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KW T4 Series Driver's Handbook Manual

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  • Page 2 VEHICLE IDENTIFICATION Owner’s Name: ......Address: ..........Suburb: ........State: ....Postcode: ....Phone Number (Business): ..............Phone Number (Private): ................. Vehicle Registration Number: ..............Colour: ..................... Model: ...................... Engine Number: ..................VlN (Vehicle Identification Number): ............Chassis Number: ..................MAXIMUM VEHICLE WEIGHT The maximum vehicle weight ratings are stamped on the Vehicle Identification Plate attached to the body.
  • Page 3 WELCOME TO THE KENWORTH FAMILY We thank you for investing in your new Kenworth. Proudly engineered and built in Australia, this vehicle has been custom designed to meet your exacting standards and the specific requirements of your application. Advanced technology, pride in workmanship and a total commitment to quality have been combined to produce a truck that is unequalled.

  • Page 5: Table Of Contents

    CONTENTS INTRODUCTION List of tables ..........xi About this Handbook .
  • Page 6 CONTENTS AIR LOSS EMERGENCY PROCEDURE ......26 Low air audible alarm ........26 Parking brake valve .
  • Page 7 CONTENTS ENGINE AFTERTREATMENT SYSTEMS (EAS) ....58 Selective Catalytic Reduction (SCR) ......58 PACCAR MX-13 engine .
  • Page 8 CONTENTS AbS warning lamp ......... .87 Automatic Traction Control (ATC) .
  • Page 9 CONTENTS SECTION TWO - PREVENTIVE MAINTENANCE INTRODUCTION ..........123 SAFETY PRECAUTIONS .
  • Page 10 CONTENTS VEHICLE jACKING ......... . .160 20 Tonne hydraulic bottle jack .
  • Page 11 CONTENTS FRONT AXLE AND SUSPENSION ......191 Axle lubrication..........191 Suspension lubrication .
  • Page 12 .......227 T4 Series - MX Engine service schedule ......228 First service: .

  • Page 13: List Of Tables

    Grade 5 Fastener Torques ..............206 Grade 8 Fastener Torques ..............207 Conversion Table ................208 Periodic Maintenance ..............227 T4 Series - MX Engine Service Schedule ........228 Master lubrication chart ..............243 Lubrication and fluid capacities ............245 A, b & C Service intervals ..............247...

  • Page 14: About This Handbook

    CONTENTS AbOUT THIS HANDbOOK Your handbook contains important information for the safe, efficient operation and service of your truck. We urge you to become familiar with the handbook's contents and use it as a ready reference. All information contained in this manual is based on the latest production information available at the time of publication.
  • Page 15 CONTENTS Some equipment described in this manual is optional and not included in the base price of the vehicle. Kenworth Trucks undertake a continual product improvement program, therefore specifications and data contained in this handbook are subject to change without notice. If there are any doubts about the safe operation of your Kenworth Truck, please contact your nearest Authorised Kenworth Dealer.

  • Page 16: Safety Symbols

    CONTENTS SAFETY SYMbOLS A number of alerting messages are used in this manual. Please read and follow them. They are for your protection and information. These messages can help you avoid personal injury and costly damage to your vehicle. WARNING! This symbol shows that the information that follows is important.

  • Page 17: Vehicle Safety

    CONTENTS VEHICLE SAFETY Make sure your Kenworth Truck 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 “Daily Checks” beginning on page 13. Please remember, this handbook is not a training manual.

  • Page 18: Driver Information Pack (Dip)

    CONTENTS DRIVER INFORMATION PACK (DIP) In addition to this Driver’s Handbook, there are many other publications that are supplied with your new Kenworth Truck. Please take the time to read them. Electronic Customised Maintenance Manual (eCMM) is included in this Driver Information Pack an Electronic Customised Parts Catalogue (eCPC) is an optional item and is available in hard copy or CD-Rom as an aftermarket purchasable item.
  • Page 19 CASTROL MASTER SERVICE CHART Lists all Kenworth recommended lubricants for use in all your major and auxiliary components. Also in the Driver Information Pack you will find the operating instructions for the radio/s, etc. Finally, there is a reminder for you to present your new Kenworth Truck to any of our Authorised Kenworth Dealers for its First Service at 10,000km or 30 days.
  • Page 21 SECTION ONE OPERATING INSTRUCTIONS...

  • Page 23: General Information

    Two new style keys with black bows are provided for Daylite II doors, ignition and toolbox, and also have the KW “bug” on both sides. Separate tool box keys have a red bow, while trucks that have doors, ignition and toolboxes keyed alike will have two keys with black bows.

  • Page 24: Keys And Locks

    OPERATING INSTRUCTIONS KEYS AND LOCKS The same key opens the doors and operates the ignition. If you have locking fuel caps, you will have a separate key for these locks. If your vehicle has a sleeper, you will have a separate key for the tool compartment lock. Ignition Key Switch The ignition key switch has four positions: ACC (Accessories), OFF, ON, and START.

  • Page 25: Remote Keyless Entry (Rke)

    OPERATING INSTRUCTIONS REMOTE KEYLESS ENTRY (RKE) Kenworth Remote Keyless Entry system gives you added security and convenience for your Kenworth truck. This system will lock or unlock the driver’s and passenger's doors with a remote keypad transmitter that alerts you with a brief sounding of the horn. It also activates the dome and door lights.

  • Page 26: Keypad Transmitter

    OPERATING INSTRUCTIONS To Lock both Doors a) Press the LOCK button once b) Both doors lock c) Door and dome lights turn ON for 2 seconds d) If Remote Verification is enabled, press the LOCK button again within 5 seconds to sound the horn. Repeated pressing of the LOCK button within a 5 second period causes the horn to sound and the interior lights to stay ON for a further 2 seconds.

  • Page 27: Cab And Frame Access

    OPERATING INSTRUCTIONS CAb AND FRAME ACCESS The following cab and frame entry/exit procedure recommendations were prepared with personal safety foremost in mind. Do not jump out of the cab or get into the cab without proper caution. You could slip or fall, possibly suffering a serious injury. To help avoid personal injury due to a slip or fall: •...
  • Page 28 OPERATING INSTRUCTIONS External Handrail Cab Access Handrail Page 6 CAT: 8030A June 2017...
  • Page 29 OPERATING INSTRUCTIONS Maintain three points of contact at all times. Using the external cab access grab rails and steps to climb up into a conventional cabin. Use the external handrail (grab handle) and internal access handrail to aid ingress and egress to the cabin. DO NOT use the steering wheel or door closer/arm rest to pull yourself up into the cabin.

  • Page 30: Engine Access

    To open the hood, if a bullbar is fitted, tilt bullbar forward, unhook the hood hold-down latches and grip on the “KW” emblem on the front of the hood. Place foot firmly on the aluminium step on the bumper, to create leverage, and pull the hood slowly forward until it stops.
  • Page 31 OPERATING INSTRUCTIONS Hood Assist Spring Attached cable If the hood is not securely latched it could open during operation and cause an accident. Be sure the hood is securely latched before moving the vehicle. The hood could hurt anyone in the way of its descent. Before lowering the hood be sure no objects or people are in the way.

  • Page 32: Safe Vehicle Operation

    OPERATING INSTRUCTIONS SAFE VEHICLE OPERATION For your safety, as well as that of those around you, be a responsible driver: • If you drink, do not drive. It is illegal to do so. • Do not drive if you are tired, ill, or under emotional stress. Much has gone into the manufacturing of your Kenworth Truck including advanced engineering techniques, rigid quality control and demanding inspections.

  • Page 33: Emergency Equipment

    OPERATING INSTRUCTIONS An unevenly distributed load or a load too heavy over one axle can affect the braking 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.

  • Page 34: Approaching Your Vehicle

    OPERATING INSTRUCTIONS IMPORTANT It is recommended that you have an engine start-up inspection performed within the first 90 days of operation. The inspection may be performed at any service shop authorised by the engine manufacturer. NEW VEHICLE PRECAUTIONS Oil changes: Engine, Transmission and Driving Axles The initial factory lubricants must be drained and the units refilled at the first 10,000 km or 30 days service.

  • Page 35: Daily Checks

    OPERATING INSTRUCTIONS DAILY CHECKS ENGINE COMPARTMENT 1. Engine fluid levels • Engine oil. • Coolant (check while engine is cold). • Power steering fluid level. 2. Engine Belt • Check tension and condition of belts. • If breaks or tears are found, the belt should be replaced before operating the vehicle.
  • Page 36 OPERATING INSTRUCTIONS 6. 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. •...

  • Page 37: Pre-Start Checks

    OPERATING INSTRUCTIONS PRE-START CHECKS DAILY 1. D moisture from the air tanks. Open the tank drains just enough rain to drain the moisture. Do not deplete the entire air supply. Doing this at the start of the day, ensures any moisture from the previous day is ejected fom the air tanks.

  • Page 38: Weekly Operations

    OPERATING INSTRUCTIONS WEEKLY OPERATIONS 1. Battery - Check battery levels and terminals. 2. Wheel Nuts - Are they all in place and torqued properly? - Tighten if necessary. See Wheel Cap Nut Torque page 159. 3. Other Controls and Wiring - Check for condition and adjustment. 4.

  • Page 39: Operating Temperatures

    OPERATING INSTRUCTIONS OPERATING TEMPERATURES Engine Oil Operating Temperature 80°C–90°C Engine Coolant Thermostat opens at Approx 75°C Thermostat opened at least 12mm at Approx 87°C Rear Axle Lubricant Normal Operating Range 79°C–107°C Maximum difference between axles 17°C Climbing steep grades 107°C Maximum allowable* (investigate cause) 121°C Transmission Lubricant...

  • Page 40: Instruments And Controls

    OPERATING INSTRUCTIONS INSTRUMENTS AND CONTROLS This section explains the location and function of the various instruments and controls in your vehicle. INSTRUMENT PANEL Please remember that each Kenworth Truck is custom-built. For this reason, your instrument panel may not look exactly like the one in the illustrations. In this handbook, we describe the most common instruments and controls available, however many of these are options.

  • Page 41: Curved Dash Layout - T409 & T409Sar

    OPERATING INSTRUCTIONS Dash Layout - T409 & T409SAR 24 25 HOURS 0 0 0 0 0 AXLE OIL REAR RR AXLE OIL FRT RR AXLE OIL AXLE OIL CTR RR REAR RR 1000 ENG OIL KPa x 100 in H2O vac PRESS ENG WATER VOLT...

  • Page 42: Warning Lights

    OPERATING INSTRUCTIONS WARNING LIGHTS Warning Light Clusters The standard Indicator Cluster contains the LH and RH turn signal indicators and the headlight high beam indicator. SUSPENSION BRAKE REVERSE LOW AIR DUMP DOOR COOLANT OPEN PRESS Left-hand Cluster STOP INTERAXLE CHECK AFTER ENGINE ENGINE...

  • Page 43: Power On Test

    OPERATING INSTRUCTIONS Stop Engine – This lights when a major engine-system problem exists. The driver should stop the vehicle as soon as safely possible and have the fault repaired before driving the vehicle again. This should be considered an emergency. The vehicle must be repaired and the problem corrected before continuing.

  • Page 44: Tachourmeter

    OPERATING INSTRUCTIONS TACHOURMETERS The Tachourmeter measures the engine speed in revolutions per minute (rpm). Watching the tachourmeter is important for efficient driving. It will 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.

  • Page 45: Speedometer/Odometer

    OPERATING INSTRUCTIONS SPEEDOMETER/ODOMETER The speedometer indicates vehicle speed in kilometres per hour (km/h). The odometer, in the centre of the speedometer, has a multi-purpose function display and can be used to calibrate the speedometer. It records the kilometres your vehicle has travelled. MMXV Km/h Speedometer/Odometer...

  • Page 46: Engine Oil Pressure Gauge

    OPERATING INSTRUCTIONS ENGINE OIL PRESSURE GAUGE It is important to maintain oil pressure within acceptable limits. If oil pressure drops below the minimum kPa, an oil pressure warning lamp in the LH warning light cluster will light, and the Stop Engine Lamp will come ON. 1000 ENG OIL PRESS...

