Peterbilt 270 Operator’s Manual 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, chemicals kno wn to the State of Calif ornia to cause cancer and reproductive harm. Wash hands after handling.

Foreword

– i –

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 parts 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

PB1340A .book Page i F r iday, September 1, 200 0 7:40 AM

Foreword

– ii –

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 special at tent ion to instructions preceded by symbols and signal words “WARNING”, “CAUTION”, or “NOTE”. Please do not ignore any of these alerts.

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.

PB1340A .book Page ii Friday, Sept e mber 1, 2000 7:40 AM

Foreword

– iii –

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.

Example:

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.

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 cause serious engine damage.

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.

Please take the time to read these messages when you see them, and

remember:

WARNING!

Something that could injure you seriously.

CAUTION:

Something that could cause injury to you or your vehicle.

NOTE:

Useful information.

PB1340A.book Page iii Friday, September 1, 2000 7:40 AM

Foreword

– iv –

PB1340A .book Page iv Friday, Sep tember 1, 2000 7:40 AM

– v –

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....... ......... 2 5

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

CONTENTS

PB1340A .book Page v Friday, Sept ember 1, 2000 7:40 AM

Contents

– vi –

Windshield Washer Fluid Le vel ..... 56

Tires .............................................. 56

Driving

General .............................................. 57

Ignition Switch.................................. 57

Startin g Pro c e d ur e .............. ... ......... . 5 8

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 br ake.. 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 Intervals....................... 72

Lubrication Specifications .............. 83

Oil Rese rvoirs .......... .. .. .......... ... ..... 8 5

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.............. ... ......... ... .. .......... .. . 99

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 ....... ... .......... .. . 112

Component Identification............. 113

General Alphabetical Index

PB1340A .book Page vi Friday, Sep tember 1, 2000 7:40 AM

Safety Precautions

– 1 –

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.

PB1340A .book Page 1 Friday, Sept ember 1, 2000 7:40 AM

Safety Preca u tions General

– 2 –

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 acci dent al short cir cuit 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

“boost”

charg-

ers is not recommended. The ignition switch, steering lock, and

its electrical circuits are designed to prevent the auxiliary circuits and starter 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

PB1340A .book Page 2 Friday, Sept ember 1, 2000 7:40 AM

Safety Precautions General

– 3 –

steering lock or its wiring. 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 unnecessary 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 sole means of support; position suitable supports beneath the chassis frame.

Do not attempt to work on the vehicle with the cab partially tilted.

Do not 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 undertaken without the prior written consent of PACCAR 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.

PB1340A .book Page 3 Friday, Sept ember 1, 2000 7:40 AM

Safety Preca u tions General

– 4 –

• 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 “

Preventive Maintenance 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.

PB1340A .book Page 4 Friday, Sept ember 1, 2000 7:40 AM

Items of Special Importance General

– 5 –

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 har mful 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.

PB1340A .book Page 5 Friday, Sept ember 1, 2000 7:40 AM

Items of Special Import ance General

– 6 –

• 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:

PB1340A .book Page 6 Friday, Sept ember 1, 2000 7:40 AM

Items of Special Importance General

– 7 –

• Ensure that all lights are switched off when not required.

•

Vehicles fitted with a liftgate:

Avoid 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.

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.

PB1340A .book Page 7 Friday, Sept ember 1, 2000 7:40 AM

Items of Special Import ance General

– 8 –

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

PB1340A .book Page 8 Friday, Sept ember 1, 2000 7:40 AM

Items of Special Importance General

– 9 –

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 OF F (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.

PB1340A .book Page 9 Friday, Sept ember 1, 2000 7:40 AM

Protecting the Environment General

– 10 –

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 Environment

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.

PB1340A .book Page 10 Friday, Sept ember 1, 2000 7:40 AM

Cleaning the Vehicle General

– 11 –

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.

PB1340A .book Page 11 Friday, Sept ember 1, 2000 7:40 AM

Cleaning the Vehicle General

– 12 –

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!

PB1340A .book Page 12 Friday, Sept ember 1, 2000 7:40 AM

Cab Getting to Know Your Vehicle

– 13 –

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 entering 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 coul d sli p and fall if the step s 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.

PB1340A .book Page 13 Friday, Sept ember 1, 2000 7:40 AM

Cab Getting to Know Your V ehi cle

– 14 –

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 c ab should only be t ilted 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.

PB1340A .book Page 14 Friday, Sept ember 1, 2000 7:40 AM

Cab Getting to Know Your Vehicle

– 15 –

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

PB1340A .book Page 15 Friday, Sept ember 1, 2000 7:40 AM

Cab Getting to Know Your V ehi cle

– 16 –

instru ment pa nel. This warni ng light must 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 -

PB1340A .book Page 16 Friday, Sept ember 1, 2000 7:40 AM

Cab Getting to Know Your Vehicle

– 17 –

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.

PB1340A .book Page 17 Friday, Sept ember 1, 2000 7:40 AM

Cab Getting to Know Your V ehi cle

– 18 –

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)”

for the

adjustment procedures.

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.

PB1340A .book Page 18 Friday, Sept ember 1, 2000 7:40 AM

Cab Getting to Know Your Vehicle

– 19 –

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.

PB1340A .book Page 19 Friday, Sept ember 1, 2000 7:40 AM

Cab Getting to Know Your V ehi cle

– 20 –

• 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.

PB1340A .book Page 20 Friday, Sept ember 1, 2000 7:40 AM

Cab Getting to Know Your Vehicle

– 21 –

Storage Tray

Your truck ma y 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.

PB1340A .book Page 21 Friday, Sept ember 1, 2000 7:40 AM

Cab Getting to Know Your V ehi cle

– 22 –

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.

PB1340A .book Page 22 Friday, Sept ember 1, 2000 7:40 AM

Cab Getting to Know Your Vehicle

– 23 –

Roof Vent (option)

Rotate the control knob (A) to open and raise the roof vent to the required position.

Courtesy Lights

All cabs are equipped with two courtesy lights which are fitted in the cab roof lining above each door.

The court esy light switch has three positions:

Position A: the lig ht will onl y illumin ate when the door is opened.

Position B: light is switched off.

Position C: light is on permanently.

PB1340A .book Page 23 Friday, Sept ember 1, 2000 7:40 AM

Cab Getting to Know Your V ehi cle

– 24 –

Interior Light Unit

All cabs are equipped with an interior light unit which is fitted in the c ab center roof pan el. T he in ter ior l igh t uni t i nco rporates a directable reading light and a courtesy inter ior light; both lights are indepen dently ope rated using the interior light mounted switches.

Courtesy interior light

The cour tesy i nterio r light swit ch (1) has three positions:

Position A: li ght is switched off. Position B: li ght is switched off. Position C: li ght is switched on.

Reading light

The reading light is operated by the on/ off swit ch (2); the lig ht beam can be directed to the required position by moving the swivel lens.

Ashtray

An ashtray is provided in the center panel. Raise the cover to open the ashtray. To empty the ashtray, close the cover and extract the complete a shtray unit from its holder . Replace the ashtray by reversing the removal procedure.

Cigarette Lighter

A cigarette lighter is provided in the center panel adj acent to the asht ray. Depress the cigarette lighter in its socket; the cigarette lighter will partially eject when ready for use.

The cigarette lighter can be used as a 12 volt accessory power supply. Before connecting electrical equipment to the

PB1340A .book Page 24 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 25 –

cigarette lighter socket it is essential to ensure that:

• only 12 volt (negative ground) electrical equipment is connected to the cigarette lighter power socket.

• the power consumption of any electrical com ponen t does no t exceed

10 amps.

Instrume n ts an d Controls

General

The instru ments and control s are located on the instrument panel, center console, center roof console, and steering column.

Warning Light s

All warning lights are color coded to indicate the level of their importance. The color codes and th e required driver's response are as follows:

Red

Illumination of any red warning light during normal dr iving conditions indicates a major system or equipment malfunction. In the event of any red warning light illuminat ing, the vehicle must be stopped and the engine switched off. Do not attempt to drive the vehicle until the fault has been fixed.

Amber

Illumination of any amber warn ing light during normal dr iving conditions indicates an eq uipment /system malfu nction. In the event of an amber warning light i llu min a ting, th e vehic le m ay con-

tinue on its jo urney but ad dition al driving caution must be observed. The fault should be fixed at the earl iest o ppor t unity.

Green Or Blue

Illumination of any green or blue warning lig ht i nd ica tes t hat a un it/sys te m is operational.

WARNING! Do not ignore a warning light or buzz er. These signa ls may tell you somethin g is wrong wit h your vehicle. It could be a failure in an impor tant system, such as t he brakes, which coul d lead to an acc ident. Have the appropriate system checked imm ediately.

PB1340A .book Page 25 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 26 –

Instru me nt Panel

A/C

RECIRC

130

175

250

100

200

130

175

CRUISE ON/OFF

SET/RESUME

22 23 24

BRAKE

AIR

PTO

TRANS TEMP

CHECK TRANS

CRUISE CONTROL

DIFF

LOCK

BRAKE

AIR

PTO

TRANS

TEMP

CHECK TRANS

CRUISE

CONTROL

DIFF

LOCK

PB1340A .book Page 26 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 27 –

1. Tachometer

2. PTO warning light

3. High beam warning light

4. Hazard switch warning light

5. Turn signal warning light - vehicle

6. Cruise control warning light

7. Cab-lock warning light

8. Oil pressure warning light

9. Low air pressure warning light

10. Battery charge warning light

11. Parking brake warning light

12. Not used

13. Differential lock warning light

14. ABS warning light

15. Maintenance - Water in Fuel

16. Check engine warning light

17. Stop engine warning light

18. Coolant temperature warning light

19. Wait to Start engine warning light

20. Transmission oil temperature warning light

21. Check transmission warning light

22. Fuel gauge

23. Coolant temperature gauge

24. A/C On-Off switch

25. Heating and ventilation controls

26. Ventilation fan indicator light

27. Air pressure gauge - (secondary)

28. Fuse box - right

29. Air pressure gauge - (primary)

30. Speedometer/odometer

31. Fuse box - left

32. Vehicle lighting switch

33. Cruise control Set/Resume switch

34. Cruise control On-Off switch

35. Hazard warning light switch

PB1340A .book Page 27 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 28 –

Switches, Gauges, and Warning Lights on the Instru me nt Panel

1. Tachometer

White field: low-idling speed Green Field: economical speed range Yellow field: maximum power range Red field: excessive/overspeed range (not permitted)

2. PTO Warning Light

(A PTO is not available from the factory.) This warning light will illuminate whenever the PTO is engaged.

Do not drive vehicle at highway speeds if PTO is engaged (light is ON).

3. High Beam Warning Light

This war nin g light w ill illu mina te whe never the headlights are in the high beam p ositio n or w hen the he adligh t flash is operated.

