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Kenworth T410SAR Driver's Handbook Manual

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T410 SERIES

DRIVER'S HANDBOOK

T410

T410SAR

Table of Contents

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Table of Contents

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Summary of Contents for Kenworth T410SAR

Page 1 T410 SERIES DRIVER’S HANDBOOK T410 T410SAR...
Page 2 VEHICLE IDENTIFICATION Owner’s Name: ......Address: ..........Suburb: ........State: ....Postcode: ....Phone Number (Business): ..............Phone Number (Private): ................. Vehicle Registration Number: ..............Colour: ..................... Model: ...................... Engine Number: ..................VlN (Vehicle Identification Number): ............Chassis Number: ..................MAXIMUM VEHICLE WEIGHT The maximum vehicle weight ratings are stamped on the Vehicle Identification Plate attached to the body.
Page 3 Please take the time to read this handbook, as it contains information that will assist you in getting the most from your new Kenworth. We know it will provide many years of productive service, and we welcome you to the family of Kenworth owners.
Page 5 ©2023 PACCAR Inc - All Rights Reserved This handbook illustrates and describes the operation of features or equipment which may be either standard or optional on this vehicle. This handbook may also include a description of features and equipment which are no longer available or were not ordered on this vehicle. Please disregard any illustrations or descriptions relating to features or equipment which are not on this vehicle.
Page 7: Table Of Contents
CONTENTS INTRODUCTION ................iii LIST OF TABLES ..................xii ABOUT THIS HANDBOOK ..............xv SAFETY SYMBOLS ................xvii VEHICLE SAFETY ................xviii A Special Word About Repairs .............xix DRIVER INFORMATION PACK (DIP) ..........xx Electronic Customised Maintenance Manual (ECMM) ....xx Electronic Customised Parts Catalogue (ECPC) ......xx PACCAR Customer Support Directory ........
Page 8 CONTENTS INSTRUMENT PANEL ................. 18 TYPICAL T410 DASH LAYOUT ............18 Main Instrument Cluster .............. 20 Driver Performance Center ............27 Warning Symbols ................44 Description of Warning Symbols ..........49 Dash Switches ................58 STEERING COLUMN AND CONTROLS ......... 71 Tilt/Telescoping Steering Column ..........
Page 9 CONTENTS Diesel Exhaust Fluid - AdBlue Quantity ........108 ‘Engine Derate’ Means; Engine Power Limiting ....... 108 Diesel Exhaust Fluid - AdBlue ............ 109 AdBlue Filling ................110 ENGINE BRAKE OPERATION ............111 OPERATING THE TRANSMISSION ..........113 Putting the Vehicle in Motion ............. 113 Shifting Gears in a New Vehicle ..........
Page 10 CONTENTS DISC BRAKES ................. 153 ELECTRONIC BRAKE SAFETY SYSTEM (EBSS) ...... 154 Anti-Lock Braking System (ABS) ..........154 ABS Warning Lamp ..............154 Automatic Traction Control (ATC)..........154 Drag Torque Control (DTC) ............155 Electronic Stability Program (ESP) ..........156 Trailer Response Management (TRM) ........
Page 11 CONTENTS AIR SUSPENSION ................197 FIFTH WHEEL .................. 198 Fifth Wheel Jaw Lock ..............198 Hook-Up ..................198 Air Activated 5 Wheel Release Procedure ......198 Fifth Wheel Lubrication .............. 199 TOW HITCH ..................199 TOWING .................... 199 Returning Vehicle to Service ............200 VEHICLE RECOVERY AND SPRING BRAKES ......
Page 12 CONTENTS ANTI-LOCK BRAKING SYSTEM (ABS) ........235 ABS Fault Codes ................. 235 AIR SUPPLY SYSTEM ..............237 Air System Function Test ............238 Air Tanks ..................238 Water Ejection Valves ..............238 AIR COMPRESSOR ................. 239 Operation ..................239 Air Gauges and Air Leaks ............240 TURBOCHARGER ................
Page 13 CONTENTS TRANSMISSION AND CLUTCH ............. 272 All Transmissions ................ 272 Transmission Service Intervals ..........273 CLUTCH SYSTEM ................273 General Information ..............273 Clutch Adjustment - Normal Wear ..........274 Clutch Adjustment ............... 275 Clutch Lubrication ............... 276 STEERING ..................278 Understeer and Oversteer ............
Page 14 THE ENVIRONMENT ............... 306 INTRODUCTION ................309 CHANGE OF ADDRESS/OWNERSHIP ......... 309 WARRANTY QUESTIONS .............. 310 KENWORTH DEALER NETWORK ..........314 MAINTENANCE SERVICES ARE THE OWNER’S RESPONSIBILITY ................314 LUBRICATION SCHEDULES ............315 T410 - MX Engine Service Schedule .......... 316 First Service .................
Page 15: List Of Tables
CONTENTS LIST OF TABLES Operating Temperatures ..............26 Operating Pressures ................ 26 Warning Symbols ................45 Dash Switches .................. 58 Eaton UltraShift PLUS Fault Codes ..........144 How Your Actions Impact the Fusion System ......173 What to Expect When Using the Fusion System ......176 Automatic Brake Adjuster Application .........
Page 16 CONTENTS Page xiv Y53-1404 (8612 08/2023)
Page 17: About This Handbook
After you’ve read this handbook, it should be stored in the cab for convenient reference and remain with this truck when sold. Your Kenworth may not have all the features or options mentioned in this manual. Therefore, you should pay careful attention to the instructions that relate to your vehicle.
Page 18 If there are any doubts about the safe operation of your Kenworth truck, contact your nearest authorised Kenworth dealer. To ensure optimum performance and safe operation of your vehicle, Kenworth recommends it is regularly inspected and serviced by an authorised Kenworth dealer.
Page 19: Safety Symbols
CONTENTS SAFETY SYMBOLS A number of alerting messages are used in this manual. Read and follow them. They are for your protection and information. These messages can help you avoid personal injury and costly damage to your vehicle. WARNINGS The safety message following this symbol provides a warning against operating procedures which could cause death or personal injury.
Page 20: Vehicle Safety
CONTENTS VEHICLE SAFETY Do not drink alcohol and drive. Your reflexes, perceptions, and judgment can be affected by even a small amount of alcohol. You could have a serious or even fatal accident, if you drive after drinking. Do not drink and drive or ride with a driver who has been drinking. Failure to comply may result in death, personal injury, equipment or property damage.
Page 21: A Special Word About Repairs
CONTENTS A SPECIAL WORD ABOUT REPAIRS Do not attempt repair work without sufficient training, service manuals, and the correct tools. You could be killed or injured, or you could make your vehicle unsafe. Do only those tasks you are fully qualified to do. Your dealer’s service center is the best place to have your vehicle repaired.
Page 22: Driver Information Pack (Dip)
DRIVER INFORMATION PACK (DIP) In addition to this Driver’s Handbook, there are many other publications that are supplied with your new Kenworth truck. Take the time to read them. Also in the Driver Information Pack you will find the operating instructions for the radio/s, etc.
Page 23: Master Service Chart
Lists all Kenworth recommended lubricants for use in all major and auxiliary components. Finally, there is a reminder for you to present your new Kenworth truck to any of our authorised Kenworth dealers for its First Service at 10,000km or 30 days. This service includes free labour and inspection, you only pay for the lubricants and filters used.
Page 24 CONTENTS Page xxii Y53-1404 (8612 08/2023)
Page 25: Section One Operating Instructions
SECTION ONE OPERATING INSTRUCTIONS...
Page 27: General Information
OPERATING INSTRUCTIONS GENERAL INFORMATION VEHICLE ACCESS DOOR LOCK AND KEYS Doors can be locked from the inside via the switch on the armrest. Close the door, then depress the switch to lock. Doors automatically unlock when you open them from inside and can be locked from the outside with the key or the Remote Keyless Entry (RKE) button on the remote control module.
Page 28: Remote Keyless Entry (Rke)
‘Operating the Engine’ on page 102. REMOTE KEYLESS ENTRY (RKE) Kenworth Remote Keyless Entry system gives you added security and convenience for your Kenworth truck. This system will lock or unlock the driver’s and passenger's doors with a remote keypad transmitter.
Page 29: Remote Verification
OPERATING INSTRUCTIONS REMOTE VERIFICATION This function is optional and is enabled during the programming stage. When pressed, the LOCK button locks both doors. To Lock and Unlock the Doors 1. To Unlock the Driver’s Door a) Press the UNLOCK button once b) Driver’s door unlocks c) Door and dome lamps turn ON for 40 seconds (Door Closed).
Page 30: Keypad Transmitter
OPERATING INSTRUCTIONS KEYPAD TRANSMITTER The range of the Remote Keyless Entry system is approximately 10 metres. This will be reduced if it is operated close to other RF sources such as TV/ Radio transmitters and cell towers. Unlock Lock Pre-Trip Test Lamp DANGER Do not ingest battery, Chemical Burn Hazard...
Page 31: Cab And Frame Access
OPERATING INSTRUCTIONS CAB AND FRAME ACCESS SAFETY Always reinstall steps before entering the cab or accessing the deck plate. Without steps you could slip and fall. Failure to comply may result in death or personal injury. Be careful whenever you get into or out of your vehicle’s cab. Always maintain at least three points of contact with your hands on the grab handles and your feet on the steps.
Page 32: Climbing Onto The Deck Plate
OPERATING INSTRUCTIONS Do not step on vehicle components without anti-slip surfaces or use components not designed for entry-and-exit use. You could slip and you step onto a slippery fall, resulting in possible injury to yourself if surface. Do not step onto the surface of a fuel tank. A fuel tank is not a step. The tank surface can get very slippery, and you might not be able to prevent a fall.
Page 33 OPERATING INSTRUCTIONS Maintain three points of contact at all times. Using the external cab access grab rails and steps to climb up into a conventional cabin. Use the external grab rail and internal access handle to aid ingress and egress to the cabin. DO NOT use the steering wheel, door handle or arm rest to pull yourself up into the cabin.
Page 34: Engine Access
OPERATING INSTRUCTIONS ENGINE ACCESS HOOD HOLD-DOWNS Hood hold-downs keep a hood from opening unexpectedly. Hood Latch in the Closed Position A hood not latched securely could open during operation and cause vehicle damage. Be sure to latch the hood securely. Pull Latch Backwards to Unlock Pull Back to Separate and Open Page 8...
Page 35: Tilting The Hood
OPERATING INSTRUCTIONS TILTING THE HOOD To open your hood, unlock the hood hold-downs by unlatching them. Put one or both hands on the top of the hood front. Tilt the hood forward by pulling from the top of the ‘KW’ emblem, pivoting on the foot placed on the bumper and using the foot on the ground for stability.
Page 36: Hood Safety Latch
OPERATING INSTRUCTIONS Hood Safety Latch The hood is equipped with a hood safety latch. In order for the hood safety latch to become engaged, the vehicle hood must be fully open. Once the vehicle hood is fully open, the safety latch will automatically engage and will need to be disengaged by the operator.
Page 37: Safe Vehicle Operation
• do not drive if you are tired, ill, or under emotional stress Much has gone into the manufacturing of your Kenworth truck including advanced engineering techniques, rigid quality control and demanding inspections. These manufacturing processes will be enhanced by a safe driver –...
Page 38: Emergency Equipment
DRIVER’S CHECKLIST To keep your Kenworth truck in peak condition and maintain a high level of safety for you, your passengers and your load, make a thorough inspection every day before you drive. You will save maintenance time later, and the safety checks could help prevent a serious accident.
Page 39: Approaching Your Vehicle
OPERATING INSTRUCTIONS IMPORTANT It is recommended that you have an engine start-up inspection performed within the first 90 days of operation. The inspection may be performed at any service shop authorised by the engine manufacturer. NEW VEHICLE PRECAUTIONS Oil changes: Driving Axles The initial factory lubricants must be drained and the units refilled at the first 10,000km or 30 days service, whichever comes first.
Page 40: Daily Checks
OPERATING INSTRUCTIONS DAILY CHECKS ENGINE COMPARTMENT 1. Engine fluid levels: • engine oil • coolant (check while engine is cold) • power steering fluid level 2. Engine Belt Check Tension and condition of belts: • if breaks or tears are found, the belt should be replaced before operating the vehicle 3.
Page 41 OPERATING INSTRUCTIONS 6. Air System - Are there leaks? • Air Tanks - Drain water from all air tanks. Make sure the drain cocks are closed. This procedure is also required for air suspension tanks equipped with automatic drain valves. See page 146 for further details on Brakes.
Page 42: Pre-Start Checks
OPERATING INSTRUCTIONS PRE-START CHECKS DAILY OPERATIONS 1. Drain moisture from the air tanks. Open the tank drains just enough to drain the moisture. Do not deplete the entire air supply. Doing this at the start of the day, ensures any moisture from the previous day is ejected from the air tanks.
Page 43: Weekly Operations
OPERATING INSTRUCTIONS WEEKLY OPERATIONS 1. Battery - Check battery levels and terminals. 2. Wheel Nuts - Are they all in place and torqued correctly? - Tighten if necessary. See Wheel Nut Torque page 247. 3. Other Controls and Wiring - Check for condition and adjustment. 4.
Page 44: Instrument Panel
OPERATING INSTRUCTIONS INSTRUMENT PANEL Getting to Know Your Instrument Panel This part explains the location of the various features on your vehicle and describes their function. For information on using these features, see the paragraphs that follow. Remember that each vehicle is custom built. Your instrument panel may not look exactly like the one in the pictures that follow.
Page 45 OPERATING INSTRUCTIONS LEGEND FOR T410 DASH LAYOUT 1. Fuses, Relay & Circuit Breaker Panel Cover 2. Air Conditioning (HVAC) Vents 3. Sun Light Sensor for HVAC (inside windscreen) 4. Overhead Console with Storage 5. Upper Switch Panel, includes Hazard Warning, ABS/ATC and Hill Start Assist 6.
Page 46: Main Instrument Cluster
OPERATING INSTRUCTIONS MAIN INSTRUMENT CLUSTER Primary Air Pressure Primary Air Pressure Let Compressor Run, Let Compressor Run, Inspect for Leaks Inspect for Leaks 1 of 3 1 of 3 3 3 4 4 80 80 ° 60 60 40 40 COOLANT Set Clock 12,345.6...
Page 47 OPERATING INSTRUCTIONS Instrument System Self Test When the ignition switch is turned on the Instrument system will undergo a self test. This test will verify the operation of the gauges and warnings. During the instrument system self test, multiple warning icons will be displayed in a sequence.
Page 48 OPERATING INSTRUCTIONS 2. Tachometer The tachometer measures the engine speed in revolutions per minute (RPM). The RPM detail is also available as a viewable screen in the Driver Performance Center. Viewing the RPM is accomplished by rotating the MCS until the Gauges screen is displayed and then selecting Tachometer. The tachometer is a useful gauge when attempting to drive efficiently.
Page 49 OPERATING INSTRUCTIONS 4. Diesel Exhaust Fluid (DEF/AdBlue) The diesel exhaust fluid gauge shows the approximate amount of AdBlue fluid in the AdBlue tank. Besides empty and full, the gauge also indicates of total capacity. AdBlue fluid is required to meet certain emission requirements.
Page 50 Turn ON the emergency flasher and use other warning devices to alert motorists. Wait a few minutes to allow oil to drain into the engine oil sump, then check the oil level. Add oil if necessary. If the problem persists, contact an authorised Kenworth service dealer. Page 24 Y53-1404 (8612 08/2023)
Page 51 OPERATING INSTRUCTIONS 8 & 9. Front and Rear Air Pressure The air gauges indicate the air pressure in the truck air system. There are two indicator dials, the primary dial and icon is for the rear air system while the secondary dial and icon is for the front air system. The gauges indicate the amount of air pressure in each system.
Page 52: Operating Temperatures
OPERATING INSTRUCTIONS OPERATING TEMPERATURES* Engine Oil Normal Operating Range 80ºC-90ºC Engine Coolant Thermostat opens at Approx 75ºC Thermostat opened at least 12mm at Approx 87ºC Rear Axle Lubricant Normal Operating Range 79°C to 107°C Maximum difference between axles 17°C Climbing steep grades 107°C Maximum allowable* (investigate cause) 121°C...
