Peterbilt 210 Operator's Manual
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Peterbilt 210 Operator's Manual

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Summary of Contents for Peterbilt 210

  • Page 2: Table Of Contents

    Table of contents Why this handbook is so important! ........9 Warnings and Safety Regulations .
  • Page 3 Table of contents Dashboard ............38 Instrument panel .
  • Page 4 Table of contents Master Display ......77 General ............78 Layout of master display .
  • Page 5 Table of contents Overview of weekly checks ........99 Power steering fluid level .
  • Page 6 Table of contents Starting procedure..........116 Engine speed control .
  • Page 7 Table of contents Jacking up the rear axle ......... . 141 Changing the wheel.
  • Page 8 Table of contents Consumer Information ....171 Federal safety standard certification label ......172 Alphabetical index .
  • Page 9 Table of contents...

  • Page 10: Why This Handbook Is So Important

    WHY THIS HANDBOOK IS SO IMPORTANT! This handbook contains the information which you, the driver, will need for optimum efficiency, safety and comfort when operating this vehicle. Besides giving instructions about operation and use, it also pays attention to maintenance and minor repairs which you may be able to carry out yourself. NOTE This handbook is based on the chassis with its fittings as it originally left the factory.
  • Page 11 Important Make sure this handbook is in the vehicle at all times. Read it carefully before making your first journey, especially the "Warnings and safety precautions", "Cab, instruments and controls", "Inspections" and "Driving" sections.

  • Page 12: Warnings And Safety Regulations

    Warnings and Safety Regulations...

  • Page 13: Safety Alerts

    Warnings and Safety Regulations SAFETY ALERTS Please read and follow all of the safety alerts contained in this manual. They are there for your protection and information. These alerts can help you avoid injury to yourself, your passengers, and it can also help prevent costly damage to the vehicle.
  • Page 14 Warnings and Safety Regulations Cautions The safety alert following this symbol and signal word provides a caution against operating procedures which could cause equipment or property damage. The alert will identify the hazard, how to avoid it, and the probable consequence of not avoiding the hazard.

  • Page 15: Warnings And Safety Regulations

    Warnings and Safety Regulations WARNINGS AND SAFETY REGULATIONS WARNING To prevent damage to the vehicle and in order not to jeopardize your health and/or safety, or that of other people, the following warning and safety regulations must be strictly observed. First read the instructions and warnings on the labels and stickers on the various components and comply with them! They have been put there for your health and safety, so do not ignore them!
  • Page 16 Warnings and Safety Regulations Environmental Protection 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.

  • Page 17: Emergency Equipment

    Warnings and Safety Regulations Cooling system filler cap WARNING Do not remove the radiator fill cap while the engine is hot. Scalding steam and fluid under pressure may escape. You could be badly burned. Failure to comply may result in death or personal injury. EMERGENCY EQUIPMENT It is good practice to carry an emergency equipment kit in your vehicle.
  • Page 18 Warnings and Safety Regulations Fire extinguisher Ensure that you are always in possession of a fire extinguisher It should be well secured under the seat, within the driver's reach and easily accessible, also for rescue workers and others providing assistance. Have the fire extinguisher checked for operational readiness each year.
  • Page 19 Warnings and Safety Regulations Tire chains If you need tire chains, install them on both sides of each driving axle. CAUTION Chains on the tires of only one tandem axle can damage the driveline U-joints and the interaxle differential. Your repairs could be costly and time-consuming.
  • Page 20 Warnings and Safety Regulations WARNING Air conditioning refrigerant can be hazardous to your health. Do not expose yourself to leaking refrigerant for prolonged periods near excessive heat, open flames, or without proper ventilation. Failure to do so may result in death or personal injury. Maintenance activities When carrying out maintenance work under the cab, make sure the cab is fully tilted and locked to prevent it from falling back accidentally.
  • Page 21 Warnings and Safety Regulations WARNING Air conditioning refrigerant can be hazardous to your health. Do not expose yourself to leaking refrigerant for prolonged periods near excessive heat, open flames, or without proper ventilation. Failure to do so may result in death or personal injury or death. WARNING The air conditioning system is under pressure.

  • Page 22: Technical Items Of Special Importance

    Warnings and Safety Regulations TECHNICAL ITEMS OF SPECIAL IMPORTANCE To prevent damage to the vehicle, the following instructions must be strictly observed. Running-in During the running-in period it is best not to subject the new vehicle to excessive loads. This also applies when an overhauled engine, transmission or differential has been installed.
  • Page 23 Warnings and Safety Regulations Air leakage If the pressure in the air reservoirs drops rapidly with the engine switched off, this indicates a leak. Since this affects the safety of the brake system, the leak must be traced and repaired as quickly as possible. System voltage The cab system of this vehicle are on 24-Volt while other areas remain 12-Volt.
  • Page 24 Warnings and Safety Regulations Charging WARNING Thaw out frozen batteries before charging them. Remove all the filler caps before charging. WARNING Charger cables must be connected positive to positive (+ to +) and negative to negative (- to -). If connected improperly, batteries could explode.
  • Page 25 Warnings and Safety Regulations Battery terminals should not be coated with improper grease. Use petroleum jelly or commercially available, noncorrosive, nonconductive terminal coatings. Never use a fast charger as a booster to start the engine. This can seriously damage sensitive electronic components such as relays, radio, etc., as well as the battery charger.

  • Page 26: Jump Starting Vehicles

    Warnings and Safety Regulations JUMP STARTING VEHICLES Introduction Jump starting a vehicle is not a recommended practice due to the various battery installations and electrical options. 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.
  • Page 27 Warnings and Safety Regulations To Jump Start Your Vehicle WARNING When jump starting using a booster battery, it is best to jump start with an equivalently powered vehicle. Verify that the booster battery has the same volt and CCA specifications as the dead battery before attempting to jump start.
  • Page 28 Warnings and Safety Regulations Preparing the vehicles: 1 Remove any jewelry that may come in contact with the battery terminals. 2 Select a jumper cable that is long enough to attach to both vehicles in a way that ensures neither vehicle touches each other. 3 Position the two vehicles together, but do not allow them to touch.
  • Page 29 Warnings and Safety Regulations Connect the batteries: 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.
  • Page 30 Warnings and Safety Regulations Remove jumper cables: WARNING When disconnecting jumper cables, make sure they do not get caught in any moving parts in the engine compartment. Failure to comply may result in death, personal injury, equipment or property damage. Reverse the above procedure exactly when removing the jumper cables.
  • Page 31 Warnings and Safety Regulations Disconnect Switch This vehicle has a disconnect switch. Ensure that your vehicle ignition has been turned off for at least 40 seconds before switching the disconnect switch to the OFF position NOTE Wait 2 minutes after key-off before disconnecting battery power. Disconnecting battery power sooner can result in damage to vehicle DEF.

