Peterbilt 535 User Manual
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Peterbilt 535 User Manual

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Summary of Contents for Peterbilt 535

  • Page 3 Contents Safety........Emergency........Controls........Driving........Maintenance........Information........
  • Page 4 Contents © 2021 PACCAR Inc. - All Rights Reserved This manual illustrates and describes the operation of features or equipment which may be either standard or optional on this vehicle. This manual may also include a description of features and equipment which are no longer available or were not ordered on this vehicle.

  • Page 6: Table Of Contents

    SAFETY - Chapter 1 | SAFETY Using this Manual..........................6 Safety Alerts............................6 Illustrations............................7 General Safety Instructions........................8 Data Recorder............................. 11 Environmental Protection Agency....................... 11 Repairs..............................11 Additional Sources of Information....................... 12 Cab Access............................12 Deckplate Access..........................14 How to Open the Hood........................15 Close the Hood...........................
  • Page 7 SAFETY - Daily Checks............................24 Weekly Checks........................... 25 Systems Check........................... 26 Y53-6113-1A1 (11/20)

  • Page 8: Using This Manual

    Peterbilt not discussed in this manual, consult your end before you operate this equipment. Motors Company reserves the right to...

  • Page 9: Illustrations

    SAFETY - Illustrations Warnings The safety message following this symbol and signal word provides a caution against NOTE operating procedures which could cause equipment or property damage. The alert Pumping the accelerator will not assist will identify the hazard, how to avoid it, and in starting the engine.

  • Page 10: General Safety Instructions

    SAFETY - General Safety Instructions to follow these instructions may cause • DO NOT wear loose-fitting or torn death or injury. Special safety precautions clothing. Tie back and/or tuck in General Safety are included in the procedures when they long hair. Remove all jewelry when Instructions apply.
  • Page 11 SAFETY - General Safety Instructions • Before removing or disconnecting • Corrosion inhibitors and lubricating any lines, fittings, or related items, oils may contain alkali. DO NOT WARNING relieve all pressure in the air, oil, get the substance in eyes and fuel, and cooling systems.
  • Page 12 SAFETY - General Safety Instructions proper understanding of how to use prolonged contact with used engine which has been determined by the the tools before performing any oil. State of California to cause cancer. service work. Use only genuine Always wear protective clothing •...

  • Page 13: Data Recorder

    SAFETY - Data Recorder environment if spilled or not disposed of led or injured, or you could make your properly. Data Recorder vehicle unsafe. Perform only those tasks you are fully qualified to do. California Vehicle Code - Section 9951 - WARNING Disclosure of Recording Device Your vehicle may be equipped with one or...

  • Page 14: Additional Sources Of Information

    SAFETY - Additional Sources of Information Your dealer’s service center is the best Final Chassis Bill of Material about regulations governing transportation place to have your vehicle repaired. You across state lines. A complete, non-illustrated computer can find dealers all over the country with printout listing of the parts used to custom- the equipment and trained personnel to get build your vehicle is available through the...
  • Page 15 SAFETY - Cab Access handholds whenever possible and handles are not provided, do not look where you are going. climb onto the area behind the cab. • Use even more care when steps • Keep the steps clean. Clean any and handholds (or footwear) are fuel, oil, or grease off the steps wet, coated with ice, snow, mud,...

  • Page 16: Deckplate Access

    SAFETY - Deckplate Access secure rolling code technology that meters) of the vehicle and should not be in prevents someone from recording the entry proximity of other RF sources such as WARNING signal. television, radio or cell phone transmitters. To unlock the cab doors: To help lessen the chance and/or se- Press the UNLOCK button once.

  • Page 17: How To Open The Hood

    SAFETY - How to Open the Hood WARNING WARNING Keep steps clean. Clean any fuel, oil, When stepping onto a surface to enter or grease off the steps before entering the cab or access the deck plate, only the cab or accessing the deck plate. use the steps and grab handles instal- Stepping on a slippery surface can led and designed for that purpose.

  • Page 18: Close The Hood

    SAFETY - Close the Hood unexpectedly. Once the Hold-downs are Pull the latch up and towards the unlatched, the hood may be tilted open. hood. WARNING Lift the latching mechanism out of its housing. Unlatching Hood Hold-downs A hood could hurt someone in the way Rest the latching mechanism of its descent.

  • Page 19: Seat

    SAFETY - Seat Seat WARNING This section covers the operation and safe DO NOT let go of the hood while it use of your vehicles seats. For further closes. Close the hood in a controlled information on features and adjustment of manner which requires hands firmly the seat, see the manufacturer's service grasping the hood and feet on a sta-...
  • Page 20 SAFETY - Seat down. The seat back angle can also be locks the belt. The belt will also lock when comply may result in death or personal adjusted. These three movements are driving up or down a steep hill or in a sharp injury.
  • Page 21 SAFETY - Seat Incorrect Use of Restraint Safety Restraint Belt Twisted Lap Belt Too High on the Hip During Pregnancy Pregnant women should always wear Safety Restraint Tips Shoulder Belt Incorrectly Under the Arm combination lap/shoulder belts. The lap • DO NOT wear a belt over rigid or belt portion must be worn snugly and as breakable objects in or on your...
  • Page 22 SAFETY - Seat properly use the seat belts and • Never bleach or dye seat or bunk How to Use Lap/Shoulder Belt bunk restraint in the vehicle. restraint belts: chemicals can Follow these steps to fasten your seat belt weaken them. Do, however, keep •...
  • Page 23 SAFETY - Seat There should be less than one belt is fastened. inch (25 mm) gap between the WARNING body and the belt. The shoulder belt must be DO NOT remove, modify, or replace positioned over the shoulder, the tether belt system with a different it must never rest against the tether system.

  • Page 24: Vehicle Loading

    SAFETY - Vehicle Loading To shorten the tether, pull on the Latch the seat belt. Belt Damage and Repair strap. If available, adjust the seat belt Damaged belts in the cab must be height adjuster to a comfortable replaced. Belts that have been stretched, driving position.

  • Page 25: Visual Inspection While Approaching The Vehicle

    SAFETY - Visual inspection while approaching the vehicle GAWR Gross Axle Weight Rating. This is the total weight that one axle is designed Visual inspection while WARNING to transmit to the ground. You will find this number listed on the driver's door approaching the vehicle edge.
  • Page 26 SAFETY - Daily Checks showing signs of excessive wear or • Fuel filter (water separator) Fuel may emit a faint glow when the lack of lubrication? Have a qualified System on page 249 door is open and the dome mechanic examine any light is illuminated.
  • Page 27 SAFETY - Weekly Checks properly? Is the trailer spare wheel • Diesel exhaust fluid - check level. • Engine air pre-cleaner (option) - secure and inflated? Is the landing Is there enough fluid? For vocational vehicles with gear up and the handle secured? optional engine air pre-cleaner, •...
  • Page 28 SAFETY - Systems Check • Cab air conditioner fresh air filter - Once the Systems Check has completed, check for condition and the results will display in a summary. A cleanliness. detailed explanation of this summary can be viewed by accessing the menu after a •...
  • Page 29 SAFETY - Systems Check • Pressing Select. • Switching the exterior lights OFF. • Turning the ignition key to OFF or ACC. • Releasing the parking brake. Y53-6113-1A1 (11/20)

  • Page 30: Emergency

    EMERGENCY - Chapter 2 | EMERGENCY Roadside Assistance...........................29 Low Air Alarm .............................29 Stop Engine Light..........................30 Low Oil Pressure..........................30 Check Engine Lamp Turns On......................30 Engine is Overheating.........................31 How to Inspect and Replace a Fuse....................32 Where are the Fuses Located?......................34 How to Jump Start a Battery....................... 34 How to Recover a Vehicle........................

  • Page 31: Roadside Assistance

    EMERGENCY - Roadside Assistance Roadside Assistance Low Air Alarm NOTE Call toll-free to talk to someone at the The instrument cluster gauges may PACCAR Customer Center. appear, if hidden from view, change brightness and change color to bring attention to a particular system. Slow down carefully.

  • Page 32: Stop Engine Light

    EMERGENCY - Stop Engine Light Move a safe distance off the road and stop. Stop Engine Light Low Oil Pressure Place the transmission in neutral (park with automatic transmissions, if equipped) and set the parking brake. Turn OFF the engine. CAUTION Turn ON the emergency flasher and use other warning devices to...

  • Page 33: Engine Is Overheating

    EMERGENCY - Engine is Overheating the parking brake. Keep the engine • Stopping after high-speed/high- running. Engine is Overheating load driving • Debris blocking air flow through WARNING the cooling module (radiator) To reduce the chance of personal in- If the engine coolant temperature warning jury, vehicle damage, and/or death lamp comes on and the audible alarm from overheated engines, which can...

  • Page 34: How To Inspect And Replace A Fuse

    EMERGENCY - How to Inspect and Replace a Fuse Make sure the engine fan is turning WARNING by switching the Engine Fan How to Inspect and Switch from AUTO to MAN Replace a Fuse Removing the fill cap on a hot engine (Manual).
  • Page 35 EMERGENCY - How to Inspect and Replace a Fuse inspected by an authorized dealer. CAUTION CAUTION When replacing a failed polyswitch If a circuit keeps blowing fuses, have (circuit breaker), always use an ap- Blown Fuse the electrical system inspected for a proved polyswitch (circuit breaker) with short circuit or overload by an author- a current rating equal to or less than...

  • Page 36: Where Are The Fuses Located

    EMERGENCY - Where are the Fuses Located? personal injury, equipment or property Where are the Fuses WARNING damage. Located? When jump starting using a battery WARNING charger/booster, verify that the battery Fuses for the cab are located in the fuse charger/booster is set to the same jump panel behind the drivers side kick panel.
  • Page 37 EMERGENCY - How to Jump Start a Battery Set the parking brake. If either vehicle is equipped with battery disconnects, ensure that Shift the transmission into park CAUTION they are in the ON position. position or neutral for manual transmissions. Start the vehicle that has the good Applying a higher voltage booster bat- battery first.

  • Page 38: How To Recover A Vehicle

    EMERGENCY - How to Recover a Vehicle Review and understand all the attach to bumpers or brackets. Use cautions and warnings of this How to Recover a Vehicle only equipment designed for this pur- section. pose. Failure to comply may result in Disconnect the drive axle shafts equipment damage.
  • Page 39 EMERGENCY - How to Recover a Vehicle if it is supplying air pressure. If you tmc@trucking.org Website: http:// don’t desire to use the recovered tmc.truckline.com WARNING vehicle’s brakes, ensure that you cage the spring brakes before Manually Release the Parking DO NOT operate a vehicle when the attempting to move the vehicle.
  • Page 40 EMERGENCY - How to Recover a Vehicle WARNING Releasing the spring brakes on an un- secured vehicle could lead to an acci- dent. The vehicle could roll, which may result in death, personal injury, equip- Insert the release stud through the ment or property damage.
  • Page 41 EMERGENCY - How to Recover a Vehicle connected. This could cause a loss of system air, which can cause the service brakes not to function, resulting in the sudden application of the spring brakes causing wheel lock-up, loss of control, or overtake by following vehicles.
  • Page 42 EMERGENCY - How to Recover a Vehicle taminate the axle fluid and cause pos- could cause a loss of system air, which CAUTION sible damage to components. Ensure can cause the service brakes not to that the hubs are covered with plastic function, resulting in the sudden appli- whenever a drive axle shaft is re- Failure to lift the driving wheels off the...
  • Page 43 EMERGENCY - How to Recover a Vehicle firmly capped to prevent loss of air Best Practices for Recovery Recovery Rigging Options pressure from the recovery vehicle. Rigging • If you don’t want to use the recovered vehicle’s brakes, ensure CAUTION that you cage the spring brakes before attempting to move the Recovery pull maximums assume the...
  • Page 44 EMERGENCY - How to Recover a Vehicle Returning to Service After What to do if the Vehicle is Stuck in • For best traction and safety, avoid spinning the wheels Recovering Sand, Mud, Snow or Ice Follow these practices to avoid Once the vehicle is recovered, the axles transmission damage: need to have oil added to prevent gear...
  • Page 45 EMERGENCY - How to Recover a Vehicle • If towing from the front, ensure that the rear axles are prepared for CAUTION towing • If towing from the rear, ensure that Chains on the tires of only one tandem all body components such as roof, axle can damage the driveline U-joints side, and chassis fairings are and the inter-axle differential.
  • Page 46 Instrument Panel..........................46 Gauges..............................47 Warning Lights and Indicators......................48 Menu Control Switch........................... 63 Steering Wheel Controls (Option)....................... 63 Exterior Lights Switch (ELS)....................... 66 Peterbilt Digital Display........................67 Display Notifications..........................69 Views..............................70 Menu..............................74 Post Trip..............................77 Dash Switches............................ 77 Steering Column Controls........................96 Door Mounted Mirror Controls......................101...

