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Peterbilt Y53-6008 User's Manual

1. 02901 when operating on road surfaces with poor traction wet icy or snow covered roads or in heavy traffic Accelerations caused by the nor mal operation of the cruise control could cause you to lose control of the vehicle resulting in an injury accident WARNING Do not operate the cruise control 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 See page 65 for instructions on how to use the cruise control Instruments and Controls Hand Throttle Control Your vehicle may be equipped with a hand throttle It is located on the floor to the left of the driver s seat It can be especially helpful in cold weather to keep your engine run ning above idle speed when you leave the vehicle briefly See page 64 for more information on idling your engine safely for cruise control or to control your road speed It could cause an accident and you could be seriously injured Always disengage the hand throttle before driving the vehicle WARNING Do not use the hand throttle control Medium Duty R10 06 Y53 6008 937 Heating and Air Conditioning Operating Instructions HEATING AND AIR CONDITIONING Introduction reduced by fog condensation or frost on the windshield Your view may be obscured which could result in an injury accident For clear visi bil
2. Remove soap with a clean damp rag If a stronger cleaning solution is required use a foam type carpet shampoo Vinyl and Fabric Upholstery upholstery do not use chemical solvents or A CAUTION To avoid possible damage to the 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 Medium Duty R10 06 Y53 6008 Cab Maintenance Safety Restraint System Inspection 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 tain 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 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 truc
3. 34 21 ELC Condition Contamination and Inhibitor Concentra ELC Extender tion 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 Medium Duty R10 06 Y53 6008 Add ELC extender if necessary at the maintenance inter val under Cooling on page 148 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 within 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 145 Engine Coo
4. 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 cedures will ensure that interior components remain in good condition for the life of the vehicle Medium Duty R10 06 Y53 6008 Cab 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 per sonal injury and property damage e Handle cleaning agents carefully Keep them out of the reach of children Commercial cleaning agents may be poisonous A 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 195 Cab Maintenance Always test a commercial cleaning agent on an inconspicuous area of the surface to be cleaned before using it
5. 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 n 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 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 222 Y53 6008 Preventive Maintenance 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 seriously injured Before turning on the ignition be sure that no one is near the fan WARNING Do not work on the fan with the
6. 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 2 Rec ommended Maintenance Intervals Page 120 and the Trans mission 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 202 Y53 6008 Preventive Maintenance 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 2 Recommended Maintenance Intervals Page 120 Medium Duty R10 06 Preventive Maintenance Transmission and Clutch Table 10 Transmission Lubrication Manual transmissions AMBIENT RECOMMENDED TEMPERATURE RANGE MODEL LUBRICANT See Note VISCOSITY SAE D
7. lubricants oil and grease can be poisonous and cause sickness They can also damage the paint on the vehicle 1 WARNING Handle lubricants carefully Vehicle cants Mixing lubricants oil and grease of dif ferent brands or types could damage vehicle components therefore drain or remove old lubricants from the unit before refilling it CAUTION Do not mix different types of lubri When switching between types of lubricants thor oughly drain all areas of the component 133 Maintenance Schedule and Lubrication Lubrication Types Use Table 4 on page 136 and the list of lubricants below to identify the type of lubricant to use on your Medium Duty For a quick summary of each lubrication point see Table 2 on page 120 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 M
8. 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 5 Brake Adjuster Stroke Correctly installed and functioning brakes auto slack will produce the strokes listed for each chamber type 151 Brake System Preventive Maintenance slack adjusters is a dangerous practice that could have serious consequences It gives the operator a false sense of security about CHAMBER the effectiveness of the brakes Contact the Service Department at your dealership if the stroke exceeds the above specifications A stroke exceeding these values may indicate a JE problem with the slack adjuster or the brake PUSHROD foundation j WARNING Manual adjustment of automatic SLACK ADJUSTER 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 01830 With the air system at 100 psi 690 kPa or more apply the brake APPLIED STROKE Measuring Pushrod Travel If adjustment is necessary and the slack adjuster is working Table 5 Brake Adjuster Stroke the adjusting h
9. The blue indicator light in the instrument panel will be ON when the high beam is being used To return to previous beam push and release the button again Medium Duty R10 06 Operating Instructions Steering Column and Mirrors Emergency Flasher Switch The four way Emergency Flasher switch is on the turn signal body just below the turn signal lever The emergency flasher makes all four turn signals front and rear flash simulta neously The flasher works independently of the ignition Switch You should always use the flasher if the vehicle is dis abled or parked under emergency conditions To operate the emergency flasher pull the lever out The flasher is self cancelling To turn it off activate the left or right turn signal Medium Duty R10 06 Y53 6008 System any time you have to stop off the road or on the side of the road day or night A hard to see vehicle can result in an injury accident Another vehicle could run into you if you do not set your flashers Always move the vehicle a safe distance off the road when stalled or stopped for repairs 1 WARNING Use your Hazard Flasher Warning Your disabled vehicle can be dangerous for you and others The hot exhaust system could ignite dry grass brush spilled fuel or other material that can cause fires Do not park or operate your vehicle in areas where the hot exhaust system could cause a fire Trailer Brake Hand Valve This hand valve mounte
10. and 11 Speed Transmissions only These transmissions utilize a clutch brake rather than syn chronizers 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 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 floorboard to stop the gears With the throttle at idle select first gear then release the clutch pedal to let the vehicle start forward until the clutch is fully engaged See the transmission manufacturer s manual that is included with your vehicle for further details 69 Operating the Transmission 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 brake and could cause gear hang up brake while the vehicle is moving The purpose of the clutch brake is to stop the transmission so that you can shift into a starting gear without grinding 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 CAUTIO
11. without the right know how and proper tools You could be 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 WARNING It is dangerous to work on a vehicle 116 Y53 6008 Safety Precautions Before attempting any procedures in the engine compartment stop the engine and let it cool down Hot components can burn skin on contact Be alert and cautious around the engine at all times while the engine is running If work has to be done with the engine running always 1 set the parking brake 2 chock the wheels and 3 ensure that the shift lever or selector is in Neutral Exercise extreme caution to prevent neckties jew elry long hair or loose clothing from getting caught in the fan blades or any other moving engine parts Disconnect the battery ground strap whenever you work on the fuel system or the electrical system When you work around fuel do not smoke or work near heaters or other fire hazard Keep an approved fire extinguisher handy Always support the vehicle with appropriate safety stands if it is necessary to work underneath the vehi cle A jack is not adequate for this purpose Medium Duty R10 06 Preventive Maintenance e When working underneath the vehicle without appropriate safety stands but with the wheels on the ground not supported make sure that 1 the vehi cle is on
12. you could be injured Switch to LOCK only when the wheels are not spinning 96 Y53 6008 Operating Instructions Look ahead for wet muddy or icy patches on the road stop your vehicle and switch to LOCK ahead of time WARNING Do not operate the vehicle on dry AN pavement with the differential locked This could lead to an injury accident On dry pavement you will not be able to steer well with the differential locked Lock the differential only when operating on surfaces with poor traction such as wet slip pery roads or loose gravel Inter Axle Differential Lock Operation WARNING Do not use the inter axle differential AN 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 characteristics This understeer condition will cause your vehicle to turn less quickly and more steering effort will be required which can cause an injury accident 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 differential while Medium Duty R10 06 Operating Instructions 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 conditions T Turning Radius When Unlocked Disen
13. 6 With a wrench turn the release stud assembly nut until the compression spring is 90 95 percent caged While doing this check to make sure the push rod adapter push rod or service Medium Duty R10 06 Y53 6008 111 112 Vehicle Recovery and Spring Brakes push rod is retracting Do not over torque the release stud assembly S Cam type maximum 50 ft lb Wedge type maximum 30 ft lb The spring brake is now mechanically released Freeing the Vehicle from Sand Mud Snow and Ice WARNING Do not spin the wheels faster N than 35 mph 55 km h Spinning a tire at speedometer readings above this can be dangerous tires can explode from spinning too fast Under some conditions a tire may be spinning at a speed twice that shown on the speedometer Any resulting tire explo sion could cause severe injury or death to a bystander or passenger as well as exten sive vehicle damage including tire trans mission 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 Operating Instructions 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 Comply with the following instructions to avoid transmission damage Always start the vehicle in motion with
14. 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 uai lI A B C DIE Cooling Hoses Check the radiator and heater hoses for leaks X X Extended Life Coolant ELC Check the freeze point see page 143 X Check for contamination using test strips see page 145 X Replace blank water filter if applicable X Perform lab analysis see page 145 X If lab analysis shows coolant is unsuitable for continued use Flush drain and refill see page 143 Add ELC Extender see page 145 Flush drain and refill with new coolant see page 143 Fan clutch housing Check for air leaks X X Surge Tank Fill Cap Check fill cap seal at each oil change XIX X X X 148 Y53 6008 Medium Duty R10 06 Preventive Maintenance BRAKE SYSTEM If your truck has an air brake system see the pages below If your truck has a hydraulic brake system please go to Hydraulic Brake System on page 153 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 tion
15. 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 Medium Duty R10 06 Air System 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 AIR INTAKE ASSEMBLY 02603 Y53 6008 Air Intake Assembly 167 Air System Preventive Maintenance 3 Remove the filter element COVER m CD i oni 00455B FILTER ELEMENT 4 Clean out the inside of the air cleaner body and outlet tube with a dry rag 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 Air Cleaner Filter Element To remove the air filter 1 Remove the two thumb screws 2 Remove air cleaner service cover 168 Y53 6008 Medium Duty R10 06 Tires and Wheels Preventive Maintenance TIRES AND WHEELS Introduction Keeping the tires in good condition is essential to the safe efficient operation of your Medium Duty Regular fr
16. It is important to maintain oil pressure within acceptable lim Ifthe oil pressure fails to rise within 10 seconds after the engine starts stop the engine and determine the cause its JP ell pressure tops Delowrlhe Tininum peta hed Warn e Check the engine manufacturer s manual for the correct ing Lamp on the oil pressure gauge and the Stop Engine oil pressure ranges for your vehicle s engine Warning Lamp will come ON If the oil pressure suddenly drops or the audible alarm and engine oil pressure warning light come on while driv For further information on engine oil and normal operatin 4 P 9 ing do the following pressures see the Engine Operation and Maintenance Man ual 1 Slow down carefully 2 Move a safe distance off the road and stop Medium Duty R10 06 Y53 6008 25 Instruments and Controls 3 Place the transmission in park and set the parking brake See Pages 68 and 74 for transmission shifting and parking brake information 4 Turn OFF the engine 5 Turn ON the emergency flasher and use other warning devices to alert other motorists 6 Wait a few minutes to allow oil to drain into the engine oil pan and then check the oil level See page 139 for details on checking oil level 7 Add oil if necessary If the problem persists con tact an Authorized Service Center For further information on operating your engine properly see page 58 Dual Air Pressure Gauge Air Reservoir The dual air
17. 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 Medium Duty R10 06 Y53 6008 Electrical System Jump Starting 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 and gases that can explode Ignoring safety pro cedures can cause you or others to be badly hurt WARNING Batteries contain acid that can burn flames or electrical sparks Batteries generate explosive gases that could explode causing serious personal injury Keep spark
18. R10 06 Operating Instructions 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 prop erly 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 98 Shifting Gears in a New Vehicle Shift carefully in a new vehicle The transmission may be a lit tle 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 surfaces of the gears Metal contacting metal in moving parts may seriously damage your transmission do not drive in one gear for long periods of time until the transmission lubricant has a chance Medium Duty R10 06 Y53 6008 Operating the Transmission 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
19. ically return to its initial position bc Using the Brake System WARNING If the air pressure falls below 60 psi 414 kPa the spring brakes may stop the vehi cle abruptly which could result in an accident and or injuries Observe the red warning lamps on the gauges If one comes on do not con tinue to drive the vehicle until it has been prop erly repaired or serviced WARNING Do not use the trailer hand brake or service brakes to park and hold an unattended vehicle use the parking brakes Because ser vice brakes work with air pressure these brakes could slowly release Your vehicle could roll causing a serious accident Someone could be hurt or killed Never rely on the service brakes to hold a parked vehicle AN Tractor and Trailer Air Supply Valve Initial Charge The red octagon knob controls the air supply to the trailer With the system completely discharged both the Red trailer air supply and the Yellow parking brake knobs are OUT thus tractor and the trailer parking spring brakes are applied zy Y53 6008 Operating Instructions To supply air to the trailer system and release the trailer park ing brakes 1 Allow the tractor air system pressure to build up to oper ating level 2 When system pressure reaches 50 psi 345 kPa the Red knob may be pushed IN 3 Hold the Red knob IN by hand until the trailer air pres sure builds to a pre set level about 45 psi At this point it will rem
20. parking brakes on the vehicle EA Y53 6008 WARNING Do not operate the vehicle in the event of a malfunction in any air circuit The vehicle should not be operated until the system is repaired and both braking circuits including all pneumatic and mechanical components are working properly Loss of system 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 severely injured Medium Duty R10 06 Operating Instructions Front Brakes Truck The following applies to full truck configurations If air pressure is lost in the front circuit the vehicle front brakes will not operate Check valves isolate the rear circuit so the rear service brakes and parking brakes are unaf fected The spring brakes will not automatically apply as long as rear service pressure is maintained WARNING If the remaining system pressure AN drops below 60 psi 414 kPa due to repeated brake applications the spring brakes will auto matically apply stopping the vehicle abruptly potentially causing 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 Rear Brakes Truck The following applies to full truck configurations If air is lost in the rear brake circuit check
21. 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 con taminants from the air as it travels from the compressor to the wet tank reservoir Medium Duty R10 06 Operating Instructions Compressed Air Tanks The wet supply and dry service 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 Rela tively dry air is then supplied to the two service tanks for dis tribution to their respective brake circuits The service 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 trac tors 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 application Medium Duty R10 06 Y53 6008 Using the Br
22. 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 e small shovel first aid kit fire extinguisher Medium Duty R10 06 Y53 6008 Start Up Driver s Check List To keep your Medium Duty in top shape and maintain 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 com mercial 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 maintenance pro cedures in this manual will help keep your Medium Duty run ning properly Approaching Your Vehicle Check the overall appearance and condition Are win dows mirrors and lights clean and unobstructed 4232 Start Up Operating Instructions Check beneath the veh
23. 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 Medium Duty R10 06 Preventive Maintenance Noise and Emission Control Transmission and Driveline Substituting a different main transmission or drive line components other than design specified units may result in increased vehicle noise emission Table 13 Maintenance Log Maintenance Log To ensure your Medium Duty s noise control requirements are maintained record maintenance checks Use the follow ing log sheet see Table 13 and retain copies of documents regarding maintenance services performed and parts replaced on the vehicle Date of Ser vice Mileage Service Performed Service Center Name and Address Medium Duty R10 06 Y53 6008 223 Noise and Emission Control Preventive Maintenance Table 13 Maintenance Log 224 Y53 6008 Medium Duty R10 06 Preventive Maintenance No
24. LIGHT OIL HIGH WAIT LOW BEAM STOP DIFF WATER ENGINE LOCK TO 1 START Pe I WATER 4 4 BRAKE FIFTH CHECK AIR WHEEL ENGINE VEHICLE WITH AIR BRAKES 53 MIRROR ENGINE LOAD CRUISE SPOT RANGE HEAT FAN HIGH rA OL Low BEAM stop P A WATER ENGINE PARK 1 WATER FIFTH CHECK Be WHEEL ENGINE a LIGHT CONTROL LIGHT INHIBIT N TRANS VEHICLE WITH HYDRAULIC BRAKES e CHECK Medium Duty R10 06 Y53 6008 19 Instruments and Controls Operating Instructions Self Test The buzzer will sound continuously as long as When you turn on your ignition the following warning lights Engine temperature is above the specified range will turn on for 3 5 seconds as a test to let you know they Air pressure to the service brakes is low are working te te Engine oil pressure is low Diff Lock Trailer ABS There is a problem in the hydraulic brake system Water Temp Left Turn If the buzzer sounds while driving or if a light comes on do the following Mirror Heat Load Light 1 Slow down carefully Brake Air or Brake High Beam 2 Move a safe distance off the road and stop Fifth Wheel Right Turn 3 Set the parking brake See Pages 68 and 74 for trans mission shifting and parking brake information Oil Pressure Engine Fan 4 If the engine is overheating do not turn it off see page ABS Park 23 otherwise for other conditions
25. 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 serious personal injury or damage to the vehicle 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 vehi cle 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 injury accident Loose U bolts can also cause uneven tire wear and poor alignment WARNING Do not operate the vehicle if the U 212 Y53 6008 Preventive Maintenance torque values or to replace worn parts can cause component system failure possibly resulting in an injury accident Improperly tightened loose suspension U bolts can lead to unsafe vehicle conditions including hard steering axle mis alignment spring breakage or abnormal tire wear See the Fastener Torque Tables for proper torque specifications CAUTION Do not spray the suspension with A chemical products or mineral oil it can cause WARNING Failure to maintain the specified damage to the bushings NOTE Failure
26. START light 59 Medium Duty R10 06 Warning Lamp Module 19 Warning Lamp Self Test 20 Warning lights and buzzer 18 Warranty 117 119 212 218 220 221 Weekly operations 16 Weight rating 12 100 Welding 191 218 Wet Brakes 92 Wet tank 87 Wheel and Tire Replacement hydraulic brakes 179 Wheel bearing grease 134 lubrication 209 wheel cylinders 88 Y53 6008 Index Wheels and tires 169 general safety requirements 169 load rating 172 overinflation 172 proper inflation 171 replacement 169 178 tightening sequence 173 tire inspection 170 tread depth 178 underinflation 171 wheel mounting and fastening 169 wheel nut torque 173 Windshield washer reservoir 201 wiper washer switch 32 237 gt Y53 6008 11 06 PRINTED IN U S A PETERBILT MOTORS COMPANY P 0 BOX 90208 e DENTON TEXAS 76202 A DIVISION OF PACCAR 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 Quick Table of Contents elntroduction eCab And Frame Access eDriver s Checklists Controls And Displays Seat And Restraint Systems Getting To Your Engine Starting And Operating The Vehicle eMaintenance and Service e eConsumer Information 02956A Vehicle Identification Custom Maintenance Manual This manual contains both proprietary and supplier service information specifically compiled for the components
27. 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 vehicle Be sure to be in the right gear before you start down a hill especially if you have a manual transmission You could get hung up in NEUTRAL and lose the benefit of engine braking Coasting is illegal and also VERY dangerous Medium Duty R10 06 Operating Instructions Anti Lock Braking System This vehicle is equipped with an Anti Lock Braking System ABS ABS reduces the likelihood of a wheel locking If a wheel is about to lock during braking the ABS will automati cally adjust hydraulic pressure to the brake calipers on the appropriate wheel s to prevent wheel lock up The ABS is automatically activated when the ignition switch is turned on line may be constantly powered for ABS Make sure it will not accidently turn on trailer equip ment CAUTION The center pin of the 7 way trailer light 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 minate when the ignition is first turned on there is a problem with the bulb or wiring You should have this checked as
28. Warning lamp module as 73 T1 3 4 wedge Y53 6008 Medium Duty R10 06 Preventive Maintenance Electrical System Electrical and Alternator Precautions Do not disconnect the battery cables or alternator con nection cables with the engine running Take the following precautions to avoid burning out e Never turn the ignition switch to the IGN amp START posi alternator diodes tion with the engine running When charging the battery installed in the vehicle dis connect the battery cables Do notreverse the cables of the alternator starter motor or battery 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 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 218 for more informa tion Do not run the engine with the batteries disconnected Medium Duty R10 06 Y53 6008 191 Cab 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 193 Chrome and Aluminum Surfaces To prevent rust keep chromed parts cle
29. accident Sizes and types are so related to one another that a seemingly unimportant change in one may result in a change in how well 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 WARNING Do not work on the brake system 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 serious personal injury or dam age 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 Y53 6008 Preventive Maintenance 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 brake grease meeting R S Specification 0 616 NLGI Grade 1 Lubricate according to Table 2 Recommended Mainte nance Intervals Page 120 WARNING Do not apply too much lubricant to AN brake components lubricate sparingly Exces sive amounts of lubricant could contaminate brake linings which could reduce brake effec tiveness and cause an accident 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 cam
30. adjusted properly Start Up 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 operating the vehicle Fuel Tank Caps are they secure WARNING Diesel fuel in the presence of an igni tion source such as a cigarette could cause an A explosion You could be 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 Use only the fuel and or additives recom mended for your engine See page 114 for more information 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 handle secured Check the fifth wheel Is the kingpin locked s the sliding fifth wheel locked 15 Start Up Prestart Daily Ur 2 oO ON O 16 Seat adjust the seat for easy reach of controls If your vehicle is equipped with an adjustable steering column adjust the steering wheel to a comfortable posi tion Mirrors check and readjust mirrors if necessary Lights turn ignition key to the IGN amp ACC position and check for warning lights and buzzer Check operation of turn signals and emergency lights Instruments
31. after your vehicle has been towed 109 Vehicle Recovery and Spring Brakes Operating Instructions 1 Into the pinion cage add 1 pint 47 liter of lubricant You may sometimes have to release your vehicle s spring 2 Into the inter axle differential add 2 pints 94 liter of brakes by hand This could happen if the system air pressure approved lubricant does not reach operating pressure because your engine or See Recommended Lubrication Types Page 136 compressor is not working properly You will have to release 3 After adding the specified type and amount of lubricant the spring brakes at the spring brake chambers drive the vehicle It should be unloaded Drive 1 to 2 miles 1 5 to 3 km at a speed lower than 25 mph 40 km h This will thoroughly circulate the lubricant through the assembly Spring Brakes Manual Release In order to tow a vehicle if there is insufficient air to release the parking brake the spring brakes can be manually released tioning brakes If one of the brake circuits should become inoperative braking distances will increase substantially and handling charac teristics while braking will be affected You could lose control of your vehicle be severely injured or cause an accident Have it towed to the near est dealer or qualified workshop for repair 1 WARNING Do not drive vehicle with malfunc 110 Y53 6008 chamber These chambers contain a powerful spring that