  • Page 32: Cab, Instruments And Controls

    Cab, Instruments and Controls...

  • Page 33: Entering And Leaving The Vehicle

    Cab, Instruments and Controls ENTERING AND LEAVING THE VEHICLE WARNING Always reinstall steps before entering the cab or accessing the deck plate. Without steps you could slip and fall. Be careful whenever you get into or out of your vehicle's cab. Always maintain at least three points of contact with your hands on the grab handles and your feet on the steps.

  • Page 34: Doors

    Cab, Instruments and Controls DOORS WARNING To help lessen the chance and/or severity of death or personal injury in case of an accident, always lock the doors while driving. Along with using the lap shoulder belts properly, locking the doors helps prevent doors from inadvertently opening and occupants from being ejected from the vehicle.

  • Page 35: Electrically Operated Windows

    Cab, Instruments and Controls Central door locking Unlocking To open the doors of a vehicle with central door locking, use the same procedure described before. The door on the co-driver's side can be locked/unlocked using the switch on the center console. Locking Both doors are locked when one of the doors is closed with the key.

  • Page 36: Mirrors

    Cab, Instruments and Controls MIRRORS The mirror housing and mounting bracket is fixed to the cab. Only the face of the mirror is adjustable within the mirror housing. The mirror bracket can be folded back against the cab and will return to its original position once the bracket is swung out again.

  • Page 37: Roof Console

    Cab, Instruments and Controls ROOF CONSOLE WARNING Overhead compartments are not intended for personnel use or for items exceeding their designed weight limits. Exceeding the weight limits may cause the shelf to collapse and or items may fall out in a sudden stop which may lead to personal injury or death.

  • Page 38: Interior Lighting

    Cab, Instruments and Controls INTERIOR LIGHTING The interior lighting operates independently of the position of the contact key. The interior light comes on when the door is opened. When the doors are open for more than 15 minutes, the interior lamps will be extinguished. The lamp stays lit by operating the switch on the lamp.

  • Page 39: Dashboard

    Cab, Instruments and Controls DASHBOARD 3 4 5 6 10 11 12 13 14 15 16 D001183...
  • Page 40 Cab, Instruments and Controls Instrument panel Dimmer, dashboard lighting (unused) (unused) Front fog lamps Menu selection switch Ashtray with 12V auxiliary socket Hazard warning lights (unused) (unused) (unused) (unused) (unused) (unused) PTO operation (unused) Air conditioning 12V connection Heater, fan speed selector switch in fresh air position or re-circulation position Heater, temperature control Heater, air distribution selector switch...

  • Page 41: Instrument Panel

    Cab, Instruments and Controls INSTRUMENT PANEL STOP DIESEL EXHAUST FLUID D001198-1...
  • Page 42 Cab, Instruments and Controls Speedometer Fuel gauge Master display Coolant temperature gauge Tachometer Reset button, trip odometer Odometer and trip meter Warning indicators Diesel exhaust fluid Circuit 1 Outside temperature and clock...
  • Page 43 Cab, Instruments and Controls A. SPEEDOMETER This vehicle’s speedometer is equipped with double scale divisions. Either major divisions in mph and minor divisions in kph or major divisions in kph and minor divisions in mph. B. FUEL GAUGE The fuel gauge only operates when the contact is on. Factor in the delay on the gauge when the contact is turned on.
  • Page 44 Cab, Instruments and Controls E. REV COUNTER Green area: economical White: less economical Blue area: only permitted when driving downhill and for optimal use of the engine brake Red area: not permitted F. TRIP METER RESET BUTTON The trip meter is set to zero with the reset button. G.
  • Page 45 Cab, Instruments and Controls J. AIR PRESSURE GAUGE, CIRCUITS 1 The air pressure gauge indicates the air pressure in the reservoirs of one of the service brake circuits. If the pressure in one of the circuits drops below 65 psi (448.15 kPa), an audible alarm is generated and the warning symbol "Air system pressure too low"...

  • Page 46: Warning Indicators

    Cab, Instruments and Controls WARNING INDICATORS STOP D0 00 786-1...
  • Page 47 Cab, Instruments and Controls Tachograph Front fog lights Parking brake Water in fuel Work lamp/loadspace lighting ABS symbol Fuel level low Engine warning Pre-Heating PTO engaged DEF level Left direction indicator, truck or tractor Main beam Central "STOP" warning indicator Right direction indicator, truck or tractor Brake air...
  • Page 48 Cab, Instruments and Controls A1. Tachograph fault See messages in Tachograph operation manual. A2. Front fog lights This warning indicator lights up if the front fog lights are switched on. A3. (unused) A4. Parking brake This warning indicator lights up if the parking brake is applied, or when the pressure in the air system is too low to enable the parking brake to be released.
  • Page 49 Cab, Instruments and Controls A7. ABS The yellow warning symbol "ABS truck fault" is activated if a fault in the ABS system of the truck or tractor. B1. Fuel level low This warning indicator lights up when the reserve fuel level is reached. The fuel reserve then is about 10% of the tank capacity.
  • Page 50 Cab, Instruments and Controls E4. (unused) E5. PTO engaged This warning indicator lights up when the PTO is switched on. E6. DEF level This warning will be activated if DEF level is lower than 10%. H1. Left direction indicator, truck or tractor This warning indicator flashes together with the direction indicators on the truck or tractor.
  • Page 51 Cab, Instruments and Controls H4. Central "STOP" warning indicator The central "STOP" warning lights up when there is a serious fault in one of the STOP vehicle functions. The master display shows which vehicle function has triggered the warning. WARNING This should be considered an emergency.

