Peterbilt 270 Operator's Manual
MODEL 270
OPERATOR’S MANUAL
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, chemical s known to the State of Cali fornia
to cause cancer and reproductive harm. Wash hands after
handling.
Foreword
FOREWORD
How to use this handbook
This handbook contains information for
you, the driver , to enable y ou to operate
the vehicle a s effici ent ly and sa fely as
possible and genera lly to ma ke your
driving ea sier and more sat isfying.
Besides subjects such as operating
instr ucti ons, at tent ion also focuses on
maintenance and minor repairs which
you may be able to carry out yourself.
NOTE: This handbook is
based on the chassis and
components as it origin ally left the factory . Depending upon the requi red body
and equ ipmen t, the bodybui lder may
have made fundamental changes to
various par ts or systems, such as the
instru ment pan el, the ligh ting , or the
electrical wiring.
The vehicles covered by this handbook
consist of various types and models.
Individual vehicles are constructed in
accordance with all Federal Motor Vehicle Safety Standards 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 no influence on its operation or maintenance.
IMPORTANT: Ensure that this
handbook is in the vehicle at
all times and read it carefully
before making your first journey, especially the “Safety precautions”,
“Technical it ems of s pecia l impor -
tance”, “Instruments and controls”
and “Drivi ng” sectio ns of th is han dbook.
In addition to this handbook (available
from your dealer) the following publications have also been produced:
Bodybuilders’ guidelines
Maintenance manual
For information on how to order the
above publications, please contact your
dealer.
Safety Signals
A number of alerting messages are in
this manual. Please read and follow
them. They are there for your protection
and in forma tio n. T he se me ssages ca n
– i –
help you avoid injury to yourself, your
passengers, and help prevent costly
damage to the vehicle.
Key symbols and “signal words” are
used to in dicate wh at kin d o f m essage
is going to follow. Pay specia l at tent ion
to instructions preceded by symbols
and signal words “WARNING”, “CAUTION”, or “NOTE”. Please do not ignore
any of these alerts.
Foreword
PACCAR Inc. 9/00
©
All rights reser ved. No p ar t of this pu blicati on may be
reproduce d, s t ored in a r e tri eval s yste m, or tran sm itted, in any form, whether electronic, or mechanical, or
by photocopying, recording, or other means without
prior permission of PACCAR Inc.
– ii –
Foreword
W ARNING
When you see this word, the
message that follows is especially vital. It signals a poten -
tially hazardous situation
which , if not avoide d, could
result in death or serious injury.
This message will tell you what
the hazard is, what can happen
if you don’t heed the warning,
and how to avoid it.
WARNING! Never c arr y a ddi tional fuel contain ers in the
vehicle. Such containers, fu ll
or empty, may leak, explode
or cause a fire in the event of
a collision.
Example:
CAUTION
Signals a potentially hazardous situation which, if not
avoided, could result in minor
or moderate injury or damage
to the vehicle.
Example:
CAUTION: Continuing to
operate your vehicle with
insufficient oil pressure will
NOTE
Provides general information: for example, the note
could warn you on how to
avoid damaging your vehicle or how to
drive the vehicle more efficiently.
Example:
NOTE: Pu mp ing t he ac cel er-
ator wi ll n ot a ssi st in st ar t in g
the engine.
cause serious engine damage.
Please take the time to read these messages when you see them, and
remember:
WARNING!
CAUTION:
NOTE:
Something that could injure you seriously.
Something that could cause injury to you or your vehicle.
Useful information.
