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Peterbilt Medium Duty Truck Owner`s Manual

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1. Warning Light Indicator Symbols Warning Light Indicator Symbols Symbol Name Symbol Color Std Opt Page Symbol Name Symbol Color Std Opt Page 28 Power Take off PTO 51 37 Transmission Oil Filter i Green e 29 Yellow e 30 labs Iz aid cd E PTO PUMP Grae e 29 38 Transmission Oil Temper MODE ature High Yellow e 31 30 Refrigerator es Green e 29 39 Turn Signal Left lt a Green e 31 31 Seat Belt Fasten A Red e 30 40 Turn Signal Right gt Green e 31 32 Suspension Dump I PU Yellow e 30 41 Voltage 31 Orange e 33 Tire Inflation Y Yellow e 30 Warni TNT 34 Transmission Auxiliary arning Light Indicator Symbol Descriptions e Yellow e 30 1 Active Warnings Exclamation Point 35 Transmission Check Q Red e 30 Illuminates when a red warning is active Use the MCS knob to view the warnings that are 36 Transmission Range fer h r ina Fiaur Inhibit RANGE Red e 30 active Refer to the preceeding Figure Warning Light Indicator Symbols on page 22 for warning color classification 24 Y53 6027 Medium Duty R05 09 CONTROLS AND DISPLAYS Medium Duty R05 09 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 sym bol 3 Active Warnings Triangle Illuminates when an yellow warning is active Use the M
2. 1 1 2 in hex Medium Duty R05 09 Y53 6027 D Tires and Wheels Tire Replacement Front replace front tires when less than 4 32 in of tread depth remains Check depth at three places equally spaced around the tire Drive Axles or Trailers replace tires on drive axles when less than 2 32 in of tread depth remains in any major groove Check depth at three places equally spaced around the tire WARNING Do not install regrooved or reinforce N ment repaired tires on steering axles They could fail unexpectedly and cause you to lose control of your vehicle resulting in an accident causing death or personal injury tires with load ratings less than the original tires Doing so could lead to unintentional over loading of the tire which could cause a failure resulting in loss of vehicle control and an acci dent causing death or personal injury f WARNING Do not replace original equipment 214 Y53 6027 Preventive Maintenance NOTE To prolong the tires life and make them safer have their radial and lateral run out checked at your Peterbilt Dealer And of course have the tires balanced any time you change a tire 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 the axle lubricant to get too hot Matched tires will help the driveline last longer and will give you bette
3. 25 000 Rear Axle Check Fluid Level 10 000 15 000 Rear Axle Drain Flush Refill 500 000 Synthetic Lube Y53 6027 Medium Duty R05 09 Preventive Maintenance Table 1 Recommended Maintenance Intervals Maintenance Schedule and Lubrication ITEM Rear Wheel Bearings Rear Brake Camshafts INTERVAL 100 000 10 000 15 000 COMMENTS With LMS Wheel End Package Synthetic Grease With Special Fittings Fifth Wheel 10 000 15 000 40 to 60K For Adjustment Spring Pins 10 000 15 000 With Rubber Bushed Pins No Service Front amp Rear Slack Adjusters 10 000 15 000 Synthetic Grease With Special Fittings King Pins 10 000 15 000 Front Wheel Bearings 100 000 Eaton LMS Accelerator Linkage None Engine Lubricating Oil Check Fluid Level Change Oil Daily Trip Check 10 000 15 000 Must Meet Engine Company Specifications Spring Shackle Pins 10 000 15 000 No Service With Rubber Bushed Spring Pins Clutch Linkage 10 000 15 000 Clutch Release Bearing 10 000 15 000 Extended Grease Fittings Clutch Cross Shaft 10 000 15 000 Extended Grease Fittings Door Weatherstrip As Required Lock Cylinders As Required Door Hinges As Required Teflon Bushing Door Latches and Striker Plate As Required Driveshaft U Joints 10 000 15 000 SPL Driveline Up To 100 000 Miles Slip Joi
4. Wet or Overheated Brakes Wet Brakes If you have been driving in heavy rain or deep stand ing water your brakes will get wet Water in the brakes can cause them to be weak to apply unevenly or to grab These conditions can cause a lack of braking power wheel lockups or pulling of the vehicle to one side or the other Avoid driving through deep puddles or flowing water if possible If not possible you should to the following Slow down Place transmission in lower gear Gently press on the brake pedal Increase engine speed while keeping light pressure on the brake pedal for a short distance to dry out the brake linings Overheated Brakes Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE While traveling down steep hills gravity will tend to speed you up You must go slow enough that your brakes can hold you back without getting too hot If you ride the brake pedal and the brakes get too hot they may fade causing you to press even harder in an attempt to maintain your desired stopping power The brakes may even fade so much that you won t be able to slow down or stop at all Using lower transmission gears will help keep the vehicle from going too fast Using lower gears allows engine compression and friction to help slow the vehi cle Be sure to be in the right gear before you start down a hill especially if you have a manual transmis sion You could get hung up in NEUTRAL and lose the benefit
5. Y53 6027 Introduction CAUTION Hydraulic brake fluid may damage A painted surfaces of the vehicle Incomplete or improper servicing may cause problems in the operation of the vehicle If in doubt about any servicing have it done by your Authorized Service Center Improper mainte nance during the warranty period may also affect the war ranty coverage Modifying your vehicle can make it unsafe Some modifica tions can affect your vehicle s electrical system stability or other important functions Before modifying your vehicle check with your Peterbilt Dealer to make sure it can be done safely and correctly Environmental Protection and Material Hazards Some of the ingredients in engine oil hydraulic oil transmis sion and axle oil engine coolant diesel fuel air conditioning refrigerant R 134a and PAG oil batteries etc may con taminate the environment if spilled or not disposed of prop 151 Introduction erly Non compliance with environmental regulations can result in fines and or jail terms Contact your local govern ment agency for information concerning proper disposal its constituents are known to the State of Cali fornia to cause cancer birth defects and other reproductive harm Other chemicals in this vehi cle are also known to the State of California to cause cancer birth defects and other reproduc tive harm This warning requirement is man dated by California law Proposition 65 and
6. 85 90 100 Water ratio Freeze point 32 25 20 15 10 5 5 12 23 34 50 65 75 84 70 55 43 30 5 F C 0 C4 7 C9 12 15 21 24 31 37 46 54 59 64 57 48 42 C34 C21 Medium Duty R05 09 Y53 6027 179 Engine Cooling System ELC Condition Contamination and Inhibitor Concentration 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 mainte nance may cause coolant degradation and could result in damage to the cooling system and engine components Consult your dealer or the ELC manufacturer s represen tative for recommended ELC test kits test strips and lab oratory sample procedures ELC Extender Add ELC extender if necessary at the maintenance inter val under Cooling on page 183 180 Y53 6027 Preventive Maintenance Topping Off WARNING Removing the fill cap on a hot AN engine can cause scalding coolant to spray out and burn you badly If the engine has been in operation wit
7. Table6 Effect of Load Pressure on Tire Life Preventive Maintenance Wheel Mounting and Fastening After the vehicle travels about 50 to 100 miles 80 to 160 km wheel mountings seat in and will lose some initial torque Check hub wheel mountings after this initial period and retighten Wheel Cap Nut Torque At the first scheduled lube interval have all wheel cap nuts torqued to their specified value See Table 7 Wheel Cap Nut Torque Page 210 After that check wheel cap nuts at least once a week Contact an Authorized Service Center 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 if you do not have the right equipment 208 Vehicle Load Normal 20 Over 4096 Over 6096 Over 8096 Over 10096 Over Tire Pressure Normal 2096 Low 3096 Low 3596 Low 45 Low 5596 Low Expeeted Total Tire Normal 70 50 40 30 25 Mileage Y53 6027 WARNING Never use oil or grease on studs or N nuts improper torque readings will result which could cause improper wheel clamping and could lead to a wheel failure resulting in an accident causing death or personal injury Wheel Bearing Adjustment For safe reliable operation and adequate service life your wheel bearings must be checked and adjusted properly at the recommended intervals See Table 2 Maintenance Schedule Page 113 and Table 2 Maintenance Sched u
8. stops have been completed Adjust the parking brake lever See the Medium Duty Maintenance Manual Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE Operating the Rear Drive Axle Introduction This section covers the operation of your Rear Drive Axle These instructions apply to the most common features of drive axles Refer to the manufacturer s instructions for further information on the operation of your axle If your vehicle is equipped with a Rockwell Tractech No spin single rear axle the wheel differential lock feature automatically engages and disengages When one wheel starts to spin on a slippery surface this rear axle feature engages to improve traction Interaxle Differential Lock On vehicles with tandem rear axles the interaxle differen tial allows each axle to turn independently Differential action between the tandems relieves stress on the rear axles and reduces tire wear The interaxle differential lock switch allows the operator to LOCK or UNLOCK the differ ential depending on road surface conditions When operating normally on paved dry surfaces keep your truck s interaxle differential in the UNLOCK position Medium Duty R05 09 Y53 6027 OPERATING THE REAR DRIVE AXLE SHIFT AT ANY SPEED EXCEPT IF A WHEEL IS SPINNING In the LOCK position an air operated clutch positively locks both sets of axles together providing greater trac tion on slippery road surfaces however
9. 00139a TREAD CONTACT ME WITH ROAD dents They wear more quickly than properly inflated tires and are more subject to punctures cracks and other damage They could fail and cause you to lose control of your vehicle result ing in an accident causing death or personal injury Be sure all tires are inflated correctly according to the manufacturer s recommenda tions f WARNING Overinflated tires can cause acci Medium Duty R05 09 Y53 6027 Tires and Wheels If overinflation is noted during travel do not deflate tires The increased pressure is caused by temperature build up during operation This condition has been taken into account during manufacturing of the tires Allow tires to cool then recheck and adjust if necessary Tire Loading tires molded on the side wall of your tire or the maximum vehicle load rating whichever is less Overloading could result in premature tire fail ure causing you to loose control of your vehicle and result in an accident causing death or per sonal injury The maximum vehicle load rating GVWR is found on the Tire and Rim Data label on the driver s door 1 WARNING Do not exceed the load rating of your Overloading your vehicle is as damaging to the tires as underinflation It significantly affects the expected life total mileage of a tire The following chart shows how neglect or deliberate abuse can affect the life of your vehicle s tires 207 Tires and Wheels
10. 1 Prefill filter with fuel 2 Moisten gasket with diesel fuel 3 Hand tighten them only 1 2 to 2 3 turn after gasket con tact Mechanical tightening of these filters may distort or crack the filter head Medium Duty R05 09 Y53 6027 Engine Maintenance When replacing a fuel filter element do not use a substi tute 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 elements soak them in clean fuel before install ing them n NOTE To expel air from density type strainer Throw away old gaskets Replace them with new ones to ensure a positive seal Position the shell and gasket properly Then tighten the cover nut or bolt just enough to prevent fuel leakage After starting the engine check for leaks around the fil ter Filter Draining Check fuel filter water separator daily Check with engine OFF Depending on the fuel storage facility more frequent draining may be required 1 Open drain valve by hand only turn valve screw counter clockwise approximately 1 1 2 to 2 turns until draining occurs Drain filter sump of water until clear fuel is visible 175 Engine Maintenance If entrapped water exceeds sump volume you can either A Close valve and run engine until smooth idle is established then repeat drain procedures or B Remove filter f
11. Before turning on the ignition or switching from AUTO to MANUAL be sure no workers are near the fan CAUTION The fan or equipment near it could be damaged if the fan turns on suddenly when you do not expect it Keep all tools and equip ment away from the fan NOTE Do not operate the engine fan in the MAN UAL 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 Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE Cruise Control Option This feature improves fuel mileage and reduces driver fatigue by maintaining a constant vehicle speed The cruise control will only operate above a programmed min imum vehicle speed 15 mph for the CAT 3126B engine 30 mph for the Cummins ISC engine Engaging the Cruise Control SET CRUSE O Rus cW SELECT Oo RESUME the minimum cruise control speed and the engine speed is above 1100 rpm 1 Move the ON OFF switch to the ON position n NOTE Ensure that the vehicle speed is above RESUME position at this point will select the pre NOTE Toggling the SET RESUME switch to the Kd viously set cruise speed Medium Duty R05 09 Y53 6027 2 Accelerate the vehicle to the desired cruise speed 3 Toggle the SET RESUME switch lever to the SET position to set the cruise speed This toggle switch has additional functions
12. Check internal baffling You can do this by listening for rattling sounds while tapping the muffler with a rubber mallet or revving the engine up and down through its nor mal operating range Medium Duty R05 09 Y53 6027 Noise and Emission Control Exhaust Tail Pipe Check the mounting Tighten as necessary The miter cut at the tip of the pipe must be facing the rear of the vehicle Do not modify the end of the pipe in any way Engine Fan and Shroud engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be killed or seriously injured Before turning on the ignition be sure that no one is near the fan f WARNING Do not work on the fan with the 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 Check to verify that the fan is disengaged not turning with the engine running at normal operating tempera tures from cold to the point that the fan engages Check fan blade mounting bolts Inspect fan blades to be sure they are not cracked or bent If problems exist refer to the Cooling System section in the Medium Duty Maintenance Manual for detailed maintenance instruc tions 259 Noise and Emission Control Transmission and Driveline e Substituting a different main transmission or drive line components other than design specified units may re
13. Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE Electrohydraulic Pump The Electrohydraulic EH pump is used as a backup boost pump The EH pump turns on and provides fluid pressure to the hydraulic booster in the event power steering fluid stops flowing through the booster head Front and Rear Wheel Calipers translate hydraulic fluid pressure into force applied at each wheel end brake rotor to retard wheel motion Hydraulic Booster The hydraulic booster applies addi tional hydraulic force from the power steering gear to the master cylinder piston when the brake pedal is applied Parking Brake Lamp illuminates when the parking brake is engaged the lever is in the up position Parking Brake Lever the hand lever located in the cab which engages or disengages the driveline drum brake Power Steering Flow Switch senses flow of power steering fluid Power Steering Fluid Reservoir stores power steering fluid and offers a place to replenish when needed Medium Duty R05 09 Y53 6027 USING THE BRAKE SYSTEM Power Steering Gear assists the steering operation and sends pressurized power steering fluid to the brake booster Power Steering Pump draws power steering fluid from the reservoir and sends it to the power steering gear Warning Buzzer sounds when either power steering fluid flow is interrupted or when a pressure differential is present between the primary and secondary brake fluid pressure Eithe
14. Medium Duty R05 09 WARNING Do not use any replacement part in the brake system unless it conforms exactly to original specifications A nonconforming part in your vehicle s brake system could cause a mal function resulting in an accident causing death or injury Consult you local dealer for suitable replacement parts WARNING Do not work on the brake system without the parking brake set the keys removed from the vehicle and wheels chocked securely If the vehicle is not properly secured to prevent inadvertent vehicle movement it could roll and cause death serious personal injury or damage to the vehicle Use wood blocks 4 in X 4 in X 6 in or larger against the front and rear surfaces of the tires Be sure the vehicle cannot move Brake System Brake Fluid Check and Refill gt B Y53 6027 WARNING Wear protective clothing when han dling hydraulic fluid It is mildly toxic and can cause skin and eye irritation WARNING Use only the type of hydraulic fluid specified Do not use or mix different types of hydraulic fluid The wrong hydraulic fluid will damage the rubber parts of the brake system which may lead to loss of braking and possibly cause an accident resulting in death or serious personal injury CAUTION Hydraulic brake systems use two dis tinct and incompatible fluids Power steering fluid is used in the hydraulic brake booster sys tem Brake fluid is used in the master cylinder and brake p
15. d NOTE Any alteration adding bulkheads head Medium Duty R05 09 Y53 6027 zii 42 Y53 6027 CAB AND FRAME ACCESS Medium Duty R05 09 ENGINE ACCESS HOOD HOLD DOWNS AND TILT Engine Access WARNING Before opening the hood make AN sure your footing is secure and stable Failure to do so may cause the hood to close uncon trollably which may result in death or personal Hood Hold Downs and Tilt The hood is locked in its closed position by an external latch on each side These latches serve as hold downs and keep the hood from opening unexpectedly CAUTION If you do not latch the hood A securely it could open during operation and cause vehicle damage Be sure to latch the hood securely before moving the vehicle WARNING A pivoting hood could hurt some AN one or be damaged itself Before opening or closing the hood be sure there are no people or objects in the way Failure to stand in a position of safety can cause death or personal injury To open the hood unlatch both of the hood hold downs injury UNLATCHED Medium Duty R05 09 Y53 6027 c3 HOOD HOLD DOWNS AND TILT ENGINE ACCESS Put one hand on the hood handle just above the Peterbilt WARNING Always make sure the lock is emblem one foot on the bumper and one foot on the ground Tilt the hood forward until you hear it lock engaged to keep your hood open while work ing in the engine compartment Failure to
16. 219 Electrical System Battery cables have a protective insulation covering the metal cable Contact your authorized service center to have the cables replaced if you find any chafing tears or breaks in the insulation and the cable is visible through the tear or break Batteries accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling f WARNING Battery posts terminals and related Battery Access The vehicle is originally equipped with two batteries Replacement batteries must meet the following specifica tions maintenance free group 31 size threaded stud 12V 650 cold cranking ampere CCA and 160 minutes of reserve capacity The battery compartment has space to install an optional third battery The battery compartment is located on the left side of the vehicle under the cab access steps 220 Y53 6027 Preventive Maintenance The cover is held in place by two latches one on each side ment cover step before entering the cab With out the step you could slip and fall resulting in death or possible injury to yourself i WARNING Always reinstall the battery compart 02601 Battery Compartment Medium Duty R05 09 Preventive Maintenance batteries or electrical system remove all jewelry If metal jewelry or other metal comes in contact with electri
17. 32 Suspension Dump IIluminates when suspension air bags are deflated 33 Tire Inflation CONTROLS AND DISPLAYS Illuminates when tire pressures need to be checked Tire Pressure Monitoring System is an option fy 34 Transmission Auxiliary ux Illuminates to indicate auxiliary transmission is in neutral 35 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 35 If the user is in this display menu the icon does not indicate a fault code 36 Transmission Range Inhibit RANGE Illuminat ith Alli 1000 2000 INHIBIT uminates WI Ison series transmissions with Range Inhibit output 37 Transmission Oil Filter Illuminates when service is required Allison 13338 transmissions only Y53 6027 Medium Duty R05 09 CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS 38 Transmission Oil Temperature High Illuminates when transmission lubricant tem perature is too high The information display will provide the current oil temperature when the icon is illuminated Trans Temp B 302 r CAUTION This should be considered an emer A gency 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 Medium Duty R05
18. Attach one end of a jumper cable to the positive terminal of the discharged dead battery This will have a large red or P on the battery case post or clamp 2 Attach the other end of the same cable to the positive terminal of the good booster battery 3 Attach the remaining jumper cable FIRST to the negative terminal black or N of the good battery 4 Attach the other end of the negative cable to a bare metal part bolted to the engine block or clamp directly to the engine block if possible IMPORTANT Always connect positive to positive and negative to negative 5 Start the engines Start the vehicle that has the good battery first Let it run for a few minutes 004 Y53 6027 Preventive Maintenance Then start the vehicle that has the discharged dead battery If the engine fails to start do not continue to crank the starter but contact the nearest Authorized Service Center Remove jumper cables WARNING When disconnecting jumper cables AN make sure they do not get caught in any moving parts in the engine compartment You could be killed or seriously injured Reverse the above procedure exactly when removing the jumper cables With engine running disconnect jumper cables from both vehicles in the exact reverse order Steps 4 1 making sure to first remove the negative cable from the vehicle with the discharged battery Battery Charging E
19. Be sure to close the drains before leaving the vehicle 4 Secure the vehicle close all the windows and lock all doors Before Stopping the Engine Do not shut off the engine immediately A hot engine stores a great amount of heat and it does not cool down immediately after you shut if off Always cool the engine down before shutting it off You will greatly increase its ser vice life Idle the engine at 1000 rpm for five minutes Then low idle for thirty seconds before shutdown This will allow circulat ing coolant and lubricating oil to carry away heat from the cylinder head valves pistons cylinder liners turbo charger and bearings This way you can prevent engine damage that may result from uneven cooling Medium Duty R05 09 Y53 6027 SHUT DOWN Turbocharger This cooling down practice is especially important for a turbocharged engine The turbocharger on your vehicle contains bearings and seals that are subjected to hot exhaust gases While the engine is operating heat is car ried away by circulating oil If you stop the engine sud denly after a hard run the temperature of the turbocharger could rise to as much as 100 F 55 C above the temperature reached during operation A sud den rise in temperature like this could cause the bearings to seize or the oil seals to loosen Refueling Air inside the fuel tanks allows water to condense in the tank To prevent this condensation while the vehicle is parke
20. Electrical System When fast charging remove the battery caps so pres sure does not accumulate Always make sure the battery charger is OFF before connecting or disconnecting the cable clamps 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 con tact with the positive battery terminal or any other metal on the vehicle that is in contact with the positive termi nal could cause a short circuit or an explosion Charging Reminders Use protective eyewear Keep all batteries away from children Never reverse battery poles Never attempt to place the vehicle in motion or run the engine with batteries disconnected Keep the battery clean and dry Look for any signs of damage distilled water It could come in contact with a terminal creating a short circuit resulting in death severe personal injury or damage to your vehicle 1 WARNING Never use a metallic funnel to add 225 Electrical System WARNING Always shield your eyes and avoid N leaning over the battery whenever possible 226 Electrolyte in batteries could splash up into your eyes causing severe burns and or serious per sonal injury Battery terminals should not be coated with improper grease Use petroleum jelly or commercially available noncorrosive nonconductive terminal coatings Battery acid that may spill during ch
21. Replace Engine Coolant a Manufacturer Specifications Air Cleaner Contaminant Accumulation Air Cleaner Restriction replace if greater than 20 Vacuator Valve Operation amp Condition Mounting Bolts Leaks Interference Engine Oil Level Daily Inspection Required Power Steering Reservoir Level Power Steering Fluid Replace vel orate Year 60 000 Mile C2 Drive Belt Condition and Adjustment Air Conditioner Compressor Mounting Cold Start Aids Governor and Pump Security Seals OK High Idle rpm Emergency Shutdown Vibration Damper Condition Y53 6027 Medium Duty R05 09 Preventive Maintenance Table2 Maintenance Schedule Maintenance Schedule and Lubrication Medium Duty R05 09 INTERVAL COMMENTS gE Eb EE OPERATION FREQUENCY s s S s S S oo oo 2o ro 2x83 Drain Water from Fuel System Engine Oil Change enaine ca T o Oil Filters Replace Fuel Filters Replace Engine Tune up C2 Cranking System Visual Inspect Loose Connections Starter Draw volts Alternator Charging System Visual Inspection Loose Connections Output Voltage volts UNDER VEHICLE A B C Steering Components Condition Steering Gear Steering Shaft Splines and Joint s Pitman Arm Drag Link Steering Arms Tie Rod Arms Tie Rod Ends Radius Rods Torque Arms Chassis Frame Cracks or Breaks
22. Y53 6027 Consumer Information and Vehicle Identification Incomplete Vehicle Certification Label The Incomplete Vehicle Certification Label for trucks is located on the driver s door frame It contains the following information DATE OF MANUFACTURE VIN Vehicle Identification Number LISTING OF APPLICABLE FEDERAL MOTOR VEHI CLE SAFETY STANDARDS Noise Emission Label The Noise Emission Label is in the map compartment It con tains information regarding U S noise emission regulations and date of manufacture Paint Data Label The Paint Data Label contains the paint colors used by the factory to paint your vehicle It lists frame wheels cab inte rior and exterior colors This label is located in the map com partment 267 Consumer Information and Vehicle Identification Federal Safety Standard Certification Label The NHTSA regulations require a label certifying compliance with Federal Safety Standard for United States and U S Ter ritories be affixed to each motor vehicle and prescribe where such label may be located This certification label which indi cates the date of manufacture and other pertinent informa tion is located on the driver s side door frame Component Identification Each of the major components on your vehicle has an identi fication label or tag For easy reference record component numbers such as model serial and assembly number See the Vehicle Component Register
23. either a Tilt or a Tilt Telescoping steering column The tilt feature allows forward and rearward move ment of the wheel The telescoping feature allows you to move the wheel up and down To activate these features locate the Tilt Telescoping han dle on the left side of the steering column To adjust the steering wheel PULL and HOLD the handle Push or pull the wheel to the desired height and angle then RELEASE the handle to lock the wheel at the correct position WARNING Make all adjustments to the steer AN ing mechanism while the vehicle is stopped Adjusting the Tilt Telescoping Steering Wheel while the vehicle is in motion could cause loss of control You wouldn t be able to steer properly and could have an accident resulting in death or personal injury 50 Y53 6027 CONTROLS AND DISPLAY Dash And Door Mounted Features Ignition Switch Your ignition switch has four unmarked positions ACC Accessory With your key in this position you can play the radio or use other accessories but your engine won t start Medium Duty R05 09 CONTROLS AND DISPLAY OFF In this position all systems are off and you can remove your key IGN amp ACC This position allows you to turn on the engine and all accessory power START Starter activation to start engine OFF ACC ONLY l IGN amp ACC START Hazard Flasher The four way Emergency Flasher switch is located to the
24. intermittent windshield wiper system A seven position rotary wiper switch located on the turn signal lever operates the wind shield wipers and washer see next illustration Rotate the end of the turn signal lever to change the wiper mode NOTE The ignition key must be turned to ON or LI 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 Medium Duty R05 09 Y53 6027 OPTIONAL GAUGES See the wiper switch settings table that follows for inter mittent delay times WARNING Clean blades regularly with a AN damp cloth to remove road film and wax build up Do not drive with worn or dirty wiper blades They can reduce visibility making driving hazardous which may lead to an injury accident resulting in death or personal injury CAUTION A Do not use antifreeze or engine coolant in the windshield washer reservoir damage to seals and other components will result If the electric pump is operated for a long period more than 15 seconds with a dry res ervoir the pump motor may be damaged To Wash The Windshield Push the rotary wash wipe knob in towards steering col umn hold for more than 0 8 seconds and then release Hold the knob in to extend the washing cycle After the lever is released the wipers will shut off automatically or resume
25. on page 19 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 Menu Bar 32 Y53 6027 Medium Duty R05 09 CONTROLS AND DISPLAYS In addition to a blank screen the following are menu items and the information available within each menu selec tions 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 A Fuel Economy Accessible while parked or driving Current Econ 0 00 mpg Trip Econ 0 00 mpg 1 Current fuel economy Indicates instanta neous fuel economy 2 Trip fuel economy Indicates trip fuel econ omy Medium Duty R05 09 Y53 6027 INSTRUMENTS AND CONTROLS RPM Detail Accessible while parked or driving gt RPM reading of actual engine RPM Engine RPM within the bar graph indicates the engine is operat ing in the most efficient RPM range The display color will change if you are operating outside of this range Ignition Timer Accessible while parked only m Ign Timer Omin 15 30 Ignition timer is set from this menu The ignition timer may be set for up to 30 minutes 33 34 D Trip Information NOTE When accessing the trip i
26. 09 Y53 6027 o 39 Turn Signal Left Blinks when the left turn signal or the hazard light function is operating 40 Turn Signal Right Blinks when the right turn signal or the haz ard light function is operating 41 Voltage Illuminates when transmission lubricant tem perature is too high The information display will provide the current oil temperature when the icon is illuminated as Voltage 12 6 Volts 31 INSTRUMENTS AND CONTROLS Driver Information Display Information Display tion 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 death or personal injury or equipment damage j WARNING Do not look at the Driver Informa 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 CONTROLS AND DISPLAYS ignition timer is active MCS button is pushed independent of ignition key switch position clock alarm sounds driver or passenger door is opened hazard warning lamp switch is on The various functions may be accessed by navigating through Menu Screens using the MCS Refer to Menu Control Switch MCS
27. CAUTION Do not spray the suspension with A chemical products or mineral oil it can cause f WARNING Failure to maintain the specified damage to the bushings NOTE Failure to follow these recommendations could void warranty See the Medium Duty Mainte nance Manual for further information on servicing the rear suspension Visual Inspection For all vehicles mandatory maintenance procedures include retightening of U bolts and complete inspection However even with proper maintenance many factors affect the ser vice life of springs and suspension components such as fatigue vehicle gross weight type of load road conditions and vehicle speed 249 Rear Axle and Suspension It is important that U bolts remain tight Severe use of your vehicle can 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 Medium Duty vehi cle New springs settle in after the vehicle s initial service caus ing the U bolts to become loose After the first 500 miles 800 km of operation inspect the suspension periodically as noted below Visually check for loose or missing fasteners cracks in hanger or axle connection brackets Check that springs are centered in hangers and in good condition Check for cracks wear marks splits or other defects on the surface
28. IN 3 Hold the Red knob IN by hand until the trailer air pres or service brakes to park and hold an unat sure builds to a pre set level about 45 psi At this tended vehicle use the parking brakes point it will remain in charging the trailer system and Because service brakes work with air pres releasing only the trailer brakes sure these brakes could slowly release Your 4 The Yellow knob will remain OUT tractor brakes ON vehicle could roll causing a serious acci dent Someone could be hurt or killed Never rely on the service brakes to hold a parked vehicle The Yellow knob system park may now be pushed Tractor and Trailer Air Supply Valve IN which will supply air to the tractor spring brakes releasing them i WARNING Do not use the trailer hand brake Normal Run Position inal enarge With both knobs pushed IN air is now being supplied The red octagon knob controls the air supply to the trailer to both the trailer and the tractor spring brakes all With the system completely discharged both the Red brakes are released trailer air supply and the Yellow parking brake knobs are OUT thus tractor and the trailer parking spring brakes are applied 108 Y53 6027 Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE The parking brakes act on the rear wheels only They are spring applied with air pressure used to release them Release air is supplied by both the front and rear circuit reservo
29. MCS The MCS is used to navigate the Driver Information Dis play unit The Menu Control Switch is located on the D Panel as shown in the illustration below e Rotate knob to scroll Push knob to select Enter The MCS has the following functions INSTRUMENTS AND CONTROLS Rotating the MSC Selecting display Setting values Pushing the MSC Confirming desired selection Standard Warning Lights and Audible Alarm The warning lights and audible alarm may indicate a sys tem malfunction Check the lights safely and frequently and respond properly as soon as you see one go on These lights could save you from a serious accident audbile alarm These signals tell you some thing is wrong with your vehicle It could be a failure in an important system such as the brakes which could lead to an accident caus ing death or injury Have the appropriate sys tem checked immediately f WARNING Do not ignore a warning light or Medium Duty R05 09 Y53 6027 19 INSTRUMENTS AND CONTROLS 1 Driver Information Display 2 Status Indicator 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 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 20 Y53 6027 1 CONTROLS AND DISPLAYS criticali
30. Peterbilt Motors Company To contact NHTSA you may either call the Auto Safety Hot line 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 infor mation about auto safety from the Hotline Medium Duty R05 09 Y53 6027 Consumer Information and Vehicle Identification 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 1 680 333 0510 or cantact Transport Canada by mail at Transport Canada ASFAD Place de Ville Tower C 330 Sparks Street Ottawa ON KIA ON5 For additional road safety information please visit the Road Safety website at http www tc gc ca roadsafety menu htm 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 263 Consumer Information and Vehicle Identification Preventive Maintenance Vehicle Identif
31. R05 09 STARTING AND OPERATING THE VEHICLE ure 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 coast ing the transmission is driven by the rear wheels and the countershaft gear which lubricates the transmission com ponents by oil splash will only be turning at idle speed Descending a Grade WARNING Do not hold the brake pedal down AN 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 an accident which could cause death or personal injury 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 opera tion could result in loss of vehicle control Medium Duty R05 09 Y53 6027 DRIVING TIPS AND TECHNIQUES Engine Overspeed the engine rpm go beyond the maximum gov erned rpm valve damage could result if over speed conditions occur CAUTION To avoid engine damage do not let NOTE Often these recommendations are sec ondary to maintaining an adequate and safe speed relative to the surrounding traffic and road conditions I Operate the engine within the optimum engine rpm range and do no
32. Spring Shackles and Hanger Brackets No Service Required Spring Pins No Service Required Y53 6027 161 Maintenance Schedule and Lubrication 162 Table2 Maintenance Schedule Preventive Maintenance King Pin Wear INTERVAL COMMENTS gElgE EE OPERATION FREQUENCY 898 9888 00o0 9o o9o NAN woo e do N OD Steer Axle Wheel Bearing End Play Adjustment and Inspection 350 000 Miles With LMS Outer Ends No Leak No Service Front Hub Lubricant Level Spring Leaves U Bolt and Suspension Fastener Torque Tighten U bolts after the first 500 miles 800 km Rear suspension fasteners retorque after first 2 000 miles 3218 km Leaks Coolant Engine Oil Power Steering Fuel Transmission Axles Inner and Outer Hub Seals Engine and Transmission Mounts Drivelines U joints and Slip Yokes Rear Axle Lubricant Level Rear Axle Lubricant Flush amp Refill C4 At 250 000 Miles Rear Axle Breathers Clear Tractor Protection Valve Breakaway Test Brake Chamber Mounting Bolt Torque Brake Hoses for Cracks and Chafing Adjust Brakes Y53 6027 Medium Duty R05 09 Preventive Maintenance Maintenance Schedule and Lubrication Table2 Maintenance Schedule INTERVAL COMMENTS gEE Eb EE OPERATION FREQUEN
33. This could lead to death or greater injuries for you Tether belts should be adjusted so that they are taut when the seat is in its most upward and for ward position 1 WARNING Failure to adjust tether belts 6 Iftethers are used be sure they are properly attached to the seat and if adjustable that they are adjusted in accordance with installation instructions Tethers must also be inspected for web wear and proper tightness of mounting hardware Medium Duty R05 09 Y53 6027 Cab Maintenance 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 the web may have deteri orated due to exposure to the sun s ultraviolet rays Replace the system Once the need for replacement of the seat belt has been determined be certain it is only replaced with an authorized PACCAR Parts replacement seat belt If the inspection indicates that any part of the seat belt sys tem requires replacement the entire system must be replaced An installation guide is attached to every replace ment belt Utilize the proper guide for your type of seat and follow the instructions very closely It is vitally important that all components be reinstalled in the same position as the original components that were removed and that the fasten ers be torqued to specific
34. VIN DATE MED SRD GAWN TYPE VEH TRUCK TRACTOR GVWR 41H GAWR LABEL NO 22 00709 REV H COMPLETE VEHICLE CERTIFICATION LABEL SAMPLE 266 Y53 6027 Medium Duty R05 09 Preventive Maintenance ing Overloading can result in loss of vehicle control and an accident involving death or per sonal injury either by causing component fail ures or by affecting vehicle handling Exceeding load ratings can also shorten the service life of the vehicle NOTE GVW is the TOTAL SCALE WEIGHT the vehicle is designed to carry This includes the weight of the empty vehicle loading platform occupants fuel and any load f WARNING Do not exceed the specified load rat The tire size and rim size and the cold inflation pressure to match that combination listed under Suitable Tire Rim Choice on the Certification Label are only representative examples for the specified axle ratings These components may not be the ones actually installed on the axle because there are many other appropriate combinations The PSI Cold inflation pressure on the Certification Label is for the tire rim combination in the example and may not be the same as the recommended inflation pressure for the actual tires on that axle Check the manufacturer s product information for the tires and rims actually on each axle to obtain recommended tire inflation pressure for specific applications Medium Duty R05 09
35. a bystander or passenger as well as extensive vehicle damage including tire transmission and or rear axle malfunction If the vehicle gets stuck in sand mud snow or ice Move the gearshift lever or selector from First to Reverse Apply light pressure on the accelerator pedal while the transmission is in gear Remove your foot from the accelerator while shifting Do not race the engine For best traction and safety avoid spinning the wheels 144 Y53 6027 Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE Comply with the following instructions to avoid transmis sion damage Always start the vehicle in motion with the shift lever in first gear Be sure that the transmission is fully engaged in gear before releasing the clutch pedal manual only Do not shift into reverse while the vehicle is moving Do not permit the vehicle to be towed for long dis tances without removing the driveshaft VEHICLE RECOVERY AND SPRING BRAKES Tire Chains If you need tire chains install them on both sides of the driving axle CAUTION Chains on the tires of only one tan A dem axle can damage the driveline U joints and the interaxle differential Repairs could be costly and time consuming Medium Duty R05 09 Y53 6027 145 SHUT DOWN STARTING AND OPERATING THE VEHICLE or service brakes to park and hold an unat Shut Down f WARNING Do not use the trailer hand brake Introduction A