  • Page 47: Air System Pressure Gauges

    OPERATING INSTRUCTIONS AIR SYSTEM PRESSURE GAUGES Front and Rear Service The air pressure gauge indicates the amount of air pressure in the brake system in kilopascals (kPa). The front air pressure gauge shows the front service tank air pressure and the rear air pressure gauge indicates pressure in the rear service tank.

  • Page 48: Air Loss Emergency Procedure

    OPERATING INSTRUCTIONS AIR LOSS EMERGENCY PROCEDURE • Slow down carefully. • Move a safe distance off the road and stop. • Place the transmission in neutral and set the parking brake. • Turn OFF the engine. • Turn ON the emergency flasher and use other warning devices to alert other motorists.

  • Page 49: Parking Brake Valve

    OPERATING INSTRUCTIONS PARKING bRAKE VALVE bEFORE YOU LEAVE THE CAb: Apply all parking brakes. Pull out the Yellow Parking Brake Control knob located on the dash. The Red (octagon-shaped) Trailer Air Supply Control knob will automatically pop out. (An optional dash warning light, if fitted,will indicate when the brake is on).

  • Page 50: Fuel Level Gauge

    OPERATING INSTRUCTIONS FUEL LEVEL GAUGE The Fuel Gauge indicates the (approximate) total amount of fuel in the fuel tanks. FUEL FUEL LEVEL FUEL LEVEL Fuel Gauge Kenworth manufactures vehicles that are built with different fuel systems and pick-up tube locations. Because of this, and the amount of road crown, it is recommended that you do not operate your vehicle with less than one quarter of your truck’s fuel capacity.

  • Page 51: Transmission Low Oil Warning Light

    OPERATING INSTRUCTIONS TRANSMISSION (GEARbOX) LOW OIL WARNING LIGHT This is located in the centre warning cluster of the main instrument panel. The transmission warning light will illuminate “self-test” when the ignition is switched on. Once the engine has been started, the light will extinguish when engine revs are increased above idle.

  • Page 52: Headlight Switch

    OPERATING INSTRUCTIONS HEADLIGHT SWITCH The headlights are controlled by the correspondingly named switch showing a headlight symbol on the main switch panel on all Conventional models, the headlight switch on COE models is located on the right hand lower dash panel next to the ignition switch. When the headlights are on, the instrument lights including Smart Wheel, side and tail lamps are also on.

  • Page 53: Panel Light Knob (Dimmer Switch)

    OPERATING INSTRUCTIONS PANEL LIGHTS DIMMER SWITCH The Panel Light Dimmer lets you vary the brightness of the instrument panel lights. It is located to the lower left of the steering column. To operate the panel light dimmer switch: 1. Turn the headlights on 2.

  • Page 54: Mirrors

    OPERATING INSTRUCTIONS MIRRORS Your vehicle comes equipped with two outside rear-view mirrors that enable you to see down both sides of your vehicle. Be sure both mirrors are adjusted properly before you begin driving. To provide good visibility, adjust the mirror so the side of your vehicle appears in the inboard part of the mirror.

  • Page 55: Air Suspension Deflate Switch (Dump Valve)

    OPERATING INSTRUCTIONS AIR SUSPENSION DEFLATE SWITCH (DUMP VALVE) Your Kenworth vehicle may have an air suspension deflation switch which allows the air in the suspension to be exhausted by using a switch on the dash. The purpose of this feature is to allow you to lower your truck to get under a trailer or to empty a tipper.

  • Page 56: Ipod & Mp3 Connectivity

    OPERATING INSTRUCTIONS IPOD & MP3 CONNECTIVITY You can connect your iPod or a USB storage device to the truck’s sound system via the Bluetooth feature on vehicles fitted with the standard sound system. Once the devices have been paired, incoming calls from your mobile phone will automatically be received through the Bluetooth enabled sound system.

  • Page 57: Cab Mounted Power Supply Socket

    OPERATING INSTRUCTIONS Turn the knob further right to the next position for higher speed continuous operation. Turn off the wipers by rotating the knob to the left. The ignition key must be turned to ON or ACC for the wiper/washer switch to operate. Washer To use the washer, push the wiper/washer collar at the end of the stalk.

  • Page 58: Cruise Control

    OPERATING INSTRUCTIONS CRUISE CONTROL (DASH MOUNTED) To Engage Cruise Control Ensure Engine Brake is switched off. Engine Brake must be switched OFF to enable Cruise Control functionality. At desired vehicle speed, press either ‘SET/INC.’ or ‘SET/DEC.’ Cruise control will maintain set vehicle speed. C R U IS E S E T / O FF...

  • Page 59: Smartwheel Mounted Controls

    OPERATING INSTRUCTIONS CRUISE CONTROL (SMART WHEEL) The Kenworth four spoke Smart Wheel puts the most frequently used controls, including cruise control right under the driver’s fingertips. Cruise control switches are located on the left & right hand control pads of the Smart Wheel.
  • Page 60 OPERATING INSTRUCTIONS Engaging Conditions A number of conditions must be met to engage the engine brake: • The engine speed must be above 1000 rpm. • The oil temperature must be above 5 ° C. and the coolant temperature must be above 15 ° C. •...

  • Page 61: Dash Mounted Engine Brake Controls

    OPERATING INSTRUCTIONS ENGINE bRAKE (DASH MOUNTED SWITCH) The ‘ENGINE BRAKE’ switch is a single throw ON/OFF switch located on the switch panel mounted in the dashboard. This switch turns the system ON or OFF. With engine speed increased (below 2,200 rpm) and throttle at 0%, the engine brake will activate with butterfly valve closed and engine compression brake active.

  • Page 62: Turbo Timer

    OPERATING INSTRUCTIONS TURbO TIMER (OPTIONAL) A turbocharger is a combination Turbine and Compressor joined by a common shaft. Super-hot exhaust gases (exceeding 700°C) from the engine pass through the turbocharger causing it to revolve at very high speeds (up to 100,000 rpm). At normal engine shutdown, the turbo temperature is high and the lubrication to the bearings stops instantly.

  • Page 63: Engine Management/Diagnostic Fault Codes

    OPERATING INSTRUCTIONS ENGINE MANAGEMENT/DIAGNOSTIC FAULT CODES All PACCAR MX-13 engines fitted to Kenworth trucks have the ability to record and log engine and exhaust after-treatment system (EAS) related faults which can be retrieved to aid mechanical diagnosis. The fault codes can only be cleared from the systems using a DAVIE diagnostic tool located at your nearest Kenworth dealership.

  • Page 64: Shift Pattern Display

    OPERATING INSTRUCTIONS SHIFT PATTERN DISPLAY The correct shift pattern for your vehicle appears on the rear of the driver’s sunvisor. But it is important that you know more about your transmission than just the shift pattern. Please read the transmission manual provided in your vehicle’s Maintenance Manual (see page 81 for shift patterns).

  • Page 65: Heating And Airconditioning

    OPERATING INSTRUCTIONS HEATING AND AIRCONDITIONING The cab heater and A/C controls are located together on the dash or overhead console, depending on the model. In addition, the sleeper compartment may contain a slave heater/airconditioning system with its controls located on the driver’s side sleeper cabinet. If a refrigerant leak develops in the presence of excessive heat or an open flame, hazardous gases can be generated.

  • Page 66: Cab Heater/Airconditioner

    OPERATING INSTRUCTIONS CAb HEATER/AIRCONDITIONER To get the most efficient performance from your heater/airconditioner system, keep the following in mind: 1. Turn airconditioner controls OFF when cooling is not required, except when de-misting the windscreen. 2. With sleeper compartment auxiliary units, cab controls must be ON for the sleeper controls to function.
  • Page 67 OPERATING INSTRUCTIONS 3. Close windows, especially in humid conditions, leaving one slightly opened to allow hot air to vent. 4. Idle the engine between 1000 and 1500 rpm and turn fan switch(es) on high, if the truck is stationary. 5. After cab temperature cools suitably, adjust blower speed and controls to sustain desired condition.
  • Page 68 OPERATING INSTRUCTIONS CAb CONTROLS 9 10 12 13* Legend to A/C Controller on previous page 1 Face Only 10 Fan LOW 2 Face & Feet 11 Fan MED 3 Feet Only 12 Fan HIGH 4 Feet & Screen 13 Fan BOOST 5 Screen Only 14 Airconditioner ON/OFF Switch...
  • Page 69 OPERATING INSTRUCTIONS SLEEPER AIRCONDITIONER (A/C) CONTROLS (IF FITTED) Heater / Airconditioner Mode Fan Control Temperature Control Sleeper A/C: The Cab Heater and A/C Controls must have the Air Direction Lever on A/C, and a fan setting selected for the sleeper A/C unit to work. Fan Control (1): Allows you to select different blower speeds.

  • Page 70: Cab Storage

    OPERATING INSTRUCTIONS CAb STORAGE GLOVE COMPARTMENT A lockable glove compartment is provided in conventional models to store important documents (including this Driver’s Handbook) and other related materials. It is accessed by pushing the knob on the front. To open the overhead storage compartments in sleeper compartments, turn the knob until it releases.

  • Page 71: Seats

    OPERATING INSTRUCTIONS SEATS This section covers the operation and safe use of your Kenworth seats. For further information on features and adjustment of the seat, see the manufacturer’s Service and Operation information supplied with the vehicle. SEAT ADjUSTMENT Do not adjust the driver’s seat while the vehicle is moving. The seat could move unexpectedly and can cause the driver to lose control of the vehicle.

  • Page 72: Safety Restraint Belts

    OPERATING INSTRUCTIONS SAFETY RESTRAINT bELTS Safety belts have proven to be the single most effective means available for reducing the potential for either serious injury or death in motor vehicle accidents. Therefore, read the following instructions and always observe user warnings pertaining to safety belts. Too High on hips Seatbelts are designed to bear upon the bony structure of the body,...

  • Page 73: Lap And Shoulder Belt

    OPERATING INSTRUCTIONS LAP & SHOULDER bELT The combination lap-shoulder belt is equipped with a locking mechanism. The system adjusts automatically to a person’s size and movements as long as the pull on the belt is slow. Hard braking or a collision locks the belt.

  • Page 74: Sleeper, Bunks And Restraints

    OPERATING INSTRUCTIONS • Make sure the belt of the unoccupied passenger seat is fully wound up on its retractor, so the belt tongue is in its stowed position. This reduces the possibility of the tongue becoming a striking object in a sudden stop.

  • Page 75: Operating The Engine

    OPERATING INSTRUCTIONS OPERATING THE ENGINE NORMAL STARTING PROCEDURE • Set Park Brake • Insert key into ignition switch • Do NOT pump the accelerator pedal • Shift main transmission into NEUTRAL • Depress clutch pedal • Turn the ignition switch to the ON position •...

  • Page 76: Engine Warm-Up

    OPERATING INSTRUCTIONS ENGINE WARM-UP The purpose of engine warm-up is to allow an oil film to be established between pistons, shafts and bearings while your engine gradually reaches operating temperature. After the engine starts, the electronics will check the coolant temperature and other engine temperature indicators.
  • Page 77 OPERATING INSTRUCTIONS 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 pressure to stabilise. In extremely cold temperatures, you may have to increase idle speed.
  • Page 78 OPERATING INSTRUCTIONS before Driving Away 1. Check ALL operating temperatures and pressures are within correct range. 2. Check operation of windshield washers and wipers. 3. Check horn (electric and air) operation. 4. Check position of the inter-axle differential control. 5. Turn Emergency flashers OFF. 6.

  • Page 79: Idling The Engine

    OPERATING INSTRUCTIONS IDLING THE ENGINE Do not idle for extended perios of time. Excessive idle time can cause poor engine performance and waste fuel. Internal combustion engines MUST NOT operate at idle speed for extended periods of time. This operating condition may lead to poor engine performance.

  • Page 80: Engine Aftertreatment Systems (Eas)

    OPERATING INSTRUCTIONS ENGINE AFTERTREATMENT SYSTEMS (EAS) In order to meet ADR 80/03 engine emission requirements, vehicles must have an Exhaust Aftertreatment System (EAS). SELECTIVE CATALYTIC REDUCTION (SCR) PACCAR MX-13 ENGINE Your truck is equiped with a Selective Catalytic Reduction (SCR) system which uses Diesel Exhaust Fluid (AdBlue) to reduce emissions from diesel engines.