– iii –
Foreword
– iv –
CONTENTS
Foreword
How to use this handbook..... .. .. ........ i
Safety Signals.............................. .. ... i
Contents
General
Safety Precautions..............................1
General .......... .. .......... .. .......... .. ... ..... 1
Engine.. .. ... ......... ... .......... .. .......... .. ... 1
Cooling System................................ 1
Components..................................... 2
Electr ic a l ........ .. .......... .. ... ......... ... ..... 2
Oils and Lubricants.......................... 3
Maintenance Acti vities......... ............ 3
Chassis Frame................................. 3
Vehicle Load ...... ... .......... .. .. .......... ... 4
First Aid Kit....................................... 4
Winter Driving Conditions ................ 4
Items of Special Importance...............5
Break-i n....... ... ......... ... ......... ... .......... 5
Cooling System................................ 6
Air Leaka g e........... .. .......... .. .......... ... 6
System Voltage................................ 6
Batte r ie s .......... .. ... .......... .. .......... .. ... 6
Batte r y C ha r g in g ................ ... .......... 7
Protecting the Environment............. 10
Cleaning the Vehicle......................... 11
Cleaning the Cab........................... 12
Waxing the Cab............................. 12
Cleaning the Cab Interior....... .. ..... 12
Getting to Know Your Vehicle
Cab..................................................... 13
Entry and Exit........................... ..... 13
Door s... .......... .. .......... .. .......... .. ... ... 1 4
Tilting the Cab............................... 14
Door Mirrors................................... 16
Windshield Wiper Blades............... 17
Seats .......... .......... .. ... ......... ... ........ 17
Seat Be lts .......... ... .......... .. .......... .. . 18
Storage Tray.. .. .......... .. .......... .. ...... 21
Glove Box ...................................... 21
Sun Visors..................................... 22
Roof Vent (option).......................... 23
Courtesy Lights ............................. 23
Interior Light Unit........................... 24
Ashtray ....... ... ......... ... ......... ... .. ...... 24
Cigarette Lighter ........................... 24
Instru ments and C o n tr ol s....... ......... 25
Instrument Panel........................... 26
Switches, Gauges , an d W arning Li ghts
on the Instrument Panel ................ 28
Chassis.............................................. 46
Towing Pin..................................... 46
Daily and Weekly
Maintenance
Driver’s Check List ........................ 47
Daily Maintenance............................ 50
Front Access Panel ....................... 50
Engine Oil Level ............................ 50
Coolant Level ................................ 51
Wheels And Tires............ .. ............ 52
Lighting And Instruments .............. 52
Driver’s Seat And Mirrors .............. 52
Weekly maintenance........................ 53
Power Steering Fluid Level ........... 53
Air Filter Restrict ion Indicator........ 53
Brake System Air Dryer (opt ional
equipment)......................... ........... 54
Clutch Fluid Level.......................... 55
– v –
Contents
Windshield Washer Fluid Lev el..... 56
Tires .............................................. 56
Driving
General .............................................. 57
Ignition Switch.................................. 57
Startin g Pro c e d ur e ................. .. ... ..... 58
Operating the Transmission............58
Introduction.................................... 58
Operating Manual Transmissions.. 59
Putting the Vehicle in Motion......... 59
More Transmission Tips ................ 61
Operating Automatic Transmissions 62
Operating Automated Manual
Transmissions................................ 63
Cruise Control ............................... 64
Steering ............................................. 65
Brakes................................................65
Service brakes............................... 66
Parking brake / emergency brake.. 66
Engine Retarder (option)............... 67
Stopping............................................69
Parking .......................................... 69
Turning off the engine.................... 69
Diesel Fuel.........................................70
Cold Weather Recommendations . 70
Periodical maintenance
General......... ........................... ...........71
Maintenance and
Lubrication Inter vals....................... 72
Lubrication Specifications.............. 83
Oil Rese rvoirs ..... ......... ... .......... .. ... 85
Lubrication Chart........................... 85
Maintenance in Speci al and
Exceptional Operating Conditions.. 88
Cab Maintenance........................... 88
Preventive Maintenance Before the
Winter Season ............................... 88
Emergency repairs
Vehicle Tool Kit............................... 93
Replacing The Drive Belt........ ....... 93
Replacing The Compressor Belt.... 93
Replacing The Fuel Filt er............... 94
Adjus ti n g T h e Bra kes... ... .......... .. ... 94
Spring Brakes — Manual Rel ease. 94
Jacking The Vehicle....................... 96
Wheels........ ... .......... .. .......... .. ... ..... 9 7
Towing Pin...................................... 99
Towing............ .. .......... .. .......... ... .. ... 9 9
Replacing Bulbs........................... 100
Fuses... ... ......... ... ......... ... .. .......... . 103
Radio (optional)...... .. ................... 103
Electrical Connections................. 104
Speakers..................................... 104
Noise and Emission Control.......... 105
Noise Emission Warranty ............ 105
Inspection and Mai ntenance
Instr uc tions......... .. ... ......... ... ........ 106
Consumer Information
and Vehi cle Identification
Reporting Safety Defects............... 109
Vehicle Id e n tificatio n. ......... ... ......... 109
Complete Vehicle Certification
Label............................................ 111
Incomp le te Vehicle Certifica tio n
Label............................................ 111
Tire and Rim Information Label... 111
Noise Emission Label.................. 112
Paint Data Label .......................... 112
Federal Safety Standard
Cer tification L abe l ... .. .......... .. ... ... 11 2
Component Identification............. 113
General Alphabetical Index
– vi –
Safety Precautions
GENERAL
Safety Precautions
The following list of safety
precau tions agai nst possi ble safety hazards is not
exhaustive and, therefore all
safety related workshop
practices and precautions
must be exercised.
General
Ensure all Warnings and Cautions
listed in this publication are strictly
adhered to. Always read carefully the
instructions printed on labels or
stamped on components and obey
them completely. Such instructions are
included for your health and safety; do
not disregard them.
Wear clean protective clothing or apparatus when necessary.
Engine
Do not r un engine in a confined space
or unventilated area or with a leaky
exhaust sys te m. If t he e ng ine must be
run in a con fined space ensu re that an
exhaust extractor is used.
