Operator's Manual T170, T270, T370 - Ohio Department of … · · 2016-06-13Diesel engine exhaust and some ofitsconstituentsareknowntothe StateofCaliforniatocausecancer, birth defects,

Contents

Safety

Emergency

Controls

Driving

Maintenance

Information

Index

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2

3

4

5

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Contents

©2014 Paccar Inc - All Rights Reserved

This manual illustrates and describes the operation of features or equipment which may be either standard or optional onthis vehicle. This manual may also include a description of features and equipment which are no longer available or werenot ordered on this vehicle. Please disregard any illustrations or descriptions relating to features or equipment which arenot on this vehicle.

PACCAR reserves the right to discontinue, change specifications, or change the design of its vehicles at any time withoutnotice and without incurring any obligation.

The information contained in this manual is proprietary to PACCAR. Reproduction, in whole or in part, by any means is strictlyprohibited without prior written authorization from PACCAR Inc.

Truck Model Example

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SAFETY

INTRODUCTIONAbout this Manual. . . . . . . . . . . . . . . . 1-3Safety Alerts . . . . . . . . . . . . . . . . . . 1-3Vehicle Safety . . . . . . . . . . . . . . . . . 1-5Environmental Protection . . . . . . . . . . . . 1-6Data Recorder . . . . . . . . . . . . . . . . . 1-7Repairs . . . . . . . . . . . . . . . . . . . . 1-7Greenhouse Gas Certification . . . . . . . . . . 1-8Additional Sources of Information . . . . . . . . . 1-9

CAB AND FRAME ACCESSSafety . . . . . . . . . . . . . . . . . . . . 1-10Door Lock and Keys . . . . . . . . . . . . . 1-11Remote Keyless Entry (Option) . . . . . . . . . 1-12

GETTING TO YOUR ENGINEHood Hold Downs. . . . . . . . . . . . . . . 1-15Hood Tilt . . . . . . . . . . . . . . . . . . . 1-15Hood Safety Lock . . . . . . . . . . . . . . . 1-16

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SAFETY

SEATS AND RESTRAINTSIntroduction . . . . . . . . . . . . . . . . . 1-18Safety Restraint Belts . . . . . . . . . . . . . 1-19Tether Belts . . . . . . . . . . . . . . . . . 1-22Komfort-Latch® Feature . . . . . . . . . . . . 1-24During Pregnancy. . . . . . . . . . . . . . . 1-25Belt Damage and Repair . . . . . . . . . . . . 1-25Safety Restraint Tips . . . . . . . . . . . . . 1-26

START-UPIntroduction . . . . . . . . . . . . . . . . . 1-28Safe Vehicle Operation . . . . . . . . . . . . 1-28Service Application / Road Type for VehiclesEquipped with 8,000 lb. or 10,000 lb. Front Axles 1-29

Vehicle Loading. . . . . . . . . . . . . . . . 1-31Emergency Equipment . . . . . . . . . . . . 1-32Driver's Check List . . . . . . . . . . . . . . 1-32

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INTRODUCTION

INTRODUCTION

About this Manual

Congratulations! Your selection of aKenworth truck was a wise investment.Kenworth trucks are recognized asthe industry standard for quality andreliability.

Please take the time to get acquaintedwith your vehicle by reading thisOperator’s Manual. We recommendthat you read and understand thismanual from beginning to end beforeyou operate your truck. This manualexplains the safe, efficient operationand maintenance of your Kenworth.

NOTEAfter you’ve read this manual, itshould be stored in the cab for con-venient reference and remain withthis truck when sold.

Your Kenworth may not have all thefeatures or options mentioned in thismanual. Therefore, you should paycareful attention to the instructions thatpertain to just your vehicle. In addition,if your vehicle is equipped with specialequipment or options not discussed inthis manual, consult your dealer or themanufacturer of the equipment.

All information contained in thismanual is based on the latestproduction information available at thetime of publication. Kenworth TruckCompany reserves the right to makechanges at any time without notice.

Safety Alerts

Please read and follow all of thesafety alerts contained in this manual.They are there for your protectionand information. These alerts canhelp you avoid injury to yourself, yourpassengers, and help prevent costlydamage to the vehicle. Safety alertsare highlighted by safety alert symbolsand signal words such as "WARNING","CAUTION", or "NOTE". Please do notignore any of these alerts.

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INTRODUCTION

WARNING

WARNING!

The safety message following thissymbol and signal word provides awarning against operating procedureswhich could cause injury or even death.They could also cause equipment orproperty damage. The alert will identifythe hazard, how to avoid it, and theprobable consequence of not avoidingthe hazard.

Example:

WARNING!

Do not attempt repair work withoutsufficient training, service manuals,and the proper tools. You could bekilled or injured, or you could makeyour vehicle unsafe. Do only thosetasks you are fully qualified to do.

CAUTION

CAUTION

The safety alert following this symboland signal word provides a cautionagainst operating procedures whichcould cause equipment or propertydamage. The alert will identify thehazard, how to avoid it, and theprobable consequence of not avoidingthe hazard.

Example:

CAUTION

Continuing to operate your vehi-cle with insufficient oil pressure willcause serious engine damage. Fail-ure to comply may result in equip-ment or property damage.

NOTE

NOTE

The alert following this symbol andsignal word provides importantinformation that is not safety relatedbut should be followed. The alertwill highlight things that may not beobvious and is useful to your efficientoperation of the vehicle.

Example:

NOTEPumping the accelerator will not as-sist in starting the engine.

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INTRODUCTION

Vehicle Safety

WARNING!

Do not drive after drinking alcohol orusing other substances that may af-fect the senses, including prescrip-tion medications. Your reflexes, per-ceptions, and judgment can be af-fected by even a small amount of al-cohol or other substances, and cancause a serious or even fatal acci-dent. Failure to comply may result indeath, personal injury, or equipmentand property damage.

WARNING!

Do not text while driving. Your re-flexes, perceptions, and judgmentcan be affected while texting orusing any other form of mobile mes-saging while driving. Failure to com-ply may result in death, personalinjury, or equipment and propertydamage.

Make sure your Kenworth is in topworking condition before headingout on the road, it is the responsibledriver's duty to do so. Inspect thevehicle according to the Driver's CheckList beginning on page 1-32.

Every new Kenworth vehicle isdesigned to conform to all FederalMotor Vehicle Safety Standardsapplicable at the time of manufacture.Even with these safety features,continued safe and reliable operationdepends greatly upon regular vehiclemaintenance. Follow the maintenancerecommendations found in PreventiveMaintenance on page 5-9. This willhelp preserve your investment.

Keep in mind that even a wellmaintained vehicle must be operatedwithin the range of its mechanicalcapabilities and the limits of its loadratings. See the Tire and Rim WeightRatings label on the driver's door edge.

Safe driving is only possible with theproper concentration on the drivingtask. Keep distraction to a minimum toimprove your concentration. Examplesof distractions may include radiocontrols, GPS navigation controls,cellular telephone calls, cellular textmessages, reading or reaching forsomething on the floor. Minimizingyour distractions will improve safedriving and will help avoid an accidentinvolving death or personal injury.

Be aware of local regulations that mayprohibit the use of cellular telephoneswhile driving. In addition to being anunsafe practice, it may be against localor federal ordinances to use cellulardevices while operating the vehicle.

This manual is not a training manual.It cannot tell you everything you needto know about driving your Kenworthvehicle. For that you need a goodtraining program or truck driving

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INTRODUCTION

school. If you have not been trained,get the proper training before youdrive. Only qualified drivers shoulddrive this vehicle.

Environmental Protection

WARNING!

Diesel engine exhaust and someof its constituents are known to theState of California to cause cancer,birth defects, and other reproduc-tive harm. Other chemicals in thisvehicle are also known to the Stateof California to cause cancer, birthdefects or other reproductive harm.This warning requirement is man-dated by California law (Proposition65) and does not result from anychange in the manner in which vehi-cles are manufactured.

Some of the ingredients in engineoil, hydraulic oil, transmission andaxle oil, engine coolant, diesel fuel,air conditioning refrigerant (R-134aand PAG oil), batteries, etc., maycontaminate the environment ifspilled or not disposed of properly.Non-compliance with environmental

regulations can result in fines and/or jailterms. Contact your local governmentagency for information concerningproper disposal.

California Proposition 65 Warning

• Diesel engine exhaust and someof its constituents are known tothe State of California to causecancer, birth defects, and otherreproductive harm.

• Other chemicals in this vehicleare also known to the State ofCalifornia to cause cancer, birthdefects or other reproductiveharm.

• Battery posts, terminals, andrelated accessories contain leadand lead compounds, chemicalsknown to the State of Californiato cause cancer and reproductiveharm. Wash hands after handling.

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INTRODUCTION

Data Recorder

California Vehicle Code - Section9951- Disclosure of Recording Device

Your vehicle may be equipped with oneor more recording devices commonlyreferred to as “event data recorders(EDR)” or “sensing and diagnosticmodules (SDM)”. If you are involved inan accident, the device(s) may havethe ability to record vehicle data thatoccurred just prior to and/or during theaccident. For additional information onyour rights associated with the use ofthis data, contact

• the California Department of MotorVehicles - Licensing OperationsDivision– or –

• www.dmv.ca.gov

Repairs

WARNING!

Do not attempt repair work withoutsufficient training, service manuals,and the proper tools. You couldmake your vehicle unsafe. Do onlythose tasks you are fully qualified todo. Failure to comply may result inpersonal injury, death, or equipmentand property damage.

WARNING!

Modifying your vehicle can makeit unsafe. Some modifications canaffect your vehicle's electrical sys-tem, stability, or other importantfunctions. Before modifying yourvehicle, check with your dealer tomake sure it can be done safely.Improper modifications may result indeath, personal injury, or equipmentand property damage.

Your dealer’s service center is the bestplace to have your vehicle repaired.You can find dealers all over thecountry with the equipment and trainedpersonnel to get you back on the roadquickly—and keep you there.

Your vehicle is a complex machine.Anyone attempting repairs on it needsgood mechanical training and theproper tools. However, all warrantyrepairs must be performed by anauthorized service facility. If you aren’tan experienced mechanic, or don’thave the right equipment, pleaseleave all repairs to an authorizedservice facility. They are the onesbest equipped to do the job safely andcorrectly.

To find a dealer near you, give us acall toll-FREE at 1-800-KW-ASSIST(1-800-592-7747) 24-7-365 daysa year or visit us online atwww.kenworth.com and click on

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INTRODUCTION

the "dealers" link. When it comestime for service work, your KenworthDealer will need your VehicleIdentification Number (VIN), seeVehicle Identification on page 6-4.

Maintenance Manuals

If you do decide to do anycomplex repair work, you’ll needthe maintenance manuals. Order themfrom your authorized dealer. Pleaseprovide your Chassis Serial Numberwhen you order, to be sure you get thecorrect manuals for your vehicle. Allowabout four weeks for delivery. Therewill be a charge for these manuals.

Final Chassis Bill of Material

A complete, non-illustrated computerprintout listing of the parts used tocustom-build your vehicle is availablethrough the dealer from whom youpurchased your vehicle.

Greenhouse GasCertification

This vehicle may be equipped withcomponents that are identified asGreenhouse Gas Certified components(GHG). A label on the door is printedwith codes that identify the componentsmanufactured on the vehicle that arepart of the GHG certification. Thecodes are translated in the followingtable:

EmissionControlIdentifier

Emissions RelatedComponents

VSL, VSLS,VSLE, or VSLD

Engine Softwareparameters that affectthe Vehicle Speed Limiter

IRT5, IRTE Engine softwareparameters that affect theautomatic engine shutdowntimer

ATS Aerodynamic side skirtsand/or fuel tank fairings

ARF Aerodynamic roof fairingARFR Adjustable height

aerodynamic roof fairingTGR Gap reducing fairing (tractor

to trailer)LRRA, LRRD,or LRRS

Greenhouse Gas (GHG)Tires

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INTRODUCTION

Additional Sources ofInformationInstalled Equipment - Operator'sManuals

Major component suppliers toKenworth also supply operationmanuals specific to their products.Additional manuals and other piecesof literature are included in the glovebox literature package. Look forinformation on products such as theengine, driver's seat, transmission,axles, wheels, tires, ABS/ESP (ifapplicable) and radio. If you aremissing these pieces of literature, askyour Kenworth Dealer for copies.

Other Sources

Another place to learn more abouttrucking is from local truck drivingschools. Contact one near you to learnabout courses they offer.

Federal and state agencies suchas the department of licensing alsohave information. The InterstateCommerce Commission can giveyou information about regulationsgoverning transportation across statelines.

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CAB AND FRAME ACCESS

CAB AND FRAMEACCESS

Safety

The following cab and frame entry/exitprocedure recommendations wereprepared with personal safety foremostin mind.

WARNING!

Do not jump out of the cab or get intothe cab without proper caution. Youcould slip or fall, possibly sufferingdeath or personal injury. You couldslip and fall if the steps are wet or icy,or if you step in fuel, oil, or grease.

To help avoid personal injury due toa slip or fall:

• Always face the vehicle whenaccessing or leaving the cab orframe access area.

• Use three points of contact(two feet one hand or one foottwo hands) to grip the steps orhandholds whenever possible andlook where you are going.

• Use even more care when stepsand handholds (or footwear) arewet, coated with ice, snow, mud,oil, fuel, or grease.

WARNING!

Do not step on vehicle componentswithout anti-skid surfaces or usecomponents not designed for en-try-and-exit use. You could fall andinjure or kill yourself if you step ontoa slippery surface.

• Do not step onto the surface ofa fuel tank. A fuel tank is not astep. The tank surface can getvery slippery, and you might not beable to prevent a fall. Use only the

steps and handholds provided, notchain hooks, quarter fenders, etc.

• Keep steps clean. Clean any fuel,oil, or grease off the steps beforeentering the cab.

WARNING!

Always reinstall the battery compart-ment cover (step) before enteringthe cab. Without the battery coverin place, you could slip and fall, re-sulting in possible injury to yourself.

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Door Lock and Keys

Doors can be locked from the inside byusing the lock button. Close the doorthen push the button down to lock.Doors automatically unlock when youopen them from inside, and can belocked from the outside with the keyonly.

As standard equipment, two keys areprovided for the doors and ignition.When necessary, additional locksand keys are provided for storagecompartments.

WARNING!

To lessen the chance and/or severityof personal injury in case of an ac-cident, always lock the doors whiledriving. Along with using the lap/shoulder belts properly, locking thedoors helps prevent occupants frombeing thrown from the vehicle. Fail-ure to comply may result in death orpersonal injury.

To lock or unlock the doors fromoutside the cab:

• Insert the key in the door lock.

• Turn the key toward the rear doorframe to lock; forward to unlock.

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Remote Keyless Entry(Option)

This vehicle may be equipped with aRemote Keyless Entry (RKE) systemthat adds security and convenience toyour Kenworth truck. The system willlock or unlock the driver's door andpassenger's door with the key fob andalert you with parking lights when theselected doors are locked or unlocked.The system includes two key fobs thatprovide secure rolling code technologythat prevents someone from recordingthe entry signal.

FCC ID: L2C0031T IC: 3432A-0031T

FCC ID: L2C0032R IC: 3432A-0032R

This device complies with Part 15 ofthe FCC Rules and with RSS-210 ofIndustry Canada. Operation is subjectto the following two conditions:

1. This device may not cause harmfulinterference.

2. This device must accept anyinterference received, includinginterference that may causeundesired operation.

NOTEChanges or modifications not ex-pressively approved by the partyresponsible for compliance couldvoid the user's authority to operatethe equipment. The term “IC:” be-fore the radio certification numberonly signifies that Industry Canadatechnical specifications were met.

OperationTo Unlock the Driver's Door

Press the UNLOCK button once. Thedriver's door will unlock and the parkinglights will come on for 40 seconds.

To Unlock the Passenger's Door

Press the UNLOCK button once andpress again within 5 seconds. Thepassenger door will unlock.

To Lock Both Doors

Press the LOCK button. The doors willlock and the parking lights will comeon for 2 seconds. If the doors are openthey will not lock.

NOTEIf this system is retrofit on vehiclesbuilt before March 2002, doors maylock when open.

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The range of the RKE system shouldbe approximately 30 feet. This willbe reduced if it is operated close toother RF sources such as TV/radiotransmitters and cell towers.

Batteries

The key fob uses one CR2032,3V battery. Batteries should lastapproximately three years, dependingon use. Consistently reduced rangeis an indicator that the battery needsreplacement. Batteries are availableat most discount, hardware and drugstores.

To Replace the Battery

1. Remove rear cover from key fob.

2. Remove the battery.

3. Install new battery.

4. Reinstall cover.

5. Synchronize the key fob.

Synchronization

The key fob may need to besynchronized to the vehicle when thebattery is replaced, or when the keyfob has not been used for an extendedperiod time.

To Synchronize a Key Fob

1. Hold the key fob near the centergauge area (middle of theinstrument panel).

2. Press either the lock or unlockbutton twice within 2 seconds.

° When the key fob isresynchronized, the doorswill lock or unlock.

° If the fob fails to synchronize,it could be programmed to adifferent vehicle or could havefailed.

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See Remote Keyless EntryTroubleshooting on page 5-77,for more information.

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GETTING TO YOUR ENGINE

GETTING TO YOURENGINE

Hood Hold Downs

The hood is locked in position by twoexternal latches. These latches serveas hold downs and keep the hood fromopening unexpectedly.

To open the hood:

A.Unlatch the hood hold downs (oneon each side of the hood)

1. Hood Latch: pull out torelease

CAUTION

If you do not latch your hood se-curely, it could open during opera-tion and cause vehicle damage. Besure to latch the hood securely.

Hood Tilt

B. Put one hand on the KW emblem,one foot on the bumper, and one footon the ground. Tilt the hood forward.Cables attached to the hood will hold

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the hood in its proper forward (open)position.

WARNING!

A hood could hurt someone in theway of its descent. Before loweringthe hood, be sure there are no peo-ple or objects in the way.

Hood Safety Lock

After opening the hood, check to seethat the hood is locked open. TheHood Safety Lock is mounted on thehood hinge, underneath the hood onthe right side. It locks the hood in theupright position, preventing the hoodfrom closing.

If the Hood Safety Lock malfunctions,have it repaired by an AuthorizedService Center or Kenworth Dealer.

To close the hood, you must firstrelease the Lock.

WARNING!

If the hood falls, anyone under itcould be injured. Always lock thehood in its open position any timeanyone gets under the hood for anyreason.

• Never work under the hood unlessthe hood is securely locked.

• The hood could hurt someone thatis in the way of its descent. Beforelowering the hood, be sure noobjects or people are in the way.

WARNING!

If the hood is not latched securely,it could open during operation andcause an accident. Be sure the hoodis latched securely before movingthe vehicle.

Hood in open position with lock locked

1 Hood Safety Lock2 Release Tab3 Hood Hinge

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Hood in open position with lockreleased ready to close

1 Hood Safety Lock2 Release Tab3 Hood Hinge

• To release hood safety lock, liftrelease tab until lock pivots to thereleased position.The hood can now be lowered andlatched into place.See Hood Safety Lock on page5-59, for maintenance.

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SEATS AND RESTRAINTS

SEATS ANDRESTRAINTS

Introduction

This section covers the operationand safe use of your Kenworth seats.For further information on featuresand adjustment of the seat, see themanufacturer's Service and OperationManual included with the vehicle.

Seat Adjustment

WARNING!

Do not adjust the driver's seat whilethe vehicle is moving. The seatcould move suddenly and unexpect-edly and can cause the driver tolose control of the vehicle. Make alladjustments to the seat while thevehicle is stopped. After adjustingthe seat and before driving off, al-ways check to ensure that the seatis firmly latched in position. Failureto comply may result in death, per-sonal injury, equipment or propertydamage.

NOTEAfter adjusting the seat and beforedriving off, always check to ensurethat the seat is firmly latched in po-sition.

Standard Driver's Seat

The standard driver's seat can beadjusted forward and rearward as wellas up and down. The seat back anglecan also be adjusted. These threemovements are each controlled bylevers located either beneath or at thesides of the seat.

Driver's Seat with Air Suspension

WARNING!

Before driving or riding in vehi-cle, ensure that there is adequatehead clearance at maximum upwardtravel of seat. Injury may occur ifhead clearance is not adequate.Failure to comply may result in per-sonal injury or death.

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Reclining Seats

• Make sure the sleeper curtain istied back.

• Raise the seat all the way upso that the seat will tilt back andcompletely clear objects behindyou.

WARNING!

Do not drive or ride with your seatback in the reclined position. Youcould be injured by sliding under theseat belts in a collision. Failure tocomply may result in personal injuryor death.

Safety Restraint Belts

Safety belts have proven to bethe single most effective meansavailable for reducing the potentialfor either injury or death in motorvehicle accidents. Therefore, readthe following instructions and alwaysobserve user warnings pertaining tosafety belts.

WARNING!

Do not drive vehicle without yourseat belt and your riders belts fas-tened. Unbelted riders could bethrown into the windshield or otherparts of the cab or could be thrownout of the cab. Injuries can be muchworse when riders are unbelted. Al-ways fasten your seat belt and besure anyone riding with you doesthe same. Failure to comply mayresult in personal injury or death.

Unbelted Person in Crash

Your vehicle may be equippedwith a seat belt indicator in thewarning light display above thespeedometer/tachometer (“Seat Belt,Fasten” “Seat Belt, Fasten” on page3-41). It will turn on if the seat belt isnot fastened and the ignition key isturned on.

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Lap/Shoulder Belt

The combination lap-shoulder belt isequipped with a locking mechanism.The system adjusts automatically to aperson's size and movements as longas the pull on the belt is slow.

Hard braking or a collision locks thebelt. The belt will also lock whendriving up or down a steep hill or in asharp curve.

To fasten the belt:

1. Grasp the belt tongue.

2. Pull belt in a continuous slowmotion across your chest and lap.

3. Insert belt tongue into buckle oninboard side of seat.

4. Push down until the tongue issecurely locked with an audibleclick. Pull belt to check for properfastening.

° Pull shoulder section to makesure belt fits snugly across thechest.

° The shoulder belt must bepositioned over the shoulder,it must never rest against theneck.

° Belts should fit snugly acrossthe pelvis and chest.Make sure any slack is woundup on the retractor.

To unfasten the belt:

• Push in the release button on thebuckle. The belt will spring out ofthe buckle.

• To release a locked belt, lean backto take the body pressure off ofthe belt.

• To store a lap-shoulder belt, allowthe belt to wind up on the retractorby guiding the belt tongue until thebelt comes to a stop.

Proper Safety Belt Adjustment

Your combination lap-shoulder beltmay need adjustment. Adjust safetybelts properly.

• The lap belt should be worn as lowand tight on the hips as possible.Make sure any slack is taken upby the belt mechanism.

• The shoulder belt should fit snuglyacross your body. It shouldbe positioned midway over theshoulder (that is next to the door);it should never rest against yourneck.

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Safety Restraint Belts

Lap Belt Shoulder Belt

Correct Incorrect (too high on hips) Correct (over arm) Incorrect (under arm) Incorrect (twisted)

• Be sure, also, that your belt is nottoo loose. A loose belt could allowyou to slide under it in an accident,and that could bring the belt uparound your abdomen.

• Ensure that you do not twist thebelt in the process of putting it on.A twisted belt will not work as wellto protect you.

WARNING!

Proper seat belt adjustment and useis important to maximize occupantsafety. Failure to wear or adjustthe safety belt properly may result indeath or personal injury.

• You can be injured if yourbelt is buckled too high. Ina crash, it would apply forceto your abdomen, not yourpelvic bones. This can result ininternal injuries.

• Do not drive with your seat beltloose. A too-loose seat belt can

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allow you to fall too far forward,possibly causing head and neckinjuries. You could strike thewheel or the windshield. Adjustyour belt so that there is nomore than 1 in. (25mm) of slack.

WARNING!

Do not wear the shoulder part ofbelt under your arm or otherwise outof position. In a crash your bodywould move too far forward, increas-ing the chance of head and neck in-jury. Also, the belt would apply toomuch force to the ribs, which are notas strong as your shoulder bones,and could cause you to suffer inter-nal injuries. Wear the shoulder beltover your shoulder (see Safety Re-straint Belts on page 1-21). Failureto comply may result in personal in-jury or death.

WARNING!

Do not twist the belt in the processof putting it on. A twisted belt willnot work as well to protect you. In acrash, the full width of the belt wouldnot be protecting you. A twisted beltcould cut into your body and causeinjuries. Straighten the belt beforebuckling it. If you are unable to wearit without twisting it, have your dealeror service person repair it as soonas possible. Failure to comply mayresult in personal injury or death.

Tether Belts

Tether belts are installed on suspensionseats. They help secure the seat to thefloor to restrain it in case of a suddenstop or an accident.

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Fixed Tethers

If your Kenworth has been equippedwith fixed length tethers, no manualadjustment is required. The sameinspection and replacement guidelinesshould be used as stated in SafetyRestraint System - Inspection on page5-55.

WARNING!

Do not remove, modify, or replacethe tether belt system with a differ-ent tether system. A failed or miss-ing tether belt could allow the seatbase to fully extend in the event ofan accident. Failure to comply mayresult in death or personal injury.

WARNING!

Failure to adjust tether belts properlycan cause excessive movement ofthe seat in an accident. Tether beltsshould be adjusted so that they aretaut when the seat is in its most up-ward and forward position. Failureto comply may result in death or per-sonal injury.

WARNING!

Before driving or riding in a vehi-cle, ensure that there is adequatehead clearance at maximum upwardtravel of seat. Shorten the tether beltas necessary to provide adequatehead clearance. Injury or death mayoccur if head clearance is not ade-quate.

Tether Adjustment

• Make sure that the tether belt isattached to the cab floor and seatframe. It should be routed throughthe buckle on each side.

• Often the attachments are madeusing a split-type hook. Make sureboth halves of the hook are aroundthe anchor bracket.

• To lengthen the tether, turn thebuckle to a right angle to thewebbing. Then pull the buckle.To shorten the tether, pull on thestrap.

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Komfort-Latch® Feature

Your vehicle includes a featuredesigned to eliminate cinching andprovide improved safety and comfort.Cinching is the condition where a beltbecomes continually tighter aroundyou during a rough, bouncy ride. Theneed for this feature increases withrough road conditions, particularly overlong distances.

To eliminate cinching, simply activatethe Komfort-Latch feature locatedon the seat belt webbing at theappropriate time:

1. Adjust the seat to its proper drivingposition.

2. Latch the seat belt.

3. If available, adjust the seat beltheight adjuster to a comfortabledriving position.

4. While seated appropriately, pushthe "on" button to engage theKomfort Latch.

5. Learn forward in the seat until youhear a "click."

6. Return to normal driving position,and the Komfort Latch maintainsthe preset amount of tension relief.

To disengage the mechanism:

1. Unbuckle the seat belt

2. Press the “OFF” button of theKomfort Latch or tug on theshoulder strap.

WARNING!

Do not set the Komfort Latch with toomuch slack. Too much slack mayreduce the effectiveness of the seatbelt. Failure to comply may result indeath or personal injury.

Komfort-Latch®

More information and videotutorials can be found at:www.clicktugsnug.com

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During Pregnancy

Pregnant women should always wearcombination lap/shoulder belts. Thelap belt portion must be worn snuglyand as low as possible across thepelvis. To avoid pressure on theabdomen, the belt must never passover the waist. Sometimes pregnantwomen worry that in a crash the seatbelt could hurt the baby. But if awoman wears her belt properly, lowover her pelvis, below her abdomen,the belt will not harm the baby, even ina crash. And remember, the best wayto keep an unborn baby safe is to keepthe mother safe.

Pregnant Woman with Belt ProperlyWorn

Belt Damage and Repair

Damaged belts in the cab mustbe replaced. Belts that have beenstretched, cut, or worn out may notprotect you in an accident.

If any seat belt is not working properly,see an Authorized Service Center forrepair or replacement.

For further information on seat beltsand seat belt maintenance, see SafetyRestraint System - Inspection on page5-55.

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Safety Restraint Tips• Anyone riding in your vehicle

should wear a seat belt. Aresponsible operator sees to itthat everyone in the vehicle ridessafely and that means with a seatbelt.

• Do not wear a belt over rigid orbreakable objects in or on yourclothing, such as eye glasses,pens, keys, etc., as these maycause injury in an accident.

• Several layers of heavy clothingmay interfere with properpositioning of belts and reducethe overall effectiveness of thesystem.

• Any authorized person sleepingin your vehicle while it is movingshould use the bunk restraint.

• Any authorized person sitting inthe sleeper area on the sofa bed

(if equipped) while it is movingshould wear a seat belt.

• A responsible operator sees to itthat everyone in the vehicle ridesor sleeps safely. The operatoris responsible to inform anypassengers or co-drivers how toproperly use the seat belts andbunk restraint in the vehicle.

• Do not strap in more than oneperson with each belt.

• Keep seat belt and bunk restraintbuckles free of any obstructionthat may prevent secure locking.

• Damaged or worn belts in the cabor sleeper, subjected to excessivestretch forces from normal wear,must be replaced. They maynot protect you if you have anaccident.

• Any belts or restraints that havebeen subjected to an accident

should be inspected for any loose(attaching) hardware or damagedbuckles.

• If belts show damage to any partof assembly, such as webbing,bindings, buckles or retractors,they must be replaced.

• Do not allow safety belts (seator bunk) to become damaged bygetting caught in door, bunk orseat hardware, or rubbing againstsharp objects.

• All belts must be kept clean or theretractors may not work properly.

• Never bleach or dye seat or bunkrestraint belts: chemicals canweaken them. Do, however, keepthem clean by following the carelabel on the belts. Let them drycompletely before allowing themto retract or be stowed away.

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• Make sure the seat belts andbunk restraint of the unoccupiedpassenger seat or bunk is fullywound up on its retractor oris stowed, so that the belt orrestraint tongue is in its properlystowed position. This reduces thepossibility of the tongue becominga striking object in case of asudden stop.

• Do not modify or disassemble theseat belts or bunk restraint in yourvehicle. They will not be availableto keep you and your passengerssafe.

• If any seat belt or bunk restraintis not working properly, see anauthorized dealer for repair orreplacement.

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START-UP

START-UP

Introduction

The following section covers start-upprocedures for getting your Kenworthready for the road.

Safe Vehicle Operation

For your safety, as well as thosearound you, be a responsible driver:

• If you drink, do not drive.

• Do not drive if you are tired, ill, orunder emotional stress.

Much has gone into the manufacturingof your Kenworth, including advancedengineering techniques, rigid qualitycontrol, and demanding inspections.These manufacturing processes willbe enhanced by you, the safe driver,who observes the following:

• knows and understands how tooperate the vehicle and all itscontrols

• maintains the vehicle properly

• uses driving skills wisely

For more information, refer toDepartment of TransportationRegulation 392.7, which states thatinterstate commercial motor vehiclesare not to be driven unless the driver issure that certain parts and accessoriesare in working order.

WARNING!

Do not drive after drinking alcohol orusing other substances that may af-fect the senses, including prescrip-tion medications. Your reflexes, per-ceptions, and judgment can be af-fected by even a small amount of al-cohol or other substances, and cancause a serious or even fatal acci-dent. Failure to comply may result indeath, personal injury, or equipmentand property damage.

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START-UP

WARNING!

The use of alcohol, drugs, and cer-tain medications will seriously im-pair perception, reactions, and driv-ing ability. These circumstances cansubstantially increase the risk of anaccident. Failure to comply may re-sult in death, personal injury, equip-ment or property damage.

WARNING!

Do not text while driving. Your re-flexes, perceptions, and judgmentcan be affected while texting orusing any other form of mobile mes-saging while driving. Failure to com-ply may result in death, personalinjury, or equipment and propertydamage.

Service Application / RoadType for Vehicles Equippedwith 8,000 lb. or 10,000 lb.Front Axles

This vehicle may be equipped withan 8,000 lb. or 10,000 lb. capacityfront axle and front brakes containingstamped steel spiders. The rearbrakes may contain stamped spiders.Due to this combination of axle andbrakes, this vehicle cannot be operatedin certain service applications or roadtypes/classes. Read the informationbelow before operating your vehicle.

WARNING!

This vehicle was only designed tobe operated in limited service appli-cations and road types. Read thefollowing list of unapproved serviceapplications and road types belowbefore placing your vehicle into ser-vice. Operating your vehicle in anunapproved service application orroad type could result in an unsafevehicle which may lead to personalinjury or equipment damage.

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START-UP

Service and Road Types

• Do NOT place vehicle intorefuse packer/compactor serviceapplications. Any other serviceapplication is acceptable so longas they do not operate in a ClassC or Class D road classification asdefined below.

• Do NOT operate vehicle on anyClass C or Class D road types:

° Class C Well-maintainedgravel roads or poorlymaintained urban roadconditions. Typical Class Croad types are maintainedgravel roads, brokenconcrete/asphalt roads,maintained logging or haulroads or farm roads.

° Class D Off-road conditions,poorly maintained gravel, dirtor farm roads, farm fields, orextended operation on gradesover 15%.

This vehicle is approved for use on anyprimary (Class A) or secondary (ClassB) type road services. The road typesor classes are defined below.

• Primary / ClassA Well-maintained pavedroad surfaces of concrete orasphalt where vehicle can beaccelerated to and operatedat speed for extended periodsof time. Grades encounteredare 6% or less. Typical ClassA operating conditions wouldbe U.S./Canadian interstate orcontrolled access Federal or statehighways.

• Secondary / ClassB Well-maintained pavedroad surfaces of concrete orasphalt with some grades over6%, frequent stop-start cycle, orin urban/ suburban conditions.Typical Class B operation wouldbe state or county secondaryhighways, urban pickup anddelivery and mountain highways.

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START-UP

Vehicle Loading

Compare your vehicle's load capacitywith the total load you are carrying. Ifadjustments need to be made, makethem, do not drive an overloadedvehicle. If you are overloaded or yourload has shifted, your vehicle may beunsafe to drive.

WARNING!

Do not exceed the specified load rat-ing. Overloading can result in lossof vehicle control, either by causingcomponent failures or by affectingvehicle handling. Exceeding loadratings can also shorten the servicelife of the vehicle. Failure to complymay result in death or personal in-jury.

• The components of yourvehicle are designed to providesatisfactory service if thevehicle is not loaded in excessof either the gross vehicle

weight rating (GVWR), or themaximum front and rear grossaxle weight ratings (GAWRs).(Axle weight ratings are listedon the driver's door edge.)

The following are some definitions ofweight you should know:

GVWR: is the Gross Vehicle WeightRating. This is the MAXIMUMWEIGHT your vehicle is allowed tocarry, including the weight of the emptyvehicle, loading platform, occupants,fuel, and any load. Never exceed theGVWR of your vehicle.

GCW: is the actual combined weight,or Gross Combination Weight (GCW),of your vehicle and its load: vehicle,plus trailer(s), plus cargo.

GAWR: is the Gross Axle WeightRating. This is the total weight thatone axle is designed to transmit to the

ground. You will find this number listedon the driver's door edge.

Load Distribution: be sure any loadyou carry is distributed so that no axlehas to support more than its GAWR.

WARNING!

An unevenly distributed load or aload too heavy over one axle can af-fect the braking and handling of yourvehicle, which could result in an ac-cident. Even if your load is under thelegal limits, be sure it is distributedevenly. Failure to comply may resultin death, personal injury, equipmentor property damage.

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START-UP

Emergency Equipment

It is good practice to carry anemergency equipment kit in yourvehicle. One day, if you have aroadside emergency, you will be gladthe following items are with you:

• window scraper

• snow brush

• container or bag of sand or salt

• emergency light

• triangles

• small shovel

• first aid kit

• fire extinguisher

• vehicle recovery hitches (seeVehicle Recovery Guidelines onpage 2-12 for details).

Driver's Check List

To keep your Kenworth in top shapeand maintain a high level of safetyfor you, your passengers, and yourload, make a thorough inspectionevery day before you drive. You willsave maintenance time later, and thesafety checks could help prevent aserious accident. Please remember,too, that Federal Motor Carrier SafetyRegulation 392.7 requires a pre-tripinspection and so do commercialtrucking companies.

You are not expected to become aprofessional mechanic. The purposeof your inspections is to find anythingthat might interfere with the safe andefficient transportation of yourself, anypassengers, and your load. If you dofind something wrong and cannot fix ityourself, have an authorized KenworthDealer or qualified mechanic repairyour vehicle right away.

The following operations are to beperformed by the driver. Performingthese checks and following themaintenance procedures in thismanual will help keep your Kenworthrunning properly.

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START-UP

Approaching Your Vehicle

• Check the overall appearance andcondition. Are windows, mirrors,and lights clean and unobstructed?

• Check beneath the vehicle. Arethere signs of fuel, oil, or waterleaks?

• Check for damaged, loose, ormissing parts. Are there partsshowing signs of excessive wearor lack of lubrication? Have aqualified mechanic examine anyquestionable items and repairthem without delay.

• Check your load. Is it securedproperly?

Daily Checks

Engine Compartment Checks - Daily

1. Engine Fluid Levels - add more ifnecessary.

° Engine oil

° Coolant (check while engineis cold)

° Power steering fluid level

2. Engine Belt - check tension andcondition of belts. This is importantto ensure proper air compressorand engine operation.

° Measure the belt tensionat the longest span of thebelt. See Accessory DriveBelts on page 5-88 for furtherinformation on checking belttension.

NOTEDeflection should be one belt thick-ness for each foot distance betweenthe pulley centers.

° If breaks or tears are found,the belt should be replacedbefore operating the vehicle.

3. Fuel Filter/Water SeparatorDraining - check and drain.Depending on the fuel storagefacility, more frequent drainingmay be required.

4. Windshield washer reservoir fluidlevel - fill if necessary.

5. Battery Cables - check thecondition of the battery andalternator cables for signs ofchafing or rubbing. Make surethat all clamps (straps) holding thecables are present and in goodworking order.

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START-UP

6. Hood closed before entering cab.Is it latched properly?

7. For trucks with hydraulic brakes:check the hydraulic brake fluidlevel. Make sure that the fluid levelregisters on or above the fluid levelmark molded on the reservoir.

WARNING!

Wear protective clothing and eyeprotection when handling hydraulicfluid. It is mildly toxic and can causeskin and eye irritation.

WARNING!

Use only the type of hydraulic fluidspecified. (See Table 9, Mainte-nance Schedule on page 5-19) Donot use or mix different types of hy-draulic fluid. The wrong hydraulicfluid will damage the rubber parts ofthe brake system which may lead toloss of braking and possibly causeserious personal injury.

CAUTIONHydraulic brake systems use twodistinct and incompatible fluids.Power steering fluid is used in thehydraulic brake booster system.Brake fluid is used in the mastercylinder and brake pipes. Do notmix these fluids when replenishingthe system or seal damage can re-sult.

CAUTION

Hydraulic brake fluid may damagepainted surfaces of the vehicle. Pro-tect or cover any painted surfacesthat may come in contact with brakefluid.

Booster and Master Cylinder Assembly

1 Refill Caps

1. Remove each reservoir cap andextract the rubber diaphragm fromeach reservoir.

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START-UP

2. Fill each reservoir with cleanhydraulic fluid of the approvedspecification. (See Table 9,Maintenance Schedule on page5-19)

3. Insert the rubber diaphragms intothe reservoirs.

4. To prevent leakage from thereservoirs, ensure that the sealin each reservoir cap is in goodcondition before refitting the cap.

WARNING!

If the brake fluid reservoir requiresan excessive amount of hydraulicfluid, the complete system must beinspected for leaks and repairedif necessary (consult your nearestKenworth dealer). Failure to keepthe brake system in good repair maylead to loss of braking and possiblycause death or personal injury.

Chassis and Cab Checks - Daily

Before entering the cab and operatingthe vehicle, check the followingequipment for proper maintenance:

1. Lights - do headlights, turn signals,emergency flashers, and exteriorlamps function and are they cleanand adjusted properly?

