Conventional Models 2007 EPA Compliant Vehicles

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Conventional
Models
2007 EPA Compliant Vehicles
Quick Table of Contents
Introduction . . . . . . . . . . . . . . . . . . 1
Cab And Frame Access . . . . . . . . . . . . 5
Getting To Your Engine . . . . . . . . . . . . . . . 11
Controls And Displays . . . . . . . . . . . . . . . . . . . 13
Seat And Restraint Systems . . . . . . . . . . . . . . . . . 73
Driver’s Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Starting And Operating The Vehicle . . . . . . . . . . . . . . . . . . 88
Maintenance and Service
. . . . . . . . . . . . . . . . . . . . . . . . . . 129
Vehicle Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Consumer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Subject Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
California Proposition 65 Warning
• Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
• Other chemicals in this vehicle are also known to the State of California to
cause cancer, birth defects or other reproductive harm.
• Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
PART 1: INTRODUCTION
HOW TO FIND WHAT YOU WANT
PART 1: INTRODUCTION
This manual contains useful information for the safe and
efficient operation of your Peterbilt vehicle. It also provides
information on maintaining your vehicle in the best condition, with an outline for performing safety checks and
basic preventive maintenance inspections.
We have tried to present the information you’ll need to
learn about your vehicle’s functions, controls, and operation - and to present it as clearly as possible. We hope
you’ll find this manual easy to use.
Please remember -- this manual is not a training manual.
It can’t tell you everything you need to know about driving
your Peterbilt vehicle. For that you need a good training
program or truck driving school. If you have not been
trained, get the proper training before you drive. Only
qualified drivers should drive this vehicle.
There will be times when you need to take this manual out
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
the vehicle on to the next user.
(08/06)
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 covered and
gives page numbers where you can find these subjects.
Use the Quick Table of Contents to find information on a
large subject like “Maintenance.”
Cross-referenced citations also help you get the information you need. If some other part of the manual contains
further information on the subject you are reading about,
we’ll indicate that in a cross-reference like this: (See
“PART 6: DRIVER’S CHECKLIST”). You won’t have to go
searching for more information.
Finally you’ll find a helpful Subject Index. It’s in the back
of the manual and alphabetically lists the subjects covered. So if you want information on brakes, for example,
just look under Brake in the Subject Index. You’ll find all
the pages listed where brakes or braking are discussed.
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–1–
A SPECIAL WORD ABOUT REPAIRS
PART 1: INTRODUCTION
A Special Word About Repairs
WARNING! Attempting repair work without sufficient training, service manuals, and the proper
tools can be dangerous. You could be injured or
you could make your truck unsafe. Do only
those tasks you are fully qualified to do.
be sure you get the correct manuals for your vehicle.
Allow about four weeks for delivery. There will be a charge
for these manuals.
Final Chassis Bill of Material. A complete, nonillustrated
computer printout listing of the parts used to custom-build
your Peterbilt vehicle is available through the Peterbilt
dealer from whom your purchased your vehicle.
Your Peterbilt dealer’s service center is the best place to
have your vehicle repaired. You can find Peterbilt dealers all
over the country with the equipment and trained personnel
to get you back on the road quickly - and keep you there.
Your vehicle is a complex machine. Anyone attempting
repairs on it needs good mechanical training and the
proper tools. If you are sure you have these requirements,
then you can probably perform some repairs yourself. However, all warranty repairs must be performed by an authorized Peterbilt service facility. If you aren’t an experienced
mechanic, or don’t have the right equipment, please leave
all repairs to an authorized service facility. They are the
ones equipped to do the job safely and correctly.
Maintenance Manuals. If you do decide to do any complex 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
–2–
WARNING! Modifying your vehicle can make it
unsafe. Some modifications can affect your
truck’s electrical system, stability, or other
important functions. Before modifying your
vehicle, check with your dealer to make sure it
can be done safely.
Additional Sources of Information
Operator’s manuals are also supplied by the manufacturers of components such as the engine, seats, transmission, and radio in your Peterbilt. If you are missing any of
these manuals, ask your Peterbilt dealer to supply them.
Your new Peterbilt’s glove box also contains a copy of the
Truck Driver’s Handbook, published by the American
Trucking Association. Refer to it for important information
on driving your vehicle. Another place to learn more about
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PART 1: INTRODUCTION
WARNINGS
trucking is a local truck driving school. Contact one near
you to find out what kinds of instruction it offers.
Federal and state agencies also have information you can ask
for. The Interstate Commerce Commission can give you information about regulations governing transportation across
state lines. And various agencies in state governments are
sources for regulations that differ from state to state.
cause serious injury or death. This message will tell you
what the hazard is, what can happen if you don’t heed the
warning, and how to avoid it. For example:
WARNING! Attempting repair work without
sufficient training, service manuals, and the
proper tools can be dangerous. You could be
injured or you could make your vehicle
unsafe. Do only those tasks you are fully qualified to do.
Warnings
We’ve put a number of warning messages in this manual.
They are there for your protection and information. Please
read them and follow them. They can help you to avoid
injury to yourself and your passengers as well as to prevent costly damage to your vehicle. We’ve used certain
symbols and “signal words” to indicate what kind of message is going to follow. When you see these symbols &
words, you know that you need to pay special attention.
Please don’t ignore any of these signals.
CAUTION:
This symbol & word signals something that could damage
your vehicle. You might receive an injury, too. For example:
CAUTION: Continuing to operate a vehicle
with insufficient oil pressure will cause serious engine damage.
NOTE:
WARNING!
When you see this symbol & word, the message that follows is especially vital. This signals something that can
(08/06)
Gives you information we feel you’d like to have. It could
have to do with care of your vehicle or with driving more
efficiently:
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VEHICLE SAFETY
PART 1: INTRODUCTION
NOTE: A cold compressor can cause refrigerant
to liquefy and warp the valve plates or cause a
hydraulic lock. Warm the engine before starting
the air conditioner.
Please take the time to read these messages when you
see them. And remember:
WARNING! Something that could injure you seriously.
CAUTION: Something that could cause injury to you
or your vehicle.
NOTE: Useful information.
Vehicle Safety
Make sure your Peterbilt is in top working condition before
heading out on the road—it is the responsible driver's duty
to do so. Inspect the vehicle according to “PART 6:
DRIVER’S CHECKLIST.”
WARNING! Do not drink and drive. Your
reflexes, perceptions, and judgment can be
affected by even a small amount of alcohol. You
could have a serious—or even fatal accident—if
you drive after drinking. Please do not drink and
drive or ride with a driver who has been drinking.
–4–
WARNING! The use of alcohol, drugs, and certain medications will seriously impair perception, reactions, and driving ability. These
circumstances can substantially increase the
risk of an accident and personal injury.
Please remember, this manual is not a training manual. It
cannot tell you everything you need to know about driving
your Peterbilt vehicle. For that you need a good training
program or truck driving school. If you have not been
trained, get the proper training before you drive. Only
qualified drivers should drive this vehicle.
Every new Peterbilt vehicle is designed to conform to all
Federal Motor Vehicle Safety Standards applicable at the
time of manufacture. However, even with these safety features, continued safe and reliable operation depends
greatly upon regular vehicle maintenance. The vehicle
must be operated within the range of its mechanical capabilities and the limits of its load ratings. (See the Tire and
Rim Weight Ratings label on the driver's door edge.)
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PART 2: CAB AND FRAME ACCESS
PART 2: CAB AND FRAME ACCESS
Be careful whenever you get into or out of your vehicle’s
cab. Always maintain at least three points of contact with
your hands on the grab handles and your feet on the
steps.
WARNING! Jumping out of the cab or getting
into the cab without proper caution is dangerous. You could slip and fall, possibly suffering
a serious injury. Keep steps clean. Clean any
fuel, oil, or grease off of the steps before
entering 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.
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DOOR LOCK AND KEYS
PART 2: CAB AND FRAME ACCESS
The picture below shows the best way to enter and exit a
Conventional Cab.
Door Lock and Keys
Doors can be locked from the inside by using the lock button. Close the door then push the button down to lock.
Doors automatically unlock when you open them from
inside, and can be locked from the outside with the key
only.
WARNING! To lessen the chance and/or severity of personal injury in case of an accident,
always lock the doors while driving. Along
with using the lap/shoulder belts properly,
locking the doors helps prevent occupants
from being thrown from the vehicle.
To lock or unlock the doors from outside the cab, insert the
key in the lock.Turn the key toward the rear to lock; forward to unlock.
Keys and Locks
The same key fits your ignition, doors, and sleeper luggage compartment.
02958B
–6–
Frame-mounted tool box locks and locking fuel tank caps
each have individual keys.
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PART 2: CAB AND FRAME ACCESS
DOOR LOCK AND KEYS
tem should be approximately 30 ft. This will be
reduced if it is operated close to other RF sources
such as TV/radio transmitters and cell towers.
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 when the selected door’s are locked or
unlocked. The system includes two key fobs that provide
secure rolling code technology that prevents someone
from recording the entry signal.
Batteries
The key fob uses one CR2032, 3V battery. Batteries
should last approximately three years, depending on use.
Consistently reduced range is an indicator that the battery
needs replacement. Batteries are available at most discount, hardware and drug stores.
To Replace The Battery
Operation
1. Remove rear cover from key fob.
To Unlock The Driver’s Door
2. Remove the battery.
Press the UNLOCK button once. The driver's door will
unlock and the parking lights will come on for 40 seconds.
3. Install new battery.
4. Reinstall cover.
To Unlock The Passenger’s Door
5. Synchronize the key fob.
Press the UNLOCK button once and press again
within 5 seconds. The passenger door will unlock.
To Lock Both Doors
Press the LOCK button. The doors will lock and the
parking lights will come on for 2 seconds. If the doors
are open they will not lock. The range of the RKE sys(08/06)
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.
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DOOR LOCK AND KEYS
PART 2: CAB AND FRAME ACCESS
To Synchronize A Key Fob
1. Hold the key fob near the receiver.
NOTE: The receiver is located behind the Speedometer/
Tachometer cluster assembly.
2. Press and hold both the Lock and Unlock buttons at
the same time for approximately 7 seconds.
3. When the key fob is resynchronized, the doors will
lock then immediately unlock.
4. If the fob fails to synchronize, it could be programmed to a different truck or could have failed.
Contact your dealer to re-program your key fob.
–8–
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PART 2: CAB AND FRAME ACCESS
CLIMBING ONTO THE DECK PLATE
Climbing Onto the Deck Plate
WARNING! Do not step on vehicle components without antiskid surfaces or use components not designed for entry-and-exit use.
You could fall and injure yourself if you step
on a slippery surface. For example:
When you are climbing onto and off the deck plate, maintain at least three points of contact with your hands on the
grab handles and your feet on the steps.
• You could fall and injure yourself if you step
onto a fuel tank surface. A fuel tank is not a
step. The tank surface can get very slippery,
and you might not be able to prevent a fall.
Don’t step onto the surface of a fuel tank. Use
only the steps and handholds provided, not
chain hooks, quarter fenders, etc.
WARNING!
• You can be hurt if you aren’t careful climbing onto and off the deck plate. You can slip
and fall, especially if the surfaces are wet or
icy, or if you step in oil, fuel, or grease. Keep
steps clean. Always maintain at least three
points of contact between your hands and
feet and the steps and deck plate.
• Always reinstall steps before entering the
cab or accessing the deck plate. Without
steps, you could slip and fall, resulting in possible injury to yourself.
• Do not climb onto and off the deckplate–use
steps and grabhandle provided. If there is no
deck plate, or if proper steps and grab handles aren’t provided, don’t climb onto the area
behind the cab. Peterbilt did not intend for the
area to be a step if handrails or proper steps
are not provided.
NOTE: Any alteration (adding bulkheads, headache racks, tool boxes, etc.) behind the cab or
sleeper that affects the utilization of grab handles,
deck plates, or frame access steps installed by
Peterbilt must comply with FMCSR 399.
The pictures on the next page show you the right way to
get on and off the area behind your cab.
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CLIMBING ONTO THE DECK PLATE
Hold handles as you
step up.
– 10 –
Maintain three points
of contact.
PART 2: CAB AND FRAME ACCESS
Maintain three points of
contact as you reach the
deck area.
(08/06)
Maintain three points of
contact as you step to
deckplate.
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PART 3: GETTING TO YOUR ENGINE
HOOD HOLD DOWNS
PART 3: GETTING TO YOUR ENGINE
Hood Hold Downs
Hood hold downs keep a hood from opening unexpectedly
front, one foot on the bumper, and one foot on the ground.
Tilt the hood forward
WARNING! Before opening or closing a hood,
ensure no people or objects are in the way. A
hood could hurt someone in the way of its
descent. If the hood falls, anyone under it
could be injured. Always ensure the hood
hold-open latch is engaged to keep the hood
open any time anyone gets under the hood for
any reason.
CAUTION: A hood not latched securely could
open during operation and cause vehicle
damage. Be sure to latch the hood securely.
.
02961
Hood Tilt
To open your hood, unlock the hood hold downs by
unlatching them. Put one hand on the top of the hood
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02962
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HOOD TILT
PART 3: GETTING TO YOUR ENGINE
Hood Hold-Open Device
The hood is equipped with a hood hold-open device. In
order for the hood hold-open device to become engaged,
the vehicle hood must be fully open. Once the vehicle
hood is fully open, the hold-open latches will automatically
engage and will need to be disengaged by the operator.
WARNING!
• Ensure the hood is fully opened. Failure to
fully open the hood will prevent engagement
of the hold-open device causing possible serious bodily injury.
To disengage the latch for hood closure, rotate the release
lever fully forward.
• Ensure the hold-open device is engaged
when underneath hood. A closing hood can
crush causing possible serious bodily injury.
WARNING! Keep people or objects clear when
opening or closing a hood. Failure to do so
can cause hood to strike or crush causing
possible serious bodily injury and/or property
damage.
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PART 4: CONTROLS AND DISPLAYS
YOUR INSTRUMENT PANEL
PART 4: CONTROLS AND DISPLAYS
Your Instrument Panel
This part explains the location of the various features on
your vehicle and describes their function. For information
on using these features in driving, see the paragraphs that
follow. Please remember that each Peterbilt is custommade. Your instrument panel may not look exactly like the
one in the pictures that follow. We have tried to describe
the most common features and controls available. You can
pick out the parts that apply to you and read them to be
fully informed on how your particular vehicle operates.
(08/06)
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YOUR INSTRUMENT PANEL
PART 4: CONTROLS AND DISPLAYS
Typical Conventional Cab Instruments and
Controls
6
5
7
8
4
LEFT SIDE
1
Directional Signal and High Beam Indicators (standard) (Note: Custom warning lights
are added in this area.)
2
Tachometer
3
Oil Pressure
4
Coolant Temperature
5
Voltmeter
6
Driver Information Display
7
Fuel Level
8
Primary Air Pressure
9
Secondary Air Pressure
9
3
2
10
Panel A
1
13
I
Speedometer
11
Ignition Key Switch
12
Headlamps
13
Clearance Lamps
14
Panel Light Dimmer
15
Hazard Flasher
I
14
12
O
10
O
I
I
11
15
O
O
Panel C
– 14 –
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PART 4: CONTROLS AND DISPLAYS
YOUR INSTRUMENT PANEL
Conventional
RIGHT SIDE
1
2
1
Oil Temperature
2
Transmission Oil Temperature
3
Front Driver Oil Temperature
4
Brake Application Pressure
5
Air Cleaner Restriction
6
Rear Driver Oil Temperature
7
Air Suspension Deflate
8
Fifth Wheel Lock
9
Interaxle Differential Lock
10
Exhaust Regeneration Display
11
Engine Fan
7
3
8
4
5
6
9
10
Panel B
(08/06)
12
Fuel Tank Selector
13
Engine Brake On/Off
14
Engine Brake Selector
15
Radio
16
HVAC Control Panel
17
Cruise Control Select
18
Cruise Control On/Off
19
Menu Control Switch (MCS)
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INSTRUMENTS AND CONTROLS
PART 4: CONTROLS AND DISPLAYS
Instruments And Controls
• Pushing the MSC
– Confirming desired selection
Menu Control Switch (MCS)
The MCS is used to navigate the Driver Information Display unit. The Menu Control Switch is located on the D Panel
as shown in the illustration below.
Standard Warning Lights and Audible Alarm
The warning lights and audible alarm may indicate a system 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 something is wrong with your vehicle. It could be a
failure in an important system, such as the
brakes, which could lead to an accident. Have
the appropriate system checked immediately.
The MCS has the following functions:
• Rotating the MSC
– Selecting display
– Setting values
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PART 4: CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
active, the menu control switch (MCS) can be used to
scroll through the additional warnings.
2. Status Indicator:
Additional lights and indicator symbols are displayed in
the Status Indicator. They are limited to:
a. Park Brake
b. Transmission Gear (Automatic transmissions
only)
c. Warnings:
Number of active warnings.
1. Driver Information Display
2. Status Indicator
A red warning is active.
3. Lower Light Bar
Warning lights and indicator symbols will be shown in both
areas 1 and 2. Area 3 is dedicated to the turn and high
beam indicator symbols.
An amber warning is active.
1. Driver Information Display:
The display can show up to six warning lights. Warnings
do not have fixed positions and are displayed in order of
criticality. The most critical warning will be displayed on
the top row and to the left. If more than six warnings are
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d. Cruise Control - active
e. Clock alarm bell
Refer to “Warning Light / Indicator Symbols” on page 19
for information on each symbol.
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INSTRUMENTS AND CONTROLS
PART 4: CONTROLS AND DISPLAYS
Instrument System Self Test:
When the ignition switch is turned on the instrumentation
system will undergo a Self Test. This test will verify the
operation of the gauges and warnings.
During the Instrumentation System Self Test, three
screens will sequentially display warning icons (approximately 3 seconds each screen) on the Information Display. These are:
First
Completing this sequence will indicate a successful Self
Test. Have your instrumentation system checked by a
qualitfied service technician if does not successfully complete.
Audible Alarm:
The audible alarm will sound during the Instrumentation
System Self Test. The audible alarm will also sound in
conjunction with most warning lights. These events
include but are not limited to headlight on, fifth wheel, stop
engine, primary/secondary air, and driver door open
warnings.
Optional Lights:
Second
Additional lights may be operational depending on individual vehicle specifications. These will be included in the
Instrument System Self Test.
Third
NOTE: Some optional lights may illuminate even
though your vehicle is not equipped with that particular feature.
Refer to “Warning Light / Indicator Symbols” on page 19
for information on each symbol.
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PART 4: CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
Warning Light / Indicator Symbols
Warning Light / Indicator Symbols
The following is a list of Warning Light / Indicator Symbols.
Reading left to right, the table header identifies
• the Symbol Name
• the appearance of the Symbol
Symbol Name
1. Active Warnings, Exclamation
Point
Symbol
Color Std
Opt Page
Red
22
Yellow
22
Yellow
22
Red
22
5. Anti-Lock Brake System
(ABS)
Yellow
22
6. Anti-Lock Brake System
(ABS), Trailer
Yellow
23
7. Axle, Inter-Axle Differential
Locked (Tandem Axles)
Yellow
23
Yellow
23
Yellow
24
2. Active Warnings, Number
• the Symbol Color when it is illuminated
• whether the symbol is standard (Std) or optional (Opt)
• the Page Number reference for additional information
3. Active Warnings, Triangle
4. Alternator
Symbols are listed by major component sections.
Example: Engine, and then in alphabetical order.
8. Clock, Alarm Bell
9. Cruise Control, Active
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INSTRUMENTS AND CONTROLS
PART 4: CONTROLS AND DISPLAYS
Warning Light / Indicator Symbols
Symbol Name
Symbol
Warning Light / Indicator Symbols
Color Std
Opt Page
10. Dump Truck, Body Up
Symbol
Color Std
Opt Page
19. Engine, Retarder (Brake)
Yellow
24
Yellow
24
12. Emissions, Diesel Particulate Filter (DPF)
Yellow
24
13. Emissions, High Exhaust
System Temperture (HEST)
Yellow
24
Yellow
24
Green
24
Yellow
24
Yellow
24
Red
25
Green
25
Red
25
Yellow
25
Red
25
Red
25
Blue
26
Green
26
Red
26
Green
26
20. Engine, Stop Engine
11. Dump Truck, Trailer Body Up
21. Engine, Wait To Start
22. Fifth Wheel, King Pin Lock
23. Fifth Wheel, Slide Unlocked
14. Engine, Check Engine
24. Lights, High Beam
15. Engine, Ether Start
25. Message Waiting
16. Engine, Heater
26. Park Brake
17. Engine, Low Coolant Level
27. Power Take-off (PTO)
18. Engine, Overspeed
– 20 –
Symbol Name
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PART 4: CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
Warning Light / Indicator Symbols
Symbol Name
28. Power Take-off (PTO), Pump
Mode
Symbol
Warning Light / Indicator Symbols
Color Std
Opt Page
Green
26
Green
26
Red
26
Yellow
26
Yellow
26
Yellow
27
Red
27
Red
27
Yellow
27
29. Refrigerator
30. Seat Belt, Fasten
Symbol Name
37. Transmission, Oil Temperature High
Symbol
Color Std
Opt Page
Yellow
27
Green
27
Green
27
38. Turn Signal, Left
39. Turn Signal, Right
31. Suspension Dump
32. Tire Inflation
33. Transmission, Auxiliary
34. Transmission, Check
35. Transmission, Do Not Shift
36. Transmission, Oil Filter
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INSTRUMENTS AND CONTROLS
PART 4: CONTROLS AND DISPLAYS
4. Alternator
Warning Light/Indicator Symbol Descriptions
1. Active Warnings, Exclamation Point
Illuminates when a red warning is active. Use
the MCS knob to view the warnings that are
active. Refer to the preceeding Figure ,
“Warning Light / Indicator Symbols,” on
page 19 for warning color classification.
2. Active Warnings, Number
Illuminates the total number of red and yellow
active warnings. Use the MCS to view the
active warnings if the display shows a > symbol.
3. Active Warnings, Triangle
Illuminates when an yellow warning is active.
Use the MCS knob to view the warnings that
are active. Refer to the preceeding Figure ,
“Warning Light / Indicator Symbols,” on
page 19 for warning color classification.
– 22 –
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Illuminates if the alternator is not charging.
(For alternators with warning lamp output
signal.)
5. Anti-Lock Brake System (ABS)
Illuminates during the Instrumentation System Self Test. Have the ABS system checked
by a Peterbilt dealer if the ABS Warning
Lamp stays on for more than 3 seconds.
Illuminates during normal operating conditions to indicate a problem with the ABS System. See “ABS Warning Lamps” on page 104
for more information.
Illuminates when a problem exists with the
optional Wheel Spin Control feature. See
“Advanced ABS with Stability Control” on
page 106 more information.
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PART 4: CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
6. Anti-Lock Brake System (ABS), Trailer
Illuminates during the Instrumentation System Self Test and the tractor/truck is connected with a ABS equipped trailer.
Illuminates during normal operating conditions to indicate a problem with the Trailer
ABS System. This should be checked by a
Peterbilt dealer as soon as possible. See
“ABS Warning Lamps” on page 104 for more
information.
NOTE:
• Tractors/Trucks and trailers built after 3/1/01
must be able to turn on an In-Cab Trailer ABS
Warning Lamp (per U.S. FMVSS121). The
industry chose Power Line Communication
(PLC) as the standard method to turn it on.
See “Trailer ABS Warning Lamp” on page 104
for more information
• 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 differential. This powers the forward rear and the
rear rear differentials equally. When the
switch is turned off (inter-axle differential
unlocked) the engine power is allowed to flow
to any of the 4 drive tires based on the differential effect (mostly to the forward rear differential). (This feature is standard on all
tandem axles).
8. Clock, Alarm Bell
Illuminates when the alarm is set. It will flash
when the clock alarm is active.
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INSTRUMENTS AND CONTROLS
PART 4: CONTROLS AND DISPLAYS
9. Cruise Control, Active
14. Engine, Check Engine
Illuminates when cruise control is active.
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 considered
an emergency.
10. Dump Truck, Body Up
Illuminates when Truck Dump Body is up.
11. Dump Truck, Trailer Body Up
15. Engine, Ether Start
Illuminates when Trailer Dump Body is up.
12. Emissions, Diesel Particulate Filter
(DPF)
16. Engine, Heater
Illuminates when diesel particulate trap is
plugged. This warning will also illuminate
when regeneration operation is disabled.
13. Emissions, High Exhaust System
Temperture (HEST)
Illuminates when the exhaust gas temperature and exhaust components become
extremely hot.
– 24 –
Illuminates when ether start switch is on.
Y53-6004
Illuminates when Engine Heater switch is on.
17. Engine, Low Coolant Level
Illuminates with an audible alarm indicating
critically low coolant level. The vehicle must
be serviced to correct the problem but the situation should not be considered an emergency.
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PART 4: CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
18. Engine, Overspeed
21. Engine, Wait To Start
Illuminates when engine RPM is exceeded.
Illuminates when engine grid heater is on
(Cummins ISB and ISC engines).
19. Engine, Retarder (Brake)
Illuminates when the engine retarder (compression brake or exhaust brake) switch is
turned on. (Engine retarders are an option.)
Illuminates when air actuated fifth wheel King
Pin is unlocked.
23. Fifth Wheel, Slide Unlocked
20. Engine, Stop Engine
Illuminates and an audible alarm tone will
sound when a major engine system problem
exists.
WARNING! This should be considered
an emergency. You should stop the vehicle as safely as possible and turn OFF
the ignition. The vehicle must be serviced and the problem corrected before
driving again. Failure to do so may cause
severe engine damage or cause an accident.
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22. Fifth Wheel, King Pin Lock
Y53-6004
Illuminates and an audible warning tone will
sound when the air operated sliding fifth
wheel switch is on, thus unlocking the sliding
fifth wheel. The light and an audible warning
tone should NOT be considered an emergency but simply as a reminder to turn off the
switch to lock the sliding fifth wheel before
driving. This switch should not be operated
while driving. (Sliding fifth wheels are an
option).
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INSTRUMENTS AND CONTROLS
PART 4: CONTROLS AND DISPLAYS
24. Lights, High Beam
28. Power Take-off (PTO), Pump Mode
Illuminates when the high beams are on.
This icon will flash with audible alarm if the
headlamps are left on when the door is open.
Illuminates with remote throttle application.
Indicates pump mode is active.
29. Refrigerator
25. Message Waiting
Illuminates with telematic equipped messaging.
Illuminates to indicate that the refrigerator is
on and ignition is off.
30. Seat Belt, Fasten
26. Park Brake
Illuminates in the status indicator when parking brakes are applied and the vehicle is stationary. This symbol will also illuminate in the
Driver Information Display if the parking
brakes are applied and the vehicle is in
motion.
31. Suspension Dump
Illuminates when suspension air bags are
deflated.
27. Power Take-off (PTO)
32. Tire Inflation
Illuminates when the PTO is engaged.
Illuminates when tire pressures need to be
checked. (Tire Pressure Monitoring System
is an option)
NOTE: Do not drive vehicle with PTO
engaged.
– 26 –
Illuminates when the ignition key is turned on
as a reminder to fasten your seat belt.
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PART 4: CONTROLS AND DISPLAYS
INSTRUMENTS AND CONTROLS
33. Transmission, Auxiliary
37. Transmission, Oil Temperature High
Illuminates to indicate auxiliary transmission
is in neutral.
Illuminates when transmission lubricant temperature is too high.
34. Transmission, Check
Illuminates when transmission has recorded
a fault code. This icon may also appear in the
Transmission Display menu of the Driver
Information Display unit (see item G; page
31). If the user is in this display menu, the
icon does not indicate a fault code.
CAUTION: This should be considered an
emergency. You should stop the vehicle as
safely as possible and turn OFF the ignition.
The vehicle must be serviced and the problem corrected before driving again. Failure to
do so may cause severe transmission damage.
38. Turn Signal, Left
Blinks when the left turn signal or the hazard
light function is operating.
35. Transmission, Do Not Shift
Illuminates with automatic transmissions
equipped with “Don’t Shift” output.
39. Turn Signal, Right
Blinks when the right turn signal or the hazard light function is operating.
36. Transmission, Oil Filter
Illuminates when service is required (Allison
transmissions only).
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DRIVER INFORMATION DISPLAY
PART 4: CONTROLS AND DISPLAYS
Driver Information Display
• 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
WARNING! Do not look at the Driver Information Display for prolonged periods while the
vehicle is moving. Only glance at the monitor
briefly while driving. Failure to do so can
result in the driver not being attentive to the
vehicle’s road position, which could lead to an
accident and possible personal injury or
equipment damage.
The various functions may be accessed by navigating
through Menu Screens using the MCS. Refer to “Menu
Control Switch (MCS)” on page 16 for more detail for the
MCS.
The bullets in the Menu Bar allow access to each item by
pushing the MCS when the desired bullet is highlighted.
The Driver Information Display, located at the top of the
instrument cluster, displays 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
– 28 –
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PART 4: CONTROLS AND DISPLAYS
DRIVER INFORMATION DISPLAY
In addition to a blank screen, the following are menu items
and the information available within each menu selections.
B. RPM Detail (Accessible while parked or driving)
NOTE: Some Driver Information Display functions are
only accessible when the vehicle is parked. Other
functions are accessible while the vehicle is moving
or when parked. Each function is identified in the following descriptions.
RPM reading of actual engine RPM. Engine RPM
within the bar graph indicates the engine is operating in the most efficient RPM range. The display
color will change if you are operating outside of this
range.
C. Ignition Timer (Accessible while parked only)
A. Fuel Economy (Accessible while parked or
driving)
1. Current fuel economy - Indicates instantaneous
fuel economy.
2. Trip fuel economy - Indicates trip fuel economy.
Ignition timer is set from this menu. The ignition
timer may be set for up to 30 minutes.
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DRIVER INFORMATION DISPLAY
PART 4: CONTROLS AND DISPLAYS
D. Trip Information
– PTO Hours
NOTE: When accessing the trip information
menu, push the MCS on this menu (bullet).
To exit, push the MCS again. To reset the trip
values, press the Trip Odometer Reset Button on the main gauge instrument cluster.
– 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 information menu, push the MCS on this menu (bullet). To exit, push the MCS again.
Certain Trip Information functions area accessible
when driving or when parked:
– Trip Economy
– Trip Average Speed
1. Chassis Number
Other Trip Information functions are accessible only
when parked:
– Trip Distance
3. Engine Model
4. Engine SW Version
– Trip Engine Hours
5. Transmission Make
– Trip Idle Hours
6. Transmission Model
– Trip Idle Percentage (%)
– 30 –
2. Engine Make
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PART 4: CONTROLS AND DISPLAYS
DRIVER INFORMATION DISPLAY
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)
7. Transmission SW Version
8. ABS (Antilock Braking System) Make
9. ABS Model
10. ABS SW Version
11. CECU (Cab Electronic Control Unit) Software
Version
NOTE: Refer to the Automated Transmission
Operator’s Manual for additional information.
12. CECU Hardware Version
F. Diagnostic Display (Accessible only while parked)
NOTE: “Faults Found” will only be active if a
red or yellow warning lamp is illuminated.
The diagnostic display menu (bullet) will indicate a
fault that is generated by the vehicle's Engine, ABS
and/or Transmission systems. While on this menu
item the display will either indicate "No Faults
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This menu will show gear number that coincides with
the current transmission gear selected. The menu
also displays the transmission icon to let the user
know what screen they are in. (Does not indicate a
fault code.)
H. Settings Menu (Accessible only while parked)
The Settings menu screen allows the driver to view
and/or change the following menu items:
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DRIVER INFORMATION DISPLAY
PART 4: CONTROLS AND DISPLAYS
• Display Format 12 Hour (AM/PM) or 24 Hour
(military)
• Home/Local Time
• Alarm ON/OFF
• Alarm Time
To Set Home, Local or Alarm Time:
• Units of measure
1. When in the Settings Menu, scroll through the
list of menu items. Press the MCS to select the
item to change.
• Language (English, Spanish or French)
2.
To Set Clock Display Format:
1. When in the Settings Menu, scroll through the
list of menu items to "Format".
3. Rotate the MCS knob to change the hour. Press
the MCS.
2. Press the MCS to display either 12 hour (AM/
PM) or 24 hour (military) time.
– 32 –
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PART 4: CONTROLS AND DISPLAYS
DRIVER INFORMATION DISPLAY
1. When in the Settings Menu, scroll through the
list of menu items to "Units". Press the MCS.
2. Press the MCS to display either Standard or
Metric units. Refer to “Engine Hours / Outside
Air Temperature” on page 36 for another
method to change units.