32. be very serious Each mounting system is engineered for use only with its correct mating part Be sure properly matched components are used for each type of mounting 1 WARNING Do not mismatch wheel components The following comparison Table 9 Comparing Hub piloted and Ball seat Wheels shows the difference between parts used in hub pilot mount and ball seat mount applications Medium Duty R10 06 Tires and Wheels Preventive Maintenance Table 9 Comparing Hub piloted and Ball seat 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 Wheel Nuts Hub piloted wheel nuts have a hex body and a flange for clamping against whee
33. be working The ABS may not function in an emergency You will still have conventional brakes but not anti lock brakes If the lamp indi cates a problem have the ABS checked 1 WARNING Do not rely on an anti lock brake sys Wheel Spin Control Warning Lamp Your ABS may have an acceleration slip regulation ASR or automatic traction control ATC feature Either of these fea tures 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 illuminate and then go out when the ignition switch is first turned on The Wheel Spin Control warning lamp will illuminate when ever the ASR or ATC system detects drive wheel spin The Medium Duty R10 06 Y53 6008 Using the Brake System 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 torque Do not allow the Wheel Spin Control lamp to remain on continuously for an extended length of time Extended continuous use of the ASR ATC can cause overheating of the drive wheel brakes Engine torque or vehicle speed should be reduced to eliminate wheel spin and prevent excessive application of the ASR ATC system Except for checking for proper illumination of the ABS and Wheel Spin Control warning lamps when first starting the truck and for monitoring these lamps while driving no special operating procedures a
34. 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 warp ing 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 manu facturer 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 dam age or defects are found the anchor plate s should be repaired or replaced Parking Brake Component Inspection Hn NOTE If you are not properly trained to perform brake inspections or service take your vehicle to your nearest Peterbilt dealer Medium Duty R10 06 Preventive Maintenance Brake System Visually inspect brake shoe lining for wear cracks or break Anti Lock Braking System ABS 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 Your Medium Duty is equipped with an anti lock braking sys cracks or damage Replace if needed tem For detailed service information see the Peterbilt Medium Duty Maintenance Manual All service work BB E should be performed by a qualified technician at an Autho _ SHOE rized Service Center The foundation brake system must be LININGS in proper working order to ensure
35. check all instruments Windshield check operation of windshield wipers and washers Horn check operation of horn Check fire extinguisher charge and road emergency kit Fuel check fuel Is there enough fuel Seat Belts fasten and adjust safety restraint belts Operating Instructions Weekly Operations 1 2 3 4 Y53 6008 Battery check battery and terminals Wheel Cap Nuts are they all in place and torqued prop erly 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 cleaner 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 R10 06 Operating Instructions Start Up SENT AJ MD N E TL M d 02599A 02595 1A DASH INSTRUMENT PANEL 1 Headlight 6 Oil Pressure 11 Voltmeter option 2 Clearance Lights 7 Water Temperature 12 Air Pressure 3 Windshield Washer Wiper 8 Speedometer 13 Transmission Temperature option 4 Panel Lights 9 Air Cleaner Restriction Filter option 14 Warning Lamp Cluster 5 Tachometer 10 Fuel 15 I
36. conditions il Operate the engine within the optimum engine rpm range and do not 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 Refer to the Engine Operation and Maintenance manual for optimum engine rpm 99 Driving Tips And Techniques Operating Instructions f the engine rom moves beyond the maximum gov Shift into higher or lower gears or apply the service erned speed indicating an overspeed condition brake to keep engine rpm near the lower end of the apply the service brake or shift to a higher gear to optimum operating range bring engine rpm within the optimum speed range When driving downhill shift to a lower gear use the engine brake if so equipped and use the service AN brake keeping the engine speed below 2 100 rpm When the engine speed reaches its maximum governed speed the injection pump governor cuts off fuel to the engine However the governor has no control over the engine
37. during Severe operating conditions such as Climbing a long hill on a hot day Stopping after high speed driving If the Engine Coolant Temperature WATER warning light comes on and the audible alarm sounds showing an over heat condition or if you have any other reason to suspect the engine may be overheating DON T TURN OFF THE ENGINE unless the LOW WATER warning light also comes on indicating a loss of coolant Instead follow these steps A Reduce engine speed or stop When stopped place the transmission in Neutral and set the parking brake See Pages 68 and 74 for transmission shifting and parking brake information B Check to ensure that the oil pressure gauge reads nor mal C Increase the engine speed to about one half of full oper ating speed or 1100 to 1200 rpm maximum 23 Instruments and Controls Operating Instructions D Return the engine speed to normal idle after two or three F Check the level of coolant in the coolant expansion tank minutes engine compartment right side E Monitor the engine temperature After the temperature returns to normal allow the engine to idle 3 to 5 minutes 1 WARNING Removing the radiator fill cap while before shutting it off This allows the engine to cool grad the engine is hot can be dangerous Never remove the caps of the expansion tank while the ually and uniformly engine is still hot you could be badly burned f the overheating came from seve
38. e Never clean interior components with chemicals or solvents such as Gasoline Naphtha Acetone Turpentine Benzene Carbon Tetrachloride Lacquer Thinner Nail Polish Remover Ammonia based Products 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 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 196 Y53 6008 Preventive Maintenance Interior Trim Dash Shell and Instrument Panels components do not use abrasive cleaners brushes chemical solvents or strong deter gents i CAUTION To avoid possible damage to these Usea clean lint free cloth Clean with the cloth dampened with a mild soap and water solution Remove soap with a clean damp rag For difficult stains on painted plastic surfaces such as the dash shell use Dupont Sontara cleaner part number PS 3909S The product is available from Dupont as a presaturated wipe Carpet Excess water may damage the carpet Keep CAUTION Do not apply water directly to carpet carpet as dry as possible Usea clean lint free cloth or clean soft fiber brush Clean with the cloth or brush dampened with a mild soap and water solution Medium Duty R10 06 Preventive Maintenance
39. ens the U bolts on your Medium Duty 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 Medium Duty R10 06 Y53 6008 Front Axle and Suspension 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 injury accident Loose U bolts can also cause uneven tire wear and poor alignment 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 a serious injury accident At the same time U bolts are tightened re torque the spring and shackle pinch bolts to 105 Ib ft 142 N m SoS Rear Axle and Suspension REAR AXLE AND SUSPENSION General
40. 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 emer gency or park This mode would be used to uncouple from the trailer and during bobtail operation running without a trailer connected 7 Using the Brake System service brakes to park and hold an unattended Operating Instructions WARNING Do not use the trailer hand brake or Trailer Charge vehicle use the parking brakes Because ser vice brakes work with air pressure these brakes f both knobs are OUT combination vehicle is parked and it is desired to recharge the trailer the Red knob could slowly release Your vehicle could roll may be pushed IN to repressurize the trailer supply line causing a serious accident Someone could be The tractor will remain parked For more information on hurt or killed Never rely on the service brakes to air supply pressure requirements see page 76 hold a parked vehicle Parking Tractor and Trailer With both knobs pushed in for normal operating modes Brake Safety and Emergency 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 simul AN taneously 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
41. in LOW and block heater if equipped 4 Disengage the transmission place the shift lever in the Neutral position Medium Duty R10 06 Y53 6008 Operating the Engine Disengage depress the clutch with manual transmis sion Turn the ignition switch to the IGN amp ACC position For normal temperatures no accelerator advance is neces sary See Use of Accelerator below If the WAIT TO START indicator lamp turns ON wait until the indicator lamp goes OFF approximately 60 seconds before attempting to start the engine For each engine and ambient temperatures warm up cycles will vary Turn the ignition switch to the IGN amp START position to engage the starter Crank the engine until it starts If the engine does not start within 30 seconds release the key Use of Accelerator For mild to warm temperatures above 60 F 16 C keep your foot OFF the accelerator pedal while cranking If the engine does not start after 5 seconds apply full throttle while cranking For below normal starting temperatures fully depress the accelerator throttle pedal after engaging the starter starting the engine n NOTE Pumping the accelerator will not assist in 59 Operating the Engine Operating Instructions motor or batteries or causing engine damage the engine is running The starter and flywheel CAUTION To help avoid overtaxing the starter A CAUTION Never operate the starter mo
42. inspection and maintenance instruc tions 221 O Off road operation 3 Oil draining 139 level 139 pressure gauge 25 60 Operating instructions 7 Operating the engine 58 Operating the Rear Drive Axle 95 Operating the transmission 67 Optional equipment 71 85 96 Overheated Brakes 92 P Paint identification label 230 Parking brake 31 74 adjustment 151 automatic 75 brake system operation 34 35 74 75 79 110 Y53 6008 Index brake system tractor trailer operation 76 use 20 23 26 27 35 59 68 92 113 116 187 valve 88 Parking Brake Burnishing 94 Parking Brake Component Inspection 156 Parking Brake Indicator 36 Parking Brake Lever 90 Parts catalog 4 5 118 Power steering 206 fluid level 207 fluid refill 208 lubrication 206 Q Quick release valve 87 R Radio 43 Rear axle 213 housing breather vent 215 identification 231 lubrication 213 214 215 oil change 213 oil level 213 Rear brake system 73 Rear suspension 212 fasteners standard 212 235 Index Rear Wheel Calipers 90 Recovering vehicles 108 Relay valve 87 Release bearing wear 71 Repairs 4 Retarders engine 85 rpm 23 63 69 114 S Safe vehicle operation 11 Safety belt adjustment 47 passengers 49 restraint belts 46 restraint tips 49 52 signals 1 stands 117 tether belts 50 Safety precautions maintenance 116 Seat adjustment 45 Seat belt system damage and repair 52 guidelines 198 inspection 197 Komfort
43. is compressed Sudden release of this spring can cause you to be severely injured f WARNING Do not disassemble a spring brake Do not operate a vehicle when the spring brakes have been manually released Driving 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 unsecured vehi cle 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 prevent rolling before manually releasing the spring brakes To move a vehicle immobilized by the spring brakes due to loss of air pressure in the brake system perform the following procedure Medium Duty R10 06 Operating Instructions Vehicle Recovery and Spring Brakes 1 Remove the cap from the 4 Insert the release stud through spring chamber the opening in the spring cham ber where the cap was removed Insert it into the pressure plate Turn the release stud 1 4 turn clockwise in the pressure plate This secures the cross pin into the cross pin area of the pressure plate and locks it into the manual release position 5 Assemble the release stud washer and nut on the release stud 2 Remove the release stud assembly from the side pocket and remove the release nut and washer from the release stud 3 Slide out the release stud 01899
44. kept clean or the retractors may not Tether Belts work properly Never bleach or dye seat belts chemicals can weaken Tether belts are installed on suspension seats They help them Do however keep them clean by following the secure the seat to the floor to restrain it in case of a sudden care label on the belts Let them dry completely before Stop or an accident allowing them to retract Make sure the belt of the unoccupied passenger seat is fully wound up on its retractor so that the belt tongue is If your Medium Duty has been equipped with fixed length in its stowed position This reduces the possibility of the tethers no manual adjustment is required The same inspec tongue becoming a striking object in case of a sudden tion and replacement guidelines should be used as stated on stop page 197 Do not modify or disassemble the seat belts in your vehi Fixed Tethers t WARNING Do not remove modify or replace cle They will not be available to keep you and your pas AN the tether belt system with a different tether sys sengers safe tem A failed or missing tether belt could allow If any seat belt is not working properly see an Authorized the seat base to fully extend in the event of an Service Center for repair or replacement accident leading to greater injuries or death i WARNING Before driving or riding in a vehicle f WARNING Failure to adjust tether belts properly ensure that there is adequate head clearance at can caus
45. 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 Medium Duty R10 06 Y53 6008 Engine Cooling System 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 220 WARNING The exhaust piping muffler con verter muffler or independent converter become extremely hot during engine operation and can cause serious burns to the skin Allow adequate cooling time before working on or near any part of the exhaust system Engine Cooling System Your engine s cooling system is standard with Extended Life Coolant ELC ELC consists of a mixture of ethylene glycol water and organic acid technology chemical inhib itors ELC prevents corrosion and scale formation as well as provides freezing and boiling point protection 143 Engine Cooling System A 44 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 e Freezing Boi
46. off the steps before entering the cab or access ing the deck plate WARNING Always reinstall the battery compart ment cover step before entering the cab With out the battery cover you could slip and fall resulting in possible injury to yourself Medium Duty R10 06 Operating Instructions 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 mn NOTE Any alteration adding bulkheads headache 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 it could open during operation and cause vehi cle damage Be sure to latch the hood securely before moving the vehicle CAUTION If you do not latch the hood securely or be damaged itself Before opening or closing the hood be sure there are no people or objects in the way i WARNING A pivoting hood could hurt someone Medium Duty R10 06 Y53 6008 Start Up To open the hood unlatch both of the hood hold downs UNLATCHED Start Up Put one hand on the hood handle just above the Peterbilt emblem one foot on the bumper and one foot on the ground Tilt the hood forward until you hear it lock 02609 1 2 could be injured Always m
47. optional third battery 183 Electrical System The battery compartment is located on the left side of the vehicle under the cab access steps 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 possible injury to yourself i WARNING Always reinstall the battery compart 02601 Battery Compartment 184 Y53 6008 Preventive Maintenance WARNING Before attempting any work on the AN batteries or electrical system remove all jewelry If metal jewelry or other metal comes in contact with electrical circuits a short circuit may occur causing you to be injured as well as electrical system failure and damage 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 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 Medium Duty R10 06 Preventive Maintenance Overcharge this condition results from improper voltage regulator adjustment
48. safety and your vehicle s performance tenance work without sufficient training service manuals and the proper tools You could be injured or you could make your vehicle unsafe Do only those tasks you are fully trained and equipped to do 1 WARNING It can be dangerous to attempt main In severe operating conditions such as mining logging or earth moving you will need to perform maintenance checks and services more frequently 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 119 Maintenance Schedule and Lubrication Preventive Maintenance Maintenance Intervals For additional Engine Cooling System information see Page 143 For additional Air System information see Page 161 Table 2 Recommended Maintenance Intervals shows ser vice intervals for normal and heavy duty operations NOTE Different lubricants or service intervals than those listed below may be required Table 2 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 Reservo
49. spill during charging should be nal could cause a short circuit or an explosion washed off with a solution of warm water and baking soda to neutralize the acid If you accidentally get acid in Charging Reminders 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 1 WARNING Never use a metallic funnel to add charger Fast charging a battery is dangerous and distilled water It could come in contact with a should only be attempted by a competent mechanic with terminal creating a short circuit resulting in severe personal injury or damage to your vehi cle 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 the proper equipment Medium Duty R10 06 Y53 6008 189 Electrical System Slow Battery Charging NOTE Follow the instructions that come with your battery charger e t is not necessary to remove the battery f
50. stainless steel and cause rust staining Medium Duty R10 06 Preventive 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 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 Keep them WARNING Handle cleaning agents carefully out of the reach of children Observe all caution labels Medium Duty R10 06 Y53 6008 Cab 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 D
51. temperature of the axle lubricant to get too hot Matched tires will help the driveline last longer and will give you better tire mileage 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 serious personal injury WARNING Do not mismatch tires it can be dan 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 R10 06 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 or serious personal injury Consult with your Peterbilt dealer before using a different tire and or wheel size than was originally installed on your vehicle Wheel and Tire Replacement A CAUTION No indication will be given via the Medium Duty R10 06 Y53 6008 179 Heater and Air C
52. that might get soaked with fuel Diesel fuel may per manently damage electrical insulation When installing spin on throwaway filters 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 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 Medium Duty R10 06 Preventive Maintenance Engine Maintenance NOTE To expel air from density type strainer A Close valve and run engine until smooth idle is elements soak them in clean fuel before install established then repeat drain procedures or ing them B Remove filter from 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 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 CAUTION Do not overtighten the valve Over A tightening can damage the thr
53. the best ABS performance CAUTION Do not weld anywhere on the vehicle A 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 CAUTION Never detach the ECU connector with A the ignition turned on The connectors could arc and damage electronic equipment Turn off the ignition before disconnecting any electronic equipment PARKING BRAKE COMPONENTS Other precautions Check ABS wiring harnesses periodically for chafing or other problems No regular maintenance is required on the ABS components Medium Duty R10 06 Y53 6008 24574 Brake System 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 pressur
54. the engine fails to start do not continue to crank the starter but contact the nearest Authorized Service Center Remove jumper cables make sure they do not get caught in any moving parts in the engine compartment You could be seriously injured 1 WARNING When disconnecting jumper cables 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 Except for using small trickle charges as explained on Page 190 to maintain battery condition you should have your vehicle s batteries charged by a qualified service facility 188 Y53 6008 Preventive Maintenance They contain acid produce poisonous and explosive gases and supply levels of electric current high enough to cause burns A spark or flame near a battery on charge may cause it to explode with great force WARNING Batteries can injure you severely 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 conta
55. 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 distances without removing the driveshaft Tire Chains If you need tire chains install them on both sides of the driv ing axle dem axle can damage the driveline U joints and CAUTION Chains on the tires of only one tan Y53 6008 the interaxle differential Repairs could be costly and time consuming Medium Duty R10 06 Operating Instructions SHUT DOWN Introduction After 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 overnight please follow the suggestions below Your vehicle will be eas ier 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 Medium Duty R10 06 Y53 6008 Shut Down Always use your parking brakes service brakes to park and hold an unattended
56. 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 Medium Duty R10 06 Preventive Maintenance 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 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 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 ar
57. truck tractor ABS warning lamp illuminates when the igni tion switch is first turned on and will remain on until the sys tem self test has been completed successfully Normally the Medium Duty R10 06 Y53 6008 Using the Brake System ABS lamp will remain on until a speed of no more than 9 mph has been reached and the speed sensors have been checked for correct output The lamp should remain off after this point unless a failure in the system is detected The truck tractor ABS lamp is located in the warning lamp cluster does not 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 truck tractor ABS warning light 81 Using the Brake System Operating Instructions Trailer ABS Warning Lamp A trailer ABS warning lamp will illuminate for a bulb check 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 ess OO 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 mn NOTE A successsful warning lamp illumination and 1 bulb check at ignition on does not indicate that the trailer you may be connected to has trailer ABS You shou
58. valve Medium Duty R10 06 Y53 6008 Using the Brake System Simultaneously on full truck configurations air is also sup plied 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 portion 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 automatically proportions the drive axle brake application pressure when driving bobtail without 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 x0 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 compresses the springs and releases the brake
59. 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 Medium Duty R10 06 Y53 6008 Using the Brake System When the brake pedal is depressed the modulating valve detects the reduction or absence of rear service delivery pres sure 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 deliv ers front service air to the spring brake chambers releasing the spring brakes in proportion to the front brake application Thus if there is a rear service failure the remaining front axle braking is supplemented by modulated spring brake action on the rear axle depends on the amount of air available in the front circuit reservoir which is sufficient for a limited number of brake applications and releases f WARNING Efficiency of emergency braking REMEMBER when the remaining system pressure drops below 60 psi 414 kPa the spring brake is automatically applied stopping the vehicle abruptly potentially causing serious injury Observe the warn ing light BRAKE AIR in the panel it 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 79 Using the Brake Sy
60. will shut off automatically 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 CAUTION If the electric pump is operated for a A long period more than 15 seconds with a dry reservoir the pump rotor may be damaged 32 Y53 6008 Operating Instructions ff S M WIPER NS S Fert WASHER NS Windshield wipers washer switch POSITION MODE 0 OFF 1 Intermittent Range long delay 2 Intermittent Range Short delay 3 Low Speed 4 High Speed Wiper washer push in Medium Duty R10 06 Operating Instructions blades They can reduce visibility making driv ing hazardous Clean the blades regularly to remove road film and wax build up Use an alco hol based cleaning solution and a lint free cloth and wipe along the blades f WARNING Do not drive with worn or dirty wiper WINDSHIELD WASHER FLUID TANK 02391 Windshield Washer Fluid Tank 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 Medium Duty R10 0
61. 0 GCW gross combination weight 12 Glove compartment 44 Governor 86 Grease index 134 GVWR defined 12 GVWR gross vehicle weight rating 12 100 172 230 H Hand brake 84 113 Hazard flasher 20 26 27 55 92 Headlight switch 31 Heater and air conditioner 38 controls 42 defogging 41 Y53 6008 maintenance 180 High beam 54 Hood Latch and Tilt 9 Hour meter 22 Hub piloted and ball seat parts 177 Hydraulic Booster 90 Hydraulic Brakes 14 15 35 88 Hydraulic Fluid Check 14 Hypoid gear oil 134 Idling the engine 64 Ignition switch 33 Incomplete vehicle certification label 230 Instrument index 18 Inter axle differential 96 J Jumper cables 186 use of 186 K Keys 7 Komfort Lok latch 51 L Lap shoulder belt 46 Lap belt 47 Load capacity 12 Load distribution 13 Low air pressure 105 Medium Duty R10 06 Lubrication 150 210 axle 209 brakes 150 chart 135 coasting 99 driveshaft 208 engine 139 front axle 210 front suspension 210 idling 63 64 power steering 206 207 rear axle 213 214 215 transmission 202 203 types and brands 133 wheel bearings 210 M Maintenance manual 4 schedule 119 Manual transmission 67 lubricants 202 oil level 203 shifting gears 67 master cylinder 88 Mirrors 56 Modifications 117 Modulating valve 87 Muffler 222 Medium Duty R10 06 N NHTSA consumer information 226 Noise and emission control 220 air intake system 220 engine 221 exhaust system 221 fan drive 220