2. Windows and Mirrors - are theyclean and adjusted properly?

3. Tires and Wheels - are theyinflated properly? Are all wheelcap nuts in place and torquedproperly - tighten if necessary.Check front wheel bearing oillevels. Inspect all tires and wheelsfor damage - correct if found.

4. Suspension - check for loose ormissing fasteners. Check damageto springs or other suspensionparts.

5. Brake Components - check lines,linkages, chambers, parking andservice brake operation.

6. Air System - are there leaks?

° Air Tanks - drain water fromall air tanks. Make sure thedrain cocks are closed. Thisprocedure is also required forair suspension tanks equippedwith automatic drain valves.

° For further details See Usingthe Brake System on page4-15.

7. For trucks with hydraulic brakes:

° Check brake system for leaks.

° Check hydraulic lines forcracks or kinks.

° Check calipers for leaks.Have any problems correctedbefore operating the vehicle.

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START-UP

8. Steps and Handholds - checkfor worn surfaces and loose ormissing fasteners.

9. Fluid Tanks - check underneaththe vehicle for signs of fluid leaks.If any are found, correct beforeoperating the vehicle.

10. Fuel Tank Caps - are they secure?

WARNING!

Do not remove a fuel tank cap nearan open flame. Diesel fuel in thepresence of an ignition source (suchas a cigarette) could cause an ex-plosion. A mixture of gasoline oralcohol with diesel fuel increasesthis risk of explosion. Use only thefuel and/or additives recommendedfor your engine. Failure to complymay result in personal injury, death,equipment or property damage. SeeRefueling on page 4-75, for moreinformation.

11. Trailer Connections - are theysecure and the lines clear? Ifthey are not being used, are theystored properly?

° Is the trailer spare wheelsecure and inflated?

° Is the landing gear up and thehandle secured?

Cab Interior - Daily

1. Seat - adjust the seat for easyreach of controls.

2. Seat Belts - fasten and adjustsafety restraint belts.

3. Steering Column - adjust for easyreach.

4. Mirrors - check and readjustmirrors if necessary.

5. Lights - turn ignition key to the ONposition and check for warninglights and buzzer. Check operation

of turn signals and emergencylights.

6. Instruments - check allinstruments.

7. Windshield - check operation ofwindshield wipers and washers.

8. Horn - check operation of horn.

9. Fuel - check fuel. Is there enoughfuel?

NOTEThe above items (Engine Com-partment, Chassis and Cab, andPrestart Checks) should be checkeddaily, as a minimum. They are inaddition to, not in place of Fed-eral Motor Carrier Safety Regula-tions. These regulations may bepurchased by writing to: Superin-tendent of DocumentsU.S. Govern-ment Printing OfficeWashington, DC20402

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START-UP

Weekly Operations

1. Battery - check battery andterminals.

2. Wheel Cap Nuts - are they allin place and torqued properly -tighten if necessary. See WheelCap Nut Torque on page 5-124.

3. Other Controls and Wiring - checkfor condition and adjustment

4. Steering Components - checkpitman arm, draglink, and powersteering hoses, etc., for loose,broken, or missing parts.

5. Other Engine CompartmentChecks

• Check condition and fastening ofengine belt, hoses, clamps, andradiator.

• Check the air cleaner, muffler, andexhaust pipes. Are they tight andsecure?

• After Engine Warm-up

° Automatic Transmission- check fluid level in theautomatic transmission oil (ifequipped).

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EMERGENCY

WHAT TO DO IF...You Need Roadside Assistance. . . . . . . . . . 2-3Low Air Alarm Turns On . . . . . . . . . . . . . 2-3Stop Engine Lamp Turns On . . . . . . . . . . . 2-4Engine Oil Pressure Lamp Turns On. . . . . . . . 2-4Check Engine Lamp Turns On . . . . . . . . . . 2-5Engine is Overheating . . . . . . . . . . . . . . 2-5Fuse or Relay Blows . . . . . . . . . . . . . . 2-7

JUMP STARTING VEHICLESIntroduction . . . . . . . . . . . . . . . . . . 2-9

VEHICLE RECOVERY AND SPRING BRAKESIntroduction . . . . . . . . . . . . . . . . . 2-12Vehicle Recovery Instructions . . . . . . . . . 2-12Recovery Rigging . . . . . . . . . . . . . . . 2-14Returning Vehicle to Service . . . . . . . . . . 2-15Spring Brakes - Manual Release . . . . . . . . 2-15Freeing the Vehicle from Sand, Mud, Snow and Ice 2-17

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WHAT TO DO IF...

WHAT TO DO IF...

You Need RoadsideAssistance

Call toll-FREE 1-800-KW-ASSIST(1-800-592-7747) to talk to someoneat the PACCAR Customer Center.

• Open 24-7-365 days a year

• They can help you get roadsideassistance.

• They have a custom mappingsystem which locates Kenworth &Peterbilt Dealers and IndependentService Providers (ISPs) near youand lists types of services offered,hours of operation and contactinformation.

• They can assist with jump andpull starts, tires, trailers, fines andpermits, chains, towing, hazardousclean-up, out of fuel (roadside),mechanical repairs and preventivemaintenance services.

• They have bilingual agents andaccess to a translation serviceto ensure quality assistancefor customers who speak anylanguage.

• They can’t answer your warrantyquestions but can get you incontact with a Kenworth dealerwho can.

• The PACCAR Customer Centerservice is FREE even if you don’tdrive a Kenworth.

Low Air Alarm Turns On1. Slow down carefully.

2. Move a safe distance off the roadand stop.

3. Place the transmission inneutral (park with automatictransmissions, if equipped) andset the parking brake. (Referto Parking Brake Valve on page3-81 and OPERATING THETRANSMISSION on page 4-65,for transmission shifting andparking brake information.)

4. Turn OFF the engine.

5. Turn ON the emergency flasherand use other warning devices toalert other motorists.

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WHAT TO DO IF...

WARNING!

If the air pressure falls below 60psi (414 kPa) the spring brakesmay stop the vehicle abruptly, whichcould cause an accident resultingin death or personal injury. Ob-serve the red warning lamps on thegauges. If one comes on, do notcontinue to drive the vehicle until ithas been properly repaired or ser-viced.

If the light and alarm do not turn offat startup, do not try to drive thevehicle until the problem is found andfixed. (Refer to USING THE BRAKESYSTEM on page 4-15, for more brakeinformation.)

Stop Engine Lamp Turns On

WARNING!

This should be considered an emer-gency. You should stop the vehicleas safely as possible and turn OFFthe ignition. The vehicle must beserviced and the problem correctedbefore driving again. Failure to doso may cause severe engine or DPFdamage, or cause an accident whichmay result in death or personal injury

If the Stop Engine warning lampilluminates, it means you have aserious engine system problem.

Engine Oil Pressure LampTurns On

1. Slow down carefully.


3. Place the transmission in parkand set the parking brake. (SeeParking Brake Valve on page3-81 and OPERATING THETRANSMISSION on page 4-65,for transmission shifting andparking brake information.)



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WHAT TO DO IF...

6. Wait a few minutes to allow oil todrain into the engine oil pan, andthen check the oil level. (See OilLevel Check on page 5-84, fordetails on checking oil level.)

7. Add oil if necessary. If the problempersists, contact an authorizedKenworth dealer as soon aspossible.

CAUTION

Continuing to operate your vehiclewith insufficient oil pressure maycause severe engine damage orcause an accident which may resultin equipment or property damage.

It is important to maintain oil pressurewithin acceptable limits. If oil pressuredrops below the minimum psi a RedWarning Lamp on the oil pressuregauge and the Stop Engine Lamp willcome ON.

Check Engine Lamp TurnsOn

Vehicle should be serviced to correctthe problem but the situation shouldnot be considered an emergency. Thevehicle can still be safely driven.

Engine is Overheating1. Reduce engine speed and safely

stop the vehicle. When stopped,place the transmission in Neutraland set the parking brake. (SeeParking Brake Valve on page3-81 and OPERATING THETRANSMISSION on page 4-65,for transmission shifting andparking brake information.) Keepthe engine running.

2. Check to ensure the Oil PressureGauge reads normal. (See EngineOil Pressure Gauge, on page3-51, for further information.)

3. Make sure the engine fan isturning by switching the EngineFan Switch from AUTO to MAN(Manual).

4. Increase the engine speed toabout one-half of full operatingspeed, or 1,100 to 1,200 rpm,maximum.

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WHAT TO DO IF...

5. Return the engine speed to normalidle after 2 or 3 minutes.

6. Monitor the engine temperature.After the temperature returns tonormal, allow the engine to idle3 to 5 minutes before shutting itoff. This allows the engine to coolgradually and uniformly.

7. If overheating came fromsevere operating conditions, thetemperature should have cooledby this time. If it has not, stopthe engine and let it cool beforechecking to see if the coolant islow.

° Wait until the coolanttemperature is below 122° F(50° C).

° Protect face, hands, and armsby covering the cap with alarge, thick rag to protectagainst escaping fluid andsteam.

° Carefully and slowly turnthe cap one-quarter of aturn or until it reaches thefirst stop—allowing excesspressure to escape—pushdown and turn for finalremoval.

See Topping Up on page 5-60, forinstructions on checking and filling thecoolant expansion tank.

WARNING!

Do not remove the radiator fill capwhile the engine is hot. Scaldingsteam and fluid under pressure mayescape. You could be badly burned.Failure to comply may result in per-sonal injury or death.

WARNING!

To reduce the chance of death,personal injury, fire and/or vehicledamage from overheated engines,never leave the engine idling withoutan alert driver present. If the en-gine should overheat, as indicatedby the engine coolant temperaturelight, immediate action is requiredto correct the condition. Continuedunattended operation of the engine,even for a short time, may resultin serious engine damage or a fire.Failure to comply may result in per-sonal injury, death, equipment orproperty damage.

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WHAT TO DO IF...

Fuse or Relay Blows

Fuses, circuit breakers, and relaysare located in the Power DistributionBox to the left of the steering columnbehind the clutch pedal. See PowerDistribution Box on page 5-67.

Additional fuses for the alternator,engine electronics and trailer batterycharge circuit may be located in thePower Distribution Center (PDC)inside the battery box and/ or on theengine side of the cab firewall. SeePower Distribution Center (PDC) onpage 5-66.

WARNING!

Do not replace a fuse with a fuse of ahigher rating. Doing somay damagethe electrical system and cause afire. Failure to comply may result indeath, personal injury, equipment orproperty damage.

CAUTION

Before replacing a fuse, turn OFF alllights and accessories and removethe ignition key to avoid damagingthe electrical system.

CAUTION

Never patch fuses with tin foil orwire. This may cause serious dam-age elsewhere in the electrical cir-cuit, and it may cause a fire.

CAUTION

If a circuit keeps blowing fuses, havethe electrical system inspected for ashort circuit or overload by an au-thorized Kenworth dealer as soonas possible. Failure to do so couldcause serious damage to the elec-trical system and/or vehicle.

NOTEIf a fuse of the same rating is notavailable, a fuse of a lower ratingmay be temporarily substituted. Youcan also use a fuse from a circuit youcan do temporarily without (for ex-ample an accessory circuit or radio).

All the electrical circuits have fusesto protect them from a short circuit oroverload. If something electrical onyour chassis stops working, the firstthing you should check for is a blownfuse.

1. TurnOFF all lights and accessoriesand remove the ignition key toavoid damaging the electricalsystem.

2. Determine from the chart on thefuse panel which fuse controls thatcomponent.

3. Remove that fuse and see if it isblown.

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WHAT TO DO IF...

1 Blown

If it is blown, replace it with a fuse ofthe same rating.

CAUTION

When replacing a failed circuitbreaker, always use an approvedcircuit breaker with a current rat-ing equal to or less than the circuitbreaker being replaced. Only usethe approved Type II modified re-set circuit breakers. NEVER usea Type I (automatic reset) or TypeIII (manual reset) circuit breaker. Afuse with a current rating equal to orless than the circuit breaker beingreplaced can also be used.

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JUMP STARTING VEHICLES

JUMP STARTINGVEHICLES

Introduction

Because of the various batteryinstallations and electrical systemoptions, Kenworth does notrecommend that you attempt tojump start your vehicle. If you have abattery problem, it is best to contact aKenworth Dealer or a reputable towingservice.

However, if your battery is discharged(dead), you may be able to start itby using energy from a good batteryin another vehicle. This is termedjump starting. Be sure to follow theprecautions and instructions below.

WARNING!

Batteries contain acid that can burnand gasses that can explode. Ignor-ing safety procedures may result indeath, personal injury, equipment orproperty damage.

WARNING!

Never jump start a battery near fire,flames, or electrical sparks. Bat-teries generate explosive gasesthat could explode. Keep sparks,flame, and lighted cigarettes awayfrom batteries. Failure to complymay result in death, personal injury,equipment or property damage.

WARNING!

Never remove or tamper with batterycaps. Ignoring this could allow bat-tery acid to contact eyes, skin, fab-rics, or painted surfaces. Failure tocomplymay result in death, personalinjury, equipment or property dam-age.

• Be careful that metal tools (orany metal in contact with thepositive terminal) do not contactthe positive battery terminal andany other metal on the vehicleat the same time. Remove metaljewelry and avoid leaning overthe battery.

• If metal jewelry or other metalcomes in contact with electricalcircuits, a short circuit mayoccur causing you to be injured,as well as electrical systemfailure and damage to thevehicle.

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To Jump Start Your Vehicle

WARNING!

The voltage of the booster bat-tery must have a 12 volt rating andthe capacity of the booster batteryshould not be lower than that of thedischarged battery. Use of batteriesof different voltage or substantiallydifferent capacity rating may causean explosion. Failure to complymay result in death, personal injury,equipment or property damage.

CAUTIONApplying a higher voltage boosterbattery will cause expensive dam-age to sensitive electronic compo-nents, such as relays, and the ra-dio. Failure to comply may result inequipment damage.

• Improper hook-up of jumpercables or not following theseprocedures can damage thealternator or cause seriousdamage to both vehicles.

WARNING!

To avoid personal injury and dam-age to the vehicle, heed all warningsand instructions of the jumper cablemanufacturer.

• The jumper cables must be longenough so that the vehicles donot touch.

Preparing the vehicles:

1. Position the two vehicles together,but do not allow them to touch.

2. Turn OFF all lights, heater, radio,and any other accessory on bothvehicles.

3. Set the parking brakes: pull outthe Yellow button located on thedash.

4. Shift the transmission into parkposition or neutral for manualtransmissions. (See OPERATINGTHE TRANSMISSION on page4-65 and Parking Brake Valve onpage 3-81, for transmission shiftingand parking brake information.)

5. If either vehicle is equipped withbattery disconnects ensure theyare in the "OFF" position prior toconnecting the two vehicles.

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Connect the batteries:

1. Attach one end of a jumper cableto the positive (+) terminal of thedischarged (dead) battery. Thiswill have a large red + or P on thebattery case, post, or clamp.

2. Attach the other end of the samecable to the positive (+) terminalof the good (booster) battery.

3. Attach the remaining jumper cableFIRST to the negative (-) terminal(black or N) of the good battery.

4. Attach the other end of thenegative cable to a bare metal partnot bolted to the engine block.IMPORTANT: Always connectpositive (+) to positive (+) andnegative (-) to negative (-).

5. If either vehicle is equipped withbattery disconnects, ensure thatthey are in the"ON" position.

6. Start the engine:

• Start the vehicle that has thegood battery first. Let it run for 5minutes.

• Then start the vehicle that has thedischarged (dead) battery.If the engine fails to start, do notcontinue to crank the starter butcontact the nearest authorizedKenworth Dealer.

Remove jumper cables:

WARNING!

When disconnecting jumper cables,make sure they do not get caughtin any moving parts in the enginecompartment. You could be injured.

• Reverse the above procedureexactly when removing the jumpercables. With engine running,disconnect jumper cables fromboth vehicles in the exact reverseorder (Steps 4-1), making sureto first remove the negativecable from the vehicle with thedischarged battery.

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VEHICLE RECOVERY AND SPRING BRAKES

VEHICLE RECOVERYAND SPRING BRAKES

Introduction

Your Kenworth may be equipped with aRecovery Device(s) designed for shortdistance recovery purposes only. Useonly the original Kenworth recoverydevice(s) and the instructions below.If your vehicle does not have theproper device contact your authorizedKenworth Dealer.

Vehicle RecoveryInstructions

Refer to the instructions below whentowing your vehicle:

• Use proper towing equipment toprevent damage to the vehicle.

CAUTION

Connect only to the Recovery De-vice(s), as described on the follow-ing pages. Do not attach to bumpersor brackets. Use only equipment de-signed for this purpose. Connec-tions to other structural parts coulddamage the vehicle.

CAUTIONRemove the driveline and axleshafts or lift the driving wheels offthe ground before towing the ve-hicle. See Driver Controlled MainDifferential Lock on page 4-55. Alllubricating and clutch applicationoil pressure is provided by an en-gine-driven pump, which will notwork when the engine is stopped.You could seriously damage yourvehicle by towing it with the drivelineconnected and the drive wheels onthe ground.

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CAUTIONWhen vehicles are towed, either bywrecker or piggy-back, the lubricantin the top front of the drive axle willdrain to the rear. This will leave thetop components dry. The resultingfriction may seriously damage them.Always remove the main driveshaftand axle shafts before towing yourvehicle.

• See the following references:

° Recovery Rigging on page2-14.

° Driver Controlled MainDifferential Lock on page4-55.

• Use a safety chain system.

• Disconnect driveline.

• Follow state/provincial and locallaws that apply to vehicles in tow.

• Do not tow vehicles at speeds inexcess of 55 mph (90 km/h).

NOTEFor additional information concern-ing heavy duty truck recovery, seeTechnology & Maintenance Council(TMC)

• Recommended Practice #602–A— “Front Towing Devices ForTrucks and Tractors.”

• Recommended Practice #602–B— “Recovery Attachment PointsFor Trucks, Tractors, andCombination Vehicles

• Recommended Practice #626— “Heavy Duty Truck TowingProcedures.”

Copies of these can be obtained fromthe following address:

Technology & Maintenance Council950 N. Glebe Road(703) 838-1763Arlington, VA 22203Email: [email protected]

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Recovery Rigging

To connect to the Kenworth, follow thesuggested rigging methods below.

• Use a double chain or cable setupthat distributes the load equallyto both hitches. See 1 or 2 inRecovery Rigging.

• Never loop a single chain or cablethrough both hitches (3).

• Use a spreader or equalizer bar todistribute the load on both hitches(1).

• If no spreader bar is available,connect the main tow chain or

cable no closer than 6 ft. from thevehicle (2).

1. Spreader Bar or Equalizer 1. Minimum 6 FT. NEVER USE SINGLE CHAIN OR CABLEPreferred Acceptable LOOPED THROUGH TOW DEVICES

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Returning Vehicle to Service

Your vehicle may have lost lubricantwhile being towed. To preventdamage, check the oil level and addoil if necessary.

After adding the specified type andamount of lubricant, drive the vehicle.It should be unloaded. Drive 1 to2 miles (1.5 to 3 km) at a speedlower than 25 mph (40 km/h). Thiswill thoroughly circulate the lubricantthrough the assembly.

Spring Brakes - ManualRelease

In order to tow a vehicle, if there isinsufficient air to release the parkingbrake, the spring brakes can bemanually released.

WARNING!

Do not drive vehicle with malfunc-tioning brakes. If one of the brakecircuits should become inoperative,braking distances will increase sub-stantially and handling characteris-tics while braking will be affected.You could lose control of your vehi-cle or cause an accident. Have ittowed to the nearest dealer or qual-ified repair facility for repair. Failureto comply may result in death, per-sonal injury, equipment or propertydamage.

You may sometimes have to releaseyour vehicle's spring brakes by hand.This could happen if the system air

pressure does not reach operatingpressure because your engine orcompressor is not working properly.You will have to release the springbrakes at the spring brake chambers.

WARNING!

Do not disassemble a spring brakechamber. These chambers con-tain a powerful spring that is com-pressed. Sudden release of thisspring may result in personal injuryor death.

WARNING!

Do not operate a vehicle when thespring brakes have been manu-ally released. Driving a vehicleafter its spring brakes are manu-ally released is extremely danger-ous. The brakes may not func-tion. Failure to comply may resultin personal injury, death, equip-ment or property damage.

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WARNING!

Releasing the spring brakes onan unsecured vehicle could leadto an accident. The vehicle couldroll, which may result in per-sonal injury, death, equipment orproperty damage. Always securethe vehicle with wheel chocks,chains, or other safe means toprevent rolling before manuallyreleasing the spring brakes.

To move a vehicle immobilized bythe spring brakes due to loss ofair pressure in the brake system,perform the following procedure:

1. Remove the cap fromthe spring chamber.

2. Remove the releasestud assembly from theside pocket, and removethe release nut andwasher from the releasestud.

3. Slide out the releasestud.

4. Insert the release studthrough the opening inthe spring chamberwhere the cap wasremoved. Insert it intothe pressure plate. Turnthe release stud 1/4turn clockwise in thepressure plate. Thissecures the cross pininto the cross pin area ofthe pressure plate andlocks it into the manualrelease position.

5. Assemble the releasestud washer and nut onthe release stud.

6. With a wrench,turn the release studassembly nut until thecompression spring is90-95 percent caged.While doing this, checkto make sure the pushrod (adapter pushrod or service pushrod) is retracting. Donot over-torque therelease stud assembly.(S-Cam type maximum:50 lb-ft, Wedge typemaximum: 30 lb-ft).The spring brake is nowmechanically released.

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Freeing the Vehicle fromSand, Mud, Snow and Ice

If the vehicle gets stuck in sand,mud, snow, or ice:

• Move the gearshift lever orselector from First to Reverse.

• Apply light pressure on theaccelerator pedal while thetransmission is in gear.

• Remove your foot from theaccelerator while shifting.

• Do not race the engine.

• For best traction and safety, avoidspinning the wheels.

WARNING!

Do not spin the wheels faster than35 mph (55 km/h). Spinning a tire atspeedometer readings faster than35mph (55 km/h) can be dangerous.Tires can explode from spinning toofast. Under some conditions, a tiremay be spinning at a speed twicethat shown on the speedometer.Any resulting tire explosion couldcause injury or death to a bystanderor passenger, as well as exten-sive vehicle damage: including tire,transmission and/or rear axle mal-function.

Comply with the followinginstructions to avoid transmissiondamage:

• Always start vehicle in motion withthe shift lever in first gear.

• Be sure that transmission is fullyengaged in gear before releasingthe clutch pedal (manual only).

• Do not shift into reverse while thevehicle is moving.

• Do not permit the vehicle to betowed for long distances withoutremoving the driveshaft.

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Tire Chains

If you need tire chains, install them onboth sides of the driving axle.

CAUTION

Chains on the tires of only one tan-dem axle can damage the drivelineU-joints and the interaxle differen-tial. Repairs could be costly andtime-consuming. Failure to complymay result in equipment damage.

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CONTROLS

ACCESSORIESIntroduction . . . . . . . . . . . . . . . . . . 3-5Radio (Option) . . . . . . . . . . . . . . . . . 3-6Cigarette Lighter and Ashtray (Option) . . . . . . . 3-6Clock . . . . . . . . . . . . . . . . . . . . . 3-7Cab Storage . . . . . . . . . . . . . . . . . 3-10

HEATING AND AIR CONDITIONINGIntroduction . . . . . . . . . . . . . . . . . 3-12Precautions . . . . . . . . . . . . . . . . . 3-13Cab Controls . . . . . . . . . . . . . . . . . 3-16

AUDIBLE ALERTSIntroduction . . . . . . . . . . . . . . . . . 3-20

INDICATORSIntroduction . . . . . . . . . . . . . . . . . 3-26

GAUGES AND DISPLAYSIntroduction . . . . . . . . . . . . . . . . . 3-43

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CONTROLS

Gauges . . . . . . . . . . . . . . . . . . . 3-44

MULTI-FUNCTION DISPLAYIntroduction . . . . . . . . . . . . . . . . . 3-57Alarms, Warning Tones and Visual Indicator Lights 3-57Warning and Information Alert Screens . . . . . 3-58Wingman® ACB Warning Tone / Alert Screens . . 3-62Multi-Function Display . . . . . . . . . . . . . 3-64

SWITCHESIntroduction . . . . . . . . . . . . . . . . . 3-76

STEERING COLUMNIntroduction . . . . . . . . . . . . . . . . . 3-87Turn Signal/High Beam Switch . . . . . . . . . 3-87Emergency Flasher Switch . . . . . . . . . . . 3-88Windshield Wipers/Washer . . . . . . . . . . . 3-89Trailer Brake Hand Valve. . . . . . . . . . . . 3-91Stop/Turn Signal Lamp Operation . . . . . . . . 3-91Adjustable Tilt/Telescoping Column . . . . . . . 3-92

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CONTROLS

Horn . . . . . . . . . . . . . . . . . . . . 3-93

MIRRORSIntroduction . . . . . . . . . . . . . . . . . 3-94Power Mirror Switch . . . . . . . . . . . . . . 3-94Mirror Heat Button . . . . . . . . . . . . . . 3-96

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ACCESSORIES

ACCESSORIES

Introduction

1 Radio (Option)2 Glove Compartment3 Combination Tractor/Trailer

Brake Control Valves

4 Heater-Air ConditionerControl

5 Wiper Switch

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ACCESSORIES

Radio (Option)

As an option, your vehicle has eitheran AM/FM Stereo Receiver or AM/FMStereo with CD.

For instructions on how to operate yourparticular radio, see the manufacturer'sRadio Operating Instructions.

Cigarette Lighter andAshtray (Option)

NOTEThe cigarette lighter will operate withthe ignition key in either the OFF,ACC (accessory), or ON position.

To operate, push in on the knob endof the lighter. After a few moments,the lighter will automatically pop out,glowing hot and ready to use. Afteruse, insert the lighter back into thesocket without pushing all the way in.

The socket of the cigarette lighter maybe used to operate 12 volt, 15 ampereappliances, such as a hand spotlightor small vacuum cleaner.

WARNING!

Do not place paper or other com-bustible substances in an ashtray, itcould cause a fire. Keep all burnablematerials, besides smoking materi-als, out of the ashtray. Failure tocomplymay result in death, personalinjury, equipment or property dam-age.

WARNING!

Do not exceed the voltage/amper-age capacity of the cigarette lighter.It could result in a fire. Follow allwarnings and instructions in the op-erator's manual for the applianceyou are using. Failure to complymay result in death, personal injury,equipment or property damage.

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ACCESSORIES

ClockDash and Sleeper ClockAnalog Clock - Dash

1 Counter Clockwise2 Clockwise

• Depress right hand button to rotateclock hands clockwise.

• Depress left hand button to rotateclock hands counter clockwise.

• Continue to depress buttons forfaster movement.

Digital Clock - Sleeper

Quick Operating Instructions for Kenworth Digital ClockMode Display Functions Buttons to UseClock Current time (flashing colon)

(note PM in upper left corner)• set time• silence alarm

+, -(hold down to change faster)Select or On/Off

Date Date (MM/DD) • set date - for month, + for dayAlarm Alarm setting (alarm symbol)

(steady symbol = alarm On• set alarm• turn alarm on/off

+, -On/Off

ElapsedTime

Elapsed time (ET displayed)(steady ET = timer On)

• start & stop timer• reset elapsed time

On/Off+ or - when timer is off

Auxiliary AUX in lower left corner • not used

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ACCESSORIES

Clock

Set the time as follows: Press andhold down either the “+” or “-” button tochange the time to the proper setting(note “PM” indicator in upper left cornerof display). After holding down eitherbutton for three seconds, the rate ofchange will increase from slow to fast.The clock will start keeping time assoon as either button is released. Aflashing display indicates that powerhas been interrupted to the clock, andall functions will need to be reset.

The clock mode is the default display,which means the display will return tothis mode after a few seconds fromevery other mode except from elapsedtime mode.

Date

Enter the date mode by pressing the“Select” button once. Set the currentmonth using the “-” button, and thedate by using the “+” button (thedisplay will automatically return to theclock mode after a few seconds).

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ACCESSORIES

Alarm

Press the “Select” button twice toswitch to the alarm mode, which isindicated by the alarm symbol on theleft side of the display. The alarm isset in the same manner as the time(again, be careful to note the status ofthe “PM” indicator). Use the “On/Off”button to turn the alarm on and offwhile in this mode. The alarm symbolflashes when the alarm is off, and turnsto steady when the alarm is turned on.

When the alarm is turned on, the alarmsymbol is displayed while in the clockmode. To silence the alarm, presseither the “Select” or “On/Off” button.

Elapsed Time

Press the “Select” button three timesto switch to the elapsed time mode,which is indicated by “ET” in the lowerleft corner of the display. Similar tothe alarm symbol, the “ET” flasheswhen the elapsed timer is turned off,and is steady while the timer is turnedon. Turn the elapsed timer on and offby using the “On/Off” button. Whenthe elapsed timer is on, “ET” is alsodisplayed while in the clock mode. Toreset the elapsed time, press eitherthe “+” or the “-” button while the timeris off. Unlike the other modes, thedisplay will stay in elapsed time modeuntil the “Select” button is pressed.

Auxiliary

This mode has no function at this timeand should be ignored.

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ACCESSORIES

Display

The display is always on. The displaycan be set to four levels of brightnessby pressing both the “+” and “-” buttonsat the same time.

Cab Storage

Glove Box

A glove box is provided to storeimportant documents, the vehicleliterature set (including this Operator'sManual) and other related materials.

WARNING!

Do not drive with the glove box open,it can be dangerous. In an accidentor sudden stop, you or a passengercould be thrown against the coverand be injured. To reduce the riskof personal injury during an accidentor sudden stop, keep the glove boxclosed when the vehicle is in motion.

Interior Compartments

You can choose from a variety ofinterior storage options to store yourpersonal supplies or small tools:

- center console

- map pocket

- overhead storage compartments

- records holder, behind seat

WARNING!

Do not carry loose objects in yourcab, it can be dangerous. In a sud-den stop, or even going over a bumpin the road, they could fly throughthe air and strike you or a passenger.You could be injured or even killed.Secure all loose objects in the cabbefore moving the vehicle. Carryany heavy objects such as luggagein the exterior storage compartmentand close it securely.

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ACCESSORIES

Appliances

If your Kenworth is equipped with atelevision, or other appliance, be surethey are compatible with your vehicle'selectrical system. And secure them inthe cab so they cannot come loose ina sudden stop.

WARNING!

In a sudden stop or collision a heavyobject in your cab could strike youor anyone with you. You could beinjured or even killed. Secure anyappliance (such as a radio, or TV)you add to your cab.

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HEATING AND AIR CONDITIONING

HEATING AND AIRCONDITIONING

Introduction

1 Heating and Air ConditioningControls

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Precautions

WARNING!

Do not drive with visibility reducedby fog, condensation, or frost on thewindshield. Your view may be ob-scured, which may result in death,personal injury, equipment or prop-erty damage. For clear visibility andsafe driving it is extremely impor-tant for you to follow the instructionspertaining to the function and useof the ventilation/heating and defog-ging/defrosting system. If in doubt,consult your dealer. Maximum heat-ing output and fast defrosting can beobtained only after the engine hasreached operating temperature.

WARNING!

The air conditioning system is un-der pressure. If not serviced prop-erly, it could explode and may resultin personal injury, death or propertydamage to your vehicle. Any servic-ing that requires depressurizing andrecharging the air conditioning sys-tem must be conducted by a quali-fied technician with the right facilitiesto do the job.

WARNING!

Excessive heat may cause the pres-surized components of the air con-ditioning system to explode. Neverweld, solder, steam clean, or use ablow torch near any part of the airconditioning system. Failure to com-ply may result in death, personal in-jury, equipment or property damage.

• If a refrigerant leak develops inthe presence of excessive heator an open flame, hazardousgases may be generated.These gases may causeunconsciousness or death.If you become aware of arefrigerant leak on your vehiclehave your system servicedimmediately and observe thefollowing precautions:

° Stay away from the hotengine until the exhaustmanifold has cooled.

° Do not permit any openflame in the area. Even amatch or a cigarette lightermay generate a hazardousquantity of poisonous gas.

° Do not smoke in the area.Inhaling gaseous refrigerantthrough a cigarette maycause violent illness.

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WARNING!

Exhaust fumes from the enginecontain carbon monoxide, a col-orless and odorless gas. Do notbreathe the engine exhaust gas.A poorly maintained, damaged orcorroded exhaust system can allowcarbon monoxide to enter the cabor sleeper. Entry of carbon monox-ide into the cab or sleeper is alsopossible from other vehicles nearby.Failure to properly maintain your ve-hicle could cause carbon monoxideto enter the cab or sleeper, resultingin illness or death.

WARNING!

Never idle your vehicle for prolongedperiods of time if you sense that ex-haust fumes are entering the cabor sleeper. Investigate the causeof the fumes and correct it as soonas possible. If the vehicle must bedriven under these conditions, driveonly with the windows open. Failureto repair the source of the exhaustfumes may result in personal injury,death, equipment or property dam-age.

NOTEKeep the engine exhaust systemand the vehicles cab/sleeper venti-lation system properly maintained.

It is recommended that the vehiclesexhaust system and cab/sleeper beinspected:

• By a competent technician every15,000 miles

• Whenever a change is noticed inthe sound of the exhaust system

• Whenever the exhaust system,underbody, or cab or sleeper isdamaged

NOTETo allow for proper operation of thevehicle ventilation system, keep theinlet grille at the base of the wind-shield clear of snow, ice, leaves andother obstructions at all times.

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CAUTIONDo not stay in the vehicle with theengine running or idling for morethan 10 minutes with the vehicle'sHeater and A/C ventilation systemin RECIRC or at LOW FAN SPEED.Even with the ventilation system on,running the engine while parked orstopped for prolonged periods oftime is not recommended.

When idling for short periods of time:

• Set the heating or cooling systemto Heat or A/C

• Set the fan to Medium or Highspeed

• Set the controls to FRESH AIR

NOTEIf you are required to idle your ve-hicle for long periods of time, installan auxiliary heater or automatic idlecontrol. These auxiliary devices canreduce fuel consumption and saveyou money.

NOTEIf you are parked next to idling ve-hicles, move your vehicle or do notstay in your vehicle for prolonged pe-riods of time.

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Cab Controls

Cab Heater - A/C Controls

1 Fan2 Air Flow Mode3 Temperature4 Amber Light “ON” =

Recirculation Mode

Amber Light “OFF” = FreshAir Mode

5 Fresh Air / Recirculate6 Amber Light “ON” = A/C ON

(Fan must be turned ON)

Amber Light “OFF” = A/COFF

7 Air Conditioner

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What Each Control Does

Fan Control Dial

Turning this dial clockwise from the OFFposition turns the fan ON and increases thefan speed.

Air Flow Control DialThis dial directs the air flow through 5 primarysets of vents:

Dash Vents

Dash and Floor Vents

Floor Vents

Floor and *Defrost Vents

*Defrost Vents*Fresh air and air conditioning areautomatically turned ON. As the dial is turnedaway from a primary position, the systemdirects an increasing amount of air flowtowards the next primary position.

Temperature Control Dial

Turn this dial clockwise for heat,counterclockwise for cool.

Air Conditioner Switch

This switch turns the air conditioner On andOff.

NOTEFan Control Dial must also be in theON position for A/C to be on.

Fresh Air/Recirculation Switch

This switch controls the source of the airflowing into the heater and air conditioner unit

Fresh Air mode = Air comes fromoutside the cab.

Recirculation mode = Air comesfrom inside the cab.

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How to Use the System

The engine must be running for theheater and air conditioner to generatehot and cold air.

To Cool

There are 2 ways to cool:

a) using cool outside air

b) using air conditioning

a) Outside air is cooler than the inside air:

1.) Push the FreshAir/RecirculationSwitch

to the Fresh Airmode.

2.) Turn ON theFan Control Dial

to the desired fanspeed.

3.) Turn the AirFlow Control Dial to Dash Vents.

b) To cool using air conditioning:

1.) Turn ON theAir ConditioningSwitch.

2.) Push the FreshAir/RecirculateSwitch




4.) Turn the AirFlow Control Dial to Dash Vents.

5.) Adjust the Temperature Control Dialcounterclockwise until the air temperaturefeels comfortable.

To Heat



2.) Turn the AirFlow Control Dial to Floor Vents.

3.) Adjust the Temperature Control Dialclockwise until the air temperature feelscomfortable.

To Dehumidify

1.) Push the FreshAir/RecirculateSwitch


2.) Turn ON the Air ConditioningSwitch.



4.) Adjust the Temperature Control Dial untilthe air temperature feels comfortable.

The air conditioner removes moisturefrom the air while the heater heats theair.

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To Defog and Defrost the Windshield

1.) Turn the FanControl Dial

clockwise to thehighest fan speed.

2.) Turn the AirFlow Control Dial to Defrost Vents.

Fresh air and air conditioning areautomatically turned ON.

3.) Adjust the Temperature Control Dialclockwise to full heat.

CAUTIONDuring extreme cold weather, do notblow hot defroster air onto cold wind-shields. This could crack the glass.Turn the Air Flow Control Dial to De-frost and adjust the fan speed ac-cordingly while the engine warms. Ifthe engine is already warm, movethe Temperature Control Dial to cool,then gradually increase the temper-ature when you see that the wind-shield is starting to warm up. Failureto comply may result in equipmentdamage.

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AUDIBLE ALERTS

AUDIBLE ALERTS

Introduction

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AUDIBLE ALERTS

Your vehicle's dash andinstrumentation uses variousmethods to indicate to you the statusof various systems, or that one ormore of your vehicles systems maybe malfunctioning. The methodto communicate or alert you of aparticular condition is by:

• Audible alarm tone

• Audible warning tone

• Indicator light(s)

In some cases, you may have both analarm or warning tone accompanied byan indicator light(s).

WARNING!

Do not ignore any type of tone orlights. These signals tell you thatsomething is malfunctioning on yourvehicle and provide you an indi-cation of what system is affected.It could be a failure of an impor-tant system, such as the brakes,which could lead to an accident andmay result in death, personal injury,equipment or property damage.

Please remember that each Kenworthis custom made. Your instrumentpanel may not look exactly like the onein the illustration.

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AUDIBLE ALERTS

Table 1 Audible Alerts

Symbol Name Symbol Color Standard Option Page

1. Brakes, Air Pressure in Primary AirSystem is Low Red ● on page 3-24

2. Brakes, Air Pressure in Secondary AirSystem is Low Red ● on page 3-24

3. Engine, Low Coolant Level Yellow ● on page 3-37

4. Engine, Oil Pressure Yellow ● on page 3-37

5. Engine, Stop Engine Red ● on page 3-38

6. Park Brake Red ● on page 3-35

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AUDIBLE ALERTS

The standard instrument clustergenerates three distinct audible tonesor sounds.

A. Alarm tone

B. Warning tone

C. Turn signal/hazard sound

A. Alarm Tone

• Series of clear bell tones, repeatedat a rate of 100 tones per minute.

• Indicates that something isseriously wrong with the vehiclethat should be considered anemergency.

WARNING!

Do not ignore an alarm tone. Youshould visually determine what sys-tem is affected by glancing at yourgauges and indicator lights, then be-gin to slow your vehicle down to astop as safely as possible. Turnoff your ignition and take appropri-ate action. The vehicle must be ser-viced and the problem corrected be-fore driving the vehicle again. Fail-ure to obey an Alarm tonemay resultin death, personal injury, equipmentor property damage.

The Alarm tone is activated under thefollowing conditions.

Stop Engine Alarm

This alarm sound is active when theStop Engine light is active (turnedon by the engine). Examples of theconditions that would cause the alarmto sound are low oil pressure or highengine coolant temperature. Followthe procedure in the EmergencySection of this manual on page 2-3.