4. Rotate the MCS knob to change the minutes.
Press the MCS.
5. Rotate the MCS to toggle AM/PM. Press the
MCS
6. Rotate the MCS to select Exit. Press the MCS to
exit the settings function.
To Turn Alarm ON/OFF:
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, Spanish or French. Press the MCS knob to select the
desired language.
1. When in the Settings Menu, scroll through the
list of menu items to "Alarm". Press the MCS.
2. Press the MCS to turn the alarm ON or OFF.
To Set Units of Measure:
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– 33 –
STANDARD GAUGES
PART 4: CONTROLS AND DISPLAYS
Standard Gauges
On the pages that follow you will find descriptions of some
of the gauges on your instrument panel. For more information about using them in driving, see “PART 7: STARTING & 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 warning light or
audbile alarm. These signals tell you something is wrong with your vehicle. It could be a
failure in an important system, such as the
brakes, which could lead to an accident. Have
the appropriate system checked immediately.
Trip Reset
Button
Odometer / Trip Meter
Odometer
Trip
Meter
Some gauges will display a red LED warning light, with
some accompanied by an audible alarm, whenever the
limits of the function being displayed are exceeded.
Speedometer
The speedometer indicates the vehicle speed in miles per
hour (mph) and in kilometers per hour (km/h). The speedometer also includes an odometer, trip meter, and trip
reset button.
– 34 –
The LCD display in the lower part of the speedometer
contains the odometer and trip meter.
The odometer displays the total distance your vehicle has
traveled. It will display in miles on an English speedometer
or in kilometers on a metric speedometer. The maximum
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PART 4: CONTROLS AND DISPLAYS
STANDARD GAUGES
Tachometer
distance that can be shown on the odometer is
“1 999 999” before it rolls over to zero.
The trip odometer displays how far the vehicle has gone
on a particular trip. The trip odometer will display in miles
on an English speedometer or in kilometers on a metric
speedometer, in one tenth divisions. The maximum distance that can be shown on the trip odometer is “9999.9”
before it rolls over to zero.
To reset the trip odometer, press and hold the trip reset
button on the speedometer. The numbers will reset to 0
and begin to count new miles/km traveled. This also
resets the trip values in the Driver Information Display.
The trip reset button also toggles all displays between
English and Metric. (See page 36.)
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 odometer without ignition switch being turned on.
(08/06)
Your tachometer measures the engine speed in revolutions-per-minute (RPM). The tachometer also includes an
engine hour meter and outside air temperature display.
Watching your tachometer is important to driving efficiently. It will let you match driving speed and gear selection to the operating range of your engine. If your engine
speed gets too high, you can select a higher gear to lower
the RPM. If your engine speed drops too low, you can
select a lower gear to raise the RPM.
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– 35 –
STANDARD GAUGES
PART 4: CONTROLS AND DISPLAYS
Engine Hours / Outside Air Temperature
Hour Meter
Snowflake
Symbol
Outside
Air
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 33 for another
method to change units.
The LCD display in the lower part of the tachometer contains the engine hour meter and the outside air temperature display.
The engine hour meter will display the total number of
hours the engine has been running. The maximum hours
that can be shown are “99999.9” before the meter rolls
over to zero.
The outside air temperature (OAT) will display the temperature outside the vehicle. The temperature can be displayed from -40° to 158° in Fahrenheit or -40° to 70°
Celsius.The display will also alert the driver when the outside temperate approaches freezing (32°F or 0°C) by displaying a snowflake symbol. The symbol will turn on when
the temperature drops below 34°F or 11°C and flash for
the first 3 seconds, then stay on until the temperature
goes above 37°F or 28°C.
– 36 –
Y53-6004
NOTE: The OAT will come on when the door is
open and the key switch is in the accessory or
ignition position. The OAT display will turn off
when the ignition switch is turned off.
NOTE: The OAT uses a sensor (located at the
bottom of the driver’s side mirror assembly) to
measure outside air temperature only. It is not
capable of displaying the temperature of the road
surface on either the temperature display or the
snowflake icon.
NOTE: The effects of direct sunlight, or the use of
mirror heat, will increase the outside air temperature displayed while the vehicle is stationary.
(08/06)
PART 4: CONTROLS AND DISPLAYS
STANDARD GAUGES
Engine Oil Pressure Gauge
• If your oil pressure suddenly drops while you are driving, bring the vehicle to a stop as soon as possible in
a safe location off the road and turn off the engine.
Wait a few minutes to allow oil to drain into the oil pan,
and then check the oil level. Add oil if necessary. If the
problem persists, contact an authorized service center.
Check the engine manufacturer’s manual for the correct
oil pressure ranges for your engine.
Water Temperature Gauge
It is important to maintain oil pressure within acceptable
limits. Your engine manual will give normal operating pressures for your engine.
CAUTION: Continuing to operate your vehicle
with insufficient oil pressure will cause serious
engine damage.
• If your oil pressure fails to rise within 10 seconds after
your engine starts, stop the engine and determine the
cause.
The water temperature gauge shows the temperature of
the engine coolant. Under normal operating conditions the
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– 37 –
STANDARD GAUGES
PART 4: CONTROLS AND DISPLAYS
water temperature gauge should register between 165°
and 205°F (74° and 90°C). Under certain conditions,
somewhat higher temperatures may be acceptable. But
the maximum allowable temperature is 210°F (99°C) with
the cooling system pressurized, except 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
serious personal injuries. You could be badly
burned.
• 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 fluid and steam.
• Carefully and slowly turn the cap one-quarter of a turn or until it reaches the first stop—
allowing excess pressure to escape—push
down and turn for final removal.
– 38 –
Wait until the coolant temperature is below 122° F (50°C).
Protect your face, hands, and arms by covering the cap
with a large, thick rag to protect you against escaping fluid
and steam. Before you completely remove the cap, carefully and slowly turn the cap part way to allow excess
pressure to escape. Then push down and turn for final
removal.
The cooling system may overheat if the coolant level is
below normal or if there is a sudden loss of coolant (such
as a worn hose splitting). It may also temporarily overheat
during severe operating conditions such as climbing a
long hill on a hot day or stopping after high-speed driving.
If the “Engine Coolant Temperature” warning light comes
on, or you have any other reason to suspect the engine
may be overheating:
• Stop the vehicle, but DO NOT TURN OFF THE
ENGINE unless a low water warning device indicates
a loss of coolant.
• With 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
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PART 4: CONTROLS AND DISPLAYS
STANDARD GAUGES
the warning light does not go off or the temperature
gauge does not begin to drop, then turn the engine
off.
Fuel Gauge
• If the overheating came from severe operating conditions, the temperature should have cooled by this
time. If it has not, stop the engine and let it cool before
checking to see if the coolant is low.
Voltmeter
WARNING! Do not remove a fuel tank cap near
an open flame. Hot fuel vapors are combustible and can cause an explosion or fire resulting in injury or death.
CAUTION: Use Ultra Low Sulfer Diesel fuel only.
Failure to do so may damage components of the
Diesel Particulate Filter (DPF).
The voltmeter displays the voltage at which your batteries
are being charged while the engine is operating.
(08/06)
The fuel gauge shows the approximate amount of fuel in
the fuel tanks. Besides empty and full, the gauge also indicates 1/4, 1/2, and 3/4 of total capacity. You will want to
keep your fuel tanks at least half full to reduce condensa-
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– 39 –
STANDARD GAUGES
PART 4: CONTROLS AND DISPLAYS
tion of moisture in the tanks. This moisture can damage
your engine.
Primary (Secondary) Air Pressure Gauge
(Air Reservoir)
The air pressure gauge indicates the amount of air pressure 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 reservoir.
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 operation, the warning light will glow and the audible alarm will
sound.
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(08/06)
PART 4: CONTROLS AND DISPLAYS
OPTIONAL GAUGES
WARNING! The air pressure warning light and
the audible alarm indicate a dangerous situation. There is not enough air pressure in the
reservoirs for repeated braking and the brake
system has failed. If air pressure falls below
60 psi (414 kPa) the spring brakes could suddenly apply, causing a wheel lockup, loss of
control, or your vehicle to be overtaken by following vehicles. You could be in an accident
and severely injured. If these alarms come on
while you are driving, bring your vehicle to a
safe stop right away. If the light and alarm do
not turn off at start-up, do not try to drive the
vehicle until the problem is found and fixed.
Optional Gauges
Air Filter Restriction Indicator or Gauge
This gauge indicates the condition of the engine air
cleaner and is measured by inches of water (H 2 O). A
clean filter should register 7 in. H2O (may vary with system design) and a filter whose life is over will register
approximately 25 in. H2O.
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OPTIONAL GAUGES
PART 4: CONTROLS AND DISPLAYS
CAUTION: Continued operation with the Air Filter
Restriction Gauge reading 25 in. H2O may cause
damage to the engine. Inspect the filter and
replace if necessary. Holes in the paper element
render an air cleaner useless and may cause the
Air Filter Restriction Gauge to give a false reading, even if the element is clogged. Replace the
element if it is damaged.
gauge goes down, there may be something wrong with
your engine. Have it checked by a qualified service person.
Fuel Pressure Gauge
Your vehicle may also have a fuel pressure gauge.
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
– 42 –
Y53-6004
WARNING! Carrying additional fuel containers
in your vehicle is dangerous. Full or empty,
they may leak, explode, and cause or feed a
fire. Don’t carry extra fuel containers - even
empty ones.
(08/06)
PART 4: CONTROLS AND DISPLAYS
OPTIONAL GAUGES
Air Application Gauge
Transmission Temperature Gauge
This gauge shows how much air pressure is being applied
from your foot brake valve or trailer brake hand valve.
Your Transmission Temperature Gauge indicates the temperature of the oil in your transmission. Watch this gauge
to know when your transmission is overheating. If it is,
have it checked by an authorized service representative.
Maximum transmission temperature may vary, depending
upon the transmission and type of lubricant. Check your
transmission’s owner’s manual.
(08/06)
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– 43 –
OPTIONAL GAUGES
PART 4: CONTROLS AND DISPLAYS
Forward Drive Axle Temperature Gauge
Rear Drive Axle Temperature Gauge
These gauges indicate the temperature of the lubricant in
your vehicle’s axle(s). These temperatures will vary with
the kind of load you are carrying and the driving conditions you encounter. Maximum axle temperature may
vary, depending upon the axle and type of lubricant. Very
high temperatures signal a need to have your axle(s) lubrication checked.
CAUTION: Driving with very hot temperatures in
your rear drive axles can cause serious damage
to axle bearings and seals. Have your axle lubrication checked if you notice a sign of overheating.
– 44 –
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(08/06)
PART 4: CONTROLS AND DISPLAYS
STEERING COLUMN-MOUNTED CONTROLS
Steering Column-Mounted Controls
WARNING! After you complete a turn, shut the
system off by returning the lever to the “OFF”
(center) position. The switch's lever action is
NOT self-canceling. Failure to shut off a turn
signal could confuse other drivers and result in
an injury accident. An indicator light in the
instrument panel will flash until the turn signal
is turned off.
Turn Signal and Indicator Lights
NOTE: The ignition key must be turned to ON for
the signal/switch to operate.
Your turn signal lever is mounted on the left side of the steering column below the steering wheel. Green directional indicator lights appear on the instrument panel. To operate the
signal, move the lever in the direction of the turn. Each time
the turn indicator is activated the audbile alarm emits a short
beep.
High Beam Headlamps
NOTE: The headlamps must be “ON” for the high
beam switch to operate.
• To switch your headlamps to lower or higher beam,
gently pull the turn signal lever towards the steering
wheel, until you hear the switch click and the beam
changes. The blue indicator light in the instrument
panel will be ON when the high beam is being used.
• To return to previous beam: pull the lever towards the
steering wheel again.
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STEERING COLUMN-MOUNTED CONTROLS
PART 4: CONTROLS AND DISPLAYS
Headlamp Flash
Windshield Wipers/Washer
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.
Your vehicle is equipped with a two-speed, intermittent
windshield wiper system. A seven-position rotary wiper
switch (located on the turn signal lever) operates the windshield wipers and washer (see next illustration). Rotate
the end of the turn signal lever to change the wiper mode.
• 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
To flash, press the button on the end of the turn signal
lever and hold. To cancel the flash, release the button.
Press In For Washer Pump
Rotate To Change Wiper Mode
NOTE: The ignition key must be turned to ON or
ACC for the wiper/washer switches to 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 intermittent delay times.
Press Button For ID and Clearance Lights Flash
If your ID and clearance lights are on, they will flash off.
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(08/06)
PART 4: CONTROLS AND DISPLAYS
STEERING COLUMN-MOUNTED CONTROLS
Hold the knob in to extend the washing cycle. After the
lever is released, the wipers will shut off automatically or
resume the wiper’s setting speed.
Wiper Switch Settings
To activate the wipers for one swipe without activating the
washer (“mist” function), push the turn signal lever in
(towards the steering column) and release in less than 0.5
seconds. The wipers will perform a single swipe and then
resume the wiper’s setting speed.
Wiper Switch Position
WARNING! Do not drive with worn or dirty
wiper blades. They can reduce visibility, making driving hazardous. Clean blades regularly
to remove road film and wax build-up. Use an
alcohol-based cleaning solution and a lintfree cloth, and wipe along the blades.
Wiper Speed
Off
Off
Intermittent #1
20 Second Delay
Intermittent #2
17 Second Delay
Intermittent #3
7 Second Delay
Intermittent #4
4 Second Delay
Low
Low Speed
High
High Speed
CAUTION:
• Do not use antifreeze or engine coolant in
the windshield washer reservoir—damage to
seals and other components will result.
To Wash The Windshield
Push the rotary wash/wipe knob in (towards steering column), hold for more than 0.8 seconds and then release.
(08/06)
Y53-6004
• If the electric pump is operated for a long
period (more than 15 seconds) with a dry reservoir, the pump motor may be damaged.
– 47 –
STEERING COLUMN-MOUNTED CONTROLS
PART 4: CONTROLS AND DISPLAYS
Check the windshield washing fluid level daily. If necessary, fill to top.
Clean all inside and outside windows regularly. Use an
alcohol-based cleaning solution and wipe dry with either a
lint-free or a chamois cloth. Avoid running the wiper
blades over a dry windshield to prevent scratching the
glass. Spray on washer fluid first. A scratched windshield
will reduce visibility.
Electric Horn
Air Horn
Your Peterbilt has an air horn in addition to an electric
horn. Control the air horn 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.
Your Peterbilt has an electric horn. To operate, press on
the horn symbol near the center of the steering wheel.
To operate the trailer brake hand valve: Pull down on
the lever under the right side of the steering wheel.
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(08/06)
PART 4: CONTROLS AND DISPLAYS
STEERING COLUMN-MOUNTED CONTROLS
WARNING! Activating the trailer hand brake
lever instead of the BrakeSaver lever could lead
to an accident. If you have these levers, they
may be close together on your steering wheel
column. Exercise care to choose the appropriate
lever. The BrakeSaver lever is located lower and
closer to the driver on the steering column (see
page 59).
See “Brake Safety and Emergency” on page 112 for more
complete information on when and how to use your trailer
brake. Or see the Index, under Brake
Tilt- Telescoping Steering Column
Depending on your vehicle’s configuration, you may have
either a Tilt/Telescoping or a fixed steering column.
• The tilt feature allows forward and rearward movement of the wheel.
• The telescoping feature allows you to move the wheel
up and down.
To activate these features, locate the Tilt/Telescoping
pedal.
NOTE: The trailer brake is not to be used as the
main means of braking. To use this brake frequently instead of using the foot brake will wear
out the trailer brake sooner.
WARNING! It is dangerous to use air-applied
trailer brakes for parking or holding a vehicle.
Air system pressure can bleed down and
release the brakes. You could have a vehicle
roll-away resulting in an accident. You or others could be badly injured. Always apply the
parking brakes for parking or holding your
vehicle on grade.
(08/06)
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DASH- AND DOOR-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
WARNING! 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. Make all adjustments to the steering
mechanism while the vehicle is stopped.
To adjust the steering wheel, PUSH and HOLD the pedal
down fully. Push or pull the wheel to the desired height
and angle, then RELEASE the pedal to lock the wheel at
the correct position.
Dash- And Door-Mounted Features
Ignition Switch
Your ignition switch has four (unmarked) positions:
OFF
ACC ONLY
• ACC (Accessory): With your key in this position you
can play the radio or use other accessories, but your
engine won’t start.
• OFF:In this position all systems are off, and you can
remove your key.
• IGN & ACC:This position allows you to turn on the
engine and all accessory power.
• START:Starter activation to start engine.
Hazard Flasher
The four-way Emergency Flasher switch is located to the
right of the ignition key switch. With the switch in the ON
position, the emergency flasher makes all four turn signals
(front and rear) flash simultaneously. The flasher works
independently of the ignition switch. You should always
use the flasher if the vehicle is disabled or parked under
emergency conditions.
IGN & ACC
START
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(08/06)
PART 4: CONTROLS AND DISPLAYS
DASH- AND DOOR-MOUNTED FEATURES
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! Use your Hazard Flasher Warning
System any time you have to stop off the road or
on the side of the road, day or night. A hard-tosee vehicle can result in an injury accident.
Another vehicle could run into you if you do not
set your flashers 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
vehicle can be dangerous for you and others.
The hot exhaust system could ignite dry
grass, spilled fuel, or other substances. Do
not park or operate your vehicle where the
exhaust system could contact dry grass,
brush, spilled fuel, or any other material that
could cause a fire.
(08/06)
Y53-6004
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 vehicle. Doing so
could lead to an injury accident.
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DASH- AND DOOR-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
CAUTION: On vehicles equipped with daytime
running lights (DRL), the high-beam headlamps
go on automatically at reduced brightness if the
engine is running and the headlamp switch is
turned off. The daytime running lights are turned
off automatically while the parking brake is
engaged. If the headlamp switch is turned on, the
DRL system is overridden & headlamps operate
normally.
To Operate Your Panel Light Dimmer:
1. Turn on either the headlights or clearance lights.
2. To brighten the instrument lights, rotate the thumbwheel up.
3. To dim the instrument lights, rotate the thumbwheel
down.
ID and Clearance Lights Switch
Panel Light Dimmer
The Panel Light Dimmer lets you vary the brightness of
your instrument panel lights.
– 52 –
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 are controlled by the
control panel switch labelled CL LPS or with the symbol
shown above.
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(08/06)
PART 4: CONTROLS AND DISPLAYS
DASH- AND DOOR-MOUNTED FEATURES
Dome Light
The center-mounted dome light is operated by gently
pushing on the lens until a click is heard. The same action
turns the light on or off, depending on its previous state.
are arranged will affect whether you can operate headlights and fog lights concurrently—always comply with the
state or provincial requirements where you are driving.
Air Suspension Deflate Switch (Dump Valve)
Fog Lights Switch
AIR SUSPENSION
If your vehicle has fog lights, turn them ON or OFF with
the control panel switch with the symbol shown above.
Your Peterbilt vehicle may have an air suspension deflation switch which allows the air in the suspension to be
exhausted from a switch on the dash. The purpose of this
feature is to allow you to lower your tractor to get under a
trailer. You may notice a guard over the switch. This prevents you from accidentally deflating the suspension.
NOTE: Across the U.S.A. and Canada, State/Provincial requirements vary as to when high beams
and fog lights can and cannot be used together.
Some states allow only four lights to be used
together, while some allow more. How your lights
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Y53-6004
WARNING! Operating the Air Suspension
Deflate Switch (Dump Valve) while driving can
lead to an accident. Sudden deflation while
– 53 –
DASH- AND DOOR-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
your vehicle is moving can affect handling and control. Use this switch only when your vehicle is not
moving.
fan switch in the AUTOMATIC position, the engine fan will
automatically turn on when the engine coolant reaches a
temperature of about 200°F.
CAUTION: Operating a vehicle with air suspension bags either overinflated or underinflated
may cause damage to driveline components. If a
vehicle must be operated under such conditions, do not exceed 5 mph.
WARNING! Do not work on the fan with the
engine running. Anyone near the engine fan
when it turns on could be badly injured. If it is
set at ON, it will turn on any time the ignition
key switch is turned to the ON position. In
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.
Engine Fan Switch
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 the fan, and take care no
one turns on the ignition when someone is
working near the fan.
The engine fan switch allows you to control the engine fan
manually or automatically. With the ignition key switch ON
and the fan switch in the ON position, the engine fan will
be on regardless of engine temperature. With the engine
– 54 –
Y53-6004
CAUTION: Do not operate the engine fan in the
manual (ON) position for extended periods of
time. The fan hub was designed for intermittent
operation. Sustained operation will shorten the
fan hub’s service life as well as reduce fuel
economy.
(08/06)
PART 4: CONTROLS AND DISPLAYS
DASH- AND DOOR-MOUNTED FEATURES
Cruise Control Switch
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.
In conventional models with Eaton transmissions, the
cruise control switches may be located on the shift control
knob (see illustration).
The master switch turns the cruise control ON or OFF.
The second switch allows you to SET the desired speed
or RESUME the desired speed after the cruise control
function has been interrupted.
WARNING! Do not operate the cruise control
when operating on road surfaces with poor
traction (wet, icy, or snow covered roads) or in
heavy traffic. Accelerations caused by the
normal operation of the cruise control could
cause you to lose control of the vehicle resulting in an injury accident.
(08/06)
Power Mirror Switch
If your vehicle is equipped with power mirrors, the mirror
controls will be located on the driver side door pad. Aerody-
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DASH- AND DOOR-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
namic-style mirrors are controlled for 4-way adjustable
movement, while Moto mirrors are controlled for 2-way
adjustable movement.
NOTE: The Power Mirror Switch does not control
the adjustment of the convex mirrors.
To Adjust Aerodynamic-Style Mirrors
1. Move the mirror selector switch to the right or left from
the neutral center position to select the desired mirror
for adjustment.
2. Depress the mirror directional control pad in one of its
four arrow directions to adjust the mirror in/out or up/
down.
Mirror Directional
Control Pad
NOTE: After mirror adjustments have been completed, return the mirror selector switch back to
the center (neutral) position, to prevent unintentional adjustments to the mirrors.
Mirror Selector
Switch
To Adjust Moto Mirrors
WARNING! Convex mirrors can distort images
and make objects appear smaller and farther
away than they really are. You could have an
accident if you are too close to another vehicle
or other object. Keep plenty of space between
your vehicle and others when you turn or
change lanes. Remember that other objects
are closer than they may appear.
– 56 –
1. For in/out mirror adjustment: Move the mirror selector
switch to the right or left from the neutral center position to select the desired mirror for adjustment.
Y53-6004
NOTE: If the mirror is fixed (non-motorized) on
the left side, then the mirror selector switch will
ONLY allow selection of the neutral and right mirror switch positions.
(08/06)
PART 4: CONTROLS AND DISPLAYS
DASH- AND DOOR-MOUNTED FEATURES
2. Depress the mirror directional control pad towards the
arrows pointing left or right to adjust the mirror in/out.
NOTES:
• Because the Moto mirrors have only 2-way
adjustment, the mirror directional control pad is
also restricted in its movement to left or right ONLY.
• After mirror adjustments have been completed,
return the mirror selector switch back to the center (neutral) position, to prevent unintentional
adjustments to the mirrors.
have an automatic 15-minute “time out” feature, where the
mirror heat-only module is automatically deactivated.
To defrost the mirrors in cold weather, depress the mirror
heat switch button and release. The mirror heat symbol in
the button will illuminate to indicate the mirror heat function has been activated. Pressing and releasing the button
again turns the mirror heat and the indicator light Off.
Mirror Heat Switch
Mirror Heat
Switch Button
NOTE: The effects of direct sunlight, or the use of
mirror heat, will increase the outside air temperature displayed while the vehicle is stationary.
Mirror Heat
Indicator Light
Your vehicle may be equipped with optional heated mirrors.
Mirror heat is controlled by the mirror heat switch button,
which is part of the mirror switch module located on the
driver side door pad. Motorized mirrors with mirror heat
(08/06)
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DASH- AND DOOR-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
Power Window Switch
Driver Window
Switch
Power Door Lock Switch
Passenger
Window Switch
Your vehicle is probably equipped with power windows.
Power window rocker switches are located on the door
pads (a switch for the passenger window is also on the
driver side door pad, as shown above). To open or close a
window, depress the switch for that window at the end that
displays a downward- or upward-directed arrow, respectively, in the window symbol on the switch face. Release the
switch to stop window movement.
– 58 –
Your vehicle is probably equipped with power door locks.
Power door lock rocker switches are located on the door
pads (switch on the driver side door pad is shown above). To
lock or unlock both cab doors as well as a sleeper door,
depress any door lock switch at the end that displays a
closed or open padlock symbol, respectively, on the switch
face.
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(08/06)
PART 4: CONTROLS AND DISPLAYS
DASH- AND DOOR-MOUNTED FEATURES
(see next illustration). How much braking you get depends
on how much you move the lever.
Manual and Automatic Control Switch
With the switch in the AUTOMATIC position, the BrakeSaver will be fully applied automatically when the operator
has the vehicle in gear and takes his or her foot off the
accelerator pedal.
With the switch in the ON position, the BrakeSaver will be
applied constantly, regardless of whether the operator has
the vehicle in gear or his or her foot off the accelerator.
Manual Control Lever
This hand-operated control lever provides modulated
application of the BrakeSaver in the manual or ON mode
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DASH- AND DOOR-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
A Control Air Pressure gauge and an Engine Oil Temperature gauge are provided with the BrakeSaver.
Jacobs Engine Brake or Cummins “C” Brake
Switch
The ON/OFF switch turns the system ON or OFF. The
second switch performs the progressive braking function
that controls the amount of retarding.
2-Mode and 3-Mode Systems
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Y53-6004
(08/06)
PART 4: CONTROLS AND DISPLAYS
DASH- AND DOOR-MOUNTED FEATURES
WARNING! Using the engine brake when
operating on surfaces with poor traction
(such as wet or icy, slippery roads or gravel)
could cause loss of control.
• If you have the two-mode system, you can select
HIGH or LOW.
• If you have the three-mode system, you can select
low, medium, or high retarding.
In conventional models with Eaton transmissions, the
engine brake switch may be located on the shift control
knob (see illustration):
For more information on when and how to use the engine
brake in your vehicle, see the engine brake manufacturer’s
owner’s manual that is included with your vehicle.
Interaxle Differential Lock Switch
The interaxle differential allows differential action between
the forward rear and the rear rear driving axles. The interaxle differential lock switch allows the operator to LOCK or
UNLOCK the differential. The guard over this switch prevents you from accidentally activating the lock.
SHIFT AT ANY SPEED EXCEPT
IF A WHEEL IS SPINNING
(08/06)
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DASH- AND DOOR-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
WARNING! Placing the differential lock in the
“LOCK” position while your wheels are spinning could cause loss of control or axle damage. You could be hurt. Switch to “LOCK”
only when your wheels are not spinning.
See “Interaxle Differential” on page 95 for more information on using your interaxle differential.
For information on how to operate your two-speed rear
axle properly and safely, see “Dual Range (Two Speed)
Axles” on page 97.
Fifth Wheel Lock (Slider Adjustment) Switch
.
Two-Speed Rear Axle (Range) Switch
.
FIFTH WHEEL
RANGE SELECTOR
If your vehicle is equipped with a two-speed rear axle, you
can select the axle range by the dash mounted switch
shown above. The low range provides maximum torque
for operating off-highway. The high range is a faster ratio
for highway speeds.
– 62 –
Y53-6004
WARNING! Do not move the fifth wheel while
the tractor-trailer is in motion. Movement of
the fifth wheel while a tractor-trailer is moving
can cause a serious accident. Your load could
shift suddenly, causing you to lose control of
the vehicle. 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.
(08/06)
PART 4: CONTROLS AND DISPLAYS
DASH- AND DOOR-MOUNTED FEATURES
Vehicles having an air slide fifth wheel have a fifth wheel
slider lock controlled by a switch on the instrument panel.
By placing the switch in the unlock position, you can slide
the fifth wheel to various positions to adjust weight distribution. There is a guard over this switch to protect you
against accidentally activating or releasing the lock.
SHIELD to its best angle by noticing the lower manifold
boost pressure at cruise (as indicated by the manifold
pressure gauge), or the reduction in road dirt deposited
on the front of the trailer.
Parking Brake Valve and Trailer Air Supply
Valve
Manual VARASHIELD® Wind Deflector
The VARASHIELD Wind Deflector is a roof-mounted,
adjustable shield for improving vehicle aerodynamics.
WARNING! You could fall and be badly injured
by trying to climb to the top of the cab without
the right equipment. Always use a ladder or
scaffolding to get up to adjust your manual
VARASHIELD.
If you have the manual VARASHIELD, you will adjust it
from the roof of the cab. Move it to the desired angle with
the telescoping strut that is secured by a bolt and locknut.
Proper VARASHIELD angle is affected by wind, trailer
height, and the gap between the tractor and trailer. Usually the VARASHIELD should be down, at 0 degrees,
when the tractor is operating without a trailer or pulling a
flatbed. With all other trailers, you adjust the VARA(08/06)
02908
Single Valve
Your parking brake valve is a yellow diamond-shaped
knob located in the center console of conventional cab
models. It controls the parking brakes for straight truck or
tractor-trailer combinations.
Y53-6004
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DASH- AND DOOR-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
Heater-Air Conditioning Controls
Your heat and air conditioning controls are mounted in the
“D” instrument panel in conventional models. Additionally,
the sleeper compartment may also contain a separate
heating and cooling system with separate controls.
02909
WARNING! Stopping with the parking brake
controls can cause a sudden wheel lock-up,
loss of control, or can cause you to be overtaken by following vehicles. You could be
severely injured. Never pull out the parking
brake valve while the vehicle is moving.
To apply all parking brakes, pull the yellow, or parking
brake, knob out. The truck or tractor parking brakes will
set, and the Trailer Air Supply Valve (red octagon knob)
will automatically trip (“pop out”) and set the trailer parking
brakes. To release both truck/tractor and trailer parking
brakes, push in BOTH yellow and red knobs. For full information on using parking brakes, see the Index, under
Brakes.
– 64 –
Y53-6004
WARNING! Exhaust fumes from the engine
contain carbon monoxide, a colorless and
odorless gas. Do not breathe the engine
exhaust gas. A poorly maintained, damaged, or
corroded exhaust system can allow carbon
monoxide to enter the cab or sleeper. Entry of
carbon monoxide into the cab is also possible
from other vehicles nearby. Failure to properly
maintain your vehicle could cause carbon
monoxide to enter the cab/sleeper and causes
serious illness.
CAUTION: Never idle your vehicle for prolonged
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 conditions, drive only with the windows
open. Failure to repair the source of the exhaust
fumes may lead to personal harm.
(08/06)
PART 4: CONTROLS AND DISPLAYS
DASH- AND DOOR-MOUNTED FEATURES
• If you are required to idle your vehicle for long
periods of time, install an auxiliary heater or automatic idle control. These auxiliary devices can
reduce fuel consumption and save you money.
NOTES:
• Keep the engine exhaust system and the vehicle’s cab/sleeper ventilation system properly
maintained. It is recommended that the vehicle’s
exhaust system and cab/sleeper be inspected:
• If other vehicles are parked next to you idling,
move your vehicle or do not stay in your vehicle
for prolonged periods of time.
– By a competent technician every 15,000
miles
• When idling for short periods of time
– Whenever a change is noticed in the sound of
the exhaust system
– Set the heating or cooling system to Heat or
A/C
– Whenever the exhaust system, underbody,
cab or sleeper is damaged
• To allow for proper operation of the vehicle ventilation system, keep the inlet grille at the base of
the windshield clear of snow, ice, leaves and
other obstructions at all times.
• Do not stay in the vehicle with the engine running or idling for more than 10 minutes with the
vehicle’s Heater and A/C ventilation system in
RECIRC or at LOW FAN SPEED. Even with the
ventilation system On, running the engine while
parked or stopped for prolonged periods of time is
not recommended.
(08/06)
– Set the fan to Medium or High speed
– Set the controls to FRESH AIR
To Set the Heater-Air Conditioning Controls
Conventional Cab:
The Conventional cab's controls will have one control unit
on the dash, and may have a rocker switch for the bunk
control unit (see illustrations that follow):
• A rotary knob (A) in the left portion controlling the
blower speed with five settings (including OFF).
Y53-6004
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DASH- AND DOOR-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
• A rotary knob (B) in the center portion controlling the
movement of air within the cab. This control is continuously variable through five modes (clockwise from
left):
– Panel
– Panel/Floor
– Floor
– Defrost/Floor
– Defrost
• A rotary knob (C) in the right portion controlling the air
temperature.