36. able to repair it Check the heater core for debris blocking the air flow If the blower and air controls are functioning properly yet the heater is not operating properly the heater core or the hot water valves may be clogged or closed Clean the heater core if necessary If the condition persists take the vehicle to a Peterbilt Dealer for proper heater Service or repair Medium Duty R05 09 Preventive Maintenance blow hot air onto cold windshields This could crack the glass Turn the air direction lever to Defrost and reduce the fan speed 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 CAUTION During extreme cold weather do not Air Conditioner pressure If not handled properly during servic ing it could explode causing death injury to you or damage 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 1 WARNING The air conditioning system is under 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 Check the evaporator core and condenser core for debris restricting air flow Clean if necessary S
37. also shorten the service life of the vehicle WARNING Do not exceed the specified load e 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 rat ings are listed on the driver s door edge Here are some definitions of weight you should know GVWR is the Gross Vehicle Weight Rating This is the MAXIMUM WEIGHT your vehicle is allowed to carry including the weight of the empty vehicle loading plat form occupants fuel and any load Never exceed the GVWR of your vehicle GCW is the actual combined weight or Gross Combina tion Weight GCW of your vehicle and its load tractor plus trailer s plus cargo Medium Duty R05 09 DRIVER S CHECK LIST GAWR is the Gross Axle Weight Rating This is the total weight that one axle is designed to transmit to the ground You will find this number listed on the driver s door edge Load Distribution be sure any load you carry is distrib uted so that no axle has to support more than its GAWR load too heavy over one axle can affect the braking and handling of your vehicle which could result in an accident causing death or personal injury Even if your load is under the legal limits be sure it is distributed evenly Emergency Equipment j WARNING An unevenly distributed load or a
38. 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 Medium Duty R05 09 Preventive Maintenance 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 under neath 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 park ing brake is applied 3 all wheels are chocked front and rear and 4 the engine cannot be started Remove the ignition key Never start or let the engine run in an enclosed unventilated area Exhaust fumes from the engine contain carbon monoxide a colorless and odorless gas Carbon monoxide can be fatal if inhaled WARNING Wear protective clothing when N handling hydraulic fluid It is mildly toxic and can cause skin and eye irritation Medium Duty R05 09
39. be enhanced by you the safe driver who knows and understands how to operate the vehicle and all its controls maintains the vehicle properly uses driving skills wisely For more information refer to Department of Transporta tion Regulation 392 7 which states that interstate com mercial motor vehicles are not to be driven unless the driver is sure that certain parts and accessories are in working order 83 reflexes perceptions and judgment can be affected by even a small amount of alcohol You could have a serious even fatal acci dent if you drive after drinking Please do not drink and drive or ride with a driver who s been drinking f WARNING Do not drink and drive Your The use of alcohol drugs and certain med ications will seriously impair perception reactions and driving ability These circum stances can substantially increase the risk of an accident and death or serious per sonal injury Vehicle Loading Compare your vehicle s load capacity with the total load you are carrying If adjustments need to be made make them do not drive an overloaded vehicle If you are over loaded or your load has shifted your vehicle may be unsafe to drive 84 Y53 6027 DRIVER S CHECK LIST rating Overloading can result in loss of vehi cle control and death or serious personal injury either by causing component failures or by affecting vehicle handling Exceeding load ratings can
40. check to be certain the oil pressure gauge reads normal Increase the engine speed to about 1100 1200 RPM maximum Return the idle speed to normal after 2 or 3 minutes If the warning light does not go off or the temperature gauge does not begin to drop then turn the engine off If the overheating came from severe operating condi tions 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 42 Y53 6027 WARNING Do not remove a fuel tank cap near an open flame Hot fuel vapors are combusti ble and can cause an explosion or fire result ing in death injury or property damage CAUTION Use Ultra Low Sulfur Diesel fuel only Failure to do so may damage components of the engine and Diesel Particulate Filter DPF Medium Duty R05 09 CONTROLS AND DISPLAY mate 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 con densation of moisture in the tanks This mois ture can damage your engine Diesel Exhaust Fluid DEF Gauge CAUTION The fuel gauge shows the approxi The deisel exhaust fluid gauge shows the approximate amount of DEF fluid in the DEF tank Besides empty and full the gauge also indicates 1 4 1 2 and 3 4 of total Medium Duty R05 09 Y53 6027
41. cr a 7 te 4a L3 su SUE a eo LI prs tee gt sn 5 T 5 J o o n LELI w we PE 5 RIDE HEIGHT Ride Height Measurement Location for Tandem Axles Shown Proprietary Rear Ride Height inches mm Air Suspension Single Drive Tandem Drive Air Trac 11 00 279 11 00 279 Low Air Leaf 6 50 165 8 50 216 These values are for a fully laden vehicle Follow this procedure to temporarily set ride height 134 Y53 6027 STARTING AND OPERATING THE VEHICLE and damage to property ensure that a vehicle is parked and the wheels chocked before beginning this procedure WARNING To prevent possible death injury enable you to safely reach the nearest autho rized Peterbilt repair facility to have ride height and pinion angle reset using the proper equipment and technique Do this as soon as possible to avoid potential driveline damage A CAUTION Completing this procedure will NOTE Suitable wheel chocks are at a minimum LI an 18 inch 46 cm long 4x4 1 Ensure that the air supply and delivery plumbing of the height control valve is consistent with the illustra tion height control valve bracket will be slotted to per H NOTE At least one of the mounting holes in the mit rotating the valve NOTE On dual valve systems begin with the LH n valve on the next step 2 Loosen the fasteners mounting a heigh
42. each type of mounting The following comparison Table 8 Comparing Hub piloted and Ball seat Wheels shows the difference between parts used in hub pilot mount and ball seat mount applications Medium Duty R05 09 Preventive Maintenance Table 8 Comparing Hub piloted and Ball seat Wheels Tires and Wheels HUB PILOTED MOUNT 00187 BALL SEAT MOUNT 00203 Hub Drum and Stud Assembly Hub piloted mountings use M22 x 1 5 metric threads about 7 8 in diameter The stud stands out at least 1 94 in beyond the brake drum All studs are right hand threads Pilot bosses machined surfaces on the hub fit tightly to the wheel center bore Ball seat stud piloted mountings use 3 4x16 or 1 1 8x16 threads The dual mounting studs provide 1 30 in 1 44 in standout Right hand and left hand threads are required Inner and outer wheel nuts center the wheels by seating against wheel ball seats Wheels Hub piloted wheels have stud holes reamed straight through no ball seats Center bore diameter is 8 21 32 in Ball seat wheels have spherical chamfers machined on each stud hole Center bore diameter is 8 23 32 in Whee Nuts Hub piloted wheel nuts have a hex body and a flange for clamping against wheel face Hex size is 1 5 16 in 33 mm Ball seat inner and outer wheel nuts mate with spherical chamfers on wheels The inner nut has 13 16 in square end The outer nut has a
43. engine manual will give normal operating pres sures for your engine with insufficient oil pressure will cause serious CAUTION Continuing to operate your vehicle A 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 40 Y53 6027 Medium Duty R05 09 CONTROLS AND DISPLAY 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 Stop the vehicle in a safe location AN if the engine temperature gauge indicates an overheating situation Failure to park the vehi cle in a safe location may result in death per sonal injury or property damage 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 care fully 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
44. fastened chest and lap Riding without a safety belt which is properly fastened can lead to increased death or injury in an accident 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 and be sure any one riding with you does the same f WARNING Do not drive vehicle without your 2 Pull the belt in a continuous slow motion across your Lap Shoulder Belt The combination lap shoulder belt is equipped with a lock TM ing mechanism The system adjusts automatically to a ibt Md 3 Insert the belt tongue into the buckle on the inboard belt is slow side of the seat Hard braking or a collision locks the belt The belt will also 4 lock when driving up or down a steep hill or in a sharp curve Push down until the tongue locks securely with an audible click Pull on the belt to check for proper fas tening To fasten the belt Pull the shoulder section to make sure the belt fits snugly across the chest TostorapitneDell tongue The shoulder belt must be positioned over the shoul der it must never rest against the neck 76 Y53 6027 Medium Duty R05 09 SEATS Belts should fit snugly across the pelvis and chest Proper Safety Belt Adjustment Mak lack i d the retractor T duce eg pe eee MIRO RE Your combination lap shoulder b
45. last page of this manual Engine For further information please refer to the Engine Operation and Maintenance Manual Clutch Enclosed in clutch housing Location depends on manufacturer 268 Y53 6027 Preventive Maintenance Transmission For both manual and automatic transmis sions the identification number is stamped on a tag affixed to the right rear side of the transmission case Steer Axle The front axle serial number is stamped on a plate located on the center of the axle beam Drive Axles The drive axle numbering system includes three labels or stamps 1 Axle Specification Number usually stamped on the right rear side of the axle housing This number identifies the complete axle 2 Axle Housing Number Tag usually located on the left for ward side of the housing arm This tag identifies the axle housing 3 Axle Differential Carrier Identification usually located on the top side of the differential carrier The following infor mation is either stamped or marked with a metal tag Model No Production Assembly No Serial No Gear Ratio and Part Number Medium Duty R05 09 A Accessories 72 Air conditioner 217 refrigerant 151 Air Dryer 200 Air filter 202 Air horns 49 Air intake 201 257 Air leaks 199 Air pressure gauge 198 Air suspension deflated air spring 137 switch operation 133 Air tanks 87 119 147 Alternator precautions 227 Anti lock brakes 112 115 125 Automatic trans
46. level is below normal or if there is a sudden loss of coolant such as a worn hose splitting It may also temporarily overheat Medium Duty R05 09 Y53 6027 STANDARD GAUGES during severe operating conditions such as climbing a long hill on a hot day or stopping after high speed driving A WARNING Do not remove the radiator fill cap while the engine is hot Scalding steam and fluid under pressure may escape and cause death or 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 e Carefully and slowly turn the cap one quar ter of a turn or until it reaches the first stop allowing excess pressure to escape push down and turn for final removal 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 41 STANDARD GAUGES is overheating and the low coolant alarm is not CONTROLS AND DISPLAY l CAUTION Keep the engine running if the engine Fuel Gauge on Allowing the engine to run with coolant in the system will help protect the engine from overheating whick will reduce the damage to the engine With the transmission in neutral
47. of engine braking Coasting is illegal and also VERY dangerous Anti Lock Braking System This vehicle is equipped with an Anti Lock Braking Sys tem ABS ABS reduces the likelihood of a wheel locking If a wheel is about to lock during braking the ABS will Medium Duty R05 09 Y53 6027 USING THE BRAKE SYSTEM automatically adjust hydraulic pressure to the brake cali pers on the appropriate wheel s to prevent wheel lock up The ABS is automatically activated when the ignition switch is turned on light line may be constantly powered for ABS Make sure it will not accidently turn on trailer equipment CAUTION The center pin of the 7 way trailer ABS Warning Lamp The ABS warning lamp will come on briefly then go off when the key switch is first turned on If the lamp remains ON until a speed of 4 mph 6 km h is reached then goes OFF there may be a stored fault code If the lamp remains ON when a speed in excess of 4 mph 6 km h is reached there may be an active fault in the ABS system illuminate when the ignition is first turned on there is a problem with the bulb or wiring You should have this checked as soon as possible CAUTION If the ABS warning light does not 495 USING THE BRAKE SYSTEM A WARNING No indication will be given via the dashboard warning lights or buzzer if tires of the wrong size are installed on your vehicle The Anti Lock Brake System ABS is cali brated for the spe
48. oil into the turbocharger oil inlet port This will keep the turbocharger bearings lubricated until the engine oil pressure gets up to normal n NOTE When any one of the following is true oil Insert key into the ignition switch Disable or turn OFF the following systems prior to starting the engine the exhaust brake the dual speed rear axle put in LOW and block heater if equipped Disengage the transmission place the shift lever in the Neutral position Disengage depress the clutch with manual trans mission Turn the ignition switch to the IGN amp ACC position For normal temperatures no accelerator advance is nec essary See Use of Accelerator below If the WAIT Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE TO START indicator lamp turns ON wait until the CAUTION To help avoid overtaxing the starter indicator lamp goes OFF approximately 60 seconds motor or batteries or causing engine damage before attempting to start the engine For each follow the recommendations listed below engine and ambient temperatures warm up cycles Do not engage starter for more than 30 seconds at a will vary time 7 Turn the ignition switch to the IGN amp START position Wait two minutes between each attempt to start the to engage the starter Crank the engine until it starts engine This allows the starter motor to cool and time If the engine does not start within 30 seconds release
49. 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 LI beam switch to operate 46 Y53 6027 CONTROLS AND DISPLAY 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 Headlamp Flash To activate headlamp flash gently push the turn signal lever away from the steering wheel until you hear and feel the switch click Release lever to deactivate If your headlamps are off low beams will flash on If your headlamps are on they will dim Maximum duration of dimming is 3 seconds When the function ends your headlamps will return to low beams ID And Clearance Lights Flash To flash press the button on the end of the turn signal lever and hold To cancel the flash release the button Medium Duty R05 09 CONTROLS AND DISPLAY Press In For Washer Pump Rotate To Change Wiper Mode Press Button For ID and Clearance Lights Flash If your ID and clearance lights are on they will flash off Windshield Wipers Washer Your vehicle is equipped with a two speed
50. parking brake could cause damage to the drive line transmission or the parking brake mecha nism itself CAUTION Unless it is an emergency do not pull Using the Parking Brake 1 Come to a complete stop 2 Apply the parking brake Pull upward on the parking brake lever until it reaches an over top center posi tion The PARK light on the dash will come on NOTE Ensure the lever is over center The light il will come on prior to brake being fully applied Medium Duty R05 09 Y53 6027 DASH AND DOOR MOUNTED FEATURES q PARKING BRAKE LEVER 65 HEATER AIR CONDITIONING CONTROLS 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 AN 66 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 causing death injury or serious illness WARNING Never idle your vehicle for pro longed periods of time if you sense that exhaust fumes ar
51. pressure to apply the trailer brakes only It operates independently of the foot treadle valve OPTIONAL GAUGES WARNING 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 Activating the trailer hand brake lever instead of the BrakeSaver lever could lead to an accident resulting in death or personal injury 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 il AN To operate the trailer brake hand valve Pull down on the lever under the right side of the steering wheel Medium Duty R05 09 Y53 6027 NOTE The trailer brake is not to be used as the main means of braking To use this brake fre quently instead of using the foot brake will wear out the trailer brake sooner WARNING Always apply the parking brakes for parking or holding your vehicle on grade 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 causing an accident resulting in death or per sonal injury 49 DASH AND DOOR MOUNTED FEATURES Tilt Telescoping Steering Column Depending on your vehicle s configuration you may have
52. provides comfort for those in the cab through accurate control of the cab environ ment in all weather conditions Regular attention to the items below will help you keep the heater air conditioner unit run ning well AN 216 WARNING Excessive heat may cause the pres surized components of the air conditioning sys tem to explode possibly causing death or personal injury Never weld solder steam clean or use a blow torch near any part of the air con ditioning system Ifa refrigerant leak develops in the presence of excessive heat or an open flame hazard ous gases may be generated These gases may cause unconsciousness or death If you become aware of a refrigerant leak on your vehicle have your system service immedi ately and observe the following precautions Stay away from the hot engine until the exhaust manifold has cooled Preventive Maintenance Do not permit any open flame in the area Even a match or a cigarette lighter may gen erate a hazardous quantity of poisonous gas Do not smoke in the area Inhaling gaseous refrigerant through a cigarette may cause violent illness Heater Y53 6027 Check all heater controls for full range operation 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 a reliable radiator shop should be
53. rear axle alignment checked and adjusted by a Peterbilt Dealer or Authorized Service Center Every 5 000 miles 8000 km or 180 days whichever occurs first and thereafter retorque all suspension fasteners to rec ommended specifications See the Fastener Torque Table for proper torque specifications 0446A peat eranc Dran Holm ane dta em Load the vehicle to its normal gross weight before tightening Axle Housing Breather Vent U bolts Loading the vehicle ensures proper adjustment of the U bolt and spring assembly Check and clean the axle housing breather vent 3 at each oil level check U bolts are difficult to tighten unless you have the right equipment If you cannot tighten them correctly yourself be sure to have them checked and tightened regularly by an authorized mechanic 252 Y53 6027 Medium Duty R05 09 Preventive Maintenance AN AN WARNING Do not replace U bolts and nuts with common U bolts or standard nuts These parts are critical to vehicle safety If the wrong U bolts or nuts are used the axle could loosen or sepa rate from the vehicle and cause an accident resulting in death or injury Use only U bolts and nuts of SAE Grade 8 specification or better WARNING Do not operate the vehicle if the U bolts are not properly tightened Loose U bolts do not properly secure the axle to the suspen sion This could cause loss of vehicle control and an accident resulting in death or inju
54. run the engine with the batteries disconnected Do not disconnect the battery cables or alternator con nection cables with the engine running Never turn the ignition switch to the IGN amp START posi tion with the engine running When charging the battery installed in the vehicle dis connect the battery cables Do not reverse the cables of the alternator starter motor or battery 227 Electrical System Preventive Maintenance Do not polarize the alternator The alternator should not be polarized like a generator To ensure correct polarity use a test lamp or a voltmeter 228 Y53 6027 Medium Duty R05 09 Preventive Maintenance CAB MAINTENANCE Exterior Maintenance Painted Surfaces Wash painted surfaces frequently to remove grime and caus tic deposits which may stain the finish See Cleaning Pro tection and Weather Stripping on page 230 Chrome and Aluminum Surfaces To prevent rust keep chromed parts clean and protected with wax at all times especially in winter conditions where the roads are salted f necessary use a commercial chrome cleaner to remove light rust 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 sur faces and apply a thin coat of rust preventive lubricant around bolts or other fasteners Medium Duty R05 09 Y53 6027 Cab Maintenance Clea
55. s literature for any special instructions Medium Duty R05 09 Y53 6027 Frame and Fifth Wheel Steam clean the fifth wheel Check lock guard operation using a commercial lock tester Clean and oil all moving parts Lubricate the following parts with a lithium base grease Lock mechanism All grease fittings especially those which grease the top surface of the fifth wheel Check for missing or loose nuts and bolts in the fifth wheel and mounting brackets Retighten loose bolts to correct torque Replace missing or damaged bolts Every 6 Months or 50 000 Miles e Refer to specific manufacturer s literature for any special instructions Remove fifth wheel from vehicle Refer to the Medium Duty Maintenance Manual Fifth Wheel Removal Steam clean the fifth wheel and mounting brackets Check all moving parts for excessive wear or damage Replace all worn or broken parts Complete two month service procedure Install fifth wheel Refer to the Medium Duty Mainte nance Manual Fifth Wheel Installation 255 Frame and Fifth Wheel Preventive Maintenance Sliding Fifth Wheel NOTE The plate must be lifted up slightly to relieve the weight of the bracket while applying Lubricate bearing surface of support bracket through the grease grease fittings on the side of the fifth wheel plate Use a water resistant lithium base grease 256 Y53 6027 Medium Duty R05 09 Preventive Ma
56. set the tem perature knob to cool the blue position on the con trol and the blower to high until the cab becomes cool Then you can turn down the blower if you wish CAUTION During extreme cold weather do not For Efficient Cooling 1 Be sure all heater air conditioner controls are off 2 Start the engine Allow time for warm up refrigerant to liquefy and warp the valve plates or cause a hydraulic lock Warm the engine before starting the air conditioner A CAUTION To avoid damage to the compres CAUTION A cold compressor can cause sor amp blower motors turn off all controls when a system is not in use 3 Set the air control in the RECIRC mode Medium Duty R05 09 Y53 6027 CIGARETTE LIGHTER 4 Close all windows 5 Idle the engine between 1000 and 1500 RPM and turn the blower speed control to High 6 After the cab temperature cools to a comfortable level adjust the blower speed and controls to keep the desired condition il 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 condition ing system is active when the Defrost mode is selected Cigarette Lighter 02912A The cigarette lighter is located at the bottom of the cup holders To operate your lighter push the center of the knob in After a fe
57. the air to leave the system after you fill your radiator Refilling Your Radiator Be sure the radiator and engine block drains are closed Move the heater control to maximum heat position Remove the surge tank pressure cap Through the surge tank fill the system with premixed coolant Pour it in a steady flow until the radiator is full Start the engine Idle at low RPM Complete the filling Do it as quickly as possible Idle the engine until it reaches normal operating temper ature 9 Fill the radiator as necessary to raise the coolant level to the proper reading Replace the surge tank pressure cap Bomc CON OD O 181 Engine Cooling System Preventive Maintenance Engine Block Heater option A CAUTION Always unplug the block heater before starting your engine Damage to the cool WARNING Do not use the heater if there are any ing system could occur if not turned OFF N signs of problems Engine block heaters can unplugged cause tes resulting In deal serious personai Use a solution of half ethylene glycol antifreeze and half injury and or property damage if not properly maintained and operated Regularly inspect the water for best heater performance Do not use more than 65 engine block heater wiring and connector for percent concentration of antifreeze as a shortened heater damaged or frayed wires Contact your Autho X life will result rized Service Center or the manufacturer of the
58. the ignition The vehicle must be ser viced and the problem corrected before driving again Failure to do so may cause severe engine damage or cause an acci dent involving death or personal injury Y53 6027 CONTROLS AND DISPLAYS 22 Engine Wait To Start Illuminates when engine grid heater is on PACCAR PX 6 and PX 8 23 Fifth Wheel King Pin Lock Illuminates when air actuated fifth wheel King Pin is unlocked 24 Fifth Wheel Slide Unlocked 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 emer gency 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 Medium Duty R05 09 CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS lt A Medium Duty R05 09 25 Lights High Beam IIluminates when the high beams are on This icon will flash with audible alarm if the headlamps are left on when the door is open In addition this icon will flash but without an audible alarm if there is a problem with the low beam headlights or the low beam head light wiring In such event the high beam headlights will turn on at 5096 normal bright ness 26 Message Waiting Illuminates with telematic equipped messag ing W
59. the two service tanks by opening the drain valves Turn valve handles counter clockwise and leave open until the escaping air is free of water WARNING If the supply and service tanks are N not drained at the recommended frequency water could enter the air lines and valves This could cause corrosion or blockage which could compromise the brake system safety and poten tially cause an accident involving death or injury 197 Air System FRONT REAR PRIMARY SECONDARY SERVICE TANK SERVICE TANK weal AE g DRAIN VALVE WET SUPPLY TANK UNDER FRONT SERVICE TANK 02602 Location of Air Tanks 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 fluid or wax based oils in the air system These fluids may cause severe damage to air system components CAUTION Do not use penetrating oil brake 198 Y53 6027 Preventive Maintenance Maintain the air compressor to prevent excessive oil by pass See the Medium Duty Maintenance Manual for maintenance details Replace worn seals in valves and air motors as they are needed Your Peterbilt Dealer carries rebuild kits for most units Dual Air Gauge and Air Leaks Your Medium Duty vehicle comes with a primary and second ary air pressure guage The gauge indicates the amount of air press
60. warning light will give a shutdown signal eIn this case the anti lock system can be turned back on and the warning light extinguished by turn ing 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 func tion test of the warning light WARNING Do not attempt to recycle the anti lock system by turning the keyswitch OFF and ON until the vehicle has been brought to a full stop and the parking brakes set Failure to do so could adversely affect steering and braking con trol and may result in loss of vehicle control which may result in an accident involving death or personal injury 193 Brake System Preventive Maintenance event of a malfunction in any air or hydraulic cir cuit Such a malfunction may prevent the brake system from operating properly and could result in an accident causing death or serious personal injury The vehicle should not be oper ated until the system is repaired and both brak ing circuits including all pneumatic hydraulic and mechanical components are working prop erly f WARNING Do not operate the vehicle in the 194 Y53 6027 Medium Duty R05 09 Preventive Maintenance AIR SYSTEM Air System can result if not properly disassembled Use only proper tools and observe all precau Introduction tions pertaining to the use of thos
61. you are not properly trained to perform brake inspections or service take your vehicle to your nearest Peterbilt dealer 191 Brake System Visually inspect brake shoe lining for wear cracks or break age If linings are worn down to 2 5 mm 0 10 in they must be replaced Inspect brake drum for deep scores heat spots cracks or damage Replace if needed BRAKE SHOE LININGS PARKING BRAKE COMPONENTS 192 Y53 6027 Preventive Maintenance Anti Lock Braking System ABS Your Medium Duty vehicle is equipped with an anti lock brak ing system For detailed service information see the Peterbilt Medium Duty Maintenance Manual All service work should be performed by a qualified technician at an Autho rized Service Center The foundation brake system must be in proper working order to ensure the best ABS performance before detaching the ABS Electronic Control Unit ECU connector and all other electronic control units Welding equipment can send an energy surge through electronic equipment and cause damage Disconnect all ECUs before attaching welding equipment A CAUTION Do not weld anywhere on the vehicle the ignition turned on The connectors could arc and damage electronic equipment Turn off the ignition before disconnecting any electronic equipment A CAUTION Never detach the ECU connector with Other precautions e Check ABS wiring harnesses periodically for chafing or other problems No r
62. 09 CONTROLS AND DISPLAY sion bags either overinflated or underinflated may cause damage to driveline components If a vehicle must be operated under such condi tions do not exceed 5 mph Cruise Control Switch CAUTION Operating a vehicle with air suspen RESUME 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 Medium Duty R05 09 Y53 6027 DASH AND DOOR MOUNTED FEATURES 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 result ing in an accident causing death or personal injury AN 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 il Press and Release e Brakes Before Setting Cruise This vehicle s electronic system will perform a rationality check every time the vehicle is started This check is to ensure that the service brakes are working before allow ing cruise control to function This safety feature is 55 DASH AND DOOR MOUNTED FEATURES de
63. 1 to 1 3 4 in 25 44mm 30 Rear 1 1 4 to 2 in 32 51mm Brake System slack adjusters is a dangerous practice that could result in an accident involving death or injury It gives the operator a false sense of security about the effectiveness of the brakes Contact the Service Department at your dealer ship if the stroke exceeds the above specifica tions A stroke exceeding these values may indicate a problem with the slack adjuster or the brake foundation i WARNING Manual adjustment of automatic f the pushrod travel reaches the above specifications check the slack adjuster installation Inspect brake adjuster and anchor bracket for damage The anchor bracket should be tight With the air system at 100 psi 690 kPa or more apply the brake If adjustment is necessary and the slack adjuster is working the adjusting hex nut will rotate during the chamber return stroke Installing a wrench on the hex nut will make this eas ier to see On each stroke after the first the amount of adjust ment and chamber travel will be less Y53 6027 187 Brake System Constant manual adjustment of automatic slack adjusters can shorten the life of the internal clutch If the installation appears to be free of damage but the applied stroke range could not be achieved the slack adjuster must be replaced NOTE The brake adjuster alone does not ensure Hn proper brake operation Inspect all brake compo nents All brake compo
64. 104D and Eaton PS 081 specifications AMBIENT MODEL RUBRIC ANT Gees TEMPERATURE RANGE VISCOSITY SAE DEG C DEG F Eaton Fuller HD engine oil API CE or CF 4 Above 12 Above 10 50 Synthetic oil Chevron RPM Synthetic Transmission Fluid or equal Above 40 Above 40 50 age components Li NOTE Do not use multi viscosity or EP extreme pressure gear oil e g axle oils in transmissions Multi viscosity or EP oils may dam Standard Transmission Oil Level n NOTE The vehicle must be parked on level ground Maintain the oil level and check it regularly Oil should be up to bottom of filler plug hole 240 Clutch System Introduction Free pedal is the distance the clutch pedal moves by applying only slight pressure During free pedal the release yoke in the transmission moves until its bearing pads contact the release bearing This movement of the release yoke is called free travel Thus free pedal and free travel are directly related to each other Y53 6027 Medium Duty R05 09 Preventive Maintenance As the clutch pedal is depressed further with harder pres sure the release yoke moves the release bearing away from the engine This causes the clutch plate to release from the driven disks in the clutch This is called release travel And finally on 9 10 and 11 speed transmissions as the pedal is pushed to the last 1 2 to 1 inch of travel the release bear ing contacts and e
65. 24 34 24 20 28 27 38 3 8 16 31 44 42 60 24 35 50 47 68 7 16 14 50 71 68 96 20 56 80 53 108 1 2 13 76 109 103 149 20 86 123 117 167 9 16 12 110 158 149 214 18 123 176 167 239 5 8 11 153 218 208 296 18 173 247 235 335 3 4 10 271 386 367 523 16 303 431 411 583 7 8 9 437 624 593 846 14 482 589 654 799 1 8 656 935 889 1268 1 12 718 1023 973 1386 254 Preventive Maintenance The torque values in the previous tables are based on the use of clean and dry threads For standard capscrews 1 Always use the torque values listed the capscrew table 2 Reduce torque by 10 when engine oil is used as a lubricant 3 Reduce torque by 20 if new plated capscrews are used Y53 6027 Medium Duty R05 09 Preventive Maintenance FRAME AND FIFTH WHEEL Engine Painting Do not electrostatically paint electronically controlled engines or vehicles with these engines Frame Rails rails or drill through the top or bottom flanges These operations could affect frame rail strength leading to a failure resulting in an acci dent causing death or injury Always leave frame repairs to your Peterbilt Dealer f WARNING Do not cut splice or weld on frame Fifth Wheel Maintenance Proper preventive maintenance is essential to trouble free service and safe operation of the fifth wheel Every 2 Months or 25 000 Miles Refer to specific manufacturer
66. AND OPERATING THE VEHICLE and read the specific instructions contained in the trans mission manufacturer s manual that is included with your vehicle cab Check to be sure you know the correct mn NOTE You will find a shift pattern diagram in the sequence for your particular transmission Operating Manual Transmissions If your truck has an automatic transmission go to page 103 6 9 10 and 11 Speed Manual The 6 speed synchronized manual transmission has 6 forward speeds and 1 reverse The 9 speed transmission has 9 forward and 2 reverse speeds consisting of a 5 speed low range section and a 4 speed high range sec tion For specific instructions on operating one of the optional 10 or 11 speed transmissions consult the transmission manufacturer s Driver Operator Instruction Manual Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE Transmission Warm Up In cold weather below 32 F 0 C you may find shifting sluggish when you first start up Transmission warm up is especially important at this time but it is always a good idea to warm your transmission oil before starting out on the road To warm the transmission lubricating oil during engine warm up 1 Put the transmission in Neutral 2 Release the clutch pedal and let the transmission operate in Neutral for three to five minutes prior to shifting into either a forward or reverse range Putting the Vehicle in Motion After making sure the
67. ARNING Do not attempt to read telematic messages while operating the vehicle Reading messages can distract you from safe vehicle operation which may cause death or personal injury 51 T vu e il PUMP MODE qe Y53 6027 27 Park Brake Illuminates in the status indicator when park ing brakes are applied and the vehicle is sta tionary This symbol will also illuminate in the Driver Information Display if the parking brakes are applied and the vehicle is in motion 28 Power Take off PTO Illuminates when the PTO is engaged NOTE Do not drive vehicle with PTO engaged 29 Power Take off PTO Pump Mode Illuminates with remote throttle application Indicates pump mode is active 30 Refrigerator Illuminates to indicate that the refrigerator is on and ignition is off 29 INSTRUMENTS AND CONTROLS 4 31 Seat Belt Fasten Illuminates when the ignition key is turned on as a reminder to fasten your seat belt 1 WARNING Do not drive vehicle without your seat belt and your riders belts fas tened Riding without a safety belt which is properly fastened can lead to increased injury or death in an accident 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 and be sure anyone riding with you does the same
68. At icina th li h hicle f heater if you are in need of repairs or informa ter servicing the coo ing system operate the vel icle ora tion day or two before using the heater Trapped air inside the engine needs time to escape PREVENTIVE MAINTENANCE PM INTERVALS l A B C D E At the first 15 000 mi 115 000 mi 24 000 km 30 000 mi 48 000 km 60 000 mi 96 000 km 120 000 mi 240 000 mi 384 000 km 24 000 km or at the first Monthly 6 months 192 000km Annually PM Recommended SYSTEM COMPONENT MAINTENANCE TASK i ull pala l A B C D E 182 Y53 6027 Medium Duty R05 09 Preventive Maintenance Engine Cooling System Cooling Hoses Check the radiator and heater hoses for leaks X X Extended Life Coolant ELC Check the freeze point see page 178 Check for contamination using test strips see page 179 Replace blank water filter if applicable Perform lab analysis see page 179 If lab analysis shows coolant is unsuitable for continued use Flush drain and refill see page 178 Add ELC Extender see page 179 Flush drain and refill with new coolant see page 178 Fan clutch housing Check for air leaks Surge Tank Fill Cap Check fill cap seal at each oil change Medium Duty R05 09 Y53 6027 183 Brake System BRAKE SYSTEM If your truck has an air brake syst
69. CANTS c WE VISCOSITY SAE EATON EP gear oil MIL L 2105D API GL 5 26 to 438 15 to 100 80W 90 ROCKWELL Synthetic Lubricant Chevron RPM Synthetic Gear Lubricant or equal meeting i MIL L 2105D and Eaton PS 037 specifica ele rae ateore tee ante tion No initial drain is required on Eaton axles that are factory filled with an Eaton approved synthetic lubricant Petroleum based lubricants must be drained within the first 5 000 miles 8000 km if converting to an approved synthetic lubricant See Table 1 Recommended Maintenance Intervals Page 154 for standard rear axle service intervals Use petroleum based lubricants meeting MIL L 2105 C D grade specifications or approved synthetic lubrica tion Do not use oil additives To change axle lubricant 1 Park the vehicle on level ground with the axle lubricant at normal operating temperature 2 Remove filler 1 and drain plug 2 3 Completely drain the oil and clean the drain plug A CAUTION Do not overfill axles 4 Reinstall the drain plug 2 and refill with recommended oil up to the bottom of filler plug hole 5 Reinstall filler plug 1 Medium Duty R05 09 Y53 6027 251 Rear Axle and Suspension Preventive Maintenance Rear Suspension Fasteners Continual road shock and load stresses may force the rear axles out of alignment If you detect rapid tire wear on the rear axles you may have misaligned axles Have your
70. COMMENDED LUBRICANT Power Steering Gear Automatic Transmission Fluid ATF Driveline U Joints EP chassis grease lithium 12 hydroxystearate or lithium complex base NLGI 2 Slip Joint Splines Hood Pivots Fan Drive Fifth Wheel Components Clutch Pedal Shaft Clutch Linkage Other chassis grease fittings not covered below Wheel Bearing Non Driving Axles OIL LUBICATED SAE 80W 90 EP gear oil MIL L 2105D API GL5 or SAE 75W 90 synthetic oil GREASE LUBRICATED EP chassis grease lithium 12 hydroxystearate or lithium complex base NLGI 2 Threaded Pins amp Bushings e g spring pins amp EP grease lithium 12 hydroxystearate or lithium complex base NLGI 2 with 3 molybdenum bushings additive Mobil Grease Special Mobil Molygrease EP Chevron or equal Suspension Fittings other than threaded pins EP chassis grease lithium 12 hydroxystearate or lithium complex base NLGI 2 amp bushings Steering Axle Grease Fittings on Steering EP chassis grease lithium 12 hydroxystearate base NLGI 2 Arm Tie Rod Ends Drag Link King Pins Clutch Release Bearing remove inspection High temperature ball bearing grease Chevron SRI Mobil Grease HP Texaco Multifax 2 or plate for access Driveshaft Center Bearing equivalent Automatic Slack Adjusters Wedge Brake High temperature EP grease Texaco Thermotex EP 1 Shell Darina EP 1 Mobilith AW 1 Components Disc Brake Caliper Rockwell 0 616A or equivalent D
71. CS knob to view the warnings that are active Refer to the preceeding Figure Warning Light Indicator Symbols on page 22 for warning color classification 4 Alternator Illuminates if the alternator is not charging For alternators with warning lamp output signal 9 6 Y53 6027 INSTRUMENTS AND CONTROLS 5 Anti Lock Brake System ABS Illuminates during the Instrumentation Sys tem Self Test Have the ABS system checked by a Peterbilt dealer if the ABS Warning Lamp stays on for more than 3 seconds Illuminates during normal operating condi tions to indicate a problem with the ABS Sys tem 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 for more information 6 Anti Lock Brake System ABS Trailer Illuminates during the Instrumentation Sys tem Self Test and the tractor truck is con nected with a ABS equipped trailer 25 INSTRUMENTS AND CONTROLS 26 Illuminates during normal operating condi tions 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 March 1 2001 must be able to turn on an In Cab Trailer ABS Warning Lamp per U S FMVSS121 The industry chose Pow