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AUDIBLE ALERTS

Primary or Secondary Low AirWarning Alarm

Primary Secondary

This alarm sound is active wheneither the Primary or Secondary LowAir Warning lamp is active and theengine RPM is above 300. This occurswhen the primary or secondary airpressure drops below 65 psi, andstays active until it increases above66.5 psi. Follow the procedure in theEmergency Section of this manual onpage 2-3.

Engine Oil Pressure Alarm

This alarm sound is active when theEngine Oil Pressure light is active(turned on by the engine). Follow the

procedure in the Emergency Sectionof this manual on page 2-3.

Park Brake Alarm

With the park brake not set and thedoor open, the Alarm tone is activatedfor approximately 4.5 minutes and parkbrake warning light will blink.

Fifth Wheel Slide Warning

Light is active (turned on by theoptional switch on the dash).

B. Warning Tone

• Series of clear bell tones, similarto the Alarm tone, repeated at arate of 60 tones per minute.

• Sounds when a problem exists,but the vehicle can still be safelydriven. Service the vehicle tocorrect the problem but thesituation should not be consideredan emergency.

CAUTION

If a warning tone sounds, determinethe system affected by glancing atyour indicator lights. The warningtone indicates a problem exists, butthe vehicle can still be safely driven.Service the vehicle at your earliestconvenience to correct the problem,but the situation should not be con-sidered an emergency.

The Warning tone is activated underthe following conditions.

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AUDIBLE ALERTS

During the Instrumentation PowerOn Self Test (POST) - Two bell tonessound when the ignition is turned on.

All gauges, indicators and warninglights will turn on for a power-onself test. All gauge pointers willmomentarily move to the maximumlimit, stay there for a short time,then move back to the zero position.Additionally, all indicator and warninglights will turn on together, then offtogether. Several different audiblewarnings will also be activated twicewithout break.

Low Coolant Level Warning

Light is active (turned on by theengine), and engine is running (RPMabove 300).

C. Turn Signal/Hazard Sound

• Generates a tic-toc sound, similarto a sound and function of amechanical flasher.

• Sounds anytime the turn signal orhazard switch is turned On.

NOTEIf the vehicle turn signals and turnsignal indicators in the dash gaugecluster ever begin flashing at anaccelerated rate (115 cycles perminute) when the turn signal leveris in the OFF (center) position, orwhen a Right/Left turn has been se-lected, the problem may be relatedto a failed turn signal switch or turnsignal module. In either case, theproblem is not a failed bulb. Contactyour nearest authorized KenworthDealer to have the problem cor-rected as soon as possible.

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INDICATORS

INDICATORS

Introduction

Numbered items in illustration are standard or common indicators.

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INDICATORS

Your vehicle's dash andinstrumentation uses variousmethods to indicate to you the statusof various systems, or that one ormore of your vehicles systems maybe malfunctioning. The methodto communicate or alert you of aparticular condition is by:




NOTEIndicator lights are also built intosome gauges. See the Gauges andDisplays Section on page 3-43 fora description of both the gauge andits indicator light.


WARNING!

Do not ignore any type of tone orlights. These signals tell you thatsomething is malfunctioning on yourvehicle and provide you an indi-cation of what system is affected.It could be a failure of an impor-tant system, such as the brakes,which could lead to an accident andmay result in death, personal injury,equipment or property damage.

Please remember that each Kenworthis custom made. Your instrumentpanel may not look exactly like the onein the illustration.

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INDICATORS

Table 2 Indicators


1. Axle, Traction Control Yellow ● on page 3-32

2. Brakes, Anti-Lock Brake System (ABS) Yellow ● on page 3-32

3. Brakes, Anti-Lock Brake System (ABS), Trailer Yellow ● on page 3-33

4. Brakes, Park Brake Red ● on page 3-35

5. Brake System Malfunction (Chassis with hydraulic brakes) Red ● on page 3-35

6. Cab Status Green ● on page 3-36

7. Engine, Check Engine Yellow ● on page 3-36

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INDICATORS


8. Engine, Fan Green ● on page 3-37

9. Engine, Low Coolant Level Yellow ● on page 3-37

10. Engine, Overspeed Air Shutdown Red ● on page 3-37

11. Engine, Retarder (Brake) Green ● on page 3-38

12. Engine, Stop Engine Red ● on page 3-38

13. Engine, Wait To Start Yellow ● on page 3-38

14. Exhaust, Diesel Particulate Filter (DPF) Yellow ● on page 3-39

15. Exhaust, High Exhaust System Temperature (HEST) Yellow ● on page 3-39

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INDICATORS


16. Lights, High Beam Blue ● on page 3-39

17. Message Waiting Green ● on page 3-40

18. Malfunction Indicator Lamp (MIL) Yellow ● on page 3-40

19. Power Take-off (PTO) Green ● on page 3-40

20. Range Inhibit Yellow ● on page 3-41

21. Seat Belt, Fasten Red ● on page 3-41

22. Transmission, Service Yellow ● on page 3-41

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INDICATORS


23. Transmission, Oil Temperature High Yellow ● on page 3-42

24. Turn Signal, Left Green ● on page 3-42

25. Turn Signal, Right Green ● on page 3-42

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INDICATORS

1. Axle, Traction Control

A. Illuminates during the power-on testwhen the ignition is turned ON. It turnsoff after a few seconds if no systemproblems are detected. If an ATCproblem is detected, the ATC Warninglamp will turn on and stay on.

B. Flashes when the ATC is regulatingwheel spin. See Anti-lock BrakingSystem on page 4-27 of Operator'sManual for more information.

C. If your vehicle has the Deep Snow& Mud Function Switch (option), theATC Warning Lamp flashes slowlyduring deep snow and mud modeengagement to alert you that thefeature is active (see Deep Snowand Mud Switch (option), in theAnti-lock Braking System on page

4-27 of the Operator's Manual for moreinformation). When in this mode, it willflash more rapidly whenever the ATCsystem is limiting wheel slippage.

NOTEFor vehicles equipped with Elec-tronic Stability Program, please referto Bendix ABS Operator's Manual,included in your glove box literaturepackage.

2. Brakes, Anti-Lock Brake System(ABS)

A. It illuminates during the power-ontest when the ignition is turned ON.It turns off after a few seconds if nosystem problems are detected.

CAUTION

If the ABS Warning Lamp does notilluminate during the power-on testthere may be a problem with thelight or wiring. You should have thischecked as soon as possible. Fail-ure to comply may result in equip-ment or property damage.

B. If it turns on and stays on at anyother time it is indicating that a problemexists with the ABS. This should bechecked by a Kenworth dealer as soonas possible.

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INDICATORS

See Anti-Lock Braking System onpage 4-27 of Operator's Manual formore information.

C. If your vehicle has the optionalWheel Spin Control feature, the ABSWarning Lamp turns on and stays onwhen a problem exists with the ATCsystem. This should be checked by aKenworth dealer as soon as possible.(Refer to your Operator’s Manual for"Anti-Lock Braking System" for moreinformation.)

NOTEAfter servicing the ABS, the lampstays on after the power-on test.This indicates that the ABS wheelsensors have not been checked bythe ABS. As soon as the vehicle isdriven at speeds above 4 mph (6km/h), the lamp turns off, indicatingthat the wheel sensors have beenchecked by the ABS.

D. If your vehicle has the Off-RoadABS Function Switch (option), the ABSWarning Lamp flashes slowly duringoff-road mode engagement. This isdone to alert you to a modificationto the ABS control software. See“Off-Road ABS Function Switch(option)” for more information.

NOTEAfter servicing the ABS, the lampstays on after the power-on test.This indicates that the ABS wheelsensors have not been checked bythe ABS. As soon as the vehicle isdriven at speeds above 4 mph (6km/h) the lamp turns off, indicatingthat the wheel sensors have beenchecked by the ABS.

3. Brakes, Anti-Lock Brake System(ABS), Trailer

A. It illuminates during the power-ontest when the ignition is turned ON.It turns off after a few seconds if nosystem problems are detected. Thebulb self-test is performed wheneverthe ignition is turned ON, regardlessof whether you have Trailer ABS. If aTrailer ABS system is detected, thelamp will turn off after a few seconds ifno system problems are detected.

CAUTION

If the Trailer ABS Warning Lampdoes not turn on during the power-ontest there may be a problem with thelight or wiring. You should have thischecked as soon as possible.

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INDICATORS

B. If it turns on at any other time, it isindicating that a problem exists withthe PLC trailer ABS. This should bechecked by a Kenworth dealer as soonas possible. (Refer to "Trailer ABS"in the Operator’s Manual for moreinformation.)

C. If your vehicle and trailer havethe "Special Trailer ABS (WithoutPLC) (Option)", (Refer to SpecialTrailer ABS (Without PLC) (Option),Anti-lock Braking System on page4-27 in the Operator's Manual for moreinformation.) this lamp will turn onwhen the trailer ABS has a systemproblem. This should be checked by aKenworth dealer as soon as possible.The Trailer ABS Warning Lamp willnot turn on for the power-on test whenconnected to these types of trailers.

NOTETractors/Trucks and trailers built af-ter 3/1/01 must be able to turn on anIn-Cab Trailer ABS Warning Lamp(per U.S. FMVSS121). The indus-try chose Power Line Communica-tion (PLC) (option) as the standardmethod to turn it on. Refer to TrailerABS in Anti-lock Braking System onpage 4-27, in the Operator's Manualfor more information.

NOTEThe Trailer ABS Warning Lampwill not turn on when connected totrailers with ABS (but without PLC)powered through the primary 7-waytrailer light line. Use the lamp on thedriver's side of the trailer to identifytrailer ABS problems.

NOTEFor doubles or triples, the lamp doesnot distinguish between trailers. AnABS problem in any of the trailerswill activate the Trailer ABSWarningLamp.

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INDICATORS

4. Park Brake

Illuminates when parking brakes areapplied.

The Park Brake lamp will flash and thewarning tone will sound anytime thePark Brake is not set and the driver'sdoor is open.

5. Brake System Malfunction(Chassis with hydraulic brakes)

Turns on and buzzer will soundindicating a malfunction in the brakesystem.

Possible malfunctions include loss ofhydraulic pressure from the powersteering circuit or a pressure differentialbetween the primary and secondarybrake circuits.

WARNING!

Do not operate the vehicle if theBrake lamp or buzzer comes on.This should be considered an emer-gency. Drive your vehicle to the sideof the road and stop as safely aspossible. Failure to comply may re-sult in death, personal injury, equip-ment or property damage.

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INDICATORS

6. Cab Status

Illuminates when the cab power is ON.

7. Engine, Check Engine

Illuminates when a problem exists, butthe vehicle can still be safely driven.Vehicle should be serviced to correctthe problem but the situation shouldnot be considered an emergency. Insome cases, the Check Engine lampwill activate in conjunction with theHigh Exhaust Temperature and DieselParticulate Filter (DPF) Warning Lights.

The Check Engine lamp will activatefor several reasons. These includebut are not limited to Water in Fueland No-Idle Shutdown alert screensand the High Exhaust Temperature,Diesel Particulate Filter (DPF), DieselEmission Fluid (DEF) warning lights.(Refer to Engine After-treatmentControls Operator's Manual foradditional information.)

NOTEOnly for engines equipped withemissions aftertreatment.

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INDICATORS

8. Engine, Fan

Illuminates when fan is active.

9. Engine, Low Coolant Level

Illuminates and an audible warningtone will sound when coolant level inthe radiator is critically low.

CAUTIONThe vehicle must be serviced to cor-rect the problem but the situationshould not be considered an emer-gency.

10. Engine, Overspeed AirShutdown

Illuminates when the EngineOverspeed Air Shutdown system isactivated.

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INDICATORS

11. Engine, Retarder (Brake)

Illuminates when the engine retarder(compression brake, BrakeSaver(export only), or exhaust brake) isactive.

12. Engine, Stop Engine

Illuminates and an audible alarm tonewill sound when a major engine systemproblem exists.

WARNING!

This should be considered an emer-gency. You should stop the vehicleas safely as possible and turn OFFthe ignition. The vehicle must beserviced and the problem correctedbefore driving again. Failure to doso may cause severe engine dam-age or cause an accident which mayresult in death or personal injury.

13. Engine, Wait To Start

Illuminates when engine grid heater ison (PACCAR PX-6 and PX-8 engines).

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INDICATORS

14. Diesel Particulate Filter (DPF)

Illuminates when diesel particulatefilter needs regeneration (controlledby engine ECM). This warning lampwill also illuminate when regenerationoperation is disabled. (Refer toPACCAR Aftertreatment SystemsOperator's Manual for additionalinformation.)


15. High Exhaust SystemTemperature

Illuminates when exhaust temperatureis high (controlled by engine ECM).(Refer to your Engine Manufacturer’sOperator Manual and to the PACCAREngine Aftertreatment SystemOperator's Manual for additionalinformation.

16. Lights, High Beam

Illuminates when the high beams areon.

The high beam indicator will flash anda tone will sound to indicate that thehead lamps are left on when: the headlamp switch is ON, the driver's door isopen, AND the key switch is OFF.

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INDICATORS

17. Message Waiting

Illuminates with telematic equippedmessaging.

18. Malfunction Indicator Lamp(MIL)

Illuminates when an engine emissionsfailure has occurred. The vehiclecan be safely driven but should beserviced to correct the problem. Thesituation should not be consideredan emergency. In some cases, theMalfunction Indicator Lamp will activatein conjunction with the High ExhaustTemperature, Diesel Particulate Filter(DPF) and Diesel Emission Fluid(DEF) Warning Lights.


19. Power Take-off (PTO)

Illuminates when PTO switch is On.See also PTO operation in the Switchsection on page 3-77.

NOTEDo not drive vehicle with PTO en-gaged.

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INDICATORS

20. Range Inhibit

Illuminates to indicate that transmissionoperation is being inhibited and therange shifts being requested may notoccur.

Shifts may be inhibited as the result oftrouble codes, programmed protectionagainst abuse, or function/featureinhibits.

21. Seat Belt, Fasten

Illuminates for 5 seconds wheneverthe ignition key is turned on, then itturns off. The warning lamp may alsocome on if the driver's seat belt is notfastened (if the vehicle was orderedwith a seat belt warning light option).

22. Transmission, Service

Illuminates when transmission hasrecorded a fault code.

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INDICATORS

23. Transmission, Oil TemperatureHigh

Illuminates when transmissionlubricant temperature is too high.

CAUTIONThis should be considered an emer-gency. You should stop the vehicleas safely as possible and turn OFFthe ignition. The vehicle must beserviced and the problem correctedbefore driving again. Failure to doso may cause severe transmissiondamage.

24. Turn Signal, Left

Blinks when the left turn signal isoperating.

25. Turn Signal, Right

Blinks when the right turn signal isoperating.

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GAUGES AND DISPLAYS

GAUGES ANDDISPLAYS

Introduction

Numbered items in illustration are standard or common gauges.Your vehicle includes both standard and optional gauges in the instrument cluster display. Some optional warning light indicators will beinoperable unless that option was specified with the vehicle. (See Warning Light/Indicator Symbols on page 3-28 , for a complete list of standard

and optional gauges and warning light indicators.)

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GAUGES AND DISPLAYS

GaugesTable 3 Gauges Symbol

Symbol Name Symbol Std Opt Page

1. Air Filter Restriction Pressure ● on page 3-48

2. Axle, Drive Oil Temperature

Front

Rear

Center(Tridem)

● on page 3-49

3. Brake, Application Air Pressure ● on page 3-50

4. Diesel Emission Fluid (DEF) ● on page 3-50

5. Engine, Coolant Temperature ● on page 3-50

6. Engine, Oil Pressure ● on page 3-51

7. Fuel Filter Restriction Pressure ● on page 3-52

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GAUGES AND DISPLAYS

Symbol Name Symbol Std Opt PagePrimary

●

8. Fuel Level, Primary and Secondary (if equipped) Secondary●

on page 3-52

9. Generic Air Pressure ● on page 3-53

10. Primary and Secondary Air Pressure (Standard on Air Brake Vehicles Only)

Primary

Secondary● on page 3-54

11. Suspension Load Air Pressure ● on page 3-55

12. Transmission Oil Temperature ● on page 3-55

13. Voltmeter ● on page 3-56

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GAUGES AND DISPLAYS

Speedometer

The Speedometer indicates the vehiclespeed in miles per hour (mph) andin kilometers per hour (km/h). TheSpeedometer cluster also includesseveral warning and indicator lampsand an Odometer/Trip Meter.

Odometer/Trip Meter

1 Odometer2 Trip Meter

The LCD display in the lower part of thespeedometer contains the Odometerand Trip Meter.

The odometer displays the distanceyour vehicle has traveled. It will displayin miles on an English cluster or inkilometers on a metric cluster. Themaximum distance that can be shownon the odometer is 999,999 before itrolls over to zero.

The trip odometer displays how far thevehicle has gone on a particular trip.The trip odometer will display in mileson an English cluster or in kilometerson a metric cluster, in one tenthdivisions. The maximum distance that

can be shown on the trip odometer is9999.9 before it rolls over to zero.

NOTEPressing the trip odometer reset but-ton 4 times in less than 4 secondswill change the odometer units frommiles (mi) to kilometers (km).

To reset the trip odometer, press andhold the button on the cluster. Thenumbers will reset to 0 and begin tocount new miles/km traveled.

NOTEThe Odometer/Trip Meter comes onwhen the door is opened and whenthe ignition key is in the ACC or ONposition. The Odometer/Trip Me-ter will remain on for 3 seconds af-ter the door is closed or the igni-tion switch is turned off. This allowsdriver and service personnel to readthe odometer without ignition switchbeing turned on.

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GAUGES AND DISPLAYS

Tachometer

The Tachometer measures the enginespeed in revolutions per minute (RPM).The Tachometer cluster also includesseveral warning and indicator lampsand an Engine Hour Meter and OutsideTemperature Display.

Watching the tachometer is importantto driving efficiently. It will let youmatch driving speed and gear selectionto the operating range of your engine.If the engine speed gets too high, youcan select a higher gear to lower theRPM's. If the engine speed drops toolow, you can select a lower gear to raisethe RPM's. (Refer to yourOperator’sManual for "More Driving Tips And

Techniques", for further instructionson driving techniques and using thetachometer.) To avoid engine damage,do not let the pointer exceed maximumgoverned speed. (See your EngineOperation and Maintenance Manualfor RPM recommendations.)

Engine Hours/Outside AirTemperature

1 Hour Meter2 Outside Air Temperature3 Snowflake Symbol

The LCD display in the lower part of thetachometer contains the Engine HourMeter and the Outside Air Temperaturedisplay.

The engine hour meter will display thetotal number of hours the engine hasbeen running. The maximum hoursthat can be shown are 99999.9 beforethe meter rolls over to zero.

The Outside Air Temperature (OAT)will display the temperature outsidethe vehicle. The temperature can bedisplayed from -40° to 158° Fahrenheitor -40° to 70° Celsius.

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GAUGES AND DISPLAYS

The display will also alert thedriver when the outside temperateapproaches freezing (32° F or 0° C)by displaying a snowflake symbol.The symbol will turn on when thetemperature drops below 34° F or 11°C and flash for the first 3 seconds,then stay on until the temperature goesabove 37° F or 28° C.

The OATs units (Fahrenheit or Celsius)can be changed by pressing the resetbutton on the cluster 4 times in lessthan 4 seconds.

CAUTION

Modifying the sensor or its locationcan impact vehicle performance,emissions, and/or reliability.

NOTEThe OAT will come on when the dooris open and when the ignition key isin the ACC or ON position. The OATdisplay will turn off when the ignitionswitch is turned off.

NOTEThe OAT uses a sensor (located atthe bottom of the driver's side mir-ror assembly) to measure outside airtemperature only. It is not capableof displaying the temperature of theroad surface on either the tempera-ture display or the snowflake icon.Additionally, the OAT reading maybe affected by exposure to directsunlight.

1. Air Filter Restriction Pressure

The Air Filter Restriction Pressuregauge indicates the condition of theengine air cleaner and is measured byinches of water (H2O). A clean filtershould register 7 in. H2O (may varywith system design) and a filter whoselife is over will register approximately20 in. H2O. The red light will come onwhen it has reached a critical level.This critical level is determined byengine and air filter selections.

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GAUGES AND DISPLAYS

CAUTION

Continued operation with the Air Fil-ter Restriction Gauge reading 20 in.H2O may cause damage to the en-gine. Inspect the filter and replaceif necessary. Holes in the paper el-ement render an air cleaner uselessand may cause the Air Filter Restric-tion Gauge to give a false reading,whether the element is clogged ornot. Replace the element if it is dam-aged. Failure to comply may resultin equipment damage.

2. Axle, Drive Oil Temperature (forMexican Market Only)

Front Drive Axle

Rear Drive Axle

Center Drive Axle (for Tridem Axleconfiguration) (If available)

The Drive Axle Oil Temperature gauges(front, rear, and center) indicate thetemperature of the lubricant in yourvehicle's axles. These temperatureswill vary with the kind of load you arecarrying and the driving conditions youencounter. The red light will come onwhen the temperature has reacheda critical level. This critical level isdetermined by axle type.

NOTEVery high temperatures signal aneed to have the axle(s) lubricationchecked.

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GAUGES AND DISPLAYS

3. Brake, Application Air Pressure

The Brake Application air gaugeindicates how much air pressure isbeing applied from the foot brake valveor trailer brake hand valve to the airbrakes.

4. Diesel Emission Fluid (DEF)

The Diesel Emission Fluid gaugeindicates the total (approximate)amount of DEF in the tank. In additionto indicating empty and full, thegauge also indicates the DEF levelin graduated increments. When theDEF level in the tank reaches 10%full, a red warning light in the gaugeilluminates. When the DEF level inthe tank reaches 5%, the red lightflashes. Refer to your PACCAR EngineAfter-Treatment Control Operator’sManual for more information.

5. Engine, Coolant Temperature

The Engine Coolant (water)Temperature gauge indicates thetemperature of the engine coolant.

If the coolant temperature exceedsthe maximum limits, a red warninglamp in the gauge will turn on andan audible warning will sound. If thecoolant temperature continues to rise,the Check Engine and/or Stop Enginelights will also come on.

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GAUGES AND DISPLAYS

CAUTIONThis should be considered an emer-gency. You should stop the vehicleas safely as possible and turn OFFthe ignition. The vehicle must beserviced and the problem correctedbefore driving again. Failure to do somay cause severe engine damage.

Under normal operating conditionsthe water temperature gauge shouldregister between 165° and 205° F (74°and 90° C). Under certain conditions,somewhat higher temperatures may beacceptable. The maximum allowabletemperature is 220° F (104° C) withthe cooling system pressurized, exceptfor certain engines. Check the enginemanual to be sure.

6. Engine, Oil Pressure

It is important to maintain oil pressurewithin acceptable limits. If oil pressuredrops below the minimum psi a redwarning light in the gauge will turn on,the Stop Engine light will come on andan audible alarm tone will sound.

CAUTION

Continuing to operate your vehi-cle with insufficient oil pressure willcause serious engine damage.

• If the oil pressure fails to rise within10 seconds after the engine starts,stop the engine and determine thecause.

• Check the engine manufacturer'smanual for the correct oil pressureranges for your vehicle's engine.

• If the oil pressure suddenly drops,or the audible alarm and engineoil pressure warning light come onwhile driving, do the following:



3. Place the transmission in park andset the parking brake. (Refer toOperator’s Manual for "ParkingBrake Valve" and "Operating theTransmission" for transmissionshifting and parking brakeinformation.)



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GAUGES AND DISPLAYS

6. Wait a few minutes to allow oil todrain into the engine oil pan, andthen check the oil level. (Refer toOperator’s Manual for "Oil LevelCheck" for details on checking oillevel.)

7. Add oil if necessary. If the problempersists, contact an authorizedKenworth Dealer.

For further information on engine oiland normal operating pressures, seethe Engine Operation and MaintenanceManual.

For further information on enginegauges and operating your engineproperly, refer to Operator’s Manual for"Engine Maintenance".

7. Fuel Filter Restriction Pressure

This gauge tells you the conditionof the fuel filter by indicating therestriction from the fuel filter to the fuelpump. The restriction is measured byinches of mercury (Hg). Check theengine manual for proper restriction.Replace the filter with an approvedfilter only. Do not substitute the wrongmicron element.

NOTEThe maximum allowable restrictioncould vary according to the type ormake of engine. Consult the en-gine manufacturers manual or en-gine dealer for fuel restriction speci-fications.

8. Fuel Level, PrimarySecondary (if equipped)

The Primary Fuel gauge andSecondary Fuel gauge (if equipped)indicate the total (approximate) amountof fuel in each fuel tank. In addition toindicating empty and full, the gauge(s)also indicate the fuel level in graduatedincrements. When the fuel level foreach tank is below 1/4 full, a redwarning light in the gauge will come on.

Primary

Secondary

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GAUGES AND DISPLAYS

NOTEFor Export vehicles, the fuel gaugeswill not state: ULTRA LOW SUL-FUR DIESEL FUEL ONLY.

CAUTION

Kenworth manufactures vehiclesthat are built with different fuel sys-tems and draw tube locations. Be-cause of this and the amount of roadcrown, it is recommended that youdo not operate your vehicle with lessthan one-quarter of your truck’s fuelcapacity. Allowing the fuel level togo below one-quarter of capacitycould result in the lack of fuel to keepthe engine running. In addition, youwill want to keep the fuel tanks atleast half-full to reduce condensa-tion of moisture in the tanks. Failureto comply may result in equipmentor property damage.

WARNING!

Do not carry fuel containers or anycontainer used to store combustibleliquids. Containers may leak or al-low fumes to escape and ignite. Fail-ure to comply may result in death,personal injury, equipment or prop-erty damage.

WARNING!

Do not remove a fuel tank cap nearan open flame. Fuel vapors may behot and combustible and can causean explosion or fire. Failure to com-ply may result in death, personal in-jury, equipment or property damage.

Refer to your Operator’s Manual for"Refueling" for more information.

9. Generic Air Pressure

The General Air Pressure gauge(s) areused for customer installed componentapplications.

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GAUGES AND DISPLAYS

10. Primary and Secondary AirPressure

Primary Air Pressure

Secondary Air Pressure

The Primary Air Pressure gaugeindicates pressure in the rear brakingsystem. The Secondary gaugeindicates pressure in the front brakingsystem. Each gauge indicates theamount of air pressure in each systemin pounds per square inch (psi).

On vehicles equipped with metric airpressure gauges, the gauge face plateincludes a kPa (major) scale and psi(minor) scale.

NOTEBe sure the air pressure registersmore than 100 psi in both servicesystems before you move the vehi-cle.

NOTEIf the pressure in either or both cir-cuits falls below 65 psi, a red warn-ing light in the gauge will turn onand an audible alarm tone will soundwhen the engine is running.

WARNING!

If the air pressure falls below 60 psi(414 kPa), the spring brakes maystop the vehicle abruptly which couldcause an accident resulting in deathor personal injury. Observe the redwarning lamps on the gauges. If onecomes on, do not continue to drivethe vehicle until it has been properlyrepaired or serviced.

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GAUGES AND DISPLAYS

WARNING!

The air pressure warning light andthe audible alarm tone indicate adangerous situation: there is notenough air pressure in the air tanksfor repeated braking and the brakesystem has failed. Without the useof your service brakes your springbrakes could suddenly apply caus-ing a wheel lock-up, loss of control,or over-take by following vehicles.This may cause an accident result-ing in personal injury or death. Bringthe vehicle to a safe stop right away,while you still have control of thevehicle. Refer to the following pro-cedure:

11. Suspension Load Air Pressure

The Suspension Load Air Pressuregauge indicates the amount of airpressure in the air suspension air bags.

When the vehicle is equipped with asecond Suspension Load Air pressuregauge, the #1 gauge indicates theair pressure in the driver's side airbags. The #2 gauge indicates the airpressure in the passenger's side airbags.

12. Transmission Oil Temperature

The Main Transmission OilTemperature Gauge indicatesthe temperature of the oil in thetransmission.

NOTEWatch this gauge to know when thetransmission is overheating.

Do not exceed maximum oiltemperature recommended by themanufacturer. (See the TransmissionOperation and Maintenance Manualfor details.)

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GAUGES AND DISPLAYS

13. Voltmeter

The Voltmeter displays the batteryvoltage. Normally, it should show 12 to14V (volts). A red warning light in thegauge turns on when an out of rangecondition exists.

NOTEEven with a healthy charge/startsystem, the voltmeter may fall wellbelow 12V during engine cranking.If voltage drops below 12V and staysthere, have the electrical systemchecked.

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MULTI-FUNCTION DISPLAY

MULTI-FUNCTIONDISPLAY

Introduction

This section explains the location andfunction of the various instruments andcontrols on your vehicle.

Please remember that each Kenworthis custom made. Your instrument panelmay not look exactly like the one inthe illustration below. Described beloware the most common instruments andcontrols available.

Alarms, Warning Tones andVisual Indicator LightsIntroduction

Your vehicle's dash andinstrumentation uses variousmethods to indicate to you the statusof various systems, or that one ormore of your vehicle's systems maybe malfunctioning. The methodto communicate or alert you of aparticular condition is by:





WARNING!

Do not ignore any type of tone orlights. These signals tell you thatsomething is malfunctioning on yourvehicle and provide you an indi-cation of what system is affected.It could be a failure of an impor-tant system, such as the brakes,which could lead to an accident andmay result in personal injury, death,equipment or property damage.

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Warning and InformationAlert Screens

The Multi-Function display has variousalert screens that are either warnings,or informational.

No Idle Shutdown

The No-Idle Shutdown screen isactivated upon engine shutdown dueto extended idle time while not moving.

Cruise Control Rationality(Brake/Clutch)

The Cruise Control Rationality screenis displayed when attempting toactivate the cruise control prior todepressing both the service brakepedal and the clutch pedal. Forvehicles with automated transmissionsand no clutch pedal, only the servicebrake pedal needs to be depressed.

Park Brake On While Moving

The Park Brake On While Movingwarning screen is displayed whenthe Park Brake is on and the vehiclespeed is greater than zero and/or theaccelerator pedal position is greaterthan 10%.

Lamp Faults - Low/High Beam

The Lamp Faults screen is displayedwhen an error is detected in theheadlamp circuits.

Regen Inhibited

The Regen Inhibited due toSwitch screen is displayed whena regeneration is required and the DPFswitch is in the inhibit position.

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DEF (Low Diesel Exhaust Fluid)

The DEF Warning screen is displayedwhen the DEF Fluid level has reacheda critically low level. It may besuppressed by pushing enter on theMCS (Menu Control Switch). SeeMenu Control Switch on page 3-66.This warning may be accompanied bythe DEF Level in the low range, DEFLamp on solid or flashing, the CheckEngine lamp, the Stop Engine lamp,the MIL lamp, and/or engine de-rate.

SCR/DEF

The Exhaust (SCR/DEF) ServiceRequired screen is displayed wheneither the SCR system has beentampered with or the DEF qualityis below standards. It may besuppressed by pushing enter on theMCS (Menu Control Switch). SeeMenu Control Switch on page 3-66.This warning may be accompaniedby the DEF Lamp flashing, the CheckEngine lamp, the Stop Engine lamp,the MIL lamp, and/or engine de-rate.

Trailer Fault

The Trailer Fault screen is displayedwhen an error is detected in the trailercircuits.

Low Voltage Disconnect

The Low Voltage Disconnect (LVD)screen is displayed when the systemvoltage falls to 12.1 volts.

Over-Crank Protection

Over-Crank Protection screen isdisplayed when the starter motor isbeing protected from over heat or frombeing engaged while the engine isrunning.

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Alarm Clock Active

The Alarm Clock Active screen isdisplayed when the Alarm is on andthe Alarm time equals clock/local time.The Alarm Clock Active screen willbe displayed for approximately 10minutes and may be suppressed bypressing MCS (Menu Control Switch)enter, which turns off the alarm. SeeMenu Control Switch on page 3-66.

Cruise Control Screen

The Cruise Control Set screen isdisplayed when the Cruise Control isactive and the Set/Resume switch isused. The current cruise control speedwill be displayed.

Water In Fuel

The Water In Fuel (WIF) screenis displayed when the WIF sensordetects water in the fuel.

Circuit Failure

The Circuit Failure screen is displayedwhen a circuit fault is detected. Thisscreen is accompanied with the hazardindicators and low beam headlamps.

Hydrocarbon Burn

The “Do Not Drive 10 Minute ParkedRegen Required” is displayed whenunburned hydrocarbons or water vaporare trapped in the Diesel ParticularFilter (DPF). These need to be burnedoff before the vehicle is driven. Thiswarning may be accompanied by theDPF lamp on or flashing, the CheckEngine Lamp, the Stop Engine Lampand/or engine derate. An audible alarmwill engage when the vehicle startsmoving while this warning is active.

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Engine Protection Shutdown Timer

The “Shutdown” is displayed when theengine has derated and the situationrequires the engine to turn off. Thetime to shutdown is displayed. Thiswarning may be accompanied by theCheck Engine Lamp, the Stop EngineLamp and/or engine derate. A restartof the engine is possible with minimalfunction to ensure safe operation. Itmay be suppressed by pushing onthe MCS (Menu Control Switch). SeeMenu Control Switch on page 3-66.

Front Drive Axle Speed Warning

The “Attention Front Axle Is Engaged”is displayed when the front driveaxle is engaged and the vehicle hasexceeded a pre-determined speed.An audible alert will sound when thewarning is displayed.

Engine Over-Speed Shutdown Low AirWarning

The “Overspeed Shutdown May notwork due to low-air” is displayed whenthe system air pressure is to low to

guarantee that the Air Inlet Valve willshut for overspeed conditions. It maybe suppressed by pushing on the MCS(Menu Control Switch). See MenuControl Switch on page 3-66. There isan accompanying audio alarm, whichwill continue to sound as long as theconditions are true even if the pop-uphas been suppressed.

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What You Should Do

If an alert screen comes on whiledriving, do the following:



3. Set the parking brake. (Refer toOperator’s Manual for "Operatingthe Transmission" and "Operatingthe Brake System".)

4. If the engine is overheating donot turn it off (see “OverheatingEngine” in the Operator’s Manual);otherwise, for other conditions turnthe engine OFF.

5. Turn on the emergency flasherand use other warning devices toalert other motorists.

Wingman® ACB WarningTone / Alert Screens• Series of high pitched rings that

repeat at different rates. See thefollowing warning descriptions andcorresponding number of tonesper minute.

• Indicates one of the followingscenarios; your vehicle is too closeto the vehicle ahead, a stationaryobject has been detected, or thereis an active fault in the Wingman®ACB system.

Level 3 Following Distance Alert

This Wingman® ACB warning tone isactive when the following distance isless than what is set in the Wingman®

ACB system. This is the least severeof all the ACB warning tones. The highpitched ring will have a single beeprepeating at a rate of 42 tones perminute.


This Wingman® ACB warning tone isactive when the following distance isless than what is set in the Wingman®ACB system. This ACB warningtone is more severe than the Level3 Following Distance Alert. The highpitched ring will have a double beeprepeating at a rate of 80 tones perminute (40 double beeps per minute).

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This Wingman® ACB warning tone isactive when the following distance isless than what is set in the Wingman®ACB system. This ACB warning toneis the most severe following distancealert. The high pitched ring will have acontinuous beep repeating at a rate of188 tones per minute.

Impact Alert

This is the most severe warning issuedby Wingman® ACB. The warning tone

is active when the driver must takeimmediate evasive action by applyingmore braking power and/or steeringclear of the vehicle ahead to avoid apotential collision. The high pitchedring will have a solid tone for a 3second duration.

Fault Alert

This Wingman® ACB warning toneis active when there is a fault in theWingman® ACB system. The highpitched ring will have a single beepthat is not repeating.

Stationary Object Alert

This Wingman® ACB warning toneis active when the system detects asizable stationary object with reflectivesurfaces in your lane of travel. Thehigh pitched ring will have a continuousbeep repeating at a rate of 188 tonesper minute.

WARNING!

The Wingman® ACB sensor maynot be able to detect vehicles andobjects with limited metal surfaces(such as recreational vehicles,horse-drawn buggies, motorcycles,logging trailers, etc.). Failure to un-derstand the system limitation mayresult in death, serious injury, and/orproperty damage.

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Disabled Alert

This Wingman® ACB is able to usethe vehicle’s foundation brakes as alast resort in attempt to keep the setfollowing distance. This alert screen isactive once the system stops applyingthe foundation brakes because cruisecontrol is disabled.

Not Available Alert

This Wingman® ACB alert screenis active after a cruise set/resumeswitch activation with a fault in the

ACB system. It is also used as thebrake overuse alert when the systemis intervening and using the foundationbrakes excessively.

Multi-Function Display

1 Multi-Function Display

WARNING!

Do not look at the Multi-FunctionDisplay for prolonged periods whilethe vehicle is moving. Only glanceat the monitor briefly while driving.Failure to do so can result in thedriver not being attentive to the vehi-cle's road position, which could leadto an accident involving personalinjury, death or vehicle damage.

The Multi-Function Display integratesthe following list of functions (menuitems) into one display.

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• Blank Screen (for night driving)

• Engine RPM Display

• Fuel Economy Display

• Ignition Timer

• Trip Information Display

• Truck Information Display

• On-Board Diagnostic Display

• Transmission Gear Display(automated transmissions only)

• Clock Display

• Collision Avoidance

• Settings Screen

The Multi-Function Display, locatedabove the primary instrumentcluster will display important vehicleinformation through a constant monitorof systems. The display will turn on

whenever one of the following areactivated:

• Ignition key is in ON or ACCpositions

• Ignition timer is ON (active)

• MCS button is pushed(independent of ignition keyswitch position)

• Clock alarm sounds

• Driver or passenger door isopened

• Hazard warning lamp switch is ON

• Head lamp switch is ON

• Dome lamp switch is ON

• Service Brake switch is ON

Menu Navigation & Definitions

Table 4 Menu Item Accessibility

Menu ItemsAccessible

whileDriving

AccessiblewhileParked

Blank Screen Yes YesFuel Economy Yes NoRPM Detail Yes YesIgnition Timer No YesTrip Information Yes YesTruck Information No YesDiagnosticDisplay No Yes

TransmissionGear Display Yes Yes

Clock Display Yes YesCollisionAvoidance Yes Yes

Settings Screen No Yes

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Right Hand Status Bar andDefinitions

Right Hand Status Bar

●

Cruise Control Active - Iconwill indicate when cruise controlis active or the cruise set speedwill be displayed (optional). Iconlooks like a clock dial face.

●

Alarm On Indicator - The righthand status bar is equippedwith a clock warning bell. If thealarm has been set, the bell willbe displayed with no animation.When the alarm is active, the bellshows animation.

●Gear Display (for automatictransmissions only) - Displayspresent gear.

NOTEThis gear display will only be dis-played in the right-hand status barif the operator has not selected theTransmission Display. If the Trans-mission Display is selected, a largergear icon and the current gear num-ber will be displayed while driving.(See Transmission Display on page3-70 for additional information.)

●Shift Indicator (option)-Prompts the driver when to shiftup on manual transmissions forfuel economy.

Left Hand Menu Bar

The left hand menu bar (menu bullets)gives the status of the current menuitem. Scroll through the menu itemsby rotating the Menu Control Switch(MCS) clockwise (down the menu)or counterclockwise (up the menu).Select a menu item by pressing theMCS. Some menu items requirethe MCS to be pressed to accessSubmenu information.

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1 Menu Control Switch (MCS)2 Heater and Air Conditioning

Controls

Menu Items

A. Blank Screen - No information orgraphics displayed.

B. Fuel Economy

Fuel Economy

1. Bar graph - Indicatesinstantaneous fuel economy.

2. Trip Econ. - Indicates trip fueleconomy.

C. RPM Detail

RPM

RPM reading of actual engine RPM.Engine RPM within the bar graphchevrons (in range zone) indicates theengine is operating in the most efficientRPM range.