4. Hazard Switch Warning Light

This warning light will flash simultaneously in conju nction with both dire ction indicators whenever the hazard warning light switch is activated.

5. Turn Signal Warning Light - Vehicle

This warning light flashes in conjunction with the vehicle turn signals.

6. Cruise Control Warning Light

This war nin g light w ill illu mina te whe never the cruise control is switched ON.

7. Cab-lock Warning Light

This warning lig ht wi ll il lu min ate a nd a warnin g buzzer will so un d if t he c ab is not correctly locked in the down position; this warning ligh t is on ly operative while the ignition is switched on. Also see the

“Cab”

section of this handbook.

Do not attempt to dr ive the vehicle while this warning light is illuminated.

8. Oil Pressure Warning Light

This warning lig ht wi ll il lu min ate a nd a warning buzzer will sound when the engine oil pressure is too low. In the event of the oil pressure warning light illuminatin g dur ing nor mal dr ivin g conditions, the vehicle mu st be stopped and the engine switched off. Do not attempt to re-start the engine until the fault has been rectified.

PB1340A .book Page 28 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 29 –

WARNING! The air pressure warning light and the au dible alarm in dica te a dange rous situation: there is not enough air pressure in the reservoirs for repeated braking and, except when the engine is started, indicates the brake system has failed. Without the use of your service brakes your spring brakes could suddenly apply causing a wheel lock-up, loss o f c o nt rol, or ove r- take by following vehicles. You coul d be in an acci den t and severely injured.

• Bring the vehicle to a safe stop right away, while you still have control of the vehicle. Follow the procedure below:

Air Loss Emergency Procedure

1. Slow down carefully.

2. Move a safe distance off the road and stop.

3. Place the transmission in park and set the parking brake. (See pages

and 66 for transmission shifting

and parking brake information.)

4. Tur n OFF the engine.

5. Turn ON the emergency flasher and use other warning devices to alert other motorists.

If the li ght an d alar m do no t tur n off at startup, do not try to drive the vehicle until the problem is found and fixed.

9. Low Air Pressure Warning Light

This war nin g light w ill ill umin ate an d a warning buzzer will sound whenever there is insufficient air pressure (less than 80 ps i or 5.5 ba r) available in a ny air reservoir.

Do not attemp t to drive th e vehicle while this warning light is illuminated.

10. Battery Charge Warning Light

This warning light will illuminate if the battery cha rg ing voltage falls below 1 1 volts.

11. Parking Brake Warning Light

This war nin g light w ill illu mina te whe never the parking brake is applied or when there is insufficient air pressure available to release the parking brake.

12. Blank

This warning light is not used.

13. Differential Lock Warning Light

(A locking differential is not available from the factory.) This warning light will illuminate whenever the differential is locked.

PB1340A .book Page 29 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 30 –

14. ABS Warning Light

This war n ing light mo nit ors the vehicle anti-lock braking syste m (ABS). This warning light will illuminate when:

• the ignition is switched on; the light should extinguish as soon as the vehicle road speed exceeds 5 mph (7 km/h);

• the vehicle ABS is defective; the conventional braking will remain operative but the vehicle must be driven with care and the ABS must be rectified at the ear lie st opp or tunity.

Also see

“Driving”

and

“Emergency

repairs”

sections of this handbook.

15. Maintenance - Water in Fuel

This warning light will illuminate if the water/fuel separator needs to be drained.

16. Check Engine Light

This warning light will illuminate when an engine problem exists, but the vehicle can still be sa fely driven. Th e vehicle should b e ser viced to correct the problem but the situation should not be considered an emergency.

17. Stop En gi ne Li ght

This warning light will illuminate when a major eng ine pr oblem exi st s. It me an s you should stop and shut down your vehicle as soon as it is safely possible.

NOTE: If you need to determine the exact engine problem that turns on warning light 16 or 17,

you must access the on-board diagnostic system. With the key switch ON but the engin e NOT running, pre ss the throttle pedal to full throttle and release to idle th ree times. The active fault codes will flash out as descr ibed in the Cummins ISB Engine Operation and Maintena nce Manual. Contact your dealer or th e Cumm ins engi ne ser vice center for t he explana tion of th e code. Turn the key switch OFF to exit the diagnostic mode.

18. Coolant Temperature Warning Light

This warning lig ht wi ll il lu min ate a nd a warning buzzer will sound whenever the engine coolant temperature exceeds the maximum permissible level.

PB1340A .book Page 30 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 31 –

19. Wait to Start Light

This warning light will illuminate when the air intake h eater is ON. Do not attempt to start the engine until the light goes out.

20. T ransmission Oil Temperature Warning Light

(Functional only if optional Allison automatic transmissi on is installed.) Thi s warning light will illuminate whenever the transmission oil temperature exceeds the maximum permissible level.

21. Check Transmission Warning Light

(Functional only if optional Allison automatic transmissi on is installed.) Thi s warning light will illuminate w hen a problem exists with the transmission,

but the vehicle can still be safely driven. The vehicle should be serviced to correct the problem, but the situation should n ot be consid ered an eme rgency.

22. Fuel Ga ug e

The fuel gauge gives an approximate indication of the fuel t ank con tents and only operates with the ignition switched on.

PB1340A .book Page 31 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 32 –

23. Coolant Temperature Gauge

The coolant operating temperature

should be between 165°F (74°C) and 198°F (92°C ). A t a tem perat ure of less than 140°F (60 °C) the eng ine should not be fully loaded by the driver. If the coolant temperature suddenly r ises and/or the gauge pointer enters the red field, then the following items should be checked:

• The coolant level. See “Coolant

Level” on page 51.

• The drive belt and water hoses.

• The operation of the viscous fan drive.

24. A/C On/Off Switch

(With optional air conditioning only) This switch turns the air conditioner compressor and t he rem otely m ounte d condenser on and off.

25. Heater And Air Conditioner Controls

WARNING! Do not drive with your visi bility reduced by fog, co nden sation, or frost on the windshield. Your view may be obscured, which could result in an injury

250

100

200

A/C

RECIRC

130

175

250

100

200

PB1340A .book Page 32 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 33 –

accident. For clear visibility and safe driving it is extremely important for you to follow the ins tru ction s on the use of the ventilation/heating and defogging/defrosting system. If in doubt, consult your dealer. Maximum heating output and fast defrosting can be obtained only after the engine has reached operating temperature.

WARNING! Excessive heat may cause the pressurized components of the air conditionin g system to explode. Never weld, sold er, steam clean, or use a blow torch near any par t of the air conditioning system.

• If a refrigerant leak develops in the presence of excessive heat or an open flame, hazardous gases may be generated. These gases may cause unconsciousness or deat h. If you become

aware of a refrigerant leak on your vehicle, have your system serviced immediately and observe the following precautions:

– Stay away from the hot

engine until the exhaust manifold has cooled.

– Do not permit any open

flame in the area. Even a match or a cigarette lighter may generate a hazardous quantity of poisonous gas.

– Do not smoke in the area.

Inhaling gas eous refr ig erant through a cigarette may cause violent illness.

The heating and air conditioner controls are located on the instrument panel.

The heater and air co nditione r controls consist of a rot ary switch for regula ting the bl ower spe ed, a slide c ontrol for selecting air distribution, a slide control

for selecting air temperature, and with optional air conditionin g, a push button switch for turning the ai r conditioning on or off.

22. Ventilation Fan Indicator Light

When illu minated , indica tes th e blower switch is on (Positions 1-3).

Rotar y switch (1) Contro ls the blower speed (3 speeds and an off position).

PB1340A .book Page 33 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 34 –

Slide control (2) Controls the air distribution within the cab.

A bi-level mode exists when the slide control is placed between Windshield and Floor position s or between Floor and Panel (Fresh) positions.

The optional air conditioner compressor is engaged when the control is placed in Windshield mode (top-most position).

Slide control 3. Controls progressive adjustment of the heater from 0 to 100% output.

Air vents and defoggers

The heater and air conditioner system has fixed and adjustable air vents for windshield defogging, heating or cooling the interior of the cab, defogging the door glass, and heating or cooling the footwell area.

The center panel has two air vents, adjustable for direction and volume of air flow.

= Windshield = Floor = Panel (Fresh)

= Panel (Recirc)

RECIRC

RECIRCRECIRC

PB1340A .book Page 34 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 35 –

The center panel incorp orate s a cen - tral defogger with two integral side vents for defogging the entire width of the windshield.

NOTE: The ce ntral defogg er outlet is fitted with a prote ctive mesh to prevent the entry of foreign objects. To maintain maximum air flow efficiency, do not place objects on the protective mesh or obstruct the central defogger in any way.

Two fixed air outlets at the left and right of the cab fascia are directed at the door glass. These vents and outlets admit heated or cooled air into the cab.

In the footwell area there are four outlets which are no t adjus table for dire ction of the air flow. These vents and outlet s admi t hea ted or cool ed ai r into the cab.

PB1340A .book Page 35 Friday, Sept ember 1, 2000 7:40 AM

Getting to Know Your Vehicle Instruments and Controls

– 36 –

NOTE: Fo r the r em aind er of the Heating section, numbers in parentheses ( ) refer to

items shown in this figure .

A/C

RECIRC

130

175

250

100

200

060752

Heating

To heat the cab: select the desired air distribution (2) and temperature (3) to hot (red position on the control). Adjust the fan speed (1) as desired.

CAUTION: During extreme cold weather, do not blow hot air onto cold windshields. This could crack the glass. Turn the air direction lever to Defrost and adjust the fan speed accordingly while the engine warms. If the engine is already war m, m ove the temperatur e selector to Coo l, then gradua lly in crease the tem perat ure w hen you see th at the wind shield is starting to warm up.

HEATING A/C CONTROL

CONTROL S

HEATING COOLING DEFOGGING

MAX NML MAX NML MAX NML

Fan Speed (1) High Adjust High Adjust High Adjust Air Dist ribution

(2) Panel

Panel or Bi-

Level

Recirc Adjust

Windshield

Wind-

shield or

Bi-Level Temperature (3) Warm Adjust Cool Adjust W arm Adjust Air Conditioner -

AC (4)

OFF OFF ON ON ——

PB1340A .book Page 36 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 37 –

Defogging

NOTE: If equipped with optional air conditioning, the air conditioning system is active when the Defrost mode is selected.

To defog the windshi eld: sele ct air dis tribution to Windshield or between Windshield/Floor and turn the fan speed switch (1) to high. Set the temperature control (3 ) to ho t (red position on the control). The air conditioner (if equipped ) is automat ically acti vated to remove moisture from the cab. After the windshi eld is cl ear, adjust the co ntrol s as desired.

Cooling

To cool the cab: turn on the air conditioner (if equipped) (switch 4), set the temperature control (3) to cool (blue

side), and the fan (1) to high until the

cab becomes cool—adjust as desired. When set to Recirc mode, the air condi-

tioning system will automatically shut off fresh air intake and will recirculate cab air.