  • Page 81: Eas Tampering

    OPERATING INSTRUCTIONS EAS SYSTEM TAMPERING If the engine system detects failures which may be the result of tampering with the EAS system, the ‘CHECK ENGINE’ and ‘AFTER TREAT(MENT)’ warning lights will come on. As the legislated NOX levels can no longer be achieved, the engine will derate to 60% of its power.

  • Page 82: 'Engine Derate' Means; Engine Power Limiting

    OPERATING INSTRUCTIONS Should a derate situation occur through low DEF level, this can be automatically corrected by adding DEF, increasing level to above 9%. Once the engine determines the legislated NOX levels can now be obtained, the engine derate will clear, returning engine to full power. ‘ENGINE DERATE’...

  • Page 83: Adblue Filling

    OPERATING INSTRUCTIONS General Warning • It is not allowable to open the dosing module EAS. Therefore internal components cannot be changed. • Replace the AdBlue filler cap as soon as filling of the AdBlue tank is completed, do not allow foreign matter to enter the AdBlue tank. •...

  • Page 84: Operating The Transmission

    OPERATING INSTRUCTIONS OPERATING THE TRANSMISSION Because each Kenworth is custom-equipped, the specific operating procedures for your particular transmission are not included in this handbook. Therefore, you should read the general guidelines and instructions that follow, and read the specific instructions contained in the transmission manufacturer’s Driver/Operator’s Instruction Manual.

  • Page 85: Putting The Vehicle In Motion

    OPERATING INSTRUCTIONS PUTTING THE VEHICLE IN MOTION After making sure the vehicle’s oil and air pressure are correct and all other parts and systems are in proper working condition: 1. Fully depress the clutch pedal (for manual transmission) until the clutch brake makes contact.

  • Page 86: Shifting Gears In A New Vehicle

    OPERATING INSTRUCTIONS The best engine performance and maximum economy are 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 Driving Tips and Techniques, page 101.

  • Page 87: Double Clutching

    OPERATING INSTRUCTIONS 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 will cause gear hang-up. Be careful not to apply the clutch brake while the vehicle is moving.

  • Page 88: Clutch Operation

    OPERATING INSTRUCTIONS CLUTCH OPERATION STARTING To properly put a vehicle into motion, depress the clutch pedal until the clutch brake is contacted. This contact should occur 25 mm or less from the floorboard - excluding carpet. Select a gear low enough to allow the vehicle to start forward with throttle at idle until the clutch is fully engaged.
  • Page 89 OPERATING INSTRUCTIONS Inspect manual clutches according to the manufacturer’s recommendations. Regular maintenance should be followed to maintain correct clutch adjustment. Have your dealer’s Service Department perform any adjustment necessary. Clutch Tips • Always use the clutch when making upshifts or downshifts. •...

  • Page 90: Transmission Oil Temperature Gauge

    OPERATING INSTRUCTIONS TRANSMISSION OIL TEMPERATURE GAUGE The Transmission Oil Temperature Gauge (option) indicates the temperature of the oil in the transmission. Watch this gauge to know when the transmission is overheating: (max 120°). If it is, have it checked by an authorised service representative.

  • Page 91: Eaton Fuller Transmissions

    OPERATING INSTRUCTIONS EATON FULLER ULTRASHIFT TRANSMISSION DRIVING THE ULTRASHIFT TRANSMISSION Start-up 1. Turn the ignition key to “ON” and allow the UltraShift to power- up. Engine cranking is delayed until the transmission power-up is complete and the gear display shows a solid “N”. 2.
  • Page 92 OPERATING INSTRUCTIONS The driver can advance a shift (by about 75 rpm) by pressing the proper up/down button (up for upshifts, down for downshifts) when the transmission is within 75 rpm of the load-based shift point. The Gear Display shows the status of the shift: •...

  • Page 93: Ultrashift Driving Tips

    OPERATING INSTRUCTIONS ULTRASHIFT DRIVING TIPS Proper Starting Gear Choose a starting gear appropriate for the load and grade conditions while at a stop in Drive and MANUAL modes by using the up/down buttons. Refer to Drive Mode for detailed information. Skip Shifting Performed in MANUAL by pressing the shift button more than once.
  • Page 94 OPERATING INSTRUCTIONS Clutch Protection As a driver of a truck equipped with a Fuller UltraShift DM2 Transmission (No Clutch Pedal) please take note of the following message: Even though your truck does not have a clutch pedal, it still has a mechanical clutch.

  • Page 95: Retrieving Fault Codes

    OPERATING INSTRUCTIONS ULTRASHIFT FAULT CODE RETRIEVAL/CLEARING RETRIEVING FAULT CODES 1. Place the shift lever in neutral. 2. Set the parking brake. 3. Turn the ignition key ON but do not start the engine. If the engine is already running, you may still retrieve codes, however, do not engage the starter if engine stalls.

  • Page 96: Ultrashift Fault Codes

    OPERATING INSTRUCTIONS If the codes have been successfully cleared, the service lamp will come on and stay on for five seconds. Clearing fault codes will permanently delete the code and cannot be retrieved for diagnosis. 2. Turn the key OFF and allow system to power down. ULTRASHIFT PLUS FAULT CODES Fault Description UltraShift...

  • Page 97: Ultrashift Plus Transmissions

    OPERATING INSTRUCTIONS ULTRASHIFT PLUS TRANSMISSIONS Shift Console Positions Selects Reverse Mode used for Start-up and Power- down Selects Drive Manual Selects Manual Selects Low Service The service indicator alerts the driver of potential transmission problems. Buttons Up/Down Used in the MANUAL mode to select upshifts and downshifts and to change start gear, if available.

  • Page 98: Start-Up & Power Down

    OPERATING INSTRUCTIONS “CA” will appear in the gear display if a clutch abuse event is occurring. In heavy-duty UltraShift PLUS models,”AN” will appear in the gear display if the transmission goes into Auto Neutral. In heavy duty UltraShift PLUS models, “GI” (Grease Interval) may briefly appear in the gear display after the engine is started.
  • Page 99 OPERATING INSTRUCTIONS Power Down 1. Select Neutral on the shift control. • If gear display does not show solid “N,” neutral has not yet been obtained. Neutral should always be reached before the Fuller UltraShift PLUS power down is performed except in cases of emergency. 2.

  • Page 100: Ultrashift Transmission Shift Pattern

    OPERATING INSTRUCTIONS EATON FULLER AUTO TRANSMISSION SHIFT PATTERN UltraShift PLUS Transmissions READ DRIVERS INSTRUCTIONS BEFORE OPERATING WARNING MINIMUM RECOMMENDED OPERATING AIR PRESSURE 621 kPa (90) PSI NEUTRAL MUST BE SELECTED TO START ENGINE SELECT NEUTRAL AND SET PARKING BRAKES BEFORE LEAVING CAB DO NOT OPERATE VEHICLE IF ALTERNATOR LAMP IS LIT OR GAUGES INDICATE LOW VOLTAGE AVOID CLUTCH DAMAGE! DEPRESS BRAKE PEDAL WHEN STOPPED ON INCLINE REVERSE...

  • Page 101: Using The Brake System

    OPERATING INSTRUCTIONS USING THE bRAKE SYSTEM The operation of the vehicle’s braking system and many vehicle accessories depends on the storage and application of a high-pressure air supply. The air brake system contains dual circuits: a circuit for the rear brakes (primary) and a circuit for the front brakes (secondary).

  • Page 102: Air Supply System

    OPERATING INSTRUCTIONS bRAKE OPERATION Do not drive through water deep enough to wet brake components, as it may cause the brakes to work less efficiently than normal. The vehicle’s stopping distance may be longer than expected and the vehicle may pull to the left or right when brakes are applied, which could contribute to an accident.

  • Page 103: Using The Parking Brake

    OPERATING INSTRUCTIONS USING THE PARKING bRAKE The yellow diamond-shaped knob on the dash controls the truck 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 brakes.

  • Page 104: To Release The Full Combination Of Brakes

    OPERATING INSTRUCTIONS TO RELEASE THE FULL COMbINATION OF bRAKES • Push IN BOTH knobs on the dash. • If the 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.
  • Page 105 OPERATING INSTRUCTIONS 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 truck air reservoirs to protect the truck air system pressure. To apply the trailer brakes only: Pull OUT the red knob.

  • Page 106: Trailer Park Brake Release Valve

    OPERATING INSTRUCTIONS TRAILER PARK bRAKE RELEASE VALVE The trailer park release valve is an optional fitment, for use with semi/full rear tipping trailers. The trailer park release valve is interlocked with the main park brake system, per ADR 35/03 requirements. The trailer brakes can only be released after all the park brakes have activated and stabilised.

  • Page 107: System Truck Park

    OPERATING INSTRUCTIONS SYSTEM TRUCK PARK With both knobs pushed in for normal operating modes, the parking brakes of both the truck and the trailer may be applied by pulling the yellow knob OUT. This will exhaust the air from the truck spring brakes, and simultaneously cause the red knob to pop OUT, which will apply the trailer brakes.

  • Page 108: For Non Abs Vehicles

    OPERATING INSTRUCTIONS FOR NON-AbS VEHICLES To stop your vehicle in an emergency, vary the service brake application pressure to provide maximum braking force without locking the wheels. Use engine compression to assist the service brakes by not depressing the clutch pedal until the engine reaches idle speed. Overheated brakes Under normal braking conditions, the energy generated will bring the internal brake drum temperature to about 260°C.