To prevent a possible fire risk, ensure
that the eng ine and its surround ing
areas are clean and free from leakages/
spillages of any inflammable liquids
(e.g. fuel oil, engine oil, etc.).
Cooling System
Do not a ttem pt to r emove th e surg e
tank fill er c ap w hil e th e en gi ne i s ru nning or still hot.
Do not att empt to f ill a hot e ngin e w ith
cold coolant.
Do not fill the cooling system through
the pressure cap aperture.
– 1 –
Safety Preca u tions General
Components
Ensure that all personnel are clear of
any rotating parts or moving components.
Synthetic rubber seals, O-rings and
gaskets which have been dama ged by
fire or come into contact with direct
heat, may produce hazardous fumes
and highly corrosive chemicals.
Allow burnt or decomposed seals etc.
to completely cool. Use impervious protective clothing and gloves. Work in a
well ventilated area when handling
these components. In the even t of
skin contact seek medical attention
immediately.
Electrical
Batteries contain electr olyte (s ulfuric
acid) wh ich is a hig hly co rrosive an d
toxic subst ance. Accide ntal sk in/eye
contact with battery electr olyte can
cause serious personal injury.
Always wear protective clothing and
suitable eye protection when handling
batteries and wash hands after use.
WARNING! Battery posts,
terminals and relat ed acce ssories contain lea d an d lea d
compounds, chemicals
known t o the St ate of Cal ifornia to cause cance r and
reproductive harm. Wash
hands after handling.
Always disconnect the ba tter ies before
commenc ing work on the vehicle. To
minimize the risk of accidental short circuits when disconnecting the batter ies,
ensure that the negative (–) lead is disconnected first and the positive (+)
lead last ; reverse this pro cedu re w hen
re-connecting the batteries.
To prevent ac cide ntal sh or t ci rcuit s do
not place tools/metal objects on or near
the battery terminals.
Batteries produce a highly flammable
and explosive gas while being charged.
It is essen tial th at th e area ar ound the
battery is we ll ventila ted and prote cted
against any flame, spark or intense
heat sourc e. The u se o f
ers is not recommended.
The ignition switch, steering lock, and
its electrical circuits are designed to
prevent the auxiliary circuits and star ter
motor from being energized while the
steering lock is engage d. Serio us consequences could result from alteration
or substitution of the ignition switch and
“boost”
charg-
– 2 –
Safety Precautions General
steering lock or its wir ing. Under no circumstances must the ignition switch be
separated from the steering lock.
Oils and Lubricants
Many liquid s and othe r substa nces
used in commercia l vehicles are high ly
toxic. These must not be consumed or
inhaled and, as far as possible , must be
kept from skin contact. These substances, amongst others, include battery acid , anti-freeze, hydraulic flu id,
lubricants, fuel, windshield w asher flui d,
refrigerant, and various adhesives.
Avoid unnece ssary contact with used
engine oil. Prolonged and repeated
contact with used engine oil may cause
serious skin disorders.
Extre me car e must be taken w hen
draining engine oil; hot engine oil can
cause severe personal injury.
Maintenance Activities
Do not use the jack as the so le means
of support; position suitable suppor ts
beneath the chassis frame.
Do not attempt to work on the vehicle
with the cab partially tilted.
Do no t attempt to stand on the cab roof.
Chassis Frame
Do not weld or subject the chassis
frame to a severe localized heat source.
Failure to obs erve th is precau tion m ay
result in irreparable damage to the
mater ial structur e of the chassis frame
with consequent loss in chassis frame
strength.
Welding or drilling on the chassis frame
must not be under taken without the
prior written consent of PACC AR Inc.
Unauthorized, indiscriminate welding or
drilling may adve rsely affect the sa fe
load-carr ying charact eristics of the
chassis frame.
Welding
• Observe these recommended procedures to protect electronic systems during welding operations.
All Electronic Engines
Before welding on vehicle s equippe d
with electronic engines, the following
precautions should be observed:
NOTE: Weldin g to fram e rail
may void frame rail warranty.
• Turn engine OFF.
• Disconnect all electronic connections to the vehicle batteries.
• Remove battery power cable and
insulate it from the vehicle.
– 3 –
Safety Preca u tions General
• Disconnect all Electronic Control
Module (ECM ) connectors (on
electronic engines).
• Do not use the ECM or engine
ground stud for the ground of the
welding probe.
• Ensure that the ground connection
for the welder is as close to the
weld point as possible. This
ensures maximu m weld current
and minimum risk to damage of
electrical comp onents on th e vehicle.
All Anti–Lock Braking Systems (ABS)
Before welding anywhere on the vehicle, detach the ABS Electronic Control
Unit (E CU) conn ector and all othe r
electronic control units.