Page 53: Driver Performance Center
OPERATING INSTRUCTIONS DRIVER PERFORMANCE CENTER The display can show multiple warning lights. Warning information will appear momentarily and then will minimise in the screen. Reviewing the warnings can be done by navigating the menu via the Menu Control Switch. Driver Information Display 1.
Page 54 OPERATING INSTRUCTIONS Description Do not look at the Driver Performance Center for prolonged periods while the vehicle is moving. Only glance at the monitor briefly while driving. Failure to do so can result in the driver not being attentive to the vehicle’s road position or situation which could lead to an accident and possible death, personal injury or equipment damage.
Page 55 OPERATING INSTRUCTIONS 2. Automated Transmission and Shift Indicator Area This area will provide the operator with feedback from the transmission. The display may reflect the transmission gear being operated, may provide Progressive Shift Cues or fault indicators specific for the transmission. 3.
Page 56 OPERATING INSTRUCTIONS 5. Odometer/Trip Odometer The Odometer/Trip Odometer comes on when the door is opened and when the ignition key is in the ACC or ON position. The odometer displays the distance your vehicle has travelled and can be configured to display Metric units or Imperial units. The current trip odometer displays how far the vehicle has travelled on a particular trip and can display in increments of a tenth of a unit.
Page 57 OPERATING INSTRUCTIONS 7. Active Warnings Active warnings will appear in this area in addition to areas around the center of the display. Active warnings are those pop-up messages that appear on the screen and/or have been suppressed with an MCS push. If there are warning icons active while the cruise control is enabled, icons will appear on each side of the cruise control icon.
Page 58 OPERATING INSTRUCTIONS How to Navigate the Functions in the Driver Performance Center with the Menu Control Switch (MCS) The MCS is used to navigate the instrument display. It comprises of a back button and a push and spin knob. The MCS is located to the left of the steering column.
Page 59 OPERATING INSTRUCTIONS PUSH to Select/Enter Spin to Navigate Here is a list of the available menu items: • Blank Screen - Use this menu item to minimise information on the screen. • Digital Gauges - This menu item provides dynamic information to the operator.
Page 60 OPERATING INSTRUCTIONS Trunk Level At this level you can navigate between functions by turning the MCS. You can enter a function by pushing the MCS; you would then be going to what is termed the ‘Branch’ level of the software. Navigation at Trunk Level Branch Level In the branch level of functions, the MCS knob rotation controls a cursor...
Page 61 OPERATING INSTRUCTIONS Leaf Level At this level, there are no more options to choose from. The MCS can be used to scroll through various information and the back button can be used to revert up to the branch (1 push) or the trunk (2 pushes) levels of the system.
Page 62 OPERATING INSTRUCTIONS Blank Screen The blank screen mode is to allow for minimised screen content, while still maintaining some of the more permanent screen elements such as the odometer, outside air temperature, warning cue, etc. This is different from the Display OFF Mode where the entire display shuts off. The blank screen mode is selected through the rotary MCS.
Page 63 OPERATING INSTRUCTIONS Fuel Economy This function displays the dynamic fuel economy performance of the vehicle. It shows Average Speed, Average Fuel Economy, and a dynamic instantaneous indication of fuel economy above or below the current average. The screen is available when driving. Average fuel economy is computed by the fuel consumed during the trip (see the next section for Trip information).
Page 64 OPERATING INSTRUCTIONS When driving, the screen only allows you to toggle which trip is viewed in the trip odometer and set the active/inactive status. When parked you can select and view a variety of data collected for each trip as seen in the list below: •...
Page 65 OPERATING INSTRUCTIONS Truck Information Only available truck information will be shown (e.g., manual transmissions do not have a software version). This information is available when the vehicle is parked. 1. Chassis Information: a. Chassis Number b. Fleet ID Number c. CECU Software Version Number 2.
Page 66 OPERATING INSTRUCTIONS 4. ABS Information: a. ABS Make b. ABS Model c. ABS Software Version Number Warning and Faults The display has a message alerting function that overrides the normal viewing and navigation of functions when an issue occurs on the truck. These alert messages are called ‘pop-ups’...
Page 67 OPERATING INSTRUCTIONS When the vehicle is parked, the Warnings and Faults function will access suppressed pop-ups that are counted and presented in the upper left corner of the screen. By selecting Review Warnings the pop-up messages are recalled, and if multiple are active, the stack can be navigated by spinning the MCS.
Page 68 OPERATING INSTRUCTIONS An example of a Fault Details screen is shown below. Fault Details Example Active Faults: Rear Suspension Active Faults: Rear Suspension Rear Suspension Rear Suspension Pressure Low Pressure Low Let Compressor Run, Let Compressor Run, Inspect for Leaks Inspect for Leaks 1 of 3 3 of 3...
Page 69 OPERATING INSTRUCTIONS To Set Clock Display Format: 1. When in the Settings Menu, scroll through the list of menu items to ‘Format’. 2. Press the MCS to display either 12 hour (AM/PM) or 24 hour time. To Set Time: Settings: Settings: Time Time...
Page 70: Warning Symbols
OPERATING INSTRUCTIONS WARNING SYMBOLS Guide to the Warning Symbols The warning lights and audible alarm may indicate a system malfunction. Check the lights frequently, and respond properly as soon as you see one go on. These lights could save you from a serious accident. When multiple warning icons are shown on the instrument cluster, they will appear at first and then minimise.
Page 71 OPERATING INSTRUCTIONS STD/ Symbol Name Symbol Colour Page Axle - Traction Control Yellow (ATC) Brakes - Anti-Lock Yellow Brake System (ABS) Brakes - Low Air BRAKE Brake - Parking brake PARK PARK Brake - Service Brakes & Trailer Low Air BRAKE BRAKE Brake Wear.
Page 72 OPERATING INSTRUCTIONS STD/ Symbol Name Symbol Colour Page Tipper Truck - Gate Yellow Open 11. Tipper Truck - Trailer AFTER MARKET Body Up 12. Emissions - Malfunction Yellow Indicator Lamp (MIL) 13. Engine - Check Engine Yellow 14. Engine - Engine Fan Green 15.
Page 73 OPERATING INSTRUCTIONS STD/ Symbol Name Symbol Colour Page 19. Fuel - Water In Fuel Yellow (WIF) 20. Lane Departure Yellow Warning (LDW) 21. Lights - High Beam Blue 22. Power Take-off (PTO) Yellow 23. Power Take-off (PTO) Green AFTER PUMP MARKET - Pump Mode MODE...
Page 74 OPERATING INSTRUCTIONS STD/ Symbol Name Symbol Colour Page 28. Transmission - Auxiliary Yellow 29. Transmission - Check 30. Transmission - Retarder Yellow (includes Brakesaver when applicable) 31. Transmission - Service Yellow Transmission (Allison) 32. Turn Signal - Left Green 33. Turn Signal - Right Green Page 48 Y53-1404 (8612 08/2023)
Page 75: Description Of Warning Symbols
OPERATING INSTRUCTIONS DESCRIPTION OF WARNING SYMBOLS 1. Axle - Traction Control (ATC or Automatic Traction Control) A. Illuminates during the power-on self test when the ignition is turned ON. It turns off after a few seconds if no system problems are detected. If an ATC problem is detected, the ATC warning lamp will turn on and stay on.
Page 76 OPERATING INSTRUCTIONS 3. Brakes - Low Air Illuminates when the air pressure in the air reservoirs are low. BRAKE 4. Brake - Parking brake Illuminates in the status indicator when parking brakes are applied. PARK PARK 5. Brake - Service Brake & Trailer Low Air Indicates that a fault exists in the brake system.
Page 77 OPERATING INSTRUCTIONS 9. Tipper Truck - Body Up Illuminates when Truck Tipper Body is up. 10. Tipper Truck - Gate Open Illuminates when Truck Tipper Gate is open. 11. Tipper Truck - Trailer Body Up Illuminates when Trailer Tipper Body is up. 12.
Page 78 OPERATING INSTRUCTIONS 17. Engine - Stop Engine Illuminates and an audible alarm will sound when a major engine system problem exists. The illumination of the Stop Engine Light should be considered an emergency. You should stop the vehicle as safely as possible and turn OFF the ignition.
Page 79 OPERATING INSTRUCTIONS 23. Power Take-off (PTO) - Pump Mode PUMP MODE Illuminates with remote throttle application. Indicates pump mode is active. 24. Refrigerator Illuminates to indicate the refrigerator is on and ignition is off. 25. Seat Belt - Fasten Illuminates when the ignition key is turned on as a reminder to fasten your seat belt.
Page 80: Optional Gauges
OPERATING INSTRUCTIONS 32 & 33. Turn Signals - Left or Right Blinks when the left or right turn signal or the hazard light function is operating. OPTIONAL GAUGES Introduction Listed here are gauges that may or may not be on your dashboard or the center instrument cluster.
Page 81 OPERATING INSTRUCTIONS Engine, Oil Temperature The Engine Oil Temperature gauge indicates the engine oil temperature. If the oil temperature exceeds the maximum limits, a red warning light in the gauge will turn on. Do not exceed maximum engine oil temperature recommended by the engine manufacturer.
Page 82 OPERATING INSTRUCTIONS Drive Axle Temperature Gauge (Forward and Rear) These gauges indicate the temperature of the lubricant in your vehicle’s axle(s). These temperatures will vary with the kind of load you are carrying and the driving conditions you encounter. Maximum axle temperature may vary, depending upon the axle and type of lubricant.
Page 83 OPERATING INSTRUCTIONS Transmission Oil Temperature, Auxiliary The Auxiliary Transmission Oil Temperature gauge indicates the temperature of the oil in the auxiliary transmission. Watch this gauge to know when the transmission is overheating. Do not exceed maximum oil temperature recommended by the manufacturer. (See the Transmission Operation and Maintenance Manual for details.) Transmission Retarder Oil Temperature The Transmission Retarder Oil Temperature gauge indicates...
Page 84: Dash Switches
OPERATING INSTRUCTIONS DASH SWITCHES This custom vehicle will have a wide variety of switch controlled equipment. However, this particular vehicle may not have every switch identified in this section of the operator manual. Some air device switches on the dash may require that the vehicle either be at a specific speed, parking brakes set or another device to be on or off for the air device to operate.
Page 85 OPERATING INSTRUCTIONS STD/ Symbol Name Symbol Colour Page Axle - Diff-Lock - Rear Amber Rear Axle - Diff-Lock - Single Amber Rear Axle - Inter-Axle Amber Differential Locked (Tandem) Axle - Two Speed Green Reversing Alarm Mute Amber Batteries - Low Voltage None Disconnect (LVD) 10.
Page 86 OPERATING INSTRUCTIONS STD/ Symbol Name Symbol Colour Page 14. Cab Dimmer Switch None 15. Tipper Truck Gate Open 16. Engine Idle Timer Green 17. Engine - Cruise Control Green On/Off 18. Engine - Cruise Control None Set/Resume RESUME RESUME 19. Engine - Fan Override Green 20.
Page 87 OPERATING INSTRUCTIONS STD/ Symbol Name Symbol Colour Page 25. Lights - Beacon Green 26. Lights - Interior None 27. Lights - Exterior Lights None Self Test 28. Lights - Flood Amber 29. Lights - Flood Amber ISO 3732 Spare 30. Lights - Fog Green 31.
Page 88 OPERATING INSTRUCTIONS STD/ Symbol Name Symbol Colour Page 36. Lights - Spot Green 37. Power Take-off (PTO) Amber 38. Suspension Dump Amber 39. Transmission - Transfer Amber Case 40. Transmission - Transfer Amber Case 2 Speed Page 62 Y53-1404 (8612 08/2023)
Page 89 OPERATING INSTRUCTIONS 1. Axle - Diff-Lock - Dual Turn switch on to engage Front and Rear Axle Diff Lock. 2. Axle - Diff-Lock - Forward Rear Turn switch on to engage Forward Rear Axle Diff Lock. 3. Axle - Diff-Lock - Steer Turn switch on to engage Front Axle Diff Lock.
Page 90 OPERATING INSTRUCTIONS 9. Batteries - Low Voltage Disconnect (LVD) If your vehicle is equipped with a Low Voltage Disconnect (LVD) feature, the LVD module is located inside the driver’s side kick panel. 10. Brakes - ABS Off Road Turn switch on to engage ABS Off-Road mode. See Anti-Lock OFF ROAD OFF ROAD Braking System on page 235.
Page 91 OPERATING INSTRUCTIONS 14. Cab Dimmer Switch This switch is used to alter the brightness of the instrument panel lights. The Headlamp Switch is an ON or OFF switch. The panel lights are on full intensity during the day and go to dimmer mode when headlights are on.
Page 92 OPERATING INSTRUCTIONS 19 Engine - Fan Override The engine fan switch allows you to control the engine fan manually or automatically. Do not work on or near the fan with the engine running. Anyone near the engine fan when it turns on could be seriously injured. If it is set at MANUAL, the fan will turn on any time the ignition key switch is turned to the ON position.
Page 93 OPERATING INSTRUCTIONS 23. Generic - Spare SPARE Turn switch on to power customer installed accessory. 24. Lights - Auxiliary Turn switch on for Auxiliary Lights. 25. Lights - Beacon Turn switch on for Beacon Light(s). 26. Lights - Dome Lights (Interior) A two-position switch, located on the dome light, controls each dome light.
Page 94 OPERATING INSTRUCTIONS 31. Lights - Hazard Warning With the switch in the ON position, the emergency flasher makes all four turn signals (front and rear) flash simultaneously. The flasher works independently of the ignition switch. You should always use the flasher if the vehicle is disabled or parked under emergency conditions.
Page 95 OPERATING INSTRUCTIONS 35. Lights - Marker/Clearance/Trailer Turn switch on to control Trailer Marker/Clearance lights separately from the vehicle marker/clearance lights. 36. Lights - Spot Turn switch on for Spot Light. 37. Power Take-off (PTO) Turn switch on to engage PTO. Your vehicle may be equipped with a dash mounted switch that controls PTO engagement/ disengagement.
Page 96 OPERATING INSTRUCTIONS 39. Transmission - Transfer Case Turn switch on to shift the Transfer Case. 40. Transmission - Transfer Case 2 Speed Turn switch on to shift the 2 Speed Transfer Case. Page 70 Y53-1404 (8612 08/2023)
Page 97: Steering Column And Controls
OPERATING INSTRUCTIONS STEERING COLUMN AND CONTROLS The steering column has controls for tilt/telescope, turn signal, wipers, engine brake and optional transmission controls. 1. Tilt/Telescoping Lever 2. Turn Signal/Wiper/Lights 3. Engine Brake (optional Transmission Shifter) The turn signal lever is mounted on the left side of the steering column. The lever controls several functions;...
Page 98 OPERATING INSTRUCTIONS To adjust the steering wheel, PUSH and HOLD the lever down fully. Adjust the steering wheel by pulling or pushing the wheel to the desired height and angle, then return the lever back into the locked position. Steering Column Locked Steering Column Unlocked Page 72 Y53-1404 (8612 08/2023)
Page 99: Turn Signal/High Beam Switch
OPERATING INSTRUCTIONS TURN SIGNAL/HIGH BEAM SWITCH The ignition key must be turned to ON for the signal/switch to operate. The lever-action turn signal/high beam switch is located on the left side of the steering column. Each time a turn signal indicator is activated the buzzer will emit a short click sound.
Page 100: High Beam
OPERATING INSTRUCTIONS HIGH BEAM The headlights must be ON for the high beam switch to operate. • To switch your headlights to low or high beam, gently pull the turn signal lever toward the steering wheel until you hear the switch click and the beam changes.
Page 101: Windscreen Wipers/Washer
OPERATING INSTRUCTIONS WINDSCREEN WIPERS/WASHER Your vehicle is equipped with a two-speed intermittent windscreen wiper system. The windscreen wiper system is integrated with the exterior lights so the low beam headlights will turn on when the windscreen wipers turn on. To override this function, turn the headlights on and then off again and the low beams will turn off.
Page 102 OPERATING INSTRUCTIONS To Wash the Windscreen Push the rotary wash/wipe knob in (towards steering column), hold for more than 0.8 seconds and then release. Hold the knob in to extend the washing cycle. After the lever is released, the wipers will shut off automatically or resume the wiper’s setting speed.
