Peterbilt 210-220 Operator's Manual

Table of contents

Warnings and safety regulations

Warning symbols..................................................................................................14

Warnings and safety regulations........................................................................16

Technical items of special importance...............................................................21

Airbag safety instructions ...................................................................................26

Alarm system

The system............................................................................................................32

Use of the hand-held transmitter.........................................................................32

Self-diagnosis .......................................................................................................33

Use when staying in the cab................................................................................34

Deactivation loadspace detection superstructure/trailer..................................35

The system LED....................................................................................................36

Loss of hand-held transmitter.............................................................................3 7

System does not respond to hand-held transmitte r..........................................37

Battery, hand-held transmitters...........................................................................38

Maintenance..........................................................................................................38

Disconnecting the vehicle battery.......................................................................38

Cab, instruments and controls

Cab.........................................................................................................................40

Cab................................................................................................................40

Table of contents

Entering and leaving the vehicle ...................................................................40

Doors.............................................................................................................41

Electrically operated windows .......................................................................43

Mirrors...........................................................................................................44

Electrical mirror adjustment...........................................................................45

Windscreen wiper blades ............................................ ... ...............................45

Bunks ............................................................................................................46

Roof console - oddments shelves.................................................................46

Tool boxes/storage compartments................................................................47

Roof hatch.....................................................................................................48

Adjusting roof spoiler.....................................................................................48

Sun visors......................................................................................................50

Stepwell lighting ............................................................................................50

Interior lighting...............................................................................................51

Bunk lamp .....................................................................................................52

Instruments and controls ....................................................................................53

Dashboard.....................................................................................................53

Instrument panel................................................. ... ..................................... ...56

Warning indicators................................................................................ ... ......60

Control panel............................................................................. ....................66

Control panel of heating/ventilation system...................................................70

Air conditioning switch...................................................................................71

Fan speed selector switch.............................................................................73

Temperature adjustment...............................................................................74

Air distribution selector switch.......................................................................76

Centre console..............................................................................................77

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Roof console............. ... .................................... ..................................... .........83

Left-hand steering column switch..................................................................85

Right-hand steering column switch............. .. ... ........................................ .. ... .87

Steering column switch, engine brake........................................................... 8 8

Adjustable steering column............................................................................89

Auxiliary cab heater (air heating)...................................................................89

Seats

Important points ...................................................................................................96

Seat settings .........................................................................................................97

Seat belts...............................................................................................................99

Master display

General ................................................................................................................104

Layout of master display ...................................................................................105

Start-up phase.....................................................................................................106

Menu selector switch .........................................................................................108

Menu overview....................................................................................................110

Faults ...................................................................................................................112

Warning symbols................................................................................................113

Table of contents

Inspections and maintenance

Inspections..........................................................................................................120

Overview of daily checks.............................................................................120

Opening the front panel...............................................................................121

Engine oil level............................................................................................121

Topping up coolant......................................................................................122

Screen washer reservoir fluid level .............................................................124

Air filter indicator..........................................................................................125

Wheels and tires..........................................................................................126

Lighting and instruments .............................................................................126

Driver's seat and mirrors .................................................. ... ... .....................127

Trailer vehicle..............................................................................................127

Overview of weekly checks.........................................................................128

Clutch fluid level..........................................................................................128

Power steering fluid level ............................................................................129

Brake system air drier .................................................................................130

Draining the water separator.......................................................................131

Batteries......................................................................................................132

Maintenance........................................................................................................134

General maintenance..................................................................................134

Lubricating fifth wheel/trailer coupling .........................................................135

Cab maintenance ........................................................................................136

Cleaning......................................................................................................136

Preventative maintenance before the winter season ..................................139

Diesel fuel....................................................................................................139

Cab heater..................................................... ... .. ..................................... ... .140

Windscreen washer reservoir......................................................................140

Maintenance after the winter season ..........................................................141

Cooling system............................................................................................141

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Coupling and uncoupling

Trailer coupling...................................................................................................144

Fifth wheel...........................................................................................................149

Connecting up the brake lines of a trailer ........................................................156

Connecting up the brake lines of a trailer with ABS or EBS ..........................157

Connecting up the trailer vehicle lights (24V electrical system)....................161

Driving

General ................................................................................................................164

Steering lock/contact/starter switch .................................................................165

Glow system........................................................................................................165

Starting procedure..............................................................................................166

Immobiliser fault................................................................................................. 167

Engine speed control .........................................................................................168

Cruise control .....................................................................................................171

Vehicle speed limitation for special applications............................................174

Driving style ........................................................................................................174

Differential lock...................................................................................................175

Steering ...............................................................................................................176