  • Page 47: Chapter 3 | Controls

    CONTROLS - Heating and Air Conditioning......................104 Cab Accessories..........................111 Y53-6113-1A1 (11/20)

  • Page 48: Instrument Panel

    A/C Controls 12V Outlet 12V Outlet Shifter (push button shifter shown) Compact Trailer Valve Ignition Hazard Switch Dimmer Switch Exterior Lights Switch (ELS) Signal Stalk Peterbilt Digital Display Steering Wheel Dash Switches Parking Brakes (air operated) Radio Stereo System Y53-6113-1A1 (11/20)

  • Page 49: Gauges

    CONTROLS - Gauges The Engine Coolant (water) Temperature ous engine damage. Failure to comply gauge indicates the temperature of the Gauges may result in equipment or property engine coolant. damage. If the coolant temperature exceeds the maximum limits, a red warning lamp in the The Engine Oil Pressure gauge monitors gauge will turn on and an audible warning the oil pressure providing coolant to the...

  • Page 50: Warning Lights And Indicators

    CONTROLS - Warning Lights and Indicators Tachometer white line, if it lowers, it indicates with a red Warning Lights line. The rpm detail is also available as a viewable screen in the instrumentation cluster as a virtual gauge. The tachometer is a useful gauge when attempting to drive Gauges that stop receiving input from the efficiently.
  • Page 51 CONTROLS - Warning Lights and Indicators popup, providing additional information Some warnings can be managed by the (see Popups). Red and amber popups are operator while others may require an tallied at the top of the display and can be authorized dealer repair.
  • Page 52 CONTROLS - Warning Lights and Indicators Indication Name Symbol Color Standard Option Anti-Lock Brake System (ABS), Trailer on page 55 Yellow ● Axle, Stability Control (Option) on page 56 Yellow ● Axle, Traction Control on page 57 Yellow ● Check Transmission on page 57 ●...
  • Page 53 CONTROLS - Warning Lights and Indicators Indication Name Symbol Color Standard Option Dump Truck, Trailer Body Up on page 58 ● Engine BrakeSaver or Transmission Retarder on page Yellow ● Engine, Check Engine on page 59 Yellow ● Engine, Brake ON/OFF on page 58 Green ●...
  • Page 54 CONTROLS - Warning Lights and Indicators Indication Name Symbol Color Standard Option Engine, Overspeed on page 59 ● Engine, Retarder (Brake) on page 59 Green ● Engine, Stop Engine on page 59 ● Engine, Wait To Start on page 60 Yellow ●...
  • Page 55 CONTROLS - Warning Lights and Indicators Indication Name Symbol Color Standard Option Fifth Wheel Slide Unlocked on page 61 ● Fifth Wheel Unlocked on page 61 ● Hill Hold (Eaton Ultrashift Plus) on page 61 Yellow ● Lane Departure Warning (LDW) on page 61 Yellow ●...
  • Page 56 CONTROLS - Warning Lights and Indicators Indication Name Symbol Color Standard Option Park Brake on page 62 ● Seat Belt, Fasten on page 62 ● Transmission, Oil Temperature High on page 62 Yellow ● Turn Signal, Left on page 62 Green ●...
  • Page 57 CONTROLS - Warning Lights and Indicators Anti-Lock Brake System (ABS) Anti-Lock Brake System (ABS), If it turns on at any other time, it is indicating that a problem exists Trailer with the Power Line Communication (PLC) trailer ABS. This should be checked by an Illuminates during the Bulb Check (See authorized dealer as soon as Bulb Check...
  • Page 58 CONTROLS - Warning Lights and Indicators individual wheel brakes to re-adjust the (but without PLC) powered NOTE path of the vehicle. through the primary 7-way trailer light • The Stability Control Icon (ESC or line. Use the lamp on the driver's side If the Trailer ABS Warning Electronic Stability Control) of the trailer to identify trailer ABS...
  • Page 59 CONTROLS - Warning Lights and Indicators Axle, Traction Control is modified (e.g. adding or removing WARNING an axle, converting from a truck to a tractor, converting from a tractor to a If this chassis is equipped with an truck, changing the body, lengthening Electronic Stability Control (ESC) and of the wheelbase and/or frame, relo- is modified (e.g.
  • Page 60 CONTROLS - Warning Lights and Indicators A fault with transmission. When the switch is turned off (inter-axle Dump Truck, Trailer Body Up (Refer to transmission manual) differential unlocked) the engine power is allowed to flow to any of the four drive tires based on the differential effect (mostly to Diesel Particulate Filter (DPF) the forward rear differential).
  • Page 61 CONTROLS - Warning Lights and Indicators Indicates the level of engine braking Engine, Engine Block Heater Engine, Retarder (Brake) applied when the engine brake is enabled. Engine, Check Engine Illuminates when the engine block heater is Illuminates when the engine retarder turned on.
  • Page 62 CONTROLS - Warning Lights and Indicators Emissions, High Exhaust System Failure to do so could result in serious Temperature WARNING injury. If the Stop Engine warning light illumi- WARNING nates, it means you have a serious en- gine system problem. This should be considered an emergency.
  • Page 63 CONTROLS - Warning Lights and Indicators Illuminates when the fifth wheel is in the Lane Departure Warning (LDW) the UNLOCK position. Always inspect locked position. the fifth wheel after you lock the switch to be sure the fifth wheel slide lock is Fifth Wheel Unlocked engaged.
  • Page 64 CONTROLS - Warning Lights and Indicators Malfunction Indicator Lamp (MIL) Park Brake Transmission, Oil Temperature High Illuminates when an engine emissions failure has occurred. The vehicle can be safely driven but should be serviced to Illuminates when transmission lubricant correct the problem. The situation should Illuminates when parking brakes are temperature is too high.

  • Page 65: Menu Control Switch

    CONTROLS - Menu Control Switch Turn Signal, Right Steering Wheel Controls (Option) Blinks when the right turn signal or the CAUTION hazard light function is operating. Under no circumstances should you Worn brake attempt to service the steering wheel, clockspring, or any of the electrical wir- Trip –...
  • Page 66 CONTROLS - Steering Wheel Controls (Option) Left Switch Pod Cruise Control (CC) SET+ and RES- The left switch pod on the steering wheel Toggle contain buttons for the Trip and cruise control (see Cruise Control) features. Trip Starts a trip or sub-trip. A long press will clear all trip data.
  • Page 67 CONTROLS - Steering Wheel Controls (Option) Scroll Roll (or Scroll) the scroll wheel to target popup message (see Popups on page menu selections, change settings when in 69). Not used the menu, and switch between Views. The display indicates that the Scroll Wheel Back/Cancel When the term Scroll is used, rolling the can be used to Select with this icon:...

  • Page 68: Exterior Lights Switch (Els)

    CONTROLS - Exterior Lights Switch (ELS) Parking/Marker Lights Exterior Lights Switch (ELS) Exterior Lights Switch Turns on all legal driving lights except headlights: (ELS) The ELS is a five-position rotary switch Headlights that controls which exterior lights are active and can also start an Exterior Lights Self Test (ELST).

  • Page 69: Peterbilt Digital Display

    CONTROLS - Peterbilt Digital Display ELST engine, a passcode prompt will appear; the Digital Display Features engine cannot be started until the correct Momentary switch position used to start passcode is entered (for more information the Exterior Light Self Test (see ELST).
  • Page 70 CONTROLS - Peterbilt Digital Display • Engine Hours Please review the ACC section of this manual, and the manufacturer’s manual, • PTO Hours NOTE prior to driving this vehicle. • Trip (Sub-trip) • Odometer Some optional lights may illuminate Bulb Check...

  • Page 71: Display Notifications

    CONTROLS - Display Notifications The default passcode is set to 0000 at the Some popups, once viewed, are removed factory. Please see an authorized dealer if from the stack; these popups are called Display Notifications a custom passcode is needed. The suppressible.

  • Page 72: Views

    CONTROLS - Views • Instructions – Contain instructions operator can cycle through the available or elaborating information. views using the Scroll. When a view is shown, its position in the view sequence is The menu is not accessible until all popups indicated on the right.
  • Page 73 CONTROLS - Views • Active Warnings (see Active Gauge Views are shown in additional gauge views until Warnings). all monitored systems are represented: Primary Gauges – The highest priority • Outside Air Temperature (OAT) gauges. For vehicles with air brakes this •...
  • Page 74 CONTROLS - Views Custom (option) not been configured, scrolling to the NOTE custom view allows the operator to enter the custom view setup (See Custom A gauge, once selected, can Setup). The custom view can also be be removed by selecting that changed in the menu.
  • Page 75 CONTROLS - Views Tire Pressure Monitoring System viewed only while the parking brake is set. Trip Info TPMS displays individual tire pressures (option) and tire locations, using color to indicate the tire pressure condition: • Gray – Normal • Amber – Low (generates a popup) •...

  • Page 76: Menu

    CONTROLS - Menu detailed trip information see Trip Summary The Adaptive Cruise view contains optional and access trip information. The menu can located in the menu. features designed to improve the driving only be accessed when the parking brake experience: is set.
  • Page 77 CONTROLS - Menu • Custom View – Configures the distance is reached, at which point no custom gauge view: further trip information will be added. The max total distance for the main trip is • Custom View ON/OFF – 99,999.9 and 9,999.9 for a sub-trip. Enables the custom view.
  • Page 78 CONTROLS - Menu Settings • Dark Cabin – Turns Dark Cabin Information specific to these categories On/Off; this prevents cab interior can be shown by navigating to a category Settings allows the operator to customize lights from turning on when a cab using the Scroll and then pressing Select.