For Efficient Cooling:

1. Ensure all heater/air conditioner controls are off.

2. Start the engine. Allow time for warm–up.

NOTE: A cold compressor can cause refrigerant to liquefy and warp the valve plates or cause a hydraulic lock. Warm the engine before starting the air conditioner.

3. Set the ai r condi tioner for maximum cooling.

4. Close all windows.

5. Idle the engine between 1,000 and 1,500 rpm and turn the fan switch to High.

6. After the cab temperature cools to a comfortable level, adjust the fan speed and other controls to keep the desired condition.

7. For efficient air flow in fresh air mode, regularly clean the HVAC filter located on the bottom of the cab. First, place the system in “recirc” mode and then clean the filter with a low pressure air hose.

• If the air conditioner does not cool the air, have the unit checked at an Authorized Service Center.

NOTE: When the air conditioner isn’t i n regular use, operate it for at least 15 minutes at

least once a month or every 5,000 miles (8,000 km), whichever comes first. This will lubricate the seals in the air conditioning system.

PB1340A .book Page 37 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 38 –

27. Air Pressure Gauge “Sec ondary”

Air gauge “2” constantly monitors the air pressure in the rear brake reservoir. At reservoir air pressures below 80 psi (5.5 bar) a warning buzzer will sound and a warning light, mounted in the instr ume nt panel , will il lumin ate; th e warning buzzer and warning light are only operative while the ignition is switched on. Do not attempt to drive the vehicle with less tha n 80 ps i (5.5 bar) of air pressure.

28. Fuse Box - Right

To gain access to th e circ uit and spar e fuses, rotate the quick release fastener (1) using a coin and then slide the fuse cover downward. To enable the fuses to be easily removed, a fuse extraction tool (2) is attached to the inside of the fuse cover. Also see the

“Emerg ency

repairs”

section of this handbook.

29. Air Pressure Gauge “Primary”

Air gauge “1” constantly monitors the air pressure in the front brake reservoir. At reservoir air pressu res below 8 0 ps i (5.5 bar) a warning buzzer will sound and a warning light, mounted in the instrument panel, will illuminate; the warning buzzer and warning light are only operative when the ignition is switched on. Do not attempt to dr ive the vehicle with le ss than 80 psi ( 5.5 bar) air pressure.

060751

130

175

060751

130

175

PB1340A .book Page 38 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 39 –

30. Speedometer/Odometer

The speedome ter indic ates the vehicle speed in miles per hour (MPH) and in kilometers per hour (kph)

The odomete r records the d istance trav eled by the vehicl e, either in miles or kilometer s, depen di ng on wh ich u nit i s installed in the vehicle.

31. Fuse Box - Left

To gain access to the circuit and spare fuses, rotate the quick release fastener (1) using a coin and then slide the fuse cover downward. To enable the fuses to be easi ly removed, a fu se extracti on tool (2) is attached to the inside of the fuse cover. Also see the

“Emergency

repairs”

section of this handbook.

32. Vehicle Lighting Switch

The vehicle lig hting is op erated by a rotary type switch with three positions:

km/hkm/h

mphmph

milesmiles

1010

2020

3030

4040

5050

5555

6060

7070

8080

2020

4040

6060

8080

100100

120120

lighting switched off side lights, instrument

panel, and cab marker lights

headlights, side lights, instrument panel, and cab marker lights

PB1340A .book Page 39 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 40 –

33. Cruise Control Set/Resume Switch

This switch allows the desired speed to be set or resumed after the cruise control function is turned on or interrupted.

34. C r uise Control On /Off Switch

This switch turns the cru ise control function ON or OFF.

WARNING! Do not operat e the c ruise cont rol when operati ng on road surf aces with p oor tract io n (w et , icy, or snow covered roads) or in heavy traffic. Accelerations cause d by t he no rmal operation of the cruise control could cause you to lose control of the vehicle resulting in an injury accident.

35. Hazard Warning Light Switch

Activating this rocker type switch causes al l the turn sig nals to flash simultaneously; a warning light on the instrument pa nel wi ll illuminate w hile the hazard lights are working. Return the rocker switch to its off positio n to cancel the hazard lights.

CRUISE ON/OFF

SET/RESUME

CRUISE ON/OFF

SET/RESUME

PB1340A .book Page 40 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 41 –

OPERATING LEVER, PARKING BRAKE

This lever i s used to ac tuate the parking brake. Also see the

“Driving”

section of

this handbook.

WARNING! Never drive your vehicle with the parking brake applied. Always release the parki ng br akes prior to moving the vehicle. Failure to disengage the parking brakes prior to moving your vehicle could result in excessive heat build-up in the brake system, resulting in a fire.

NOTE: Today’s diesel electronic engines have significant torque and startability power at low RPM. Combinations of engine speed and available torque may over-power the vehicle’s parking brakes.

PB1340A .book Page 41 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 42 –

CENTER ROOF CONSOLE

NOTE: Optional radio shown

PB1340A .book Page 42 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 43 –

Interior Light

The interior light unit incorporates a directable read ing light an d a cour tesy interior light; both lights are independently operated using the interior light unit mounted switches. Refer to the

“Cab” section of this handbook for the interior light unit operating procedures.

Mirror Heating Switch

The door mirror heating can be activated with this switch. When the door mirror heating is on, the switch warning light will illuminate.

CAUTION: The mirror heating must be swit ched on

only for the period of time required to clear moisture from the mirror glass; excessive use may damage the mirror and th e heating element.

Instrument Panel Lighting Switch

The instrument panel w ill automatically illuminate whe n t he li ghts are switche d on. The intensity of the instrument panel il lumi nation ca n be inc reased by activating this rocker switch. Return the rocker switch to its off position to revert to low level illumination.

NOTE: Optional radio shown on this page

PB1340A .book Page 43 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 44 –

Controls Arou nd The Steering Col um n

SET/RESUME

A/C

RECIRC

km/h

mph

miles

100

120

CRUISEON/OFF

PB1340A .book Page 44 Friday, Sept ember 1, 2000 7:40 AM

Instruments and Controls Getting to Know Your Vehicle

– 45 –

Adjustable Steering Column

WARNING! Do not adjust the steering column while the vehicle is in mot ion, it co uld cause loss of control. You would not be able to steer properly and could have an accid ent. Make all ad justments to th e steering column while the vehicle is stopped.

Loosen the lo cking control a nd move the steering w he el forward or r earward to the required position; ensure that the locking control is tightened and that the steering column is locked in posit ion before attempting to drive the vehicle.

Multi-func t io n Sw itc h, Left

Headlight flash, low beam, high beam

Position H: rest position. Position I: lift against spring pressure =

headlight flash.

Position J: position for switching

between low beam or high beam. The lever al ways re tur ns to pos itio n H

when it is released.

Turn Signals

The lane -chang e m ode of th e turn signals is operated by keeping the lever pushed in against spring pressure. The turn sig nal s wo r k only w ith the ig ni tio n switched on.

Position L:

turn signals, left

Position H:

rest position

Position R:

turn signals, right

Horn

The ho rn works w hen button K is pushed in against spring pressure.

PB1340A .book Page 45 Friday, Sept ember 1, 2000 7:40 AM

Chassis Getting to Know Your Vehicle

– 46 –

Multi-funct ion Switch, Right

Windshield wipers

Position A:

wipers off.

Position B:

wipers on, normal speed.

Position C:

wipers on, high speed.

Position D:

single wipe and intermittent

wipe function

Momentarily depress the switch (up to

½ sec.) and the n release to ob tain a single wipe of the windshield. Depress the switch for between ½ to 1½ secs to activate the intermittent wipe function; depress the switch for ½ to 1½ secs t o cancel the intermittent wipe mode.

NOTE: A single wipe can be carried out between interm ittent wipes withou t cancelling the intermittent wipe cycle.

The windshield wipers work only with the ignition switched on.

Windshield washers

The windshield washers are activated by depressing button (E) against spring pressure.

The wipers simul tan eous ly m ake th ree sweeps across the windshield.

Chassis

Towing Pin

The front bumper incorporates a towing pin which can be fitted to the left or right side of the bumper and is suitable f or all norm al towing. Refer to the “

Emer-

gency Rep airs

” section of this handbook for the recommended towing procedures.

PB1340A .book Page 46 Friday, Sept ember 1, 2000 7:40 AM

Daily and Weekly Maintenance

– 47 –

DAILY AND WEEKLY MAINTENANCE

Driver’s Check List

To keep your truck in top shape and mainta in a h igh level of s afety for you, your passengers, an d your load, make a thorough inspection every day before you drive. You will save maintenance time later, and the safety ch ecks could help prevent a serious accident. Please remember, too, that the Federal law requires a pre-trip inspection per Federal Motor Carrier Safety Regulation

392.7 and so do commercial tr ucking companies.

You are not expected to become a professional mechanic. The purpose of your inspections is to find anything that might interfere with the safe and efficient transportation of yourself, any

passengers, and your load. If you do find something wrong and cannot fix it yourself, have an Authorized S ervice Center or qualified mechanic repair your vehicle right away.

The following operations are to be performed by the d r iver. Performing the se checks and follow ing th e main tenan ce procedure s in this manual will h elp keep your truck running properly.

Approaching Your Vehicle

• Check the overall appearance and cond ition. Are wi ndows, mi rrors, and lights clean and unobstructed?

• Check beneath the vehicle. Are there signs of fuel, oil, or w ater leaks?

• Check for da maged, loose , or missing par ts. Are th ere pa rt s showing signs of excess ive wear or lack o f lubrication? Have a qualified mechanic examine any q uestionable items and repair them witho ut delay.

• Check your load. Is i t secur ed properly?

Daily Checks

Engine Compartment

1. Engine Fluid Levels—add more if necessary.

• Engine oil

• Coolant (check while engine is cold)

• Power steering fluid level

PB1340A .book Page 47 Friday, Sept ember 1, 2000 7:40 AM

Daily and Weekly Maintenance

– 48 –

2. Engine Belt—check tension and condition of belts per engine manufacturer’s Operation and Maintenance Manual.

• Measure the belt tension at the longest span of the belt.

• If cracks, breaks or tears are found in any belt, the belt should be replaced before operating the vehicle.

Air conditioner compressor belt (with opt ional air conditio ning only) The best method of testing belt tension is to apply a good quality commercial gauge. If a tension gauge is not available, use this method of testing:

• Apply 25 pounds (111 N.) of force midway between the pulleys.

• Deflection should be one belt thickness for each foot distance between the pulley centers.

Retensioning New Belts

A belt is cons idered “us ed” after 30 minutes of operation. After running for an hour or more, new belts will loosen. Check for proper tension after the first period of operation. If the belt can be deflecte d 1/8 in. (3 mm) more tha n specified, tighten according to the instructions above.