Page 103: Controls On Right Hand Side Of The Steering Column
OPERATING INSTRUCTIONS CONTROLS ON RIGHT HAND SIDE OF THE STEERING COLUMN The lever on the right hand side of the steering column will operate the engine brake for vehicles with manual transmissions. This vehicle may be equipped with a PACCAR Transmission or Eaton UltraShift Plus Transmission.
Page 104: Steering Wheel Controls (Optional)
OPERATING INSTRUCTIONS STEERING WHEEL CONTROLS (OPTIONAL) Under no circumstances should you attempt to service the steering wheel, clockspring or any of the electrical wiring in the multiplex system or any steering components (steering column, steering driveline or steering gear). Tampering with these components may result in an inoperable multiplex system.
Page 105: Cruise Control
OPERATING INSTRUCTIONS CRUISE CONTROL Vehicles with steering wheel controls will have cruise control options on the right hand of the wheel instead of the switches on the dashboard. These optional switches for cruise control include a third switch to allow the operator to accelerate or coast while maintaining cruise control operation.
Page 106: Door Mounted Controls
OPERATING INSTRUCTIONS DOOR MOUNTED CONTROLS Introduction Your vehicle is fitted with power mirrors, the mirror controls will be located on the driver side door pad. Mirrors can be adjusted in 4 directions. Mirror Heat Switch Power Mirror Switch Mirror Selector Switch Power Window Switch...
Page 107 OPERATING INSTRUCTIONS 1. Mirror Heat Switch Your vehicle may be equipped with standard heated mirrors. Mirror heat is controlled by the mirror heat switch button, which is part of the mirror switch module located on the driver side door pad. 2.
Page 108 OPERATING INSTRUCTIONS Exterior Lights Self Test This feature allows the operator to verify and inspect exterior lighting operation typically performed during a pre-trip inspection. When the feature is engaged, via a switch on the key fob, it will illuminate the: •...
Page 109: Curb Side Mirror
OPERATING INSTRUCTIONS CURB SIDE MIRROR General information on using the curb side mirror. A mirror is located above the passenger door that provides a quick view of the blind spot created by the passenger door. Rotate the mirror up or down to get the desired view. Y53-1404 (8612 08/2023) Page 83...
Page 110: Cab Hvac Controls
OPERATING INSTRUCTIONS CAB HVAC CONTROLS 1. Fan Control Dial 4. MAX Defrost Button 7. T emperature Sensor 2. AUTO Mode Button 5. Air Distribution Dial 8. Air Conditioner Button 6. Sleeper Override Button 9. Outside Air/Recirculation 3. T emperature Control Dial (for vehicles with a Air Button sleeper and optional...
Page 111 OPERATING INSTRUCTIONS Do not drive with visibility reduced by fog condensation or frost on the windscreen. Your view may be obscured which may result in death, personal injury, equipment or property damage. For clear visibility and safe driving it is extremely important for you to follow the instructions pertaining to the function and use of the ventilation/ heating and defogging/defrosting system.
Page 112 OPERATING INSTRUCTIONS When idling for short periods of time: • set the heating or cooling system to heat or A/C • set the fan to medium or high speed • set the controls to FRESH AIR If you are required to idle your vehicle for long periods of time, install an auxiliary heater or automatic idle control.
Page 113 OPERATING INSTRUCTIONS Automatic Control Mode Your vehicle’s air conditioning system is equipped with an automatic button that provides complete cab climate control without driver intervention. When selected, the system will manipulate the air distribution, air temperature, fan speed, A/C compressor, and cab air recirculation to achieve the comfort level selected on the temperature dial.
Page 114 OPERATING INSTRUCTIONS Partial Automatic During AUTO mode the operator may override any setting and operate in a partial automatic mode. This can be done via the dials and/or buttons on the HVAC control. In the partial automatic mode, the AUTO button indicator will cease to be illuminated.
Page 115: Buttons And Dials
OPERATING INSTRUCTIONS BUTTONS AND DIALS Fan Speed Control Dial The fan speed is adjusted by rotating the dial clockwise to increase speed or counter clockwise to decrease speed. Setting the fan dial to ‘O’ turns the HVAC system off. Fan Speed Adjustment The source of air entering the cab can be set to either outside air or recirculation air using the button inside the fan speed control dial.
Page 116 OPERATING INSTRUCTIONS *Defrost and demister vents *Automatically engages outside air and A/C compressor. Power to the sleeper HVAC unit can be toggled using the button inside the air distribution dial. When activated, the indicator on the button illuminates. The sleeper HVAC unit will function to the settings of the sleeper control. Sleeper Override Button (for vehicles with a sleeper) Temperature Control Dial The cab temperature is set using the temperature control dial.
Page 117: Operating Tips
OPERATING INSTRUCTIONS OPERATING TIPS Defrosting and Defogging the Windscreen The cab windscreen and side windows can be cleared of ice and fog in two ways. The first is to use the MAX defrost mode (See MAX Defrost Section on page 88). The second is to manually adjust the air distribution dial to the defrost position.
Page 118 OPERATING INSTRUCTIONS For Maximum Cooling Step 1 Adjust the fan speed to high by rotating the fan control dial clockwise. Step 2 Set the air distribution dial to the panel setting. Step 3 Adjust the air temperature to maximum cool by rotating the temperature dial counter clockwise.
Page 119: Cab Air Distribution
OPERATING INSTRUCTIONS CAB AIR DISTRIBUTION Equal distribution of air is important in maintaining a constant cab interior temperature. For best performance, all vents should remain open to allow the AUTO mode to function properly. To maintain the selected cab temperature the AUTO mode may provide an air temperature from the vents that differs from the temperature set point.
Page 120: Radio (Option)
OPERATING INSTRUCTIONS RADIO (OPTION) As an option, your vehicle has either an AM/FM stereo receiver, which may or may not have a CD, or may have the stereo system integrated with your navigation and telematics unit. Other radio options include a bluetooth or satellite receiver. For instructions on how to operate your particular radio, see the supplemental operating manual for your unit, there is also a PDF version user manual which is loaded onto the Customised Maintenance Manual...
Page 121: Ignition Key Switch
OPERATING INSTRUCTIONS IGNITION KEY SWITCH The ignition key switch (located to the right of the steering column) has four positions; ACC (Accessories), OFF, ON, and START. With the key in this position you can play the radio, defrost mirrors or use other accessories.
Page 122: Vehicle Telematic System
OPERATING INSTRUCTIONS VEHICLE TELEMATIC SYSTEM Your vehicle may be equipped with an onboard telematics system. This system is a Global Positioning Satellite (GPS) linked computer. It receives input from multiple sources to locate your vehicle. Read and understand the Supplemental Telematics and Navigation System Owner’s Manual and observe the Warnings, Cautions, and Notes that follow before using the system.
Page 123 OPERATING INSTRUCTIONS Care of the Display Screen From time to time it may be necessary to clean the display screen. To clean the screen, dampen a clean, soft, lint-free cloth with water only. A mild glass cleaner that does not contain alcohol or ammonia may also be used.
Page 124: Seats
OPERATING INSTRUCTIONS SEATS This section covers the operation and safe use of your Kenworth seats. For further information on features and adjustment of the seat, see the seat manufacturer’s Service and Operation information supplied with the vehicle. SEAT ADJUSTMENT Do not adjust the driver’s seat while the vehicle is moving. The seat could move unexpectedly and can cause the driver to lose control of the vehicle.
Page 125: Safety Restraint Belts
OPERATING INSTRUCTIONS SAFETY RESTRAINT BELTS Seatbelts have proven to be the single most effective means available for reducing the potential for either serious injury or death in motor vehicle accidents. Therefore, read the following instructions and always observe user warnings pertaining to seatbelts. Too High on hips Seatbelts are designed to bear upon the bony structure of the body,...
Page 126: Lap & Shoulder Belt
OPERATING INSTRUCTIONS LAP & SHOULDER BELT The combination lap-shoulder belt is equipped with a locking mechanism. The system adjusts automatically to a person’s size and movements as long as the pull on the belt is slow. Hard braking or a collision locks the belt.
Page 127: Sleeper - Bunks And Restraints
SLEEPER - BUNKS AND RESTRAINTS For Kenworth cabs equipped with a sleeper, be sure to use the fitted restraint devices. Your vehicle may have belts and/or a net restraint system which are over the bunk or cover the opening.
Page 128: Operating The Engine
OPERATING INSTRUCTIONS OPERATING THE ENGINE NORMAL STARTING PROCEDURE 1. Ensure the parking brake is set ON and the transmission shift selector is in neutral. For automatic transmissions that have park position, place the shift selector in park. 2. With the accelerator pedal in the idle position, turn the ignition key to the START position.
Page 129: Engine Warm-Up
OPERATING INSTRUCTIONS ENGINE WARM-UP The purpose of engine warm-up is to allow an oil film to be established between pistons and liners, shafts and bearings while your engine gradually reaches operating temperature. After the engine starts, the electronics will check the coolant temperature and other engine temperature indicators.
Page 130 OPERATING INSTRUCTIONS In colder climates where the temperatures are often below freezing, sufficient warm-up for turbocharged engines is especially important. Chilled external oil lines leading to the turbocharger will slow the oil flow until the oil warms, reducing oil available for the bearings. Watch the engine oil temperature or pressure gauge for a warming trend before increasing engine idle speed (rpm).
Page 131 OPERATING INSTRUCTIONS Before Driving Away 1. Check ALL operating temperatures and pressures are within correct range. 2. Check operation of windscreen washers and wipers. 3. Check horn (electric and air) operation. 4. Check position of the inter-axle differential control. 5. Turn emergency flashers OFF. 6.
Page 132: Idling The Engine
OPERATING INSTRUCTIONS IDLING THE ENGINE Do not idle for extended periods of time. Excessive idle time can cause poor engine performance and waste fuel. Internal combustion engines must not operate at low idle speed for extended periods of time. This operating condition may lead to poor engine performance.
Page 133: Engine Aftertreatment Systems (Eas)
OPERATING INSTRUCTIONS ENGINE AFTERTREATMENT SYSTEMS (EAS) In order to meet ADR 80/03 engine emission requirements, vehicles must have an Exhaust Aftertreatment System (EAS) which will include either Selective Catalytic Reduction (SCR) or a Diesel Particulate Filter (DPF). These are two very different systems and the T410 uses SCR for the PACCAR MX-13 Euro V engines.
Page 134: Eas System Tampering
OPERATING INSTRUCTIONS If the AdBlue indicator light turns on, check the AdBlue level and refill if necessary. Failure to refill may cause the engine to derate and limit vehicle speed. EAS SYSTEM TAMPERING If the engine system detects failures that may be the result of tampering with the EAS system, the Check Engine light will come on, the engine will derate, and if fitted the warning lamp will be on.
Page 135: Diesel Exhaust Fluid - Adblue
OPERATING INSTRUCTIONS DIESEL EXHAUST FLUID - AdBlue Diesel Exhaust Fluid, AdBlue is also known as: AUS32 (Aqueous Urea Solution 32), NoNOx, NOx Reduction Agent or Catalyst Solution. Diesel Exhaust Fluid must meet ISO22241-1. To avoid malfunction and damage of the system, it is important to strictly observe the following precautions.
Page 136: Adblue Filling
OPERATING INSTRUCTIONS Inhalation • If fumes, aerosols or combustion products are inhaled remove from contaminated area. • Other measures are usually unnecessary. Ingestion • Immediately give a glass of water. • First aid is not generally required. If in doubt, contact a Poisons Information Centre or seek medical attention.
Page 137: Engine Brake Operation
OPERATING INSTRUCTIONS ENGINE BRAKE OPERATION Engine Brake Operation for T410 with Manual Transmission Moving the lever clockwise will engage the engine brake. Increase the amount of engine brake by moving the lever further clockwise. Each position has a corresponding level of engine brake. Position Engine Brake Level HIGH...
Page 138 OPERATING INSTRUCTIONS The corresponding engine brake level (or MAX mode) will be illuminated in the instrument cluster. Position Engine Brake Level HIGH MAX (HIGH and will engage transmission low gear) * Position 3 is a momentary position and will revert back to position 2 when the lever is released.
Page 139: Operating The Transmission
OPERATING INSTRUCTIONS OPERATING THE TRANSMISSION Because each Kenworth is custom-equipped, the specific operating procedures for your particular transmission are not included in this handbook. Therefore, you should read the general guidelines and instructions that follow, and read the specific instructions contained in the transmission manufacturer’s Driver/Operator’s Instruction Manual.
Page 140: Shifting Gears In A New Vehicle
OPERATING INSTRUCTIONS 3. Push the parking brake valve handle (Yellow) against the dash panel to release the brakes. 4. Release the clutch pedal (manual only), then gradually accelerate to permit smooth starting. 5. Do not allow your vehicle to roll (even a little) in the opposite direction during clutch engagement.
Page 141: Clutch Brake And Travel
OPERATING INSTRUCTIONS CLUTCH BRAKE AND TRAVEL The clutch brake is used for stopping transmission gears, allowing you to easily shift into first gear or reverse without grinding gears. Approximately the last 25mm of clutch pedal travel activates the clutch brake (see page 275).
Page 142: Double Clutching
OPERATING INSTRUCTIONS DOUBLE CLUTCHING Whether you are up-shifting or down-shifting, it is best to double clutch. Double clutching is easier on the transmission and engine, helping your vehicle match engine speed with driveline speed and achieving clash-free shifts. To double clutch: 1.
Page 143: Clutch Operation
OPERATING INSTRUCTIONS CLUTCH OPERATION STARTING To properly put a vehicle into motion, depress the clutch pedal until the clutch brake is contacted. This contact should occur 25mm or less from the floorboard - excluding carpet. Select a gear low enough to allow the vehicle to start forward with throttle at idle until the clutch is fully engaged.
Page 144: Transmission Oil Temperature Gauge
OPERATING INSTRUCTIONS Inspect manual clutches according to the manufacturer’s recommendations. Regular maintenance should be followed to maintain correct clutch adjustment. Have your dealer’s service department perform any adjustment necessary. Clutch Tips • Always use the clutch when making upshifts or downshifts. •...
Page 145: Transmission Shift Patterns
OPERATING INSTRUCTIONS TRANSMISSION SHIFT PATTERNS 18 SPEED Eaton Fuller Eaton Fuller RANGE RANGE Transmissions Transmissions SPLITTER SELECTOR SPLITTER SELECTOR SELECTOR SELECTOR MAY BE SHIFTED MAY BE SHIFTED IN ALL GEAR SHIFT IN ALL GEAR SHIFT LEVER POSITIONS LEVER POSITIONS PRE-SELECT PRE-SELECT ALL RANGE AND SPLITTER ALL RANGE AND SPLITTE R SHIFTS...
Page 146: Automated Transmissions
OPERATING INSTRUCTIONS AUTOMATED TRANSMISSIONS OPERATING AUTOMATED TRANSMISSIONS An automated transmission makes shifting much easier, but because your truck pulls a heavy load, it is important to use it efficiently. For correct automated transmission operation, see the manufacturer’s Driver/ Operator’s Instruction Manual. On most automated transmissions there is no Park position, so you will need to apply the parking brake before leaving the cab.
Page 147: Controls For Vehicles With A Paccar Or Eaton Automated Transmission
OPERATING INSTRUCTIONS CONTROLS FOR VEHICLES WITH A PACCAR OR EATON AUTOMATED TRANSMISSION This vehicle may be equipped with either an Eaton Automated or a PACCAR Transmission. The PACCAR or Eaton Automated Transmission controls are located on the right hand side of the steering column, refer page 77 for functions.
Page 148 OPERATING INSTRUCTIONS This button will put the transmission into manual mode. Manual mode will allow the operator to select the gear. See Up or Down Shifting on page 122. To activate Manual mode, put the gear selector in the D (Drive) mode and then depress the M/A button.
Page 149: Paccar Transmissions
OPERATING INSTRUCTIONS PACCAR TRANSMISSIONS Gear Display The Gear Display indicates the current gear position of the transmission. During an upshift or downshift the gear display may momentarily flash the target gear position. Current Gear Gear Shift Transition Successful Gear Shift SOLID FLASHING SOLID...