  • Page 79: Post Trip

    CONTROLS - Post Trip Post Trip presents information the driver might require for the next time the vehicle Post Trip is operated, such as active warnings and the distance to empty. Post trip is shown when the ignition switch is turned to OFF. During Post Trip, the menu can be accessed by pressing Select.
  • Page 80 CONTROLS - Dash Switches Dash Switches Symbol Name Symbol Color Standard Option Refer to Axle, Automatic Traction Control None ● Axle, Automatic Traction Control on page 86 Axle, Diff-Lock - Dual Amber ● Axle, Diff-Lock - Dual on page Axle, Diff-Lock - Forward Rear Amber ●...
  • Page 81 CONTROLS - Dash Switches Symbol Name Symbol Color Standard Option Refer to Axle, Inter-Axle Differential Locked Amber ● Axle, Inter-Axle Differential (Tandem) Locked (Tandem) on page 87. Axle, Two Speed Green ● Axle, Two Speed on page 87. Back Up Alarm Mute Amber ●...
  • Page 82 CONTROLS - Dash Switches Symbol Name Symbol Color Standard Option Refer to Cab Dimmer Switch None ● Cab and Panel Dimmer Switch page 89 Dump Truck Gate ● Dump Truck Gate on page 89. Engine, Brake Level None ● Engine, Brake Level on page 89.
  • Page 83 CONTROLS - Dash Switches Symbol Name Symbol Color Standard Option Refer to Engine, Remote Throttle Amber ● Engine, Remote Throttle on page Engine, Shutdown None ● Engine, Shutdown on page 90. Exhaust, Brake On/Off Green ● Exhaust Brake on page 145 Exhaust, Diesel Particulate Filter None ●...
  • Page 84 CONTROLS - Dash Switches Symbol Name Symbol Color Standard Option Refer to Kingpin Release None ● Kingpin Release on page 91 Ignition Key Switch None ● Ignition Key Switch on page 103. Lights, Beacon Green ● Lights, Beacon on page 92. Lights, Daytime Running (Override) Green ●...
  • Page 85 CONTROLS - Dash Switches Symbol Name Symbol Color Standard Option Refer to Lights, Footwell (option) Green ● Lights, Footwell Lights, Hazard ● Lights, Hazard on page 93. Lights, Headlight None ● Exterior Lights Switch (ELS) page 66 Lights, Auxiliary None ●...
  • Page 86 CONTROLS - Dash Switches Symbol Name Symbol Color Standard Option Refer to Suspension, Air Retention Amber ● Suspension, Air Retention page 94. Suspension, Axle, Pusher Green ● Suspension, Axle, Pusher page 94. Suspension, Axle, Tag Green ● Suspension, Axle, Tag on page Suspension, Lift Amber...
  • Page 87 CONTROLS - Dash Switches Symbol Name Symbol Color Standard Option Refer to Trailer, Axle (3rd Axle) Lift Green ● Trailer, Axle (3rd Axle) Lift page 95. Trailer, Axle Lift Forward Green ● Trailer, Axle Lift Forward on page Trailer, Axle Lift Rear Green ●...
  • Page 88 CONTROLS - Dash Switches Symbol Name Symbol Color Standard Option Refer to Trailer, Dump Gate Rear ● Trailer, Belly Dump Gate Rear page 95. Trailer, Hotline Green ● Trailer, Hotline on page 95. Trailer, Suspension Air Dump Amber ● Trailer, Suspension Air Dump page 96.
  • Page 89 CONTROLS - Dash Switches Axle, Diff-Lock - Forward Rear Axle, Diff-Lock - Single Rear The high range (On) is a faster ratio for highway speeds. Back Up Alarm Mute Turn switch on to engage Forward Rear Turn switch on to engage Single Rear Axle Axle Diff Lock.
  • Page 90 CONTROLS - Dash Switches Purpose Council (TMC) of the American Truck- The LVD may increase battery life and NOTE ing Association. To review the recom- prevent unnecessary jump start conditions mended practice, see TMC RP-136. by ensuring that an unattended load does All LVD circuits are color-coded blue not deplete the battery charge to a level on the central electrical panel cover la-...
  • Page 91 CONTROLS - Dash Switches Cab and Panel Dimmer Switch position 33% engine braking when engine Turn switch on to activate Cruise Control braking is active. System. This switch is used to alter the brightness For more information on when and how to of the instrument panel lights and controls use the engine brake in your vehicle, see Engine, Cruise Control Set/Resume...
  • Page 92 CONTROLS - Dash Switches With an electronic engine, the fan may also Engine, Shutdown be activated by air intake temperature, oil CAUTION temperature and compression brake usage. DO NOT operate the engine fan in the MANUAL position for extended peri- WARNING ods of time.
  • Page 93 CONTROLS - Dash Switches Exhaust, Diesel Particulate Filter Generic Air, Accessory operate the vehicle with the switch in (DPF) Regeneration the UNLOCK position. Always inspect the fifth wheel after you lock the switch Provides accessory air to the end of the to be sure the fifth wheel slide lock is frame connection when switch is turned on.
  • Page 94 CONTROLS - Dash Switches guarded to protect you from accidentally Lights, Beacon a substitute for headlights or other releasing the lock. See How to Release the lights during operations that require Kingpin Remotely (option) on page 157 lighting of your vehicle. Failure to com- ply may result in personal injury, prop- Lane Departure Warning Disable erty damage or death.
  • Page 95 CONTROLS - Dash Switches Turn switch on for trailer mounted Flood Lights, Footwell (option) night. A hard-to-see vehicle can result Lights. in an injury or accident. Another vehi- cle could run into you if you do not set Lights, Fog your flashers and follow the placement of emergency signals per FMCSR Two position switch that illuminates both...
  • Page 96 CONTROLS - Dash Switches Power Take-off (PTO) Turn switch on to lower Single or Forward Pusher Axle. CAUTION Suspension, Axle, Tag Increasing engine rpm before the PTO is actually engaged could prevent the This vehicle may be equipped with a dash PTO from engaging and/or cause PTO mounted switch that controls PTO damage.
  • Page 97 CONTROLS - Dash Switches Trailer Air Supply Turn switch on to lift Rear Trailer Axle. Trailer, Belly Dump Gate Front Trailer, Belly Dump The red octagonal knob controls the air Turn switch on to open Trailer Front Belly supply to the trailer. Dump Gate.

  • Page 98: Steering Column Controls

    CONTROLS - Steering Column Controls Tilt/Telescoping Steering Wheel Trailer, Suspension Air Dump Steering Column Controls Depending on your vehicle’s configuration, you may have either a tilt/telescoping feature. • The tilt feature allows forward and rearward movement of the wheel. Turn switch on to deflate trailer air •...
  • Page 99 CONTROLS - Steering Column Controls flash with the turn signal activated, even High Beam with the brakes applied. NOTE How to Use the Turn Signal The lever-action turn signal/high beam The headlights must be ON for the switch is located on the left side of the high beam switch to operate.
  • Page 100 CONTROLS - Steering Column Controls WARNING NOTE Clean blades regularly with a damp • You cannot momentarily flash cloth to remove road film and wax headlights when high beams are buildup. DO NOT drive with worn or on. The headlights will flash on if dirty wiper blades.
  • Page 101 CONTROLS - Steering Column Controls A seven-position rotary wiper switch • Transmission Mode selection (D - (located on the turn signal lever) operates N - R or D - N - R - P) CAUTION the windshield wipers and washer. If you •...
  • Page 102 CONTROLS - Steering Column Controls moving forward, or to the Park (P) or Drive operator to select the gear (See Upshifting acknowledge an upshift or downshifting (D) position while the vehicle is moving and Downshifting). request from the Gear Shift Lever. backward, will not change the transmission To activate, put the gear selector in the D When in Manual mode, the transmission...

  • Page 103: Door Mounted Mirror Controls

    CONTROLS - Door Mounted Mirror Controls optional air horns. To operate, pull on the controlled by the mirror heat switch button. lanyard extending from the overhead If the vehicle has optional hood-mounted header panel. heated mirrors, this switch will also activate heat to those mirrors.
  • Page 104 CONTROLS - Door Mounted Mirror Controls and the window will continue to open until it could have an accident if you are too close to another vehicle or other ob- is completely open. close to another vehicle or other ob- ject.

  • Page 105: Ignition Key Switch

    CONTROLS - Ignition Key Switch lights as part of a pre-trip inspection. An • marker lamps ELST can be activated via the dash switch Ignition Key Switch • headlights or the key fob. A full ELST can only be • radio station memory activated with the ignition switch in the ON The ignition key switch located to the right...
  • Page 106 CONTROLS - Heating and Air Conditioning • Fog lights (option) Test the Exterior Lights • Driving lights (option) Heating and Air For a full ELST, the parking brake must be • Daytime Running Lights (option) set and the ignition switch must be in the Conditioning ON position.
  • Page 107 CONTROLS - Heating and Air Conditioning hicles nearby. Failure to properly main- longed periods of time is not recom- WARNING tain your vehicle could cause carbon mended. monoxide to enter the cab, resulting in DO NOT drive with visibility reduced death or personal injury.
  • Page 108 CONTROLS - Heating and Air Conditioning Air Conditioner Controls NOTE If you are parked next to idling vehi- cles, move your vehicle or do not stay in your vehicle for prolonged periods of time. Fan control Dial AUTO mode button Temperature control dial MAX defrost button...
  • Page 109 CONTROLS - Heating and Air Conditioning Air Conditioning Functions Image Function Image Function Short Description: These symbols for the The button inside the Defrost Vents (and Fresh air conditioner operate various system temperature control dial air intake) functions. engages the A/C Panel and Floor Vents compressor.
  • Page 110 CONTROLS - Heating and Air Conditioning To adjust the air distribution, turn button that enables automatic mode is the Air Distribution dial to labeled AUTO. NOTE distribute cab air as indicated by the dial graphics. The system will remain in automatic mode Fan Control Dial must also be in the Press the Recirculation button to until the driver adjusts the dials on the...
  • Page 111 CONTROLS - Heating and Air Conditioning automatic mode. This can be done via the How to Operate Automatic Cab Air dials and/or buttons on the HVAC control. Conditioner In Semi-automatic mode, the AUTO button Follow these steps to activate the Auto indicator will cease to be illuminated.
  • Page 112 CONTROLS - Heating and Air Conditioning Air Conditioner Operating Tips defrosting the windshield. However, note • Set the air source to recirculation that performance may be reduced. mode by pressing the outside air/ recirculation air button. The button • Adjust the fan speed to high by CAUTION indicator light should be rotating the fan control dial...
  • Page 113 CONTROLS - Cab Accessories • Adjust fan speed to the desired have difficulties in obtaining the desired airflow setting. cabin temperature if the temperature Cab Accessories setting is repeatedly changed. • Engage the air conditioner The mode of air distribution inside the cab compressor by pressing the air is set using the air distribution dial.
  • Page 114 CONTROLS - Cab Accessories particular radio, see the supplemental Previous/Cancel tacle. A cigarette lighter inserted into operating manual for those units. Media source the 12V power port will heat up and be Controls for the infotainment system are Next/Accept expelled into the cab, potentially caus- located on the Right Switch Pod of the ing personal injury, fire, and property steering wheel.
  • Page 115 CONTROLS - Cab Accessories Glove Box Appliances road, they could fly through the air and A glove box is provided to store important If your vehicle is equipped with a television strike you or a passenger. You could documents, the vehicle literature set or other appliance, be sure they are be injured or even killed.
  • Page 116 CONTROLS - Cab Accessories the road, which could result in an acci- services. Not all emergency services WARNING dent involving death, personal injury or are in the database. equipment damage. Verify legal weight and height restric- NOTE tions for the route suggested by the WARNING telematic system.
  • Page 117 CONTROLS - Cab Accessories WARNING Warning/Informational Screen WARNING DO NOT let this device distract you while driving. Always concentrate on your driving. Distractions could cause an accident resulting in injuries to DO NOT let this device distract you or others. you while driving.

  • Page 118: Driving

    DRIVING - Chapter 4 | DRIVING Starting and Operating........................117 Starting and Warming Up........................117 Engine Operations..........................121 Transmission.............................128 Hydraulic Brakes..........................133 Air Brake System (option)......................... 135 Brake Safety and Emergency......................141 Retarders............................144 Axle and Suspension........................147 Fifth Wheel............................156 Driving Tips and Techniques......................

  • Page 119: Starting And Operating

    DRIVING - Starting and Operating Remember When Starting Vehicle in Cold may come in contact with dry grass, Weather on page 118. Starting and Operating brush, spilled fuel, or other material that can cause a fire. For detailed information on starting and WARNING operating the engine, refer to the Engine Operation and Maintenance Manual...
  • Page 120 DRIVING - Starting and Warming Up procedure. If Anti-Theft is enabled, the first As soon as the engine starts, begin warm up (approximately 3-5 time you turn the ignition switch to START, to watch the oil pressure gauge. minutes) before operating vehicle. you will need to enter the Passcode.
  • Page 121 DRIVING - Starting and Warming Up below 32°F (0°C). Engaging the under NOTE CAUTION hood air intake while temperatures are above freezing may result in engine In colder climates where the tempera- damage. Always unplug heater before starting ture is often below freezing, the warm- the engine.
  • Page 122 DRIVING - Starting and Warming Up haust fumes are entering the cab. In- NOTE vestigate the cause of the fumes and CAUTION correct it as soon as possible. If the vehicle must be driven under these Under most circumstances, idling your The use of a winterfront can result in conditions, drive only with the windows engine for long periods merely wastes...

  • Page 123: Engine Operations

    DRIVING - Engine Operations transmission before starting out on the When enabled, the tachometer will NOTE road. represent PTO operation, and may display To warm-up the transmission lubricating oil the following additional PTO related during engine warm-up, with a single information: Keep the engine exhaust system and transmission (manual and automatic):...
  • Page 124 DRIVING - Engine Operations should observe during this process; speed control operations. A white Stopping the PTO will return the engine however, defer to your PTO manufacturer's speed control enabled icon will speed to its default setting. It is not advised Operating Instructions in all cases where appear to stop the PTO when engine speed is...
  • Page 125 DRIVING - Engine Operations as the ambient temp reaches 41°F WARNING CAUTION (5°C). The use of a winterfront above 40°F (4°C) can result in excessive DO NOT work on or near the fan with coolant, engine oil, and intake air tem- The fan or equipment near it could be the engine running.
  • Page 126 DRIVING - Engine Operations System (EAS), to control vehicle exhaust Engine Aftertreatment System Detail Cruise Control emissions. The Engine Aftertreatment system consist of a Diesel Particulate Filter WARNING (DPF), Selective Catalyst Reduction (SCR), DPF Switch and warning lights. The DO NOT operate the cruise control DPF will trap soot from the engine exhaust when operating on road surfaces with gases.
  • Page 127 DRIVING - Engine Operations been pressed since the vehicle has been Trip started. In vehicles with Eaton Variable Road Speed Limiter transmissions, the cruise control switches (VRSL) LIM+ and LIM- may be located on the shift control knob. Cruise Control ON/OFF The left switch pod on the steering wheel Cruise Control (CC) SET+ and contain buttons for the cruise control.
  • Page 128 DRIVING - Engine Operations Following Distance Alerts • Press the SET portion of the RESUME feature. Pressing RESUME will The display will be white when the vehicle SET/RESUME switch on the resume the vehicle speed previously set. in front is at a proper distance ahead of the dash When turning the system off, the previous truck.
  • Page 129 DRIVING - Engine Operations Lane Departure Warning (Option) The Lane Keeping Assist feature is enabled by default when the vehicle is on A visual and audible alert will occur when a as indicated by a white icon. When the lane marking is unintentionally crossed. vehicle speed is above 40 MPH (65 km/h), The operator can mute the Lane Departure the conditions are right, and the system is...