CAUTION: Do no t tighten belts beyond specified limits. Damage to bearings and belts may occur.

3. Fuel Filter/Water Separator Draining—check and drain. Depending on th e fu el s tor age facili ty, more frequent draining may be required.

4. Windshield washer reservoir fluid level—fill if necessary.

Chassis and Cab

Before entering the cab and operating the veh ic le, check th e foll owin g e qu ip ment for proper maintenance:

1. Lights—do headlights, turn signals, emergency flashers, and exterior lamps function and are they clean and adjusted properly?

2. Windows and Mirrors—are they clean and adjusted properly?

Tension Test

02953

PB1340A .book Page 48 Friday, Sept ember 1, 2000 7:40 AM

Daily and Weekly Maintenance

– 49 –

3. Tires and Wheels—are they inflated properly? Are all wheel cap nuts in place and torqued properly—tighten if necessar y. Check front wh eel bearing oil levels. Inspect all tires and wheels for damage—correct if found.

4. Suspension—check for loose or missing fast ener s. Check da ma ge to springs or other suspension parts.

5. Brake Components—check lines, linkages, c hambe rs, pa rkin g and service brake operation.

6. Air System—are there leaks?

• Air Tanks—drain water from all air tank s. Make sure th e drain cocks are closed.

7. Steps and Handholds—check for worn surfaces and loose or missing fasteners.

8. Fluid Tanks—check underneath the vehicle f or signs of flui d leaks . If any are found, correct before operating the vehicle.

9. Fuel Tank Caps—are they secure?

WARNING! Diesel fuel in the presence of an ignition source (such as a cigarette) could cause an explos ion. You coul d be seriously injured. A mixture of gasoline or alcohol with diesel f uel increases this risk of explosion.

• Do not remove a fuel tank cap near an open flame.

• Use only the fuel and/or additives recommended for your engine.

Cab Interior

1. Seat—adjust the seat for easy reach of controls.

2. Seat Belts—fasten and adjust safety restraint belts.

3. Steering Column—adjust for easy reach.

4. Mirrors—check and readjust mirrors if necessary.

5. Lights—turn ignition key to the ON position and check for warning lights and buzzer. Check operation of turn signals and emergency lights.

6. Instruments—check all instruments.

7. Windshield—check operation of windshield wipers and washers.

8. Horn—check operation of horn.

PB1340A .book Page 49 Friday, Sept ember 1, 2000 7:40 AM

Daily Maintenance Daily and Weekly Maintenance

– 50 –

9. Storage Compartment—all loose items stowed securely. Is the fire extinguisher fully charged? Is your road emergency kit complete? Compartments closed?

10. Fuel—check fuel. Is there enough fuel?

NOTE: The above items (Engine Compartment, Chassis and Cab, and Prestart Checks) should be checked daily, as a m inim um. T hey ar e in additi on to, not in pla ce of Federal Mot or Carrie r Safety Regula tions. The se regulations may be purchased by writing to:

Superintendent of Documents U.S. Government Printing Office Washington, DC 20402

Daily Maintenan ce

Front Access Panel

To O pen

The hinged front panel can be unlocked by pushing the release control sideways. The front acce ss panel can the n be swung up and secured in position with the support stay.

To Close

To close the front access panel, releas e and stow the support stay and lo w er the front panel into position. Gently push each lower corner of the front access panel un til the in ternal locks ar e he ard to engage.

Engine Oil Level

1. The vehicle must be parked on flat and level ground.

2. Pull the dipstick (1) out of the dipstick tube and wipe it clean with a lint-free cloth.

3. Place the dipstick completely back in the dipstick tube.

4. Withdraw the dipstick again and check the oil level; the oi l level should always be bet ween t he two marks on the dipstick.

PB1340A .book Page 50 Friday, Sept ember 1, 2000 7:40 AM

Daily and Weekly Maintenance Daily Maintenance

– 51 –

5. If necessary, add oil through the filler opening ( 2). A lways use oil of the same brand and grade. Never overfill with oil!

NOTE: Difference between the MAX and MIN marks on the dipstick is approximately 1 3/4 quarts (2 liters).

Coolant Level

WARNING! Do not attempt to remove the surge tank filler cap while the engine is running or still hot. The com-

plete co oling system is under pressure in these conditions. Scalding steam and fluid under pressure may e scap e and caus e s er ious injuries . You could be b adly bur ne d.

Before attempting to check the coolant level, ensure that the following safety instructions are observed:

– Do not fill the cooling sys-

tem thro ugh the pres sure cap aperture.

– Do not attempt to fill a hot

engine with cold coolant.

– Anti-freeze solutions con-

tain t oxic chemi cal s wh ich must not be consumed or allowed to come in to skin contact. Use impervious protective clothing an d gloves when handling antifreeze. In the event of slight skin contact, thoroughly rinse the affected area with water. If there is ex ce ss iv e sk in c on tact, ing est io n, or i nha latio n seek medical advice immediately.

PB1340A .book Page 51 Friday, Sept ember 1, 2000 7:40 AM

Daily Maintenance Daily and Weekly Maintenance

– 52 –

1. Remov e the filler cap (1) and check that the engine coolant is level with the lower lip of the filler neck; if necessary, fill the surge tank with approved coolant.

CAUTION: The use of unapproved coolants ca n cause severe damage to the cooling system an d it s c omp onents. Should the cooling system require an excessive amount of coo lant , the co mplete system must be inspec ted for leaks and repaired (consult your dealer).

Wheels And Tires

Remove any stones or other foreign objects from the tire tread and from between the tires (axles fitted with dual wheels).

• Check for evidence of wear and damage and for nails or other foreign objects embedded in the tires.

• Check the wheel lug nuts.

• Check the tire pressures. Do this while the tires are cold.

Lighting And Instruments

• Check the vehicle lighting, stoplights, and instruments for correct operation.

• Also check the operation of the horn, windshield wipers, and washers.

Driver’s Seat And Mirrors

• Adjust the seat and mirrors to the correct position.

PB1340A .book Page 52 Friday, Sept ember 1, 2000 7:40 AM

Daily and Weekly Maintenance Weekly maintenance

– 53 –

Weekly maintenance

Power Steering Fluid Level

WARNING! Hydraulic fluid is a toxic substance which must not be co nsumed or allowed to com e into skin contact.

WARNING! Ensure that the parking brake is on or all wheels are chocked prior to inspecting the power steering fluid level.

NOTE: Suitable wheel chocks are at a minimum an 18-inch (46 cm) long 4x4.

CAUTION: Do not operate the vehicle if the power steering fluid level is low.

1. Thoroughly clean the area around the dipstick.

2. Check the fl uid level in the reservoir with the dipstick.

3. With the engine running, the fluid level should be u p to the upper mark (MAX) on the dipstick. With the engine switched off the fluid level is approximately 3/4 inch (2 cm) higher.

Air Filter Restriction Indicator

The air induction syst em is equipped with a vacuum operated restriction indicator. The air filter elem ent mus t be replaced whenever the restriction indicator has been activated; this is indicated by the appearance of a redcolored plunger within the indicato r body. For furthe r infor matio n con tact your dealer.

PB1340A .book Page 53 Friday, Sept ember 1, 2000 7:40 AM

Weekly maintenance Daily and Weekly Maintenance

– 54 –

Brake System Air Dryer (optional equipment)

WARNING! Do not operate the veh icle in the eve nt o f a

malfunction in any ai r circuit. Such a malfunction may prevent the brake system from operati ng p roperly, and could r e sult in an injury accident. The vehicle should not be operated until the sys-

tem is repaired and both braking circuits, including all pneumatic and mechanical components, are working properly.

WARNING! Ensure that the following safety instructions are strictly observed:

• Fully charged air reservoirs contain air at an approximate pressure of 120 psi (8.4 bar). It is essential that su itable eye protection and protective gloves are worn wh ile releasi ng the air pressure from the reservoirs.

• The air dryer and filter cartridg e contain pressurized air at the brake system op erating pressure. Do not puncture nor attempt to remove the filter cartridge.

1. Chock the road wheels and fully charge the vehicle air system.

WARNING! If the supply a nd service tanks are not

drained at the recommended frequency, water could enter the air lines and valves. This cou ld cause corrosion or blockage, which could compromise the brake system safety and potentially caus e an inju ry accident.

2. Pull each air reservoir drain valve ring and check that the expelled air is free of any condensate (water/ oil/particles); should any condensate be observed from any air reservoir consult your dealer.

PB1340A .book Page 54 Friday, Sept ember 1, 2000 7:40 AM

Daily and Weekly Maintenance Weekly maintenance

– 55 –

Clutch Fluid Level

WARNING! Hydraulic fluid is a toxic substance which must not be co nsumed or allowed to com e into skin contact.

1. Open the cab front panel to gain access to the clutch reservoir.

2. Check that the hydraulic fluid level registers on or above the level mark (5), molded on the clutch reservoir; if necessary, fill the fluid level as follows:

– Remove the reservoir cap (1)

and extract the rubber diaphragm (3) from the reservoir (4).

– Fill the reservoir with clean

hydraulic fluid of th e app roved specification (DOT 3 brake fluid).

– Insert the rubber diaphragm

into the reservoir.

– To prevent leakage from the

reser voir, ens ur e th at t he seal (2) in the reser voir cap is in good condition before refitting the cap.

CAUTION: Should the clu tch fluid reservoir require an excessive amount of hydraulic fluid, the complete system must be inspected for leaks and repaired if necessary (consult your dealer).

CAUTION: Do not allow th e clutch hydraulic fluid to contact pai nt f in ishe d sur faces . It could damage the paint.

PB1340A .book Page 55 Friday, Sept ember 1, 2000 7:40 AM

Weekly maintenance Daily and Weekly Maintenance

– 56 –

Windshield Washer Fluid Level

1. Open the cab front panel to access the reservoir filler tube.

2. Remove the filler cap and refill the reservoir with a suitable windshield cleaning solution.

NOTE: During the winter period, it is re co mm en de d t ha t a suitable solutio n with antifreeze protection is used.

Tires

• Check the tread depth of the tires.

• Check that the wear pattern is evenly distributed over the ru nning surface of each tire.

PB1340A .book Page 56 Friday, Sept ember 1, 2000 7:40 AM

General Driving

– 57 –

DRIVING

General

Before starting the engine o r setting out on a trip, always check:

• The vehicle for water, fuel, or oil leaks.

• The seat and mirrors for correct positioning.

• The operation of the lights and instruments.

• That the vehicle load is correctly secured.

After each trip always check that:

• The doors of the vehicle are locked.

• The load is still properly secured.

Ignition Switch

WARNING! Do NOT remove the key from the steering lock/ignition and starter

switch while the vehicle is in motio n because this may cause the steering wheel lock to engage.