Page 150: Start-Up And Power-Down
OPERATING INSTRUCTIONS START-UP AND POWER DOWN Start-up 1. Ensure Neutral is selected on the Transmission Mode Selector on the right-hand steering column stalk. The transmission will not allow the engine to crank if a mode other than Neutral is selected, on Transmission Mode Selector, when attempting to start the engine.
Page 151: Paccar Transmission Modes
OPERATING INSTRUCTIONS Power Down 1. Select Neutral on the Transmission Mode Selector. If gear display does not show solid N, neutral has not yet been • obtained. Neutral should always be reached before initiating power down, except in cases of emergency. 2.
Page 152 OPERATING INSTRUCTIONS Multiple gear upshifts and downshifts may be allowed when the up/ downshift request procedure is performed multiple times (Each request equals one gear change request). • The transmission may also deny a shift while ascending or descending grades if the load of the vehicle, and grade of the terrain in combination with the drivetrain ratio and engine torque will fall outside of the acceptable range to perform a shift.
Page 153 OPERATING INSTRUCTIONS MANUAL Mode MANUAL mode should be used whenever the driver wants to select the shifts instead of letting the transmission select them automatically. For example, when the driver is moving around the yard, over railroad tracks, or on steep grades. •...
Page 154: Paccar Transmission Features
OPERATING INSTRUCTIONS Creep Mode Creep allows the vehicle to be driven at a constant speed at engine idle without the need to apply the accelerator pedal. The configuration is useful for slow speed applications where steady vehicle speed is required. Upshifts and downshifts can be requested to increase or decrease vehicle speed.
Page 155 OPERATING INSTRUCTIONS • If the PACCAR Automated Transmission clutch does start to overheat, the display will show CA along with a warning tone. If CA is active in the gear display, immediately discontinue the operation that is being performed which is causing the clutch to overheat. •...
Page 156 OPERATING INSTRUCTIONS Load-Based Shifting The transmission will adapt to the changing conditions of the vehicle to change the shift points based on the following inputs: • Vehicle grade • Engine RPM • Throttle position • Vehicle load After changing loads or powering up, the transmission system needs to relearn these inputs for the first few shifts to make the proper adjustments.
Page 157: Eaton Transmissions
OPERATING INSTRUCTIONS EATON TRANSMISSIONS ULTRASHIFT PLUS TRANSMISSIONS Shift Lever Patterns and Shifting Controls UltraShift PLUS is an automated manual Eaton Fuller transmission that automatically selects and engages the transmission’s gears with an ECA (Electronic Clutch Actuator) that operates the clutch. Refer to UltraShift PLUS Automated Transmission Driver Instruction booklet included in you Driver's Information Pack for further information relating to operation, service and maintenance of your UltraShift PLUS transmission.
Page 158 OPERATING INSTRUCTIONS ‘CA’ will appear in the gear display if a clutch abuse event is occurring. If abuse continues the clutch will open and throttle control is removed till clutch cools. The transmission system will automatically shift to neutral if the vehicle is left in Drive and the parking brakes are set.
Page 159: Start-Up And Power-Down
OPERATING INSTRUCTIONS START-UP AND POWER DOWN Start-up 1. Turn the ignition key to ON and allow the UltraShift PLUS to ® power-up: • Engine cranking is delayed until the transmission power-up is complete and the gear display shows a solid N (neutral). 2.
Page 160: Eaton Transmission Modes
OPERATING INSTRUCTIONS EATON TRANSMISSION MODES Reverse Mode Selects default Reverse gear (see Note* below). • Each time Reverse is selected from Neutral, the default Reverse • gear is engaged. • The vehicle will not engage Reverse above 2 mph. • On multi-speed auxiliary models, R1 to R2 and R3 to R4 shifts will only be made by manually up or down shifting while driving.
Page 161 OPERATING INSTRUCTIONS DRIVE Mode • Automatically selects the start gear (see Note* page 134). The selected start gear will vary depending on several vehicle inputs like load, grade, and axle/transmission ratio. This start gear can be changed by up or down shifting using the righthand steering column stalk, as long as the selection still falls into a gear that would allow the vehicle to launch without causing damage to the transmission.
Page 162 OPERATING INSTRUCTIONS MANUAL Mode MANUAL mode should be used whenever the driver wants to select the shifts instead of letting the transmission select them automatically. For example, when the driver is moving around the yard, over railroad tracks, or on steep grades. •...
Page 163 OPERATING INSTRUCTIONS LOW Mode LOW mode should be used to maximize engine braking and minimize the use of the brake pedal. For example, when driving down long grades or when coming to a stop. • Selects lowest available gear for start gear (see Note* page 134). The starting gear cannot be changed in LOW mode.
Page 164 OPERATING INSTRUCTIONS Urge to Move • Urge to Move allows the vehicle to automatically start moving when the transmission is in gear and the driver releases the service brake. After the vehicle has launched the vehicle will creep at a constant speed at engine idle without the need to hold the throttle pedal position.
Page 165 OPERATING INSTRUCTIONS Creep • Creep allows the vehicle to be driven at a constant speed at engine idle without the need to hold the throttle pedal position. The configuration is useful for slow speed applications where steady vehicle speed is required (e.g. dump / spreader applications). •...
Page 166: Ultrashift Plus Features
OPERATING INSTRUCTIONS ULTRASHIFT PLUS FEATURES Proper Starting Gear Choose a starting gear appropriate for the load and grade conditions while at a stop in DRIVE and MANUAL modes by using the up/downshift request procedure. Refer to DRIVE Mode (page 135) for detailed information. Skip Shifting •...
Page 167 OPERATING INSTRUCTIONS Below are some examples of situations which may initiate clutch abuse along with some helpful hints on how to avoid them. Example How to Avoid Starting on hills using Use the service brakes to hold on a hill. To start the throttle rather than moving, apply the throttle and release the brakes the brake...
Page 168 OPERATING INSTRUCTIONS Load-Based Shifting In DRIVE Mode, the transmission will adapt to the changing conditions of the vehicle to change the shift points based on the following inputs: • Vehicle grade • Engine RPM • Throttle position • Vehicle load After changing loads or powering up, the UltraShift PLUS transmission needs to relearn the new conditions.
Page 169: Driver Diagnosis - Ultrashift
OPERATING INSTRUCTIONS DRIVER DIAGNOSIS - ULTRASHIFT PLUS During power-up, the service light will come on for 1 second and go off. This is normal operation. But if the service light comes on and stays on, or comes on while driving, it means UltraShift has detected a fault. Book in to an authorised service dealer as soon as possible.
Page 170: Fault Codes
OPERATING INSTRUCTIONS FAULT CODES Fault Description UltraShift Codes No ECU Operation Test Improper ECU Configuration J1939 Control Device Invalid Shift Lever Voltage HIL Shift Device Communication High Integrity Link Start Enable Relay CAN ECA message Auto-Neutral Parking brake Switch ABS CAN message Urge to Move Brake Switch Signal No Faults Found Clutch Slip...
Page 171 OPERATING INSTRUCTIONS FAULT CODES Fault Description UltraShift Cont..Codes ECA Battery Voltage ECA Ignition Voltage Grade Sensor Unable to Disengage Gear Failed to Select Rail Failed to Engage Gear Engine Speed Response Fault Engine Torque Response Fault Shift Quality Power Down in Gear Gear Engagement Detected Shift Lever Missing Shift Controller Device not Configured...
Page 172: Using The Brake System
OPERATING INSTRUCTIONS USING THE BRAKE SYSTEM The operation of the vehicle’s braking system and many vehicle accessories depends on the storage and application of a high-pressure air supply. The air brake system contains dual circuits; a circuit for the rear brakes (primary) and a circuit for the front brakes (secondary).
Page 173: Brake Operation
OPERATING INSTRUCTIONS BRAKE OPERATION Do not drive through water deep enough to wet brake components, as it may cause the brakes to work less efficiently than normal. The vehicle’s stopping distance may be longer than expected and the vehicle may pull to the left or right when brakes are applied, which could contribute to an accident.
Page 174: Using The Parking Brake
OPERATING INSTRUCTIONS USING THE PARKING BRAKE The yellow diamond-shaped knob on the dash controls the truck parking brakes. These are spring brakes that you activate by releasing air pressure from their chambers. When they are not in use, air pressure compresses the springs and releases the brakes.
Page 175: To Release The Full Combination Of Brakes
OPERATING INSTRUCTIONS TO RELEASE THE FULL COMBINATION OF BRAKES • Push IN BOTH knobs on the dash. • If the air pressure is reduced below a safe level, the low-air warning light will come on first. If air pressure continues to drop the parking brake valve will pop OUT, automatically applying the spring brakes.
Page 176: Trailer Parking Brake Release Valve
OPERATING INSTRUCTIONS To apply the trailer brakes only: Pull OUT the red knob. This will exhaust air from the trailer supply line, causing the truck protection valve to close and the trailer spring brakes to apply. The trailer is now in ‘emergency’ or ‘park’...
Page 177: System Truck Park
OPERATING INSTRUCTIONS WARNING The trailer parking brake release valve is only designed to be used by the driver during tipping. DO NOT leave the driving position while activated. Only operate on relatively flat ground, if the truck brakes are insufficient to hold the combination, release the parking brakes and operate the service brakes SYSTEM TRUCK PARK With both knobs pushed in for normal operating modes, the parking brakes...
Page 178: Emergency Braking
OPERATING INSTRUCTIONS EMERGENCY BRAKING Unless you have an anti-lock braking system (ABS), always avoid completely depressing the service brake pedal, if possible, even during emergency braking. Depressing the brake pedal too aggressively can cause the wheels to lock, which can lead to an uncontrolled skid and can result in an accident.
Page 179: Disc Brakes
OPERATING INSTRUCTIONS DISC BRAKES The air disc brakes are high performance, low weight, high efficiency brakes designed for trucks and other commercial vehicles requiring between 10,000 and 23,000Nm of braking torque at each wheel. Clamping force is produced by a globular cast iron caliper located above the rotor and housing two lining pads.
Page 180: Electronic Brake Safety System (Ebss)
ELECTRONIC BRAKE SAFETY SYSTEM (EBSS) ANTI-LOCK BRAKING SYSTEM (ABS) Your Kenworth may be equipped with an anti-lock braking system (ABS). The ABS reduces the possibility of wheel lock-up. If a wheel is about to lock during braking, the ABS will automatically adjust air pressure to the brake chambers on the appropriate wheel(s) to prevent wheel lock-up.
Page 181: Drag Torque Control (Dtc)
OPERATING INSTRUCTIONS The traction control warning lamp will briefly illuminate and then go out when the ignition switch is first turned on. The traction control warning lamp will illuminate whenever the ATC system detects drive wheel spin. The lamp will remain illuminated as long as wheel spin is detected and the ATC system is applying the drive wheel brakes or reducing engine torque.
Page 182: Electronic Stability Program (Esp)
ABS OFF-ROAD FUNCTION SWITCH Your Kenworth vehicle may be equipped with a separate electrical switch to activate an ABS off-road function. This function is NOT to be used for on-highway driving, but is intended to be used to improve stopping performance in off-highway conditions (e.g.
Page 183: Hill Start Assist (Hsa)
OPERATING INSTRUCTIONS Never drive your vehicle on improved roads/highways with the ABS off-road function turned on. When you drive your vehicle onto an improved road surface/highway, immediately turn off the ABS off-road switch. Failure to do so will cause the ABS system to not function properly if required and could result in an accident and/or injury.
Page 184: Fusion - Active Safety System
OPERATING INSTRUCTIONS FUSION - ACTIVE SAFETY SYSTEM All vehicles equipped with the Fusion system are also equipped with the ESP stability system. The ESP stability system is an always ready, full-stability system which monitors vehicle performance. When necessary, ESP automatically intervenes to reduce the throttle and/ or apply the foundation brakes to help you maintain stability during potential loss-of-control or rollover events.
Page 185: System Overview
OPERATING INSTRUCTIONS The Fusion radar locates and tracks moving vehicles. The radar is located at the front of your vehicle– either on the bumper or just behind it on a cross-member. When located behind the bumper, in some cases the unit may also be behind a protective covering that allows the radar signal to pass through.
Page 186: Active Cruise With Braking
OPERATING INSTRUCTIONS The Fusion system reacts ONLY to vehicles that are stationary or moving in the same direction as your vehicle. The Fusion system DOES NOT respond to side-to-side moving traffic, or oncoming traffic. The system will not slow your vehicle or provide an alert as you approach vehicles in these circumstances.
Page 187 OPERATING INSTRUCTIONS Once cruise control is set and the system is maintaining a set following distance between you and the forward vehicle: • If the vehicle in front of you slows down below your cruise control’s set speed, the system will intervene, as necessary, in this order: •...
Page 188: Forward Detected Vehicle Icon
OPERATING INSTRUCTIONS Forward Detected Vehicle Icon When cruise control is switched on and set, and a vehicle ahead of you is detected by the radar, the forward detected vehicle icon (or similar) on the vehicle dashboard or Driver Interface Unit (DIU) display will illuminate. No LEDs Illuminated Object Detected Bendix...
Page 189: Alerts And Warnings
OPERATING INSTRUCTIONS Alerts and Warnings The Fusion system functions differently than other cruise control/forward collision alert and mitigation systems. The system also assists by giving audible and visual alerts, whether or not cruise control is on. It is important for you to fully understand the system’s features, especially the driver indications and alerts.
Page 190: Impact Alert / Collision Mitigation Braking
OPERATING INSTRUCTIONS Impact Alert (IA) / Collision Mitigation Braking (CMB) • Always available above 24km/h The Impact Alert (IA)/Collision Mitigation Braking (CMB) is the most severe warning issued by the Fusion system. This alert indicates that a collision with the detected forward vehicle is likely. As the driver, you must immediately act to potentially avoid, or lessen the severity of, a collision.
Page 191: Following Distance Alert
OPERATING INSTRUCTIONS Following Distance Alert (FDA) • Always available above 8km/h Following distance refers to the time gap – measured in seconds – between the vehicle with Fusion and the vehicle ahead of it. The actual physical distance between the two will vary based on the speeds of both vehicles; however, the set gap will remain the same for all set cruise speeds.
Page 192: Stationary Object Alert
OPERATING INSTRUCTIONS Stationary Object Alert (SOA) • Typically available above 16km/h The Fusion system will give up to three (3) seconds alert to you when approaching a detected, sizable, stationary object with metallic (radar- reflective) surfaces in your lane of travel. This alert indicates that a collision with a stationary object is likely and you must immediately act to potentially avoid, or lessen the severity of, a collision.
Page 193: Stationary Vehicle Braking
OPERATING INSTRUCTIONS Stationary Vehicle Braking (SVB) • Typically available above 24km/h Fusion’s Stationary Vehicle Braking (SVB) is designed to be ready to react to the presence of stationary vehicles in front of your vehicle (whether or not cruise control is set, as long as your vehicle is traveling above 24km/h.) See the DARK GREY area in the diagram on page 159.
Page 194: Lane Departure Warning
OPERATING INSTRUCTIONS Lane Departure Warning (LDW) • Enabled above 60km/h The Fusion system has the ability to warn you if the vehicle is not tracking in the intended roadway path. In most vehicle applications the LDW system is enabled above 60km/h. The Lane Departure Warnings will be issued through the dedicated speakers and, in some cases, may mute the radio.
Page 195 OPERATING INSTRUCTIONS You should use appropriate gearing and brake techniques on downhill grades. When the system detects brake overuse a text message will be displayed on the dashboard and an audible alert will be activated. You should intervene immediately. Blue LED stays on Bendix ACB BRAKING OVERUSE Press OK for Menu...
Page 196: Potential False Alerts
OPERATING INSTRUCTIONS Potential False Alerts Radar and camera technology is not perfect, and false alerts sometimes occur. Radar misalignment will likely lead to increases in stationary object false alerts. Drivers should take into account the road conditions, and any other factors they are encountering, as they choose how to react to any alerts they receive from the Fusion system.
Page 197 OPERATING INSTRUCTIONS Tracking Vehicles in a Curve: With cruise control set, when following a detected forward vehicle around a curve, the forward vehicle may be lost by the Fusion system. The Active Cruise with Braking feature will delay acceleration back to the set speed until it regains contact with the vehicle ahead, or detects that there is no longer a vehicle ahead, or after a time gap (based on the last following distance recorded).