• A push button switch (D) in the center left portion to
engage the air conditioner compressor (only vehicles
with air conditioning).
• A push button switch (E) in the center right portion to
select either fresh- or recirculated-air mode.
NOTE: For vehicles equipped with the Peterbilt
Comfort Control (PCC) option: The PCC option
lets the temperature knob function as a thermostat that regulates duct temperatures based on
the knob settings. When active, the “COMFORT
CONTROL” icon (F) will be illuminated under the
temperature knob (C).
– 66 –
.
B
A
C
02980A
D
E
F
Conventional Cab Control Panel (vehicle with air conditioner and PCC)
Conventional Cab Sleeper:
A separate rocker switch on the dash will send power to
the “bunk” or sleeper control unit (only vehicles with a
sleeper unit); see next illustration.
Y53-6004
(08/06)
PART 4: CONTROLS AND DISPLAYS
DASH- AND DOOR-MOUNTED FEATURES
I
REAR
A/C
O
Bunk or Sleeper Control Unit Power Switch
The conventional sleeper control panel will have three
controls (two for vehicles without air conditioning); see
illustration that follows:
• A rotary knob (A) in the left portion controlling the
blower speed with four settings.
• A rotary knob (B) 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.
• A rocker switch or a push button switch (C) to engage
the air conditioner compressor (vehicles equipped
with air conditioning).
(08/06)
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DASH- AND DOOR-MOUNTED FEATURES
PART 4: CONTROLS AND DISPLAYS
WARNING! Do not drive with visibility reduced
by fog, condensation, or frost on the windshield. Your view may be obscured, which
could result in an injury accident. For clear visibility and safe driving, it is extremely important
for you to follow the instructions pertaining to
the function and use of the ventilation/heating
and defogging/defrosting system. If in doubt,
consult your dealer. Maximum heating output
and fast defrosting can be obtained only after
the engine has reached operating temperature.
CAUTION: During extreme cold weather, do not
blow hot defroster air onto cold windshields.
This could crack the glass. Turn the air flow control lever to Defrost and adjust the fan speed
accordingly while the engine warms. If the
engine is already warm, move the temperature
selector to Cool, then gradually increase the
temperature when you see that the windshield is
starting to warm up.
• To defog the windshield, select the Defrost mode
and turn the blower speed to high. Set the temperature knob to hot (the red position on the control). The
air conditioner is automatically activated to remove
– 68 –
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 temperature knob to cool (the blue position on the control), and the blower to high until the cab becomes
cool. Then you can turn down the blower if you wish.
For Efficient Cooling:
1. Be sure all heater - air conditioner controls are off.
2. Start the engine. Allow time for warm-up.
CAUTION: A cold compressor can cause refrigerant to liquefy and warp the valve plates or
cause a hydraulic lock. Warm the engine before
starting the air conditioner.
CAUTION: To avoid damage to the compressor &
blower motors, turn off all controls when a system is not in use.
3. Set the air control in the RECIRC mode.
4. Close all windows.
5. Idle the engine between 1000 and 1500 RPM and
turn the blower speed control to High.
Y53-6004
(08/06)
PART 4: CONTROLS AND DISPLAYS
DASH- AND DOOR-MOUNTED FEATURES
6. After the cab temperature cools to a comfortable level,
adjust the blower speed and controls to keep the
desired condition.
NOTE: When the air conditioner is not in regular
use, operate it for at least 15 minutes at least
once a month or every 5,000 miles (8,000 Km),
whichever comes first. This will lubricate the seals
in the air conditioning system. The air conditioning system is active when the Defrost mode is
selected.
in. The lighter circuit is protected by a 10-ampere fuse to
prevent damage should the lighter get stuck in the IN position. If this fuse needs replacement, check to ensure that
the lighter is not stuck before replacing the fuse.
WARNING! Do not exceed the voltage/amperage capacity of the cigarette lighter. It could
result in a fire . Follow all warnings and
instructions in the operator's manual for the
appliance you are using.
The lighter receptacle may be used to power auxiliary
equipment not drawing more than 10 amperes maximum.
Cigarette Lighter
Ashtray
WARNING! Paper or other combustible substances in an ashtray could cause a fire. Keep
all burnable materials besides smoking materials out of the ashtray.
Glove Compartment
02912A
To open your glove compartment, lift the latch. To close it,
push the cover up and press to latch it.
Lighter
To operate your lighter, push the center of the knob in.
After a few moments the lighter will automatically pop out,
ready to use. After use, insert the knob, but do not push it
(08/06)
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CAB FEATURES
PART 4: CONTROLS AND DISPLAYS
The glove compartment can be locked. Turn your glove
box key clockwise (right) to lock and counterclockwise
(left) to unlock.
mirror so you can just see the side of your vehicle in the
inboard part of the mirror.
WARNING! Optional convex outside rear view
mirrors make objects appear smaller and farther away than they really are. You could have
an accident if you were too close to another
vehicle or other object. Keep plenty of space
between your vehicle and others when you
turn or change lanes. Remember that other
objects are closer than they seem.
WARNING! An open glove compartment can
be dangerous. In an accident or sudden stop,
you or a passenger could be thrown against
the cover and injured. Keep the cover closed
when the vehicle is in motion.
Shift Pattern Display
The correct shift pattern for your vehicle appears on your
control panel or windshield or on a medallion in the shift
knob. It is important that you know more about your transmission than just the shift pattern. Please read the manufacturer’s manual that is included with your vehicle.
Cab Features
Luggage Compartment(s)
An interior luggage compartment is under the bunk in the
Conventional sleeper. The exterior compar tment is
beneath the bunk, opening from the driver’s side, on the
outside of the cab.
Mirrors
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
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Y53-6004
WARNING! Carrying objects loose in your cab
or sleeper can be dangerous. In a sudden stop,
or even going over a bad bump, they could fly
forward and strike you or a passenger, possibly
causing serious injury. Secure loose objects.
Carry any heavy objects in the exterior luggage
compartment and close it securely.
(08/06)
PART 4: CONTROLS AND DISPLAYS
CAB FEATURES
Appliances in the Cab
You may decide to equip your vehicle with a radio, a refrigerator, or other appliances and conveniences. Be sure they
are compatible with your truck’s electrical system. Secure
them in the cab so they cannot fly loose in a sudden stop.
WARNING! In a sudden stop or collision a
heavy object in your cab could strike you or
anyone with you. You could be injured or even
killed. Secure any appliance (such as a refrigerator or radio) you add to your cab.
Peterbilt Navigation System
Your vehicle may be equipped with a Peterbilt Navigation
System. This system is a Global Positioning Satellite
(GPS)-linked computer. It receives input from multiple
sources to locate your vehicle. Read and understand the
Supplemental Navigation System Owner’s Manual and
observe the Warnings, Cautions, and Notes that follow
before using the system.
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Y53-6004
WARNING! Verify legal weight and height
restrictions for the route suggested by the
Navigation System. Failure to verify height
restrictions could lead to personal injury. Failure to verify weight restrictions could result in
a traffic infraction.
WARNING! Only glance at the Navigation
System monitor while driving. Prolonged periods of viewing while driving could result in an
accident and possible personal injury.
WARNING! Do not program the Navigation
System while driving. Always stop your vehicle when programming or changing the settings 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 so could lead to
serious injury or equipment damage.
CAUTION: Do not rely on the Navigation System
to route you to the closest emergency services.
Not all emergency services are in the database.
– 71 –
CAB FEATURES
PART 4: CONTROLS AND DISPLAYS
NOTE: Regardless of how and where the navigation system directs you, it is your responsibility to
operate the vehicle in a safe and legal manner.
NOTE: Ensure the volume level of all audio
devices is set to a level that still allows you to hear
outside traffic and emergency vehicles.
NOTE: The map database is the most current
available at the time of production. The database
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.
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(08/06)
PART 5: SEAT AND RESTRAINT SYSTEMS
SEAT
PART 5: SEAT AND RESTRAINT SYSTEMS
Seat
For information on the features and adjustment of the
seat, see the seat manufacturer’s literature included with
the vehicle.
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 or ride with your seat back in
the reclined position. You could be injured by
sliding under the seat belts in a collision.
• Do not adjust the driver's seat while the
vehicle is moving. The seat could move suddenly and unexpectedly and can cause you to
lose control of the vehicle. Make all adjustments to the seat while the vehicle is stopped.
After adjusting the seat and before driving off,
ensure that the seat is firmly latched in position.
WARNING! Do not drive vehicle without your
seat belt and your riders’ belt fastened. Riding
without a safety belt properly fastened can
lead to increased injury or death in an emergency. Unbelted riders could be thrown into
the windshield or other parts of the cab or
could be thrown out of the cab. They could
strike another person. Injuries can be much
worse when riders are unbelted. Always fasten your seat belt.
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
02998
Person In Crash, Unbelted
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SEAT BELTS AND THEIR PROPER USE
PART 5: SEAT AND RESTRAINT SYSTEMS
Lap/Shoulder Belt
To unfasten the belt:
The combination lap-shoulder belt is equipped with a locking mechanism. The system adjusts automatically to a
person's size and movements as long as the pull on the
belt is slow. Hard braking or a collision locks the belt. The
belt will also lock when driving up or down a steep hill or in
a sharp curve. To fasten the belt,
1. Grasp the belt tongue and pull the belt in a continuous
slow motion across your chest and lap.
2. Insert the belt tongue into the buckle on the inboard
side of the seat.
3. Push down until the tongue locks securely (with an
audible click). Pull on the belt to check for proper fastening.
• Pull the shoulder section to make sure the belt fits
snugly across the chest.
• The shoulder belt must be positioned over the shoulder—it must never rest against the neck.
• Belts should fit snugly across the pelvis and chest.
Make sure any slack is wound up on the retractor.
– 74 –
1. Push in the release button on the buckle. The belt will
spring out of the buckle.
Unfastening a belt
2. To release a locked belt, lean back to take the body
pressure off of the belt.
3. To store a lap-shoulder belt, allow the belt to wind up
on the retractor by guiding the belt tongue until the
belt comes to a stop.
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PART 5: SEAT AND RESTRAINT SYSTEMS
SEAT BELTS AND THEIR PROPER USE
Proper Safety Belt Adjustment
Your combination lap-shoulder belt may need adjustment.
Adjust safety belts properly.
• The lap belt should be worn as low and tight on the
hips as possible. Make sure any slack is taken up by
the belt mechanism.
• The shoulder belt should fit snugly across your body. It
should be positioned midway over the shoulder (nearer
to the door); it should never rest against your neck. It you
put the belt under your arm, it can’t protect you properly.
• Be sure, also, that your belt is not too loose. A loose
belt could allow you to slide under it in an accident,
and that could bring the belt up around your abdomen.
• Do not twist the belt in the process of putting it on. A
twisted belt will not work as well to protect you.
Lap Belt
Shoulder Belt
Too High
on Hips
Correct
Incorrect
Correct (over arm)
Incorrect (under arm)
Incorrect (twisted)
Safety Restraint Belts
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SEAT BELTS AND THEIR PROPER USE
PART 5: SEAT AND RESTRAINT SYSTEMS
WARNING!
• Do not twist the belt in the process of putting it on. A twisted belt will not work as well to
protect you. In a crash, the full width of the belt
would not be protecting you. A twisted belt
could cut into your body and cause serious
injuries. Straighten the belt before buckling it.
If you are unable to wear it without twisting it,
have your dealer or service person repair it as
soon as possible.
• Always wear your seat belt low over your
pelvic bones.
• You can be seriously injured if your belt is
buckled too high. In a crash, it would apply
force to your abdomen, not your pelvic bones.
This can result in serious internal injuries.
• Do not drive with your seat belt loose. A
seat belt that is too loose can allow you to fall
too far forward, possibly causing head and
neck injuries. You could strike the wheel or the
windshield. Adjust your belt so that there is no
more than 1 in. (25mm) of slack.
• Do not wear the shoulder belt under your
arm or otherwise out of position. In a crash
your body would move too far forward, increasing the chance of head and neck injury. Also,
the belt would apply too much force to the ribs,
which are not as strong as your shoulder
bones, and could cause you to suffer internal
injuries. Wear the shoulder belt over your
shoulder.
– 76 –
Komfort-Lok® Feature
Your Peterbilt contains a feature designed to eliminate
cinching and provide improved safety and comfort. Cinching is the condition where a belt becomes continually
tighter around you during a rough, bouncy ride. The need
for this feature increases with rough road conditions, particularly over long distances.
To eliminate cinching simply activate the Komfort-Lok feature at the appropriate time:
1. Fasten your seat belt according to the directions.
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PART 5: SEAT AND RESTRAINT SYSTEMS
SEAT BELTS AND THEIR PROPER USE
2. You are now ready to activate the Komfort-Lok. Lean
forward to pull a little slack (maximum of one inch,
measured from the belt to your chest) in the belt. Be
sure to allow only a small amount of slack (see the
Warning on a loose belt).
3. When the slack is right, flip the latch cover up, cinching it into place. This locks the Komfort-Lok.
4. To release the Komfort-Lok latch, reach up and pull
the latch cover open (down), or simply pull down on
the shoulder belt.
5. When you want to get out of the cab, release the
latch, then just push the button on the buckle.
Pregnant Women
Sometimes pregnant women worry that in a crash the
seat belt could hurt the baby. But if a woman wears her
belt properly - low over her pelvis, below her abdomen the belt won’t harm the baby, even in a crash. And remember - the best way to keep an unborn baby safe is to keep
the mother safe.
.
Komfort-Lok®
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SEAT BELTS AND THEIR PROPER USE
PART 5: SEAT AND RESTRAINT SYSTEMS
You will notice that if your Peterbilt has an upper bunk, it
has no restraint 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 seriously injured. He
or she could be thrown from the bunk. Be sure
anyone occupying the sleeper is restrained
while a vehicle is moving.
• Be sure that no one ever rides in the upper
bunk. That person would be thrown out in an
accident and could be very seriously injured.
Passengers
02932A
Anyone riding in your vehicle should wear a seat belt. The
responsible operator sees to it that everyone in the vehicle
rides safely - and that means with a seat belt.
Pregnant Woman With Belt Properly Worn
Sleeper Bunk Restraints
If your cab is equipped with a sleeper, be sure to use the
restraint device. You may have belts which either are over
the bunk or cover the opening. Of course, you do not need
to use a restraint if you sleep in a parked vehicle. But anyone using the sleeper while the truck is in motion should
be restrained in a safety device.
– 78 –
Some Other Safety Restraint Tips:
• Don’t wear belts over rigid or breakable objects in or on
your clothing. Such things might be eyeglasses, pens,
keys, etc. These could cause injury in an accident.
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PART 5: SEAT AND RESTRAINT SYSTEMS
SEAT BELTS AND THEIR PROPER USE
• Damaged belts in the cab or sleeper must be
replaced. Belts that have been stretched, cut, or worn
out may not protect you in an accident.
• Avoid catching belts in the doors or seat hardware.
They could be damaged.
• Don’t modify or disassemble the seat belts in your
vehicle. They won’t be available to keep you and your
passengers safe.
• Never bleach or dye seat belts; chemicals can
weaken them. Do, however, keep them clean by following the care label on the belts. Let them dry completely before allowing them to retract.
Tether Adjustment
WARNING!
• Failure to adjust tether belts properly can
cause excessive movement of the seat in an
accident. This could lead to greater injuries
for you. Tether belts should be adjusted so
that they are taut when the seat is in its most
upward and forward position.
• Before driving or riding in a vehicle, ensure
that there is adequate head clearance at maximum upward travel of seat. Serious injury
may occur if head clearance is not adequate.
Shorten the tether belt as necessary to provide adequate head clearance.
• If any seat belt is not working properly, see an authorized Peterbilt dealer for repair or replacement.
Tether Belts
Tether belts are installed on suspension seats. They help
secure the seat to the floor to restrain it in case of a sudden stop or an accident.
WARNING! Do not remove, modify, or replace
the tether belt system with a different tether system. A failed or missing tether belt could allow a
seat base to fully extend in the event of an accident leading to greater injuries or death.
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• 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.
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– 79 –
INSPECTION OF THE RESTRAINT SYSTEM
PART 5: SEAT AND RESTRAINT SYSTEMS
Inspection of the Restraint System
seat belt system, except when the user puts on or
takes off the belt. In trucks, however, there is almost
constant movement of the belt through hardware due
to ride characteristics and seats which are designed
to move, in order to enhance driver comfort. There
can even be movement of the webbing in the seat belt
system when the belt in not being used. Relative
movement between the seat and the cab, which normally occurs whenever the truck is in operation, can
cause wear of the seat belt webbing.
WARNING! Failure to properly inspect and
maintain restraint systems can lead to serious
injury or loss of life. Without periodic inspection and maintenance to detect unsafe conditions, seat restraint components can wear out
or not protect you in an accident.
The typical three-point seat systems in passenger cars
may seem very similar to the three-point seat belt system
in heavy duty vehicles, but there are some key differences
that all users of this system should be aware of:
• In typical passenger vehicle automotive seat belt
applications, the normal life of the vehicles is usually 8
to 10 years and the total mileage frequently does not
exceed 125,000 miles (200,000 km). Heavy duty vehicles often see this type of mileage in a very short
period of time, and accumulation of mileage in excess
of 500,000 miles (800,000 km) during the vehicle lifetime is not unusual.
• A significant difference in the two systems is the
amount of movement of webbing in the system. In an
automotive application, there is little movement of the
– 80 –
• Environmental conditions represent another major difference in the systems in automobiles and heavy duty
and specialty vehicles. Unlike the automotive environment, heavy duty and specialty vehicles may be very
dirty, and have more exposure to the sun’s damaging
ultraviolet rays, thus resulting in a reduction of the life
of the seat belt system.
The high mileage associated with heavy duty vehicles and
possible wear of the 3-point seat belt system, the continual relative movement of the system, the possible contact
with the vehicle seat or other parts of the cab structure,
and the potential exposure of this system to severe environmental conditions make it crucial to inspect the three-
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PART 5: SEAT AND RESTRAINT SYSTEMS
INSPECTION OF THE RESTRAINT SYSTEM
point seat belt systems regularly. It is recommended that
the seat belt system in a vehicle be inspected every
20,000 miles (32,000 km) or more often if the vehicle is
exposed to severe environmental conditions. Any seat belt
system that shows cuts, fraying, extreme or unusual wear,
significant discoloration due to UV exposure, abrasion to
the seat belt webbing, or damage to the buckle, latch
plate, retractor hardware or any other obvious problem
should be replaced immediately, regardless of mileage.
WARNING! It is important to remember that
any time a vehicle is involved in an accident,
the entire seat belt system must be replaced.
Unexposed damage caused by the stress of
an accident could prevent the system from
functioning properly the next time it is
needed, which could result in severe injury or
even death.
webbing, etc. and damage to the buckle, retractor, hardware, or other factors which indicate that belt replacement
is necessary.
1. Check the web wear in the system. The webbing must
be closely examined to determine if it is coming into
contact with any sharp or rough surfaces on the seat
or other parts of the cab interior. These areas are typical places where the web will experience cutting or
abrasion. Cuts, fraying, or excessive wear would indicate the need for replacement of the seat belt system.
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 detail how to
inspect for cuts, fraying, extreme or unusual wear of the
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INSPECTION OF THE RESTRAINT SYSTEM
PART 5: SEAT AND RESTRAINT SYSTEMS
2. The D-loop web guide is the area where almost constant movement of the seat belt webbing occurs
because of relative movement between the seat and
the cab.
3. Check the Komfort Latch™ for cracks or possible
damage and that it works properly.
4. Check the buckle and latch for proper operation and
to determine if the latch plate is worn, deformed, or
damaged.
5. Inspect the retractor web storage device, that is
mounted on the floor or B-pillar of the vehicle for damage. The retractor is the hear t 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.
03004A
– 82 –
WARNING! Failure to adjust tether belts properly can cause excessive movement of the
seat in an accident. This could lead to greater
injuries for you. Tether belts should be
adjusted so that they are taut when the seat is
in its most upward and forward position.
6. If adjustable tethers are being used, be sure they are
adjusted in accordance with installation instructions.
Tethers must also be inspected for web wear, just as
with the seat belt systems.
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PART 5: SEAT AND RESTRAINT SYSTEMS
INSPECTION OF THE RESTRAINT SYSTEM
7. Mounting hardware should be evaluated for corrosion,
and for tightness of bolts and nuts.
8. Check web in areas exposed to ultraviolet rays from
the sun. If the color of the web in these areas is gray
to light brown, the physical strength of this web may
have deteriorated due to exposure to the sun’s ultraviolet rays; replace the system.
WARNING! Replace the entire belt system
(retractor and buckle side) if replacement of any
one part is necessary. Unexposed damage to one
or more components could prevent the system
from functioning properly the next time it is
needed, which could result in severe injury or
even death.
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 of the seat belt has been
determined, be certain that it is only replaced with the recommended replacement seat belt. The occupant restraint
system has been developed and tested specifically for this
vehicle. If the vehicle was originally equipped with a lap
belt, it cannot be replaced with a three-point shoulder harness system, because the cab mounting points are not
structurally designed for a three-point seat belt.
If the inspection indicates that any part of the seat belt
system requires replacement, the entire system must be
replaced, both retractor and buckle side. An installation
guide is attached to every replacement belt. This set of
instructions is entitled “THREE-POINT SEAT BELT
INSTALLATION GUIDE.” There are separate seat 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 components must be remounted back in the same position as
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– 83 –
SAFE VEHICLE OPERATION
PART 6: DRIVER’S CHECKLIST
PART 6: DRIVER’S CHECKLIST
Safe Vehicle Operation
To keep your vehicle in top shape, and to maintain its high
level of safety for you, your passengers, and your load,
make a thorough inspection every day before you drive.
You’ll save maintenance time later -- and the safety
checks could help prevent a serious accident. Please
remember, too, that Federal law requires a pre-trip inspection and so do commercial trucking companies.
For more information, you can refer to Federal Motor Carrier Safety Regulation 392.7 which tells you that interstate
commercial motor vehicles are not to be driven unless the
driver is sure that certain parts and accessories 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
– 84 –
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 responsible driver:
• If you drink, do not drive.
• Do not drive if you are tired, ill, or under emotional
stress.
Much has gone into the manufacturing of your Peterbilt,
including advanced engineering techniques, rigid quality
control, and demanding inspections. These manufacturing processes will be enhanced by you—the safe driver—
who observes the following:
• knows & understands how to operate a vehicle and all
its controls
• maintains the vehicle properly
• uses driving skills wisely
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PART 6: DRIVER’S CHECKLIST
SAFE VEHICLE OPERATION
WARNING! Do no t drink an d drive . Yo ur
reflexes, perceptions, and judgment can be
affected by even a small amount of alcohol. You
could have a serious—or even fatal accident—if
you drive after drinking. Please do not drink and
drive or ride with a driver who has been drinking. The use of alcohol, drugs, and certain medications will seriously impair perception,
reactions, and driving ability. These circumstances can substantially increase the risk of an
accident and personal injury.
The daily checks listed below are the foundation of your
overall preventive maintenance program. See “PART 8:
MAINTENANCE AND SERVICE” for the complete preventive maintenance schedule for your vehicle.
Approaching the Vehicle
1. Check the overall appearance and condition. Are windows, mirrors, and lights clean and unobstructed?
2. Check beneath the vehicle. Are there signs of fuel, oil,
or water leaks?
3. Check for damaged, loose, or missing parts. Are there
parts showing signs of excessive wear or lack of lubrication? Have a qualified mechanic examine any questionable items and repair them without delay.
(08/06)
Checking Under the Hood or Cab
With the engine stopped:
1. Check the engine oil level; top off as necessary. Refer
to your engine’s operating manual for the type of oil to
use.
2. Check the engine coolant level. Top off as necessary
with premixed coolant. Refer to the instructions on
page 183 for adding coolant to the proper level.
3. Check the condition of the engine belt(s).
4. Check brake lines and hoses.
5. Check all other accessories, controls, belts, hoses,
and wiring for condition and adjustment.
6. Check the windshield washer fluid level; top off as
necessary.
7. Check the power steering fluid reservoir; top off as
necessary.
8. Check the steering components (pitman arm;
draglink; power steering hoses, etc.)
9. Drain the fuel/water separator.
Checking the Luggage Compartment
Check the fire extinguisher charge and check the road
emergency kit.
Y53-6004
– 85 –
SAFE VEHICLE OPERATION
PART 6: DRIVER’S CHECKLIST
Checking Outside the Vehicle
WARNING!
• Diesel fuel in the presence of an ignition
source (such as a cigarette) could cause an
explosion. You could be seriously injured. A
mixture of gasoline or alcohol with diesel fuel
increases this risk of explosion. Use only the
fuel recommended for your engine.
• Hot fuel vapors are combustible and can
cause an explosion or fire resulting in injury
or death. Do not remove a fuel tank cap near
an open flame.
1. Be sure all wheel studs and cap nuts are secure.
Check wheel cap nut torque weekly; refer to the
instructions on page 176.
2. Check tires for condition and proper 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.
– 86 –
7. Check the fuel tanks. Is there enough fuel? Are the
tank caps secure?
8. Visually inspect the fuel tank mounting hardware. Are
the tank straps tight? Is the webbing in place?
9. If equipped with fuel tank steps: are they damaged or
broken? Is the grommet/windlace in place between
the tank and side plate? Are bolts missing or loose?
10. Check the air cleaner and muffler(s). Are they tight
and secure?
11. Check the trailer connections. Are they secure and
the lines clear? If they are not being used, are they
stored properly?
12. Is the trailer spare wheel secure? Inflated?
13. Is the landing gear up and the handle secured?
14. Check the 5th wheel. Is the kingpin locked?
15. Is the sliding 5th wheel locked?
16. Check for loose or missing suspension fasteners.
17. Check springs or other suspension parts for damage
such as cracks, gouges, distortions, bulges, or chafing.
18. Check the air system. Are there leaks?
19. 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 automatic drain valves.
20. Check that cab latch or hood hold-downs are hooked.
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PART 6: DRIVER’S CHECKLIST
SAFE VEHICLE OPERATION
In - Cab Checklist
CAUTION: To avoid injury while entering or
leaving the cab, keep your feet in contact with
the steps and your hands on the handhold.
Always have three points of contact as you
enter or exit a cab. See “PART 2: CAB AND
FRAME ACCESS” of this manual for more
information.
4. Adjust the steering column.
5. Check mirror adjustment.
6. Operate air-powered devices to circulate lubricants.
After Engine Warmup
1. Check automatic transmission oil (if equipped).
1. Adjust the seats.
2. Fasten and adjust safety restraint belts. (See “PART
5: SEAT AND RESTRAINT SYSTEMS” or the Index,
under Restraint Systems.)
3. Sleeper Restraints: Check and inspect condition.
(See “PART 5: SEAT AND RESTRAINT SYSTEMS”
or the Index, under Restraint Systems.)
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Y53-6004
NOTE: The above items should be checked daily,
as a minimum. They are in addition to, not in
place of Federal Motor Carrier Safety Regulations. These may be purchased by writing to:
Superintendent of Documents
U.S. Government Printing Office
Washington, DC 20402
– 87 –
NORMAL TEMPERATURE STARTING PROCEDURE
PART 7: STARTING & OPERATING THE VEHICLE
PART 7: STARTING & OPERATING THE VEHICLE
CAUTION: Never operate the starter motor
while the engine is running. The starter and
flywheel gears could clash or jam, severely
damaging them.
Since each vehicle is custom-equipped, all engine operation instructions in this manual are general. You will want
to consult the manual for your engine to find out details
about your specific engine’s needs. You may need to use
a slightly different procedure from the one outlined here.
Also check the ATA Truck Driver’s Handbook in your glove
box. It will give you tips on starting, shifting, and driving a
truck.
Below are instructions for both normal-temperature starting and cold-weather starting.
Normal Temperature Starting Procedure
NOTE: Some starters are equipped with overcrank
protection. Check the “Engine Operation and Maintenance Manual” for details.
5. Turn the ignition key to the START position. If the
engine does not start within 30 seconds, release the
starter button. To avoid overtaxing the starter motor or
the batteries, don’t use the starter for more than 30
seconds. Let the starter motor cool and the batteries
recover for two minutes before trying again.
If the engine still won’t start after a couple of tries,
check the manual override shutdown valve and fuel
lines for possible fuel starvation or air leaks. Starting
failure may mean fuel isn’t reaching the injectors.
When the outside temperature is above 50° F (10° C), you
can use the following procedure.
1. Set the parking brake.
2. Put your main transmission in Neutral.
3. Disengage (depress) the clutch (with manual transmission).
4. Turn the key switch to ON.
– 88 –
6. As soon as the engine starts, begin to watch the oil
pressure gauge. Check your engine manufacturer’s
manual for the right pressure for your engine. If the oil
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PART 7: STARTING & OPERATING THE VEHICLE
COLD TEMPERATURE STARTING PROCEDURE
pressure doesn’t rise within a few seconds, stop the
engine. Find out what is wrong before restarting the
engine.
7. Slowly engage (release) the clutch after the engine
has started.
8. Wait until normal engine oil pressure registers on the
gauge before idling or accelerating the engine beyond
1000 RPM.
Ether Metering Equipment
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 service life of your engine.
• Keep the electrical system in top condition.
• Use the best quality fuel of the recommended grade.
• Use recommended engine lubricating oil.
(08/06)
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WARNING! The fluid in ether starting systems
is extremely flammable and poisonous. If
ignited, it could burn you badly. If you swallow
it, it can be harmful or fatal.
• Do not smoke when testing, installing, or
servicing an ether starting unit. Service it in a
well-ventilated area away from heat, open
flames, or sparks.
• If swallowed, do not induce vomiting. Call a
physician immediately.
• Wear goggles to avoid getting fluid in your
eyes. Avoid getting it on your skin and avoid
breathing the fumes. If fluid does get in your
eyes or fumes irritate your eyes, flush for 15
minutes with large amounts of clean water.
Contact an eye specialist.
• Do not move or relocate the ether cylinder
or tubing from its original installation. It must
be mounted to protect it from engine exhaust
heat and from moving parts which could damage it.
• Do not store the spare cylinder in the cab.
– 89 –
ENGINE WARMUP
PART 7: STARTING & OPERATING THE VEHICLE
• In warm weather, when you will not need the
ether starting system, remove the ether bottle
from your truck and store it safely. Return the
protective cap to the bottle mounting connector.
In cold weather the engine will start faster and the starter
motor will work more easily if ether is injected into the
engine cylinder while the engine is being cranked.
Automatic System
When you turn the ignition switch to the START position,
the cranking motor and the ether system are engaged.
When needed, starting fluid is released from a pressurized cylinder, flows through a valve and tubing, and sprays
from a nozzle in you engine’s air intake system.
Warmup Procedure
1. After you’ve started your engine, idle it at approximately 600 RPM while you check
• oil pressure
• air pressure
• alternator output
2. After a few minutes of idling at 600 RPM, increase
your idle 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 temperatures, you may have to increase idle speed.
For more helpful starting information, refer to the engine
manual that came with your vehicle.
Engine Warmup
The purpose of engine warmup is to allow oil film to be
established between pistons and liners, shafts and bearings while your engine gradually reaches operating temperature.
– 90 –
Y53-6004
NOTE: In colder climates where the temperature
is often below freezing, the warmup for turbocharged engines is especially important. Chilled
external oil lines leading to the turbocharger will
slow the oil flow until the oil warms, reducing oil
available for the bearings. Watch the engine oil
temperature or pressure gauge for a warming
trend before increasing engine idle speed (RPM).
(08/06)
PART 7: STARTING & OPERATING THE VEHICLE
ENGINE WARMUP
3. Continue the engine warmup until the coolant temperature reaches at least 130° F (54° C). At this temperature, you can use partial throttle. Wait until the
coolant temperature is at least 160° F (71° C) before
operating at full throttle.
(08/06)
CAUTION: The use of a winterfront can result
in excessive engine coolant, oil, and charge
air (intake) temperatures, which can lead to
overheating and possible engine damage. If
you must use a winterfront
WARNING! Exhaust fumes from the engine contain carbon monoxide, a colorless and odorless
gas. Do not breathe the engine exhaust gas. A
poorly maintained, damaged or corroded exhaust
system can allow carbon monoxide to enter the
cab or sleeper. Entry of carbon monoxide into the
cab is also possible from other vehicles nearby.
Failure to properly maintain your vehicle could
cause carbon monoxide to enter the cab/sleeper
and causes serious illness.
• Refer to the “Engine Operation and Maintenance Manual” for operating restrictions and
recommendations.
