Peterbilt 220, 210 Operator's Manual
Table of contents
Why this handbook is so important! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Warnings and Safety Regulations . . . . . . . . . . . 11
Safety alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Warnings and safety regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Emergency equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Technical items of special importance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Jump starting vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cab, Instruments and Controls . . . . . . . . . . . . . 31
Entering and leaving the vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Electrically operated windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Heated Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Electrical mirror adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Windshield wiper blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Roof console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Sun visors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Stepwell lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Interior lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1
Table of contents
Dashboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Warning indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Control panel of heating/ventilation system. . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Air conditioning switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Fan speed selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Temperature adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Air distribution selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Center console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Left-hand steering column switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Right-hand steering column switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Steering wheel switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Adjustable steering column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Important points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2
Table of contents
Master Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Layout of master display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Start-up phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Menu selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Menu overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Warning symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Inspections and Maintenance. . . . . . . . . . . . . . . 91
Overview of daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Opening the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Engine oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Topping up coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Special coolant fill instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Windshield washer reservoir fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Air filter indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Wheels and tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Lighting and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Driver's seat and mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3
Table of contents
Overview of weekly checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Power steering fluid level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Brake system air drier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Draining the water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
General maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Cab maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Preventative maintenance before the winter season. . . . . . . . . . . . . . . . . . . 107
Diesel fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Cab heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Windshield washer reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Maintenance after the winter season. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
PDC & Voltage Converter . . . . . . . . . . . . . . . . . .109
Power distribution center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Steering lock/contact/starter switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4
Glow system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Table of contents
Starting procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Engine speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Cruise control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Vehicle speed limitation for special applications. . . . . . . . . . . . . . . . . . . . . . 122
Driving style . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
ABS brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Parking brake and service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Engine brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Automatic Gearbox . . . . . . . . . . . . . . . . . . . . . . 129
Allison 2100 series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Emergency Repairs . . . . . . . . . . . . . . . . . . . . . . 133
Tilting the cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Replacing the poly-V belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Replacing the fuel fine filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Draining the water separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Releasing the parking brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Jacking up the front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
5
Table of contents
Jacking up the rear axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Changing the wheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Tire inflating connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Replacing bulbs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Technical Data and Identification . . . . . . . . . . .157
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
tire pressure table (Metric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Lubricant-, engine coolant- and fuel specifications. . . . . . . . . . . . . . . . . . . . 162
Engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Coolants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Steering gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Cab tilting mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Chassis number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Engine number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Paint identification plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Vehicle identification label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
6
Table of contents
Consumer Information . . . . . . . . . . . . . . . . . . . 171
Federal safety standard certification label . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Alphabetical index . . . . . . . . . . . . . . . . . . . . . . . 177
7
Table of contents
8
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.
Certain descriptions or illustrations in this handbook may not correspond entirely to
the situation on your own vehicle. However, this has practically no influence on its
operation or maintenance.
Every new vehicle is designed to conform to all Federal Motor Vehicle Safety
Standards applicable at the time of manufacture. Even with these safety features,
continued safe and reliable operation depends greatly upon regular vehicle
maintenance. Follow the maintenance recommendations found in Preventive
Maintenance on page 107. This will help preserve your investment
9
Important
Make sure this handbook is in the vehicle at all times.
Read it carefully before making your first journey, especially the "Warnings and
safety precautions", "Cab, instruments and controls", "Inspections" and
"Driving" sections.
10
Warnings and Safety Regulations
11
Warnings and Safety Regulations
SAFETY ALERTS
Please read and follow all of the safety alerts contained in this manual. They are
there for your protection and information. These alerts can help you avoid injury to
yourself, your passengers, and it can also help prevent costly damage to the
vehicle. Safety alerts are highlighted by safety alert symbols and signal words such
as "WARNING", "CAUTION", or "NOTE". Please do not ignore any of these alerts.
Warnings
The safety message following this symbol and signal word provides a warning
against operating procedures which could cause injury or even death. They could
also cause equipment or property damage. The alert will identify the hazard, how to
avoid it, and the probable consequence of not avoiding the hazard.
Example:
WARNING
Do not carry additional fuel containers in your vehicle. Fuel
containers, either full or empty, may leak, explode, and cause or
feed a fire. Do not carry extra fuel containers. Even empty ones are
dangerous. Failure to comply may result in death or personal injury.