62. 0 06 53 6008 199 Cab 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 This could lead to greater injuries for you Tether belts should be adjusted so that they are taut when the seat is in its most upward and forward posi tion f WARNING Failure to adjust tether belts 6 If tethers are used be sure they are properly attached to the seat and if adjustable that they are adjusted in accordance with installation instructions Tethers must also be inspected for web wear and proper tightness of mounting hardware 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 200 Y53 6008 Preventive Maintenance 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 determine
63. 08 Lubrication Chart The following lubrication specifications see Table 4 on page 136 are for an ambient operating temperature range of 15 to 100 F 26 to 38 C For extreme temperature opera tions consult the component manufacturer s manuals 135 Maintenance Schedule and Lubrication Preventive Maintenance Table 4 Recommended Lubrication Types COMPONENTS RECOMMENDED 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
64. 105D and Eaton PS 037 specifica 40105498 40104109 JY tion Noinitial drain is required on Eaton axles that are factory To change axle lubricant filled with an Eaton approved synthetic lubricant 1 Park the vehicle on level ground with the axle lubricant at e Petroleum based lubricants must be drained within the normal operating temperature first 5 000 miles 8000 km if converting to an approved 2 Remove filler 1 and drain plug 2 synthetic lubricant 3 Completely drain the oil and clean the drain plug See Table 2 Recommended Maintenance Intervals Page CAUTION Do not overfill axles 120 for standard rear axle service intervals Use petroleum based lubricants meeting MIL L 2105 4 Reinstall the drain plug 2 and refill with recommended C D grade specifications or approved synthetic lubrica oil up to the bottom of filler plug hole tion Do not use oil additives 5 Reinstall filler plug 1 214 Y53 6008 Medium Duty R10 06 Preventive Maintenance 2 0446A Rear Axle Filler and Drain Holes and Breather Vent Axle Housing Breather Vent Check and clean the axle housing breather vent 3 at each oil level check Medium Duty R10 06 Y53 6008 Rear Axle and Suspension 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
65. 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 Medium Duty R10 06 Rear Axle and Suspension 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 1096 when engine oil is used as a 3 Reduce torque by 20 if new plated capscrews are Y53 6008 217 Frame and Fifth Wheel FRAME AND FIFTH WHEEL Introduction drill through the top or bottom flanges These operations could affect frame rail strength lead ing to a failure resulting in serious personal injury and or an accident Always leave frame repairs to your Peterbilt Dealer WARNING Do not cut or splice frame rails or Engine Painting Do not electrostatically paint electronically controlled engines or vehicles with these engines Welding Observe these recommended procedures to protect electronic systems during welding operations Engines Before welding on vehicles equipped with electronic engines the following precautions should be observed 218 Y53 6008 Preventive Maintenance NOTE Welding to frame rail may void frame rail war i ranty Disconnect all electronic connections to the vehicle bat teries Remove battery power cable and i
66. 25 Maintenance Schedule and Lubrication 126 Table3 Maintenance Schedule Preventive Maintenance INTERVAL COMMENTS ES EE ES OPERATION FREQUENCY ss ississ GS 20 20 VNI T Q 98 Fan Shroud Fan Assembly and Idler Pulley No Service Required Check Water Pump for Leaks Play Radiator Exterior Condition Replace Engine Coolant ZI a 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 dus dd Near GOOG Mile Power Steering Filter Replace 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 6008 Medium Duty R10 06 Preventive Maintenance Maintenance Schedule and Lubrication Table 3 Maintenance Schedule INTERVAL COMMENTS ge EE EE OPERATION FREQUENCY ssiss ss Do 209 29 roa 2a 8 Drain Water from Fuel System Engine Oil Change Elnecs Hecaenions e Oil Filters Replace Fuel Filters Replace Engine Tune up C2 Cranking System Visual Inspect Loose Connections Starter Draw volts Alternator Charging System Vis
67. 6 Y53 6008 Instruments and Controls Ignition Key Switch The engine ignition key switch located to the left of the steer ing column has four positions ACC Accessories OFF IGN amp ACC and IGN amp START OFF In this position all accessories are OFF except those listed below and you can remove the key The following lights and accessories have power when the key is in the OFF position brake lights marker lamps cigarette lighter headlights tail lights radio station memory horn instrument lights emergency hazard flasher dome and courtesy lamps on doors auxiliary Power Body or Trailer noid valve located on the left side of the engine NOTE In the OFF position fuel is cut off by a sole L near the ejection pump ACC Accessory With the key in this position you can play the radio defrost mirrors if equipped with mirror heat or use other accessories 33 Instruments and Controls IGN amp ACC In this position all circuits are energized Panel warning lights will light and the buzzer will sound until 1 the engine is started 2 normal oil operating pressure is reached and 3 air brake system pressure is above 64 psi 441 kPa In this position the ignition key cannot be removed IGN amp START Turn the key to this position to start your engine it energizes the starter and retracts the solenoid valve to allow fuel supply to the engine See page 59 for detai
68. 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 Joints 10 000 15 000 SPL Driveline Center Bearing None Suspension Per Specifications AG200 Synthetic Grease With Special Fitting Medium Duty R10 06 Y53 6008 dio Maintenance Schedule and Lubrication 122 Table 2 Recommended Maintenance Intervals Preventive Maintenance ITEM Hydraulic Brakes INTERVAL COMMENTS 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 Y53 6008 Check Fluid Level 7 500 miles Use Automatic Transmission Fluid ATF Change Fluid 60 000 een twice per Use Automatic Transmission Fluid ATF Medium Duty R10 06 Preventive Maintenance Maintenance Schedule Use Table 3 Maintenance Schedule as a guide to plan ser vice work Be sure and follow the frequ
69. ED LOCK UNLOCK B FIFTH WHEEL Fifth Wheel Slide Switch 106 Y53 6008 Operating Instructions 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 accessory 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 various positions to adjust weight distribution There is a guard on this switch to protect you against accidentally activating or releasing the lock the tractor trailer is in motion Your load could shift suddenly causing you to lose control of the vehicle which can result in a serious accident 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 1 WARNING Do not move of the fifth wheel while Medium Duty R10 06 Operating Instructions Driving Tips And Techniques slide tracks if a slider should be cleaned and lubricated periodically to ensure smooth turning and sliding action Failure to keep these sur faces lubricated can lead to frame or driveline damage Fifth Wheel Lubrication A CAUTION Both the fifth wheel plate and the Frequently operate and lubricate movable or sliding fifth wheels to prevent corrosion See page 219 for maintenance infor
70. EG 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 meeting MIL L 2104D and Eaton PS 0g1 bove 40 ADOVE 40 3H specifications j 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 age components Standard Transmission Oil Level Clutch System Introduction n NOTE The vehicle must be parked on level ground 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 Maintain the oil level and check it regularly Oil should be bearing This movement of the release yoke is called free travel Thus free pedal and free travel are directly related to each other up to bottom of filler plug hole Medium Duty R10 06 Y53 6008 9035 Transmission and Clutch 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 engages the clutch brake This is called clutch brake squeeze When the c
71. Frequent checks are impor tant for driving safety especially after traveling over rough roads n NOTE If the steering feels unbalanced from side to f WARNING Do not operate the vehicle if the side while turning check for the following possible causes e unequal tire pressures vehicle overloaded or unevenly distributed load e wheels out of alignment e wheel bearings improperly adjusted 206 Y53 6008 Preventive Maintenance If you cannot correct the problem check with an Authorized Service Center The Medium Duty is equipped with integral power steering The system includes an engine driven fluid pump a fluid res ervoir 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 steer ing 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 e 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 crosstube lack of lubrication Medium Duty R10 06 Preventive Maintenance If these c
72. IL L 2105B SD Engine oils with increased protection against temperature deposits rust wear and corrosion WB Wheel Bearing grease Timken Specification 0 610 134 Preventive Maintenance APPLICATION LUBRICANT Universal Joints EP Drive Shaft Splines CL Wheel Bearings driven hubs HD Wheel Bearings nondriven 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 6008 Medium Duty R10 06 Preventive Maintenance Oil 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 R10 06 Maintenance Schedule and Lubrication Proper Oil Level Improper Oil Level Y53 60
73. 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 Deviations from the above list of lubricants should be based on specifications published in the component manufacturer s manuals or otherwise approved by the manufacturer 136 Y53 6008 Medium Duty R10 06 Preventive Maintenance Table 4 Recommended Lubrication Types Maintenance Schedule and Lubrication COMPONENTS Clevis Pins Cam Brake Camshaft Splines Disc Brake Shaft Splines and Slide Pin Retainers Brake RECOMMENDED LUBRICANT Antiseize type grease Rockwell specification 0 637 Brake Camshaft Bushings EP Chassis grease lithium 12 hydroxystearate base NLGI 2 AN 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 manu
74. Lok latch 51 replacement part 200 tether belts 200 Seats 45 236 Serial number 228 Service Brake Components 155 Shackle pinch bolts 211 Shift pattern diagram 67 69 Shifting gears 22 59 67 68 69 70 71 99 100 112 Shifting gears in a new vehicle 69 Shock absorber 209 Shop manuals 4 Shoulder belt 47 Single check valve 87 Slack adjusters 151 Speedometer 21 Spring brakes manual release 110 Spring pins 210 Springs 209 Starting procedure cold weather 61 Starting procedure normal temperature 59 Steering column controls 54 Steering maintenance 206 Stopping procedures 113 Storage compartment 44 Suspension 212 fasteners 212 fasteners torque 212 T Tachometer 22 99 Y53 6008 Tether belts 50 200 adjustment 51 Tire chains 112 inflation pressure 171 inspection 170 replacement tread depth 178 Towing 110 112 vehicle recovery precautions 108 Tractor park 78 Tractor protection manifold 88 Trailer hand brake 55 83 84 park 77 spring brakes 80 supply valve red 88 Trailer ABS 82 Trailer park 76 Transmission automatic 71 clutch 67 identification 231 lubrication 202 203 205 maintenance 203 manual 67 operation 67 service notes 202 Truck tractor ABS 81 Medium Duty R10 06 Turbocharger 114 166 Turn signal high beam switch 54 U U Bolt torque 211 Underbody maintenance 194 Underinflated tires 171 V Vehicle driving 11 loading 12 weight rating 12 100 230 Vehicle inspections 11 W WAIT TO
75. Medium Duty R10 06 Y53 6008 Tires and Wheels 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 3 Maintenance Schedule Page 123 The person best equipped to do this is your Autho rized Service Center s mechanic Proper Torque and Sequence Proper wheel torque can best be obtained on level ground Install lug nuts and finger tighten in the numerical sequence as shown below see Crisscross Tightening Sequence on page 176 This procedure will ensure that the wheel is drawn evenly against the hub Torque each nut to the torque value listed in Table 8 on page 174 WARNING Tighten wheel cap nuts properly If AN they are not tightened properly wheel nuts could eventually cause the wheel to become loose to fail and or to come off while the vehi cle is moving possibly causing loss of control and or serious personal injury or damage to the vehicle 173 Tires and Wheels Table 8 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
76. Medium Duty Models MANUAL CLASS PAYS Quick Table of Contents elntroduction eCab And Frame Access eDriver s Checklists Controls And Displays Seat And Restraint Systems Getting To Your Engine Starting And Operating The Vehicle eMaintenance and Service eConsumer Information Vehicle Identification Subject Index 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 basic preventive maintenance inspections We have tried to present the information you ll need to learn about your vehicle s functions controls and operation 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 finished using it That way it will be there when you need it the next time or when you pass the vehicle on to the next user Your Medium Duty may not have all the features or options mentioned in this manual Therefore you should pay careful attention to the instructions that pertain to just your vehicle In Medium Duty R10 06 Y53 6008 addition if your vehicle is equipped with special equipment or options not discussed in t
77. Minimum level indicators 207 Steering and Driveline 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 2 Recommended Mainte nance Intervals Page 120 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 109 208 Preventive Maintenance SLIP JOINT UNIVERSAL JOINT Y53 6008 s D 01904 Driveshaft Lubrication WARNING Improper lubrication of U joints can AN cause them to fail prematurely The driveshaft could separate from the vehicle and result in an injury accident and or vehicle damage Make sure lubricant is purged at all four ends of each U joint and loosen caps if necessary Also reg ularly inspect U joints for excessive wear or movement and repair or replace as necessary Medium Duty R10 06 Preventive Maintenance FRONT AXLE AND SUSPENSION Inspection For all vehicles manda
78. N Medium Duty R10 06 Y53 6008 Consumer Information and Vehicle Identification 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 Table 14 Model Year Letter Designations CODE YEAR 2 2002 3 2003 4 2004 5 2005 6 2006 VIN Location The VIN is marked on the Incomplete Vehicle Certification Label on trucks or on the Tire Rim and Weight Rating Data Label on tractors Both labels are located on the driver s door frame 227 Consumer Information and Vehicle Identification Preventive Maintenance Chassis Number Locations A2378 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 hae VIN LOCATION 228 Y53 6008 Medium Duty R10 06 Preventive Maintenance VEHICLE NAME PLATE Pitt Mots Company O Quat ADIVISION OF PACCAR DENTON TEXAS U S A C ewsew Consumer Information and Vehicle Identification Complete Vehicle Certification Label The Complete Vehicle Certi
79. N Be careful not to apply the clutch Double Clutching Whether you are upshifting or down shifting it is best to dou ble clutch Double clutching is easier on the transmission and on the engine helping your vehicle match engine speed with driveline speed and achieving clash free shifts 70 Y53 6008 Operating Instructions 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 out put shaft 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 clutch 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 Medium Duty R10 06 Operating Instructions 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 prevent u
80. NG Low air pressure could make the AN brakes unsafe for driving Before driving the vehicle make sure the pressure does pump up to over 100 psi for normal brake operation If the air pressure does not pump up to at least 100 psi don t try to move the vehicle CAUTION Operating a vehicle with air 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 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 98 Y53 6008 Operating Instructions Coasting WARNING Do not coast with the transmis N 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 due to mechanical failures Do not coast with the transmission in neutral or with the clutch pedal dep
81. 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 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 Puca ee Teon 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 10 270 305 200 225 174 Y53 6008 Medium Duty R10 06 Preventive Maintenance Table 8 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 5 8 11 Front amp Rear EE TONER 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 X Cast Wheel with Demountable Rim 14 000 Lb GAWR 325 359 240 265 Other Front amp Rea
82. System 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 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 jackknife if the wheels begin to skid resulting in an accident WARNING Do not use the engine retarder when However 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 System on page 81 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 86 Y53 6008 Operating Instructions 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 actuat ing the compressor discharge mechanism Its cut out pres sure 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
83. Turbocharger This cooling down practice is especially important for a turbo charged engine The turbocharger on your vehicle contains bearings and seals that are subjected to hot exhaust gases While the engine is operating heat is carried away by circu lating oil If you stop the engine suddenly after a hard run the temperature of the turbocharger could rise to as much as 100 F 55 C above the temperature reached during opera tion A sudden 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 parked 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 approximately the same amount to each fuel tank on vehicles with more than one tank Medium Duty R10 06 Operating Instructions Shut Down ers in your vehicle Fuel containers either full or mended by engine manufacturers If you need further infor empty may leak explode and cause or feeda mation on Grade 2 D fuel specifications consult the Engine fire Do not carry extra fuel containers even Operation and Maintenance Manual empty ones are dangerous 1 WARNING Diesel fuel in the presence of an igni Location of Fuel Shut Off Valves f WARNING Do no
84. ad 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 00139a TREAD CONTACT I 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 injury accident Be sure all tires are inflated correctly according to the manufac turer s recommendations WARNING Overinflated tires can cause acci Table 7 Effect of Load Pressure on Tire Life Preventive Maintenance 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 WARNING Do not exceed the load rating of your AN 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 injury accident The maximum vehicle load rating GVWR is f
85. ain in charging the trailer system and releasing only the trailer brakes 4 The Yellow knob will remain OUT tractor brakes ON Normal Run Position The Yellow knob system park may now be pushed IN which will supply air to the tractor spring brakes releas ing them With both knobs pushed IN air is now being supplied to both the trailer and the tractor spring brakes all brakes are released Medium Duty R10 06 Operating Instructions 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 res ervoirs through a double check valve Using the Brake System NORMAL OPERATING POSITION PARKING BRAKE TRAILER AIR SUPPLY TRAILER AIR SUPPLY J RED PARK TRAILER WITH TRACTOR RELEASED OR BOBTAIL TRACTOR PARKING BRAKE RED YELLOW J h YELLOW J SYSTEM PARK OR CHARGE TRAILER WITH TRACTOR PARKED TRAILER AIR SUPPLY J RED PARKING 02393 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 reser voirs to protect the tractor air system pressure Medium Duty R10 06 Y53 6008 To apply the trailer brakes only Pull OUT the Red knob This will
86. ajor components installed on your Medium Duty For detailed service informa tion 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 infor Medium Duty R10 06 Y53 6008 mation see Consumer Information and Vehicle Identifica tion on page 226 This section explains vehicle identification and provides space to record model and serial numbers of major components installed on your vehicle Additional Sources of Information Installed Equipment Operator s Manuals Major component suppliers to Peterbilt also supply operation manuals specific to their products Additional manuals and other pieces of literature are included in the glove compart ment literature set Look for information on products such as the engine driver s seat transmission axles tires and radio If you are missing these pieces of literature ask your Peterbilt Dealer for copies Truck Driver s Handbook Your set of glove compartment literature also contains a copy of the Truck Driver s Handbook published by the American Trucking Association ATA Refer to it for important informa tion on driving your Medium Duty 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 Introduction Feder
87. ake 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 fea ture Brake Proportioning BP R1 valve tractor this valve delivers air to the tractor s service brake chambers It auto matically proportions the drive axle brake app lication pressure when driving bobtail without a trailer con nected 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 automatically 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 Single Check Valve allows air flow in one direction only 87 Using the Brake System Parking Brake Valve yellow diamond shaped knob It con trols 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 pressur
88. ake sure the lock is f WARNING If the hood falls anyone under it engaged to keep your hood open any time any one gets under the hood for any reason Never work under the hood unless the hood safety lock is engaged 10 Y53 6008 Operating Instructions To close the hood you must first release the hood safety lock 1 WARNING Before closing the hood be sure the area is clear no people or objects are in the Way the hood firmly squeeze the handle to release the hold open lock NN x CAUTION To avoid hood damage when closing E HOOD HOLD OR RELEASE HAND OQ ARE TNS ANANN DS SS A Qo i S EN S SSS RRR BARR IRS WE RS RRR Medium Duty R10 06 Operating Instructions After lowering the hood latch the hood closed with the hold downs could open during operation and cause an acci dent Be sure the hood is latched securely before moving the vehicle WARNING If the hood is not latched securely it LATCHED Medium Duty R10 06 Y53 6008 Start Up Safe Vehicle Operation For your safety as well as those around you be a responsi ble 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 including advanced engineering techniques rigid quality con trol and demanding inspections These manufacturing pro cesse
89. al and state agencies such as the department of licens ing also have information you can ask for The Interstate Commerce Commission can give you information about reg ulations governing transportation across state lines Regula tions that differ from state to state can be found at various agencies in state governments Y53 6008 Medium Duty R10 06 Operating Instructions Start Up OPERATING INSTRUCTIONS START UP Introduction The following section covers start up procedures for getting your Medium Duty ready for the road Door Lock and Keys Doors can be locked from the inside by using the lock button Close the door then push the button down to lock Doors automatically unlock when you open them from inside and can be locked from the outside with the key only As standard equipment two keys are provided for the doors and ignition When necessary additional locks and keys are provided for storage compartments Medium Duty R10 06 Y53 6008 WARNING To help lessen the chance and or N severity of personal injury in case of an acci dent always lock the doors while driving Along with using the lap shoulder belts properly lock ing the doors helps prevent occupants from being thrown from the vehicle To lock or unlock the doors from outside the cab Insert the key in the door lock Turn the key toward the rear door frame to lock forward to unlock Cab and Frame Access The following cab and frame en
90. als 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 WARNING Exhaust fumes from the engine con AN tain carbon monoxide a colorless and odorless AN 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 serious ill nesses Medium Duty R10 06 Y53 6008 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 personal harm 137 Maintenance Schedule and Lubrication Preventive Maintenance 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 Hn NOTE Keep the engine exhaust system and the 138 Y53 6008 Medium Duty R10 06 Preventive Maintenance ENGINE MAINTENANCE Engin
91. an 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 192 Y53 6008 Preventive Maintenance Clean aluminum wheels and bumpers with warm water Tar remover will get rid of heavy deposits of road grime To prevent spotting wipe aluminum surfaces dry after washing Under corrosive conditions such as driving on salted roads clean aluminum parts with steam or high pressure water from a hose A mild soap solution will help Rinse thoroughly 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 f 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
92. ansmissions If your truck has an automatic transmission go to page 71 6 9 10 and 11 Speed Manual The 6 speed synchronized manual transmission has 6 for ward 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 section For specific instructions on operating one of the optional 10 or 11 speed transmissions consult the transmission manu facturer s Driver Operator Instruction Manual 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 67 Operating the Transmission 2 Release the clutch pedal and let the transmission oper Operating Instructions range to start the vehicle in motion The use of a 1 Put the transmission in Neutral A CAUTION Always use first gear or a low speed ate in Neutral for three to five minutes prior to shifting into either a forward or reverse range 3 Putting the Vehicle in Motion After making sure the vehicle s oil and air pressure are cor 4 rect and all other parts and systems are in proper working condition 5 1 If your truck is equipped with a hand throttle disengage the hand throttle before driving
93. arm 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 sys tems 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 minutes 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 R10 06 Y53 6008 Operating the Engine 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 speed rpm n NOTE In colder climates where the tempera 3 Continue the engine warm up until the coolant tempera ture reaches at least 130 F 54 C At this temperature you can use partial throttle Wait until the coolant temper ature is at least 160 F 71 C before operating at full throttle See Operating Manual Transmi
94. ased injury or death in an acci have proven to be the single most effective means available M MENDES hor Dus Ordo iia E ae wi i for reducing the potential for either serious injury or death in thrown out of the cab They could strike another motor vehicle accidents Therefore read and follow these person Injuries can be much worse when riders instructions and always observe user warnings pertaining to are unbelted Always fasten your seat belt and safety belts be sure anyone riding with you does the same Safety Restraint Belts WARNING Do not drive vehicle without your Lap Shoulder Belt The combination lap shoulder belt is equipped with a locking ar mechanism The system adjusts automatically to a person s Ue size and movements as long as the pull on the belt is slow WD Y Hard braking or a collision locks the belt The belt will also lock when driving up or down a steep hill or in a sharp curve To fasten the belt 0917A 1 Grasp the belt tongue 2 Pull the belt in a continuous slow motion across your chest and lap Unbelted Person in Crash 46 Y53 6008 Medium Duty R10 06 Operating Instructions 01888 3 Insert the belt tongue into the buckle on the inboard side of the seat 4 Push down until the tongue locks securely with an audi ble click Pull on the belt to check for proper fastening Pull the shoulder section to make sure the belt fits snugly across the ch
95. ation 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 132 Y53 6008 Medium Duty R10 06 Preventive 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 running at top economy and in prolonging its life is proper lubrication servicing Neglecting this essential aspect of vehi cle 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 R10 06 Y53 6008 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
96. ave the cab A Using the Brake System USING THE BRAKE SYSTEM NOTE Today s diesel engines have significant torque and startability power at low RPMs Combi nations of engine speed and available torque may overpower the vehicle s parking brakes WARNING Never drive your vehicle with the N parking brakes applied Always release the park ing brakes prior to moving the vehicle Failure to disengage the parking brakes prior to moving your vehicle could result in excessive heat build up of the brakes and start a fire NOTE If your truck is equipped with hydraulic brakes go to page 88 H Introduction The operation of the vehicle s braking system and many vehi cle accessories depends upon the storage and application of a high pressure air supply e Y53 6008 Operating Instructions This air brake system is a multiple circuit type it has a circuit for the front wheels a separate circuit for the rear wheels and one for the trailer tractors only The system is supplied by a compressor driven by the engine The vehicle s com pressor 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
97. 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 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 6 Air System Scheduled Maintenance Page 161 Inspect 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 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 Medium Duty R10 06 Preventive Maintenance 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 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 143 and the Medium Duty Maintenance Manual for further information Air Dryer A CAUTION W
98. d 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 specification 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 Windshield Wiper Washer Check wiper blades annually or every 60 000 miles 96 000 km Anco 18 inch 450mm wiper blades are recommended See Windshield Wipers Washer on page 32 for more infor mation Medium Duty R10 06 Preventive Maintenance RESERVOIR 02604 Windshield Washer Reservoir Medium Duty R10 06 Cab Maintenance 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 fill to the proper level Y53 6008 201 Transmission and Clutch
99. d drivers should drive this vehicle Every new Peterbilt vehicle is designed to conform to all Fed eral Motor Vehicle Safety Standards applicable at the time of manufacture However even with these safety features con tinued safe and reliable operation depends greatly upon reg ular vehicle maintenance The vehicle must be operated within the range of its mechanical capabilities and the limits Medium Duty R10 06 Y53 6008 of its load ratings See the tire and rim weight ratings infor mation 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 There are several tools built into this manual to help you find what you need quickly and easily First is the Contents Located at the front of the manual this lists the main subjects covered and gives page numbers where you can find these subjects Use the Contents to find information on a large sub ject 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 46 for more information on Safety Restraint Belts Finally you will find a helpful Index at the back of the manual listing subjects alphabetically For example if you want infor mation on brakes just look under Brakes i
100. d on the steering wheel column of tractor trailer vehicles provides air pressure to apply the trailer brakes only It operates independently of the foot trea dle valve See page 83 for more instructions on proper use of the Trailer Brake Hand Valve 55 Steering Column and Mirrors Adjustable Steering Column option Some vehicles are equipped with an optional tilt telescoping steering column The tilt feature allows forward and rearward movement of the wheel The telescoping feature allows you to move the wheel up and down WARNING Do not adjust the Tilt Telescoping AN Steering Wheel while the vehicle is in motion it could cause loss of control You would not be able to steer properly and could have an acci dent Make all adjustments to the steering col umn while the vehicle is stopped The Tilt Telescoping Lever is located on the left side of the steering column To tilt the wheel e PULL the lever up toward yourself Move the steering wheel to the desired angle then release the lever to lock the wheel in the correct position To raise or lower the wheel e Push or pull the steering wheel to the desired height then release the lever to lock the wheel at that position 56 Y53 6008 Operating Instructions Horn To sound the electric horn press the button in the center of the steering wheel Mirrors Your vehicle comes equipped with two outside rear view mir rors that enable you to see to
101. damaged See page 167 for information on Air Filter Replacement Air Filter Restriction Indicator Headlight Switch The headlights are controlled by a toggle Air Filter Restriction Indicator option D switch on the left instrument panel See page 17 When the headlights are ON the This gauge indicates the condition of the engine air cleaner dash lights side and tail lamps are also and is measured by inches of water A clean filter should reg on ister 7 in of water and a filter whose life is over will register approximately 25 in For High Beam operation see page 54 30 Y53 6008 Medium Duty R10 06 Operating Instructions Daytime Running Lights option On vehicles equipped with the Daytime Running Light DRL System the low beam headlights are turned ON automati cally at reduced brightness to conserve headlamp life Three controls or conditions will affect whether the system is ON or OFF headlight switch engine on parking brake If the headlight switch is turned OFF the DRL system engages automatically after the engine starts and you 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 l
102. disengage the cruise control 66 Y53 6008 Operating Instructions Move the ON OFF switch to the OFF position or 02901 off Depress the brake pedal or Depress the clutch pedal Reengaging the Cruise Control 1 Move the ON OFF switch to the ON position or 2 Toggle the SET RESUME lever to the RESUME position Medium Duty R10 06 Operating Instructions OPERATING THE TRANSMISSION Introduction Your Medium Duty is equipped with either a manual or auto matic transmission with special features and gearing to meet your particular needs It is important for you the driver to understand how your particular transmission is operated To do this you have two sources of information this Operator s Manual and the transmission manufacturer s Driver Opera tor 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 and read the specific instructions contained in the transmission manufacturer s manual that is included with your vehicle il Medium Duty R10 06 NOTE You will find a shift pattern diagram in the cab Check to be sure you know the correct sequence for your particular transmission Y53 6008 Operating the Transmission Operating Manual Tr
103. dium Duty R10 06 Operating Instructions blow hot air onto cold windshields This could crack the glass Turn the air direction 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 CAUTION During extreme cold weather do not Defogging ii To defog the windshield select air direction mode 4 or 5 and turn the fan speed switch A to high Set the temperature knob C to hot red position on the control The air condi tioner if equipped is automatically activated to remove mois ture from the cab After the windshield is clear adjust the controls as desired NOTE The air conditioning system is active when the Defrost mode is selected Medium Duty R10 06 Heating and Air Conditioning Y53 6008 HEATING A C CONTROL HEATING COOLING DEFOGGING CONTROLS MAX NML MAX NML MAX NML Fan Speed A High 4 Adjust High 4 Adjust High 4 Adjust Air Direction Panel Defrost i Def Mode B Panel or Bi Adjust Adjust efrost or Bi 1 Level 5 Level 4 2 Temperature C Warm Adjust Cool Adjust Warm Adjust oa Recirc Fresh Record Fresh Recirc Fresh Air Conditioner FF EF N N LN AC E Oo O O O Cooling To cool the cab turn on the air conditioner if
104. draulic cir cuit Such a malfunction may prevent the brake system from operating properly and could result in an injury accident 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 WARNING Do not operate the vehicle in the Medium Duty R10 06 Y53 6008 159 Air System AIR SYSTEM Introduction AN 160 WARNING Prior to the removal of any air system component always block and hold the vehicle by a secure means other than the vehicle s own brakes Depleting air system pressure may cause the vehicle to roll unexpectedly resulting in an accident and 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 con taining air pressure It may whip as air escapes Never remove a component or pipe plug unless you are certain all system pressure has been depleted Never exceed recommended air pressure and always wear safety glasses when working with air pressure Never look into air jets or direct them at anyone Never attempt to disassemble a component until you have read and understood recom mended procedures Some components contain powerful springs and injury or death can result if not properly disassembled Use only proper tools and observe all precautions pertaining to the use of those t
105. ds See Table 2 Recommended Maintenance Intervals Page 120 Lack of lubrication causes premature wear and hard steering Lubrication schedule may be shortened if necessary Suspension Lubrication Each spring anchor pin has a grease fitting Pressure lubri cate spring pins according to Table 2 Recommended Main tenance Intervals Page 120 using EP chassis lube with 12 Hydroxy Lithium Stearate Base NLGI 2 with 3 molybdenum additive e g Mobil grease EP or equal 210 Preventive Maintenance KINGPIN TOP KINGPIN BOTTOM 00445 Y53 6008 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 Medium Duty R10 06 Preventive Maintenance 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 on page 123 Be sure someone with the proper training and the right tools checks and tight
106. e Safety Restraint Tips il Medium Duty R10 06 NOTE Per FMCSR 392 60 Unauthorized Persons Not to be Transported Federal law prohibits the transportation of persons in commercial vehicles unless they are specifically authorized in writing by the motor carrier See the cited FMCSR for a com plete description of the regulation and exemptions Y53 6008 Seats Any authorized person riding in your vehicle should wear a seat belt A responsible operator sees to it that every one 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 effec tiveness of the system Keep belt buckles free of any obstruction that may pre vent secure locking 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 getting caught in door or seat hardware or rubbing against sharp objects 49 Seats Operating Instructions The belts must be
107. e detected After replacement of any part or discovery of loose com ponents check the torque of all fasteners Medium Duty R10 06 Y53 6008 Rear Axle and Suspension 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 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 CAUTION Do not mix lubricants of different NOTE In all cases the lubricant supplier assumes 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 913 Rear Axle and Suspension Preventive Maintenance Table 12 Drive Axle Lubrication AMBIENT TEMPERATURE RANGE MODEL RECOMMENDED LUBRICANTS sc oF VISCOSITY SAE EATON EP gear oil MIL L 2105D API GL 5 26 to 38 15 to 100 80W 90 ROCKWELL Synthetic Lubricant Chevron RPM Synthetic Gear Lubricant or equal meeting 7 7 MIL L 2
108. e 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 NOTE For engine oil specifications oil change n intervals engine filter requirements or general engine maintenance procedures refer to the Engine Operation Manual included with your vehicle or the engine manufacturer s service manual Service Intervals Check engine oil daily Oil 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 Medium Duty R10 06 Y53 6008 Engine Maintenance could be seriously burned Let the engine oil 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 dip
109. e Maintenance 8 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 Engine Block Heater option WARNING Do not use the heater if there are any N signs of problems Engine block heaters can cause fires resulting in serious personal injury and or property damage if not properly main tained and operated Regularly inspect the engine block heater wiring and connector for damaged or frayed wires Contact your Autho rized Service Center or the manufacturer of the heater if you are in need of repairs or informa tion Engine Cooling System before starting your engine Damage to the cool ing system could occur if not turned OFF unplugged Use a solution of half ethylene glycol antifreeze and half water for best heater performance Do not use more than 65 percent concentration of antifreeze as a shortened heater life will result A CAUTION Always unplug the block heater After servicing the cooling system operate the vehicle for a day or two before using the heater Trapped air inside the engine needs time to escape Medium Duty R10 06 Y53 6008 147 Engine Cooling System Preventive Maintenance PREVENTIVE MAINTENANCE PM INTERVALS l A B C D E At the first 15 000 mi 15 000 mi 24 000 km 30 000 mi 48 000 km 160 000 mi
110. e S roa 2a 83 Color of charge indicator for each battery 1 2 3 4 TIRES AND WHEELS A B C Missing Valve Caps and Stem Locks Cracks or Loose Wheel lugs Tandem Mating Irregular Wear Tire Pressure Record below Remaining Tread Record below Tires amp Wheels Inspection Right p3 f Ps Y ih ws a a chal mm nm PS PS Y kPa WPa A gt 130 Y53 6008 Medium Duty R10 06 Preventive Maintenance Maintenance Schedule and Lubrication Table 3 Maintenance Schedule INTERVAL COMMENTS ge EE EE OPERATION FREQUENCY ss ssiss Do 209 29 na 2a 8 Left PSL P iPa Pa PSI s m i e Air Pressure Adjusted to ALIGNMENT A B C Toe in in mm Caster L R Rear Axle Alignment C2 ROAD TEST A B C 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 R10 06 Y53 6008 Jets Maintenance Schedule and Lubrication Preventive Maintenance Table3 Maintenance Schedule INTERVAL COMMENTS ee eS EE OPERATION FREQUENCY 98 98 S98 GS 20 20 M REFSEE Air Conditioner Instruments and Gauges Speedometer odometer Tachometer Oil Pressure Engine Temperature Illumin
111. e excessive movement of the seat in an maximum upward travel of seat Shorten the accident This could lead to greater injuries to tether belt as necessary to provide adequate you Tether belts should be adjusted so that they head clearance Serious injury may occur if head are taut when the seat is in its most upward and clearance is not adequate forward position 50 Y53 6008 Medium Duty R10 06 Operating Instructions Tether Adjustment Make sure that the tether belt is attached 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 Seats Komfort Lok Latch Your Peterbilt contains a feature designed to eliminate cinch ing and provide improved safety and comfort Cinching is the condition where a belt becomes continually tighter around you during a rough bouncy ride The need for this feature increases with rough road conditions particularly over long distances To eliminate cinching simply activate the Kom fort Lok feature at the appropriate time 1 Fasten the seatbelt according to the directions in the pre vious Safety Belt Restraint section 2 You are now ready to activate the Komfort Lok Lean for ward to pull a l
112. e heating System If the heater core is leaking a reliable radiator shop should be 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 R10 06 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 injury to you and 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 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 evaporat
113. e in the area Inhaling gaseous refrigerant through a cigarette may cause violent illness 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 personal harm j WARNING Never idle your vehicle for prolonged Medium Duty R10 06 Y53 6008 Heating and Air Conditioning 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 e 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 il NOTE To allow for proper operations of the vehicle ventilation system keep the inlet grille at the base of the windshield clear of snow ice leaves and other obstructions at all times WARNING Do not stay in the vehicle with the engine running or idling for more than 10 min utes with the vehicle s Heater and A C ventila tion system in RECIRC or at LOW FAN SPEED Even with the ventilation system ON running the engine while parked or stopped for pro longed periods of time is not recommended il A Controls The heater and air conditioning contr
114. e 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 158 H Y53 6008 Preventive Maintenance 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 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 and an injury accident Medium Duty R10 06 Preventive Maintenance Brake System event of a malfunction in any air or hy
115. e 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 position until the system pressure exceeds 50 psi 345 kPa It automatically 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 operation of the trailer brake system 2 transmit these signals to the trailer and 3 protect the tractor air supply in case of separa tion of the air lines connecting the tractor to the trailer 88 Y 53 6008 Operating Instructions Hydraulic Brakes WARNING Do not operate the vehicle in the AN 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 injury accident 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 Introduction The operation of the vehicle s braking system is based on the princi
116. e used to release them Release air is supplied by both the front and rear circuit res ervoirs 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 automati cally return to the OUT position if you attempt to push it in See page 26 for more information Medium Duty R10 06 Y 53 6008 Using the Brake System To release the trailer brakes ONLY Push IN the Red knob on the dash The truck or tractor will remain parked To release the full combination of brakes Push IN BOTH knobs on the dash n 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 motion before pressure in the system reaches 100 psi 689 kPa because the wheels are locked by the spring brake action CAUTION Do not try to put the vehicle in e 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 automat
117. e 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 Fluid Check and Refill gt b b Y53 6008 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 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 pipes 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 Medium Duty R10 06 Preventive Maintenance 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 re
118. ead to an injury accident Medium Duty R10 06 Y53 6008 Instruments and Controls Panel Lights The Panel Lights knob lets you vary the brightness of your instrument panel lights The knob is located on the left instrument panel See page 17 To Operate the Panel Lights Turn on either the headlights clearance lights or fog driving lights To brighten the instrument panel lights turn the knob clock wise to the right To dim the instrument lights or to turn them off turn the knob counterclockwise to the left ID and Clearance Lights N oZ A toggle switch controls the amber lights on FO UE top of your cab plus any additional lights that were installed on the front sides and rear of your vehicle The switch is located on the left instrument panel and is labeled CL LPS See page 17 29 Instruments and Controls Windshield Wipers Washer NOTE The ignition key must be turned to ACC or nm IGN amp ACC for the wiper washer switch to operate A five position windshield wiper switch controls the wipers and washer To turn ON the wipers turn the knob clockwise For intermittent operation turn to the 1st and 2nd posi tions for continuous operation advance to the 3rd and 4th positions The final option activates the washer cycle To wash the windshield push knob IN and release Hold knob IN to extend washing cycle After one to three wipes depend ing on how long you hold the switch in the wipers
119. eads ter Filter Draining Fuel Tanks Check fuel filter water separator daily Check with engine 1 Inspect fuel tanks fuel hoses and fittings to ensure OFF Depending on the fuel storage facility more frequent proper positioning and fastening check for leaks draining may be required 2 Inspect mounting brackets straps and pins to ensure proper positioning amp fastening every 15 000 miles 1 O drai by hand only t Rev Chall valve Oy Wane On AUT ae Scie 24 000 km see label on fuel tank and data below counter clockwise approximately 1 1 2 to 2 turns until draining occurs Drain filter sump of water until clear fuel is visible Type of Tank Tank Strap T Bolt Nut Torque If entrapped water exceeds sump volume you can Aluminum 30 Lb ft 41 Nm either NA Oylindrical Steel 8 Lb ft 11 Nm Medium Duty R10 06 Y53 6008 141 Engine Maintenance Preventive Maintenance Engine Accesories Accessory Drive Belts You can extend the reliability and service life of your vehicle s drive belts with proper attention to installation 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 pul
120. ear 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 82 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 stops have been completed Adjust the parking brake lever See the Medium Duty Maintenance Manual Medium Duty R10 06 Operating Instructions 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 fur ther 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 auto matically 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 differential 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 differential depend
121. ency recommenda tions for your vehicle Maintenance Schedule and Lubrication TABLE KEY 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 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 Service Interval G2 Synthetic Lube Required 500 000 Drain Table 3 Maintenance Schedule INTERVAL COMMENTS ge gEEIEgE OPERATION FREQUENCY Ss S s 2 S 0oloco eo re Palos INITIAL DRIVE IN A B C 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 Y53 6008 123 Medium Duty R10 06 Maintenance Schedule and Lubrication Preventive Maintenance Table3 Maintenance Schedule INTERVAL COMMENTS EE EE EE e e e OPERATION FREQUENCY 3 8 S S S S na 2x9 Wiper Blade Condition Horns Electric and Air Mirrors SAFETY EQUIPMENT A B C 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 Ext
122. endent of Documents U S Government Printing Office Washington DC 20402 Engine Compartment Checks Daily Chassis and Cab Checks Daily 1 Engine Fluid Levels add more if necessary Engine oil Coolant check while engine is cold Before entering the cab and operating the vehicle check the following equipment for proper maintenance 14 Y53 6008 Medium Duty R10 06 Operating Instructions 1 2 Windows and Mirrors are they clean and adjusted properly 3 Tires and Wheels are they inflated properly Are all 10 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 5 Brake Components check lines linkages chambers and brake operation 6 If your truck has hydraulic brakes check the brake system for leaks hydraulic lines for cracks or kinks calipers for leaks 11 7 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 72 for further details on Using the Brake 12 System Medium Duty R10 06 Y53 6008 Lights do headlights turn signals emergency flashers and exterior lamps function and are they clean and
123. ent in front of the axle in the area forward of the tires but not past the suspension bracket When at the correct ride height ensure that the height control valve lever is in the neutral position then install either the built in alignment pin or a 1 8 inch 3 mm dowel see page 102 Torque the mounting fasteners to 55 75 Ib in 6 2 8 5 N m Remove the alignment pin or dowel Repeat Steps 2 through 6 above for the RH valve on vehicles with a dual valve system Medium Duty R10 06 Operating Instructions Driving with Deflated Air Springs Vehicles with the air suspension option If an air spring rup tures there will be enough air pressure to drive the vehicle to a safe stop off the highway to investigate the problem 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 injury accident Do not continue to operate the vehicle in this condition 1 WARNING Do not continue to drive with rup To get to a repair facility do the following 1 Remove the height control link connected to the axle and to the suspension air valve control arm This will cause the air valve control arm to center in the closed position 2 The air system can then be pumped up to normal pres sure for continued operation unsafe for driving by not providing sufficient air brake application pressure in an emergency which could lead to an
124. equent inspection and the right care will give you the assurance of safe and reliable tire operation General Safety Requirements factured OEM components Use of non original equipment could cause wheel breakage and wheel separation from vehicle which could result in an injury accident Each mounting sys tem is engineered only for use with its correct mating part Be sure that properly matched com ponents are used for each type of mounting The comparison chart on Page 177 illustrates the dif ferences between parts used in hub piloted mount and ball seat mount applications Only OEM supplied hub piloted or ball seat mounted wheels may be used on this vehicle WARNING Use only original equipment manu Medium Duty R10 06 Y53 6008 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 per son can be seriously injured and or damage can result from using the wrong service methods Truck tires and wheels should be serviced only by trained personnel using proper equipment Do not reinflate a tire that has been run flat or is seriously low on air without first removing the tire from the rim and inspecting for damage Follow OSHA regulations per section 1910 177 Do not exceed the speed rating of tires Exceeding the speed rating may result in sudden tire failure and loss of vehicle co