CAUTION: Never idle your vehicle for prolonged 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 conditions, drive only with
the windows slightly open. Failure to repair
the source of the exhaust fumes may lead to
personal harm.
• Keep the engine exhaust system and the vehicle’s cab/sleeper ventilation system properly
maintained. It is recommended that the vehicle’s
exhaust system and cab/sleeper be inspected
– By a competent technician every 15,000 miles
– Whenever a change is noticed in the sound of
the exhaust system
– Whenever the exhaust system, underbody, cab
or sleeper is damaged
Y53-6004
• Use only a winterfront available from your
Peterbilt dealer that is compatible with a 2002
EPA-compliant engine cooling system. These
winterfronts are specifically designed for use
with new grill snap patterns.
NOTES:
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ENGINE WARMUP
PART 7: STARTING & OPERATING THE VEHICLE
WARNING! To reduce the chance of personal
injury and/or vehicle damage from overheated
engines, which can result in a fire, never leave
the engine idling without an alert driver present.
If the engine should overheat, as indicated by
the engine coolant temperature light, immediate
action is required to correct the condition. Continued unattended operation of the engine, even
for a short time, may result in serious engine
damage or a fire.
NOTES:
• Do not stay in the vehicle with the engine running or idling for more than 10 minutes with the
vehicle’s Heater and A/C ventilation system in
RECIRC or at LOW FAN SPEED. Even with the
ventilation system On, running the engine while
parked or stopped for prolonged periods of time is
not recommended.
• If other vehicles are parked next to you idling,
move your vehicle or do not stay in your vehicle
for prolonged periods of time.
CAUTION: Do not allow your engine to idle, at
low rpm's (400–600 rpm), longer than five minutes. Long periods of idling after the engine
has reached operating temperatures can
decrease engine temperature and cause
gummed piston rings, clogged injectors, and
possible engine damage from lack of lubrication. The normal torsional vibrations generated can also cause transmission wear.
Idling the Engine
Under most circumstances, idling your engine for long
periods merely wastes fuel. In severe arctic weather conditions, however, you may need longer idling to be sure all
parts of your engine are fully lubricated.
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
longer than five minutes.
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PART 7: STARTING & OPERATING THE VEHICLE
PUTTING THE VEHICLE IN MOTION
Putting The Vehicle In Motion
This section discusses the clutch and transmission operation to get your Peterbilt underway.
WARNING! Do not carry loose objects in your
cab, it can be dangerous. In a sudden stop, or even
going over a bump in the road, they could fly
through the air and strike you or a passenger. You
could be injured or even killed. Secure all loose
objects in the cab before moving the vehicle.
Shifting The Transmission
You will find a shift pattern either on a decal in your cab or
on a medallion in the shift knob. Check to be sure you
know the correct sequence for your particular transmission. Refer to the transmission manual included with your
vehicle for complete instructions in the operation of your
transmission.
lubricant to circulate and coat the contacting surfaces of
the gears. Metal contacting metal in moving 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
CAUTION: Always use first gear or a low
speed range to start the vehicle in motion.
The use of a higher gear or speed range
forces undue strain on the engine, clutch,
other transmission components, and may
cause damage.
Shifting Gears in a New Vehicle
Shift carefully in a new vehicle. The transmission may be
a little stiff at first. So be careful to avoid gear clashing.
When you are operating a new vehicle or one that has
been exposed to cold weather, you want the transmission
(08/06)
To put your vehicle into motion, push down on the clutch
pedal until the clutch brake makes contact. This contact
will occur at about 1/2 inch to 1 inch from the end of pedal
stroke. Select a gear low enough to let your vehicle start
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PUTTING THE VEHICLE IN MOTION
PART 7: STARTING & OPERATING THE VEHICLE
forward with the throttle at idle until the clutch is fully
engaged.
The total stroke of the clutch pedal is about 10 inches. The
first 1 3/4 to 2 inches is free travel. After that is the release
stroke, the part that fully releases the clutch. The last 1/2
to 1 inch engages the clutch brake. If your vehicle is new,
watch the free travel in your clutch carefully for the first few
hundred miles. As your clutch lining wears and high spots
get worn smooth, you will get less free travel.
Always start out in a low gear with a ceramic-faced clutch.
Starting in higher gears, even with a light load, will cause
a very jumpy start and excessive wear.
And don’t allow your vehicle to roll in the opposite direction at all during clutch engagement. If you need to start
up on an incline, apply your service brakes before you
release the parking brake. Then release your service
brakes as you engage the clutch and apply throttle.
Release Bearing Wear
When you must idle your engine for any period of time,
shift your transmission to neutral and engage the clutch
(take your foot off the pedal). This helps prevent unneces– 94 –
sary wear of your clutch release bearing. And it is less tiring 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 the external linkage
without first checking (and correcting if necessary) the
internal clutch adjustment. Using only the external linkage
adjustment could damage the clutch.
Clutch Brake
Your clutch brake is used for stopping gear rotation to let
you shift into 1st gear or reverse when your vehicle is at a
standstill.
About the last 1/2 to 1 inch of clutch pedal travel activates
your clutch brake. So if you are stopped and want to shift
directly into 1st or reverse, depress the clutch pedal until
contact with the clutch brake is made to stop transmission
gear rotation.
If you have a butt-tooth condition and can’t shift the transmission, gradually release the clutch. Then the drive gear
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PART 7: STARTING & OPERATING THE VEHICLE
PUTTING THE VEHICLE IN MOTION
Upshifts - Let the engine and gears slowdown to the
RPM required for the next gear. Use the tachometer to
determine optimum RPM for gear engagement.
can roll enough to allow the teeth to line up properly and
complete the shift.
CAUTION: Be careful not to apply the clutch
brake while the vehicle is moving. The purpose of the clutch brake is to stop the transmission so that you can shift into a starting
gear without grinding. Applying the clutch
brake when the vehicle is moving causes a
braking effect on the entire vehicle. This wear
naturally shortens the service life of your
clutch brake.
Interaxle Differential
Double Clutching
Whether you are upshifting or down shifting, it is best to
double clutch. Double clutching is easier on your transmission and on your engine, helping your vehicle match
engine speed with driveline speed and achieving clashfree shifts. To double clutch:
1. Push down the clutch pedal to disengage the clutch.
2. Move the gear shift lever to neutral.
3. Release the pedal to 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.
(08/06)
Downshifts - Press accelerator to increase engine
and gear speed to the RPM required in the lower gear.
Use the tachometer to determine optimum RPM for
gear engagement.
4. Now quickly press the pedal to disengage the clutch.
Move the gear shift lever to the next gear speed position.
5. Release the pedal to engage the clutch.
On vehicles with tandem rear axles, the interaxle differential allows each axle to turn independently. Differential
action between the tandems relieves stress on the rear
axles and tires and provides better performance. When
operating normally on paved, dry surfaces, keep your
truck’s interaxle differential in the UNLOCK position.
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PUTTING THE VEHICLE IN MOTION
PART 7: STARTING & OPERATING THE VEHICLE
WARNING!
• Do not put the differential lock in the LOCK
position while the wheels are spinning freely
(slipping), you could lose control of the vehicle or cause axle damage—you could be
injured. Switch to LOCK only when the wheels
are not spinning.
SHIFT AT ANY SPEED EXCEPT
IF A WHEEL IS SPINNING
Switch In Unlock Position
In the LOCK position, continuous operation on a paved,
dry surface stresses the tandem axles, possibly causing
internal damage to them.
• Shift into the LOCK position to operate on slippery
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.
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Y53-6004
• Do not operate the vehicle on dry pavement
with the differential locked; it could lead to an
injury accident. On dry pavement, you will not
be able to steer well with the differential
locked. Lock the differential only when operating on surfaces with poor traction, such as
wet, slippery roads or loose gravel.
• Do not use the differential lock during
downhill operation or at speeds above 25 mph
(40 km/h). When it is engaged under these
conditions, your vehicle will exhibit “understeer” handling characteristics. This “understeer” condition will cause your vehicle to not
turn as quickly and more steering effort will
be required, which can cause an injury accident.
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PART 7: STARTING & OPERATING THE VEHICLE
PUTTING THE VEHICLE IN MOTION
To reduce load on the drive train, ease up on the throttle
pedal whenever you shift into LOCK or UNLOCK.
How to use your dual range axle:
WARNING! Never shift the axle when moving
downhill. Engine driveline disengagement
may occur, eliminating engine retardation and
allowing the wheels to spin faster than the
current speed of the engine. This may require
severe braking to slow the vehicle down and
can result in an injury accident.
Dual Range (Two Speed) Axles
If you have this option, dual range axles provide two rear
axle ratios for operating under heavy loads or off-highway
as well as for over the road trucking. The Low range provides 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
Range Selector
(08/06)
1. Unlock the interaxle differential before starting.
2. Put the Range Selector in the LOW range. Shift the
transmission to start the truck moving.
3. Off-Highway: When you are driving on rough terrain
and secondary roads, or under a very heavy load,
keep the axle in the LOW range. Shift your transmission to maintain the road speed you want.
4. When you go from off-highway to highway driving,
shift the axle to the HIGH range this way:
A. Be sure the differential is UNLOCKED.
B. Keep the accelerator down and move the Range
Selector lever to HIGH.
C. Keep driving with the accelerator down until you
want the axle to shift.
D. Then release the accelerator until the axle has
shifted.
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PUTTING THE VEHICLE IN MOTION
PART 7: STARTING & OPERATING THE VEHICLE
• When driving on a surface with good traction, keep the
interaxle differential unlocked. You can drive with the
axle in LOW or HIGH range.
E. You are now in the HIGH axle range on the highway. Shift the transmission normally to reach your
desired 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
quickly to increase the engine RPM.
D. The axle will shift to the LOW range.
Important Tips on Operating Your Dual Range Axle
NOTE: If your vehicle has an automatic transmission, it may be necessary to shift it to the Neutral
position momentarily to allow the main differential
lock splines to fully engage or disengage.
• To avoid damaging your vehicle, shift the axle at a
slower speed until you are used to driving with the
dual range axle.
PRESS TO
LOCK
PRESS TO
UNLOCK
SHIFT AT ANY SPEED EXCEPT
IF A WHEEL IS SPINNING
.
• When you are driving with poor traction, lock the differential. When you have the differential locked, drive
with the axle in LOW range only.
• Always UNLOCK the interaxle differential before shifting the axle speed range.
CAUTION: If you shift the axle range with the
interaxle differential in LOCK, you could do
serious damage to your axles. Never shift the
axle range with the differential locked.
• Park the truck with the Range Selector in LOW.
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PART 7: STARTING & OPERATING THE VEHICLE
PUTTING THE VEHICLE IN MOTION
Automatic and Automated Transmissions
WARNING!
An automatic or automated transmission makes shifting
much easier. It remains important to completely understand how to operate the transmission to optimize its efficiency. Please read the manual for your automatic or
automated transmission included with your vehicle.
• If your vehicle has a Freedomline™ 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. This
could cause serious damage or personal
injury. Observe the following guidelines:
There is no “park” position. So you will need to apply the
parking brake before leaving the cab.
• When stopped on a hill or grade, press the
brake pedal.
WARNING! Do not leave the cab without applying the parking brake. The truck could roll and
cause an injury accident. Always apply the parking brake before you leave the cab.
• When starting from a stop on a hill or grade,
quickly remove your foot from the brake pedal
and firmly press on the accelerator pedal.
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PUTTING THE VEHICLE IN MOTION
PART 7: STARTING & OPERATING THE VEHICLE
Transmission Retarder
WARNING! Do not rely on your automatic transmission hydraulic retarder to stop your vehicle. If
your engine shuts down, the vehicle’s retarder will
cease to operate. Always be ready to suddenly
apply the service brakes.
Auxiliary Transmission
If you have an auxiliary transmission, see your transmission manufacturer’s manual for its proper operation.
If Your Vehicle Must Be Towed
Follow these directions to ensure your vehicle is not damaged when towing is required.
Retarder Switch
If you have this option, it will act like a brake to slow your
vehicle without using the brakes. Take your foot off the
throttle and operate the retarder switch. When you do not
need full retarder effect, you can apply it intermittently (off
and on) to cause gradual or partial slowing. Continuous
application of your retarder will cause your hydraulic fluid
to get hotter. Intermittent application will help prevent
overheating.
– 100 –
1. Lift driving wheels off the ground or remove the driveline and axle shafts before towing the vehicle.
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PART 7: STARTING & OPERATING THE VEHICLE
PUTTING THE VEHICLE IN MOTION
CAUTION: Failure to lift the driving wheels off
the ground or remove the driveline and axle
shafts before towing the vehicle could seriously damage your vehicle. All lubricating
and clutch application oil pressure is provided by an engine-driven pump, which does
not work when the engine is stopped. When
vehicles are towed either by wrecker or piggyback, 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.
A. Remove the air line and firmly cap
Air Line - Remove to Install
Caging Bolt
Caging Bolt Storage Location
CAUTION: Water, dirt and other material can
enter an open hub or axle. This can contaminate the axle fluid and cause possible damage
to components. Ensure that the hubs are covered with plastic whenever a drive axle shaft
is removed.
3. For vehicles with driver-controlled main differential
lock, install the caging bolt before removing the axle
shafts for towing.
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Y53-6004
Illustration of Driver-Controlled Main Differential Lock
A. Remove the caging bolt from its storage hole.
B. Screw the caging bolt into the air line hole. When
fully engaged, a 0.25 - 0.5 in. (6-1/2 mm) space
will remain between the air cylinder and the bolt
head. This action will lock the differential by pushing a piston into a “lock” position.
– 101 –
PUTTING THE VEHICLE IN MOTION
PART 7: STARTING & OPERATING THE VEHICLE
CAUTION: Failure to install the caging bolt
when towing vehicles with driver-control main
differential lock can result in damage by failing to lock internal components in position.
WARNING! Ensure there are no open air lines
on the recovered vehicle if the recovery vehicle and recovered vehicle brake systems are
connected. An open air line on the recovered
vehicle will cause a leak in the air brake system of the recovery vehicle ppossibly causing
an accident and personal injury.
CAUTION: A recovered vehicle will have no
operational brake system. Additionally, the rear
axle spring brakes will probably be applied.
• If you desire to use the recovered vehicle’s
brakes, ensure that the vehicles air system is
connected to that of the recovery vehicle.
Also ensure that any air line that has been
removed from a driver-controlled main differential lock is firmly capped to prevent loss of
air pressure from the recovery vehicle.
– 102 –
• If you don’t desire to use the recovered
vehicle’s brakes, ensure that you cage the
spring brakes before attempting to move the
vehicle.
4. Install recovery hitches and rigging.
CAUTION: Connect recovery rigging only to
hitches intended for that purpose. Do not
attach to bumpers or brackets. Connections
to other structural parts could damage the
vehicle.
5. Follow all state/provincial and local laws that apply to
vehicles in tow.
6. Do not tow vehicles at speeds in excess of 55 mph
(90 kph).
Returning a Towed Vehicle to Service
You will have to add lubricant to prevent damage after
your vehicle has been towed.
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 Specifications, for the lubricant required by each axle.
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PART 7: STARTING & OPERATING THE VEHICLE
ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
2. After adding the specified type and amount of lubricant, drive the vehicle. It should be unloaded. Drive 1
to 2 miles (1.5 to 3 km) at a speed lower than 25 mph
(40 km/h).
This will thoroughly circulate the lubricant through the
assembly.
Anti-Lock Braking System Operating
Information
This vehicle may be equipped with an anti-lock braking
system (ABS). This ABS reduces the possibility of wheel
lock-up. If a wheel is about to lock during braking, the ABS
will automatically adjust air pressure to the brake chambers on the appropriate wheel(s) to prevent wheel lock-up.
The ABS is automatically turned on when the ignition
switch is turned on.
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WARNING!
• The brake system is a critical vehicle safety
system. For the safety of you and others
around you, have the vehicle submitted for
periodic preventive maintenance checks as
well as having any suspected problems immediately checked by an Authorized Service
Center. Failure to properly maintain your
brake system can lead to serious injury accidents.
• Do not drive through water deep enough to
wet brake components, as it may cause the
brakes to work less efficiently than normal.
The vehicle's stopping distance may be
longer than expected, and the vehicle may
pull to the left or right when brakes are
applied, which could contribute to an accident.
– 103 –
ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
WARNING! Do not rely on an anti-lock brake
system that is functioning improperly. You
could lose control of the vehicle resulting in a
severe accident and personal injury. If any
ABS lamp goes on while you are driving or
stays on after the self-check, that anti-lock
system might not be working. That ABS may
not function in an emergency. You will still
have conventional brakes, but not anti-lock
brakes. If any warning lamp indicates a problem, have that ABS checked.
PTC218a
CAUTION: If the truck/tractor ABS warning
lamp does not illuminate when the ignition is
first turned on, there is a problem with the
bulb or wiring. The driver should have this
checked as soon as possible.
ABS Warning Lamps
Truck/Tractor ABS Warning Lamp
A truck/tractor ABS warning lamp illuminates when the
ignition switch is first turned on and will remain on until the
system self-test has been completed successfully. Normally, this ABS lamp will remain on until a speed of no
more than 9 mph has been reached and the speed sensors have been checked for correct output. The lamp
should remain off after this point unless a failure in the
system is detected. The truck/tractor ABS lamp is located
in the warning lamp cluster (see page 19).
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PART 7: STARTING & OPERATING THE VEHICLE
Trailer ABS Warning Lamp
Trucks, tractors, and trailers built on and after March 1,
2001 are equipped with power line communication (PLC)
per U.S. FMVSS 121, including a trailer ABS warning
lamp in the cab (see page 19):
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PART 7: STARTING & OPERATING THE VEHICLE
ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
1. If no trailer is connected, or if a non-ABS-equipped
trailer is connected, the trailer ABS lamp will go off
after one second.
NOTES:
• A “properly connected” ABS-equipped trailer is
–a trailer with PLC hooked up to the J560 connector
–a trailer without PLC that is hooked up to an
optional ISO 3731 connector
PTC220
CAUTION: If the trailer ABS warning lamp
does not illuminate when the ignition is first
turned on, there is a problem with the bulb or
wiring. The driver should have this checked
as soon as possible.
NOTE: A successful warning lamp illumination
and bulb check at ignition on does not indicate
that a trailer 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 the vehicle. If the bulb check is
satisfactory, the lamp will next do either of the following:
(08/06)
• For doubles or triples: PLC does not distinguish
between trailers. An ABS problem in any trailer
will activate the trailer ABS warning lamp.
2. If an ABS-equipped 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.
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ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
Advanced ABS with Stability Control
A Real World Example
Of How The RSP
System Operates:
This vehicle may be equipped with an optional Electronic
Stability Program (ESP). ESP is a feature for ABSequipped vehicles that reduces the risk of rollovers, jackknifing and other loss of control. ESP features include Roll
Stability Program (RSP) and Yaw Control.
Excessive speed for road
conditions creates forces
that exceed the threshold at
which a vehicle is likely to
rollover on a higher-friction
surface.
During operation, the ECU of the Bendix Advanced ABS
system constantly compares performance models to the
vehicle’s actual movement, using the wheel speed sensors of the ABS system, as well as lateral, yaw, and steering angle sensors. If the vehicle shows a tendency to
leave an appropriate travel path, or if critical threshold values are approached, the system will intervene to assist
the driver.
Roll Stability Program
Bendix RSP, an element of the 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 at all wheel ends to slow the vehicle
combination. The level of braking application during an
RSP event will be proportional to roll risk.
PART 7: STARTING & OPERATING THE VEHICLE
The system automatically
reduces engine torque and
ap pl ie s the se r v i c e b rake s
(based on the projected rollover
r i s k ) t o r e d u c e t h e ve hi c le
speed, thereby reducing the
tendency to roll over.
RSP Example
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PART 7: STARTING & OPERATING THE VEHICLE
ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
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.
vehicle (in addition to potentially applying the trailer
brakes), thus applying a counter-force to better align the
vehicle with an appropriate path of travel. For example, in
an over-steer situation, the system applies the “outside”
front brake; while in an under-steer condition, the “inside”
rear brake is applied.
These yaw events are referred to as either “under-steer”
(where there is a lack of vehicle response to steering input
due to tire slide on the steer axle) or “over-steer” (where
the tractor's rear end slides out due to tire slide on the rear
axle) situation. Generally, shorter wheelbase 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, steering geometry, weight distribution front to rear, and vehicle
track width.
Yaw Control
Yaw Control responds to a wide range of low- to high-friction surface scenarios including rollover, jackknife and
loss of control. In the case of vehicle slide (over-steer or
understeer situations), the system will reduce the throttle
and then brake one or more of the “four corners” of the
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ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
PART 7: STARTING & OPERATING THE VEHICLE
IMPORTANT SAFETY INFORMATION ABOUT
THE STABILITY SYSTEM
ESP May Reduce The Vehicle Speed Automatically
To minimize unexpected deceleration and reduce the risk
of a collision the operator must:
• Avoid aggressive driving maneuvers, such as sharp
turns or abrupt lane changes at high speeds, which
might trigger the stability system.
• Always operate the vehicle safely, drive defensively,
anticipate obstacles and pay attention to road,
weather and traffic conditions. ABS, ATC and ESP
stability systems are no substitute for prudent, careful
driving.
A Real World Example
Of How Yaw Control Operates:
Excessive speed exceeds the threshold, creating a
situation where a vehicle is likely to spin and jackknife.
Towing Doubles Or Triples May Reduce The Effectiveness Of Stability Systems
The Bendix® Yaw Control system reduces engine throttle
and selectively applies brakes to reduce the vehicle
speed, thereby reducing the tendency to jackknife.
Yaw Control Example
– 108 –
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
may be greatly reduced.
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PART 7: STARTING & OPERATING THE VEHICLE
ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
WARNING! Exercise extreme care when towing doubles or triples with a vehicle equipped
with Electronic Stability Program. Excessive
speed and aggressive maneuvers, such as
sharp turns, sudden steering inputs or abrupt
lane changes should be avoided because
these maneuvers could cause loss of vehicle
control possibly resulting in severe personal
injury.
Limitations Of Stability Systems
The ESP stability system’s effectiveness may be greatly
reduced if:
• The load shifts due to improper retention, accident
damage or the inherently mobile nature of some loads
(for example, hanging meat, live animals or partially
laden tankers),
• The vehicle has an unusually high or off-set center of
gravity (CG),
• One side of the vehicle drops off the pavement at an
angle that is too large to be counteracted by a reduction in speed,
• The vehicle is used to haul double or triple trailer combinations,
(08/06)
• If very rapidly winding steering inputs are inputted at
high speeds,
• There are mechanical problems with suspension leveling of the tractor or trailer resulting in uneven loads,
• The vehicle is maneuvering on a high banked road
creating either additional side forces due to the weight
(mass) of the vehicle or a deviation between expected
& actual yaw rates,
• Gusty winds are strong enough to cause significant
side forces on the vehicle and any towed vehicles.
To Maximize The Effectiveness Of ESP:
• Loads must be properly secured and evenly distributed at all times.
• Drivers need to exercise extreme caution at all times,
and avoid sharp turns, sudden steering inputs or
abrupt lane changes at high speeds, particularly if:
Y53-6004
– the vehicle hauls loads that could shift,
– the vehicle or load has a high or off-set center of
gravity (CG) when loaded, or
– the vehicle tows doubles or triples.
– 109 –
ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
Truck Chassis Modifications
The ESP system was specifically calibrated and validated
only for your vehicle’s original factory-built configuration. If
your 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 ESP system must be disabled
immediately by a qualified mechanic.
PART 7: STARTING & OPERATING THE VEHICLE
the steering wheel is changed or re-centered, the Steering Angle Sensor must be re-calibrated.
WARNING! If the Steering Angle Sensor is not
re-calibrated, the Yaw Control system will not
function properly, which could result in a loss
of control of your vehicle.
WARNING! Failure to disable ESP “Electronic
Stability Program” when modifying a vehicle
could result in a loss of vehicle control possibly resulting in severe personal injury.
WARNING! For vehicles equipped with ESP
“Electronic Stability Program” do not replace
the vehicle’s steering wheel. Using a different
steering wheel could cause ESP to malfunction causing a loss of vehicle control possibly
resulting in severe personal injury.
Steering Angle Sensor Re-Calibration
Whenever maintenance or repair work is performed to the
steering mechanism, linkage, gear, adjustment of the
wheel track, or if the steering angle sensor is replaced or
– 110 –
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PART 7: STARTING & OPERATING THE VEHICLE
ANTI-LOCK BRAKING SYSTEM OPERATING INFORMATION
Wheel Spin Control Warning Lamp
Your truck/tractor ABS may have an acceleration slip regulation (ASR) or automatic traction control (ATC) feature.
This feature is controlled by a switch as shown in the next
illustration. Either of these features is monitored by a
warning lamp located on the switch.
torque. Do not allow the Wheel Spin Control lamp to
remain on continuously for an extended length of time.
Extended continuous use of the ASR / ATC can cause
overheating of the drive wheel brakes. Engine torque or
vehicle speed should be reduced to eliminate wheel spin
and prevent excessive application of the ASR/ATC system. Except for checking for proper illumination of the
ABS and Wheel Spin Control warning lamps when first
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.
Bobtail Brake Proportioning System
NOTE: The following information is applicable only
to tractor configurations built on or after March 1,
1997 and not registered in the United States.
The Wheel Spin Control warning lamp will briefly illuminate and then go out when the ignition switch is first
turned on. The Wheel Spin Control warning lamp will illuminate whenever the ASR or ATC system detects drive
wheel spin. The lamp will remain illuminated as long as
wheel spin is detected and the ASR or ATC system is
applying the drive wheel brakes or reducing engine
(08/06)
Peterbilt tractors without anti-lock brake systems (ABS)
are typically equipped with a bobtail brake proportioning
system. When a trailer is not connected, the drive axle
brake application pressure will automatically be limited by
the proportioning system. When driven in a bobtail mode,
these tractors will require greater brake pedal application
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– 111 –
BRAKE SAFETY AND EMERGENCY
PART 7: STARTING & OPERATING THE VEHICLE
WARNING!
to provide the equivalent braking to a bobtail tractor not
equipped with a proportioning system.
• Do not operate the vehicle in the event of a
malfunction in any air circuit. The vehicle
should not be operated until the system is
repaired and both braking circuits, including
all pneumatic and mechanical components,
are working properly. Loss of system air can
cause the service brakes not to function
resulting in the sudden application of the
spring brakes causing wheel lock-up, loss of
control, or overtake by following vehicles. You
could be in an accident and severely injured.
WARNING! Because of the increased use of
the steer axle brakes when driving bobtail,
always ensure the steer axle brakes are functioning and properly adjusted. Failure to do so
can lead to decreased braking ability, longer
stopping distances, loss of vehicle control,
and can cause an accident.
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 engine compression
to assist the service brakes; i.e., don’t depress the clutch
pedal until the engine reaches idle speed.
• Unless you have an anti-lock braking system, always avoid completely depressing the
service brake pedal, even during emergency
braking. This action can cause the wheels to
lock, which can lead to an uncontrolled skid
and could cause an accident.
Overheated Brakes
Overheated brakes may be detected by a burning smell or
smoke coming from a brake assembly. If this occurs, you
should immediately stop and check for cracked brake
drums, cracked brake rotors or lining fires. If neither
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PART 7: STARTING & OPERATING THE VEHICLE
BRAKE SAFETY AND EMERGENCY
exists, resume at slow speeds to help cool the brakes.
Schedule an appointment with an authorized service technician at your earliest convenience.
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 putting the valve in the Park position exhausts air from the
chambers and allows the springs to extend and apply the
brakes. Also, if your system air drops below the safe operating level, the spring brakes will apply automatically,
bringing your vehicle to a stop.
(08/06)
Y53-6004
02909
Red / Yellow Controls
WARNING! On trailers built before March 1975
you may not have parking brakes if the trailer
reservoir pressure leaks down. If you depend
on them to hold your vehicle, they could
release, causing a serious accident. These
older trailers have emergency brakes not
designed for parking. They will apply only if
there is enough trailer reservoir pressure.
Don’t use your trailer emergency brakes for
parking. Apply your tractor parking valve too.
– 113 –
BRAKE SAFETY AND EMERGENCY
PART 7: STARTING & OPERATING THE VEHICLE
your vehicle could result in excessive heat
build-up in the brake system, resulting in a
fire.
WARNING!
• Do not leave the cab without applying the
parking brake. The truck could roll and cause
an injury accident. Always apply the parking
brake before you leave the cab.
• Stopping with the parking brake controls
can cause a sudden wheel lock-up, loss of
control, or can cause you to be overtaken by
following vehicles. You could be 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 vehicle—use the parking brakes. Because service
brakes work with air pressure, these brakes
could slowly release. Your vehicle could roll,
causing a serious accident. Someone could
be hurt or killed. Never rely on the service
brakes to hold a parked vehicle.
• Never drive your vehicle with the parking
brake applied. Always release the parking
brakes prior to moving the vehicle. Failure to
disengage the parking brakes prior to moving
– 114 –
NOTE: Today’s diesel electronic engines have
significant torque and startability power at low
RPM. Combinations of engine speed and available torque may over-power the vehicle’s parking
brakes.
To apply all your parking brakes, pull the yellow knob
Out. The parking brakes will set. And the trailer air supply
valve (red octagon knob) will automatically pop out,
releasing air pressure and setting the trailer brakes.
CAUTION: Do not try to put the vehicle in
motion before pressure in the system reaches
100 psi (689 kPa) because the wheels are
locked by the spring brake action. Unnecessary stress and possible brake malfunction
could occur if the vehicle is forced to move
before the air system 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 trailer brakes ONLY, push in the red
knob. The truck or tractor will remain parked.
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PART 7: STARTING & OPERATING THE VEHICLE
BRAKE SAFETY AND EMERGENCY
• 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 pressure to build up to
operating level.
• Push the red knob in.
• Hold the red knob in by hand until the trailer air pressure builds to a pre-set level, about 45 psi. At this
point it will remain in.
The yellow knob will remain out; the tractor will remain
parked. If you ever have a failure or disconnect of the air
supply hose to the trailer, the trailer parking brakes will
set. The red knob will automatically pop out and seal off
the tractor air reservoirs to protect the tractor air system
pressure. When operating the tractor “bobtail”: The red
knob must remain out to protect the tractor air system
pressure
Manually Releasing Spring Brakes
There may be an occasion when you need to tow the vehicle but the air system does not produce enough operating
pressure to release the parking brakes. For these situations, the spring brakes may be manually released to
allow the vehicle to be towed. This sections details how to
release a drum or an air disc brake.
WARNING!
• Do not operate a vehicle when the spring
brakes have been released manually. Driving
a vehicle that has had its spring brakes manually released is extremely dangerous. You
would probably have no brakes at all. You
could have a serious or fatal accident.
• Releasing the spring brakes on an unsecured vehicle could lead to an accident. The
truck could roll, causing severe injury. Always
secure the truck with wheel chocks, chains, or
other safe means to prevent rolling before
manually releasing the spring brakes.
NOTE: The primar y purpose of the manual
release feature is to permit the vehicle to be
towed to a repair facility.
(08/06)
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– 115 –
BRAKE SAFETY AND EMERGENCY
PART 7: STARTING & OPERATING THE VEHICLE
To release spring brakes manually
:
1. Remove the cap from the spring chamber.
02936A
2. Remove the release stud assembly from the side
pocket; remove the release nut and washer from the
release stud.
02936B
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PART 7: STARTING & OPERATING THE VEHICLE
BRAKE SAFETY AND EMERGENCY
3. Slide out the release stud
02936C
4. Insert the release stud through the opening in the
spring chamber where the cap was removed. Insert it
into the pressure plate. Turn the release stud 1/4-turn
clockwise in the pressure plate. This secures the
cross pin into the cross pin area of the pressure plate
and locks it into the manual release position.
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02937A
– 117 –
BRAKE SAFETY AND EMERGENCY
PART 7: STARTING & OPERATING THE VEHICLE
5. Assemble the release stud washer and nut on the
release stud.
:
02937B
6. With a wrench, turn the release stud 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.
02937C
– 118 –
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PART 7: STARTING & OPERATING THE VEHICLE
BRAKE SAFETY AND EMERGENCY
WARNING! Disassembling the spring brake
chamber is dangerous and could cause serious injury. These chambers contain a powerful spring that is compressed. Sudden release
of this spring could cause you to be badly
injured. Do not disassemble a spring brake
chamber.
Retarders
Various retarders are available which function against the
engine, driveline, or transmission. These are devices that
use your engine’s power to slow down your vehicle. They
save wear and tear on your service brakes and can be a
safety feature, too, because they can keep your brakes
from overheating.