  • Page 130: Transmission

    DRIVING - Transmission Air Filter Restriction Indicator (Option) WARNING An Air Filter Restriction Indicator may be installed on the air filter housing or air Ultimate responsibility for the safe op- induction piping for access to clean, filtered eration of the vehicle remains with the air.
  • Page 131 DRIVING - Transmission will allow your clutch to slip, causing of your transmission. Double • Gear Shift Assist (option) excessive heat and wear, damage could clutching refers to a technique Vehicles with PACCAR or Eaton result. where the clutch pedal is used automated transmissions will show the twice per shift instead of once.
  • Page 132 DRIVING - Transmission For further instructions on operating your gears. Metal contacting metal in moving transmission, see the transmission parts may seriously damage your CAUTION manufacturer's Driver/Operator's transmission, do not drive in one gear for Instruction Manual. long periods of time until the transmission Always use first gear or a low speed If you want to shift directly into any gear lubricant has a chance to coat all...
  • Page 133 DRIVING - Transmission How to Use the Hydraulic Clutch Depress the clutch pedal another • Never coast with the transmission 1/2 in. (13 mm) to engage the in neutral and the clutch clutch brake. disengaged. CAUTION • To provide smooth gear The clutch brake is used for stopping engagements while shifting, use transmission gears, allowing you to easily...
  • Page 134 DRIVING - Transmission • Upshifts: let the engine and jury. Always apply the parking brake from the brake pedal and firmly press gears slow down to the rpm before you leave the cab. on the accelerator pedal. required for the next gear. •...

  • Page 135: Hydraulic Brakes

    DRIVING - Hydraulic Brakes read the automated transmission manual Driver/Operator's Instruction Manual to pressurized fluid from the master cylinder included with your vehicle for instructions learn how to operate correctly. has two mutually independent circuits. The on how to change shift configurations. primary circuit supplies the front wheels while the secondary circuit supplies the Controls for Vehicles with an Eaton...
  • Page 136 DRIVING - Hydraulic Brakes NOTE NOTE Today's diesel engines have significant Failure to fully release the parking torque and startability power at low brake before moving can cause the rpm. Combinations of engine speed brakes to overheat. and available torque may over-power the vehicle's parking brakes.

  • Page 137: Air Brake System (Option)

    DRIVING - Air Brake System (option) Adjust the parking brake lever. See your vehicle. The Anti-Lock Brake Sys- the Medium Duty Maintenance WARNING tem (ABS) is calibrated for the specific Manual. tire revolutions per mile. Use of a tire If a new drum or new brake shoes are and/or wheel size different from that ABS Warning Lamp installed, the driveline brake must be...
  • Page 138 DRIVING - Air Brake System (option) takes outside air and compresses it, Simultaneously (on full truck usually to 100-130 psi (689-896 kPa). The configurations), air is also supplied to the WARNING compressor air then goes to the air tanks modulating valve control port. In the event to be stored until needed.
  • Page 139 DRIVING - Air Brake System (option) To Release the Vehicle Parking automatically pop out. (A dash Brakes ONLY warning light will indicate when the WARNING brake is ON.) • Push IN the Yellow knob on the dash. Your trailer will remain Shift the transmission into PARK DO NOT leave the cab of your vehicle parked.
  • Page 140 DRIVING - Air Brake System (option) When system pressure reaches 50 psi (345 kPa) the Red knob may be WARNING CAUTION pushed IN. Hold the Red knob IN by hand until Using the trailer hand brake or air Do not try to put the vehicle in motion the trailer air pressure builds to a brakes to hold a parked vehicle is dan- before pressure in the system reaches...
  • Page 141 DRIVING - Air Brake System (option) To apply the trailer brakes only: the trailer brakes. This complies with the Pull OUT the Red knob. This will exhaust Federal Motor Vehicle Safety Standards air from the trailer supply line, causing the (FMVSS) 121 requirement that one control vehicle protection valve to close and the should apply all the parking brakes on the...
  • Page 142 DRIVING - Air Brake System (option) Governor controls the air pressure in the system spring brake by actuating the compressor chambers. NOTE discharge mechanism. Its cut-out • Provides a quick pressure is 115 to 125 psi (793 to 862 kPa). Its preset cut-in pressure is set release of air The trailer brake is not to be used as a to between 13 to 25 psi (90 to 172...

  • Page 143: Brake Safety And Emergency

    DRIVING - Brake Safety and Emergency pressure drops below 60 psi (414 the parking (spring) brakes of the kPa), the trailer spring brakes are vehicle or of the vehicle-trailer Brake Safety and combinations. If the air system is automatically applied, and the being charged from zero pressure, Emergency vehicle air pressure circuits are...
  • Page 144 DRIVING - Brake Safety and Emergency Automatic Traction Control Emergency Braking CAUTION WARNING If the ABS warning light does not illu- Unless you have an anti-lock braking minate when the ignition is first turned on, there is a problem with the bulb or system (ABS), always avoid complete- Your truck/tractor ABS is equipped with an wiring.
  • Page 145 DRIVING - Brake Safety and Emergency steering circuit or a pressure differential • Use the parking brake - The wet. Water in the brakes can cause them between the primary and secondary brake parking or emergency brake is to be weak, to apply unevenly, or to grab. circuits.

  • Page 146: Retarders

    DRIVING - Retarders Brake Operation drum type brakes is usually about 800˚ F transmission. These are devices that use (427˚ C). your engine’s power to slow down your If service brakes are used for emergency vehicle. They save wear and tear on your WARNING braking, used improperly, or for prolonged service brakes and can be a safety feature,...
  • Page 147 DRIVING - Retarders you may need. When you are bobtail ing death or personal injury. Always be WARNING or unloaded, you can have a serious ready to suddenly apply the service accident if your wheels lock suddenly brakes. The service brakes must be used in an during braking.
  • Page 148 DRIVING - Retarders Engine Brake Level Switch stop and/or in situations of WARNING poor traction (such as wet, icy, or snow covered roads). Trying Using an engine retarder can to use the engine compression cause a wheel lockup. The brake or exhaust brake instead trailer is not loading the tires of the service brakes may enough to give the traction you...

  • Page 149: Axle And Suspension

    DRIVING - Axle and Suspension provides acceleration. In these cases, the internal gears. The switch has a guard to engine brake indicator will turn white while prevent accidental operation of the switch. Engine Brake Level (3 position) acceleration is being applied. Locking the differentials is typically used during ice or snow conditions and without Switch Position...
  • Page 150 DRIVING - Axle and Suspension To LOCK the Inter-Axle Differential Inter-Axle Differential Lock WHEEL DIFFERENTIAL. By moving the switch you can LOCK or UNLOCK Operation Anticipate when you might need the main differential when the vehicle increased traction, slow down to a is moving or stopped.
  • Page 151 DRIVING - Axle and Suspension resume and the light on the switch Remove the caging bolt from its • When you are driving with poor will turn off. storage hole. traction, lock the differential. When you have the differential locked, Screw the caging bolt all the way drive with the axle in LOW range into the air line hole.
  • Page 152 DRIVING - Axle and Suspension transmission normally to reach your desired cruising speed. CAUTION CAUTION How to Operate Two-Speed Axle - If you shift the axle range with the in- To avoid damaging your vehicle shift High to Low ter-axle differential in LOCK, you could the axle at slower travel speeds until These steps should be used if operating a seriously damage the axles.
  • Page 153 DRIVING - Axle and Suspension Auxiliary Axle axle will raise when the park brakes are applied or if the vehicle is placed in WARNING reverse. For Non-Steer Lift Axles, the axle will only automatically raise if the park DO NOT operate or park the vehicle brakes are applied and there are no park with auxiliary axles in the down/loaded brakes on the lift axle.
  • Page 154 DRIVING - Axle and Suspension Axle Creep Rating After the trailer is coupled or uncoupled, in death, personal injury, equipment or Vehicles outfitted with auxiliary axles and then increase pressure to balance traction property damage. full truck configuration will have an axle and axle load requirements.
  • Page 155 DRIVING - Axle and Suspension • Maximum tire static loaded radius Setting the To obtain the desired axle load (SLR) per axle manufacturers Pressure-to- distribution, you must correlate the CAUTION Load Ratio suspension air gauge pressure to the specifications actual axle load by scaling the axle weight(s) and adjusting the pressure to DO NOT modify the air system and/or Pusher or Tag Suspension...
  • Page 156 DRIVING - Axle and Suspension assist you in achieving an height may result in improper interaxle U- Locate the air suspension ride estimated ground load). joint working angles. This can result in height valve. premature driveline wear and driveline After setting the pressure to obtain vibration.
  • Page 157 DRIVING - Axle and Suspension Rotate the valve either clockwise or Torque the mounting fasteners to Single Axle Unladen Ride Height -in. counterclockwise until air pressure 55-75 lb-in. (6.2-8.5 N·m). (mm) in the air springs provides the ride Remove the alignment pin or height specified for that Air Trac 11.39 (289)

  • Page 158: Fifth Wheel

    DRIVING - Fifth Wheel What to do if an Air Spring Ruptures Suspension Air Pressure Gauge & CAUTION Switch If an air spring has ruptured, drive the vehicle to a safe stop off the highway to Operating a vehicle with air suspen- investigate the problem.
  • Page 159 DRIVING - Fifth Wheel How to Release the Kingpin tractor to a trailer (the kingpin is en- Remotely (option) WARNING gaged in a closed lock jaw with the lock jaw secured by a closed plunger) Ensure that all fifth wheel mainte- may cause trailer separation which CAUTION nance, adjustments, and rebuilding are...
  • Page 160 DRIVING - Fifth Wheel The popup will inform the operator How to Release the Kingpin NOTE when to release the switch. Manually JOST Fifth Wheel Indication Do not drive tractor free of trailer. CAUTION If the tractor has a rear air suspension, deflate (dump) the Do not deflate the rear suspension be- rear suspension enough so that the...
  • Page 161 DRIVING - Fifth Wheel Disconnect brake air and electric Suspension Dump Symbol lines from trailer, and secure lines. WARNING Unlock the fifth wheel release handle if necessary, then unlock Do not move the fifth wheel while the the fifth wheel. tractor-trailer is in motion.
  • Page 162 DRIVING - Fifth Wheel Position the tractor and trailer in a If plungers are still not fully straight line on firm, level ground. withdrawn, lower the landing WARNING gear and deflate the rear Place the tractor in neutral, and set suspension (if available) to the tractor and trailer parking DO NOT move the fifth wheel while...

  • Page 163: Driving Tips And Techniques

    DRIVING - Driving Tips and Techniques and lubricated periodically to ensure lose control of the vehicle which can WARNING smooth turning and sliding action. Fail- lead to an accident involving death or ure to keep these surfaces lubricated personal injury. Do not operate the vehicle un- can lead to frame or driveline damage.
  • Page 164 DRIVING - Driving Tips and Techniques Descending a Grade higher gear to bring engine rpm within the optimum speed range. NOTE • When driving downhill: shift to a WARNING lower gear, use the engine brake (if Often these recommendations are so equipped), and use the service DO NOT hold the brake pedal down secondary to maintaining an adequate...