D. Ignition Timer

Ignition Timer

Ignition timer is set from this menu.To set the timer, push the MCS onthe ignition timer menu (bullet). Thenrotate the MCS to the desired time (0to 30 minutes). After the time expires,the vehicles ignition (switched) powerwill be shut off (if the ignition key is inthe OFF position).

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E. Trip Information

NOTEWhen accessing the trip informationmenu, push the MCS on this menu(bullet). To exit, push the MCSagain. To reset the trip values, pressthe Trip Odometer Reset Button onthe main gauge instrument cluster.

Trip Information

Trip Info (submenu):

Instant Info

1. Trip Economy (Accessible whendriving) - Indicates trip fueleconomy.

2. Average Speed (Accessible whendriving) - Indicates trip averagespeed (not including idling).

Trip Result

1. Trip Distance - Indicates total tripdistance.

2. Trip Engine Hours - Indicates totaltrip engine hours.

Idle Info

1. Trip Engine Hours - Indicates totaltrip engine hours.

2. Trip Idle Percentage (%) -Indicates total trip idle percentage.

PTO Info (Optional)

1. PTO Hours - Indicates total vehiclePTO operation hours.

2. PTO Trip Hours - Indicates totaltrip PTO operation hours. To resetthe Trip Values, press the TripOdometer Reset Button on themain gauge instrument cluster.

3. PTO Trip (%) (Accessible whenparked) - Indicates total trip PTOpercentage.

4. PTO Trip Fuel - Indicates total tripPTO fuel.

5. PTO Trip Economy - Indicatestotal trip PTO economy.

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NOTEDisplay functions for PTO hours,PTO Trip Hours and PTO Trip Per-centage will only be available if sup-ported by the engine installed. If thetruck has a factory-installed PTO,these fields will appear in the TripInformation screen. If the enginedoes not support the data, dasheswill be shown.

F. Truck Information

NOTEOnly available truck informationwill be shown (i.e., manual trans-missions do not have a softwareversion).

NOTEWhen accessing the truck informa-tion menu, push the MCS on thismenu (bullet). To exit, push theMCSagain.

Truck Information

Truck Info (submenu):

Chassis Info

1. Chassis Number

2. Fleet ID Number (Optional)

3. Cab Electronic Control Unit(CECU) Software Version

Engine Info

1. Engine Make

2. Engine Model

3. Engine Software Version

4. Governed Speed Limit (Optional)

Transmission Info (AutomatedTransmissions only)

1. Transmission Make

2. Transmission Model

3. Transmission Software Version

ABS Info

1. ABS (Anti-Lock Braking System)Make

2. ABS Model

3. ABS Software Version

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G. Diagnostic Display

NOTE"Faults Found" will only be active ifa red or yellow warning lamp is il-luminated and additional informationis available.

Diagnostic Display

The diagnostic display menu (bullet)will indicate a fault that is present.While on this menu item the displaywill either indicate "No Faults Found"or "Faults Found". If "Faults Found"is active, pushing the MCS on thismenu item will show "Exit", "Engine","Transmission", "ABS", "Truck", and/or"Soot Filter".

Exit will take you back to the diagnosticmenu bullet and clicking on any ofthe other items will display an activevehicle diagnostic message.

H. Transmission Display (AutomatedTransmissions only)

NOTERefer to the Automated Transmis-sion Operator's Manual for completedescription of arrow symbols.

Transmission Display

Shows gear number that coincideswith the current transmission gearselected. Can also indicate to driverto shift up or down.

I. Speed Control ManagementDisplay (Automated Transmissionsonly)

Upshift Indicator while on TransmissionGear Screen with Autoshift or UltrashiftTransmissions

The “Shift for fuel econ.” is displayedwhen the current screen isTransmission Display And theengine requests an upshift for betterfuel economy.

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J. Clock Display

Clock Display

Shows Local or Home time as selectedby the driver. The time can also beset to show 12 hour time (AM/PM) or24 hour time (military). Refer to the"Settings Menu" section for additionalinformation covering clock/alarm andformatting options.

K. Settings Menu

The Settings menu screen allowsthe driver to view and/or change thefollowing menu items:

• Clock Display Format 12 Hour(AM/PM) or 24 Hour (military)

• Clock Home/Local Time

• Clock Alarm ON/OFF

• Clock Local Time (Set)

• Clock Alarm Time (Set)

• Trailer Detect

• Headlamps With Wipers

• Units Standard or Metric

• Language English, Spanish orFrench

• Pre-Trip Lamp Test

• Exit

Settings Menu

To Set Clock Display Format:

1. When in the settings menu, scrollthrough the list of menu items to"Format".

2. Press the MCS to display either 12hour (AM/PM) or 24 hour (militarytime).

Clock Display Format

To Set Clock Home/Local Time:

1. Scroll through the list of menu itemsto Time: Home or Local. Press theMCS to toggle between Home or Localtime.

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Clock Home/Local Time

2. To change the selected time (Homeor Local), rotate the MCS to theSettings screen. Press the MCS toselect it.

3. When in the menu settings, scrollthrough the list of menu items to SetClock Time (for home time) or SetLocal Time. Press the MCS to select it.

Set Clock Time

4. Rotate the MCS to change the hour.Press the MCS. Rotate the MCS againto change the minutes. Press the MCSto set the new time.

Set Hour/Minutes

5. To exit the screen, rotate the MCSto Exit, then press the MCS.

Exit

To Set Alarm Time:

1. Rotate the MCS to the "Settings"menu. Press the MCS.

2. When in the Settings menu, scrollthrough the list of menu items to "SetAlarm Time". Press the MCS to selectit.

Set Alarm Time

3. Rotate the MCS to change the hour.Press the MCS. Rotate the MCS again

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to change the minutes. Press the MCSto set the new alarm time.


Set Alarm Hour/Minutes

To Turn Alarm ON/OFF:


2. When in the setting menu, scrollthrough the list of menu items to"Alarm".

3. Press the MCS to turn the alarmON or OFF.

NOTEUnless there is a loss of batterypower, the display will always main-tain the last screen from key off afterthe key is turned back to the on posi-tion and the POST cycle completes.


NOTEA bell icon appears in the clock dis-play when the alarm has been set toON.

Alarm "On"

To Activate Trailer Detect:

The trailer outputs on your vehiclemay be able to detect whether or nota trailer is attached. Should a trailerconnection be detected and later lostwhile driving the driver will be notifiedof the error. Errors will be presentedto the driver as either intermittent orpersistent depending on the durationof the error. All notifications may besuppressed by the driver.

1. Scroll to TRLR Detect and selectby pressing the MCS.

2. Scroll to the desired ON/OFFsetting.

3. When set to 'ON' Trailer Detect willbe active when the ignition switchis in the 'ON' position.

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Trailer Detect

To Activate Headlamps with Wipers:

1. Scroll to HL + Wiper and select bypressing the MCS.

2. Press MCS to toggle to the desiredON/OFF setting.

3. When set to 'ON' the Low BeamLamps will be active when theignition switch is in the 'ON'position and the Wiper ControlSwitch is 'ON'.

Headlamps with Wipers

To Set Standard or Metric Units:


2. When in the Settings menu, scrollthrough the list of menu items to"Units". Press the MCS to displayeither Standard or Metric units.

To Set Language:

1. Rotate the MCS knob to the"Settings" menu. Press the MCS.

2. When in the Settings menu, scrollthrough the list of menu items to"Language". Press the MCS todisplay either English, Spanish orFrench.

L. Pre-trip Lamp Test

When activated with the MCS,‘Pre-trip Lamp Test Active’ appearson the Multi-function display and willre-appear periodically while the test

is active. The test will illuminate thefollowing lamps:

Lamp SequenceMarker* 1, 2Clearance* 1, 2Headlamp low-beam 1Headlamp high-beam 2Auxiliary (fog or driving) 1, 2Stop 2Park* 1, 2Hazard/Turn lamps 1

All lamps with sequence #1 willilluminate simultaneously for 10seconds. All lamps with sequence#2 will illuminate simultaneously for10 seconds immediately followingsequence #1. Each sequence willilluminate lamps for 10 seconds.With the default settings and withoutintervention the Pre-trip Lamp Test willdeactivate after 10 minutes. Sequencetime can vary from 10 seconds with a10 minute duration up to 30 secondsand a 30 minute duration.

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Asterisks (*) indicate that dash switchmust be ON for the Pre-trip Self Test tooperate these lamps.

Pre-trip Lamp Test

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SWITCHES

SWITCHES

Introduction

Numbered items in illustration are standard or common indicators.

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SWITCHES

Table 5 Dash Switches


1. Axle, Automatic Traction Control None ● See Axle, Automatic Traction Control on page3-81.

2. Axle, De-Clutch - Front Green ● See Axle, De-Clutch - Front on page 3-81.

3. Axle, Diff-Lock - Dual Amber ● See Axle, Diff-Lock - Dual on page 3-81.

4. Axle, Diff-Lock - Forward Rear Amber

●

See Axle, Diff-Lock - Forward Rear on page3-81.

5. Axle, Diff-Lock - Rear Rear Amber ● See Axle, Diff-Lock - Rear Rear on page 3-81.

6. Axle, Diff-Lock - Single Rear Amber ● See Axle, Diff-Lock - Single Rear on page 3-81.

7. Axle, Inter-Axle Differential Locked (Tandem) Amber ● See Axle, Inter-Axle Differential Locked(Tandem) on page 3-81.

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SWITCHES


8. Axle, Two Speed Green ● See Axle, Two Speed on page 3-81.

9. Back Up Alarm Mute Amber ● See Back Up Alarm Mute on page 3-81.

10. Brakes, Parking Brake Valve Red ● SeeBrakes, Parking Brake Valve on page 3-81

11. Dump Truck Gate Red ● See Dump Truck Gate on page 3-81.

12. Engine, Brake Level None ● See Engine, Brake Level on page 3-81.

13. Engine, Brake On/Off Green ● See Engine, Brake On/Off on page 3-81.

14. Engine, Cruise Control On/Off Green ● See Engine, Cruise Control On/Off on page3-81.

15. Engine, Cruise Control Set/Resume None ● See Engine, Cruise Control Set/Resume onpage 3-81.

16. Engine, Fan Override Green ● See Engine, Fan Override on page 3-82.

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SWITCHES


17. Engine, Heater Green ● See Engine, Heater on page 3-83

18. Engine, Overspeed Air Shutdown (Test) None ● See Engine, Overspeed Air Shutdown (Test)on page 3-83.

19. Engine, Overspeed Air Shutdown (Manual) Red ● See Engine, Overspeed Air Shutdown (Manual)on page 3-83.

20. Exhaust, Diesel Particulate Filter (DPF)Regeneration None ● See Exhaust, Diesel Particulate Filter (DPF)

Regeneration on page 3-83.

21. Generic Air, Accessory Green ● See Generic Air, Accessory on page 3-83.22. Generic, Spare SPARE Green ● See Generic, Spare on page 3-83

23. Lights, Auxiliary Green ● See Lights, Auxiliary on page 3-84.

24. Lights, Beacon Green ● See Lights, Beacon on page 3-84.

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SWITCHES


25. Lights, Flood Amber ● See Lights, Flood on page 3-84.

26. Lights, Headlight None ● See Lights, Headlight on page 3-85.

27. Lights, Panel Dimmer None ● See Lights, Panel Dimmer on page 3-85.

28. Lights, Park Light None ● See Lights, Park Light on page 3-85.

29. Power Take-off (PTO) Amber ● See Power Take-off (PTO) on page 3-85.

30. Suspension, Dump Amber ● See Suspension, Dump on page 3-86.

31. Trailer Air Supply Red ● See Vehicle/Trailer Air Supply Valve on page4-22

32. Transfer Case, Two-Speed Amber ● See Two-Speed Transfer Case on page 3-86.

33. Trip Odometer Reset Button ● See Odometer/Trip Meter on page 3-46.

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SWITCHES

1. Axle, Automatic TractionControlMomentarily push switch in to engageTraction Control (TC).

2. Axle De-clutch - FrontYour vehicle maybe equipped witha front drive axle declutch , forcorrect operation, please see themanufactures operators instructionmanual.

3. Axle Diff-Lock - DualTurn switch on to engage Front andRear Axle Diff Lock.

4. Axle Diff-Lock - Forward RearTurn switch on to engage ForwardRear Axle Diff Lock.

5. Axle Diff-Lock Rear RearTurn switch on to engage Rear RearAxle Diff Lock.

6. Axle Diff Lock - Single RearTurn switch on to engage Single RearAxle Diff Lock.

7. Axle, Inter-Axle DifferentialLocked (Tandem)Turn switch on to engage Inter-AxleDifferential Lock.

8. Axle, Two SpeedIf equipped, the two speed axleswitch allows you to select axle highand low ranges. The low range(Off) provides maximum torque foroperating off-highway. The highrange (On) is a faster ratio forhighway speeds.

9. Back Up Alarm MuteTurn switch on to mute Back UpAlarm.

10. Brakes, Parking Brake ValvePull yellow knob to activate parkingbrakes. See Parking Brake Valve onpage 3-81

11. Dump Truck GateTurn switch on to open Dump TruckGate.

12. Engine, Brake LevelIn the up position there will be 100%engine retarding. In the middleposition there will be 60% engineretarding. In the down position therewill be 33% engine retarding

For more information on when andhow to use the engine brake in yourvehicle, see the engine brake owner’smanual for additional engine brakeinformation.

13. Engine, Brake On/OffTurn switch on to activate EngineBrake system.

For more information on when andhow to use the engine brake in yourvehicle, see the engine brake owner’smanual for additional engine brakeinformation.

14. Engine, Cruise Control On/OffTurn switch on to activate CruiseControl System.

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SWITCHES

15. Engine, Cruise ControlSet/ResumeThe Cruise Control Set/Resumeswitch allows you to SET the desiredspeed or RESUME the desired speedafter the cruise control function hasbeen interrupted.

WARNING!

Do not operate the cruise controlwhen operating on road surfaceswith poor traction (wet, icy, or snowcovered roads) or in heavy traffic.Accelerations caused by the normaloperation of the cruise control couldcause you to lose control of the ve-hicle resulting in an injury accident.

16. Engine Fan OverrideThe engine fan switch allows youto control the engine fan manuallyor automatically. With the ignitionkey switch ON and the fan switch inthe MANUAL position, the enginefan will be on regardless of enginetemperature. With the engine fanswitch in the AUTOMATIC position,the engine fan will automatically turnon when the engine coolant reachesa temperature of about 200°F (93°C)or when the air conditioning systemhas reached setpoint pressure.With an electronic engine, the fanmay also be activated by air intaketemperature, oil temperature andcompression brake usage.

WARNING!

Do not work on or near the fan withthe engine running. Anyone near theengine fan when it turns on could beseriously injured. If it is set at MAN-UAL, the fan will turn on any time theignition key switch is turned to theON position. In AUTO, it could en-gage suddenly without warning. Be-fore turning on the ignition or switch-ing from AUTO to MANUAL, be sureno workers are near the fan.

CAUTION

The fan or equipment near it couldbe damaged if the fan turns on sud-denly when you do not expect it.Keep all tools and equipment awayfrom the fan.

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SWITCHES

CAUTION

Do not operate the engine fan inthe MANUAL position for extendedperiods of time. The fan hub wasdesigned for intermittent operation.Sustained operation will shorten thefan hub’s service life as well as re-duce fuel economy.

17. Engine HeaterTurn switch on to activate the EngineHeater

18. Engine, Overspeed AirShutdown (Test)Set the park brake. Hold downswitch and increase engien RPMto test that Engine Overspeed AirShutdown system functions correctly.A system reset will be required beforere-starting engine.

19. Engine, Overspeed AirShutdown (Manual)Turn switch on to engage the EngineOverspeed Air Shutdown system. Asystem reset will be required beforere-starting engine

20. Exhaust, Diesel ParticulateFilter (DPF) Regeneration SwitchManually controls the dieselparticulate filter regeneration process.(Refer to Engine After-treatmentControls Operator's Manual foradditional information.)

21. Generic, Air, AccessoryProvides accessory air to the endof frame connection when switch isturned on.

SPARE 22. Generic, SpareTurn switch on to power customerinstalled accessory.

The ignition key switch (located to theleft of the steering column) has fourpositions: ACC (Accessories), OFF,ON, and START.

OFF: In this position all accessoriesare OFF (except those listed below)and you can remove the key.

• The following lights andaccessories have power when thekey is in the OFF position:

° brake lights

° emergency hazard flasher

° dome and courtesy lamps (ondoors)

° electric horn

° tail lights

° marker lamps

° headlights

° radio station memory

° instrument lights

° multi-function display memory

NOTEIn the OFF position, fuel is cut off bya solenoid valve.

ACC (Accessory): With the key in thisposition you can play the radio, defrost

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SWITCHES

mirrors (if equipped with mirror heat)or use other accessories.

ON: In the ON position all circuits areenergized. Panel warning lights willlight and the buzzer will sound until(1) the engine is started, (2) normal oiloperating pressure is reached, and (3)air brake system pressure is above64 psi (441 kPa). In this position, theignition key cannot be removed.

START: Turn the key to this positionto start your engine: it energizes thestarter and retracts the solenoid valveto allow fuel supply to the engine.Release the key after the engine hasstarted. If your Kenworth is equippedwith the optional push button starterswitch, use it to engage the starter. Forcomplete engine starting procedures,see OPERATING THE ENGINE onpage 4-38.

23. Lights, AuxiliaryTurn switch on for Auxiliary Lights.

24. Lights, BeaconTurn switch on for Beacon Light(s).

On vehicles equipped with the DaytimeRunning Light (DRL) system, the frontturn signals are used as DRL’s at fullintensity.

Three controls (or conditions) will affectwhether the system is ON or OFF:

• headlight (master) switch

• engine cranking

• parking brake

If the headlight switch is turned OFF,the DRL system engages automaticallyafter the engine starts and you releasethe parking brake. If the headlightswitch is ON, the DRL system isoverridden, and headlights operatenormally. Also, during engine crankingthe DRL is temporarily turned off.

WARNING!

Do not use daytime running lights(DRL) during periods of darkness orreduced visibility. Do not useDRL asa substitute for headlights or otherlights during operations that requirelighting of your vehicle. Failure tocomplymay result in death, personalinjury, equipment or property dam-age.

25. Lights, FloodTurn switch on for cab mounted FloodLights.

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SWITCHES

WARNING!

Use your HazardWarning Light Sys-tem any time you have to stop off theroad or on the side of the road, dayor night. A hard-to-see vehicle canresult in an injury accident. Anothervehicle could run into you if you donot set your flashers and follow theplacement of emergency signals perFMCSR 392.22.

26. Lights, HeadlightAll lights on the vehicle arecontrolled by a master switch. It is athree–position (rocker type) switch.The switch controls the followinglights:• The first position (all the way down)is the OFF position.• The second position (middle) turnsON the instrument panel lights, taillights, marker lamps and side lights.• The third position (all the way up)turns ON the headlights.

CAUTION

If you have confirmed there is aproblem in the low beam wiring cir-cuit, proceed with caution to thenext available exit/turnoff and safelypull your vehicle completely off theroad and call for assistance. Driv-ing your vehicle with the headlampson high beam (at reduced intensity)for a prolonged period could leadto an injury accident. Contact yournearest Kenworth dealer to havethe problem corrected as soon aspossible.

27. Lights, Panel DimmerRotate thumb wheel up to brightenpanel lights. Rotate thumb wheeldown to dim panel lights.

NOTEThe Headlight Switch must be in oneof two ON positions for the panellights to operate.

28. Lights, Park LightTurn switch on for Park Lights. Whenthe Park Lights are on the dash lights,side and tail lights are also on.

29. Power Take-off (PTO)Turn switch on to engage PTO.

Your Kenworth vehicle may beequipped with a dash mountedair switch that controls PTOengagement/disengagement.

When the operator activates the switchfor the PTO, the status indicatorlamp (located on the switch) willimmediately illuminate even thoughPTO engagement may not haveoccurred.

If the PTO is engaged and the operatorturns the switch OFF, the PTO statusindicator lamp (located on the switch)will go out immediately even thoughPTO disengagement may not haveoccurred.

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SWITCHES

NOTEDo not drive vehicle with PTO en-gaged.

NOTEActual PTO engagement / disen-gagement may be delayed momen-tarily since it is controlled by the airsystem and mechanical movement.

CAUTION

Increasing engine RPM before thePTO is actually engaged could pre-vent the PTO from engaging and/orcause PTO damage.

30. Suspension, DumpTurn switch on to deflate suspensionair bags. The switch is guardedto protect you from accidentallydeflating the suspension.

WARNING!

Do not operate the Air SuspensionDeflate Switch (Dump Valve) whiledriving. Sudden deflation while yourvehicle is moving can affect handlingand control and could lead to an ac-cident. Use this switch only whenyour vehicle is not moving. Failure tocomply may result in personal injury,death, equipment or property dam-age.

CAUTION

Operating a vehicle with air suspen-sion bags either overinflated or un-derinflated may cause damage todriveline components. If a vehiclemust be operated under such condi-tions, do not exceed 5 mph (8 km/h).

31. Trailer Air SupplyThe red octagon knob controls the airsupply to the trailer.

32. Transfer Case Switch,Two-SpeedYour vehicle maybe equipped witha two speed transfer case, forcorrect operation, please see themanufactures operators instructionmanual.

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STEERING COLUMN

STEERING COLUMN

Introduction

Steering Column Controls

1. Turn Signal Lever2. Trailer Brake Hand Valve (optional)3. Tilt Steering Column Lever (optional)

Turn Signal/High BeamSwitch

NOTEThe ignition key must be turned toON for the signal/switch to operate.

The lever-action turn signal/high beamswitch is located on the left side of thesteering column.. Each time a turnindicator is activated the buzzer emitsa short beep.

Turn Signals

• To signal a right turn, push thelever up (clockwise).

• To signal a left turn, pull the leverdown (counterclockwise).

CAUTION

After you complete a turn, shutthe system off by returning thelever to the “OFF” (center) position.The switch's lever action is NOTself-canceling. Failure to shut offa turn signal could confuse otherdrivers and result in an injury ac-cident. An indicator light in theinstrument panel will flash until theturn signal is turned off.

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STEERING COLUMN

High Beam

NOTEThe headlights must be ON for thehigh beam switch to operate.

• To switch your headlights to loweror higher beam, gently pull the turnsignal lever, toward the steeringwheel, until you hear the switchclick and the beam changes.The blue indicator light in theinstrument panel will be ON whenthe high beam is being used.

• To return to previous beam: pullthe lever towards the steeringwheel again.

• To momentarily flash yourheadlights (illuminating thehigh-beams), push the turn signallever forward.

NOTE• You cannot momentarily flash

headlights when high beams areon. The headlights will flash on ifthey are off, if headlamps are onas low beams, headlamps dim to25%.

• Headlight flash is not availableon models with high intensitydischarge (HID) headlight option.

• Check your local state’sregulations for any restriction onthe use of the high-beam flashingfunction.

Emergency Flasher Switch

The four-way Emergency Flasherswitch is on the turn signal body,just below the turn signal lever. Theemergency flasher makes all fourturn signals (front and rear) flashsimultaneously. The flasher worksindependently of the ignition switch.You should always use the flasher ifthe vehicle is disabled or parked underemergency conditions.

• To operate the emergency flasher,pull the switch tab out.

• The flasher is self-cancelling. Toturn off, activate left or right turnsignal.

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STEERING COLUMN

WARNING!

Use your Hazard Flasher WarningSystem any time you have to stop offthe road or on the side of the road,day or night. A hard to see vehi-cle can result in an injury accident.Another vehicle could run into you ifyou do not set your flashers. Alwaysmove the vehicle a safe distance offthe road when stalled or stopped forrepairs.

WARNING!

Your disabled vehicle can be dan-gerous for you and others. Thehot exhaust system could ignite drygrass, brush, spilled fuel, or othermaterial that can cause fires. Donot park or operate your vehicle inareas where the hot exhaust systemcould cause a fire.

Windshield Wipers/Washer

Your Kenworth is equipped with atwo-speed, intermittent windshieldwiper. A five-position switch with pushbutton, (located low on the dash, to theright of the steering column), operatesthe windshield wipers and washer.

NOTEThe ignition key must be turned toON or ACC for the wiper/washerswitches to operate.

Wiper Switch Settings

Wiper SwitchPosition

Wiper Speed

0 Off1 Intermittent Range: Long

Delay2 Intermittent Range:

Short Delay3 Low Speed4 High Speed

Wiper/Washer (Push In)

• Turn knob clockwise to changewiper mode. The first positionafter OFF (0) is intermittent delay,ranging from long delay (1) toshort delay (2) modes. Turn toposition 3 and 4 for low or highwiper speeds.

• The final option activates thewasher cycle. To wash thewindshield, push knob IN andrelease. Hold knob IN to extendwashing cycle.

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STEERING COLUMN

After one to three wipes(depending on how long you holdthe switch in) the wipers will shutoff automatically. The windshieldwasher reservoir is located insidethe engine compartment below theradiator expansion tank. Checkthe windshield washing fluid leveldaily. If necessary, fill to top.

1. Windshield Washer Reservoir

WARNING!

Do not drive with worn or dirty wiperblades. They can reduce visibility,making driving hazardous. Cleanblades regularly to remove road filmand wax build-up. Use an alco-hol based cleaning solution and alint-free cloth, and wipe along theblades.

CAUTION

If the electric pump is operated for along period (more than 15 seconds)with a dry reservoir, the pump rotormay be damaged.

Clean all inside and outside windowsregularly. Use an alcohol- basedcleaning solution and wipe dry witheither a lint free or a chamois cloth.Avoid running the wiper blades over adry windshield to prevent scratchingthe glass. Spray on washer fluid first.A scratched windshield will reducevisibility.

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STEERING COLUMN

Trailer Brake Hand Valve

This hand valve, mounted on thesteering wheel column, provides airpressure to apply the trailer brakesonly. It operates independently ofthe foot treadle valve. See Using theBrake System on page 4-15, for moreinstructions on proper use of the TrailerBrake Hand Valve.

Stop/Turn Signal LampOperation

Your Kenworth vehicle uses combinedstop/turn signal lamps at the rear ofthe vehicle, using the same bulb toperform both functions. This means asingle bulb is used for the brake lampas well as the turn signal lamp. Thisbulb will burn steadily with the brakesapplied. The same bulb will flash withthe turn signal activated, even with thebrakes applied.

Maximum Number of LampsAllowed per Circuit

• Vehicle Stop/Turn Signal Circuit

The lighting control unit is limitedto 5 amps total, or two (2) 25 wattincandescent bulbs per side. Do notwire more than two incandescent bulbsper side to the vehicle tail lamp fixtures.If more than two bulbs are requiredfor each tail lamp fixture, install LEDtype lamps, or contact your nearestKenworth dealer for other options.

• Trailer Turn and Vehicle ForwardSide Facing Turn Lamp Circuit

The lighting control unit is limitedto 20 amps or nine (9) 25 wattincandescent bulbs total (per side) forthe combination of trailer turn lampsand vehicle forward side facing turnlamps. Do not wire more than nineincandescent bulbs per side for thecombination of trailer turn lamps andvehicle forward side facing turn lamps.

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STEERING COLUMN

If more than nine bulbs per side arerequired, install LED type lamps, orcontact your nearest Kenworth dealerfor other options.

CAUTION

Before installing additional vehiclestop/turn lamps, trailer turn lamps oradditional forward side facing turnlamps on the vehicle, make sure thelighting circuit limits described aboveare not exceeded. Exceeding thenumber of lamps designated abovecan/will cause the electronic controlunit to default to a protection mode,causing the lamps to not functionproperly.

Similar to the headlamp system, if aproblem is detected with the electroniccontrol unit, the control unit will cyclethe turn signals off once every 9seconds. You can detect that this isoccurring if the turn signal indicatorsin the dash operate intermittently. If

you experience intermittent turn signaloperation, the problem is either ashort in the turn signal circuit or themaximum number of bulbs has beenexceeded for the circuit.

If you experience any vehicle stop/turnsignal issues, contact your nearestKenworth dealer.

Adjustable Tilt/TelescopingColumn

The Adjustable Tilt/TelescopingColumn is an option on yourKenworth. Depending on yourvehicle’s configuration, you mayhave a Tilt/Telescoping steeringcolumn or Fixed steering column.The tilt feature allows forward andrearward movement of the wheel.The telescoping feature allows youto move the wheel up and down. Toactivate these features, locate theTilt/Telescoping pedal at the base ofthe steering column.

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STEERING COLUMN

WARNING!

Do not adjust the Tilt-TelescopingSteering Wheel while the vehicle isin motion, it could cause loss of con-trol. You would not be able to steerproperly and could have an acci-dent. Make all adjustments to thesteering column while the vehicle isstopped. Failure to comply may re-sult in death, personal injury, equip-ment or property damage.

To tilt, raise or lower the Telescopingsteering wheel:

• Push the pedal down fully. Movethe wheel to the desired heightand angle, then release the pedalto lock the wheel at the desiredposition.

1 Tilt / Telescoping SteeringColumn Lever (optional)

Horn

Your vehicle may be equipped withair horns. To operate, pull on thelanyard extending from the overheadheader panel. Your vehicle may alsohave an electric horn. To sound theelectric horn, press the button in thecenter of the steering wheel, whichis the standard location for electrichorns (optional horn locations may berequested).

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MIRRORS

MIRRORS

Introduction

Your vehicle comes equipped with twooutside rear view mirrors that enableyou to see to the sides and behindyour vehicle. Be sure both mirrors areadjusted properly before you begindriving.

WARNING!

Adjust all mirrors before driving. Ad-justing the mirrors while driving cancause you to take your eyes off theroad, which could result in an acci-dent. Failure to do so could lead toserious injury or equipment damage.

To provide good visibility, adjust themirror so the side of your vehicleappears in the inboard part of themirror.

WARNING!

Convex mirrors can distort imagesand make objects appear smallerand farther away than they reallyare. You could have an accidentif you are too close to another ve-hicle or other object. Keep plentyof space between your vehicle andothers when you turn or changelanes. Remember that other objectsare closer than they may appear.

Power Mirror Switch

If your vehicle is equipped with powermirrors, the directional controls forboth mirrors are located near the top ofthe driver side door trim pad.

1. Power Mirror & HeatedMirror Controls

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MIRRORS

1. Mirror Directional ControlPad

2. Mirror Selector Switch

To Adjust Kenworth AerodynamicStyle Mirrors

1. Move the mirror selector switchto the right or left from the neutralcenter position to select thedesired mirror for adjustment.

2. Depress the mirror directionalcontrol pad in one of its four arrowdirections to adjust the mirrorin/out or up/down.

NOTEAfter mirror adjustments have beencompleted, return the mirror selec-tor switch back to the center (neu-tral) position to prevent unintentionaladjustments to the mirrors.

To Adjust Moto Mirrors

1. For in/out mirror adjustment: Movethe mirror selector switch to theright or left from the neutral centerposition to select the desiredmirror for adjustment.

NOTEIf the mirror is fixed (non-motorized)on the left side, then the mirror se-lector switch will ONLY allow selec-tion of the neutral and right mirrorswitch positions.

2. Depress the mirror directionalcontrol pad towards the arrows

pointing left or right to adjust themirror in/out.

NOTEBecause the Moto mirrors have only2- way adjustment, the mirror direc-tional control pad is also restricted inits movement to left or right ONLY.

NOTEAfter mirror adjustments have beencompleted, return the mirror selec-tor switch back to the center (neu-tral) position to prevent unintentionaladjustments to the mirrors.

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MIRRORS

Mirror Heat Button

Your Kenworth vehicle may beequipped with optional heated mirrors.Mirror heat is controlled by the mirrorheat switch button, which is part of themirror switch module located on thedriver side door pad.

1. Mirror Heat Switch Button2. Mirror Heat Indicator Light

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DRIVING

DRIVING TIPS AND TECHNIQUESIntroduction . . . . . . . . . . . . . . . . . . 4-5Coasting . . . . . . . . . . . . . . . . . . . . 4-5Descending a Grade . . . . . . . . . . . . . . 4-6Economical Driving . . . . . . . . . . . . . . . 4-6Fuel - Excess Consumption . . . . . . . . . . . 4-8Safe Driving . . . . . . . . . . . . . . . . . 4-10Cruise Control . . . . . . . . . . . . . . . . 4-11Air Suspension Height/Air Pressure . . . . . . . 4-12

OPERATING THE BRAKE SYSTEMIntroduction . . . . . . . . . . . . . . . . . 4-15Using the Brake System:. . . . . . . . . . . . 4-16Air Supply System . . . . . . . . . . . . . . 4-17Using the Parking Brake . . . . . . . . . . . . 4-19Vehicle/Trailer Air Supply Valve . . . . . . . . . 4-22Brake Safety and Emergency. . . . . . . . . . 4-25Anti-Lock Braking System . . . . . . . . . . . 4-27

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DRIVING

Trailer Brake Hand Valve. . . . . . . . . . . . 4-32Driving with an Unloaded Trailer . . . . . . . . 4-32Engine Retarders . . . . . . . . . . . . . . . 4-33Exhaust Brake . . . . . . . . . . . . . . . . 4-34Engine Brakes . . . . . . . . . . . . . . . . 4-35Brake Components . . . . . . . . . . . . . . 4-35

OPERATING THE ENGINEIntroduction . . . . . . . . . . . . . . . . . 4-38Normal Weather . . . . . . . . . . . . . . . 4-39Cold Weather . . . . . . . . . . . . . . . . 4-40Engine Block and Oil Pan Heater (Option) . . . . 4-40Engine Warm-up . . . . . . . . . . . . . . . 4-41Ether Metering Equipment . . . . . . . . . . . 4-44Idling the Engine . . . . . . . . . . . . . . . 4-45Engine Shutdown System (ESS) . . . . . . . . 4-46Cruise Control . . . . . . . . . . . . . . . . 4-47Engine Fan Control . . . . . . . . . . . . . . 4-49Engine Control Display . . . . . . . . . . . . 4-50

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DRIVING

Engine Shutdown System . . . . . . . . . . . 4-50

OPERATING THE REAR/DRIVE AXLEIntroduction . . . . . . . . . . . . . . . . . 4-52Inter-Axle Differential Lock . . . . . . . . . . . 4-52Driver Controlled Main Differential Lock . . . . . 4-55Dual Range (Two-Speed) Rear Axle . . . . . . . 4-56Auxiliary Axles - Pusher or Tag . . . . . . . . . 4-58

OPERATING THE TRANSMISSIONIntroduction . . . . . . . . . . . . . . . . . 4-65Transmission Warm-Up . . . . . . . . . . . . 4-65Operating Manual Transmissions . . . . . . . . 4-66Putting the Vehicle in Motion . . . . . . . . . . 4-66More Transmission Tips . . . . . . . . . . . . 4-69Operating Automatic Transmissions . . . . . . . 4-71Auxiliary Transmissions . . . . . . . . . . . . 4-72Steerable Drive Axle . . . . . . . . . . . . . 4-72

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DRIVING

SHUT-DOWNIntroduction . . . . . . . . . . . . . . . . . 4-73Final Stopping Procedures . . . . . . . . . . . 4-73Before Stopping the Engine . . . . . . . . . . 4-74Refueling . . . . . . . . . . . . . . . . . . 4-75

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DRIVING TIPS AND TECHNIQUES

DRIVING TIPS ANDTECHNIQUES

Introduction

This section covers driving tips andtechniques on how to drive yourKenworth efficiently. For furtherinformation on driving techniques, readthe Truck Driver Handbook includedin your glove box literature package.It will give you more tips on starting,shifting, and driving your vehicle.

Coasting

Do not coast with the transmissionin neutral or with the clutch pedaldepressed.

WARNING!

Do not coast with the transmissionin neutral or with the clutch pedaldepressed, it is a dangerous prac-tice. Without the use of the retardingpower of the drivetrain, your vehiclecan reach dangerous speeds. Atvery high speeds you may not beable to put the transmission in anygear. At high speeds you could seri-ously damage your vehicle or causean accident when you put the trans-mission in gear. The engine speedcould exceed the maximum gov-erned speed and cause a seriousaccident due to mechanical fail-ures. Failure to comply may resultin death, personal injury, equipmentor property damage.

Besides being illegal and dangerous,coasting is also expensive. It causespremature failure or damage to theclutch and transmission and overloadsthe brake system.

Coasting with the transmissionin neutral also prevents propertransmission component lubrication.During coasting the transmission isdriven by the rear wheels, and thecountershaft gear (which lubricatesthe transmission components by oilsplash) will only be turning at idlespeed.

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Descending a Grade

WARNING!

Do not hold the brake pedal downtoo long or too often while goingdown a steep or long grade. Thiscould cause the brakes to overheatand reduce their effectiveness. Asa result, the vehicle will not slowdown at the usual rate. To reducethe risk of personal injury and/or anaccident, before going down a steepor long grade, reduce speed andshift the transmission into a lowergear to help control your vehiclespeed. Failure to follow proceduresfor proper downhill operation couldresult in loss of vehicle control andmay result in death, personal injury,equipment or property damage.

Economical Driving

The following section includesrecommendations for best engineperformance and economy:

Engine Overspeed - RPM

• Operate the engine within theoptimum engine RPM range anddo not allow the RPM's to exceedthe maximum governed speed.See your Engine Operationand Maintenance manual forinformation regarding engineRPM.

• When the engine is used as abrake to control vehicle speed(e.g., while driving down a grade),do not allow the engine RPMto exceed maximum governedspeed.

• Under normal load and roadconditions operate the engine inthe lower end of the range.

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NOTEOften these recommendations aresecondary to maintaining an ade-quate and safe speed relative to thesurrounding traffic and road condi-tions.

CAUTIONTo avoid engine damage, do not letthe engine RPM go beyond the max-imum governed RPM valve damagecould result if overspeed conditionsoccur.

Use of Tachometer

The tachometer is an instrument thataids in obtaining the best performanceof the engine and manual transmission,serving as a guide for shifting gears.Refer to the Engine Operation andMaintenance manual for optimumengine RPM.

• If the engine RPM moves beyondthe maximum governed speed,indicating an overspeed condition,apply the service brake or shift toa higher gear to bring engine RPMwithin the optimum speed range.

• When driving downhill: shift to alower gear, use the engine brake(if so equipped), and use theservice brake, keeping the enginespeed below 2,100 rpm.

When the engine speed reachesits maximum governed speed, theinjection pump governor cuts off fuelto the engine. However, the governor

has no control over the engine RPMwhen it is being driven by the vehicle'stransmission, for example, on steepdowngrades. Apply service brakes orshift to a higher gear.

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Fuel economy and engineperformance are also directlyrelated to driving habits:

• The best results in trip time andfuel economy are obtained whiledriving the vehicle at a steadyspeed.

• Shift into higher or lower gears (orapply the service brake) to keepengine RPM near the lower end ofthe optimum operating range.

• Avoid rapid acceleration andbraking.

Fuel - Excess Consumption

The vehicle's fuel consumption isconnected to three important factors:maintenance, driving habits, andgeneral condition of the road, trafficconditions, and vehicle load.

Maintenance

Proper maintenance will keep thevehicle running like new even afterlong periods of use. The driver mustperform the daily and weekly checksof the vehicle.

Maintenance factors affecting fuelconsumption:

• air and/or fuel filters partiallyclogged

• engine valves out of adjustment

• injection pump improperlysynchronized

• injection nozzles defective oruncalibrated

• improperly inflated tires

• wheel bearings improperlyadjusted

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• clutch improperly adjusted or worn(slipping)

• fuel leaks

Driving Habits

Wrong driving habits must becorrected and the recommendationson economic driving should befollowed.