Position A: rest position

The key can be removed. When the key is removed from the switch, the steering wheel is locked.

Position B: accessories position

Steering wheel unlocked. The key cannot be removed. Access ories, such as a radio, can be switched on.

Position C: ON position

All power consumers can be switched on.

Position D: starting

When the key is released, it automatically returns to position C.

PB1340A .book Page 57 Friday, Sept ember 1, 2000 7:40 AM

Starting Procedure Driving

– 58 –

Starting Procedure

WARNING! Ensure that the following safety instructions are strictly observed:

– Do not start the engine in a

confined space or unventilated area. Exhaust fumes contain toxic gases which, if inhaled, can prove fatal.

– Before driving away, ensure

that all warning lights h ave been ext inguis hed an d the warning buzzer has ceased to sound.

CAUTION: When the engine starts and runs, do not allow the engine to exceed its idling speed for 10 seconds; this procedure will ensure

that adequate oil p ressure is available at the turbocharger bearings.

1. Ensure that the parking brake is applied an d the shif t lever is in the neutral position.

2. Tur n ignition key to position ‘C’ and check that the oil pressu re and parking brake warning lights illuminate and that the fuel gauge shows sufficient fuel for the trip.

3. If the engine WAIT light is on, wait until it goes out.

4. With the accelerator pedal releas ed, turn the ign ition key t o position D; release the key immediately after the engine has started. If the engine fails to start after 10 seconds, release the key. Wait 10 seconds and repeat the starting procedure.

Operating the Transmission

Introduction

Your is equipped with either a manual, automatic, or aut omated manua l transmission with special features and gearing to me et your pa r t icu lar n ee ds. I t i s impor t an t for yo u, t he dr iver, t o un de r stand how your pa r ticul ar tran smission is operated.

In addition to the instructions listed in this

Operator’s Manual,

additional instructions a nd guid elines ar e available in the transmission manufacturer’s

Driver/Operator ’s Instr uc tion M anu al

in your glovebox. Read the general guidelines and instruct ions that follow and

PB1340A .book Page 58 Friday, Sept ember 1, 2000 7:40 AM

Operating the T ransmission Driving

– 59 –

read the specific instructions contained in the transmission manufacturer’s

Driver/Operator’s Instruction Manual

Operating Manual Transmissions

If your truck has an automatic transmission, go to page 62

If your truck h as an au tom ated manua l

transmission, such as the Eaton® Autoshift™, go to page 63

Your transmis sion has six forward gears with full synchromesh engagement, and one reverse gear. Yo u will find a shift pattern diagram on the gearshift knob. Make sure you follow the cor rect sequence for shi fting y our tr ans missi on.

Transmission Warm–Up

In cold weather [below 32°F (0°C)], you may find shifting sluggis h when you first start up. Transmission warm-up is especially important at this time, but it is always a good idea to warm your transmission oil before startin g out on the road.

To warm the transmission lubricating oil during engine warm-up:

1. Put the transmission in Neutral.

2. Release the clutch pedal and let the transmission operate in Neutral for three to five minutes prior to shifting into either a forward or reverse range.

Putting the Vehicle in Motion

WARNING! Never drive your vehicle with the parking brake applied. Always releas e the parkin g brakes prior to moving the vehicle. Failure to disengage th e parking brakes prior to moving your vehicle could result in excessive heat build-up in the brake system, resulting in a fire.

NOTE: Today’s dies el elec tronic engines have significant torque and startability power at low RPM. Combinations of engine speed a nd available torque may over-power the vehicle’s parking brakes.

PB1340A .book Page 59 Friday, Sept ember 1, 2000 7:40 AM

Operating the Transmission Drivin g

– 60 –

CAUTION: Always us e first gear or a low speed range to start the veh icle in mo tion. The use of a higher gear or speed range forces undue strain o n th e e ngine , clut ch, other transmission components, and may cause damage.

After ma king sure the ve hicle’s oil a nd air pressure a re correct a nd all other par ts and sy stems are in prop er wor king condition:

1. Fully depress the clutch pedal and shift the transmission into first gear.

2. Lift the sleeve on the parking brake handle and push the han dle fully forward to release the brakes.

3. Release the clutch pedal, then gradually accelerate.

4. Do not allow your vehicle to roll (even a little) in the opposite direction during clutch engagem ent. If

you need to star t up on a n incline, apply your ser vice b rakes before you release the parking brake. Then release your service brakes as you engage the clutch and apply throttle.

For further instructions on operating your transmission, see the transmi ssion manufacturer’s

Driver/Operator’s

Instruction Manual

If you have a misaligned gear condition in your vehicle’s transmission and cannot start, gradually release the clutch, allowing t he dr ive ge ar t ee th t o l ine u p properly. Then the dr ive gear can roll enough to allow the teeth to line up properly and complete the shift.

The best engine performance and maximum economy is obtained if gears are properly selected. This efficiency is achieved by always selecting gears

within optim um engine rpm, whic h is where maximum to rqu e and p ower are obtained.

Shifting Gears in a New Vehicle

Shift carefully in a new vehicle. The transmission may be a little stiff at first. Avoid gear clashing by closely following these procedures.

When you are o pe rati ng a new vehicle or one that has been exposed to cold weather, you want the transmission lubricant (fluid) to circulate and coat the contacting surfaces of the gears. Meta l contacting metal in moving parts may

seriously damage your transmission— do not drive in one gear f or long periods of time until the transmission lubricant has a chance to coat all contacting surfaces.

PB1340A .book Page 60 Friday, Sept ember 1, 2000 7:40 AM

Operating the T ransmission Driving

– 61 –

WARNING! Do not coast with the transmission in neutral or with the clutch

pedal depressed—it is a dangerous practice. W ithout the use of the retarding power of the drivet rain, your vehicle can reach dangerous speeds. At very high speeds you may no t be able to p ut the transmission in any gear. At high speeds you could seriously damage your vehicle or cau se an acci dent whe n yo u pu t th e tr an smis sion in gear. The engine speed co uld exceed the maximum governed speed and cause a serious accident due to m echan ical failures.

More Transmission Tips

“Riding” the Clutch

The clutch is not a footrest. DO NOT DRIVE WITH YOUR FOOT RESTING ON THE CLUTCH PEDAL. It will allow your clutch to slip, causing excessive

heat and wear—damage could result.

Release Bearing Wear

When you must idle your engine for any period of time, shift y our tr ans mission to Neutral and dise ngage th e clutch (t ake your foot OFF of the pedal) . Th is helps prevent unnecessary wear to your clutch release bearing, and it is less tiring for you, too.

Clutch Adjustment

If your truck has an Eaton® Solo clutch,

no adjustments are necessary . This is a self-adjusting clutch and requires no adjustments for wear.

Inspect manual clutches according to the maintenance and lubrication intervals in this manual. Regular maintenance must be followed to maintain correct clutch ad justment . Have your dealer’s Service Depar tment perfor m any adjustment necessary.

Tips for Manual Transmission Operation

• Always use the clutch when making upshifts or downshifts.

• Always start in first gear.

• Never downshift when the vehicle is moving too fast.

PB1340A .book Page 61 Friday, Sept ember 1, 2000 7:40 AM

Operating the Transmission Drivin g

– 62 –

• Never slam or jerk the shift lever to complete gear engagement.

• Never coast with the transmission in Neutral and the clutch disengaged.

• To provide smooth gear engagements while shifting, use proper coordination between shift lever and clutch.

Operating Automatic Transmissions

An automatic transmission makes shifting much easier, of course. But because your truck pulls a heavy load, it is important to use it efficiently. For correct automatic transmission operation, also see the transmission manufacturer's

Operator’s Manual.

• On most automatic transmissions there is no “PAR K” position, so you will need to apply the parking brake before leaving the cab. See page

66.

WARNING! Do not leave the cab without app lying the parking br ake. The truck could roll and cause an injury accident . Always apply the parking brake before you leave the cab.

The MD Automatic Transmission

The MD (electronic) Series of transmissions have four, five, or six forward speeds, a Neutral position, and one reverse speed. Pressing the appropriate button selects the desired gear.

Vehicles equipped with the MD transmissions have various diagnostic features. Refer to the transmission manufacturer’s

Operator’s Manual

for

information on all diagnostic features.

MD Automati c Transmission - Elect ronic

Shift Selector

01916

PB1340A .book Page 62 Friday, Sept ember 1, 2000 7:40 AM

Operating the T ransmission Driving

– 63 –

The MD transmission is programmed to restrict full operation until specific temperatures are reached. See the trans-

missi on manu facture r’s

Operator’s

Manual

for details.

Operating Automated Manual Transmissions

The Eaton® Autoshift™ transmission is an automated manual transmission. The Autoshift™ is a partially automated

Eaton

Fuller® Roadranger® transmis-

sion that automatica lly selects and

engages the transmission’s gears. The driver mu st use th e cl utch t o s tart and stop the vehicle, but not for shifting through the gears. A shift begins when

the Autoshift™ computer detects that conditio ns are r ight for a shift. T he transmission signals the engine contr oller to brea k driveline torque an d provides engine RPM for synchroniz i ng the next gear. When engine speed and gear speed are synchronized the transmission engages the next gear and signals the eng ine to resume operation. Please see the transmission

Operator’s

Manual

for fur ther d eta ils o n the tra ns-

mission’s operation and components.

WARNING! Do not leave the cab without applying t he parking brake. The truck could roll and cause an injury accident. Always apply the park ing brake before you leave the cab.

Eaton® Autoshift™ Trans mission -

Electronic Shif t Sel ector

PB1340A .book Page 63 Friday, Sept ember 1, 2000 7:40 AM

Operating the Transmission Drivin g

– 64 –

Cruise Control

This feature improves fuel mileage and reduces driver fatigue by maintaining a constant vehicle speed. The cruise control will only operate above a programmed minimum vehicle speed of 30 mph for the Cummins ISB engine.

Engaging the Cruise Control

NOTE: Ensure that the vehicle speed is above the minimum cruise control speed and the engine speed is above 1100 rpm.

1. Mov e the ON/OFF s wit ch to the ON position.

NOTE: Toggling the SET/ RESUME switch to the RESUME position at this point will select the previously set cruise speed.

2. Accelerate the vehicle to the desired cruise speed.

3. Toggle the SET/RESUME switch to the SET position to set the c ruise speed.

•To decrease the cr uise set speed, hold the SET /RESUM E swi tch i n the SET position and coast to a lower speed.

•To increase the cruise set speed, hold th e SET /RESU ME switch in the RESUME position; this will accelerate the vehicle to a higher speed.

Disengaging the Cruise Control

Do one of these steps to disengage the cruise control:

• Move the ON/OFF switch to the OFF position.

• Depress the brake pedal.

• Depress the clutch pedal.