72. CY s8 ss ss D02020 na a 98 Front amp Rear Brake Camshaft Tube Lubrication EE Grease Required Special Clutch Pedal Shaft No Service Required Clutch Linkage Suspension Fittings AG 200 250 000 Mile Service Clutch Release Bearing Required Extended Fittings Driveline Center Bearing No Service Required Automatic Slack Adjusters Synthetic Lube Required Special Fittings Brakes Lining Remaining replace as required RF RRF RRR LF LRF LRR Drum Condition RF RRF RRR LF LRF LRR Chassis Lubrication Transmission Lubricant Level Transmission Lubricant and Filter Change C2 Synthetic Lube Required 500 000 Drain Rear Axle Lubricant Change C2 Synthetic Lube Required 500 000 Drain Front Hub Lubricant Change C2 Synthetic Lube Required 500 000 Drain BATTERIES A B C Battery cables signs of chafing Signs of Over Charging Remove Corrosion and Seal Terminals Hold down and Box Mounting Bolts Load Test Batteries Medium Duty R05 09 53 6027 163 Maintenance Schedule and Lubrication Preventive Maintenance Table2 Maintenance Schedule INTERVAL COMMENTS gEE EB EE OPERATION FREQUENCY s8 ss ss me e2ceo0 eo ro a 98 Sealed Type Condition Color of charge indicator for each battery 1 2 3 4 TIRES AND WHEELS A B Cc Missing Valve Caps and Stem Locks Cracks or Loose Wheel lugs Tandem Mating Irregular Wear Tire Pressure Record below Remaini
73. DOOR MOUNTED FEATURES Manual Control Lever This hand operated control lever provides modulated application of the BrakeSaver in the manual or ON mode see next illustration How much braking you get depends on how much you move the lever A Control Air Pressure gauge and an Engine Oil Temper ature gauge are provided with the BrakeSaver 60 Y53 6027 CONTROLS AND DISPLAY 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 Medium Duty R05 09 CONTROLS AND DISPLAY f you have the two mode system you can select HIGH or LOW f you have the three mode system you can select low medium or high retarding the primary means of slowing or stopping the vehicle The Jacob s brake is designed to be used in conjunction with the service brakes Failure to do this may cause death or personal j WARNING Do not use the Jacob s brake as injury Interaxle Differential Lock Switch AN The interaxle differential allows differential action between the forward rear and the rear rear driving axles The inter axle differential lock switch allows the operator to LOCK or DASH AND DOOR MOUNTED FEATURES SHIFT AT ANY SPEED EXCEPT IF A WHEEL IS SPINNING WARNING Placing the differential lock in the LOCK position while you
74. Do not apply wax in the hot sun and do not friction burn the paint with a buffing machine Occasionally spray weather stripping 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 Vehicle Cleaning Precautions Cleaning agents may be poisonous and cause death or personal injury if swallowed or inhaled Keep them out of the reach of children f WARNING Handle cleaning agents carefully Observe all caution labels 230 Y53 6027 Preventive Maintenance Always read directions on the container before using any product Do not use any solution that can damage the body paint Most chemical cleaners are concentrates which require dilution Use spot removing fluids only in well ventilated areas Do not use gasoline kerosene naphtha nail polish remover or other volatile cleaning fluids They may be toxic flammable or hazardous in other ways Do not clean the underside of chassis fenders wheel covers etc without protecting your hands and arms You may cut yourself on sharp edged metal parts Moisture ice and road salt on brakes may affect braking efficiency Test the brakes carefully after each vehicle wash Any vehicle is subject to deterioration from industrial fumes ice snow corrosive road salt etc to name just a few causes A well cared for vehicle can look like new
75. Do not tow vehicles at speeds in excess of 55 mph 90 km h Medium Duty R05 09 VEHICLE RECOVERY AND SPRING BRAKES Recovery Rigging To connect to the Medium Duty vehicle attach the towing chain or cable and the hitches to the 2 tow recievers through the center access hole in the bumper Y53 6027 Front Tow Hook Recievers Returning 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 141 VEHICLE RECOVERY AND SPRING BRAKES STARTING AND OPERATING THE VEHICLE 2 Into the inter axle differential add 2 pints 94 liter of You may sometimes have to release your vehicle s spring approved lubricant brakes by hand This could happen if the system air pres e See Recommended Lubrication Types Page sure does not reach operating pressure because your 136 engine or compressor is not working properly You will 3 After adding the specified type and amount of lubri cant drive the vehicle It should be unloaded Drive 1 40 km h This will thoroughly circulate the lubricant through the assembly Spring Brakes Manual Release to 2 miles 1 5 to 3 km at a speed lower than 25 mph j In order to tow a vehicle if there is insufficient air to release the parking brake the spring brakes can be man ually released WARNING Do not drive vehicle with malfunc AN tioning bra
76. Double Cap Nut Mounting 1 15 16 12 1020 1090 750 800 3 16 Radius Ball Seat 11 816 385 950 650 700 1 15 16 12 1020 1090 750 800 Hub Piloted Disc Type Wheel w Two Piece Flanged Cap Nuts Steel Wheel 505 590 370 435 Budd Nut w Teflon Coating Alum Wheel 475 580 350 425 Motor Wheel Nut Steel Wheel 545 630 400 465 Alum Wheel 530 625 390 460 Stud Backnuts when used 3 4 16 240 270 175 200 1 14 240 410 175 300 Heavy Duty Cast Wheel w Demountable Rim 1 8 585 640 430 470 1 12 585 640 430 470 1 14 585 640 430 470 Rockwell or Clark Demountable Rims on Planetary Axles 3 4 10 270 305 200 225 210 Y53 6027 Medium Duty R05 09 Preventive Maintenance Table 7 Wheel Cap Nut Torque Tires and Wheels DYNAMIC TORQUE FOR WHEEL amp NUT INNER amp OUTER CAP CONFIGURATION STUD SIZE NUTS amp RIM CLAMP NUTS N m Lb Ft Dayton E A 5 8 11 Front amp Rear seien TRES 3 4 10 Cad Plated Studs Front 306 340 225 250 Cast Wheel with Demountable Rim Rear 272 340 220 250 3 4 10 PHOS amp Oil Coated Studs Front amp Rear 238 258 175 190 Gunite 5 8 11 Front amp Rear 220 250 160 185 a 3 4 10 Front Over E Cast Wheel with Demountable Rim 14 000 Lb GAWR 325 359 240 265 Other Front amp Rear 271 305 200 225 Disc Wheels tools when working on wheels Grooves in the wheel disc or other damage to the disc can weaken the wheel and cause it to eventually come off This could cause
77. GINE MAINTENANCE WARNING Exhaust fumes from the engine con tain carbon monoxide a colorless and odorless gas A poorly maintained damaged or corroded exhaust system can allow carbon monoxide to enter the cab or sleeper Failure to properly maintain your vehicle could cause carbon mon oxide to enter the cab and cause death personal injury or serious illness WARNING Never idle your vehicle for prolonged periods of time if you sense that exhaust fumes are entering the cab Investigate the cause of the fumes and correct it as soon as possible If the vehicle must be driven under these conditions drive only with the windows slightly open Fail ure to repair the source of the exhaust fumes may lead to death personal injury or serious ill ness il Engine Maintenance NOTE Keep the engine exhaust system and the vehicle s cab ventilation system properly main tained It is recommended that the vehicle s exhaust system and cab be inspected By a competent technician every 15 000 miles Whenever a change is noticed in the sound of the exhaust system Whenever the exhaust system underbody cab or sleeper is damaged Engine Lubrication Proper engine lubrication depends on ambient temperature and where the vehicle will be operated Use the recom mended oil for the weather conditions outside il NOTE For engine oil specifications oil change intervals engine filter requirements or general engine maintenance pr
78. ING Do not use the inter axle differen tial lock when travelling downhill or at speeds above 25 mph 40 km h When it is engaged under these conditions your vehicle will exhibit understeer handling characteris tics This understeer condition will cause your vehicle to turn less quickly and more steering effort will be required which can cause an accident resulting in death or per sonal injury To LOCK the inter axle differential 1 Anticipate when you might need increased traction slow down to a steady speed under 25 mph 40 km h or stop the vehicle Do not lock the inter axle differen tial while going down steep grades or traveling faster than 25 mph or while wheels are spinning or traction is minimal lock it before you encounter these condi tions Y53 6027 Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE Turning Radius When Unlocked Disengaged 2 lt b Turning Radius When Locked Engaged e A 02871 Understeer Condition 2 Put the inter axle differential lock switch labeled MAIN DIFFERENTIAL LOCK in the LOCK position A light DIFF LOCK in the warning module on the dash will turn on indicating that the differential is locked engaged 3 If you LOCK or UNLOCK the inter axle differential while moving let up momentarily on the accelerator pedal to relieve torque on the gearing and allow full engagement of the clutch the mechanism th
79. INTAKE INC ASSEMBLY ex S amr 02603 004558 FILTER ELEMENT Air Intake Assembly To remove the air filter 1 Remove the two thumb screws 2 Remove air cleaner service cover 3 Remove the filter element Clean out the inside of the air cleaner body and outlet tube with a dry rag Medium Duty R05 09 Y53 6027 Air Cleaner Filter Element To install air cleaner element 1 Slide air cleaner element into housing 2 Install air cleaner end cap 3 Install thumbscrews around air cleaner housing end cap NOTE The air cleaner is internally sealed by a radial seal around Inlet tube of air cleaner element For further information on servicing the air cleaner see the Medium Duty Maintenance Manual 203 Tires and Wheels TIRES AND WHEELS Introduction Keeping the tires in good condition is essential to the safe efficient operation of your Medium Duty vehicle Regular fre quent inspection and the right care will give you the assur ance of safe and reliable tire operation factured OEM components Use of non original equipment could cause wheel breakage and wheel separation from vehicle which could result in an accident causing death or personal injury 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 213 illustrates the differences between parts used in h
80. IPS AND TECHNIQUES Fifth Wheel Lubrication Frequently operate and lubricate movable or sliding fifth wheels to prevent corrosion slide tracks if a slider should be cleaned and lubricated periodically to ensure smooth turn ing and sliding action Failure to keep these surfaces lubricated can lead to frame or drive line damage CAUTION Both the fifth wheel plate and the See page 219 for maintenance information Medium Duty R05 09 53 6027 d VEHICLE RECOVERY AND SPRING BRAKES Vehicle Recovery and Spring Brakes Introduction Your Medium Duty vehicle is equipped with built in recov ery provisions designed for short distance use only If your vehicle must be recovered disconnect the driveline at the rear U joint and remove or support the rearmost section of the driveline This is necessary because if the transmission is driven by the driveshaft rear wheels on the ground no lubricant will reach the gears and bear ings causing damage to the transmission shafts or lift the driving wheels off the ground before towing the vehicle See More Driving Tips and Techniques on page 130 All lubricat ing and clutch application oil pressure is pro vided by an engine driven pump which will not work when the engine is stopped You could seriously damage your vehicle by tow ing it with the driveline connected and the drive wheels on the ground CAUTION Remove the driveline and axle 140 Y53 6027 STAR
81. It is good practice to carry an emergency equipment kit in your vehicle One day if you have a roadside emergency you will be glad the following items are with you window scraper snow brush container or bag of sand or salt emergency light small shovel first aid kit fire extinguisher Medium Duty R05 09 Y53 6027 Approaching Your Vehicle Check the overall appearance and condition Are win dows mirrors and lights clean and unobstructed Check beneath the vehicle Are there signs of fuel oil or water leaks Check for damaged loose or missing parts Are there parts showing signs of excessive wear or lack of lubri cation Have a qualified mechanic examine any ques tionable items and repair them without delay Check your load Is it secured properly Daily Checks NOTE The following items Engine Compart ment Chassis and Cab and Prestart Checks should be checked daily as a minimum They are in addition to not in place of federal motor Carrier Safety Regulations These regulations may be purchased by writing to Superintendent of Documents U S Government Printing Office Washington DC 20402 85 Engine Compartment Checks Daily 1 Engine Fluid Levels add more if necessary Engine oil Coolant check while engine is cold Power steering fluid level f your truck has hydraulic brakes check the fluid level in the master cylinder reservoir See page 154 for more i
82. Local or Alarm Time 1 When in the Settings Menu scroll through the list of menu items Press the MCS to select the item to change Unit Standard Set Alarm Time Set Local Time 3 Rotate the MCS knob to change the hour Press the MCS Medium Duty R05 09 CONTROLS AND DISPLAY Standard Gauges On the pages that follow you will find descriptions of some of the gauges on your instrument panel For more infor mation about using them in driving see Starting and 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 AN audbile alarm These signals tell you some thing is wrong with your vehicle It could be a failure in an important system such as the brakes which could lead to an accident involving death or personal injury Have the appropriate system checked immediately 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 speed ometer also includes an odometer trip meter and trip reset button Medium Duty R05 09 Y53 6027 STANDARD GAUGES Trip Reset Button The LCD display in the lower part of the speedometer contains the odometer and tr
83. Manual and other related materials You can open it by pushing the knob on the front Medium Duty R05 09 Y53 6027 with your ignition key turn it clockwise to lock and counterclockwise to unlock WARNING Do not drive with the glove com partment open it can be dangerous In an accident or sudden stop you or a passenger could be thrown against the cover and be killed or injured To reduce the risk of death or personal injury during an accident or sudden stop keep the glove compartment closed when the vehicle is in motion 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 73 Seats SEATS Introduction Standard Driver s Seat This section covers the operation and safe use of your Medium Duty vehicle s seats For further information on features and adjustment of the seat see the manufac turer s literature included with the vehicle The standard driver s seat can be adjusted forward and rearward These movements are each controlled by levers located on the FRONT of the seat Driver s Seat with Air Suspension Option Seat Adjustment WARNING Do not adjust the driver s seat while the vehicle is moving A sudden or unexpected seat movement can cause the driver to lose control of
84. Other severe operating condi tions to be aware of are rough extreme temperature envi ronments conditions where heavy loads are being hauled contaminated environments or steep grades Consult the component manufacturer s maintenance manuals for further information on maintenance procedures specific to these conditions 153 Maintenance Schedule and Lubrication Maintenance Intervals Table 1 Recommended Maintenance Intervals shows service intervals for normal and heavy duty operations For additional Engine Cooling System information see 154 Preventive Maintenance Page 178 For additional Air System information see Page 196 NOTE Different lubricants or service intervals than il those listed below may be required Table 1 Recommended Maintenance Intervals ITEM INTERVAL COMMENTS Hood Pivot None Front Brake Camshaft 10 000 15 000 Synthetic Grease With Special Fittings Tie Rod Ends 10 000 15 000 Power Steering Reservoir Check Fluid Level 10 000 15 000 Change Fluid amp Filter 60 000 2 Times Year After Summer amp Winter Drag Link 10 000 15 000 Steering Gear Box None Steering U joints 10 000 15 000 Steering Slip Joint 10 000 15 000 Brake Treadle 10 000 15 000 Clutch Pedal Shaft None Transmission Check Drain and Refill Manual Drain and Refill Automatic 10 000 15 000 50 000
85. QT MEDIUM OUVY MOWELS OWNER S MANUAL GC A PACCAR COMPANY Quick Table of Contents Introduction Cab And Frame Access Getting To Your Engine Controls And Displays Seat And Restraint Systems Driver s Checklists Starting And Operating The Vehicle Maintenance and Service Consumer Information and Vehicle Identification Subject Index 2009 PACCAR Inc All Rights Reserved This manual illustrates and describes the operation of features or equipment which may be either standard or optional on this vehicle This manual may also include a description of features and equipment which are no longer available or were not ordered on this vehicle Please disregard any illustrations or descriptions relating to featuures or equipment which are not on this vehicle Peterbilt reserves the right to discontinue change specifications or change the design of its vehicles at any time without notice and without incurring any obligation The information contained in this manual is proprietary to Peterbilt Reproduction in whole or in part by any means is strictly pro hibited without prior written authorization from PACCAR Inc INTRODUCTION Introduction How to Use This Manual This Operator s Manual contains useful information for the safe and efficient operation of your Medium Duty vehicle It also provides information on maintaining your vehicle in the best condition with an outline for performing safety checks and bas
86. STANDARD GAUGES capacity DEF fluid is required to meet certain emission requirements Do not allow your DEF tank to remain empty Please refer to your emission supplemental man ual for more details about DEF fluid to do so may damage components of the Diesel Particulate Filter DPF Primary Secondary Air Pressure Gauge Air Reservoir CAUTION Use Diesel Exhaust Fluid only Failure The air pressure gauge indicates the amount of air pres sure in the brake system in pounds per square inch psi The primary gauge shows front reservoir air pressure The secondary gauge shows pressure in the rear res ervoir Ensure the air pressure registers more than 100 psi in both service systems before you move the vehicle If the pressure in either circuit is too low for normal brake oper ation the warning light will glow and the audible alarm will sound 43 OPTIONAL GAUGES 44 CONTROLS AND DISPLAY WARNING The air pressure warning light and the audible alarm indicate a dangerous situa tion 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 sud denly apply causing a wheel lockup loss of control or your vehicle to be overtaken by fol lowing vehicles You could be in an accident involving death or personal injury If these alarms come on while you are driving imme diately brin
87. TING AND OPERATING THE VEHICLE Worse when vehicles are towed either by wrecker or piggy back the lubricant in the top front of the drive axle will drain to the rear This will leave the top components dry The resulting friction may seriously damage them Always remove the main driveshaft and axle shafts before towing your vehicle NOTE For additional information concerning i heavy duty truck recovery see Truck Mainte nance Council Recommended Practice 602 A Front Towing Devices For Trucks and Trac tors and 626 Heavy Duty Truck Towing Pro cedures Copies of these can be obtained from the following address The Maintenance Council American Trucking Association Inc 2200 Mill Rd Alexandria VA 22314 703 838 1763 Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE Vehicle Recovery Guidelines Refer to the guidelines below when towing to prevent pos sible damage Use proper towing equipment to prevent damage to the vehicle CAUTION Connect only to the towing provi A sions as described on the following pages Connections to other structural parts could damage the vehicle Do not attach to bumpers or bumper brackets Use only equipment designed for this purpose Use a safety chain system and the vehicle s 2 hitches Be sure to use both hitches together to recover a vehicle Disconnect driveline Follow state provincial and local laws that apply to vehicles in tow
88. TION Vehicle Safety Make sure your Medium Duty 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 the Driver s Check List page 83 reflexes perceptions and judgment can be affected by even a small amount of alcohol You could have a serious or even fatal acci dent if you drive after drinking Please do not drink and drive or ride with a driver who has been drinking WARNING Do not drink and drive Your 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 fea tures continued safe and reliable operation depends greatly upon regular vehicle maintenance The vehicle Medium Duty R05 09 Y53 6027 must be operated within the range of its mechanical capa bilities and the limits of its load ratings See the tire and rim weight ratings information on the Vehicle Certification Label on the driver s door frame This vehicle is not approved for off road operation How to Find What You Want T
89. Warning Lights and Buzzers 19 Water Temperature Gauge 40 GAWR defined 85 GAWR gross axle weight rating 84 132 267 GCW gross combination weight 84 Glove compartment 73 Governor 119 Grease index 168 GVWR defined 84 GVWR gross vehicle weight rating 84 132 207 267 H Hand brake 116 146 Hazard flasher 124 Hazard Switch 17 Headllights 17 Heater and air conditioner maintenance 216 High beam 46 Hood Latch and Tilt 11 13 hood lock release cable 14 Hub piloted and ball seat parts 213 HVAC 18 Hydraulic Booster 123 Hydraulic Brakes 64 86 87 121 Hydraulic Fluid Check 86 Hypoid gear oil 168 Medium Duty R05 09 Idling the engine 95 Ignition 17 Incomplete vehicle certification label 267 Inter axle differential 128 J Jumper cables 222 use of 223 K Keys 9 Keys and Locks Ignition Switch 50 Komfort Lok latch 81 L Lap shoulder belt 76 Lap belt 77 Load capacity 84 Load distribution 85 Load Lights 17 Low air pressure 137 Lubrication 185 247 axle 246 brakes 185 chart 169 coasting 131 driveshaft 245 engine 173 174 Y53 6027 273 front axle 247 front suspension 247 idling 94 95 power steering 243 244 rear axle 250 251 252 transmission 239 240 types and brands 167 wheel bearings 247 Maintenance manual 6 schedule 153 Manual transmission 98 lubricants 239 oil level 240 shifting gears 98 master cylinder 121 Menu Control Switch 17 Modifications 151 Modulating valve 119 Muffle
90. ack behind the wheel and resume a slow speed as soon as possible to cool the brakes If the vehicle was to remain stopped the heat transfer could destroy the linings and distort the brake drum Medium Duty R05 09 Y53 6027 USING THE BRAKE SYSTEM To prevent drums from distortion while they cool down Park the vehicle on level surface and block the wheels Release the parking brake and allow the brakes to cool down See page 106 Anti Lock Braking System 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 cham bers on the appropriate wheel s to prevent wheel lock up The ABS is automatically turned on when the ignition switch is turned on 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 Nor mally the ABS lamp will remain on until a speed of no more than 9 mph has been reached and the speed sen sors have been checked for correct output The lamp 113 USING THE BRAKE SYSTEM 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 light does not illuminate when the ignition is fir
91. age 197 Medium Duty R05 09 DRIVER S CHECK LIST Driver s Check List Safe Vehicle Operation To keep your Medium Duty vehicle in top shape and main tain a high level of safety for you your passengers and your load make a thorough inspection every day before you drive You will save maintenance time later and the safety checks could help prevent a serious accident Please remember too that the Federal law requires a pre trip inspection and so do commercial trucking companies You are not 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 any passengers and your load If you do find something wrong and cannot fix it yourself have an Authorized Service Center or qualified mechanic repair your vehicle right away The following operations are to be performed by the driver Performing these checks and following the mainte nance procedures in this manual will help keep your Medium Duty vehicle running properly Medium Duty R05 09 Y53 6027 For your safety as well as those around you be a respon sible driver f 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 Medium Duty vehicle including advanced engineering techniques rigid quality control and demanding inspections These manufacturing processes will
92. agnostics Faults Found 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 Y53 6027 INSTRUMENTS AND CONTROLS Found or Faults Found If Faults Found is active pushing the MCS will display new menus for more information Transmission Display Automated Transmissions only Accessible while parked or driving NOTE Refer to the Automated Transmission Operator s Manual for additional information This menu will show gear number that coincides with the current transmission 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 Settings Menu Accessible only while parked The Settings menu screen allows the driver to view and or change the following menu items 35 INSTRUMENTS AND CONTROLS Display Format 12 Hour AM PM or 24 Hour military Home Local Time Alarm ON OFF Alarm Time Units of measure Language English Spanish or French Settings To Set Clock Display Format 1 When in the Settings Menu scroll through the list of menu items to Format 2 Press the MCS to display either 12 hour AM PM or 24 hour military time 96 Y53 6027 CONTROLS AND DISPLAYS Exit Alarm Off Time Home Format 12Hr E To Set Home
93. ake and could cause gear hang up Medium Duty R05 09 Y53 6027 OPERATING THE TRANSMISSION CAUTION Be careful not to apply the clutch brake while the vehicle is moving The pur pose of the clutch brake is to stop the trans mission so that you can shift into a starting gear without grinding gears Applying the clutch brake when the vehicle is moving causes a braking effect on the drivetrain and shortens the service life of the clutch brake Double Clutching Whether you are upshifting or down shifting it is best to double clutch Double clutching is easier on the transmis sion and on the engine helping your vehicle match engine speed with driveline speed and achieving clash free shifts To double clutch 1 Push the clutch pedal down 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 allowing you to match the rpm of the mainshaft gears to those of the output shaft 101 OPERATING THE TRANSMISSION Upshifts let the engine and gears slow down to the rpm required for the next gear Downshifts press accelerator increase engine and gear speed to the rpm required in the lower gear 4 Now quickly press the pedal to disengage the clutch and move the gear shift lever to the next gear speed position 5 Release the pedal to engage the clutch More Transmission Tips Riding the Clutch The clut
94. ake linings should be inspected for wear by a qualified mechanic at an Authorized Service Center See Table 2 Maintenance Schedule Page 157 In severe service applications inspect the linings more frequently 186 Y53 6027 Preventive Maintenance Automatic Slack Adjusters Your Medium Duty vehicle is equipped with automatic brake slack adjusters Periodically brake adjustment should be checked using the following procedure 1 Check brakes when the temperature of the service brake linings are cool and the system air pressure is at 100 psi 690 kPa minimum 2 Release the parking brakes to allow the slack adjusters to retract 3 Measure the retracted pushrod length from the face of the brake chamber to the center of the pushrod pin 4 Apply 80 to 90 psi brake application and measure the same distance 5 The difference is the pushrod travel distance applied stroke Verify that the result is within the correct range see Table 4 Brake Adjuster Stroke Correctly installed and functioning brakes auto slack will produce the strokes listed for each chamber type Medium Duty R05 09 Preventive Maintenance SLACK ADJUSTER BRAKE CHAMBER APPLIED STROKE 01830 Measuring Pushrod Travel Table4 Brake Adjuster Stroke Medium Duty R05 09 80 90 PSI 552 621 KPA BRAKE APPLICATION AIR CHAMBER BRAKE PUSHROD TRAVEL TYPE Size Applied Stroke 20 Front
95. and shackle pinch bolts to 105 Ib ft 142 N m Medium Duty R05 09 Preventive Maintenance REAR AXLE AND SUSPENSION General Maintenance the parking brake set and wheels chocked securely If the vehicle is not secured to prevent uncontrolled vehicle movement it could roll and cause death personal injury or damage to the vehicle 1 WARNING Do not work on the vehicle without Use wood blocks 4 in X 4 in or larger against the front and rear surfaces of the tires Be sure the vehicle cannot move Your vehicle s suspension by design requires a minimal amount of maintenance However suspensions in over the road operations require periodic inspection to ensure trou ble free performance bolts are not properly tightened Loose U bolts do not properly secure the axle to the suspen sion This could cause loss of vehicle control and an accident resulting in death or injury Loose U bolts can also cause uneven tire wear and poor alignment f WARNING Do not operate the vehicle if the U Medium Duty R05 09 Y53 6027 Rear Axle and Suspension torque values or to replace worn parts can cause component system failure possibly resulting in an accident causing death or injury Improperly tightened loose suspension U bolts can lead to unsafe vehicle conditions including hard steering axle misalignment spring breakage or abnormal tire wear See the Fastener Torque Tables for proper torque specifications
96. arging 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 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 Never use a fast charger as a booster to start the engine This can seriously damage sensitive electronic compo nents 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 Preventive Maintenance Slow Battery Charging il NOTE Follow the instructions that come with your battery charger It is not necessary to remove the battery from the com partment WARNING Charger cables must be connected N positive to positive to and negative to neg N Y53 6027 ative to If connected improperly batteries could explode causing death or serious per sonal injury eAlways make sure the battery charger is OFF before connecting or disconnecting the cable clamps To reduce the danger of explosions and resulting death or serious personal injury do not connect or disconnect charger cables while the charger is operating Make sure the electrolyte level in each cell is between the MIN a
97. arting Vehicles Because of the various battery installations and optional electrical systems Peterbilt does not recommend that you attempt to jump start your vehicle If you have a battery prob lem it is best to contact a Peterbilt Dealer or a reputable tow ing service However 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 Be sure to follow the precautions and instructions below WARNING Batteries contain acid that can burn N and gases that can explode Ignoring safety pro cedures can cause you or others to be killed or badly hurt WARNING Never jump start a battery near fire AN flames or electrical sparks Batteries generate explosive gases that could explode causing death or serious personal injury Keep sparks flame and lighted cigarettes away from batter ies 222 Y53 6027 Preventive Maintenance WARNING 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 neu tralize 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 con tact with the positive terminal do not contact the positive battery ter
98. at locks the wheels Medium Duty R05 09 Y53 6027 OPERATING THE REAR DRIVE AXLE mission it may be necessary to shift the trans mission to the Neutral position momentarily to allow the main inter axle differential lock splines to fully engage or disengage mn NOTE If your vehicle has an automatic trans 4 Drive the vehicle through the poor traction area keep ing your speed under 25 mph 40 km h To UNLOCK the inter axle differential 1 When you reach dry pavement or better road condi tions where the differential lock is not needed switch the differential lock to UNLOCK 2 Let up momentarily on the accelerator pedal to relieve torque and allow the clutch to disengage 3 When you unlock the differential normal vehicle han dling will resume and the light on the warning module will turn off 129 MORE DRIVING TIPS AND TECHNIQUES More Driving Tips and Techniques AN A 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 as it may cause an accident possibly resulting in death or personal injury CAUTION Operating a vehicle with air sus pension bags either overinflated or underin flated may cause damage to driveline components If a vehicle must be operated under such conditions do
99. ate a warm tire to the specified pressure CAUTION Pressure should be checked when Underinflated tires will adversely affect the operation of the vehicle and tires making steering difficult causing extra strain on the tire sidewalls reducing the tread life of tires due to the high tempera tures generated from excess flexing of the tire Inflate tires to the manufacturer s cold air pressure spec ification molded into the tire side wall Lower tire pressure does not give you more traction on ice or snow Underinflation actually reduces traction and steering control See the tire manufacturer s Drivers Handbook for more information on proper operation and use of tires Proper Inflation the correct profile for full contact with the road 00137a TREAD CONTACT WITH ROAD Medium Duty R05 09 Preventive Maintenance Underinflation causes abnor mal tire deflection which builds up excessive heat running the sindici pid nci Wm cosse risk of failure It also causes irregular wear 00138a CONTACT WITH ROAD Overinflation reduces the tread contact area with the road surface concentrating all of the vehicle weight on the center of the tread This causes prema ture wear of the tire Too much air pressure reduces the tire tread contact area and results in rapid wear in the center of the tire It also causes tires to run hard and makes them more vul nerable to impact and other road hazard damage
100. ate of manufac ture before waxing Do not apply wax in the hot sun Never dust off dry surfaces with a cloth because it will scratch the finishes Cleaning the Chassis agents are not recommended Do not use stiff brushes paper towels steel wool or abrasive cleaning compounds because they will scratch painted plated and polished metal sur faces 3 Rinse surfaces frequently while washing to flush away dirt that might scratch the finishes during the washing operation Medium Duty R05 09 Y53 6027 oil leak develops you will be able to detect it easier Corrosive materials used for ice and snow removal and dust control can collect on the underbody If these mate rials are not removed accelerated corrosion rust can occur on underbody parts such as fuel lines frames floor pan and exhaust system even though they have been provided with corrosion protection 231 Cab Maintenance At least every spring flush these materials from the under body with plain water Be sure to clean any area where mud and other debris can collect Sediment packed in closed areas of the frame should be loosened before being flushed If desired your Peterbilt Dealer or Authorized Service Center can do this service for you Cleaning Cab Interiors Peterbilt cab and sleeper interiors are built using a variety of different materials including fabrics carpet polyure thane and painted plastic surfaces These cleaning pro cedure
101. ation This will maintain the design integrity of the mounting points for the seat belt assembly Contact your Authorized Peterbilt Dealer if you have any questions concerning seat belt replacement 237 Cab Maintenance Windshield Wipers Washer Check wiper blades annually or every 60 000 miles 96 000 km Anco 18 inch 450mm wiper blades are recommended The windshield washer tank is located inside the engine compartment below the radiator expansion tank See Washer Reservoir on page 201 Check the windshield washing fluid level weekly If necessary fill to top long period more than 15 seconds with a dry CAUTION If the electric pump is operated for a reservoir the pump rotor may be damaged Clean all inside and outside windows regularly Use an alco hol 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 238 Y53 6027 Preventive Maintenance WINDSHIELD WASHER FLUID TANK 02391 Windshield Washer Fluid Tank Washer Reservoir ant in the windshield washer reservoir damage CAUTION Do not use antifreeze or engine cool to seals and other components will result Weekly check reservoir water level located in the engine compartment under the coolant expansion tank If necessary fil
102. ation and mainte nance 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 Rotate 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 auto matic tensioner 3 Release the automatic tensioner 4 Check the belt alignment on each pulley The belt must fall between the flanges of each pulley Medium Duty R05 09 Engine Maintenance Y53 6027 Engine Fan Thermatic Clutch Type Fan engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be killed or seriously injured Before turning on the ignition be sure that no one is near the fan 1 WARNING Do not work on the fan with the 177 Engine Cooling System To Check the Fan Check the fan assembly mounting bolts for tightness Inspect the blades for damage Check the clutch operation by starting the engine when it is cold Then idle it at about 800 RPM Listen for air leaks Check that the fan is not working while the en
103. aution the pressurized fluid from the master cylinder has two mutually indepen dent circuits The primary circuit supplies the front wheels while the secondary circuit supplies the rear wheels The displaced fluid from the master cylinder travels through brake pipes terminating at the wheel cylinders which actu ate the brake pad mechanisms Actuation of these mech anisms force the brake pads against the rotors to stop the wheels A reserve electric motor pump provides a redundant power source for the hydraulic booster in the event normal flow from the power steering pump is interrupted Manual braking is also available in the event both the power and reserve systems are inoperative WARNING Never drive your vehicle with the parking brakes applied Always release the parking brakes prior to moving the vehicle Failure to disengage the parking brakes prior to moving your vehicle could result in exces sive heat build up of the brakes and start a fire possibly causing death personal injury or porperty damage 121 USING THE BRAKE SYSTEM significant torque and startability power at low RPM Combinations of engine speed and avail able torque may over power the vehicle s parking brakes mn NOTE Today s diesel electronic engines have cle 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 check
104. available for a minimal charge from your Peterbilt Dealer or direct from the component manufacturer In addition supporting manuals and literature are included in the glove compartment of your Medium Duty vehicle Preventive Maintenance Intervals and Schedule Your preventive maintenance program begins with daily checks you perform See Driver s Check List on page 13 If your Medium Duty vehicle is serviced regularly you can avoid many large expensive and time consuming repairs as Medium Duty R05 09 Y53 6027 Maintenance Schedule and Lubrication well as ensuring many years of safe and smooth operation Also be advised that neglect of recommended service may in some cases void your vehicle s warranty So for your safety and life of your vehicle please follow Table 2 Mainte nance Schedule Page 157 But remember there may be maintenance operations that demands skills and equipment you do not have If so please take your Medium Duty vehicle to an expert mechanic for your safety and your vehicle s per formance WARNING It can be dangerous to attempt main AN tenance work without sufficient training service manuals and the proper tools You could be killed injured or you could make your vehicle unsafe Do only those tasks you are fully trained and equipped to do In severe operating conditions such as mining logging or earth moving you will need to perform maintenance checks and services more frequently
105. cal circuits a short circuit may occur causing death injury or property damage 1 WARNING Before attempting any work on the Removing and Installing Batteries 1 Be sure all switches on the vehicle are turned OFF 2 Disconnect negative ground cable 3 Disconnect positive cable 4 Unscrew bolt of holding plate with open end wrench To reinstall batteries 1 Place batteries in vehicle and tighten bolt of holding plate 2 Reconnect positive cable 3 Reconnect negative ground cable Medium Duty R05 09 Y53 6027 Electrical System Battery Care Regular attention to the charging system will help prolong the service life of the batteries Here are some common causes of battery failure Overcharge this condition results from improper voltage regulator adjustment It results in overheating of the battery warped plates and evaporation of electrolyte Undercharge the voltage regulator is 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 Vibration loose battery hold downs may cause battery plate failure Short Circuits these discharge the battery by draining electricity Dirty or Loose Connections improper connections may stop the flow of electrical power to and from the battery 221 Electrical System Jump St