  • Page 109: Electronic Braking Safety Systems

    OPERATING INSTRUCTIONS Clamping force generated by the primary actuation is applied to the inner pad which forces it into contact with the rotor. Reactive force through the caliper body applies equal clamping force to the outer pad applying a balanced clamping force to the rotor. The slide pins also allow the caliper to freely position itself on the saddle to compensate for the reduction in lining pad thickness due to wear.
  • Page 110 OPERATING INSTRUCTIONS The ABS warning lamp will come on momentarily when the key switch is first turned. The lamp will go out and stay off unless the system detects a failure or malfunction. Except for checking the proper illumination of the ABS and wheel spin control warning lamps when first starting the truck, and for monitoring these lamps while driving, no special operating procedures are required.
  • Page 111 OPERATING INSTRUCTIONS If the ATC Off Road switch is enabled, the ATC sensitivity threshold will be decreased up to a speed of approximately 50 kp/h, at which normal ATC operation will automatically resume. Optional features of the Electronic Brake Safety System are outlined below, and a more comprehensive section is located on the CD in the Driver's Information Pack.
  • Page 112 OPERATING INSTRUCTIONS OFF-ROAD FUNCTION AbS OFF-ROAD FUNCTION SWITCH Your Kenworth vehicle may be equipped with a separate electrical switch to activate an ABS off-road function. This function is NOT to be used for on- highway driving, but is intended to be used to improve stopping performance in off-highway conditions (e.g.
  • Page 113 OPERATING INSTRUCTIONS • At speeds between 16 and 40 km, the ABS control software is modified to allow short periods (0.25 seconds) of locked-wheel cycles. • At speeds below 16 km, the ABS control software is turned off to allow locked wheels. •...
  • Page 114 OPERATING INSTRUCTIONS The trailer brake is not to be used as a substitute for the service brakes. Using this brake frequently, instead of using the foot brake, will cause the trailer brakes to wear prematurely. DRIVING bObTAIL OR WITH AN UNLOADED TRAILER The following information is applicable only to truck and trailer configurations.
  • Page 115 OPERATING INSTRUCTIONS ENGINE COMPRESSION AND EXHAUST bRAKE The engine retardation system on the PACCAR MX-13 is a combination of single-stage engine compression brake and exhaust brake and will operate at its most efficient between engine speeds of 2200 RPM and 1500 RPM. The higher the engine speed is in this range, the more effective the engine brake operates.
  • Page 116 OPERATING INSTRUCTIONS OPERATING THE REAR/DRIVE AXLE This section covers the operation of your rear/drive axle. These instructions apply to the most common features of drive axles. Refer to the manufacturer’s instructions for further information on the operation of your axle. DRIVER CONTROLLED DIFFERENTIAL LOCK (DCDL) When to use the Cross Wheel Differential Lock (can be on Rear/Rear Axle or both Rear Axles)
  • Page 117 OPERATING INSTRUCTIONS Turning Radius when Unlocked (Disengaged) Turning Radius when Locked (Engaged) Understeer Condition INTER-AXLE DIFFERENTIAL LOCK (IADL OR POWER DIVIDER) The inter-axle differential, also refered to as the Power Divider, allows each axle to turn independently, which relieves stress on the rear axles and reduces tyre wear.
  • Page 118 OPERATING INSTRUCTIONS differential is locked (engaged). 3. If you LOCK or UNLOCK the differential while moving, let up momentarily on the accelerator pedal to relieve torque on the gearing and allow full engagement of the clutch (mechanism that locks the wheels).
  • Page 119 OPERATING INSTRUCTIONS TOWING WITH AXLES FITTED WITH DCDL If your Kenworth has a Meritor axle with a driver-controlled main differential lock, install the caging bolt before removing the axles for towing. Installation of the caging bolt prevents damage by locking internal axle components in position.
  • Page 120 OPERATING INSTRUCTIONS DUAL RANGE AXLE OPERATION Following are important tips on operating a Dual Range Axle with Interaxle Differential: 1. Shift the axle with the interaxle differential in the UNLOCKED position only. 2. When you are driving with poor traction, lock the differential. When you have the differential locked, drive with the axle in LOW range only.
  • Page 121 OPERATING INSTRUCTIONS When the vehicle is going down hill, the wheels will not slow down, but will tend to speed up, which makes gear synchronisation almost impossible. As a result, the axle is neither in HIGH nor LOW range and all engine/driveline retardation is lost.
  • Page 122 OPERATING INSTRUCTIONS DRIVE AXLE TEMPERATURE GAUGE Optional Axle Temperature gauges may be installed in your Kenworth. Either a set of two gauges, one for each drive axle, or one for both forward and rear axles, indicate the lubricant temperature in each drive axle. The temperatures indicated will vary with the kind of load you are carrying and the driving conditions you encounter.
  • Page 123 OPERATING INSTRUCTIONS DRIVING TIPS AND TECHNIQUES This section covers additional driving tips and techniques on how to drive your Kenworth more efficiently. It will give you information on starting, shifting and driving your Kenworth vehicle. Coasting Do not coast with the transmission in neutral or with the clutch pedal depressed.
  • Page 124 OPERATING INSTRUCTIONS Climbing and Descending When approaching an uphill grade, apply light throttle early to build up engine temperature gradually, so that when power is applied for the climb, the engine won’t be subjected to a sudden, large heat change. Use the tachometer and pyrometer to maintain optimum power/temperature relationship during the climb.
  • Page 125 OPERATING INSTRUCTIONS Level Cruising If the pyrometer indicates excessive temperature while cruising, ease off slightly on the throttle. Normally, on a smooth, level road, there should be no loss of rpm and speed, and the pyrometer should indicate a drop in temperature.
  • Page 126 OPERATING INSTRUCTIONS Use regular, moderate brake applications to bring the speed to about 10 KMH below desired speed, and release the brakes to allow the truck to speed up again. This procedure allows all brakes to contribute to brake performance, whereas a light continuous application can cause one axle to do all the braking.
  • Page 127 OPERATING INSTRUCTIONS 2. Tyre tread depth must be sufficient to get water out from under most of the tyre contact patch (3 mm is the minimum tread depth for truck tyres). 3. Jacobs or other auxiliary brake systems should never be used simultaneously with the foot brake.
  • Page 128 OPERATING INSTRUCTIONS ECONOMICAL DRIVING The following section includes recommendations for best engine performance and economy. Engine Overspeed - RPM • Operate the engine within the optimum engine rpm range and do not allow the rpm to exceed the maximum governed speed. See your Engine Operation and Maintenance Manual for information regarding engine rpm.
  • Page 129 OPERATING INSTRUCTIONS Fuel economy and engine performance is also directly related to driving habits: • The best results in trip time and fuel economy are obtained while driving the vehicle at a steady speed. • Shift into higher or lower gears (or apply the service brake) to keep engine rpm near the lower end of the optimum operating range.
  • Page 130 OPERATING INSTRUCTIONS Driving Habits Wrong driving habits must be corrected and the recommendations on economic driving should be followed. Driving factors affecting fuel consumption: • Excessive speed and unnecessary fast acceleration. • Long periods of idling. • Driving with foot resting on the clutch pedal (manual transmission).
  • Page 131 OPERATING INSTRUCTIONS The following guidelines will help you to drive the vehicle safely: • Make a thorough inspection of the vehicle, daily and weekly. See Driver’s Checklist, page 11. • Ensure windows, mirrors and lights are clean. • Check all tyres for damage and correct inflation pressure. •...
  • Page 132 OPERATING INSTRUCTIONS AIR SUSPENSION Air Suspension Height/Air Pressure Your vehicle may have an air suspension and a deflation switch which allows the air in the suspension to be exhausted using a switch on the dash. The normal purpose of this feature is to allow you to lower the vehicle for loading.
  • Page 133 OPERATING INSTRUCTIONS FIFTH WHEEL The following applies to prime mover configurations: Ensure that all fifth wheel maintenance, adjustments and rebuilding are done only by a qualified mechanic. An improperly maintained fifth wheel can cause a trailer to separate from a truck. This could lead to an injury or accident and damage to property.
  • Page 134 OPERATING INSTRUCTIONS FIFTH WHEEL LUbRICATION Frequently operate and lubricate movable or sliding fifth wheels to prevent corrosion. Both the fifth wheel plate and the slide tracks (if a slider) should be cleaned and lubricated periodically to ensure smooth turning and sliding action. Failure to keep these surfaces lubricated can lead to frame and/or driveline damage.
  • Page 135 OPERATING INSTRUCTIONS RETURNING VEHICLE TO SERVICE Your vehicle may have lost lubricant while being towed. To prevent damage, check the oil level and add oil if necessary. After adding the specified type and amount of lubricant, drive the vehicle. It should be unloaded.
  • Page 136 OPERATING INSTRUCTIONS 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. Do not drive a vehicle with malfunctioning brakes. If one of the brake circuits should become inoperative, braking distances will increase substantially and handling characteristics while braking will be affected.
  • Page 137 OPERATING INSTRUCTIONS To move a vehicle immobilised by the spring brakes due to loss of air pressure in the brake system, perform the following procedure: 1. R e m o v e t h e d u s t plug from the spring chamber.
  • Page 138 OPERATING INSTRUCTIONS Freeing the Vehicle from Sand, Mud or Ice If the vehicle gets stuck in sand, mud or ice: • Move the gearshift lever or selector from First to Reverse. • Apply light pressure on the accelerator pedal while the transmission is in gear.
  • Page 139 OPERATING INSTRUCTIONS SHUT-DOWN 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 easier to get going when you are ready, and it will be safer for everyone who might be around it.
  • Page 140 OPERATING INSTRUCTIONS 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.
  • Page 141 OPERATING INSTRUCTIONS REFUELLING Air inside the fuel tanks allows Filler Cap water to condense in the tank. To prevent this condensation while the vehicle is parked for extended Air Gap Filler Neck periods, do not overfill the tanks above 95 percent of capacity. 95 percent is to the lower edge of the filler neck so that air gap Round fuel tank - Maximum fill level = 95%...
  • Page 143 SECTION TWO PREVENTIVE MAINTENANCE...
  • Page 145 PREVENTIVE MAINTENANCE INTRODUCTION This section will help you keep your Kenworth 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 Authorised Kenworth Dealer do any work you do not have the tools or skill to perform.
  • Page 146 PREVENTIVE MAINTENANCE 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 it is running.
  • Page 147 PREVENTIVE MAINTENANCE ENVIRONMENTAL PROTECTION AND MATERIAL HAzARDS Some of the ingredients in engine oil, hydraulic oil, transmission and axle oil, engine coolant, diesel fuel, airconditioning refrigerant (R-134a and PAG oil), batteries, etc., may contaminate the environment if spilled or not disposed of properly.
  • Page 148 PREVENTIVE MAINTENANCE LUbRICATION SPECIFICATIONS - ENGINE You will find Engine Lubrication Specifications in the Castrol Master Lubrication Chart located on page 243. One key to keeping your Kenworth running at top economy and to prolonging its life is proper lubrication and servicing. Neglecting this essential aspect of vehicle care can cost time and money in the long run.
  • Page 149 PREVENTIVE MAINTENANCE • Check if the red oil pressure warning in the instrument panel disappears within ten seconds; if not, switch off engine and investigate the problem. • Check oil lines, housing and connections for leaks, damage or deterioration. Leaks could be the result of damaged oil lines or seals. The lubrication system consists of an oil cooler module mounted on right hand side of engine.
  • Page 150 PREVENTIVE MAINTENANCE 9. Position the screw cap carefully onto the oil module. 10. Tighten the screw cap (1) by hand until it reaches the end position. 11. Tighten the screw cap (1) to the specified tightening torque. 12. Slide the lock (3) over the thermostat housing of the oil module. 13.
  • Page 151 PREVENTIVE MAINTENANCE 7. Remove the O-ring from the screw cap (4). 8. Install a new O-ring onto the screw cap (4). 9. Lightly oil the new O-ring and threads of the screw cap. 10. Check the O-rings on the thorn of the oil filter element are present and in good condition.
  • Page 152 PREVENTIVE MAINTENANCE Oil Draining Hot engine oil can be dangerous. You could be seriously burned. Let the engine oil cool down before changing the oil. • Drain the oil into a container designed for this purpose. • When draining the oil, remove the plug with the proper size spanner and keep as far away as possible.
  • Page 153 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. Hub reduction axles may require specific oil volumes to ensure correct levels. (Refer to Electronic Customised Maintenance Manual, rear axle section.) Use care when checking the oil level with your finger.
  • Page 154 PREVENTIVE MAINTENANCE FUEL SYSTEM FUEL SPECIFICATION FOR PACCAR MX-13 DIESEL ENGINES Based on the present status of PACCAR MX-13 engine development, the fuel (compositions) used must meet certain international standards to be assured of the required engine performance, durability and emission goals. Therefore PACCAR prescribes for all its engines that: Any diesel or alternative fuel mixture must fully comply with European Fuel Standard EN 590.
  • Page 155 PREVENTIVE MAINTENANCE FUEL SYSTEM PRIMING The PACCAR MX-13 fuel system incorporates two filtration units. A fuel/ water separator with primary filter mounted to the left hand chassis rail and a main filter cartridge mounted on the left hand side of the engine. The priming pump button on the primary fuel filter (2), must be used correctly to prevent premature failure.
  • Page 156 PREVENTIVE MAINTENANCE 5 Loosen bleed screw on the main fuel filter (3) 6 Pump the primer button (2) until all air is expelled from the bleed screw (3) 7 Tighten bleed screw (3) 8 Rotate main primer (4) anticlockwise and release 9 Pump main primer (4) until pressure increases (approx.
  • Page 157 PREVENTIVE MAINTENANCE AIR CLEANER SYSTEMS AIR CLEANERS AND FILTER REPLACEMENT Complete disassembly and cleaning is recommended at each ‘C’ Service interval. Under severe operating conditions, this should be done more frequently. Damaged or defective parts should (with the possible exception of mounting brackets) be replaced, not patched or repaired.
  • Page 158 PREVENTIVE MAINTENANCE ACCESSORY DRIVE bELTS The reliability and service life of drive belts can be extended with proper attention to installation, adjustment and maintenance. Neglect in these matters could cause belt failure, resulting in potential hazards through loss of the electrical or air system and possible engine damage due to overheating.
  • Page 159 PREVENTIVE MAINTENANCE Removing Poly-V-belt 7PK - Alternator and A/C Compressor 1. Move the tensioner against the spring force and lock it with a 4- 5mm thick locking pin or drill bit. 2. Remove the poly-V-belt from the guide roller first and then from the alternator and air-conditioning compressor pulleys.
  • Page 160 PREVENTIVE MAINTENANCE 6. Position the tensioner against the belt. 7. Check that the mark (2) on the tensioner arm is within range (A). • Mark (1) represent the nominal V-belt tension, deviating ± 2 mm. • Outside range(A), a belt is either routed incorrectly or outside its specification.
  • Page 161 PREVENTIVE MAINTENANCE COOLING SYSTEM Kenworth trucks come with air-to-air cooling systems as standard. These cooling systems incorporate a radiator to cool engine jacket water, a charge air cooler to cool turbocharged engine intake air, and a refrigerant condenser to provide cab airconditioning. COOLANT Use extreme caution when removing the radiator cap if the engine has been in operation within the previous thirty minutes.
  • Page 162 PREVENTIVE MAINTENANCE From the bottom of the radiator, the coolant returns to the coolant pump (1) via the coolant return pipe. The radiator and the coolant reservoir are directly connected. The connection pipe to the coolant reservoir (5) is also connected to the return pipe from the radiator. When the coolant heats up, it flows to the coolant reservoir.
  • Page 163 PREVENTIVE MAINTENANCE bleed line are connected to the engine and connected correctly. If these lines ARE NOT connected, it will be impossible to fill the cooling system with coolant and engine failure is inevitable. If frequent topping up becomes necessary and there are no visible signs of coolant leaks when the engine is cold, check for leaks with the engine in operation at normal operating temperature.
  • Page 164 PREVENTIVE MAINTENANCE The air bleed line (No. 6 Aeroquip Hose) connects into the engine side of the engine thermostat. This line allows air to bleed from the running engine when the engine thermostat is closed. It also allows air to bleed from the engine when filling the cooling system.
  • Page 165 PREVENTIVE MAINTENANCE bRAKE SYSTEM 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. Tyres are also a very important part of the whole system.
  • Page 166 PREVENTIVE MAINTENANCE Lubrication Cam-actuated brake components such as anchor pins and brake camshafts are subjected to high temperatures. They must be lubricated with non- melting, water resistant brake grease meeting R-S Specification 0-616 (NLGI-Grade 2). • Lubricate according to Recommended Maintenance Schedules, pages 227-246.
  • Page 167 PREVENTIVE MAINTENANCE AUTOMATIC SLACK ADjUSTERS During preventive maintenance on an in-service brake, check both the free stroke as described below and the adjusted chamber stroke as described on page 146. FREE STROKE MEASUREMENT Your Kenworth may be equipped with automatic brake (slack) adjusters. Periodically, brake adjustment should be checked using the following procedure: 1.