Page 198 OPERATING INSTRUCTIONS Passing a Vehicle/Changing Lanes: With cruise control set, if you decide to change lanes or pass a vehicle by applying the throttle, the vehicle being passed will no longer be detected by the radar and camera. NOT TO SCALE Lane changes and dynamic steering input.
Page 199: How Your Actions Impact The Fusion System
OPERATING INSTRUCTIONS How Your Actions Impact the Fusion System This chart illustrates how the Fusion system will react to various actions you may initiate. Your Action Reaction of the Fusion System If you, the driver, do this: Expect the Fusion system to do this: Step on the brake.
Page 200: System Maintenance And Troubleshooting
OPERATING INSTRUCTIONS The system responses above are typical, but may vary from the descriptions shown here. These represent examples of driver actions and typical Fusion system responses, however this chart does not attempt to cover all possible situations. Stability System Performance System Maintenance and Troubleshooting Importance of Antilock Braking System (ABS) Maintenance –...
Page 201 OPERATING INSTRUCTIONS Camera Inspection – The Fusion camera is mounted to the windshield of the vehicle. The camera will be mounted inside the wiper pattern and should be clear of any obstructions. If the windscreen requires replacement, the camera will need to be refitted, aligned and recalibrated by an authorised PACCAR dealer.
Page 202: What To Expect When Using The Fusion System
OPERATING INSTRUCTIONS What to Expect When Using the Fusion System Part One: All driving scenarios (Cruise is either “ON” or “OFF”) What to Expect Typical System Typical System Situation Indication / Alerts Actions / Cautions Stationary objects/vehicles ahead in your lane of travel A stationary –...
Page 203 OPERATING INSTRUCTIONS Part One: All driving scenarios (Cruise is either “ON” or “OFF”) What to Expect Typical System Typical System Situation Indication / Alerts Actions / Cautions Another vehicle crosses the None. None. road perpendicular to your You must respond as path of travel –...
Page 204 OPERATING INSTRUCTIONS Part Two: Cruise is “ON” and speed is “SET” What to Expect Typical System Typical System Situation Indication / Alerts Actions / Cautions The detected forward The Following Distance You must respond as vehicle slows moderately. Alert (FDA) will sound needed.
Page 205: Trailer Brake Hand Valve
OPERATING INSTRUCTIONS TRAILER BRAKE HAND VALVE This dash mounted hand valve provides air pressure to apply the trailer brakes only. It operates independently of the foot treadle valve. To operate the trailer brake hand valve, press the lever down to engage the Trailer Hand Brakes.
Page 206: Driving Bobtail Or With An Unloaded Trailer
OPERATING INSTRUCTIONS DRIVING BOBTAIL OR WITH AN UNLOADED TRAILER The following information is applicable only to truck and trailer configurations. Do not use the engine retarder (for example engine brake) to slow the vehicle down when you are bobtail or pulling an empty trailer. Using engine retarders while bobtailing or with an unloaded trailer can cause a wheel lock-up resulting in less control and/or a jackknife.
Page 207: Operating The Rear/Drive Axle
OPERATING INSTRUCTIONS OPERATING THE REAR/DRIVE AXLE This section covers the operation of your rear/drive axle. These instructions apply to the most common features of drive axles. Refer to the manufacturer’s instructions for further information on the operation of your axle. DRIVER CONTROLLED DIFFERENTIAL LOCK (DCDL) When to use the Cross Wheel Differential Lock (can be on Rear/Rear Axle or both Rear Axles)
Page 208: Inter-Axle Differential Lock (Power Divider)
OPERATING INSTRUCTIONS Turning Radius when Unlocked (Disengaged) Turning Radius when Understeer Condition Locked (Engaged) INTER-AXLE DIFFERENTIAL LOCK (POWER DIVIDER) The inter-axle differential, also referred to as the Power Divider, allows each axle to turn independently, which relieves stress on the rear axles and reduces tyre wear.
Page 209: Tridem Drive Axles
OPERATING INSTRUCTIONS The Meritor main differential lock or Dana wheel differential lock is controlled by the switch labelled INTER AXLE DIFF LOCK. By moving the switch, you can LOCK or UNLOCK the main differential when the vehicle is moving or stopped. If your vehicle has an automatic transmission, it may be necessary to shift the transmission momentarily to the neutral position to allow the main differential lock splines to fully engage or disengage.
Page 210: Towing With Axles Fitted With Dcdl
OPERATING INSTRUCTIONS TOWING WITH AXLES FITTED WITH DCDL If your Kenworth has a Meritor axle with a driver-controlled main differential lock, install the caging bolt before removing the axles for towing. Installation of the caging bolt prevents damage by locking internal axle components in position.
Page 211: Dual Range Axle Operation
OPERATING INSTRUCTIONS DUAL RANGE AXLE OPERATION The following are important tips on operating a Dual Range Axle with Interaxle Differential: 1. Shift the axle with the interaxle differential in the UNLOCKED position only. 2. When you are driving with poor traction, LOCK the differential. When you have the differential locked, drive with the axle in LOW range only.
Page 212 OPERATING INSTRUCTIONS When the vehicle is going down hill, the wheels will not slow down, but will tend to speed up, which makes gear synchronisation almost impossible. As a result, the axle is neither in HIGH nor LOW range and all engine/ driveline retardation is lost.
Page 213: Drive Axle Temperature Gauge
OPERATING INSTRUCTIONS DRIVE AXLE TEMPERATURE GAUGE Optional Axle Temperature gauges may be installed in your Kenworth. Either a set of two gauges, one for each drive axle, or one for both forward and rear axles, indicate the lubricant temperature in each drive axle.
Page 214: Driving Tips And Techniques
OPERATING INSTRUCTIONS DRIVING TIPS AND TECHNIQUES This section covers additional driving tips and techniques on how to drive your Kenworth more efficiently. It will give you information on starting, shifting and driving your Kenworth vehicle. Coasting Do not coast with the transmission in neutral or with the clutch pedal depressed.
Page 215 OPERATING INSTRUCTIONS Climbing and Descending When approaching an uphill grade, apply light throttle early to build up engine temperature gradually, so that when power is applied for the climb, the engine won’t be subjected to a sudden, large heat change. Use the tachometer and pyrometer to maintain optimum power/temperature relationship during the climb.
Page 216 OPERATING INSTRUCTIONS Establishing Optimum Operating Temperatures: • Climb an uphill grade at maximum operating rpm and full throttle for one minute. Record the pyrometer reading at the end of this time interval, then ease up on the throttle. • Subtract 110°C from the recorded temperature reading. This is your maximum (and optimum) operating temperature.
Page 217: Instructions To Prevent Jackknifing
OPERATING INSTRUCTIONS City Driving — Cruising Operate the engine in the preferred rpm range to obtain optimum performance, and reduce stresses and wear. Avoid lugging the engine for any extended period of time as this reduces engine life. Consult your engine manufacturer’s operation manual for the preferred operating range.
Page 218 OPERATING INSTRUCTIONS 3. Engine brakes or other auxiliary brake systems should never be used simultaneously with the foot brake. To do so unbalances the brakes and can cause the drive wheels to skid, resulting in a jackknife. Operating the engine brakes when the semi is unladen during wet weather should be prohibited because, in an emergency, the driver will instinctively apply the service brakes and possibly skid the drive wheels, which can cause a jackknife.
Page 219: Economical Driving
OPERATING INSTRUCTIONS ECONOMICAL DRIVING The following section includes recommendations for best engine performance and economy. Engine Overspeed - RPM: • Operate the engine within the optimum engine rpm range and do not allow the rpm to exceed the maximum governed speed. See your Engine Operation and Maintenance Manual for information regarding engine rpm.
Page 220 OPERATING INSTRUCTIONS Fuel economy and engine performance is also directly related to driving habits: • The best results in trip time and fuel economy are obtained while driving the vehicle at a steady speed. • Shift into higher or lower gears (or apply the service brake) to keep engine rpm near the lower end of the optimum operating range.
Page 221: Safe Driving
OPERATING INSTRUCTIONS Driving Habits Wrong driving habits must be corrected and the recommendations on economic driving should be followed. Driving Factors Affecting Fuel Consumption: • excessive speed and unnecessary fast acceleration • long periods of idling • driving with foot resting on the clutch pedal (manual transmission) General Conditions Other factors affecting fuel consumption are related to loads and the type of roads on which the vehicle operates.
Page 222 OPERATING INSTRUCTIONS The Following Guidelines Will Help You to Drive the Vehicle Safely: • Make a thorough inspection of the vehicle, daily and weekly. See Driver’s Checklist, page 12. • Ensure windows, mirrors and lights are clean. • Check all tyres for damage and correct inflation pressure. •...
Page 223: Air Suspension
Do not tamper with the height adjustment valve on your Airglide rear suspension. The height is factory-set for optimum performance. Consult an authorised Kenworth dealer if the ride height requires adjustment. Suspension Air Pressure Gauge The Suspension Air Pressure gauge (optional) indicates the amount of air pressure in the air suspension springs in kilopascals (kPa).
Page 224: Air Activated 5 Th Wheel Release Procedure
OPERATING INSTRUCTIONS FIFTH WHEEL The following applies to prime mover configurations: Ensure that all fifth wheel maintenance, adjustments and rebuilding are done only by a qualified technician. An improperly maintained fifth wheel can cause a trailer to separate from a truck. This could lead to an injury or accident and damage to property.
Page 225: Fifth Wheel Lubrication
OPERATING INSTRUCTIONS FIFTH WHEEL LUBRICATION Frequently operate and lubricate movable or sliding fifth wheels to prevent corrosion. Both the fifth wheel plate and the slide tracks (if a slider) should be cleaned and lubricated periodically to ensure smooth turning and sliding action.
Page 226: Returning Vehicle To Service
OPERATING INSTRUCTIONS RETURNING VEHICLE TO SERVICE Your vehicle may have lost lubricant while being towed. To prevent damage, check the oil level and add oil if necessary. After adding the specified type and amount of lubricant, drive the vehicle. It should be unloaded. Drive 1.5 to 3km at a speed not exceeding 40km/h. This will thoroughly circulate the lubricant through the assembly.
Page 227 OPERATING INSTRUCTIONS Recovery Procedure: 1. Review and understand all the cautions and warnings of this section, see Vehicle Recovery Guidelines on page 200. 2. Install the recovery hitches, see Recovery Hitch Installation on page 201. Recovery Hitch Sockets 3. Disconnect the drive axle shafts and cover the open hubs. This is necessary because if the transmission is driven by the driveshaft (rear wheels on the ground), no lubricant will reach the gears and bearings, causing damage to the transmission.
Page 228: Recovery Hitch Connection
OPERATING INSTRUCTIONS Before towing a vehicle, test your air brakes to ensure that you have properly connected and inspected the recovery vehicle’s brake system. Failure to do so could lead to a loss of vehicle control which may result in an accident involving death or personal injury. 7.
Page 229 OPERATING INSTRUCTIONS Recovery Hitch Assembly Tow Pin Square Hitch Socket Lock Pin Tow Hitch Lock Tab Recovery Hitch Installation Use the following procedure to install the Vehicle Recovery Hitches. See Recovery Hitch Assembly illustration for part identification: 1. Check square sockets behind lower bumper for obstructions, clear if necessary.
Page 230 OPERATING INSTRUCTIONS Recovery Rigging To connect to the vehicle, follow the suggested rigging methods below. Use a double chain or cable setup that distributes the load equally to both hitches. See illustration below.: 1. Use a spreader or equaliser bar to distribute the load on both hitches.
Page 231: Spring Brakes - Manual Release
OPERATING INSTRUCTIONS SPRING BRAKES - MANUAL RELEASE In order to tow a vehicle, if there is insufficient air to release the parking brake, the spring brakes can be manually released. Do not drive a vehicle with malfunctioning brakes. If one of the brake circuits should become inoperative, braking distances will increase substantially and handling characteristics while braking will be affected.
Page 232 OPERATING INSTRUCTIONS To move a vehicle immobilised by the spring brakes due to loss of air pressure in the brake system, perform the following procedure: 1. Remove the dust plug from the spring chamber. 2. Remove the release bolt assembly from the side pocket.
Page 233 OPERATING INSTRUCTIONS Freeing the Vehicle from Sand, Mud or Ice If the vehicle gets stuck in sand, mud or ice: • Move the gearshift lever or selector from First to Reverse. • Apply light pressure on the accelerator pedal while the transmission is in gear.
Page 234: Shut-Down
OPERATING INSTRUCTIONS SHUT-DOWN After you have parked in a safe place, check your vehicle to make sure it will be ready for the next trip. To make sure your vehicle is ready to go after a long stop (such as overnight), follow the suggestions below. Your vehicle will be easier to get going when you are ready, and it will be safer for everyone who might be around it.
Page 235: Refuelling
OPERATING INSTRUCTIONS Always use your parking brakes! Do not use the trailer hand brake or service brakes to park and hold an unattended vehicle. Use the parking brakes. Because service brakes work with air pressure, these brakes could slowly release. Your vehicle could roll, causing a serious accident.
Page 236: Fuel Specification
OPERATING INSTRUCTIONS Do not carry additional fuel containers in your vehicle. Fuel containers, either full or empty, may leak or explode and cause or feed a fire. Diesel fuel in the presence of an ignition source (such as a cigarette) could cause an explosion.
Page 238: Section Two Preventive Maintenance
SECTION TWO PREVENTIVE MAINTENANCE...
Page 240: Introduction
PREVENTIVE MAINTENANCE INTRODUCTION This section will help you keep your Kenworth in good running condition. There are a number of checks you can do, and you may be able to do some of the service work yourself. Let your authorised Kenworth dealer do any work you do not have the tools or skill to perform.
Page 241: Safety Precautions
Modifying your vehicle can make it unsafe. Some modifications can affect your vehicle’s electrical system, stability, or other important functions. Before modifying your vehicle, check with your Kenworth dealer to make sure it can be done safely and correctly. Y53-1404 (8612 08/2023)
Page 242: Lubrication Specifications - Engine
You will find Engine Lubrication Specifications in the Master Lubrication Chart located on page 331. One key to keeping your Kenworth running at top economy and to prolonging its life is proper lubrication and servicing. Neglecting this essential aspect of vehicle care can cost time and money in the long run.
Page 243 PREVENTIVE MAINTENANCE The lubrication system consists of an oil cooler module mounted on right hand side of engine. This module contains a dual filtration system – centrifugal oil filter and main oil filter. 1. Centrifugal Oil Filter 2. Lock Stop 3.
Page 244 PREVENTIVE MAINTENANCE To Change Main Oil Filter Element 1. Lift the lock up to its stop catch in order to replace the oil filter element. Fig 4 2. Using a single hex socket or ring spanner (to prevent cap damage), loosen the cap. Fig 5 3.
Page 245 PREVENTIVE MAINTENANCE 10. Check the O-rings on the thorn of the oil filter element are present and in good condition. Fig 7 11. Install the screw cap (4), with the oil filter element, onto the filter housing, and tighten it by hand as far as possible ensuring the cap and filter are upright when it picks up the thread.
Page 246 PREVENTIVE MAINTENANCE • The oil filler cap must be secured to avoid oil spill causing a potential fire hazard. Oil Level Check - Check engine oil daily 1. Make sure the vehicle is parked on level ground 2. The engine must be at operating temperature (76 deg. C.) AND the engine switched off for a minimum of 15 minutes.
Page 247: Fuel System
7% biodiesel according to standard EN590 are used. Using a fuel with a biodiesel blend will a more regular service schedule, discuss with an authorised Kenworth dealer. To prevent condensation while the vehicle is parked for extended periods,...
Page 248 PREVENTIVE MAINTENANCE 3. Bleed Screw 6. Main Filter Main Priming Plunger 2. Priming Button DO NOT OPERATE UNLESS BLEED SCREWS 1 OR 3 ARE OPEN 1. Bleed Screw 5. Primary Filter Fuel System Priming Procedure 1 Make sure vehicle has enough fuel for priming. 2 Loosen the bleed screw on the primary fuel filter (1) 3 Pump the primer button (2) until all air is expelled from the bleed screw (1)
Page 249: Fuel Tank Strap Tension
PREVENTIVE MAINTENANCE 8 Rotate main primer (4) anticlockwise and release 9 Pump main primer (4) until pressure increases (approx. 80 ~ 100 pumps) 10 Crank the engine for 5 seconds only. If the engine starts, allow it to idle until all cylinders are firing evenly. Once engine starts, it will ‘self-bleed’...