106. ch is not a footrest Do not drive with your foot resting on the clutch pedal It will allow your clutch to slip causing excessive heat and wear damage could result Release Bearing Wear When you must idle your engine for any period of time shift your transmission to Neutral and disengage the clutch take your foot OFF of the pedal This helps pre vent unnecessary wear to your clutch release bearing and it is less tiring for you too 102 Y53 6027 STARTING AND OPERATING THE VEHICLE Clutch Adjustment Inspect manual clutches according to the manufacturer s recommendations Regular maintenance should be fol lowed to maintain correct clutch adjustment Have your dealer s Service Department perform any adjustment nec essary Tips Always use the clutch when making upshifts or down shifts Always select a starting gear that will provide suffi cient gear reduction for the load and terrain Never downshift when the vehicle is moving too fast Never slam or jerk the shift lever to complete gear engagement Never coast with the transmission in Neutral and the clutch disengaged To provide smooth gear engagements while shifting use proper coordination between shift lever and clutch Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE OPERATING THE TRANSMISSION Operating Automatic Transmissions There may not be a park position with your automatic transmission Always be sure you apply the par
107. cific tire revolutions per mile Use of a tire and or wheel size different from that originally installed on your vehicle may cause the ABS system to not function during a hard braking event This could cause an accident resulting in death or personal injury Consult with your Peterbilt dealer before using a different tire and or wheel size than was originally installed on your vehicle Parking Brake Burnishing N 126 WARNING If a new drum or new brake shoes are installed the driveline brake must be bur nished Failure to properly burnish the park ing brake before putting it in service could result in an inoperative parking brake possi ble vehicle rollaway and death personal injury or damage to the vehicle STARTING AND OPERATING THE VEHICLE This procedure is recommended for new vehicles where less lever actuation force is required This procedure is mandatory whenever the driveline brake shoes or brake drum are replaced 1 Y53 6027 Drive the vehicle at 15 mph 24 km h in a low gear first or second on a dry hard road surface Apply the parking brake lever with a moderate force approximately 40 pounds until the vehicle is brought to a stop Do not allow the wheels to lock up After stopping release the parking brake lever and drive the vehicle at 20 mph 32 km h in a low gear for approximately 2 5 miles to allow the brake drum to cool Repeat steps 1 2 and 3 above until a total of 10
108. crosstube lack of lubrication 243 Steering and Driveline If these checks do not reveal the problem or if you correct them and still have a steering problem take your truck to an authorized Peterbilt Dealer for evaluation Fluid Level and Refill Have the power steering fluid and filters changed at an Authorized Service Center Check and completely change the fluid level according to Table 1 Recommended Maintenance Intervals Page 154 Use the following procedure NOTE Before removing reservoir cover wipe outside of cover so that no dirt can fall into the reservoir The power steering fluid reservoir is attached to an under hood bracket on the LH side of the engine Maximum Minimum level is marked on the reservoir These same levels are also marked by lines on the dip stick in the reservoir There are two ways to check whether the power steering fluid is at its proper level Both checks are with the engine NOT running 244 Y53 6027 Preventive Maintenance RESERVOIR 02603 Power Steering Fluid Reservoir 1 If you check the fluid with the engine and steering sys tem COLD the fluid level should be at or above the Mini mum indicator level and should generally not exceed the middle point between Maximum and Minimum level indi cators If you check the fluid with the engine and steering sys tem WARM the fluid should NOT exceed the Maximum level indicat
109. d circuit allowing this circuit to continue normal operation The trailer brakes are still functional 112 Y53 6027 braking system always avoid completely depressing the service brake pedal if possi ble even during emergency braking Depressing the brake pedal too aggressively can cause the wheels to lock which can lead to an uncontrolled skid and can result in an accident involving death or personal injury WARNING Unless you have an anti lock For Non ABS Vehicles To stop your vehicle in an emer gency vary the service brake application pressure to pro vide maximum braking force without locking the wheels Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE Use engine compression to assist the service brakes by not depressing the clutch pedal until the engine reaches idle speed Overheated Brakes Under normal braking conditions the energy generated will bring the internal brake drum temperature to about 500 F 260 C This is well within the safe zone the max imum safe temperature of lining for drum type brakes is usually about 800 F 427 C But if service brakes are used for emergency braking used improperly or for prolonged periods internal brake drum temperatures may exceed 800 F 427 C Such brake overheating may be detected by a burning smell or smoke coming from a drum If this occurs you should immediately stop and check for cracked brake drums or lining fires If neither exists get b
110. d dry ser vice tanks are located behind the battery box and on the frame rail the supply tank is below the front service tank See Air Tanks on page 162 The wet tank receives air from the air dryer and cools it somewhat allowing moisture to condense for draining Relatively dry air is then supplied to the two service tanks for distribution to their respective brake circuits The ser vice tanks are isolated from each other by check valves Dual Service Brake Treadle Valve delivers air to the two service brake circuits Double Check Valve directs the higher air pressure from either the rear primary or front secondary service tank to the modulating valve Modulating Valve SR 1 used only on full trucks not tractors It performs four functions Limits spring brake hold off air pressure delivered to the spring brake chambers Provides a quick release of air pressure from the spring brake chambers to speed spring brake applica tion 119 USING THE BRAKE SYSTEM Modulates spring brake application in proportion to front service application in the event of a rear service failure Prevents compounding of service and spring applica tions Relay valve full truck speeds up the application of the rear service brake It also incorporates a quick release feature Brake Proportioning BP R1 valve tractor this valve delivers air to the tractor s service brake chambers It automatically proportions the dr
111. d equipment two keys are provided for the doors and ignition When necessary additional locks and keys are provided for storage compartments WARNING To help lessen the chance and or severity of death or personal injury in case of an accident always lock the doors while driv ing Along with using the lap shoulder belts properly locking the doors helps prevent doors from inadvertently opening and occu pants from being ejected from the vehicle Medium Duty R05 09 Y53 6027 To lock or unlock the doors from outside the cab Insert the key in the door lock Turn the key toward the rear door frame to lock for ward to unlock Cab and Frame Access The following cab and frame entry exit procedure recom mendations were prepared with personal safety foremost in mind into the cab without proper caution You could slip or fall possibly suffering death or serious injury You could slip and fall if the steps are wet or icy or if you step in fuel oil grease snow or mud f WARNING Do not jump out of the cab or get To help avoid personal injury due to a slip or fall e ALWAYS FACE TORWARDS THE CAB AND USE THREE POINTS OF CONTACT TWO FEET ONE HAND OR ONE FOOT TWO HANDS TO GRIP THE STEPS OR HANDHOLDS WHENEVER POSSIBLE AND LOOK WHERE YOU ARE GOING 9 N 02611 Use even more care when steps and handholds or footwear are wet coated with ice snow mud oil fuel or gr
112. d for extended periods of time fill the tanks to 95 percent of capacity Never fill to more than 95 percent capacity as this provides room for expansion resulting from temperature extremes When refueling add approxi mately the same amount to each fuel tank on vehicles with more than one tank 147 SHUT DOWN N N 148 WARNING Do not carry additional fuel con tainers in your vehicle Fuel containers either full or empty may leak explode and cause or feed a fire possibly causing death or personal injury Do not carry extra fuel containers even empty ones are dangerous WARNING Diesel fuel in the presence of an ignition source such as a cigarette could cause an explosion You could be killed or seriously injured A mixture of gasoline or alcohol with diesel fuel increases this risk of explosion Do not remove a fuel tank cap near an open flame e Use only the fuel and or additives recom mended for your engine STARTING AND OPERATING THE VEHICLE Specification Use only Diesel Fuel Grade 2 D as rec ommended by engine manufacturers If you need further information on Grade 2 D fuel specifications consult the Engine Operation and Maintenance Manual Location of Fuel Shut Off Valves If your vehicle is equipped with shut off valves for the take off and return lines they are located on the fuel lines entering the top of the fuel tank Fuel shut off valves for the fuel crossover line are on t
113. d on the dash The Red octagon shaped Trailer Air Supply Control knob on tractors will automatically pop out An optional dash warning light will indicate when the brake is ON 2 Shift the transmission into PARK position manual transmission select First or Reverse gear automatic transmission select Neutral 3 Turn the key to OFF 4 Remove the key 02394 1 Full Truck Parking Brake Control Knob Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE 2 Trailer Air Supply Control Red 1 Parking Brake Control Yellow A TO DB TRAILERS SUP NOT FOR PARKING 02394 Combination Tractor Trailer Parking Brake Control Valves The parking brakes act on the rear wheels only They are spring applied with air pressure used to release them Release air is supplied by both the front and rear circuit reservoirs through a double check valve To release the truck or tractor parking brakes ONLY Push IN the Yellow knob on the dash Your trailer will remain parked Below 60 psi 414 kPa the Yellow parking brake valve remains OUT ON position If air pressure is not restored above 60 psi 414 kPa the knob will auto matically return to the OUT position if you attempt to push it in See page 43 for more information Medium Duty R05 09 Y53 6027 USING THE BRAKE SYSTEM To release the trailer brakes ONLY Push IN the Red knob on the dash The truck or trac to
114. derstood recom mended procedures Some components contain powerful springs and injury or death Y53 6027 hold vehicle while parked This control uti lizes air pressure for brake application Because acceptable air leakage levels cause all truck air systems to gradually lose pres sure vehicle rollaway could occur resulting in an accident and death or injuries Always apply the tractor and trailer parking brakes when the vehicle is unattended 195 Air System Contamination of the air supply system is the major cause of problems in air operated components such as brake valves wiper motors and suspension height control valves To keep contaminants to the lowest possible level follow these main tenance procedures Table5 Air System Scheduled Maintenance Preventive Maintenance Scheduled Maintenance Use Table 5 Air System Scheduled Maintenance to schedule service operations and air system tests MAXIMUM INTERVALS TEST Air Compressor EACH WEEK EACH MONTH 10 000 mi 16 000 km THREE MONTHS 25 000 mi 40 000 km SIX MONTHS 50 000 mi 80 000 ANNUALLY 100 000 mi km 160 000 km Air Governor System Leakage Dual Air Brake Treadle Valve Hand Operated Trailer Brake Valve Tractor Parking Valve Parking Brake Valve Trailer Air Supply Tractor Protection Valves Relay Valve Spring Brake Inversion Valve Automatic Limitin
115. dium Duty R05 09 INTRODUCTION Medium Duty Body Builders Manual Contains general guidelines on mechanical and electrical modifications required by your dealer to add bodies accessories and special equipment to straight truck configurations WARNING Modifying your vehicle can make it unsafe Some modifications can affect your vehicle s electrical system stability or other important functions Before modifying your vehicle check with your dealer to make sure it can be done safely Improper modifications can cause death or personal injury Preventive Maintenance Section The Preventive Maintenance section pages 116 226 in this manual contains general service information for the operator such as lubrication points making adjustments and other helpful service information This is summary information only used for general maintenance of major components installed on your Medium Duty For detailed service information see your Medium Duty Maintenance Manual When it comes time for major service work your Peterbilt Dealer or Authorized Service Center will need vehicle and component information To help you gather this vehicle Medium Duty R05 09 Y53 6027 information see Consumer Information and Vehicle Iden tification on page 226 This section explains vehicle iden tification and provides space to record model and serial numbers of major components installed on your vehicle Additional Sources of Informatio
116. do so may allow the hood to fall unexpectedly resulting in death or personal injury To close the hood you must first release the hood safety lock WARNING Before closing the hood be sure the area is clear no people or objects are in the way Failure to do so may result in death or personal injury CAUTION To avoid hood damage when clos A ing the hood firmly pull the cable to release the hold open lock Locate the hood lock release cable as shown in the illus tration below The cable is located on the Drivers side bumper visable when the hood is in the open position 14 Y53 6027 Medium Duty R05 09 ENGINE ACCESS Medium Duty R05 09 if HOOD HOLD DOWNS AND TILT After lowering the hood latch the hood closed with the hold downs WARNING If the hood is not latched securely AN it could open during operation and cause an accident resulting in death or personal injury Be sure the hood is latched securely before moving the vehicle LATCHED Y53 6027 15 INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS Controls and Displays Instruments and Controls The dash includes standard gauges and switches Your vehicle may come with all or some of the switches and gauges discussed here The location of switches on the dash will vary depending on the options ordered and how your vehicle was configured Introduction Your Medium Duty vehicle s dashboard is shown
117. does not result from any change in the manner in which Peterbilt Motors Company trucks are manufactured f WARNING Diesel engine exhaust and some of lubricants oil and grease can be poisonous WARNING Handle lubricants carefully Vehicle and cause death injury or sickness 152 Y53 6027 Preventive Maintenance How to Order Parts Replacement parts can be ordered through your local Peter bilt Dealer For service parts information two parts catalogs are also available the Medium Duty Operator s Parts Catalog and the Peterbilt Electronic Parts Catalog ECAT When ordering replacement parts please provide the Medium Duty vehicle s Chassis Serial Number See Page 265 Operator s Parts Catalog a complete non illustrated listing of the Final Chassis Bill of Material It includes all parts used to custom build your Medium Duty Electronic Parts Catalog a complete illustrated parts listing for your specific vehicle with drawings and exploded views available only in electronic CD ROM format Medium Duty R05 09 Preventive Maintenance MAINTENANCE SCHEDULE AND LUBRICATION Introduction The following section summarizes preventive maintenance and lubrication requirements for the maintenance of your Medium Duty vehicle For specific maintenance procedures and complete lubrication instructions of specific components consult the Medium Duty Maintenance Manual and manu facturer s service manuals These manuals are
118. e Lubricate each pivot point on the clutch linkage 241 Transmission and Clutch Automatic Transmissions Service Intervals Check daily with engine idling See Table 1 Recom mended Maintenance Intervals Page 154 for service intervals Preventive Maintenance Automatic Transmission Oil Level n NOTE The vehicle must be parked on level ground Maintain the oil level and check it daily Oil should be up to the HOT mark on the dipstick when 1 the engine is run ning 2 the transmission is at operating temperature and 3 the transmission is in Neutral See the Transmission Opera tor s Manual in the glove compartment for more information on checking the transmission oil level Table 10 Transmission Lubrication Automatic transmissions AMBIENT RECOMMENDED TEMPERATURE RANGE MODEL LUBRICANTS VISCOSITY SAE DEG C DEG F ALLISON TranSynd Castrol Above 23 Above 10 10W 242 Y53 6027 Medium Duty R05 09 Preventive Maintenance STEERING AND DRIVELINE Power Steering Oil under low pressure provides the power to operate the steering gear It also serves to lubricate moving parts and remove heat A loss of steering efficiency will occur if too much heat builds up in the system WARNING Do not operate the vehicle if the N steering system is not working properly You could lose control of your vehicle if the steering system is not in good working condit
119. e has reached operating temperatures can decrease engine temperature and cause gummed piston rings clogged injectors and possible engine damage from lack of lubrica tion The normal torsional vibrations gener ated can also cause transmission wear Medium Duty R05 09 Y53 6027 95 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 Do not allow your engine to idle longer than five minutes Engine Fan Switch Option During the time it takes you to drink a cup of coffee f Your Medium Duty vehicle may have an engine fan switch installed as an option The switch which is mounted on the accessory switch panel allows you to control the engine fan manually or automatically e With the ignition key switch ON and the fan switch in the ON position the engine fan will be on regardless of engine temperature e With the engine fan switch in the AUTOMATIC posi tion the engine fan will automatically turn on when the engine coolant reaches a temperature of about 200 F 93 C 96 Y53 6027 STARTING AND OPERATING THE VEHICLE WARNING Do not work on or near the fan with the engine running Anyone near the engine fan when it turns on could be killed or seriously injured If it is set at MANUAL the fan will turn on any time the ignition key switch is turned to the ON position In AUTO it could engage suddenly without warning
120. e Do not drive with your seat belt loose A seat belt that is too loose can allow you to fall too far forward possibly causing head and neck injuries resulting in death or per sonal injury You could strike the wheel or the windshield Adjust your belt so that there is no more than 1 in 25mm of slack Y53 6027 SEATS WARNING Do not wear the shoulder belt under your arm or otherwise out of position In a crash your body would move too far for ward increasing the chance of death or 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 see Safety Restraint Belts on page 75 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 death or 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 Medium Duty R05 09 SEATS Safety Restraint Tips sons Not to be Transported Federal law prohib n NOTE Per FMCSH 392 60 Unauthorized Per Medium Duty R05 09 its the transportation of persons in commercial vehicles unless they are specifically authorized in wri
121. e Interval G2 Synthetic Lube Required 500 000 Drain Table 2 Maintenance Schedule INTERVAL COMMENTS gEe EE EE OPERATION FREQUENCY es 989 88 ooloco oo UN Pealss INITIAL DRIVE IN A B Cc Clutch Brake Clutch Pedal Free Travel inches Glass for Cracks or Chips Door Window Operation Radio Interior Lights Interior Appearance Seats Floor Mats Door Panels Headliner Sleeper Dash Covers Wiper Operation Medium Duty R05 09 Y53 6027 157 Maintenance Schedule and Lubrication 158 Table2 Maintenance Schedule Preventive Maintenance INTERVAL COMMENTS gEE Eb EE OPERATION FREQUENCY 8 8 SS 3s VYNITA S9S8 Wiper Blade Condition Horns Electric and Air Mirrors SAFETY EQUIPMENT A B Cc Drain Water from Air Tanks Air Tank Check Valve Emergency Operation of Spring Brakes Air Press Build up time min Governed Air Pressure psi Air Press Drop Brakes not Applied Air Press Drop Brakes Applied Fire Extinguisher Charge Flare Kit Reflectors CIRCLE INSPECTION A B Cc Physical Damage Exterior Sheet Metal Grille and Radiator Trailer Light Cord and Connectors Air Lines and Gladhands 5th Wheel Mounting and Condition Pintle Hook Eye Condition Headlights High and Low Beams Road Lights Marker Lights Turn Signals Y53 6027 Medium Duty R05 09 P
122. e 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 CONTROLS AND DISPLAY the windows open Failure to repair the source of the exhaust fumes may lead to death injury or personal harm il Y53 6027 NOTES Keep the engine exhaust system and the vehi cle 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 eTo allow for proper operation of the vehicle venti lation system keep the inlet grille at the base of the windshield clear of snow ice leaves and other obstructions at all times Medium Duty R05 09 CONTROLS AND DISPLAY elf you are required to idle your vehicle for long periods of time install an auxiliary heater or automatic idle control These auxil iary devices can reduce fuel consumption and save you money elf other vehicles are parked next to you idling move your vehicle or do not stay in your vehicle for prolonged periods of time When idling for short periods of time Set to Heat or A C Set the fan to Medium or High speed Set the controls to FRESH AIR To Set the Heater Air Conditioning C
123. e rear wheels and one for the trailer tractors only The system 104 Y53 6027 STARTING AND OPERATING THE VEHICLE is supplied by a compressor driven by the engine The vehicle s compressor takes outside air and compresses it usually to 100 130 psi 690 896 kPa This 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 truck and trailer brakes That is why when you push down on the brake pedal you do not 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 WARNING The brake system is a critical vehi AN cle 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 Ser vice Center Failure to properly maintain your brake system can lead to serious accidents involving death or personal injury Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE Brake Operation 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 wh
124. e tools Completely bypassing a Bendix AD IS air dryer will bypass the system s pressure pro tection valves This could lead to loss of air pressure or damage to the vehicle s air sys tem which could cause an accident involv ing death or personal injury Always adhere to the manufacturer s procedure if it is nec essary in an emergency to temporarily bypass an AD IS series air dryer f WARNING Do not release the parking brake or WARNING Prior to the removal of any air system 7 component always block and hold the vehicle by a secure means other than the vehicle s own brakes Depleting air system pressure may cause the vehicle to roll unexpectedly resulting in an accident causing death or injuries Keep hands away from chamber push rods and slack adjusters they may apply as system pressure drops 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 pres sure has been depleted attempt to move the vehicle until air pressure in both circuits is at least 100 psi 690 kPa the level required for normal brake operation Do not use the trailer hand brake control to Medium Duty R05 09 Never exceed recommended air pressure and always wear safety glasses when work ing with air pressure Never look into air jets or direct them at anyone Never attempt to disassemble a component until you have read and un
125. eaner muffler and exhaust pipes Are they tight and secure After Engine Warm up Automatic Transmission check fluid level in the automatic transmission oil if equipped Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE Starting and Operating the Vehicle Introduction For detailed information on starting and operating the engine refer to the Engine Operation and Maintenance Manual provided with your Medium Duty vehicle Because each vehicle is custom equipped all engine operation instructions presented in this section are gen eral You will want to consult the engine manual to find out details about your vehicle s specific engine requirements You may need to use a slightly different procedure from the one outlined here Also read the American Trucking Association s ATA Truck Driver s Handbook It will give you tips on starting shifting and driving your vehicle Medium Duty R05 09 N N Y53 6027 WARNING Do not use ether or other starting fluids as a cold starting aid in your Medium Duty vehicle Your engine uses either an elec trical grid or an open flame inside the mani fold to heat the air fuel mixture for cold weather starting If ether or another starting fluid is used the air fuel will ignite inside the manifold which could cause an explosion and death or severe injury WARNING Do not start or let the engine run in an enclosed unventilated area Exhaust fumes from the eng
126. ease WARNING Always reinstall the battery com MN partment cover step before entering the cab Without the battery cover you could slip and fall resulting in death or possible injury to yourself 10 Y53 6027 CAB AND FRAME ACCESS WARNING Do not step on vehicle compo nents without antiskid surfaces or use com ponents not designed for entry and exit use You could fall and kill or injure yourself if you step onto a slippery surface For example Do not step onto the surface of a fuel tank A fuel tank is not a step The tank surface can get very slippery and you might not be able to prevent a fall Use only the steps and handholds provided not chain hooks quarter fenders etc Do not climb onto and off the deck plate use steps and grab handle provided If there is no deck plate or if proper steps and grab handles are not provided do not climb onto the area behind the cab Do not climb onto or stand on the frame rails The frame rails are very slippery and could cause you to fall resulting in death or personal injury Keep steps clean Clean any fuel oil debris ice snow or grease off the steps before entering the cab or accessing the deck plate Medium Duty R05 09 CAB AND FRAME ACCESS ache racks tool boxes etc behind the cab that affects the utilization of grab handles deck plates or frame access steps installed by Peterbilt should comply with Federal Motor Carrier Safety Regulation 399
127. ed by an Authorized Ser vice Center Failure to properly maintain your brake system can lead to accident resulting in death or personal injury f WARNING The brake system is a critical vehi Brake Components The following is a brief description of the hydraulic brake system It is intended to supply you with general informa tion on how the system works For complete information see the Peterbilt Medium Duty Maintenance Manual 122 Y53 6027 STARTING AND OPERATING THE VEHICLE Anti Lock Brake System ABS Modulator Valve Body adjusts brake fluid flow between the master cylinder and the wheel calipers to avoid wheel lockup ABS Warning Lamp lights when the ABS controller detects wheel lock up while driving and activates the ABS Lights also when a fault in the ABS is detected Brake Fluid Reservoir stores brake fluid and offers a place to replenish when needed Brake Master Cylinder translates brake pedal force into hydraulic fluid pressure in the primary and secondary cir cuits Brake Pedal applies actuation force from operator s foot to the master cylinder pistons Brake Warning Lamp illuminates when either power steering fluid flow is interrupted or when a pressure differ ential is present in the primary and secondary brake fluid pressure Either case adversely affects braking operation Differential Switch measures the hydraulic fluid pres sure difference between the primary and secondary cir cuits
128. ed in excess of maximum rated speed Failure to comply with these speed restrictions could cause sudden tire failure which can result in death personal injury or property damage Tire Inspection and Replacement Visually inspect your tires frequently for any abnormal condi tions such as scrapes bulges and uneven wear This must be done immediately after known or suspected contact with an object in the road with a pothole road irregularity or after severe braking Refer these conditions to an Authorized Tire Service Center for repair or replacement Never drive on a tire if such conditions appear If the tire looks underinflated stand off to the side and check for damage to the wheel assembly This can be done by visu ally comparing the wheel in question to other wheels on the Medium Duty R05 09 Y53 6027 Tires and Wheels vehicle For dual wheel assemblies check between the wheels for damage If any damage is found or you suspect damage do not attempt further repair Call for expert tire ser vice Tire Inflation and Loading 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 And low pressure may affect con trol of your vehicle especially at the front wheels flated tires The extra heat caused by underinfla tion can cause sudden tire failure such as a tire
129. egular maintenance is required on the ABS components Medium Duty R05 09 Preventive Maintenance During wheel balancing dyno testing or any time the ignition is on with part of the ABS disconnected a failure code will be recorded Consult with your Peterbilt Dealer or Authorized Service Center for information on clearing the failure code 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 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 panel mounted amber warning light will come on indicating both a malfunc tion and automatic shut down of the system If the founda tion brake system is intact the service brakes will continue to function normally but without benefit of the anti lock feature Medium Duty R05 09 il Y53 6027 Brake System NOTE 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
130. elt may need adjustment To unfasten the belt Adjust safety belts properly Push in the release button on the buckle The belt will The lap belt should be worn as low and tight on the spring out of the buckle hips as possible Make sure any slack is taken up by To release a locked belt lean back to take the body the belt mechanism pressure off of the belt The shoulder belt should fit snugly across your body To store a lap shoulder belt allow the belt to wind up It should be positioned midway over the shoulder on the retractor by guiding the belt tongue until the nearer to the door it should never rest against your belt comes to a stop neck Lap Belt Shoulder Belt Too High on Hips j Fr Correct Incorrect 4 Correct over arm Incorrect under arm Incorrect twisted Safety Restraint Belts Medium Duty R05 09 Y53 6027 77 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 abdo men Do not twist the belt in the process of putting it on A twisted belt will not work as well to protect you A 78 WARNING Always wear your seat belt low over your pelvic bones Youcan be killed or seriously injured if your belt is buckled too high In a crash it would apply force to your abdomen not your pel vic bones This can result in death or seri ous internal injuries
131. em see the pages below If your truck has a hydraulic brake system please go to Hydraulic Brake System on page 188 Introduction To operate your vehicle safely you need some understanding of its brake systems Brake adjustment and brake balance must be set carefully to allow equal stopping forces at all wheels Tires are also a very important part of the whole sys tem How fast you can stop depends on how much friction there is between the road and your tires was configured for ONE of the following opera tions 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 CAUTION The air brake system of this vehicle 184 Y53 6027 Preventive Maintenance All of the following areas are interrelated and must conform to original specifications cam radius drum radius brake chambers tire size wedge angle brake linings slack adjusters Once a brake system is set to specifications changing any one of its components or any combination of components may degrade the system All parts have to work together to perform as they should Because your brake system is air operated see the following section Air System on
132. engine manufacturer s Engine Operation and Maintenance Manual supplied with the vehicle Fuel System Specification Use only Diesel Fuel Grade 2 D as recom mended by engine manufacturers If you need further infor mation on Grade 2 D fuel specifications consult the Engine Operation Manual in the glove compartment tion source such as a cigarette could cause an explosion You could be killed or seriously injured A mixture of gasoline or alcohol with diesel fuel increases this risk of explosion 1 WARNING Diesel fuel in the presence of an igni your fuel tank drain the entire system Other wise the pump and engine will be damaged Don t try to dilute the gasoline by adding diesel fuel see Warning above CAUTION If anyone ever pours gasoline into Medium Duty R05 09 Preventive Maintenance Failure to do so may damage components of the WARNING Use Ultra Low Sulfur Diesel fuel only A engine and Diesel Particulate Filter DPF Please follow these recommendations when you are chang ing your fuel filters or strainer elements Your vehicle s engine will run better and last longer if you do See the engine man ufacturer s recommendations for proper water and micron requirements Installing Fuel Filters When removing filters cover any electrical equipment and wiring that might get soaked with fuel Diesel fuel may per manently damage electrical insulation When installing spin on throwaway filters
133. er 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 March 1 2001 verify trailer ABS system status via the required external warning lamp mounted on the trailer The indicator lamp on the trailer should be yel low and identified with the letters ABS x ig C BRAKE A Y53 6027 CONTROLS AND DISPLAYS 7T Axle Inter Axle Differential Locked Tandem Axles IIluminates when the inter axle differential switch is ON thus locking the inter axle differ ential 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 differ ential effect mostly to the forward rear differ ential This feature is standard on all tandem axles 8 Brake System Illuminates to indicate a malfunction in the hydraulic brake system when equipped with Hybraulic brakes 9 Clock Alarm Bell Illuminates when the alarm is set It will flash when the clock alarm is active Medium Duty R05 09 CONTROLS AND DISPLAYS Medium Duty R05 09 10 Cruise Control Active Illuminates when cruise control is active 11 Dump Truck Body Up Illuminates when Truck Dump Body is up 12 Dump Truck Trailer Body Up Illuminates when Trailer Dump Body is up 13 Emissions Diesel Pa
134. ery 20 000 miles 32 000 km If the vehicle is exposed to severe environmental or working conditions more frequent inspec tions may be necessary Any seat belt system that shows cuts fraying extreme or unusual wear significant discoloration due to UV ultraviolet exposure abrasion to the seat belt webbing or damage to the buckle latch plate retractor hardware or any other obvi ous problem should be replaced immediately regardless of mileage Medium Duty R05 09 Y53 6027 Cab Maintenance time a vehicle is involved in an accident the entire seat belt system must be replaced Unex posed damage caused by the stress of an acci dent could prevent the system from functioning properly the next time it is needed which could result in severe injury or even death f WARNING It is important to remember that any Inspection Guidelines Follow these guidelines when inspecting for cuts fraying extreme or unusual wear of the webbing and damage to the buckle retractor hardware or other factors Damage to these areas indicates that belt system replacement is neces sary 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 sys tem from functioning properly the next time it is needed which could result in severe injury or even death 1 Check the web wear in the system The webbing must be clo
135. eventive Maintenance Lubrication Specifications You will find a complete Engine Lubrication Service Guide in the Engine Operation and Maintenance Manual There the engine manufacturer explains more fully all the maintenance operations you and a qualified service mechanic will need And please remember one key to keeping your Medium Duty vehicle 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 Below you will find basic information needed to perform rou tine vehicle lubrication 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 rough roads etc For any special service require Medium Duty R05 09 Y53 6027 Maintenance Schedule and Lubrication ments consult your service manuals and your lubricant sup plier The component manufacturer s specification and requirements take precedence over other specifications WARNING Handle lubricants carefully Vehicle AN lubricants oil and grease can be poisonous and cause death injury or sickness They can also damage the paint on the vehicle CAUTION Do not mix different types of lubri cants Mixing lubricants oil and grease of dif ferent brands or types could damage vehicle components therefore drain or remove old lubricants from the unit before re
136. eviations from the above list of lubricants should be based on specifications published in the component manufacturer s manuals or otherwise approved by the manufacturer 170 Y53 6027 Medium Duty R05 09 Preventive Maintenance Table 3 Recommended Lubrication Types Maintenance Schedule and Lubrication COMPONENTS Cam Brake Camshaft Splines Disc Brake Shaft Splines and Slide Pin Retainers Brake Clevis Pins RECOMMENDED LUBRICANT Antiseize type grease Rockwell specification 0 637 Brake Camshaft Bushings EP Chassis grease lithium 12 hydroxystearate base NLGI 2 CAUTION Do not contaminate brake linings with grease Steering Shaft Grease Fittings EP chassis grease lithium 12 hydroxystearate base NLGI 2 Brake Treadle Hinge and Roller Engine oil Lock Cylinders Lock lubricant Door Hinges Not required Teflon bushings Door Latches amp Striker Plates Polyethylene grease stick Door Weatherstrip Silicone lubricant Other Items Use manufacturer s manuals approved by the manufacturer Deviations from the above list of lubricants should be based on specifications published in the component manufacturer s manuals or otherwise Medium Duty R05 09 Y53 6027 ep Maintenance Schedule and Lubrication Preventive Maintenance 172 Y53 6027 Medium Duty R05 09 Preventive Maintenance AN A Medium Duty R05 09 EN
137. filling it When switching between types of lubricants thoroughly drain all areas of the component 167 Maintenance Schedule and Lubrication Lubrication Types Use Table 3 on page 170 and the list of lubricants below to identify the type of lubricant to use on your Medium Duty vehicle For a quick summary of each lubrication point see Table 1 on page 154 ATF DEXRONO 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 L 45199B w 1 85 max sulfated ash content CD Engine oil meeting API Five engine test sequence CD50 SAE 50W synthetic transmission fluid CE Engine oil meeting severe duty service requirements for direct injection turbocharged 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 Specification 0 616 MP Multipurpose gear lubricant MIL L 2105B SD Engine oils with increased protection against temperature deposits rust wear and corrosion WB Wheel Bearing grease Timken Specification 0 610 168 Preventive Maintenance APPLICATION LUBRICANT Universal Joints EP Drive Shaft Splines CL Wheel Bearings driven hubs HD Wheel Bearings n
138. fire or blow out which can cause an accident resulting in death or personal injury Low pres sure may affect control at the front wheels which could result in an accident and serious injury Keep your tires inflated to the manufac turer s recommended air pressure 1 WARNING Do not operate vehicle with underin 205 Tires and Wheels Tire Inflation Most tire wear problems are caused by underinflation as the result of slow leaks So you will want to check tire pressure regularly Give the 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 dual wheels tires etc If a tire appears underinflated check for damage to the wheel assembly Do not forget to check between dual wheels If you find wheel damage have an expert tire service repair it you are fully qualified and equipped to do so Wheel and tire assemblies cannot be worked on without proper tools and equipment such as safely cages or restraining devices Have all tire repairs performed by an expert And stand away from the tire assembly while the expert is work ing Failure to do this may result in death or injury f WARNING Do not repair damaged tires unless 206 Y53 6027 Preventive Maintenance the tires are cool Warm or hot tires cause pres sure buildup and will give you an inaccurate reading So never defl
139. for the batteries to regain power the key If the engine fails to start after a couple of tries there could be a malfunction with the engine or other Use of Accelerator related system Make any adjustments or repairs nec essary before trying to start the engine again For mild to warm temperatures above 60 F 16 C y bs 9 9 keep your foot OFF the accelerator pedal while crank When the engine starts ing If the engine does not start after 5 seconds apply Watch the oil pressure gauge Oil pressure should full throttle while cranking rise within 15 seconds after the engine starts If the oil For below normal starting temperatures fully depress pressure does not rise stop the engine Find what is the accelerator throttle pedal after engaging the wrong before restarting Check the Engine Operation starter and Maintenance Manual for the right oil pressure for NOTE Pumping the accelerator will not assist in your vehicle s engine In most engines idle pressure i starting the engine should be about 15 psi Medium Duty R05 09 Y53 6027 91 while the engine is running The starter and flywheel gears could clash or jam severely damaging them CAUTION Never operate the starter motor Wait until normal engine oil pressure registers on the gauge before idling or accelerating the engine beyond 1000 rpm Watch the air pressure gauge Wait until both pointers register at least 100 psi 689 kPa before releasing the spr
140. ft 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 trans mission than just the shift pattern Please read the manu facturer s manual that is included with your vehicle Y53 6027 eu ACCESSORIES CONTROLS AND DISPLAY Accessories 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 AN AN 79 WARNING Verify legal weight and height restrictions for the route suggested by the Navigation System Failure to verify height restrictions could lead to causing death per sonal injury or property damage Failure to verify weight restrictions could result in a traf fic infraction WARNING Only glance at the Navigation System monitor while driving Prolonged peri ods of viewing while driving could result in an accident involving death or personal injury A A il il Y53 6027 WARNING Do not program the Navigation System while driving Always stop your vehi cle when programming or changing the set tings on the Navigation System Programming the system while driving can cause you to take your eyes off