  • Page 168: Brake Adjuster Application

    PREVENTIVE MAINTENANCE ADjUSTED CHAMbER STROKE Mark push rod here to STROKE measure stroke 120 psi in air tank. Engine OFF • Spring brakes • Spring brakes released released • Service brakes • Service brakes applied - not applied Automatic brake Adjuster Application Air Chamber Type (size) Brake Pushrod Travel (applied...
  • Page 169 PREVENTIVE MAINTENANCE ANTI-LOCK bRAKING SYSTEM (AbS) Below are some general notes on your Kenworth anti-lock braking system. For detailed service information see the Kenworth Maintenance Manual. All service work should be performed by a qualified technician at an Authorised Service Centre. The foundation brake system must be in proper working order to ensure the best ABS performance.
  • Page 170 PREVENTIVE MAINTENANCE If the air system is intact (indicated by the pressure gauges), the service brakes will continue to function normally, but without benefit of the anti-lock feature. 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.
  • Page 171 PREVENTIVE MAINTENANCE AIR SUPPLY SYSTEM 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 a vehicle to roll unexpectedly resulting in an accident and/or injury.
  • Page 172 PREVENTIVE MAINTENANCE AIR SYSTEM FUNCTION TEST Scheduled maintenance should be performed on the Kenworth air system, as outlined in the Kenworth Maintenance Manual Section 5 CAT: 8047. In addition, perform an Air System Function Test at least every 3 months or if there is any indication of a potential problem.
  • Page 173 PREVENTIVE MAINTENANCE AIR COMPRESSOR OPERATION All compressors, regardless of make or model, run continuously while the engine is running. System pressure is controlled by the governor which (acting in conjunction with the unloading mechanism in the compressor cylinder block) starts and stops compression of air by loading or unloading the compressor when pressure in the system reaches a minimum of 690 kPa or a maximum of 827 kPa (100-120 psi).
  • Page 174 PREVENTIVE MAINTENANCE AIR GAUGES AND AIR LEAKS Your Kenworth comes with two separate air pressure gauges for two separate systems, Primary and Secondary. The Primary gauge indicates pressure in the rear braking system, the Secondary gauge indicates pressure in the front braking system. Each gauge indicates the amount of air pressure in kilopascals (kPa).
  • Page 175 PREVENTIVE MAINTENANCE TURbOCHARGER When servicing the air intake and exhaust systems on a turbocharged engine, check the following items: Lubricating System: Check oil lines, housing and connections. Look for leaks, damage or deterioration. Leaks could mean you have damaged oil lines or oil seals.
  • Page 176 PREVENTIVE MAINTENANCE TYRES TYRE INFLATION AND LOADING Regular and frequent inspection, and proper care will give you the assurance of safe, reliable tyre operation. Most tyre wear problems are caused by under inflation as the result of slow leaks. Low pressure is the tyres worst enemy; it allows tyres to flex badly and this causes high temperatures to build up.

  • Page 177: Recommended Laden Tyre Pressures

    PREVENTIVE MAINTENANCE TYRE INFLATION Most tyre wear problems are caused by underinflation. So you will want to check tyre pressure regularly. Give the tyres a visual test every day and check inflation with a gauge every week. When checking tyre pressure, inspect each tyre for damage to sidewalls, cuts, cracks, uneven wear, rocks between dual wheels (tyres) etc.
  • Page 178 PREVENTIVE MAINTENANCE It is also important to regularly have a wheel alignment. • Too much air pressure reduces the tyre tread contact area and results in rapid wear in the centre of the tyre. It also causes tyres to run hard and makes them more vulnerable to impact and other road hazard damage.

  • Page 179: Maximum Vehicle Load Rating

    PREVENTIVE MAINTENANCE Overinflated tyres can cause accidents. They wear more quickly than properly inflated tyres and are more subject to punctures, cracks and other damage. They could fail and cause you to lose control of your vehicle resulting in an injury and/or accident. Be sure all tyres are inflated correctly according to the manufacturer’s recommendations.
  • Page 180 PREVENTIVE MAINTENANCE REPLACING TYRES Front tyres should be replaced before less than 3 mm of tread remains. This does not include tie-bars or tread wear indicators. Replacement tyre and rim sizes must conform with those listed on the “Tyre Decal”, which is located in the cab (see pages 210-211) on all trucks manufactured up to December 31st 2004.

  • Page 181: Wheel Nut Torques

    PREVENTIVE MAINTENANCE WHEEL CAP NUT TORQUE At the first scheduled lube interval, have all wheel cap nuts torqued to their specified value. Thereafter, wheel nuts MUST be checked at least once a week. Contact the Service Department at any Authorised Kenworth Dealership for information on torque values applicable to the wheels installed on your truck or see the table below.
  • Page 182 PREVENTIVE MAINTENANCE VEHICLE jACKING Ordinary pedestal jacks are designed ONLY to LIFT a vehicle. Once lifted, the vehicle should be supported by other appropriate means, such as stands. NEVER get under, or work under, a vehicle supported ONLY by a jack. Only work under a vehicle supported by stands and with wheels chocked.
  • Page 183 PREVENTIVE MAINTENANCE jACK OPERATING INSTRUCTIONS Before use: Visually inspect the jack for any abnormal conditions and refer to the preceding WARNINGS, SAFE USAGE STATEMENTS and NOTES on page 160 and below. WARNING: There may be circumstances where dirt or residue on the ball seat may cause the jack to lower quickly and the jack handle to fly up in force.
  • Page 184 PREVENTIVE MAINTENANCE 2. To maximise the lifting height, unscrew the extension screw/head cap to the required height. 3. Insert the handle into the handle sleeve. Check that the handle or any part of your hand or arm does not come into contact with the vehicle when the handle is at its highest point.
  • Page 185 PREVENTIVE MAINTENANCE 3. Keep your jack clean and lubricate the pumping collar and extension screw. 4. Operate your jack at least twice per year. This will keep the seals moist. 4. Service kits are available and comprise the necessary washers and seals which would be required for a general overhaul of the hydraulic unit.
  • Page 186 PREVENTIVE MAINTENANCE bATTERIES battery Care Regular attention to the charging system will help prolong the service life of batteries. Common causes for battery failure are: Isolation Switch Essential for vehicles carrying dangerous loads i.e. petroleum products, gases, acids, explosives etc. The switch is designed to shut off all battery power, this will disable the Remote Keyless Entry and radio pre-sets in order to maintain total emergency electrical isolation.
  • Page 187 PREVENTIVE MAINTENANCE FAST CHARGING: If the battery(s) has lost its charge rapidly, from cranking an engine that failed to start, recharge at 30 to 40 amps for 1 to 2 hours. A rapid charge rate generates an explosive mixture of hydrogen and oxygen gases.
  • Page 188 PREVENTIVE MAINTENANCE • When fast charging, remove the battery caps so pressure does not accumulate. • Always make sure the battery charger is OFF before connecting or disconnecting the cable clamps. • To avoid short circuits and damage to yourself or the vehicle, never place metal tools or jumper cables on the battery or nearby.
  • Page 189 PREVENTIVE MAINTENANCE • Never use a fast charger as a booster to start the engine. This can seriously damage sensitive electronic components such as engine management systems, radio, etc., as well as the battery charger. Fast charging a battery is dangerous and should only be attempted by a competent mechanic with the proper equipment.

  • Page 190: Hydrometer Readings

    PREVENTIVE MAINTENANCE Use care when fast-charging. Watch for gassing. Check electrolyte. If it starts gassing violently, reduce the charging rate. Battery voltage should not exceed 28.4 volts. This is the recommended alternator voltage setting. ° HYDROMETER READINGS AT 27 Minimum Specific Gravity Percentage of Charge 1.260 100 %...
  • Page 191 PREVENTIVE MAINTENANCE ELECTRICAL SYSTEMS - 24 VOLT A vehicle with a 24V starting circuit should be jump-started ONLY with a vehicle having the SAME kind of system and ground. Jump-starting a vehicle with a 24V circuit requires two pairs of jumper cables.
  • Page 192 PREVENTIVE MAINTENANCE When the batteries are fully discharged and the engine is running, it is important that the jump leads are not immediately disconnected. The engine must run for at least 2 to 3 minutes before the jump leads are disconnected to prevent damage to the electrical system (peak voltage!).
  • Page 193 PREVENTIVE MAINTENANCE WELDING PRECAUTIONS FOR VEHICLES WITH ELECTRONIC INSTRUMENTATION To prevent damage to gauges, interface modules and other electronic and electrical equipment, disconnect the battery cables before electric arc welding on a vehicle. If arc welding of any frame-mounted components is required, ensure the welding ground lead is connected directly to the component, preferably directly adjacent to the weld groove.
  • Page 194 PREVENTIVE MAINTENANCE CHASSIS AND CAb – FINISH, APPEARANCE AND CLEANING CHASSIS AND CAb THE ENAMEL ON THIS VEHICLE IS NOT YET HARDENED. DO NOT STEAM CLEAN, WAX, POLISH, OR RUb THE FINISH UNTIL A MINIMUM 45 DAYS AFTER DELIVERY. CLEAN WITH COLD WATER AND SPONGE ONLY. High water pressure water washers and steam cleaners can dislodge seals and enter electrical circuits causing serious damage to the vehicle's systems.
  • Page 195 PREVENTIVE MAINTENANCE • Trees are also likely to attract birds. Bird droppings have a high acid content and will damage a freshly painted surface. Droppings should be washed off as soon as possible. • Try to avoid spilling petrol, oil, anti-freeze, transmission fluid, brake fluid and windshield solvent on the new finish.
  • Page 196 PREVENTIVE MAINTENANCE For the material to be maintained properly, it is important that you are aware of the correct methods for cleaning the trim so as to avoid any accidental damage which may occur if the wrong cleaning products are used. The procedures used for cleaning depend on the nature of the spill or stain.
  • Page 197 PREVENTIVE MAINTENANCE Weather-stripping Occasionally spray weather-stripping on doors and windows with silicone compound to help preserve resiliency. This is especially useful in freezing weather to keep doors and windows from sticking shut with ice. It is good practice to hose dirt and grime from the whole chassis. If an oil leak develops, it will be more easily detected.
  • Page 198 PREVENTIVE MAINTENANCE CAb HEATER/AIRCONDITIONING The combination heater/airconditioner provides comfort for those in the cab through accurate control of the cab environment in all weather conditions. Regular attention to the items below will help you keep the heater/airconditioner performance at an optimal level. Keep the vehicle’s ventilation system, engine exhaust system and cab/ sleeper joints properly maintained.
  • Page 199 PREVENTIVE MAINTENANCE SPECIAL PRECAUTIONS Excessive heat may cause the pressurised components of the airconditioning system to explode. Never weld, solder, steam clean or use a blowtorch near any part of the airconditioning system. If a refrigerant leak develops in the presence of excessive heat or an open flame, hazardous gases may be generated.
  • Page 200 PREVENTIVE MAINTENANCE AIRCONDITIONER Any servicing that requires depressurising and recharging the airconditioning system should be conducted by a qualified licensed technician with proper facilities. Check compressor belt for condition and proper tension (see pages 136- 138 for applicable data). Check compressor and drive clutch for noise and vibration. If problems exist, have the system checked thoroughly.
  • Page 201 PREVENTIVE MAINTENANCE SAFETY RESTRAINT SYSTEM The seatbelt system, including webbing, buckles, latches and mounting hardware, endures heavy use in heavy-duty vehicles - much more than seatbelt systems in passenger cars. All users should be aware of the factors contributing to this heavy use and reduced belt life. Failure to properly inspect and maintain restraint systems can lead to serious injury or loss of life.
  • Page 202 PREVENTIVE MAINTENANCE INSPECTION GUIDELINES Follow the guidelines below when inspecting for cuts, fraying, extreme or unusual wear of the webbing, and damage to the buckle, retractor, hardware, or for other factors. Damage to these areas indicates that belt system replacement is necessary. It is important to remember that any time a vehicle is involved in an accident, the entire seatbelt system must be replaced.
  • Page 203 PREVENTIVE MAINTENANCE Web cut/frayed at Web cut/frayed or D-Loop web guide extremely worn at latch area Adjustable turning D-Loop Comfort clip Buckle casting broken Retractor web storage 5. Check buckle and latch for proper operation and to determine if latch plate is worn, deformed or damaged. 6.
  • Page 204 PREVENTIVE MAINTENANCE 8. Check web in areas exposed to ultraviolet rays from the sun. If the colour of the web in these areas is grey to light brown, the physical strength of the web may have deteriorated due to exposure to the sun’s ultraviolet rays.
  • Page 205 PREVENTIVE MAINTENANCE TRANSMISSION AND CLUTCH Follow the procedures below to ensure parts are properly lubricated: • 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 Initial Change: drain and replace according to Recommended Service Maintenance Schedules on (pages 227-246).