  • Page 52: Control Panel

    Cab, Instruments and Controls CONTROL PANEL 21 20 19 18 17 D0 00 705-1...
  • Page 53 Cab, Instruments and Controls Dimmer, dashboard lighting (unused) (unused) Front fog lights Master display menu selection switch Air conditioning 12-V connection Heater, fan speed selector switch in fresh air position or re-circulation position Heater, temperature control Heater, air distribution selector switch Lighting switch...
  • Page 54 Cab, Instruments and Controls 2. DIMMER, DASHBOARD LIGHTING When the lighting is switched on, the dashboard lighting will also illuminate. The setting wheel enables dimming of the lighting. 3. SWITCH FOR CROSS-AXLE DIFFERENTIAL LOCK The cross-axle differential lock can be activated with this switch. NOTE This switch has a lock.
  • Page 55 Cab, Instruments and Controls 5. FOG LAMPS, FRONT There is a two position switch to operate the rear fog lamps. 6. MASTER DISPLAY MENU SELECTION SWITCH See "MASTER DISPLAY". 17. AIR CONDITIONING See "CONTROL PANEL OF HEATING/VENTILATION SYSTEM" 18. 12V CONNECTION There are two auxiliary connections for a 12-V accessory.
  • Page 56 Cab, Instruments and Controls 23. LIGHTING SWITCH The vehicle lighting switch is a rotary switch with three positions: position "0": lighting switched off position "1": parking and marker lights on position "2": headlamps, parking and marker lights on...

  • Page 57: Control Panel Of Heating/Ventilation System

    Cab, Instruments and Controls CONTROL PANEL OF HEATING/VENTILATION SYSTEM D0 00 672 Air conditioning Fan speed selector switch in fresh air or re-circulation position Temperature adjustment Air distribution 17. AIR CONDITIONING See "AIR CONDITIONING SWITCH" 19. FAN SPEED See "FAN SPEED SELECTOR SWITCH" 20.

  • Page 58: Air Conditioning Switch

    Cab, Instruments and Controls AIR CONDITIONING SWITCH The cab air can be heated, cooled or dehumidified using the air conditioning unit. The air conditioning unit only functions if: the engine is running the fan is running. Use of the air conditioning D0 00 566 D0 00 566 1.
  • Page 59 Cab, Instruments and Controls Cooling 1. Switch the air conditioning on. 2. Switch the recirculation to position 1, 2 or 3. 3. Turn the temperature control switch to the desired position. For maximum cooling set the knob to the far left position in the blue area. 4.
  • Page 60 Cab, Instruments and Controls WARNING Excessive heat may cause the pressurized components of the air conditioning system to explode. Never weld, solder, steam clean, or use a blow torch near any part of the air conditioning system. Failure to comply may result in personal injury, death, equipment or property damage.

  • Page 61: Fan Speed Selector Switch

    Cab, Instruments and Controls FAN SPEED SELECTOR SWITCH FRESH AIR POSITION OR RE-CIRCULATION POSITION The fan has two speeds: one applies to re-circulation the other to fresh air. The re- circulation position is suited to quickly de-mist or cool the cab with the air conditioning, quickly heat the cab, de-frost the windows with the heater and keep out undesirable odors.

  • Page 62: Air Distribution Selector Switch

    Cab, Instruments and Controls AIR DISTRIBUTION SELECTOR SWITCH Dashboard D0 00 640 Dashboard vents and footwell D0 00 639 Footwell vent D0 00 638 Footwell and windshield vents D0 00 643 D0 00 637 Defrost...

  • Page 63: Center Console

    Cab, Instruments and Controls CENTER CONSOLE 11 12 13 14 15 16 D000706-3...
  • Page 64 Cab, Instruments and Controls Ashtray with 12V auxiliary connection Hazard warning lights (unused) (unused) (unused) (unused) (unused) (unused) PTO operation (unused)
  • Page 65 Cab, Instruments and Controls 7. ASHTRAY In the center console there is an ashtray with auxiliary connection for the driver and co-driver. Do not connect any accessories above 180 Watt or any combination of accessories that would require a combined amount greater than 180 Watts. To remove the ashtray, there are two springs on the top of the tray which should be pressed in, after which the tray can be removed.

  • Page 66: Left-Hand Steering Column Switch

    Cab, Instruments and Controls LEFT-HAND STEERING COLUMN SWITCH Horn Main beam Direction indicator, right Direction indicator, left A. HORN The horn is operated with button A. D0 00 600 B. MAIN BEAM Position B: The main beam is activated when the lights are on. The main beam indicator on the instrument panel will also light up.

  • Page 67: Right-Hand Steering Column Switch

    Cab, Instruments and Controls RIGHT-HAND STEERING COLUMN SWITCH The right-hand steering column switch has the following functions: Position 1: Intermittent wipe. Position 2: Wipe speed (low). Position 3: Wipe speed (high). Position A: Wipe/wash. D001199...

  • Page 68: Steering Wheel Switches

    Cab, Instruments and Controls STEERING WHEEL SWITCHES Depending on the vehicle version, the steering wheel either has or does not have steering wheel switches. Left-hand switches A (unused) D0 01 190-3 B (unused) C Engine brake Right-hand switches D Variable speed limiter E Cruise control, resume, off F Cruise control setting/engine speed control...

  • Page 69: Adjustable Steering Column

    Cab, Instruments and Controls ADJUSTABLE STEERING COLUMN The position of the steering column is adjustable. To adjust, pull the handle towards you and simultaneously move the steering column to the desired position. The steering column is locked by releasing the handle. A pneumatically adjustable steering column is available as an option.

  • Page 70: Seats

    Seats...

  • Page 71: Important Points

    Seats IMPORTANT POINTS WARNING Make all adjustments to the steering mechanism while the vehicle is stopped. Adjusting the Tilt-Telescoping Steering Wheel while the vehicle is in motion could cause loss of control. You wouldn't be able to steer properly and could have an accident resulting in death or personal injury.
  • Page 72 Seats Driver's seat Operation: Seat fore/aft adjustment Shock absorber setting: The suspension characteristics of the seat (in terms of comfort) can be optimized by means of the infinitely adjustable shock absorber (from "hard" to "soft") for each driving situation. Position switch up: minimum damping ("soft" comfort) Position switch down: maximum damping ("hard"...