141. fter you have parked in a safe place check your vehicle to make sure it will be ready for the next trip To make sure your vehicle is ready to go after a long stop such as over night please follow the suggestions below Your vehicle will be easier to get going when you are ready and it will be safer for everyone who might be around it Please remember too that in some states it is illegal to leave the engine running and the vehicle unattended Final Stopping Procedures 1 Set the parking brake before leaving the driver s seat To hold your vehicle while it is parked DO NOT rely on the following air brakes hand control valve for trailer brakes engine compression Always use your parking brakes 146 Y53 6027 2 tended vehicle use the parking brakes Because service brakes work with air pres sure these brakes could slowly release Your vehicle could roll causing an accident result ing in death or personal injury Someone could be hurt or killed Never rely on the ser vice brakes to hold a parked vehicle If you must park on a steep grade ALWAYS BLOCK THE WHEELS 02440 Blocked Wheels Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE 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 enough to drain the mois ture Do not deplete the entire air supply
142. g This suction could draw your hand or anything else near it into the impeller fan You could be killed or seri ously injured Always keep the intake piping connected when you will be running the engine 1 WARNING Do not operate engine with the turbo Lubricating System Check the oil lines housing and con nections Look for leaks damage or deterioration Leaks could mean you have damaged oil lines or oil seals 202 Y53 6027 Preventive Maintenance Manifold With the engine operating check for leaking man ifold or flange gaskets High Frequency Vibration Vibration may indicate turbo rotor imbalance Have your Peterbilt Dealer or Authorized Service Center investigate this immediately If you detect any deficiencies take the vehicle to an Authorized Service Cen ter for servicing Delay could lead to severe and expensive damage to your vehicle Air Filter Replacement Service the filter elements when the Air Cleaner Restriction gauge option locks in the extreme High position Have the element serviced at a Peterbilt Dealer or Authorized Service Center Paper elements require care and proper handling because they are critical to engine service life Service the air cleaner periodically If the vehicle operates in areas with heavy dust maintenance should be more fre quent Follow the instructions below to remove the air filter Medium Duty R05 09 Preventive Maintenance Air System AIR
143. g Valve Single Check Valves Double Check Valves Stop Light Switch Low Pressure Wig Wag Low Pressure Switch 196 Y53 6027 Medium Duty R05 09 Preventive Maintenance Table5 Air System Scheduled Maintenance Air System MAXIMUM INTERVALS EACH MONTH THREE MONTHS SIX MONTHS ANNUALLY TEST EACH WEEK 10 000 mi 16 000 25 000 mi 40 000 50 000 mi 80 000 100 000 mi km km km 160 000 km Automatic Drain Valve Safety Valve Quick Release Valve Manual Drain Valve Air System Function Test Scheduled maintenance should be performed on the Medium Duty vehicle s air system as outlined in the Medium Duty Maintenance Manual and Table 5 In addition perform an Air System Function Test at least every 3 months or if there is any indication of a potential problem Air Tanks The front secondary service tank is underneath the cab on the driver s side the wet supply tank is underneath the front service tank behind the battery box and the rear primary service tank is attached to the left frame just behind the cab Medium Duty R05 09 Y53 6027 The supply tank or wet tank must be drained on a daily basis Drain the supply tank by pulling the drain valve lan yard Hold it open until the escaping air is free of water The two service tanks or dry tanks must be drained on a weekly basis Drain
144. g in death or serious personal injury Consult your nearest Peterbilt dealer f WARNING When replacing disc brake pads be Disc brake pads Visually inspect all brake pad linings Brake pads should be replaced when the remaining lining reaches 3 16 inch thickness or less Medium Duty R05 09 Preventive Maintenance It is recommended that all disc brake pads be replaced at the same time since this will maintain bal anced braking At a minimum replace all disc brake pads on one axle both ends at the same time ANCHOR PLATES BRAKE PADS BRAKE PADS CALIPERS CALIPERS REAR SYSTEM COMPONENTS Medium Duty R05 09 Y53 6027 Brake System Calipers Visually inspect calipers for brake fluid leakage dam aged or defective pistons or piston boots If there is evidence of leakage damage or other defects the caliper should be replaced or repaired Disc brake rotors Visually inspect rotors for scoring warping cracks bluing or heat spots or other damage or defects If signs of damage or defects are found the rotor s should be resurfaced or replaced in accordance with the vehicle manufacturer s recommended service procedure Anchor plates Visually inspect anchor plates for worn or damaged slippers damaged or dislodged guide pin boots or other defects If signs of wear damage or defects are found the anchor plate s should be repaired or replaced Parking Brake Component Inspection Hn NOTE If
145. g your vehicle to a safe stop off of the road 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 Maximum transmission temperature may vary depending upon the transmission and type of lubricant Check your transmission s owner s manual Y53 6027 Medium Duty R05 09 CONTROLS AND DISPLAY 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 condi tions 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 lubri cation checked Medium Duty R05 09 Y53 6027 OPTIONAL GAUGES your rear drive axles can cause serious damage to axle bearings and seals Have your axle lubri cation checked if you notice a sign of overheat ing Steering Column Mounted Controls CAUTION Driving with very hot temperatures in Turn Signal and Indicator Lights NOTE The ignition key must be turned to ON for i the signal switch to operate Your turn signal lever is mounted on the left side of the steering column below the steering wheel Green direc tional indicator lights appear on the instrument panel To 45 OPTIONAL GAUGES
146. gine is warming When the clutch engages note the reading on the vehicle s panel mounted coolant temperature gauge If the fan clutch engages at low engine tempera ture or cycles on and off more frequently than it should receives false signals have the problem corrected at an Authorized Service Center Fan Drive and Blade Fan Blade Clearance Around the fan shroud the recom mended distance is 1 in 25 mm from front edge of any fan blade to radiator side member Minimum clearance is 3 4 in 19 mm Rear edge of any blade must be no closer than 3 8 in 9 mm to the nearest engine component If this cannot be obtained the fan spacer or fan is not correct 178 Y53 6027 Preventive Maintenance The leading edge of any fan blade must be 1 in 25 mm from the inside edge of the shroud Exhaust System The exhaust system is part of the noise control system Peri odically check the exhaust for wear and loose or missing parts For details see Noise and Emission Control on page 257 verter muffler or independent converter become extremely hot during engine operation and can cause death or personal injury including serious burns to the skin Allow adequate cooling time before working on or near any part of the exhaust system 1 WARNING The exhaust piping muffler con Engine Cooling System Your engine s cooling system is standard with Extended Life Coolant ELC ELC consists of a mixture of ethylene
147. glycol water and organic acid technology chemical inhib Medium Duty R05 09 Preventive Maintenance itors ELC prevents corrosion and scale formation as well as provides freezing and boiling point protection A CAUTION The engine cooling system has very specific maintenance and inspection require ments Failure to follow requirements can dam age the engine Engine damage can include but is not limited to Freezing Boiling Corrosion Pitted cylinder liners This information is found in the engine manufac turers owner s manual It is the owner s respon sibility to follow all requirements listed in the engine manufacturers owner s manual Engine Cooling System What To Check In An ELC filled Cooling System ELC Concentration Check the level of freeze boilover protection which is determined by the ELC concentration Use a glycol refrac tometer 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 il In an ELC filled cooling system the freeze point should be maintained between 30 F and 45 F 34 C and 43 C NOTE Maximum recommended ELC concentra tion is 60 ELC and 40 water by volume a 60 40 coolant mixture The minimum recommended concentration is 40 Desired ELC 0 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80
148. handling Exceeding load ratings can also shorten the When the engine speed reaches its maximum governed service life of the vehicle speed the injection pump governor cuts off fuel to the engine However the governor has no control over the engine rpm when it is being driven by the vehicle s trans the vehicle is not loaded in excess of either mission for example on steep downgrades Apply service the gross vehicle weight rating GVWR or brakes or shift to a higher gear the maximum front and rear gross axle Fuel economy and engine performance are also directly weight faungs GAWAS Axle weight rat ui us ings are listed on the driver s door edge related to driving habits mn NOTE For your safety and the safety of others e The components of your vehicle are designed to provide satisfactory service if The best results in trip time and fuel economy are a follow routine and periodic maintenance sched obtained while driving the vehicle at a steady speed ules for all components on your vehicle See Table 3 Maintenance Schedule Page 123 132 Y53 6027 Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE Air Suspension Height Air Pressure Your vehicle may have an air suspension A deflation switch on the dash allows you to exhaust the air in the suspension which allows you to lower the height of your vehicle for loading On tractors the deflate switch allows you to lower the fifth wheel to slide unde
149. he c n tromi the Bs was removed Insert it into the ening eran P REE CHS DOM pressure plate Turn the release Ca 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 2 Remove the release stud position assembly from the side pocket and remove the release nut and washer from the release stud 5 Assemble the release stud washer and nut on the release stud 3 Slide out the release stud Medium Duty R05 09 Y53 6027 143 VEHICLE RECOVERY AND SPRING BRAKES STARTING AND OPERATING THE VEHICLE 6 With a wrench turn the release stud assembly nut until Gat the compression spring is 90 ho EE a 2 95 percent caged While doing Freeing the Vehicle from Sand Mud Snow and Ice VE 35 mph 55 km h Spinning a tire at speedom eter readings above this can be dangerous tires can explode from spinning too fast this check to make sure the aM S Rr push rod adapter push rod or 7 7 ww service push rod is retracting WARNING Do not spin the wheels faster than Do not over torque the release stud assembly S Cam type maximum 50 ft Ib Wedge type maximum 30 ft lb The spring brake is now mechanically released Under some conditions a tire may be spin ning at a speed twice that shown on the speedometer Any resulting tire explosion could cause severe injury or death to
150. he bottom of the fuel tank at the crossover line connection Y53 6027 Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE SHUT DOWN Medium Duty R05 09 Y53 6027 149 Introduction Preventive Maintenance PREVENTIVE MAINTENANCE INTRODUCTION This section will help you keep your Medium Duty 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 Peterbilt Dealer or Authorized Service Center do any work you do not have the tools or skill to perform Authorized service mechanics are trained in the proper technical and safety procedures to maintain your Medium Duty vehicle correctly Good driving practices daily and weekly driver maintenance inspections and periodic service inspections by an Autho rized Service Center will help keep your Medium Duty vehi cle in good working order and provide many years of dependable service 150 AN Y53 6027 WARNING It is dangerous to work on a vehicle without the right know how and proper tools You could be killed or seriously injured cause damage to the vehicle or make your vehicle unsafe to drive Do only work you know you are fully able to do and for which you have the right tools Before attempting any procedures in the engine compartment stop the engine and let it cool down Hot components can burn skin on con tact Be alert and cautious around the engine
151. he electrical system 2 Determine from the chart on the fuse panel which fuse controls that component 3 Remove that fuse and see if it is blown If itis blown replace it with a fuse of the same rating A Adding Electrical Options higher than 30 amps Doing so may damage the electrical system and cause a fire possibly causing death personal injury or property dam age CAUTION Follow all manufacturers circuit pro 1 WARNING Do not add a fuse with a rating tection recommendations for the components and wires being added Medium Duty R05 09 Y53 6027 Electrical System Spare circuits are located throughout the wiring for the dash For proper electrical system performance refer to a wiring diagram for your chassis before adding electrical options Truck Body Connection Your vehicle includes a junction box mounted to the frame for wiring the vehicle body to the main chassis harness Refer to the Body Builder s Manual for further information on using the Truck and Body Connection Battery Cables ing in death or serious personal injury and or property damage if not properly maintained and located Regularly inspect the battery cables and connectors for damaged or compromised cable insulation Contact your Authorized Ser vice Center if you are in need of repairs or infor mation WARNING Battery cables can cause fires result Turn off the ignition and disconnect the negative battery cable
152. hen pressure is removed from the valve lever it will return to the OFF position substitute for the service brakes Using this brake frequently instead of using the foot brake will cause the trailer brakes to wear out sooner f WARNING Do not use the trailer hand brake d NOTE The trailer brake is not to be used as a or service brakes to park and hold an unat tended vehicle use the parking brakes Because service brakes work with air pres sure 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 Driving Bobtail or With an Unloaded Trailer NOTE The following information is applicable only to tractor configurations Do not use the engine retarder such as an exhaust brake to slow the vehicle down when you are bobtailing or pulling an empty trailer Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE when you are driving bobtail or with an unloaded trailer Using engine retarders while bobtailing or with an unloaded trailer can cause a wheel lockup resulting in less control and or jackknife The trailer may not load the rear tractor tires enough to provide necessary traction When you are bobtail or unloaded you can have a serious accident causing death or personal injury if your wheels lock suddenly during braking WARNING Do not use an engine retarder Bobtail Brake Proportion
153. here are several tools built into this manual to help you find what you need quickly and easily First is the Con tents 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 Contents to find information on a large subject like Operating the Transmission Cross references 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 a cross reference will refer you to another page for example See page 75 for more information on Safety Restraint Belts Finally you will find a helpful Index at the back of the man ual listing subjects alphabetically For example if you want information on brakes just look under Brakes in the Index You will find the pages where brakes or related top ics are discussed A Special Word About Repairs This is not a repair or workshop manual Your Peterbilt Dealer s Service Center is the best place to have your Medium Duty repaired You can find Peterbilt dealers all over the country with the equipment and trained person nel to quickly get you back on the road and to keep you there Your Medium Duty is a complex machine Anyone attempting repairs on it needs good mechanical training proper specifications and proper tools If you are sure you meet these qualifications then you can probably perform some repairs yourself But if yo
154. hin the previous 30 minutes be very careful in removing the fill cap Pro tect 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 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 fully Ethylene glycol antifreeze is poisonous and can cause death or personal injury Store in original fluid container only and always keep out of reach of children 1 WARNING Handle coolant and antifreeze care Medium Duty R05 09 Preventive Maintenance FILL COOLANT EE EXPANSION ps TANK T Cooling System Expansion Tank Proper Coolant Level il NOTE Do not overfill a cooling system Excess coolant may result in overflow loss of antifreeze and reduced corrosion protection Medium Duty R05 09 Y53 6027 Engine Cooling System 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
155. ic preventive maintenance inspections We have tried to present the information you ll need to learn about your vehicle s functions controls and opera tion as clearly as possible We hope you ll find this manual easy to use There will be times when you need to take this manual out of your Peterbilt vehicle When you do please be sure to return it to the cab when you are fin ished 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 Your Medium Duty may not have all the features or options mentioned in this manual Therefore you should pay care ful attention to the instructions that pertain to just your Medium Duty R05 09 Y53 6027 vehicle In addition if your vehicle is equipped with special equipment or options not discussed in this manual con sult your dealer or the manufacturer of the equipment All information contained in this manual is based on the latest production information available at the time of publi cation Peterbilt Motors Company reserves the right to make changes at any time without notice Safety Signals A number of alerting messages are in this manual Please read and follow them They are there for your protection and information These messages can help you avoid injury to yourself and your passengers and can help pre vent costly damage to the vehicle Key symbols and signal words are used to indicate what kind of message is goi
156. ication Thus if there is a rear service failure the remaining front axle braking is supplemented by modulated spring brake action on the rear axle did USING THE BRAKE SYSTEM WARNING Efficiency of emergency braking depends on the amount of air available in the front circuit reservoir which is sufficient for a limited number of brake applications and releases REMEMBER when the remaining system pressure drops below 60 psi 414 kPa the spring brake is automatically applied stop ping the vehicle abruptly potentially caus ing death or serious injury Observe the STARTING AND OPERATING THE VEHICLE If air pressure is lost in the trailer supply park circuit and the pressure drops below 60 psi 414 kPa the trailer spring brakes are automatically applied and the tractor air pressure circuits are unaffected If air pressure is lost in the trailer brake service circuit and the pressure in the tractor front and rear circuits drops below 60 psi 414 kPa the tractor and trailer spring brakes are automatically applied warning light BRAKE AIR in the panel it Emergency Braking will come on before the spring brakes are applied If it comes on do not continue to drive the vehicle until it has been properly repaired or serviced Brakes Tractor Trailer The following applies to tractor trailer configurations If pressure is lost in the tractor front or rear circuit the check valves isolate the unaffecte
157. ication The Chassis Serial Number refers to the last seven char acters of the VIN including the assembly plant designa tor eleventh character position and a six digit serial number This number will allow your Peterbilt Dealer to identify your vehicle You will be asked for this number when you bring your vehicle in for service All Peterbilt vehicles are identified by a 17 digit Vehicle Iden tification Number VIN This unique numeral and letter com bination identifies the manufacturer the model year it was built and other vehicle attributes The VIN is in compliance with 49CFR565 Code of Federal Regulations As an exam ple the model year and assembly plant are designated by a letter in the tenth and eleventh character positions see 4 and Table 13 Model Year Letter Designations 5 below CODE YEAR 2 2002 3 2003 SAMPLE VIN 4 2004 2iNIP NHHD 8X X Y M 5 6 7 8 9 0 5 2005 Vy NL 6 2006 LU e 66 i6 y VIN Location Manufacturer ldentifi r The VIN is marked on the Incomplete Vehicle Certification Vehicle Attributes Label on trucks or on the Tire Rim and Weight Rating Check Digit Data Label on tractors Both labels are located on the Model Year DDR 6 Assembly Plant driver s door frame Serial Chassis Number Vehicle Identification Number VIN 264 Y53 6027 Medium Duty R05 09 Pre
158. ich could contribute to an accident that could cause death or personal injury j WARNING Do not drive through water deep If you think your brakes have become wet check the rear and both sides of the vehicle for clear traffic then gently apply the brakes releasing and gently reapplying until the brakes dry out restoring normal operation Always check your brakes after driving through deep water to help reduce the possibility of personal injury or an accident Front Brake System When the brake pedal is depressed the front circuit por tion of the treadle valve delivers air from the front service reservoir to the front axle brake chambers via a quick release valve Medium Duty R05 09 Y53 6027 USING THE BRAKE SYSTEM Simultaneously on full truck configurations air is also supplied to the modulating valve control port In the event of a rear service circuit failure the modulating valve will exhaust air from the spring brake chambers applying the spring brakes in proportion to the front circuit application Rear Brake System When the brake pedal is depressed the rear circuit por tion of the treadle valve delivers air from the rear service reservoir to the service brake relay valve control port The relay valve then delivers air directly from the rear service reservoir to the rear brake chambers in proportion to the treadle pressure On tractors without ABS the relay valve is part of the BP R1 brake valve which a
159. if your vehicle is equipped with Rockwell WABCO anti lock brakes ABS the operation of the exhaust brake if turned ON will be controlled by the ABS For more ABS information see Anti Lock Braking Sys tem on page 113 For more information on when and how to use the engine retarder in your vehicle see the owner s manual for the engine brake that is included with your vehicle Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE Brake Components The following is a brief description of the air brake system It is intended to supply you with general information on how the system works For complete information see the Medium Duty Maintenance Manual Compressor supplies air to the system System pressure is controlled by the governor Governor controls the air pressure in the system by actuating the compressor discharge mechanism Its cut out pressure is 115 to 125 psi 793 to 862 kPa Its preset cut in pressure is set to between 13 to 25 psi 90 to 172 kPa below the cut out pressure setting cut out and cut in interval is not adjustable Safety Valve installed on the supply reservoir outlet It should vent off at 150 psi 1034 kPa permitting air to escape Air Dryer Option collects and removes moisture and contaminants from the air as it travels from the compres Sor to the wet tank reservoir Medium Duty R05 09 Y53 6027 USING THE BRAKE SYSTEM Compressed Air Tanks The wet supply an
160. ight control link connected to the axle and to the suspension air valve control arm This will DRIVING TIPS AND TECHNIQUES WARNING Low air pressure could make brakes unsafe for driving by not providing sufficient air brake application pressure in an emergency which could lead to an accident resulting in death or personal injury Before driving the vehicle make sure the air pressure pumps up to over 100 psi for normal brake operation If it does not reach 100 psi do not try to move the vehicle CAUTION Do not operate a vehicle with air suspension bags either over or under inflated This could cause damage to drive line components If you must drive under such conditions do not exceed 5 mph 8 km h Fifth Wheel cause the air valve control arm to center in the closed The following applies to tractor configurations position 2 The air system can then be pumped up to normal AN pressure for continued operation Medium Duty R05 09 Y53 6027 WARNING Ensure that all fifth wheel mainte nance adjustments and rebuilding are done only by a qualified mechanic An improperly maintained fifth wheel can cause a trailer to separate from a tractor This could lead to an accident causing death personal injury and damage to property 137 DRIVING TIPS AND TECHNIQUES Your Medium Duty vehicle may be equipped with either a fixed or an air controlled sliding fifth wheel Either type should self lock when a trailer king pi
161. ine contain carbon monox ide a colorless and odorless gas Carbon monoxide can be fatal if inhaled e Do not park or operate the vehicle in areas where the hot exhaust system may come in contact with dry grass brush spilled fuel or other material that can cause a fire 89 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 CAUTION The use of a winterfront can result Refer to the Engine Operation and Mainte nance Manual for operating restrictions and recommendations 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 Starting Procedure Normal Temperatures Use the following procedure to start your Medium Duty vehicle when outside temperatures are at or ABOVE nor mal starting temperatures Check the Engine Operation and Maintenance Manual for starting temperatures 1 Set the parking brake 90 Y53 6027 STARTING AND OPERATING THE VEHICLE should be applied to the turbocharger oil inlet port 1 if the engine has not been started for more than 25 days or 2 the outside tempera ture is very cold or 3 the oil filter has been changed With an oil can squirt approximately one half cup 120 ml of clean specified engine
162. ine of the suspension see illustration on page 134 For a single axle make the measurement in front of v the axle in the area forward of the tires but not past E POS ere et the suspension bracket m3 3 4 When at the correct ride height ensure that the height a a control valve lever is in the neutral position then s tn a install either the built in alignment pin or a 1 8 inch 3 T LINK ROD mm dowel see page 134 EXHAUST ces 02941B 5 Torque the mounting fasteners to 55 75 Ib in 6 2 8 5 N m Typical Height Control Valve Rear View Looking Forward 6 Remove the alignment pin or dowel 7 Repeat Steps 2 through 6 above for the RH valve on vehicles with a dual valve system 136 Y53 6027 Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE Driving with Deflated Air Springs Vehicles with the air suspension option If an air spring ruptures there will be enough air pressure to drive the vehicle to a safe stop off the highway to investigate the problem WARNING Do not continue to drive with rup tured air springs The air loss can cause the spring brakes to apply allowing your brakes to drag and burn up the linings which could lead to an accident causing death or personal A injury Do not continue to operate the vehicle in this condition To get to a repair facility do the following 1 Remove the he
163. information 3 Turn the key to OFF 4 Remove the key valve while the vehicle is moving Stopping with the parking brake controls can cause a sudden wheel lock up loss of control or over take by following vehicles possibly resulting in an accident involving death or personal injury f WARNING Do not pull out the parking brake 64 Y53 6027 CONTROLS AND DISPLAY WARNING Before operating your vehicle after it has been parked do not forget to push in the parking brake valve to release the parking brakes Failure to release your parking brakes before putting the vehicle into motion can cause fire or loss of control of the vehicle which can result in death or personal injury See Using the Brake System on page 104 for more infor mation for vehicles with hydraulic brakes The parking brake consists of a driveline drum brake actu ated by a lever and cable The hand lever mounted on the vehicle s cab floor pulls or releases the cable controlling the brake Pulling upward on the parking brake lever pulls the cable and expands the driveline brake shoes outward against the driveline brake drum The driveline brake is disengaged by pushing the handle downward to its lowest position NOTE Failure to fully release the parking brake LE can cause the brakes to overheat Medium Duty R05 09 CONTROLS AND DISPLAY upward on the parking brake lever while the vehicle is moving Attempting to stop with the
164. ing 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 Units of measure on page 36 for another method to change units NOTE The OAT will come on when the door is LI 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 LE 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 tempera ture displayed while the vehicle is stationary 39 STANDARD GAUGES CONTROLS AND DISPLAY Engine Oil Pressure Gauge If your oil pressure suddenly drops while you are driv ing 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 cen ter 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
165. ing System When a trailer is not connected the drive axle brake appli cation pressure will automatically be limited by the propor tioning system The brake proportioning system regulates the application pressure to the rear drive axle To provide equivalent brak ing power tractors driven bobtail will require greater brake pedal application than other types of vehicles not equipped with a proportioning system Medium Duty R05 09 Y53 6027 USING THE BRAKE SYSTEM On tractors that do not have anti lock brake systems ABS a bobtail brake proportioning system is installed When a trailer is not connected bobtail mode the brake application pressure on the rear drive axle will automati cally be limited by the proportioning system Engine Retarder option An engine retarder or exhaust brake may be installed as an option to create a braking effect on the drive wheels This device uses your engine s power to slow your vehicle down Because it can help keep your vehicle s brakes from overheating it can save wear and tear on the service brakes However the retarder is not an emergency brake Ideally on normal road surfaces you should slow your vehicle with the retarder where permitted by law and use the service brakes only for stopping completely Operating this way will greatly prolong the life of the brakes dic USING THE BRAKE SYSTEM in an emergency The engine or retarder alone might not stop you fast e
166. ing brake and moving the vehicle Also check the alarm system for any type of faults and correct them before moving the vehicle CAUTION Do not try to put the vehicle in motion before pressure in the air system reaches 100 psi 689 kPa because the wheels will still be locked by the spring brake action e Unnecessary stress and possible brake malfunction could occur if the vehicle is forced to move before the air system reaches 100 psi 689 kPa 92 Y53 6027 STARTING AND OPERATING THE VEHICLE Starting Procedure Cold Temperatures In addition to the previous Normal Starting Procedures use these Cold Weather Starting guidelines when the air temperature falls below a certain temperature Check your Engine Operation and Maintenance Manual for further details on when cold weather starting aids are needed Using special cold starting equipment will help the engine start easier And in cold weather fast engine starting helps relieve the loads on the electrical system and crank ing motor If you follow these few simple guidelines you will extend the service life of your vehicle s engine Keep the electrical system in top condition Use the best quality and recommended grade of fuel see Engine Operation and Maintenance Manual Use the recommended engine lubricating oil As stated in the Normal Starting Procedures when temperatures are below normal fully depress the accelerator pedal after engaging the starte
167. intenance NOISE AND EMISSION CONTROL 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 manufac tured 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 Peter bilt 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 Medium Duty R05 09 Y53 6027 Noise and Emission Control Tampering with Noise Control System Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorpo rated into any new vehicle for the purpose of noise con trol prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 The use of the vehicle after such device or element of design has been removed or rendered inoperative by any pe
168. ion which could result in an accident causing death or injury For driving safety visually check the steering gear and components Frequent checks are important for driving safety especially after traveling over rough roads NOTE If the steering feels unbalanced from side to Hn side while turning check for the following possible Causes e unequal tire pressures e vehicle overloaded or unevenly distributed load e wheels out of alignment e wheel bearings improperly adjusted Medium Duty R05 09 Y53 6027 Steering and Driveline If you cannot correct the problem check with an Authorized Service Center The Medium Duty vehicle is equipped with integral power steering The system includes an engine driven fluid pump a fluid reservoir the steering gear and connecting hoses Because of the hydraulic power assist little effort is required to turn the steering wheel When no input is applied through the steering wheel the steering gear will return to the neutral position If for any reason the power assist system goes out steering the vehicle is still possible yet it will require much greater effort Visually check the following parts Crosstube Is it straight Draglink tube clamp Check for looseness or interfer ence Ball joints and steering U joints Check for looseness Steering wheel for excessive free play Check the sim plest probable causes first unequal tire pressures loose cap nuts bent
169. ip 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 37 STANDARD GAUGES 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 dis tance 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 39 il NOTE The Odometer Trip Meter comes on when the door is opened or the key is in the accessory or ignition position The Odometer Trip Meter will remain on for 3 seconds after the door is closed or the ignition switch is turned off This allows driver and service personnel to read the odome ter without ignition switch being turned on 38 Y53 6027 CONTROLS AND DISPLAY Tachometer HHHHH Has A BR ovs Your tachometer measures the engine speed in revolu tions per minute RPM The tachometer also i
170. ipes Do not mix these fluids when replenishing the system or seal damage can result CAUTION Hydraulic brake fluid may damage painted surfaces of the vehicle 189 Brake System Make sure that the fluid level registers on or above the fluid level mark molded on the reservoir add more if necessary as follows 1 Remove each reservoir cap and extract the rubber dia phragm from each reservoir 2 Fill each reservoir with clean hydraulic fluid of the approved specification DOT 3 brake fluid 3 Insert the rubber diaphragms into the reservoirs REFILL CAPS BOOSTER AND MASTER CYLINDER ASSEMBLY 4 To prevent leakage from the reservoirs ensure that the seal in each reservoir cap is in good condition before refitting the cap 190 Y53 6027 Preventive Maintenance excessive amount of hydraulic fluid the com plete system must be inspected for leaks and repaired if necessary consult your nearest Peterbilt dealer Failure to keep the brake sys tem in good repair may lead to loss of braking and possibly cause an accident resulting in death or serious personal injury f WARNING If the brake fluid reservoir requires an Service Brake Component Inspection Remove each wheel to inspect the brake components sure to use the same lining material on both axles Mixing lining types can result in unbal anced braking increased pad wear or degraded Stopping performance possibly cause an acci dent resultin
171. ir pressure gauge 92 E Economical driving 130 Electrical system 220 alternator 227 batteries 220 221 225 battery charging 221 224 226 jumper cables 222 Electrolyte 225 Emergency braking 112 equipment 85 Emission Components 176 Engine belt tension 86 221 block heater 93 compression 146 daily checks 86 fan switch 96 heater 182 215 218 53 6027 a identification 268 idling 95 lubrication 173 oil draining 174 oil level check 174 overspeed 131 retarder 117 rpm 147 service notes 173 starting procedure 89 stopping the engine 147 vital engine systems 94 warmup procedure 94 weekly checks 88 winterfronts 90 Engine Oil Pressure 17 Environmental protection 152 Ether 89 Exhaust brake 117 118 fumes 151 F Fan blade 259 switch 96 Federal motor regulations 83 85 Federal motor vehicle safety standards 5 Federal safety label 268 Fifth wheel 137 272 air controlled 138 fixed 138 lock switch 138 maintenance 255 sliding maintenance 256 Frame precautions 255 Front axle 247 front axle identification 268 Front brake system 105 Front suspension u bolts 246 Front Wheel Calipers 123 Fuel filter 86 175 filter draining 175 refueling 147 System 148 Fuel Level 17 Fuel Tank Inspection 176 Fuel tanks 176 G Gauges and Displays 37 Drive Axle Temperature Gauge 45 Engine Oil Pressure Gauge 40 Fuel Gauge 42 Speedometer Odometer 32 37 Tachometer 38 Voltmeter 42 Y53 6027 Medium Duty R05 09
172. irs through a double check valve USING THE BRAKE SYSTEM TRAILER TRAILER AIR PARKING AIR SUPPLY BRAKE SUPPLY NORMAL OPERATING PARK TRAILER WITH SYSTEM PARK OR POSITION TRACTOR RELEASED OR CHARGE TRAILER BOBTAIL TRACTOR WITH TRACTOR PARKED PARKING REC PARKING BRAKE SUPPLY BRAKE YELLOW 2393 Trailer Park or Emergency Brake Application Only If you ever have a failure or disconnect 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 To apply the trailer brakes only Pull OUT the Red knob This will exhaust air from the trailer supply line causing the tractor protection valve to close and the trailer spring brakes to apply The trailer is now in emergency or park This mode would be used to uncouple from the trailer and during bobtail operation running without a trailer connected Medium Duty R05 09 53 6027 109 USING THE BRAKE SYSTEM or service brakes to park and hold an unat tended vehicle use the parking brakes Because service brakes work with air pres sure 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 WARNING Do not use the trailer hand brake Parking Tractor and Trailer With both
173. is the same as that used by Peter bilt dealers It includes inspection maintenance overhaul and troubleshooting procedures Y53 6027 05 09 X Printed in the U S A Peterbilt Motors Company A PACCAR Company P O Box 90208 Denton Texas 76202
174. ium Duty R05 09 DRIVER S CHECK LIST 5 Medium Duty R05 09 Brake Components check lines linkages cham bers camtubes for cracks or broken parts and brake operation If your truck has hydraulic brakes check the brake system for leaks hydraulic lines for cracks or kinks calipers for leaks Air System are there leaks Air Tanks drain water from all air tanks Make sure the drain cocks are closed This procedure is also required for air suspension tanks equipped with automatic drain valves See page 104 for further details on Using the Brake System Steps and Handholds check for worn surfaces and loose or missing fasteners Fluid Tanks check underneath the vehicle for signs of fluid leaks If any are found correct before operat ing the vehicle Fuel Tank Caps are they secure ignition source such as a cigarette could cause an explosion You could be killed or seriously injured A mixture of gasoline or alcohol with diesel fuel increases this risk of explosion Do not remove a fuel tank cap near an open flame WARNING Diesel fuel in the presence of an Use only the fuel and or additives recom mended for your engine See page 147 for more information 11 Trailer Connections Tractor are they secure and the lines clear If they are not being used are they stored properly e Is the trailer spare wheel secure and inflated s the landing gear up and the hand
175. ive axle brake app lication pressure when driving bobtail without a trailer connected Proportioning the brakes allows full use of the steer axle brakes and reduces lockup of the drive axle brakes The bobtail brake proportioning system is auto matically turned off when a trailer is connected Quick Release Valve speeds the release of air from the brake chambers When air is released the air in the brake chambers is exhausted at the quick release valve rather than exhausting back through the treadle valve 120 Y53 6027 STARTING AND OPERATING THE VEHICLE Single Check Valve allows air flow in one direction only Parking Brake Valve yellow diamond shaped knob It controls the application and release of the parking spring brakes of truck or tractor trailer combinations or of the tractor alone If the air system is being charged from zero pressure the parking brake valve will not hold in the release position until the system pressure exceeds 60 psi 414 kPa which is the pressure required to override the load of this valve s plunger return spring Trailer Supply Valve tractor The Red octagonal shaped knob protects the tractor system it functions in conjunction with the parking brake valve yellow The trailer supply valve is responsible for synchronizing the tractor and trailer parking and emergency brakes If the air system is being charged from zero pressure the trailer supply valve will not hold in the applied p