Page 250: Air Cleaner Systems
(optional) reads 25 inches H O or higher. If your vehicle is equipped with a dry-type air cleaner, have the element serviced at an authorised Kenworth dealer. 2. Paper elements require care and proper handling, because they are critical to engine service life.
Page 251: Accessory Drive Belts
PREVENTIVE MAINTENANCE ACCESSORY DRIVE BELTS The reliability and service life of drive belts can be extended with proper attention to installation, adjustment and maintenance. Neglect in these matters could cause belt failure, resulting in potential hazards through loss of the electrical or air system and possible engine damage due to overheating.
Page 252 PREVENTIVE MAINTENANCE Removing Poly-V-belt 7PK - Alternator and A/C Compressor 1 Move the tensioner against the spring force and lock it with a 4- 5mm thick locking pin or drill bit. 2 Remove the poly-V-belt from the guide roller first and then from the alternator and air-conditioning compressor pulleys.
Page 253 PREVENTIVE MAINTENANCE 6 Position the tensioner against the belt. 7 Check that the mark (2) on the tensioner arm is within range (A). • Mark (1) represent the nominal V-belt tension, deviating ± 2 mm. • Outside range(A), a belt is either routed incorrectly or outside its specification.
Page 254: Cooling System
PREVENTIVE MAINTENANCE COOLING SYSTEM Kenworth trucks come with air-to-air cooling systems as standard. These cooling systems incorporate a radiator to cool engine jacket coolant, a charge air cooler to cool turbocharged engine intake air, and a refrigerant condenser to provide cab airconditioning.
Page 255 PREVENTIVE MAINTENANCE Topping Up With the engine cold, top up with premixed ELC30 coolant. Add coolant through the filler cap on top of the surge tank atop the radiator. For correct level, see illustration below. Top View Rear View Filler Cap Max Level Min Level PRESSURE CAP (DO NOT REMOVE)
Page 256 Time must pass for all the trapped air to be purged from the system. Kenworth radiators with de-aeration system - When installing Kenworth radiators that have a built-in surge tank, the engine fill-line or anti-cavitation line and air bleed line (see illustration on page 228) MUST be connected to the engine, and connected correctly.
Page 257: Brake System
PREVENTIVE MAINTENANCE BRAKE SYSTEM To operate your vehicle safely, you need some understanding of its brake systems. Brake adjustment and brake balance must be set carefully to allow equal stopping forces at all wheels. Tyres are also a very important part of the whole system.
Page 258: Brake Linings
PREVENTIVE MAINTENANCE Lubrication Cam-actuated brake components such as anchor pins and brake camshafts are subjected to high temperatures. They must be lubricated with non- melting, water resistant brake grease meeting R-S Specification 0-616 (NLGI-Grade 2). • Lubricate according to Recommended Maintenance Schedules, pages 315-342.
Page 259: Automatic Slack Adjusters
234. FREE STROKE MEASUREMENT Your Kenworth may be equipped with automatic brake (slack) adjusters. Periodically, brake adjustment should be checked using the following procedure: 1.
Page 260: Adjusted Chamber Stroke
PREVENTIVE MAINTENANCE ADJUSTED CHAMBER STROKE Mark push rod here to STROKE measure stroke 120 psi in air tank. Engine OFF • Spring brakes • Spring brakes released released • Service brakes • Service brakes applied - not applied Automatic Brake Adjuster Application Air Chamber Type (size) Brake Pushrod Travel...
Page 261: Anti-Lock Braking System (Abs)
PREVENTIVE MAINTENANCE ANTI-LOCK BRAKING SYSTEM (ABS) Below are some general notes on your Kenworth anti-lock braking system. For detailed service information see the Kenworth Maintenance Manual. All service work should be performed by a qualified technician at an authorised service centre. The foundation brake system must be in proper working order to ensure the best ABS performance.
Page 262 PREVENTIVE MAINTENANCE Any malfunction of the ABS system on one or more axles will cause the system to fail-safe, and the panel-mounted amber warning light will illuminate, indicating both a malfunction and automatic shut-down of the system. If the air system is intact (indicated by the pressure gauges), the service brakes will continue to function normally, but without benefit of the ABS feature.
Page 263: Air Supply System
PREVENTIVE MAINTENANCE AIR SUPPLY SYSTEM Prior to the removal of any air system component, always block and hold the vehicle by a secure means other than the vehicle’s own brakes. Depleting air system pressure may cause a vehicle to roll unexpectedly resulting in an accident and/or injury.
Page 264: Air System Function Test
AIR SYSTEM FUNCTION TEST Scheduled maintenance should be performed on the Kenworth air system, as outlined in the Kenworth Maintenance Manual Section 5 CAT: 8047. In addition, perform an Air System Function Test at least every 3 months or if there is any indication of a potential problem.
Page 265: Air Compressor
The following service checks are provided for your information only and should be performed by a certified technician. Contact your authorised Kenworth dealer or consult the Kenworth Maintenance Manual and the engine manufacturer’s Maintenance Manual for further information on servicing air compressors. After completing any repairs to the air system,...
Page 266: Air Gauges And Air Leaks
PREVENTIVE MAINTENANCE AIR GAUGES AND AIR LEAKS Your Kenworth comes with two separate air pressure gauges for two separate systems, Primary and Secondary. The Primary gauge indicates pressure in the rear braking system, the Secondary gauge indicates pressure in the front braking system. Each gauge indicates the amount of air pressure in kilopascals (kPa).
Page 267: Turbocharger
Manifold -With the engine operating, check for leaking manifold or flange gaskets. High Frequency Vibration - Vibration may indicate turbo rotor imbalance. Have your authorised Kenworth dealer investigate this immediately. Delay could lead to severe and expensive damage to your vehicle. Do not operate engine with turbocharger intake piping disconnected.
Page 268: Tyres
PREVENTIVE MAINTENANCE TYRES TYRE INFLATION AND LOADING Regular and frequent inspection, and proper care will give you the assurance of safe, reliable tyre operation. Most tyre wear problems are caused by under inflation as the result of slow leaks. Low pressure is the tyres worst enemy; it allows tyres to flex badly and this causes high temperatures to build up.
Page 269: Tyre Inflation
PREVENTIVE MAINTENANCE TYRE INFLATION Most tyre wear problems are caused by underinflation. So you will want to check tyre pressure regularly. Give the tyres a visual test every day and check inflation with a gauge every week. When checking tyre pressure, inspect each tyre for damage to sidewalls, cuts, cracks, uneven wear, rocks between dual wheels (tyres) etc.
Page 270 PREVENTIVE MAINTENANCE It is also important to regularly have a wheel alignment: • Too much air pressure reduces the tyre tread contact area and results in rapid wear in the centre of the tyre. It also causes tyres to run hard and makes them more vulnerable to impact and other road hazard damage.
Page 271: Maximum Vehicle Load Rating
PREVENTIVE MAINTENANCE Overinflated tyres can cause accidents. They wear more quickly than properly inflated tyres and are more subject to punctures, cracks and other damage. They could fail and cause you to lose control of your vehicle resulting in an injury and/or accident. Be sure all tyres are inflated correctly according to the manufacturer’s recommendations.
Page 272: Replacing Tyres
MATCHING TYRES In addition to having tyres balanced, and having their radial and lateral run-out checked, we recommend that you have an authorised Kenworth dealer match your tyres, particularly on the rear axles. Mismatched tyres can cause interaxle conflict and unusually high axle lubricant temperatures.
Page 273: Wheel Cap Nut Torque
At the first scheduled lube interval, have all wheel nuts torqued to their specified value. Thereafter, wheel nuts MUST be checked at least once a week. Contact the service department at any authorised Kenworth dealership for information on torque values applicable to the wheels installed on your truck or see the table below.
Page 274: Vehicle Jacking
PREVENTIVE MAINTENANCE VEHICLE JACKING Ordinary pedestal jacks are designed ONLY to LIFT a vehicle. Once lifted, the vehicle should be supported by other appropriate means, such as stands. NEVER get under, or work under, a vehicle supported ONLY by a jack. Only work under a vehicle supported by stands and with wheels chocked.
Page 275: Jack Operating Instructions
PREVENTIVE MAINTENANCE JACK OPERATING INSTRUCTIONS The following instructions are a general guide only, please refer to your jack manufacturer's user manual for more specific details and instructions. Before use, visually inspect the jack for any abnormal conditions and refer to the preceding WARNINGS, SAFE USAGE STATEMENTS and NOTES below.
Page 276 PREVENTIVE MAINTENANCE 3. Insert the handle into the handle sleeve. Check that the handle or any part of your hand or arm does not come into contact with the vehicle when the handle is at its highest point. If it does, change the position of the jack under the load or lifting point.
Page 277: Storage Of The Vehicle Jack
PREVENTIVE MAINTENANCE STORAGE OF THE VEHICLE JACK The vehicle jack must be stored upright and securely clamped in its storage location. The main cause of ‘Air in the Hydraulic System’ and ‘Oil Level too Low’ are both due to poor maintenance or jacks being stored incorrectly, i.e. laid on their side.
Page 278: Batteries
PREVENTIVE MAINTENANCE BATTERIES Battery Care Regular attention to the charging system will help prolong the service life of batteries. Following are some of the common causes for battery failure. Isolation Switch Essential for vehicles carrying dangerous loads i.e. petroleum products, gases, acids, explosives etc.
Page 279: Battery Charging
PREVENTIVE MAINTENANCE Heat Heat from other adjacent components can cause overheating of batteries, resulting in warped plates and ‘boiling off’ of electrolyte. Check that any necessary heat shields are in place and that adjacent components are not overheating. BATTERY CHARGING Except for using small trickle chargers (slow battery charge, as explained on page 255) to maintain battery condition, you should have your vehicle’s batteries charged by a qualified service facility.
Page 280 PREVENTIVE MAINTENANCE • To avoid short circuits and damage to yourself or the vehicle, never place metal tools or jumper cables on the battery or nearby. Metal that accidentally comes in contact with the positive battery terminal or any other metal on the vehicle (that is in contact with the positive terminal) could cause a short circuit or an explosion.
Page 281 PREVENTIVE MAINTENANCE Slow Battery Charging If a battery has lost charge gradually over a long period of time, recharge at 6 to 8 amps for about 8 to 10 hours. • Follow the instructions that come with your battery charger. •...
Page 282: Maintenance-Free Batteries
PREVENTIVE MAINTENANCE ° HYDROMETER READINGS AT 27 Minimum Specific Gravity Percentage of Charge 1.260 100 % 1.235 80 % 1.230 75 % 1.200 50 % 1.170 25 % 1.140 Very little charge left 1.110 Completely discharged Removing and Installing Batteries: 1.
Page 283: Electrical Systems - 12 Volt
PREVENTIVE MAINTENANCE ELECTRICAL SYSTEMS - 12 VOLT JUMP STARTING VEHICLES Introduction Jump starting a vehicle is not a recommended practice due to the various battery installations and electrical options. However, if your battery is discharged, you may be able to start it by using energy from a good battery in another vehicle.
Page 284 PREVENTIVE MAINTENANCE NEVER start the vehicle by means of a fast/boost-charging device. The high voltage levels may cause damage to the electronic components. Best method is to remove the batteries for charging and refit when fully charged. Always observe battery safety. Preparing the vehicles 1.
Page 285 PREVENTIVE MAINTENANCE 7. Start the vehicle that has the discharged battery. If the engine fails to start, do not continue to crank the starter but contact the nearest authorized dealer. When the batteries are fully discharged and the engine is running, it is important that the jump leads are not immediately disconnected.
Page 286: Welding Precautions
PREVENTIVE MAINTENANCE WELDING PRECAUTIONS To prevent damage to gauges, interface modules and other electronic and electrical equipment, disconnect the battery cables before electric arc welding on a vehicle. If arc welding of any frame-mounted components is required, ensure the welding ground lead is connected directly to the component, preferably directly adjacent to the weld groove.
Page 287: Chassis And Cab - Finish, Appearance And Cleaning
PREVENTIVE MAINTENANCE CHASSIS AND CAB – FINISH, APPEARANCE AND CLEANING CHASSIS AND CAB THE ENAMEL ON THIS VEHICLE IS NOT YET HARDENED. DO NOT STEAM CLEAN, WAX, POLISH, OR RUB THE FINISH UNTIL A MINIMUM 45 DAYS AFTER DELIVERY. CLEAN WITH COLD WATER AND SPONGE ONLY.
Page 288 Cleaning of Cabin Trim Aside from its classic aesthetic appearance, one of the features of the vinyl trim used inside all Kenworth cabs is the material’s ease of maintenance. The vinyl offers exceptional service life if given proper care. Page 262...
Page 289 PREVENTIVE MAINTENANCE For the material to be maintained properly, it is important that you are aware of the correct methods for cleaning the trim so as to avoid any accidental damage which may occur if the wrong cleaning products are used. The procedures used for cleaning depend on the nature of the spill or stain.
Page 290: Smart (Steering) Wheel
PREVENTIVE MAINTENANCE Weather-stripping Occasionally spray weather-stripping on doors and windows with silicone compound to help preserve resiliency. This is especially useful in freezing weather to keep doors and windows from sticking shut with ice. It is good practice to hose dirt and grime from the whole chassis. If an oil leak develops, it will be more easily detected.
Page 291: Cab Heater/Airconditioning
PREVENTIVE MAINTENANCE CAB HEATER/AIRCONDITIONING The combination heater/airconditioner provides comfort for those in the cab through accurate control of the cab environment in all weather conditions. Regular attention to the items below will help you keep the heater/airconditioner performance at an optimal level. Keep the vehicle’s ventilation system, engine exhaust system and cab/ sleeper joints properly maintained.
Page 292: Cab Heater/Airconditioner
PREVENTIVE MAINTENANCE CAB HEATER/AIRCONDITIONER The combination heater/airconditioner uses R-134a (also known as HFC 134a) refrigerant and provides comfort for the operator through accurate control of the cab environment in all weather conditions. Regular attention to the following items will help ensure its reliable operation. Take special note of the safety precautions.
Page 293: Airconditioner
Have the airconditioning system fully serviced annually by your authorised Kenworth dealer, as it requires evacuating and recharging the system, using specialised equipment. Keep any open flame away from the area. Even a match or cigarette lighter can generate a hazardous quantity of phosgene gas.
Page 294: Safety Restraint System
PREVENTIVE MAINTENANCE SAFETY RESTRAINT SYSTEM The seatbelt system, including webbing, buckles, latches and mounting hardware, endures heavy use in heavy-duty vehicles - much more than seatbelt systems in passenger cars. All users should be aware of the factors contributing to this heavy use and reduced belt life. Failure to properly inspect and maintain restraint systems can lead to serious injury or loss of life.
Page 295: Inspection Guidelines
PREVENTIVE MAINTENANCE INSPECTION GUIDELINES Follow the guidelines below when inspecting for cuts, fraying, extreme or unusual wear of the webbing, damage to the buckle, retractor, hardware, or for other factors. Damage to these areas indicate that belt system replacement is necessary. It is important to remember that any time a vehicle is involved in an accident, the entire seatbelt system must be replaced.
Page 296 PREVENTIVE MAINTENANCE Web cut/frayed at web guide Web cut/frayed or extremely worn at latch area • Check buckle and latch (not shown) for proper operation and to determine if latch plate is worn, deformed or damaged. • Check web in areas exposed to ultraviolet rays from the sun. If the colour of the web in these areas is grey to light brown, the physical strength of the web may have deteriorated due to exposure to the sun’s ultraviolet rays.
Page 297 This will maintain the design integrity of the mounting points for the seatbelt assembly. Contact your authorised Kenworth dealer if you have any questions concerning seat belt replacement. Y53-1404 (8612 08/2023)
Page 298: Transmission And Clutch
PREVENTIVE MAINTENANCE TRANSMISSION AND CLUTCH Follow the procedures below to ensure parts are properly lubricated: • maintain oil level, check it regularly • change oil regularly • use the correct grade and type of oil • buy oil from a reputable dealer ALL TRANSMISSIONS Initial Change - Drain and replace according to Recommended Service Maintenance Schedules on (pages 315-342).