CRUISE ON/OFF

SET/RESUME

PB1340A .book Page 64 Friday, Sept ember 1, 2000 7:40 AM

Steering Driving

– 65 –

Reengaging the Cruise Control

1. Mov e the ON/OFF s witch to the ON position.

2. Toggle the SET/RESUME switch to the RESUME position.

Steering

The steering gear is hydraulically assisted. As excessive pressure may damage the hydraulic pum p, stop tur ning the steering wheel when the wheels are at full lock or are blocked by an obstacle. Steering is also possible without power assistance, but th is r equire s considerable effort.

Brakes

Anti-Lock Braking System (ABS)

Your truck is equipped with an anti-lock braking system (ABS). The ABS reduces the possibility of wheel lock - up . If a w hee l i s a bou t to lo ck dur ing b raking, the ABS will automatic ally adjust air pressure to the brake chambers on the appropriate wheel(s) to prevent wheel lock-up. The ABS is automatically turned on w hen the ignition switch is turned on.

WARNING! Do not rely on an anti-lock brake system that is functio ning imprope rly. You could lose control of the vehicle result ing in a sever e accident and personal injury. If your ABS lamp goes on while you are driving or stays on after the selfcheck, your anti-lock system might not be working. The ABS may not function in an emergency. You will still have conventional brakes, but not anti-lock brakes. If the lamp indicates a problem, have the ABS checked.

CAUTION: It is essential that the following driving procedures are observed:

– Do not abuse the ABS sys-

tem by exce ssive ly h ars h or delayed applicatio ns of th e service brakes.

PB1340A .book Page 65 Friday, Sept ember 1, 2000 7:40 AM

Brakes Driving

– 66 –

– Do not adapt your normal

drivi ng st yle wh en dri ving a vehicle equipped with ABS. It is essential that the braking system is operated in a safe and conventional manner.

– ABS does not shorten the

overall vehicle braking (stopping) distance.

– In the event of an ABS mal-

function, the ABS w ill be automatically disengaged and the ABS warning light will illuminate. The conventional brak ing system w ill remain operative, but the vehicle must be driven with care and the fault repaired as soon as possible.

NOTE: The operation and function of the ABS warning lights are detailed in the

“Instruments and controls” section of this handbook.

Service brakes

The service brakes are operated by the footbrake pedal. If the vehicle has been driven through water or subjected to high pressure washing, full braking power may not be available; dry the brakes by lightly applying the brakes while the vehicle is in motion.

If ther e is a mal func tio n in t he ser v ice brake system, the parking brake can be used for emergency braking; do not continue a trip w ith a faulty service brake system.

Parki ng br ake / emer gen cy brake

WARNING! Do not attempt to release the parking brake while the steering lock is engaged; failure to observe this preca uti on can result in vehicle moveme nt with the loss of steering control.

PB1340A .book Page 66 Friday, Sept ember 1, 2000 7:40 AM

Brakes Driving

– 67 –

The parking brake control operates the spring brake actuators to apply the rear brakes on the vehicle.

Move the control lever (1) fully rearward to apply the parking brakes; a locking sleeve (2) will lock the control lever in position . To release th e par king br ake, lift the locking s lee v e and mo v e the control lever fully forward to the off position. A red warning light in the inst rument panel will illuminate whenever the park-

ing brake is applied; refer to the “

Instru-

ments and controls

” section of thi s

handbook. In the event of a failure in the service

brakes, the par king b rake can b e used as an emergency brake. Gradually move the par king brake cont rol lever rearward to slo wl y appl y the rear brak es on the vehicle. B raking effor t will be proportion al t o t he c ontr o l l ever m ovement.

WARNING! Do not drive this vehicle with malfunctioning brakes. If one of the brake

circuits should become inoperativ e, braking distan ces will increase substantially and handling character istics wh ile braking will be affected. You could lose control of your ve hicle , b e seve re ly in ju re d, o r caus e an ac ci de nt. Have i t towe d t o the nearest dealer o r quali fied workshop for repair.

Engine Exhaust Brake (option)

An engine exhaust brake may be installed (as an option) to create a braking effect on the drive wh eels. This device uses your engine's power to slow your vehicle down. Because it can help keep your vehicle's brakes from overheating, it can save wear and tear

on the service brakes. However, the engine exhaust brake is not an emergency brake.

Ideally ( on no rma l road su rfaces ), you should slow your vehicle with the engine exhaust brake (where perm itted by law) and use the service brakes only for stopping co mp let ely. Operating th is way will greatly prolong the life of the service brakes.

WARNING! The service brakes must be used in an emergency. The engine exhaust brake alone might not stop you fast enough to prevent an acciden t. You could be badly hurt if you relied only on the engine exhaust brake.

• The engine exhaust brake is NOT intended as the primary brake for the vehicle, nor is it an emergency brake. The engine

PB1340A .book Page 67 Friday, Sept ember 1, 2000 7:40 AM

Brakes Driving

– 68 –

exhaust brake only helps the service brakes by using pressure to slow the drivetrain. Use the serv ice brakes for qui ck stops.

Exhaust Brake Operation

With the exhaust brake switch ON, the engine exhaust brake automatically creates its bra king effect when you remove your foot from the accelerator pedal a nd all ot her req uir ed conditi ons are met (see below).

The brake switch is located on the switch panel between the seats. It controls whether the brake is ON (ready to slow the vehicle down) or OFF (no braking action).

• Make sure the exhaust brake switch is OFF before star ting the engine.

• After the engine is started, warmed up, and you are ready to get under way, turn the exhaust brake switch ON for added braking effect.

The engine exhaust brake activates if

all

of the following conditions are true:

• 0% throttle

• Clutch pedal is not depressed

• PTO and cruise control are inactive

• Engine speed is greater than 1000 rpm

WARNING! Do not use the engine exhaust brake when operating on road surfaces with po or tr act ion (such as wet, icy, or snow covered roads or gravel). The engine exhaust brake can cause the wheels to skid on a slippery surface. You could lose control of the vehicle and/or jackknife if the wheels begin to skid, resulting in an accident.

Your vehicle is equipped with Rockwell/ WABCO anti-loc k brak es ( ABS) and the operation of the engine exhaust brake (if tur ned ON ) will be contr olled by the ABS. For more AB S inform ation, see

“

Anti-Lock Braking System (ABS)” on

page 65.

PB1340A .book Page 68 Friday, Sept ember 1, 2000 7:40 AM

Stopping Driving

– 69 –

Stopping

Parking

When the vehicle is parked on a grade, one or mo re of the followin g precau tions should also be taken:

• Chock the wheels at front and rear.

NOTE: Suitable wheel chocks are at a minimum an 18-inch (46 cm) long 4x4.

• Angle the front wheels so that the vehicle will not move into the traffic stream if it is accidentally set in motion.

Appl y the par king brake w ith th e park ing brake lever. Check that all th e windows and the roof vent are closed. Turn off the ignition and remove the key. Then lock all the doors of the vehicle.

Turning off the engine

WARNING! Do not remove the ignition key nor turn off the engine while the vehicle is in motion. Failure to observe t his p recau ti on c an result in steering lock engagement.

With the vehicle stationa ry, apply the parki ng brake and pla ce the sh ift lever in Neutral. Before stopping the eng ine, allow it to idle for one to two minutes. This will allow the following:

• An adequate oil supply to the turbocharger bearings while the turbocharger rotor assembly is cooling preventing the possibility of turbocharger bearing failure.

• Prevention of excessive engine coolant temperatures.

Turn the en gine of f by tur ning th e ignition key to the OFF position. Then remove the key.

PB1340A .book Page 69 Friday, Sept ember 1, 2000 7:40 AM

Diesel Fuel Drivin g

– 70 –

Diesel Fuel

Cold Weather Recommendations

When diesel fuel is subjected to low temperatures (below 21 °F or -6°C), paraffin wax par ticulates will form within the fuel which will eventually create blockages in the fuel system. To minimize the risk of f uel

‘waxing’,

it is rec ommended that the following precautions are observed:

• The use of winter grade fuel will give added pr otecti on to the fue l system during cold we ather conditions. Ensure that the vehicle is using winter grade fu el i n an ticip ation of cold weather conditions.

• In the event of the fuel waxing, it is recommended that a replacement fuel filte r is carried to enable a blocked filter to be replaced; wax particulates cannot be dissolved by the application of heat.

• For extreme and prolonged cold weather conditions, it is recommended that the vehicle be equipped with a h eated fuel filter and that all fuel pipes and fuel tanks are adequately insulated; refer to your dealer for further information.

PB1340A .book Page 70 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 71 –

PERIODICAL MAINTENANCE

General

The dur ability, safety, trade-in value, and relia bilit y of your veh icle larg ely depends on the care you give it. This includes regular servicing in accordance with the maintenance schedules specified here.

The drivin g style of the crew membe rs and how they care for the vehicle have a direct influence on the c ondition of the vehicle. The driver can frequently give the dealer information which is very important for correct maintenance.

The maintenance intervals stated in the Maintenance Sched ule are bas ed on the oil specifications stated in “

Recommended Lubrication Types” on page 86.

PB1340A .book Page 71 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 72 –

Maintenance and Lubrication Intervals

Table 1, ”Recommended Maintenance Intervals”, shows service intervals for

normal pick-up and delivery operations. For all other applications, se e your dealer for intervals.

NOTE: Different lubricants or service intervals than those listed below may be required.