Veh i c le Lo ad
The load must always be properly
secured so tha t it cannot move while
the vehicle is in motion, even during an
emergency stop. Side walls, pa rtitions,
headboards, etc., are not designed to
withstand high forces. Loads must not
project mo re than is per mitte d by local
or nationa l regu lation s. The sta bility of
the vehicle may be impaired by the load
and an increased turning circle may be
required.
Fire Extinguisher
Ensure t hat you always have a fire
extinguisher with you. It shou ld be w ell
secured within hand ’s reach of th e
driver and easi ly accessible for rescue
workers and others providing assistance. Have the fire extinguisher
checked for operational readiness as
recommended by the manufacturer.
When it has been use d, have it refilled
at the earliest opportunity.
First Aid Kit
Make sure that you always have a first
aid kit with you. Replenish the contents
as soon as possible after use.
Winter Driving Conditions
When winter driving conditions are
expected, ensure that your vehicle is
prepared in accordance w ith the recommendations in “
Before the Winter Season” on page 88.
When severe winter driving conditions
are anticipated, ensure that your vehicle is fitte d wit h win ter ti res or th at you
have snow equipment, as allowed by
state law.
Preventive Maintenance
– 4 –
Items of Special Importance General
Items of Special Importance
To prevent damage to the vehicle,
the following instru ction s must be
strictly observed.
Break-in
The following “break-in” recommendations should be applied dur ing the first
1,000 miles (1,600 km) of a new vehicle:
•Do not operate at full engine power
in any gear.
•Do not allow the engine to labor in
any gear.
•Do not allow the engine to run at
idling speeds for ex cessi ve periods.
During the “break-in” p eriod do not
subject the n ew vehicle to excess ive
loads; this also applies when an overhauled engine, transmission, or differential has been installed.
After a cold start continue to drive in a
low gear and at a mode rate engine
speed until the engine coolant temperature has reached 140°F (60°C).
Check the instrument panel regularly
when driving and take immediate steps
to rect ify po ssi ble pr o blem s at t he f ir st
sign of trouble.
Do not let the engine idle for longer
than necessary. This is harmful for the
engine and also causes unnecessary
pollution of the environment.
CAUTION: In the event of the
engine st alling while th e
vehicle is in motio n, power
assistance to the steering will be lost
and, consequently, greater effort will
be required to steer the vehicle.
The engine turbocharger is a preci-
sion instrument. For this reason the following operating procedures should be
observed:
• When starting the engine, do not
allow it to exceed its idling speed
for 10 seconds; this proce dure will
ensure that adequate oil pressure
is available at the turbocharge r
bearings thus preventing initial oil
starvation.
– 5 –
Items of Special Import ance General
• Before stopping the engine, allow it
to idle for one t o tw o m inutes (pa rticularly if the engine has been subjected to a high speed journey or
high engine loadings). This procedure will ensure an adequate oil
supply to the turbocharger bearings while the rotor assembly is
cooling, thus improving the life
span of the turbocharger bearings.
• Any abnormal noises or vibrations
from the turbocharger must be
reported immediately.
Cooling System
CAUTION: Damage to the
engine and cooling system,
such as c orrosion and cav itation erosion, will occur unless antifreeze ZEREX PENRAY 2792 is used
and ma intained with suppl ement al
coolant additive Pencool 3000 with
Stabil-A id . As n eed ed , f ill or to p off
the cooling system only with a
ready-mixe d clean water/ approved
antifreeze solution using these products. The use of other antifreeze
products will void your engine , radiator, and cooling system warranties.
The engine cooling system is thermostatically controlled, so the use of a
radiator cover in cold weather is
unnecessary.
Air Leakage
If the pressure in the air rese rvoirs
drops rapid ly with th e engin e switched
off, this indicates a leak in the compressed air system. Since this affects
the safety of the brake system, the leak
must be traced and repaired a s quickly
as possible.
System Voltage
The vehicle is equipped with a 12 volt
negative ground electrical system.
When replacing or fitting electrical or
electronic compon ents, always verify
that th ey are suita ble for t his s ystem
voltage, polarity, and capacity.
Batteries
Do not disconnect the battery terminals
while the engine is running; failure to
observe this precaution may result in
major damage to the alternator.
Serious battery damage and vehicle
starti ng dif fi cult ies will o ccur if the b at teries are discharged (“drained”) below
12 volt s. To prevent th e b a tte r i es fr om
being inadvertently discharged, it is
essential the followin g preca ut ion s a re
observed:
– 6 –
Items of Special Importance General
• Ensure that all lights are switched
off when not required.
Vehicles fitted with a liftgate:
•
excessive and severe battery drain
when operating the liftgate.
Battery Charging
WARNING! Battery posts,
terminals and r elated accessories contain lead and lead
compounds, chemicals
known to the State of California to cause cancer and
reproductive harm. Wash
hands after handling.
Avoid
WARNING! Do not try to
charge a frozen battery.