  • Page 73: Seat Belts

    Seats SEAT BELTS Safety Restraint System - Inspection The seat belt system, including webbing, buckles, latches, and mounting hardware, endures heavy use in heavy-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.
  • Page 74 Seats Due to these factors, the three-point safety belt system installed in your vehicle requires thorough inspection every 20,000 miles (32,000 km). If the vehicle is exposed to severe environmental or working conditions, more frequent inspections may be necessary. Any seat belt system that shows cuts, fraying, 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 obvious problem should be replaced immediately, regardless of mileage.
  • Page 75 Seats 1. Check the web wear in the system. The webbing must be closely examined to determine if it is coming into contact with any sharp or rough surfaces on the seat or other parts of the cab interior. These areas are typical places where the web will experience cutting or abrasion.
  • Page 76 Seats Seat Belt Inspection Points 1. Web cut or frayed or extremely worn at latch area. 2. Web cut or frayed at D-loop web guide. 3. Comfort Clip cracked or damaged. 4. Buckle casting broken. 5. Retractor Web Storage for damage. (located behind trim panel) 6.
  • Page 77 Seats Wearing seat belts The belt must be tight against the body and not distorted. With a three-point type belt, the shoulder section must be across center of the shoulder, not against the neck. The pelvis section should be as low as possible across the pelvis, not across the abdomen.

  • Page 78: Master Display

    Master Display...

  • Page 79: General

    Master Display GENERAL In the master display a menu can be displayed to show the driver all the information regarding the function and operation of the various systems in as useful a way as possible. The master display is a part of the Central Warning System. In addition, the system contains a menu selection switch, a buzzer and a central "STOP"...

  • Page 80: Layout Of Master Display

    Master Display LAYOUT OF MASTER DISPLAY D001192-3 Indication bar Information screen (yellow and red) Information screen (yellow) Number of active red warnings Number of active yellow warnings Alarm function engaged Gear engaged, AS Tronic Lite or automatic gearbox (AGC-A) Speed set Vehicle speed setting functions (review) (unused)

  • Page 81: Start-Up Phase

    Master Display START-UP PHASE If the ignition has been switched on and the engine is not yet running, the start-up screen is shown in the master display. The following warning symbols, if present, are then displayed: Oil pressure (red) Alternator voltage (red) Steering circuit 1 output (red) ABS of prime mover (yellow) NOTE...
  • Page 82 Master Display If there is a less serious fault, the respective yellow symbol with the accompanying text will appear on the screen and an acoustic signal will be heard for a certain time. If the indication bar mentions several red and/or yellow warnings, the other warnings can be called up by turning the menu selector switch one step further each time.

  • Page 83: Menu Selector Switch

    Master Display MENU SELECTOR SWITCH By pressing the menu selector switch, the main menu will be selected and the selector bar will become visible. Turning the menu selector switch will switch between screens in the main menu. The triangle on the right-hand side of the display shows the direction in which you can proceed.
  • Page 84 Master Display By turning the menu selector switch, sub-menu 2 can be accessed. The triangle on the right-hand side of the display shows the direction in which you can proceed. By pressing the menu selector switch, the menu function will be switched off. D000556...

  • Page 85: Menu Overview

    Master Display MENU OVERVIEW Main menu Sub-menu 1 Sub-menu 2 Vehicle information Fuel consumption Current Average Average trip Turbocharger pressure Oil level Service inspection Date Distance PTO counter PTO 1 counter PTO consumption Chassis number Back Faults All faults Back...
  • Page 86 Master Display Main menu Sub-menu 1 Sub-menu 2 Trip info Trip info Distance Time Average speed Average consumption Fuel consumption Trip reset Close Settings Language 1 or 2 Alarm on/off Setting alarm Setting alarm: hours Setting alarm: minutes Alarm time Time, local/home Set local time Clock AM/PM/24H...

  • Page 87: Faults

    Master Display FAULTS Serious fault A red warning symbol is activated when there is a serious fault. When a red warning symbol is activated, the "STOP" warning lamp and an audible alarm are activated at the same time. WARNING This should be considered an emergency. You should stop the vehicle as safely as possible and turn OFF the ignition.

  • Page 88: Warning Symbols

    Master Display WARNING SYMBOLS Red warnings Oil pressure low If the oil pressure suddenly drops, or the audible alarm and engine oil pressure warning light come on while driving, do the following: 1. Slow down carefully. 2. Move a safe distance off the road and stop. 3.
  • Page 89 Master Display Cab lock open See "Cab tilting" in "EMERGENCY REPAIRS". Air pressure low This warning symbol is active when the pressure in one of the service brake circuits is lower than 65 psi or 4.48 bar. Coolant Level Low This warning symbol will come on when the coolant level is below the minimum permissible level.
  • Page 90 Master Display Yellow warnings Truck ABS fault This symbol is activated when: there is a fault in the ABS of the prime mover; Engine fault Depending on the fault, the engine can switch over to emergency control. PTO fault Engine speed control does not meet the conditions. See "Engine speed control" in "DRIVING".
  • Page 91 Master Display No warning Coolant level sensor This symbol will light up if the coolant level sensor is not latched into it proper position. The sensor is part of the filler cap. Key to abbreviations Anti-lock Braking System Power Take Off Vehicle Intelligence Center...

  • Page 92: Inspections And Maintenance

    Inspections and Maintenance...

  • Page 93: Overview Of Daily Checks

    Inspections and Maintenance OVERVIEW OF DAILY CHECKS Overview of the driver's daily checks: engine oil level coolant level, fill cap secure fluid level in windshield washer reservoir air filter indicator tires and rims lighting and instruments driver's seat and mirrors trailer Visual check before starting the trip: check that no situation can occur (such as loose objects, improperly attached...

  • Page 94: Engine Oil Level

    Inspections and Maintenance ENGINE OIL LEVEL 1. Ensure that the vehicle is standing on a flat and level surface. 2. Open the front panel. 3. Pull the dipstick (2) out of the holder. 4. Wipe the dipstick clean with a lint-free cloth. 5.