  • Page 165: Stopping The Vehicle

    DRIVING - Stopping the Vehicle Maintenance factors affecting fuel always possible to choose the most consumption: adequate road, but the ideal road is the WARNING one that allows a steady speed in high • Air and/or fuel filters partially gear, without requiring frequent braking clogged DO NOT look at the Instrument Cluster and acceleration.
  • Page 166 DRIVING - Stopping the Vehicle Turbocharger top of the fuel tank. Fuel shut off valves for comply may result in death or personal the fuel crossover line are on the bottom of This cooling-down practice is especially injury. the fuel tank, at the crossover line important on a turbocharged engine.

  • Page 167: Antilock Brake Systems (Abs)

    DRIVING - Antilock Brake Systems (ABS) WARNING Lift axles that are not equipped with parking brakes should be fully raised when parking the vehicle. Lift axles, that are not equipped with parking brakes, left in the down position while parked, in certain cases, could cause the parked vehicle to roll, causing an accident involving death or personal injury.
  • Page 168 DRIVING - Antilock Brake Systems (ABS) cates a problem, have the ABS WARNING checked. CAUTION The antilock brake system is a critical Vehicles without ABS are typically DO NOT splice into the non-switchable vehicle safety system. For the safety equipped with a bobtail brake proportioning Auxiliary circuit on the primary 7-way of you and others around you, have system.
  • Page 169 DRIVING - Antilock Brake Systems (ABS) problem in any of the trailers will activate with the option to turn on this lamp for the Trailer ABS Warning Lamp. these types of trailers, then this lamp will If you change the intended service in any turn on when that trailer ABS has a system way (e.g., number of axles, multiple problem.
  • Page 170 MAINTENANCE - Chapter 5 | MAINTENANCE New Vehicle Maintenance Schedule....................171 First Day............................171 First 50-100 mi / 80-160 km......................171 First 500 mi / 800 km.........................172 First 2,000 mi / 3,218 km........................172 First 3,000-5,000 mi / 4,800-8,000 km....................172 Preventive Maintenance Intervals..................... 173 Fender Liners............................
  • Page 171 MAINTENANCE - Cab Maintenance..........................217 Safety Restraint System - Inspection....................223 Cooling System Maintenance......................225 Windshield Wiper/Washer.........................229 Headlights............................230 Electrical System..........................232 Engine Maintenance......................... 241 Fuel System............................249 Frame..............................250 Front Axle and Suspension....................... 252 Heater and Air Conditioner Maintenance..................255 Noise and Emission Control......................257 Diesel Exhaust Fluid Tank.........................260 Rear Axle and Suspension........................260 Rear Axle Alignment.........................
  • Page 172 MAINTENANCE - Transmission Maintenance....................... 273 Hydraulic Clutch..........................273 Specification Reference Charts......................274 Y53-6113-1A1 (11/20)

  • Page 173: New Vehicle Maintenance Schedule

    MAINTENANCE - New Vehicle Maintenance Schedule New Vehicle Maintenance First Day Schedule First Day Perform a total vehicle alignment once a body is installed on the truck chassis. Steering U-joint Pinch Bolt • Refer to Steering Shaft Bolt Torque Specifications on page 265 for maintenance instructions.

  • Page 174: First 500 Mi / 800 Km

    MAINTENANCE - First 500 mi / 800 km First 500 mi / 800 km First 500 mi / 800 km Front Axle U-Bolt Torque • Refer to Suspension U-Bolts, Grade 8 on page 282 for maintenance instructions. Charge Air Cooler and Air Intake Pipe Clamps •...

  • Page 175: First 3,000-5,000 Mi / 4,800-8,000 Km

    MAINTENANCE - Preventive Maintenance Intervals First 3,000-5,000 mi / 4,800-8,000 km Transmission Lubrication • For Fuller transmission, refer to Fuller Transmission Lubrication on page 199 for maintenance instructions. • For Allison transmission, refer to Allison Transmission Lubrication on page 200 for maintenance instructions. Axle Lubrication.
  • Page 176 MAINTENANCE - Preventive Maintenance Intervals parking brake is applied, (3) all wheels may result in death, personal injury, WARNING are blocked (front and rear) and (4) re- equipment or property damage. move the ignition key so that the en- Exercise extreme caution to prevent The following pages contain a table of gine cannot be started.
  • Page 177 MAINTENANCE - Preventive Maintenance Intervals where discrepancies develop between • The initial fill of drive axle lubricant maintenance interval. See the these recommendations in this table and must be changed before the end of transmission manufacturer's component supplier recommendations. the first scheduled maintenance operator's manual for interval.
  • Page 178 MAINTENANCE - Preventive Maintenance Intervals Driveshafts - Models SPL-90, 1710 and 1810 slip member and U-joints • Inspect. U-joint inspections should be performed every time a vehicle comes in for scheduled maintenance. Driveshafts - Models SPL-100 slip member and U-joints •...
  • Page 179 MAINTENANCE - Preventive Maintenance Intervals • Overhaul. 360,000 miles/576,000 km (Refer to Air Dryer Maintenance on page 206 for maintenance instructions.) Safety - Three-point Safety Belt System • Inspect. 20,000 miles/32,000km If the vehicle is exposed to severe environmental or working conditions, more frequent inspections may be necessary.
  • Page 180 MAINTENANCE - Preventive Maintenance Intervals Every 750 mi / 1,207 km / 1 mo Front Axle (Meritor) - Total Vehicle Alignment • Check and adjust as required. (Refer to Front Axle and Suspension on page 252 for maintenance instructions.) Front Axle (Meritor) - Drawkeys •...
  • Page 181 MAINTENANCE - Preventive Maintenance Intervals Every 7,500 mi / 12,000 km / 6 mo Frame - Frame Fasteners • Check for tightness. (Refer to Frame Fastener Torque Requirements on page 280 for maintenance instructions.) Frame - Engine Mounting • Refer to Engine Mounting on page 249 for maintenance instructions.
  • Page 182 MAINTENANCE - Preventive Maintenance Intervals Every 7,500 mi / 12,000 km / 6 mo Disc Brakes (Bendix ® ) - Caliper sliding function • Ensure caliper slides freely with no obstructions or excessive play. (Refer to Air Disc Brakes on page 212 for maintenance instructions.) Disc Brakes (Bendix ®...
  • Page 183 MAINTENANCE - Preventive Maintenance Intervals Every 7,500 mi / 12,000 km / 6 mo Driveshafts - Models SPL-90, 1710 and 1810 slip member and U-joints • Lubricate Driveshafts - Models SPL-100 slip member and U-joints • Lubricate Driveshafts - Models SPL-140/140HD/170/170HD/250/250HD slip members and U-joints (OFF HIGHWAY) •...
  • Page 184 MAINTENANCE - Preventive Maintenance Intervals Every 7,500 mi / 12,000 km / 6 mo Battery Boxes, Tool Boxes, and Steps - Battery box and tray (OFF HIGHWAY) • Check the box integrity. Clean the drain tube and check for acid leaks. Check condition of all equipment mounted under the box. (Refer to Batteries on page 236 for maintenance instructions.)
  • Page 185 MAINTENANCE - Preventive Maintenance Intervals Every 7,500 mi / 12,000 km / 6 mo Electrical and lights - ECM connector • Check the tightness of the ECM connector. (Refer to Electrical System on page 232 for maintenance instructions.) Electrical and lights - Wheel sensors •...
  • Page 186 MAINTENANCE - Preventive Maintenance Intervals Every 7,500 mi / 12,000 km / 6 mo Air - Air compressor governor • Replace air strainer. (Refer to Air Compressor on page 210 for maintenance instructions.) Air - Air lines • Check condition and routing to prevent chafing. (Refer to Air Compressor on page 210 for maintenance instructions.) Air - System...
  • Page 187 MAINTENANCE - Preventive Maintenance Intervals Every 15,000 mi / 24,000 km / 12 mo Air Intake - Pre-cleaner Filter Assembly • Clean Pre-cleaner filter media. (Refer to How to Clean the Pre-cleaner Filter on page 247.) Frame - Crossmembers and Mounting Brackets •...
  • Page 188 MAINTENANCE - Preventive Maintenance Intervals Every 15,000 mi / 24,000 km / 12 mo Front Axle (Dana) - Steering knuckle spindles, thrust bearings, kingpins, drawkeys, tie rod ends, steering stops, and bushings (ON HIGHWAY) • Inspect for wear and damage and for endplay. Shim or replace as required. (Refer to Front Axle and Suspension on page 252 for maintenance instructions.)
  • Page 189 MAINTENANCE - Preventive Maintenance Intervals Every 15,000 mi / 24,000 km / 12 mo Front Suspension - U-bolts (ON HIGHWAY) • Check the general condition and the tightness of the nuts. Tighten the nuts to the specified torque value as required. (Refer to Suspension U-Bolts, Grade 8 on page 282 for maintenance instructions.) Front Suspension - U-bolts (OFF HIGHWAY)
  • Page 190 MAINTENANCE - Preventive Maintenance Intervals Every 15,000 mi / 24,000 km / 12 mo Drive Axle (Dana) - Lube Pump (OFF HIGHWAY) • Remove the magnetic strainer and inspect for wear particles. Wash in solvent and dry in air. (Refer to Drive Axle - Dana page 263.) Drive Axle (Dana) - Lube Filter (ON HIGHWAY)
  • Page 191 MAINTENANCE - Preventive Maintenance Intervals Every 15,000 mi / 24,000 km / 12 mo Drive Axle (Meritor) - Input shaft and pinion shaft • Check and adjust the endplay. (Refer to Drive Axle - Meritor on page 263.) Drive Axle (Meritor) - Axle shaft •...
  • Page 192 MAINTENANCE - Preventive Maintenance Intervals Every 15,000 mi / 24,000 km / 12 mo Drum Brakes (All) - Brake air system • Clean or replace the inline filters. (Refer to Air System on page 204.) Disc Brakes (Bendix ® ) - Brake disc/rotor •...
  • Page 193 MAINTENANCE - Preventive Maintenance Intervals Every 15,000 mi / 24,000 km / 12 mo Cooling - Extended Life Coolant (ELC) • Check the freeze point. (Refer to Cooling System Maintenance on page 225) • Check for contamination using test strips. (Refer to Cooling System Maintenance on page 225 for maintenance instructions.) •...
  • Page 194 MAINTENANCE - Preventive Maintenance Intervals Every 15,000 mi / 24,000 km / 12 mo Power Steering - Steering gear • Check the lash of the sector shaft; adjust as required. (Refer to Steering System on page 264 for maintenance instructions.) •...
  • Page 195 MAINTENANCE - Preventive Maintenance Intervals Every 15,000 mi / 24,000 km / 12 mo Power Steering - Steering intermediate shaft • Check the torque on the pinch bolt and nut. (Refer to Steering System on page 264 for maintenance instructions.) Power Steering - Steering intermediate shaft U-joints (ON HIGHWAY) •...
  • Page 196 MAINTENANCE - Preventive Maintenance Intervals Every 15,000 mi / 24,000 km / 12 mo Cab structure, doors and hoods - Hinges and latch • Lubricate with silicone spray. Cab structure, doors and hoods - Body and cab holddown bolts • Check the condition and tightness.
  • Page 197 MAINTENANCE - Preventive Maintenance Intervals Every 60,000 mi / 96,000 km / 6 mo Every 60,000 mi / 96,000 km / 6 mo Every 60,000 mi / 96,000 km • Use Delo SF, Mobil SHC 007: See Steer Axle Wheel Ends - Steer Axle Oil PACCAR 20K Front Axle Bath (Adjusted) with Mineral Base Lubrication...

  • Page 198: Fender Liners

    MAINTENANCE - Fender Liners Every 60,000 mi / 96,000 km Air - Air dryer (OFF HIGHWAY) • Overhaul. (Refer to Air Dryer Maintenance on page 206 for maintenance instructions.) Every 120,000 miles /193,000 km / 2 yr Every 120,000 miles /193,000 km / 2 Fender Liners •...