Driving factors affecting fuelconsumption:

• excessive speed and unnecessaryfast acceleration

• long periods of idling

• driving with foot resting on the(manual transmission) clutchpedal

General Condition

Other factors affecting fuelconsumption are related to loadsand type of roads on which the vehicleoperates. It is not always possible tochoose the most adequate road, butit must be kept in mind that the idealroad is the one that allows a steadyspeed in high gear, without requiringfrequent braking and acceleration.

The following general conditionscan affect fuel consumption:

• overload

• unbalanced load

• very high load

• inadequate roads

• traffic conditions

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Safe Driving

NOTEThe following recommendations aremerely informative and do not coverall safety precautions. Safe drivingis, above all, the responsibility of thedriver.

The safe operation of a vehicle isnot just following the establishedtraffic rules, but should also include:maintaining the vehicle in goodmechanical condition, and properoperation of the engine, transmission,and brakes.

The following guidelines will helpyou to drive the vehicle safely:

• Make a thorough inspection of thevehicle, daily and weekly. SeeDriver's Check List on page 1-32.

• Ensure that windows, mirrors, andlights are clean.

• Check all tires for damage andcorrect inflation pressure.

• Adjust the seat to a comfortabledriving position, for easy access topedals and vehicle controls.

• Adjust rear view mirrors.

• Always use the safety belts.

• Do not exceed the GVWR.

• Proportionally distribute loads onthe frame.

• Always keep the brakes adjustedand in proper condition. See

Checks and Adjustments on page5-46.

• Obey speed limits and all trafficsignals.

• When driving downhill, select onegear lower than the up-hill gear.And use the brakes properly, donot ride them.

• Do not exceed maximum governedspeed (as specified in the EngineOperation and MaintenanceManual).

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WARNING!

Do not exceed the specified load rat-ing. Overloading can result in lossof vehicle control and personal in-jury, either by causing componentfailures or by affecting vehicle han-dling. Exceeding load ratings canalso shorten the service life of thevehicle. Failure to comply may re-sult in death, personal injury, equip-ment or property damage.

• The components of yourvehicle are designed to providesatisfactory service if the vehicleis not loaded in excess of eitherthe gross vehicle weight rating(GVWR), or the maximum frontand rear gross axle weight ratings(GAWRs). (Axle weight ratings arelisted on the driver's door edge.)

NOTEFor your safety and the safety ofothers, follow routine and periodicmaintenance schedules for all com-ponents on your vehicle. See Table9, Maintenance Schedule on page5-19.

Cruise Control

This feature can improve fuel mileageand can reduce driver fatigue bymaintaining a constant vehicle speed.

WARNING!

Do not operate the cruise controlwhen operating on road surfaceswith poor traction (wet, icy, or snowcovered roads) or in heavy traffic.Accelerations caused by the nor-mal operation of the cruise controlcould cause you to lose control ofthe vehicle and may result in death,personal injury, equipment or prop-erty damage.

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NOTECruise control functions and fea-tures may vary depending uponwhich engine is installed in yourKenworth. For specific instructionson operating the cruise control, seethe Engine Operation and Mainte-nance Manual.

NOTECruise Control will not function untilthe operator has depressed both theservice brake pedal and the clutchpedal at least one time after eachstart-up. For vehicles with auto-mated transmissions and no clutchpedal, only the service brake pedalneeds to be depressed.

Air Suspension Height/AirPressure

Your vehicle may have an airsuspension and a deflation switchwhich allows the air in the suspensionto be exhausted from a switch on thedash. The normal purpose of thisfeature is to allow you to lower thevehicle for loading.

A guard on the switch preventsyou from accidentally deflating thesuspension.

WARNING!

Do not operate the Air SuspensionDeflate Switch (Dump Valve) whiledriving. Sudden deflation while yourvehicle is moving can affect handlingand control and could lead to an ac-cident. Use this switch only whenyour vehicle is not moving. Failureto comply may result in death, per-sonal injury, equipment or propertydamage.

CAUTION

Operating a vehicle with air sus-pension bags either overinflated orunder-inflated may cause damageto driveline components. If a vehi-cle must be operated under suchconditions, do not exceed 5 mph (8km/h). Failure to comply may resultin equipment damage.

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Suspension Air Pressure Gauge

The Suspension Air Pressure gauge(option), see Optional Gauges on page3-55, which indicates the amount of airpressure in the air suspension springsin pounds per square inch (psi). Airpressure in the spring is related tothe rear axle load. The greater therear axle load, the greater the airpressure in the air bags. Therefore,the air pressure displayed will vary,depending upon the rear axle load.

Driving with Deflated Air Springs

If an air spring ruptures, there willbe enough air pressure to drive thevehicle to a safe stop off the highwayto investigate the problem.

WARNING!

Do not drive with ruptured airsprings. The air loss can cause thespring brakes to apply. This allowsyour brakes to drag and may burnup the linings, which could lead toan accident. Do not continue tooperate the vehicle in this condi-tion. Failure to comply may result indeath, personal injury, equipment orproperty damage.

To get to a repair facility, do thefollowing:

1. Remove the height control linkconnected to the axle and tothe suspension air valve controlarm. This will cause the air valvecontrol arm to center in the closedposition.

2. The air system can then bepumped up to normal pressure forcontinued operation.

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WARNING!

Low air pressure could make brakesunsafe for driving by not provid-ing sufficient air brake applicationpressure in an emergency, whichcould lead to an accident. Beforedriving the vehicle, make sure theair pressure pumps up to over 100psi for normal brake operation. If itdoes not reach 100 psi, do not try tomove the vehicle. Failure to complymay result in death, personal injury,equipment or property damage.

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OPERATING THE BRAKE SYSTEM

OPERATING THEBRAKE SYSTEM

Introduction

The operation of the vehicle's brakingsystem and many vehicle accessoriesdepends upon the storage andapplication of a high-pressure airsupply.

This air brake system is of the dualcircuit type: it has a circuit for the frontwheels, a separate circuit for the rearwheels, and one for the trailer. Thesystem is supplied by an engine-drivencompressor. The vehicle's compressortakes outside air and compresses it,usually to 100-130 psi (690-896 kPa).The compressor air then goes to theair tanks to be stored until needed.

When you operate your air brakes, thestored compressed air flows into thechambers where it is used to applyyour truck and trailer brakes.

That is why, when you push down onthe brake pedal, you do not feel thesame amount of pressure on the pedalthat you do when you apply the brakeson your car. All you are doing on yourtruck is opening an air valve to allowair to flow into the brake chambers.

WARNING!

The brake system is a critical vehiclesafety system. For the safety of youand others around you, have the ve-hicle submitted for periodic preven-tive maintenance checks as well ashaving any suspected problems im-mediately checked by an authorizedKenworth Dealer. Failure to properlymaintain your brake system can leadto serious accidents. Failure to com-ply may result in death, personal in-jury, equipment or property damage.

WARNING!

Never drive your vehicle with theparking brake applied. Always re-lease the parking brakes prior tomoving the vehicle. Failure to dis-engage the parking brakes prior tomoving your vehicle could result inexcessive heat buildup in the brakesystem, resulting in a fire. Failureto comply may result in death, per-sonal injury, equipment or propertydamage.

NOTEToday's diesel electronic engineshave significant torque and starta-bility power at low RPM. Combina-tions of engine speed and availabletorque may over-power the vehiclesparking brakes.

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Using the Brake System:Hydraulic Brakes

WARNING!

Do not operate the vehicle in theevent of a malfunction in the hy-draulic circuit. The vehicle shouldnot be operated until the system isrepaired and both braking circuits,including all mechanical compo-nents, are working properly. Loss ofhydraulic pressure can cause loss ofcontrol. You could be in an accidentand severely injured.

Introduction

The operation of the vehicle's brakingsystem is based on the principle ofhydraulics. Hydraulic action beginswhen force is applied to the brakepedal. This force creates hydraulicpressure in the master cylinder and isamplified with assistance of a powerbooster. The supplemental boost inforce is developed when pressurizedpower steering fluid from the steeringpump presses on the master cylinderpiston. As a safety precaution, thepressurized fluid from the mastercylinder has two mutually independentcircuits. The primary circuit suppliesthe front wheels while the secondarycircuit supplies the rear wheels. Thedisplaced fluid from the master cylindertravels through brake pipes terminatingat the wheel cylinders which actuatethe brake pad mechanisms. Actuationof these mechanisms force the brakepads against the rotors to stop thewheels.

A reserve electric motor pump providesa redundant power source for thehydraulic booster in the event normalflow from the power steering pump isinterrupted. Manual braking is alsoavailable in the event both the powerand reserve systems are inoperative.

WARNING!

Never drive your vehicle with theparking brake applied. Always re-lease the parking brakes prior tomoving the vehicle. Failure to dis-engage the parking brakes prior tomoving your vehicle could result inexcessive heat build-up in the brakesystem, resulting in a fire.

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NOTEToday’s diesel electronic engineshave significant torque and starta-bility power at low RPM. Combina-tions of engine speed and availabletorque may over-power the vehicle’sparking brakes.

WARNING!

The brake system is a critical vehiclesafety system. For the safety of youand others around you, have the ve-hicle submitted for periodic preven-tive maintenance checks as well ashaving any suspected problems im-mediately checked by an AuthorizedService Center. Failure to properlymaintain your brake system can leadto serious injury accidents.

Air Supply System

Contamination of the air supply systemis the major cause of problems inair-operated components such asbrake valves and suspension heightcontrol valves. To keep contaminantsto the lowest possible level, follow allmaintenance procedures.

Air Dryer

Bendix AD-IS Series Air Dryers

Your Kenworth vehicle may beequipped with a Bendix AD-IS seriesair dryer. Any air dryer replacementshould be made with an identicalcomponent.

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WARNING!

If a different air dryer brand or modelis installed on the vehicle other thanwhat was originally installed, it couldcause the air system to not performcorrectly unless the full air systemdesign is reviewed and modifica-tions made to comply with FederalMotor Vehicle Safety Standards(FMVSS 121 - Air Brake Systems)or, in the case of chassis equippedwith the European air system, ECER13. Failure to abide by this warningand maintain compliance to FMVSS121 or ECE R13 could cause lossof vehicle control and may lead topersonal injury or death.

The AD-IS Series air dryer hasincorporated into its design variouscomponents that have typically beeninstalled separately on the vehicle (seebelow for components/ areas affected).

• Pressure protection valves

• Safety valve

• Governor and plumbing

• Plumbing of the front and rearservice air tanks

• Plumbing to accessory systems

These components are requiredto meet the Federal Motor VehicleSafety Standards (FMVSS 121 - AirBrake Systems) or, in the case ofchassis equipped with the Europeanair system, ECE R13. As the Warningabove states, any other type of airdryer installed in the place of anAD-IS Series will require changes,modifications, and/or additions toyour vehicle’s air system to maintaincompliance with FMVSS 121 or ECER13. Kenworth strongly recommendsthat if the air dryer is changed from anAD-IS series, you consult your nearestauthorized Kenworth dealer.

Brake Operation

WARNING!

Do not drive through water deepenough to wet brake components,as it may cause the brakes to workless efficiently than normal. Thevehicle's stopping distance may belonger than expected, and the vehi-cle may pull to the left or right whenbrakes are applied, which couldcontribute to an accident. Failureto comply may result in death, per-sonal injury, equipment or propertydamage.

To rectify this condition, check the rearand both sides of the vehicle for cleartraffic, then apply the brakes gently,releasing and gently reapplying untilthe brakes dry out, restoring normaloperation. Always check brakes afterdriving through deep water to helpreduce the possibility of personal injuryor an accident.

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Front Brake System

When the brake pedal is depressed,the front circuit portion of the treadlevalve delivers air from the frontservice air tank to the front axle brakechambers via a quick-release valve.

Simultaneously (on full truckconfigurations), air is also suppliedto the modulating valve control port.In the event of a rear service circuitfailure, the modulating valve willexhaust air from the spring brakechambers, applying the spring brakesin proportion to the front circuitapplication.

Rear Brake System

When the brake pedal is depressed,the rear circuit portion of the treadlevalve delivers air from the rear serviceair tank to the service brake relayvalve control port. The relay valvethen delivers air directly from therear service air tank to the rear brakechambers in proportion to the treadlepressure.

Using the Parking Brake

The yellow diamond-shaped knob onthe dash controls the vehicle parkingbrakes. These are spring brakes thatyou activate by releasing air pressurefrom their chambers. When they arenot in use, air pressure compressesthe springs and releases the brakes.Pulling the valve OUT applies theparking brake, which exhausts air fromthe chambers and allows the springsto extend and apply the brakes.

WARNING!

Do not leave the cab without apply-ing the parking brake. The vehiclecould roll and cause an accident. Al-ways apply the parking brake beforeyou leave the cab. Failure to complymay result in death, personal injury,equipment or property damage.

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Combination ( Vehicle/Trailer) ParkingBrake Control Valves

1 Parking Brake Control(Yellow)

2 Trailer Air Supply Control(Red)

Before you leave the cab:

1. Apply all parking brakes. Pullout the Yellow Parking BrakeControl knob (1) located on thedash. The Red (octagon-shaped)Trailer Air Supply Control knob willautomatically pop out. (A dashwarning light will indicate when thebrake is ON.)

2. Shift the transmission into PARKposition:

° manual transmission, selectFirst or Reverse gear.

° automatic transmission, selectNeutral.

3. Turn the key to OFF.

4. Remove the key.

WARNING!

Do not pull out the parking brakevalve while the vehicle is moving.Stopping with the parking brake con-trols can cause a suddenwheel lock-up, loss of control, or over-take byfollowing vehicles. Failure to complymay result in death, personal injury,equipment or property damage.

The parking brakes act on the rearwheels only. They are spring-applied,with air pressure used to release them.Release air is supplied by both thefront and rear circuit air tanks througha double check valve.

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To release the vehicle parkingbrakes ONLY:

• Push IN the Yellow knob on thedash. Your trailer will remainparked.

• Below 60 psi (414 kPa) the Yellowparking brake valve remains OUT(ON position). If air pressure is notrestored above 60 psi (414 kPa),the knob will automatically returnto the OUT position if you attemptto push it in. See Primary andSecondary Air Pressure on page3-54.

To release the trailer brakes ONLY:

• Push IN the Red knob on the dash.The vehicle will remain parked.

To release the full combination ofbrakes:

• Push IN BOTH knobs on the dash.

• In the event that air pressure isreduced below a safe level: thelow air warning light will come onfirst; if air pressure continues todrop, the parking brake valve willpop OUT, automatically applyingthe spring brakes.

CAUTIONDo not try to put the vehicle in mo-tion before pressure in the systemreaches 100 psi (689 kPa) becausethe wheels are locked by the springbrake action. Unnecessary stressand possible brake malfunctioncould occur if the vehicle is forced tomove before the air system reaches100 psi (689 kPa). Failure to complymay result in equipment damage.

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WARNING!

If the air pressure falls below 60psi (414 kPa) the spring brakesmay stop the vehicle abruptly, whichcould result in an accident. Ob-serve the red warning lamps on thegauges. If one comes on, do notcontinue to drive the vehicle until ithas been properly repaired or ser-viced. Failure to comply may resultin death, personal injury, equipmentor property damage.

WARNING!

Do not use the trailer hand brakeor service brakes to park and holdan unattended vehicle, use theparking brakes. Because servicebrakes work with air pressure, thesebrakes could slowly release. Yourvehicle could roll, causing a seri-ous accident. Never rely on theservice brakes to hold a parked ve-hicle. Failure to comply may resultin death, personal injury, equipmentor property damage.

Vehicle/Trailer Air SupplyValveInitial Charge

The red octagon knob controls the airsupply to the trailer. With the systemcompletely discharged, both the Red(trailer air supply) and the Yellow(parking brake) knobs are OUT; thus,vehicle and the trailer parking (spring)brakes are applied.

To supply air to the trailer systemand release the trailer parkingbrakes:

1. Allow the vehicle air systempressure to build up to operatinglevel.

2. When system pressure reaches50 psi (345 kPa) the Red knobmay be pushed IN.

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3. Hold the Red knob IN by handuntil the trailer air pressure buildsto a pre-set level, about 45 psi. Atthis point it will remain in, chargingthe trailer system and releasingonly the trailer brakes.

4. The Yellow knob will remain OUT(vehicle brakes ON).

Normal Run Position

• The Yellow knob (system park)may now be pushed IN, which willsupply air to the vehicle springbrakes, releasing them.

1. Normal Run Position2. Trailer Park with Vehicle

Released3. System Park or Trailer

Charge with Vehicle Parked

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Trailer Park or Emergency BrakeApplication Only

If you ever have a failure or disconnectthe air supply hose to the trailer, thetrailer parking brakes will set. The Redknob will automatically pop OUT andseal off the vehicle air tanks to protectthe vehicle air system pressure.

To apply the trailer brakes only:

Pull OUT the Red knob. This willexhaust air from the trailer supply line,causing the vehicle protection valve toclose and the trailer spring brakes toapply. The trailer is now in emergencyor park. This mode would be usedto uncouple from the trailer (runningwithout a trailer connected).

WARNING!


System Park

With both knobs pushed in for normaloperating modes, the parking brakesof both the vehicle and the trailermay be applied by pulling the Yellowknob OUT. This will exhaust the airfrom the vehicle spring brakes, andsimultaneously cause the Red knob topop OUT, which will apply the trailerbrakes. This complies with the FederalMotor Vehicle Safety Standards(FMVSS) 121 requirement that onecontrol should apply all the parkingbrakes on the vehicle.

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Trailer Charge

If both knobs are OUT (combinationvehicle is parked), and it is desired torecharge the trailer, the Red knob maybe pushed IN repressurizing the trailersupply line. The vehicle will remainparked. For more information on airsupply pressure requirements, seeInitial Charge on page 4-22.

Brake Safety and Emergency

WARNING!

Do not operate the vehicle in theevent of a malfunction in any air cir-cuit. The vehicle should not be op-erated until the system is repairedand both braking circuits, includingall pneumatic and mechanical com-ponents, are working properly. Lossof system air can cause the servicebrakes to not function resulting inthe sudden application of the springbrakes causing wheel lock-up, lossof control, or overtake by followingvehicles. Failure to comply may re-sult in death, personal injury, equip-ment or property damage.

• If pressure is lost in the vehiclefront or rear circuit, the “check”valves isolate the unaffectedcircuit, allowing this circuit tocontinue normal operation. Thetrailer brakes are still functional.

• If air pressure is lost in thetrailer supply/park circuit, and thepressure drops below 60 psi (414kPa), the trailer spring brakes areautomatically applied, and thevehicle air pressure circuits areunaffected.

• If air pressure is lost in the trailerbrake service circuit, and thepressure in the vehicle front andrear circuits drops below 60 psi(414 kPa), the vehicle and trailerspring brakes are automaticallyapplied.

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Emergency Braking

WARNING!

Unless you have an anti-lock brak-ing system (ABS), always avoidcompletely depressing the servicebrake pedal, if possible, even dur-ing emergency braking. Depressingthe brake pedal too aggressivelycan cause the wheels to lock, whichcan lead to an uncontrolled skid andcan result in an accident. Failureto comply may result in death, per-sonal injury, equipment or propertydamage.

For Non-ABS Vehicles: to stop yourvehicle in an emergency, vary theservice brake application pressureto provide maximum braking forcewithout locking the wheels. Use enginecompression to assist the servicebrakes by not depressing the clutchpedal until the engine reaches idlespeed.

Overheated Brakes

Under normal braking conditions, theenergy generated will bring the internalbrake drum temperature to about 500˚F (260˚ C). This is well within the safezone: the maximum safe temperatureof lining for drum type brakes is usuallyabout 800˚ F (427˚ C).

If service brakes are used foremergency braking, used improperly,or for prolonged periods, internal brakedrum temperatures may exceed 800˚F (427˚ C). Such brake overheatingmay be detected by a burning smellor smoke coming from a drum. If thisoccurs, you should immediately stopand check for cracked brake drums orlining fires. If neither exists, continuedriving and resume a slow speed assoon as possible to cool the brakes. Ifthe vehicle was to remain stopped, theheat transfer could destroy the liningsand distort the brake drum.

To prevent drums from distortionwhile they cool down:

• Park the vehicle on level surfaceand block the wheels.

• Release the parking brake andallow the brakes to cool down.See Parking Brake Valve on page3-81.

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Anti-Lock Braking SystemIntroduction

North American on-highway Kenworthshave anti-lock braking system (ABS)as standard equipment. The ABSreduces the possibility of wheel lock-upduring hard braking. If a wheel is aboutto lock during braking, the ABS willautomatically adjust air pressure to thebrake chambers on the appropriatewheel(s) to prevent wheel lock-up.The ABS is automatically turned onwhen the ignition switch is turned on.See Anti-Lock Brake System (ABS) onpage 3-32.

WARNING!

Do not rely on an anti-lock brake sys-tem that is functioning improperly.You could lose control of the vehicleresulting in a severe accident. Fail-ure to comply may result in personalinjury, death, equipment or propertydamage.

NOTEIf your ABS lamp goes on whileyou are driving or stays on after thepower-on test, your anti-lock systemmight not be working. The ABS maynot function in an emergency. Youwill still have conventional brakes,but not anti-lock brakes. If the lampindicates a problem, have the ABSchecked

NOTEImportant Safety Reminders

• ABS does not reduce the timeor distance it takes to stopthe vehicle, it only helps withsteering control during braking.You should always maintain asafe following distance from othervehicles.

• ABS will not prevent a skid thatresults from changing directionabruptly, such as trying to takea corner too fast or making asudden lane change. Alwaysdrive at a safe, prudent speed forthe road and weather conditions.

• ABS cannot prevent a lossof stability. Always steermoderately when you are brakinghard. Severe or sharp steeringwheel movement can still causeyour vehicle to veer into oncomingtraffic or off the road.

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Wheel Spin Control (option)

Your ABS may have the optionalAcceleration Slip Regulation(ASR)/Automatic Traction Control(ATC) feature. This feature ismonitored by a wheel spin control ASRWarning Lamp. See the appropriatevehicle section in this manual fordetails. This feature helps improvetraction when vehicles are on slipperysurfaces by reducing drive wheeloverspin. Wheel spin control worksautomatically in two different ways:

• If a drive wheel starts to spin,wheel spin control applies airpressure to brake the wheel. Thistransfers engine torque to thewheels with better traction.

• If all drive wheels spin, wheel spincontrol reduces engine torque toprovide improved traction.

Wheel spin control turns itself on andoff, you do not have to select this

feature. If drive wheels spin duringacceleration, the ASR Warning Lampcomes on, indicating wheel spin controlis active.

Do not allow the ASR Warning Lampto remain on continuously for anextended length of time. Extended,continuous use of the ASR/ATC cancause overheating of the drive wheelbrakes.

Deep Snow and Mud Switch (option)

A deep snow and mud switch isincluded with Wheel Spin Control. TheDeep Snow and Mud feature is helpfulduring acceleration This functionincreases available traction on extrasoft surfaces like snow, mud or gravel,by slightly increasing the permissiblewheel spin. When this function is inuse, the ASR Warning Lamp blinkscontinuously.

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Off-Road ABS Function Switch(option)

Your Kenworth vehicle may beequipped with a separate switch toactivate an Off-Road ABS function.This function is NOT to be usedfor On-Highway driving but isintended to be used to improvestopping performance in Off-Highwayconditions (e. g. loose gravel andmud). The Off-Road ABS function isaccomplished by allowing a “wedge”of material to build-up in front ofmomentarily locked wheels.

Features and Benefits

• Changes the ABS control limits toallow for a more aggressive ABSfunction while off-road.

• Improves vehicle control andhelps reduce stopping distancesin off-road conditions or on poortraction surfaces such as loosegravel, sand and dirt.

• Allows retarders to functionindependently of the ABS function.

• If your vehicle does not have anengine retarder, the Off- RoadABS switch will function the same.

CAUTIONNever drive your vehicle on im-proved roads/highways with theOff-Road ABS function turned on.When you drive your vehicle onto animproved road surface or highway,immediately turn off the Off-RoadABS switch. Failure to do so willcause the ABS system to not func-tion properly in an ABS event under25 mph and could result in an acci-dent or personal injury.

WARNING!

While the off-road mode can im-prove vehicle control and shortenstopping distances, some steeringability may be reduced on certainsurfaces resulting from the momen-tarily sliding tires. Always oper-ate your vehicle at safe operatingspeeds. Failure to do so may causeyou to lose control of the vehicleand could result in an accident orpersonal injury.

How the Off-Road ABS FunctionWorks

• The ABS lamp flashes slowlyduring off-road mode engagement.This is done to alert you of amodification to the ABS controlsoftware.

• At speeds above 25 mph, the ABScontroller operates in the normalon-highway mode.

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• At speeds between 10 and 25mph, the ABS control software ismodified to allow short periods(0.25 seconds) of locked-wheelcycles.

• At speeds below 10 mph, the ABScontrol software is turned off toallow locked wheels.

• When the Off-Road ABS functionis enabled, the Retarder Disableoutput is turned off. That is,the engine retarders are left tofunction without ABS intervention.For additional information, see theOff-Road ABS pamphlet in yourvehicle’s glove box.

Trailer ABSPower Line Communication (PLC)

North American on-highway Kenworthsare equipped with a separate electricalcircuit to power the anti-lock brakesystem (ABS) on towed vehicle(s).In most cases, the ABS power willbe supplied through the Auxiliarycircuit on the primary 7- way trailerlight line connector. If the vehiclewas manufactured with a switchableAuxiliary circuit for trailer accessories,an additional 7-way connector wouldhave been provided for trailer ABSpower. In either case, the ABSpower line on the vehicle will be PLCequipped.

CAUTIONDo not splice into the non-switchableAuxiliary circuit on the primary 7-waytrailer light line. Doing so may causethe trailer ABS to malfunction. Thiscircuit is dedicated for trailer ABSpower. To add a switchable auxiliarycircuit, contact a Kenworth Dealer-ship.

Vehicles and trailers built after3/1/01 must be able to turn on anIn-Cab Trailer ABS Warning Lamp(per Federal Motor Vehicle SafetyStandards (FMVSS) 121). The industrychose Power Line Communication(PLC) as the standard method to turnit on.

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NOTETrailers not equipped with PLC cannot turn on the In-Cab Trailer ABSWarning Lamp.(There is one optionthat is an exception to this rule. SeeSpecial Trailer ABS (Without PLC)Option in the Anti-lock Braking Sys-tem section on page 4-27 for de-tails.)

NOTEFor doubles or triples, the lamp doesnot distinguish between trailers. AnABS problem in any of the trailerswill activate the Trailer ABSWarningLamp.

NOTEIf you change the intended service inanyway (i.e. number of axles, mul-tiple trailers, add switchable traileraccessories, etc.) from the datethe vehicle was manufactured, youshould contact your trailer manufac-turer and/or trailer anti-lock brakemanufacturer to determine if thepower available at the 7-way trailerlight line is adequate. Failure to doso might result in insufficient powerto the trailer ABS system which mayaffect its operation.

CAUTION

The center pin of the 7-way trailerlight line may be constantly poweredfor ABS. Make sure it will not acci-dently turn on trailer equipment.

Special Trailer ABS (Without PLC)Option

If a trailer does not have PLC, butit does have ABS that is poweredthrough an optional second trailerconnector (ISO 3731) and that trailerABS is designed to control the TrailerABS Warning Lamp in the cab andthe vehicle has been ordered with theoption to turn on this lamp for thesetypes of trailers, then this lamp will turnon when that trailer ABS has a systemproblem. This should be checked by aKenworth Dealer as soon as possible.The Trailer ABS Warning Lamp willnot turn on for the power-on test whenconnected to these types of trailers.

NOTEVery few trailers built before 3/1/01have this option. Trailers built after3/1/01 are built with PLC technology.

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Trailer Brake Hand Valve

This hand valve provides air pressureto apply the trailer brakes only. Itoperates independently of the foottreadle valve.

To operate the trailer brake handvalve:

• Pull down on the lever under theright side of the steering wheel.See Steering Column And Mirrorson page 3-87.

• The valve is self-returning. Whenpressure is removed from thevalve lever, it will return to the OFFposition.

NOTEThe trailer brake is not to be used asa substitute for the service brakes.Using this brake frequently, insteadof using the foot brake, will cause thetrailer brakes to wear out sooner.

WARNING!


Driving with an UnloadedTrailer

Do not use the engine retarder (suchas an exhaust brake) to slow thevehicle down when you are pulling anempty trailer.

WARNING!

Do not use an engine retarder whenyou are driving with an unloadedtrailer. Using engine retarders withan unloaded trailer can cause awheel lockup resulting in less con-trol and/or jackknife. When youare unloaded, you can have a se-rious accident if your wheels locksuddenly during braking. Failureto comply may result in death, per-sonal injury, equipment or propertydamage.

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Engine Retarders

WARNING!

The engine retarder isNOT intendedas the primary brake for the vehi-cle, nor is it an emergency brake.The engine retarder only helps theservice brakes by using pressure toslow the drivetrain. Use the servicebrakes for quick stops. DO NOT relyonly on the engine retarder. Fail-ure to comply may result in personalinjury, death, equipment or propertydamage.

WARNING!

Do not operate the engine retarderwhen driving/operating your vehicleon road surfaces with poor traction(wet, icy, or snow covered roads)or in heavy traffic. Braking causedby the normal operation of the en-gine retarder could cause you to losecontrol of the vehicle resulting in anaccident. Failure to comply may re-sult in death, personal injury, equip-ment or property damage.

NOTEThe exhaust brake and engine brakeare two types of engine retarders.See your Engine Operation andMaintenance Manual and EngineRetarder or Engine Brake OperationManual for further details on usingthese types of engine retarders.

A variety of engine retarders orexhaust brakes may be installed (asan option) to create a braking effecton the drive wheels. These devicesuse your engine's power to slow yourvehicle down. Because they canhelp keep your vehicle's brakes fromoverheating, they save wear and tearon the service brakes. However, theretarder is not an emergency brake.

Ideally (on normal road surfaces),you should slow your vehicle withthe retarder (where permitted by law)and use the service brakes only forstopping completely. Operating thisway will greatly prolong the life of thebrakes.

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Exhaust Brake

With the exhaust brake switch ON, thebrake automatically creates its brakingeffect when you remove your foot fromthe accelerator pedal.

The brake switch is located on theaccessory dash panel. It controlswhether the brake is ON (ready to slowthe vehicle down) or OFF (no brakingaction).

• Do not use the engine retarder(such as an exhaust brake) toslow the vehicle down when youare pulling an empty trailer. SeeEngine Brakes for further details.

WARNING!

Do not use an engine retarder whenyou are driving with an unloadedtrailer. Using engine retarders withan unloaded trailer can cause awheel lockup resulting in less con-trol and/or jackknife. When youare unloaded, you can have a se-rious accident if your wheels locksuddenly during braking. Failure tocomply may result in personal injury,death, equipment or property dam-age.

• Make sure the brake is OFF beforestarting the engine.

• After the engine is started, warmedup, and you are ready to get underway, turn the exhaust brake switchON for added braking effect.

WARNING!

Do not use the engine retarder whenoperating on road surfaces with poortraction (such as wet, icy, or snowcovered roads or gravel). Retarderscan cause the wheels to skid ona slippery surface. You could losecontrol of the vehicle and/or jack-knife if the wheels begin to skid, re-sulting in an accident. Failure tocomplymay result in death, personalinjury, equipment or property dam-age.

If your vehicle is equipped withanti-lock brakes (ABS), the operationof the exhaust brake (if turned ON)will be controlled by the ABS. Forfurther details on how to use theexhaust brake, see the exhaust brakemanufacturers Owner's Manual.

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Engine Brakes

On/Off Switch Symbol

Retardation Level Switch Symbol

There are two switches that controlyour vehicle's engine brake. Oneswitch turns the system On/Offand the second switch controls theretardation level. These are locatedin the right-hand switch panel. Withthe engine brake switch ON, the brakeautomatically creates its braking effectwhen you remove your foot from theaccelerator pedal.

Depending on the engine, yourvehicle may be equipped with eithera 2-position or 3-position RetardationLevel Switch. If your vehicle has thetwo-speed system, you can selectFULL or HALF. If it has the three-speedsystem, you can select LOW (1),MEDIUM (2), or HIGH (3) retarding.

See your Engine Operation andMaintenance Manual or Engine BrakeOperation Manual for further details onusing engine retarders.

Brake Components

The following is a brief description ofthe air/brake system. It is intended tosupply you with general information onhow the system works.

Compressor: supplies air to thesystem. System pressure is controlledby the governor.

Governor: controls the air pressurein the system by actuating thecompressor discharge mechanism. Itscut-out pressure is 115 to 125 psi (793to 862 kPa). Its preset cut-in pressureis set to between 13 to 25 psi (90 to172 kPa) below the cut-out pressuresetting (cut-out and cut-in interval isnot adjustable).

Safety Valve: installed on the supplyair tank outlet. It should vent off at 150psi (1034 kPa) permitting air to escape.

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Air Dryer: collects and removesmoisture and contaminants from theair as it travels from the compressorto the wet tank.

Compressed Air Tanks: The wettank receives air from the air dryer andcools it somewhat, allowing moistureto condense for draining. Relativelydry air is then supplied to the twoservice air tanks for distribution to theirrespective brake circuits. The serviceair tanks are isolated from each otherby check valves.

Dual Service Brake Treadle Valve:delivers air to the two service brakecircuits.

Double Check Valve: directs thehigher air pressure from either the rear(primary) or front (secondary) serviceair tank to the modulating valve.

Modulating Valve (SR-1): used onlyon full trucks, not tractors, performsfour functions:

• Limits spring brake hold-off airpressure delivered to the springbrake chambers.

• Provides a quick release of airpressure from the spring brakechambers to speed spring brakeapplication.

• Modulates spring brake applicationin proportion to front serviceapplication in the event of a rearservice failure.

• Prevents compounding of serviceand spring applications.

Quick-Release Valve: speeds therelease of air from the brake chambers.When air is released, the air in thebrake chambers is exhausted atthe quick-release valve, rather than

exhausting back through the treadlevalve.

Single Check Valve: allows air flow inone direction only.

Parking Brake Valve:Yellowdiamond-shaped knob. It controls theapplication and release of the parking(spring) brakes of the vehicle or of thevehicle-trailer combinations. If the airsystem is being charged from zeropressure, the parking brake valve willnot hold in the release position until thesystem pressure exceeds 60 psi (414kPa), which is the pressure required tooverride the load of this valve's plungerreturn spring.

Trailer Supply Valve: The Redoctagonal-shaped knob protectsthe vehicle system; it functions inconjunction with the parking brakevalve (yellow). The trailer supplyvalve is responsible for synchronizingthe vehicle and trailer parking and

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emergency brakes. If the air systemis being charged from zero pressure,the trailer supply valve will not hold inthe applied position until the systempressure exceeds 50 psi (345 kPa). Itautomatically pops out and exhaustsair if supply air pressure drops below60 psi (414 kPa).

Vehicle Protection Valve: Thefunctions of this valve are to (1) receiveall pneumatic signals pertinent to theoperation of the trailer brake system,(2) transmit these signals to the trailer,and (3) protect the vehicle air supplyin case of separation of the air linesconnecting the vehicle to the trailer.

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OPERATING THE ENGINE

OPERATING THEENGINE

Introduction

For detailed information on startingand operating the engine, refer to theEngine Operation and MaintenanceManual provided with your Kenworth .

Because each vehicle iscustom-equipped, all engine operationinstructions presented in this sectionare general. You will want to consultthe engine manual to find out detailsabout your vehicle's specific engineneeds. You may need to use a slightlydifferent procedure from the oneoutlined here.

Also, read the American TruckingAssociation's (ATA) Truck Driver'sHandbook. It will give you tips onstarting, shifting, and driving yourvehicle.

This section includes instructions forboth Normal Temperature starting andCold Weather starting. The enginetype (brand) and size determines whattype of cold weather starting aid isinstalled in your vehicle. Refer to yourEngine Operation and MaintenanceManual to learn what precautionsyou should take before starting theengine. Many new electronic enginescannot use ether or other startingfluids. These engines are equippedwith a flame-start air intake heatingsystem. See Starting Procedure - ColdWeather on page 4-40.

WARNING!

Do not use ether or starting fluid inconjunction with flame-start air in-take heating systems. Flame-startsystems use an open flame insidethe manifold to heat the air/fuel mix-ture for cold weather starting. Ifether is also used with flame-start,the air/fuel will ignite inside the man-ifold, which could cause an explo-sion. Failure to comply may resultin death, personal injury, equipmentor property damage.

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WARNING!

Do not start or let the engine run inan enclosed, unventilated area. Ex-haust fumes from the engine containcarbon monoxide, a colorless andodorless gas. Carbon monoxide canbe fatal if inhaled. Failure to com-ply may result in personal injury ordeath.

CAUTIONDo not park or operate the vehicle inareas where the hot exhaust systemmay come in contact with dry grass,brush, spilled fuel or other materialthat can cause a fire.

Normal Weather

When the outside temperature isabove 50° F (10° C), you can use thefollowing procedure:

1. Set the parking brake.

2. Put your main transmission inNeutral.

3. Disengage (depress) the clutch(with manual transmission).

4. Turn the key switch to ON.

CAUTIONNever operate the starter motorwhile the engine is running. Thestarter and flywheel gears couldclash or jam, severely damagingthem.

NOTESome starters are equipped withovercrank protection. Check the“Engine Operation and MaintenanceManual” for details.

5. Turn the ignition key to the STARTposition. If the engine does notstart within 30 seconds, releasethe ignition switch. To avoidovertaxing the starter motor orthe batteries, don’t use the starterfor more than 30 seconds. Letthe starter motor cool and thebatteries recover for two minutesbefore trying again.If the engine still won’t start after acouple of tries, check the fuel linesfor possible fuel starvation or airleaks. Starting failure may meanfuel isn’t reaching the injectors.

6. As soon as the engine starts, beginto watch the oil pressure gauge.Check your engine manufacturer’s

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manual for the right pressure foryour engine. If the oil pressuredoesn’t rise within a few seconds,stop the engine. Find out whatis wrong before restarting theengine.

7. Slowly engage (release) the clutchafter the engine has started.

8. Wait for the oil pressure gauge toreach normal operating pressurebefore operating the vehicle oridling faster than 1000 rpm.

Cold Weather

In cold weather, fast engine startinghelps relieve the loads on the electricalsystem and cranking motor. Using thespecial cold starting equipment willhelp starting. If you follow a few simpleguidelines, you will extend the servicelife of your engine:

• Keep the electrical system in topcondition.

• Use the best quality fuel of therecommended grade.

• Use recommended enginelubricating oil.

• For manual transmissions andauxiliary transmissions, leave thetransmission in neutral and allowthe transmission lubricating oilto warm up (approximately 3-5minutes) before operating vehicle.

Engine Block and Oil PanHeater (Option)

To preheat the engine before starting,plug the optional engine block heaterinto a properly grounded AC electricalsource. Do not start the engine withthe heater plugged in.

WARNING!

Engine block and oil pan heaterscan cause fires which may result indeath, injury and/or property dam-age if not properly maintained andoperated. Regularly inspect the en-gine block heater wiring and connec-tor for damaged or frayed wires. Donot use the heater if there are anysigns of problems. Contact your au-thorized dealer or the manufacturerof the heater if you are in need of re-pairs or information.

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CAUTION

Always unplug heater before startingthe engine. Damage to the coolingsystem could occur if the heater isnot turned OFF (unplugged).

Depending on engine make, when thetemperature falls below -10° F (-24°C), the block heater is recommended.

• Use a solution of half ethyleneglycol antifreeze and half water forbest heater performance. Do notexceed 65 percent concentrationof antifreeze, as a shortenedheater life will result. See EngineCooling System on page 5-60, formore information.

• After servicing the cooling system,operate the vehicle for a day or twobefore using the heater. Trappedair inside the engine needs timeto escape.