Table 1 Recommended Maintenance Intervals

ITEM

MILEAGE INTERVAL (miles)

/TIME INTERVAL (Which-

ever Occu rs Fir st)

COMMENTS

Engine Lubricating Oil

-Check Fluid Level

See Engine Manufacturer’s Specifications and Recommendations

-Change Oil, Oil Filter Per Engine Manufact urer’s Specifications and Recommendations

Clutch Inspect an d Adjust Per Manufacturer’s Specifications

7500 / 3 mos

w/ Eaton SAS 1401 Clutch

Clutch Release Bearing 7500 / 3 mos Clutch Cross Shaft 7500 / 3 mos Drivelines:

City appli c at i on s #

7500 / 3 mos

Grease Yokes and Slip Splines if lubrication zerks are provided

On-Highway applications## 15,000 / 3 mos

Grease Yokes and Slip Splines if lubrication zerks are provided

PB1340A .book Page 72 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 73 –

HVAC Filter Inspect and Clean as necessary per this manual 7500 / 3 mos

Clean the filter regularly with low pressure air. See

page 37

Replace HVAC Filter Annually Inspec t Front Axle Fluid Level * 7500 / 3 mos Inspect Transmission Fluid Level *

7500 / 3 mos

Inspec t Flu id Le v el per Ma n ufacturer ’s Recomm en ded

Procedures Inspec t Rear Axle Fluid Level *

7500 / 3 mos

Inspec t Flu id Le v el per Ma n ufacturer ’s Recomm en ded

Procedures Inspect all Brake Components,

replace per Manufacturers Recommendations

7500 / 3 mos

Inspect Engine Air Filter

7500 / 3 mos

Have Filter Element Clea ned, as required via Restric-

tion Indicator, at a Certified PACC AR Dealership,

Replace Filter Element Annually Front and Rear Brake Camshafts 15,000 / 6 mos Front and Rear Brake Autoslack

Adjusters

15,000 / 6 mos

Front Axle Kingpins, Tie Rod Ends 15,000 / 6 mos Replace Pow er St ee ri ng F l ui d and

Filter

15,000 / 6 mos

T wice Yearly ( After Summer and Winter )

Steering Column Shaft U-joint 15,000 / 6 mos

Table 1 Recommended Maintenance Intervals

ITEM

MILEAGE INTERV AL (miles)

/TIME INTERVAL (Which-

ever Occu rs Firs t)

COMMENTS

PB1340A .book Page 73 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 74 –

Steering Shaft Telescopic Slide Surfaces

15,000 / 6 mos

Door Hinges, Latches, and Striker Plate

15,000 / 6 mos

Test Coolant for Freeze Point and Nitrite Levels with 2-Way Test Strip

15,000 / 6 mos

Maintain as Indicated by Test Strip Replace Coolant annually

Front Axle Fluid Replace * Perform at brake lining

replacement

Per Manufacturer’s Specif ications and Recommendations

Inspect and Adjust Per TMC RP618 Guidelines

-Front Wheel Bearings 30,000 / Annually

-Rear Wheel Bearings 30,000 / Annually Lock Cylinders 30,000 or As Required Door W eatherstrip 30,00 0 or As Requi red Transmission Fluid Replace * 250,000 / 3 yrs Rear Ax le Fluid Replace * 250,000 / 3 yrs # City applications are defined as all applications that require a minimum of 90% of operation time within c ity limits. ## On-Highway applications are defined as all applications requiring less than 10% of operating time on gravel, dirt or unpaved

roads. * Use only synthetic fluid Per Manufacturers Spec ifications and Recommendati ons

Table 1 Recommended Maintenance Intervals

ITEM

MILEAGE INTERVAL (miles)

/TIME INTERVAL (Which-

ever Occu rs Fir st)

COMMENTS

PB1340A .book Page 74 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 75 –

Maintenance Schedule

Use Table 2, ”Maintenance Schedule,” as a guide to pl an service work. B e sure and follow the frequency recommendations for you r vehicle. Als o refer to engine manufacturer’s maintenance guidelines.

TABLE KEY

NOTE: If a scheduled service interval is s haded, s kip to the next interval..

I Inspect and Service as required R Replace G2 Synthetic Lube Required

Table 2 Maintenance Schedule

INTERVAL COMMENTS

OPERAT ION \ FREQUENCY

7,500 m i

12 000 km

15,000 mi

24 000 km

30,000 mi

48 000 km

60,000 mi

96 000 km

INITIAL DRIVE–IN A B C D

Clutch Inspect and Adjust per mfr’s instructions I Glass for Cracks or Chips I Door Window Operation

Radio

Interior Lights

I Replace As Required

Interior Appearance / Condition: Check For Tears, Stains, Wear

Seats I

Floor Mats I

Door Panels I

Headliner I

Dash I

Covers I

PB1340A .book Page 75 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 76 –

Wiper Operation I Wiper Blade Condition I Replace As Required Horns (Electric and Air) - Operation I Mirrors - Cracks or Mounting I

SAFETY EQUIPMENT A B C D

Drain Water from Air Tanks I Air Tank Check Valve

Emergency Operation of Spring Brakes I

Air Press. Build–up time:

Governed Air Pressure:

Air Press. Drop–Brakes not Applied: ___

Air Press. Drop–Brakes Applied: ___

Fire Extinguisher Charge

Replace or Recharge Per Extinguisher Manufacturer Recommendation

Flare Kit / Reflectors

CIRCLE INSPECTION A B C D

Physical Damage:

Exterior Sheet Metal I

Grille and Radiator I

Air Lines I Headlights – High and Low Beams I Road Lights I Marker Lights I Turn Signals I Emergency Flasher I Brake Lights I Backup/Loading Lights I License Plates: Permits and Mounting I Mud Flaps / Serviceable I Fuel Tank Mounting I Check Fastener Torque And Condition Of Rubber Lining Exhaust System–Condition and Mounting Bolts I Leaks / Corrosion

Table 2 Maintenance Schedule

PB1340A .book Page 76 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 77 –

Frame F astener Torque: I Cab: Hold–down Latches

Mounts

Front Pivot Assembly

Jack Operation and Leaks

ENGINE SERVICE A B C D

Cooling: Test Coolant for Freeze Point and Nitrite Level w/2-way Test Strip

Maintain Coolant as Indicated by Test Strips Replace Coolant Annually

Coolant Level I

Coolant Protection:

_______ degrees

Pressu re Test

Check At Time Of Coolant Replacement

Hose Condition and Connections

I Leaks And Cracking

Radiator Mounting

I Check Rubber Bushings

Fan Shroud

I Check For Damage

Fan Assembly and Idler Pulley

I Check For Cracks, Chips; Check Belt Tensioner Bearing

Check Water Pump for Leaks / Play

Radiator – Exterior Condition

Air Cleaner:

Replace Annually / Air Cleaner Restriction: Replace If Restriction Indicator displays service required

Contaminant Accumulation

Check Every 7,500 Miles (12,000 km) In Dirty Conditions

Vacuator Val ve–Operation & Condition

Mounting Bolts and Clamps

Interference

I Power Steering Fluid and Filter– Replace R Service 2 Times Per Year (after summer and winter) Drive Belt Condition and Adjustment

I Per Engine Manufacturer’s recommendations

Air Conditioner Compressor Mounting

Cold Start Aids

I High Idle: ________ rpm

Emergency Shutdown

I Vibration Damper Condition

Table 2 Maintenance Schedule

PB1340A .book Page 77 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 78 –

Drain Water from Fuel System I Per Engine Manufacturer Requirements

Engine Oil – Change

Per Engine Manufacturer Requirements

Oil Filters – Replace

Per Engine Manufacturer Requirements

Fuel Filters – Replace

Cranking System:

Visual Inspect./Loose Connecti ons I

Alternator/Charging System:

Visual Inspection/Loos e Connecti ons I

UNDER VEHICLE A B C D

Steering Components – Condition: I

Steering Gear

Steering Shaft Splines and Joint(s) I

Pitman Arm

Drag Link

Steering Arms

Tie Rod Arms

Tie Rod Ends

Radius Rods / Torque Arms

Chassis Frame – Cracks or Breaks

Spring Shackles and Hanger Brackets

I Check For Cracks Check Fastener Torque Spring Pins I King Pin Wear I Per Manufacturer’s Specification

Steer Axle Wheel Bearing End Play Inspection

With LMS Outer Ends 350,000 Miles

• No Leak – No Service Front Hub Lubricant Level I Spring Leaves

U–Bolt and Suspension Fastener Torque

Tighten U-bolts after the first 500 miles (800 km). Rear suspension fasteners: retorque after first 2,000 miles (3218 km).

Table 2 Maintenance Schedule

PB1340A .book Page 78 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 79 –

Leaks:

Coolant I

Engine Oil I

Power Steering I

Fuel I

Tr ansmission I

Axles I

Inner and Outer Hub Seals I

Engine and Transmission Mounts

I Check Rubber Bushings for Cracks And Condition

Transmission Lubricant Level - Check

I Inspect Fluid Level per Manufacturer’s Recommended Procedures

Drivelines – U–joints and Slip Yokes - Check I Rear Axle Lubricant Level - Check I Inspect Fluid Level per Manufacturer’s Recommended Procedures Rear Axle Lubricant Replace

I Replace per “Recommended Maintenance Intervals” on page 72 Rear Axle Breathers – Clear I Inspect All Brake Component Condition

Brake Chamber Mounting Bolt Torque

I Brake Hoses for Cracks and Chafing I Clutch Pedal Shaft - Worn or Loose I Clutch Linkage - Worn or Loose I Clutch Adjust I Per manufacturer’s specifications Driveline Center Bearing I Automatic Slack Adjusters I

Table 2 Maintenance Schedule

PB1340A .book Page 79 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 80 –

Brakes: Lining Remaining (replace as required) I RF ______ RRF ______ RRR ______ LF ______ LRF ______ LRR ______ Drum Condition: I RF ______ RRF ______ RRR ______ LF ______ LRF ______ LRR ______

BATTERIES A B C D

Signs of Over–Charging I Check As Required Remove Corrosion and Seal Terminals

I Clean As Required

Hold-down and Box – Mounting Bolt Tight

Battery Cables - Chafing and Protective Coating

I (Color of charge indicator for each battery) 1 ______ 2 ______ 3 ______ 4 ______ I

Table 2 Maintenance Schedule

PB1340A .book Page 80 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 81 –

TIRES AND WHEELS A B C D

Missing Valve Caps and Stem Locks I Cracks or Loose Wheel lugs I Irregular Wear I Tire Pressure (Record below) I Remaining Tread (Record below) I Tires & Wheels Inspection I

Right

Left

Air Pressure Adjusted to: _____________ I

Table 2 Maintenance Schedule

PB1340A .book Page 81 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 82 –

ALIGNMENT A B C D

Toe–in: ______________ in (mm) I Caster: L ________ R ________

ROAD TEST A B C

Steering / Steering Play I Shifting

I Brakes

Engine Operation (noises, surging, black smoke)

I Seat Belts

I Seat Adjustment Operation

I Cab Heater

I Air Conditioner - Performance and Condition

I Instruments and Gauges: Speedometer/odometer I Tachometer

I Oil Pressure

I Engine Temperature

I Illumination

ABS Warning

Low Brake Pressure Warning Devices

Table 2 Maintenance Schedule

PB1340A .book Page 82 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 83 –

Lubrication Specifications

You will find a complete Engine Lubrication Service Guide in the

Engine Oper-

ation and Ma inten ance Manua l

. There, the engine manufacturer explains more fully all the maintenance operations y ou and a qualified se rvice m echanic will need. And please remember: one key to keeping your vehicle running at top performance and in prolonging its life is proper lubrication servicing. Neglecting this essential aspect of vehicle care can cost time and money in the long run.

Below you will fin d basic informa tion needed to perform routine vehicle lubrication. Of course you will want to schedule service more frequently if you are operating under severe conditions such as extreme heat or cold, with very heavy loads, rou gh roa ds, etc. For any special service requirements, consult your ser vice ma nuals a nd your lubricant supplier. The component man uf acturer’s specification and requirements take precedence over other specifications.

CAUTION: Handle lubricants carefully. Vehicle lubricants (oil and grease) can be poisonous and c ause s ickness. They can also damage the paint on the vehicle.