125. equipped switch E set the temperature knob C to cool blue side and the fan A to high until the cab becomes cool adjust as desired For Efficient Cooling 1 Ensure all heater air conditioner controls are off 2 Start the engine Allow time for warm up 41 Heating and Air Conditioning Operating Instructions NOTE A cold compressor can cause refrigerant to If the air conditioner does not cool the air have the liquefy and warp the valve plates or cause a hydrau unit checked at an Authorized Service Center lic lock Warm the engine before starting the air con ditioner NOTE When the air conditioner isn t in regular use 3 Set the air conditioner for maximum cooling operate it for at least 15 minutes at least once a 4 Close all windows month or every 5 000 miles 8 000 km whichever 5 Idle the engine between 1000 and 1500 rpm and turn the comes first This will lubricate the seals in the air fan switch to High conditioning system 6 After the cab temperature cools to a comfortable level adjust the fan speed and other controls to keep the desired condition 42 Y53 6008 Medium Duty R10 06 Operating Instructions ACCESSORIES 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 Cigarette Lighter ignitio
126. erty 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 heater if there are any signs of problems Contact your Authorized Service Center or the manufacturer of the heater if you are in need of repairs or information A CAUTION Always unplug the heater before 1 WARNING Engine block heaters can cause fires starting the engine Damage to the cooling sys tem could occur if the heater is not turned OFF unplugged When the temperature falls below O F 18 F for Caterpillar engines or 10 F 24 C for Cummins engines the block heater is required 61 Operating the Engine Use a solution of half ethylene glycol antifreeze and 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 information After servicing the cooling system operate the vehicle for a day or two before using the heater Trapped air inside the engine needs time to escape Cold Weather Starting Air Intake Heater Do not use ether or any other starting fluid as a cold starting aid in your Medium Duty Engine conditions are automatically monitored and in cold weather the fuel air mixture is pre heated in the manifold ids as a cold starting aid in your Medium Duty Your engine uses either an electrical grid or an open flame inside the manifold to heat
127. essive engine coolant oil and charge air intake temperatures which can lead to over heating and possible engine damage If you must use a winterfront 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 Medium Duty R10 06 Operating Instructions Starting Procedure Normal Temperature Use the following procedure to start your Medium Duty when outside temperatures are at or ABOVE normal starting tem peratures Check the Engine Operation and Maintenance Manual for starting temperatures 1 Set the parking brake NOTE When any one of the following is true oil nm 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 oil into the turbocharger oil inlet port This will keep the turbocharger bearings lubricated until the engine oil pressure gets up to normal 2 Insert key into the ignition switch 3 Disable or turn OFF the following systems prior to start ing the engine the exhaust brake the dual speed rear axle put
128. est The shoulder belt must be positioned over the shoul der it must never rest against the neck Medium Duty R10 06 Y53 6008 Seats Belts should fit snugly across the pelvis and chest Make sure any slack is wound up on the retractor To unfasten the belt Push in the release button on the buckle The belt will spring out of the buckle Torelease a locked belt lean back to take the body pres sure off of the belt To store a lap shoulder belt allow the belt to wind up on the retractor by guiding the belt tongue until the belt comes to a stop Proper Safety Belt Adjustment Your combination lap shoulder belt may need adjustment Adjust safety belts properly The lap belt should be worn as low and tight on the hips as possible Make sure any slack is taken up by the belt mechanism The shoulder belt should fit snugly across your bogy It should be positioned midway over the shoulder nearer to the door it should never rest against your neck 47 Seats Operating Instructions Lap Belt Shoulder Belt Too High on Hips 4 p Incorrect Correct Correct over arm Incorrect under arm Incorrect twisted Safety Restraint Belts Be sure also that your belt is not too loose A loose belt You can be seriously injured if your belt is buckled could allow you to slide under it in an accident and that too high In a crash it would apply force to your abdomen not your pel
129. event possible injury and damage to property ensure that a vehicle is parked and the wheels chocked before begin ning this procedure CAUTION Completing this procedure will enable you to safely reach the nearest autho rized Peterbilt repair facility to have ride height and pinion angle reset using the proper equipment and technique Do this as soon as possible to avoid potential driveline damage RIDE HEIGHT gt NOTE Suitable wheel chocks are at a minimum an 18 inch 46 cm long 4x4 1 Ensure that the air supply and delivery plumbing of the Ride Height Measurement Location for Tandem Axles Shown height control valve is consistent with the illustration j Ride Height inches mm ipie Abad 2 fi Dii NOTE At least one of the mounting holes in the T T ac xus E UE height control valve bracket will be slotted to permit R y Low Air Leaf 6 50 165 8 50 216 rotating the valve These values are for a fully laden vehicle nm Mu osi systems begin with the LH Follow this procedure to temporarily set ride height n E y 9 2 Loosen the fasteners mounting a height control valve to its bracket 102 Y53 6008 Medium Duty R10 06 Operating Instructions Driving Tips And Techniques the air springs The rear of the vehicle will drop about 3 1 2 inches 88 mm when the air springs are deflated Make sure that no persons or objects that could be injured or da
130. ex nut will rotate during the chamber return stroke Installing a wrench on the hex nut will make this eas 80 90 PSI 552 621 KPA BRAKE APPLICATION f Oo h kostet iban h adi AIR CHAMBER RUM PUSHROD TRAVEL ier to see On each stroke after t e first the amount of adjust TYPE Size Applied Stroke ment and chamber travel will be less 20 Front 1 to 1 3 4 in 25 44mm 30 Rear 1 1 4 to 2 in 32 51mm 452 Y53 6008 Medium Duty R10 06 Preventive Maintenance 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 n proper brake operation Inspect all brake compo nents All brake components 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 Medium Duty R10 06 Y53 6008 Brake S
131. fication 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 Date of manufacture GVWR Gross Vehicle Weight Rating 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 o T I 75 50 amp 2 8 766 9 8 821 2506 72 8 7 EO p A7 M zx e es 6 o 827 ga3 ASA 58 02 25 8 3 7 5 702 7256 82 5 5 6 7 67 1 5 6 1 Y87 ot 7 9621 2 388855 CF 1 35 7 2 0 18 amp 785 6 2 1 29 X 0 5 5 9 1 rE ns MAR TRENTS Medium Duty R10 06 COMPLETE VEHICLE CERTIFICATION LABEL SAMPLE Y53 6008 229 Consumer Information and Vehicle Identification ing Overloading can result in loss of vehicle control and serious personal injury either by causing component failures or by affecting vehi cle 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 WARNING Do not exceed the specified load rat The tire size and rim size and the cold
132. g Adjust Brakes Y53 6008 Medium Duty R10 06 Preventive Maintenance Maintenance Schedule and Lubrication Table 3 Maintenance Schedule INTERVAL COMMENTS ge EE EE OPERATION FREQUENCY 928 98 98 oooco oo na 2a 8 Front amp Rear Brake Camshaft Tube Lubrication Es 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 Signs of Over Charging Remove Corrosion and Seal Terminals Hold down and Box Mounting Bolts Load Test Batteries Sealed Type Condition Medium Duty R10 06 Y53 6008 129 Maintenance Schedule and Lubrication Preventive Maintenance Table3 Maintenance Schedule INTERVAL COMMENTS gE EE EE e e e OPERATION FREQUENCY S S S g
133. gaged Turning Radius When Locked Engaged m MlPr 0287 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 Medium Duty R10 06 Y53 6008 Operating the Rear Drive Axle 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 that locks the wheels NOTE If your vehicle has an automatic trans nm 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 4 Drive the vehicle through the poor traction area keeping your speed under 25 mph 40 km h To UNLOCK the inter axle differential 1 When you reach dry pavement or better road conditions where the differential lock is not needed switch the dif ferential 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 97 More Driving Tips and Techniques MORE DRIVING TIPS AND TECHNIQUES WARNI
134. ge to your vehicle Location Of Fuses Fuses are located inside the cab left side next to the driver s door Fuse Inspection and Replacement WARNING Do not replace a fuse with one of a AN higher rating Doing so may damage the electri cal system and cause a fire CAUTION Before replacing a fuse turn OFF all A lights and accessories and remove the ignition key to avoid damaging the electrical system A gt 182 Y53 6008 CAUTION Never patch fuses with tin foil or wire This may cause serious damage elsewhere in the electrical circuit and it may cause a fire 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 R10 06 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 the electrical system 2 Dete
135. gnition Switch Medium Duty R10 06 Y53 6008 17 Instruments and Controls INSTRUMENTS AND CONTROLS Introduction Your Medium Duty dashboard is shown on the opposite page The dash includes standard gauges and switches Your vehi cle 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 For your convenience all gauges and their corresponding page numbers are listed here see Index of Gauges Refer to the page listed to learn what each gauge does and how it should be used 18 Y53 6008 Operating Instructions Instrument Index Table 1 Index of Gauges GAUGE REFERENCE PAGE Tachometer 22 Engine Oil Pressure 25 Engine Coolant Temperature 23 Speedometer 21 Air Cleaner Restriction option 30 Fuel Level 28 Voltmeter option 29 Air System Pressure 26 Transmission Temperature option 29 Warning Lights and Buzzer Many vehicle systems are linked to the instruments on your instrument panel Warning lights in each instrument may indicate something is wrong with one of the many vehicle Systems Check the lights frequently and respond properly as soon as a light or buzzer comes on Medium Duty R10 06 Operating Instructions Instruments and Controls WARNING LAMP MODULE MIRROR ENGINE LOAD CRUISE SPOT HEAT FAN LIGHT CONTROL
136. gy generated will bring the internal brake drum temperature to about 500 F 260 C This is well within the safe zone the maximum 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 over heating 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 back 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 dis tort the brake drum Medium Duty R10 06 Operating Instructions To prevent drums from distortion while they cool down Parkthe vehicle on level surface and block the wheels Release the parking brake and allow the brakes to cool down See page 74 Anti Lock Braking System This vehicle may be equipped with an anti lock braking sys tem ABS This ABS reduces the possibility of wheel lock up If a wheel is about to lock during braking the ABS will automatically adjust air pressure to the brake chambers on the appropriate wheel s to prevent wheel lock up The ABS is automatically turned on when the ignition switch is turned on ABS Warning Lamps Truck Tractor ABS Warning Lamp A
137. h allows you to lower the fifth wheel to slide under a trailer A guard on the switch prevents you from accidentally deflat ing the suspension Deflate Switch Dump Valve while driving Sud den deflation while your vehicle is moving can affect handling and control and could lead to an accident Use this switch only when your vehicle is not moving f WARNING Do not operate the Air Suspension CAUTION Operating a vehicle with air suspen A 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 8 km h Medium Duty R10 06 Y53 6008 Driving Tips And Techniques NORMAL DEFLATE 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 vehicle is equipped with a Peterbilt rear air suspension and if it becomes necessary to reset the ride height you may temporarily set it by following the next procedure Proper ride height measurement and val ues are shown in the illustration and table below 101 Driving Tips And Techniques Operating Instructions WARNING To pr
138. hard level ground 2 the parking brake is applied 3 all wheels are chocked front and rear and 4 the engine cannot be started Remove the ignition key Never start or let the engine run in an enclosed unventilated area Exhaust fumes from the engine contain carbon monoxide a colorless and odorless gas Carbon monoxide can be fatal if inhaled WARNING handling hydraulic fluid It is mildly toxic and can cause skin and eye irritation Wear protective clothing when painted surfaces of the vehicle i CAUTION Hydraulic brake fluid may damage 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 Medium Duty R10 06 Y53 6008 Introduction 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 erly Non compliance with env
139. hecks 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 2 Recommended Maintenance Intervals Page 120 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 Medium Duty R10 06 Y53 6008 Steering and Driveline 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 indicator and should generally not drop below the middle point between the Maximum and
140. hen draining the engine cooling WARNING Use of incorrect air dryer could AN cause air system failure leading to loss of vehicle control and serious personal injury or death If your vehicle is equipped with a Ben dix 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 consisting of a wet tank forward dry Medium Duty R10 06 Y53 6008 Air System 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 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 Li 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
141. his manual consult 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 publication 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 prevent costly damage to the vehicle Key symbols and signal words are used to indicate what kind of message is going to follow Pay special attention to instructions prefaced by symbols and the signal words WARNING CAUTION and NOTE Please do not ignore any of these alerts 1 WARNING When you see this word the message that follows is AN 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 contain N ers in the vehicle Such containers full or empty may leak explode or cause a fire in the event of a collision CAUTION Signals a potentially hazardous situation which if A not avoided could result in property or vehicle dam age Example CAUTION Continui
142. ible exception of mounting brackets do not repair defective parts 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 running This suction could draw your hand or anything else near it into the impeller fan You could be seriously injured Always keep the intake piping con nected when you will be running the engine 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 Manifold With the engine operating check for leaking man ifold or flange gaskets Medium Duty R10 06 Preventive Maintenance 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
143. ich 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 220 Y53 6008 Preventive Maintenance 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 person 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 Medium Duty R10 06 Preventive Maintenance 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 interval
144. icle Are there signs of fuel oil or Power steering fluid level water leaks f your truck has hydraulic brakes check the fluid Check for damaged loose or missing parts Are there level in the master cylinder reservoir See page 154 for more information 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 nm NOTE The following items Engine Compart Hn NOTE Deflection should be one belt thick parts showing signs of excessive wear or lack of lubrica tion Have a qualified mechanic examine any question able items and repair them without delay Check your load Is it secured properly Daily Checks ment Chassis and Cab and Prestart Checks ness for each foot distance between the should be checked daily as a minimum They pulley centers are in addition to not in place of federal motor e f breaks or tears are found the belt should be Carrier Safety Regulations These regulations replaced before operating the vehicle may be purchased by writing to 3 Fuel Filter Water Separator Draining check and drain Depending on the fuel storage facility more frequent draining may be required 4 Windshield washer reservoir fluid level fill if necessary 5 Hood closed before entering cab Is it latched properly Superint
145. ies of dif ferent voltage or substantially different capacity rating may cause an explosion and serious per sonal injury CAUTION Applying a higher voltage booster 1 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 following these procedures can damage the alternator or cause serious damage to both vehicles damage to the vehicle heed all warnings and WARNING To avoid serious personal injury and instructions of the jumper cable manufacturer The 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 it is OK replace the caps before going further If the level is low add distilled water and replace the caps Medium Duty R10 06 Preventive Maintenance 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 hurt someone or damage the vehi cle 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 1 WARNING If you do not cover the filler openings Preparing the vehicles 1 Position the two vehicles together but do not le
146. ife of the vehicle f WARNING Do not exceed the specified load rat The components of your vehicle are designed to provide satisfactory service if the vehicle is not loaded in excess of either the gross vehicle weight rating GVWR or the maximum front and rear gross axle weight ratings GAWRs Axle weight ratings are listed on the driver s door edge 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 includ ing the weight of the empty vehicle loading platform occu pants fuel and any load Never exceed the GVWR of your vehicle GCW is the actual combined weight or Gross Combination Weight GCW of your vehicle and its load tractor plus trailer s plus cargo Medium Duty R10 06 Operating Instructions 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 distributed So that no axle has to support more than its GAWR WARNING An unevenly distributed load or a AN load too heavy over one axle can affect the brak ing and handling of your vehicle which could result in an accident Even if your load is under the legal limits be sure it is distributed evenly Emergency Equipment It is good practice to carry an emergency equipment kit in
147. ility power at low RPM Combinations of engine speed and available torque may over power the vehicle s parking brakes Medium Duty R10 06 Y53 6008 Using the Brake System safety system For the safety of you and others around you have the vehicle submitted for peri odic preventive maintenance checks as well as having any suspected problems immediately checked by an Authorized Service Center Fail ure to properly maintain your brake system can lead to serious injury accidents f WARNING The brake system is a critical vehicle Brake Components The following is a brief description of the hydraulic brake sys tem It is intended to supply you with general information on how the system works For complete information see the Peterbilt Medium Duty Maintenance Manual 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 89 Using the Brake System 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 ill
148. in a normal fashion or it may be due to excessive leaks in the air system NOTE A small amount of oil in the system may be normal and should not by itself be considered reason to replace a desiccant cartridge oil stained desiccant can function adequately 165 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 amounts of moisture is normal and should not be consid ered as an indication that the dryer is not performing properly An outside air source may have been used to charge the air system in which case this air did not pass through the drying bed 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 166 Y53 6008 Preventive Maintenance ing should be more frequent Replace any defective parts With the poss
149. 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 230 Y53 6008 Preventive Maintenance 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 Medium Duty R10 06 Preventive Maintena
150. ing on road surface conditions Medium Duty R10 06 Y53 6008 Operating the Rear Drive Axle When operating normally on paved dry surfaces keep your truck s interaxle differential in the UNLOCK position GUARD UNLOCK SHIFT AT ANY SPEED EXCEPT IF A WHEEL IS SPINNING Interaxle Differential Lock Switch in normal unlocked position SHIFT AT ANY SPEED EXCEPT IF A WHEEL IS SPINNING Interaxle Differential Lock Switch in locked position 95 Operating the Rear Drive Axle In the LOCK position an air operated clutch positively locks both sets of axles together providing greater traction on slip pery road surfaces however steering around corners and on dry pavement is more difficult Continuous operation on a paved dry surface stresses the tandem axles possibly caus ing internal damage Use this feature only when driving on surfaces with poor trac tion 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 con ditions such as these e Ice or snow with or without tire chains Dirt roads Loose sand mud or other rough road conditions WARNING Do not put the differential lock in the AN LOCK position while the wheels are spinning freely slipping you could lose control of the vehicle or cause axle damage
151. inguisher Charge Flare Kit Reflectors CIRCLE INSPECTION A B C 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 124 Y53 6008 Medium Duty R10 06 Preventive Maintenance Table 3 Maintenance Schedule Maintenance Schedule and Lubrication Medium Duty R10 06 INTERVAL COMMENTS ge EEb EE OPERATION FREQUENCY 2 s 2 s S S Do 209 29 AEAEE 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 148 of this manual Coolant Level Pressure Test Replace Water Filter New Release At 100 120K Per Engine Filter Manufacturer Recommendations Radiator Mounting Y53 6008 1
152. injury accident Before driving the vehicle make sure the air pressure f WARNING Low air pressure could make brakes Medium Duty R10 06 Y53 6008 Driving Tips And Techniques pumps up to over 100 psi for normal brake operation If it does not reach 100 psi do not try to move the vehicle A CAUTION Do not operate a vehicle with air sus pension bags either over or under inflated This could cause damage to driveline compo nents If you must drive under such conditions do not exceed 5 mph 8 km h Fifth Wheel The following applies to tractor configurations nance adjustments and rebuilding are done only by a qualified mechanic An improperly maintained fifth wheel can cause a trailer to sep arate from a tractor This could lead to an injury accident and damage to property 1 WARNING Ensure that all fifth wheel mainte Your Medium Duty may be equipped with either a fixed or an air controlled sliding fifth wheel Either type should self lock when a trailer king pin trips the locking dogs as the tractor is backed under a trailer 105 Driving Tips And Techniques 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 CAB CONTROLL
153. ins 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 R10 06 Preventive Maintenance Electrical System When fast charging remove the battery caps so pres WARNING Always shield your eyes and avoid sure does not accumulate AN leaning over the battery whenever possible Always make sure the battery charger is OFF before Electrolyte in batteries could splash up into your connecting or disconnecting the cable clamps eyes causing severe burns and or serious per 1 EA sonal injury To avoid short circuits and damage to yourself or the vehicle never place metal tools or jumper cables on the Battery terminals should not be coated with improper battery or nearby Metal that accidentally comes in con grease Use petroleum jelly or commercially available tact with the positive battery terminal or any other metal noncorrosive nonconductive terminal coatings on the vehicle that is in contact with the positive termi Battery acid that may
154. ir 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 t Brake Treadle 10 000 15 000 Clutch Pedal Shaft None Transmission Check 10 000 15 000 Drain and Refill Manual 50 000 Drain and Refill Automatic 25 000 Rear Axle Check Fluid Level 10 000 15 000 Rear Axle Drain Flush Refill 500 000 Synthetic Lube 120 Y53 6008 Medium Duty R10 06 Preventive Maintenance Table 2 Recommended Maintenance Intervals Maintenance Schedule and Lubrication ITEM Rear Wheel Bearings INTERVAL 100 000 COMMENTS With LMS Wheel End Package Rear Brake Camshafts 10 000 15 000 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
155. ironmental 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 f WARNING Diesel engine exhaust and some of 117 Introduction tive harm This warning requirement is mandated by Cal ifornia law Proposition 65 and does not result from any change in the manner in which Peterbilt Motors Com pany trucks are manufactured lubricants oil and grease can be poisonous 1 WARNING Handle lubricants carefully Vehicle and cause sickness 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 118 Y53 6008 Preventive Maintenance and the Peterbilt Electronic Parts Catalog ECAT When ordering replacement parts please provide the Medium Duty Chassis Serial Number See Page 228 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 view
156. ise and Emission Control Table 13 Maintenance Log Medium Duty R10 06 53 6008 225 Consumer Information and Vehicle Identification 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 Peterbilt Motors Company To contact NHTSA you may either call the Auto Safety Hot line toll free at 12800 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 226 Y53 6008 Preventive Maintenance 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 Stree
157. ittle slack in the belt maximum 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 cinching it into place 4 To release the Komfort Lok latch reach up and pull the latch cover open down or simply pull down on the shoulder belt 5 When you want to get out of the cab release the latch then just push the button on the buckle Medium Duty R10 06 Y53 6008 51 Seats LATCH COVER UP J LATCH COVER DOWN 02395 The Komfort Lok latch 52 Operating Instructions During Pregnancy Pregnant women should always wear combination lap shoul der belts The lap belt portion must be worn snugly and as low as possible across the pelvis To avoid pressure on the abdomen the belt must never pass over the waist Some times pregnant women worry that in a crash the seat belt could hurt the baby But if a woman wears her belt properly low over her pelvis below her abdomen the belt 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 c