Engine Warm-upEngine

The purpose of engine warm-up is toallow oil film to be established betweenpistons and liners, shafts and bearingswhile your engine gradually reachesoperating temperature.

Warm-up Procedure

1. After you’ve started your engine,idle it at approximately 600 RPMwhile you check:

a. oil pressure

b. air pressure

c. alternator output

2. After a few minutes of idling at600 RPM, increase your idlespeed to 900 or 1000 RPM.Continue your warm-up. Thisprocedure allows oil to warm andflow freely while pistons, liners,shafts, and bearings expand

slowly and evenly. In extremelycold temperatures, you may haveto increase idle speed.

NOTEIn colder climates where the tem-perature is often below freezing, thewarm-up for turbocharged enginesis especially important. Chilled ex-ternal oil lines leading to the tur-bocharger will slow the oil flow untilthe oil warms, reducing oil availablefor the bearings. Watch the engineoil temperature or pressure gaugefor a warming trend before increas-ing engine idle speed (RPM).

3. Continue the engine warm-up untilthe coolant temperature reachesat least 130° F (54° C). At thistemperature, you can use partialthrottle. Wait until the coolanttemperature is at least 160° F (71°C) before operating at full throttle.

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WARNING!

Exhaust fumes from the enginecontain carbon monoxide, a color-less and odorless gas. A poorlymaintained, damaged, or corrodedexhaust system can allow car-bon monoxide to enter the cab orsleeper. Failure to properly main-tain your vehicle could cause car-bon monoxide to enter the cab andcause death or personal injury.

WARNING!

Never idle your vehicle for prolongedperiods of time if you sense that ex-haust fumes are entering the cab.Investigate the cause of the fumesand correct it as soon as possible.If the vehicle must be driven underthese conditions, drive only with thewindows slightly open. Failure to re-pair the source of the exhaust fumesmay lead to death or personal injury.

CAUTION

The use of a winterfront can resultin excessive engine coolant, oil, andcharge air (intake) temperatures,which can lead to overheating andpossible engine damage. If youmust use a winterfront:

• Refer to the “Engine Operationand Maintenance Manual”for operating restrictions andrecommendations.

• Use only a winterfront availablefrom your dealer that iscompatible with an EPA-compliantengine cooling system. Thesewinterfronts are specificallydesigned for use with new grillsnap patterns.

NOTEKeep the engine exhaust systemand the vehicle’s cab/sleeper venti-lation system properly maintained.It is recommended that the vehicle’sexhaust system and cab/sleeper beinspected:

• By a competent technician every15,000 miles,

• Whenever a change is noticed inthe sound of the exhaust system,

• Whenever the exhaust system,underbody, cab or sleeper isdamaged.

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NOTE• Do not stay in the vehicle with

the engine running or idlingfor more than 10 minutes withthe vehicle’s Heater and A/Cventilation system in RECIRCor at LOW FAN SPEED. Evenwith the ventilation system On,running the engine while parkedor stopped for prolonged periodsof time is not recommended.

• If other vehicles are parked nextto you idling, move your vehicleor do not stay in your vehicle forprolonged periods of time.

Idling the Engine

Under most circumstances, idlingyour engine for long periods merelywastes fuel. In severe arctic weatherconditions, however, you may needlonger idling to be sure all parts of yourengine are fully lubricated.

WARNING!

To reduce the chance of death orpersonal injury and/or vehicle dam-age from overheated engines, whichcan result in a fire, never leave theengine idling without an alert driverpresent. If the engine should over-heat, as indicated by the enginecoolant temperature light, immedi-ate action is required to correct thecondition. Continued unattendedoperation of the engine, even fora short time, may result in seriousengine damage or a fire.

CAUTIONDo not allow your engine to idle,at low rpm's (400–600 rpm), longerthan five minutes. Long peri-ods of idling after the engine hasreached operating temperaturescan decrease engine temperatureand cause gummed piston rings,clogged injectors, and possible en-gine damage from lack of lubrica-tion. The normal torsional vibrationsgenerated can also cause transmis-sion wear.

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Transmission

In cold weather [below 32° F (0°C)], you may find shifting sluggishwhen you first start up. Transmissionwarm-up is especially important atthis time, but it is always a goodidea to warm-up your transmissionbefore starting out on the road. Towarm-up the transmission, follow theseprocedures.

To warm-up the transmissionlubricating oil during engine warm-up,with a single transmission (manual andautomatic):

1. Put the transmission in Neutral.

2. Release the clutch pedal (manualonly) and operate the transmissionin neutral for 3 to 5 minutes priorto operating the transmission ineither forward or reverse range.

3. If you have a two-transmissioncombination:

a. Put the main transmission ingear.

b. Put the auxiliary transmissionin Neutral. This will allowthe transmission countershaftto turn, agitating the oil andwarming it.

Ether Metering Equipment

WARNING!

Ether starting fluid is flammableand poisonous. Do not smoke nearether or ether equipment, do notingest ether fluid and wear safetygoggles when handling ether fluid.Follow all safety literature providedwith your ether equipment. Failureto take these precautions may resultin death, personal injury.

WARNING!

Do not move or relocate the ethercylinder or tubing from its original in-stallation. It must bemounted to pro-tect it from engine exhaust heat andfrom moving parts which could dam-age it. Failure to comply may resultin death, personal injury, equipmentor property damage.

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WARNING!

Do not store the spare cylinder in thecab. Failure to comply may result indeath, personal injury, equipment orproperty damage.

Do not smoke when testing, installing,or servicing an ether starting unit.Service it in a well-ventilated area awayfrom heat, open flames, or sparks.

If swallowed, do not induce vomiting.Call a physician immediately.

Wear goggles to avoid getting fluid inyour eyes. Avoid getting it on your skinand avoid breathing the fumes. If fluiddoes get in your eyes or fumes irritateyour eyes, flush for 15 minutes withlarge amounts of clean water. Contactan eye specialist.

In warm weather, when you will notneed the ether starting system, removethe ether bottle from your truck and

store it safely. Return the protectivecap to the bottle mounting connector.

For more helpful starting information,refer to the engine manual that camewith your vehicle.

Ether injected into the engine cylinderduring cold weather startup will helpthe engine start faster. Using etherduring cold weather startup will resultin reduced demands on the batteriesand the starter motor.

When you turn the ignition switch to theSTART position, the cranking motorand the ether system are engaged.When needed, starting fluid is releasedfrom a pressurized cylinder, flowsthrough a valve and tubing, and spraysfrom a nozzle in you engine’s air intakesystem.

Idling the Engine

Under most circumstances, idlingyour engine for long periods merelywastes fuel. In severe Arctic weatherconditions, however, you may needlonger idling to be sure all parts of yourengine are fully lubricated.

WARNING!

To reduce the chance of death, per-sonal injury, and/or vehicle damagefrom overheated engines, which canresult in a fire, never leave the en-gine idling without an alert driverpresent. If the engine should over-heat, as indicated by the enginecoolant temperature light, immedi-ate action is required to correct thecondition. Continued unattendedoperation of the engine, even fora short time, may result in seriousengine damage or a fire.

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CAUTIONDo not allow your engine to idle, atlow RPM's (400-600 rpm), longerthan five minutes. Long peri-ods of idling after the engine hasreached operating temperaturescan decrease engine temperatureand cause gummed piston rings,clogged injectors, and possible en-gine damage from lack of lubrica-tion. The normal torsional vibrationsgenerated can also cause transmis-sion wear.

During the time it takes you to drink acup of coffee, your engine can cool asmuch as 60° F (33° C) below normaloperating temperature. To keep theengine warm during a short break, turnit off. Do not allow your engine to idlelonger than five minutes.

Engine Shutdown System(ESS)

If the vehicle’s engine does not meetthe low exhaust emission standard itwill have an Engine Shutdown System(ESS) to meet limited idle regulationsimplemented by CARB and someadditional states. These regulationsrequire that the engine have anautomatic system to restrict the idletime on certain vehicles.

An Engine Shutdown System will shutdown the engine after 5 minutes ifthe vehicle idles with the park brakeset and the transmission in ‘neutral’or ‘park’. The ESS will also allow thevehicle 15 minutes of idle time if thedriver does not set the park brake andshifts the transmission to ‘neutral’ or‘park’.

The ESS, however, will not shutdown the engine if the engine isoperating in Power Take Off (PTO)mode, if the engine coolant is below60° Fahrenheit, or if the engine isperforming a parked regeneration.

The check engine light will alert youwhen the ESS shutdown timer reachesthe last 30 seconds before the engineshuts down. The last 30 seconds priorto engine shutdown is the only timethe driver may reset the idle time bypressing on the accelerator.

More detailed information may beavailable in the Engine Operator’sManual provided with your vehicle.

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Cruise Control

If your vehicle is equipped with cruisecontrol dash switches, follow theoperating instructions below.

WARNING!

Do not operate the cruise controlwhen driving on road surfaces withpoor traction (wet, icy, or snowcovered roads) or in heavy traffic.Accelerations caused by the normaloperation of the cruise control couldcause you to lose control of the ve-hicle resulting in an injury accident.

On/Off Switch, Set/Resume Switch

Using Cruise Control While Driving:

Setting Cruise Speed

1. Ensure that the vehicle speed isabove the minimum cruise controlspeed (30 mph or 48 kph) and theengine speed is above 1100 rpm.

2. Move the ON/OFF switch to the"ON" position.

3. Accelerate the vehicle to thedesired cruise speed.

4. Toggle the SET/RESUME switchto the "SET" position to set thecruise speed.

NOTECruise Control may not hold the setspeed going down hills. If the speedincreases going down a hill, use thebrakes to slow down. This will can-cel Cruise Control.

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Changing the Cruise Set Speed

• To increase the cruise set speed;Hold the SET/ RESUME switch inthe "SET" position until the desiredspeed is achieved then releasethe switch.

• To decrease the cruise set speed;Hold the SET/ RESUME switch inthe "RESUME" position and coastto the desired lower speed thenrelease the switch.

Cancelling Cruise Control

You can cancel cruise control in anyof these ways:

• Tap the brake pedal.

• Tap the clutch pedal.

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

Resuming Cruise Control

1. If you tapped the brake orclutch pedal, the cruise/idlecontrol remembered thepreviously set cruise speed.To resume that set speed,accelerate above the minimumcruise control speed and;Toggle the SET/RESUME switchto the "RESUME" position.

2. If you moved the ON/OFF switchto the "OFF" position or turned theignition key OFF, this cleared thesystem memory and you will needto set a new cruise speed.

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Using Cruise Control for StationaryPTO Operation:

Setting Idle Speed

1. Ensure parking brakes are applied.

2. Ensure transmission is in Neutral.

3. Engage PTO per themanufacturer's operatinginstructions.

4. Move the ON/OFF switch to the"ON" position.

5. Toggle the SET/RESUME switchto obtain the desired engine rpm.

Cancelling Cruise Control

You can cancel cruise control in anyof these ways:

• Tap the brake pedal.

• Tap the clutch pedal.

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

Engine Fan Control

The engine fan can be turned ONusing a switch that is mounted on theaccessory switch panel. This lets youset the fan to manual or automaticoperation.

• With the ignition key turned ONand the fan switch in the MANUALposition, the engine fan will be ONregardless of engine temperature.

• With the engine fan switch inthe AUTO position, the enginefan will automatically turn ONwhen any one of the followingconditions occur: 1) the enginecoolant temperature reaches 200ºF (93º C) approximately, 2) theAir Conditioning system is turnedON or has reached a set pressure

point, or 3) the Engine Control Unitdetects that air intake temperature,oil temperature, or compressionbrake usage requires it.

WARNING!

Do not work on or near the fan withthe engine running. Anyone near theengine fan when it turns on could beinjured. If it is set at MANUAL, thefan will turn on any time the ignitionkey switch is turned to the ON posi-tion. In AUTO, it could engage sud-denly without warning. Before turn-ing on the ignition or switching fromAUTO toMANUAL, be sure no work-ers are near the fan.

CAUTION

The fan or equipment near it couldbe damaged if the fan turns on sud-denly when you do not expect it.Keep all tools and equipment awayfrom the fan.

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NOTEDo not operate the engine fan inthe MANUAL position for extendedperiods of time. The fan hub wasdesigned for intermittent operation.Sustained operation will shorten thefan hub's service life as well as re-duce fuel economy.

Engine Control Display

Your Kenworth may come withan optional Engine and DriverInformation Display. This instrumentrecords information on enginediagnostics, scheduled maintenance,driving conditions, and general tripinformation. The specific featuresof your display may vary dependingon engine make. For completeinformation on the display see theengine manufacturer's manual.

Engine Shutdown System

This system is an option with eachengine. The engine shutdown systemcontinually monitors oil pressure andengine temperature. If either conditionchanges beyond the normal range ofoil pressure or temperature readings,the engine shuts down automatically,sounding the alarm and turning awarning light on. The buzzer will soundcontinuously as long as Stop Engineindicator is on.

After the engine starts, and until oilpressure reaches normal operatingpressures, a warning alarm will sound.As soon as oil pressure increases, thebuzzer turns off automatically. If theengine shuts down automatically or ifthe buzzer and light turn on while theengine is running, have your engineserviced at an authorized KenworthDealer.

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Each shutdown system is enginespecific; therefore to learn howthis system works on your vehicle,you should consult the enginemanufacturer's manual.

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OPERATING THE REAR/DRIVE AXLE

OPERATING THEREAR/DRIVE AXLE

Introduction

This section covers the operationof your Rear/Drive Axle. Theseinstructions apply to the most commonfeatures of drive axles. Refer to themanufacturers instructions for furtherinformation on the operation of youraxle.

Inter-Axle Differential Lock

The inter-axle differential allows eachaxle to turn independently, whichrelieves stress on the rear axles andreduces tire wear. A switch on theaccessory switch panel locks theinter-axle differentials, which gives youbetter traction for slippery surfaces.You will notice that the switch has aguard to protect you from activating itaccidentally.

When to Use the Differential Lock

In the LOCK position, an air operatedclutch positively locks both sets ofaxles together, providing greatertraction on slippery road surfaces;however, steering around cornersand on dry pavement is more difficult.Continuous operation on a paved, drysurface stresses the tandem axles,possibly causing internal damage.

Only use this feature when driving onsurfaces with poor traction, such asheavy mud or snow, or loose gravel.And do not use it when going downhillor at speeds greater than 25 mph (40km/h).

Lock the differential when youencounter road conditions such asthese:

• Ice or snow, with or without tirechains.

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• Dirt roads.

• Loose sand, mud, or other off-roadconditions.

WARNING!

Do not put the differential lock in theLOCK position while the wheels arespinning freely (slipping), you couldlose control of the vehicle or causeaxle damage. Switch to LOCK onlywhen the wheels are not spinning.Failure to comply may result indeath, personal injury, equipment orproperty damage.

• Look ahead for wet, muddy, or icypatches on the road, stop yourvehicle and switch to LOCK aheadof time.

WARNING!

Do not operate the vehicle ondry pavement with the differentiallocked, this could lead to an acci-dent. On dry pavement, you will notbe able to steer well with the differ-ential locked. Lock the differentialonly when operating on surfaceswith poor traction, such as wet, slip-pery roads or loose gravel. Failureto comply may result in death, per-sonal injury, equipment or propertydamage.

Inter-Axle Differential LockOperation

WARNING!

Do not use the differential lock dur-ing downhill operation or at speedsabove 25 mph (40 km/h). When itis engaged under these conditions,your vehicle will exhibit understeerhandling characteristics. This un-dersteer condition will cause yourvehicle to not turn as quickly andmore steering effort will be required,which can cause an accident. Fail-ure to comply may result in death,personal injury, equipment or prop-erty damage.

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Understeer Condition

1 Turning Radius WhenUnlocked (Disengaged)

2 Turning Radius WhenLocked (Engaged)

To LOCK the inter-axle differential:

1. Anticipate when you might needincreased traction, slow down to asteady speed under 25 mph (40km/h) or stop the vehicle. Do notlock the differential while goingdown steep grades or travelingfaster than 25 mph, or whilewheels are spinning or traction isminimal; lock the differential beforeyou encounter these conditions.

2. Put the inter-axle differential lockswitch in the LOCK position. Alight on the switch will turn on,indicating that the differential islocked (engaged).

3. If you LOCK or UNLOCK thedifferential while moving, let upmomentarily on the acceleratorpedal to relieve torque on thegearing and allow full engagementof the clutch (mechanism thatlocks the wheels).

NOTEThe Meritor main differential lock orDana Spicer wheel differential lockis controlled by the switch labelledWHEEL DIFFERENTIAL. By mov-ing the switch you can LOCK or UN-LOCK the main differential when thevehicle is moving or stopped.

NOTEIf your vehicle has an automatictransmission, it may be necessary toshift the transmission to the Neutralposition momentarily to allow themain differential lock splines to fullyengage or disengage.

4. Drive the vehicle through the poortraction area, keeping your speedunder 25 mph (40 km/h).

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To UNLOCK the inter-axledifferential:

1. When you reach dry pavementor better road conditions wherethe differential lock is not needed,switch the differential lock toUNLOCK.

2. Let up momentarily on theaccelerator pedal to relieve torqueand allow the clutch to disengage.

3. When you unlock the differential,normal vehicle handling willresume and the light on the switchwill turn off.

Driver Controlled MainDifferential Lock

If your Kenworth has a Meritoraxle with a Driver Controlled MainDifferential Lock, install the cagingbolt before removing the axles fortowing. Installation of the caging boltprevents damage by locking internalaxle components in position. Use theprocedure below to lock the Meritordifferential.

1. Remove the air line.

2. Remove the caging bolt from itsstorage hole.

3. Screw the caging bolt all the wayinto the air line hole. This locksthe differential by pushing a pistoninto lock position.

Driver Controlled Main DifferentialLock

1 Air Line - Remove to InstallCaging Bolt

2 Caging Bolt StorageLocation

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Dual Range (Two-Speed)Rear Axle

Your vehicle may be equipped with atwo-speed or dual range axle (option).You can select two rear axle ratios foroperating under heavy loads or roughterrain as well as for over the roadhauling.

The Low Range provides maximumtorque for hauling heavy loads ortraveling over rough terrain. The HighRange is a faster ratio for highwayspeeds and general over the roadconditions. A switch on the accessoryswitch panel controls the Dual RangeRear Axle. You will notice that theswitch has a guard to protect you fromactivating it accidentally. Always parkyour vehicle with the range selector inLOW.

Dual Range Axle Operation

Important tips on operating a DualRange Axle with Interaxle Differential:

1. Shift the axle with the inter-axledifferential in the unlocked positiononly.

2. When you are driving with poortraction, lock the differential. Whenyou have the differential locked,drive with the axle in LOW rangeonly.

3. When you are driving on a surfacewith good traction, keep theinteraxle differential unlocked. Youcan drive with the axle in the LOWor HIGH range.

4. Always UNLOCK the inter-axledifferential before shifting the axlespeed range.

CAUTION

If you shift the axle range with theinter-axle differential in LOCK, youcould seriously damage the axles.Never shift the axle range with thedifferential locked.

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Starting-Up

1. Unlock the inter-axle differentialbefore starting.

2. Put the Range Selector in theLOW range. Shift the transmissionto start the vehicle moving.

3. When you are driving on roughterrain and secondary roads, orunder a very heavy load, keep theaxle in the LOW range. Shift thetransmission to maintain properroad speed.

WARNING!

Never shift the axle when movingdown hill. Engine driveline disen-gagement may occur, eliminatingengine retardation and allowing thewheels to spin faster than the cur-rent speed of the engine. This mayrequire severe braking to slow thevehicle down and can result in an ac-cident. Failure to comply may resultin death, personal injury, equipmentor property damage.

Proper shifting of the axle depends onthe synchronization of engine/drivelineand wheel speed. When you shiftthe axle, the connection between theengine and wheels is momentarilydisengaged while the gearing issynchronized. Normally when the axleis shifted the speed of the engine, axle,and wheels adjust, allowing for propergear engagement.

When going down hill the wheels willnot slow down, but will tend to speedup, which makes gear synchronizationalmost impossible. As a result, theaxle is neither in HIGH nor LOW rangeand all engine/driveline retardation islost. Without engine retardation it ismore difficult to slow the vehicle downand greater stress is put on the brakesystem.

CAUTION

To avoid damaging your vehicle shiftthe axle at slower travel speeds untilyou are used to driving with a dualrange axle.

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LOW to HIGH (Cruising)

When you go from rough terrain tohighway driving, shift the axle to theHIGH range following this procedure:

1. Be sure the differential isUNLOCKED.

2. Maintain your vehicle speed(accelerator depressed) and movethe Range Selector lever to HIGH.

3. Keep driving with the acceleratordepressed until you want the axleto shift.

4. To make the axle shift, release theaccelerator until the axle shifts.You are now in the HIGH axlerange for highway speeds. Shiftthe transmission normally to reachyour desired cruising speed.

HIGH to LOW (Rough Terrain)

If you need to downshift the axle formore power or you are driving onrough terrain:

1. Maintain your vehicle speed(accelerator depressed) and movethe Range Selector lever to LOW.

2. Keep driving with the acceleratordepressed until you want the axleto downshift.

3. To make the axle downshift,release and depress theaccelerator quickly to increase theengine RPM. The axle will shift toLOW range.

4. You are now in the LOW axlerange for rough terrain and heavyloads. Shift the transmissionnormally to maintain the desiredspeed.

Auxiliary Axles - Pusher orTag

Adjustable auxiliary axles can addto the productivity of your vehicle. Itis important to recognize that whenadjustable auxiliary axles are notdeployed while the vehicle is carryinga load, excessive loads may be forcedonto other vehicle components (frame,axles, suspension, brakes, steering,tires, etc.). This overload conditionmay reduce the service life of thesevehicle components. Acceptableservice life is maintained throughcareful operation, proper maintenanceand proper adherence to the vehiclesand auxiliary axle manufacturersoperating limits.

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If your vehicle is equipped withfactory-installed pusher or tagaxle(s), or you have a third-party (i.e.body-builder) install these axles, it isyour responsibility to ensure that theaxle lift controls or air-dump valve (ifequipped) are calibrated prior to puttingthe vehicle into service. The reasonfor doing this important calibration is toobtain the proper axle load distributionfor the entire vehicles axles. As withthe entire vehicles axles, the pusheror tag axle load cannot exceed thecertified GAWR and/or the legal loadlimit of the axle assembly and itsrelated components.

There are three types of pusher or tagaxles:

• Liftable/steerable (axle liftcalibration required)

• Liftable/non-steerable (axle liftcalibration required)

• Non-liftable (some suspensionsrequire dump valve calibration)

Functionality of Auxiliary Axlesinstalled by Kenworth

• Any liftable steerable auxiliaryaxles installed by Kenworth willraise when the parking brake isengaged.

• Any liftable steerable auxiliaryaxles installed by Kenworth willraise when the vehicle is placedinto reverse.

• Liftable/non-steerable axles donot raise when parking brake isengaged or if vehicle is in reverse.

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WARNING!

Do not operate or park the ve-hicle with auxiliary axles in thedown/loaded position when vehicleis unladen, or is being unloaded.Raise or dump air into driver-con-trolled auxiliary axle(s) prior to un-loading vehicle. Failure to do socan result in loss of vehicle controlor rollaway that may result in death,personal injury, equipment or prop-erty damage.

CAUTION

Never exceed the manufacturersassigned gross axle weight ratings(GAWR) of each axle when the aux-iliary axles are downloaded. Neverexceed the manufacturers creepratings when operating with a loadwhen the auxiliary axles are un-loaded. Refer to your vehicles com-pliance decals located on the LHdoorjamb for the maximum allow-able load for each axle. Exceedingthe specified weight rating of anyaxle can cause equipment damage.

NOTEAxle Creep Ratings are assignedby the axle manufacturer and arebased on axle model and intendedservice of the vehicle. To find outwhat the allowable creep rating isfor your vehicle, contact the nearestauthorized Kenworth Dealer or axlerepresentative.

Axle Creep Rating DefinitionCreep Ratings

Low speed, off-highway (work site)axle loads, which exceed the standardgross axle weight rating (GAWR) of aparticular axle.

Operator's using vehicles equippedwith liftable auxiliary axles mustconsider creep ratings when anyliftable axle is unloaded or in the raisedposition. Liftable auxiliary axles shouldonly be raised (or unloaded) to improvemaneuverability in an off-road use orwhen vehicle is unloaded.

NOTEAxle Creep ratings MUST NOT beexceeded.

Contact your Kenworth Dealer oraxle manufacturer to determine whatthe creep rating is for your particularaxle(s) and configuration. Creep

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ratings are generally limited to thefollowing:

• Tandem rear axles only

• Straight trucks only

• Maximum spring mountcenters per axle manufacturersspecifications

• Maximum tire static loaded radius(SLR) per axle manufacturersspecifications

CAUTIONAlways lower the axles as soonas possible after receiving a load.Never exceed 5 miles per hour whendriving with a load with the auxil-iary axle(s) raised/unloaded. Failureto lower the axle(s) can overloadthe frame and remaining axles, andcould cause equipment damage.

WARNING!

Never operate the vehicle with morepressure in the lift axles than is nec-essary to carry the load, as deter-mined by the calibration proceduredescribed. Failure to do so can re-sult in loss of traction and stability atthe steer and/or drive axles and canresult in increased braking distancewhich could cause loss of vehiclecontrol resulting in an accident. Fail-ure to comply may result in death,personal injury, equipment or prop-erty damage.

CAUTION

Do not modify the air system and/orcontrol functionality on a factory in-stalled auxiliary axle(s). Modifyingthe factory operation of the pusherand/or tag axle(s) will void your war-ranty, and can cause equipmentdamage.

CAUTIONA change in tire size on either theauxiliary axles or the drive/steeraxles can change the calibrationof the auxiliary axles. If tires areinstalled with a different loaded ra-dius, the calibration procedure mustbe repeated. Failure to do so cancause equipment damage.

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Liftable/Steerable orLiftable/Non-Steerable Pusherand/or Tag Axle CalibrationProcedure

Below are some general instructionson how to adjust and calibrate the aircontrol valve for the auxiliary axles toobtain the proper load distribution ofthe axle(s). For additional operatingand maintenance instructions, see thepusher or tag suspension manufacturerliterature in the glove box or contactthem directly.

NOTEThis procedure must be performedprior to placing the vehicle into ser-vice.

Setting the Pressure-to-Load Ratio

To obtain the desired axle loaddistribution, you must correlate thesuspension air gauge pressure to theactual axle load by scaling the axleweight(s) and adjusting the pressureto obtain the desired load. Once thedesired load or load range is achieved,document the pressure-to-load ratio orsetting for future use.

General Calibration Guidelines

These instructions are general innature. For more specific instructions,review the pusher or tag suspensionmanufacturers maintenance manual orcontact the nearest authorized dealer.

NOTEPerform this procedure at or near aweight scale. Procedure can be per-formed while parked on the weightscale if scale is available.

1. Park loaded vehicle on levelsurface with wheels blocked.

2. Release vehicles springbrakes. (Do not release forLiftable/Non-Steerable pusher ortag axles).

3. Lower the pusher/tag axles withthe axle lift control flip valve. (Forsome non-liftable axles, inflate airsuspension).

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4. Adjust the amount of load oneach axle by turning the pressureregulator clockwise to increasethe load or counterclockwiseto decrease the load. (Thesuspension manufacturermay publish pre-establishedPressure-to- Load Ratio PressureSettings to assist you in achievingan estimated ground load).

5. After setting the pressure to obtainthe desired axle load, verify properground loading with the weightscale.

NOTEExceeding local, state or federalweight limits may result in cita-tions. Contact your local commercialweight enforcement office for limitsin your area.

Operation Guidelines

NOTESteerable-pusher and/or tag axle(s)will raise when the transmission isshifted into reverse or when theparking brakes are applied.

Maximizing Drive Axle Traction

Adjust the pressure regulator controlknob to a lower pressure until desiredtraction is obtained. By reducing airpressure at pusher or tag axle, loadwill be transferred to drive axles. Donot overload drive axles.

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Coupling to a Loaded Trailer

Inflate air springs of the auxiliary axlesto the desired pressure after couplingto a loaded trailer while still maintainingproper traction of the drive axles.

Unloading Operation

Always deflate air springs of theauxiliary axles before attempting tounload vehicle. This allows maximumtraction of the drive axles to control thevehicle.

Non-liftable (Non-steerable) Axles

Some suspensions require dump valvecalibration.

Example: Neway dead axles do notlift, but the air can be dumped out ofthem to unload them when empty. Airpressure is controlled via an adjustableregulator. These axles need to becalibrated for load.

Contact your authorized KenworthDealer or axle/suspensionmanufacturer for dump valvecalibration procedures.

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OPERATING THE TRANSMISSION

OPERATING THETRANSMISSION

Introduction

Your Kenworth is equipped with either amanual or automatic transmission withspecial features and gearing to meetyour particular needs. It is importantfor you, the driver, to understandhow your particular transmission isoperated. To do this, you have twosources: this Operator's Manualand the transmission manufacturer'sDriver/Operator's Instruction Manual.Because of the wide variety of differenttransmissions installed in Kenworthvehicles, operating procedures foryour particular transmission are notincluded in this manual; therefore,you should read and understand bothmanuals.

Read the general guidelines andinstructions that follow and readthe specific instructions containedin the transmission manufacturer'sDriver/Operator's Instruction Manual.

You will find a shift pattern diagramin the cab. Check to be sure youknow the correct sequence for yourparticular transmission.

Transmission Warm-Up

In cold weather (below 32° F (0°C), you may find shifting sluggishwhen you first start up. Transmissionwarm-up is especially important atthis time, but it is always a goodidea to warm-up your transmissionbefore starting out on the road. Towarm-up the transmission, follow theseprocedures.

To warm-up the transmissionlubricating oil during engine warm-up,with a single transmission (manual andautomatic):

1. Put the transmission in Neutral.

2. Release the clutch pedal (manualonly) and operate the transmissionin neutral for 3 to 5 minutes priorto operating the transmission ineither forward or reverse range.

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3. If you have a two-transmissioncombination:

° Put the main transmission ingear.

° Put the auxiliary transmissionin Neutral. This will allowthe transmission countershaftto turn, agitating the oil andwarming it.

Operating ManualTransmissions

The transmission shift pattern for yourvehicle may be located on the driver’ssun visor and shift control knob. Inaddition to understanding the shiftpattern and its location, you shouldread the transmission manufacturer’smanual provided with your vehiclebefore operating the vehicle.

Putting the Vehicle in Motion

After making sure the vehicle's oiland air pressure are correct and allother parts and systems are in properworking condition:

1. Fully depress the clutch pedal (formanual transmission) until theclutch brake makes contact. Thecontact will occur at about 1 inchor less from the floorboard.

° The total stroke of the clutchpedal is about 10 inches. Thefirst 1-½ inches is free travel.After the free travel comesthe release stroke, which isthe part that fully releasesthe clutch. The last 1 inchengages the clutch brake.

° Always start out in a lowgear. Starting in higher gears,even with a light load, willcause a very jumpy start andexcessive wear.

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CAUTION

Always use first gear or a low speedrange to start the vehicle in motion.The use of a higher gear or speedrange forces undue strain on theengine, clutch, other transmissioncomponents, and may cause dam-age.

2. Evaluate the road surfaceconditions and terrain your vehicleis on. Select a gear low enough tolet your vehicle start forward withthe throttle at idle.

3. Push the parking brake valvehandle (Yellow) against the dashpanel to release the brakes.

4. Release the clutch pedal (manualonly), then gradually accelerate topermit smooth starting,

5. Do not allow your vehicleto roll (even a little) in theopposite direction during clutchengagement. If you need tostart up on an incline, apply yourservice brakes before you releasethe parking brake. Then releaseyour service brakes as you engagethe clutch and apply throttle.

For further instructions onoperating your transmission, seethe transmission manufacturer'sDriver/Operator's Instruction Manual.

If you have a misaligned gear conditionin your vehicle's transmission andcannot start, gradually release theclutch, allowing the drive gear teeth toline up properly. Then the drive gearcan roll enough to allow the teeth toline up properly and complete the shift.

The best engine performance andmaximum economy is obtained if gearsare properly selected. This efficiencyis achieved by always selecting gearswithin optimum engine RPM, whichis where maximum torque and powerare obtained. For further information,see MORE DRIVING TIPS ANDTECHNIQUES on page 4-5.

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Shifting Gears in a New Vehicle

Shift carefully in a new vehicle. Thetransmission may be a little stiff atfirst. Avoid gear clashing, by closelyfollowing these procedures.

When you are operating a new vehicleor one that has been exposed to coldweather, you want the transmissionlubricant (fluid) to circulate and coatthe contacting surfaces of the gears.Metal contacting metal in movingparts may seriously damage yourtransmission, do not drive in onegear for long periods of time until thetransmission lubricant has a chance tocoat all contacting surfaces. Carefullyobserve the free travel in the clutchfor the first few hundred miles. As theclutch lining wears and high spots getworn smooth, you will get less freetravel.

Clutch Brake and Travel

The clutch brake is used for stoppingtransmission gears, allowing you toeasily shift into first gear or reversewithout grinding gears. Approximatelythe last one inch of clutch pedal travelactivates the clutch brake.

• To apply the clutch brake (whilethe vehicle is stopped) fullydepress the clutch pedal to thefloorboard to stop the gears. Withthe throttle at idle, select first gearthen release the clutch pedal to letthe vehicle start forward, until theclutch is fully engaged. See themanufacturer's Driver/Operator'sInstruction Manual for furtherdetails.

If the transmission has a butt-toothcondition and you cannot engage agear, gradually release the clutch.Then the drive gear can roll enough toallow the teeth to line up properly andcomplete the shift.

During Normal Driving

If you want to shift directly into any gearother than first or reverse, depress theclutch pedal only far enough to releasethe clutch. Pushing the clutch to thefloor applies the clutch brake and couldcause gear hang-up.

CAUTION

Be careful not to apply the clutchbrake while the vehicle is moving.The purpose of the clutch brake isto stop the transmission so that youcan shift into a starting gear withoutgrinding gears. Applying the clutchbrake when the vehicle is movingcauses a braking effect on the drive-train and shortens the service life ofthe clutch brake.

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Double Clutching

Whether you are upshifting or downshifting, it is best to double clutch.Double clutching is easier on thetransmission and on the engine,helping your vehicle match enginespeed with driveline speed andachieving clash-free shifts.

To double clutch:

1. Push the clutch pedal down todisengage the clutch.

2. Move the gear shift lever toneutral.

3. Release the pedal to engagethe clutch. This lets you controlthe RPM of the mainshaft gears,allowing you to match the RPM ofthe mainshaft gears to those of theoutput shaft.

° Upshifts: let the engine andgears slow down to the RPMrequired for the next gear.

° Downshifts: press accelerator,increase engine and gearspeed to the RPM required inthe lower gear.

4. Now quickly press the pedal todisengage the clutch and movethe gear shift lever to the next gearspeed position.

5. Release the pedal to engage theclutch.

More Transmission TipsRiding the Clutch

The clutch is not a footrest. Do notdrive with your foot resting on theclutch pedal. It will allow your clutch toslip, causing excessive heat and wear,damage could result.

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Release Bearing Wear

When you must idle your engine for anyperiod of time, shift your transmissionto neutral and disengage the clutch(take your foot OFF of the pedal). Thishelps prevent unnecessary wear toyour clutch release bearing, and it isless tiring for you, too.

Clutch Adjustment

Inspect manual clutches according tothe manufacturer's recommendations.Regular maintenance should befollowed to maintain correct clutchadjustment. Have your dealer'sService Department perform anyadjustment necessary.

Tips

• Always use the clutch whenmaking upshifts or downshifts.

• Always select a starting gearthat will provide sufficient gearreduction for the load and terrain.

• Never downshift when the vehicleis moving too fast.

• Never slam or jerk the shift leverto complete gear engagement.

• Never coast with the transmissionin neutral and the clutchdisengaged.

• To provide smooth gearengagements while shifting,use proper coordination betweenshift lever and clutch.

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Transmission Oil TemperatureGauge

The Transmission Temperature Gauge(option), indicates the temperature ofthe oil in the transmission. Watch thisgauge to know when the transmissionis overheating: if it is, have itchecked by an authorized servicerepresentative.

Operating AutomaticTransmissions

An automatic transmission makesshifting much easier, of course. Butbecause your truck pulls a heavyload, it is important to use it efficiently.For correct automatic transmissionoperation, see the manufacturer'sDriver/Operator's Instruction Manual.

WARNING!

If your vehicle has a Freedomlinetransmission, be aware that it canroll backwards when stopped on ahill or grade, or when starting froma stop on a hill or grade. Failure tocomplymay result in death, personalinjury, equipment or property dam-age. Observe the following guide-lines:

• On most automatic transmissionsthere is no PARK position, soyou will need to apply the parkingbrake before leaving the cab. SeeUsing the Parking Brake on page4-19.

WARNING!

Do not leave the cab without apply-ing the parking brake. The truckcould roll and cause an accident. Al-ways apply the parking brake beforeyou leave the cab. Failure to complymay result in death, personal injury,equipment or property damage.

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Auxiliary Transmissions

If you have an auxiliary transmissioninstalled on your Kenworth , seethe transmission manufacturer'sDriver/Operator's Instruction Manual tolearn how to operate it correctly.

Steerable Drive Axle

CAUTIONThe customer cannot change axleratios or tires without Kenworth En-gineering approval.

If you have a Steerable Drive Axleinstalled on your Kenworth , referto the auxiliary transmission/transfercase manufacturer's Driver/Operator'sInstruction Manual to learn how tooperate correctly.

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SHUT-DOWN

SHUT-DOWN

Introduction

After you have parked in a safe placecheck your vehicle to make sure it willbe ready for the next trip. To makesure your vehicle is ready to go after along stop (such as overnight), pleasefollow the suggestions below. Yourvehicle will be easier to get going whenyou are ready, and it will be safer foreveryone who might be around it.

Please remember, too, that in somestates it is illegal to leave the enginerunning and the vehicle unattended.

Final Stopping Procedures1. Set the parking brake before

leaving the driver's seat.To hold your vehicle while itis parked, DO NOT rely on thefollowing:

° air brakes

° hand control valve for trailerbrakes

° engine compressionAlways use your parkingbrakes!

WARNING!

Do not use the trailer hand brakeor service brakes to park and holdan unattended vehicle, use the park-ing brakes. Because service brakeswork with air pressure, these brakescould slowly release. Your vehiclecould roll, causing a serious acci-dent. Always set the parking brakes.Never rely on the service brakes tohold a parked vehicle. Failure tocomplymay result in death, personalinjury, equipment or property dam-age.

2. If you must park on a steep grade,always block the wheels.

3. Drain water from the air tanks.

4. While the engine and air supplysystem are still warm, drainmoisture from the air tanks. Openthe tank drains just enough todrain the moisture. Do not depletethe entire air supply.

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SHUT-DOWN

5. Secure the vehicle, close all thewindows, and lock all doors.

Blocked Wheels

Before Stopping the Engine

Do not shut off the engine immediately.A hot engine stores a great amountof heat and it does not cool downimmediately after you shut if off.Always cool the engine down beforeshutting it off. You will greatly increaseits service life.

Idle the engine at 1,000 rpm for fiveminutes. Then low idle for thirtyseconds before shutdown. This willallow circulating coolant and lubricatingoil to carry away heat from the cylinderhead, valves, pistons, cylinder liners,turbocharger, and bearings. This wayyou can prevent engine damage thatmay result from uneven cooling.

Turbocharger

This cooling-down practice isespecially important for a turbochargedengine. The turbocharger on yourvehicle contains bearings and sealsthat are subjected to hot exhaustgases. While the engine is operating,heat is carried away by circulating oil.If you stop the engine suddenly aftera hard run, the temperature of theturbocharger could rise to as much as100° F (55° C) above the temperaturereached during operation. A suddenrise in temperature like this couldcause the bearings to seize or the oilseals to loosen.