  • Page 199: Lubricants

    MAINTENANCE - Lubricants Gently pull liner up and away from truck running at top economy and engine lubrication service guide in the hood to remove. prolonging its life is proper lubrication Engine Operation Manual that came with servicing. Neglecting this essential aspect your vehicle.
  • Page 200 MAINTENANCE - Lubricants finger does not mean the oil level is correct. WARNING NOTE Improper Oil Level Never idle your vehicle for prolonged Use only an exact replacement DPF in periods of time if you sense that ex- exhaust systems. Using a noncompli- haust fumes are entering the cab.
  • Page 201 MAINTENANCE - Lubricants should be made any time after 3000 miles circulated by the motion of gears and observed for a short time in a fully (4800 km) but never longer than 5000 shafts. Grey iron parts have built-in loaded vehicle performing normally. miles (8000 km) of over-the-road service.
  • Page 202 MAINTENANCE - Lubricants Type Grade (SAE) Ambient Temperature Heavy Duty Engine Oil MIL-L-2104B, C, or Above 10° F (-12° C) D; API - SF, or API-CD Above 10° F (-12° C) Below 10° F (-12° C) Mineral gear oil with rust and oxidation Above 10°...
  • Page 203 MAINTENANCE - Lubricants Meritor Axle Lubrication NOTE Axles utilized in 100% off-highway use are not eligible for Meritor's Advanced Lube Rear Drive Axle program. Under Meritor’s Advanced Lube Rear Drive Axle program, the axles listed below are exempt from an initial lubricant change: Available Advanced Lube Axles RS-19-145 RS-26-180...
  • Page 204 MAINTENANCE - Lubricants Application Type Of Lubricant Mileage Interval On Highway Synthetic 240,000 mi. (384,000 km) Synthetic with Pump and Filter 500,000 mi. (800,000 km) Mineral Base 120,000 mi. (192,000 km) City Delivery Synthetic 120,000 mi. (192,000 km) Synthetic with Pump and Filter 240,000 mi.
  • Page 205 MAINTENANCE - Lubricants Type of Lubricant On-Highway Mi. (km) Maximum Change On/Off Highway Severe Maximum Change Interval Service Mi. (km) Interval Mineral-Based 120,000 (192,000) Yearly 60,000 (96,000) Yearly Eaton-Approved 240,000 (384,000) 2 Years 120,000 (192,000) Yearly Synthetic Eaton-Approved 350,000 (560,000) Synthetic in axle with extended drain interval option...

  • Page 206: Air System

    MAINTENANCE - Air System fluids, although harmless to individual internal components, may initiate a WARNING CAUTION chemical reaction that produces a new compound that will attack seals and other Prior to the removal of any air system When adding fluid, be sure to use fluid internal components.
  • Page 207 MAINTENANCE - Air System springs and injury can result if not cause the air system to not perform WARNING properly disassembled. Use only prop- correctly unless the full air system de- er tools and observe all precautions sign is reviewed and modifications Never connect or disconnect a hose or pertaining to use of those tools.

  • Page 208: Dual Air System Function Test

    MAINTENANCE - Dual Air System Function Test Twice a Year into the chambers where it is used to apply your truck and trailer brakes. That is why, Air Dryer Maintenance • Maintain the air compressor to when you push down on your brake pedal, prevent excessive oil bypass.
  • Page 209 MAINTENANCE - Air Dryer Maintenance Maintenance accumulation and should be considered before replacing the desiccant cartridge. NOTE • Air usage is exceptionally high and CAUTION not normal for a highway vehicle. Review the warranty policy before per- This may be due to accessory air forming any maintenance procedures.

  • Page 210: Air Tanks

    MAINTENANCE - Air Tanks Standards (FMVSS 121 - Air Brake vere damage to air system compo- Systems). As the Warning above states, WARNING nents. any other type of air dryer installed in the place of an AD-HF Series will require Use of an air dryer brand or model that changes, modifications and/or additions to differs from what was originally instal-...

  • Page 211: Air Gauges And Air Leaks

    MAINTENANCE - Air Gauges and Air Leaks solvent. Blow them dry with pressurized air The Primary and Secondary Air Pressure personal injury, property damage, or before reinstalling them. gauges are shown in the Primary Gauges death. • Maintain the air compressor to View on the Digital Display.

  • Page 212: Air Compressor

    MAINTENANCE - Air Compressor • When an air system component is The Primary Gauges View will replaced appear. NOTE • When a leak is suspected Release the service brakes, and observe the rate of air pressure • Periodically, to ensure system Park brakes lock up at 60 psi (414 drop.

  • Page 213: Brake System

    MAINTENANCE - Brake System running. System pressure is controlled by excessive carbon is found, clean or the governor. The governor acts in replace the compressor cylinder CAUTION conjunction with the unloading mechanism head. Also, check compressor in the compressor cylinder block to start discharge line for carbon, and The air brake system of this vehicle and stop compression of air.
  • Page 214 MAINTENANCE - Brake System original components. Any changes from • Temporarily release the parking the original specifications can affect the brakes. WARNING whole system. All of the following areas are • Compare the relative position of interrelated and must conform to original two notches;...
  • Page 215 MAINTENANCE - Brake System • Temporarily release the parking brakes. Chamber Type Stroke Caliper Detail • Grab the caliper and move it. This 36 (rear brakes) 1-1/2" - 2-1/4" (38 - movement is Running Clearance. 57 mm) • Proper Running Clearance is 0.08 inch (2 mm) of movement of the 30 (rear brakes) 1-1/2"...
  • Page 216 MAINTENANCE - Brake System Automatic Slack Adjuster Stroke pressure. Do not apply the parking Specification brake. WARNING Apply pressure to the brake pedal Chamber Type Stroke and measure the distance the air Manual adjustment of automatic slack chamber pushrod traveled. adjusters is a dangerous practice that 36 (rear brakes) 1.5-2.5 in.
  • Page 217 MAINTENANCE - Brake System • brake rotors you local dealer for suitable replace- • front wheel bearings WARNING ment parts. • front end alignment • parking brake drum radius Use only the type of hydraulic fluid WARNING Once a brake system is set to specified.
  • Page 218 MAINTENANCE - Brake System Make sure that the fluid level registers on WARNING or above the fluid level mark molded on the CAUTION reservoir - add more if necessary, as follows: If the brake fluid reservoir requires an When replacing disc brake pads, be excessive amount of hydraulic fluid, Remove each reservoir cap and sure to use the same lining material on...

  • Page 219: Cab Maintenance

    MAINTENANCE - Cab Maintenance guide pin boots or other defects. If signs of wear, damage or defects are found, the WARNING anchor plate(s) should be repaired or replaced. Handle cleaning agents carefully. Cleaning agents may be poisonous. Parking Brake Component Keep them out of the reach of children.
  • Page 220 MAINTENANCE - Cab Maintenance accumulations throughout the underbody and engine compartment. If these WARNING CAUTION materials are not removed, accelerated corrosion (rust) can occur on underbody Moisture, ice, and road salt on brakes Do not direct high pressure water onto parts such as fuel lines, frame rails, floor may affect braking efficiency.
  • Page 221 MAINTENANCE - Cab Maintenance Cleaning Interior Vinyl and spotting, wipe aluminum surfaces particles of the steel wool can Upholstery dry after washing. become embedded in the surface of the stainless steel part and • Under corrosive conditions, such cause rust staining. as driving on salted roads, clean NOTE aluminum parts with steam or high-...
  • Page 222 MAINTENANCE - Cab Maintenance soap and lukewarm water, then dry How to Wash the Exterior of the thoroughly. Vehicle WARNING • If the stain does not come out use Your dealer has a number of vehicle-care an upholstery shampoo specially products and can advise you on which DO NOT clean the underside of chas- formulated for this purpose.
  • Page 223 MAINTENANCE - Cab Maintenance and may damage the vehicle's ter the part which will contaminate the paint. system lubricants and fluids. To pre- CAUTION vent damage to these components, • Do not use stiff brushes, paper keep a gentle flow of water moving at towels, steel wool, or abrasive DO NOT aim the water jet directly at all times.
  • Page 224 MAINTENANCE - Cab Maintenance compartment. The filter can be replaced without using any tools. CAUTION Tilt the hood open. Do not direct high pressure water onto Locate the air intake housing at the electrical components, plug connec- passenger side rear corner of the tors, seals or flexible hoses on the en- engine bay, below the rain tray.

  • Page 225: Safety Restraint System - Inspection

    MAINTENANCE - Safety Restraint System - Inspection Care of Display Screens on the Seat Belt Inspection Points Dashboard WARNING To clean the screen, dampen a clean, soft, lint-free cloth with water only. A mild glass It is important to remember that any cleaner that does not contain alcohol or time a vehicle is involved in an acci- ammonia may also be used.
  • Page 226 MAINTENANCE - Safety Restraint System - Inspection Mounting hardware for corrosion, be necessary. Any seat belt system that examined to determine if it is proper tightness of bolts and nuts shows cuts, fraying, extreme or unusual coming into contact with any sharp wear, significant discoloration due to UV or rough surfaces on the seat or Web for deterioration, due to...

  • Page 227: Maintenance

    MAINTENANCE - Cooling System Maintenance that it spools out and retracts instructions very closely. It is vitally Unless otherwise optioned, factory fill webbing properly. important that all components be coolant is an ethylene glycol, nitrited reinstalled in the same position as the organic acid technology (NOAT) extended If tethers are used, be sure they original components that were removed...
  • Page 228 MAINTENANCE - Cooling System Maintenance Glycol Concentration Level CAUTION CAUTION Desired The engine cooling system has very Use of non-genuine PACCAR coolant Freeze Coolant specific maintenance and inspection filters can cause severe engine dam- Level Point °F / Water requirements. Failure to follow require- age.
  • Page 229 MAINTENANCE - Cooling System Maintenance degradation and could result in damage to operator's manual. Never use filters that the cooling system and engine contain supplemental coolant additives CAUTION components. Consult your dealer or (SCAs) in an ELC-filled system. Consult the coolant manufacturer’s representative your engine operator's manual for The use of sealing additives or soluble for recommended extended life coolant test...
  • Page 230 MAINTENANCE - Cooling System Maintenance The minimum fluid level is determined by How to Add Coolant to the Cooling the line on the surge tank indicated by the System NOTE letters "MIN." This indicator is located below the fill cap. The cooling system will DO NOT overfill a cooling system.

  • Page 231: Windshield Wiper/Washer

    MAINTENANCE - Windshield Wiper/Washer bleed valve before filling the surge may take up to 2 minutes, Check the washer reservoir water level tank. depending on the outside daily, located in the engine compartment. If temperature. necessary, refill to the proper level. Close any open coolant drain valves in the lower engine coolant Maintain a low idle until the...

  • Page 232: Headlights

    MAINTENANCE - Headlights one headlamp. Headlight Features Headlights NOTE Maintaining Headlight Performance Know what type of headlamps your ve- hicle is equipped with (Standard Incan- WARNING descent, Halogen, or LED). For light bulb replacement types, refer to Vehicle LED replacement light sources are not Light Bulb Specifications on page 283.
  • Page 233 MAINTENANCE - Headlights • Fender liners and access caps powder or soap, nor with How to Replace a Headlight Bulb must be re-installed after service to petrochemicals like Gasoline or Each headlight assembly contains three protect the headlamp from high Diesel as these will break down the bulbs: pressure water spray and gravel...

  • Page 234: Electrical System

    MAINTENANCE - Electrical System Twist bulb socket counter- headlight reduces performance and should be performed by an authorized clockwise to loosen and creates glare. dealer. Improper repair or modifica- remove socket and bulb from tions will void your warranty and/or the headlight assembly.
  • Page 235 MAINTENANCE - Electrical System Low Voltage Disconnect (LVD) ty/work related lighting. Before adding (option) any device to the vehicle's electrical The Low Voltage Disconnect (LVD) may system, consult your nearest author- increase battery life and avoid depleting ized dealer or read the contents of the battery below the minimum charge TMC RP136.
  • Page 236 MAINTENANCE - Electrical System LVD Setup • CAB ACC • CB PWR Change the LVD battery voltage set point WARNING for LVD to turn on Low Voltage Disconnect • CECU - BATT (2 PLCS) (LVD) (option) on page 233. • CECU IGN Never install a circuit breaker/poly- switch in a location indicated for “fuse...
  • Page 237 MAINTENANCE - Electrical System The lighting control unit is limited to 5 amps are provided on the driver's side of the cab, lighting circuit limits described above total, or two (2) 25 watt incandescent bulbs near to the interior fuse panel. Access to are not exceeded.
  • Page 238 MAINTENANCE - Electrical System WARNING CAUTION CAUTION Batteries contain acid that can burn The use of scotch locks, scraped off insu- Properly secure battery tie downs and and gases that can explode. Ignoring lation, and electrical tape are not ap- battery box cover when reinstalling safety procedures may result in death, proved CAN connection techniques.
  • Page 239 MAINTENANCE - Electrical System Undercharge: the voltage regulator is have your vehicle's batteries charged by a positive terminal), could cause a malfunctioning, the drive belt is slipping, or qualified service facility. To help reduce the short circuit or an explosion. your vehicle has undergone long periods of risk of personal injuries, follow these Charging Reminders...
  • Page 240 MAINTENANCE - Electrical System Under Cab Battery Access Installation is the reverse of uses battery power to circulate DEF removal. The battery compartment is located on the and prevent overheating of the DEF left side of the vehicle, under the cab system.
  • Page 241 MAINTENANCE - Electrical System Installing Batteries Place batteries in vehicle and Install fairing and install four bolts. tighten bolt of holding plate Torque to 6-7 lb-ft (8-9 N·m). Follow the procedure below to reinstall Reconnect positive cable Install steps by installing two bolts main batteries on the vehicle: in each step.
  • Page 242 MAINTENANCE - Electrical System more than 10 percent of its rated • DO NOT reverse the cables of the capacity. alternator, starter motor, or battery. NOTE After charging, turn OFF charger • DO NOT polarize the alternator. and disconnect charger cables. The alternator should not be Some vehicles may have an ultra ca- polarized like a generator.