(Even a ba tte ry w i th ice par ticles on the ele ctrolyte surface is dangerous.) Allow it
to thaw out first. And always
allow the batter y to thaw
gradually—do not apply
direct heat . Gas trapped in
the ice m ay c au se an expl osion.
First connect the positive (+) terminal of
the battery charger to the positive (+)
term inal po st of the batte ry and th en
the negative (–) terminal to the negative
(–) terminal post. After charging, switch
off the battery charger and then disconnect th e negat ive (–) ter min al followed
by the positive (+) terminal. For norm al
charging, the battery cables may
remain in place. For fast-charging, both
battery cables must be disconnected.
Jump Starting Vehicles
It is not recommended that you attempt
to jump start your vehicle. If you have a
battery problem, it is best to contact a
dealer or a reputable towing service.
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
start ing.” Be sur e to follow the preca utions and instructions below.
WARNING! Batteries can
injure you severely. They
contain acid, produce poisonous and explosive
gases, and supply levels of
electric current high enoug h
to cause bur ns. A spark or
flame near a battery on
charge may cause it to
explode with great force.
– 7 –
Items of Special Import ance General
WARNING! Do not allow b attery fluid to contact eyes,
skin, fabrics, or p ainted sur faces. A lw ays wea r eye protection. Battery acid that
may spill during cha rging
should b e wash ed o ff with a
solution of warm water and
baking soda to neutralize
the acid. If you accidentally
get acid in your eyes or on
your skin, immediat ely ri nse
with cold water for several
minutes and call a doctor.
• Be careful that metal tools (or
any meta l in contact with the
positive terminal) do not contact
the positive battery terminal and
any other metal on th e vehicle at
the same time . Remove metal
jewelry and avoid leaning over
the battery.
• If metal jewelry or other metal
comes in contact with electrical
circuits, a short circuit may
occur causing you to be injure d,
as well a s ele ctr ica l syst em f ailure and damage to the vehicle.
• If the level of electrolyte is low, add
distilled water and repla ce th e ba ttery c ap s b efor e p roc ee di ng . If n o
water is avail able, rem ove the ba ttery caps and cover the filler openings with a cloth before proceeding.
After jump starting the vehicle, dispose of the cloth.
To Jump Start Your Vehicle
WARNING! The voltage of
the booster battery must
have a 12–volt rating. And
the capacity of the booster
battery should not be lower
than that of the discharged
battery. Use of bat teries of
different voltage or substan tially different capacity rating may cause an explos ion
and personal injury.
CAUTION: Applying a higher
voltage booster battery will
caus e expensi ve da mage to
sensitive electronic components, such as relays, and
the radio.
• Improper hook-up of jumper
cables o r not follow ing these
procedures can damage the
alternator or cause serious damage to both vehicles.
WARNING! To avoid serious
personal injury and damage
to the vehicle, heed all warnings and instructions of the
jumper cable manufacturer.
• The jum per cables must be long
enough so that the veh icles do
not touch.
If either ba tte r y has vent caps, r em ove
them and check th e fluid level. If it is
OK, replace the caps before proceeding. If no water is available, remove the
– 8 –
Items of Special Importance General
caps and cover the filler openi ngs with
a cloth before proceeding. After jump
starti ng the vehicle, di spose of the
cloth.
WARNING! If you do not
cover the filler openings on
the battery, electrolyte could
boil out of the openings and
hurt someone or damage the
vehicle. Replace caps
securely if the battery has
the full level of electrolyte. If
the electrolyte is low and no
water is available, cover with
a cloth.
Preparing the vehicles:
1. Position the two vehicles together, but do not let them touch.
2. Turn OFF all lights, heater, radio, and any other accessories.
3. Set the parking brakes
.
4. Ensure that the transmission is in
neutral position or, if auto shift, that
it is in park position.
5. Turn engine OFF (booster vehicle).
6. Disconnect ground cable on booster battery.
Connect the batteries:
1. Attach one end of a jumper c abl e to
the po sitive terminal of the discharged (dead) battery. This will
have a large red “+” or “P” on the
battery case, post, or clamp.
• Attach the other end of the
same cable to the positive (+)
term inal of the go od (boo ster )
battery.
• Attach the remaining jumper
cable FIRST to the negative
terminal (black “–” or “N”) of
the good battery.
• Attach the other end of the
negative cable to a bar e me tal
part bolted t o the engine block
(of the vehicle with the dead
battery) or, if possible, clamp
directly to the engine block.
IMPORTANT: Alw a ys c onnect positive (+) to positive (+) and negative
(–) to negative (–).
2. Start the engine:
• Start the vehicle that has the
good batter y firs t. Let it run for
a few minutes.
• Then start the vehicle that has
the discharged (dead) battery.
If the engine fail s to sta rt, do not
continue to crank the starter.
Contact the nearest Authorized
Service Center.