Ideally, you should always slow your vehicle with your
retarder (where permitted by law) and use your service
brakes only for stopping completely. Operating this way
will greatly prolong the life of your brakes.
(08/06)
Y53-6004
WARNING!
• In an emergency, the retarder might not
stop you fast enough to prevent an accident.
You could be badly hurt 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 drivetrain. Use the service brakes for quick stops.
• The service brakes must be used in an
emergency. The retarder alone might not stop
you fast enough to prevent an accident. You
could be badly hurt if you relied only on the
retarder.
• Do not use the retarder when operating on
road surfaces with poor traction (such as wet,
icy, or snow covered roads or gravel). Retarders can cause the wheels to skid on a slippery
surface. You could lose control of the vehicle
if the wheels begin to skid, resulting in an
accident.
– 119 –
STOPPING THE ENGINE
PART 7: STARTING & OPERATING THE VEHICLE
Driving Bobtail or with an Unloaded Trailer
We recommend that you do not use your engine retarder
to slow down when you are bobtailing or pulling an empty
trailer.
WARNING! Using an engine retarder can
cause a wheel lockup. The trailer is not loading the tires enough to give the traction you
may need. When you are bobtail or unloaded,
you can have a serious accident if your
wheels lock suddenly during braking. You
could be injured. Don’t use your retarder
when you are driving bobtail or with an
unloaded trailer.
Stopping The Engine
Turbochargers
This cooling-down practice is especially important on a
turbocharged engine. The turbocharger contains bearings
and seals that are subjected to hot exhaust gases. While
the engine is operating, heat is carried away by circulating
oil. If you stop the engine suddenly after a hard run, the
temperature of the turbocharger could rise as much as
100°F (55°C) above the temperature reached during operation. A sudden rise in temperature like this could cause
the bearings to seize or the oil seals to loosen.
Refuel Before the Final Stop
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. This will allow circulating coolant and lubricating oil to carry away heat from
– 120 –
the cylinder head, valves, pistons, cylinder liners, turbocharger, and bearings. This way you can prevent serious
engine damage that may result from uneven cooling.
Air space in your fuel tanks allows water to condense
there. To prevent this condensation while you are stopped,
fill your tanks to 95% of capacity.
Final Stop
To make sure your vehicle is ready to go after a long stop
(such as over night), please follow the suggestions below.
Your vehicle will be easier to get going when you are
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PART 7: STARTING & OPERATING THE VEHICLE
STOPPING THE ENGINE
ready, and it will be safer for anyone who might be around
it. Please remember, too, that in some states it is illegal to
leave the engine running and the vehicle unattended.
2. If you are parked on a steep grade, block the wheels.
Final Stopping Procedures
1. Set the parking brake before leaving the driver’s seat.
To hold your vehicle while it is parked, don’t rely on
• Air Brakes
• Hand Control Valve for Trailer Brakes
• Engine Compression
02938
WARNING! Using the trailer hand brake or air
brakes to hold a parked vehicle is dangerous.
Because they work with air pressure, these
brakes could come loose. Your vehicle could
roll, causing a serious accident. Someone
could be hurt or killed. Always set the parking
brakes. Never rely on the trailer hand brake or
truck air brakes to hold a parked vehicle.
(08/06)
Blocked Wheels
3. Drain water from the air reservoirs. While the engine
and air supply system are still warm, drain moisture
from the air reservoirs. Open the reservoir drains just
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– 121 –
SETTING RIDE HEIGHT
PART 7: STARTING & OPERATING THE VEHICLE
enough to drain the moisture. Don’t deplete the entire
air supply. Be sure to close the drains before leaving
the vehicle.
interaxle U-joint working angles. This can result in premature driveline wear and driveline vibration. If your vehicle is equipped with a Peterbilt rear air suspension, and if
it becomes necessary to reset the ride height, you may
temporarily set it by following the next procedure. Proper
ride height measurement and values are shown in the
illustration and table below.
02939
Opening Drains
4. Secure the vehicle. Close all the windows and lock all
the doors.
Ride Height Measurement
(Location for Tandem Axles Shown)
Setting Ride Height
Vehicles equipped with rear air suspensions have their
ride height and axle (pinion) angle(s) preset at the factory.
These are precision settings and should not be altered.
Incorrectly adjusted ride height may result in improper
– 122 –
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PART 7: STARTING & OPERATING THE VEHICLE
Proprietary Rear
Air Suspension
Air Leaf
Air Trac
Low Air Leaf
Low Low Air Leaf
FLEX Air
SETTING RIDE HEIGHT
Ride Height [inches (mm)]*
Single Drive
Tandem Drive
N/A
11.00 (279)
6.50 (165)
N/A
N/A
11.70 (297)
11.00 (279)
8.50 (216)
6.50 (165)
8.50 (216)
1. Ensure the air supply and delivery plumbing of the
height control valve is consistent with the following
illustrations.
*These values are for a fully laden vehicle
Follow this procedure to temporarily set ride height.
ALIGNMENT PIN OR DOWEL CONTROL ARM
WARNING! To prevent possible injury and
damage to property, ensure that a vehicle is
parked and the wheels chocked before beginning this procedure.
CAUTION: Completing this procedure will
enable you to safely reach the nearest authorized Peterbilt repair facility to have ride
height and pinion angle reset using the proper
equipment and technique. Do this as soon as
possible to avoid potential driveline damage.
NOTE: Suitable wheel chocks are at a minimum
an 18-inch (46 cm) long 4x4.
(08/06)
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LINK BOLT
FROM DUMP VALVE SWITCH
FORWARD
02941A
Typical Height Control Valve (Top View)
– 123 –
SETTING RIDE HEIGHT
PART 7: STARTING & OPERATING THE VEHICLE
NOTES:
DELIVERY TO RH AIR BAG(S)
• At least one of the mounting holes in the height
control valve bracket will be slotted to permit
rotating the valve.
SUPPLY FROM FORWARD
AIR TANK
MOUNTING NUTS
• 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.
WARNING!
EXHAUST
DELIVERY TO LH AIR BAG(S)
• The rear of a vehicle will drop about 3 1/2
inches (88 mm) when the air springs are
deflated. Ensure that no persons or objects
that could be injured or damaged are under
the vehicle before deflating the air springs.
AIR BAG
LINK ROD
• To minimize risk of damage or injury, do not
use a dump valve to deflate the air springs.
Rotate the height control valve(s) manually to
ensure positive control of air spring deflation.
02941B
Typical Height Control Valve
(Rear View Looking Forward)
• To minimize risk of injury, keep away from
air springs as they are being inflated.
– 124 –
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PART 7: STARTING & OPERATING THE VEHICLE
SETTING RIDE HEIGHT
3. Rotate the valve either clockwise or counterclockwise
until air pressure in the air springs provides the ride
height specified for that suspension. Measure the ride
height from the bottom of the frame rail to the approximate centerline of the rearmost drive axle hub:
Driving With Deflated Air Springs
If an air spring is ruptured, there will be enough air pressure to drive the vehicle to a safe stop off the highway to
investigate the problem.
WARNING! Your brakes could fail if you continue driving with deflated air springs. Air
escaping from the system will lower the air
pressure, which could cause a spring brake to
engage. The spring brake may cause your
brakes to drag and burn up the linings. Don’t
continue to operate in this condition.
• For tandem axles, make the vertical measurement at the centerline of the suspension (see
illustration on page 123).
4.
5.
6.
7.
• 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.
When at the correct ride height, ensure that the height
control valve lever is in the neutral position, then
install either the built-in alignment pin or a 1/8-inch (3
mm) dowel (see page 123).
Torque the mounting fasteners to 55 — 75 Lb. in.
(6.2 — 8.5 N.m.).
Remove the alignment pin or dowel.
Repeat Steps 2 through 6 above for the RH valve on
vehicles with a dual-valve system.
(08/06)
You can get to a repair facility if you do the following:
1. Remove the height control link connected to the axle
and to the suspension air valve control arm. This will
cause the air valve control arm to center in the closed
position.
2. The air system can then be pumped up to normal
pressure for continued operation.
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DRIVING TIPS AND TECHNIQUES
PART 7: STARTING & OPERATING THE VEHICLE
WARNING! Low air pressure could make the
brakes unsafe for driving. Before driving the
vehicle, make sure the pressure does pump
up to over 100 psi for normal brake operation.
If the air pressure does not pump up to at
least 100 psi, don’t try to move the vehicle.
Coasting
WARNING! Do not coast with the transmission in neutral or with the clutch pedal
depressed—it is a dangerous practice. Without the use of the retarding power of the drivetrain, your vehicle can reach dangerous
speeds. At very high speeds you may not be
able to put the transmission in any gear. At
high speeds you could seriously damage your
vehicle or cause an accident when you put the
transmission in gear. The engine speed could
exceed the maximum governed speed and
cause a serious accident due to mechanical
failures.
CAUTION: Operating a vehicle with air suspension bags either overinflated or underinf l a t e d m ay c a u s e d a m a g e t o d r i v e l i n e
components. If a vehicle must be operated
under such conditions, do not exceed 5 mph.
Driving Tips And Techniques
This section covers additional driving tips and techniques
on how to drive your vehicle more efficiently. For further
information, read the American Trucking Association's
(ATA) Truck Driver's Handbook. It will give you more tips
on starting, shifting, and driving your vehicle.
Do not coast with the transmission in neutral or with the
clutch pedal depressed. Besides being illegal and dangerous, coasting is also expensive. It causes premature failure or damage to the clutch and transmission and
overloads the brake system.
Coasting with the transmission in neutral also prevents
proper transmission component lubrication. During coasting the transmission is driven by the rear wheels, and the
– 126 –
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PART 7: STARTING & OPERATING THE VEHICLE
DRIVING TIPS AND TECHNIQUES
NOTE: Often these recommendations are secondary to maintaining an adequate and safe
speed relative to the surrounding traffic and road
conditions.
countershaft gear (which lubricates the transmission components by oil splash) will only be turning at idle speed.
Descending a Grade
WARNING! Do not hold the brake pedal down
too long or too often while going down a steep
or long grade. This could cause the brakes to
overheat and reduce their effectiveness. As a
result, the vehicle will not slow down at the
usual rate. To reduce the risk of personal injury
and/or an accident, before going 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 loss of
vehicle control.
Engine Overspeed
CAUTION: To avoid engine damage, do not let
the engine rpm go beyond the maximum governed rpm—valve damage could result if overspeed conditions occur.
(08/06)
Operate the engine within the optimum engine rpm range
and do not allow the rpm's to exceed the maximum governed speed. See your Engine Operation and Maintenance manual for information regarding engine rpm.
When the engine is used as a brake to control vehicle
speed (e.g., while driving down a grade), do not allow the
engine rpm to exceed maximum governed speed.
Under normal load and road conditions operate the
engine in the lower end of the range.
Use of Tachometer
The tachometer is an instrument that aids in obtaining the
best performance of the engine and manual transmission,
serving as a guide for shifting gears.
Refer to the Engine Operation and Maintenance manual
for optimum engine rpm.
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DRIVING TIPS AND TECHNIQUES
PART 7: STARTING & OPERATING THE VEHICLE
• If the engine rpm moves beyond the maximum governed speed, indicating an overspeed condition,
apply the service brake or shift to a higher gear to
bring engine rpm within the optimum speed range.
• When driving downhill: shift to a lower gear, use the
engine brake (if so equipped), and use the service
brake, keeping the engine speed below 2,100 rpm.
Use of Driver Information Display
The Driver Information Display provides information to
help the driver optimiize vehicle efficiency. Refer to the
section “Driver Information Display” on page 28 for details.
A driver will find the section describing Trip Information
and the RPM Detail useful.
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 transmission, for example, on steep downgrades. Apply service
brakes or shift to a higher gear.
Fuel economy and engine performance are also directly
related to driving habits:
• The best results in trip time and fuel economy are
obtained while driving the vehicle at a steady speed.
• Shift into higher or lower gears (or apply the service
brake) to keep engine rpm near the lower end of the
optimum operating range.
• Avoid rapid acceleration and braking.
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PART 8: MAINTENANCE AND SERVICE
PREVENTIVE MAINTENANCE SCHEDULE
PART 8: MAINTENANCE AND SERVICE
Preventive Maintenance Schedule
Your preventive maintenance program begins with the
daily checks you perform. See “PART 6: DRIVER’S
CHECKLIST” for these. If you check your Peterbilt vehicle
regularly, you can avoid many large, expensive, and timeconsuming repairs. Your vehicle will operate better, be
safer, and last longer. Neglect of recommended maintenance can void your vehicle’s warranty. Some maintenance operations demand skills and equipment you may
not have. For such situations, please take your vehicle to
an authorized Peterbilt Service Center.
WARNING! It can be dangerous to attempt
maintenance work without sufficient training
and the proper tools. You could be injured, or
you could make your vehicle unsafe. Do only
those maintenance items you are fully trained
and equipped to do.
• Before attempting any procedures in the
engine compartment, stop the engine and let
it cool down. Hot components can burn skin
on contact.
• Be alert and cautious around the engine at
all times while the engine is running.
• If work has to be done with the engine running, always (1) set the parking brake, (2)
chock the wheels, and (3) ensure that the shift
lever or selector is in Neutral.
• Exercise extreme caution to prevent neckties, jewelry, long hair, or loose clothing from
getting caught in the fan blades or any other
moving engine parts.
(08/06)
Y53-6004
– 129 –
PREVENTIVE MAINTENANCE SCHEDULE
PART 8: MAINTENANCE AND SERVICE
NOTE: Suitable wheel chocks are at a minimum
an 18-inch (46 cm) long 4x4
•Disconnect the battery ground strap
whenever you work on the fuel system or
the electrical system. When you work
around fuel, do not smoke or work near
heaters or other fire hazard. Keep an
approved fire extinguisher handy.
•Always support the vehicle with appropriate safety stands if it is necessary to work
underneath the vehicle. A jack is not adequate for this purpose.
•When working underneath the vehicle
without appropriate safety stands but with
the wheels on the ground (not supported),
make sure that (1) the vehicle is on hard
level ground, (2) the parking brake is
applied, (3) all wheels are chocked (front
and rear) and (4) the engine cannot be
started. Remove the ignition key.
PREVENTIVE MAINTENANCE (PM) INTERVALS
I
A
B
C
D
E
At the first
15,000 mi./
24,000 km
or at the
first PM
15,000
mi./
24,000
km/
Monthly
30,000
mi./48,000
km
60,000
mi./
96,000
km/6
months
120,000
mi./
192,000
km/Annually
240,000
mi./
384,000
km
•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 monoxide can be fatal if inhaled.
– 130 –
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
PREVENTIVE MAINTENANCE SCHEDULE
NOTES:
• Where questions or discrepancies develop
between these recommendations and component
supplier recommendations, consult the supplier
for specific recommendations.
• Maintenance requirements of specific vocational configurations will dictate whether the intervals used are determined based on mileage, time
in service, hours operating, etc.
• These maintenance practices and intervals are
intended as additional requirements and are not
to replace, in whole or in part, the pretrip inspection requirements of the Commercial Driver’s
License (CDL) as established in the Federal
Commercial Motor Vehicle Safety Act of 1986.
If you operate your vehicle off-highway or in very heavyduty applications such as mining, logging, or earth moving, you will need to perform maintenance checks and services more frequently. The charts on the following pages
show the maintenance intervals for recommended maintenance practices.
(08/06)
Y53-6004
NOTES:
• Engine lubricating oil change intervals aren’t
listed here. Refer to your engine’s operating manual for recommendations. For specific information
on maintenance procedures consult your vehicle
maintenance manual.
• The initial fill of drive axle lubricant must be
changed before the end of the first scheduled
maintenance interval. Refer to “Oil Changes” on
page 159 before you put a new vehicle into service.
• The initial fill of lubricant in manual transmissions must be changed before the end of the first
maintenance interval. See “Fuller Transmission
Lubrication” on page 156 for specific information.
• If your vehicle is equipped with an automatic
transmission, consult the owner’s manual for it
that came with your vehicle to obtain lubricant
check and change intervals.
– 131 –
PART 8: MAINTENANCE AND SERVICE
PREVENTIVE MAINTENANCE SCHEDULE
*
SYSTEM
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Frame
Front Axle
(Arvin
Meritor)
Front Axle
(Dana)
(08/06)
A
B
C
D
Fifth Wheel
Check the kingpin lock and plate for wear and function; lubricate
(NLGI #2 grease).
Frame Fasteners
Check for tightness; tighten to the specified torque value as
required (see page 194).
X
Crossmembers and
Mounting Brackets
Inspect for cracks and loose fasteners. Replace or tighten to the
specified torque value as required (see page 194).
X
Total Vehicle Alignment
Check and adjust as required.
Steering knuckle spindles,
thrust bearings, kingpins,
drawkeys, tie rod ends,
steering stops, & bushings
Inspect for wear and damage and endplay. Shim or replace as
required (see page 191).
Kingpin bushings, thrust
bearings, & tie rod ball ends
Lubricate with approved grease.
X
X
X
X
X
Drawkeys
Tighten nuts
X
Total Vehicle Alignment
Check and adjust as required.
X
Kingpin bushings, thrust
bearings, & tie rod ball ends
(ON HIGHWAY)
Check and adjust as required.
Y53-6004
E
X
X
X
– 132 –
PREVENTIVE MAINTENANCE SCHEDULE
SYSTEM
COMPONENT
PART 8: MAINTENANCE AND SERVICE
Recommended
PM Interval
MAINTENANCE TASK
I
Front Axle
(Dana)
Front
Suspension
– 133 –
A
B
C
Kingpin bushings, thrust
bearings, & tie rod ball ends
(OFF HIGHWAY AND
VOCATIONAL)
Lubricate with approved grease.
Steering knuckle spindles,
thrust bearings, kingpins,
drawkeys, tie rod ends,
steering stops, & bushings
(ON HIGHWAY)
Inspect for wear and damage and for endplay. Shim or replace
as required.
Steering knuckle spindles,
thrust bearings, kingpins,
drawkeys, tie rod ends,
steering stops, & bushings
(OFF HIGHWAY AND
VOCATIONAL)
Inspect for wear and damage and for endplay. Shim or replace
as required.
X
Front Spring
Inspect for cracked leaves, worn bushings, & excessive
corrosion.
X
Spring Pins & Shackles
Inspect for worn parts and excessive joint clearance. Shim or
replace as required.
X
Y53-6004
D
E
X
X
(08/06)
PART 8: MAINTENANCE AND SERVICE
SYSTEM
PREVENTIVE MAINTENANCE SCHEDULE
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Front
Suspension
Shock Absorbers
Inspect for leaking, body damage, and damaged or worn
bushings. Replace as required. Check the shock mounting stud
torque.
C
X
U-bolts (OFF HIGHWAY)
Check the general condition and the tightness of the nuts.
Tighten the nuts to the specified torque value as required (see
page 192).
Axle Housing
Visually inspect for damage or leaks.
X
Check oil level. Check “cold.” Torque the drain plug.
X
Air Shift Unit
Breather
Check the lubricant level.
X
See information on
page 160
X
Remove the housing cover and drain the lubricant. Wash the
parts thoroughly and dry in air.
X
Clean or replace.
X
Y53-6004
E
X
Check the general condition and the tightness of the nuts.
Tighten the nuts to the specified torque value as required (see
page 192).
Drain the lubricant while warm. Flush each unit with clean
flushing oil. Change the lubricant.
D
X
U-bolts (ON HIGHWAY)
(Dana)
(08/06)
B
X
Check for proper function.
Drive Axle
A
– 134 –
PREVENTIVE MAINTENANCE SCHEDULE
SYSTEM
PART 8: MAINTENANCE AND SERVICE
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Drive Axle
(Dana)
Drive Axle
B
C
Lube Pump (ON HIGHWAY)
Remove the magnetic strainer and inspect for wear particles.
Wash in solvent and dry in air.
Lube Pump (OFF
HIGHWAY)
Remove the magnetic strainer and inspect for wear particles.
Wash in solvent and dry in air.
Lube Filter (ON HIGHWAY)
Change.
Lube Filter (OFF HIGHWAY)
Change.
Magnetic drain plug and
breather (ON HIGHWAY)
Clean or replace.
Magnetic drain plug and
breather (OFF HIGHWAY)
Clean or replace.
X
Axle Housing
Check the “cold” fill level at the differential carrier plug for a
pinion angle of less than 7 degrees, or at the axle bowl plug for a
pinion angle of greater than 7 degrees. Tighten the plug to 35 50 Lb. ft. (47 - 68 N.m.)
X
Visually inspect for damage or leaks.
X
(Meritor)
D
E
X
X
X
X
Drain and replace the lubricant.
– 135 –
A
Lubricant filter
Change the filter.
Breather
Check the operation. If the cap doesn’t rotate freely, replace.
Y53-6004
X
See information on
page 159
X
X
(08/06)
PART 8: MAINTENANCE AND SERVICE
SYSTEM
PREVENTIVE MAINTENANCE SCHEDULE
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
A
B
C
D
Drive Axle
Input shaft & pinion shaft
Check and adjust the endplay.
X
(Meritor)
Axle shaft
Tighten the rear axle flange nuts to the specified torque value.
X
Interaxle differential
Check the operation.
X
Axle Housing
Change the oil in the differential carrier and the hubs, and clean
the magnetic oil drain plugs.
X
Check the wheel bearing hubs and adjust if necessary.
X
X
Visually inspect for damage or leaks.
X
X
Check the oil level in the differential carrier and hubs.
X
X
Drive Axle
(SISU)
(08/06)
X
Breather
Check the breather for proper operation.
Lube Filter
Clean the suction filter for the optional pressure lubrication
system
X
S-cam brakes
Overhaul the brakes; degrease all moving parts; check the
bushings and seals for wear.
X
Y53-6004
E
X
– 136 –
PREVENTIVE MAINTENANCE SCHEDULE
SYSTEM
COMPONENT
PART 8: MAINTENANCE AND SERVICE
Recommended
PM Interval
MAINTENANCE TASK
I
Rear
Suspension
Drum Brakes
(All)
A
U-bolts
Check the torque. Tighten to specified torque value as required
(see page 192).
Frame & crossmember bolts
Check the torque. Tighten to specified torque value as required
(see page 194).
Mounting brackets and
fasteners
Check the condition and the fastener torque. Tighten to the
specified torque value as required (see page 194).
Slack adjusters
Check the push rod travel and check the control arm for cracks.
Adjust at reline (see page 164).
X
Lubricate (NLGI #2 grease).
X
B
X
C
X
X
X
Lubricate (NLGI #2 grease).
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 fittings for leaks (see page 164). Adjust
routing as required to reduce chafing. Check tank mounting and
condition.
Rebuild through an authorized Peterbilt service facility.
– 137 –
Clean or replace the inline filters.
Brake lining
Inspect; replace as required.
Y53-6004
E
X
Brake camshaft bearing
Brake air system
D
X
X
X
X
(08/06)
PART 8: MAINTENANCE AND SERVICE
SYSTEM
COMPONENT
PREVENTIVE MAINTENANCE SCHEDULE
Recommended
PM Interval
MAINTENANCE TASK
I
Disc Brakes
(Bendix)
(08/06)
A
B
C
D
Brake pads
Inspect; replace as required.
Brake disc/rotor
Inspect for visible cracks, heat checking, galling, or scoring of
surface. Check thickness minimum of 1.46” (37 mm).
Caliper sliding function
Ensure caliper slides freely with no obstructions or excessive
play (see manufacturer’s service literature for “Checking
Running Clearance”).
Caliper function
Inspect bearings, seals, tappet and boots of the guide pins for
damage or cracking.
X
Adjuster
Check operation; inspect as per manufacturer’s service
literature.
X
Y53-6004
E
X
X
X
– 138 –
PREVENTIVE MAINTENANCE SCHEDULE
SYSTEM
COMPONENT
PART 8: MAINTENANCE AND SERVICE
Recommended
PM Interval
MAINTENANCE TASK
I
Hub, Drum,
& Hubcap
Hubs (non-LMS)
Meritor Unitized Wheel End
Check the bearing endplay and adjust as required
(see page 174).
Hubs (non-LMS) with
outrunner seals
Clean the components and check for excessive wear or
damage. Change the oil and seal (see page 161).
Hubs (non-LMS) with
standard seals
Clean the components and check for excessive wear or
damage. Change the oil and seal (see page 161).
B
C
X
Check for leaks; replace as required.
Check the bearing endplay and adjust as required
(see page 174).
LMS Hubs (Dana) with
Clean the components and check for excessive wear or
damage. Change the oil and seal (see page 161).
500,000 miles/
Clean the components and check for excessive wear or
damage. Change the oil and seal (see page 161).
350,000 miles/
Mineral Lubricant
Brake drums
Inspect for visible cracks, heat checking, galling or scoring of the
braking surface, and for severe corrosion on the outside surface.
Check for out-of-round or oversize condition [0.080 in. (2 mm)
more than the original diameter]. Replace as required.
Hubcaps
Clean the sight window. Check the center plug, mounting flange,
and fill plug for leaks and for proper installation. Replace broken
or damaged parts. Check the lubricant level and add as
required.
Y53-6004
E
X
LMS Hubs (Dana)
Synthetic Lubricant
D
X
Hub seals (all)
LMS Hubs (Dana) with
– 139 –
A
X
X
800,000 km
560,000 km
X
X
(08/06)
PART 8: MAINTENANCE AND SERVICE
SYSTEM
Main &
auxiliary
transmission
COMPONENT
PREVENTIVE MAINTENANCE SCHEDULE
Recommended
PM Interval
MAINTENANCE TASK
I
A
X
X
B
C
Main & auxiliary
transmission and transfer
case
Inspect for visible damage, signs of overheating, and leaks.
Mounting Brackets and
Fasteners
Check the condition of the fasteners and their torque. Tighten to
the specified torque value as required.
X
Oil cooler
Clean the fins (air-to-oil type) and body. Check the hose
condition and for leaks; replace as required.
X
Main &
auxiliary
transmission
(except
Freedomline)
Main & aux.transmission
Check the oil level; refill as required.
Main & auxiliary
transmission (ON
HIGHWAY)
Drain lubricant while warm. Flush each unit with clean flushing
oil.
500,000 miles/
800,000 km
Main & auxiliary
transmission (OFF
HIGHWAY)
Drain lubricant while warm. Flush each unit with clean flushing
oil.
X
Main
transmission
Freedomline Transmission
Change the oil (see page 159).
500,000 miles/
800,000 km
(08/06)
Check the drain plugs for tightness.
Y53-6004
D
E
X
X
X
– 140 –
PREVENTIVE MAINTENANCE SCHEDULE
SYSTEM
PART 8: MAINTENANCE AND SERVICE
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Auxiliary
transmission
Cotta Transfer Case
TR2205
Inspect: Check oil level; inspect for leaks and any visible
damage
Initial oil change: Drain oil while warm; flush case with gear oilcompatible fluid; clean magnetic drain plug; refill. Do not flush
the case with any solvent.
A
E
X
Inspect: Check oil level; inspect for leaks and any visible
damage
Initial oil change: Drain oil while warm; flush case with gear oilcompatible fluid; clean magnetic drain plug; refill. Do not flush
the case with any solvent.
X
X
X
Inspect: Check oil level; inspect for leaks and any visible
damage
Initial oil change: Drain oil while warm; flush case with gear oilcompatible fluid; clean magnetic drain plug; refill. Do not flush
the case with any solvent.
Change oil.
– 141 –
D
X
Change oil.
Marmon-Harrington
Transfer Case MVG2000/
MVG2000SD
C
X
Change oil.
Fabco Transfer Case
TC142/ TC143/TC170/
TC270
B
X
X
X
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
SYSTEM
COMPONENT
PREVENTIVE MAINTENANCE SCHEDULE
Recommended
PM Interval
MAINTENANCE TASK
I
Air Intake
(08/06)
Air intake piping, mounting,
and charge air cooler
Check the system for broken pipes, leaks, joint integrity,
cleanliness, and proper support (see page 196).
Cold starting aids
Check for leaks and proper operation (see page 89).
Air cleaner
Replace the engine intake air cleaner element (see page 196).
Y53-6004
A
B
C
D
E
X
X
When required by air
restriction indicator*
– 142 –
PREVENTIVE MAINTENANCE SCHEDULE
SYSTEM
COMPONENT
PART 8: MAINTENANCE AND SERVICE
Recommended
PM Interval
MAINTENANCE TASK
I
A
B
C
D
E
*When an air restriction indicator is not installed, use the air cleaner manufacturer’s recommendation except as specified below:
Exceptions to Air Cleaner Element Replacement Intervals for Vehicles in either 100% Class AA or 100% Class A On-Highway Usage:
Models 365, 367 and 386 with C11/C13 engine and engine-mounted air cleaner: Replace the element
every 140,000 miles (224,000 km) OR
at engine oil change if the interval being used for oil changes is close to but does not exceed 140,000 miles (224,000 km)
Models 367 and 386 with C15 engine and engine-mounted air cleaner: Replace the element
every 90,000 miles (144,000 km) OR
at engine oil change if the interval being used for oil changes is close to but does not exceed 90,000 miles (144,000 km)
Model 386 with C15 engine: Replace the element
every 90,000 miles (144,000 km) OR
at engine oil change if the interval being used for oil changes is close to but does not exceed 90,000 miles (144,000 km)
Models 365, 367 and 386 with firewall-mounted air cleaner: Replace the element
every 70,000 miles (112,000 km) OR
at engine oil change if the interval being used for oil changes is close to but does not exceed 70,000 miles (112,000 km)
– 143 –
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
SYSTEM
PREVENTIVE MAINTENANCE SCHEDULE
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Clutch
Cooling
A
B
Clutch pedal shaft
Check for excessive looseness and lubricate (NLGI #2 grease).
X
Clutch pedal
Check for proper free pedal (see page 180).
X
Clutch release linkage
Check for excessive looseness and lubricate (NLGI #2 grease).
X
Clutch release bearing
Lubricate.
X
Clutch release shaft
Lubricate.
X
Hoses
Check the radiator and heater hoses for leaks.
Extended Life Coolant (ELC)
Check the freeze point (see page 181).
X
Check for contamination using test strips (see page 182).
X
X
C
D
E
X
Replace blank water filter if applicable.
X
Perform lab analysis (see page 182).
X
If lab analysis shows coolant is unsuitable for continued use
Flush, drain, and refill (see page 183).
Add ELC Extender (see page 182).
X
Flush, drain, and refill with new coolant (see page 183).
(08/06)
Fan clutch housing
Check for air leaks. (see page 195).
X
Surge Tank Fill Cap
Check fill cap seal at each oil change.
X
Y53-6004
X
X
X
X
X
X
– 144 –
PREVENTIVE MAINTENANCE SCHEDULE
SYSTEM
COMPONENT
PART 8: MAINTENANCE AND SERVICE
Recommended
PM Interval
MAINTENANCE TASK
I
Tires &
Wheels
Power
Steering
– 145 –
Tires
Check inflation pressure (see page 168).
A
X
Disc wheels
Inspect the wheel disc for any cracks or surface irregularities.
Inspect the rim edge and bead seat area for damage. Replace
any damaged wheels - DO NOT ATTEMPT TO REPAIR.
X
Demountable rims
Inspect the mounting ring, rim gutter, side ring, and lock ring for
damage; replace as required.
X
Wheel nuts and studs
Check the tightness of the fasteners and tighten the fasteners to
the specified torque as required (see page 174).
X
Wheel nuts and studs
Inspect for damaged hex corners, stripped or damaged threads,
and excessive corrosion; clean or replace as required.
X
Check the fluid level (see page 162).
Reservoir (ON HIGHWAY)
Drain, replace the filter, and refill (see page 162).
Y53-6004
C
D
E
Weekly “cold” using
calibrated gauge
Inspect for cuts, irregular wear, missing lugs, sidewall damage,
etc.
Reservoir
B
X
X
X
(08/06)
PART 8: MAINTENANCE AND SERVICE
SYSTEM
COMPONENT
PREVENTIVE MAINTENANCE SCHEDULE
Recommended
PM Interval
MAINTENANCE TASK
I
Power
Steering
(08/06)
A
B
C
Reservoir (OFF HIGHWAY)
Drain, replace the filter, and refill (see page 162).
X
Steering gear
Check the lash of the sector shaft; adjust as required.
X
Grease the trunnion bearing
(EP NLGI #2 lithium-based, moly-filled, HD grease).
X
Grease the input shaft seal
(EP NLGI #2 lithium-based, moly-filled, HD grease).
X
E
X
Power assist cylinder
Lubricate the ball joints. Inspect for leaking rod seals, damaged
ball joint boots, and damage to cylinder rod or barrel.
Hoses and tubes
Check for leaks and chafing.