CAUTION: Do not mix different type s o f lu b rican t s. Mixing lubricants (oil and grease) of differ ent br ands or types could damage vehicle components; therefore, drain (or remove) old lubricants from the unit before refilling it.

• When switching between types of lubricants, thoroughly drain all areas of the component.

PB1340A .book Page 83 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 84 –

Lubrication Types

Use Table 4 on page 86 and the list of lubricants below to identify the type of lubricant to use on your vehicle.

BB: Ball Bearing grease CB: Engine oil for mild to moderate requirements CC/CD: Engine oil for severe requirements (MIL–L–2104B /MIL–L–

45199B w/ 1.85% max sulfated ash content)

CD: Engine oil meeting API “Five engine test sequence” CE: Engine oil mee ting s evere duty ser vice req uirement s for direct—

injection turbocharged engines.

CL: Multipu rpose chassis grease EP: Extreme Pressure lubricant GL: Straight mineral gear lubrican t, Gra de 2 HD: Synthetic SAE 75W90 HT: High Temperature grease (Timken Specification 0–616) SD: Engine oils with increased protection against temperature deposits,

rust, wear, and corrosion.

PS: Chevron Torque Fluid, Dexron III, or Mercon

NOTE: The re sponsibil ity for mee ting t hese spe cifications, the quality of the product, an d its performance in service rests with the lubricant supplier.

Table 3 Lubricant Applications

APPLICATION LUBRICANT

Universal Joints EP Drive Shaft Splines CL Wheel Bearings HD Steering Column CL Alternator Bearing BB* Fan Hub BB* Power Steering Reservoir PS Steering Drag Link CL Steering Knuckles CL Clutch Release Bearings BB Brake Shoe Anchor Pins HT Brake Cam Bearings HT Slack Adjusters CL Starter Bearings * CC Turbocharger Aneroid * CC Water Pump BB*

*Consult manufacturer or lubricant supplier for special details.

PB1340A .book Page 84 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 85 –

Oil Reservoirs

For oil reservoirs with side filler plugs (transmissions, rear axl es, transfer cases, etc.), the oil must be level with the filler opening.

NOTE: Use care when checking the o il level with a fing er.

Just because you can reach the oil le v el with a finger, does not mean the oil level is correct.

Lubrication Chart

The following l ubrication sp ecificat ion s (see Table 4 on page 86) are for an ambient operating tempera ture r ange of

–15 to 10 0°F (–26 to 38°C) . For extreme temperature operations, consult the comp onent manufact urer's manuals.

PB1340A .book Page 85 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 86 –

Table 4 Recommended Lubrication Types

COMPONENTS RECOMMENDED LUBRICANT

Power Steering Gear Chevron Torque Fluid C4, Dexron III, or Mercon Driveline U-Joints

Slip-Joint Splines Cab Pivots Clutch Pedal Shaft Other chassis grease fittings not covered below.

EP chassis grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2.

Wheel Bearing-Non Driving Axles OIL LUBRICATED: SAE 75W-90 synthetic oil Threaded Pins & Bushings (e.g., spring pins &

bushings)

EP grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2, with 3% molybdenum additive: Mobil Grease Special (Mobil), Molygrease EP (Chevron), or equal.

Suspension Fittings (other than threaded pins & bushings)

EP chassis grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2.

Steering Axle: Grease Fittings on Steering Arm; Tie Rod Ends; Drag Link; King Pins

EP chassis grease, lithium 12-hydroxystearate base, NLGI 2.

Clutch Release Bearing (remove inspection plate for access); Driveshaft Center Bearing

High temperature ball bearing grease. Chevron SRI Mobil Grease HP, Texaco Multifax 2, or equivalent.

Automatic Slack Adjusters; Wedge Brake Components; Disc Brake Caliper

High temperature EP grease; Texaco Thermotex EP-1, Shell Darina EP-1, Mobilith AW-1, Rockwell 0-616A, or equivalent.

Cam Brake Camshaft Splines; Disc Brake Shaft Splines and Slide Pin Retainers; Brake Clevis Pins

Antiseize type grease, Rockwell specification 0-637.

Deviations from the above list of lubricants should be based on specifications published in the component manufacturer’s manuals or otherwise approved by the manufacturer.

PB1340A .book Page 86 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 87 –

Brake Camshaft Bushings EP Chassis grease, lithium 12-hydroxystearate base, NLGI 2.

CAUTION: Do not contaminate brake linings with grease.

Steering Shaft Grease Fittings EP chassis grease, lithium 12-hydroxystearate base, NLGI 2. Brake Treadle Hinge and Roller Engine oil Lock Cylinders Lock lubricant. Door Hinges Not required — Teflon bushings

Door Latches & Striker Plates. Polyethylene grease stick. Door Weatherstrip Silicone lubricant. Other Items Use manufacturer’s manuals.

Table 4 Recommended Lubrication Types

COMPONENTS RECOMMENDED LUBRICANT

Deviations from the above list of lubricants should be based on specifications published in the component manufacturer's manuals or otherwise approved by the manufacturer.

PB1340A .book Page 87 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 88 –

Maintenance in Special and Exceptional Operating Conditions

When the vehicle is operated under exceptional conditions, it is important to consult your local dealer as it may be necessar y to change the servic e intervals to suit the ope rating cond itions. The service intervals can be adapted, as necessary, in consultation with the local dealer to suit the appropriate operating conditions.

First Service

The first service inspection should be carried out at 7500 miles (12,000 km) and no later than twelve weeks after the vehicle delivery date, whichever comes first.

Cab Ma intenance

In order to maintain the quality of the surface and paint finish during vehicle operation, regular maintenance must be carried out on t he exposed areas of the cab.

To prevent the formation of rust in b oxsection areas and other hollow areas, the cab is double galvanized and waxed during production.

Preventive Maintenance Before the Winter Season

Checking the Anti-freeze Content

WARNING! Before attempting t o ch eck t h e an ti- fr eez e ensure that the following safety instructions are observed:

– Do not attempt to remove

the surge tank filler cap while the engine is running or still hot.

– Do not fill/top off the cooling

system through the pressure cap aperture.

– Do not attempt t o fill/top off

a hot engine with cold coolant.

– Anti-freeze solutions con-

tain toxic chemicals which must not be consumed or allowed to come into skin contact. Use impervious protective clothing and gloves when handli ng antifr eez e . In the event of sl ight ski n contact, thoroughly rinse the affected area with water. If there i s exces si ve s kin co n tact, ingestion or inhalation seek medical advice immediately.

PB1340A .book Page 88 Friday, Sept ember 1, 2000 7:40 AM

General Periodical maintenance

– 89 –

NOTE: All new vehicles are

factory filled with a 50% anti-

freeze so lut ion w hich w ill g ive

frost pr otection dow n to - 34

(-36

C).

CAUTION: The use of anti-

freeze that does not conform

to the req uired s pecif ication

can cause severe damage to

the cooling system and its

components. The anti-free ze m ixt ure must rema in

in the cooling system during the summer months.

1. Remove the filler cap from the surge tank.

2. Using 2-way test strips, perform freeze point and nitrite level tests

per coolant supplier’s recommendations. Supply additives and coolant/water mixture as indicated.

CAUTION: Damage to the engine and cooling system, such a s co r rosio n a nd cav itation erosion, will occur unless an tifreeze ZEREX PENRAY 2792 is used and maintaine d wi th s upp lemen tal coolant additive Pencool 3000 with Stabil-Aid. As needed, fill or top off the cooling s ystem o nly with a ready-mixed clean water/ approved antifreeze solution using these product s. The use of other antifreeze products will void your engine, radiator, and cooling system warranties.

3. The cooling system should be filled with rea dy-mixed clea n water /anti freeze solut ion whic h conforms with the required specifications.

PB1340A .book Page 89 Friday, Sept ember 1, 2000 7:40 AM

Periodical maintenance

– 90 –

NOTES

PB1340A .book Page 90 Friday, Sept ember 1, 2000 7:40 AM

Emergency repairs

– 91 –

EMERGEN CY REPAIRS

Vehicl e Tool Ki t

All vehicles are equipped wi th an e xtension ha ndle for tiltin g the cab. It is

secured within the passenger’s

seat stowage compartment (twin seat) or, alternatively, secured behind the passenger’s seat (single seat).

Replacing The Drive Belt

IMPORTANT: Always inst all the correct replacement drive belt.

Refer to the engine manufacturer’s Operation and Maintenance Manual.

Drive belt tension

All engines a re equ ippe d with an au tomatic drive belt t ensioner and, the refore, cannot be manually adjusted. In the event of incorrect drive belt tension, consult your dealer at the earliest opportunity.

Replacing The Compressor Belt

(A/C and Compressor is optional)

IMPORTANT: Always install the correct replacement drive belt.

1. Disconnect the batteries, nega-

tive termi nal first, the n positive terminal

2. Fully tilt the cab.

3. Loosen the adjusting screw retainer bolt (1) , but do not remove.

4. Loosen the jam nut (3).

5. Loosen the tensioning bolt (4).

6. Pivot the compressor to slacken the belt.

7. Remove the compressor belt (5).

PB1340A .book Page 91 Friday, Sept ember 1, 2000 7:40 AM

Emergency repairs

– 92 –

8. Clean the pulleys and ensure that they are free of any contaminants (oil/fuel/dirt).

9. Install a new belt.

10. Pivot the compressor to tighten the belt and hold the tension by setting the adjustment screw. Torque the mount ing screw s to 17 to 23 lb. ft. (23 to 31 Nm).

11. Lower the cab and re-connect the batteries, positive terminal first.

Replacing The Fuel Filter

WARNING! Diesel fuel is flammable and must not be exposed to an open flame or other sources of h eat such as a hot engine. Collect the escaping fuel in a suitable container.

For deta iled infor mati on, refer to the

Engine Operation and Maintenance Manual

provided.

NOTE: Small amounts of air introduced into the fuel system when refitting the filter cartridge will be vented automat ically providing the filter cartridge has been filled with diesel fuel prior to installation.

Adjusting The Brakes

Adjustment of the brake shoes is fully automatic.

Spring Brakes — Manual Release

In order to tow a vehicle, if there is insufficient air to release the p arkin g brake, the spring bra kes can b e ma nually released.

WARNING! Never drive you r vehicle with the parking brake applied. Always release the parking brakes prior to moving the vehicle. Failure to di sengage the parking brakes prior to moving your vehicle could result in excessive heat build-up in the brake system, resulting in a fire.

NOTE: Today’s diesel electronic engines have significant torque and startability power at low RPM. Combinations of engine spee d and available torque may over-power the vehicle’s parking brakes.

NOTE: Suitable wheel chocks are at a minimum an 18-inch (46 cm) long 4x4.

PB1340A .book Page 92 Friday, Sept ember 1, 2000 7:40 AM

Peterbilt 270 Operator’s Manual Peterbilt 270 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual