fluid gauge shows the approximate amount of DEF fluid in the DEF tan...

Page 40: ...ble alarm sounds or when the pressure in one of the circuits is lower than approx 65 psi 448 15 kPa NOTE The air pressure warning will be acti vated when primary or secondary air systems drops below 65 psi 9 Tachometer Green area economical Blue area only permitted when driving downhill and for optimal use of the engine brake Red area not permitted 10 Speedometer Display When the steering wheel sw...

Page 41: ... lights up 2 PTO switch PTO can be an engine PTO or a gearbox PTO Use this switch to activate or deactivate PTO 1 3 Hazard warning lights When this switch is pressed all the direction indicator lights flash simultaneously The hazard warning lights are switched off by depressing the switch again The warning light in the switch indicated that the hazard warning is switched on 4 Air suspension switch...

Page 42: ...he windows must remain closed 2 To reduce the temperature quickly first use maximum air speed Later the air speed can be reduced 3 Avoid direct cold draught on your body 4 Make sure that the temperature difference between the inside and outside of the cab does not exceed 40 F 5 C when you leave the cab You are therefore advised to switch off the air conditioning towards the end of your journey 5 A...

Page 43: ...s will protect the engine WARNING Excessive heat may cause the pres surized components of the air condi tioning system to explode Never weld solder steam clean or use a blow torch near any part of the air condition ing system Failure to comply may re sult in personal injury death equip ment or property damage WARNING Air conditioning refrigerant can be haz ardous to your health Do not expose yours...

Page 44: ...eeds with re circulation valve closed hardly any supply of fresh outside air Temperature Adjustment The supply of heat can be smoothly set from 0 blue to 100 red To achieve faster heating when the temperature outside is low switch on the recirculation In damp weather conditions it is recommended to reopen the recirculation flap after heating to prevent the windows from misting Air Distribution Sel...

Page 45: ...gnals C Direction Indicator Right Position C Right turn signal on the instrument panel the right direction indicator will flash and there will also be an audible signal To briefly operate the direction indicators changing lanes etc the switch can be pushed slightly against the spring pressure It will spring back when released D Direction Indicator Left Position D Left turn signal on the instrument...

Page 46: ...g Column The position of the steering column is adjustable To adjust pull the handle towards you and simultaneously move the steering column to the desired position The steering column is locked by releasing the handle A pneumatically adjustable steering column is available as an option WARNING Make all adjustments to the steering mechanism while the vehicle is stop ped Adjusting the Tilt Steering...

Page 47: ... only be repaired by trained personnel Driver s Seat Operation 1 Seat fore aft adjustment 2 Shock absorber setting The suspension characteristics of the seat in terms of comfort can be optimized by means of the infinitely adjustable shock absorber from hard to soft for each driving situation Position switch up minimum damping soft comfort Position switch down maximum damping hard comfort NOTE The ...

Page 48: ...ns such as dirt and ultraviolet rays from the sun will reduce the life of the seat belt system Due to these factors the three point safety belt system installed in your vehicle requires thorough inspection every 20 000 miles 32 000 km If the vehicle is exposed to severe environmental or working conditions more frequent inspections may be necessary Any seat belt system that shows cuts fraying extre...

Page 49: ...f the vehicle for damage The retractor is the heart of the occupant restraint system and can often be damaged if abused even unintentionally Check operation to ensure that it is not locked up and that it spools out and retracts webbing properly 6 If tethers are used be sure they are properly attached to the seat and if adjustable that they are adjusted in accordance with installation instructions ...

Page 50: ...hree point type belt the shoulder section must be across center of the shoulder not against the neck The pelvis section should be as low as possible across the pelvis not across the abdomen Do not put any hard sharp or fragile objects such as pens glasses or phones between your body and the seat belt Checking the Seat Belts Give a short pull on the seat belt to test the locking mechanism Repeat th...

Page 51: ...ow information about settings and the values of these settings Grey information These messages show information about the status engaged or disengaged of systems Green Driver Performance Assistant These messages show information about the driver performance Start Up Phase If the ignition has been switched on and the engine is not yet running the start up screen is shown in the master display On th...

Page 52: ...ning the Menu Control Switch MCS brings up the hidden ones An arrow with a line attached to it indicated the beginning or end of the list NOTE A red warning cannot be removed from the screen when the engines is running The red warning can be suppressed by pressing the Menu Control Switch when the engine is not running This allows selection of other menu options The Warning always reappears after r...

Page 53: ...ttings screens are opened by entering one of the displayed options See section Menu Overview on page 52 Scroll through the various options in the information screens by turning the MCS Change the values in the settings screens by turning the MCS Select an option or confirm a value by pushing the MCS Use the Exit key under the MCS to go back in the menus A short press to go back to the main menu an...

Page 54: ...e selected after which sub menu 2 will appear if present If there is no sub menu 2 the menu function will be switched off By turning the menu selector switch sub menu 2 can be accessed The triangle on the right hand side of the display shows the direction in which you can proceed By pressing the menu selector switch the menu function will be switched off Menu Overview NOTE To go back to the main m...

Page 55: ...r pressure circuit 1 Actual air pressure circuit 2 Soot filter information Soot filter Actual soot level DPF filter Status DPF switch Duration indication of regeneration process Safety instructions Instructions on how to start a regeneration safely CONTROLS Master Display Y53 6078 1B1 12 18 18 53 3 ...

Page 56: ...nsumption Recent 15 minutes Average fuel Distance Eco settings Fuel target Reset Eco driving Coaching Tips tricks Various information accessible by selecting the icon on the picture using the Menu Control Switch MCS Opening the information by pushing the MCS Power Take Off PTO Total hours PTO 1 Total hours PTO 2 Fuel consumption PTO CONTROLS Master Display 54 Y53 6078 1B1 12 18 18 3 ...

Page 57: ...ings Service information Warning list All activate warnings Next service Date Mileage VIN number Vehicle Identification Number Total fuel The total amount of fuel used since the vehicle went into service CONTROLS Master Display Y53 6078 1B1 12 18 18 55 3 ...

Page 58: ...gs 12h 24h Language List of available languages Units Temperature F C Distance miles km Fuel consumption gallons 62 mile l 100 km km l Pressure bar psi Dim Settings Coupling the dashboards lights dim function with the reverse gear Speed control Coupling cruise control with downhill speed control CONTROLS Master Display 56 Y53 6078 1B1 12 18 18 3 ...

Page 59: ...ings are displayed in a pop up text screen followed by a post warning indicator This post warning indicator is identical to the information screen selected using the Menu Control Switch MCS Serious Fault A red warning pop up is activated on the master display when there is a serious fault When a red warning pop up is activated it displays A red hazard warning triangle A text explaining the fault T...

Page 60: ...ing pop up and a short acoustic signal are activated The yellow warning pop up displays A yellow hazard warning triangle A text explaining the fault The corresponding icon When yellow warnings appear on the master display you may continue driving but take action at the first opportunity to remedy the fault Have a service dealer correct the problem as soon as possible CAUTION The vehicle may behave...

Page 61: ...kground color of the screen See section Layout of Master Display on page 49 Master Display Warning Indicator Description Park brake not applied If the driver s door is opened while the engine has been switched off and the park brake has not been applied an acoustic signal is given and a warning symbol is shown on the master display NOTE On the master display this warning can be changed from red to...

Page 62: ...k if the cabin is fully tilted back See Tilting the Cab DPF soot filter This warning is activated when the soot level in the Diesel Particulate Filter DPF is too high or the soot filter is contaminated or the EAS system malfunctions High Exhaust System Temperature HEST This indicator is shown when regeneration is in progress and the exhaust gas temperature reaches levels that can potentially harm ...

Page 63: ...warning symbol can give the following text descriptions DEF level low or DEF tank empty Fill up the DEF tank Incorrect DEF Replace the incorrect DEF DEF dosing malfunction NOTE When this warning is active the MIL appears the engine power is derated and eventually the vehicle speed is limited After refilling the DEF tank this warning the MIL engine de rate and speed limit are switched off A small q...

Page 64: ...peed is limited to 12 mph or 20 km h Coolant level too low Coolant level low See Topping Up Coolant on page 103 Coolant level sensor Coolant temperature too high This warning symbol is visible when the temperature of the coolant exceeds the maximum permissible value Check the following points The coolant level Caution danger of scalding See Topping Up Coolant on page 103 The poly V belt and water ...

Page 65: ...d do not continue to drive under any circumstances NOTE Depending on the fault the engine can switch over to emer gency control Transmission warning This warning symbol can give the following text description When the vehicle has an AS Tronic gearbox depending on the malfunction the gearbox can only be shifted manually Central vehicle controller error This means there is a fault in the electronics...

Page 66: ...l See Engine Oil Level on page 102 PTO fault Engine speed control does not meet the conditions See Engine Speed Control on page 76 Wait to start This warning indicator is visible when the grid heater is active Fasten seat belt Seat belt isn t properly fastened CONTROLS Master Display 64 Y53 6078 1B1 12 18 18 3 ...

Page 67: ...alfunction Text depends on vehicle configuration Water in fuel The system has detected fuel quality issues such as water present in the fuel Brake information This warning symbol indicates Brake release CONTROLS Master Display Y53 6078 1B1 12 18 18 65 3 ...

Page 68: ...ts off E3 Not used E4 Safety belt reminder E5 Not used E6 Exhaust brake active E7 Park brake E8 Stop Engine E9 Not used F1 Front fog lights F2 Not used F3 MIL indicator F4 Not used F5 Not used G1 Check Engine G2 Diesel Particulate Filter DPF G3 Not used G4 Cross axle differential lock Diff lock G5 PTO G6 Not used G7 Right direction indicator truck H1 Tachometer display H1a Selected gear H1b Manual...

Page 69: ...l Fuel level low This warning indicator is visible when the reserve fuel level is reached DEF level low This warning indicator turns on when a critical DEF level is reached ABS warning The yellow warning indicator ABS fault is activated when there is a fault in the truck or tractor ABS system CONTROLS Master Display Y53 6078 1B1 12 18 18 67 3 ...

Page 70: ...ning lights off This warning indicator is visible when the daytime running lights are switched off Safety belt reminder This warning indicator is visible when safety belt is not used Exhaust brake active This warning indicator is visible when the exhaust brake is active CONTROLS Master Display 68 Y53 6078 1B1 12 18 18 3 ...

Page 71: ... switched on MIL indicator This warning indicator is visible when the emission level is above the legal limits High exhaust system temperature A regeneration is in progress and the exhaust gas temperature reaches values which potentially can be harmful to bystanders or the surrounding area and the vehicle speed is below a certain value CONTROLS Master Display Y53 6078 1B1 12 18 18 69 3 ...

Page 72: ...this warning indicator is visible PTO This warning indicator is visible when the PTO is active Cross axle lock Diff lock This warning indicator is visible when the PTO is active Right direction indicator truck This warning indicator flashes together with the truck s right direction turn signal CONTROLS Master Display 70 Y53 6078 1B1 12 18 18 3 ...

Page 73: ...ity Control ESC system is regulating individual wheel brakes to correct the vehicle s direction of travel Engine Check Engine Illuminates when a non emissions related problem exists but the vehicle can still be safely driven Vehicle should be serviced to correct the problem but the situation should not be considered an emergency CONTROLS Master Display Y53 6078 1B1 12 18 18 71 3 ...

Page 74: ...ax output 64 I O pins color coded 4 power input terminals Customer configurable PACCAR branded Component labeling Voltage Converter The Voltage converter provides 24V to cab systems It is located in the battery box below the PDC support The Voltage converter has the following Specifications 12V input 24V output Input current 80 amps Output current 40 amps Temperature range 40C to 85C CONTROLS PDC ...

Page 75: ...e 75 Engine Speed Control 76 Cruise Control 77 Adaptive Cruise Control Optional 79 Vehicle Speed Limitation for Special Applications 81 Driving Style 81 Steering 85 ABS Brakes 85 Park Brake and Service Brake 90 Engine Brake 90 Stopping 91 Allison Automatic Gearbox 91 DRIVING Y53 6078 1B1 12 18 18 73 4 ...

Page 76: ...to the rest position 0 or remove it while the vehi cle is in motion This may cause the steering wheel lock to engage Position 0 rest position When the key is removed in this position the steering wheel can be locked If the steering wheel is turned slightly the steering wheel will lock Position A accessories position Steering wheel unlocked The key cannot be removed Accessories such as a radio can ...

Page 77: ...ion device will not allow the starter motor to activate If the engine is running the engine speed may not be increased before the oil pressure warning symbol has extin guished NOTE Depending on the coolant temperature measured by the electronic unit it is possible that in extremely cold condi tions the maximum engine speed is limited for a specific period of time In case of an optional engine spee...

Page 78: ...ximum engine speeds that can be set are limited by a programmed value in the electronic unit This value may be below the idling speed In this case it will however not fall below idling speed The programmed engine speeds and conditions for activation or deactivation of the engine speed control can be modified by an Authorized Dealership on request Activating the Engine Speed Control Press the SET o...

Page 79: ...an overrule the cruise control at any time by pushing the accelerator pedal The cruise control can be activated at a programmed minimum vehicle speed This speed is 21 7 mph 35 km h as standard The programmed standard speed and the conditions for activation and deactivation of the cruise control can be modified by an authorized dealer upon request WARNING Check whether the stated conditions for act...

Page 80: ...e Authorized Dealership Modifying Cruise Control Speed When cruise control is activated the speed can be increased by pressing SET or be decreased by pressing SET on the steering wheel switch 1 Briefly operate the switch to increase or decrease speed in small increments of 0 31 mph 0 5 km h Keep the switch down to gradually increase or decrease speed This limits the minimum and maximum adjustable ...

Page 81: ...vironment and be ready to intervene at any moment Failure to comply may result in death personal injury equipment or property damage Adaptive Cruise Control uses a radar sensor or camera to detect objects in front of the vehicle The system will adjust the speed of the vehicle to accommodate a slower moving object in front of it The driver has the option of setting the adjustment to either 1 mainta...

Page 82: ...ehicle in front is at a proper distance ahead of the truck When a target is locked in the truck icon will appear above the icon of the path along with the target speed and the time to impact in seconds below the path icon mph s 49 Collision Alert Driver Screens The driver information display will show these messages with icons if the system detects a collision either from approaching speed or beca...

Page 83: ...daptive Cruise Control system detects a malfunction System Malfunction Adaptive cruise control system malfunction Front Radar Malfunction Display with Multiple System Malfunctions Adaptive cruise control system malfunction Vehicle Speed Limitation for Special Applications Speed limitation for special applications consists of a switch which is fitted on the vehicle superstructure With this switch t...

Page 84: ...coasting event This event occurs whenever the vehicle coasting speed decreases by at least 3 mph 5 km h A brake saving event efficient wear This event occurs whenever the vehicle speed decreases by at least 6 mph 10 km h including some element of braking under foot In both cases the starting speed must be above 25 mph 40 km h If an Event is registered the system provides feedback by showing a numb...

Page 85: ...icle ignition stays on When the ignition is switched off and then back on the DPA feedback is again active Fuel Consumption The Driving support menu displays relevant information about the fuel consumption and vehicle usage Set a fuel consumption target to improve the fuel economy The fuel consumption display consists of two screens Fuel consumption screen This screen is part of the Economic drivi...

Page 86: ...reliable value is calculated by the vehicle s electronics This can take a short while depending on the load on the engine Average The average fuel consumption over a driving time interval as measured by DPA since last reset is displayed in gallons per 62 miles liters per 100 km A driving time interval is not only the current drive It is the total distance traveled since the last reset of the DPA S...

Page 87: ... is an Anti lock Braking System The ABS ensures good brake stability and good steering in a critical braking situation By preventing the wheels from locking the steering characteristics of the vehicle are retained WARNING The ABS does not release the driver from his obligation to adapt his driving style to the traffic and road surface conditions The anti lock protection cannot offset the results o...

Page 88: ...modified e g adding or removing an axle converting from a truck to a tractor converting from a tractor to a truck changing the body lengthening of the wheelbase and or frame relo cating frame components or modifying pneumatic or electrical ABS ESC har nesses the ESC must be disabled by a qualified technician If you have any questions contact your authorized dealer Failure to comply may result in d...