176. jumper cables must be long enough so that the vehicles do not touch If either battery has vent caps remove them and check the fluid level If itis OK replace the caps before going further If the level is low add distilled water and replace the caps Medium Duty R05 09 Y53 6027 Electrical System before proceeding If no water is available remove the caps and cover the filler openings with a cloth After jump starting the vehicle dispose of the cloth on the battery electrolyte could boil out of the openings and cause death injury or damage the vehicle Replace caps securely if the battery has the full level of electrolyte If the electrolyte is low and no water is available cover with a cloth WARNING If you do not cover the filler openings Preparing the vehicles 1 Position the two vehicles together but do not let them to touch 2 Turn OFF all lights heater radio and any other acces sory 3 Set the parking brakes pull out the Yellow button located on the dash 4 Shift the transmission into park position See Pages 67 and 34 for transmission shifting and parking brake infor mation 5 Turn engine OFF booster vehicle 6 Disconnect ground cable on booster battery 223 Electrical System Connect the batteries WARNING When connecting jumper cables AN make sure they can not get caught in any mov ing parts in the engine compartment You could be killed or seriously injured 1
177. ke grease meeting R S Specification 0 616 NLGI Grade 1 Lubricate according to Table 1 Recommended Main tenance Intervals Page 154 brake components lubricate sparingly Exces sive amounts of lubricant could contaminate brake linings which could reduce brake effec tiveness and cause an accident resulting in death or injury f WARNING Do not apply too much lubricant to Brake and Slack Adjuster Lubrication According to the interval pressure lubricate the slack adjuster and brake camshaft bracket tube Two grease fit tings are provided for both the slack adjuster and camshaft bracket tube e Use standard chassis lubricant meeting No 1 grade high temperature water proof specifications 185 Brake System Do not use moly disulfide loaded grease or oil they may shorten the service life of the slack adjuster Do not use pressure release grease fittings when lubri cating the slack adjuster Checks and Adjustments All vehicle operators should check the brakes regularly Always adjust the brakes when they are cool Parkthe vehicle on a level surface and block the wheels before attempting any brake checks or adjustments Brake Linings WARNING Do not use brake linings with a thick AN ness below the specified minimum Such linings will have lining rivets exposed that can damage the brake drum and reduce brake efficiency which could cause death personal injury or system failure Br
178. ked up to an optional ISO 3731 connector NOTE For doubles or triples PLC does not dis tinguish 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 e f no trailer ABS problems are detected the lamp will go off e f a trailer ABS problem is detected the lamp will remain on The driver should have the trailers ABS problem corrected before the vehi cle is driven with that trailer attached Medium Duty R05 09 Y53 6027 USING THE BRAKE SYSTEM system that is functioning improperly You could lose control of the vehicle resulting in a severe accident causing death or personal injury If your ABS lamp goes on while you are driving or stays on after the self check your anti lock system might not be working The ABS may not function in an emergency You will still have conventional brakes but not anti lock brakes If the lamp indicates a prob lem have the ABS checked WARNING Do not rely on an anti lock brake Wheel Spin Control Warning Lamp Your ABS may have an acceleration slip regulation ASR or automatic traction control ATC feature Either of these features is monitored by a wheel spin control warning lamp This lamp is located in the warning lamp cluster The Wheel Spin Control warning lamp will briefly ill
179. kes If one of the brake circuits should become inoperative braking dis tances will increase substantially and han dling characteristics while braking will be affected You could lose control of your vehi cle and cause an accident resulting in death or personal injury Have it towed to the near est dealer or qualified workshop for repair 142 Y53 6027 have to release the spring brakes at the spring brake chambers WARNING Do not disassemble a spring brake chamber These chambers contain a powerful spring that is compressed Sudden release of this spring can cause death or personal injury Do not operate a vehicle when the spring brakes have been manually released Driv ing a vehicle after its spring brakes are manually released is extremely dangerous You will probably have no brakes at all You could have a serious or fatal accident Releasing the spring brakes on an unse cured vehicle could lead to an accident The vehicle could roll causing severe injury Always secure the vehicle with wheel chocks chains or other safe means to pre vent rolling before manually releasing the spring brakes Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE VEHICLE RECOVERY AND SPRING BRAKES To move a vehicle immobilized by the spring brakes due to 4 Insert the release stud loss of air pressure in the brake system perform the fol through the opening in the lowing procedure spring chamber where the cap 4c Remove t
180. king brake An automatic transmission makes shifting much easier before leaving the cab however it is important to understand how to operate the transmission efficiently Please read the transmission WARNING Do not leave the cab of your vehicle manufacturer s operation manual supplied with your vehi without applying the parking brake The truck cle could roll and cause an accident resulting in death or personal injury Always apply the park ing brake before you leave the cab Medium Duty R05 09 Y53 6027 103 USING THE BRAKE SYSTEM Using the Brake System Li NOTE Today s diesel engines have significant torque and startability power at low RPMs Com binations of engine speed and available torque may overpower the vehicle s parking brakes WARNING Never drive your vehicle with the parking brakes applied Always release the parking brakes prior to moving the vehicle Failure to disengage the parking brakes prior to moving your vehicle could result in exces sive heat build up of the brakes and start a fire possibly resulting in death personal injury or property damage NOTE If your truck is equipped with hydraulic brakes go to page 121 H The operation of the vehicle s braking system and many vehicle accessories depends upon the storage and appli cation of a high pressure air supply This air brake system is a multiple circuit type it has a cir cuit for the front wheels a separate circuit for th
181. knobs pushed in for normal operating modes the parking brakes of both the tractor and the trailer may be applied by pulling the Yellow knob OUT This will exhaust the air from the tractor spring brakes and simultaneously cause the Red knob to pop OUT which will apply the trailer brakes This complies with the FMVSS 121 requirement that one control should apply all the parking brakes on the vehicle 110 Y53 6027 STARTING AND OPERATING THE VEHICLE Trailer Charge If both knobs are OUT combination vehicle is parked and it is desired to recharge the trailer the Red knob may be pushed IN to repressurize the trailer supply line The tractor will remain parked For more information on air supply pressure requirements see page 108 Brake Safety and Emergency WARNING Do not operate the vehicle in the AN event of a malfunction in any air circuit The vehicle should not be operated until the sys tem is repaired and both braking circuits including all pneumatic and mechanical com ponents are working properly Loss of sys tem air can cause the service brakes to not function resulting in the sudden application of the spring brakes causing wheel lock up loss of control or over take by following vehicles You could be in an accident and killed or severely injured Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE Front Brakes Truck The following applies to full truck configurations If air pressure is l
182. l to the proper level Medium Duty R05 09 Preventive Maintenance TRANSMISSION AND CLUTCH Introduction Follow these steps to ensure parts are properly lubri cated Maintain oil level check it regularly Change oil regularly Use the correct grade and type of oil Buy oil from a reputable dealer All Transmissions Oil Change Drain and replace according to Table 1 Rec ommended Maintenance Intervals Page 154 and the Transmission Service Manual Use the recommended types of oil as specified in the Operation and Service Manual included with vehicle Select the appropriate lubricant for the expected ambient outside air temperatures Medium Duty R05 09 Y53 6027 Transmission and Clutch Transmission Lubricants oil should not be intermixed because of possible incompatibility which could decrease the effec tiveness of the lubrication or cause component failure CAUTION When adding oil types and brands of Manual Transmissions Manual transmissions are designed so that the internal parts operate in a bath of oil circulated by the motion of gears and shafts Service Intervals For recommended types and brands of all lubricants see the transmission manufacturer s Service Manual and Table 1 Recommended Maintenance Intervals Page 154 239 Transmission and Clutch Table9 Transmission Lubrication Manual transmissions Preventive Maintenance meeting MIL L 2
183. le Page 157 The person best equipped to do this is your Authorized Service Center s mechanic Medium Duty R05 09 Preventive Maintenance Tires and Wheels they are not tightened properly wheel nuts Proper Torque and Sequence f WARNING Tighten wheel cap nuts properly If could eventually cause the wheel to become Proper wheel torque can best be obtained on level ground Install lug nuts and finger tighten in the numerical sequence loose to fail and or to come off while the vehi as shown below see Crisscross Tightening Sequence on cle is moving possibly causing loss of control if page 212 This procedure will ensure that the wheel is drawn the vehicle and death serious personal injury or evenly against the hub Torque each nut to the torque value damage to the vehicle listed in Table 7 on page 210 Medium Duty R05 09 53 6027 209 Tires and Wheels Table 7 Wheel Cap Nut Torque Preventive Maintenance DYNAMIC TORQUE FOR WHEEL amp NUT INNER amp OUTER CAP CONFIGURATION STUD SIZE NUTS amp RIM CLAMP NUTS N m Lb Ft Steel Disc Type Wheel Double Cap Nut Mounting Standard 3 4 16 545 630 400 465 7 8 Radius Ball Seat or Flanged Nuts 1 1 8 16 545 630 400 465 Alum Disc Type Wheel Double Cap Nut Mounting Standard 3 4 16 530 625 390 460 7 8 Radius Ball Seat or Flanged Nuts 1 1 8 16 530 625 390 460 Heavy Duty Steel Disc Type Wheel
184. le secured 12 Check the fifth wheel Is the kingpin locked sthe sliding fifth wheel locked Prestart Daily 1 Seat adjust the seat for easy reach of controls Y53 6027 87 If your vehicle is equipped with an adjustable steering column adjust the steering wheel to a comfortable position 3 Mirrors check and readjust mirrors if necessary 4 Lights turn ignition key to the IGN amp ACC position and check for warning lights and buzzer Check oper ation of turn signals and emergency lights 5 Instruments check all instruments 6 Windshield check operation of windshield wipers and washers 7 Horn check operation of horn 8 Check fire extinguisher charge and road emergency kit 9 Fuel check fuel Is there enough fuel 10 Seat Belts fasten and adjust safety restraint belts 88 DRIVER S CHECK LIST Weekly Operations 1 Y53 6027 Battery check battery and terminals Check battery and alternator cables for signs of chafing Wheel Cap Nuts are they all in place and torqued properly tighten if necessary See Wheel Cap Nut Torque Page 173 Other Controls and Wiring check for condition and adjustment Steering Components check pitman arm draglink and power steering hoses etc for loose broken or missing parts Other Engine Compartment Checks Check condition and fastening of engine belt hoses clamps and radiator Check the air cl
185. mall parti Medium Duty R05 09 Y53 6027 Heater and Air Conditioner cles may be removed with compressed air blown through the core in the opposite direction of normal air flow WARNING Wear eye protection any time N you blow compressed air Small particles blown by compressed air could injure your eyes Check the compressor belt for condition and proper ten sion Check all hoses for kinks deterioration chafing and leaks Adjust kinked or chafing hoses to eliminate restric tions and prevent further wear Check all components and connections for refrigerant leaks If you discover a leak do not try to tighten a con nection 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 Have the air conditioning system fully serviced annually by your Peterbilt Dealer or Authorized Service Center Qualified service technicians will have to evacuate and recharge the System 217 Electrical System ELECTRICAL SYSTEM CAUTION Do not modify or improperly repair the vehicle s electrical system or power distribu tion box All electrical repairs should be per formed by an authorized Peterbilt dealer Improper repair or modifications will void your warranty and or cause serious damage to your vehicle Location Of Fuses Fuses are located inside the cab left side next to the driver s d
186. many years later Regular and correct care will contribute to main taining the beauty and the value of your vehicle Your Peterbilt Dealer has a number of vehicle care products and can advise you on which ones to use for cleaning the exterior and interior of your vehicle Medium Duty R05 09 Preventive Maintenance CAUTION Do not aim the water jet directly at 4 door locks or latch Tape the key holes to pre vent water from seeping into the lock cylinders Water in lock cylinders should be removed with 5 compressed air To prevent locks from freezing in the winter squirt glycerin or lock deicer into 6 the lock cylinders Washing the Exterior 1 Begin by spraying water over the dry surface to remove all loose dirt before applying the car wash and wax solu tion Do not wash the vehicle in direct sunshine Do not spray water directly into any vents 2 Using soapy water wash the vehicle with a clean soft cloth or a soft brush made for automotive cleaning Use cool or warm water and a mild household type Cab Maintenance Wipe everything dry with a chamois to avoid water spots To prevent water spotting dry off the cosmetic sur faces with a clean cloth or chamois Remove road tar with an automotive type tar remover or mineral spirits After cleaning and drying apply a quality automotive wax NOTE To allow enough time for your truck s finish to cure wait at least thirty days after the d
187. minal and any other metal on the vehicle at the same time Remove metal jewelry and avoid leaning over the battery If metal jewelry or other metal comes in contact with electrical circuits a short circuit may occur causing death or serious personal injury as well as electrical system failure and damage to the vehicle Do not try to jump start or charge a frozen bat tery Even a battery with ice particles on the electrolyte surface is dangerous 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 Medium Duty R05 09 Preventive Maintenance To Jump Start Your Vehicle 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 capac ity rating may cause an explosion and death or serious personal injury CAUTION Applying a higher voltage booster f WARNING The voltage of the booster battery battery will cause expensive damage to sensi tive electronic components such as relays and the radio Improper hook up of jumper cables or not fol lowing these procedures can damage the alter nator or cause serious damage to both vehicles WARNING To avoid death serious personal N injury and damage to the vehicle heed all warn ings and instructions of the jumper cable manu facturer The
188. mission 88 103 242 fluid 245 oil level 242 Axle weight rating 84 85 132 267 B Ball bearing grease 168 Ball seat mounted wheels 213 Battery access 220 care 221 compartment cover 10 electrolyte 225 Medium Duty R05 09 recharging 224 226 slow battery charging 226 Belts seat 75 78 Block heater 93 182 Bobtail brake 109 117 Brake adjustment 186 air pressure gauge 198 checks and adjustments 185 components 119 compounding 120 emergency braking 112 hand valve trailer 116 linings 186 lubrication 185 operation 105 overheating 113 parking 106 proportion valve 105 safety front 111 safety rear 111 safety tractor trailer 112 System safety and emergency 110 194 system towing and spring brakes 142 System checks 184 188 System malfunction 142 System park tractor 110 trailer brake hand valve 116 Y53 6027 269 trailer charge 110 treadle valve 119 Brake Fluid Check 189 Brake Fluid Reservoir 122 Brake Master Cylinder 122 Brake Warning Lamp 123 C Cab access 9 heater maintenance 216 maintenance 234 Calipers 191 Charge air cooler 202 Chassis grease 168 number 264 265 Cleaning the vehicle 230 Clutch 98 clutch adjustment 102 clutch brake 100 clutch travel 100 fan drive 259 operating the clutch 98 riding the clutch 102 Coasting 102 Component lubrication index 168 Compressed air reservoir 87 119 197 Compressor 119 270 Consumer information 263 Controls Air Suspensio
189. n Installed Equipment Operator s Manuals Major component suppliers to Peterbilt also supply opera tion manuals specific to their products Additional manuals and other pieces of literature are included in the glove compartment literature set Look for information on prod ucts such as the engine driver s seat transmission axles tires and radio If you are missing these pieces of litera ture ask your Peterbilt Dealer for copies Other Sources Another place to learn more about trucking is from local truck driving schools Contact one near you to learn about courses they offer Federal and state agencies such as the department of licensing also have information you can ask for The National Highway Traffic Safety Administration and the Federal Motor Carrier Safety Administration can give you EE Der INTRODUCTION information about regulations governing transportation across state lines Regulations that differ from state to state can be found at various agencies in state govern ments 8 Y53 6027 Medium Duty R05 09 CAB AND FRAME ACCESS Cab and Frame Access Introduction The following section covers procedures for accessing the cab and the frame Door Lock and Keys Doors can be locked from the inside by using the lock but ton Close the door then push the button down to lock Doors automatically unlock when you open them from inside and can be locked from the outside with the key only As standar
190. n Deflate Switch Dump Valve 54 Brakesaver 59 Cruise Control Switch 55 Dome Light Switch 53 Electric Horn 48 Fifth Wheel Lock Slider Adjustment Switch 62 Fog Lights Switch 54 Hazard Flasher 51 Heater Air Conditioning Controls 66 ID and Clearance Lights Switch 53 Interaxle Differential Lock Switch 61 Mirror Heat Switch 58 Panel Light Dimmer 53 Parking Brake Valve and Trailer Air Supply Valve 63 Power Door Lock Switch 59 Power Mirror Switch 57 Power Window Switch 58 Tilt Telescoping Steering Column 50 Trailer Brake Hand Valve 49 Two Speed Rear Axle Range Switch 62 Windshield Wipers and Washers 47 Cooling system conventional coolant 181 extended life coolant 179 temperature 41 topping up 180 Y53 6027 Medium Duty R05 09 Cruise control operation 97 Cruise Control On Off 17 Cruise Control Select 17 D Daily operations 86 dash 16 dashboard 16 Daytime running lights 52 DEF 43 176 DEF Gauge 17 Defogging defrosting system 68 Deisel Exhaust Fluid 176 Department of transportation regulation 392 7 83 Diesel fuel 148 Dipstick 174 Disc brake pads 190 Disc brake rotors 191 Door Lock 9 Door lock 59 231 Double check valve 119 Downshift 102 Driver Information Display 17 Driver s checklist 83 daily and weekly checks 85 86 88 seat 74 tips 102 Medium Duty R05 09 Driveshaft 245 lubrication 245 Driving bobtail 116 122 vehicle inspection 83 with deflated air springs 137 DRL 52 Dry tank 119 Dual a
191. n 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 62 Y53 6027 Medium Duty R05 09 CONTROLS AND DISPLAY DASH AND DOOR MOUNTED FEATURES the fifth wheel to various positions to adjust weight distri bution There is a guard over this switch to protect you against accidentally activating or releasing the lock Parking Brake Valve and Trailer Air Supply Valve Before you leave the cab apply all parking brakes for vehicles with air brakes 02391 1 1 Apply all parking brakes Pull out the Yellow Parking Brake Control knob 1 located on the dash In trac Full Truck Parking Brake Valve tors the Red octagon shaped Trailer Air Supply Control knob 2 will automatically pop out WARNING Do not leave the cab without applying the parking brake The truck could roll and cause an accident involving death or personal injury Always apply the parking brake before you leave the cab Medium Duty R05 09 Y53 6027 63 DASH AND DOOR MOUNTED FEATURES 1 Parking Brake Control Yellow 2 Trailer Air Supply Control Red amp TO KS D A TRAILERS AIR SUP NOT FOR PARKING 02394 Combination Tractor Trailer Parking Brake Control Valves 2 Shift the transmission into its PARK position See Pages 100 and 146 for transmission shifting and park ing brake
192. n 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 Stainless Steel Even high quality stainless steel parts can rust under pro longed exposure to salt water especially when the salt laden moisture is held against the metal surface by road grime It is therefore important to frequently clean salty moisture and grime from stainless steel surfaces e If surface rust is encountered wash the surface and use a commercial polishing compound to clean off the rust followed by a coating of wax do not apply wax to hot parts such as exhaust pipes Never use steel wool when cleaning stainless steel because minute particles of the steel wool can embed in the surface of the stainless steel and cause rust staining 229 Cab Maintenance Cleaning Protection and Weather Stripping Frequent washings of the vehicle are required to remove grime and contaminants that can stain and oxidize paint and accelerate corrosion of plated and polished metal surfaces Waxing offers added protection against staining and oxida tion But to allow enough time for your truck s finish to cure wait about 30 days after the date of manufacture before wax ing
193. n trips the locking dogs as the tractor is backed under a trailer Fifth Wheel Jaw Lock To unlock the fifth wheel lock Pull out on the lever usually located on the left hand side of the fifth wheel until it remains in an overcenter position Hook Up After connecting your tractor to the trailer always inspect the jaws to be sure they have locked on the kingpin before driving 138 Y53 6027 STARTING AND OPERATING THE VEHICLE FIFTH WHEEL Fifth Wheel Slide Switch Air Controlled Sliding Fifth Wheel Vehicles having an air controlled sliding fifth wheel have a fifth wheel slider lock controlled by a switch on the acces Sory switch panel To operate this type of lock move the switch to the appropriate position By placing the switch in the UNLOCK position you can slide the fifth wheel to var ious positions to adjust weight distribution There is a guard on this switch to protect you against accidentally activating or releasing the lock Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE WARNING Do not move of the fifth wheel AN while the tractor trailer is in motion Your load could shift suddenly causing you to lose con trol of the vehicle which can result in a acci dent causing death or personal injury 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 lock is engaged DRIVING T
194. ncludes an engine hour meter and outside air temperature display Watching your tachometer is important to driving effi ciently It will let you match driving speed and gear selec tion 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 Medium Duty R05 09 CONTROLS AND DISPLAY Engine Hours Outside Air Temperature HESABA wes air Hour Meter Snowflake Symbol Temperature amp EB g Be The LCD display in the lower part of the tachometer con tains the engine hour meter and the outside air tempera ture 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 temper ature outside the vehicle The temperature can be dis played from 40 to 158 in Fahrenheit or 40 to 70 Celsius The display will also alert the driver when the out side temperate approaches freezing 32 F or 0 C by dis playing a snowflake symbol The symbol will turn on when the temperature drops below 34 F or 11 C and flash for Medium Duty R05 09 Y53 6027 STANDARD GAUGES the first 3 seconds then stay on until the temperature goes above 37 F or 28 The temperature can display us
195. nd MAX marks If the fluid level is below the MIN mark correct the condition Disconnect the battery cables Connect charger cables 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 Medium Duty R05 09 Preventive Maintenance 5 After charging turn OFF charger and disconnect charger cables Bulb Replacement Tail Lights To replace the tail lamps remove lens The bulbs are all of the bayonet type 1 To remove the bulbs turn bayonet counter clockwise and pull out 2 To install fit the bulb in the socket push in and turn bay onet clockwise Replacement Bulbs DESCRIPTION PART NO Headlights 9007BULB Front turn signal 3157K LL BULB Marker 1895BULB Stop tail turn 1157BULB Backup 1156BULB Hood marker 4157NAK LL BULB Roof marker 194BULB Electrical System Dome 1141BULB Warning lamp module 37 or 73 T1 3 4 wedge base Electrical and Alternator Precautions Take the following precautions to avoid burning out alternator diodes Medium Duty R05 09 Y53 6027 Do not start the engine with alternator disconnected connections removed from the circuit Before welding disconnect all electronic connections to the vehicle batteries Remove battery power cable and insulate it from the vehicle See Welding on page 250 for more informa tion Do not
196. nded periods of time will result in increased soot levels in the DPF which can affect engine performance or disable the engine Power Mirror Switch A CAUTION Do not leave the three position switch If your vehicle is equipped with power mirrors the mirror controls will be located on the driver side door pad Aero dynamic style mirrors are controlled for 4 way adjustable movement while Moto mirrors are controlled for 2 way adjustable movement WARNING Convex mirrors can distort images AN and make objects appear smaller and farther away than they really are You could have an accident resulting in death or personal injury 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 Medium Duty R05 09 Y53 6027 Mirror Selector Mirror Directional M NI AM Switch Control Pad oma e il To Adjust Moto Mirrors NOTE The Power Mirror Switch does not control the adjustment of the convex mirrors 1 Move the mirror selector switch to the right or left from the neutral center position to select the desired mirror for adjustment il 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 mir ror switch positions 57 DASH AND DOOR MOUNTED FEATURES 2 Depress
197. nents work together and must be checked periodically to ensure the brake system works properly See the Medium Duty Maintenance Manual for more information on brake maintenance Hydraulic Brake System Introduction To operate your vehicle safely you need some understanding of its brake systems Brake adjustment and brake balance must be set carefully to allow equal stopping forces at all wheels Tires are also a very important part of the whole sys tem How fast you can stop depends on how much friction there is between the road and your tires 188 Y53 6027 Preventive Maintenance All of the following areas are interrelated and must conform to original specifications wheel size tire size brake pads brake rotors front wheel bearings front end alignment parking brake drum radius Once a brake system is set to specifications changing any one of its components or any combination of components may degrade the system All parts have to work together to perform as they should Your brake system is hydraulically operated Refer to the sec tion titled Service Brake Component Inspection on page 190 for more information on inspecting the brakes Any replacement components in the brake system must meet the specifications of the original components Any changes from the original specifications can affect the performance of the entire system Medium Duty R05 09 Preventive Maintenance A A
198. nformation 2 Engine Belt check tension and condition of belts This is important to ensure proper air compressor and engine operation Measure the belt tension at the longest span of the belt See page 142 for further information on check ing belt tension NOTE Deflection should be one belt thick mn ness for each foot distance between the pulley centers f breaks or tears are found the belt should be replaced before operating the vehicle 3 Fuel Filter Water Separator Draining check and drain Depending on the fuel storage facility more fre quent draining may be required 86 Y53 6027 DRIVER S CHECK LIST 4 Windshield washer reservoir fluid level fill if neces sary 5 Hood closed before entering cab Is it latched prop erly Chassis and Cab Checks Daily Before entering the cab and operating the vehicle check the following equipment for proper maintenance 1 Lights do headlights turn signals emergency flash ers and exterior lamps function and are they clean and adjusted properly 2 Windows and Mirrors are they clean and adjusted properly 3 Tires and Wheels are they inflated properly Are all wheel cap nuts in place and torqued properly tighten if necessary Check front wheel bearing oil levels Inspect all tires and wheels for damage correct if found 4 Suspension check for loose or missing fasteners Check damage to springs or other suspension parts Med
199. nformation dl menu push the MCS on this menu bullet To exit push the MCS again To reset the trip values press the Trip Odometer Reset But ton on the main gauge instrument cluster Trip Information Certain Trip Information functions area accessible when driving or when parked Trip Economy Trip Average Speed Other Trip Information functions are accessible only when parked Trip Distance Trip Engine Hours Trip Idle Hours Trip Idle Percentage 96 Y53 6027 INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS PTO Hours PTO Trip Hours PTO Trip Percentage 96 To reset the Trip Values press the Trip Odometer Reset Button on the main gauge instrument cluster E Truck Information Accessible only while parked NOTE When accessing the truck informa tion menu push the MCS on this menu bul let To exit push the MCS again Truck Information 1 Chassis Number Engine Make Engine Model Engine SW Version Transmission Make oan RK OD Transmission Model Medium Duty R05 09 Medium Duty R05 09 CONTROLS AND DISPLAYS 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 12 CECU Hardware Version Diagnostic Display Accessible only while parked NOTE Faults Found will only be active if a red or yellow warning lamp is illuminated Di
200. ng Tread Record below Tires amp Wheels Inspection Right E Y53 6027 Medium Duty R05 09 164 Preventive Maintenance Maintenance Schedule and Lubrication Table2 Maintenance Schedule INTERVAL COMMENTS gE E5b EE OPERATION FREQUENCY ss ss ss mwe eco eo na 2a 83 Left rz Air Pressure Adjusted to ALIGNMENT A B c Toe in in mm Caste L ORE Rear Axle Alignment C2 ROAD TEST A B Cc Steering Steering Play Shifting Brakes Engine Operation noises surging black smoke Throttle Linkage Jake Brake Operation Seat Belts Air Seat Operation Cab Heater Medium Duty R05 09 53 6027 165 Maintenance Schedule and Lubrication Preventive Maintenance Table2 Maintenance Schedule INTERVAL COMMENTS gEE EBb EE OPERATION FREQUENCY 9898 88 oo oo 2o VYNITA SS Air Conditioner Instruments and Gauges Speedometer odometer Tachometer Oil Pressure Engine Temperature Illumination BODY A B C Interior Liner Damage Door Operation Roll up Door Tracks Lubricate Lift gate Operation OTHER A B C Hood Pivots Fifth Wheel Components 40 60K For Adjustment Brake Treadle Hinge and Roller Lock Cylinders Door Hinges Door Latches and Striker Plate Door Weatherstrip Air Dryer Drain Tanks Replace Desiccant as Required 166 53 6027 Medium Duty R05 09 Pr
201. ng to follow Pay special attention to instructions prefaced by symbols and the signal words WARNING CAUTION and NOTE Please do not ignore any of these alerts WARNING When you see this word the message that fol lows is especially vital It signals a potentially hazardous situation which if not avoided could result in an injury or death This message will tell you what the hazard is what can happen if you don t heed the warning and how to avoid it Example WARNING Never carry additional fuel con tainers in the vehicle Such containers full or empty may leak explode or cause a fire in the event of a collision CAUTION A A Z Signals a potentially hazardous situation which if not avoided could result in property or vehicle damage Example CAUTION Continuing to operate your vehicle with insufficient oil pressure will cause seri ous engine damage NOTE il il INTRODUCTION Provides general information for example the note may suggest how to operate the vehicle more efficiently Example NOTE Pumping the accelerator will not assist in starting the engine Please take the time to read these messages when WARNING Something that could seriously injure or kill you or oth ers CAUTION Something that could cause property or vehicle dam age NOTE Useful information you see them and remember Y53 6027 Medium Duty R05 09 INTRODUC
202. ngages the clutch brake This is called clutch brake squeeze When the clutch wears the release bearing gradually moves toward the engine decreasing free pedal and free travel When all free pedal and free travel are gone the clutch requires adjustment The clutch is adjusted by turning an adjustment ring that is built into the clutch When the ring is turned the release bearing moves back toward the transmission restoring free pedal and clutch free travel Under normal clutch wear this is the only adjustment needed Do not attempt to change any other component See the Medium Duty Maintenance Man ual for details Medium Duty R05 09 Y53 6027 Transmission and Clutch Clutch Adjustment Normal Wear 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 Also if it becomes increas ingly difficult to shift into gears or the truck creeps with the clutch pedal depressed your clutch needs adjustment See the Medium Duty Maintenance Manual for the proper adjustment procedures 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 13mm Clutch Linkage The Medium Duty vehicle is equipped with a rod and lever mechanical clutch linkag
203. nger s hands and body Failure to do so can result in death or personal injury Medium Duty R05 09 CONTROLS AND DISPLAY 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 respec tively in the window symbol on the switch face Release the Switch to stop window movement Power Door Lock Switch 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 Medium Duty R05 09 Y53 6027 DASH AND DOOR MOUNTED FEATURES closed or open padlock symbol respectively on the switch face Manual and Automatic Control Switch oooo O With the switch in the AUTOMATIC position the Brake Saver 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 59 DASH AND
204. 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 130 STARTING AND OPERATING THE VEHICLE 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 Coasting AN WARNING Do not coast with the transmis sion in neutral or with the clutch pedal depressed it is a dangerous practice With out the use of the retarding power of the driv etrain 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 resulting in death or personal injury due to mechanical failures Do not coast with the transmission in neutral or with the clutch pedal depressed Besides being illegal and danger OUS coasting is also expensive It causes premature fail Y53 6027 Medium Duty
205. nough to prevent an accident You could be killed or injured if you relied only on the engine retarder f WARNING The service brakes must be used e The engine retarder is NOT intended as the primary brake for the vehicle nor is it an emergency brake The engine retarder only helps the service brakes by using pressure to slow the drivetrain Use the service brakes for quick stops Exhaust Brake With the exhaust brake switch ON the brake automati cally creates its braking effect when you remove your foot from the accelerator pedal The brake switch is located on the accessory dash panel It controls whether the brake is ON ready to slow the vehicle down or OFF no braking action Do not use the engine retarder such as an exhaust brake to slow the vehicle down when you are bobtail ing or pulling an empty trailer 118 Y53 6027 STARTING AND OPERATING THE VEHICLE Make sure the brake is OFF before starting the engine After the engine is started warmed up and you are ready to get under way turn the exhaust brake switch ON for added braking effect WARNING Do not use the engine 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 and or jack knife if the wheels begin to skid resulting in an accident causing death or personal injury However
206. nstrumentation System Self Test The audible alarm will also sound in conjunction with some warning lights These events 4 INSTRUMENTS AND CONTROLS include but are not limited to headlight on fifth wheel stop engine primary secondary air and driver door open warnings Optional Lights Additional lights may be operational depending on individ ual vehicle specifications These will be included in the Instrument System Self Test NOTE Some optional lights may illuminate even though your vehicle is not equipped with that par ticular feature 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 the Symbol Color when it is illuminated whether the symbol is standard Std or optional Opt the Page Number reference for additional information Symbols are listed by major component sections 22 CONTROLS AND DISPLAYS Example Engine and then in alphabetical order Warning Light Indicator Symbols Symbol Name Symbol Color Std Opt Page 1 Active Warnings Exclama tion Point Red 24 2 Active Warnings Number Yellow e 25 3 Active Warnings Triangle Yellow e 25 4 Alternator I 1 A Red e 25 5 Anti Lock Brake System ABS 9 Yellow e 25 6 Anti Lock Brake System ABS Trailer Yelow i us 25 7 A
207. nts 10 000 15 000 SPL Driveline Center Bearing None Suspension Per Specifications AG200 Synthetic Grease With Special Fitting Medium Duty R05 09 Y53 6027 155 Maintenance Schedule and Lubrication Preventive Maintenance Table 1 Recommended Maintenance Intervals ITEM INTERVAL COMMENTS Hydraulic Brakes Brake Pad Lining Inspection 7 500 mile Minimum 3 16 in thickness Rotor Inspection 15 000 miles or 15 mos Park Brake Inspection 15 000 miles or 15 mos Brake Fluid Reservoir Check Fluid Level 7 500 miles Use DOT 3 brake fluid only Change Fluid Every 2 years Use DOT 3 brake fluid only Power Steering Fluid Reservoir Check Fluid Level 7 500 miles Use Automatic Transmission Fluid ATF Change Fluid 60 000 bed twice per Use Automatic Transmission Fluid ATF 156 Y53 6027 Medium Duty R05 09 Preventive Maintenance Maintenance Schedule Use Table 2 Maintenance Schedule as a guide to plan service work Be sure and follow the frequency recommenda Maintenance Schedule and Lubrication TABLE KEY n NOTE If a scheduled service interval is shaded skip to the next interval The frequency of each service operation is identified by open non shaded areas tions for your vehicle C2 Federal Annual Inspection 120 000 miles 192 000 km only C4 Federal Annual Inspection 240 000 miles 384 000 km only E2 50 000 Mile Servic
208. ocedures refer to the Engine Operation Manual included with your vehicle or the engine manufacturer s service manual Service Intervals Check engine oil daily Y53 6027 173 Engine Maintenance Cil Draining Refer to the engine manufacturer s Engine Operation and Maintenance Manual supplied with your vehicle for information about draining and refilling engine oil engine crankcase capacity engine oil type and changing oil fil ters etc could be seriously burned Let the engine oil f WARNING Hot engine oil can be dangerous You cool down before changing it Drain the oil into a container designed for this purpose When draining the oil remove the plug with the proper size wrench and keep as far away as possible Always keep your forearm parallel to the ground to help prevent hot oil from running down your arm The oil filler cap must be secured to avoid oil spill caus ing a potential fire hazard Oil Level Check To check the engine oil level park the vehicle on level ground and wait 5 minutes after shutting the engine OFF This allows time for the oil to drain to the oil pan Remove the dipstick and wipe it off with a clean lint free rag duc Y53 6027 Preventive Maintenance Reinsert the dipstick all the way in and pull it out again to check oil level Correct oil level is between the low L and high H marks on the dipstick For further information regarding oil level see the
209. of one inch measured from the belt to your chest Be sure to allow only a small amount of slack 3 When the slack is right flip the latch cover up cinch ing it into place 02395 The Komfort Lok latch Medium Duty R05 09 Y53 6027 81 During Pregnancy Pregnant women should always wear combination lap shoulder belts The lap belt portion must be worn snugly and as low as possible across the pelvis To avoid pres sure on the abdomen the belt must never pass over the waist 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 abdo men the belt will not harm the baby even in a crash And remember the best way to keep an unborn baby safe is to keep the mother safe Passengers Anyone riding in your vehicle should wear a seat belt A responsible operator sees to it that everyone in the vehicle rides safely and that means with a seat belt Belt Damage and Repair Damaged belts in the cab must be replaced Belts that have been stretched cut or worn out may not protect you in an accident 82 Y53 6027 SEATS Pregnant Woman with Belt Properly Worn If any seat belt is not working properly see an Authorized Service Center for repair or replacement For further information on seat belts and seat belt mainte nance see Safety Restraint System Inspection P
210. of the spring Replace defective parts Because repaired springs can not be fully restored to their original service life replace the complete assembly if cracks or other defects are detected After replacement of any part or discovery of loose com ponents check the torque of all fasteners 250 Y53 6027 Preventive Maintenance Rear Axle Lubrication Check oil level with the vehicle parked on level ground and the fluid warm The level should be even with the bottom of the filler hole CAUTION Do not mix lubricants of different A grades although mixing different brands of the same grade lubricant meeting MIL L 2105 C is acceptable Lubricants of different grades are not compatible and could damage the axle NOTE In all cases the lubricant supplier assumes Ld full responsibility for the performance of their prod uct and for product and patent liability Initial Change Change lubricant in new or rebuilt axle assemblies within the first 3 000 to 5 000 miles 4800 to 8000 km For recommended types and brands of lubricants con tact your Peterbilt Dealer or Authorized Service Center See the Medium Duty Maintenance Manual and the axle manu facturer s Service Manual for further information on servicing drive axles Medium Duty R05 09 Preventive Maintenance Table 11 Drive Axle Lubrication Rear Axle and Suspension AMBIENT TEMPERATURE RANGE MODEL RECOMMENDED LUBRI