158. ity and safe driving it is extremely important for you to follow the instructions on the use of 1 WARNING Do not drive with your visibility the ventilation heating and defogging defrosting system If in doubt consult your dealer Maxi mum heating output and fast defrosting can be 02593 obtained only after the engine has reached oper Heater and Air Conditioner Controls ating temperature Internal air circulation control is provided by three sets of AN outlets e Front outlets on the dashboard panel with directional louvers Floor outlets under the dashboard Window defrost vents on the dashboard _ 38 Y53 6008 WARNING Excessive heat may cause the pres surized components of the air conditioning sys tem to explode Never weld solder steam clean or use a blow torch near any part of the air con ditioning system If a refrigerant leak develops in the presence of excessive heat or an open flame hazardous gases may be generated These gases may cause unconsciousness or death If you become Medium Duty R10 06 Operating Instructions aware of a refrigerant leak on your vehicle have your system serviced immediately and observe the fol lowing precautions Stay away from the hot engine until the exhaust manifold has cooled Do not permit any open flame in the area Even a match or a cigarette lighter may generate a haz ardous quantity of poisonous gas Do not smok
159. ks there is almost con stant movement of the belt due to ride characteristics and seat design The constant movement of the belt 197 Cab 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 every 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 198 Y53 6008 Preventive 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 WARNING It is important to remember that any Inspection Guidelines Follow these guidelines when inspecting f
160. l 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 1 1 2 in hex Medium Duty R10 06 Y53 6008 177 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 ment repaired tires on steering axles They could fail unexpectedly and cause you to lose control of your vehicle resulting in an injury accident WARNING Do not install regrooved or reinforce 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 injury accident WARNING Do not replace original equipment 178 Y53 6008 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
161. ld personally inspect every trailer to determine 2 its braking system 82 Y53 6008 when the ignition switch is first turned on whether or not a trailer is connected to the vehicle If the bulb check is satis factory the lamp will next do either of the following 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 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 hooked up to an optional ISO 3731 connector tinguish between trailers An ABS problem in any trailer will activate the trailer ABS warning lamp mn NOTE For doubles or triples PLC does not dis 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 f no trailer ABS problems are detected the lamp will go off Medium Duty R10 06 Operating Instructions 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 tem that is functioning improperly You could lose control of the vehicle resulting in a severe accident and serious 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
162. 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 231 Index A Accessories 43 Adjustable Tilt Column 56 Air conditioner 181 refrigerant 117 Air Dryer 165 Air filter 167 Air horns 43 Air intake 166 220 Air leaks 163 Air loss emergency procedure 27 Air pressure gauge 26 163 Air suspension deflated air spring 105 switch operation 101 Air tanks 15 87 114 alteration 9 Alternator precautions 191 218 Anti lock brakes 80 83 93 Ashtray 43 Automatic transmission 16 71 205 fluid 208 oil level 205 Axle weight rating 12 13 100 230 B Ball bearing grease 134 Ball seat mounted wheels 177 Battery 232 access 183 care 184 compartment cover 8 electrolyte 188 recharging 188 189 slow battery charging 190 Belts seat 46 48 Block heater 61 147 Bobtail brake 77 85 Brake adjustment 151 air pressure gauge 26 163 checks and adjustments 150 components 86 compounding 87 emergency braking 80 hand valve trailer 55 83 linings 151 lubrication 150 operation 73 overheating 80 parking 74 proportion valve 73 safety front 79 safety rear 79 safety tractor trailer 80 system safety and emergency 78 159 Y53 6008 syste
163. leys 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 Engine Fan matic tensioner 3 Release the automatic tensioner Thermatic Clutch Type Fan 4 Check the belt alignment on each pulley The belt must fall between the flanges of each pulley engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seriously injured Before turning on the ignition be sure that no one is near the fan WARNING Do not work on the fan with the 142 Y53 6008 Medium Duty R10 06 Preventive Maintenance 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 engine 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
164. ling 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 Preventive Maintenance 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 H 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 In an ELC filled cooling system the freeze point should be maintained between 30 F and 45 F 34 C and 43 Y53 6008 Medium Duty R10 06 Preventive Maintenance Engine Cooling System Desired ELC 0 10 15 20 25 30 35 40 4595 50 55 60 65 70 75 80 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 4 7 9 12 15 21 24 31 37 46 54 59 64 57 48 42
165. ling System Li f WARNING Handle coolant and antifreeze care 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 Store in original fluid container only and always keep out of reach of children FILL COOLANT EXPANSION TANK Cooling System Expansion Tank 146 Y53 6008 Preventive Maintenance Proper Coolant Level il NOTE Do not overfill a cooling system Excess coolant may result in overflow loss of antifreeze and reduced corrosion protection Check the coolant level after each trip Add coolant as necessary You may find your coolant level is not up to the correct level soon after you have filled the radiator This may be because all the trapped air in the system has not yet been purged It takes a little time for all the air to leave the system after you fill your radiator 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 7 Complete the filling Do it as quickly as possible ROD Oo Oi Medium Duty R10 06 Preventiv
166. ling or pulling an empty trailer 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 if your wheels lock suddenly during braking you could be severely injured WARNING Do not use an engine retarder when Bobiail Brake Proportioning System When a trailer is not connected the drive axle brake applica tion pressure will automatically be limited by the proportion ing system The brake proportioning system regulates the application pressure to the rear drive axle To provide equivalent braking power tractors driven bobtail will require greater brake pedal application than other types of vehicles not equipped with a proportioning system Medium Duty R10 06 Operating Instructions 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 pres sure on the rear drive axle will automatically 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 you
167. ll let you match driving speed and gear selection to the operating range of your engine If the engine speed gets too high you can select a higher gear to lower the rpm s If the engine speed drops too low you can select a lower gear to raise the rpms See page 99 for further instructions on driving techniques and using the tachometer To avoid engine damage do not let the pointer exceed maximum governed speed When driving downhill shift to a lower gear and use the service brake keeping the engine speed below the max imum governed speed The hour meter option records the time in hours the engine is operating Y53 6008 Medium Duty R10 06 Operating Instructions Coolant Water Temperature Gauge The water temperature gauge shows the temperature of the engine coolant Under normal operating conditions the water temperature gauge should register between 165 and 205 F 74 and 90 C Under certain conditions somewhat higher temperatures may be acceptable The maximum allowable temperature is 210 F 99 C with the cooling system pressur ized except for certain special engines Check the engine manual to be sure 02580 Water Temperature Gauge Medium Duty R10 06 Y53 6008 Instruments and Controls Engine Overheating The cooling system may overheat if the coolant level is below normal or if there is sudden loss of coolant such as a split hose The system may also temporarily overheat
168. ls on starting the engine Parking Brake Before you leave the cab apply all parking brakes for vehicles with air brakes 34 Y53 6008 Operating Instructions 1 Apply all parking brakes Pull out the Yellow Parking Brake Control knob 1 located on the dash In tractors the Red octagon shaped Trailer Air Supply Control knob 2 will automatically pop out 02391 1 Full Truck Parking Brake Valve ing the parking brake The truck could roll and cause an injury accident Always apply the park ing brake before you leave the cab WARNING Do not leave the cab without apply Medium Duty R10 06 Operating Instructions 2 Trailer Air Supply Control Red 1 Parking Brake Control Yellow 02394 Combination Tractor Trailer Parking Brake Control Valves 2 Shift the transmission into its PARK position See Pages 68 and 74 for transmission shifting and parking brake 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 You could be severely injured 1 WARNING Do not pull out the parking brake Medium Duty R10 06 Y53 6008 Instruments and Controls See Using the Brake System on page 72 for more informa tion for vehicles with hydraulic brakes The parking brake consists of a d
169. luid 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 Either case adversely affects braking operation Medium Duty R10 06 Operating Instructions Using the Brake System Brake Warning Lamp When the brake warning lamp comes on it indicates a mal s iim function in the brake system Possible malfunctions include MIRROR loss of hydraulic pressure from the power steering circuit or a ex acu pressure differential between the primary and secondary brake circuits OIL Low WATER WARNING Do not operate the vehicle if the l AN brake light or buzzer comes on The light or WATER buzzer indicates a failure in one of the brake v oa E components system Drive your vehicle to the BRAKE side of the road immediately Failure to do this 7 j may lead to an accident and severe injury SERVICE BRAKE WARNING INDICATOR 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 Medium Duty R10 06 Y53 6008 91 Using the Brake System Pump the brakes Pumping the brake pedal may generate enough hydraulic pressure
170. lutch 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 204 Y53 6008 Preventive Maintenance 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 is equipped with a rod and lever mechani cal clutch linkage Lubricate each pivot point on the clutch linkage Medium Duty R10 06 Preventi
171. m towing and spring brakes 110 system checks 149 153 system malfunction 110 system park tractor 78 trailer brake hand valve 84 trailer charge 78 treadle valve 87 Brake Fluid Check 154 Brake Fluid Reservoir 89 Brake Master Cylinder 90 Brake Warning Lamp 91 C Cab access 7 heater maintenance 180 heater precautions 38 maintenance 197 Calipers 156 Charge air cooler 166 Chassis grease 134 number 227 228 Cigarette lighter 43 Cleaning the vehicle 193 Clutch 67 clutch adjustment 71 clutch brake 69 clutch travel 69 Medium Duty R10 06 fan drive 222 operating the clutch 67 riding the clutch 70 Coasting 71 Component lubrication index 134 Compressed air reservoir 15 87 162 Compressor 86 Consumer information 226 Cooling system conventional coolant 146 expansion tank 24 extended life coolant 144 temperature 23 24 temperature gauge 23 topping up 145 Cruise control operation 65 switch 37 D Daily operations 14 Daytime running lights 31 Defogging defrosting system 38 Department of transportation regulation 392 7 11 Diesel fuel 115 Dipstick 139 Disc brake pads 155 Disc brake rotors 156 Medium Duty R10 06 Dome light 44 Door Lock 7 Door lock 194 Double check valve 87 Downshift 71 Driver s checklist 13 daily and weekly checks 13 14 16 handbook American Trucking Assoc 5 Seat 45 tips 71 Driveshaft 208 lubrication 208 Driving bobtail 84 89 vehicle inspection 11 with deflated air springs 105 Dry
172. maged are Sr WARNING Be extremely careful when deflating s under the vehicle To minimize the risk of damage or injury do not ALIGNMENT PIN OR DOWEL CONTROL ARM LINK BOLT use the dump valve to deflate the air springs Operate the height control valve s manually to mmu E ensure positive control of air spring deflation i p E lt q FROM DUMP VALVE SWITCI 1 To minimize risk of injury keep away from air ar springs as they are being inflated FORWARD 02941A Typical Height Control Valve Top View Medium Duty R10 06 Y53 6008 103 Driving Tips And Techniques Operating Instructions Rotate the valve either clockwise or counterclockwise SUPPLY FROM FORWARD A MOUNTING NUTS ce 90 9 js EXHAUST 9 gt ud TO LH AIR BAG S Oum 2 AIR BAG Jl LINK ROD T 3 02941B 4 Typical Height Control Valve 5 Rear View Looking Forward 104 Y53 6008 DELIVERY TO RH AIR BAG S Yoon A until air pressure in the air springs provides the ride AIR TANK height specified for that suspension Measure the ride T height from the bottom of the frame rail to the approxi mate centerline of the rearmost drive axle hub For tandem axles make the vertical measurement at the centerline of the suspension see illustration on page 102 Fora single axle make the measurem
173. 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 hold it down for five minutes The pres sure drop should not exceed 3 0 psi 21 kPa per minute 7 If you detect excessive leakage air pressure loss greater than 3 0 psi 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 164 Y53 6008 Preventive Maintenance 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
174. mation Medium Duty R10 06 Y53 6008 107 Vehicle Recovery and Spring Brakes VEHICLE RECOVERY AND SPRING BRAKES Introduction Your Medium Duty is equipped with built in recovery provi sions 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 driv eline This is necessary because if the transmission is driven by the driveshaft rear wheels on the ground no lubricant will reach the gears and bearings causing damage to the transmission or lift the driving wheels off the ground before towing the vehicle See More Driving Tips and Techniques on page 98 All lubricating and clutch application oil pressure is provided by an engine driven pump which will not work when CAUTION Remove the driveline and axle shafts 108 Y53 6008 Operating Instructions the engine is stopped You could seriously damage your vehicle by towing it with the driveline connected and the drive wheels on the ground 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 result ing friction may seriously damage them Always remove the main driveshaft and axle shafts before towing your vehicle duty truck recovery see Truck Maintenance Council Recommended Practice 602 A Front To
175. mation on starting and operating the engine refer to the Engine Operation and Maintenance Manual pro vided with your Medium Duty Because each vehicle is custom equipped all engine opera tion instructions presented in this section are general 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 out lined 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 WARNING Do not use ether or other starting flu AN ids as a cold starting aid in your Medium Duty Your engine uses either an electrical grid or an open flame inside the manifold 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 severe injury 58 A Y53 6008 Operating Instructions WARNING Do not start or let the engine run in an enclosed unventilated area Exhaust fumes from the engine contain carbon monoxide a col orless and odorless gas Carbon monoxide can be fatal if inhaled Do not park or operate the vehicle in areas where the hot exhaust system may come in con tact with dry grass brush spilled fuel or other material that can cause a fire CAUTION The use of a winterfront can result in exc
176. 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 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 162 Preventive Maintenance 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 injury accident WARNING If the supply and service tanks are FRONT REAR PRIMARY SECONDARY SERVICE TANK SERVICE TANK X Nt c I DRAIN VALVE WET SUPPLY TANK UNDER FRONT SERVICE TANK 02602 Y53 6008 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 Medium Duty R10 06 Preventive Maintenance 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 Maintain the air compressor to prevent excessive oil by pass See the Medium Duty Maintenance Manual for maintenance details Replace worn seals in valves a
177. n cause an explosion or fire resulting in injury or death 02584 See page 114 for more information Fuel Gauge 28 Y53 6008 Medium Duty R10 06 Operating Instructions Voltmeter option The voltmeter shows the voltage your vehicle s electrical sys tem is putting out Normally it should show 10 to 16 volts If voltage drops have the electrical system checked Voltmeter Instruments and Controls Transmission Temperature Gauge option Your vehicle may be equipped with a transmission tempera ture gauge It indicates the temperature of the oil in your transmission Watch this gauge to know when your transmis sion is overheating If it is have it checked by an Authorized Service Center 02579 Transmission Temperature Gauge temperature may vary depending upon your transmission and type of lubricant Check your transmission Owner s Manual CAUTION Maximum allowable transmission Medium Duty R10 06 Y53 6008 29 Instruments and Controls Operating Instructions Air Filler Restriction Gauge reading 25 in start of red area It could lead to damage to the engine Inspect the filter and replace if neces sary CAUTION Do not continue to operate with the Holes in the paper element render an air cleaner useless and may cause the Air Filter Restriction Gauge to give a false reading even if the element is clogged Replace the element if itis
178. n key in either the OFF ACC accessory or IGN ACC position To operate push in on the knob end of the lighter After a few moments the lighter will automatically pop out glowing hot and ready to use After use insert the lighter back into the Socket without pushing all the way in n NOTE The cigarette lighter will operate with the The socket of the cigarette lighter may be used to operate 12 volt 15 ampere appliances such as a hand spotlight or small vacuum cleaner Medium Duty R10 06 Y53 6008 Accessories capacity of the cigarette lighter It could result in a fire Follow all warnings and instructions in the operator s manual for the appliance you are using f WARNING Do not exceed the voltage amperage Ashtray To open pull on the upper side of the panel To close push against the panel WARNING Do not place paper or other combus N tible substances in an ashtray It could cause a fire Keep all burnable materials besides smok ing materials out of the ashtray Air Operated Horn Option Your Medium Duty may be equipped with an air horn To operate pull on the lanyard extending from the overhead header panel Your vehicle also has an electric horn See page 56 43 Accessories Operating Instructions Glove Compartment WARNING Do not carry loose objects in your N cab it can be dangerous In a sudden stop or A glove compartment is provided to store important docu even going ove
179. n the Index You will find the pages where brakes or related topics are dis cussed 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 personnel 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 specifi cations and proper tools If you are sure you meet these qualifications then you can probably perform some repairs yourself But if you are not an experienced mechanic or do 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 correctly sufficient training service manuals and the proper tools You could be injured or you could make your vehicle unsafe Do only those tasks you are fully qualified to do WARNING Do not attempt repair work without Y53 6008 Introduction Shop Manuals If you do decide to do complex repair work you will need the Medium Duty Maintenance Manual It contains service pro cedures parts information and supporting material on major components in your vehicle such as Suspensions Drive lines Axles and the Heater Air Conditioner Listed below are manuals available from your Peterbil
180. nce 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 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 Medium Duty R10 06 Y53 6008 Consumer Information and Vehicle Identification 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
181. nd air motors as they are needed Your Peterbilt Dealer carries rebuild kits for most units Dual Air Gauge and Air Leaks Your Medium Duty comes with a dual circuit air pressure gauge for two separate systems Primary and Secondary the WHITE pointer indicates pressure in the front Second ary braking circuit the ORANGE pointer indicates pressure in the rear Primary braking circuit The gauge indicates the amount of air pressure in pounds per square inch psi in the air system is detected Conduct the follow ing procedure and contact an Authorized Ser vice Center or any other properly equipped WARNING Do not operate the vehicle if leakage Medium Duty R10 06 Y53 6008 Air System 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 injury accident FRONT SECONDARY SERVICE CIRCUIT WHITE ORANGE 02581 Dual Air Pressure Gauge Air Reservoir 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 163 Air System Follow the procedure below to check the compressed air system for leaks 1 Periodically or after
182. ng to operate your vehicle A with insufficient oil pressure will cause serious engine damage 2 Introduction NOTE Provides general information for example the note could warn you on how to avoid damaging your vehi cle or how to drive 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 you see them and remember WARNING Something that could seriously injure you CAUTION Something that could cause property or vehicle damage NOTE Useful information Y53 6008 Medium Duty R10 06 Introduction 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 13 WARNING Do not drink and drive Your reflexes AN perceptions and judgment can be affected by even a small amount of alcohol You could have a serious or even fatal accident if you drive after drinking Please do not drink and drive or ride with a driver who has been drinking 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 pro gram or truck driving school If you have not been trained get the proper training before you drive Only qualifie
183. nnecessary wear to your clutch release bearing and it is less tiring for you too Clutch Adjustment Inspect manual clutches according to the manufacturer s rec ommendations Regular maintenance should be followed to maintain correct clutch adjustment Have your dealer s Ser vice Department perform any adjustment necessary Tips Always use the clutch when making upshifts or down shifts Always select a starting gear that will provide sufficient gear reduction for the load and terrain Never downshift when the vehicle is moving too fast Medium Duty R10 06 Y53 6008 Operating the Transmission 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 Operating Automatic Transmissions An automatic transmission makes shifting much easier however it is important to understand how to operate the transmission efficiently Please read the transmission manufacturer s operation manual supplied with your vehi cle There may not be a park position with your automatic transmission Always be sure you apply the parking brake before leaving the cab WARNING Do not leave the cab of your vehicle AN without applying the parking brake The truck could roll and cause an injury accident Always apply the parking brake before you le
184. nsulate it from the vehicle Disconnect all Electronic Control Module ECM connec tors on electronic engines Do not use the ECM or engine ground stud for the ground of the welding probe Ensure that the ground connection for the welder is as close to the weld point as possible This ensures maxi mum weld current and minimum risk to damage of elec trical components on the vehicle Turn engine OFF All Anti Lock Braking Systems ABS Before welding anywhere on the vehicle detach the ABS Electronic Control Unit ECU connector and all other electronic control units Medium Duty R10 06 Preventive Maintenance 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 s literature for any special instructions 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 Frame and Fifth Wheel Every 6 Months or 50 000 Miles Refer to specific manufacturer s literature for any
185. ntrol Follow all warnings and cautions contained within the tire and wheel manufacturers literature Only properly trained personnel should service tire and rim assemblies See page 179 for specific safety requirements for trucks with hydraulic brakes 169 Tires and Wheels Speed Restricted Tires speed restricted tires Check each tire s side wall for maximum rated speed Vehicle should not be operated at sustained speed in excess of maximum rated speed Failure to comply with these speed restrictions could cause sudden tire failure which can result in prop erty damage or personal injury 1 WARNING This vehicle may be equipped with 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 170 Y53 6008 Preventive Maintenance vehicle For dual wheel assemblies check between the wheels for damage If any damage is found or you suspect damage do not attempt fu
186. o 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 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 193 Cab Maintenance 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 A CAUTION Do not aim the water jet directly at 4 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 h
187. ol unit is mounted in the center dash console below the radio The standard control unit has four controls to regulate air flow and temperature in 39 Heating and Air Conditioning the cab fan speed switch A air directional control switch B air temperature switch C and air circulating mode switch D With optional air conditioning a fifth switch E is used Fan Speed Control The fan speed rotary switch A allows you to select one of four blower speeds 1 4 Air Direction Control The air direction rotary switch B controls the air movement within the cab Five modes direct the air flow to the three sets of air outlets front panel floor and window defrost 1 Front Panel only 2 Panel and Floor Bi level 3 Floor only 4 Defrost and Floor Bi level 5 Defrost only 40 Y53 6008 Operating Instructions Temperature Control The temperature rotary switch C allows you to adjust and maintain a comfortable internal cab temperature Air Circulation Control The air circulation rocker switch D allows you to select FRESH air from outside the cab or recirculate RECIRC air from within the cab Air Conditioner Control The optional air conditioner is engaged with this rocker switch E Heating To heat the cab select the desired air direction and circulat ing mode B and D and set the temperature knob C to hot red position on the control Adjust the fan speed A as desired Me