Page 89: ...to roll over Yaw Stability Yaw stability counteracts the tendency of a vehicle to spin about its vertical axis During operation if the friction between the road surface and the tires is not sufficient to oppose lateral side forces one or more of the tires can slide causing the truck tractor to spin These yaw events are referred to as either under steer where there is a lack of vehicle response to ...

Page 90: ...ific ABS that was provided with your vehicle This feature helps improve traction when vehicles are on slippery surfaces or surfaces with poor traction i e mud or snow by reducing drive wheel overspin Automatic traction control works automatically in two different ways If a drive wheel starts to spin ATC applies air pressure to brake the wheel This transfers engine torque to the wheels with better ...

Page 91: ...our vehicle s chassis components are altered for example a wheelbase extension or reduction tag axle addition or removal tractor to truck conversion or steering system component change the ESC system must be disabled immediately by a qualified mechanic WARNING Failure to disable ESC Electronic Sta bility Control when modifying a vehi cle could result in a loss of vehicle control possibly resulting...

Page 92: ... primarily intended for prolonged braking for example when decelerating from high speed on a level road or when driving downhill This reduces service brake wear The engine brake is activated by operating steering wheel switch C NOTE The engine brake is activated by operating steering wheel switch C To save the service brakes and to prevent the engine brake valve from becoming stuck it is wise to r...

Page 93: ...ng trip or when the engine has been subjected to high loading let it idle for at least 5 minutes It is important to let the engine run for a while in order to prevent the coolant temperature becoming too high and to allow the turbocharger to cool down Switch the engine off by turning the ignition key to 0 position rest position Allison Automatic Gearbox General The automatic gearbox is fully elect...

Page 94: ...s active move vehicle to a safe location before turning off the engine Conditions which illuminate a transmission fault warning will disable the shift selector and the MONITOR digit will show the actual range attained instead of range selected Once D Drive is attained the transmission will shift into the lowest forward range programmed for the D position usually the first range To display stored c...

Page 95: ...highest range available Down Arrow Press the Down Arrow when in D Drive to request the next lower range Continually pressing the Down Arrow will request the lowest range available Faults If the transmission fault warning symbol lights up in the master display a fault has been detected in the gearbox Read the following recommendations first or consult an authorized dealer if necessary Gearbox The E...

Page 96: ...limits gearbox shifting to the first four gears It is important to drive to a safe place as soon as possible and let the engine idle in neutral at an increased idling speed As a result the cooling system of the engine will try to cool the gearbox oil If after approximately two minutes the warning in the master display has not disappeared the engine must be turned off and contact made with the near...

Page 97: ...Overview of Daily Checks 101 Opening the Front Panel 102 Engine Oil Level 102 Topping Up Coolant 103 Special Coolant Fill Instructions 103 Windshield Washer Reservoir Fluid Level 104 Air Filter Indicator 105 Wheels and Tires 105 Lighting and Instruments 105 Driver s Seat and Mirrors 105 MAINTENANCE Y53 6078 1B1 12 18 18 95 5 ...

Page 98: ...g the Water Separator 107 Batteries 107 General Maintenance 108 Cab Maintenance 108 Cleaning 108 Preventative Maintenance before the Winter Season 110 Diesel Fuel 110 Windshield Washer Reservoir 110 Maintenance after the Winter Season 110 Cooling System 110 MAINTENANCE 96 Y53 6078 1B1 12 18 18 5 ...

Page 99: ...hicle in service Failure to comply may result in death personal injury equipment or property damage WARNING Never connect or disconnect a hose or line containing air pressure It may whip as air escapes Never remove a component or pipe plug unless you are certain all system pressure has been depleted Failure to comply may result in death personal injury equipment or property damage WARNING Never at...

Page 100: ...t of pressure on the pedal that you do when you apply the brakes on your car All you are doing on your truck is opening an air valve to allow air to flow into the brake chambers Contamination of the air supply system is the major cause of problems in air operated components such as brake valves and suspension height control valves To keep contaminants to the lowest possible level follow these main...