211. old it down for five minutes The pres sure drop should not exceed 3 0 psi 21 kPa per minute Medium Duty R05 09 Y53 6027 Air System 7 If you detect excessive leakage air pressure loss greater than 3 0 psi after five minutes of brake application a leakage test should be made at the air line connections and at all air brake control units These tests should determine where air is escaping Air Compressor Operation All compressors regardless of make or model run continu ously while the engine is running System pressure is con trolled by the governor The governor acts in conjunction with the unloading mechanism in the compressor cylinder block to start and stop compression of air The compressor is unloaded when the system pressure reaches 120 psi 827 kPa and compression is re established when system pres sure falls to 100 psi 690 kPa Preventive Maintenance The following service checks are provided for your informa tion only and should be performed by a certified mechanic Contact your Peterbilt Dealer or consult the Medium Duty Maintenance Manual and the engine manufacturer s Main tenance Manual for further information on servicing air com 199 Air System pressors After completing any repairs to the air system always test for air leaks and check the brakes for safe opera tion before putting the vehicle in service According to Table 5 Air System Scheduled Mainte nance Page 196 In
212. on The seat belt system including webbing buckles latches and mounting hardware endures heavy use in medium duty vehicles much more than seat belt systems in passenger cars All users should be aware of the factors contributing to this heavy use and reduced belt life train 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 pro tect you in an accident f WARNING Failure to properly inspect and main Factors contributing to reduced seat belt life High mileage heavy trucks often accumulate mileage in excess of 500 000 total miles 800 000 km during the vehicle lifetime This is much greater than a typical pas senger car which frequently will not exceed 125 000 total miles 200 000 km Seat and cab movement in trucks there is almost con stant movement of the belt due to ride characteristics and seat design The constant movement of the belt Medium Duty R05 09 Preventive Maintenance inside the restraint hardware and the potential for the belt to come in contact with the cab and other vehicle parts contributes to the wear of the entire system Environmental conditions such as dirt and ultraviolet rays from the sun will reduce the life of the seat belt sys tem Due to these factors the three point safety belt system installed in your vehicle requires thorough inspection ev
213. on page 157 Be sure someone with the proper training and the right tools checks and tight ens the U bolts on your Medium Duty vehicle New springs can settle in after service relieving the tension on the U bolts Loose U bolts can cause leaf spring break age axle misalignment hard steering and abnormal tire wear e All vehicles should have suspension U bolts tightened after the first 500 miles 800 km of operation Torque the front suspension U bolts to 245 300 Ib ft 333 408 N m 248 Y53 6027 Preventive Maintenance bolts are not properly tightened Loose U bolts do not properly secure the axle to the suspen sion This could cause loss of vehicle control and an accident resulting in death or injury Loose U bolts can also cause uneven tire wear and poor alignment 1 WARNING Do not operate the vehicle if the U U bolts are difficult to tighten unless you have the right equipment If you cannot tighten them correctly yourself be sure to have them checked and tightened regularly by an authorized mechanic WARNING Do not replace U bolts and nuts with AN common U bolts or standard nuts Use only U bolts and nuts of SAE Grade 8 specification or better These parts are critical to vehicle safety If the wrong U bolts or nuts are used the axle could loosen or separate from the vehicle and cause an accident resulting in death or injury At the same time U bolts are tightened re torque the spring
214. on the opposite page 16 Y53 6027 Medium Duty R05 09 CONTROLS AND DISPLAYS INSTRUMENTS AND CONTROLS LEFT SIDE DEF Cale Fuel Level Tachometer Driver Information Display Speedometer Primary Air Pressure Secondary Air Pressure oO oo N oO oO A j N Water Temperature 10 Headllights 11 Load Lights 12 Hazard Switch 13 Optional 14 Optional 15 Panel Lights 16 Optional 17 Cruise Control On Off 18 Cruise Control Select 19 Menu Control Switch 20 Ignition 1 Engine Oil Pressure Medium Duty R05 09 Y53 6027 17 INSTRUMENTS AND CONTROLS RIGHT SIDE 18 CONTROLS AND DISPLAYS Radio Navigation HVAC Controls Emission Controls Engine Brake on off Engine Brake Select Optional Switch Optional Switch oO OO NI mo ao A wo N Optional Switch eo Park Brake Controls Transmission Display Automatic N Optional Switch wo Optional Switch A Optional Switch oa Optional USB Port o Optional Switch These switches are not shown These switch locations are available only if the automatic transmission selector is not mounted item 11 Y53 6027 Medium Duty R05 09 CONTROLS AND DISPLAYS Menu Control Switch
215. ondriven hubs CD50 Steering Column CL Alternator Bearing BB Fan Hub BB Power Steering Reservoir ATF Steering Drag Link CL Steering Knuckles CL Spring Pins CL Clutch Release Bearings BB Brake Shoe Anchor Pins HT Brake Cam Bearings HT Slack Adjusters CL Starter Bearings CC Turbocharger Aneroid cc Water Pump BB Consult manufacturer or lubricant supplier for special details NOTE The responsibility for meeting these specifi cations the quality of the product and its perfor mance in service rests with the lubricant supplier Y53 6027 Medium Duty R05 09 Preventive Maintenance Cil Reservoirs For oil reservoirs with side filler plugs transmissions axles steering gear boxes transfer cases etc the oil must be level with the filler opening NOTE Use care when checking the oil level with a finger Just because you can reach the oil level with a finger does not mean the oil level is correct Medium Duty R05 09 Maintenance Schedule and Lubrication Proper Oil Level Improper Oil Level Y53 6027 Lubrication Chart The following lubrication specifications see Table 3 on page 170 are for an ambient operating temperature range of 15 to 100 F 26 to 38 C For extreme temperature operations consult the component manufacturer s manuals 169 Maintenance Schedule and Lubrication Preventive Maintenance Table 3 Recommended Lubrication Types COMPONENTS RE
216. ontrols 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 Medium Duty R05 09 Y53 6027 HEATER AIR CONDITIONING CONTROLS A rotary knob A in the left portion controlling the blower speed with five settings including OFF A rotary knob B in the center portion controlling the movement of air within the cab This control is contin uously 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 c5 HEATER AIR CONDITIONING CONTROLS es H l i jj 02980A F NOTE For vehicles equipped with the Peterbilt Comfort Control PCC option The PCC option lets the temperature knob function as a thermo stat that regulates duct temperatures based on the knob settings When active the COMFORT CONTROL icon F will be illuminated under the temperature knob C 5 E Conventional Cab Control Panel vehicle with air condi tioner and PCC To heat the cab select the desired air mode and set the temperature knob to hot the
217. oor Fuse Inspection and Replacement WARNING Do not replace a fuse with one of a N higher rating Doing so may damage the electri cal system and cause a fire possibly causing death personal injury or property damage CAUTION Before replacing a fuse turn OFF all A lights and accessories and remove the ignition key to avoid damaging the electrical system 218 D Y53 6027 Preventive Maintenance WARNING Never patch fuses with tin foil or wire This may cause serious damage elsewhere in the electrical circuit and it may cause a fire possibly causing death personal injury or prop erty damage CAUTION If a circuit keeps blowing fuses have the electrical system inspected for a short cir cuit or overload by an authorized Peterbilt dealer as soon as possible Failure to do so could cause serious damage to the electrical system and or vehicle NOTE If a fuse of the same rating is not available a fuse of a lower rating may be temporarily substi tuted You can also use a fuse from a circuit you can temporarily do without for example an accessory circuit or radio BLOWN Medium Duty R05 09 Preventive Maintenance All the electrical circuits have fuses to protect them from a short circuit or overload If something electrical on your chas sis stops working the first thing you should check for is a blown fuse 1 Turn OFF all lights and accessories and remove the igni tion key to avoid damaging t
218. or and should generally not drop below the middle point between the Maximum and Minimum level indicators Medium Duty R05 09 Preventive Maintenance Fluid Refill Use Automatic Transmission Fluid ATF Type E or F or Dexron II For other approved brands and types of fluid see the Medium Duty Maintenance Manual Steering Driveline Torque on U joint pinch bolt and nut 45 55 Ib ft 61 75 N m lubricated Torque on Pitman arm clamp bolt and nut 180 210 Ib ft 244 285 N m lubricated Driveshaft and U Joints The slip joints and universal joints of the drive shaft should be lubricated according to Table 1 Recommended Mainte nance Intervals Page 154 Use a good quality lithium soap base or equivalent extreme pressure E P grease NLGI Grade 2 For Towing Guidelines and Returning a Towed Vehicle to Service see Vehicle Recovery Guidelines on page 109 Steering and Driveline SLIP JOINT 01904 Driveshaft Lubrication AN Medium Duty R05 09 Y53 6027 WARNING Improper lubrication of U joints can cause them to fail prematurely The driveshaft could separate from the vehicle and result in an accident causing death injury or vehicle dam age Make sure lubricant is purged at all four ends of each U joint and loosen caps if neces sary Also regularly inspect U joints for exces sive wear or movement and repair or replace as necessary 245 Fron
219. osition until the system pressure exceeds 50 psi 345 kPa It automati cally pops out and exhausts air if supply air pressure drops below 60 psi 414 kPa Tractor Protection Valve The functions of this valve are to 1 receive all pneumatic signals pertinent to the opera tion of the trailer brake system 2 transmit these signals Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE to the trailer and 3 protect the tractor air supply in case of separation of the air lines connecting the tractor to the trailer Hydraulic Brakes event of a malfunction in any air or hydraulic circuit Such a malfunction may prevent the brake system from operating properly and could result in an accident causing death or personal injury The vehicle should not be operated until the system is repaired and both braking circuits including all pneumatic hydraulic and mechanical components are working properly f WARNING Do not operate the vehicle in the The operation of the vehicle s braking system is based on the principle of hydraulics Hydraulic action begins when force is applied to the brake pedal This force creates hydraulic pressure in the master cylinder and is amplified with assistance of a power booster The supplemental boost in force is developed when pressurized power steer ing fluid from the steering pump presses on the master Medium Duty R05 09 Y53 6027 USING THE BRAKE SYSTEM cylinder piston As a safety prec
220. ost in the front circuit the vehicle front brakes will not operate Check valves isolate the rear cir cuit so the rear service brakes and parking brakes are unaffected The spring brakes will not automatically apply as long as rear service pressure is maintained drops below 60 psi 414 kPa due to repeated brake applications the spring brakes will automatically apply stopping the vehicle abruptly potentially causing death or serious injury Observe the warning light BRAKE AIR in the panel If it comes on do not continue to drive the vehicle until it has been properly repaired or serviced j WARNING If the remaining system pressure Medium Duty R05 09 Y53 6027 USING THE BRAKE SYSTEM Rear Brakes Truck The following applies to full truck configurations If air is lost in the rear brake circuit check valves isolate the front circuit and front brake operation is unaffected Because this is a dual air system spring brakes will not automatically apply as long as pressure is maintained in the front circuit When the brake pedal is depressed the modulating valve detects the reduction or absence of rear service delivery pressure and exhausts air from the spring chambers applying the spring brakes in proportion to the front brake application When releasing the brake pedal the modulating valve delivers front service air to the spring brake chambers releasing the spring brakes in proportion to the front brake appl
221. ound up on its retractor so that the belt tongue is in its stowed position This reduces the pos sibility of the tongue becoming a striking object in case of a sudden stop Do not modify or disassemble the seat belts in your vehicle They will not be available to keep you and your passengers safe 79 SEATS rized Service Center for repair or replacement the tether belt system with a different tether If any seat belt is not working properly see an Autho f WARNING Do not remove modify or replace system A failed or missing tether belt could WARNING Before driving or riding in a vehi allow the seat base to fully extend in the event cle ensure that there is adequate head clear of an accident leading to greater injuries or ance at maximum upward travel of seat death Shorten the tether belt as necessary to pro vide adequate head clearance Death or seri WARNING Failure to adjust tether belts prop ous injury may occur if head clearance is not erly can cause excessive movement of the adequate seat in an accident This could lead to death Tether Belt or greater injuries to you Tether belts should Spon be adjusted so that they are taut when the Tether belts are installed on suspension seats They help seat is in its most upward and forward posi secure the seat to the floor to restrain it in case of a sud tion den stop or an accident Tether Adjustment Fixed Tethers Make sure that the tether belt is at
222. oved lubricant Lubricate knuckle thrust bearings knuckle pins and tie rod ends See Table 1 Recommended Maintenance Intervals Page 154 Lack of lubrication causes premature wear and hard steering Lubrication schedule may be short ened if necessary Suspension Lubrication Each spring anchor pin has a grease fitting Pressure lubri cate spring pins according to Table 1 Recommended Maintenance Intervals Page 154 using EP chassis lube with 12 Hydroxy Lithium Stearate Base NLGI 2 with 3 molybdenum additive e g Mobil grease EP or equal Medium Duty R05 09 Front Axle and Suspension KINGPIN TOP KINGPIN BOTTOM 00445 Y53 6027 Front Axle At regular intervals the spring leaves may be lubricated with a rust inhibiting oil applied with a spray gun or brush Lubricate all spring pins until grease flows out of both ends of the bushing Look for signs of rust or water in the flushed grease If a pin will not accept grease it should be removed cleaned and inspected 247 Front Axle and Suspension chemical products or mineral oil it can cause CAUTION Do not spray the suspension with damage to the bushings Torque U Bolts Spring and Shackle Pinch Bolts It is important that U bolts remain tight Severe use of your vehicle will cause them to loosen faster But all vehicles need to have their U bolts checked and tightened regularly See Maintenance Schedule
223. page 195 for more information on checking your brakes Any replacement components in the brake system should be the same or better than the original components Any changes from the original specifications can affect the perfor mance of the entire system Medium Duty R05 09 Preventive Maintenance the brake system unless it conforms exactly to original specifications A nonconforming part in your vehicle s brake system could cause a mal function resulting in an accident causing death or personal injury Sizes and types are so related to one another that a seemingly unimportant change in one may result in a change in how well the brakes work for you on the road If parts do not work together properly you could lose control of your vehicle which could cause a serious accident f WARNING Do not work on the brake system 1 WARNING Do not use any replacement part in without the parking brake set and wheels chocked securely If the vehicle is not secured to prevent uncontrolled vehicle movement it could roll and cause death serious personal injury or damage to the vehicle Use wood blocks 4 in X 4 in or larger against the front and rear surfaces of the tires Be sure the vehicle cannot move Medium Duty R05 09 Y53 6027 Brake System Lubrication Cam actuated brake components such as anchor pins and brake camshafts are subjected to high temperatures and must be lubricated with nonmelting water resistant bra
224. r Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE Engine Block Heater Option Use a solution of half ethylene glycol antifreeze and To preheat the engine before starting plug the optional engine block heater into a properly grounded AC electrical source Do not start the engine with the heater plugged in half water for best heater performance Do not exceed 60 percent concentration of antifreeze as it can shorten heater life See page 146 for more informa tion fires resulting in death or serious personal for a day or two before using the heater Trapped air A WARNING Engine block heaters can cause e After servicing the cooling system operate the vehicle injury and or property damage if not properly maintained and operated Regularly inspect the engine block heater wiring and connector for damaged or frayed wires Do not use the inside the engine needs time to escape Cold Weather Starting Air Intake Heater heater if there are any signs of problems Con Do not use ether or any other starting fluid as a cold start tact your Authorized Service Center or the ing aid in your Medium Duty vehicle Engine conditions manufacturer of the heater if you are in need are automatically monitored and in cold weather the fuel of repairs or information air mixture is preheated in the manifold CAUTION Always unplug the heater before A starting the engine Damage to the cooling AN system could occur if the heater is not
225. r 147 202 U U Bolt torque 248 Underbody maintenance 231 Underinflated tires 206 V Vehicle driving 83 loading 84 weight rating 84 132 267 Y53 6027 Medium Duty R05 09 Vehicle inspections 83 wheel cylinders 121 W Wheels and tires WAIT TO START light 91 load rating 207 Warning Light Symbols table 22 overinflation 207 Warranty 151 153 249 257 258 proper inflation 206 Water Temperature 17 replacement 204 214 Weekly operations 88 tightening sequence 208 Weight rating 84 132 tire inspection 205 Welding 227 tread depth 214 Wet Brakes 124 underinflation 207 Wet tank 119 wheel nut torque 209 Wheel and Tire Replacement hydraulic brakes 215 Windshield Wheel bearing washer reservoir 238 grease 168 Windshield washer reservoir 47 lubrication 246 Medium Duty R05 09 Y53 6027 2717 278 Y53 6027 Medium Duty R05 09 Other Publications Order either of the two publications shown below through your Peterbilt dealer There is a charge for each Allow four weeks for delivery e custo anusi maintenance EE 02956B Custom Maintenance Manual Owner s Custom Parts Book This manual contains both proprietary and supplier service This book is a complete unillustrated computer generated information specifically compiled for the components on your list of the parts used to custom build your Peterbilt vehicle vehicle Please provide your Chassis Serial Number when ordering The material in this manual
226. r 259 N NHTSA consumer information 263 Noise and emission control 257 air intake system 257 engine 258 exhaust system 258 fan drive 257 274 inspection and maintenance instructions 258 O Off road operation 5 Oil draining 174 level 174 pressure gauge 91 Operating the engine 89 Operating the Rear Drive Axle 127 Operating the transmission 98 Optional equipment 103 117 128 Overheated Brakes 124 P Paint identification label 267 parked regeneration 56 Parking brake 106 adjustment 186 automatic 107 brake system operation 63 64 106 107 111 142 brake system tractor trailer operation 108 use 64 90 99 100 124 146 150 223 valve 120 Parking Brake Burnishing 126 Parking Brake Component Inspection 191 Parking Brake Indicator 65 Parking Brake Lever 123 Parts catalog 6 7 152 Power steering 243 Y53 6027 Medium Duty R05 09 fluid level 244 fluid refill 245 lubrication 243 Primary Air Pressure 17 Q Quick release valve 120 R Radio 18 73 Rear axle 250 housing breather vent 252 identification 268 lubrication 250 251 252 oil change 250 oil level 250 Rear brake system 105 Rear suspension 249 fasteners standard 249 Rear Wheel Calipers 123 Recovering vehicles 140 Regeneration Switch 56 Relay valve 120 Release bearing wear 102 Repairs 6 Retarders engine 117 rpm 94 100 147 S Safe vehicle operation 83 Medium Duty R05 09 Safety belt adjustment 77 passengers 79 restraint belts 75 restrain
227. r a trailer A guard on the switch prevents you from accidentally deflating the suspension WARNING Do not operate the Air Suspension MN Deflate Switch Dump Valve while driving Sudden deflation while your vehicle is moving can affect handling and control and could lead to an accident possibly resulting in death or personal injury Use this switch only when your vehicle is not moving CAUTION Operating a vehicle with air sus A pension bags either overinflated or underin flated may cause damage to driveline components If a vehicle must be operated under such conditions do not exceed 5 mph 8 km h Medium Duty R05 09 Y53 6027 DRIVING TIPS AND TECHNIQUES AIR SUSPENSION Air Suspension Deflate Switch Setting Ride Height Vehicles equipped with rear air suspensions have their ride height and axle pinion angle s preset at the factory These are precision settings and should not be altered Incorrectly adjusted ride height may result in improper interaxle U joint working angles This can result in pre mature driveline wear and driveline vibration If your vehi cle 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 133 DRIVING TIPS AND TECHNIQUES 5y y o oo ae r A
228. r case adversely affects braking operation Brake Warning Lamp When the brake warning lamp comes on it indicates a malfunction in the brake system Possible malfunctions include loss of hydraulic pressure from the power steering circuit or a pressure differential between the primary and secondary brake circuits WARNING Do not operate the vehicle if the AN brake light or buzzer comes on The light or buzzer indicates a failure in one of the brake components system Safely drive your vehicle to the side of the road immediately Failure to do this may lead to an accident causing death or personal injury 123 USING THE BRAKE SYSTEM O SERVICE BRAKE WARNING INDICATOR BRAKE If the buzzer sounds while driving or if the BRAKE light comes on do the following 1 Slow down carefully Here are some things you can do to assist in slowing the vehicle Downshift Putting the transmission into a lower gear will help slow the vehicle Pump the brakes Pumping the brake pedal may generate enough hydraulic pressure to stop the vehicle Use the parking brake The parking or emergency brake is separate from the hydraulic system There fore it can be used to slow the vehicle 2 Move a safe distance off the road and stop 3 Set the parking brake See page 106 124 Y53 6027 STARTING AND OPERATING THE VEHICLE 4 Turn on the emergency flasher and use other warning devices to alert other motorists
229. r tire mileage WARNING Do not mismatch tires it can be dan N gerous Never mix tires of different design such as steel belted radials and bias ply tires etc Mixing tire types and sizes will adversely affect the road holding ability of both types of tires and can lead to loss of vehicle control and causing death or personal injury Make sure too that you use the right size tires on each wheel Some trucks require different sizes on front and rear wheels For safety always use the recommended size and type of tires Medium Duty R05 09 Preventive Maintenance Tires and Wheels dashboard warning lights or buzzer if tires of the WARNING The Anti Lock Brake System ABS is wrong size are installed on your vehicle See the N calibrated for the specific tire revolutions per warning above for consequences of tires of the mile Use of a tire and or wheel size different wrong size from that originally installed on your vehicle may cause the ABS system to not function during a hard braking event This could cause an accident resulting in death or serious personal injury Consult with your Peterbilt dealer before using a different tire and or wheel size than was origi nally installed on your vehicle Wheel and Tire Replacement A CAUTION No indication will be given via the Medium Duty R05 09 Y53 6027 215 Heater and Air Conditioner HEATER AND AIR CONDITIONER Introduction The combination heater air conditioner
230. r wheels are spin ning could cause loss of control or axle dam age there could be an accident involving death or personal injury Switch to LOCK only when your wheels are not spinning UNLOCK the differential The guard over this switch pre See Interaxle Differential on page 95 for more informa vents you from accidentally activating the lock tion on using your interaxle differential Medium Duty R05 09 Y53 6027 61 DASH AND DOOR MOUNTED FEATURES Two Speed Rear Axle Range Switch 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 For information on how to operate your two speed rear axle properly and safely see Dual Range Two Speed Axles on page 97 CONTROLS AND DISPLAY Fifth Wheel Lock Slider Adjustment Switch FIFTH WHEEL the tractor trailer is in motion Movement of the fifth wheel while a tractor trailer is moving can cause a serious accident involving death or personal injury Your load could shift sud denly causing you to lose control of the vehi cle Never operate the vehicle with the switch in the unlock position Always inspect the fifth wheel after you lock the switch to be sure the fifth wheel is engaged j WARNING Do not move the fifth wheel while Vehicles having a
231. r will remain parked To release the full combination of brakes Push IN BOTH knobs on the dash In the event that air pressure is reduced below a safe level the low air warning light will come on first if air pressure continues to drop the parking brake valve will pop OUT automatically applying the spring brakes A 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 mal function could occur if the vehicle is forced to move before the air system reaches 100 psi 689 kPa Below 60 psi 414 kPa the parking brake valve button remains in the applied ON position If air pressure is not restored the button will automatically return to its initial position 107 USING THE BRAKE SYSTEM STARTING AND OPERATING THE VEHICLE psi 414 kPa the spring brakes may stop the parking brakes vehicle abruptly which could result in an accident involving death or personal injuries l Observe the red warning lamps on the operating level gauges If one comes on do not continue to drive the vehicle until it has been properly repaired or serviced i WARNING If the air pressure falls below 60 To supply air to the trailer system and release the trailer 1 Allow the tractor air system pressure to build up to 2 When system pressure reaches 50 psi 345 kPa the Red knob may be pushed
232. red position on the control and the blower to whatever speed makes you most comfortable 68 CONTROLS AND DISPLAY To defog the windshield select the Defrost mode and turn the blower speed to high Set the tempera ture knob to hot the red position on the control The air conditioner is automatically activated to remove moisture from the cab After the windshield is clear adjust the mode blower speed and temperature to your comfort A Y53 6027 WARNING Do not drive with visibility reduced by fog condensation or frost on the wind shield Your view may be obscured which could result in an accident involving causing death or personal injury 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 tempera ture Medium Duty R05 09 CONTROLS AND DISPLAY blow hot defroster air onto cold windshields This could crack the glass Turn the air flow con trol 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 cool the cab turn on the A C switch
233. reventive Maintenance Maintenance Schedule and Lubrication Table2 Maintenance Schedule INTERVAL COMMENTS gE Eb EE OPERATION FREQUENCY 28 98 88 oo oo 2o VNITA SS Emergency Flasher Brake Lights Backup Loading Lights License Plates Permits and Mounting Mud Flaps Serviceable Fuel Tank Mounting Exhaust System Condition and Mounting Bolts Frame Fastener Torque does NOT apply to Le C2 Jeune frame fasteners Lubricate Door Hinges and Latches Body Mounts Straight Truck Only Body Sides and Roof Panels Straight trucks Cab Hold down Latches Mounts Front Pivot Assembly Jack Operation and Leaks Safety Lock Tip Over Stop ENGINE SERVICE A B C Cooling Extended Life Coolant maintenance is located on page 183 of this manual Coolant Level Pressure Test New Release At 100 120K Per Engine RIBPIBEO STO ilar Filter Manufacturer Fcoifiehdalldns Radiator Mounting Medium Duty R05 09 53 6027 159 Maintenance Schedule and Lubrication 160 Table2 Maintenance Schedule Preventive Maintenance INTERVAL COMMENTS gElgE EE OPERATION FREQUENCY 898 9888 oo0 96 92o MN OPRISS Fan Shroud Fan Assembly and Idler Pulley No Service Required Check Water Pump for Leaks Play Radiator Exterior Condition Fill as Required Extended Drain Per Power Steering Filter Replace
234. 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 Medium Duty R05 09 Y53 6027 DASH AND DOOR MOUNTED FEATURES oooo A WARNING Use your Hazard Flasher Warning System any time you have to stop the vehicle on or off the road day or night A hard to see vehicle can result in an accident causing death or personal injury Another vehicle could run into you if you do not set your flash ers and follow the placement of emergency signals per FMCSR 392 22 Always move the vehicle a safe distance off the road when Stalled or stopped for repairs A disabled vehi cle can be dangerous for you and others 51 DASH AND DOOR MOUNTED FEATURES CONTROLS AND DISPLAY release the parking brake If the headlight switch is ON the DRL system is overridden and headlights operate normally WARNING Do not use daytime running lights AN DRL during periods of darkness or reduced visibility Do not use DRL as a substitute for headlights or other lights during operations that require lighting of your vehicle Doing so could lead to an accident resulting in death or personal injury Daytime Running Lights NOTE On vehicles equipped with daytime running LI ligh
235. rom mounting head completely drain all fluid and reassemble filter assembly Be sure to follow new filter assembly instructions 2 Close drain valve by turning valve screw clockwise approximately 1 1 2 to 2 turns CAUTION Do not overtighten the valve Over A tightening can damage the threads Fuel Tanks 1 Inspect fuel tanks fuel hoses and fittings to ensure proper positioning and fastening check for leaks 2 Inspect mounting brackets straps and pins to ensure proper positioning amp fastening every 15 000 miles 24 000 km see label on fuel tank and data below Type of Tank Tank Strap T Bolt Nut Torque Aluminum 30 Lb ft 41 Nm Cylindrical Steel 8 Lb ft 11 Nm 176 Y53 6027 Preventive Maintenance Emission Components Deisel Exhaust Fluid Tank Vehicles that comply with 2010 EPA emission requirements will have a Deisel Exhaust Fluid DEF tank mounted to the vehicle frame During normal operating situations your vehi cle may consume 2 3 gallons of DEF for every 100 gallons of deisel fuel Be sure to maintain sufficient fluid in the DEF tank for proper vehicle performance Specifications of the DEF Medium Duty R05 09 Preventive Maintenance What to do if you run out of DEF and are stranded call a dealership Engine Accesories Accessory Drive Belts You can extend the reliability and service life of your vehicle s drive belts with proper attention to install
236. rson Among those acts presumed to constitute tampering are the acts listed below Air Intake System Removing or rendering inoperative the air cleaner silenc ers or intake piping Engine Cooling System Removing or rendering inoperative the fan clutch Removing the fan shroud 257 Noise and Emission Control Engine Removing or rendering engine speed governor inopera tive so as to allow engine speed to exceed manufac turer s specifications Modifying ECU parameters Exhaust System Removing or rendering inoperative exhaust system com ponents Inspection and Maintenance Instructions The following instructions are based on inspection of the noise control system at regular intervals If during periodic inspection and maintenance of other sys tems and components it is found that parts of the noise con trol system require attention we recommend that those parts be inspected at more frequent intervals to assure adequate maintenance and performance Air Intake System Do all checks and maintenance procedures listed in this manual under Engine Air Intake System and Air Cleaner See Air Intake System on page 201 258 Y53 6027 Preventive Maintenance Check the induction tubing elbow connections clamps brackets and fasteners for deterioration cracks and security f you find an air leak anywhere between the air cleaner and the engine repair that leak immediately may res
237. rticulate Filter DPF IIluminates when diesel particulate trap is plugged This warning will also illuminate when regeneration operation is disabled 14 Emissions High Exhaust System Tem perture HEST Illuminates when the exhaust gas tempera ture and exhaust components become extremely hot DOG Q Y53 6027 INSTRUMENTS AND CONTROLS 15 Engine Check Engine Illuminates when a problem exists but the vehicle can still be safely driven Vehicle should be serviced to correct the problem but the situation should not be considered an emergency 16 Engine Ether Start Illuminates when ether start switch is on 17 Engine Heater Illuminates when Engine Heater switch is on 18 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 sit uation should not be considered an emer gency 27 INSTRUMENTS AND CONTROLS Kee A 28 19 Engine Overspeed Illuminates when engine RPM is exceeded 20 Engine Retarder Brake Illuminates when the engine retarder com pression brake or exhaust brake switch is turned on Engine retarders are an option 21 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 vehi cle as safely as possible and turn OFF
238. ry Loose U bolts can also cause uneven tire wear and poor alignment Suspension alignment should be checked when any one of the following conditions exist il Medium Duty R05 09 Discovery of loose suspension fasteners Any torque below the recommended torque value Discovery of elongated holes in a suspension com ponent Bushing replacement Excessive or abnormal tire wear NOTE To ensure an accurate torque reading use properly maintained and calibrated torque wrenches Rear Axle and Suspension Grade 5 Capscrew Torque Specifications Capscrew Body Torque Size inches thread Lb ft N m 1 4 20 6 9 8 12 28 7 10 9 5 14 5 16 18 13 18 18 24 24 14 20 19 27 3 8 16 22 32 30 43 24 25 40 34 54 7 16 14 35 50 47 68 20 39 56 53 76 1 2 13 54 77 73 104 20 58 87 79 118 9 16 12 78 111 105 151 18 87 124 118 168 5 8 11 108 154 147 209 18 122 174 166 236 3 4 10 192 273 260 370 16 214 305 290 414 7 8 9 309 441 419 598 14 341 486 462 659 1 8 464 662 629 898 1 12 508 724 689 982 Y53 6027 253 Rear Axle and Suspension Grade 8 Capscrew Torque Specifications Capscrew Body Torque Size inches thread Lb ft N m 1 4 20 9 12 12 16 28 10 14 14 19 5 16 18 18 25
239. s will ensure that interior components remain in good condition for the life of the vehicle 232 Y53 6027 Preventive Maintenance General Cleaning Guidelines WARNING AN Cleaning agents may contain hazardous agents Thoroughly read understand and fol low the manufacturer s instructions when using a cleaning agent to avoid possible death personal injury and property damage e Handle cleaning agents carefully Keep them out of the reach of children Commercial cleaning agents may be poisonous CAUTION To avoid possible property damage e 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 Medium Duty R05 09 Preventive Maintenance Cab Maintenance e Always test a commercial cleaning agent on Interior Trim Dash Shell and Instrument Panels an inconspicuous area of the surface to be RES CAUTION To avoid possible damage to these cleaned before using it A components do not use abrasive cleaners e Never clean interior components with brushes chemical solvents or strong deter chemicals or solvents such as gents uni Use a clean lint free cloth Acetone Clean with the cloth dampened with a mild soap and Turpentine water solution Benzene Carbon Tetrachloride Remove soap with a clean damp rag Lacquer Thinner opie
240. sely examined to determine if it is coming into contact with any sharp or rough surfaces on the seat or other 235 Cab Maintenance Preventive Maintenance 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 2 The pillar web guide D loop is the area where almost constant movement of the seat belt webbing occurs because of relative movement between the seat and Web cut or frayed or extremely worn cab at latch area 3 Check the Komfort Lok Latch for cracks or possible dam age and check for proper operation Web cut or frayed at D loop web guide Buckle casting broken 03004 Seat Belt Inspection Points 236 Y53 6027 Medium Duty R05 09 Preventive Maintenance 4 Check buckle and latch for proper operation and to deter mine if latch plate is worn deformed or damaged 5 Inspect the retractor web storage device which is mounted on the floor of the vehicle for damage The retractor is the heart of the occupant restraint system and can often be damaged if abused even unintention ally Check operation to ensure that it is not locked up and that it spools out and retracts webbing properly properly can cause excessive movement of the seat in an accident
241. signed to ensure that a driver is able to cancel the cruise set speed by using the service brake pedal The system will not allow cruise control operation if it does not pass the rationality check The Driver Information Display will prompt you to press the service brake pedal if it has not been pressed since the vehicle has been started Regeneration Switch In order to meet 2007 EPA engine emission requirements vehicles will have a either a two or three position switch to help control and maintain the exhaust Diesel Particulate Filter Please refer to Exhaust After Treatment System on page 128 for more information about the emission con trol system and how it affects normal operating proce dures START Depressing the button in the START direction for 4 to 8 seconds will initiate a parked regeneration Be sure to release the button to ensure that the system will begin the regerenation cycle 56 Y53 6027 CONTROLS AND DISPLAY Three Position Two Position CENTER three position switch only Center is the normal position of the switch The center position will allow an automatic regenera tion to occur STOP three position switch only When STOP is pressed the system will not regenerate under any conditions Medium Duty R05 09 CONTROLS AND DISPLAY DASH AND DOOR MOUNTED FEATURES in the STOP position unless you need to cancel or stop regeneration Leaving the switch in the STOP position for exte
242. sisting of a wet tank forward dry tank and rear dry tank The dry tanks have a single check valve in the tank inlet The check valves prevent a com plete loss of air in the event of an air system failure tank or hose failure This ensures a controlled stop with Medium Duty R05 09 Preventive Maintenance 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 il Every 900 operating hours or 25 000 miles 40 000 km or 3 months check for moisture in the air brake system by open ing 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 accessory air demands or some other unusual air requirement that doesn t allow the compressor to load unload in a normal fashion or it may be due to excessive leaks in the air system When more than a 30 degree F 17 degree C range of temperature occurs in one day small amounts of water can accumulate in the air brake system due to conden sation Under these conditions the presence of small 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 f
243. spect compressor air filter element if so equipped and replace element if clogged Check compressor mounting and drive for alignment and belt tension Adjust if necessary e Remove compressor discharge valve cap nuts and check for presence of excessive carbon If excessive car bon is found clean or replace the compressor cylinder head Also check compressor discharge line for carbon and clean or replace the discharge line if necessary Disassemble compressor and thoroughly clean and inspect all parts Repair or replace all worn or damaged parts or replace compressor with a factory exchange unit 200 Y53 6027 Preventive Maintenance system is required to prevent damage from freezing the compressor must also be drained at the cylinder head and block Engine damage could occur if the cooling system is not periodi cally drained and maintained See Engine Cool ing System Page 178 and the Medium Duty Maintenance Manual for further information Air Dryer CAUTION When draining the engine cooling WARNING Use of incorrect air dryer could AN cause air system failure leading to loss of vehi cle 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 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 con
244. speed rpm HU NOTE In colder climates where the tempera 3 Continue the engine warm up until the coolant tem perature reaches at least 130 F 54 C At this tem perature you can use partial throttle Wait until the coolant temperature is at least 160 F 71 C before operating at full throttle See Operating Manual Transmissions on page 98 WARNING Exhaust fumes from the engine MN contain carbon monoxide a colorless and odorless gas A poorly maintained damaged or corroded exhaust system can allow carbon monoxide to enter the cab or sleeper Failure to properly maintain your vehicle could cause carbon monoxide to enter the cab and cause death or serious illnesses longed periods of time if you sense that exhaust fumes are entering the cab Investi gate the cause of the fumes and correct it as soon as possible If the vehicle must be driven under these conditions drive only with the windows slightly open Failure to repair the source of the exhaust fumes may lead to death injury or serious illness Idling the Engine 1 WARNING Never idle your vehicle for pro Under most circumstances continuous idling of your engine merely wastes fuel In severe Arctic weather condi tions however you may need longer idling to be sure all parts of your engine are fully lubricated CAUTION Do not allow your engine to idle at A low rpm 400 600 rpm longer than five min utes Long periods of idling after the engin