  • Page 206: Transmission Service Intervals

    PREVENTIVE MAINTENANCE TRANSMISSION SERVICE INTERVALS For recommended types and brands of all lubricants, see the transmission manufacturer’s Service Manual and Recommended Maintenance Schedules and fluid quantities, page 245. MODEL RECOMMENDED AMBIENT VISCOSITY LUBRICANT TEMPERATURE (SAE) RANGE - °C Main Transmissions Roadranger Lube SAE 50 Eaton Fuller 18***...
  • Page 207 PREVENTIVE MAINTENANCE CLUTCH SYSTEM Free pedal is the distance the clutch pedal moves by applying only slight pressure. During free pedal, the release yoke in the transmission moves until its bearing pads contact the release bearing. This movement of the release yoke is called free travel.
  • Page 208 PREVENTIVE MAINTENANCE CLUTCH ADjUSTMENT - NORMAL WEAR Clutch pedal free travel is normally 25 to 38 mm. This should be your guide to determining if clutch adjustment is necessary. On vehicles not equipped with automatic clutch adjustment you should have an Authorised Kenworth Dealer adjust the clutch before pedal free travel is reduced to the minimum allowable 13 mm.
  • Page 209 PREVENTIVE MAINTENANCE CLUTCH LUbRICATION To ensure long life and proper operation of the release mechanism of the clutch it is important to properly lubricate the following areas: Release bearing The cast iron bearing housing will be equipped with either a standard grease fitting or a lube tube extension.
  • Page 210 PREVENTIVE MAINTENANCE STEERING Frequent visual checks of the steering gear and components are vital to driving safety. Check the crosstube for straightness. Check draglink ends, ball joints and steering U-joints for looseness. Check draglink for evidence of tyre rubbing and draglink clamp for looseness or interference.
  • Page 211 PREVENTIVE MAINTENANCE AXLE STOPS Your vehicle is equipped with power steering, have an Authorised Kenworth Dealer make axle stop adjustments. The power steering pressure relief valves must be adjusted in conjunction with the axle stops to prevent damage to the steering gear. After front axle alignment, it is recommended that axle stops and steering gear poppets are checked for proper relief on turns.
  • Page 212 PREVENTIVE MAINTENANCE U-jOINTS • The slip joints and universal joints of the drive shaft should be lubricated according to Recommended Maintenance Schedules, pages 227-246. Use a good quality lithium-soap base or equivalent extreme pressure (E.P.) grease: NLGI Grade 2. Improper lubrication of U-joints can cause them to fail prematurely. The driveshaft could separate from the vehicle and result in an injury accident and/or vehicle damage.
  • Page 213 PREVENTIVE MAINTENANCE FRONT AXLE AND SUSPENSION AXLE LUbRICATION • Change bearing lubrication when seats are replaced, or brakes are relined. See Recommended Maintenance Schedules, pages 227- 246. • 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 lubricant.
  • Page 214 PREVENTIVE MAINTENANCE VISUAL INSPECTION • For all vehicles mandatory maintenance procedures include re- tightening 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, including fatigue, vehicle gross weight, type of load, road conditions and vehicle speed.

  • Page 215: Spring Suspension U-Bolts Grade 8

    PREVENTIVE MAINTENANCE Tighten U-bolt nuts to the specified torque value with the vehicle loaded to its normal gross weight. The torque values below apply to U-bolts and nuts with clean threads lubricated with Chevron zinc lubricant SAE 20 or 30 oil. Do not operate the vehicle if the U-bolts are not properly tightened.

  • Page 216: Front Wheel Alignment Specifications

    PREVENTIVE MAINTENANCE WHEEL ALIGNMENT FRONT WHEEL ALIGNMENT For driving safety and comfort and to prolong the life of your vehicle, it is important to have wheels correctly aligned. Check tyre wear frequently. Uneven tyre wear is a sign the wheels may be misaligned. If you see uneven wear, take your vehicle to a service centre familiar with aligning wheels on Kenworth vehicles.
  • Page 217 PREVENTIVE MAINTENANCE REAR AXLE AND SUSPENSION GENERAL MAINTENANCE Your vehicle’s suspension, by design, requires a minimal amount of maintenance. However, suspensions in “over-the-road” operations require periodic inspection to ensure trouble-free performance. Do not work on the vehicle without the parking brake set and wheels chocked securely, using rubber wheel chocks against the front and rear surfaces of the tyres.
  • Page 218 PREVENTIVE MAINTENANCE VISUAL INSPECTION For all vehicles, mandatory maintenance procedures include re-tightening of U-bolts and complete inspection. However, even with proper maintenance, many factors affect the service life of springs and suspension components, for example fatigue, vehicle gross weight, type of load, road conditions and vehicle speed.
  • Page 219 PREVENTIVE MAINTENANCE REAR AXLE LUbRICATION Check oil level with the vehicle parked on level ground and the fluid warm. The level should be even with the bottom of the filler hole. Do not mix lubricants of different grades, although mixing different brands of the same grade lubricant (meeting MIL-L-2105-C) is acceptable.

  • Page 220: Rear Wheel Alignment

    PREVENTIVE MAINTENANCE REAR AXLE ALIGNMENT Continual road shock and load stresses may force the rear axles out of alignment. If you detect rapid tyre wear on the rear axles, you may have misaligned axles. If you suspect rapid tyre wear, have your rear axle alignment checked and adjusted by an Authorised Kenworth Dealer.

  • Page 221: Torque Requirements Frame Fasteners

    PREVENTIVE MAINTENANCE REAR SUSPENSION ALIGNMENT Check and adjust as necessary (refer to Maintenance Manual for your specific suspension). These torque limits are valid ONLY when the U-Bolt and nut threads are clean and have been lubricated with an SAE 20 or SAE 30 oil. Never re-use a self-locking nut.
  • Page 222 PREVENTIVE MAINTENANCE NOISE CONTROL SYSTEM Kenworth Trucks warrants to the first owner who purchases this vehicle (for purpose other than resale) and to each subsequent purchaser that this vehicle, as manufactured by Kenworth Trucks, was designed, built and equipped to conform, at the time it left Kenworth’s control, with all applicable Australian Design Rules and Noise Control Regulations.
  • Page 223 PREVENTIVE MAINTENANCE Exhaust System: Removing or rendering inoperative the exhaust system components. The exhaust system is part of the noise control system. Periodically check the exhaust for wear and loose or missing parts. On COE installations check exhaust ball joint for condition and proper fit. Inner Fender Shields and Cab Skirts: Removing shields or skirts.
  • Page 224 PREVENTIVE MAINTENANCE INSPECTION AND MAINTENANCE Use the following procedures to check the Noise Control System for sources of noise or deterioration that results in noise. Preventive maintenance and repair information is supplied. Wherever other systems are involved, such as electrical or cooling, reference is made to the applicable sections for more specific information.
  • Page 225 PREVENTIVE MAINTENANCE Engine-mounted Noise Insulators: Depending on the method of attaching noise insulators on engine and around oil pan (bolts, snap fasteners or straps), check for condition and security. Tighten loose fasteners and repair or replace any worn or damaged fasteners.
  • Page 226 PREVENTIVE MAINTENANCE Transmission and Driveline: Substituting different transmission or drive-line components, other than design-specified units, may result in increased vehicle noise emission. Hood Insulation blanket: Check all fasteners for condition and security. Repair or replace any broken or defective fasteners. Check for chafing, tears etc.
  • Page 227 PREVENTIVE MAINTENANCE MAGNETIC DRAIN PLUGS Engines, Gear Boxes and Differentials that have metal on metal contact create friction wear as the metal surfaces wear, giving off a fine greyish metal dust that contaminates the oil. All the contaminants cannot be removed by the oil filter alone, an oil filter is only capable of catching particles over 35 microns as these particles are extremely fine Magnetic drain plugs on Engines, Gear Boxes and Differentials perform...

  • Page 228: Grade 5 Fastener Torques

    PREVENTIVE MAINTENANCE TORQUE SPECIFICATIONS GRADE 5 FASTENERS The table below shows torques for assemblies of Grade 5, cadmium-plated, nylon insert nuts; plain cadmium-plated Grade 5 bolts or studs (with cadmium or zinc/chromate plated hardened washers). SAE GRADE 5 FASTENERS – NON LUbRICATED FASTENER TORQUE Size...

  • Page 229: Grade 8 Fastener Torques

    PREVENTIVE MAINTENANCE GRADE 8 FASTENERS The table below shows torques for assemblies of Grade 8, cadmium-plated, nylon insert nuts; plain cadmium-plated Grade 8 bolts or studs (lightly lubricated; with cadmium or zinc/chromate-plated hardened washers). SAE GRADE 8 FASTENER TORQUE REQUIREMENTS FASTENER SIzE TORQUE N.m.