  • Page 95: Topping Up Coolant

    Inspections and Maintenance TOPPING UP COOLANT WARNING When the coolant is hot, there is an overpressure in the cooling system. If circumstances dictate that it is necessary to top up the coolant when the engine is warm, unscrew the filler cap carefully one turn to relieve the overpressure.
  • Page 96 Inspections and Maintenance 1. Turn the rotary knob for the heating temperature control to "maximum hot". 2. Open the front panel. 3. Remove the black filler cap from the cooling system reservoir. 4. Run the engine for several minutes. 5. Stop the engine and check the coolant level. 6.

  • Page 97: Special Coolant Fill Instructions

    Inspections and Maintenance SPECIAL COOLANT FILL INSTRUCTIONS CAUTION RADIATOR FILL PROCEDURE REQUIRED FOR THIS VEHICLE 1. Remove the surge tank pressure cap (do not remove the surge tank coolant level sensor cap). 2. Fill system with premixed coolant to “MAX” level on surge tank and allow coolant level to settle.

  • Page 98: Windshield Washer Reservoir Fluid Level

    Inspections and Maintenance WINDSHIELD WASHER RESERVOIR FLUID LEVEL 1. Open the front panel. 2. Check the fluid level in the screen washer reservoir. 3. Top up, if necessary, via the filler opening. NOTE When topping up, it is recommended to add a windshield cleaner to the water in the windshield washer reservoir.

  • Page 99: Wheels And Tires

    Inspections and Maintenance WHEELS AND TIRES Remove any stones, etc. from the tread and from between the tires (if twin wheels are fitted). Check for evidence of wear and damage and for nails or other foreign objects caught in the tires. Check the attachment of the wheels.

  • Page 100: Driver's Seat And Mirrors

    Inspections and Maintenance DRIVER'S SEAT AND MIRRORS Set the seat and mirrors to the correct positions. Mirrors with field of vision projected on the ground Side window Dead angle mirror Wide view mirror Main mirror Pavement mirror D0 01 062 OVERVIEW OF WEEKLY CHECKS Overview of the driver's weekly checks: clutch fluid level...

  • Page 101: Power Steering Fluid Level

    Inspections and Maintenance POWER STEERING FLUID LEVEL 1. Tilt the cab. 2. Clean the dipstick and its immediate surroundings to prevent any dirt from entering the reservoir. 3. Check the fluid level in the reservoir using the dipstick. 4. The fluid level must be between the two marks. 5.

  • Page 102: Draining The Water Separator

    Inspections and Maintenance DRAINING THE WATER SEPARATOR WARNING When draining the water separator, an amount of fuel will escape. Collect the fuel and avoid the risk of fire. Water in the fuel system may lead to significant damage. 1. Place a container beneath the water separator. 2.

  • Page 103: Batteries

    Inspections and Maintenance BATTERIES WARNING Avoid sparks and open flames in the vicinity of batteries. Battery acid is an aggressive fluid. In the event of contact with the skin: rinse the skin profusely with plenty of water. Consult a doctor in the event of persistent redness or pain. Remove polluted clothing and rinse in water.

  • Page 104: General Maintenance

    Inspections and Maintenance GENERAL MAINTENANCE The durability, safety, trade-in value and reliability of your vehicle largely depend on the care you give it. This includes regular service in accordance with the maintenance schedules specified. The driving style of the person at the wheel and the care given to the vehicle will have a direct influence on the condition of the vehicle.

  • Page 105: Cleaning

    Inspections and Maintenance CLEANING Cleaning the vehicle Before the vehicle is cleaned, check for leaks in the engine, axles, gearbox, etc. This is no longer possible after cleaning the vehicle and carrying out maintenance work. When a high-pressure cleaner is used, take special note of the following points: Make sure that the doors, windows and roof hatch are properly closed.
  • Page 106 Inspections and Maintenance The engine and engine compartments can be cleaned with a high-pressure/ steam cleaner. Avoid spraying directly onto electrical components such as the fuel system pump units, electronic units the starter motor, alternator, air-conditioning compressor, headlights, etc. Carefully clean the engine encapsulation and its fittings. Remove any spilled oil and diesel oil to avoid the risk of fire.
  • Page 107 Inspections and Maintenance Waxing the cab The paintwork of new vehicles is waxed to protect it against the elements. After a time this wax coating will gradually wear away as a result of cleaning and other external influences. To give corrosive substances less chance of attacking the paint, it is advisable to protect the paintwork with a new wax coating at least twice a year.

  • Page 108: Preventative Maintenance Before The Winter Season

    Inspections and Maintenance PREVENTATIVE MAINTENANCE BEFORE THE WINTER SEASON Your authorized Service dealer can always give you good advice to prepare your vehicle for winter. DIESEL FUEL If outside temperatures are persistently low, only fill up with winter diesel oil produced by a reputable oil company.

  • Page 109: Cab Heater

    Inspections and Maintenance CAB HEATER If necessary, install a separate fuel tank for the cab heater. If the tank has been filled up with winter diesel oil because of a cold weather period or a trip to a colder country, allow the cab heater to run on the new fuel for half an hour to ensure that all the old fuel has been used up.

  • Page 110: Pdc & Voltage Converter

    PDC & Voltage Converter...

  • Page 111: Power Distribution Center

    PDC & Voltage Converter POWER DISTRIBUTION CENTER Power Distribution Center (PDC) The PDC provides a fused 24V/12v to the cab and controls 12V to chassis systems, inside of the box and relays 12V to chassis and cab systems. PDC box has the following Specifications: 400 amps max output D0 02 012 64 I/O pins (color coded)
  • Page 112 PDC & Voltage Converter Voltage converter. The Voltage converter provides 24V to cab systems. It is located in the battery box. Below to the PDC support. The Voltage converter has the following Specifications: 12V input - 24V output Input current: 90 amps Output current: 45 amps Temperature range: -40C to+85C D0 02 013...
  • Page 113 PDC & Voltage Converter...

  • Page 114: Driving

    Driving...

  • Page 115: General

    Driving GENERAL Before setting out on a journey, always check: vehicle for possible water or oil leaks engine oil level fluid level in the screen washer reservoir air filter indicator coolant level drawn vehicle coupling for correct attachment and correct operation connection and operation of the drawn vehicle lighting and brakes wheel attachment and tire pressures tread depth of tires...