Page 299: Transmission Service Intervals
PREVENTIVE MAINTENANCE TRANSMISSION SERVICE INTERVALS For recommended types and brands of all lubricants, see the transmission manufacturer’s Service Manual and Recommended Service and Maintenance Schedules pages 315-342 and fluid quantities, page 333. Maintain the oil level and check it regularly. Oil should be level with the bottom of the filler plug hole with Manual, PACCAR and UltraShift PLUS Transmissions.
Page 300: Clutch Adjustment - Normal Wear
If the hydraulic brake fluid is not leaking but the fluid level is getting lower, then the clutch may need adjusted. You should have an authorised Kenworth dealer adjust the clutch before pedal free travel is reduced to the minimum allowable 13mm.
Page 301: Clutch Adjustment
PREVENTIVE MAINTENANCE MANUAL CLUTCH ADJUSTMENT See the clutch manufacturers service manual on the Customised Maintenance Manual on the USB in the Driver Information Pack supplied with your vehicle for the correct adjustment procedures. Pedal free travel 13 mm ( in.) Clutch brake travel 25 - 40 mm (1 - 1 in.)
Page 302: Clutch Lubrication
PREVENTIVE MAINTENANCE CLUTCH LUBRICATION To ensure long life and proper operation of the release mechanism of the clutch it is important to properly lubricate the following areas. Release Bearing The cast iron bearing housing will be equipped with either a standard grease fitting or a lube tube extension.
Page 303 PREVENTIVE MAINTENANCE Master Cylinder The fluid reservoir for the hydraulic clutch system is located on the engine side of the firewall, adjacent to the dual brake foot valve and below the windscreen wiper motor. Y53-1404 (8612 08/2023) Page 277...
Page 304: Steering
If these checks do not reveal the problem, have the problem diagnosed and corrected by an authorised Kenworth dealer. While operating the vehicle, the driver should avoid deep ruts or obstructions which cause a binding condition on front wheels.
Page 305: Axle Stops
PREVENTIVE MAINTENANCE AXLE STOPS Your vehicle is equipped with power steering, have an authorised Kenworth dealer make axle stop adjustments. The power steering pressure relief valves must be adjusted in conjunction with the axle stops to prevent damage to the steering gear.
Page 306: Steering Driveline
• For off-highway vehicles, tighten the U-bolts after the first day or two of operation. Then check weekly. For your particular driveline, see the electronic Customised Kenworth Maintenance Manual. DRIVESHAFT Greasable slip joints and universal joints of the drive shaft should be lubricated periodically.
Page 307: Adjustable Steering Column
PREVENTIVE MAINTENANCE ADJUSTABLE STEERING COLUMN Never adjust your steering column when the vehicle is in motion. Loss of steering may cause an accident. The steering column is fully adjustable, height and tilt are both controlled by the easy access lever on the lower left hand side of the column housing. Locked Position Unlocked Position...
Page 308: Front Axle And Suspension
PREVENTIVE MAINTENANCE FRONT AXLE AND SUSPENSION AXLE LUBRICATION • Change bearing lubrication when seats are replaced, or brakes are relined. See Recommended Maintenance Schedules, pages 315-342. • Thoroughly clean hubs and bearings with solvent and a stiff bristle brush, then dry and inspect components for wear or damage. Re- lubricate with approved axle lubricant.
Page 309: Visual Inspection
All vehicles need to have their U-bolts checked and tightened regularly. Be sure someone with the proper training and the right tools checks and tightens the U-bolts on your Kenworth. New springs can ‘settle in’ after service relieving the tension on the U-bolts.
Page 310: Spring Suspension U-Bolts Grade 8
PREVENTIVE MAINTENANCE Tighten U-bolt nuts to the specified torque value with the vehicle loaded to its normal gross weight. The torque values below apply to U-bolts and nuts with clean threads lubricated with Chevron zinc lubricant SAE 20 or 30 oil. Do not operate the vehicle if the U-bolts are not properly tightened.
Page 311: Wheel Alignment
Uneven tyre wear is a sign the wheels may be misaligned. If you see uneven wear, take your vehicle to a service centre familiar with aligning wheels on Kenworth vehicles. Consult the table below for alignment specifications for each type of axle.
Page 312: Rear Axle And Suspension
10,000km of service and every 40,000km thereafter. Torque recommendations apply to fasteners supplied and installed by Kenworth. The values listed in the tables on pages 290 are for cadmium- plated or phosphate and oil fasteners only. See the Kenworth Maintenance Manual for complete details on Suspension Maintenance.
Page 313: Visual Inspection
All vehicles need to have their U-bolts checked and tightened regularly. Be sure someone with the proper training and the right tools checks and tightens the U-bolts on your Kenworth. After the first 1,000km of operation, inspect the suspension periodically, as noted below: •...
Page 314: Rear Axle Lubrication
Petroleum-based lubricants must be drained within the first 10,000km if converting to an approved synthetic lubricant. For recommended types and brands of lubricants, contact your Kenworth dealer or authorised service centre. See the Kenworth Maintenance Manual and the axle manufacturer’s Service Manual for further information on servicing drive axles.
Page 315: Rear Axle Alignment
If you detect rapid tyre wear on the rear axles, you may have misaligned axles. If you suspect rapid tyre wear, have your rear axle alignment checked and adjusted by an authorised Kenworth dealer. In addition to pre-delivery inspections, suspension alignment should be checked when any one of the following conditions exist: •...
Page 316: Rear Suspension Alignment
PREVENTIVE MAINTENANCE REAR SUSPENSION ALIGNMENT Check and adjust as necessary (refer to Maintenance Manual for your specific suspension). These torque limits are valid ONLY when the U-Bolt and nut threads are clean and have been lubricated with an SAE 20 or SAE 30 oil. Never re-use a self-locking nut.
Page 317: Noise Control System
(for purpose other than resale) and to each subsequent purchaser that this vehicle, as manufactured by Kenworth Trucks, was designed, built and equipped to conform, at the time it left Kenworth’s control, with all applicable Australian Design Rules and Noise Control Regulations.
Page 318: Air System Silencers
PREVENTIVE MAINTENANCE Exhaust System Removing or rendering inoperative the exhaust system components. The exhaust system is part of the noise control system. Periodically check the exhaust for wear and loose or missing parts. Inner Fender Shields and Cab Skirts Removing shields or skirts. Cutting away parts of shields, skirts or damaged or loose portions of shields or skirts.
Page 319: Inspection And Maintenance
PREVENTIVE MAINTENANCE INSPECTION AND MAINTENANCE Use the following procedures to check the Noise Control System for sources of noise or deterioration that results in noise. Preventive maintenance and repair information is supplied. Wherever other systems are involved, such as electrical or cooling, reference is made to the applicable sections for more specific information.
Page 320 If the fan clutch engages at low engine temperatures or cycles ON and OFF more frequently than it should (i.e. receives ‘false signals’), have the problem repaired at an authorised Kenworth dealer. Page 294 Y53-1404 (8612 08/2023)
Page 321 Cab skins, sills and brackets should be checked for overall condition, and repaired as necessary. This work can be accomplished at an authorised Kenworth dealership. Damaged rubber fender shields or cab skirting must be replaced.
Page 322: Magnetic Drain Plugs
PREVENTIVE MAINTENANCE MAGNETIC DRAIN PLUGS Engines, Gear Boxes and Differentials that have metal on metal contact create friction wear as the metal surfaces wear, giving off a fine greyish metal dust that contaminates the oil. All the contaminants cannot be removed by the oil filter alone, an oil filter is only capable of catching particles over 35 microns as these particles are extremely fine Magnetic drain plugs on Engines, Gear Boxes and Differentials perform...
Page 323: Torque Specifications
PREVENTIVE MAINTENANCE TORQUE SPECIFICATIONS GRADE 5 FASTENERS The table below shows torques for assemblies of Grade 5, cadmium-plated, nylon insert nuts; plain cadmium-plated Grade 5 bolts or studs (with cadmium or zinc/chromate plated hardened washers). SAE GRADE 5 FASTENERS – NON LUBRICATED FASTENER TORQUE Size...
Page 324: Grade 8 Fasteners
PREVENTIVE MAINTENANCE GRADE 8 FASTENERS The table below shows torques for assemblies of Grade 8, cadmium-plated, nylon insert nuts; plain cadmium-plated Grade 8 bolts or studs (lightly lubricated; with cadmium or zinc/chromate-plated hardened washers). SAE GRADE 8 FASTENER TORQUE REQUIREMENTS FASTENER SIZE TORQUE N.m.
Page 325: Customer Information And Vehicle Identification
VEHICLE IDENTIFICATION CUSTOMER INFORMATION AND VEHICLE IDENTIFICATION Each vehicle manufactured by Kenworth Trucks Australia will have a certification label fixed to the cab as required by Australian Motor Vehicle Certification. The compliance plate is located inside the driver’s side door frame below the latch mechanism.
Page 326 VEHICLE IDENTIFICATION Vehicle Identification Placard A DIVISION OF PACCAR AUSTRALIA PTY. LTD. TRUCK MODEL FRONT AXLE ASSY RATING REAR AXLE ASSY RATING GROSS VEHICLE MASS GROSS COMBINATION MASS APPLICATION APP GCM APPROVED FOR CUSTOMER ROADTRAIN AND/OR B-DOUBLE DATE OF MANUFACTURE A Vehicle Identification Number (VIN) or chassis number is stamped on the top flange of the right (ALL INFORMATION VALID...
Page 327: Vehicle Identification Number (Vin)
N N N + N N N N N N + N N N N N-Numeric character WMI (World Manufacturer Index) Manufacturer, e.g. Kenworth Country, e.g. Australia Geographic Region, e.g. Oceania VDS (Vehicle Descriptor Section) A A A A A A...
Page 328: Serial Numbers And Capacities
VEHICLE IDENTIFICATION SERIAL NUMBERS AND CAPACITIES CHASSIS VIN / Chassis No: ........../ ......... Air comp: Serial No: ................Unit Trans. Model: .................. Unit Trans. Serial No: ................Aux. Trans. Model: ................. Aux. Trans. Serial No: ................Rear Suspension: ................... Rear Axle Model: ........
Page 329: Emergency Contact Numbers
EMERGENCY CONTACT NUMBERS AUSTRALIA WIDE ROADSIDE ASSISTANCE For Australian Kenworth or DAF owners, if you need Australia wide roadside assistance simply call 1800 4 PACCAR (1800 472 222). Trained operators are available 24-7 to connect you with your nearest PACCAR dealer for support.
Page 331: Section Three Maintenance & Lubrication Schedules
SECTION THREE MAINTENANCE & LUBRICATION SCHEDULES...
Page 332: The Environment
THE ENVIRONMENT Pollution forms a serious threat to the environment. In order to keep pollution to a minimum, you are recommended to take the following measures: • Never discharge used oil, hydraulic fluids, or coolants via drains, sewers or onto the soil. Such practices are not only illegal, but also contribute considerably to environmental pollution.
Page 333 Tear along perforation Tear along perforation...
Page 335: Introduction
Service Inspection Records ......347 CHANGE OF ADDRESS/OWNERSHIP To assist Kenworth Trucks to keep vehicle records up to date. If you change any of your details (i.e. trading name or address) or subsequently sell this vehicle, please complete and return the pre-paid card provided opposite page to the reply paid address on the reverse.
Page 336: Warranty Questions
Q. What parts are covered under Kenworth Trucks warranty? Any part, other than engines manufactured by, and for PACCAR fitted to your vehicle at the Kenworth factory is covered by warranty. This includes all original equipment supplied by manufacturers including Eaton, Meritor, Dana.
Page 337: Lubrication Schedule
Kenworth service dealer. When such emergency service has been performed by someone other than an authorised Kenworth service dealer, you should take your vehicle to an authorised Kenworth dealer for inspection and/or the completion of any required warranty service as soon as possible.
Page 338 12 months from the date on which you purchased it. Where the part or accessory has been installed in a vehicle by an authorised Kenworth service dealer, the cost of labour will also be covered for a period of 12 months from the date of installation.
Page 339 LUBRICATION SCHEDULE If you operate under extreme conditions, your vehicle may require more frequent maintenance services. See your servicing dealer for advice on these matters. The maintenance items, except where they are required as a result of defects in materials or workmanship, for which you will be required to pay, include: •...
Page 340: Kenworth Dealer Network
Each has been selected for their experience and commitment to supporting the truck industry. Each one is required to carry set levels of spare parts, and maintain a trained service facility. You can be assured that all Kenworth trucks are supported by Australia’s most professional truck dealer network.
Page 341: Lubrication Schedules
LUBRICATION SCHEDULE LUBRICATION SCHEDULES SAE 15W-40, API CK-4 Lubricant may be used providing it meets spec- ifications Schedule service intervals more frequently for severe operational conditions. Do not mix lubricants of different brands or types. If brand or type of lubricant is changed, the unit must be drained and flushed out prior to refill.
Page 342: T410 - Mx Engine Service Schedule
LUBRICATION SCHEDULE T410 - MX ENGINE SERVICE SCHEDULE Maintenance Groups Depending on the use to which the vehicle is put, the vehicle is placed in maintenance group I, II or III. PTO (ESC) hours must also be incorporated into schedule. The following schedule states maximum service intervals only.
Page 343: A Service Intervals
LUBRICATION SCHEDULE Maintenance Group I Total fuel consumption ˂ 1.66 kms / Ltr AND/OR Operation on building sites, in quarries, etc. AND/OR Operation on gravel roads AND/OR Traffic in dusty conditions AND/OR Sanitation department vehicles AND/OR With an annual mileage of up to 90,000 km Service Sequence: A (Every Fortnight), B, A (Every Fortnight),B, A (Every Fortnight),B, A (Every Fortnight),B, A (Every Fortnight),B, A (Every Fortnight), C (Repetative)
Page 344 LUBRICATION SCHEDULE LUBRICATION SCHEDULE (T4 SERIES – MX ENGINE) 1st SERVICE FULL SYSTEM DOWNLOAD: Download and archive log file recording all active/ inactive fault codes and engine/EAS system statistics, ie. fuel burn figures, overspeeds, etc. CHECK OIL LEVELS: Top up as necessary: Engine, transmission, rear carrier(s), power steering reservoir and oil lubricated wheel bearings.
Page 345 LUBRICATION SCHEDULE 1st Service Continued... 15 WHEELS AND TYRES: Check torque of all wheel nuts. Check for missing valve caps and stem locks, cracked or loose wheel lugs (cleats) and tyre pressures. 16 CAB: Check glass for scratches, window mechanism operation and general interior condition/appearance.
Page 346 LUBRICATION SCHEDULE LUBRICATION SCHEDULE (T4 SERIES – MX ENGINE) A SERVICE FULL SYSTEM DOWNLOAD: Download and archive log file recording all active/ inactive fault codes and engine/EAS system statistics, ie. fuel burn figures, overspeeds, etc. CHECK OIL LEVELS: Top up as necessary: Engine, transmission, rear carrier(s), power steering reservoir and oil lubricated wheel bearings.
Page 347 LUBRICATION SCHEDULE A Service Continued... 17 CHASSIS: Grease all lube points. Check torque of chassis/frame fasteners, suspension to frame bolts, cab/sleeper mounting points, transmission mounting bolts, suspension u-bolts, torque rod mounting bolts and fuel tank mountings. Check routing of fuel, air and electrical. Check operation of air dryers, moisture ejectors and air tank check valves.
Page 348 LUBRICATION SCHEDULE LUBRICATION SCHEDULE (T4 SERIES – MX ENGINE) B SERVICE FULL SYSTEM DOWNLOAD: Download and archive log file recording all active/ inactive fault codes and engine/EAS system statistics, ie. fuel burn figures, overspeeds, etc. ENGINE: Change engine oil and oil filters (including centrifugal filter). Change primary and secondary fuel filters.
Page 349 LUBRICATION SCHEDULE B Service Continued... 16 FRONT SUSPENSION: Check and lubricate (where applicable) spring shackle and hanger brackets, spring pins, shackle pins and bushes, spring leaves, king pins, bushings, thrust bearings and spindles, u-bolt torque, steering and tierod arms/ joints, steering stops and general inspection for wear. 17 REAR SUSPENSION: General inspection for wear.