  • Page 243: Engine Maintenance

    MAINTENANCE - Engine Maintenance available at most discount, hardware, and Turn the ignition switch to the ON drug stores. The battery can be accessed position. Engine Maintenance by removing the cover of the key fob. After Open the driver and passenger a new battery is installed, the key fob may doors.
  • Page 244 MAINTENANCE - Engine Maintenance Park the vehicle on level ground and wait 15 minutes after shutting WARNING NOTE the engine OFF. This allows time for the oil to drain to the oil pan. NEVER start or let the engine run in Keep the engine exhaust system and Remove the dipstick and wipe it off an enclosed, unventilated area.
  • Page 245 MAINTENANCE - Engine Maintenance Topping Up the Engine Oil Top up with oil, if necessary, via the filler opening. Use the correct grade in the correct quantity. For oil replacement, please see engine Operator’s Manual included with this chassis. After topping up, wait 1 minute and check the oil level again.
  • Page 246 MAINTENANCE - Engine Maintenance Application Type of Clamp lb-in. N•m Plastic Air Intake Pipes Constant Torque CT-L 10.0 Charge Air Intake Hoses Flex Seal 70-100 7.9-11.3 B9296 50-60 Fuel, Oil and Water Heat Miniature 3600L 10-15 1.1-1.7 Exchangers (for hoses less than 9/16 in.
  • Page 247 MAINTENANCE - Engine Maintenance Engine Fan growl when the engine is at operating temperature and the fan clutch is engaged. If noise is WARNING detected, have the fan bearings inspected by an authorized DO NOT work on or near the fan with dealership.
  • Page 248 MAINTENANCE - Engine Maintenance around inspection, carefully check all Service the filter elements when the ways keep the intake piping connected tubing, elbows, clamps, supports, and (option) locks in the extreme High position. when you will be running the engine. fasteners for condition and tightness.
  • Page 249 MAINTENANCE - Engine Maintenance Engine Air Filter Pre-Cleaner The filter can be removed by Remove upper left and lower right (Option) gently pulling it directly out of the Pre-cleaner fasteners using Certain truck models may have an engine main enclosure. Be careful not to wrench, and set aside.
  • Page 250 MAINTENANCE - Engine Maintenance Flush dirt from filter using warm, Install and tighten remaining low-pressure water applied to fasteners, then torque to 7–11 lb-ft CAUTION cleaner (engine side) side of filter (9–15 N∙m). until water runs clear. Reinstall Fender Liner (How to Do not use high-pressure water or air Rinse Pre-cleaner using warm,...

  • Page 251: Fuel System

    MAINTENANCE - Fuel System Engine Mounting Open drain valve (by hand only) until draining occurs. Fuel System If draining to replace the filter, CAUTION before opening valve, push one Please follow these recommendations end of hose onto drain valve and when you are changing your fuel filters or DO NOT re-torque or reuse existing route other end to the container.

  • Page 252: Frame

    MAINTENANCE - Frame • Bowl wrench RK61680 Install new filter element: Fuel Tank • 1" wrench Install new upper and lower • New PACCAR primary fuel filter O-rings. element designed for this Install new fuel filter element. Frame application Reconnect clip-type electrical •...
  • Page 253 MAINTENANCE - Frame electronics that could be affected, devices, diagnostic devices, and but a few examples include the monitoring devices. WARNING following: alternator, engine Electronic Control Unit (ECU), Fifth Wheel Monthly Maintenance Frame welding is NOT recommended. transmission ECU, ABS ECU, The high heat of welding nullifies the •...

  • Page 254: Front Axle And Suspension

    MAINTENANCE - Front Axle and Suspension • Remove fifth wheel from vehicle. pins, and tie rod ends. Lack of lubrication Refer to the Shop Manual, "Fifth causes premature wear and hard steering. Front Axle and Wheel Removal." Lubrication schedule may be shortened if Suspension necessary.
  • Page 255 MAINTENANCE - Front Axle and Suspension Wheel Alignment WARNING For driving safety and comfort, and to CAUTION prolong the life of your vehicle, it is important to have wheels correctly aligned. DO NOT operate the vehicle if the sus- DO NOT spray the suspension with Check tire wear frequently.
  • Page 256 MAINTENANCE - Front Axle and Suspension • A more frequent lubrication cycle is required for axles used in on/off- WARNING NOTE highway, refuse, or other severe service applications. Use heavy- DO NOT replace U-bolts and nuts with If it is difficult to grease either the up- duty, multipurpose lithium base (#2 common U-bolts or standard nuts.

  • Page 257: Heater And Air Conditioner Maintenance

    MAINTENANCE - Heater and Air Conditioner Maintenance • Keep the exhaust pipe area clear ventilation. Failure to do so may result to help reduce the buildup of Heater and Air Conditioner in death or personal injury. exhaust gas under the vehicle. Maintenance •...
  • Page 258 MAINTENANCE - Heater and Air Conditioner Maintenance Heater • Check the engine belt for condition and recharging the air conditioning and proper tension. system must be conducted by a quali- • Check all hoses for kinks, CAUTION fied technician with the right facilities deterioration, chafing, and leaks.

  • Page 259: Noise And Emission Control

    Peterbilt, which, at the the cabin recirculation air filter. panel out from the bottom to release the time it left Peterbilt's control, caused noise clips, then pivot the panel outward so the emissions to exceed Federal standards, tabs at the top allow the panel to drop...
  • Page 260 MAINTENANCE - Noise and Emission Control Air Intake Removing or rendering inoperative Cutting holes in, or cutting away part System the air filter housing/silencers or of noise insulators CAUTION intake piping Removing hood-mounted noise insulation Engine Removing or rendering the fan Air leaks cause excessive noise and Cooling clutch inoperative...
  • Page 261 MAINTENANCE - Noise and Emission Control gasket; replace gasket if at flanges and mounting brackets of the vehicle. Do not modify the necessary. for tightness. end of the pipe in any way. • Check cap screws for tightness, Diesel Particulate Filter (DPF) Engine Fan and Shroud including those at the flanges.

  • Page 262: Diesel Exhaust Fluid Tank

    MAINTENANCE - Diesel Exhaust Fluid Tank specified units, may result in strength by installing a suitable increased vehicle noise emission. reinforcing plate. This plate should Rear Axle and Suspension be drilled to accept a rivet and Hood Insulation Blanket laminated to the shield with •...
  • Page 263 MAINTENANCE - Rear Axle and Suspension periodically inspect the suspension as noted below: WARNING CAUTION • Visually check for loose or missing fasteners, cracks in hanger, or axle DO NOT operate the vehicle if the sus- DO NOT spray the suspension with connection brackets pension U-bolts are not properly tight- chemical products or mineral oil;...
  • Page 264 MAINTENANCE - Rear Axle and Suspension vehicle manufacture. The values listed at vehicle control and an accident. Loose death, personal injury, equipment or the back of this chapter (See Suspension U-bolts can also cause uneven tire property damage. U-Bolts, Grade 8 on page 282 and Frame wear and poor alignment.

  • Page 265: Rear Axle Alignment

    MAINTENANCE - Rear Axle Alignment Drive Axle - Dana Initial Change: See Preventive Drain the lubricant while warm. Flush each Maintenance Intervals on page 173 for CAUTION unit with clean flushing oil. Change the standard rear axle service intervals. lubricant. Change mineral-based lubricant in other DO NOT mix lubricants of different Dana Spicer and Fabco axle assemblies...

  • Page 266: Steering System

    MAINTENANCE - Steering System • Bushing replacement • Wheels out of alignment • Excessive or abnormal tire wear • Wheel bearings improperly WARNING adjusted • Immediately after post body installation (See First Day in the If you cannot correct the problem, check If this chassis is equipped with an Maintenance Chapter) with an authorized dealer.
  • Page 267 MAINTENANCE - Steering System If these checks do not reveal the problem, Open the fill cap to the power or if you correct them and still have a steering reservoir. Steering U-joint Pinch Bolt steering problem, take your vehicle to an •...

  • Page 268: Driveline

    MAINTENANCE - Driveline operation. Here are some tips on maintaining your tires. WARNING WARNING Proper Over Under If this chassis is equipped with an Improper lubrication of U-joints can Electronic Stability Control (ESC) and cause them to fail prematurely. The is modified (e.g.
  • Page 269 MAINTENANCE - Tires such as flex break, radial cracks, and ply equipment. Follow OSHA regulations separation. Low pressure may affect WARNING per section 1910.177. control of your vehicle, especially at the front wheels. Most tire wear problems are DO NOT operate a vehicle with under- caused by underinflation as the result of NOTE inflated tires.
  • Page 270 MAINTENANCE - Tires Vehicle Tire Expected rectly according to the manufacturer's cause you to lose control of your vehi- Load Pressure Total Tire recommendations. cle resulting in an accident causing Mileage death or personal injury. Matching Tires 60% Over 35% Low Replacing Tires Be sure to buy matched tires for your 80% Over...