245. st turned on there is a problem with the bulb or wiring You should have this checked as soon as possible CAUTION If the truck tractor ABS warning 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 114 Y53 6027 STARTING AND OPERATING THE VEHICLE ess XE 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 successsful warning lamp illumination n and bulb check at ignition on does not indicate that the trailer you may be connected to has trailer ABS You should personally inspect every trailer to determine its braking system A trailer ABS warning lamp will illuminate for a bulb check when the ignition switch is first turned on whether or not a trailer is connected to the vehicle If the bulb check is satisfactory the lamp will next do either of the following 1 If no trailer is connected or if a non ABS equipped trailer is connected the trailer ABS lamp will go off after a few seconds Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE NOTE A properly connected ABS equipped trailer is e a trailer with PLC hooked up to the J560 con nector e a trailer without PLC that is hoo
246. steering around corners and on dry pavement is more difficult Continuous operation on a paved dry surface stresses the tandem axles possibly causing internal damage Use this feature only when driving on surfaces with poor traction such as wet slippery roads heavy mud or snow or loose gravel And do not use it when going downhill or at speeds greater than 25 mph 40 km h Lock the inter axle differential when you encounter road conditions such as these ce or snow with or without tire chains 127 OPERATING THE REAR DRIVE AXLE Dirt roads Loose sand mud or other rough road conditions WARNING Do not put the differential lock in the LOCK position while the wheels are spin ning freely slipping you could lose control of the vehicle resulting in death personal injuryor property damage Switch to LOCK only when the wheels are not spinning Look ahead for wet muddy or icy patches on the road stop your vehicle and switch to LOCK ahead of time N 128 WARNING Do not operate the vehicle on dry pavement with the differential locked This could lead to an accident resulting in death or personal injury On dry pavement you will not be able to steer well with the differential locked Lock the differential only when operat ing on surfaces with poor traction such as wet slippery roads or loose gravel STARTING AND OPERATING THE VEHICLE Inter Axle Differential Lock Operation N WARN
247. sult in increased vehicle noise emission Table 12 Maintenance Log Maintenance Log Preventive Maintenance To ensure your Medium Duty vehicle s noise control require ments are maintained record maintenance checks Use the following log sheet see Table 12 and retain copies of docu ments regarding maintenance services performed and parts replaced on the vehicle PUT Mileage Service Performed Service poea ape 260 Y53 6027 Medium Duty R05 09 Preventive Maintenance Noise and Emission Control Table 12 Maintenance Log Medium Duty R05 09 Y53 6027 261 Noise and Emission Control Preventive Maintenance Table 12 Maintenance Log 262 Y53 6027 Medium Duty R05 09 Preventive Maintenance CONSUMER INFORMATION AND VEHICLE IDENTIFICATION Reporting Safety Defects 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 Administration NHTSA in addition to notifying Peterbilt Motors Company If NHTSA receives similar complaints it may open an investi gation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign How ever NHTSA cannot get involved in individual problems between you your Peterbilt Dealer and
248. t Axle and Suspension FRONT AXLE AND SUSPENSION Inspection For all vehicles mandatory maintenance procedures include retightening all U bolts and inspecting the suspension for loose fasteners abnormal wear or damage However even with proper maintenance the service life of leaf springs is affected by many factors such as fatigue vehicle gross weight type of load road conditions and vehicle speed Check for cracks wear marks splits or other e ects on the surface of the spring Defective parts must be replaced Because repaired springs cannot be fully restored to their original service life replace the com plete assembly if cracks or other defects are detected Visually inspect shock absorbers and rubber bushings See the Medium Duty Maintenance Manual for further information on servicing the front suspension 246 Preventive Maintenance SPRING AND SHACKLE PINCH BOLTS SPRING ANCHOR PINS U BOLTS SPRING ANCHOR PIN Joa Y53 6027 Front Suspension Axle Lubrication Change bearing lubrication when seals are replaced or brakes are relined See Table 1 Recommended Main tenance Intervals Page 154 Medium Duty R05 09 Preventive Maintenance Thoroughly clean hubs and bearings with solvent and a stiff bristle brush then dry and inspect components for wear or damage Re lubricate with approved axle lubri cant Kingpin Lubrication Lubricate with appr
249. t allow the rpm s to exceed the maximum gov erned speed See your Engine Operation and Mainte nance 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 131 DRIVING TIPS AND TECHNIQUES STARTING AND OPERATING THE VEHICLE Refer to the Engine Operation and Maintenance manual Shift into higher or lower gears or apply the service for optimum engine rpm brake to keep engine rpm near the lower end of the If the engine rpm moves beyond the maximum gov opunum operating range erned speed indicating an overspeed condition Avoid rapid acceleration and braking apply the service brake or shift to a higher gear to bring engine rpm within the optimum speed range WARNING Do not exceed the specified load AN rating Overloading can result in loss of vehi When driving downhill shift to a lower gear use the cle control and an accident causing death or engine brake if so equipped and use the service personal injury either by causing component brake keeping the engine speed below 2 100 rpm failures or by affecting vehicle
250. t control valve to its bracket Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE DRIVING TIPS AND TECHNIQUES ing the air springs The rear of the vehicle will WARNING Be extremely careful when deflat AN drop about 3 1 2 inches 88 mm when the air springs are deflated Make sure that no per sons that could be killed or injured or any Sp objects that could be damaged are under the vehicle ALIGNMENT PIN OR DOWEL CONTROL ARM LINK BOLT To minimize the risk of damage death or a l Am injury do not use the dump valve to deflate cud the air springs Operate the height control H p valve s manually to ensure positive control of air spring deflation anaa x qa h M FROM DUMP VALVE SWITCH To minimize risk of death or injury keep away from air springs as they are being inflated FORWARD 02941A Typical Height Control Valve Top View Medium Duty R05 09 Y53 6027 185 DRIVING TIPS AND TECHNIQUES STARTING AND OPERATING THE VEHICLE 3 Rotate the valve either clockwise or counterclockwise until air pressure in the air springs provides the ride SUPPLY FROM FORWARD k Aa SEINEN height specified for that suspension Measure the ride e height from the bottom of the frame rail to the approx imate centerline of the rearmost drive axle hub DELIVERY TO RH AIR BAG S A MOUNTING NUTS A T For tandem axles make the vertical measurement l D at the centerl
251. t drive in one gear for long periods of time until the transmission lubricant has a chance to coat all contacting surfaces Carefully observe the free travel in the clutch for the first few hundred miles As the clutch lining wears and high spots get worn smooth you will get less free travel Clutch Brake and Travel 9 10 and 11 Speed Transmissions only These transmissions utilize a clutch brake rather than synchronizers The clutch brake works by stopping all of the gears in the transmission allowing you to easily shift into first gear or reverse without grinding gears The total Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE stroke of the clutch pedal is about 10 inches The first part is the release stroke the part that fully releases the clutch The last inch engages the clutch brake During hard shifting with vehicle not moving To apply the clutch brake while the vehicle is stopped fully depress the clutch pedal to the floor board to stop the gears With the throttle at idle select first gear then release the clutch pedal to let the vehi cle start forward until the clutch is fully engaged See the transmission manufacturer s manual that is included with your vehicle for further details During Normal Driving If you want to shift directly into any gear other than first or reverse depress the clutch pedal only far enough to release the clutch Pushing the clutch to the floor applies the clutch br
252. t tips 79 82 signals 3 stands 151 tether belts 80 Safety precautions maintenance 150 Seat adjustment 74 Seat belt system damage and repair 82 guidelines 235 inspection 234 Komfort Lok latch 81 replacement part 237 tether belts 237 Seats 74 Secondary Air Pressure 17 Serial number 265 Service Brake Components 190 Shackle pinch bolts 248 Shift pattern diagram 98 101 Shifting gears 90 98 100 101 102 131 132 145 Shifting gears in a new vehicle 100 Shock absorber 246 Shop manuals 6 Shoulder belt 77 Y53 6027 275 Single check valve 120 Slack adjusters 186 Speedometer 17 Spring brakes manual release 142 Spring pins 247 Springs 246 Starting Procedure Cold Temperatures 92 Normal Temperatures 90 Steering Column Mounted Controls 45 Steering maintenance 243 Stopping procedures 146 Storage compartment 73 Suspension 249 fasteners 249 fasteners torque 249 T Tachometer 17 131 Tether belts 80 237 adjustment 80 Tire chains 145 inflation pressure 206 inspection 205 replacement tread depth 214 Towing 142 145 vehicle recovery precautions 140 Tractor park 110 276 Tractor protection manifold 121 Trailer hand brake 116 park 109 spring brakes 112 supply valve red 120 Trailer ABS 114 Trailer park 108 Transmission automatic 103 clutch 98 identification 268 lubrication 239 240 242 maintenance 240 manual 98 operation 98 Service notes 239 Truck tractor ABS 113 Turbocharge
253. tached to the cab floor and seat frame It should be routed through the buckle on each side Often the attachments are made using a split type hook Make sure both halves of the hook are around the anchor bracket 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 If your Medium Duty vehicle has been equipped with fixed length tethers no manual adjustment is required The same inspection and replacement guidelines should be used as stated on page 197 80 Y53 6027 Medium Duty R05 09 SEATS Komfort Lok Latch 4 To release the Komfort Lok latch reach up and pull re the latch cover open down or simply pull down on Your Peterbilt contains a feature designed to eliminate the shoulder belt cinching and provide improved safety and comfort Cinch ing is the condition where a belt becomes continually 5 When you want to get out of the cab release the tighter around you during a rough bouncy ride The need latch then just push the button on the buckle for this feature increases with rough road conditions par ticularly over long distances To eliminate cinching simply activate the Komfort Lok feature at the appropriate time 1 Fasten the seatbelt according to the directions in the previous Safety Belt Restraint section 2 You are now ready to activate the Komfort Lok Lean forward to pull a little slack in the belt maximum
254. that are set by the manufac turer The two functions are To decrease the cruise set speed hold the SET RESUME switch in the RESUME position and coast to a lower speed To increase the cruise set speed hold the SET RESUME switch in the SET position this will accel erate the vehicle to a higher speed Disengaging the Cruise Control Do one of these steps to disengage the cruise control Move the ON OFF switch to the OFF position or Depress the brake pedal or Depress the clutch pedal 97 OPERATING THE TRANSMISSION Reengaging the Cruise Control 1 Move the ON OFF switch to the ON position or 2 Toggle the SET RESUME lever to the RESUME posi tion Operating the Transmission Introduction Your Medium Duty vehicle is equipped with either a man ual or automatic transmission with special features and gearing to meet your particular needs It is important for you the driver to understand how your particular trans mission is operated To do this you have two sources of information this Operator s Manual and the transmission manufacturer s Driver Operator s Instruction Manual Because of the variety of different transmissions installed in Medium Duty vehicles operating procedures for your particular transmission are not included in this manual therefore you should read and understand both manuals Read the general guidelines and instructions that follow 98 Y53 6027 STARTING
255. the mirror directional control pad towards the arrows pointing left or right to adjust the mirror in out pleted return the mirror selector switch back to the center neutral position to prevent uninten tional adjustments to the mirrors Mirror Heat Switch d NOTE After mirror adjustments have been com Mirror Heat Indicator Light Mirror Heat m Switch Button Your vehicle may be equipped with optional heated mir rors Mirror heat is controlled by the mirror heat switch but ton which is part of the mirror switch module located on the driver side door pad Motorized mirrors with mirror heat have an automatic 15 minute time out feature where the mirror heat only module is automatically deacti vated 58 Y53 6027 CONTROLS AND DISPLAY 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 func tion has been activated Pressing and releasing the button again turns the mirror heat and the indicator light Off NOTE The effects of direct sunlight or the use of H mirror heat will increase the outside air tempera ture displayed while the vehicle is stationary Power Window Switch Driver Window Switch hae Passenger a Switch WARNING When closing the power windows AN be sure that they are free of obstructions including your or your passe
256. the preheat cycle is complete and you can start the engine normally 94 Y53 6027 STARTING AND OPERATING THE VEHICLE After the engine starts and until operating conditions reach a certain point the system will continue to operate to eliminate white smoke exhaust Engine Warm Up and Idling The purpose of engine warm up is to allow an oil film to be established between pistons shafts and bearings while your engine gradually reaches operating temperature Warm Up Procedure 1 After you have started the engine idle the engine at approximately 600 rpm while you check vital engine systems oil pressure air pressure alternator output with the optional voltmeter 2 Before placing engine under a load continue warm up with the engine at 900 to 1000 rpm for 3 to 5 min utes When a cold engine is started increase the engine speed rpm slowly to be sure adequate lubrication is available to the bearings and to allow the oil pres sure to stabilize In extremely cold temperatures you may have to increase idle speed Medium Duty R05 09 STARTING AND OPERATING THE VEHICLE tures are often below freezing sufficient warm up for turbocharged engines is especially impor tant Chilled external oil lines leading to the tur bocharger will slow the oil flow until the oil warms reducing oil available for the bearings Watch the engine oil pressure gauge for a warming trend before increasing engine idle
257. the road which could result in an accident involving death personal 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 NOTE Regardless of how and where the naviga tion 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 Medium Duty R05 09 CONTROLS AND DISPLAY ACCESSORIES available at the time of production The database You can lock and unlock the glove compartment door Hn NOTE The map database is the most current To close push the cover up and press to latch it 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 AN Manual for more information Radio As an option your vehicle has either an AM FM Stereo Receiver or an AM FM Stereo Cassette Player For instructions on how to operate your particular radio see the manufacturer s Radio Operating Instructions in the glove compartment AN Glove Compartment A glove compartment is provided to store important docu ments the vehicle literature set including this Operator s
258. the vehicle causing death or personal injury Make all adjustments to the seat while the vehicle is stopped After adjusting the seat and before driving off always check to be sure that the seat is firmly latched in position 74 Y53 6027 WARNING Before driving or riding in the vehicle be sure that there is adequate head clearance at maximum upward travel of seat Death or personal injury may occur if head clearance is not adequate Medium Duty R05 09 SEATS Safety Restraint Belts The right and left seats are equipped with 3 point lap shoulder belts the center seat has a 2 point seat belt Safety belts have proven to be the single most effective means available for reducing the potential for either seri ous injury or death in motor vehicle accidents Therefore Meee te read and follow these instructions and always observe Rotate knob for user warnings pertaining to safety belts infinite selection of settings CHUGGER SNUBBER LOCK OUT FEATURE Move handle down to unlock N FRONT CUSHION HEIGHT Lift and pull forward to raise position J SEAT RIDE HEIGHT LUMBAR ADJUSTMENT Push switch up to inflate PEORES BET ISOLATOR Push down to deflate Move to left and slide seat to desired position 03017 Peterbilt Ultraride II Highback Air Seat Unbelted Person in Crash Medium Duty R05 09 Y53 6027 75 SEATS seat belt and your riders belts
259. the wiper s setting speed 47 OPTIONAL GAUGES Wiper Switch Settings Wiper Switch Position 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 To activate the wipers for one swipe without activating the washer mist function push the turn signal lever in 48 Y53 6027 CONTROLS AND DISPLAY 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 Check the windshield washing fluid level daily If neces sary 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 Your Peterbilt has an electric horn To operate press on the horn symbol near the center of the steering wheel Medium Duty R05 09 CONTROLS AND DISPLAY Air Operated Horn Option Your Medium Duty vehicle may be equipped with an air A horn To operate pull on the lanyard extending from the overhead header panel Trailer Brake Hand Valve This hand valve provides air
260. ting by the motor carrier See the cited FMCSR for a complete description of the regula tion and exemptions Any authorized person riding in your vehicle should wear a seat belt A responsible operator sees to it that everyone in the vehicle rides safely and that means with a seat belt Do not strap in more than one person with each belt Do not wear a belt over rigid or breakable objects in or on your clothing such as eye glasses pens keys etc as these may cause injury in an accident Several layers of heavy clothing may interfere with proper positioning of belts and reduce the overall effectiveness of the system Keep belt buckles free of any obstruction that may prevent secure locking Y53 6027 Damaged or worn belts subjected to excessive stretch forces from crashes cuts or tears or normal wear must be replaced they may not protect you if you have an accident If belts show damage to any part of assembly such as webbing bindings buckles or retractors they must be replaced Do not allow safety belts to become damaged by get ting caught in door or seat hardware or rubbing against sharp objects The belts must be kept clean or the retractors may not work properly Never bleach or dye seat belts chemicals can weaken them Do however keep them clean by fol lowing the care label on the belts Let them dry com pletely before allowing them to retract Make sure the belt of the unoccupied passenger seat is fully w
261. ts DRL the high beam headlamps go on auto On vehicles equipped with the Daytime Running Light matically at reduced brightness if the engine is run DRL system the low beam headlights are turned ON ning and the headlamp switch is turned off The automatically at reduced brightness to conserve head daytime running lights are turned off automatically lamp life while the parking brake is engaged If the head lamp switch is turned on the DRL system is over If the headlight switch is turned OFF the DRL system ridden amp headlamps operate normally engages automatically after the engine starts and you 52 Y53 6027 Medium Duty R05 09 CONTROLS AND DISPLAY Panel Light Dimmer 9 3 AUC The Panel Light Dimmer lets you vary the brightness of your instrument panel lights To Operate Your Panel Light Dimmer 1 Turn on either the headlights or clearance lights 2 To brighten the instrument lights rotate the thumb wheel up 3 To dim the instrument lights rotate the thumbwheel down Medium Duty R05 09 Y53 6027 DASH AND DOOR MOUNTED FEATURES ID and Clearance Lights Switch 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 Dome Light The center mounted dome light is operated by gently p
262. ttle in the opposite direction 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 For further instructions on operating your transmission see the transmission manufacturer s manual that is included with your vehicle If you have a misaligned gear condition in your vehicle s transmission and cannot start gradually release the clutch allowing the drive gear teeth to line up properly Then the drive gear can roll enough to allow the teeth to line up properly and complete the shift The best engine performance and maximum economy is obtained if gears are properly selected This efficiency is achieved by always selecting gears within optimum engine rpm which is where maximum torque and power are obtained For further information see More Driving Tips and Techniques on page 130 100 Y53 6027 STARTING AND OPERATING THE VEHICLE Shifting Gears in a New Vehicle Shift carefully in a new vehicle The transmission may be a little stiff at first Avoid gear clashing by closely following these procedures When you are operating a new vehicle or one that has been exposed to cold weather you want the transmission lubricant fluid to circulate and coat the contacting sur faces of the gears Metal contacting metal in moving parts may seriously damage your transmission do no
263. turned OFF unplugged When the temperature falls below 0 F 18 F for Cater pillar engines or 10 F 24 C for Cummins engines the block heater is required Medium Duty R05 09 Y53 6027 WARNING Do not use ether or other starting fluids as a cold starting aid in your Medium Duty vehicle Your engine uses either an elec trical grid or an open flame inside the mani fold to heat the air fuel mixture for cold weather starting If ether or another starting fluid is used the air fuel will ignite inside the manifold which could cause an explosion and death or severe injury 93 With each engine make the air intake heating system works differently To understand fully how your engine s heating system operates see the engine Operation and Maintenance Manual for details On most systems the engine block temperature is moni tored at startup other systems monitor the engine oil pressure coolant temperature and time as well When the pre set conditions are met the heater automatically engages Air Intake Heater The air intake heater system will alert you when the engine requires preheat On the dash is a WAIT TO START warning light See page 28 This light alerts you to wait before starting the engine Turn the key to IGN amp ACC the WAIT TO START light will light up for bulb check Wait until the WAIT TO START light goes off before you start the engine When the WAIT TO START light goes off
264. ty The most critical warning will be displayed on the top row and to the left If more than six warnings are 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 b Park Brake Transmission Gear Automatic transmissions only Warnings Number of active warnings Medium Duty R05 09 CONTROLS AND DISPLAYS A red warning is active A An amber warning is active d Cruise Control active e Clock alarm bell Refer to Warning Light Indicator Symbols on page 22 for information on each symbol 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 approxi mately 3 seconds each screen on the Information Dis play These are Medium Duty R05 09 Y53 6027 INSTRUMENTS AND CONTROLS Third Refer to Warning Light Indicator Symbols on page 22 for information on each symbol Completing this sequence will indicate a successful Self Test Have your instrumentation system checked by a qualitfied service technician if does not successfully com plete Audible Alarm The audible alarm will sound during the I
265. u are not an experienced mechanic anddo not have the right equipment or training please leave the repairs to an authorized service facility They are the ones equipped to do the job safely and cor rectly WARNING Do not attempt repair work without AN sufficient training service manuals and the proper tools You could be killed or injured or you could make your vehicle unsafe Do only those tasks you are fully qualified to do Y53 6027 INTRODUCTION Shop Manuals If you do decide to do complex repair work you will need the Medium Duty Maintenance Manual It contains ser vice procedures parts information and supporting mate rial on major components in your vehicle such as Suspensions Drivelines Axles and the Heater Air Condi tioner Listed below are manuals available from your Peterbilt Dealer There is a charge for these manuals Please pro vide the Chassis Serial Number when ordering to be sure you get the correct manuals for your vehicle Medium Duty Maintenance Manual This manual includes detailed service procedures specifically compiled for the components on your vehicle including electrical information maintenance disassembly assembly repairs overhaul and troubleshooting procedures The information contained in this manual is the same used by Peterbilt dealers Medium Duty Master Parts Catalog Contains illustrated parts lists with drawings and exploded views for Medium Duty series vehicles Me
266. ub piloted mount and ball seat mount applications Only OEM supplied hub piloted or ball seat mounted wheels may be used on this vehicle 1 WARNING Use only original equipment manu 204 Y53 6027 Preventive Maintenance 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 killed or 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 Exceed ing 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 litera ture Only properly trained personnel should service tire and rim assemblies See page 215 for specific safety requirements for trucks with hydraulic brakes Medium Duty R05 09 Preventive Maintenance Speed Restricted Tires WARNING This vehicle may be equipped with AN speed restricted tires Check each tire s side wall for maximum rated speed Vehicle should not be operated at sustained spe
267. ult in serious damage to the engine If you do not repair them the engine damage will not be covered by your warranty Repair all air leaks as soon as you find them CAUTION Air leaks cause excessive noise and Exhaust System Check for exhaust leaks which would indicate a leaking manifold gasket replace gasket if necessary Check cap screws for tightness including those at the flanges Refer to the engine manufacturer s service man ual for proper tightening sequence and torque values 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 Medium Duty R05 09 Preventive Maintenance Piping Check exhaust piping for rust corrosion or damage Replace deteriorated piping before holes appear If pip ing is perforated at any point temporary patching or lag ging is acceptable until you can have permanent repairs made On turbocharged engines check joints at flanges and mounting brackets for tightness Mufflers NOTE Use only an exact replacement muffler in exhaust systems Certain mufflers contain integral catalytic converters essential for compliance with EPA emission standards Using a noncompliant muf fler as a replacement could violate these standards and also void the emission system s warranty Check muffler clamps and mounting brackets Tighten if necessary Inspect muffler for signs of rust or corrosion
268. umi nate and then go out when the ignition switch is first turned on The Wheel Spin Control warning lamp will illu minate 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 115 USING THE BRAKE SYSTEM 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 sys tem Except for checking for proper illumination of the ABS and Wheel Spin Control warning lamps when first starting the truck 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 Trailer Brake Hand Valve Tractor trailer vehicles are equipped with a trailer brake hand valve mounted on the right side of the steering wheel column This hand valve provides air pressure to apply the trailer brakes only It operates independently of the foot treadle valve 116 Y53 6027 STARTING AND OPERATING THE VEHICLE To operate the trailer brake hand valve Pull down on the lever The valve is self returning W
269. unction adequately Medium Duty R05 09 Y53 6027 Air System amounts of moisture is normal and should not be consid ered as an indication that the dryer is not performing properly e 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 Air Intake System Engine heat vibration and age combine to loosen air intake connections and cause cracks in the tubing and elbows Leaks in the intake system allow abrasive dust to enter the engine 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 Peterbilt recom mends complete disassembly and cleaning of the air intake system at each 25 000 mile 40 000 km Under Severe operating conditions the disassembly and clean ing should be more frequent Replace any defective parts With the possible exception of mounting brackets do not repair defective parts 201 Air System Check the Charge Air Cooler for air leaks annually The air leaks can be caused by cracked tubes or header For service see your Peterbilt Dealer or Authorized Service Center Turbocharger When servicing the air intake and exhaust systems on a tur bocharged engine check the items listed below charger intake piping disconnected A suction is created when the engine is runnin
270. ure in pounds per square inch psi See Primary Secondary Air Pressure Gauge Air Reservoir on page 43 If the pressure in either or both systems is too low for normal brake operation i e either pointer falls below 60 psi 414 kPa a warning light on the gauge will glow and the audible alarm will sound 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 Medium Duty R05 09 Preventive Maintenance in the air system is detected Conduct the follow ing procedure and contact an Authorized Ser vice Center or any other properly equipped service center if a leak is detected Failure to check the brakes or follow these procedures could cause a system failure increasing the risk of an accident resulting in death or personal injury f WARNING Do not operate the vehicle if leakage Follow the procedure below to check the compressed air system for leaks 1 Periodically or after maintenance or replacement of air system components 2 Build up air pressure in the system to the governor cut out point or until 120 psi 827 kPa is reached 3 Stop the engine and release the service brakes 4 Without applying the brake pedal observe the rate of air pressure drop This rate should not exceed 2 0 psi 14 kPa per minute 5 Start the engine and build up the air pressure again 6 Stop the engine and apply the brakes fully Apply the brake pedal and h
271. ushing on the lens until a click is heard The same action turns the light on or off depending on its previous state 53 DASH AND DOOR MOUNTED FEATURES Fog Lights Switch If your vehicle has fog lights turn them ON or OFF with the control panel switch with the symbol shown above il 54 NOTE Across the U S A and Canada State Pro vincial 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 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 CONTROLS AND DISPLAY Air Suspension Deflate Switch Dump Valve AIR SUSPENSION Your Peterbilt vehicle may have an air suspension defla tion 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 pre vents you from accidentally deflating the suspension A Y53 6027 WARNING Operating the Air Suspension Deflate Switch Dump Valve while driving can lead to an accident causing death or personal injury Sudden deflation while your vehicle is moving can affect handling and control Use this switch only when your vehicle is not mov ing Medium Duty R05
272. utomatically proportions the drive axle brake application pressure when driving bobtail with out a trailer connected The proportioning BP R1 brake valve allows full use of the steer axle front brakes and reduces the chance that the drive axle brakes will lockup The bobtail brake proportioning system is automatically turned off when a trailer is connected 105 USING THE BRAKE SYSTEM Using the Parking Brake The yellow diamond shaped knob on the dash controls the truck tractor parking brakes These are spring brakes that you activate by releasing air pressure from their chambers When they are not in use air pressure com presses the springs and releases the brakes Pulling the knob OUT applies the parking brake which exhausts air from the chambers and allows the springs to extend and apply the brakes WARNING Do not pull out the parking brake AN valve while the vehicle is moving Stopping with the parking brake controls can cause a sudden wheel lock up loss of control or over take by following vehicles You could be killed or severely injured WARNING Do not leave the cab without AN applying the parking brake The truck could roll and cause an accident resulting in death or personal injury Always apply the parking brake before you leave the cab 106 Y53 6027 STARTING AND OPERATING THE VEHICLE Before you leave the cab 1 Apply all parking brakes Pull out the Yellow Parking Brake Control knob locate
273. vehicle s oil and air pressure are correct and all other parts and systems are in proper working condition 1 If your truck is equipped with a hand throttle disen gage the hand throttle before driving the vehicle Medium Duty R05 09 Y53 6027 OPERATING THE TRANSMISSION 2 Fully depress the clutch pedal until the clutch brake makes contact see page 100 The contact will occur at about 1 inch or less from the floorboard The total stroke of the clutch pedal is about 10 inches The first 1 inches is free travel After the free travel comes the release stroke which is the part that fully releases the clutch The last inch engages the clutch brake Always start out in a low gear Starting in a higher gear even with a light load will cause a very jumpy start and excessive wear CAUTION Always use first gear or a low A 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 3 Evaluate the road surface conditions and terrain your vehicle is on Select a gear low enough to let your vehicle start forward with the throttle at idle 4 Push the parking brake valve handle Yellow against the dash panel to release the brakes 99 OPERATING THE TRANSMISSION 5 Release the clutch pedal then gradually accelerate to permit smooth starting 6 Do not allow your vehicle to roll even a li
274. ventive Maintenance Chassis Number Locations The chassis serial number is shown in three places Right frame rail top flange about 3 ft from the front end Components and Weights Label on driver s door frame Tire and Rim Info Label on driver s door frame Medium Duty R05 09 Y53 6027 Consumer Information and Vehicle Identification VIN LOCATION A2378 265 Consumer Information and Vehicle Identification Preventive Maintenance Complete Vehicle Certification Label VEHICLE NAME PLATE The Complete Vehicle Certification label certifies that the vehicle complies with all applicable Federal Motor Vehicle Safety Standards It is located on the driver s side door frame and contains the following information O Palaki Motsa Company O A LADNBON OE pacon Date of manufacture AN CHASSIS WT M O VN o GVWR Gross Vehicle Weight Rating d GAWR FRONT and REAR Gross Axle Weight Rat ings for Front and Rear Axle TIRE RIM SIZES AND INFLATION PRESSURES Tire Rim Sizes and Cold Pressure Minimums VIN Vehicle Identification Number SUITABLE TIRE RIM CHOICE THIS VEHICLE CONFORMS TO ALL MANUFACTURED BY TIRE SIZE RIM SIZE PSI COLD APPLICABLE FEDERAL MOTOR VEHICLE PETERBILT MOTORS CO FR GAWR SAFETY STANDARDS IN EFFECT ON THE DIVISION OF PACCAR Inc 2ND GAWR DATE OF MANUFACTURE SHOWN ABOVE
275. w moments the lighter will automatically pop out ready to use After use insert the knob but do 69 CUPHOLDERS ASHTRAY not push it in The cigarette 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 replac ing the fuse WARNING Do not exceed the voltage amper N age capacity of the cigarette lighter It could result in a fire causing death or personal injury Follow all warnings and instructions in the operator s manual for the appliance you are using 70 Y53 6027 CONTROLS AND DISPLAY The power port at the top of the dash may be used to power auxiliary equipment not drawing more than 15 amperes maximum per port Devices designed to use these power ports will not fit into the cigarette lighter port Cupholders Ashtray Your vehicle comes standard with two cupholders located in the center of the cab below the dashboard This vehicle may have an optional ashtray which is designed to fit into one cupholder WARNING Paper or other combustible sub AN stances in an ashtray could cause a fire resulting in death or personal injury Keep all burnable materials besides smoking materials out of the ashtray Medium Duty R05 09 CONTROLS AND DISPLAY Medium Duty R05 09 CUPHOLDER SHIFT PATTERN DISPLAY Shift Pattern Display The correct shi
276. xcept for using small trickle charges as explained on Page 226 to maintain battery condition you should have your vehicle s batteries charged by a qualified service facility Medium Duty R05 09 Preventive Maintenance severely They contain acid produce poisonous and explosive gases and supply levels of elec tric current high enough to cause burns A spark or flame near a battery on charge may cause it to explode with great force f WARNING Batteries can kill or injure you To help reduce the risk of personal injuries follow these guidelines carefully when recharging a battery Before attempting any service in the electrical installa tion disconnect the battery negative cable Allow no sparks or open flame anywhere near the charg ing area Charge a battery only in a well ventilated area such as outdoors or in a fully open garage which contains no pilot lights or other flames Gases generated during the charging process must be allowed to escape 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 dis tilled 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 Medium Duty R05 09 Y53 6027
277. xle Inter Axle Differential tyt Locked Tandem Axles H Yellow e 26 Fu 8 Brake System O 26 9 Clock Alarm Bell T LX elow e 26 Y53 6027 Medium Duty R05 09 CONTROLS AND DISPLAYS Warning Light Indicator Symbols INSTRUMENTS AND CONTROLS Warning Light Indicator Symbols Symbol Name Symbol Color Std Opt Page Symbol Name Symbol Color Std Opt Page 10 Cruise Control Active 19 Engine Overspeed O Yelow o 27 Red e 28 11 Dump Truck Body U Engine R Brak p y Up a 27 20 Engine Retarder Brake Sican 28 12 Dump Truck Trailer Body 21 Engine Stop Engine Up S Yellow e 27 Red e 28 O00 13 Emissions Diesel Particu 22 Engine Wait To Start late Filter DPF Yellow e 27 too Yellow e 28 se WAIT 14 Emissions High Exhaust E 23 Fifth Wheel King Pin Lock System Temperture HEST 723 Yellow e 27 18 Red e 28 15 Engine Check Engine Yellow 27 24 Fifth Wheel Slide to Unlocked d Red o 28 16 Engine Ether S edd zb seat e 27 25 Lights High Beam 32 e Blue e 29 17 Engine Heater 26 Message Waiting g KIN Yellow 27 D Green 29 27 Park Brake 18 Engine Low Coolant Level m P Red e 29 Lad Yellow e Medium Duty R05 09 Y53 6027 23 INSTRUMENTS AND CONTROLS CONTROLS AND DISPLAYS
278. you to lose control of your vehicle and may result in an accident caus ing death or personal injury 1 WARNING Use the correct components and Medium Duty R05 09 Y53 6027 The end of the wheel wrench must be smooth Burrs on the end of the wrench can tear grooves in the disc These grooves may lead to cracks in the disc and can cause it to fail ppc Tires and Wheels Demounted Rims To check the torque on demountable rims follow the criss cross sequence shown below See Table 7 Wheel Cap Nut Torque Page 210 for proper torque specifications 00118 DISK WHEEL DEMOUNTED RIMS Crisscross Tightening Sequence 212 Y53 6027 Preventive Maintenance ing tire and rim assemblies is dangerous Failure to observe proper precautions could cause the tire rim assembly to burst explosively causing serious injury or death See the wheel manufac turer s literature for the proper way to mount and demount your tires and rims Follow their pre cautions exactly f WARNING Improperly mounting and demount Comparing Hub Piloted and Ball Seat Parts WARNING Do not mismatch wheel components N Equipment that does not exactly match original specifications or that is mismatched could cause the wheels to break and separate from the vehicle causing death or personal injury Each mounting system is engineered for use only with its correct mating part Be sure properly matched components are used for
279. z Man RA Remover For difficult stains on painted plastic surfaces such as Ammonia based Products the dash shell use Dupont Sontara cleaner part number PS 3909S The product is available from Dupont as a presaturated wipe e 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 Carpet e Avoid application of conditioning products containing silicones or waxes to the top sur face of the dash panel This may cause glare that can be a driver distraction Use a clean lint free cloth or clean soft fiber brush Excess water may damage the carpet Keep CAUTION Do not apply water directly to carpet carpet as dry as possible Clean with the cloth or brush dampened with a mild soap and water solution Medium Duty R05 09 53 6027 233 Cab Maintenance Remove soap with a clean damp rag If a stronger cleaning solution is required use a foam type carpet shampoo Vinyl and Fabric Upholstery CAUTION To avoid possible damage to the A upholstery do not use chemical solvents or strong detergents on these components Use a clean lint free cloth Clean with the cloth dampened with a mild soap and water solution Remove soap with a clean damp rag For difficult stains use a commercial fabric or vinyl cleaner 234 Y53 6027 Preventive Maintenance Safety Restraint System Inspecti

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