– 9 –
Protecting the Environment General
Remove jumper cables:
WARNING! When disconnecting jumper cables, make
sure they do not get caught
in any moving parts in the
engine co mpartmen t. You
could be seriously injured.
• Reverse the above procedure
exactly when removin g the ju mpe r
cables. With engine ru nning, disconnect jumper cables from both
vehicles in th e exact reverse ord er
(Steps 4 – 1), making sure to first
remove the negative cable from the
vehicle with the discharged battery.
Protecting the Environm ent
The growing scarcity of the world's natural resources and the escalating problem of pollution pose serious t hreats to
the environment. In order to conserve
resources and to minimize pollution it is
recommended that the following practices are adopted:
• Do not dispose of used oils,
hydraulic fluids, or engine coolant
in drains, sewers, water courses, or
land-fill sites. These fluids are
harmful to the environment and
must be disposed of properly.
• Used oils, coolant, and hydraulic
fluids should be returned to the
appropria te au th orit y for recycli ng.
Ensure that all waste fluid products
are segregated and are not intermixed; this practice will in crease
the efficiency and viability of the recycling process.
• Ensure that the vehicle is regularly
serviced to maintain peak efficiency. A correctly maintained vehicle will contribute t o maximum fuel
economy and a reduction in
exhaust gas pollutants.
– 10 –
Cleaning the Vehicle General
Cleaning the Vehicle
Before cleaning the vehicle, check for
evidence of leakage around the engine,
axles, transmission, etc., because this
will not be possible when carrying out
service operations after the vehicle has
been cleaned.
When a high-pressur e cleaner is used,
take special note of the f ol low ing points:
• Ensure that all doors, w indo ws, and
cab grille are correctly closed.
• Do not spray directly on seals.
There is a danger of the seals
being forced open by the high-pressure jet of water so that the grease
packed behind them is flushed
away.
• The hydraulic fluid reservoir for the
steering gear is provided with a
ventilation opening. Water may
enter the reser voir through this
opening and damage the steering
gear.
• When cleaning the radiator/intercooler, tak e care not to damage the
ribs or fins of the cores.
• Make sure that no water can enter
the differential or transmission via
the ventilation openings.
• Ensure that no water is allowed to
enter the clutch fluid reservoir via
the ventilation opening.
• The engine and engine compartment may be clea ned with a hi ghpressure cleaner. However, do not
aim the jet of water directly at electrical components such as the
starter motor, alternator, etc.
• Do not aim the jet of water directly
at electrical connections such as
connecto rs, cable feed-through for
the vehicle lighting, etc.
• When cleaning the vehicle, make
sure that no water enters the air
intake system via the air inlet or its
flexible joints.
CAUTION: After steam
cleaning the vehicle, it is
essential that all grease
points are lubricated with a
grease gun or with the automatic ch assis l ubricat ion
system to prevent moisture
and dirt from entering the
various pivot points.
– 11 –
Cleaning the Vehicle General
Cleaning the Cab
The external paintwork of the cab is
subject to attack by aggressive substances, the severity of which de pends
upon the specific transport role and
operating conditions of the vehicle, for
example salt scattered on icy roads,
and air pollution. The paintwork must
therefore be cleaned regularly.
When cleaning the cab, make sure that:
• no aggressive cleaners are used;
• no stiff brushes are used;
• all seams, gaps, and door frames
are thoroughly cleaned.
Waxing the Cab
To maintain and protect the cab paintwork, it is recommende d that a coat ing
of wax is applied at least twice a year.
Your dealer can advise you about additional anti-rust treatment and maintenance of the paintwork when the
vehicle is in service.
Cleaning the Cab Interior
Clean the car pets and se ats with a
brush or vacuum cleaner and occasionally with dil ute d u pho lste ry cle ane r ; do
not attempt to “dry clean” the carpets
or seats.
Clean vinyl faced upholstery and paintwork with a mild household detergent;
do not use harsh abrasives or solventbased cleaning solutions.
NOTE: The appeara nce of
your vehicle is the calling card
of your company!
– 12 –
Cab Getting to Know Your Vehicle
GETTING TO KNOW YOUR VEHICLE
Cab
The equip men t, contro ls, an d switches
within the cab may vary depending on
the vehicle specification.
Entry and Exit
When entering or exiting th e cab
observe the following procedures:
• Always face the cab when enter ing
or exiting the cab.
• Always use the grab handles fitted
to the driver`s and passengers
door pillars when entering or exiting the cab.
•Do not use the steering wheel or
instrument panel as a grab handle.
• Always use all cab steps when
entering or exiting the cab.
•Do not use the fender as a step.
WARNING! Do not jump out
of the cab or get into the cab
without proper caution. You
could slip or fall, possibly
suffering a serious injur y.
You c ould slip and fa ll if t he st eps
are wet or icy, or if you step in fuel,
oil, or grease.
To help avoid personal injury due to a slip or fall:
• Use three points of contact (two
feet-one hand or one foot- two
hands) to grip the steps or han dholds whenever possible and look
where you are going.