Steering linkage
Check all joints for excessive lash; replace as required
(see page 191).
Draglink tube clamp
and ball socket
Check the torque; tighten to specified torque value as required.
X
X
Pitman arm clamp bolt
and nut
Check the torque; tighten to specified torque value as required.
X
X
Steering intermediate shaft
Check the torque on the pinch bolt and nut.
X
X
Steering intermediate shaft
U-joints (ON HIGHWAY)
Lubricate [EP NLGI #2 HD grease,
+325° F to -10° F (+163° C to -23° C) range].
X
X
Y53-6004
D
X
X
X
– 146 –
PREVENTIVE MAINTENANCE SCHEDULE
SYSTEM
COMPONENT
PART 8: MAINTENANCE AND SERVICE
Recommended
PM Interval
MAINTENANCE TASK
I
Power
Steering
Fuel & Tanks
– 147 –
A
B
Steering intermediate shaft
U-joints (OFF HIGHWAY or
CITY DELIVERY)
Lubricate [EP NLGI #2 HD grease,
+325° F to -10° F (+163° C to -23° C) range].
X
X
Draglink and tie rod arm ball
sockets (ON HIGHWAY)
Lubricate (EP NLGI #2 lithium-based, moly-filled, HD grease).
X
X
Draglink and tie rod arm ball
sockets (OFF HIGHWAY or
CITY DELIVERY)
Lubricate (EP NLGI #2 lithium-based, moly-filled, HD grease).
X
Fuel tanks
Inspect tanks, brackets, hoses, and fittings for correct location,
tightness, abrasion damage, and leaks; repair or replace
as required.
Fuel tank breathers
Check for proper function; clean the drain hoses.
Fuel tank straps
Check the strap tightness; tighten to proper torque value as
required:
-Aluminum tank: 30 Lb. ft. (41 N.m.)
-Cylindrical Steel tank: 8 Lb. ft. (11 N.m.)
Fuel tank steps
Check for snug fit of side plates against tank and tank straps.
Check for damaged or broken steps, missing bolts, and missing
grommet between tank and side plate. Replace missing or
damaged parts and adjust for fit as required.
Y53-6004
C
D
E
X
X
X
X
X
X
(08/06)
PART 8: MAINTENANCE AND SERVICE
SYSTEM
Driveshafts
(08/06)
PREVENTIVE MAINTENANCE SCHEDULE
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
A
X
X
B
C
Models SPL-90 slip member
& U-joints
Lubricate.
Model SPL-100 slip member
& U-joints
Lubricate.
X
Models SPL-140/140HD/
170/170HD/250/250HD slip
members & U-joints
Lubricate.
X
Models SPL-140XL/170XL/
250XL slip members and Ujoints (ON HIGHWAY &
LINE HAUL)
Lubricate.
350,000 miles/
Models SPL-140XL/170XL/
250XL slip members and
U-joints (OFF HIGHWAY
& CITY)
Lubricate.
D
E
560,000 km/
every 3 years
X
Y53-6004
– 148 –
PREVENTIVE MAINTENANCE SCHEDULE
SYSTEM
COMPONENT
PART 8: MAINTENANCE AND SERVICE
Recommended
PM Interval
MAINTENANCE TASK
I
Battery
Boxes, Tool
Boxes, and
Steps
– 149 –
A
C
D
E
X
Battery cables (ON
HIGHWAY & LINE HAUL)
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 excessive wear)
(see page 184).
Battery cables
(VOCATIONAL & SEVERE
SERVICE)
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 excessive wear)
(see page 184).
Batteries (ON HIGHWAY &
LINE HAUL)
Check for cracks and damage, electrolyte level, condition of
terminals, and tightness of holddowns (see page 184).
Batteries (VOCATIONAL &
SEVERE SERVICE)
Check for cracks and damage, electrolyte level, condition of
terminals, and tightness of holddowns (see page 184).
Battery box and tray (ON
HIGHWAY & LINE HAUL)
Check the box integrity. Clean the drain tube and check for acid
leaks. Check condition of all equipment mounted under the box.
Battery box and tray
(VOCATIONAL & SEVERE
SERVICE)
Check the box integrity. Clean the drain tube and check for acid
leaks. Check condition of all equipment mounted under the box.
X
Battery Cable Fasteners
Check battery cable fasteners and tighten as necessary to 10 15 Lb. ft. (13.6 - 20.3 N.m.) as specified on the battery label.
X
Y53-6004
B
X
X
X
X
(08/06)
PART 8: MAINTENANCE AND SERVICE
SYSTEM
PREVENTIVE MAINTENANCE SCHEDULE
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Electrical &
lights
Headlamps
Check the aim and adjust as required.
Warning lights in light bar
Check at the ignition start position to verify bulbs function
(see page 19).
X
Turn, Stop, Reverse lights
and signals
Visual check.
X
Alternator
Check operation and output.
B
C
E
X
X
Check the tension of the drive belt (see page 195).
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 tank sending unit
Check the mounting screws and electrical connections for worn
or damaged wires and connectors.
Power supply harnesses
(engine, transmission, etc.)
Check for worn or damaged insulation, corroded terminals,
frayed wires, and oil or fluid leaks on the connectors or wiring.
Y53-6004
D
X
Check tightness of the pulley nut.
Wash to remove excess grease.
(08/06)
A
X
X
X
X
– 150 –
PREVENTIVE MAINTENANCE SCHEDULE
SYSTEM
PART 8: MAINTENANCE AND SERVICE
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
A
B
C
Cab
structure,
doors &
hoods
Hood
Lubricate the lower hood pivot (only if lube fittings are present).
X
Hinges and latch
Lubricate with silicone spray.
X
Body & cab holddown bolts
Check the condition and tightness.
Heating & Air
Conditioning
Air conditioner
Operate the system.
E
X
X
X
Heater & air conditioner
Perform the checks listed on page 200.
Cab air filter
Clean; replace after a maximum of three cleanings.
Heater & air conditioner
Full operational and diagnostic check.
Exhaust
System
Check for leaks and proper support (see page 198).
Air
Air compressor governor
Replace air strainer.
X
Air lines
Check condition and routing to prevent chafing.
X
System
Lubricate (see page 178).
Inline filters
Replace elements or clean with solvent.
Air dryer
Perform the checks listed on page 179.
Air dryer (ON HIGHWAY)
Overhaul.
– 151 –
D
X
X
X
X
X
X
360,000 miles/
576,000 km
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
SYSTEM
PREVENTIVE MAINTENANCE SCHEDULE
COMPONENT
Recommended
PM Interval
MAINTENANCE TASK
I
Air
Air dryer (OFF HIGHWAY)
Overhaul.
Engine
Basic Engine
Maintenance and service interval recommendations are detailed
in the engine manufacturer’s Operations and Maintenance
Manual included with the vehicle. The engine manufacturer’s
recommendations vary depending engine model. Information is
also available from Peterbilt dealers, the engine manufacturer’s
authorized service centers, and the engine manufacturer’s web
site.
(08/06)
A
B
C
D
E
X
Y53-6004
– 152 –
PART 8: MAINTENANCE AND SERVICE
LUBRICANT SPECIFICATIONS
Lubricant Specifications
Engine
NOTE: The engine in this vehicle comply with
2007 EPA emission standards. Consult the engine
manufacturer’s manual for changed lubrication and
maintenance requirements.
WARNING! Handle lubricants carefully. Vehicle
lubricants (oil and grease) are poisonous and
can cause sickness. They can also damage the
paint on the vehicle.
In this section you will find the basic information you need
to do the routine lubrication your vehicle requires. Of
course you will want to schedule service more frequently if
you are operating under severe conditions such as
extreme heat or cold, with very heavy loads, off-road, etc.
For any special service requirements, consult your service
manuals and your lubricant supplier. And please remember: one key to keeping your truck running at top economy
and in prolonging its life is proper lubrication servicing.
Neglecting this essential aspect of vehicle care can cost
time and money in the long run.
Proper engine lubrication depends on the outside temperatures where you will be driving. Use the oil recommended for the conditions you are most likely to be facing.
You will find a complete engine lubrication service guide in
the Engine Operation Manual that came with your vehicle.
There, the engine manufacturer explains more fully all the
maintenance operations that you and a qualified service
mechanic need to perform on your engine.
CAUTION: Do not mix different types of lubricants. Mixing lubricants (oil and grease) of different brands or types could damage vehicle
components; therefore, drain (or remove) old
lubricants from the unit before refilling it.
(08/06)
Y53-6004
WARNING! Exhaust fumes from the engine contain carbon monoxide, a colorless and odorless
gas. Do not breathe the engine exhaust gas. A
poorly maintained, damag ed or corroded
exhaust system can allow carbon monoxide to
enter the cab or sleeper. Entry of carbon monoxide into the cab is also possible from other vehicles nearby. Failure to properly maintain your
vehicle could cause carbon monoxide to enter
the cab/sleeper and causes serious illness.
– 153 –
LUBRICANT SPECIFICATIONS
PART 8: MAINTENANCE AND SERVICE
CAUTION: Never idle your vehicle for prolonged
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 conditions, drive only with the windows
slightly open. Failure to repair the source of the
exhaust fumes may lead to personal harm.
NOTES:
Keep the engine exhaust system and the vehicle’s cab/sleeper ventilation system properly
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 an exact replacement DPF in
exhaust systems. Using a noncompliant DPF as a
replacement could violate these standards and
also void the emission system’s warranty.
– 154 –
Master Lubrication Index
Lubricant Symbol Key
ATF
DEXRON® III/MERCON®-approved
automatic transmission fluid
BB
Ball Bearing grease
CB
Engine oil for mild to moderate requirements
CC/CD
Engine oil for severe requirements (MIL-L-2104B /MIL-L45199B 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
CI-4
Engine oil for Cummins EGR engines
CL
Multipurpose chassis grease
EP
Extreme Pressure Lubricant
GL
Straight mineral gear lubricant
HD
Hypoid Gear Oil, A.P.I. - GL-5, SAE 80W-90
HT
High Temperature grease (Timken Spec. 0-616)
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
LUBRICANT SPECIFICATIONS
Component Lubrication Index
Lubricant Symbol Key
MP
Multipurpose gear lubricant (MIL-L-2105B)
WB
Wheel Bearing grease (Timken Spec. 0-610)
NOTE: The responsibility for meeting these specifications, the quality of the product, and its performance in service rests with the lubricant supplier.
Component Lubrication Index
Universal Joints
EP
Drive Shaft Splines
CL
Wheel Bearings (driven hubs)
HD
Wheel Bearings (nondriven hubs)
CD50
Wheel Bearings (all grease-lubricated hubs)
WB
Steering Column
CL
Alternator Bearing
BB*
Fan Hub
BB*
Power Steering Reservoir
ATF
Steering Drag Link
CL
Steering Knuckles
CL
(08/06)
Spring Pins
CL
Clutch Release Bearings
BB
Brake Shoe Anchor Pins
HT
Brake Cam Bearings
HT
Slack Adjusters
CL
Starter Bearings
CC
Turbocharger Aneroid
CC
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
Y53-6004
– 155 –
LUBRICANT SPECIFICATIONS
PART 8: MAINTENANCE AND SERVICE
Lubrication Change and Inspection
Off-Highway Use
Refer to the Eaton Fuller transmission manual for servicing information.
Highway Use
• Refer to the Eaton Fuller transmission manual for servicing information.
02942
Fuller Transmission Lubrication
Fuller transmissions are designed so that the internal
parts operate in a bath of oil circulated by the motion of
gears and shafts. Grey iron parts have built-in channels
where needed to help lubricate bearings and shafts. All
parts will be amply lubricated if these procedures are
closely followed:
1.
2.
3.
4.
• Refer to the oil change vs. temperature chart that follows for special oil change information. The “intermittent peak temperature” is the maximum temperature
observed for a short time in a fully loaded vehicle performing normally.
Maintain oil level; check it regularly.
Change oil regularly.
Use the correct grade and type of oil.
Buy oil from a reputable dealer.
– 156 –
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
LUBRICANT SPECIFICATIONS
Recommended Lubricants
Type
02944
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
40
Above 10° F (-12° C)
30
Below 10° F (-12° C)
Mineral gear oil
with rust and oxidation inhibitor APIGL-1
90
Above 10° F (-12° C)
80W
Below 10° F (-12° C)
Synthetic Lubricant*
50
All
* See your Peterbilt dealer for approved brands.
CAUTION: Exceeding the recommended oil
change intervals may be harmful to the life of the
transmission and the transmission oil cooler.
Allison Transmission Lubrication
Refer to your transmission manual (furnished separately)
for lubrication information.
(08/06)
Y53-6004
– 157 –
LUBRICANT SPECIFICATIONS
PART 8: MAINTENANCE AND SERVICE
Spicer Transmission Lubrication
It is extremely important to use the proper lubricants and
maintain the correct oil levels in Spicer units. This will
ensure proper lubrication and operating temperatures in
these units.
Recommended Lubricants
The lubricants listed below are recommended, in order of
preference, for use in all Spicer mechanical transmissions, auxiliaries, and transfer cases. Do not use extreme
pressure additives such as those found in multipurpose or
rear axle-type lubricants. These additives are not required
in Spicer transmissions, and may in some 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.
– 158 –
Type
Heavy Duty Engine Oil MIL-L2104D or MIL-L-46152B, API-SF
or API-CD (MIL-L-2104B or C or
MIL-L-46152 designations are
acceptable)
Mineral gear oil
(R & O type) API-GL-1
Grade (SAE)
Ambient
Temperature
30, 40, or 50
Above 0° F
(-18° C)
30
Below 0° F
(-18° C)
90
Above 0° F
(-18° C)
80
Below 0° F
(-18° C)
Synthetic Engine Oil meeting MIL- CD50
CD30
L-2104D or MIL-L-46152B, APISF or API-CD
All
*Synthetic Gear Oil Meeting MIL- EP75W90
2105C or API-GL5
EP75W140
All
*EP Gear Oils are not recommended when lubricant operating temperatures are above 230° F (110° C).
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
LUBRICANT SPECIFICATIONS
Oil Changes
CAUTION: When adding oil, types and brands of
oil should not be intermixed because of possible
incompatibility, which could decrease the effectiveness of the lubrication or cause component
failure.
An initial oil change and flush should be performed after
the transmission has been placed in actual service. This
change should be made any time after 3000 miles (4800
km) but never longer than 5000 miles (8000 km) of overthe-road service. In off-highway use, the change should
be made after 24 hours but before 100 hours of service
have elapsed.
can also escape onto clutch or parking brakes. When adding oil, do not mix different types of oil.
Allison Transmission Lubrication
Lubrication Change and Inspection
• Refer to your transmission manual (furnished separately) for lubrication information.
• Refer to the Allison Transmission manual for servicing
information.
Meritor Axle Lubrication
NOTE: Axles utilized in 100% off-highway use are
not eligible for Meritor’s Advanced Lube Rear
Drive Axle program.
Refilling
Remove all dirt around filler plug. Refill with new oil of the
grade recommended for the existing season and prevailing service. Fill to the bottom of the level testing plug positioned on the side of the transmission. Do not overfill the
transmission. Overfilling usually results in oil breakdown
due to excessive heat and aeration from the churning
action of the gears. Early breakdown of the oil will result in
heavy varnish and sludge deposits that plug up oil ports
and build up on the splines and bearings. Overflow of oil
(08/06)
Under Meritor’s Advanced Lube Rear Drive Axle program,
the axles listed below are exempt from an initial lubricant
change:
Y53-6004
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
– 159 –
LUBRICANT SPECIFICATIONS
PART 8: MAINTENANCE AND SERVICE
AVAILABLE ADVANCED LUBE AXLES
Application
RS-21-145
RS-30-180
SQ-100A
RT-46-160P
RS-23-160
RT-34-145
SQ-100AP
RT-52-160
RS-23-161
RT-34-145P
RT-44-145
RT-52-160P
Meritor rear axles that do not appear on the list above will
continue to require an initial drain at 3000-5000 miles
(4800-8000 km).
City Delivery
Vocational
• Refer to the Meritor Field Maintenance Manual for a
particular axle for lubricant specifications.
• See your Peterbilt dealer for Meritor-approved lubricant brands.
• Refer to the following chart for lubricant change intervals:
Application
Linehaul
– 160 –
Type Of Lubricant
Mileage Interval
Synthetic
240,000 mi. (384,000
km)
Synthetic with Pump
and Filter
500,000 mi. (800,000
km)
Mineral Base
120,000 mi. (192,000
km)
Type Of Lubricant
Mileage Interval
Synthetic
120,000 mi. (192,000
km)
Synthetic with Pump
and Filter
240,000 mi. (384,000
km)
Mineral Base
120,000 mi. (192,000
km)
Synthetic
120,000 mi. (192,000
km)
Synthetic with Pump
and Filter
120,000 mi.(192,000
km)
Mineral Base
120,000 mi. (192,000
km)
• Change the lubricant filter every 120,000 miles
(192,000 km). Top off the lubricant level with a similar
lubricant.
Eaton/Dana Axle Lubrication
• The original mineral-based lubricant must be drained
within 3000-5000 miles (4800-8000 km) on all Eaton
axles. This initial change is very important because it
flushes out break-in contaminants that might otherwise cause premature wear.
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
LUBRICANT SPECIFICATIONS
• No initial drain is required on Eaton axles that are factory filled with an Eaton-approved synthetic lubricant.
• Mineral-based lubes must be drained within the first
5000 miles (8000 km) if converting to an Eatonapproved synthetic lube.
• Change the lubricant within the first 5000 miles (8000
km) of operation 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.
• Refer to the chart below for lubricant change interval.
Type of
Lubricant
Mineral-Based
On-High- Maximum
Change
way
Interval
Mi.(km)
120,000 Yearly
(192,000)
Eaton-Approved 240,000 2 Years
Synthetic
(384,000)
(08/06)
On/Off
Highway
Severe Service Mi.(km)
Maximum
Change
Interval
60,000
(96,000)
Yearly
120,000
(192,000)
Yearly
Type of
Lubricant
On-High- Maximum
Change
way
Interval
Mi.(km)
On/Off
Highway
Severe Service Mi.(km)
Maximum
Change
Interval
Eaton-Approved 350,000
(560,000)
Synthetic in
axle with
extended drain
interval option
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 each drive hub. Add oil through the filler hole
in the hub; if none, add oil through the differential filler
hole. (Note: Remember to replace vent plug or threaded
filler plug when done.) Allow time for the oil to seep
through the bearings when initially filling a hub. Maintain
the differential oil level by adding oil until its surface is
even with the bottom of the filler hole (see page 155).
Y53-6004
– 161 –
LUBRICANT SPECIFICATIONS
PART 8: MAINTENANCE AND SERVICE
Oil-lubricated Nondriven Hubs
2. Check fluid for contamination, discoloration, or burnt
smell; correct source of such problems before replacing fluid & filter.
Use CD50 synthetic transmission fluid SAE 50W or equivalent. A minimum of 9 oz. (270 ml) of lubricant is required
for proper lubrication of an LMS™ hub; 10 - 13 oz. (295 400 ml) is required for a non-LMS hub, depending on
wheel design. Allow time for the fluid to seep through the
bearings when initially filling a hub. When properly filled,
the fluid level will lie between the fluid level line and 1/4”
above the line. (Note: Remember to replace vent plug
when done.)
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 incompatible
additives.
• If incompatible (insoluble) fluids are mixed in
a power steering system, air bubbles can be produced at the interface of the two fluids. This can
cause cavitation, which reduces the lubrication
between moving parts in the gear. This could
result in worn components.
• The mixture of two different fluids, although
harmless to individual internal components,
may initiate a chemical reaction that produces a
new compound that will attack seals and other
internal components.
Grease-Lubricated Hubs
Repack the hub bearing with clean wheel bearing grease
after disassembling, cleaning, and inspecting.
Steering Gear Lubrication
Inspection
NOTE: Before removing reservoir cover, wipe
outside of cover so that no dirt can fall into the
reservoir.
1. Check the fluid level; add fluid if required.
– 162 –
• Do not mix different fluids.
Universal Joint Lubrication
Refer to the Spicer Universal Joints and Driveshafts service manual and lubrication specifications.
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
LUBRICANT SPECIFICATIONS
Replacement
1. Replace both fluid and filter as per the chart below.
2. Bleed the system if necessary
.
Inspect
[mi.(km)]
Replace
[mi. (km)/
months]
ATF
Every 15,000
(24,000)
Every 240,000
(384,000)/24
ATF
Every 15,000
(24,000)
Every 240,000
(384,000)/24
Steering
Gear
Fluid *
TRW
Sheppard
*Extremely low temperatures may require lower viscosity
fluids; consult your Peterbilt dealer for recommendations
(08/06)
Y53-6004
– 163 –
SERVICING SPECIFIC SYSTEMS AND UNITS
PART 8: MAINTENANCE AND SERVICE
Servicing Specific Systems And Units
This section will help you keep your Peterbilt vehicle in
good running condition. There are a number of checks
you can do, and you may be able to do some of the service work yourself. But please: let your dealer’s service
department do any work you don’t have the tools or skill to
perform. Authorized service mechanics are trained in the
proper technical and safety procedures to fix your Peterbilt
vehicle right.
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 this vehicle
was configured for ONE of the following operations: tractor or truck, and complies with the
respective portions of FMVSS 121. A tractor
shall not be operated or configured as a truck,
nor shall a truck be operated or configured as a
tractor, without significant modifications to the
air brake system in order to retain compliance
with FMVSS 121. Contact your Peterbilt dealer for
instructions.
WARNING! It is dangerous to work on a vehicle without the right know-how and proper
tools. You could be badly injured, and you
could damage the vehicle. Do only work you
know you are fully capable of doing, and for
which you have the right tools.
Brake Adjustment
WARNING! To prevent uncontrolled vehicle
movement and reduce risk of personal injury,
park the vehicle on a hard level surface, apply
the parking brake, and chock all wheels
securely.
– 164 –
Once a brake system is set to specifications, changing
any one of its components or any combination of components may cause the system to not work as well. All parts
have to work together to perform as they should. Any
replacement components in your brake system should be
exactly equal to the original components. Any changes
from the original specifications can affect the whole sys-
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
BRAKE ADJUSTMENT
tem. All of the following areas are interrelated and must
conform to original specifications:
• Tire Size
• Drum brakes
A.
B.
C.
D.
E.
F.
Cam Radius
Wedge Angle
Drum Radius
Brake Linings
Brake Chambers
Slack Adjusters
All vehicle operators should check their brakes regularly.
Always adjust your brakes when they are cool.
WARNING! Brake linings and pads with a
thickness below the specified minimum will
have exposed rivets. Use of such linings can
damage the braking surface and also reduce
brake efficiency, which could cause an accident or system failure.
Air System
• Build up air pressure in the system to the governor
cut-out point.
• Disc Brakes
A. Disc Rotors
• Stop the engine.
WARNING! A nonconforming part in your
brake system could cause an accident. Sizes
and types are so related to one another that a
seemingly unimportant change in one may
result in a change in how well your brakes
work for you on the road. If parts don’t work
together properly, you could lose control of
your vehicle. Be sure any replacement parts
in your brake system conform exactly to original specifications.
• Release the parking brakes (push in the yellow knob).
• Watch the rate of air pressure drop. The rate of drop
should not be more than 2 psi (14 kPa) per minute.
• Now start the engine and build up the air pressure
again.
• Stop the engine. Ensure that the parking brakes are
still released (i.e., the yellow knob is pushed in).
• Fully apply the service brakes.
(08/06)
Y53-6004
– 165 –
BRAKE ADJUSTMENT
PART 8: MAINTENANCE AND SERVICE
• Watch the rate of air pressure drop registered by the
air gauge. The rate of drop should not be more than 3
psi (21 kPa) per minute.
• If you find excessive leakage, a leakage test should
be made at the air line connections and at all air brake
control units. To perform a leakage test, refer to the
detailed instructions in the Peterbilt Maintenance
Manual, or take your vehicle to an authorized Peterbilt
dealer.
• Have a qualified mechanic perform a detailed inspection if the notches are not found. The pads and rotors
should be measured and compared against the manufacturers specifications located in the brake manufacturer’s service manual.
Air Disc Brakes
Have brake pads inspected by a qualified mechanic for
wear at regular intervals according to the “Preventive
Maintenance Schedule” on page 129. In severe service or
off-highway applications inspect the linings more frequently.
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
require a detailed inspection by a qualified mechanic.
– 166 –
Regularly inspect caliper for Running Clearance:
• Stop the vehicle on level ground and let the brakes
cool down. Hot brake calipers can burn skin on contact.
• Chock the wheels.
• Temporarily release the parking brakes.
• Grab the caliper and move it. This movement is Running Clearance.
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
BRAKE ADJUSTMENT
• Proper Running Clearance is 0.08” (2 mm) of movement of the brake caliper (approximately the thickness
of a nickel) in the inboard/outboard direction.
• Have a qualified mechanic provide further inspection
if the caliper does not move or appears to move more
than the specified clearance.
• A correctly installed and functioning auto slack
adjuster will produce the following strokes:
Drum Brakes
Have brake drum linings and disc brake pads inspected by
a qualified mechanic for wear at regular intervals according to the maintenance schedule. In severe service or offhighway applications inspect the linings more frequently.
Chamber Type
Stroke
36 (rear brakes)
11/2” - 21/4” (38 - 57 mm)
30 (rear brakes)
11/2” - 2” (38 - 51 mm)
16, 20, & 24 (front brakes)
1” - 13/4” (25.4 - 44.4 mm)
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 retracted position of the air chamber
pushrod.
(08/06)
Y53-6004
02945a
Brake Chamber Stroke
– 167 –
TIRES, WHEELS, AND RIMS
PART 8: MAINTENANCE AND SERVICE
WARNING! Manual adjustment of automatic
slack adjusters is a dangerous practice that
could have serious consequences. It gives
the operator a false sense of security about
the effectiveness of the brakes. Contact the
Service Department at your dealership if the
stroke exceeds the above specifications. A
stroke exceeding these values may indicate a
problem with the slack adjuster or the brake
foundation.
Tires, Wheels, And Rims
Tires
WARNING! You can be badly injured trying to
fix tires. Don’t mount or dismount a tire yourself; have any wheel service performed by an
expert. And stand away from the tire assembly
while the expert is working.
Your tires are a very important part of your vehicle’s whole
braking system. How fast you can stop depends in large
measure on how much friction you get between the road
and your tires. In addition, keeping your tires in good condition is essential to the safe, efficient operation of your
vehicle. Regular, frequent inspection and the right care
– 168 –
will give you the assurance of safe and reliable tire operation. Here are some tips on maintaining your tires.
Checking Inflation Pressure
Give your tires a visual test every day, and check inflation
with a gauge every week:
• When checking tire pressure, inspect each tire for
damage to sidewalls, cuts, cracks, uneven wear, rocks
between duals, etc. If a tire appears underinflated,
check for damage to the wheel assembly. Don’t forget
to check between dual wheels. If you find wheel damage, have an expert tire service repair it.
• Maximum tire pressure will be indicated on the sidewall of a tire.
• Check pressure only when the tires are cool. Warm or
hot tires cause pressure buildup and will give you an
inaccurate reading. So never 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 control and tire load capacity.
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
TIRES, WHEELS, AND RIMS
Underinflated Tires
EFFECT OF LOAD PRESSURE ON TIRE LIFE
Low pressure is a tire’s worst enemy. Underinflation allows
tires to flex improperly, causing high temperatures to build
up. Heat causes early tire damage such as flex break,
radial cracks, and ply separation. Low pressure may affect
control of your vehicle, especially at the front wheels. Most
tire wear problems are caused by underinflation as the
result of slow leaks, so you’ll want to check tire pressure
regularly.
WARNING! Underinflated tires could cause a
serious accident. The extra heat caused by
underinflation can cause sudden tire failure.
Low pressure may affect control at the front
wheels. You could be seriously hurt in an
accident that could result. Keep your tires
inflated to the manufacturer’s recommended
limit.
Vehicle
Load
Normal
20%
Over
40%
Over
60%
Over
80%
Over
100%
Over
Tire Pressure
Normal
20%
Low
30%
Low
35%
Low
45%
Low
55%
Low
Expected
Total Tire
Mileage
Normal
70%
50%
40%
30%
25%
Overinflated tires
Too much air pressure reduces the tire tread contact area
and results in rapid wear in the center of the tread.
WARNING! Overinflated tires can cause accidents. They wear more quickly than properly
inflated tires. And they are more subject to
punctures, cracks, & other damage. They
could fail and cause you to lose control of
your vehicle. Be sure all tires are inflated correctly according to the manufacturer’s recommendations.
Overloaded tires
Overloading your truck is as damaging to your tires as
underinflation. The following chart shows how neglect or
deliberate abuse can affect the life of your tires.
(08/06)
The chart on page 172 gives you the right load and inflation rates for different tire sizes. Please follow it for the safest and most economical use of your tires. (Consult the
Y53-6004
– 169 –
TIRES, WHEELS, AND RIMS
PART 8: MAINTENANCE AND SERVICE
• Regrooved tires or tires with reinforcement
repairs can be dangerous on steering axles.
They could cause you to lose control of your
vehicle. Do not install regrooved or reinforcement-repaired tires on your steering axles.
tire manufacturer for proper pressure settings with tires
not listed in this table.)
Matching tires
Be sure to buy matched tires for your vehicle, especially
on the rear axles. Mismatched tires can cause stress
between axles and cause the temperature of your axle
lubricant to get too hot. Matched tires will help your driveline last longer and will give you better tire mileage.
WARNING!
• Mismatched tires are dangerous. Mixing tire
types may lessen the road-holding ability of
both types of tires. You can lose control and
be injured. Never mix tires of different design,
such as steel belted radials and bias ply tires.
Make sure, too, that you use the right size
tires on each wheel. Some vehicles require
different sizes on front and rear wheels. For
safety, always use the recommended size and
type of tires.
– 170 –
Replacing Tires
Front: Replace front tires when less than 4/32 in. of tread
remains. Check at three places equally spaced around the
tire.
Drive Axles or Trailers: 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 illustration for recommended
measuring points for tread depth.
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(08/06)
PART 8: MAINTENANCE AND SERVICE
TIRES, WHEELS, AND RIMS
NOTE: To prolong your tires’ life and make them
safer, have their radial and lateral run-out
checked at your dealer. And of course you should
have your tires balanced anytime you change a
tire.
Tire chains
If you need tire chains, install them on both sides of each
driving axle.
CAUTION: Chains on the tires of only one tandem 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 sidewall for maximum rated speed. Vehicle should
not be operated at sustained speed in excess
of maximum rated speed. Failure to comply
with these speed restrictions could cause
sudden tire failure which can result in property damage or personal injury.
02946
Steer Tire Points in Upper View, Drive Tire in Lower View
(08/06)
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– 171 –
PART 8: MAINTENANCE AND SERVICE
TIRES, WHEELS, AND RIMS
Tire Load and Inflation Tables
Load Range Letters and Corresponding Ply Rating
(G = 14 ply; H = 16 ply)
SINGLE RADIAL TIRES FOR VEHICLES IN HIGHWAY SERVICE
Tire
Size
11R22.5
11R22.5
11R24.5
11R24.5
275 / 70R22.5
295 / 75R22.5
285 / 75R24.5
Load
Range
G
H
G
H
H
G
G
Tire Load Limits At Various Cold Inflation Pressures (psi)
70
75
80
85
90
95
4530
4770
4990
5220
5510
5730
4530
4770
4990
5220
5510
5730
4820
5070
5310
5550
5840
6095
4820
5070
5310
5550
5840
6095
4850
5050
5250
5480
5705
4500
4725
4940
5155
5370
5510
4545
4770
4940
5210
5420
5675
100
5950
5950
6350
6350
5945
5780
5835
105
6175
6175
6610
6610
6195
5980
6040
110
115
120
6320
6465
6610
6790
6450
6175
6175
6970
6720
7160
7000
5895
5950
6005
6205
5890
5675
5675
6405
6135
6610
6395
DUAL RADIAL TIRES FOR VEHICLES IN HIGHWAY SERVICE
11R22.5
G
4380
4580
4760
4950
11R22.5
H
4380
4580
4760
4950
11R24.5
G
4660
4870
5070
5260
11R24.5
H
4660
4870
5070
5260
275 / 70R22.5
H
4430
4610
4795
295 / 75R22.5
G
4095
4300
4540
4690
285 / 75R24.5
G
4135
4340
4540
4740
NOTE:
1. Pressure listed is the minimum for the load.
2. All tire load figures are in pounds.
3. Figures in Bold face indicate maximum recommended load.
Source: Bridgestone Tire 2/02
(08/06)
Y53-6004
5205
5205
5510
5510
5005
4885
4930
5415
5415
5675
5675
5210
5070
5205
5625
5625
5840
5840
5430
5260
5310
5840
5840
6005
6005
5660
5440
5495
– 172 –
PART 8: MAINTENANCE AND SERVICE
TIRES, WHEELS, AND RIMS
Wheels And Rims
Wheels
02949
• Pilot mount wheels have stud holes that are reamed
straight through (no ball seats). Center bore diameter is 821/32 in. Budd Uni-Mount - 10 wheels have UNIMOUNT
stamped on the disc.