12
Warnings and Safety Regulations
Cautions
The safety alert following this symbol and signal word provides a caution against
operating procedures which could cause equipment or property damage. The alert
will identify the hazard, how to avoid it, and the probable consequence of not
avoiding the hazard.
Example:
CAUTION
Continuing to operate your vehicle with insufficient oil pressure will
cause serious engine damage. Failure to comply may result in
equipment or property damage
Notes
The alert following this symbol and signal word provides important information that
is not safety related but should be followed. The alert will highlight things that may
not be obvious and is useful to your efficient operation of the vehicle.
Example:
NOTE
Pumping the accelerator will not assist in starting the engine.
13
Warnings and Safety Regulations
WARNINGS AND SAFETY REGULATIONS
WARNING
To prevent damage to the vehicle and in order not to jeopardize
your health and/or safety, or that of other people, the following
warning and safety regulations must be strictly observed.
First read the instructions and warnings on the labels and stickers on the various
components and comply with them!
They have been put there for your health and safety, so do not ignore them!
Modifications to the vehicle
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 dealer to make sure it can be done safely.
Improper modifications can cause death or personal injury.
14
Warnings and Safety Regulations
Environmental Protection
CALIFORNIA PROPOSITION 65 WARNING
• Diesel engine exhaust and some of its constituents are known to
the State of California to cause cancer, birth defects, and other
reproductive harm.
• Other chemicals in this vehicle are also known to the State of
California to cause cancer, birth defects or other reproductive
harm.
• Battery posts, terminals, and related accessories contain lead
and lead compounds, chemicals known to the State of California
to cause cancer and reproductive harm. Wash hands after
handling.
Components
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. In AUTO, it could
engage suddenly without warning. Before turning on the ignition or switching from
AUTO to MANUAL, be sure no one is near the fan.
15
Warnings and Safety Regulations
Cooling system filler cap
WARNING
Do not remove the radiator fill cap while the engine is hot. Scalding
steam and fluid under pressure may escape. You could be badly
burned. Failure to comply may result in death or personal injury.
EMERGENCY EQUIPMENT
It is good practice to carry an emergency equipment kit in your vehicle. One day, if
you have a roadside emergency, you will be glad the following items are with you:
- Window scraper
- Snow brush
- Container or bag of sand or salt
- Emergency light
- Warning triangles
- Small shovel
- First aid kit
- Fire extinguisher
- Vehicle recovery hitches
(see Towing on page 147 for details).
16
Warnings and Safety Regulations
Fire extinguisher
Ensure that you are always in possession of a fire extinguisher It should be well
secured under the seat, within the driver's reach and easily accessible, also for
rescue workers and others providing assistance. Have the fire extinguisher checked
for operational readiness each year. 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. Do not touch any fire extinguisher fluid on the vehicle
without protective gloves.
Cab
WARNING
Do not carry loose objects in your cab, it can be dangerous. In a
sudden stop, or even going over a bump in the road, they could fly
through the air and strike you or a passenger. You could be injured
or even killed. Secure all loose objects in the cab before moving the
vehicle. Carry any heavy objects such as luggage in the exterior
storage compartment and close it securely.
First aid kit
Ensure that you are always in possession of a first aid kit and replace first aid items
as soon as possible after use to have the kit always ready.
17
Warnings and Safety Regulations
Tire chains
If you need tire chains, install them on both sides of each driving axle.
CAUTION
Chains on the tires of only one tandem axle can damage the
driveline U-joints and the interaxle differential. Your repairs could
be costly and time-consuming.
Approaching Your Vehicle
- Check the overall appearance and condition. Are windows, mirrors, and lights
clean and unobstructed?
- Check beneath the vehicle. Are there signs of fuel, oil, or water leaks?
- Check for damaged, loose, or missing parts. Are there parts showing signs of
excessive wear or lack of lubrication? Have a qualified mechanic examine any
questionable items and repair them without delay.
- Check your load. Is it secured properly?
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,
windshield washer fluid, refrigerant in air conditioning systems, battery acid and
diesel fuel. So avoid direct contact as much as possible.