  • Page 230: Conversion Table

    (l) 3.785412 MASS: ounce gram (g) 28.3495 pounds kilogram (kg) 0.45259237 hundredweights kilogram (kg) 50.8023 tons kilogram (kg) 1016.05 tons tonnes (t) 1.01605 POWER: horsepower kilowatts (kw) 0.7456999 horsepower (DIN) megawatts (mw) 0.0007456999 Page 208 CAT: 8030A June 2017...
  • Page 231 CONVERSION TABLES To Convert into Multiply by FORCE: pounds-force newtons (N) 4.44822 kilograms-force newtons (N) 9.80665 tons-force kilonewtons (kN) 9.96402 TORQUE: pounds-force/feet newton metres (Nm) 1.35582 pounds-force/inches millinewton metres (mNm) 112.985 tons-force feet kilonewton metres (kNm) 3.03703 PRESSURE AND STRESS: pounds-force per inch pascals (Pa) 6894.76...
  • Page 232 VEHICLE IDENTIFICATION CUSTOMER INFORMATION AND VEHICLE IDENTIFICATION Each vehicle manufactured by Kenworth Trucks Australia will have a certification label fixed to the cab as required by Australian Motor Vehicle Certification. On conventional models, the vehicle certification label is located on the inside of the passenger seat.
  • Page 233 VEHICLE IDENTIFICATION A Vehicle Identification Number (VIN) or chassis number is stamped on the top flange of the right hand side chassis rail, approximately one metre from the front of the rail, in the vicinity of the turbo. The location of the compliance plate is on the right hand side of the steering column, affixed to the steering column bracket below the dash CAT: 8030A June 2017 Page 211...
  • Page 234 VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMbER (VIN) All trucks are required to have a unique identifying number. ADR43/01, effective 1 January 1989, requires that the format of the VIN comply with ISO standards. These vary slightly from US SAE standards with regard to year codes. A A A + A A A A A A+ A A N N N N N N...
  • Page 235 VEHICLE IDENTIFICATION SERIAL NUMbERS AND CAPACITIES CHASSIS VIN / Chassis No: ........../ ......... Air comp: Serial No: ................Unit Trans. Model: .................. Unit Trans. Serial No: ................Aux. Trans. Model: ................. Aux. Trans. Serial No: ................Rear Suspension: ................... Rear Axle Model: ........
  • Page 236 EMERGENCY CONTACT NUMBERS After Hours After Hours Telephone: Service No: Parts No: Dealership: AUSTRALIAN CAPITAL TERRITORY Queanbeyan (02) 6297 3862 (0408) 697 151 (0409) 323 561 NEW SOUTH WALES Arncliffe (02) 9335 9080 (0447) 911 757 (0458) 088 885 Broken Hill (08) 8088 7777 (0447) 877 873 (0433) 977 478...
  • Page 237 EMERGENCY CONTACT NUMBERS After Hours After Hours Telephone: Service No: Parts No: Dealership: SOUTH AUSTRALIA Adelaide (08) 8139 4000 1800 472 222 1800 472 222 Berri (08) 8582 2944 Bordertown (08) 8752 0077 (0418) 838 437 (0417) 860 749 Burton (08) 8280 4800 Mt Gambier (08) 8721 3400...
  • Page 238 EMERGENCY CONTACT NUMBERS After Hours After Hours Telephone: Service No: Parts No: Dealership: WESTERN AUSTRALIA Albany (08) 6820 2400 (0417) 411 249 1800 472 222 Bunbury (08) 9722 8100 1800 472 222 1800 472 222 Geraldton (08) 9960 8000 (0429) 641 197 (0428) 233 934 Kalgoorlie (08) 9080 0500...
  • Page 239 SECTION THREE MAINTENANCE & LUbRICATION SCHEDULES...
  • Page 240 CAUTION THE UNITS IN THIS VEHICLE, ENGINE, TRANSMISSION AND DRIVE AXLES ARE FILLED WITH BREAKING-IN OIL AND MUST BE DRAINED AND REFILLED BEFORE OPERATING THE VEHICLE IN REGULAR SERVICE OR BEFORE A MAXIMUM OF 10,000 KM, FIRST SERVICE OR 250 HOURS OF OPERATION. 2050 &...
  • Page 241 Tear along perforation Tear along perforation...
  • Page 243 Master Lubrication Chart ......227 T4 Series - MX Engine Service Schedule ....228 First Service .
  • Page 244 LUBRICATION SCHEDULE WARRANTY QUESTIONS This section will assist you to understand the terms of the Warranty provided with your new vehicle. The following are some of the more frequently asked questions: Q. Who is an Authorised Kenworth Trucks Dealer? There are 55 Authorised Kenworth Trucks/PACCAR Parts Dealers throughout Australia, New Zealand and Papua New Guinea, as listed on pages 214-216 of this handbook.
  • Page 245 LUBRICATION SCHEDULE other qualified service technician or repairer. A warranty claim for the reasonable cost of such service may be made through your Authorised Kenworth Service Dealer. When such emergency service has been performed by someone other than an Authorised Kenworth Service Dealer, you should take your vehicle to an Authorised Kenworth Dealer for inspection and/or the completion of any required Warranty Service as soon as possible.
  • Page 246 LUBRICATION SCHEDULE Q. Are my tyres covered by New Vehicle Warranty? The tyres fitted to your vehicle are covered by a separate warranty provided by the tyre manufacturer. Your Authorised Kenworth Service Dealer will assist you by discussing any queries you may have with respect to the tyre with the tyre manufacturer’s representatives.
  • Page 247 LUBRICATION SCHEDULE If you operate under Extreme Conditions, your vehicle may require more frequent maintenance services. See your Servicing Dealer for advice on these matters. The Maintenance items, except where they are required as a result of defects in materials or workmanship, for which you will be required to pay, include: •...
  • Page 248 LUBRICATION SCHEDULE CUSTOMER ASSISTANCE We want you and the people you deal with to be happy with your new vehicle, while you have the vehicle. Normally, any problems which may arise with the sale, operation or servicing of your vehicle will be handled by your Dealer’s Sales or Service Departments.

  • Page 249: Periodic Maintenance

    LUBRICATION SCHEDULE MASTER LUbRICATION CHART (ALL KENWORTH TRUCKS) SAE 15W-40, API CJ-4 Lubricant may be used providing it meets specifications Schedule Service Intervals more frequently for severe operational conditions. Do not mix lubricants of different brands or types. If brand or type of lubricant is changed, the unit must be drained and flushed out prior to refill.

  • Page 250: T4 Series - Mx Engine Service Schedule

    LUBRICATION SCHEDULE T4 SERIES - MX ENGINE SERVICE SCHEDULE Maintenance Groups Depending on the use to which the vehicle is put, the vehicle is placed in maintenance group I, II or III. PTO (ESC) hours must also be incorporated into schedule.
  • Page 251 LUBRICATION SCHEDULE Maintenance Group I IMPORTANT: For trucks using PTO, use the following formula to calculate Total fuel consumption ˂ 1.66 kms / Ltr schedule: AND/OR Operation on building sites, in quarries, etc. AND/OR Operation on gravel roads 1 PTO (ESC) hour = 40 kms AND/OR Traffic in dusty conditions AND/OR Sanitation department vehicles AND/OR With an annual mileage of up to 90,000 km...
  • Page 252 LUBRICATION SCHEDULE LUbRICATION SCHEDULE (T4 SERIES – MX ENGINE) 1st SERVICE FULL SYSTEM DOWNLOAD: Download and archive log file recording all active/ inactive fault codes and engine/EAS system statistics, ie. fuel burn figures, overspeeds, etc. CHECK OIL LEVELS: Top up as necessary: Engine, transmission, rear carrier(s), power steering reservoir and oil lubricated wheel bearings.
  • Page 253 LUBRICATION SCHEDULE 1st Service Continued... 15 WHEELS AND TYRES: Check torque of all wheel nuts. Check for missing valve caps and stem locks, cracked or loose wheel lugs (cleats) and tyre pressures. 16 CAb: Check glass for scratches, window mechanism operation and general interior condition/appearance.
  • Page 254 LUBRICATION SCHEDULE LUbRICATION SCHEDULE (T4 SERIES – MX ENGINE) A SERVICE FULL SYSTEM DOWNLOAD: Download and archive log file recording all active/ inactive fault codes and engine/EAS system statistics, ie. fuel burn figures, overspeeds, etc. CHECK OIL LEVELS: Top up as necessary: Engine, transmission, rear carrier(s), power steering reservoir and oil lubricated wheel bearings.
  • Page 255 LUBRICATION SCHEDULE A Service Continued... 17 CHASSIS: Grease all lube points. Check torque of chassis/frame fasteners, suspension to frame bolts, cab/sleeper mounting points, transmission mounting bolts, suspension u-bolts, torque rod mounting bolts and fuel tank mountings. Check routing of fuel, air and electrical. Check operation of air dryers, moisture ejectors and air tank check valves.
  • Page 256 LUBRICATION SCHEDULE LUbRICATION SCHEDULE (T4 SERIES – MX ENGINE) b SERVICE FULL SYSTEM DOWNLOAD: Download and archive log file recording all active/ inactive fault codes and engine/EAS system statistics, ie. fuel burn figures, overspeeds, etc. ENGINE: Change engine oil and oil filters (including centrifugal filter). Change primary and secondary fuel filters.
  • Page 257 LUBRICATION SCHEDULE B Service Continued... 16 FRONT SUSPENSION: Check and lubricate (where applicable) spring shackle and hanger brackets, spring pins, shackle pins and bushes, spring leaves, king pins, bushings, thrust bearings and spindles, u-bolt torque, steering and tierod arms/ joints, steering stops and general inspection for wear. 17 REAR SUSPENSION: General inspection for wear.
  • Page 258 LUBRICATION SCHEDULE LUbRICATION SCHEDULE ( T4 SERIES – MX ENGINE) C SERVICE (Minimum 1 x Year) FULL SYSTEM DOWNLOAD: Download and archive log file recording all active/ inactive fault codes and engine/EAS system statistics, ie. fuel burn figures, overspeeds, etc.
  • Page 259 LUBRICATION SCHEDULE C Service Continued... 15 STEERING SYSTEM: Check sector shaft, steering shaft u-joints, slip joint, drive line pinch bolts (75-80 Nm lubricated), drag link and pitman arm, steering wheel free play and centralisation, steering gear mounting bolts, hoses and fittings, fluid level and operation.
  • Page 260 CHASSIS LUBRICATION POINTS 6 18 30 22* 23* 24* 25* 26* 10 19 21 Page 238 CAT: 8030A June 2017...
  • Page 261 CHASSIS LUBRICATION POINTS Not to scale Drawing specification may vary from actual vehicle CAT: 8030A June 2017 Page 239...
  • Page 262 CHASSIS LUBRICATION POINTS T409 CHASSIS LUbRICATION POINTS Key# ITEM ..................Lube HOOD PIVOTS (one each side) ................. CL POWER STEERING GEAR/RESERVOIR Refer to the Engine/Steering Gear Manufacturer’s Manuals for change intervals Change fluid & filter Ross (integral)** or Sheppard (integral)** ......ATF Grease fitting provided in housing trunion ........
  • Page 263 CHASSIS LUBRICATION POINTS Key# ITEM ..................Lube REAR AXLES Mineral Check oil level ................. GO Drain, flush & refill ..............GO REAR AXLES Synthetic Check ..................SO Drain & refill (Dependent on Oil Sample) .........SO 14*. FIFTH WHEEL ................CL 15*. SPRING PINS (one fittings each side) ........CL 16*.
  • Page 264 CHASSIS LUBRICATION POINTS Legend to Lubrication Schedule Items not shown on illustration See Operator’s Manual for Off-Highway Conditions Ball Bearing Grease EP NLGI-2 Brake Grease (See Lube Specs) Chassis Grease NLGI-2 ELC30 PACCAR Genuine ELC30 Coolant ALLlube Ultra SAE 15W-40, API CJ-4 Drive Axles Gear Oil Mineral Oil Synthetic Oil (Requires Periodic Sampling) Major...

  • Page 265: Master Lubrication Chart

    CASTROL MASTER LUBRICATION CHART ENGINES LUbRICANT CHECK NORMAL SERVICE INTERVAL Refer to A, B & C Service Castrol Vecton Long Drain 10W-40 LS PACCAR MX-13 Intervals for oil and filter Daily Castrol Vecton 15W-40 CJ-4/E9 changes ACEA E6/API CJ-4 XXW-40 TRANSMISSION LUbRICATION CHECK...
  • Page 266 CASTROL MASTER LUBRICATION CHART COMPONENT LUbRICANT CHECK NORMAL SERVICE INTERVAL Power Steering/Gear Castrol ATF Heavy Duty 10,000 km 160,000 km Drain & Replace Non-Driving Steer Axle Standard Pins: 10,000 km Knuckle Pins Sealed Pins: 40,000 km Steering Drive Axle, U-Joints, bearings and Knuckle Pins Chassis Fittings Suspension Fittings...