188. 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 vehicle AN safety system For the safety of you and others around you have the vehicle submitted for peri odic preventive maintenance checks as well as having any suspected problems immediately checked by an Authorized Service Center Fail ure to properly maintain your brake system can lead to serious injury accidents Medium Duty R10 06 Operating Instructions 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 which could contribute to an accident 1 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 portion of the treadle valve delivers air from the front service reser voir to the front axle brake chambers via a quick release
189. on your vehicle The material in this manual is the same as that used by Peterbilt dealers It includes inspection maintenance over haul and troubleshooting procedures Subject Index 02956B Owner s Custom Parts Book This book is a complete unillustrated computer generated list of the parts used to custom build your Peterbilt vehicle Please provide your Chassis Serial Number when ordering
190. onditioner HEATER AND AIR CONDITIONER Introduction The combination heater air conditioner 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 Special Precautions surized components of the air conditioning sys tem to explode Never weld solder steam clean or use a blow torch near any part of the air con ditioning system WARNING Excessive heat may cause the pres If a refrigerant leak develops in the presence of excessive heat or an open flame hazardous gases may be generated These gases may cause uncon sciousness or death If you become aware of a refrig erant leak on your vehicle have your system service immediately and observe the following precautions 180 Y53 6008 Preventive Maintenance Stay away from the hot engine until the exhaust manifold has cooled Do not permit any open flame in the area Even a match or a cigarette lighter may generate a haz ardous quantity of poisonous gas Do not smoke in the area Inhaling gaseous refrigerant through a cigarette may cause violent illness Heater 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 th
191. ools Preventive Maintenance Completely bypassing a Bendix AD IS air dryer will bypass the system s pressure protection valves This could lead to loss of air pressure or damage to the vehicle s air system which could cause an acci dent or personal injury Always adhere to the manu facturer s procedure if it is necessary in an emergency to temporarily bypass an AD IS series air dryer AN WARNING Do not release the parking brake or 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 hold vehicle while parked This control utilizes air pressure for brake application Because accept able air leakage levels cause all truck air sys tems to gradually lose pressure vehicle rollaway could occur resulting in an accident and or injuries Always apply the tractor and trailer parking brakes when the vehicle is unattended 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 Y53 6008 Medium Duty R10 06 Preventive Maintenance Scheduled Maintenance Table 6 Air System Scheduled Maintenance Air System Use Table 6 Air System Scheduled Maintenance to sched ule ser
192. or 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 AN 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 closely examined to determine if it is coming into contact with any sharp or rough surfaces on the seat or other Medium Duty R10 06 Preventive Maintenance parts of the cab interior These areas are typical places Cab Maintenance 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 cab 3 Check the Komfort Lok Latch for cracks or possible dam age and check for proper operation Web cut or frayed or extremely worn at latch area Buckle casting broken Web cut or frayed at D loop web guide IN 03004 Seat Belt Inspection Points Medium Duty R1
193. or core and condenser core for debris restricting air flow Clean if necessary Small parti Medium Duty R10 06 Y53 6008 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 AN 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 181 Electrical System Preventive Maintenance ELECTRICAL SYSTEM CAUTION Do not modify or improperly repair A 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 dama
194. or near the fan with Cruise Control Option Engaging the Cruise Control 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 equipment CRUISE CONTROL away from the fan ON SET NOTE Do not operate the engine fan in the MAN nm UAL position for extended periods of time The fan hub was designed for intermittent operation Sus tained operation will shorten the fan hub s service life as well as reduce fuel economy Hn NOTE Ensure that the vehicle speed is above the 02901 minimum cruise control speed and the engine speed is above 1100 rpm 1 Move the ON OFF switch to the ON position RESUME position at this point will select the previ NOTE Toggling the SET RESUME switch to the nm ously set cruise speed 2 Accelerate the vehicle to the desired cruise speed Medium Duty R10 06 Y53 6008 65 Operating the Engine 3 Toggle the SET RESUME switch lever to the SET posi tion to set the cruise speed This toggle switch has addi tional functions that are set by the manufacturer 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 SUME 02901b To increase the cruise set speed B hold the SET RESUME switch in the SET position this will accelerate the 9 vehicle to a higher speed E 02901a Disengaging the Cruise Control Do one of these steps to
195. ound on the Tire and Rim Data label on the driver s door 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 Vehicle Load Normal 2096 Over 4096 Over 60 Over 80 Over 10095 Over Tire Pressure Normal 2096 Low 3096 Low 3596 Low 45 Low 5596 Low Expected total Mire ioina 70 50 40 30 25 Mileage 172 Y53 6008 Medium Duty R10 06 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 8 Wheel Cap Nut Torque Page 174 After that check wheel cap nuts at least once a week Contact an Authorized Service Center for infor mation 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 WARNING Never use oil or grease on studs or AN nuts improper torque readings will result which could cause improper wheel clamping and could lead to a wheel failure resulting in an injury acci dent
196. ousehold type soap Strong industrial detergents and cleaning 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 194 Y53 6008 Preventive 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 date 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 Hose dirt and grime from the entire chassis Then if an 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 Medium Duty R10 06 Preventive Maintenance
197. ple of hydraulics Hydraulic action begins when force is applied to the brake pedal This force creates hydraulic pres sure in the master cylinder and is amplified with assistance of a power booster The supplemental boost in force is devel oped when pressurized power steering fluid from the steering pump presses on the master cylinder piston As a safety pre caution the pressurized fluid from the master cylinder has two mutually independent circuits The primary circuit sup plies 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 cylin Medium Duty R10 06 Operating Instructions ders which actuate the brake pad mechanisms Actuation of these mechanisms 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 sys tems are inoperative WARNING Never drive your vehicle with the parking brakes applied Always release the park ing brakes prior to moving the vehicle Failure to disengage the parking brakes prior to moving your vehicle could result in excessive heat build up of the brakes and start a fire NOTE Today s diesel electronic engines have signif n icant torque and startab
198. pressure gauge indicates the amount of air pres sure in the brake system in pounds per square inch psi The WHITE pointer shows the front secondary service reservoir air pressure and the ORANGE pointer indicates pressure in the rear primary service reservoir 06 Y53 6008 Operating Instructions FRONT SECONDARY SERVICE CIRCUIT WHITE 02581 ORANGE Dual Air Pressure Gauge Air Reservoir If the pressure in either or both circuits is too low for normal brake operation below 64 psi a warning light in the panel will glow and the audible alarm will sound at start up do not try to drive the vehicle until WARNING If the light and alarm do not turn off the problem is found and fixed Medium Duty R10 06 Operating Instructions A A Medium Duty R10 06 WARNING If the air pressure falls below 60 psi 414 kPa the spring brakes may stop the vehicle abruptly which could result in an accident and or injuries Observe the warning light in the panel If it comes on do not continue to drive the vehicle until it has been properly repaired or ser viced WARNING The air pressure warning light and the audible alarm indicate a dangerous situa tion there is not enough air pressure in the res ervoirs for repeated braking and the brake system has failed Without the use of your ser vice brakes your spring brakes could suddenly apply This could cause a wheel lock up loss of control o
199. que 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 Y53 6008 Preventive Maintenance 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 Medium Duty R10 06 Preventive Maintenance 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 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 80 538 108 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
200. r 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 you to lose control of your vehicle and may result in an injury acci dent f WARNING Use the correct components and Medium Duty R10 06 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 Y53 6008 175 Tires and Wheels Demounted Rims To check the torque on demountable rims follow the criss cross sequence shown below See Table 8 Wheel Cap Nut Torque Page 174 for proper torque specifications 00118 DISK WHEEL DEMOUNTED RIMS Crisscross Tightening Sequence 176 Y53 6008 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 1 WARNING Improperly mounting and demount Comparing Hub Piloted and Ball Seat Parts Equipment that does not exactly match original specifications or that is mismatched could cause the wheels to break and separate from the vehicle The resulting accident could
201. r a bump in the road they could ments the vehicle literature set including this Operator s fly through the air and strike you or a passenger Manual and other related materials You can open it by You could be injured or even killed Secure all pushing the knob on the front loose objects in the cab before moving the vehi cle To close push the cover up and press to latch it You can lock and unlock the glove compartment door with your ignition key turn it clockwise to lock and coun Dome Light terclockwise to unlock are T The dome light is automatically activated when you open the WARNING Do not drive with the glove compart door To turn the dome light on when you are inside the cab AN ment open it can be dangerous In an accident turn the headlight switch counter clockwise until it clicks and or sudden stop you or a passenger could be ihe light comes on thrown against the cover and be injured To reduce the risk of personal injury during an acci dent or sudden stop keep the glove compart ment closed when the vehicle is in motion 44 Y53 6008 Medium Duty R10 06 Operating Instructions SEATS Introduction This section covers the operation and safe use of your Medium Duty seats For further information on features and adjustment of the seat see the manufacturer s literature included with the vehicle Seat Adjustment WARNING Do not adjust the driver s seat while AN the vehicle is moving A s
202. r over take by following vehicles You could be in an accident and severely injured Bring the vehicle to a safe stop right away while you still have control of the vehicle Instruments and Controls Air Loss Emergency Procedure i Y53 6008 Slow down carefully Move a safe distance off the road and stop Place the transmission in park and set the parking brake See Pages 68 and 74 for transmission shifting and park ing brake information Turn OFF the engine Turn ON the emergency flasher See Emergency Flasher Switch on page 55 and use other warning devices to alert other motorists log Instruments and Controls Operating Instructions Fuel Gauge Your truck has one main fuel tank and up to four optional tanks The fuel gauge shows the total amount of fuel It is a The fuel gauge shows the approximate amount of fuel in the good idea to keep fuel tanks at least half full otherwise fuel tanks Besides empty and full the gauge also indicates water that condenses in an empty tank will contaminate the 1 4 1 2 and 3 4 of total fuel capacity fuel and could damage the engine ers in your vehicle Fuel containers either full or empty may leak explode and cause or feed a fire Do not carry extra fuel containers even empty ones are dangerous f WARNING Do not carry additional fuel contain WARNING Do not remove a fuel tank cap near N an open flame Hot fuel vapors are combustible and ca
203. r vehicle down Because it can help keep your vehicle s brakes from over heating 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 vehi cle 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 Medium Duty R10 06 Y53 6008 Using the Brake System an emergency The engine or retarder alone might not stop you fast enough to prevent an accident You could be badly hurt if you relied only on the engine retarder f WARNING The service brakes must be used in 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 ser vice brakes for quick stops Exhaust Brake With the exhaust brake switch ON the brake automatically 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 bobtailing or pulling an empty trailer Make sure the brake is OFF before starting the engine 85 Using the Brake
204. re operating con Scalding steam and fluid under pressure may ditions the temperature should have cooled by this escape and cause serious personal injuries time 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 against escaping fluid and steam FILL WARNING Carefully and slowly turn cap one AN turn to allow excess pressure to escape then push down and turn for final removal G See page 143 for instructions on checking and filling the coolant expansion tank 02604 Coolant Expansion Tank 24 Y53 6008 Medium Duty R10 06 Operating Instructions Instruments and Controls injury and or vehicle damage due to engine overheating never leave the engine idling with out an alert driver present If the engine should overheat as indicated by the engine coolant temperature light immediate action is required to correct the condition Continued unattended operation of the engine even for a short time may result in serious engine damage or a fire WARNING To reduce the chance of personal For further details on engine operation see the Engine Oper ation and Maintenance Manual in the glove compartment of your vehicle Engine Oil Pressure Gauge CAUTION Continuing to operate your vehicle A with insufficient oil pressure will cause serious Engine Oil Pressure Gauge engine damage
205. re 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 83 Using the Brake System To operate the trailer brake hand valve Pull down on the lever The valve is self returning When pressure is removed from the valve lever it will return to the OFF position NOTE The trailer brake is not to be used as a sub nm stitute for the service brakes Using this brake fre quently instead of using the foot brake will cause the trailer brakes to wear out sooner WARNING Do not use the trailer hand brake or service brakes to park and hold an unattended vehicle use the parking brakes Because ser vice brakes work with air pressure these brakes could slowly release Your vehicle could roll causing a serious accident Someone could be hurt or killed Never rely on the service brakes to hold a parked vehicle Driving Bobtail or With an Unloaded Trailer NOTE The following information is applicable only to tractor configurations 84 Y53 6008 Operating Instructions Do not use the engine retarder such as an exhaust brake to slow the vehicle down when you are bobtai
206. ressed Besides being illegal and danger ous coasting is also expensive It causes premature fail 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 Medium Duty R10 06 Operating Instructions 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 personal injury and or an accident before going down a steep or long grade reduce speed and shift the trans mission into a lower gear to help control your vehicle speed Failure to follow procedures for proper downhill operation could result in loss of vehicle control Engine Overspeed 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 Medium Duty R10 06 Y53 6008 Driving Tips And Techniques NOTE Often these recommendations are sec ondary to maintaining an adequate and safe speed relative to the surrounding traffic and road
207. riveline 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 can cause the brakes to overheat upward on the parking brake lever while the vehicle is moving Attempting to stop with the 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 35 Instruments and Controls Operating Instructions Using the Parking Brake 2 Apply the parking brake Pull upward on the parking brake lever until it reaches an over top center posi 1 Comento a completo step tion The PARK light on the dash will come on NOTE Ensure the lever is over center The light will i come on prior to brake being fully applied SPOT LIGHT T CRUISE CONTROL PARKING BRAKE INDICATOR Shift the transmission into NEUTRAL position Turn the key OFF Remove the key If you are parked on a grade always block the wheels Oo WO PARKING BRAKE LEVER 36 Y53 6008 Medium Duty R10 06 Operating Instructions Cruise Control Switch
208. rmine 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 WARNING Do not add a fuse with a rating electrical system and cause a fire CAUTION Follow all manufacturers circuit pro A tection recommendations for the components and wires being added 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 Medium Duty R10 06 Y53 6008 Electrical System 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 Batteries WARNING Battery posts terminals and related AN accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Wash hands after handling 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
209. rom the com partment WARNING Charger cables must be connected AN positive to positive to and negative to neg ative to If connected improperly batteries could explode causing serious personal injury Always make sure the battery charger is OFF before connecting or disconnecting the cable clamps To reduce the danger of explosions and resulting seri ous personal injury do not connect or disconnect charger cables while the charger is operating 1 Make sure the electrolyte level in each cell is between the MIN and MAX marks If the fluid level is below the MIN mark correct the condition 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 5 After charging turn OFF charger and disconnect charger cables C TP 190 Preventive Maintenance 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 Dome 1141BULB
210. rpm when it is being driven by the vehicle s trans mission for example on steep downgrades Apply service brakes or shift to a higher gear Fuel economy and engine performance are also directly related to driving habits The best results in trip time and fuel economy are obtained while driving the vehicle at a steady speed nm 100 Y53 6008 Avoid rapid acceleration and braking WARNING Do not exceed the specified load rat ing Overloading can result in loss of vehicle control and serious personal injury either by causing component failures or by affecting vehi cle handling Exceeding load ratings can also shorten the service life of the vehicle The components of your vehicle are designed to provide satisfactory service if the vehicle is not loaded in excess of either the gross vehicle weight rating GVWR or the maximum front and rear gross axle weight ratings GAWRs Axle weight ratings are listed on the driver s door edge NOTE For your safety and the safety of others fol low routine and periodic maintenance schedules for all components on your vehicle See Table 3 Main tenance Schedule Page 123 Medium Duty R10 06 Operating Instructions 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 load ing On tractors the deflate switc
211. rther 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 WARNING Do not operate vehicle with underin AN flated tires The extra heat caused by underinfla tion can cause sudden tire failure such as a tire fire or blow out Low pressure may affect control at the front wheels which could result in an acci dent and serious injury Keep your tires inflated to the manufacturer s recommended air pres sure Medium Duty R10 06 Preventive Maintenance 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 s
212. s 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 166 Medium Duty R10 06 Y 53 6008 Noise and Emission Control Check the induction tubing elbow connections clamps brackets and fasteners for deterioration cracks and security e f you find an air leak anywhere between the air cleaner and the engine repair that leak immediately CAUTION Air leaks cause excessive noise and A may result 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 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 221 Noise and Emission Control Piping
213. s available only in electronic CD ROM format Medium Duty R10 06 Preventive Maintenance MAINTENANCE SCHEDULE AND LUBRICATION Introduction The following section summarizes preventive maintenance and lubrication requirements for the maintenance of your Medium Duty For specific maintenance procedures and complete lubrication instructions of specific components con sult the Medium Duty Maintenance Manual and manufac turer s service manuals These manuals are 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 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 is serviced regularly you can avoid many large expensive and time consuming repairs as well as Medium Duty R10 06 Y53 6008 Maintenance Schedule and Lubrication 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 3 Maintenance Sched ule Page 123 But remember there may be maintenance operations that demands skills and equipment you do not have If so please take your Medium Duty to an expert mechanic for your
214. s Pulling the knob OUT applies the parking brake which exhausts air from the cham bers and allows the springs to extend and apply the brakes 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 severely injured f WARNING Do not pull out the parking brake WARNING Do not leave the cab without apply N ing the parking brake The truck could roll and cause an injury accident Always apply the park ing brake before you leave the cab Operating Instructions Before you leave the cab 1 Apply all parking brakes Pull out the Yellow Parking Brake Control knob located on the dash The Red octa gon 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 74 Y53 6008 Medium Duty R10 06 Operating Instructions 2 Trailer Air Supply Control Red 1 Parking Brake Control Yellow 02394 Combination Tractor Trailer Parking Brake Control Valves The parking brakes act on the rear wheels only They are spring applied with air pressur
215. s flame and lighted cigarettes away from batteries WARNING Never jump start a battery near fire 185 Electrical System 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 WARNING Do not allow battery fluid to contact Be careful that metal tools or any metal in contact with the positive terminal do not contact the posi tive battery terminal and any other metal on the vehi cle at the same time Remove metal jewelry and avoid leaning over the battery f metal jewelry or other metal comes in contact with electrical circuits a short circuit may occur causing you to be injured as well as electrical system failure and damage to the vehicle Do not try to jump start or charge a frozen battery Even a battery with ice particles on the electrolyte surface is dangerous Allow it to thaw out first And always allow the battery to thaw gradually do not apply direct heat Gas trapped in the ice may cause an explosion 186 Y53 6008 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 batter
216. s 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 A CAUTION The air brake system of this vehicle Medium Duty R10 06 Y53 6008 Brake System All of the following areas are interrelated and must con form 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 page 160 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 149 Brake System A 150 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 injury
217. s will 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 Transportation Regulation 392 7 which states that interstate commercial motor vehicles are not to be driven unless the driver is sure that certain parts and accessories are in working order 11 Start Up perceptions and judgment can be affected by even a small amount of alcohol You could have a serious even fatal accident 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 reflexes The use of alcohol drugs and certain medica tions will seriously impair perception reactions and driving ability These circumstances can substantially increase the risk of an accident and serious personal 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 overloaded or your load has shifted your vehicle may be unsafe to drive xo Y53 6008 Operating Instructions ing Overloading can result in loss of vehicle control and serious personal injury either by causing component failures or by affecting vehi cle handling Exceeding load ratings can also shorten the service l
218. servoirs ensure that the seal in each reservoir cap is in good condition before refitting the cap Medium Duty R10 06 Y53 6008 Brake System 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 serious personal injury j 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 Consult your nearest Peterbilt dealer A CAUTION 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 It is recommended that all disc brake pads be replaced at the same time since this will main tain balanced braking At a minimum replace all disc brake pads on one axle both ends at the same time 155 Brake System BRAKE PADS ANCHOR PLATES BRAKE PADS CALIPERS CALIPERS FRONT REAR SYSTEM COMPONENTS 156 Y53 6008 Preventive Maintenance Calipers Visually inspect calipers for brake fluid leakage damaged or defective pistons or piston
219. shaft bracket tube e Use standard chassis lubricant meeting No 1 grade high temperature water proof specifications Do not use moly disulfide loaded grease or oil they may shorten the service life of the slack adjuster Medium Duty R10 06 Preventive Maintenance 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 Park the vehicle on a level surface and block the wheels before attempting any brake checks or adjustments Brake Linings 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 an injury accident or system failure WARNING Do not use brake linings with a thick Brake linings should be inspected for wear by a qualified mechanic at an Authorized Service Center See Table 3 Maintenance Schedule Page 123 In severe service applications inspect the linings more frequently Medium Duty R10 06 Y53 6008 Brake System Automatic Slack Adjusters Your Medium Duty 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