RAS-EC system...................................................................................................176

ASR (Anti Slip Control).......................................................................................177

Table of contents

ABS brakes .........................................................................................................178

Parking brake and service brake......................................................................179

Engine brake.......................................................................................................180

Stopping..............................................................................................................181

Manual gearbox

ZF gearbox ..........................................................................................................184

Eaton gearbox.....................................................................................................186

Automatic gearbox

Allison 1000 & 2000 series.................................................................................190

Allison MD3060...................................................................................................192

Air suspension

General ................................................................................................................200

Remote control...................................................................................................201

Engaging air suspension...................................................................................203

Setting memory keys (M-keys)..........................................................................203

Stop button .........................................................................................................204

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Emergency repairs

Vehicle tool kit .................................................................................................... 206

Tilting the cab ..................................................................................................... 206

Replacing the poly-V belt...................................................................................209

Replacing the fuel fine filter...............................................................................211

Bleeding the fuel system ...................................................................................212

Draining the water separator .............................................................................213

Releasing the parking brake..............................................................................214

Wheel winch........................................................................................................214

Jacking up the front axle ...................................................................................215

Jacking up the rear axle.....................................................................................216

Changing the wheel............................................................................................217

Tire inflating connection....................................................................................221

Towing .................................................................................................................222

Replacing bulbs ..................................................................................................224

Fuses and relays.................................................................................................230

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Technical data and identification

Technical data.....................................................................................................236

Engine.........................................................................................................236

Electrical system .........................................................................................238

Wheels ........................................................................................................239

Tire pressure table ......................................................................................240

Lubricant-, engine coolant- and fuel specifications .....................................242

Engine oil.....................................................................................................244

Coolants......................................................................................................245

Diesel fuel....................................................................................................247

Steering gear..................... ......................................................................... .248

Cab tilting mechanism................................................................................. 248

Clutch..........................................................................................................248

Identification.......................................................................................................249

Chassis number ..........................................................................................249

Engine number............................................................................................249

Engine identification plate ...........................................................................250

Paint identification plate ..............................................................................250

Vehicle identification plate...........................................................................251

ALR type plate.............................................................................................251

Table of contents

Consumer Information

Federal Safety Standard Certification Label....................................................254

How To Order Parts.................................................................................254

NHTSA Consumer Information...............................................................254

Canadian Consumer Information...........................................................255

State of California.....................................................................................255

California Proposition 65 Warning...............................................................256

Alphabetical index

Alphabetical index..............................................................................................258

Table of contents

WHY THIS HANDBOOK IS SO IMPORTANT!

This handbook contains the information which you, the driver, will need for optimum efficiency, safety and comfort when operating this vehicle. Besides giving instructions about operation and use, it also pays attention to maintenance and minor repairs which you may be able to carry out yourself.

Note:

This handbook is based on the chassis with its fittings as it originally left the factory. Depending upon the required body and equipment, the bodybuilder may have made

fundamental changes to various parts or systems, such as the instrument panel, the lighting or the electric wiring. The vehicles covered by this handbook consist of various types and models. Individual vehicles are furthermore constructed in accordance with the legal regulations in the country concerned and in accordance with the expected operating conditions. Certain descriptions or illustrations in this handbook may therefore not correspond entirely to the situation on your own vehicle. However, this has practically no influence on its operation or maintenance.

Important

Make sure this handbook is in the vehicle at all times. Read it carefully before making your first journey, especially the "Warnings and

safety precautions", "Cab, instruments and controls", "Inspections and maintenance" and "Driving" sections.

Warnings and Safety Regulations

D000500

WARNING SYMBOLS

To ensure the highest level of safety in the operation of your vehicle, various warnings are included in this handbook. Each warning is indicated by a special warning symbol.

When text is accompanied by the adjacent warning symbol, this indicates that the information in question is very important for the health and/or safety of those concerned.

Disregarding this information may result in serious damage, injury or even death.

Warnings and Safety Regulations

When text is accompanied by the adjacent warning symbol, this indicates that the

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information in question is very important for the operating safety of the vehicle. Disregarding this information may result in the loss of directional stability, steering

problems or the vehicle otherwise getting out of control, causing serious damage, injury and other life-threatening situations.

Warnings and Safety Regulations

WARNINGS AND SAFETY REGULATIONS

To prevent damage to the vehicle and in order not to jeopardise your health and/or safety, or that of other people, the following

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First read the instructions and warnings on the labels and stickers on the various components and comply with them! They have been put there for your health and safety, so do not ignore them!

Modifications to the vehicle

Modifications to the vehicle or the vehicle configuration may require the reprogramming of electronic units by an approved an authorized dealer.