Page 350: C Service Intervals
LUBRICATION SCHEDULE LUBRICATION SCHEDULE ( T4 SERIES – MX ENGINE) C SERVICE (Minimum 1 x Year) FULL SYSTEM DOWNLOAD: Download and archive log file recording all active/ inactive fault codes and engine/EAS system statistics, ie. fuel burn figures, overspeeds, etc. ENGINE: Change engine oil and oil filters (including centrifugal filter).
Page 351 LUBRICATION SCHEDULE C Service Continued... 15 STEERING SYSTEM: Check sector shaft, steering shaft u-joints, slip joint, drive line pinch bolts (75-80 Nm lubricated), drag link and pitman arm, steering wheel free play and centralisation, steering gear mounting bolts, hoses and fittings, fluid level and operation.
Page 352: Chassis Lubrication Points
CHASSIS LUBRICATION POINTS 5 26 8 25 27 12* 13* 14* 20* 22 23 24 6* 7* 11 Page 326 Y53-1404 (8612 08/2023)
Page 353 CHASSIS LUBRICATION POINTS VEHICLE LUBRICATION POINTS Legend on page 328. 18* 21* 31* Y53-1404 (8612 08/2023) Page 327...
Page 354: Vehicle Lubrication Points Legend
CHASSIS LUBRICATION POINTS VEHICLE LUBRICATION POINTS Key# ITEM ..................Lube 1. POWER STEERING GEAR/RESERVOIR Refer to the Engine/Steering Gear Manufacturer’s Manuals for change intervals Change fluid and filter Ross (integral) or Sheppard (integral) ........ATF Grease fitting provided in housing trunion ........ CL (lubricate by hand NOT by pressure gun) Sector Shaft and Input Shaft ............
Page 355 CHASSIS LUBRICATION POINTS Key# ITEM ..................Lube 15. REAR WHEEL BEARINGS ............GO 16. REAR BRAKE CAMSHAFTS (Lube sparingly) one fitting each brake ........BG 17. REAR AXLES Mineral Check oil level ................. GO Drain, flush and refill ..............GO REAR AXLES Synthetic Check ..................SO Drain and refill (Dependent on Oil Sample) ......SO 18.
Page 356 CHASSIS LUBRICATION POINTS Legend to Lubrication Schedule Items not shown on illustration See Operator’s Manual for Off-Highway Conditions Brake Fluid Brake Grease (See Lube Specs) Chassis Grease NLGI-2 PACCAR Genuine ELC30 Coolant Castrol Vecton 15W-40 CK-4/E9 Drive Axles Gear Oil Mineral Oil Synthetic Oil (Requires Periodic Sampling) Major Components Require Different Specific Oils...
Page 357: Master Lubrication Chart
MASTER LUBRICATION CHART NORMAL SERVICE COMPONENT LUBRICANT CHECK INTERVAL NORMAL SERVICE ENGINE LUBRICATION CHECK INTERVAL Castrol Vecton 15W-40 CK-4/E9 Refer to A, B & C Service Intervals for PACCAR MX-13 Castrol Vecton Long Drain 10W-40 Daily oil and filter changes E6/E9 NORMAL SERVICE TRANSMISSION...
Page 358: Master Lubrication Chart
40,000km 10,000km (Mineral Oil) KENWORTH TRUCKS recommends the use of the lubricants specified in these charts. Schedule service intervals more frequently for severe operational conditions. For special service requirements, consult your lubricant supplier. In all cases, the lubricant manufacturer assumes responsibility for the performance of their product and patent liability.
Page 359: Lubrication & Fluid Capacities
LUBRICATION AND FLUID CAPACITIES Component T410 Engine Oil PACCAR MX-13 460hp 34 ltrs PACCAR MX-13 510hp 34 ltrs Refill quantities include oil filter change Transmission Oil RTLO18918B 13 ltrs RTLO20918B 13 ltrs FO-18E318-MXP 13 ltrs FO-20E318-MXP 13 ltrs PO-18F112C PACCAR Transmission 7.5 ltrs (9.1 with PTO) plus Remote Filter 0.5 ltrs...
Page 360: A, B & C Service Intervals
A, B & C SERVICE INTERVALS ENGINE GENERAL Oil Levels Check oil levels and top up as necessary: ü ü ü ü Engine, transmission, rear axle(s), front drive axle (if applicable), power steering reservior and oil lubricated front wheel bearings Engine Oil Change engine oil ü...
Page 361: A, B, & C Service Intervals
A, B & C SERVICE INTERVALS System Download Complete system download for active / inactive ü ü ü ü faults, ECU statistics, etc... RADIATOR Engine Coolant Check for leaks. Check level and top up as ü ü ü ü necessary. Use only PACCAR Genuine ELC30 Coolant or coolant approved to DAF MAT 74002 Coolant and Strainer Replace coolant and strainer every 4 years...
Page 362 A, B & C SERVICE INTERVALS POWER STEERING Sector Shaft More frequent under Severe Working Conditions ü ü ü ü Steering U-Joints Check for wear and lubricate with chassis lube ü ü ü ü (where applicable) Steering Driveline Check torque on U-joint pinch bolt and nut (75- ü...
Page 363 A, B & C SERVICE INTERVALS S u s p e n s i o n U - B o l t ü ü ü ü Torques General Inspection for ü ü ü Wear Steering & Tie Rod Arms ü ü...
Page 364 A, B & C SERVICE INTERVALS Check Play and Adjust More frequently under Severe Working ü ü ü ü Conditions Drain and Refill Rear Hubs ü CHASSIS All Chassis Lube / Grease More frequently under Severe Working ü ü ü ü...
Page 365 A, B & C SERVICE INTERVALS R e m o v e a n d I n s p e c t Replace worn brushes as required ü ü Alternator Brushes O u t p u t V o l t a g e : Check every service - Normal 27.6 to 28.4 Volts ……………….
Page 366 A, B & C SERVICE INTERVALS Brakes: Linings Remaining ü ü ü (replace if required) Emergency Operation of ü ü ü ü Spring Brakes Air Pressure Buildup Time Record in minutes ü ü ü Governed Air Pressure Record in kPa ü...
Page 367 A, B & C SERVICE INTERVALS Cab and Sleeper Panels Check no exhaust leaks enter the cab area ü ü ü ü / Joints I n t e r i o r C o n d i t i o n / ü...
Page 368 A, B & C SERVICE INTERVALS Engine Operation (Noise, ü ü ü ü Surging, Black Smoke) Throttle Operation ü ü ü ü Air Seat Operation ü ü ü ü Seat Belts and Operation ü ü ü ü Cab HVAC (and Sleeper ü...
Page 369: Section Four - Service Records
SECTION FOUR SERVICE RECORDS...
Page 370: Maintenance Service Records
What the owner should do When service, according to the time or distance interval is due, the owner should present this voucher book to an authorised Kenworth service dealer as an authority to have the items listed attended to. After the service is completed, the owner should ensure the validation record is stamped and signed by the servicing dealer.
Page 371: First Service Inspection Record
FIRST SERVICE INSPECTION RECORD PLEASE USE BLOCK LETTERS Chassis No: ......Model: ........Kilometres: ......Date Inspected: ....Owner: ..................Servicing Dealer: ..............Owner's Address: ..................................Mechanic to inspect, make adjustments, tighten, correct or add fluids on all operations listed. Consult applicable service information for adjustments and specification. Action Service Item Result...
Page 372 SERVICE INSPECTION RECORDS First Service Inspection Record This is a free service (except for any lubricants and filters used). All other major components (Gearbox, Drive axles etc...) specified with synthetic oil must be drained and filled with synthetic oils at this service interval CHECK AND RECORD BELOW Radiator Coolant Condition: Battery Electrolyte Level &...
Page 373: Service Inspection Records
SERVICE INSPECTION RECORDS SERVICE INSPECTION RECORDS B-SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with B Service on page 322. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Clutch Engine Transmission* Check all Oil Levels Steering System*...
Page 374 SERVICE INSPECTION RECORDS B-Service Inspection Record Technician’s Notes: Use separate sheet of paper if necessary. Page 348 Y53-1404 (8612 08/2023)
Page 375 SERVICE INSPECTION RECORDS A-SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with A Service on page 320. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Steering System* Check all Oil Levels Front Suspension Belts and Pulleys Rear Suspension...
Page 376 SERVICE INSPECTION RECORDS A-Service Inspection Record CHECK AND RECORD BELOW Battery Electrolyte Level & Tighten Terminals: Technician’s Notes: Use separate sheet of paper if necessary. Page 350 Y53-1404 (8612 08/2023)
Page 377 SERVICE INSPECTION RECORDS C-SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with C Service on page 324. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Clutch Engine Transmission* Check all Oil Levels Steering System* Valve Clearance Adjustment Front Suspension...
Page 378 SERVICE INSPECTION RECORDS C-Service Inspection Record Technician’s Notes: Use separate sheet of paper if necessary. Page 352 Y53-1404 (8612 08/2023)
Page 379 SERVICE INSPECTION RECORDS A-SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with A Service on page 320. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Steering System* Check all Oil Levels Front Suspension Belts and Pulleys Rear Suspension...
Page 380 SERVICE INSPECTION RECORDS A-Service Inspection Record CHECK AND RECORD BELOW Battery Electrolyte Level & Tighten Terminals: Technician’s Notes: Use separate sheet of paper if necessary. Page 354 Y53-1404 (8612 08/2023)
Page 381 SERVICE INSPECTION RECORDS B-SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with B Service on page 322. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Clutch Engine Transmission* Check all Oil Levels Steering System* Valve Clearance Adjustment Front Suspension...
Page 382 SERVICE INSPECTION RECORDS B-Service Inspection Record Technician’s Notes: Use separate sheet of paper if necessary. Page 356 Y53-1404 (8612 08/2023)
Page 383 SERVICE INSPECTION RECORDS A-SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with A Service on page 320. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Steering System* Check all Oil Levels Front Suspension Belts and Pulleys Rear Suspension...
Page 384 SERVICE INSPECTION RECORDS A-Service Inspection Record CHECK AND RECORD BELOW Battery Electrolyte Level & Tighten Terminals: Technician’s Notes: Use separate sheet of paper if necessary. Page 358 Y53-1404 (8612 08/2023)
Page 385 SERVICE INSPECTION RECORDS C-SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with C Service on page 324. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Clutch Engine Transmission* Check all Oil Levels Steering System* Valve Clearance Adjustment Front Suspension...
Page 386 SERVICE INSPECTION RECORDS C-Service Inspection Record Technician’s Notes: Use separate sheet of paper if necessary. Page 360 Y53-1404 (8612 08/2023)
Page 387 SERVICE INSPECTION RECORDS A-SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with A Service on page 320. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Steering System* Check all Oil Levels Front Suspension Belts and Pulleys Rear Suspension...
Page 388 SERVICE INSPECTION RECORDS A-Service Inspection Record CHECK AND RECORD BELOW Battery Electrolyte Level & Tighten Terminals: Technician’s Notes: Use separate sheet of paper if necessary. Page 362 Y53-1404 (8612 08/2023)
Page 389 SERVICE INSPECTION RECORDS B-SERVICE - SERVICE INSPECTION RECORD Carry out this service in conjunction with B Service on page 322. Check Boxes - Tick = OK A = Adjust R = Repair Full System Download Clutch Engine Transmission* Check all Oil Levels Steering System* Valve Clearance Adjustment Front Suspension...
Page 390 SERVICE INSPECTION RECORDS B-Service Inspection Record Technician’s Notes: Use separate sheet of paper if necessary. Page 364 Y53-1404 (8612 08/2023)
Page 391 SERVICE INSPECTION RECORDS A Service Inspection C Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
Page 392 SERVICE INSPECTION RECORDS A Service Inspection B Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
Page 393 SERVICE INSPECTION RECORDS A Service Inspection C Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
Page 394 SERVICE INSPECTION RECORDS A Service Inspection B Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
Page 395 SERVICE INSPECTION RECORDS A Service Inspection C Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
Page 396 SERVICE INSPECTION RECORDS A Service Inspection B Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
Page 397 SERVICE INSPECTION RECORDS A Service Inspection C Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
Page 398 SERVICE INSPECTION RECORDS A Service Inspection B Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
Page 399 SERVICE INSPECTION RECORDS A Service Inspection C Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............Change In-Tank AdBlue Filter ................
Page 400 SERVICE INSPECTION RECORDS A Service Inspection B Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
Page 401 SERVICE INSPECTION RECORDS A Service Inspection C Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
Page 402 SERVICE INSPECTION RECORDS A Service Inspection B Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
Page 403 SERVICE INSPECTION RECORDS A Service Inspection C Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
Page 404 SERVICE INSPECTION RECORDS A Service Inspection B Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
Page 405 SERVICE INSPECTION RECORDS A Service Inspection C Service Inspection Servicing Dealer ........Servicing Dealer ........Date of Service ........Date of Service ........Odometer..........Odometer..........Signed ............. Signed ............. Additional Services Performed: Additional Services Performed: ..............................................................................
Page 407: Index
INDEX Automatic traction control Automated transmissions indicator A-Service operating Accelerating oil change Accessory drive belts oil sampling remove & installation parking brake serpentine belts Automatic slack adjusters Active warnings free stroke measurement adjusted 233 AdBlue (DEF) chamber stroke DEF AdBlue level Axle stops AdBlue filling Axle, cross wheel differential lock...
Page 408 INDEX full combination oil & grease linings smartwheel lubrication weather stripping normal run position Clearance lights 61, 68 operation Climbing and descending overheated brakes Clock parking brake to set rear brakes Clutch 117, 273 spring brakes manual release clutch adjustment 117, 274, 275 system-safety and emergency clutch brake &...
Page 409 INDEX Eaton transmissions Daily checks Shift patterns engine compartment Economical driving chassis and cab 14, 261 Electronic brake safety system Dana rear axle (EBSS) Dashboard layout dash switches off road function Descending a grade warning lamp fault codes Diagnostic/fault/flash codes UltraShift PLUS Dimmer switch Disc Brakes...
Page 410: Grade 5 Fastener Torques
INDEX idling Front suspension U-bolts idle timer axle lubrication lubrication specifications 216, 331 Fuel system oil pressure gauge dual fuel tank pick-ups oil temperature gauge economy overspeed excessive consumption shut down filters Electrical systems restriction batteries level gauge battery isolation switch refuelling field isolated alternator maximum fill level...
Page 411 ID & Clearance lights remote verification Ignition key switch 1, 95 Keypad transmitter power on self-test programming Instruments and controls Kenworth dealer network air system pressure gauges Kingpin lubrication coolant temperature gauge driver performance center 23, 27 fuel level gauge instrument panel 18, 20 Lap &...
Page 412 INDEX Owner’s responsibility New vehicle precautions Noise control system air intake system 291, 294 PACCAR customer support directory air system silencers PACCAR transmission engine Shifting controls cooling gear display Start up engine fan shroud Power down exhaust system 292, 293 hood insulation blankets Drive mode inner fender &...
Page 413 INDEX Lubrication 216, 232, 279, 282, 288, 315 Seats oil pressure gauge adjustment Rear brake system 25, 147 driver’s seat with air suspension Rear suspension reclining seats alignment Selective Catalytic Reduction (SCR) 107 dump valve Serial numbers and capacities fastener torque Service inspection records visual inspection Service inspection boxes...
Page 414 INDEX Stopping procedures UltraShift PLUS transmission Storage compartment Shifting controls Suspension gear display deflate switch driver diagnosis fasteners, torque retrieving fault codes general maintenance Start up lubrication Power down visual inspection Drive mode Suspension air pressure manual mode low mode Reverse mode UltraShift PLUS features coast mode...
Page 415 INDEX Wheels nut torque tightening sequence Vehicle Wheel mounting and fastening access Windscreen washer and wipers approaching your intermittent wipers identification (VIN) washer reservoir jacking jacking points primary jacking points secondary jacking points X-wheel differential lock loading to lock safety xviii towing with axles fitted with Vehicle identification plate...
Page 417 AUSTRALIA’S BEST DEALER NETWORK PACCAR Australia Pty Ltd, Kenworth has built an extensive truck dealer 64 Canterbury Road, network across Australia, New Zealand and Bayswater, Victoria 3153 Papua New Guinea that is renowned for its professionalism and excellence in the heavy duty truck industry.

This manual is also suitable for:

T410 series