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SHUT-DOWN

Refueling

Air inside the fuel tanks allows waterto condense in the tank. To preventthis condensation while the vehicle isparked for extended periods of time,fill the tanks to 95 percent of capacity.Never fill to more than 95 percentcapacity as this provides room forexpansion resulting from temperatureextremes. When refueling, addapproximately the same amount toeach fuel tank on vehicles with morethan one tank.

WARNING!

Do not carry additional fuel contain-ers in your vehicle. Fuel containers,either full or empty, may leak, ex-plode, and cause or feed a fire. Donot carry extra fuel containers, evenempty ones are dangerous. Failureto comply may result in death, per-sonal injury, equipment or propertydamage.

WARNING!

Do not remove a fuel tank cap nearan open flame. Diesel fuel in thepresence of an ignition source (suchas a cigarette) could cause an ex-plosion. A mixture of gasoline oralcohol with diesel fuel increasesthis risk of explosion. Use only thefuel and/or additives recommendedfor your engine. Failure to complymay result in personal injury, death,equipment or property damage.

Specification: Use only UltraLow Sulfur Diesel (ULSD) Fuel,as recommended by enginemanufacturers. If you need furtherinformation on fuel specifications,consult the Engine Operation andMaintenance Manual.

Location of Fuel Shut-Off Valves

If your vehicle is equipped with shut-offvalves for the take-off and return lines,they are located on the fuel linesentering the top of the fuel tank. Fuelshut-off valves for the fuel crossoverline are on the bottom of the fuel tank,at the crossover line connection.

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MAINTENANCE

PREVENTIVE MAINTENANCEIntroduction . . . . . . . . . . . . . . . . . . 5-9Safety Precautions . . . . . . . . . . . . . . . 5-9Environmental Protection and Material Hazards . . 5-10

MAINTENANCE SCHEDULE AND LUBRICATIONIntroduction . . . . . . . . . . . . . . . . . 5-12Preventive Maintenance Intervals and Schedule . 5-12Lubrication Specifications . . . . . . . . . . . 5-30Oil Reservoirs . . . . . . . . . . . . . . . . 5-31Lubrication Chart . . . . . . . . . . . . . . . 5-32

AIR SYSTEM MAINTENANCEIntroduction . . . . . . . . . . . . . . . . . 5-34Scheduled Maintenance . . . . . . . . . . . . 5-35Air Tanks . . . . . . . . . . . . . . . . . . 5-36Air Gauges and Air Leaks . . . . . . . . . . . 5-37Air Compressor . . . . . . . . . . . . . . . . 5-38Air Dryer . . . . . . . . . . . . . . . . . . . 5-40

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MAINTENANCE

Air Intake System . . . . . . . . . . . . . . . 5-42Turbocharger . . . . . . . . . . . . . . . . . 5-43Air Cleaners and Filter Replacement . . . . . . 5-43

BRAKE SYSTEM MAINTENANCEIntroduction . . . . . . . . . . . . . . . . . 5-44Checks and Adjustments. . . . . . . . . . . . 5-46Anti-Lock Braking System (ABS) . . . . . . . . 5-49

CAB MAINTENANCEIntroduction . . . . . . . . . . . . . . . . . 5-51Exterior Maintenance . . . . . . . . . . . . . 5-51Cleaning, Protecting and Weather Stripping . . . 5-53Safety Restraint System - Inspection . . . . . . 5-55Windshield Wiper/Washer . . . . . . . . . . . 5-59Hood Safety Lock . . . . . . . . . . . . . . . 5-59

COOLING SYSTEM MAINTENANCETopping Up. . . . . . . . . . . . . . . . . . 5-60Adding Coolant . . . . . . . . . . . . . . . . 5-61

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MAINTENANCE

Change and Refilling . . . . . . . . . . . . . 5-63Radiator Cap . . . . . . . . . . . . . . . . . 5-64Engine (Block) Heater . . . . . . . . . . . . . 5-65

ELECTRICAL MAINTENANCEElectrical System . . . . . . . . . . . . . . . 5-66Fuses, Circuit Breakers, and Relays . . . . . . . 5-66Adding Electrical Options . . . . . . . . . . . 5-67Turn Signal Flasher . . . . . . . . . . . . . . 5-70Batteries . . . . . . . . . . . . . . . . . . . 5-70Battery Care . . . . . . . . . . . . . . . . . 5-73Battery Charging . . . . . . . . . . . . . . . 5-74Electrical and Alternator Precautions . . . . . . 5-76Remote Keyless Entry . . . . . . . . . . . . . 5-77Halogen/HID Lamp Headlamp Servicing . . . . . 5-78

ENGINE MAINTENANCEEngine Maintenance . . . . . . . . . . . . . 5-83Engine Lubrication . . . . . . . . . . . . . . 5-84Master Lubrication Index . . . . . . . . . . . . 5-85

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MAINTENANCE

Fuel System . . . . . . . . . . . . . . . . . 5-87Accessory Drive Belts . . . . . . . . . . . . . 5-88Engine Fan . . . . . . . . . . . . . . . . . 5-89Exhaust System . . . . . . . . . . . . . . . 5-89Engine Mounting . . . . . . . . . . . . . . . 5-90All Models . . . . . . . . . . . . . . . . . . 5-90Multi-Function Message Display . . . . . . . . 5-91

FRAME MAINTENANCEIntroduction . . . . . . . . . . . . . . . . . 5-92

FRONT AXLE AND SUSPENSION MAINTENANCEAxle Lubrication . . . . . . . . . . . . . . . 5-95Inspection . . . . . . . . . . . . . . . . . . 5-96Wheel Alignment . . . . . . . . . . . . . . . 5-96U-Bolt Torque . . . . . . . . . . . . . . . . 5-96

HEATER AND AIR CONDITIONER MAINTENANCEIntroduction . . . . . . . . . . . . . . . . . 5-98Heater. . . . . . . . . . . . . . . . . . . . 5-99

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MAINTENANCE

Air Conditioner . . . . . . . . . . . . . . . . 5-100

NOISE AND EMISSION CONTROL MAINTENANCENoise Emission Warranty . . . . . . . . . . . 5-101Inspection and Maintenance Instructions . . . . . 5-103Noise Control System - Maintenance Log . . . . 5-108

REAR AXLE AND SUSPENSION MAINTENANCEGeneral Maintenance . . . . . . . . . . . . . 5-109Visual Inspection . . . . . . . . . . . . . . . 5-110Rear Suspension Fasteners . . . . . . . . . . 5-111Rear Axle Lubrication . . . . . . . . . . . . . 5-112Rear Axle Alignment . . . . . . . . . . . . . 5-114

STEERING AND DRIVELINE MAINTENANCEPower Steering . . . . . . . . . . . . . . . . 5-115Fluid Level and Refill . . . . . . . . . . . . . 5-116Steering Driveline . . . . . . . . . . . . . . . 5-117Driveshaft . . . . . . . . . . . . . . . . . . 5-118

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MAINTENANCE

TIRES AND WHEEL MAINTENANCEIntroduction . . . . . . . . . . . . . . . . . 5-119General Safety Requirements . . . . . . . . . 5-119Speed Restricted Tires . . . . . . . . . . . . 5-120Tire Inspection and Replacement . . . . . . . . 5-121Tire Inflation and Loading . . . . . . . . . . . 5-121Wheel Mounting and Fastening . . . . . . . . . 5-124Wheel Replacement with Disc Brake Option . . . 5-127Wheel and Tire Replacement for Trucks withHydraulic Brakes . . . . . . . . . . . . . . 5-128

Disc Wheels . . . . . . . . . . . . . . . . . 5-129Comparing Hub Piloted and Ball Seat Parts . . . 5-129Tire Replacement . . . . . . . . . . . . . . . 5-130Matching Tires . . . . . . . . . . . . . . . . 5-132

TRANSMISSION AND CLUTCH MAINTENANCEIntroduction . . . . . . . . . . . . . . . . . 5-133All Transmissions . . . . . . . . . . . . . . . 5-133Transmission Lubricants . . . . . . . . . . . . 5-134

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MAINTENANCE

Automatic Transmissions . . . . . . . . . . . 5-135Clutch System Introduction . . . . . . . . . . . 5-136Clutch Linkage . . . . . . . . . . . . . . . . 5-136Clutch Adjustment - Normal Wear . . . . . . . . 5-137

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PREVENTIVE MAINTENANCE

PREVENTIVEMAINTENANCE

Introduction

This section will help you keep yourKenworth in good running condition.There are a number of checks youcan do, and you may be able to dosome of the service work yourself. Butplease, let your Kenworth Dealer doany work you do not have the toolsor skill to perform. Authorized servicemechanics are trained in the propertechnical and safety procedures tomaintain your Kenworth correctly.

Good driving practices, dailyand weekly driver maintenanceinspections, and periodic serviceinspections by an authorized KenworthDealer, will help keep your Kenworth ingood working order and provide manyyears of dependable service.

WARNING!

It can be dangerous to attemptmaintenance work without sufficienttraining, service manuals, and theproper tools. You could be injured,or you could make your vehicle un-safe. Do only those tasks you arefully trained and equipped to do.Failure to comply may result in per-sonal injury, death, equipment orproperty damage.

Safety Precautions• Before attempting any

procedures in the enginecompartment, stop the engineand let it cool down. Hotcomponents can burn skin oncontact.

• Be alert and cautious aroundthe engine at all times while theengine is running.

• If work has to be done with theengine running, always (1) setthe parking brake, (2) chockthe wheels, and (3) ensure thatthe shift lever or selector is inNeutral.

• Exercise extreme caution toprevent neckties, jewelry, longhair, or loose clothing fromgetting caught in moving engineparts.

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• Disconnect the battery groundstrap whenever you work onthe fuel system or the electricalsystem. When you work aroundfuel, do not smoke or worknear heaters or other firehazards. Keep an approved fireextinguisher handy.

• Always support the vehicle withappropriate safety stands if it isnecessary to work underneaththe vehicle. A jack is notadequate for this purpose.

• When working underneath thevehicle without appropriatesafety stands but with thewheels on the ground (notsupported), make sure that (1)the vehicle is on hard levelground, (2) the parking brakeis applied, (3) all wheels arechocked (front and rear) and (4)the engine cannot be started.Remove the ignition key.

• Never start or let the engine runin an enclosed, unventilatedarea. Exhaust fumes fromthe engine contain carbonmonoxide, a colorless andodorless gas. Carbon monoxidecan be fatal if inhaled.

Incomplete or improper servicingmay cause problems in the operationof the vehicle. If in doubt aboutany servicing, have it done by yourauthorized Kenworth Dealer. Impropermaintenance during the warrantyperiod may also affect the warrantycoverage.

Modifying your vehicle can makeit unsafe. Some modifications canaffect your vehicle's electrical system,stability, or other important functions.Before modifying your vehicle, checkwith your Kenworth Dealer to makesure it can be done safely and correctly.

Environmental Protectionand Material Hazards

Some of the ingredients in engineoil, hydraulic oil, transmission andaxle oil, engine coolant, diesel fuel,air conditioning refrigerant (R-134aand PAG oil), batteries, etc., maycontaminate the environment ifspilled or not disposed of properly.Non-compliance with environmentalregulations can result in fines and/or jailterms. Contact your local governmentagency for information concerningproper disposal.

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WARNING!

This vehicle contains materialknown by the State of California tocause cancer and/or birth defectsor other reproductive harm. Thiswarning requirement is mandatedby California law (Proposition 65)and does not result from any changein the manner in which KenworthTruck Company vehicles are manu-factured.

CAUTION

Handle lubricants carefully. Vehi-cle lubricants (oil and grease) canbe poisonous and cause sickness.They can also damage the paint onthe vehicle.

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5

MAINTENANCE SCHEDULE AND LUBRICATION

MAINTENANCESCHEDULE ANDLUBRICATION

Introduction

The following section summarizespreventivemaintenance and lubricationrequirements for the maintenance ofyour Kenworth . In addition, supportingmanuals and literature are included inthe glove box literature package.

Preventive MaintenanceIntervals and Schedule

Your preventive maintenance programbegins with daily checks you perform.See Driver's Check List on page 1-32.If your Kenworth is serviced regularly,you can avoid many large, expensive,and time-consuming repairs, as wellas ensuring many years of safe andsmooth operation. Also, be advisedthat neglect of recommended servicemay in some cases void your vehicle'swarranty. So, for your safety and lifeof your vehicle, please follow Table9, Maintenance Schedule on page5-19. But remember, there may bemaintenance operations that demandsskills and equipment you do not have.If so, please take your Kenworth to anexpert mechanic, for your safety andyour vehicle's performance.

WARNING!

It can be dangerous to attemptmaintenance work without sufficienttraining, service manuals, and theproper tools. You could be injured,or you could make your vehicle un-safe. Do only those tasks you arefully trained and equipped to do.Failure to comply may result in per-sonal injury, death, equipment orproperty damage.

In severe operating conditions suchas earth moving, you will need toperform maintenance checks andservices more frequently. Othersevere operating conditions to beaware of are: where the vehicle isconsistently operated under conditionsof extreme temperature; conditionswhere heavy loads are being hauled;and contaminated environments, orsteep grades.

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Consult the component manufacturer'smaintenance manuals for furtherinformation on maintenanceprocedures specific to theseconditions.

Maintenance and LubricationIntervals

The following table (Table 6,Recommended Lubrication Intervals)shows service intervals for Kenworthvehicles. All intervals shown are fornormal and heavy-duty operations.

NOTEDifferent lubricants or service inter-vals than those listed below may berequired.

Table 6 Recommended Lubrication Intervals

ITEM INTERVAL COMMENTSHood Pivot NoneHood Safety Lock 60,000-120,000 EP chassis grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2.Front Brake Camshaft 10,000-15,000 Synthetic Grease with Special FittingsFront Brake Camshaft 120,000 With LMSTie-Rod Ends 10,000-15,000

10,000-15,000Power Steering Reservoir- Check Fluid Level- Change Fluid & Filter 60,000 2 Times/Year (After Summer & Winter)

Drag Link 10,000-15,000 #2 NLGI extreme pressure, lithium based, moly filled, heavy duty grease with hand operatedgun only.

Steering Gear BoxTrunnion

10,000-15,000 #2 NLGI extreme pressure, lithium based, moly filled, heavy duty grease with hand operatedgun only.

Steering U-joints 10,000-15,000 #2 NLGI extreme pressure, lithium based, moly filled, heavy duty grease with hand operatedgun only.

Steering Slip Joint 10,000-15,000 #2 NLGI extreme pressure, lithium based, moly filled, heavy duty grease with hand operatedgun only.

Brake Treadle 10,000-15,000

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5


ITEM INTERVAL COMMENTSClutch Pedal Shaft NoneMain and Aux.Transmission- Check Fluid Level- Drain and Refill

Kenworth is Standard with Synthetic Lube (mineral gear lube optional)See Transmission Manufacturer's Specifications and Recommendations - Contact yourKenworth Dealer for Preventive Maintenance Specifications/Schedule

Rear Wheel Bearings -Standard

12 mo./100,000 See www.conmet.com for maintenance details.

Rear Wheel Bearings -LMS

12 mo./100,000 -Inspect

3 years/350,000 -Service

Inspect for leaks and check for end-play: 12 mo.\100,000 miles.See hub manufacturer's service manual for details:www.conmet.com/pdfs/preset_service_manual.pdfIf no oil leaks, then no need for service prior to 3 years/350,000 miles.

Rear Axle- Check Fluid Level- (Rear Axle) Drain, Flush, Refill

Kenworth is Standard with Synthetic Lube (mineral gear lube optional)See Axle Manufacturers Specifications and Recommendations - Contact your Kenworth Dealerfor Preventive Maintenance Specifications/Schedule

Rear Brake Camshafts 10,000-15,000 Synthetic Grease with Special FittingsRear Brake Camshafts 120,000 With LMSSpring Pins 10,000-15,000 With Rubber Bushed Pins - No ServiceFront & Rear SlackAdjusters

10,000-15,000 Synthetic Grease with Special Fittings

King Pins 10,000-15,000Front Wheel Bearings -Standard

12 mo./100,000 See www.conmet.com for maintenance details

Front Wheel Bearings -LMS

12 mo./100,000 -Inspect

3 years/350,000 -Service

Inspect for leaks and check for end-play: 12 mo.\100,000 miles.See hub manufacturer's service manual for details:www.conmet.com/pdfs/preset_service_manual.pdfIf no oil leaks, then no need for service prior to 3 years/350,000 miles.

Accelerator Linkage None Electronic Engines Only

Daily Trip Check See Engine Manufacturers RecommendationsEngine Lubricating Oil- Check Fluid Level- Change Oil 10,000-15,000 Must Meet Engine Manufacturers Specifications

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ITEM INTERVAL COMMENTSSpring Shackle Pins 10,000-15,000 No Service with Rubber Bushed Spring PinsClutch Linkage 10,000-15,000Clutch Release Bearing 10,000-15,000 Extended Grease FittingsClutch Cross Shaft 10,000-15,000 Extended Grease FittingsDoor Weatherstrip 100,000 or As

RequiredLock Cylinders 100,000 or As

RequiredDoor Hinges 100,000 or As

RequiredTeflon Bushing

Door Latches and StrikerPlate

100,000 or AsRequired

Driveshaft (all) See Table 7 and 8.Center Bearing NoneSuspension Per Specifications

AG200 15,000 EP grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2, with 3% molybdenumadditive: Mobil Grease Special (Mobil), Molygrease EP (Chevron), or equal. See Table Key onpage 5-19

AG380 None No Lube RequiredAG400 None No Lube RequiredChalmers

HendricksonNewayReyco

See Suspension Manufacturers Specifications & Recommendations - Contact your KenworthDealer for Preventive Maintenance Specifications/Schedule

For additional Air System ScheduledMaintenance information see AirSystem Scheduled Maintenance onpage 5-35.

(02/14) Y53-1212-1B1 5-15

5


Table 7 Spicer Driveshaft Lubrication Intervals*

SERIES CITY ON-HWY LINEHAUL ON/OFF-HWY10-Series(1480 thru 1810 & SPL-90)Slip member also requireslubrication.

5,000/8,000 mi(8,000/12,800 km)

or 3 Months (whichevercomes first)

10,000/15,000 mi(16,000/24,000 km)


10,000/15,000 mi(16,000/24,000 km)


5,000/8,000 mi(8,000/12,800 km)


Spicer Life Series® -Heavy Duty(SPL-140, 140HD, 170,170HD, 250 & 250HD)Standard Spicer LifeSeries u-joint Booted &permanently lubricated slipmember.

25,000 mi(40,000 km)


100,000 mi(160,000 km)


100,000 mi(160,000 km)


25,000 mi(40,000 km)or 6 Months

* Spicer Driveshaft Division recommends re-lubrication with Chevron Ulta-Duty EP-2 or a compatible grease meeting N.L.G.I. Grade 2 specificationswith an operating range of +325F/+163C to -10F/-23C.** Spicer Life XL u-joints are best identified by the rubber seal guards (a soft, pliable boot) fitted to the bearing cups. Spicer Life XL u-jointshave a plastic zerk cover attached prior to the required initial 350,000 mile re-lubrication. Standard Spicer Life Series u-joints have a hardplastic slinger fitted to the bearing cups.City is defined as all applications that require a minimum of 90% of operation time within the city limits.On-Highway is defined as all applications requiring less than 10% of operating time on gravel, dirt or unpaved roads.Linehaul is defined as 100% of operation time on smooth concrete or asphalt.On/Off-Highway is defined as all applications operating primarily on paved roads, but requiring more than 10% of operating time on gravel,dirt or unpaved roads.

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Table 8 XL Lubrication Cycles

SERIES CITY ON-HWY LINEHAUL ON/OFF-HWYSPICER LIFE XL - FIRST LUBRICATION CYCLE*SPICER LIFE XL** - HEAVYDUTY(SPL-140XL, 170XL &250XL)Extended Lubricationu-joints. Booted &permanently lubricatedslip member. After initialmiles (kilometers) or time isreached, the plastic greasezerk cover must be removedand the joints re-lubricated.

100,000 mi(160,000 km)

or 1 year (whichever comesfirst)

350,000 mi(560,000 km)

or 3 years (whichever comesfirst)

350,000 mi(560,000 km)

or 3 years (whichever comesfirst)

100,000 mi(160,000 km)

or 1 year (whichever comesfirst)

SPICER LIFE XL - RE-LUBRICATION CYCLE*SPICER LIFE XL** - HEAVYDUTY(SPL-140XL, 170XL &250XL)Extended Lubricationu-joints. Booted &permanently lubricatedslip member. After initialmiles (kilometers) or time isreached, the plastic greasezerk cover must be removedand the joints re-lubricated.

25,000 mi(40,000 km)


100,000 mi(160,000 km)


100,000 mi(160,000 km)


25,000 mi(40,000 km)


(02/14) Y53-1212-1B1 5-17

5


SERIES CITY ON-HWY LINEHAUL ON/OFF-HWY* Spicer Driveshaft Division recommends re-lubrication with Chevron Ulta-Duty EP-2 or a compatible grease meeting N.L.G.I. Grade 2 specificationswith an operating range of +325F/+163C to -10F/-23C.** Spicer Life XL u-joints are best identified by the rubber seal guards (a soft, pliable boot) fitted to the bearing cups. Spicer Life XL u-jointshave a plastic zerk cover attached prior to the required initial 350,000 mile re-lubrication. Standard Spicer Life Series u-joints have a hardplastic slinger fitted to the bearing cups.City is defined as all applications that require a minimum of 90% of operation time within the city limits.On-Highway is defined as all applications requiring less than 10% of operating time on gravel, dirt or unpaved roads.Linehaul is defined as 100% of operation time on smooth concrete or asphalt.On/Off-Highway is defined as all applications operating primarily on paved roads, but requiring more than 10% of operating time on gravel,dirt or unpaved roads.

Maintenance Schedule

Depending on the service packagebuilt into your Kenworth, use Table9, Maintenance Schedule on page5-19, as a guide to plan servicework for Non-ESI and ESI vehicles.Be sure and follow the frequencyrecommendations for your vehicle.

Maintenance Interval

Perform the listed operation in theshortest interval indicated. Forexample, if there is an “I” for Inspectlisted under 15,000 mi, 60,000 miand 120,000 mi, the shortest interval

indicated is 15,000 mi; therefore, youshould inspect the operation listedevery 15,000 miles. It just so happensthat both 60,000 and 120,000 milesare multiples of 15,000 and the tableindicates that a 15,000 mile intervalwill also occur at 60,000 and 120,000miles.

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TABLE KEY

A Part of Federal Annual Inspection Every 120,000 Miles (192,000 km)I InspectR ReplaceG2 Synthetic Lube Required - 500,000 Drain

Table 9 Maintenance Schedule

INTERVALS COMMENTSOPERATION \ FREQUENCY 7,500 mi

(12,000km)

15,000 mi(24,000

km)

60,000 mi(96,000 km)

120,000 mi(193,000km)

AnnuallyINITIAL DRIVE-IN A B C D

Clutch Brake Operation I I IClutch Pedal Free Travel _____ inches I I IGlass for Cracks or Chips I I I ADoor Window OperationInterior Lights Replace as RequiredBrake (Hydraulic) Fluid-Reservoir Level I I I IBrake (Hydraulic) Fluid-Replace Every two yearsParking Brake I I IDisk Brake Rotor I I IBrake Pad Lining I I I

Dash I I I ICovers I I I I

Wiper Operation I I I AWiper Blade Condition I I I A

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(12,000km)

15,000 mi(24,000

km)

60,000 mi(96,000 km)

120,000 mi(193,000km)

AnnuallyHorns (Electric and Air) I I I AMirrors I I I A

SAFETY EQUIPMENT A B C DDrain Water from Air Tanks I I I I DailyAir Tank Check Valve I I I AEmergency Operation of Spring Brakes I I I AAir Press. Build-up time: _______ min. I AGoverned Air Pressure: _______ psi I AAir Press. Drop-Brakes not Applied: ___ I AAir Press. Drop-Brakes Applied: ___ I AFire Extinguisher Charge Replace or Recharge per Extinguisher

Manufacturer RecommendationsFlare Kit/Reflectors A

CIRCLE INSPECTION A B C DPhysical Damage:

Exterior Sheet Metal I I I IGrille and Radiator I I I I

Trailer Light Cord and Connectors I I I AAir Lines and Gladhands I I I A

Pintle - Hook/Eye Condition I I I AHeadlights - High and Low Beams I I I ARoad Lights I I I AMarker Lights I I I ATurn Signals I I I AEmergency Flasher I I I A

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(12,000km)

15,000 mi(24,000

km)

60,000 mi(96,000 km)

120,000 mi(193,000km)

AnnuallyBrake Lights I I I ABackup/Loading Lights I I I ALicense Plates: Permits and Mounting I I I AMud Flaps/Serviceable I I I AFuel Tank Mounting I I I AExhaust System-Condition and MountingBolts

I I I A

Frame Fastener Torque: I A See Table Key on page 5-19.Lubricate:

Door Hinges and Latches I I

Body Mounts (Straight Truck Only) I IBody Sides and Roof Panels (Straight

trucks) I I

Cab Air Suspension Mounts I I See Manufacturers RecommendationsHood:

Hold Down Latches I I Replace if Damaged

Hood Safety Lock I I Lubricate as needed for proper lockingoperation

Front Pivot Assembly I I

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(12,000km)

15,000 mi(24,000

km)

60,000 mi(96,000 km)

120,000 mi(193,000km)

AnnuallyENGINE SERVICE A B C D

Engine Oil - ChangeEngine Oil LevelOil FiltersFuel FiltersDiesel Particulate Filter (DPF)Drain Water from Fuel SystemEngine Tune-upCooling:Check Supplemental Additive/Conditionerto Manufacturer Specifications_______%

See Engine Manufacturer's OperatorManual provided with this chassis

Coolant Level I I I ICoolant Protection: _______ degrees I I

Pressure Test I I I Check at Time of Coolant ReplacementReplace Water Filter R New Release at 100-120K - per Engine

Filter Manufacturer RecommendationsHose Condition and Connections I I I

Radiator Mounting I IFan Shroud I IRing Shroud I I

Fan Assembly and Idler Pulley I I No Service Required on ESI UnitsCheck Water Pump for Leaks/Play I I

Radiator - Exterior Condition Once every 240,000 Miles (384,000 km)Replace Engine Coolant For coolant replacement, please see

engine Operator’s Manual included with thischassis

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(12,000km)

15,000 mi(24,000

km)

60,000 mi(96,000 km)

120,000 mi(193,000km)

AnnuallyAir Cleaner: R Replace Annually/Air Cleaner Restriction:

Replace if Greater than 20Contaminant Accumulation I I Check Every 15,000 Miles (24,000 km) in

Dirty ConditionsAir Cleaner Restriction ___ (replace if

greater than 20) I I I

Vacuator Valve-Operation & Condition I IMounting Bolts I I

Leaks I IInterference I I

Hose Condition and Connections I I I Check for Leaks and CrackingPower Steering - Reservoir Level I I I IPower Steering Fluid - Replace R R Service 2 Times per Year - 60,000 Mile

IntervalsPower Steering Filter - Replace R R See Table Key on page 5-19Fan and Accessory Drive Belt(s) Condition

I I IFor details on belt replacement see theEngine Operator's Manual included withthis chassis.

Air Conditioner Compressor Mounting I ICold Start Aids I I IGovernor and Pump Security Seals OK AHigh Idle: ________ RPM A

Emergency Shutdown I I IVibration Damper Condition I I

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(12,000km)

15,000 mi(24,000

km)

60,000 mi(96,000 km)

120,000 mi(193,000km)

AnnuallyI I ICranking System:

Check Harness/Cables For LooseConnections, Chafing, Broken RetentionClipsStarter Draw: _________ volts

ATo ensure proper inspection it may benecessary to inspect under and inside framerails and unclip harness/cable bundles.

I I IAlternator/Charging System:Check Harness/Cables For LooseConnections, Chafing, Broken RetentionClipsOutput Voltage: _________ volts

I ATo ensure proper inspection it may benecessary to inspect under and inside framerails and unclip harness/cable bundles.

Exhaust System I Check for leaks and proper support.Engine Mounting I Inspect engine mounts every 60,000 miles

(96,560 km) (shown on page 5-90). Contactan authorized vehicle OEM dealership ifengine mounts need servicing.

UNDER VEHICLE A B C DSteering Components Condition: I I I I

Steering Gear I ASteering Shaft Splines and Joint(s) I I I A

Pitman Arm I I ADrag Link I I A

Steering Arms I I ATie Rod Arms I I ATie Rod Ends I I A

Radius Rods/Torque Arms I I AChassis Frame Cracks or Breaks I I I A

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(12,000km)

15,000 mi(24,000

km)

60,000 mi(96,000 km)

120,000 mi(193,000km)

AnnuallySpring Shackles and Hanger Brackets I A No Service Required on ESI UnitsSpring Pins I I A No Service Required on ESI UnitsKing Pin Wear ISteering Axle Wheel Bearing - End PlayAdjustment and Inspection

I I I I Inspect for leaks and check for end-play: 12mo.\100,000 miles.See hub manufacturer's service manual fordetails:www.conmet.com/If no oil leaks, then no need for service priorto 3 years/350,000 miles.

Front Hub Lubricant Level I I ASpring Leaves I AU-Bolt and Suspension Fastener Torque I I I Tighten U-bolts after the first 500 miles (800

km).Rear suspension fasteners: re-torque afterfirst 2,000 miles (3,218 km).See Table Key on page 5-19.

Rear Suspension Components - Condition I I ITrack/Torque Rods I I I

Suspension Brackets & Welds - Cracks I I ISprings, Hangers & Shackles I I I

Walking Beams I I IBushings - Worn I I I

Air Springs & Mounts I I ILubrication I I I

For Kenworth Non-Proprietary Suspensions,see your Kenworth Dealer for PreventiveMaintenance Specifications/Schedule

Suspension Air Fittings - Leaks I I I

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(12,000km)

15,000 mi(24,000

km)

60,000 mi(96,000 km)

120,000 mi(193,000km)

AnnuallyLeaks:

Coolant I I I IEngine Oil I I I A

Power Steering I I I IFuel I I I I

Transmission I I I IAxles I I I I

Inner and Outer Hub Seals I I I IEngine and Transmission Mounts I IDrivelines - U-joints and Slip Yokes I IRear Axle Lubricant Level I I IRear Axle Lubricant Flush & Refill Non ESI - 250,000 Miles/ESI - 500,000

Miles.See Table Key on page 5-19.

Rear Axle Breathers - Clear I I I IVehicle Protection Valve Breakaway Test I I I IBrake Chamber Mounting Bolt Torque I I ABrake Hoses for Cracks and Chafing I I I AAdjust Brakes I I AFront & Rear Brake Camshaft TubeLubrication I A Synthetic Grease Required - Special Fitting

Clutch Pedal Shaft I I No Service Required on ESI UnitsClutch Linkage I ISuspension Air Fittings I I I

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(12,000km)

15,000 mi(24,000

km)

60,000 mi(96,000 km)

120,000 mi(193,000km)

AnnuallySuspension Fittings - AG200

I I

EP grease, lithium 12-hydroxystearateor lithium complex base, NLGI 2, with3% molybdenum additive: Mobil GreaseSpecial (Mobil), Molygrease EP (Chevron),or equal. See Table Key on page 5-19,

Clutch Release Bearing A Required Extended FittingsDriveline Center Bearing I I No Service Required on ESI UnitsAutomatic Slack Adjusters I I I I Standard (non LMS)Automatic Slack Adjusters I With LMS, Synthetic Lube Required -

Special FittingI I ABrakes: Lining Remaining (replace as

required)RF ______RRF ______RRR ______LF ______LRF ______LRR ______

I ADrum Condition:RF ______RRF ______RRR ______LF ______LRF ______LRR ______Chassis Lubrication

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(12,000km)

15,000 mi(24,000

km)

60,000 mi(96,000 km)

120,000 mi(193,000km)

AnnuallyTransmission Lubricant Level See Transmission Manufacturers

Specifications and RecommendationsSupplied with Vehicle.

Transmission Lubricant and Filter Change A Synthetic Lube Required - 500,000 Drain.Rear Axle Lubricant Change A Synthetic Lube Required - 500,000 Drain.Front Hub Lubricant Change A Synthetic Lube Required - 500,000 Drain.

BATTERIES A B C DCheck Harness/Cables For LooseConnections, Chafing, Broken RetentionClips

I I I

Signs of Over-Charging I IRemove Corrosion and Seal Terminals I IHold-down and Box - Mounting Bolts I ILoad Test Batteries ASealed Type - Condition: I I I I(Color of charge indicator for each battery) I I I I

1 ______ 2 ______ 3 ______ I ITIRES AND WHEELS A B C D

Missing Valve Caps and Stem Locks I I I ICracks or Loose Wheel lugs I I I ATandem Mating I I I IIrregular Wear I I I ATire Pressure (Record below) I I I IRemaining Tread (Record below) I I I ATires & Wheels Inspection I I I A

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(12,000km)

15,000 mi(24,000

km)

60,000 mi(96,000 km)

120,000 mi(193,000km)

AnnuallyRight

Left

Air Pressure Adjusted to: _____________ I I I IALIGNMENT A B C D

Toe-in: ______________ in (mm) I ICaster: L ________ R ________ I IRear Axle Alignment I A

ROAD TEST A B C DSteering/Steering Play I I I IShifting I I IBrakes I I IEngine Operation (noises, surging, blacksmoke)

I I I

Throttle Linkage I I I IEngine Brake Operation I I I

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(12,000km)

15,000 mi(24,000

km)

60,000 mi(96,000 km)

120,000 mi(193,000km)

AnnuallySeat Belts I I IAir Seat Operation I I ICab Heater I I IAir Conditioner I IInstruments and Gauges:Speedometer/odometer I I ITachometer I I IOil Pressure I I IEngine Temperature I I IIllumination I I ISRS Warning I IABS Warning I ILow Brake Pressure Warning Devices I I I A

Lubrication Specifications

You will find a complete EngineLubrication Service Guide in the EngineOperation and Maintenance Manual.There, the engine manufacturerexplains more fully all the maintenanceoperations you and a qualified servicemechanic will need. And pleaseremember: one key to keeping your

Kenworth running at top economyand in prolonging its life is properlubrication servicing. Neglecting thisessential aspect of vehicle care cancost time and money in the long run.

Below you will find basic informationneeded to perform routine vehiclelubrication. Of course you will wantto schedule service more frequently

if operating in severe conditionssuch as extreme heat or cold, withvery heavy loads, off-road, etc. Forany special service requirements,consult your service manuals and yourlubricant supplier. The componentmanufacturer's specification andrequirements take precedence overother specifications.

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CAUTION

Handle lubricants carefully. Vehi-cle lubricants (oil and grease) canbe poisonous and cause sickness.They can also damage the paint onthe vehicle.

CAUTION

Do not mix different types of lubri-cants. Mixing lubricants (oil andgrease) of different brands or typescould damage vehicle components;therefore, drain (or remove) old lu-bricants from the unit before refillingit.

Oil Reservoirs

For oil reservoirs with side filler plugs(transmissions, axles, steering gearboxes, transfer cases, etc.), the oilmust be level with the filler opening.

NOTEUse care when checking the oil levelwith a finger. Just because you canreach the oil level with a finger, doesnot mean the oil level is correct.

NOTEFactory oil level may be above thislevel because it is measured as avolume and not as a specific oil level.This is acceptable to the axle man-ufacturers; however, refill should beper the Proper Oil Level as shown inthe figure below.

1 Improper Oil Level2 Proper Oil Level

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Lubrication Chart

The following lubrication specifications(Table 10) are for an ambient operating

temperature range of -15° to 100°F (-26° to 38° C). For extremetemperature operations, consult thecomponent manufacturers manuals.

Table 10 Recommended Lubrication Types * Non-ESI Units

COMPONENTS RECOMMENDED LUBRICANTPower Steering Gear ATF Dexron® IIManual Steering Gear SAE 80W-90 CP gear oil, miL-L-2105D, API GL5.Driveline U-JointsSlip-Joint SplinesHood Pivots and Hood Safety LockFan DriveClutch Pedal ShaftClutch LinkageOther chassis grease fittings not covered below.

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

OIL LUBRICATED: SAE 80W-90 EP gear oil, miL-L-2105D, API GL5; orSAE 50 Synthetic Transmission Oil (CD50).

Wheel Bearings-Non Driving AxlesIncluding Steerable Pushers and Tag Axles

GREASE LUBRICATED: EP chassis grease, lithium 12-hydroxystearateor lithium complex base, NLGI 2.OIL LUBRICATED: SAE 80W-90EP gear oil, miL-L-2105D, API GL5; orSAE 75W-90 Synthetic Oil

Wheel Bearings-Non Steerable Pushers and Tag Axles

GREASE LUBRICATED: EP chassis grease, lithium 12-hydroxystearateor lithium complex base, NLGI 2.

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), MolygreaseEP (Chevron), or equal.

Suspension Fittings (other than threaded pins & bushings) EP chassis grease, lithium 12-hydroxystearate or lithium complex base,NLGI 2.

5-32 Y53-1212-1B1 (02/14)

5


COMPONENTS RECOMMENDED LUBRICANTSteering Axle: Grease Fittings on Steering Arm; Tie Rod Ends; DragLink; King Pins

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

Clutch Release Bearing (remove inspection plate for access); DriveshaftCenter Bearing

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

Manual Slack Adjusters EP chassis grease, lithium 12-hydroxystearate base, NLGI 2.Automatic Slack Adjusters; Wedge Brake Components; Disc BrakeCaliper

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

Cam Brake Camshaft Splines; Disc Brake Shaft Splines and Slide PinRetainers; Brake Clevis Pins

Anti-seize type grease, Meritor specification 0-637.

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

CAUTIONDo 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 oilLock Cylinders Lock lubricant.Door Hinges Not required - Teflon bushingsDoor Latches & Striker Plates Polyethylene grease stick.Door Weatherstrip Silicone lubricant.Axle U-Bolt Threads Chevron Zinc Lubrication anti-seize compound is recommended; or use

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

Hub-piloted Aluminum Wheels Coat the wheel pilot or hub pads with Freylube #3 lubricant (light colored)or Chevron Zinc lube. Do not get lubricant on the face of the wheel orthe hub.

Other Items Use manufacturers manuals.*ESI units may require different lubricants for some components. See Maintenance Schedule on page 5-19.Deviations from the above list of lubricants should be based on specifications published in the component manufacturer's manuals or otherwiseapproved by the manufacturer.

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5

AIR SYSTEM MAINTENANCE

AIR SYSTEMMAINTENANCE

Introduction

WARNING!

Prior to the removal of any air sys-tem component, always block andhold the vehicle by a secure meansother than the vehicle's own brakes.Depleting air system pressure maycause vehicle to roll unexpectedlyresulting in an accident. Keep handsaway from chamber push rods andslack adjusters, they may apply assystem pressure drops. Failure tocomplymay result in death, personalinjury, equipment or property dam-age.

• Never connect or disconnecta hose or line containing airpressure. It may whip as airescapes. Never remove acomponent or pipe plug unless

you are certain all systempressure has been depleted.

• Never exceed recommendedair pressure and always wearsafety glasses when workingwith air pressure. Never lookinto air jets or direct them atanyone.

• Never attempt to disassemble acomponent until you have readand understood recommendedprocedures. Some componentscontain powerful springs andinjury or death can result if notproperly disassembled. Useonly proper tools and observeall precautions pertaining to theuse of those tools.

WARNING!

Do not release the parking brake orattempt to move the vehicle until airpressure in both circuits is at least100 psi (690 kPa), the level requiredfor normal brake operation. Failureto comply may result in death, per-sonal injury, equipment or propertydamage.