220. soon as possible CAUTION If the ABS warning light does not illu Medium Duty R10 06 Y53 6008 Using the Brake System MIRROR HEAT LOW H a WATER WATER ABS WARNING INDICATOR 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 calibrated for the specific tire revolutions per mile Use of a tire and or wheel size different from that originally installed on your vehicle may cause the ABS sys tem to not function during a hard braking event This could cause an accident or serious per sonal injury Consult with your Peterbilt dealer before using a different tire and or wheel size than was originally installed on your vehicle 93 Using the Brake System Parking Brake Burnishing This procedure is recommended for new vehicles where less lever actuation force is required This procedure is manda tory whenever the driveline brake shoes or brake drum are replaced are installed the driveline brake must be bur nished Failure to properly burnish the parking brake before putting it in service could result in an inoperative parking brake possible vehicle rollaway and serious personal injury or dam age to the vehicle i WARNING If a new drum or new brake shoes 94 Y53 6008 Operating Instructions Drive the vehicle at 15 mph 24 km h in a low g
221. 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 Sliding Fifth Wheel Medium Duty R10 06 Y53 6008 Lubricate bearing surface of support bracket through the grease fittings on the side of the fifth wheel plate Use a water resistant lithium base grease NOTE The plate must be lifted up slightly to relieve the weight of the bracket while applying grease 219 Noise and Emission Control 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 wh
222. ssions on page 67 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 serious ill nesses 63 Operating the Engine 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 personal harm WARNING Never idle your vehicle for prolonged Idling the Engine Under most circumstances continuous idling of your engine merely wastes fuel In severe Arctic weather conditions how ever you may need longer idling to be sure all parts of your engine are fully lubricated low rpm 400 600 rpm longer than five minutes Long periods of idling after the engine has reached operating temperatures can decrease engine temperature and cause gummed piston rings clogged injectors and possible engine CAUTION Do not allow your engine to idle at 64 Y53 6008 Operating Instructions damage from lack of lubrication The normal torsional vibrations generated can also cause transmission wear During the time it takes
223. stem 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 unaffected circuit allowing this circuit to continue normal operation The trailer brakes are still func tional e f 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 f 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 Emergency Braking WARNING Unless you have an anti lock brak AN ing system always avoid completely depress ing the service brake pedal if possible even during emergency braking Depressing the brake pedal too aggressively can cause the wheels to lock which can lead to an uncon trolled skid and can result in an accident 80 Y53 6008 Operating Instructions For Non ABS Vehicles To stop your vehicle in an emer gency vary the service brake application pressure to provide maximum braking force without locking the wheels 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 ener
224. stick and wipe it off with a clean lint free rag 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 engine manufacturer s Engine Operation and Maintenance Manual supplied with the vehicle 139 Engine Maintenance 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 seriously injured A mixture of gasoline or alcohol with diesel fuel increases this risk of explosion 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 140 Y53 6008 Preventive Maintenance 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
225. t 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 Medium Duty R10 06 Preventive Maintenance Vehicle Identification 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 5 below SAMPLE VIN 2INP NHHD 8JX X Y M 5 6 7 8 9 0 mies nose Wee Manufacturer Identifier Vehicle Attributes Check Digit Model Year Assembly Plant Serial Chassis Number Vehicle Identification Number VI
226. t 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 Medium Duty R10 06 Introduction Medium Duty Body Builders Manual Contains general guidelines on mechanical and electrical modifications required by your dealer to add bodies accessories and spe cial equipment to straight truck configurations 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 1 WARNING Modifying your vehicle can make it Preventive Maintenance Section The Preventive Maintenance section pages 116 226 in this manual contains general service information for the oper ator such as lubrication points making adjustments and other helpful service information This is summary informa tion only used for general maintenance of m
227. t carry additional fuel contain Specification Use only Diesel Fuel Grade 2 D as recom tion source such as a cigarette could cause an N explosion You could be seriously injured A If your vehicle is equipped with shut off valves for the take off mixture of gasoline or alcohol with diesel fuel and return lines they are located on the fuel lines entering increases this risk of explosion the top of the fuel tank Fuel shut off valves for the fuel cross Do not remove a fuel tank cap near an open over line are on the bottom of the fuel tank at the crossover flame line connection Use only the fuel and or additives recom mended for your engine Medium Duty R10 06 Y53 6008 115 Introduction Preventive Maintenance PREVENTIVE MAINTENANCE INTRODUCTION This section will help you keep your Medium Duty 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 per form Authorized service mechanics are trained in the proper technical and safety procedures to maintain your Medium Duty 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 in good working order and provide many years of dependable Service
228. t 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 Medium Duty R10 06 Y53 6008 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 seriously injured 1 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 Startthe vehicle that has the good battery first Let it run for a few minutes Then start the vehicle that has the discharged dead battery 187 Electrical System If
229. tank 87 Dual air pressure gauge 26 60 E Economical driving 98 Electrical system 183 alternator 191 batteries 183 184 188 battery charging 185 187 188 189 jumper cables 186 Electrolyte 188 Emergency Y53 6008 Index braking 80 equipment 13 flasher switch 55 Engine belt tension 14 185 block heater 61 compression 113 daily checks 14 fan switch 65 heater 147 179 182 identification 231 idling 64 lubrication 139 oil draining 139 oil level check 139 oil pressure 25 oil pressure gauge 25 overheating 23 overspeed 99 retarder 84 rpm 114 service notes 139 speed 23 starting procedure 58 stopping the engine 114 temperature 24 vital engine systems 63 warmup procedure 63 233 Index water temperature gauge 23 weekly checks 16 winterfronts 58 Environmental protection 117 Ether 58 Exhaust brake 84 85 fumes 117 F Fan blade 222 switch 65 Federal motor regulations 11 14 Federal motor vehicle safety standards 3 Federal safety label 231 Fifth wheel 105 air controlled 106 fixed 106 lock switch 106 maintenance 219 sliding maintenance 219 Frame precautions 218 Front axle 210 front axle identification 231 Front brake system 73 Front suspension u bolts 209 Front Wheel Calipers 90 Fuel 234 filter 14 140 filter draining 141 gauge 28 refueling 114 system 115 tanks 28 Fuel Tank Inspection 141 Fuel tanks 141 G GAWR defined 13 GAWR gross axle weight rating 12 100 23
230. 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 severe injury 1 WARNING Do not use ether or other starting flu 62 Y53 6008 Operating Instructions With each engine make the air intake heating system works differently To understand fully how your engine s heating sys tem operates see the engine Operation and Maintenance Manual for details On most systems the engine block temperature is monitored 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 warn ing light See page 20 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 the preheat cycle is complete and you can start the engine normally Medium Duty R10 06 Operating Instructions 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 ldling The purpose of engine w
231. the sides and behind your vehi cle Be sure both mirrors are adjusted properly before you begin driving To provide good visibility adjust each mirror so the side of your vehicle appears in the inboard part of the mirror and make objects appear smaller and farther away than they really are You could have an accident if you are too close to another vehicle or other object Keep plenty of space between your vehicle and others when you turn or change lanes Remember that other objects are closer than they may appear 1 WARNING Convex mirrors can distort images Medium Duty R10 06 Operating Instructions Power Mirror Option Your Medium Duty may have motorized side mirrors A switch for each located on the dash controls the adjustment To adjust the mirror Push the arrow that points toward the direction you want to move the mirror Li NOTE The power mirror switch does not control the adjustment of the convex mirrors Medium Duty R10 06 Y53 6008 Steering Column and Mirrors Heated Mirrors Option Your vehicle also may have heated mirrors To defrost mirrors in cold weather turn the mirror heat switch to ON You can keep the mirror heat on to ensure that the mirrors stay free of ice or condensation They automatically adjust to the temperature outside providing the right amount of heat to keep them clear 57 Operating the Engine OPERATING THE ENGINE Introduction For detailed infor
232. the vehicle 6 2 Fully depress the clutch pedal until the clutch brake makes contact see page 69 The contact will occur at about 1 inch or less from the floorboard e The total stroke of the clutch pedal is about 10 higher gear or speed range forces undue strain on the engine clutch other transmission com ponents and may cause damage 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 Push the parking brake valve handle Yellow against the dash panel to release the brakes Release the clutch pedal then gradually accelerate to permit smooth starting Do not allow your vehicle to roll even a little in the oppo site 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 inches The first 172 inches is free travel After the For further instructions on operating your transmission see free travel comes the release stroke which is the part that fully releases the clutch The last inch the transmission manufacturer s manual that is included with engages the clutch brake XOU Verde 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 68 Y53 6008 Medium Duty
233. to cle s engine In most engines idle pressure should be move before the air system reaches 100 psi 689 about 15 psi kPa 60 Y53 6008 Medium Duty R10 06 Operating Instructions Starting Procedure Cold Weather In addition to the previous Normal Starting Procedures use these Cold Weather Starting guidelines when the air temper ature 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 cranking 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 tem peratures are below normal fully depress the accelera tor pedal after engaging the starter Medium Duty R10 06 Y53 6008 Operating the Engine Engine Block Heater Option 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 resulting in serious personal injury and or prop
234. to stop the vehicle Usethe parking brake The parking or emergency brake is separate from the hydraulic system There fore it can be used to slow the vehicle Operating Instructions 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 2 Move a safe distance off the road and stop Overheated Brakes C5 Set the parking brake See page 36 4 Turn on the emergency flasher and use other warning devices to alert other motorists 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 92 Y53 6008 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
235. tor while follow the recommendations listed below gears could clash or jam severely damaging Do not engage starter for more than 30 seconds at a em time e Wait until normal engine oil pressure registers on the e Wait two minutes between each attempt to start the gauge before idling or accelerating the engine beyond engine This allows the starter motor to cool and time for 1000 rpm the batteries to regain power f the engine fails to start after a couple of tries there could be a malfunction with the engine or other related system Make any adjustments or repairs necessary before trying to start the engine again Watch the air pressure gauge Wait until both pointers register at least 100 psi 689 kPa before releasing the spring brake and moving the vehicle Also check the alarm system for any type of faults and correct them before moving the vehicle When the engine starts e Watch the oil pressure gauge Oil pressure should rise before pressure in the air system reaches 100 within 15 seconds after the engine starts If the oil pres psi 689 kPa because the wheels will still be locked by the spring brake action i CAUTION Do not try to put the vehicle in motion sure does not rise stop the engine Find what is wrong before restarting Check the Engine Operation and Main Unnecessary stress and possible brake mal tenance Manual for the right oil pressure for your vehi function could occur if the vehicle is forced
236. tory 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 defects 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 Medium Duty R10 06 Front Axle and Suspension SPRING AND SHACKLE PINCH BOLTS SPRING ANCHOR PINS U BOLTS SPRING ANCHOR PIN 00439 Y53 6008 Front Suspension Axle Lubrication Change bearing lubrication when seals are replaced or brakes are relined See Table 2 Recommended Mainte nance Intervals Page 120 209 Front Axle and Suspension 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 approved lubricant Lubricate knuckle thrust bearings knuckle pins and tie rod en
237. try exit procedure recommen dations were prepared with personal safety foremost in mind WARNING Do not jump out of the cab or get into AN the cab without proper caution You could slip or fall possibly suffering a serious injury You could slip and fall if the steps are wet or icy or if you step in fuel oil or grease Start Up To help avoid personal injury due to a slip or fall f e 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 02611 Use even more care when steps and handholds or foot wear are wet coated with ice snow mud oil fuel or grease 8 Y53 6008 Operating Instructions WARNING Do not step on vehicle components without antiskid surfaces or use components not designed for entry and exit use You could fall and injure yourself if you step 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 pre vent 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 Keep steps clean Clean any fuel oil or grease
238. turn the engine OFF 5 Turn on the emergency flasher and use other warning devices to alert other motorists Vehicle with hydraulic brakes only buzzer These signals tell you something is wrong With your vehicle It could be a failure in an important system such as the brakes which could lead to an accident Have the appropriate system checked immediately 1 WARNING Do not ignore a warning light or 20 Y53 6008 Medium Duty R10 06 Operating Instructions BRAKE warning lamp illuminates or the buzzer sounds The vehicle should not be operated until the system is repaired Failure to respond to a brake warning lamp or buzzer could result in an accident and or severe injury j WARNING Do not operate the vehicle if the Speedometer and Odometer The speedometer indicates the vehicle speed in miles per hour MPH and in kilometers per hour km h The odometer records the distance traveled by the vehicle either in miles or kilometers depending on which unit is installed in the vehicle Medium Duty R10 06 Y53 6008 Instruments and Controls Speedometer MPH km h 21 Instruments and Controls HOURMETER OPTION 02586 Tachometer 22 Operating Instructions Tachometer The vehicle s tachometer measures the engine speed in rev olutions per minute rpm Watching the tachometer is important to driving efficiently It wi
239. ual 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 Spring Shackles and Hanger Brackets Spring Pins No Service Required No Service Required Medium Duty R10 06 Y53 6008 127 Maintenance Schedule and Lubrication 128 Table3 Maintenance Schedule Preventive Maintenance INTERVAL COMMENTS ee es EE OPERATION FREQUENCY ss ssiss DGS 20 20 ONT 959 King Pin Wear Steer Axle Wheel Bearing End Play Adjustment 350 000 Miles With LMS Outer Ends and Inspection No Leak No Service Front Hub Lubricant Level Spring Leaves Tighten U bolts after the first 500 miles U Bolt and Suspension Fastener Torque 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 Chafin
240. uch 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 CAUTION Pressure should be checked when WARNING Do not repair damaged tires unless the tires are cool Warm or hot tires cause pres sure buildup and will give you an inaccurate reading So never deflate a warm tire to the specified pressure Medium Duty R10 06 Y53 6008 Tires and Wheels 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 00137a road TREAD CONTACT Mun WITH ROAD 0o 138a Underinflation causes abnor mal tire deflection which builds up excessive heat running the P Hoses risk of failure It also causes TREAD CONTACT WITH ROAD irregular wear SS Tires and Wheels Overinflation reduces the tre
241. udden or unexpected seat movement can cause the driver to lose con trol of the vehicle 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 Standard Driver s Seat The standard driver s seat can be adjusted forward and rear ward These movements are each controlled by levers located on the FRONT of the seat Medium Duty R10 06 Y53 6008 Seats Driver s Seat with Air Suspension Option cle be sure that there is adequate head clear ance at maximum upward travel of seat Serious injury may occur if head clearance is not ade quate f WARNING Before driving or riding in the vehi CHUGGER SNUBBER LOCK OUT FEATURE Move handle down to unloc BACKREST TILT Rotate knob for infinite selection of settings FRONT CUSHION HEIGHT Lift and pull forward to raise position 2 AJ SEAT RIDE HEIGHT LUMBAR ADJUSTMENT Push switch up to inflate FORES AFT ISOLATOR Push down to deflate Move to left and slide ir ition seat to desired positio pani Peterbilt Ultraride II Highback Air Seat 45 Seats Operating Instructions seat belt and your riders belts fastened Riding The right and left seats are equipped with 3 point lap shoul without a safety belt which is properly fastened der belts the center seat has a 2 point seat belt Safety belts can lead to incre
242. uminates when either power steer ing fluid flow is interrupted or when a pressure differential is present in the primary and secondary brake fluid pressure Either case adversely affects braking operation Differential Switch measures the hydraulic fluid pressure difference between the primary and secondary circuits 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 90 Y53 6008 Operating Instructions Hydraulic Booster The hydraulic booster applies additional 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 Power Steering Gear assists the steering operation and sends pressurized power steering fluid to the brake booster Power Steering Pump draws power steering f
243. ut or worn out may not protect you in an accident Y53 6008 Medium Duty R10 06 Operating Instructions Seats 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 Page 197 Pregnant Woman with Belt Properly Worn Medium Duty R10 06 Y53 6008 53 Steering Column and Mirrors STEERING COLUMN AND MIRRORS Introduction This section covers the standard steering column controls and mirror operation Depending on how your Medium Duty is configured some or all of these features are installed on your vehicle Turn Signal High Beam Switch NOTE The ignition key must be turned to IGN amp Li ACC for the signal switch to operate The lever action turn signal high beam switch is located on the left side of the steering column Turn Signals To signal a right turn push the lever up clockwise To signal a left turn push the lever down counterclock wise B54 Y53 6008 Operating Instructions TRAILER BRAKE VALVE TURN SIGNAL HIGH BEAM SWITCH EMERGENCY FLASHER 02596 Steering Column Controls High Beam NOTE The headlights must be ON for the high n beam switch to operate To switch your headlights to lower or higher beam push and release the button on the end of the turn signal stalk
244. ve Maintenance Automatic Transmissions Service Intervals Check daily with engine idling See Table 2 Recommended Maintenance Intervals Page 120 for service intervals Transmission and Clutch 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 11 Transmission Lubrication Automatic transmissions RECOMMENDED MODEI LUBRICANTS ALLISON TranSynd Castrol AMBIENT TEMPERATURE RANGE VISCOSITY SAE DEG C DEG F Above 23 Above 10 10W Medium Duty R10 06 Y53 6008 205 Steering and Driveline 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 steering system is not working properly You could lose control of your vehicle if the steering system is not in good working condition which could result in a serious injury accident For driving safety visually check the steering gear and components
245. vehicle use the parking brakes Because ser vice brakes work with air pressure these brakes could slowly release Your vehicle could roll causing a serious accident Someone could be hurt or killed Never rely on the service brakes to hold a parked vehicle WARNING Do not use the trailer hand brake or 2 If you must park on a steep grade always block the wheels 02440 Blocked Wheels 113 Shut Down 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 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 shut ting it off You will greatly increase its service life Idle the engine at 1000 rpm for five minutes Then low idle for thirty seconds before shutdown This will allow circulating coolant and lubricating oil to carry away heat from the cylin der head valves pistons cylinder liners turbocharger and bearings This way you can prevent engine damage that may result from uneven cooling 114 Y53 6008 Operating Instructions
246. vic bones This can result in serious internal injuries Do not drive with your seat belt loose A seat belt could bring the belt up around your abdomen Do not twist the belt in the process of putting it on A twisted BEI WI nob Work AS Welo protect you that is too loose can allow you to fall too far forward WARNING Always wear your seat belt low over possibly causing head and neck injuries You could AN your pelvic bones strike the wheel or the windshield Adjust your belt so that there is no more than 1 in 25mm of slack 48 Y53 6008 Medium Duty R10 06 Operating Instructions AN AN WARNING Do not wear the shoulder belt under your arm or otherwise out of position In a crash your body would move too far forward increas ing the chance of head and neck injury Also the belt would apply too much force to the ribs which are not as strong as your shoulder bones and could cause you to suffer internal injuries Wear the shoulder belt over your shoulder see Safety Restraint Belts on page 46 WARNING Do not twist the belt in the process of putting it on A twisted belt will not work as well to protect you In a crash the full width of the belt would not be protecting you A twisted belt could cut into your body and cause serious inju ries 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 possibl
247. vice 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 km ANNUALLY 100 000 mi 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 Limiting Valve Single Check Valves Double Check Valves Stop Light Switch Low Pressure Wig Wag Low Pressure Switch Automatic Drain Valve Safety Valve Quick Release Valve Manual Drain Valve Medium Duty R10 06 Y53 6008 161 Air System Air System Function Test Scheduled maintenance should be performed on the Medium Duty air system as outlined in the Medium Duty Mainte nance Manual and Table 6 In addition perform an Air Sys tem 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 The supply tank or wet tank
248. wing Devices For Trucks and Tractors and 626 Heavy Duty Truck Towing Procedures Copies of these can be obtained from the following address mn NOTE For additional information concerning heavy The Maintenance Council American Trucking Association Inc 2200 Mill Rd Alexandria VA 22314 703 838 1763 Medium Duty R10 06 Operating Instructions Vehicle Recovery Guidelines Refer to the guidelines below when towing to prevent possi ble damage Use proper towing equipment to prevent damage to the vehicle 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 CAUTION Connect only to the towing provi Use a safety chain system Disconnect driveline Follow state provincial and local laws that apply to vehi cles in tow Do not tow vehicles at speeds in excess of 55 mph 90 km h The front tow hook has a maximum working load limit of 26 000 Ib 11 700 kg Medium Duty R10 06 Vehicle Recovery and Spring Brakes Recovery Rigging To connect to the Medium Duty attach the towing chain or cable to the tow hook through the access hole in the bumper TOW HOOK Y53 6008 Front Tow Hook Returning Vehicle to Service You will have to add lubricant to prevent damage
249. you to drink a cup of coffee your engine can cool as much as 60 F 33 C below normal operating temperature To keep the engine warm during a short break turn it off Do not allow your engine to idle longer than five minutes Engine Fan Switch Option Your Medium Duty 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 With the ignition key switch ON and the fan switch in the ON position the engine fan will be on regardless of engine temperature With the engine fan switch in the AUTOMATIC position the engine fan will automatically turn on when the engine coolant reaches a temperature of about 200 F 93 C Medium Duty R10 06 Operating Instructions Operating the Engine the engine running Anyone near the engine fan when it turns on could be seriously injured If it This feature improves fuel mileage and reduces driver is set at MANUAL the fan will turn on any time fatigue by maintaining a constant vehicle speed The the ignition key switch is turned to the ON posi cruise control will only operate above a programmed min tion In AUTO it could engage suddenly without imum vehicle speed 15 mph for the CAT 3126B engine warning Before turning on the ignition or 30 mph for the Cummins ISC engine switching from AUTO to MANUAL be sure no workers are near the fan WARNING Do not work on
250. your 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 Load the vehicle to its normal gross weight before tightening U bolts Loading the vehicle ensures proper adjustment of the U bolt and spring assembly 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 215 Rear Axle and Suspension 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 a serious injury accident 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 injury accident 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 H 216 Discovery of loose suspension fasteners Any tor
251. ystem All of the following areas are interrelated and must con form to original specifications wheel size e 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 155 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 153 Brake System Preventive Maintenance AN AN 154 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 injury accident 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 serious personal injury or damage to the vehicle Us

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