18
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
WARNING
Air conditioning refrigerant can be hazardous to your health. Do not
expose yourself to leaking refrigerant for prolonged periods near
excessive heat, open flames, or without proper ventilation. Failure
to do so may result in death or personal injury.
Maintenance activities
When carrying out maintenance work under the cab, make sure the cab is fully tilted
and locked to prevent it from falling back accidentally.
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.)
WARNING
Always support the vehicle with appropriate safety stands if it is
necessary to work underneath the vehicle. A jack is not adequate
for this purpose.
Maintenance of air conditioning system
WARNING
Excessive heat may cause the pressurized components of the air
conditioning system to explode. Never weld, solder, steam clean, or
use a blow torch near any part of the air conditioning system.
Failure to comply may result in personal injury, death, equipment or
property damage.
19
Warnings and Safety Regulations
WARNING
Air conditioning refrigerant can be hazardous to your health. Do not
expose yourself to leaking refrigerant for prolonged periods near
excessive heat, open flames, or without proper ventilation. Failure
to do so may result in death or personal injury or death.
WARNING
The air conditioning system is under pressure. If not handled
properly during servicing, it could explode. Any servicing that
requires depressurizing and recharging the air conditioning system
must be conducted by a qualified technician with the right facilities
to do the job. Failure to comply may result in personal injury, death,
equipment or property damage.
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 optimize fuel economy and
reduce the level of harmful constituents in the exhaust gases.
20
Warnings and Safety Regulations
TECHNICAL ITEMS OF SPECIAL IMPORTANCE
To prevent damage to the vehicle, the following instructions must be strictly
observed.
Running-in
During the running-in period it is best not to subject the new vehicle to excessive
loads. This also applies when an overhauled engine, transmission or differential has
been installed. 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 or 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.
The engine cooling system is thermostatically controlled.
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.
21
Warnings and Safety Regulations
Air leakage
If the pressure in the air reservoirs drops rapidly with the engine switched off, this
indicates a leak. Since this affects the safety of the brake system, the leak must be
traced and repaired as quickly as possible.
System voltage
The cab system of this vehicle are on 24-Volt while other areas remain 12-Volt.
When replacing or fitting electrical or electronic components, always verify that they
are suitable for this system voltage.
Batteries
WARNING
Never disconnect the battery leads while the engine is running!
Always disconnect the battery negative (ground) lead before carrying out repairs or
service on the electrical system.
WARNING
Before attempting any work on the batteries or electrical system,
remove all jewelry. If metal jewelry or other metal comes in contact
with electrical circuits, a short circuit may occur causing you to be
injured, as well as causing electrical system failure and damage.
22
Warnings and Safety Regulations
Charging
WARNING
Thaw out frozen batteries before charging them. Remove all the
filler caps before charging.
WARNING
Charger cables must be connected positive to positive (+ to +) and
negative to negative (- to -). If connected improperly, batteries could
explode. Failure to comply may result in personal injury, death,
equipment or property damage.
WARNING
Always make sure the battery charger is OFF before connecting or
disconnecting the cable clamps. To reduce the danger of
explosions and resulting death or personal injury, do not connect
or disconnect charger cables while the charger is operating.
Charging Reminders
- Use protective eyewear.
- Keep all batteries away from children.
- Never reverse battery poles.
- Never attempt to place the vehicle in motion, or run the engine with batteries
disconnected.
- Keep the battery clean and dry.
- Look for any signs of damage.
23
Warnings and Safety Regulations
- Battery terminals should not be coated with improper grease. Use petroleum
jelly or commercially available, noncorrosive, nonconductive terminal coatings.
- Never use a fast charger as a booster to start the engine. This can seriously
damage sensitive electronic components such as relays, radio, etc., as well as
the battery charger. Fast charging a battery is dangerous and should only be
attempted by a competent mechanic with the proper equipment.
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 electrical components have used so much power that there is
not enough to start the engine.
If the high current draw electrical components, such as the cab heater, refrigerator,
coffee percolator, microwave oven or tail-lift are used, it is recommended that you
obtain batteries of an adequate higher capacity in consultation with your dealer.
Welding
24
For welding on the vehicle and/or superstructure, see the "Bodybuilders Manual".
Not following the welding instructions can cause damage to the electronic
components.