• Ball seat wheels have spherical chamfers machined
on each stud hole. Center bore diameter is 8-23/32 in.
Wheel Nuts
Hub Pilot Mount SystemBall Seat Mount System
Hub, Drum, and Stud Assembly
• The hub pilot mounting system uses M22x1.5 metric threads (about 7/8 in. dia.). The stud stands out at
least 1.9 in. beyond the brake drum. All studs are right
hand threads. Pilot bosses machined 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.
(08/06)
• Hub pilot nut has a hex body and a flange for clamping against wheel face. Hex size is 33 mm (same as 15/16 in.).
• Inner and outer cap nuts mate with spherical chamfers on wheels. Inner nut has 13/16 in. square end.
Outer nut has 1-1/2 in. hex.
Y53-6004
WARNING! Mismatched wheel components
are dangerous. Equipment that does not
exactly match original specifications or that is
mismatched could cause your wheels to
break and separate from the vehicle. The
resulting accident could be very serious.
Each mounting system is engineered for use
– 173 –
TIRES, WHEELS, AND RIMS
PART 8: MAINTENANCE AND SERVICE
only with its correct mating part. Be sure properly
matched components are used for each type of
mounting.
Wheel Cap Nut Torque At the first 100 miles, have all
wheel cap nuts torqued to their specified value. After that,
check wheel cap nuts at least once 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!
• Grooves in the wheel disc or other damage
to the disc can lead to a serious accident. The
disc will be weakened and can eventually
come off, maybe causing you to lose control
of your vehicle. Be sure to use the right components and the right tools.
• The end of the wheel wrench must be
smooth. Burrs on the end of the wrench can
tear grooves in the disc, especially on aluminum wheels. These grooves may lead to
cracks in the disc, and can cause it to fail.
Wheel Bearing Adjustment
For safe, reliable operation and adequate service life, your
wheel bearings must be checked and adjusted properly.
The person best equipped to do this is your authorized
dealer’s service mechanic.
Disc Wheels
To check the torque on disc wheels, follow the crisscross
sequence shown. See the Specifications chart for proper
torque specification.
02950
Crisscross Sequence For Disc Wheels
– 174 –
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PART 8: MAINTENANCE AND SERVICE
TIRES, WHEELS, AND RIMS
Demountable Rims
To check the torque on demountable rims, follow the crisscross sequence shown. See the Specifications chart for
proper torque specification.
WARNING!
• Use only components marketed by PACCAR
Parts. Use of non–original equipment could
cause wheel breakage and wheel separation
from vehicle. Each mounting system is engineered only for use with its correct mating
part. Be sure that properly matched components are used for each type of mounting. The
comparison chart on page 142 illustrates the
differences between parts used in hub–
piloted mount and ball seat mount applications. Only PACCAR Parts supplied hub–
piloted or ball–seat mounted wheels may be
used on this vehicle.
(08/06)
Y53-6004
• If you are not fully qualified and not
equipped with the proper tools and equipment, do not attempt to raise the vehicle or
remove or install the damaged tire and wheel
assembly. Obtain expert help. A person can
be seriously injured and/or damage can result
from using the wrong service methods. Truck
tires and wheels should be serviced only by
trained personnel using proper equipment. Do
not reinflate a tire that has been run flat or is
seriously low on air without first removing the
tire from the rim and inspecting for damage.
• Follow OSHA regulations per section
1910.177.
• Do not exceed the speed rating of tires.
Exceeding the speed rating may result in sudden tire failure and loss of vehicle control.
• Follow all warnings and cautions contained
within the tire and wheel manufacturers literature.
• Only properly trained personnel should service tire and rim assemblies.
– 175 –
TIRES, WHEELS, AND RIMS
PART 8: MAINTENANCE AND SERVICE
CAP NUT TORQUE SPECIFICATIONS (R12/01)
PHP-10; Budd UniMount-10; WHD-8
M22 x 1.5-6H
450-500
610-680
Rim Clamp Nut Torque
Cast Spoke Wheel
Assembly
1/2” Dia.
5/8” Dia.
3/4” Dia.
80-90
110-120
160-185
220-250
225-245
305-335
02951
Crisscross Sequence For Demountable Rims
CAP NUT TORQUE SPECIFICATIONS (R12/01)
TORQUES FOR INNER &
OUTER CAP NUTS
WHEEL AND NUT
CONFIGURATION
STUD SIZE
Lb. Ft.
N.m
Stud-Piloted Disc
Wheels
3/4”-16 Inner
1 1/8”-16 Outer
450-500
610-680
Heavy Duty StudPiloted Disc Wheels
15/16”-12 Inner
1 5/16”-12
Outer
750-900
1025-1225
– 176 –
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(08/06)
PART 8: MAINTENANCE AND SERVICE
VEHICLE LOADING
Vehicle Loading
carry so heavy a load that you exceed the GVW rating of
your Peterbilt vehicle.
WARNING!
• The components of your vehicle are
designed to provide satisfactory service if the
vehicle is not loaded in excess of either the
gross vehicle weight rating (GVWR) or the
maximum front and rear gross axle weight ratings (GAWRs). Axle weight ratings are listed
on the driver’s door edge. Supervise all loading to ensure that (1) the Gross Vehicle
Weight Rating (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, difficult handling, or an
accident could occur if your vehicle is not
loaded properly.
Axle Weight: Your front and rear axles are rated according to the load they are designed to carry. You will find this
number listed on the driver’s door frame.
Load Distribution: Be sure any load you carry is distributed so that no axle has to support more than its load
limit.
• An unevenly distributed load or a load too
heavy over one axle can affect the braking
and handling of your vehicle and cause an
accident. Even if your load is under the legal
limits, be sure it is distributed evenly.
03002
GVW: GVW is the Gross Vehicle Weight. This is the
TOTAL WEIGHT your vehicle is designed to carry. Never
(08/06)
Y53-6004
– 177 –
AIR SYSTEM
PART 8: MAINTENANCE AND SERVICE
Air System
•Never attempt to disassemble a component until you have read and understood
recommended procedures. Some components contain powerful springs and injury
can result if not properly disassembled.
Use only proper tools and observe all precautions pertaining to use of those tools
WARNING!
• Prior to the removal of any air system component, always block and hold the vehicle by
a secure means other than the vehicle's own
brakes. Depleting air system pressure may
cause vehicle to roll. Keep hands away from
chamber push rods and slack adjusters, they
may apply as system pressure drops.
•Completely bypassing a Bendix AD-IS air
dryer will bypass the system’s pressure
protection valves. This could lead to loss
of air pressure or damage to the vehicle’s
air system, which could cause an accident
or personal injury. Always adhere to the
manufacturer’s procedure if it is necessary in an emergency to temporarily
bypass an AD-IS-series air dryer.
• After completing any repairs to the air system, always test for air leaks, and check the
brakes for safe operation before putting the
vehicle in service.
• 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.
• Never exceed recommended air pressure
and always wear safety glasses when working
with air pressure. Never look into air jets or
direct them at anyone.
– 178 –
The operation of the vehicle’s braking system and many
vehicle accessories depends upon the storage and application of a high-pressure air supply.
Your vehicle’s compressor takes outside air and compresses it, usually to 100-120 psi. The compressed air
then goes to the reservoirs to be stored until needed.
When you operate your air brakes, the stored compressed
air flows into the chambers where it is used to apply your
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
AIR SYSTEM
truck and trailer brakes. That is why, when you push down
on your brake pedal, you don’t feel the same amount 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
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 compromise the brake system safety and potentially
cause an accident.
Periodically
• Clean filter screens ahead of the valves by removing
the screens and soaking them in solvent. Blow them
dry with pressurized air before reinstalling them.
Twice a Year
• Maintain the air compressor to prevent excessive oil
by-pass. See your maintenance manual for details.
• Replace worn seals in valves and air motors as they
are needed.
Air Dryer
WARNING! Use of incorrect air dryer could
cause air system failure, leading to loss of
vehicle control and serious personal injury or
death. If your vehicle is equipped with a Bendix AD-IS air dryer, it is important that future
replacements be identical or similar in design.
Daily
• Drain moisture from the supply and service air tanks.
• Operate air devices to circulate lubricants within the
unit.
(08/06)
Any deviation from the Bendix AD-IS type air dryer would
require changes to the vehicle air system. Some vehicles
use a dual air system consisting of a wet tank, forward dry
tank, and rear dry tank. The dry tanks have a single-check
Y53-6004
– 179 –
TRANSMISSION AND DRIVE TRAIN
PART 8: MAINTENANCE AND SERVICE
valve in the tank inlet. The check valves prevent a complete loss of air in the event of an air system failure (tank
or hose failure). This ensures a controlled stop (with
reduced braking capability). Other vehicles 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 reason 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, check for moisture in the air brake system by
opening reservoirs, drain cocks, or valves and checking
for the presence of water. A tablespoon of water in a reservoir would point to the need for a desiccant cartridge
change. However, the following should be considered first:
• Air usage is exceptionally high/abnormal for a highway vehicle. This may be due to accessor y air
demands or some other unusual air requirement that
doesn’t allow the compressor to load/unload in a normal fashion or it may be due to excessive leaks in the
air system.
– 180 –
• When more than a 30-degree F (17-degree C) range
of temperature occurs in one day, small amounts of
water can accumulate in the air brake system due to
condensation. Under these conditions, the presence
of small amounts of moisture is normal and should not
be considered as an indication that the dryer is not
performing properly.
• An outside air source may have been used to charge
the air system, in which case this air did not pass
through the drying bed.
Transmission And Drive Train
Clutch Adjustment
Clutch pedal free travel 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 certified mechanic. Have the adjustment done before clutch
pedal free travel is reduced to the minimum allowable 1/2
in. (13 mm).
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
ENGINE COOLING SYSTEM
Engine Cooling System
What To Check In An ELC-filled Cooling System
Your engine’s cooling system is standard with Extended
Life Coolant (ELC). ELC consists of a mixture of ethylene
glycol, water, and organic acid technology chemical inhibitors. ELC prevents corrosion and scale formation as well
as provides freezing and boiling point protection.
ELC Concentration
Check the level of freeze/boilover protection, which is
determined by the ELC concentration. Use a glycol refractometer to determine glycol level. Add ELC to obtain the
ELC to water ratio required to provide the protection you
need. Use the chart below to help determine how much
ELC you need to add.
CAUTION: The engine cooling system has very
specific maintenance and inspection requirements. Failure to follow requirements can damage the engine. Engine damage can include but
is not limited to:
• Freezing
• Boiling
• Corrosion
• Pitted cylinder liners
This information is found in the engine manufacturers owner’s manual. It is the owner’s responsibility to follow all requirements listed in the
engine manufacturers owner’s manual.
35%
40%
In an ELC-filled cooling system, the freeze point should be
maintained between -30° F and -45° F (-34° C and -43° C)
Desired ELC/
Water ratio:
0%
10%
15%
20%
25%
Freeze point
°F (°C)
+32
(0)
+25
(-4)
+20
(-7)
+15
(-9)
+10
+5
-5
-12
-23
-34
-50
-65
-75
-84
-70
-55
-43
-30
-5
(-12) (-15) (-21) (-24) (-31) (-37) (-46) (-54) (-59) (-64) (-57) (-48) (-42) (-34) (-21)
(08/06)
30%
NOTE: Maximum recommended ELC concentration is 60% ELC and 40% water by volume (a 60/
40 coolant mixture). The minimum recommended
concentration is 40%.
45%
50%
Y53-6004
55%
60%
65%
70%
75%
80%
85%
90% 100%
– 181 –
ENGINE COOLING SYSTEM
PART 8: MAINTENANCE AND SERVICE
ELC Condition (Contamination and Inhibitor Concentration)
page 129. Never use filters that contain SCAs in an ELCfilled system.
Perform a visual inspection of the ELC. It should have no
cloudiness or floating debris. Determine the chemical
inhibitor concentration level by using an ELC-specific test
kit or test strips. Inhibitor concentration level determines
corrosion protection. If you are concerned about possible
coolant quality, contamination, or mechanical problems,
submit a coolant sample for analysis. Improper maintenance may cause coolant degradation and could result in
damage to the cooling system and engine components.
Consult your dealer or the ELC manufacturer’s representative for recommended ELC test kits, test strips, and laboratory sample procedures.
Topping Off
WARNING! Removing the fill cap on a hot
engine can cause scalding coolant to spray
out and burn you badly. If the engine has been
in operation within the previous 30 minutes,
be very careful in removing the fill cap. Protect face, hands, and arms against escaping
fluid and steam by covering the cap with a
large, thick rag. Do not try to remove it until
the surge tank cools down if you see any
steam or coolant escaping. In any situation,
remove the cap very slowly and carefully. Be
ready to back off if any steam or coolant
begins to escape.
ELC Extender
NOTE: If frequent topping off is necessary and
there are no visible signs of coolant leaks when
the engine is cold, check for leaks with the engine
operating at normal temperature.
Add ELC extender if necessary at the maintenance interval under “Cooling” on page 144.
Coolant Filter
If your vehicle came with a non-chemical filter (“blank filter”), replace it only with a blank filter at the interval specified in the “Preventive Maintenance Schedule” on
– 182 –
Top off the cooling system when coolant does not rise to
the level indicated as ‘MIN’ on the surge tank. The surge
tank is transluscent which allows the coolant level to be
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(08/06)
PART 8: MAINTENANCE AND SERVICE
ENGINE COOLING SYSTEM
seen. Add coolant through the surge tank fill cap. Do not
remove the pressure cap to fill the cooling system.
.
• The minimum fluid level is determined by the line on
the surge tank indicated by the letters “MIN”. This indicator is located below the fill cap.
• The cooling system will need fluid if the surge tank
level does not rise to the “MIN” line regardless if the
system is hot or cold.
Refilling Your Radiator
Surge Tank
NOTE: Do not use the pressure cap to fill the
surge tank with fluid.
Proper Coolant Level
NOTE: Do not overfill a cooling system. Excess
coolant may result in overflow, loss of antifreeze,
and reduced corrosion protection.
(08/06)
1. Be sure the radiator and engine block drains are
closed.
2. Remove the surge tank fill cap (Do not remove the
surge tank pressure cap)
3. Fill the system with premixed coolant through the
surge tank fill cap. Pour coolant at a steady flow rate
until the surge tank is full.
4. Start the engine and idle at low RPM.
5. As air is purged from the cooling system, continue to
fill the system until the coolant level remains above
the "MIN" level.
6. Idle the engine until the operating temperature stabilizes.
7. Fill the surge tank as necessary to raise the coolant
level to the “MIN” level. Replace the surge tank fill cap.
Y53-6004
– 183 –
ELECTRICAL
PART 8: MAINTENANCE AND SERVICE
Check the coolant level after each trip. Add coolant as
necessary. You may find your coolant level is not up to the
correct level soon after you have filled the radiator. This
may be because all the trapped air in the system has not
yet been purged. It takes a little time for all the air to leave
the system after you fill your radiator.
• Undercharge: Your voltage regulator may be malfunctioning or is improperly adjusted, the drive belt is slipping, or your vehicle has undergone long periods of
standing idle or short distance driving. These conditions result in battery plates becoming covered with a
hard coating.
Electrical
• Vibration: Loose battery hold-downs may cause battery plate failure.
CAUTION: Do not modify or improperly repair
the vehicle’s electrical system or power distribution box. All electrical repairs should be performed by a qualified service technician.
Improper repair or modifications will void your
warranty and/or cause serious damage to your
vehicle.
• Short Circuits: These discharge a battery by draining
electricity.
• Dirty or Loose Connections: Bad connections may
stop the flow of electrical power to and from the battery.
Battery Care
Recharging Batteries
Regular attention to the charging system will help prolong
the service life of your batteries. Here are some common
causes of battery failure:
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:
• Overcharge: This condition may result from improper
voltage regulator adjustment. It results in overheating
of the battery, warped plates, and evaporation of electrolyte.
– 184 –
Y53-6004
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PART 8: MAINTENANCE AND SERVICE
ELECTRICAL
WARNING! A battery contains gas that is
explosive and flammable. It could injure you
severely. 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.
WARNING! Always make sure the battery
charger is OFF before connecting or disconnecting the cable clamps. Do not connect or
disconnect charger cables while the charger
is operating to reduce the danger of explosions.
• Always make sure the battery charger is OFF before
connecting or disconnecting the cable clamps.
WARNING! Always shield your eyes and avoid
leaning over the battery whenever possible.
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 electrolyte 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.
• Before attempting any work on the batteries or electrical system, remove all jewelry. If metal jewelry or
other metal comes in contact with electrical circuits, a
short circuit may occur causing you to be injured—
plus electrical system failure and damage.
• To avoid short circuits and damage to yourself or the
vehicle, never place metal tools or jumper cables on
the battery or nearby. Metal that accidentally comes in
contact with the positive battery terminal or any other
• Use protective eyewear.
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Y53-6004
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ELECTRICAL
PART 8: MAINTENANCE AND SERVICE
metal on the vehicle (that is in contact with the positive terminal), could cause a short circuit or an explosion.
• Keep all batteries away from children.
WARNING! Charger cables must be connected positive to positive (+ to +) and negative to negative (– to –). Reversing polarity can
damage the electrical system.
• Never reverse battery poles.
• Battery terminals should not be coated with improper
grease. Use petroleum jelly or commercially available,
noncorrosive, nonconducting terminal coatings.
• Keep the battery clean and dry.
• Look for any signs of damage.
• Never attempt to place the vehicle in motion, or run
the engine with batteries disconnected.
• When fast charging, remove the battery caps so pressure doesn’t accumulate.
• Never use a fast charger as a booster to start the
engine. This can seriously damage sensitive electronic components such as relays, radio, etc., as well
as the battery charger. Fast charging a battery is dangerous and should only be attempted by a competent
mechanic with the proper equipment.
Slow Battery Charging
• Battery acid that may spill during charging should be
washed off with a solution of warm water and baking
soda to neutralize the acid. If you accidentally get acid
in your eyes or on your skin, immediately rinse with
cold water for several minutes and call a doctor.
– 186 –
• Do not charge a frozen battery; allow it to thaw out
first. And always allow the battery to thaw gradually—
do not apply direct heat. Gas trapped in the ice may
cause an explosion.
NOTE: Follow the instructions that come with
your battery charger. It is not necessary to
remove the battery from the compartment.
1. Make sure the electrolyte level in each cell is between
the “MIN” and “MAX” marks. If the fluid level is below
the “MIN” mark, correct the condition.
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PART 8: MAINTENANCE AND SERVICE
ELECTRICAL
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 cables.
WARNING! Batteries contain acid that can
burn and gasses that can explode. Ignoring
safety procedures can cause you or others to
be badly hurt.
• Never jump start a battery near fire, flames,
or electrical sparks. Batteries generate explosive gases. Keep sparks, flame, and lighted
cigarettes away from batteries.
Jump Starting Batteries
If your battery is discharged (dead), you may be able to
start it by using energy from a good battery in another
vehicle. This is termed “jump starting.” Because of the various battery installations in optional electrical systems,
Peterbilt does not recommend that you attempt to jump
start your vehicle. If you have a battery problem, contact a
Peterbilt Dealer or a reputable towing service. But if you
are unable to do this, and must jump-start your vehicle,
then ensure that you follow the precautions and instructions below.
(08/06)
Y53-6004
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ELECTRICAL
PART 8: MAINTENANCE AND SERVICE
• Do not allow battery fluid to contact eyes,
skin, fabrics, or painted surfaces. Always
wear eye protection. Battery acid that may
spill during charging should be washed off
with a solution of warm water and baking
soda to neutralize the acid. If you accidentally
get acid in your eyes or on your skin, immediately rinse with cold water for several minutes
and call a doctor.
• Be careful that metal tools or any metal in
contact with the positive terminal do not contact the positive battery terminal and any
other metal on the vehicle at the same time.
Remove metal jewelry; avoid leaning over a
battery. If metal jewelry or other metal comes
in contact with electrical circuits, a short circuit may occur causing you to be injured—
plus electrical system failure and damage to
the vehicle.
• Do not try to jump start or charge a frozen
battery. (Even a battery with ice particles on
the electrolyte surface is dangerous.) Allow it
to thaw out first. And always allow battery to
thaw gradually—do not apply direct heat. Gas
trapped in the ice may cause an explosion.
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Y53-6004
• Do not try to jump start a vehicle if the electrolyte level in the battery of either vehicle is
low. Maintain the full level of electrolyte in the
batteries. This reduces the volume of gas in
the cells.
• The voltage of the booster battery must
have a 12–volt rating. And the capacity of the
booster battery should not be lower than that
of the discharged battery. Use of batteries of
different voltage or substantially different
capacity rating may cause an explosion. To
avoid serious personal injury and damage to
the vehicle, heed all warnings and instructions of the jumper cable manufacturer. The
jumper cables must be long enough so that
the vehicles do not touch.
• Applying a higher voltage booster battery
will cause expensive damage to sensitive
electronic components, such as relays, and
the radio. Improper hook–up of jumper cables
or not following these procedures can damage the alternator or cause serious damage to
both vehicles or yourself.
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PART 8: MAINTENANCE AND SERVICE
ELECTRICAL
• 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 after handling.
CAUTION: Departures from these procedures
could also cause serious damage to both vehicles. Improper use of a booster battery to start a
vehicle may cause an explosion.
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 vent caps, remove them and
check the fluid level. If it is OK, replace the caps
before going further. If the level is low, add distilled
water, and replace the caps before proceeding. If no
water is available, remove the caps and cover the filler
openings with a cloth before proceeding. After jump
starting the vehicle, dispose of the cloth.
(08/06)
WARNING! If you do not cover the filler openings on the battery, electrolyte could boil out
of the openings and hurt someone or damage
the vehicle. Replace caps securely if there is
enough fluid in the battery, or cover with a
cloth if no water is available and your fluid is
low.
4. Attach one end of a jumper cable to the dead battery’s
positive terminal. This will have a large red “+” or “P”
on the battery case, post, or clamp. Attach the other
end of the same cable to the positive terminal of the
good battery.
5. Attach the remaining jumper cable FIRST to the negative battery terminal (black “-” or “N”) of the good battery, and then to the chassis or ground of the vehicle
being jump started.
6. Start the engine in the vehicle with the good battery.
Let it run a few minutes. Then start the engine in the
vehicle with the dead battery. If the engine fails to start,
do not continue to crank the starter but contact the nearest Authorized Service Center.
Y53-6004
WARNING! When disconnecting jumper
cables, make sure they do not get caught in
any moving parts in the engine compartment.
– 189 –
FUEL SYSTEM
PART 8: MAINTENANCE AND SERVICE
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
vehicle that was jump-started.
Removing and Installing Batteries
CAUTION: Always reinstall the battery compartment cover (step) before entering the cab. Without the battery cover you could slip and fall,
resulting in possible injury to yourself.
Fuel System
Location of Fuel Shut-off Valves
Fuel shut-off valves for the fuel crossover line are on the
bottom of the secondary fuel tank, at the crossover line
connection. They are optional on the primary fuel tank.
Specification
Use only diesel fuel as recommended by engine manufacturers.
Whenever you have to install a battery or remove one, follow these guidelines for the safety of yourself and the battery.
WARNING! A mixture of gasoline or alcohol
with diesel fuel in the presence of an ignition
source (such as a cigarette) could cause an
explosion. You could be seriously injured.
Use only the recommended diesel fuel.
• Ensure all switches on the vehicle are turned Off.
• Disconnect the ground cable first when removing a
battery.
CAUTION: If anyone ever pours gasoline into
your fuel tank, drain the entire system. Otherwise, the pump and engine will be damaged.
Don’t try to dilute the gasoline by adding diesel
fuel (See Warning above).
• Connect the ground cable last when installing a battery.
Fuel Filters
Please follow these recommendations when you are
changing your fuel filters or strainer elements. Your engine
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PART 8: MAINTENANCE AND SERVICE
STEERING
will run better and last longer if you do. See the engine
manufacturer’s recommendations for proper water and
micron requirements.
• Position the shell and gasket properly. Then tighten
the cover nut or bolt just enough to prevent fuel leakage.
• When removing filters, cover any electrical equipment
and wiring that might get soaked with fuel. Diesel fuel
may permanently damage electrical insulation.
• After starting the engine, check for leaks around the
filter.
• When installing spin-on (throwaway) filters, hand
tighten them only to 1/2 to 2/3 turn after gasket contact. Mechanical tightening of these filters may distort
or crack the filter head.
Steering
Guidelines For Checking A Steering System
WARNING! A steering system that is not working properly can cause an accident. You could
lose control of your vehicle if the steering is
not in good order. For driving safety, give your
steering gear and components the following
visual checks frequently. Check them especially after trips over rough roads.
NOTE: To expel air from density-type strainer elements, soak them in clean fuel before installing
them.
• When replacing a fuel filter element, don’t use a substitute. Install only filter elements designed for fuel filtration. First clean and inspect the shell. Then insert
the new element and fill the container at least 2/3 full
of clean fuel before installing the shell.
• Throw away old gaskets. Replace them with new ones
to ensure a positive seal.
• Check tie-rod for straightness
• Check draglink clamp for looseness or interference
• Check ball joints and steering U-joints for looseness
• Check steering wheel for excessive freeplay. Check
the simplest probable causes first:
– Unequal tire pressures
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STEERING
PART 8: MAINTENANCE AND SERVICE
– Loose cap nuts
U-Bolt Tension for Front and Rear Axles
– Bent tie-rod
It is important that U-bolts remain tight. Off-highway use of
your vehicle will cause them to loosen faster. But all vehicles need to have their U-bolts checked and tightened
regularly. Be sure someone with the proper training and
the right tools checks and tightens the U-bolts on your
Peterbilt. The proper torque requirements are specified in
the Peterbilt Maintenance Manual for your vehicle.
– Loose wheel bearing
If these checks do not reveal 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 alignment. Check tire wear frequently. Uneven tire wear is a
sign that your front end or rear axles may be misaligned.
If you see uneven wear, take your vehicle to a service center familiar with aligning Peterbilt vehicles.
Rear Axle Alignment
Continual road shock and load stresses may force your
rear axles out of alignment. If you detect rapid tire wear on
front or rear axle tires, you may have misaligned axles. If
you suspect you do, have your rear axle alignment
checked and adjusted by an authorized dealership.
– 192 –
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
FASTENERS
WARNING! U-bolts that are too loose can
cause an injury accident. Loose U-bolts can
cause uneven tire wear, poor alignment, and
loss of control of your vehicle. You probably
can’t tighten U-bolts correctly yourself. But be
sure to have them checked and tightened regularly by an authorized mechanic.
• For on-highway vehicles, tighten the Ubolts after the first 15,000 miles (24,000 km).
Then tighten them every 60,000 miles (96,000
km) after that.
• For off-highway vehicles, tighten the Ubolts after the first day or two of operation.
Then tighten them every 15,000 miles (24,000
km) after that.
• Failure to maintain the specified torque values or to replace worn parts can cause component system failure, possibly resulting in
an injury accident. Improperly tightened
(loose) suspension U–bolts can lead to
unsafe vehicle conditions, including: hard
steering, axle misalignment, spring breakage
or abnormal tire wear.
(08/06)
Fasteners
Frame Fastener Torque Specifications
Fastener
Type
Bolt / Locknut /
Hardened Washer
Torque
Fastener
Size
Lb. ft.
N.m.
1/2 Inch
86 - 108
117 - 147
5/8 Inch
130 - 163
176 - 221
M12
65 - 85
89 -115
M16
155 -195
210 - 264
M20
315 - 385
427 - 523
CAUTION: When installing bolts on the frame,
use only metric grade 10.9 bolts of the proper
length.
Standard Capscrew Torque Specifications
SAE Grade
Number
Capscrew
Body Size
(inchesthread)
Y53-6004
5
8
Torque
Torque
Lb. ft.
N.m.
Lb. ft.
N.m.
1/4-20
6-9
8 - 12
9 - 12
12 - 16
1/4-28
7 - 10
9.5 - 14
10 - 14
14 - 19
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FASTENERS
PART 8: MAINTENANCE AND SERVICE
SAE Grade
Number
5
SAE Grade
Number
8
5
8
5/16-18
13 - 18
18 - 24
18 - 25
24 - 34
7/8-14
341 - 486
462 - 659
482 - 589
654 - 799
5/16-24
14 - 20
19 - 27
20 - 28
27 - 38
1 -8
464 - 662
629 - 898
656 - 935
889 - 1268
3/8-16
22 - 32
30 - 43
31 - 44
42 - 60
1-12
508 - 724
689 - 982
718 - 1023
973 - 1386
3/8-24
25 - 40
34 - 54
35 - 50
47 - 68
7/16-14
35 - 50
47 - 68
50 - 71
68 - 96
7/16-20
39 - 56
53 - 76
56 - 80
76 - 108
1/2-13
54 - 77
73 - 104
76 - 109
103 - 149
1/2-20
58 - 87
79 - 118
86 - 123
117 - 167
9/16-12
78 - 111
105 - 151
110 - 158
149 - 214
9/16-18
87 - 124
118 - 168
123 - 176
167 - 239
5/8-11
108 - 154
147 - 209
153 - 218
208 - 296
5/8-18
122 - 174
166 - 236
173 - 247
235 - 335
3/4-10
192 - 273
260 - 370
271 - 386
367 - 523
3/4-16
214 - 305
290 - 414
303 - 431
411 - 583
7/8-9
309 - 441
419 - 598
437 - 624
593 - 846
The torque values in the previous tables are based on the
use of clean and dry threads.
Frame Fasteners
– 194 –
• Go around your vehicle as per the “Preventive Maintenance Schedule” on page 129 and tighten all frame
fasteners with a torque wrench.
• Always use the torque values listed in the frame fastener table.
• Always torque fasteners from the nut end.
For standard capscrews
• Always use the torque values listed in the capscrew
table.
Y53-6004
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PART 8: MAINTENANCE AND SERVICE
ENGINE ACCESSORIES
• Reduce torque by 10% when engine oil is used as a
lubricant.
• Reduce torque by 20% if new plated capscrews are
used.
3. Release the automatic tensioner.
4. Check the belt alignment on each pulley. The belt
must fall between the flanges of each pulley.
Engine Accessories
Accessory Drive Belts
You can extend the reliability and service life of your vehicle's drive belts with proper attention to installation, and
maintenance. Neglect could cause belt failure. The result
could be the loss of the electrical or air system as well as
possible engine damage from overheating. So it's a very
good idea to check your belts frequently and replace them
as soon as you detect trouble.
Follow this procedure to install an accessory drive belt:
1. Route the new belt around the pulleys, and then
rotate the automatic tensioner so that the idler pulley
swings toward the belt routing. Figure 1 shows an
example of the rotation direction to release the tensioner.
2. Slip the belt around the idler pulley attached to the
automatic tensioner.
(08/06)
Fan Clutch / Fan
WARNING! Engine fans engage suddenly
without warning and can badly hurt you. Stay
away from the fan when the engine is running.
Your truck may be equipped with an On/Off or Viscous
Fan Drive. Follow these guidelines to check your engine
fan:
Y53-6004
– 195 –
AIR INTAKE SYSTEM
PART 8: MAINTENANCE AND SERVICE
• 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 working while the engine is warming up.
When the clutch engages, note the reading on the
vehicle's panel-mounted coolant temperature gauge.
If the fan clutch engages at low engine temperature or
cycles on and off more frequently than it should
(receives "false signals"), have the problem corrected
at your dealership.
• Viscous Fan Drives - Check the clutch operation by
starting the engine when it is cold. When the truck is
cold the viscous fan clutch will require more time to
disengage. This time will depend on the engine RPM.
Run the engine above idle and you will audibly notice
the fan turning off. If the fan clutch does not disengage, have the problem corrected at your dealership.
Air Intake System
Engine heat, vibration, and age combine to loosen air
intake connections and cause cracks in the tubing and
– 196 –
elbows. Leaks in the intake system allow abrasive dust to
enter the engine and quickly cause expensive damage.
During your daily walk-around inspection, carefully check
all tubing, elbows, clamps, supports, and fasteners for
condition and tightness.