Engine

Do not run the engine in an enclosed or unventilated area. Make sure exhaust gases are properly extracted.

Components

Remain at a safe distance from rotating and/or moving components.

Cooling system filler cap

Do not remove the filler cap of the cooling system when the engine is at operating temperature. Do not loosen the filler cap of the cooling system when the cab is tilted.

warning and safety regulations must be strictly observed.

Warnings and Safety Regulations

Warning triangle

Ensure that you are always in possession of a hazard warning triangle (obligatory in certain countries), possibly in combination with other marking equipment.

In the event of a breakdown en route, wear reflective clothing when outside the vehicle.

Fire extinguisher

Ensure that you are always in possession of a fire extinguisher (obligatory in certain countries). It should be well secured under the seat, within the driver's reach and easily accessible, also for rescue workers and others providing assistance. Have the fire extinguisher checked for operational readiness each year. If it has been used, have it refilled at the earliest opportunity.

In the event of fire:

In the event of a fire, certain plastic seals can produce gases which together with water form a corrosive acid. Therefore do not touch any fire extinguisher fluid on the vehicle without protective gloves.

Cab

Make sure there are no loose objects on the floor on the driver's side. Bottles, cans etc. may get stuck under the brake pedal while driving, giving rise to extremely dangerous situations.

While driving, do not use the clutch pedal as a footrest since this may cause excessive wear of the clutch.

First aid kit

Ensure that you are always in possession of a first aid kit (obligatory in certain countries). Replace first aid items as soon as possible after use to make the kit complete again.

Warnings and Safety Regulations

Winter conditions

When winter driving conditions are expected (especially if the vehicle is operated in mountainous areas), make sure that your vehicle is fitted with winter tires or that you have snow chains with you. Also refer to "Maintenance operations before the winter season" in "Inspections and maintenance".

Load

The load should always be properly secured so that it cannot move, not even during an emergency stop. Remember that sidewalls, partitions, etc. are often not designed to withstand high forces. Loads must not project more than is permitted by local regulations. Bear in mind that the stability of the vehicle may be impaired by the load and that you may also need a larger turning circle. Make sure when loading that the following values are not exceeded:

- maximum permissible gross combination weight (GCW)

- maximum permissible gross vehicle weight (GVW)

- maximum permissible axle load

Oils and lubricants

Various kinds of oil and other lubricants used on the vehicle may constitute a health hazard if they come into contact with the skin. This also applies to engine coolant, windscreen washer fluid, refrigerant in air conditioning systems, battery acid and diesel fuel. So avoid direct contact as much as possible.

The engine and the surrounding area must be free of inflammable materials to avoid the risk of fire.

Exercise caution when changing hot oil; it can cause serious bodily injury.

Warnings and Safety Regulations

Maintenance activities

When carrying out maintenance work under the cab, make sure the cab is fully tilted and locked to prevent it from falling back accidentally.

If a cooler box/refrigerator has been fitted, it should be switched off and if necessary unplugged before tilting (depending on the type). The cooler box/refrigerator should remain switched off at least 30 minutes after the cab has been tilted back.

Following a collision, only tilt the cab in an emergency situation. The tilting mechanism may be damaged. (The end stop may no longer be on the lifting cylinder.)

Always use stands to support the chassis when carrying out work under a vehicle which is resting on a jack.

Warnings and Safety Regulations

Maintenance of air conditioning system

The air conditioning system contains coolant under high pressure. Removal of any parts of the air conditioning system is not permitted. Work on the air conditioning system may only be carried out by qualified personnel.

If the air conditioning fails to work, it must be repaired by a dealer as soon as possible, to avoid further damage to the system.

Environment

Pollution constitutes a serious threat to the environment. To keep pollution to a minimum, the following rules should be observed:

- Do not dump used oil, fuel, lubricants, hydraulic fluid or coolants in drains, sewers, in landfills or on the ground. This is illegal. These fluids should be returned to the designated authority or appropriate chemical waste collection company for recycling or destruction. All used fluids should be stored separately.

- Make sure that the vehicle is serviced regularly according to the instructions and recommendations. A properly serviced vehicle helps to optimise fuel economy and reduce the level of harmful constituents in the exhaust gases.

Warnings and Safety Regulations

TECHNICAL ITEMS OF SPECIAL IMPORTANCE

To prevent damage to the vehicle, the following instructions must be strictly observed.

Running-in

During the running-in period it is best not to subject the new vehicle to excessive loads. This also applies when an overhauled engine, gearbox or differential has been installed. Therefore, for the first 1,500 km (932 miles): drive carefully and avoid accelerating sharply.