• Use even more care when steps
and handholds (or footwear) are
wet, coat ed w ith ice, snow, mud,
oil, fuel, or grease.
– 13 –
Cab Getting to Know Your Vehicle
Doors
Do not drive the vehicle if the doors are
not closed.
To open the vent window:
depress the sliding collar and push
handle A downwards.
To open the door:
pull handle B upwards.
To lock the door from the inside:
depress button C.
To open the door window:
turn the window crank D.
Both doors can be locked and unlocked
from the outside with the key.
Tilting the Cab
The cab is tilted and lowered hydraulically. The cab should only b e tilted
while the vehicle is parked on level
ground.
WARNING! You can be seriously injured by the cab if
you do not follow safety precautions. Whenever you
raise or lower the cab, or
when you work under the
cab, please remember the
following safety rules:
– Ensure that the area in front
of the cab is clear.
– Ensure that the vehicle tool
kit an d hydr aulic jack ar e
secured in their stowed
positions.
– Ensure that there are no
loose objects in the cab.
– Ensure that the engine is
switched off, the parking
brake is applied, and the
shift lev er is in n eu tral po si tion.
– Ensure that the cab tilt cylin-
der is fully extended before
attempting to work on the
vehicle.
– 14 –
Cab Getting to Know Your Vehicle
Tilting
• Ensure that all cab doors and cab
grille are closed and secure.
• Rotate the tilt pump spool valve pin
(A) to the up position.
• Using the pump handle from the
tool kit, operate the hydraulic tilt
pump until the cab attains its fully
tilted position.
NOTE: The cab is secured in
the d own p os iti on by hydraulically operated mounting locks;
operation of the tilt pump will
automatically disengage the
mounting locks.
Lowering
• Ensure that all personnel are
standing clear and that there are no
obstructions that would impede the
lowering of the cab.
• Ensure that the shift lever is in the
neutral position.
• Rotate the tilt pump spool valve pin
(A) to the down position.
• Operate the hydraul ic til t pump until
the cab is fully lowered and the cab
mounting locks have automatically
engaged. Ensure that the spool
valve pin remains in the down position while the vehicle is in service.
• Check that the cab is correctly
secured by both cab mounting
locks. This condition is shown by
the lock-d own wa r n ing lig ht on th e
– 15 –
Cab Getting to Know Your Vehicle
instru ment pa nel. This warni ng
light mu st remain extinguished
when the ignition is switched on.
Door Mirrors
This vehi cle is equippe d w ith elect rically heated door mirrors, a passengerside m ir ror a nd, dep en de nt upo n vehicle specification, an auxiliary wide
angle mirror (electrically heated).
Mirror head attachment
When required, the attachment of the
door mirror he ad to t he mirror arm can
be loosened (to aid adjustment) or tightened (to secure in position) using the
following procedure:
• Using a suitable implement
inserted into the slot provided,
release the trim cover (1) and then
extract it from its slotted location in
the mirror head.
• As applicable, release/tighten the
mirror head retainin g b olt (2) to 11
lb. ft. (15 Nm).
• When replacing the mirror head
trim cover, ensure that it is correctly
located with in its s lotted location
and then pushed firmly in to its
engaged position; no gaps must
exist between the trim cover (slotted end) and mirror head.
Mirror arm fold position s
The mirror arms ar e held in position by
a detent located under the mirror arm
shroud. The detent is equipped with a
spring-loade d c lutch to en able the mir -
– 16 –
Cab Getting to Know Your Vehicle
ror arm s to rem ain in position dur ing
normal conditions; this enables the mirror arms to be folded forward or rearward against the cab when
maneuvering the vehicle in a confined
space.
WARNIN G! It is u nsafe t o
drive without full visibility to
the rear. Do not attempt to
drive the vehicle wi th the
mirror arms in the folded
position.
Windshield Wiper Blades
To prevent damage to the wiper blades
during operation in winter conditions,
always check that the blades are not
frozen to the windshield. Th is can be
prevented by placing something under
the wiper blades. Clean the wiper
blades regularly with water and dr y
them with a soft cloth.
Seats
WARNING! Do not adjust the
driver’s seat while the vehicle is moving. The seat
could move sudd enly and
unexpectedly and can cause
the driver to lose control of
the vehicle. Make all adjustments to the seat while the
vehicle is stopped.
• After adjusting the seat and
before dri vin g o ff, always ch eck
to ensure that the seat is firmly
latched in position.
The driver’s seat must be adjusted only
when the vehicle is stationary. Do not
attempt to adjust the seat while the
vehicle is in motion.
– 17 –
Cab Getting to Know Your Vehicle
Driver’s Seat (adjustable)
The driver’s seat has the following adjustment modes:
Fore/aft adjustment
Pull up bar 1 and slide the seat to the
required position.