  • Page 116: Steering Lock/Contact/Starter Switch

    Driving STEERING LOCK/CONTACT/STARTER SWITCH WARNING NEVER turn the ignition key to the rest position (0) or remove it while the vehicle is in motion. This may cause the steering wheel lock to engage. Position 0: rest position When the key is removed in this position the steering wheel can be locked. If the steering wheel is turned slightly the steering wheel will lock.

  • Page 117: Starting Procedure

    Driving STARTING PROCEDURE WARNING If you start the engine inside a building, open the doors fully to ensure adequate ventilation. Exhaust gases contain carbon monoxide, an invisible, odorless, but highly toxic gas. Inhalation of these gases may cause unconsciousness and death. 1.

  • Page 118: Engine Speed Control

    Driving NOTE Depending on the coolant temperature measured by the electronic unit, it is possible that, in extremely cold conditions, the maximum engine speed is limited for a specific period of time. In case of an optional engine speed control, one of various engine speeds can be selected with the right-hand steering column switch, if so desired.
  • Page 119 Driving NOTE If the engine speed control is active, the engine brake is deactivated. NOTE Depending on how the electronic unit is programmed, the accelerator pedal is active or not. When speed is increased via the accelerator pedal, the speed reduces to the set speed value once the accelerator pedal is released.

  • Page 120: Cruise Control

    Driving CRUISE CONTROL Cruise control is a facility that can be used to have the vehicle maintain a constant vehicle speed. The desired driving speed is set, and the electronics maintain this speed. The driver can overrule the cruise control at any time by pushing the accelerator pedal.
  • Page 121 Driving Disengaging conditions When the cruise control has been engaged, there are various conditions on which it disengages. Cruise control is deactivated when: - vehicle speed is outside the programmed limit values. - parking brake is operated. 3 2 1 - clutch is operated.
  • Page 122 Driving Accelerator pedal function during cruise control When cruise control is active, the vehicle speed can be increased above the control speed using the accelerator pedal. When the accelerator pedal is released, the vehicle speed will return to the last valid control speed. Disengaging cruise control 3 2 1 Press the 'OFF' switch (2) on the steering wheel to deactivate cruise control.

  • Page 123: Vehicle Speed Limitation For Special Applications

    Driving VEHICLE SPEED LIMITATION FOR SPECIAL APPLICATIONS Speed limitation for special applications consists of a switch which is fitted on the vehicle superstructure. With this switch, the vehicle speed can be limited to a pre- programmed value. The programmed value can be modified by an authorized Service dealer on request.

  • Page 124: Steering

    Driving STEERING The steering gear is hydraulically assisted. As excessive pressure may damage the hydraulic pump, stop turning the steering wheel when the wheels are at full lock or are blocked by an obstacle. The steering gear may be damaged, if this is ignored. ABS BRAKES The ABS system is an Anti-lock Braking System.
  • Page 125 Driving WARNING Do not adapt your driving style to the ABS system! Above all, do not brake later and then harder. This only causes unnecessary tire wear. It may also be hazardous for other road users. NOTE Occasionally, but not always, your braking distance will be shorter with ABS.

  • Page 126: Parking Brake And Service Brake

    Driving PARKING BRAKE AND SERVICE BRAKE WARNING Always apply the parking brake when parking the vehicle. Do not release the parking brake while the steering lock is still engaged. The vehicle cannot be steered if the steering lock is still engaged. The service brake is operated by the foot pedal.

  • Page 127: Engine Brake

    Driving ENGINE BRAKE The engine brake is primarily intended for prolonged braking, for example when decelerating from high speed on a level road or when driving downhill. This reduces service brake wear. The engine brake is activated by operating steering wheel switch (C). NOTE -The engine cannot be switched off with the engine brake.

  • Page 128: Stopping

    Driving WARNING If the ABS/ASR control is activated, the engine brake will be switched off as long as the control is in operation. On vehicles where the ABS/ASR control fails to function or on vehicles not equipped with ABS/ASR, use of the engine brake may lead to the risk of skidding on slippery surfaces.
  • Page 129 Driving If the tractor-trailer does not remain in place in the test position, find a flatter place to park the vehicle. Always carry out this test if the vehicle is parked in unfavourable circumstances (gradient, slippery road surface, etc.). In this way, the tractor-trailer will remain safely parked, even if air leakage should make the drawn vehicle brakes ineffective.

  • Page 130: Automatic Gearbox

    Automatic Gearbox...

  • Page 131: Allison 2100 Series

    Automatic Gearbox ALLISON 2100 SERIES General The automatic gearbox is fully electronically controlled. The automatic gearbox has 5 forward gears and 1 reverse gear. The automatic gearbox is operated by a selector lever. The selector lever is located next to the driver's seat. Shifting gears The various gears are selected with the selector lever.
  • Page 132 Automatic Gearbox Faults If the transmission fault warning symbol lights up in the master display, a fault has been detected in the gearbox. Read the following recommendations first or consult an authorized dealer if necessary. Gearbox The ECU will block the functions of the selector lever and ensure that the gearbox will select a "safe gear".
  • Page 133 Automatic Gearbox Gearbox The ECU will block the functions of the selector and the gearbox will select a "safe gear" for the gearbox. It is important to drive the vehicle to a safe place as soon as possible and turn the contact off. It will no longer be possible to shift the gearbox to neutral.

  • Page 134: Emergency Repairs

    Emergency Repairs...

  • Page 135: Tilting The Cab

    Emergency Repairs TILTING THE CAB General WARNING Make sure that the filler caps of the cooling system, the hydraulic clutch and the windshield washer reservoir are tightened. Do not loosen the filler caps when the cab is tilted. WARNING Only tilt the cab when the engine has stopped. WARNING Make sure there is sufficient clearance around the cab.
  • Page 136 Emergency Repairs WARNING Make sure that there is no one in the cab. Also make sure there are no loose objects inside the cab; this includes objects in the refrigerator. Make sure there are no people immediately in front of the cab.
  • Page 137 Emergency Repairs Tilting forward Apply the parking brake. Put the gear lever in "neutral" position. Close the doors. Turn the lever fully to the right, against the spring pressure, until it is locked in  position ; use the jack rod. Operate the pump so that the cab tilts forward.