Under normal operating conditions, we recommend complete disassembly and cleaning of the air intake system
annually.
Under severe operating conditions, such as heavy offhighway use, the disassembly and cleaning should be
more frequent. Replace any defective parts. With the possible exception of mounting brackets, don’t repair defective 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” on page 129. If your
vehicle is equipped with an optional air inlet restriction
indicator, service the filter elements when the air inlet
restriction indicator locks in the extreme Up position.
Paper elements require care and proper handling
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
AIR INTAKE SYSTEM
because they are critical to engine service life. If your
vehicle has an external air cleaner and cab-mounted mirrors, the mirror must be pivoted to provide access for servicing the filter element.
STEPS
1,6
STEPS
2,5,6
1. Loosen (do not remove) upper 5/16 in. mounting
hardware.
2. Remove acorn nut and flat washer, then pivot upper
stabilizer rod away from cab.
3. Loosen the two rearmost M6 hex socket head screws
on the lower clamp.
NOTE: The two forward screws secure the cover
to the base. The two rearmost screws provide the
clamping force on the main support tube.
4. Rotate the main support tube rearward to provide
clearance to remove and replace the air cleaner filter
element.
CAUTION: To prevent possible engine damage,
torque the four hex nuts attaching the air cleaner
cover assembly to the body assembly to 8 Lb. ft.
(10 N.m.) after installing the new air cleaner filter
element.
STEPS
(08/06)
3-7
5. After installation of the new filter element, rotate the
main support tube forward and reinstall the upper stabilizer rod to its mounting bracket.
6. In any sequence, tighten the upper fasteners to a
torque of 13 - 17 Lb. ft. (17 - 23 N.m.)
7. Tighten the two rearmost screws in the lower clamp to
a torque of 4 - 4.5 Lb. ft. (5 - 6 N.m.)
Y53-6004
– 197 –
EXHAUST SYSTEM
PART 8: MAINTENANCE AND SERVICE
Turbocharger
When servicing the air intake and exhaust systems on a
turbocharged engine, check the items that follow. If you
detect any deficiencies, take the vehicle to an authorized
dealer for servicing. Delay could lead to severe and
expensive damage to your vehicle.
WARNING! Do not operate engine with turbocharger intake piping disconnected. Working
around a turbocharger with the intake piping
removed can be dangerous. A suction is created when the engine is running. This suction
could draw your hand or anything else near it
into the impeller fan. You could be seriously
injured. Always keep the intake piping connected when you will be running the engine.
• Lubricating System: Check the oil lines, housing, and
connections. Look for leaks, damage, or deterioration.
Leaks could mean you have damaged oil lines or oil
seals.
• Manifold: With the engine operating, check for leaking
manifold or flange gaskets.
– 198 –
• High Frequency Vibration: Vibration may indicate
turbo rotor imbalance. Have your dealer investigate
this immediately.
Exhaust System
Details of inspection and maintenance of your exhaust
system are covered under “Noise Control System” on
page 209.
Anti-lock Braking System (ABS)
For details of use and maintenance of your anti-lock system, see the anti-lock braking system service literature
that came with your truck.
Below are some general notes on repairing your anti-lock
braking system:
• The foundation brake system must be in proper working order to ensure the best ABS performance.
• Before welding anywhere on the vehicle, detach the
ABS ECU connector and all other electronic control
units.
• Never detach the ECU connector with the ignition
turned on.
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
ANTI-LOCK BRAKING SYSTEM (ABS)
• Do not attempt to repair ABS/ASR/ATC electrical
cables that are outside the vehicle. Replace faulty
cables as an assembly.
• When servicing brakes, hubs, or axle, recoat the ABS
sensors with anti-seize compound. Make sure the
sensor is pushed against the pulse wheel after the
hub is reinstalled. On rear axles, the sensor should be
pushed fully into the mounting block before reinstalling the hub.
• Check ABS wiring harnesses and piping periodically
for chafing or other problems. No regular maintenance is required on the ABS components.
• During wheel balancing, dyno testing, or any time the
ignition is on with part of the ABS disconnected, a failure 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 responds
instantly by signaling the solenoids in the modulator which
activate the air valves, reducing application pressure as
needed to prevent the wheels from locking up. If this over-
(08/06)
riding correction is effective, application pressure is
allowed to build up to the original input.
Any malfunction of the anti-lock system on one or more
axles will cause the system to fail-safe, and the panelmounted amber warning light will come on, indicating both
a malfunction, and automatic shut-down of the system. If
the air system is intact (indicated by the pressure
gauges), the service brakes will continue to function normally, but without benefit of the anti-lock feature.
WARNING! Although the brakes will continue to
operate with a malfunction in either circuit, the
vehicle should not be operated until the system
is repaired, and both braking circuits, including
all pneumatic and mechanical components, are
working properly.
CAUTION: Do not attempt to recycle the antilock system until the vehicle has been brought
to a full stop.
If one wheel on any driven axle continues to slip or spin for
approximately 4 seconds, this will cause the anti-lock controller for that axle to go into the fail-safe mode, and the
warning light will give a shutdown signal. In this case, the
anti-lock system can be turned back on, and the warning
Y53-6004
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CAB HEATER-AIR CONDITIONER
PART 8: MAINTENANCE AND SERVICE
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.
NOTES:Keep the engine exhaust system and the
vehicle’s cab/sleeper ventilation system properly
maintained. It is recommended that the vehicle’s
exhaust system and cab/sleeper be inspected:
Cab Heater-Air Conditioner
• whenever a change is noticed in the sound of
the exhaust system
• by a competent technician every 15,000 miles
The combination heater-air conditioner provides comfort
for those in the cab through accurate control of the cab
environment in all weather conditions. Regular attention
will help you keep your unit running well.
• whenever the exhaust system, underbody, cab
or sleeper is damaged
• Allow for the proper operation of the vehicle
ventilation system:
• Keep the inlet grille at the base of the windshield clear of snow, ice, leaves, and other
obstructions at all times.
• Keep the exhaust pipe area clear to help
reduce the buildup of exhaust gases under the
vehicle.
Perform the following checks every 3 months or 30,000
miles / 48,000 km, whichever occurs first:
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Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
CAB HEATER-AIR CONDITIONER
Heater
Air Conditioner
• Check all heater controls for full-range operation.
WARNING! The air conditioning system is
under pressure. If not handled properly, it
could explode, causing injury to you and your
vehicle. Any servicing that requires depressurizing and recharging the air conditioning
system must be conducted by a qualified
technician with the right facilities to do the
job.
• Check hoses, connections, and heater core for condition and leaks.
• Check the drain pan of the fresh air vent for trapped
water before assuming that there is a leak in the heating system.
• If the heater core is leaking, take the vehicle to a
Peterbilt dealer for proper heater service 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.
(08/06)
NOTE: Engines equipped with poly-vee belts are
equipped with tensioners. No belt adjustments
can be made. Replace a poly-vee belt when the
indicator on the tensioner is no longer within the
recommended (green) range.
• Check the compressor belt for condition and proper
tension. Adjust 105 - 125 pounds.
• Check the compressor and drive clutch for noise and
vibration. If you find problems, have the system
checked thoroughly. A malfunctioning clutch usually
indicates trouble elsewhere in the system.
Y53-6004
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CAB HEATER-AIR CONDITIONER
PART 8: MAINTENANCE AND SERVICE
• Check the evaporator core and condenser core for
debris restricting air flow. Clean if necessary. Small
particles may be removed with compressed air blown
through the core in the opposite direction of normal air
flow.
• Have the air conditioning system fully inspected annually by your dealer.
Special Precautions
WARNING! Small particles blown by compressed air could injure your eyes. Wear eye
protection any time you blow compressed air.
• Check all hoses for kinks, deterioration, chafing, and
leaks. Adjust kinked or chafing hoses to eliminate
restrictions and prevent further wear.
• On tilt-cab vehicles, verify that hoses are routed
around the pivot point so that lifting the cab does not
strain them.
• Check all components and connections for refrigerant
leaks. If you discover a leak, don’t try to tighten a connection. Tightening a connection may cause a worse
leak. Have a qualified technician correct the problem.
NOTE: A leaking evaporator or condenser core
cannot be repaired; it must be replaced.
– 202 –
Y53-6004
WARNING! Excessive heat may cause your air
conditioning system to explode. Never weld,
solder, steam clean, or use a blow torch near
any part of the air conditioning system. If a
refrigerant leak develops in the presence of
excessive heat or an open flame, hazardous
gases may be generated. These gases may
cause unconsciousness or death. If the system is leaking refrigerant:
• Stay away from the hot engine until the
exhaust manifold has cooled.
• Don’t permit any open flame in the area.
Even a match or a cigarette lighter may generate a hazardous quantity of phosgene gas.
• Don’t smoke in the area. Inhaling gaseous
refrigerant through a cigarette may cause violent illness.
(08/06)
PART 8: MAINTENANCE AND SERVICE
APPEARANCE
Appearance
before waxing. Don’t wax in the hot sun. Don’t friction burn
the paint with a buffing machine.
Painted Surfaces
Aluminum and Chrome Surfaces
CAUTION: Do not aim the water jet directly at
door locks or hatch. Tape the key holes to prevent water from seeping into the lock cylinders.
Water in lock cylinders should be removed with
compressed air. To prevent locks from freezing
in the winter, squirt glycerin or lock deicer into
the lock cylinders.
Wash frequently to remove grime and caustic deposits
that may stain the finish. Apply cool or lukewarm water.
You may want to use a mild soap. Avoid washing your
vehicle in bright sunlight.
WARNING! Handle cleaning agents carefully.
Cleaning agents may be poisonous. Keep
them out of the reach of children.
Road tar may be removed 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 finish to
cure, wait about ninety days after the date of manufacture
(08/06)
• Clean aluminum wheels and bumpers with warm
water.
• Tar remover will get rid of heavy deposits of road
grime.
• To prevent spotting, wipe aluminum surfaces dry after
washing.
• Under corrosive conditions, such as driving on salted
roads, clean aluminum parts with steam or high pressure water from a hose. A mild soap solution will help.
Rinse thoroughly.
• Chrome surfaces are best cleaned with fresh water.
Wipe dry to preserve their luster. A commercial
chrome cleaner will remove light rust. After cleaning,
wax flat surfaces and apply a thin coat of rust preventive lubricant around bolts or other fasteners.
Y53-6004
– 203 –
APPEARANCE
PART 8: MAINTENANCE AND SERVICE
Stainless Steel
Follow this procedure to clean and restore the finish of
stainless steel components:
cedures will ensure that interior components remain in
good condition for the life of the vehicle.
General Cleaning Guidelines
1. In a plastic pail mix 4 tsp of alum (a powder found in
grocery stores or drugstores), with 32 oz. of water
(warm water will dissolve alum faster, but cool will
work).
2. Apply the alum/water solution with a pad of steel wool
(0000 grade or finer). GENTLY wipe the component
lengthwise; no pressure is necessary.
3. It is the chemical reaction between the carbon steel of
the wool and the alum solution that cleans the stainless,
not the scrubbing or abrasive action of application.
4. You may also use any stainless cleaner recommended for cleaning boat parts.
Interior
Cleaning Cab Interiors
Peterbilt cab and sleeper interiors are built using a variety
of different materials including fabrics, carpet, polyurethane, and painted plastic surfaces. These cleaning pro-
– 204 –
Y53-6004
WARNING!
•Cleaning agents may contain hazardous
agents. Thoroughly read, understand and follow the manufacturer’s instructions when
using a cleaning agent to avoid possible personal injury and property damage.
• Handle cleaning agents carefully. Keep
them out of the reach of children. Commercial
cleaning agents may be poisonous.
CAUTION: To avoid possible property damage
• Do not spray any kind of liquid directly at
instruments or controls. Apply cleaner to a
rag first and then clean instruments and
gauges. Excess fluid may damage the use
and function of instruments and gauges.
(08/06)
PART 8: MAINTENANCE AND SERVICE
APPEARANCE
• Always test a commercial cleaning agent on
an inconspicuous area of the surface to be
cleaned before using it.
• Never clean interior components
chemicals or solvents such as
– Gasoline
– Naphtha
– Acetone
– Turpentine
– Benzene
– Carbon Tetrachloride
– Lacquer Thinner
– Nail Polish Remover
– Ammonia-based Products
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 detergents.
with
• Use a clean, lint-free cloth.
• Clean with the cloth dampened with a mild soap-andwater solution.
• Remove soap with a clean, damp rag.
• Clean difficult stains such as oil, grease,
and mustard as soon as possible. The longer
a stain goes untreated, the more difficult it is
to remove.
• Avoid application of conditioning products
containing silicones or waxes to the top surface of the dash panel. This may cause glare
that can be a driver distraction.
• For difficult stains on painted plastic surfaces, such as
the dash shell, use Dupont™ Sontara® cleaner, part
number PS-3909S. The product is available from
Dupont as a presaturated wipe.
Carpet
CAUTION: Do not apply water directly to carpet.
Excess water may damage the carpet. Keep
carpet as dry as possible.
• Use a clean, lint-free cloth or clean, soft-fiber brush.
• Clean with the cloth or brush dampened with a mild
soap-and-water solution.
(08/06)
Y53-6004
– 205 –
APPEARANCE
PART 8: MAINTENANCE AND SERVICE
• Remove soap with a clean, damp rag.
• Clean with the cloth dampened with lukewarm water.
• If a stronger cleaning solution is required, use a foamtype carpet shampoo.
• Dry with a clean cloth.
• For difficult stains, use a commercial leather cleaner.
Weatherstripping
Vinyl and Fabric Upholstery
CAUTION: To avoid possible damage to the
upholstery, do not use chemical solvents or
strong detergents on these components.
• Use a clean, lint-free cloth.
• Clean with the cloth dampened with a mild soap-andwater solution.
• Remove soap with a clean, damp rag.
• For difficult stains, use a commercial fabric or vinyl
cleaner.
Leather Upholstery
CAUTION: To avoid possible damage to the
upholstery, do not use oils, varnishes, solvents,
abrasive cleaners or shoe polish on these components.
Occasionally spray weatherstripping on doors and windows 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 grime from the entire chassis. Then if an oil
leak develops, you will be able to detect it easier.
Passenger Door Lower View Window
There may be occasions when the inner view window
must be removed for maintenance cleaning and/or damage. Follow this procedure when installing and removing
an inner view window. The recommended tool for removal
of the glass is a glass stick, although other tools may be
used provided proper caution is observed.
• Use a clean, lint-free cloth.
– 206 –
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
APPEARANCE
CAUTION: The use of screw drivers, gasket
tools, knives or other similar instruments may
damage the seal or break the glass. Use a glass
stick as a tool whenever possible when removing
or installing a window. If another tool must be
used, exercise extreme care when performing
this procedure with such a tool.
OUTBOARD
* / $ 66
5 ,' * (
,1 %2 $ 5 '
: ( ( 3 6/ 2 7
,1 1 ( 5 3 $ 1 ( /
NOTES:
• Always make sure that a gasket is installed
properly so the weep slots will be indexed correctly. The notch in the gasket is to face forward
on the RH side. This places the weep slots at the
bottom of the window opening (see next illustration).
1. To install a window, slide the glass from the rear of the
door toward the removal slot until the forward edge of
the glass is against the inside edge of the seal (see
next illustration; arrow indicates forward).
• There is a ridge on the bottom surface of the
gasket (see next illustration). Install the glass outboard of this ridge. The polished satin finish on
the glass, which leaves a rounded edge, rests
against the edge of the ridge.
Removal
Slot
• The installation and removal will be easier by
using water or soap as a lubricant on the edge of
the glass.
(08/06)
Y53-6004
– 207 –
APPEARANCE
PART 8: MAINTENANCE AND SERVICE
2. When the forward edge of the glass reaches the forward inside edge of the seal, the glass should pivot
outboard into the remaining seal (see arrow in next
illustration).
3. Press and slide the glass into the aft portion of the
seal to seat it.
4. To remove an inner view window, insert the glass stick
into the removal slot, then use the glass stick to push
the glass as far aft as possible.
5. Use the glass stick to leverage the glass out of the
seal.
– 208 –
6. Continue this process along the entire front edge of
the seal until the glass is free.
Storing and Reintroducing Vehicles Into
Service
To help maintain a vehicle in storage as well as ease its
reintroduction into service, perform the following actions
at least monthly:
• Wash and protect painted and metal surfaces, and
also weatherstripping, as outlined in the preceding
“Appearance” information.
• Operate the vehicle to circulate fluids and lubricants
that have settled to the lowest part of a component.
This will provide protection against corrosion on gears
and bearings and keep seals resilient.
Before starting the engine, do the following:
– Check the engine oil level and fill as required.
– Check and maintain batteries as outlined on page
184.
– Drain any condensation from the fuel/water separator, if so equipped.
– Start the engine and bring to normal operating
temperature:
– Operate the air conditioning system at least 10
minutes.
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
NOISE CONTROL SYSTEM
– Drive the vehicle a short distance to allow lubricants to circulate in the transmission and axles.
Noise Control System
Noise Emission Warranty
Peterbilt Motors Company warrants to the first person who
purchases this vehicle for purposes other than resale and
to each subsequent purchaser that this vehicle, as manufactured by Peterbilt Motors Company, was designed, built
and equipped to conform at the time it left Peterbilt’s control with all applicable U.S. EPA Noise Control Regulations.
This warranty covers this vehicle as designed, built and
equipped by Peterbilt, and is not limited to any particular
part, component or system of the vehicle manufactured by
Peterbilt. Defects in design, assembly or in any part, component or system of the vehicle as manufactured by Peterbilt, which at the time it left Peterbilt’s control caused noise
emissions to exceed Federal standards, are covered by
this warranty for the life of the vehicle.
Tampering with Noise Control System
Prohibited
Federal law prohibits the following acts or the causing
thereof:
(1) The removal or rendering inoperative by any person
other than for maintenance, repair, or replacement, of any
device or element of design incorporated into any new
vehicle for the purpose of noise control prior to its sale or
delivery to the ultimate purchaser or while it is in use, or
(2) the operation of the vehicle after such device or element of design has been removed or rendered inoperative
by any person.
Among those acts presumed to constitute tampering are
• Noise Insulating Blankets
Removing noise insulators from engine block or from
around the oil pan.
Cutting holes in, or cutting away part of, noise insulators.
Removing hood-mounted noise insulation.
• Engine Electronic Control Unit (ECU)
(08/06)
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NOISE CONTROL SYSTEM
PART 8: MAINTENANCE AND SERVICE
Removing air signal attenuator on engines equipped
with this device.
Modifying ECU parameters.
• Engine Cooling System
Inspection & Maintenance Instructions for
Noise Control System
Removing or rendering inoperative the fan clutch.
Removing the fan shroud.
• Air Intake System
Removing or rendering inoperative the air cleaner /
silencers or intake piping.
• Exhaust System
Removing or rendering inoperative the exhaust system components.
• Inner Fender Shields and Cab Skirts
Removing shields or skirts.
The following instructions are based on regular inspection
of the noise control system. If, during regular inspection or
maintenance of other systems or components, you find
something wrong with parts of the noise control system,
inspect those parts more frequently to be sure they are
performing up to specification. At the end of this section
you will find the Maintenance Log. This is a schedule of
inspection and maintenance intervals for each component.
Exhaust System
Cutting away parts of shields, skirts or damaged or
loose portions of shields or skirts.
NOTE: Vehicles with engines built to meet 2007
EPA Emission Requirements also have a Diesel
Par ticulate Filter (DPF). Use only an exact
replacement DPF in exhaust systems. Using a
noncompliant DPF as a replacement could violate
these standards and also void the emission system’s warranty.
• Fuel System
Removing or rendering engine speed governor inoperative, allowing engine speed to exceed manufacturer’s specifications.
Turbo/Emission Control Components
– 210 –
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
NOISE CONTROL SYSTEM
NOTE: Use only an exact replacement DPF in
exhaust systems. Using a noncompliant DPF as a
replacement could violate these standards and
also void the emission system’s warranty.
The vehicle may have emission control components to
meet 2007 EPA requirements. Refer to the engine manufacturer’s service manual for the maintenance of these
components.
Check the DPF for looseness. Tighten loose mounting
bolts as necessary.
Joints and Clamps
Check for leaks, and tighten as necessary. Check for
deterioration or dents in pipes and clamps which
could allow exhaust to escape.
NOTE: The EPA requires 2007 compliant vehicles
to have a leak free exhaust system. Replace
components as necessary to ensure EPA compliance.
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
Piping
WARNING! The engine fan can engage at any
time without warning. Anyone near the fan
when it turns on could be badly injured.
Before turning on the ignition, be sure that no
one is near the fan. Do not work on the fan
with the engine running.
Check for rust, corrosion, and damage. Replace any
piping if it is perforated at any point. Temporary patching or lagging is not acceptable
NOTE: The EPA requires 2007 compliant vehicles
to have a leak free exhaust system. Replace
exhaust piping as necessary to ensure EPA compliance.
Diesel Particulate Filter (DPF)
(08/06)
Check all fasteners for tightness. Check for stress cracks
in the shroud. Make sure the shroud is adjusted so that it
does not touch the fan blades.
Y53-6004
– 211 –
NOISE CONTROL SYSTEM
PART 8: MAINTENANCE AND SERVICE
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 damaged fiberglass
fender shields with fiberglass and resin.
Engine Mounted Noise Insulators
Fasteners
Check for condition and security. How you do this will
depend on the method of attaching the noise insulators on the engine and around the oil pan (bolts, snap
fasteners, or straps). Tighten loose fasteners; repair
or replace any worn or damaged fasteners.
If you find damage at a fastening point, you can gain
additional strength by installing a suitable reinforcing
plate. This plate should be drilled to accept a rivet and
laminated to the shield with fiberglass and resin.
Insulators
Check insulators around fasteners and stress points,
especially where they may be affected by engine
vibration. Repair any cracked or damaged mounting
points. Use suitable reinforcing plates to ensure that
the insulators will remain in position.
Inner Fender Shields and Cab Skirts
Check all fasteners for security, especially the self-tapping hex head screws. Remove and replace any loose
rivets.
– 212 –
Your authorized dealership can perform all of these
checks and repairs or replacements.
Air Intake System
Fasteners
Shields and Skirts
Check cab skirts, sills, and brackets for overall condition and repair them as necessary. Damaged rubber
fender shields or cab skirting cannot be repaired. You
will need to replace it.
Do all checks and maintenance chores listed in this manual under Engine Air Intake System and Air Cleaner (See
Index).
Check the induction tubing, elbow connections, clamps,
brackets, and fasteners for deterioration, cracks, and
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
NOISE CONTROL SYSTEM
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.
(08/06)
Y53-6004
– 213 –
NOISE CONTROL SYSTEM
PART 8: MAINTENANCE AND SERVICE
NOISE CONTROL SYSTEM MAINTENANCE LOG
COMPONENT
RECOMMENDED
INTERVAL
(MILES)
DATE &
R.O. NUMBER
REPAIR
FACILITY &
LOCATION
WORK PERFORMED
DATE &
R.O. NUMBER
REPAIR
FACILITY &
LOCATION
WORK PERFORMED
EXHAUST SYSTEMROUTING
25,000
INTEGRITY
MUFFLER
INTERNAL
250,000
BAFFLES
SHUTTERS
SHROUDS
25,000
ENGINE-MOUNTED
HOSE INSULATORS 10,000
FASTENERS
INNER
FENDER SHIELDS
50,000
CAB SKIRT
FASTENERS
50,000
AIR INTAKE
SYSTEM INTEGRITY 5,000
ELEMENT
CLUTCH-TYPE
FAN DRIVE
– 214 –
10,000
Y53-6004
(08/06)
PART 8: MAINTENANCE AND SERVICE
(08/06)
NOISE CONTROL SYSTEM
Y53-6004
– 215 –
PART 9: VEHICLE IDENTIFICATION NUMBERS
PART 9: VEHICLE IDENTIFICATION NUMBERS
Each vehicle completed by Peterbilt Motors Company
uses a Vehicle Identification Number (VIN) that contains
the model year designation of your Peterbilt. The practice
is in compliance with 49 CFR 565, Code of Federal Regulations.
The Vehicle Identification Number is on the brass Peterbilt
name plate and also on the foil labels on the left hand door
post. The VIN contains 17 digits. The 10th digit is the code
for the model year of your vehicle. The example VIN below
from a 1999 model shows how this code works:
EXAMPLE VIN: 1XP 9D2X9 6 X D 345678
Model Year
Serial Number
Plant Code
X = 1999
Y = 2000
D = Denton Factory
1 = 2001
2 = 2002
N = Nashville Factory
3 = 2003
4 = 2004
5 = 2005
6 = 2006
7 = 2007
8 = 2008
9 = 2009
02954
(08/06)
0 (zero) = Glider Kit
Y53-6004
– 215 –
FEDERAL SAFETY STANDARD CERTIFICATION LABEL
PART 10: CONSUMER INFORMATION
PART 10: CONSUMER INFORMATION
Federal Safety Standard Certification
Label
When you order, it is IMPORTANT than you have the following information ready:
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 date of manufacture and other pertinent information, is located on the left hand cab door post.
• 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
02955
How To Order Parts
When you need replacement parts for your Peterbilt vehicles, contact your nearest authorized Peterbilt dealer, who
may be located from the “Peterbilt Authorized U.S. and
Canadian Dealers” listing (Cat. No. 5212).
– 216 –
The National Highway Traffic Safety Administration
requires that the following information be included in the
owner’s manual of motor vehicles manufactured after
September 1, 1990:
If you believe that your vehicle has a defect which could
cause a crash or could cause injury or death, you should
immediately inform the National Highway Traffic Safety
Y53-6004
(08/06)
PART 10: CONSUMER INFORMATION
ENVIRONMENTAL PROTECTION
Administration (NHTSA) in addition to notifying Peterbilt
Motors Company.
For additional road safety information, please visit the
Road Safety website at
If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of
vehicles, it may order a recall and remedy campaign. However, NHTSA cannot get involved in individual problems
between you, your dealer, and Peterbilt Motors Company.
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 California to
cause cancer, birth defects or other reproductive harm. This warning requirement is mandated by California law (Proposition 65) and
does not result from any change in the manner
in which Peterbilt trucks are manufactured.
To contact NHTSA, you may either call the Auto Safety
Hotline toll-free at 1-800-424-9393 (366-0123 in Washington, D.C.) or write to: Administrator, NHTSA, 400 Seventh
Street, S.W., Washington, D.C. 20590. You can also get
other information about auto safety from the Hotline.
Canadian Consumer Information
Canadian customers who wish to report a safety-related
defect to Transport Canada, Defect Investigations and
Recalls, may telephone the toll free hotline 1-800-3330510, or contact Transport Canada by mail at
Transport Canada, ASFAD
Place de Ville Tower C
330 Sparks Street
Ottawa ON K1A 0N5.
(08/06)
Some of the ingredients in engine oil, hydraulic oil, transmission and axle oil, engine coolant, diesel fuel, air conditioning refrigerant (R12, R134a, and PAG oil), batteries,
etc., may contaminate the environment if spilled or not disposed of properly. Contact your local government agency
for information concerning proper disposal.
Y53-6004
– 217 –
STATE OF CALIFORNIA
PART 10: CONSUMER INFORMATION
State of California
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 accident, the device(s) may have the
ability to record vehicle data that occurred just prior to
and/or during the accident.
For additional information on your rights associated with
the use of this data, contact
the California Department of Motor Vehicles - Licensing
Operations Division
or
http://www.dmv.ca.gov/pubs/vctop/d03_6/vc9951.htm
– 218 –
Y53-6004
(08/06)
A
Anti-lock brakes 104
Appearance 203
Appliances in the Cab 71
B
Battery
compartment cover 190
electrolyte 185
recharging 185
slow battery charging 186
Belts, seat 73
Brake
operation 103
Brake system
Electronic Stability Control 106
truck & tractor 104
C
Cap Nut Torque Specifications 176
Cleaning the vehicle 203
Consumer Information 216
Controls
Air Horn 48
Air Suspension Deflate Switch (Dump Valve) 53
Brakesaver 59
Cruise Control Switch 55
Dome Light Switch 53
Electric Horn 48
Engine Fan Switch 54
(08/06)
Fifth Wheel Lock (Slider Adjustment) Switch 62
Fog Lights Switch 53
Hazard Flasher 50
Headlamps 51
Heater-Air Conditioning Controls 64
ID and Clearance Lights Switch 52
Interaxle Differential Lock Switch 61
Jacobs Engine Brake or Cummins "C" Brake Switch 60
Mirror Heat Switch 57
Panel Light Dimmer 52
Parking Brake Valve and Trailer Air Supply Valve 63
Power Door Lock Switch 58
Power Mirror Switch 55
Power Window Switch 58
Tilt- Telescoping Steering Column 49
Trailer Brake Hand Valve 48
Turn Signal and Indicator Lights 45
Two-Speed Rear Axle (Range) Switch 62
VARASHIELD® Wind Deflector Switch 63
Windshield Wipers and Washers 46
Cooling system
coolant level 183
extended life coolant 181
temperature 38
topping up 182
D
Dash 13–15
Defogging/defrosting system 68
Y53-6004
– 219 –
Door lock 58
Driver’s Checklist 84
Driving
vehicle inspection 84
E
Economical driving 126
Electrical system
batteries 184
battery charging 184
jump starting 189
Electrolyte 185
Engine
overspeed 127
winterfronts 91
Engine Warmup 90
Environmental Protection 217
Exhaust fumes 130
F
Federal motor vehicle safety standards 4
Federal Safety Standard Certification Label 216
Frame Fastener Torque Specifications 193
G
Gauges and Displays 34
Air Application Gauge 43
Air Filter Restriction Indicator or Gauge 41
Drive Axle Temperature Gauge 44
Dual Air Pressure Gauge (Air Reservoir) 42
Engine Oil Pressure Gauge 37
– 220 –
Fuel Gauge 39
Manifold Pressure Gauge 42
Pyrometer 45
Speedometer / Odometer 28, 34
Tachometer 35
Transmission Temperature Gauge 43
Voltmeter 39
Warning Lights and Buzzers 16
Water Temperature Gauge 37
Glove Compartment 69
GVWR - gross vehicle weight rating 177
H
High beam 45
Hood Tilting 11
J
Jumper cables 188
K
Keyless Entry 7
Keys 6
Keys and Locks
Ignition Switch 50
L
Lowrance Navigation System 71
Lubrication
Axle 159–160
coasting 127
Steering Gear 162
Y53-6004
(08/06)
Transmission 156–159
types and brands 153
Universal Joint 163
Wheel Bearing 161
Lubrication Index 154
Luggage Compartment(s) 70
M
Maintenance Schedule 129
Mirrors 70
N
Noise Control System 209
P
Parking brake 113
R
Remote Keyless Entry 7
Restraint Systems 73
Inspection 80
Komfort-Lok® Feature 76
Shoulder Belt 74
Sleeper Bunk Restraints 78
Tether Belts 79
S
Safe vehicle operation 84
Safety stands 130
Seat 73
Servicing Specific Systems 164
Air Intake System 196
(08/06)
Air System 178
Anti-lock Braking System (ABS) 198
Brake Adjustment 164
Cab Heater-Air Conditioner 200
Electrical 184
Engine Accessories 195
Engine Cooling System 181
Fasteners 193
Steering System 191
Tires, Wheels, And Rims 168
Transmission And Drive Train 180
Shifting gears 127, 128
Standard Capscrew Torque Specifications 193
Starting and Operating 88
Anti-Lock Braking System 103
Automatic And Automated Transmissions 99
Auxiliary Transmission 100
Bobtail Brake Proportioning System 111
Brake Safety and Emergency 112
Clutch Operation 93
Driving Bobtail or with an Unloaded Trailer 120
Driving With Deflated Air Springs 125
Dual Range (Two Speed) Axles 97
Idling the Engine 92
Interaxle Differential 95
Overheated Brakes 112
Parking Brakes and Their Use 113
Retarders 100, 119
Y53-6004
– 221 –
Setting Ride Height 122
Shifting The Transmission 93
Spring Brakes 115
Starting Procedure
Cold Temperature 89
Normal Temperature 88
Stopping The Engine 120
Trailer Air Supply Valve 115
T
V
Vehicle
driving 84
Vehicle Identification Number 215
Vehicle inspections 84
Vehicle weight rating 177
W
Tachometer 127
Towing 100
Transmission lubrication 156
Warning Light Symbols table 19
Wheels and tires
replacement 175
Windshield washer reservoir 47
U
Numerics
Units of Measure 33
49 CFR 565, Code of Federal Regulations 215
– 222 –
Y53-6004
(08/06)

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