Seat cushion height adjustmentfront
Pull up handle 2 and adjust the front
end of the seat cush ion to the requ ired
height.
Seat cushion height adjustment-rear
Pull up handle 3 and adju st the rear
end of the seat cush ion to the requ ired
height.
Backrest adjustment
Pull up handle 4 and adjust the back-
rest to the required position.
Passenger’s Seat (2-man)
The 2-man passenger seat is fixed and
non-adjustable. A storage compar tment, con taini ng the vehicl e tool kit, is
located beneath the seat cushion. To
gain access to the storage compartment depress the lock cont rol lever 1
and lift the seat cushion. When the seat
cushion is fully upr ight, it will aut omatically lock in position; depress the lock
control lever to release the seat cushion.
Passenger’s Seat (single-adjustable)
The single passenger’s seat can be
adjusted for fore/aft position, seat cushion height, and backrest rake. Refer to
“Driver's Seat (adjustable)”
adjustment procedures.
for the
Seat Belts
The driver’s seat and pa ssenge rs seat
are equipped with seat belts, these
should be w or n by t he se at u ser w hen
the vehicle is in motion.
– 18 –
Cab Getting to Know Your Vehicle
WARNING! Do not drive
vehicle without your seat
belt and your riders’ belt fastened. Riding without a
safety belt properly fastened
can lead to increased injury
or death in an emergency.
Unbelted riders could be
thrown into the wind shie ld
or other parts of the cab or
coul d be thrown out of t he
cab. They could strike
another p erson . In juries can
be much worse when riders
are unbelted. Always fasten
your seat belt and be sure
anyone riding with you does
the same.
WARNING! Always wear your seat b el t low over you r pelvic bones.
• You can be seriously injured if
your belt is buckled too high. In a
crash, it would apply force to
your abdomen, not your pelvic
bones. This can result in serious
internal injuries.
• Do not drive with your seat belt
loose. A too-loose seat belt can
allow you to fall too far forward,
possibly causing head an d ne ck
injuries. You could strike the
whee l or the win dsh iel d. Ad jus t
your belt so that there is no more
than 1 in. (25mm) of slack.
WARNING! Do not wear the
shoulder part of belt und er
your arm or otherwise out of
position. In a crash your
body would move too far forward, increasin g the chan ce
of head and neck injury.
Also, the belt would apply
too much force to the ribs,
which are not as strong as
your shoulde r bones , and
could cause you to suffer
internal injuries. Wear the
shoulder belt over your
shoulder.
WARNING! Do not twist the
belt in the process of putting
it on. A twisted belt will not
work as well to protect you.
In a crash, the full w idth of
the belt would not be protecting you. A twisted belt
could cut into your body and
cause serious injuries.
Straighten t he belt b efore
buckling it. If you are unable
to wear it withou t tw isting it,
have your dealer or service
person replace it as soon as
possible.
Observe the following recommendations:
•Do not use any seat belt for more
than one person.
– 19 –
Cab Getting to Know Your Vehicle
• Before securing a seat belt, ensure
that the webbing is not twisted,
looped or obstructed in any way
that co uld impair the operat ing
mechanism.
• Optimal safety can be offered by a
seat be lt only when i t is prop erly
tightened.
• Never have repair s or modifica tions
made to the seat belts.
• Replace the seat belt when the
webbing is worn or damaged.
• If the seat belts have been subjected to high loading during a collision, then the complete assembly
must be replaced, even if there is
no visible evidence of damage.
Seat belt upper anchorage adjustment
The seat belt upper anchorage point
should be adjusted so that the belt webbing crosses m idway betw een th e
user’s neck and the edge of the
shoulder.
To adjust the position of the upper
anchorage point, depress the locking
button a nd, simult aneou sly, slide the
anchorage point to the desired position;
release the locking button when the
required position is obtained.
Seat belt care
• Regularly inspect all seat belt webbing, anchorage points, and locking
mechanisms for correct operation
and for evidence of excessive wear
or damage.
• Check the seat belt locking action
by rapidly pu lli ng t he b el t webb ing
out o f its re trac ting un it; t he belt
webbing must lock, i.e. i t must not
be pulled out of the retracting unit.
•Do not clean the belts with aggres-
sive cleaning agents; if ne cessary,
use an all-purpose cleaner.
– 20 –
Cab Getting to Know Your Vehicle
Storage Tray
Your truck may be equipped with a fixed
storage tray. The storage tray is of a
pre-formed construction incorporating
storage bins and cup holders.
Glove Box
All vehicles are equipped with a lockable glove box.
NOTE: The “ Operator’s Man-
ual” is stored in the glove box.
Keep this book in the cab at all
times.
– 21 –
Cab Getting to Know Your Vehicle
Sun Visors
The cab is fitted with 3 sun visors
which are provided for the driver and
passenger. The sun visors can be
swung down to block the sun.
– 22 –
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