  • Page 138: Replacing The Poly-V Belt

    Emergency Repairs REPLACING THE POLY-V BELT Important Always fit the same type of poly-V-belt as the one being replaced. 1. Disconnect the earth lead from the battery. 2. Place a ratchet (A) with a 3/8" socket in the arm of the automatic belt tensioner (B).

  • Page 139: Replacing The Fuel Fine Filter

    Emergency Repairs REPLACING THE FUEL FINE FILTER WARNING When removing the fuel fine filter, a quantity of fuel will escape. Collect the fuel and avoid the risk of fire. Dirt in the fuel system can lead to significant damage to the fuel system.

  • Page 140: Draining The Water Separator

    Emergency Repairs Fitting the fuel filter 1. Lightly lubricate the sealing ring (see arrow in illustration) with clean engine oil (not diesel fuel). 2. Fit the filter unfilled until the sealing ring abuts and manually rotate it a ½ to ¾ turn further.

  • Page 141: Releasing The Parking Brake

    Emergency Repairs RELEASING THE PARKING BRAKE WARNING Never release the parking brake on an incline. 1. Place wheel chocks in front of and behind the wheels. 2. Turn the release bolt counter-clockwise as far as the stop using a ring spanner. 3.

  • Page 142: Jacking Up The Rear Axle

    Emergency Repairs JACKING UP THE REAR AXLE When jacking up the rear axle, the jack should always be positioned under the jacking point at the bottom of the spring bracket. WARNING Always use stands to support the chassis when carrying out repairs or service under a vehicle which is resting on a jack.

  • Page 143: Changing The Wheel

    Emergency Repairs CHANGING THE WHEEL NOTE After changing a wheel/tire, the difference between the diameters of the various tires on the vehicle may have become too large (for example, as a result of differences in tread depth and/or tire pressure). WARNING The ABS system cannot cope with too great a difference in tire diameter and the system will automatically be disengaged.
  • Page 144 Emergency Repairs General Only use the original tire wheel rims specified for the vehicle concerned. Make sure that tires of the same type are fitted on both sides of the axle. Insufficient cleaning of the mating surfaces and/or uneven tightening of the wheel nuts may cause vibrations during driving or braking.
  • Page 145 Emergency Repairs 2. Apply a thin layer of grease to the fitting edge of the wheel hub. 3. Also apply a thin layer of grease to the fitting edge of the wheel rim. This grease layer should prevent the wheel rim and the wheel hub from becoming "rust- bound".
  • Page 146 Emergency Repairs NOTE Wheel nuts should always be tightened and retightened in cold condition. However, tightening wheel studs in extreme cold should be avoided. 8. Check the tire pressure. 9. Retorque the wheel nuts after 100 km (62 miles). If new wheel studs are fitted, they need additional retorquing after 500 km (31 miles).

  • Page 147: Tire Inflating Connection

    Emergency Repairs TIRE INFLATING CONNECTION Next to the brake system air dryer to the left rear of the cab there is a tire inflating connection. 1. Remove the rubber protective cap from the tire inflating connection. 2. Connect the tire inflating hose. 3.

  • Page 148: Towing

    Emergency Repairs TOWING It is possible to install a towing eye behind the grille. Always use a towing bar when towing. Departure from this rule is only allowed in emergencies. When towing, the fault message "Engine management fault" may appear in the master display when the ignition is turned on.
  • Page 149 Emergency Repairs WARNING The towed vehicle can be located asymmetrically (left or right) behind the tractor. Towing may not take place at an angle larger than 20ð with the vehicle centerline. To clear the towing eyes, the black grid must be removed from the lower grille by turning the attachment screws a quarter turn.

  • Page 150: Replacing Bulbs

    Emergency Repairs REPLACING BULBS Do not touch the glass of the halogen lamps with bare fingers. If necessary, this glass can be cleaned with a cloth, which has been dampened with industrial alcohol (methylated spirits). When fitting a new bulb, make sure that the lugs on the bulb holder engage in the slots of the reflector.
  • Page 151 Emergency Repairs Direction indicator 1. Tilt the cab forwards. 2. Detach the plug from the rear of the bulb holder (3). 3. Screw the bulb holder anti-clockwise out of the headlamp unit. 4. Pull the bulb carefully out of the bulb holder. Rear lights 1.
  • Page 152 Emergency Repairs Stepwell lighting 1. Remove the stepwell lighting housing from the bottom of the door by inserting a screwdriver in the notch. 2. If necessary, remove the plug. 3. Unscrew the bulb holder anti-clockwise out of the stepwell lighting housing. 4.

  • Page 153: Fuses And Relays

    Emergency Repairs FUSES AND RELAYS WARNING To prevent overload and the risk of fire you must NEVER replace a burnt-out fuse with a fuse with a higher rating than specified. If a specific fuse repeatedly blows, this means there is a fault in the circuit, which MUST be inspected and remedied.
  • Page 154 Emergency Repairs Fuses E004 Fuse, driver’s side dipped beam E005 Fuse, co-driver’s side dipped beam E006 Fuse, driver’s side main beam E009 Fuse, rear fog lights E013 Fuse, stop lights E016 Fuse, reversing lights and cross-axle lock control E018 Fuse, G.O reverse lamp E019 Fuse, horn E023...
  • Page 155 Emergency Repairs Fuses E053 Fuse, diagnostic connector/ECAS E058 (unused) E062 Fuse, ECAS remote E091 Fuse, Mechanical clutch/air Orer E108 Fuse, VIC E114 Fuse, cab heater E142 Fuse, accessories unswitched power E143 Fuse, option / various/ ABS E144 Fuse, automatic gearbox AGC E145 Fuse, gear box E153...
  • Page 156 Emergency Repairs Fuses E282 (unused) E283 Fuse, side lights E284 Width marker light E285 Fuse, fog lights switch E286 (unused) E290 Fuse, customer adaptation cab E297 Fuse, airbag and seat belt tensioner system E299 (unused) E310 Fuse, instrument panel, DIP-4 E330 (unused) E349...
  • Page 157 Emergency Repairs...

  • Page 158: Technical Data And Identification

    Technical Data and Identification...