  • Page 271: Wheels

    MAINTENANCE - Wheels Warranty for warranty on greenhouse gas book for maximum rated speed. The certified tires. NOTE vehicle should not be operated at speeds in excess of the maximum rat- To prolong your tires' life and make ed speed. Failure to comply with these Wheels them safer, have their radial and later- speed restrictions could cause sudden...
  • Page 272 MAINTENANCE - Wheels Wheel Replacement with Disc raise the front of the vehicle off the ground Brake Option to allow the wheel to spin freely. While WARNING rotating the wheel, check to ensure there is adequate clearance between the wheel WARNING Always support the vehicle with appro- and disc brake assembly.
  • Page 273 MAINTENANCE - Wheels Wheel Bearings Hub Piloted Disc Wheels This is a job you may not be able to do yourself. You need the right torquing Service the bearings, seals and oil. This equipment to do it. interval may be different depending on the results of the regular inspection.
  • Page 274 MAINTENANCE - Wheels Comparing Hub Piloted and Ball original specifications or that is mis- mounting. Failure to comply may result Seat Parts matched could cause the wheels to in property damage, personal injury, or break and separate from the vehicle. death.
  • Page 275 MAINTENANCE - Transmission Maintenance Hub-piloted mountings use M22 x 1.5 metric threads (about 7/8 in. Ball-seat (stud-piloted) mountings use 3/4x16 or 1-1/8x16 threads. diameter). The stud stands out at least 1.94 in. beyond the brake The dual mounting studs provide 1.30 in. 1.44 in. standout. Right- drum.
  • Page 276 MAINTENANCE - Specification Reference Charts Clutch Hydraulic Fluid Be sure to maintain the fluid between the will require the operator to know when to MIN and MAX levels indicated on the adjust the clutch. The clutch will need plastic reservoir. If the fluid level repeatedly adjustment when your clutch pedal stroke goes below the MIN line, then it is time to seems to get longer and its effectiveness...
  • Page 277 MAINTENANCE - Specification Reference Charts Application Type of Clamp lb-in. N•m Heater Hoses Constant Tension not required not required Air Intake Pipes Hi Torque HTM-L 100-125 11.3-14.2 Plastic Air Intake Pipes Constant Torque CT-L 10.0 Charge Air Intake Hoses Flex Seal 70-100 7.9-11.3 B9296...
  • Page 278 MAINTENANCE - Specification Reference Charts Torque for Inner and Outer Cap Nuts and Rim Clamp Nuts Wheel and Nut Configuration Stud Size lb-ft N•m Heavy-Duty Steel Disc-Type 15/16-12 750-900 1,020-1,220 Wheel; Double Cap Nut 1-1/8-16 750-900 1,020-1,220 Mounting; 1-3/16 Radius Ball Seat: 1-15/16-12 750-900...
  • Page 279 MAINTENANCE - Specification Reference Charts Lubricant Symbol Key Type Application MD3 or MERCON®-approved automatic transmission fluid High temperature ball bearing grease. Chevron SRI Mobile Grease HP, Texaco Multifax 2 Engine oil for mild to moderate requirements CC/CD Engine oil for severe requirements (MIL-L-2104B /MIL-L-45199B) w/ 1.85 % max. sulfated ash Engine oil meeting API “Five engine test sequence”...
  • Page 280 MAINTENANCE - Specification Reference Charts Type Application DOT3 Brake Fluid Component Lubrication Index Application Type Steering Column Alternator Bearing BB (1) Fan Hub BB (1) Power Steering Reservoir Steering Drag Link Steering Knuckles Spring Pins Clutch Release Bearings Brake Shoe Anchor Pins Brake Cam Bearings Slack Adjusters Starter Bearings...
  • Page 281 MAINTENANCE - Specification Reference Charts Application Type Turbocharger Aneroid Water Pump BB (1) Suspension Fittings (other than threaded pins and bushings) Steering Axle: Grease Fittings on Steering Arm; Tie Rod Ends; Drag Link; King Pins Steering Shaft Grease Fittings Brake Treadle Hinge and Roller Engine oil Lock Cylinders Lock lubricant...
  • Page 282 MAINTENANCE - Specification Reference Charts Where Nylon lock-nuts are Frame Fastener Torque Fastener Size Tightening indicated in the following tables, Requirements (-in.) Specification lb-ft (N•m) • Use only ESNA Style Lock Nut, with nylon insert. CAUTION 290-340 (394-462) • Lubricate nylon insert nut lightly with SAE 20W or 30W oil.
  • Page 283 MAINTENANCE - Specification Reference Charts • Bolts and washers can be reused, Noise Control System - Metric Fastener Tightening but nuts can only be reused once. Maintenance Log Size (with all Specification lb-ft If in doubt, install new nuts. METAL Lock- (N•m) To ensure your vehicle's noise control •...
  • Page 284 Torque for Grade 8 U-Bolts Suspension U-Bolts, Grade 8 Tighten all U-bolts with a torque wrench. Torque requirements in the table below Peterbilt Front Suspension U-bolts apply to PACCAR proprietary suspensions U-Bolt Size Torque (lb- Torque using Protec Torque/TEXO coated U-bolts, Diameter (- (N•m)
  • Page 285 MAINTENANCE - Specification Reference Charts Peterbilt Front Suspension U-bolts Peterbilt Rear Suspension U-bolts NOTE U-Bolt Size Torque (lb- Torque Rear U-Bolt Torque lb-ft Diameter (- (N•m) Suspensio Diamet (N•m) The values shown here are for sus- in.) n Type pension U-bolts and should not be ap-...
  • Page 286 MAINTENANCE - Specification Reference Charts Bulb Type of Notes Bulb Type of Notes TORQUE SIZE/TYPE Location Bulb Location Bulb lb-ft N•m Turn Signal/ 4157K Dual Interior 1/2 -in. nut 80-90 109-122 Side Marker (SAE) Filament Ambient Light/ Side Bulb Light 3/4 -in.
  • Page 287 MAINTENANCE - Specification Reference Charts Air-Trac Fastener Torque Values Fastener Torque lb-ft Fastener Fastener Fastener lb•ft (N•m) Name (N•m) Name 0.75 NF Spring 165–210 1.0 NF Refer to Fastener U-bolt Fastener lb•ft (N•m) center bolt section on (224–285) Name Suspension Tracking 155–195 1 NF...
  • Page 288 MAINTENANCE - Specification Reference Charts Flex Air Fastener Torque Values Low Air Leaf Torque Values Fastener Torque lb-ft Fastener Low Air Leaf Torque values apply to both Name (N•m) single and tandem axles. Tracking Fastener Torque lb-ft Fastener rod bolts Name (N•m) (all)
  • Page 289 MAINTENANCE - Specification Reference Charts 18K Taper Leaf Torque Values 13.5K Taper Leaf Torque Values 18K Air Leaf Torque Values Fastener Torque lb•ft Fastener Torque lb•ft Fastener Torque lb•ft Fastener Fastener Fastener Name (N•m) Name (N•m) Name (N•m) Spring Pivot 260–340 Spring Pivot 260–340...

  • Page 290: Information

    INFORMATION - Chapter 6 | INFORMATION Consumer Information........................289 Vehicle Identification Labels......................289 Clean Idle............................292 Greenhouse Gas Certified Configuration..................293 Vehicle Emissions Limited Express Warranty................... 296 Y53-6113-1A1 (11/20)

  • Page 291: Consumer Information

    Serial number of the truck Toll Free 1-888-327-4236 (800-424-9153 • The name of the part you need Each vehicle completed by Peterbilt Motors TTY) 8:00 a.m. to 10:00 p.m. EST • The name and number of the Company uses a vehicle identification...
  • Page 292 INFORMATION - Vehicle Identification Labels • Back of cab, left-hand rear panel, edge or on the driver’s side door frame. It lower edge contains the following information: • Tire, Rim, and Weight Rating Data • GVWR - Gross Vehicle Weight label (truck) Rating •...
  • Page 293 INFORMATION - Vehicle Identification Labels Paint Identification Label indicates the date of manufacture and other pertinent information, is located on NOTE The Paint Identification Label contains the the driver’s side door edge or on the paint colors used by the factory to paint driver’s side door frame.

  • Page 294: Clean Idle

    INFORMATION - Clean Idle Axle Differential Carrier Identification Usually located on the top side of the differential carrier. The following information is either stamped, or marked with a metal tag: Model No., Production Assembly No., Serial No., Gear Ratio, and Part Number. Engine Shutdown System able to help you to determine whether or not your vehicle's engine may be a...

  • Page 295: Greenhouse Gas Certified Configuration

    INFORMATION - Greenhouse Gas Certified Configuration only time the driver may reset the idle time regulatory ject to fines and penalties. Please con- by pressing on the accelerator. More subcategory tact the vehicle manufacturer for fur- detailed information may be available in ther information about this vehicle’s the Engine Operator’s Manual provided certified configuration.
  • Page 296 INFORMATION - Greenhouse Gas Certified Configuration LRRD Low rolling technology configuration. resistance tires components Changing (drive) aluminum wheels ADVO Vehicle includes to a steel wheels LRRS Low rolling other advanced- may be a violation resistance tires technology of the Clean Air Act (steer) components and subject to fines...
  • Page 297 INFORMATION - Greenhouse Gas Certified Configuration GHG Regulated Powertrain GHG Regulated Air Conditioning Idle Reduction This vehicle may Parameters Not On the Emission Leakage Standards be equipped with Control Information Label factory installed Loss of refrigerant from the air conditioning automatic engine systems may not exceed a total leakage shutdown (AES),...

  • Page 298: Vehicle Emissions Limited Express Warranty

    INFORMATION - Vehicle Emissions Limited Express Warranty tires. PACCAR MAKES NO OTHER U.S. and Canadian GHG regulations, VEHICLE EMISSIONS WARRANTIES subject to limitations and conditions Vehicle Emissions Limited RELATING TO THE ORIGINAL contained within the tire manufacturer’s Express Warranty EQUIPMENT TIRES, EXPRESS OR warranty agreement.
  • Page 299 INFORMATION - Vehicle Emissions Limited Express Warranty Manufacturer's Warranty Coverage component has failed due to abuse, reached for each system. Owner is neglect, improper maintenance, responsible for maintaining all physical This warranty coverage is provided for five unapproved modifications (both physical parts related to GHG-regulations in the as- years or 100,000 miles (160,000 km), components and computer programming)
  • Page 300 INFORMATION - Vehicle Emissions Limited Express Warranty to use parts other than new or genuine "warrantable failures", for replacement material and functional specifications as approved rebuilt parts and assemblies for parts that are similar in material and manufactured from the factory. Any such maintenance, replacement or repair;...
  • Page 301 INFORMATION - Vehicle Emissions Limited Express Warranty THE ABOVE LIMITED WARRANTY, PACCAR AND THE SELLING DEALER MAKE NO OTHER WARRANTIES, EXPRESS OR IMPLIED. PACCAR AND THE SELLING DEALER EXPRESSLY DISCLAIM ANY WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
  • Page 302 300 | Glossary | Glossary Anti-lock Braking System A federally mandated anti-skid braking device used on cars and trucks. Low Voltage Disconnect An electronic system that will disconnect or turn off electrical systems when a preset voltage is reached on the batteries caused by too much electrical drain from appliances or heaters inside the sleeper.
  • Page 303 | Glossary | 301...
  • Page 304 Index Index Numerics Air-Trac Fastener Torque ValueRear Suspension Fasteners Allison Transmission Lubrication Alternator 18K Taper Leaf SuspensionRear Suspension Fasteners Anti-Lock Brake System (ABS) Anti-Lock Brake System (ABS), Trailer Anti-Theft Appliances Ashtray, See Cigarette Lighter and Ashtray Automatic Slack Adjuster Stroke Specification ABS Warning Lamp 135, Axle, Automatic Traction Control Accessories...
  • Page 305 Index Brake Safety and Emergency Custom View, See Custom Brake System Brake Warning Lamp Brake, ParkingManual release Brakes, ABS Off-Road Bulb Check Daily Checks Dana Spicer and Fabco Dash Brightness, See Cab and Panel Dimmer Switch Dash Switches Dashboard Display Screen Diesel Exhaust Fluid Tank Diesel Particulate Filter (DPF) Warning Light How to Lock and Unlock the Doors...
  • Page 306 Index Emissions, High Exhaust System Temperature Fifth Wheel Locked IndicatorFifth Wheel Engine Aftertreatment System Fifth Wheel Lubrication Engine Air filter Fifth Wheel Monthly Maintenance Engine Air Filter Pre-Cleaner Fifth Wheel Slide, See How to Slide the Fifth Wheel Engine Air Filters Fifth Wheel Slide Switch Engine Brake Fifth Wheel Slide Unlocked...
  • Page 307 Index Headlight Adjustment Inter-Axle Differential Lock Operation Headlight Performance Interior Storage, See Glove Box Headlights, See Exterior Lights Switch Introduction Heater and Air Conditioner Maintenance Heating and Air Conditioning High Beam High Beam Flash Hill Hold Jump Starting Horn Horn honking, Aftertreatment Warning How to Add Coolant to the Cooling System How to Adjust Mirrors How to Check the Compressed Air System for Leaks...
  • Page 308 Index Operational checks of automatic slack adjusters Overflow tank Overheated Brakes Main transmission Maintenance Manuals Malfunction Indicator Lamp (MIL) Manual Kingpin ReleaseFifth Wheel Operation Manually lock a differential PACCAR 20k Front Axle Lubrication Marker lights, See Exterior Lights Switch PACCAR 8 SpeedRecommended Lubricants Maximum Number of Lamps Allowed per Circuit PACCAR Shifter MCS, See Menu Control Switch...
  • Page 309 Index Rear Axle Lubrication Sliding the Fifth Wheel, See How to Slide the Fifth Wheel Rear Brake System Slow Battery Charging Rear Suspension Fasteners18K Air Leaf Suspension Snow Rear Suspension U-Bolts, Grade 8 Speedometer Rear Suspension13.5K Taper Leaf Fastener Torque Values Stability Control 56, Reclining Seats Standard Driver's Seat...
  • Page 310 Index Trailer Brake Hand Valve Vehicle Loading Trailer Charge Vehicle Telematic System Trailer Dump Gate Vehicle/Trailer Air Supply Valve Trailer Hand Brake Views Trailer Park or Emergency Brake Application Only Visual inspection while approaching the vehicle Trailer, Axle Lift Forward Trailer, Axle Lift Rear Transmission Gear Display Transmission Oil Temperature Gauge...
  • Page 312 Denton, Texas 76202 Do not remove the manual from vehicle. Before operating vehicle study the manual carefully. Read and understand all warnings, cautions and notes. Need help? Give us a call 24 hours a day Y53-6113-1A1 Printed in the U.S.A. 11/20 1.800.4.PETERBILT...

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