Page 101: ...ral factors may increase the moisture accumulated in the system including Saturated air dryer cartridge Higher than normal accessory air demands High daily temperature fluctuations 30 F Outside air source used to charge truck air system post air dryer At a minimum PACCAR recommends changing the air dryer cartridge annually WARNING If a different air dryer brand or model is installed on the vehicle...

Page 102: ... brake flu id or wax based oils in the air system These fluids may cause severe dam age to air system components Maintain the air compressor to prevent excessive oil bypass Replace worn seals in valves and air motors as they are needed Your authorized dealer carries rebuild kits for most units Air Gauges and Air Leaks Your vehicle comes with air pressure gauges for two separate systems Primary and...

Page 103: ...cessive leakage air pressure loss greater than 3 0 psi 21 kPa after two minutes of brake application a leakage test should be made at the air line connections and at all air brake control units These tests should determine where air is escaping Air Compressor Operation All compressors regardless of make or model run continuously while the engine is running System pressure is controlled by the gove...

Page 104: ... with a lint free cloth 5 Re place the dipstick in its holder Withdraw the dipstick again and check the oil level NOTE It takes approx 20 minutes for all the oil to run into the sump when the engine is warm If the dip stick is checked immediately af ter switching the engine off or im mediately after oil has been add ed the level shown on the dip stick will be too low 6 Fill oil through the filler ...

Page 105: ...loosen the filler cap of the cool ing system when the cab is tilted The filler cap houses the coolant level sen sor Take necessary precautions to protect the sensor from damage when removing it 1 Turn the rotary knob for the heating temperature control to maximum hot 2 Open the front panel 3 Remove the black filler cap from the cooling system reservoir 4 Run the engine for several minutes 5 Stop t...

Page 106: ...p off surge tank to MAX level 10 Allow engine to cool and top off surge tank to MAX level if necessary 11 Replace the surge tank pressure cap CAUTION Failure to follow this procedure and maintain proper coolant level can cause engine damage It is OK for a hot system to have coolant above the MAX level but a cold system should not have coolant above the MAX level Windshield Washer Reservoir Fluid L...

Page 107: ...chment of the wheels 4 Check the tire pressures do not forget the spare wheel The tire pressures should be checked and corrected while the tires are cold See Tire Pressure Table Imperial on page 113 or Tire Pressure Table Metric on page 114 for the correct tire pressures NOTE If a worn tire is underinflated by 30 psi the ABS control will be inoperative un der extreme conditions Lighting and Instru...

Page 108: ...fluid level must be between the two marks 5 Top up oil if necessary via the filler opening Oil type see Steering Gear on page 118 6 If the level is below the minimum mark this is a sign of leakage Contact an authorized Service dealer as soon as possible Brake System Air Drier The air drier can be checked for correct operation by inspecting the air reservoirs for condensed water 1 Check the air res...

Page 109: ...n flames in the vi cinity of batteries Battery acid is an aggressive fluid In the event of contact with the skin rinse the skin profusely with plenty of water Consult a doctor in the event of persis tent redness or pain Remove polluted clothing and rinse in water In the event of contact with the eyes rinse with plenty of water for at least 15 minutes and consult a doctor If swallowed do NOT induce...

Page 110: ...taken into service If this does not happen the warranty will become invalid The relevant warranty conditions are listed in the warranty manual Cleaning Cleaning the Vehicle Before the vehicle is cleaned check for leaks in the engine axles gearbox etc This is no longer possible after cleaning the vehicle and carrying out maintenance work When a high pressure cleaner is used take special note of the...

Page 111: ...it prevents the penetration of moisture and dirt at the various pivot points Cleaning the Cab Depending on the vehicle s operating conditions the external paintwork of the cab is subject to attack by corrosive substances for example road salt grit and polluted air For instance road salt and air pollution The paintwork must therefore be cleaned regularly When cleaning the cab make sure that no caus...

Page 112: ... purely preventative effect They can not dissolve the paraffin crystals once they have been precipitated Always carry a spare fuel line filter in the vehicle so that you can replace it quickly if it becomes blocked in any way for example by paraffin crystals Always preferably fill up in the evenings to prevent condensation especially in winter Windshield Washer Reservoir When topping up it is advi...

Page 113: ...gine Coolant and Fuel Specifications 116 Engine Oil 117 Coolants 117 Steering Gear 118 Cab Tilting Mechanism 118 Chassis Number 118 Engine Number 118 Paint Identification Plate 119 Vehicle Identification Label 119 Consumer Information 119 Operator s Manual Supplement 121 INFORMATION Y53 6078 1B1 12 18 18 111 6 ...

Page 114: ...6 09 liters Sump capacity maximum level 4 75 gallons 18 liters w OP9517 Option Sump capacity minimum level 4 23 gallons 16 liters w OP9517 Option Capacity of cooling system including heater 30 5 quarts 28 9 liters Capacity of cooling system including heater with a dry engine 43 quarts 40 7 liters Output and Torque Typ e Max output P kW hp Engine speed at max output np rpm Max torque M lb ft Engine...

Page 115: ...hting 24V 15W Stepwell lighting 24V 5W Side repeater lights 12V 21W Roof lights 24V 5W Wheels Whenever the wheel nuts have been slackened or removed they must be retorqued with a torque wrench after 62 miles 100 km WARNING If a wheel stud is renewed the other wheel studs on the relevant wheel must also be renewed If new wheel studs are fitted the nuts must be retor qued after 310 miles 500 km Whee...

Page 116: ... 5740 6175 6395 D 4365 4400 4675 4735 4900 5070 5255 5675 6005 75 70 R22 5 E 4850 5050 5250 5480 5705 5945 6195 6450 6720 7000 D 4430 4610 4795 5005 5210 5430 5660 5890 6135 6395 295 75 R22 5 E 4500 4725 4940 5155 5370 5510 5780 5980 6175 D 4095 4300 4540 4690 4885 5070 5260 5440 5675 11 R22 5 E 4990 5220 5510 5730 5950 6175 D 4760 4950 5205 5415 5625 5840 Tire Pressure Table Metric Recommended lo...

Page 117: ... 4 D 1857 1 1950 1 2058 9 2126 9 2215 3 2299 2 2385 4 2467 0 2573 6 11 R22 5 E 2263 0 2367 3 2498 8 2598 6 2698 3 2800 4 D 2158 7 2244 8 2360 5 2455 7 2550 9 2648 4 Checking the Tire Pressures Tire pressures depend on axle load and tire size Tire Pressure Table The tire pressures shown in the table apply to cold tires Unnecessary tire wear is frequently caused by vehicle operation with tire pressu...

Page 118: ...s or coolants have been used which do not meet the requirements specified WARNING Avoid physical contact with Lubricants Coolants Fuel Battery acid In the event of skin contact remove substance with paper or cloth wash with soap and water Consult a doctor in the event of persistent irritation In the event of contact with the eyes remove substance with soft cloth and rinse with water Consult a doct...

Page 119: ...orrosion inhibiting additives The coolant present in the cooling system from the factory consists of an ethylene glycol base Climatech Coolant Identification A sticker behind the grille states the information on the coolant used Coolant According to Specification 74002 The below table lists the current suppliers that meet specification 74002 It is not allowed to fill the cooling system with anothe...

Page 120: ...with valid approval number Cab Tilting Mechanism Cab tilting pump Oil must meet MIL H 5606C The following may be used ESSO Univis J13 FINA Hydran B5219B TEXACO Aircraft Hydraulic Oil 5606G Total Aero hydraulic 520 Chassis Number The chassis number is the last 6 digits of the VIN number It is stamped on the right chassis side member close to the front axle Engine Number The engine number is located...

Page 121: ...om a 1999 model shows how this code works Consumer Information Federal Safety Standard Certification Label The National Highway Traffic Safety Administration regulations require a label certifying compliance with Federal Safety Standards for United States and U S Territories be affixed to each motor vehicle and prescribe where such label may be located This certification label which indicates the ...

Page 122: ...either call the Auto Safety Hotline toll free at 1 800 327 4236 TTY 1 800 424 9153 email to nhtsa webmaster dot gov or write to Office of Defects Investigations CRD NVS 216 1200 New Jersey Ave SE Washington D C 20590 You can also get other information about auto safety from the Hotline For additional road safety information please visit the NHTSA website at http www safercar gov Canadian Consumer ...

Page 123: ...re known to the State of California to cause cancer birth defects and other reproductive harm Other chemicals in this vehicle are also known to the State of California to cause cancer birth defects or other reproductive harm Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands aft...

Page 124: ... and Canadian greenhouse gas emission limits Warrantable Emissions Failures This vehicle emissions limited express warranty relating to original equipment tires is valid for two 2 years or 24 000 miles 38 000 km whichever occurs first YOUR SOLE AND EXCLUSIVE REMEDY AGAINST PACCAR Inc IS LIMITED TO THE REPAIR OR REPLACEMENT OF ORIGINAL EQUIPMENT TIRES SUBJECT TO PACCAR S TIME AND MILEAGE LIMITATION...

Page 125: ...the first purchaser or first lessee and each subsequent purchaser or lessee This warranty does not override any extended warranty purchased to cover specific vehicle components Owner s Warranty Responsibilities The vehicle owner is responsible for performing required maintenance that is listed in your engine and vehicle Operator s Manuals The owner is responsible for presenting the vehicle to a se...

Page 126: ... determines that the replacement part is not of similar material and function as the OEM part assembled to the vehicle at the factory PACCAR Responsibilities The warranty coverage begins when the vehicle is delivered to the first purchaser or first lessee Repairs and service will be performed by any authorized PACCAR dealer using new or genuine approved rebuilt parts and assemblies PACCAR will uti...

Page 127: ...re not genuine approved parts PACCAR is not responsible for the material and labor costs of emission control parts and assemblies replaced during Scheduled Maintenance of the engine as specified in PACCAR Operator s Manuals THIS WARRANTY TOGETHER WITH THE EXPRESS COMMERCIAL WARRANTIES ARE THE SOLE WARRANTIES MADE BY PACCAR IN REGARD TO THIS VEHICLE THIS LIMITED GHG WARRANTY IS THE SOLE WARRANTY MA...

Page 128: ...INFORMATION Operator s Manual Supplement 126 Y53 6078 1B1 12 18 18 6 ...

Page 129: ...d whenever the vehicle coasting speed decreases by at least 3 mph 5 km h A brake saving event efficient wear This event is registered whenever the vehicle speed decreases by at least 6 mph 10 km h including some element of braking under foot A driving time interval is not only the current drive It is the total distance traveled since the last reset of the DPA The average fuel consumption over a dr...

Page 130: ...128 Glossary ...

Page 131: ...nging the Wheel 22 Chassis Number 118 Checking the Tire Pressures 115 Cleaning 108 Control Panel 39 Control Panel of Heating Ventilation System 40 Coolants 117 Cooling System 110 Cruise Control 77 D Dashboard 36 Deep Snow and Mud Switch 88 Diesel Fuel 110 Doors 33 DPA 82 83 Draining the Water Separator 21 107 Driver Performance Assistant 82 83 Driver Standard Interface 79 Driver s Seat and Mirrors...

Page 132: ... and Service Brake 90 Power Distribution Center 72 Power Steering Fluid Level 106 Preventative Maintenance before the Winter Season 110 R Replacing Bulbs 26 Replacing the Fuel Line Filter 20 Replacing the Poly V Belt 19 Right Hand Steering Column Switch 43 Roll Stability 87 Roll Stability Example 87 Roof Console 35 Running in 12 S Safety Alerts 6 Seat Belts 45 Special Coolant Fill Instructions 103...

Page 133: ...ings and Safety Regulations 7 Wheels 113 Wheels and Tires 105 WHY THIS HANDBOOK IS SO IMPORTANT 6 Windshield Washer Reservoir 110 Windshield Washer Reservoir Fluid Level 104 Windshield Wiper Blades 35 Y Yaw Control 87 Yaw Control Example 88 Yaw Stability 87 Index Y53 6078 1B1 12 18 18 131 ...

Page 134: ...Index 132 Y53 6078 1B1 12 18 18 ...

Page 135: ......

Page 136: ...Y53 6078 1B1 12 18 18 Printed in U S A Peterbilt Motors Company A PACCAR Company P O Box 90208 Denton Texas 76202 ...

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