  • Page 267: Lubrication And Fluid Capacities

    LUBRICATION AND FLUID CAPACITIES T409/T409SAR with MX-13 Engine Oil (in Litres) PACCAR MX-13 460hp PACCAR MX-13 510hp Refill quantities include oil filter change Transmission Oil (in Litres) RTO16910B-AS3 RTLO16913A RTLO16918B RTLO16918A-AS3 RTLO18913A RTLO18918B RTLO18918A-AS3 RTLO20918B FO-16E318-MXP FO-18E318-MXP FO-20E318-MXP plus Remote Filter plus Oil Cooler Approx 1.1 ltr of oil per 7 metre run including oil cooler and standard size 10 hose...
  • Page 268 LUBRICATION AND FLUID CAPACITIES MAINTENANCE SERVICE RECORDS The remainder of this book contains a separate record for each of the scheduled maintenance services recommended for vehicles operating under normal conditions. Printed on each voucher is a list of all the items requiring attention for that particular service.

  • Page 269: A, B & C Service Intervals

    A, B & C SERVICE INTERVALS ENGINE GENERAL Oil Levels ü ü ü ü Check oil levels and top up as necessary: Engine, transmission, rear axle(s), front drive axle (if applicable), power steering reservior and oil lubricated front wheel bearings Engine Oil ü...
  • Page 270 A, B & C SERVICE INTERVALS System Download ü ü ü ü Complete system download for active / inactive faults, ECU statistics, etc... RADIATOR Engine Coolant ü ü ü ü Check for leaks. Check level and top up as necessary. Use only PACCAR Genuine ELC30 Coolant Coolant and Strainer ü...
  • Page 271 A, B & C SERVICE INTERVALS Change oil ü Drain mineral oil on first service. Refill with ü synthetic oil. Take oil samples to determine correct oil change interval. For severe service, refer to OEM's Service Manuals Change oil filter ü...
  • Page 272 A, B & C SERVICE INTERVALS Spring Leaves for Damage ü ü ü ü Clean of dirt and debris. Lightly lubricate. More frequent under Severe Work Conditions K i n g P i n s , B u s h i n g s , ü...
  • Page 273 A, B & C SERVICE INTERVALS REAR WHEEL bEARINGS Check Play and Adjust ü ü ü ü More frequently under Severe Working Conditions Drain and Refill Rear Hubs ü CHASSIS All Chassis Lube / Grease ü ü ü ü More frequently under Severe Working Points Conditions Chassis Bolts / Frame...
  • Page 274 A, B & C SERVICE INTERVALS bATTERY AND ELECTRICS Visual Inspection / Loose ü ü ü ü Connections R e m o v e a n d I n s p e c t ü ü Replace worn brushes as required Alternator Brushes O u t p u t V o l t a g e :...
  • Page 275 A, B & C SERVICE INTERVALS Air Pressure Buildup Time ü ü ü Record in minutes Governed Air Pressure ü ü ü Record in kPa Air Pressure Drop - Brakes ü ü ü Not Applied Air Pressure Drop - Brakes ü...
  • Page 276 A, B & C SERVICE INTERVALS HVAC System ü ü ü Check no exhaust leaks enter the cab area HVAC Fresh Air Filter ü ü ü More frequently under Severe Working Conditions Floor Mats ü ü ü Door Panels ü ü ü Headlining ü...
  • Page 277 A, B & C SERVICE INTERVALS ROAD TEST VEHICLE Steering / Steering Play ü ü ü ü Gear Shifting ü ü ü ü Brake Operation ü ü ü ü Engine Operation (Noise, ü ü ü ü Surging, Black Smoke) Throttle Operation ü...
  • Page 279 SECTION FOUR SERVICE RECORDS...
  • Page 281 FIRST SERVICE INSPECTION RECORD PLEASE USE BLOCK LETTERS Chassis No: ......Model: ........Kilometres: ......Date Inspected: ....Owner: ..................Servicing Dealer: ..............Owner's Address: ..................................Mechanic to inspect, make adjustments, tighten, correct or add fluids on all operations listed. Consult applicable service information for adjustments and specification. Tick = OK A = Adjust R = Repair...
  • Page 282 SERVICE INSPECTION RECORDS First Service Inspection Record Blue copy for Dealer files Yellow copy remains in Handbook. This is a free service (except for any lubricants and filters used). All other major components (Gearbox, Drive axles etc...) specified with synthetic oil must be drained and filled with synthetic oils at this sercice interval CHECK AND RECORD bELOW Radiator Coolant Condition:...
  • Page 283 SERVICE INSPECTION RECORDS “b” SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with b Service on page 234. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Clutch Engine Transmission* Check all Oil Levels Steering System* Valve Clearance Adjustment Front Suspension...
  • Page 284 SERVICE INSPECTION RECORDS “B” Service Inspection Record Technician’s Notes: Use separate sheet of paper if necessary. Page 262 CAT: 8030A June 2017...
  • Page 285 SERVICE INSPECTION RECORDS “A” SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with A Service on page 232. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Steering System* Check all Oil Levels Front Suspension Belts and Pulleys Rear Suspension...
  • Page 286 SERVICE INSPECTION RECORDS “A” Service Inspection Record Technician’s Notes: Use separate sheet of paper if necessary. CHECK AND RECORD bELOW Battery Electrolyte Level & Tighten Terminals: Page 264 CAT: 8030A June 2017...
  • Page 287 SERVICE INSPECTION RECORDS “C” SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with C Service on page 236. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Clutch Engine Transmission* Check all Oil Levels Steering System* Valve Clearance Adjustment Front Suspension...
  • Page 288 SERVICE INSPECTION RECORDS “C” Service Inspection Record Technician’s Notes: Use separate sheet of paper if necessary. Page 266 CAT: 8030A June 2017...
  • Page 289 SERVICE INSPECTION RECORDS “A” SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with A Service on page 232. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Steering System* Check all Oil Levels Front Suspension Belts and Pulleys Rear Suspension...
  • Page 290 SERVICE INSPECTION RECORDS “A” Service Inspection Record Technician’s Notes: Use separate sheet of paper if necessary. CHECK AND RECORD bELOW Battery Electrolyte Level & Tighten Terminals: Page 268 CAT: 8030A June 2017...
  • Page 291 SERVICE INSPECTION RECORDS “b” SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with b Service on page 234. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Clutch Engine Transmission* Check all Oil Levels Steering System* Valve Clearance Adjustment Front Suspension...
  • Page 292 SERVICE INSPECTION RECORDS “B” Service Inspection Record Technician’s Notes: Use separate sheet of paper if necessary. Page 270 CAT: 8030A June 2017...
  • Page 293 SERVICE INSPECTION RECORDS “A” SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with A Service on page 232. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Steering System* Check all Oil Levels Front Suspension Belts and Pulleys Rear Suspension...
  • Page 294 SERVICE INSPECTION RECORDS “A” Service Inspection Record Technician’s Notes: Use separate sheet of paper if necessary. CHECK AND RECORD bELOW Battery Electrolyte Level & Tighten Terminals: Page 272 CAT: 8030A June 2017...
  • Page 295 SERVICE INSPECTION RECORDS “C” SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with C Service on page 236. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Clutch Engine Transmission* Check all Oil Levels Steering System* Valve Clearance Adjustment Front Suspension...
  • Page 296 SERVICE INSPECTION RECORDS “C” Service Inspection Record Technician’s Notes: Use separate sheet of paper if necessary. Page 274 CAT: 8030A June 2017...
  • Page 297 SERVICE INSPECTION RECORDS “A” SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with A Service on page 232. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Steering System* Check all Oil Levels Front Suspension Belts and Pulleys Rear Suspension...
  • Page 298 SERVICE INSPECTION RECORDS “A” Service Inspection Record Technician’s Notes: Use separate sheet of paper if necessary. CHECK AND RECORD bELOW Battery Electrolyte Level & Tighten Terminals: Page 276 CAT: 8030A June 2017...
  • Page 299 SERVICE INSPECTION RECORDS “b” SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with b Service on page 234. Check Boxes - Tick = OK A = Adjust R = Repair Carry out all of the A Service Items - Plus the following items: Full System Download Clutch Engine...
  • Page 300 SERVICE INSPECTION RECORDS “B” Service Inspection Record Technician’s Notes: Use separate sheet of paper if necessary. Page 278 CAT: 8030A June 2017...
  • Page 301 SERVICE INSPECTION RECORDS “A” Service Inspection “C” Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
  • Page 302 SERVICE INSPECTION RECORDS “A” Service Inspection “b” Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
  • Page 303 SERVICE INSPECTION RECORDS “A” Service Inspection “C” Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
  • Page 304 SERVICE INSPECTION RECORDS “A” Service Inspection “b” Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
  • Page 305 SERVICE INSPECTION RECORDS “A” Service Inspection “C” Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
  • Page 306 SERVICE INSPECTION RECORDS “A” Service Inspection “b” Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
  • Page 307 SERVICE INSPECTION RECORDS “A” Service Inspection “C” Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
  • Page 308 SERVICE INSPECTION RECORDS “A” Service Inspection “b” Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
  • Page 309 SERVICE INSPECTION RECORDS “A” Service Inspection “C” Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
  • Page 310 SERVICE INSPECTION RECORDS “A” Service Inspection “b” Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
  • Page 311 SERVICE INSPECTION RECORDS “A” Service Inspection “C” Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
  • Page 312 SERVICE INSPECTION RECORDS “A” Service Inspection “b” Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
  • Page 313 SERVICE INSPECTION RECORDS “A” Service Inspection “C” Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
  • Page 314 SERVICE INSPECTION RECORDS “A” Service Inspection “b” Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
  • Page 315 SERVICE INSPECTION RECORDS “A” Service Inspection “C” Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
  • Page 317 INDEX free stroke measurement adjusted chamber stroke Axle stops A-Service 10,000 klms Axle, cross wheel differential lock Accelerating Axle, inter-axle differential lock Accessory drive belts Axle, two-speed rear axle removing 136, 137 Axle housing breather vents replacing 137, 138 serpentine belts AdBlue (DEF) B-Service 20,000 klms DEF AdBlue quality...
  • Page 318 INDEX system-safety and emergency cross shaft bushings system truck park clutch control linkage trailer brake 83, 84 pilot bearing initial charge wear pads 66, 187 trailer park 81, 83, 84 protection using brake system riding the clutch starting tips Coasting C-Service 40,000 klms Column mounted stalk control Cab -...
  • Page 319 INDEX Driver diagnosis AutoShift 73, 74 AdBlue 59, 60 Drive axle AdBlue level Drive axle temperature gauge filling Driver information pack (DIP) Selective Catalytic Reduction (SCR) 58 Driver controlled diff-lock EAS tampering Driver’s checklist EAS warning lights Driver’s seat before driving away Driving tips &...
  • Page 320 INDEX Hand (parking) trailer brake Fifth-wheel Hazard flasher hook up Headlight switch jaw lock emergency left hand headlight air activated 5th wheel Heater lubrication Heater and airconditioning 43, 176 Final stopping procedures special precautions before stopping the engine Hill start assist First service inspection record 230, 259 High beam Flash/fault codes - engine...
  • Page 321 INDEX Jacking Magnetic drain plugs general care of your jack Main differential lock jacking points Maintenance factors - operating instructions affecting fuel consumption 107, 108 to raise the load Maintenance service records to lower the load Manual transmission 20 tonne hydraulic bottle jack oil change storage of the jack operating...
  • Page 322 INDEX Odometer Rear axle Off-road function ABS/ATC alignment Oil - cross-wheel diff lock change transmission oil general maintenance draining housing breather vent level check inter-axle differential lock pressure gauge lubrication reservoirs operating rear drive axle sampling to lock Operating the engine to unlock temperatures U-bolts...
  • Page 323 INDEX Speedometer/Odometer Spring brakes - manual release Steering Safe driving axle stops Safe vehicle operation column Safety - driveline symbols u-joints restraint belts driveshafts tether belts steering wheel Safety precautions care & maintenance Seat adjustment cleaning Safety restraint system 50, 179 filter service and parts belts oversteer &...
  • Page 324 INDEX Trailer - park brake release valve brake hand valve U-Bolts supply valve, (red knob) torque Trailer ABS U-joints Traction control (ATC) UltraShift Plus Transmission 69, 75 Trailer park valve clearing fault codes Transmission 62, 183 clutch protection UltraShift Plus 69, 75 "D"...
  • Page 325 INDEX Warning - alarm/buzzer check engine lamp ABS light clusters stop engine Warnings, cautions, & notes Warranty questions Weekly operations Welding precautions - for vehicles with electronic - instrumentation for vehicles with electronic - engines Bearing adjustment front wheel alignment Wheels and tyres - cap nut torque tightening sequence...

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