Warnings and Safety Regulations
JUMP STARTING VEHICLES
Introduction
Jump starting a vehicle is not a recommended practice due to the various battery
installations and electrical options. However, if your battery is discharged (dead),
you may be able to start it by using energy from a good battery in another vehicle.
This is termed jump starting. Be sure to follow the precautions and instructions
below.
WARNING
Batteries contain acid that can burn and gasses that can explode.
Ignoring safety procedures may result in death, personal injury,
equipment or property damage.
WARNING
Never jump start a battery near fire, flames, or electrical sparks.
Batteries generate explosive gases that could explode. Keep
sparks, flame, and lighted cigarettes away from batteries. Failure to
comply may result in death, personal injury, equipment or property
damage.
WARNING
Never remove or tamper with battery caps. Ignoring this could allow
battery acid to come in contact with the eyes, skin, fabrics, or
painted surfaces. Failure to comply may result in death, personal
injury, equipment or property damage. Be careful that metal tools
(or any metal in contact with the positive terminal) do not contact
the positive battery terminal and any other metal on the vehicle at
the same time. Remove metal jewelry and avoid leaning over the
battery.
25
Warnings and Safety Regulations
To Jump Start Your Vehicle
WARNING
When jump starting using a booster battery, it is best to jump start
with an equivalently powered vehicle. Verify that the booster battery
has the same volt and CCA specifications as the dead battery
before attempting to jump start. Failure to comply may cause an
explosion resulting in death, personal injury, equipment or property
damage.
CAUTION
Applying a higher voltage booster battery will cause expensive
damage to sensitive electronic components such as relays, and the
radio. Failure to comply may result in equipment damage. Improper
hook-up of jumper cables or not following these procedures can
damage the alternator or cause serious damage to both vehicles.
WARNING
Heed all warnings and instructions of the jumper cable
manufacturer. Failure to comply may result in personal injury, death
and equipment or property damage.
26
Warnings and Safety Regulations
Preparing the vehicles:
1 Remove any jewelry that may come in contact with the battery terminals.
2 Select a jumper cable that is long enough to attach to both vehicles in a way that
ensures neither vehicle touches each other.
3 Position the two vehicles together, but do not allow them to touch.
4 Turn OFF all lights, heater, radio, and any other accessory on both vehicles.
5 Set the parking brakes: pull out the Yellow button located on the dash.
6 Shift the transmission into park position or neutral for manual transmissions.
(See “Shifting Gears” on page 130 and “PARKING BRAKE AND SERVICE
BRAKE” on page 125, for transmission shifting and parking brake information.)
7 If either vehicle is equipped with battery disconnects ensure they are in the
"OFF" position prior to connecting the two vehicles.
27
Warnings and Safety Regulations
Connect the batteries:
1 Attach one end of a jumper cable to the positive (+) terminal of the discharged
(dead) battery. This will have a large red + or P on the battery case, post, or
clamp.
2 Attach the other end of the same cable to the positive (+) terminal of the good
(booster) battery.
3 Attach the remaining jumper cable FIRST to the negative (-) terminal (black or
N) of the good battery.
4 Attach the other end of the negative cable to a bare metal part not bolted to the
engine block.
IMPORTANT: Always connect positive (+) to positive (+) and negative (-) to
negative (-).
5 If either vehicle is equipped with battery disconnects, ensure that they are in the
"ON" position.
6 Start the vehicle that has the good battery first. Let it run for 5 minutes.
7 Start the vehicle that has the discharged (dead) battery. If the engine fails to
start, do not continue to crank the starter and contact the nearest authorized
dealer
28
Warnings and Safety Regulations
Remove jumper cables:
WARNING
When disconnecting jumper cables, make sure they do not get
caught in any moving parts in the engine compartment. Failure to
comply may result in death, personal injury, equipment or property
damage.
Reverse the above procedure exactly when removing the jumper
cables. With the engine running, disconnect jumper cables from
both vehicles in the exact reverse order (Steps 4-1), making sure to
first remove the negative cable from the vehicle with the discharged
battery.
NOTE
Review the warranty policy before performing any maintenance
procedures. An extended warranty may be voided if unauthorized
maintenance is performed during this period.
CAUTION
Do not modify or improperly repair the vehicles electrical system or
power distribution center. All electrical repairs should be performed
by an authorized dealer. Improper repair or modifications will void
your warranty and/or cause serious damage to your vehicle.
29
Loading...