The following technical items of special importance apply to both the runningin period and to the period thereafter.

After a cold start continue to drive in a low gear and at a moderate engine speed

until the engine coolant temperature is out of the blue zone. While driving, check the instrument panel regularly and take appropriate action if

you notice anything unusual, such as strange engine and transmission noises, smoke, or poor performance. Do not let the engine idle for longer than necessary.. This is harmful to the engine and also causes unnecessary pollution of the environment.

Be aware that engine stalling while driving will lead to power steering failure. Consequently, the vehicle will be more difficult to steer.

Before switching off the engine after a long trip or when the engine has been subjected to high loading, let it idle for at least 5 minutes. It is important to let the engine run for a while in order to prevent the coolant temperature becoming too high and to allow the turbocharger to cool down.

The engine cooling system is thermostatically controlled.

Warnings and Safety Regulations

Removing the thermostat when the coolant temperature is (too) high serves no useful purpose and is strongly advised against, since this will only cause the engine temperature to rise to an even higher level.

The turbocharger is a precision component. You should therefore immediately report any abnormal noise that seems to be coming from this component.

Air leakage

If the pressure in the ai r reser voirs drops rapidly with the engine switched off, this indicates a leak. Since this affects the safety of the brake system, the leak must be traced and repaired as quickly as possible.

System voltage

The vehicle is equipped with a 24-Volt electrical system. When replacing or fitting electrical or electronic components, always verify that they are suitable for this system voltage.

Batteries

Never disconnect the battery leads while the engine is running!

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Always charge batteries in a properly ventilated area and avoid sparking and naked flames due to the danger of explosion.

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Always disconnect the battery earth lead before carrying out repairs or service on the electrical system. Never place tools on a battery. This may cause a short circuit and may even cause the battery to explode.

Warnings and Safety Regulations

Charging

Thaw out frozen batteries before charging them. Remove all the filler caps before charging.

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Connect the positive lead (+) of the battery charger to the positive terminal (+) of the battery first and then the negative lead (–) to the negative terminal (–). After charging, switch off the battery charger and then disconnect the negative terminal (–) and subsequently the positive terminal (+). For normal charging, the battery leads may remain in place. Fast charging should only be used in an emergency. For "fast charging" both battery leads must be disconnected, otherwise the electronics may become defective.

Battery capacity

Using electrical components, such as the cab heater or refrigerator when the engine is not running, power will be drawn from the batteries. Approximately half the battery capacity is required to start the engine.

If this is the case over a protracted period, particularly during low temperatures, the result may be that the electrics have used so much power that there is not enough to start the engine.

If the larger consumers, such as the cab heater, refrigerator, coffee percolator, microwave oven or tail-lift are used, it is recommended that you obtain batteries of a higher capacity in consultation with your dealer.

Warnings and Safety Regulations

Welding

For welding on the vehicle and/or superstructure, see the "Workshop manual" and "Bodybuilders Guidelines". Not following the welding instructions can cause damage to the electronic components.

Starting with auxiliary batteries

The engine may be started with the aid of jump leads using the power from separate auxiliary batteries (approx. 24 V) or from another vehicle with the engine running (approx. 28 V). When this starting procedure is followed, the battery leads must not be disconnected. Connect the jump leads first to the positive terminal (+) and then to the negative terminal (–). To disconnect, first release the negative terminal (–) and then the positive terminal (+). In the event that the batteries are fully discharged and the engine is running, it is important that the jump leads are not immediately disconnected. The engine must be allowed to run for at least 2 to 3 minutes before the jump leads are disconnected to prevent damage to the electrical system (peak voltage!).

Proceed as follows as soon as the engine starts running:

- switch on as many power consumers as possible (for example: headlights, fog lamps, heater fan, etc.);

- remove the jump leads after the engine has run for 2 to 3 minutes;

- switch off the consumers again.

Never start the engine using a fast charger!

Warnings and Safety Regulations

Mobile telephones and transmitters

If mobile telephones and transmitting equipment are used, the following points must be taken into account:

- Mobile telephones or transmitters must not be used in the vehicle without a

separate outside aerial!

The use of mobile telephones or transmitters without a separate outside aerial may cause excessively high electromagnetic fields in

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- Moreover, an outside aerial is necessary in order to achieve the maximum range

Note:

It is important to observe the instructions for use of mobile telephones and transmitters!

Original components

In order to meet the warranty conditions and guarantee the service life, safety and reliability, the use of non original components, sensors and engine management units/software is not permitted. The application of engine management software that has not been approved will adversely affect critical systems in terms of the safety of the vehicle, the braking system for instance.

the cab interior (resonance effect). In this case, there may be interference to the operation of the vehicle electronics.

of the equipment.