  • Page 159: Engine

    Technical Data and Identification ENGINE Type Model: KW: K270, K370 or PB:210, 220, PX6-2010 Engine Engine type B ENGINE Model EPA 10, water-cooled, four-stroke diesel engine with electronically controlled fuel injection system, 4 valves per cylinder and turbo-intercooling. Number of cylinders...

  • Page 160: Electrical System

    Technical Data and Identification ELECTRICAL SYSTEM Voltage 12/24 V Alternator 160 A / 14 V Batteries 700 / 1000 CCA Starter motor 3.3 Kw / 12 V Bulbs Dipped beam Left/right 12V/55W Main beam Left/right 12V/55W Auxiliary high beam 12V/55W Fog lights 12V/55W Tail light Left/right...

  • Page 161: Wheels

    If new wheel studs are fitted, the nuts must be retorqued after 500 km (310 miles). Wheel nut tightening torques Model K270 / K370, 210 / 220 Version with 8 M20 wheel nuts 485 Nm (357.7 lb ft)

  • Page 162: Tire Pressure Table (Metric)

    Technical Data and Identification TIRE PRESSURE TABLE (METRIC) Recommended pressure (bar) at various loads (kg) E= single fitting D= twin fitting Tires 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500 7000 7500 8000 8500 9000 10000 11000 12000 13000 Max.

  • Page 163: Lubricant-, Engine Coolant- And Fuel Specifications

    Technical Data and Identification Checking the tire pressures Tire pressures depend on axle load and tire size. Tire pressure table* The tire pressures shown in the table apply to cold tires. Unnecessary tire wear is frequently caused by vehicle operation with tire pressures which do not match the axle load.
  • Page 164 Technical Data and Identification Ask your lubricant and fuel suppliers whether their products comply with specifications. The manufacturer is not liable for damage or problems in the following instances: If oil has been used of a lower grade than specified. If oil has been used of a different viscosity than specified.

  • Page 165: Engine Oil

    Technical Data and Identification Battery acid: In the event of skin contact: rinse the skin profusely with plenty of water. Consult a doctor in the event of persistent redness or pain. Remove polluted clothing and rinse in water. In the event of contact with the eyes: rinse with plenty of water for at least 15 minutes and see a doctor.

  • Page 166: Coolants

    Technical Data and Identification COOLANTS WARNING Coolant is a toxic fluid. Protect skin and eyes. In case of accidental contact with skin and/or eyes, see "Lubricant, engine coolant and fuel specifications". Coolant is harmful to the environment; after use, it should be processed as industrial chemical waste.
  • Page 167 Technical Data and Identification Coolant according to specification 74002 The below table lists the current suppliers that meet specification 74002. It is not allowed to fill the cooling system with another product than the one specified in this overview. Brand name Supplier Long Life Coolant N.V.

  • Page 168: Steering Gear

    Technical Data and Identification STEERING GEAR Hydraulic power steering ATF DEXRON III with valid approval number CAB TILTING MECHANISM Cab tilting pump Oil must meet MIL-H-5606C The following may be used: ESSO Univis J13 FINA Hydran B5219B TEXACO Aircraft Hydraulic Oil 5606G TOTAL Aerohydraulic 520...

  • Page 169: Chassis Number

    Technical Data and Identification CHASSIS NUMBER The chassis number is the last 6 digits of the VIN number. It is stamped on the right chassis side member close to the front axle. D0 02 015 D0 00 597-1 ENGINE NUMBER Cummins C.I.D./L Engine Serial No.

  • Page 170: Paint Identification Plate

    Technical Data and Identification PAINT IDENTIFICATION PLATE XXXXXXXXXXXXX XXXXXXXXXXXX XXXXXXXX The paint identification plate is attached to the bulkhead behind the front panel. xxxkxxxx xmxxxkxjxhxhxlx xxxkxxxx xmx xxxkxxxx xxxkxxxx xmxxxkxjxhxhxlx xxxkxxxx xmxxxx xxx VEHICLE IDENTIFICATION LABEL xxxkxxxx xmxxxkxjxhxhxlx XXXXXXXXXXXXX XXXXXXXXXXXX XXXXXXXX The vehicle identification plate is located on the door jamb.
  • Page 171 Technical Data and Identification...

  • Page 172: Consumer Information

    Consumer Information...

  • Page 173: Consumer Information

    How To Order Parts When you need replacement parts for your Kenworth / Peterbilt vehicles, contact your nearest authorized Kenworth / Peterbilt dealer, who may be located from the "Kenworth / Peterbilt Authorized U.S. and Canadian Dealers" listing (Cat. No. 5212).
  • Page 174 Consumer Information NHTSA Consumer Information The National Highway Traffic Safety Administration requires that the following information be included in the owner’s manual of motor vehicles manufactured after September 1, 1990: If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying KW/PB Motors Company.
  • Page 175 Consumer Information Canadian Consumer Information Canadian customers who wish to report a safety-related defect to Transport Canada, Defect Investigations and Recalls, may telephone the toll free hotline 1- 800-333-0510, or contact Transport Canada by mail at Transport Canada, ASFAD Place de Ville Tower C 330 Sparks Street Ottawa ON K1A 0N5.
  • Page 176 Consumer Information State of California California Vehicle Code, Section 9951 - Disclosure of Recording Device Your vehicle may be equipped with one or more recording devices commonly referred to as “event data recorders (EDR)” or “sensing and diagnostic modules (SDM)”. If you are involved in an accident, the device(s) may have the ability to record vehicle data that occurred just prior to and/or during the accident.
  • Page 177 Consumer Information...

  • Page 178: Alphabetical Index

    Alphabetical index...
  • Page 179 Draining the water separator ......... 101, 139 Adjustable steering column..........68 Driving style ..............122 Air conditioning switch ............ 57 Air filter indicator ............. 97 Air pressure gauge, circuits 1 and 2 ....... 40 Electrical mirror adjustment ..........35 Antifreeze..............165 Electrical system............
  • Page 180 Jacking Seat belts................ 72 front axle..............140 Starting procedure ............116 Rear axle ..............141 Steering ................ 123 Steering column switch Engine brake ............. 67 Lubricant, coolant and fuel specifications ..... 162 left ................65 right ................66 Steering gear ..............167 Maintenance Steering lock/contact/starter switch ......

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