Warnings and Safety Regulations

AIRBAG SAFETY INSTRUCTIONS

Vehicles equipped with an airbag and seat belt tensioner system can be identified by a sticker with the airbag symbol on the windscreen and the word "AIRBAG" on the airbag unit on the steering wheel. A vehicle equipped with an airbag also has an automatic seat belt tensioner.

Equipment or objects using strong electromagnetic radiation in the vicinity of the airbag or seat belt tensioner system may cause this

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Work

- The safety precautions laid down must be observed when repairing, removing or

- Do not make any modifications to the airbag and seat belt tensioner system or

- Safety precautions regarding the airbag and seat belt tensioner system must be

- Retrofitting of accessories is only permitted if the accessories have been

system to fail or, in extreme cases, may cause the system to be activated. The use of such equipment or objects in the vicinity of airbag/seat belt tensioner systems is therefore not recommended.

replacing the airbag or seat belt tensioner system or parts thereof. For this reason, have this work carried out by an approved Service dealer or workshop only.

parts thereof. This would cause an injury hazard and correct activation can then no longer be guaranteed.

observed when the vehicle is scrapped or dismantled. approved for vehicles with an airbag and seat bel t tensioner. Installation must

take place at the position indicated and according to the procedure specified by.

Warnings and Safety Regulations

- When replacing the windscreen, observe a longer drying time for the

windscreen sealant. This longer drying time is usually stated on the win dscreen sealant packing/tube. If in doubt, contact an authorized dealer or the windscreen sealant supplier.

- If any welding is required, observe safety precautions for welding jobs.

Operation

- The airbag and seat belt tensioners are activated in the event of a (nearly) head-

on collision when a specific vehicle deceleration is exceeded. The airbag and seat belt tensioners will not be activated when:

- the ignition is switched off.

- the vehicle is involved in a minor head-on collision.

- the vehicle is involved in a lateral collision.

- the vehicle is involved in a tail collision.

- the vehicle overturns.

- The system only provides optimal protection when the seat belt is correctly worn

and the seat, seat belt and steering wheel are well adjusted to the driver.

Do not keep any parts of the body (trunk, hand, head, foot) unnecessarily close to the airbag cover.

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The space between the driver and airbag must be free. Do not place any animals, objects or persons between the driver and

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the airbag.

Hold the steering wheel by the outer rim as much as possible to allow unimpeded deployment of the airbag.

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Warnings and Safety Regulations

Activation

- If the airbag is activated in a collision, a white powder/gas will be released. This is in no way an indication of fire. The powder itself is not health-damaging.

- The airbag and seat belt tensioners can be activated only once. After activation of the system the parts must be replaced by an authorized Service dealer to provide the same protection.

- In the event of a minor collision not causing the airbag and seat belt tensioner system to be activated, it is recommended to have the system checked as yet by an authorized Service dealer.

The airbag fabric could cause slight injur y because of the rapid movement of the airbag during activation. People wearing

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spectacles and persons smoking when driving run an increased risk of facial injury in a collision involving deployment of the airbag. Usually the injuries are by no means as serious as the injuries that may occur in a collision without airbag and seat belt tensioners.

Avoid touching parts of the airbag shortly after deplo yment of the airbag unit because they may be hot.

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Warnings and Safety Regulations

Inspections

- The system is only functioning correctly if:

- after turning the ignition on, an airbag message appears on the master display which disappears after approx. 5 to 10 seconds.

- The system is not functioning correctly if:

- after turning the ignition on, no airbag message appears on the master display.

- the airbag message on the master display has still not disappeared after approx. 10 seconds after turning on the ignition.

- the airbag message appears on the master display when driving.

- If the system signals a fault, it will be unable to activate the airbag and/or seat belt tensioners and will therefore not provide extra protection in the event of a collision. Have the fault remedied by an approved Service dealer as soon as possible.

Warnings and Safety Regulations

Maintenance

- Clean the airbag cover only with a dry or damp cloth. If it is heavily fouled, ask an authorized Service dealer for an approved cleaning agent.

Do not stick anything to the airbag cover. Do not treat the cover with a cleaning agent, solvent, grease, paint, lacquer or other

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substance.

Check that the cover of the airbag unit is not damaged. Do not damage the tear seams or the cover of the airbag unit.

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- After a maximum of 15 years the main components of the airbag and seat belt tensioner system must be replaced by an authorized Service dealer. This does not apply to the electronic unit, which must be replaced after 10 years.

Sales

- If ownership of the vehicle is transferred, the previous owner must make the new owner aware of the above instructions.

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