• Do not use the trailer hand brakecontrol to hold vehicle whileparked. This control utilizes airpressure for brake application.Because acceptable air leakagelevels cause all truck airsystems to gradually losepressure, vehicle rollawaycould occur, resulting in anaccident, injuries or death.

• Always apply the vehicle andtrailer parking brakes when thevehicle is unattended.

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Contamination of the air supplysystem is the major cause of problemsin air-operated components suchas brake valves, wiper motors,

and suspension height controlvalves. To keep contaminants to thelowest possible level, follow thesemaintenance procedures.

Scheduled Maintenance

Use the following table, to scheduleservice operations and air systemtests.

Table 11 Air System Scheduled Maintenance

MAXIMUM INTERVALSTEST EACH WEEK EACH MONTH

(10,000 mi)(16,000 km)

THREE MONTHS(25,000 mi)(40,000 km)

SIX MONTHS(50,000 mi)(80,000 km)

ANNUALLY(100,000 mi)(160,000 km)

Air Compressor ●Air Dryer ●Air Governor ●System Leakage ●Dual Air Brake Treadle Valve ● –––––– or –––––– ●Hand Operated Trailer Brake Valve ● –––––– or –––––– ●Vehicle Parking Valve ●Parking Brake Valve ●Trailer Air Supply ●Vehicle Protection Valves ●Relay Valve ●Spring Brake Inversion Valve ●Automatic Limiting Valve ●Single Check Valves ●Double Check Valves ●Stop Light Switch ●Low Pressure Wig Wag ●Low Pressure Switch ●

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MAXIMUM INTERVALSTEST EACH WEEK EACH MONTH

(10,000 mi)(16,000 km)

THREE MONTHS(25,000 mi)(40,000 km)

SIX MONTHS(50,000 mi)(80,000 km)

ANNUALLY(100,000 mi)(160,000 km)

Automatic Drain Valve ●Safety Valve ●Quick Release Valve ●Manual Drain Valve ●

Air System Function Test

Scheduled maintenance should beperformed on the Kenworth's airsystem, as outlined on Table 11.In addition, perform an Air SystemFunction Test at least every 3 monthsor if there is any indication of a potentialproblem.

Air Tanks

To eject moisture from the air systemtanks, pull the line which is connectedto the moisture ejection valve.Continue pulling until the air comes outfree of water.

Daily: The supply and service airtanks, must be drained on a dailybasis. Operate air devices daily tocirculate lubricants within the unit.

Periodically: Clean filter screensahead of the valves by removing thescreens and soaking them in solvent.Blow them dry with pressurized airbefore reinstalling them.

WARNING!

If the supply and service air tanksare not drained at the recommendedfrequency, water could enter theair lines and valves. This couldcause corrosion or blockage, whichcould compromise the brake systemsafety and potentially cause an ac-cident. Failure to comply may resultin death, personal injury, equipmentor property damage.

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CAUTIONDo not use penetrating oil, brakefluid, or wax-based oils in the air sys-tem. These fluids may cause severedamage to air system components.

• Maintain the air compressor toprevent excessive oil bypass.

• Replace worn seals in valves andair motors as they are needed.Your Kenworth Dealer carriesrebuild kits for most units.

Air Gauges and Air Leaks

Your Kenworth comes with twoseparate air pressure gauges fortwo separate systems, Primary andSecondary: the Primary gaugeindicates pressure in the rear brakingsystem; the Secondary gaugeindicates pressure in the front brakingsystem. Each gauge indicates theamount of air pressure in pounds persquare inch (psi).

WARNING!

Do not operate the vehicle if leak-age in the air system is detected.Failure to check the brakes or followthese procedures could cause a sys-tem failure, increasing the risk of anaccident and may result in personalinjury, death, equipment or propertydamage.

If the light and alarm do not turn off atstart-up, do not try to drive the vehicle

until the problem is found and fixed. Ifthe pressure in either or both systemsis too low for normal brake operation,i.e., the pointer of one gauge fallsbelow 60 psi (414 kPa), a warning lighton the gauge will glow and the audiblealarm will sound.

Primary Air Pressure Gauge

Secondary Air Pressure Gauge

Follow the procedure below tocheck the compressed air systemfor leaks:

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1. Periodically, or after maintenanceor replacement of air systemcomponents:

2. Build up air pressure in the systemto the governor cutout point or until120 psi (827 kPa) is reached.

3. Stop the engine and release theservice brakes.

4. Without applying the brake pedal,observe the rate of air pressuredrop. This rate should not exceed2.0 psi (14 kPa) per minute.

5. Start the engine and build up theair pressure again.

6. Stop the engine, and apply thebrakes fully. Apply the brake pedaland hold it down for five minutes.The pressure drop should notexceed 3.0 psi (21 kPa) perminute.

7. If you detect excessive leakage(air pressure loss greater than3.0 psi after five minutes of brakeapplication), a leakage test shouldbe made at the air line connectionsand at all air brake control units.These tests should determinewhere air is escaping.

Air CompressorOperation

All compressors, regardless of makeor model, run continuously while theengine is running. System pressureis controlled by the governor. Thegovernor acts in conjunction withthe unloading mechanism in thecompressor cylinder block to startand stop compression of air. Thecompressor is unloaded when thesystem pressure reaches 120 psi (827kPa) and compression is reestablishedwhen system pressure falls to 100 psi(690 kPa).

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Preventive Maintenance

The following service checks areprovided for your information onlyand should be performed by acertified mechanic. Contact yourKenworth Dealer or the enginemanufacturer's Maintenance Manualfor further information on servicing aircompressors.

After completing any repairs to the airsystem, always test for air leaks, andcheck the brakes for safe operationbefore putting the vehicle in service.

According to Table 11, Air SystemScheduled Maintenance on page 5-35:

• Inspect compressor air filterelement, if so equipped, andreplace element if clogged. Checkcompressor mounting and drivefor alignment and belt tension.Adjust if necessary.

• Remove compressor dischargevalve cap nuts and check forpresence of excessive carbon. Ifexcessive carbon is found, cleanor replace the compressor cylinderhead. Also, check compressordischarge line for carbon, andclean or replace the discharge lineif necessary.

• Disassemble compressor andthoroughly clean and inspectall parts. Repair or replaceall worn or damaged parts, orreplace compressor with a factoryexchange unit.

CAUTIONWhen draining the engine coolingsystem is required, to prevent dam-age from freezing, the compressormust also be drained at the cylin-der head and block. Engine dam-age could occur if the cooling sys-tem is not periodically drained andmaintained. See Cooling System onpage 5-60 for further information.

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Air Dryer

The function of the air dryer is to collectand remove air system contaminants insolid, liquid and vapor form before theyenter the brake system. It providesclean, dry air to the components ofthe brake system, which increasesthe life of the system and reducesmaintenance costs.

NOTEBecause no two vehicles operateunder identical conditions, mainte-nance and maintenance intervalswill vary. Experience is a valuableguide in determining the best main-tenance interval for any one partic-ular operation.

Every 900 operating hours or 25,000miles or every three (3) months checkfor moisture in the air brake systemby opening air tanks, drain cocks, or

valves and checking for presence ofwater.

NOTEA small amount of oil in the systemmay be normal and should not, in it-self, be considered a reason to re-place the desiccant cartridge. Oilstained desiccant can function ade-quately.

A tablespoon of water found in theair tank would point to the need for adesiccant cartridge change. However,the following conditions can alsocause water accumulation and shouldbe considered before replacing thedesiccant cartridge.

• Air usage is exceptionally highand not normal for a highwayvehicle. This may be due toaccessory air demands or someunusual air requirement thatdoes not allow the compressorto load and unload (compressing

and non-compressing cycle) in anormal fashion or it may be due toexcessive leaks in the air system.

• In areas where more than a 30°F (17° C) range of temperatureoccurs in one day, small amountsof water can accumulate inthe air brake system due tocondensation. Under theseconditions, the presence of smallamounts of moisture is normaland should not be considered asan indication that the dryer is notperforming properly.

• An outside air source has beenused to charge the air system.This air did not pass through thedrying bed.

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Overhaul

Maintenance intervals typical foron-highway operation would be 2 - 3years, 350,000 miles or 10,800 hours.

Maintenance intervals typical for highduty cycle usage such as transit bus,refuse hauler, dump truck, cementmixers and off-highway operationwould be 1 year, 100,000 miles or3,600 hours.

NOTEReview the warranty policy beforeperforming any maintenance proce-dures. An extended warranty maybe voided if unauthorized mainte-nance is performed during this pe-riod.

Bendix AD-IS Series Air Dryer

Your Kenworth vehicle may beequipped with a Bendix AD-IS seriesair dryer. Any air dryer replacementshould be made with an identicalcomponent.

WARNING!

If a different air dryer brand or modelis installed on the vehicle other thanwhat was originally installed, it couldcause the air system to not performcorrectly unless the full air systemdesign is reviewed and modifica-tions made to comply with FederalMotor Vehicle Safety Standards(FMVSS 121 - Air Brake Systems)or, in the case of chassis equippedwith the European air system, ECER13. Failure to abide by this warningand maintain compliance to FMVSS121 or ECE R13 could cause lossof vehicle control and may lead topersonal injury or death.

NOTEThe AD-IS Series air dryer has incor-porated into its design various com-ponents that have typically been in-stalled separately on the vehicle.

See below for components/areasaffected.

• Pressure protection valves

• Safety valve

• Governor and plumbing

• Plumbing of the front and rearservice air tanks

• Plumbing to accessory systems

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These components are requiredto meet the Federal Motor VehicleSafety Standards (FMVSS 121 - AirBrake Systems) or, in the case ofchassis equipped with the Europeanair system, ECE R13. As the Warningabove states, any other type of airdryer installed in the place of anAD-IS Series will require changes,modifications, and/or additions toyour vehicle’s air system to maintaincompliance with FMVSS 121 or ECER13. Kenworth strongly recommendsthat if the air dryer is changed from anAD-IS series, you consult your nearestauthorized Kenworth dealer.

Air Intake System

Engine heat, vibration, and agecombine to loosen air intakeconnections and cause cracks inthe tubing and elbows. Leaks in theintake system allow abrasive dust toenter the engine and quickly causeexpensive damage. During your dailywalk-around inspection, carefullycheck all tubing, elbows, clampssupports and fasteners for conditionand tightness.

• Check the Charge-Air-Cooler forair leaks annually. The air leakscan be caused by cracked tubesor header. For service see yourauthorized Kenworth Dealer.

CAUTIONDo not use air intake pipes and con-nections as a step or to pull your-self up. This could loosen the con-nections and open the system to un-filtered air which could damage theengine.

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Turbocharger

When servicing the air intake andexhaust systems on a turbochargedengine, check the items listed below.

WARNING!

Do not operate engine with tur-bocharger intake piping discon-nected. A suction is created whenthe engine is running. This suctioncould draw your hand or anythingelse near it into the impeller fan. Youcould be injured. Always keep theintake piping connected when youwill be running the engine.

Lubricating System: Check the oillines, housing, and connections. Lookfor leaks, damage, or deterioration.Leaks could mean you have damagedoil lines or oil seals.

Manifold: With the engine operating,check for leaking manifold or flangegaskets.

High Frequency Vibration: Vibrationmay indicate turbo rotor imbalance.Have your Kenworth Dealer investigatethis immediately. If you detect anydeficiencies, take the vehicle toan authorized Kenworth Dealer forservicing. Delay could lead to severeand expensive damage to your vehicle.

Air Cleaners and FilterReplacement

The following service information isbasic to all air cleaner makes andmodels. Service the filter elementswhen the (option) locks in the extremeHigh position. Have the elementserviced at an authorized KenworthDealer. Paper elements require careand proper handling, because they arecritical to engine service life.

Service the air cleaner periodically.If the vehicle operates in areas withheavy dust, maintenance should bemore frequent.

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5

BRAKE SYSTEM MAINTENANCE

BRAKE SYSTEMMAINTENANCE

Introduction

To operate your vehicle safely, youneed some understanding of its brakesystems. Brake adjustment and brakebalance must be set carefully to allowequal stopping forces at all wheels.Tires are also a very important part ofthe whole system. How fast you canstop depends on how much frictionthere is between the road and yourtires.

All of the following areas areinterrelated and must conform tooriginal specifications:

• tire size

• cam radius

• wedge angle

• drum radius

• brake linings

• brake chambers

• slack adjusters

NOTEThe air brake system of this vehi-cle was configured for ONE of thefollowing operations, TRACTOR orTRUCK, and complies with the re-spective portions of Federal MotorVehicle Safety Standards (FMVSS121 - Air Brake Systems) or, in thecase of chassis equipped with theEuropean air system, ECE R13.A tractor shall not be operated orconfigured as a truck, nor shall atruck be operated or configuredas a tractor without significantmodifications to the air brakesystem in order to retain compli-ance with FMVSS 121 or ECE R13.Contact your Kenworth dealer forinstructions.

Once a brake system is set tospecifications, changing any one ofits components or any combination ofcomponents may cause the system notto work as well. All parts have to worktogether to perform as they should.

Because your brake system is airoperated, see Air System Maintenanceon page 5-34 for more information onchecking your brakes.

Any replacement components inthe brake system should be thesame or better than the originalcomponents. Any changes from theoriginal specifications can affect theperformance of the entire system.

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WARNING!

Do not use any replacement part inthe brake system unless it conformsexactly to original specifications. Anonconforming part in your vehi-cle's brake system could cause amalfunction resulting in an injuryaccident. Sizes and types are sorelated to one another that a seem-ingly unimportant change in onemay result in a change in how wellthe brakes work for you on the road.If parts do not work together prop-erly, you could lose control of yourvehicle, which could cause a se-rious accident. Failure to complymay result in death, personal injury,equipment or property damage.

WARNING!

Do not work on the brake systemwithout the parking brake set andwheels chocked securely. If thevehicle is not secured to preventuncontrolled vehicle movement, itcould roll and may result in death,personal injury, equipment or prop-erty damage.

CAUTION

Use wood blocks (4 in. X 4 in. orlarger) against the front and rear sur-faces of the tires. Be sure the vehi-cle cannot move.

Lubrication

Cam-actuated brake componentssuch as anchor pins and brakecamshafts are subjected to hightemperatures, and must be lubricatedwith non-melting, water resistant brakegrease meeting R-S Specification0-616 (NLGI-Grade 1).

• Lubricate according to Table6, Recommended LubricationIntervals on page 5-13.

WARNING!

Do not apply too much lubricantto brake components, lubricatesparingly. Excessive amounts oflubricant could contaminate brakelinings, which could reduce brakeeffectiveness and cause an acci-dent. Failure to comply may resultin death, personal injury, equipmentor property damage.

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Brake and Slack AdjusterLubrication

According to the interval, pressurelubricate the slack adjuster and brakecamshaft (bracket/tube). Two greasefittings are provided for both the slackadjuster and camshaft bracket/tube.

• Use standard chassis lubricant(meeting No. 1 grade hightemperature, water proofspecifications).

• Do not use moly-disulfide loadedgrease or oil (they may shorten theservice life of the slack adjuster).

• Do not use pressure-releasegrease fittings when lubricatingthe slack adjuster.

Checks and Adjustments

All vehicle Operator's should check thebrakes regularly. Always adjust thebrakes when they are cool.

• Park the vehicle on a level surfaceand block the wheels beforeattempting any brake checks oradjustments.

Brake Linings

WARNING!

Do not use brake linings with a thick-ness below the specified minimum.Such linings will have lining rivetsexposed that can damage the brakedrum and reduce brake efficiency,which could cause an accident orsystem failure. Failure to complymay result in death, personal injury,equipment or property damage.

• Brake linings should be inspectedby a qualified mechanic at anauthorized Kenworth Dealer forwear. See Table 9, MaintenanceSchedule on page 5-19. In severeservice applications inspect thelinings more frequently.

NOTEDepending on your vehicles servicepackage (ESI or Non-ESI), brakeservice requirements will vary.

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Automatic Slack Adjusters

Your Kenworth is equipped withautomatic brake (slack) adjusters.

WARNING!

Do not work on the brake systemwithout the parking brake set and/orthe wheels chocked securely. If thevehicle is not secured to preventuncontrolled vehicle movement, itcould roll and may result in death,personal injury, equipment or prop-erty damage.

CAUTION

Use wood blocks (4 in. X 4 in. orlarger) against the front and rear sur-faces of the tires. Be sure the vehi-cle cannot move.

Periodically, brake adjustmentshould be checked using thefollowing procedure:

1. Check brakes when thetemperature of the servicebrake linings are cool and thesystem air pressure at 100 psi(690 kPa) minimum.

NOTEChock the tires before proceeding.

2. Release the parking brakes toallow the slack adjusters to retract.

3. Measure the retracted pushrodlength from the face of the brakechamber to the center of thepushrod pin.

4. Apply 80 to 90 psi brake applicationand measure the same distance.

5. The difference is the pushrodtravel distance (applied stroke).

6. Verify that the result is within thecorrect range. See the followingBrake Adjuster Stroke table foracceptable limits.

Measuring Pushrod Travel

1 Short as Possible WithoutBrakes Dragging "AppliedStroke"

2 Released Position3 Applied Position

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WARNING!

Automatic slack adjusters should notbe manually adjusted to correct ex-cessive pushrod travel/stroke. Ex-cessive pushrod travel indicates aproblem in either the automatic slackadjuster itself, the adjuster installa-tion or with related foundation brakecomponents. Improperly adjustingthe slack adjuster(s) could reducebrake effectiveness and lead to anaccident. Failure to comply may re-sult in death, personal injury, equip-ment or property damage.

Correctly installed and functioningautomatic slack adjusters will producethe pushrod travel for each chambertype listed in the following table.

Table 12 Brake Adjuster Stroke

80-90 PSI (552 - 621 KPA) BRAKEAPPLICATION

AIRCHAMBERTYPE (Size)

BRAKE PUSHRODTRAVEL(AppliedStroke)

20-24 Front 1 to 1-3/4 in.(25-44mm)

16 Front 3/4 in. to 1-1/2in.(19-38mm)

30 Rear 1-1/2 to 2 in.(38-51mm)

• If the pushrod travel exceedsthe above specifications, haveyour Kenworth dealer inspect theslack adjuster and all other brakerelated components for excessivewear and/or damage. Replacecomponents that are damaged orshow signs of excessive wear.

NOTEThe automatic brake adjuster alonedoes not ensure proper brake op-eration. Inspect all brake compo-nents. All brake components worktogether and must be checked peri-odically to ensure the brake systemworks properly.

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Anti-Lock Braking System(ABS)

Below are some general notes on yourKenworth anti-lock braking system. Allservice work should be performed bya qualified technician at an authorizedKenworth Dealer. The foundationbrake system must be in properworking order to ensure the best ABSperformance.

CAUTION

Before welding anywhere on thevehicle, detach the ABS ElectronicControl Unit (ECU) connector and allother electronic control units. Fail-ure to comply may result in equip-ment damage.

CAUTION

Never detach the ECU connectorwith the ignition turned on. Failureto comply may result in equipmentdamage.

NOTECheck ABS wiring harnesses andpiping periodically for chafing orother problems. No regular main-tenance is required on the ABScomponents.

NOTEDuring wheel balancing, dyno test-ing, or any time the ignition is onwith part of the ABS disconnected, afailure code will be recorded. Con-sult with your authorized KenworthDealer for information on clearingthe failure code.

If, due to operating conditions, a brakeapplication causes either wheel on thesame axle to begin skidding, wheelspeed sensors immediately signal theanti-lock controller in the modulatorassembly. The controller respondsinstantly by signaling the solenoids inthe modulator which activate the airvalves, reducing application pressureas needed to prevent the wheels fromlocking up. If this over-riding correctionis effective, application pressure isallowed to build up to the original input.

Any malfunction of the anti-locksystem on one or more axles willcause the system to fail-safe, andthe panel-mounted amber warninglight will come on, indicating both amalfunction, and automatic shut-downof the system. If the air system is intact(indicated by the pressure gauges),the service brakes will continue tofunction normally, but without benefitof the anti-lock feature.

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NOTEIf one wheel on any driven axle con-tinues to slip or spin for approxi-mately 4 seconds, this will cause theanti-lock controller for that axle togo into the fail-safe mode, and thewarning light will give a shutdownsignal.

• In this case, the anti-lock systemcan be turned back on, and thewarning light extinguished, byturning the key switch OFF andON, after the vehicle has beenbrought to a full stop. When thekey switch is turned back on, thewarning light will illuminate andremain on for 3 to 5 seconds. Thisis a built-in function test of thewarning light.

WARNING!

Do not attempt to recycle theanti-lock system by turning the keyswitch OFF and ON until the vehiclehas been brought to a full stop andthe parking brakes set. Failure to doso could adversely affect steeringand braking control, and may resultin loss of vehicle control and an ac-cident. Failure to comply may resultin death, personal injury, equipmentor property damage.

WARNING!

Do not operate the vehicle in theevent of a malfunction in any air cir-cuit. Such a malfunction may pre-vent the brake system from operat-ing properly, and could result in aninjury accident. The vehicle shouldnot be operated until the system isrepaired and both braking circuits,including all pneumatic andmechan-ical components, are working prop-erly. Failure to comply may result indeath, personal injury, equipment orproperty damage.

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CAB MAINTENANCE

CAB MAINTENANCE

Introduction

This truck brings new cab technologyto the heavy truck industry by usingmodular aluminum and compositestructural and exterior components:

CAUTION

Do not drill holes in the floor. Thefloor of the Kenworth is made ofcomposite/balsa, which is sealedto keep moisture from penetratingthe core. Any holes drilled into thefloor will allow moisture to enter thebalsa core and eventually degradethe structure.

The design and materials arelightweight, strong, noncorrosive, andprovide an extremely quiet occupantenvironment. However, these newmaterials and construction methodsrequire different repair processes as

well as some new tools and equipmentto perform satisfactory repairs. Somematerials and processes have beendeveloped over the years as theautomobile industry has movedtowards lightweight but strong unibodyconstruction using bonded aluminum,steel, and composite panels and framemembers. Other repair processeshave been developed specifically forthe Kenworth.

For repair procedures, refer to theKenworth Collision Repair Manual,available from your Kenworth Dealer.

Exterior MaintenancePainted Surfaces

Wash painted surfaces frequently toremove grime and caustic depositswhich may stain the finish. SeeCleaning, Protecting, and WeatherStripping on page 5-53.

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CAB MAINTENANCE

Chrome and Aluminum Surfaces

To prevent rust, keep chromed partsclean and protected with wax at alltimes, especially in winter conditionswhere the roads are salted.

• If necessary, use a commercialchrome cleaner to remove lightrust.

• Chrome surfaces are bestcleaned with fresh water. Wipedry to preserve their luster. Acommercial chrome cleaner willremove light rust. After cleaning,wax flat surfaces and apply a thincoat of rust preventive lubricantaround bolts or other fasteners.

• Clean aluminum wheels andbumpers with warm water. Tarremover will get rid of heavydeposits of road grime. To preventspotting, wipe aluminum surfacesdry after washing.

• Under corrosive conditions, suchas driving on salted roads, cleanaluminum parts with steam or highpressure water from a hose. Amild soap solution will help. Rinsethoroughly.

• Tail Pipe Surface CleaningTo maintain your quality finish,wash with a soft cloth, mild soapand water or glass cleaner. Anon-abrasive chrome polish canbe used sparingly on hard to cleanareas. Do Not clean your highheat chrome using scouring pads,abrasive chrome polish, highlyacidic chemical cleaners or anyother abrasive cleaners.

CAUTIONUsing improper cleaning agents canharm your high heat chrome and in-validate your warranty.

Stainless Steel

Even high quality stainless steel partscan rust under prolonged exposureto salt water, especially when thesalt-laden moisture is held againstthe metal surface by road grime. Itis, therefore, important to frequentlyclean salty moisture and grime fromstainless steel surfaces.

• If surface rust is encountered,wash the surface and use acommercial polishing compoundto clean off the rust, followed bya coating of wax (do not applywax to hot parts, such as exhaustpipes).

• Never use steel wool whencleaning stainless steel becauseminute particles of the steel woolcan embed in the surface of thestainless steel and cause ruststaining.

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CAB MAINTENANCE

Cleaning, Protecting andWeather Stripping

Frequent washings of the vehicleare required to remove grime andcontaminants that can stain andoxidize paint and accelerate corrosionof plated and polished metal surfaces.

Waxing offers added protection againststaining and oxidation. But to allowenough time for your truck's finish tocure, wait about 30 days after the dateof manufacture before waxing. Do notapply wax in the hot sun and do notfriction burn the paint with a buffingmachine.

Occasionally spray weather-strippingon doors and windows with siliconecompound to help preserve resiliency.This is especially useful in freezingweather to prevent doors and windowsfrom sticking shut with ice.

Vehicle Cleaning

Precautions

WARNING!

Handle cleaning agents carefully.Cleaning agents may be poisonous.Keep them out of the reach of chil-dren.

• Observe all caution labels.

• Always read directions on thecontainer before using anyproduct.

• Do not use any solution that candamage the body paint.

• Most chemical cleaners areconcentrates which requiredilution.

• Only use spot removing fluids inwell ventilated areas.

• Do not use gasoline, kerosene,naphtha, nail polish removeror other volatile cleaning fluids.They may be toxic, flammable orhazardous in other ways.

• Do not clean the underside ofchassis, fenders wheel covers,etc. without protecting your handsand arms. You may cut yourselfon sharp-edged metal parts.

• Moisture, ice, and road salton brakes may affect brakingefficiency. Test the brakescarefully after each vehicle wash.

• Any vehicle is subjected todeterioration from industrialfumes, ice, snow, corrosive roadsalt, etc., to name just a fewcauses.

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CAB MAINTENANCE

A well-cared-for vehicle can looklike new many years later. Regularand correct care will contribute tomaintaining the beauty and thevalue of your vehicle.

Your Kenworth Dealer has a number ofvehicle-care products and can adviseyou on which ones to use for cleaningthe exterior and interior of your vehicle.

CAUTIONDo not aim the water jet directly atdoor locks or latch. Tape the keyholes to prevent water from seepinginto the lock cylinders. Water in lockcylinders should be removed withcompressed air. To prevent locksfrom freezing in the winter, squirtglycerin or lock deicer into the lockcylinders.

Washing the Exterior

1. Begin by spraying water over thedry surface to remove all loose dirtbefore applying the car wash andwax solution.Do not wash the vehicle in directsunshine.Do not spray water directly into thecab and sleeper vents.

2. Using soapy water, wash thevehicle with a clean soft cloth ora soft brush made for automotivecleaning.Use cool or warm water and amild, household type soap. Strongindustrial detergents and cleaningagents are not recommended.Do not use stiff brushes, papertowels, steel wool, or abrasivecleaning compounds becausethey will scratch painted, plated,and polished metal surfaces.

3. Rinse surfaces frequently whilewashing to flush away dirt that

might scratch the finishes duringthe washing operation.

4. Wipe everything dry with achamois to avoid water spots.To prevent water spotting, dry offthe cosmetic surfaces with a cleancloth or chamois.

5. Remove road tar with anautomotive type tar remover ormineral spirits.

6. After cleaning and drying, apply aquality automotive wax.

° Do not apply wax in the hotsun.

° Never dust off dry surfaceswith a cloth because it willscratch the finishes.

NOTETo allow enough time for your truck'sfinish to cure, wait at least thirty daysafter the date of manufacture beforewaxing.

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CAB MAINTENANCE

Cleaning the Chassis

• Hose dirt and grime from theentire chassis. Then, if an oilleak develops, you will be able todetect it easier.

• Corrosive materials used for iceand snow removal and dust controlcan collect on the underbody. Ifthese materials are not removed,accelerated corrosion (rust) canoccur on underbody parts such asfuel lines, frames, floor pan, andexhaust system, even though theyhave been provided with corrosionprotection.

At least every spring, flush thesematerials from the under body withplain water. Be sure to clean anyarea where mud and other debris cancollect. Sediment packed in closedareas of the frame should be loosenedbefore being flushed. If desired, yourKenworth Dealer can do this servicefor you.

Cleaning Interior Vinyl andUpholstery

• Wipe vinyl upholstery and liningwith a good commercial upholsterycleaner. Do not use acetone orlacquer thinner.

• Clean fabric upholstery withupholstery shampoo speciallyformulated for this purpose. Followinstructions on the container.

Safety Restraint System -Inspection

The seat belt system, includingwebbing, buckles, latches, andmounting hardware, endures heavyuse in heavy-duty vehicles, much morethan seat belt systems in passengercars. All users should be aware of thefactors contributing to this heavy useand reduced belt life.

WARNING!

Failure to properly inspect and main-tain restraint systems can lead to in-jury or loss of life. Without periodicinspection and maintenance to de-tect unsafe conditions, seat restraintcomponents can wear out or not pro-tect you in an accident.

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CAB MAINTENANCE

Factors contributing to reducedseat belt life:

• High mileage heavy trucks, oftenaccumulate mileage in excess of500,000 total miles (800,000 km)during the vehicle lifetime. Thisis much greater than a typicalpassenger car, which frequentlywill not exceed 125,000 total miles(200,000 km).

• Seat and cab movement intrucks, there is almost constantmovement of the belt due to ridecharacteristics and seat design.The constant movement of the beltinside the restraint hardware andthe potential for the belt to comein contact with the cab and othervehicle parts, contributes to thewear of the entire system.

• Environmental conditions, such asdirt and ultraviolet rays from thesun, will reduce the life of the seatbelt system.

Due to these factors, the three-pointsafety belt system installed in yourvehicle requires thorough inspectionevery 20,000 miles (32,000 km). Ifthe vehicle is exposed to severeenvironmental or working conditions,more frequent inspections may benecessary.

Any seat belt system that shows cuts,fraying, extreme or unusual wear,significant discoloration due to UV(ultraviolet) exposure, abrasion to theseat belt webbing, or damage to thebuckle, latch plate, retractor hardwareor any other obvious problem shouldbe replaced immediately, regardlessof mileage.

WARNING!

It is important to remember that anytime a vehicle is involved in an ac-cident, the entire seat belt systemmust be replaced. Unexposed dam-age caused by the stress of an acci-dent could prevent the system fromfunctioning properly the next time itis needed. Failure to comply may re-sult in death or personal injury.

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CAB MAINTENANCE

Inspection Guidelines

Follow these guidelines wheninspecting for cuts, fraying, extremeor unusual wear of the webbing,and damage to the buckle, retractor,hardware, or other factors. Damage tothese areas indicates that belt systemreplacement is necessary.

WARNING!

Replace the entire belt system (re-tractor and buckle side) if replace-ment of any one part is necessary.Unexposed damage to one or morecomponents could prevent the sys-tem from functioning properly thenext time it is needed. Failure tocomply may result in death or per-sonal injury.

1. Check the web wear in the system.The webbing must be closelyexamined to determine if it iscoming into contact with any sharpor rough surfaces on the seat or

other parts of the cab interior.These areas are typical placeswhere the web will experiencecutting or abrasion. Cuts, fraying,or excessive wear would indicatethe need for replacement of theseat belt system.

2. The pillar web guide (D-loop) isthe area where almost constantmovement of the seat beltwebbing occurs because ofrelative movement between theseat and cab.

3. Check the Comfort Clip for cracksor possible damage and check forproper operation.

4. Check buckle and latch for properoperation and to determine iflatch plate is worn, deformed, ordamaged.

5. Inspect the retractor web storagedevice, which is mounted on thefloor of the vehicle, for damage.The retractor is the heart of the

occupant restraint system and canoften be damaged if abused, evenunintentionally. Check operationto ensure that it is not locked upand that it spools out and retractswebbing properly.

6. If tethers are used, be sure theyare properly attached to theseat and, if adjustable, that theyare adjusted in accordance withinstallation instructions. Tethersmust also be inspected for webwear and proper tightness ofmounting hardware.

7. Mounting hardware should beevaluated for corrosion, and fortightness of bolts and nuts.

8. Check web in areas exposed toultraviolet rays from the sun.

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CAB MAINTENANCE

If the color of the web in theseareas is gray to light brown, thephysical strength of the webmay have deteriorated due toexposure to the sun's ultravioletrays. Replace the system.

Seat Belt Inspection Points

1 Web cut or frayed orextremely worn at latcharea.

2 Web cut or frayed at D-loopweb guide.

3 Comfort Clip cracked ordamaged.

4 Buckle casting broken.5 Retractor Web Storage for

damage. (located behindtrim panel)

6 Tethers for web wear andproper tightness of mountinghardware.

7 Mounting hardware forcorrosion, proper tightnessof bolts and nuts.

8 Web for deterioration, dueto exposure to the sun

WARNING!

Failure to adjust tether belts properlycan cause excessive movement ofthe seat in an accident. Tether beltsshould be adjusted so that they aretaut when the seat is in its most up-ward and forward position. Failureto comply may result in death or per-sonal injury.

Once the need for replacement ofthe seat belt has been determined,be certain it is only replaced withan authorized PACCAR Partsreplacement seat belt.

If the inspection indicates that anypart of the seat belt system requiresreplacement, the entire system mustbe replaced. An installation guide isattached to every replacement belt.Utilize the proper guide for your typeof seat, and follow the instructionsvery closely. It is vitally importantthat all components be reinstalledin the same position as the originalcomponents that were removed andthat the fasteners be torqued tospecification. This will maintain thedesign integrity of the mounting pointsfor the seat belt assembly. Contactyour Authorized Kenworth Dealer ifyou have any questions concerningseat belt replacement.

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CAB MAINTENANCE

Windshield Wiper/Washer

The windshield wiper system ismaintenance free. Check wiperblades annually or every 60,000 miles(96,000 km). Anco wiper bladesare recommended. See WindshieldWipers/Washer on page 3-89, for moreinformation.

Washer Reservoir

CAUTION

Do not use antifreeze or enginecoolant in the windshield washerreservoir, damage to seals and othercomponents will result.

Daily: Check reservoir water level,located in the engine compartment. Ifnecessary, refill to the proper level.

Hood Safety Lock

Check the hood safety lock annuallyor every 60,000 miles (96,000 km) /120,000 miles (193,000 km).

• Clean and reapply greasebetween washers. See Table 10Recommended Lubrication Typeson page 5-32, for recommendedlubricant types.

• Ensure the torque specification forthe bolted connection that holdsthe Hood Blow-over Stop togetheris: 16-20 Lb-Ft (22-27 Nm).

For more details contact your dealer.

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COOLING SYSTEM MAINTENANCE

COOLING SYSTEMMAINTENANCE

WARNING!

Do not remove the radiator cap ona hot engine. It can cause scaldingcoolant to spray out and you couldbe burned. If the engine has beenoperated within the last 30 minutes,be very careful in removing the radi-ator cap.

WARNING!

Do not work on the fan with the en-gine running. The engine fan canengage at any time without warning.Anyone near the fan when it turnson could be injured. Before turningon the ignition be sure that no one isnear the fan.

Topping Up

Check the coolant level after eachtrip when the engine has cooled. Thecoolant level should be visible withinthe sight gauge (glass level indicator)on the surge tank. Add coolant asnecessary (see Adding Coolant onpage 5-61).

With the engine cold, top up withpremixed coolant. Add the coolantthrough the pressure cap neck on thesurge tank. The surge tank is locatedon the firewall, right side.

With the engine cold, the coolant levelshould be at the full cold coolant level.Use caution not to overfill the systemwith coolant. An overfilled coolingsystem will cause loss of cool antthrough the radiator cap as the coolantexpands during heating. Replacementor makeup coolant should havethe same antifreeze concentrationand corrosion inhibitor content asthe original coolant in the cooling

system. Never add 100% antifreezeto the cooling system. Always diluteanti-freeze to the correct concentrationbased on freeze protection prior toadding it to the cooling system. Addingor using 100% antifreeze in a coolingsystem may result in cooling systemplugging and overheating problems.

NOTEIf frequent topping up is necessaryand there are not visible signs ofcoolant leaks when the engine iscold, check for leaks with the engineoperating at normal operating tem-perature.

WARNING!

Do not remove the radiator cap ona hot engine. It can cause scaldingcoolant to spray out and you couldbe burned. If the engine has beenoperated within the last 30 minutes,be very careful in removing the radi-ator cap.

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• Protect face, hands, and armsagainst escaping fluid andsteam by covering the cap witha large, thick rag.

• Carefully and slowly turn cap (onexpansion surge tank) one quarterof a turn to allow excess pressureto escape before completelyremoving cap. If you see anysteam or coolant escaping, donot even try to remove it until theradiator cools down. If you seenothing escaping, still remove thecap very slowly and carefully. Beready to back off if any steam orcoolant begins to escape.

WARNING!

Never remove the cap on the surgetank while the engine is still hot. Waituntil the coolant temperature is be-low 120º F (50º C). Scalding steamand fluid under pressure may es-cape and cause personal injuries.

WARNING!

Handle coolant and antifreeze care-fully. Ethylene glycol antifreeze ispoisonous. Store in original fluidcontainer only, and always keepout of reach of children. Failure tocomply may result in personal injury,death, equipment or property dam-age.

WARNING!

Do not work on the fan with the en-gine running. The engine fan canengage at any time without warning.Anyone near the fan when it turns oncould be injured. Before turning onthe ignition, be sure that no one isnear the fan.

Adding Coolant

A mixture of water and low silicateantifreeze should be used forcoolant. Water must be clean andfree of corrosive and scale-formingchemicals. Drinking water may not begood for your vehicle. New vehiclescome premixed with antifreeze andcorrosion inhibitor. Be sure differenttypes of coolant are not mixed. Staywith the same coolant until a completeReplacement is performed.

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Coolant Conditioner

A variety of test methods are availablefor measuring coolant conditionerlevels. Test strips provide convenientand consistent results with minimaltraining. Other test methods can beused when appropriate training isprovided. The actual test (i.e. teststrips, etc.) and coolant conditionermaintenance schedule should bedone in accordance with the actualcoolant conditioner manufacturerrecommendations.

The coolant conditioner should berecharged according to Table 6,Recommended Lubrication Intervalson page 5-13, unless otherwisespecified in the Engine ManufacturersMaintenance Manual.

CAUTION

Never install 100% antifreeze fortop-up coolant. Failure to complymay result in equipment damage.The maximum efficient Low SilicateEthylene Glycol antifreeze concen-tration for extended low temperatureoperation is 68% glycol by volume.Exceeding this 68% limit reducesfreeze protection.

In an emergency, if the radiatorbecomes filled with water known tocontain gypsum, sulfur, or chlorine,follow the below procedure:

• Drain the cooling system as soonas possible

• Flush the system

• Replace the filters

• Refill with premixed coolant.

Additives

If you add supplemental coolantadditives to the radiator, maintain themat the recommended levels. Readthe label carefully. Too much additivecould harm your vehicle.

Approved additives help neutralizethe water's harmful effects on yourvehicle's cooling system. Ask yourdealer to recommend the best onesfor you.

• Do not add rust inhibitors,radiator sealants, or water pumplubricants containing soluble oil tothe coolant. These additives cancause the anti-corrosion chemicalsnot to work.

• If the cooling system in your truckhas a treated spin-on water filter,install the service filter on all B or Escheduled service intervals. SeeTable 9, Maintenance Scheduleon page 5-19. For more detailed

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recommendations check with yourKenworth Dealer or check themanufacturer's Engine Operationand Maintenance Manual.

• Antifreeze solutions containinganti-leak additives will quicklyrestrict the water filter. If thishappens, the filter will not work.So stay away from anti-leakadditives.

CAUTION

Do not add inhibitor if the engine hasa Dry Charge Additive (DCA4) waterfilter cartridge containing corrosioninhibitor, engine damage from overconcentration of silicates may occur.

• The water filter cartridgecontaining DCA4 inhibitor mustbe periodically changed. Referto the Engine Operation andMaintenance Manual for details.

CAUTIONDo not mix inhibitor types. Impropermixing of coolant may damage theengine.

• For coolant conditioner rechargeintervals see the Engine Operationand Maintenance Manual.

Change and Refilling

The coolant must be changedperiodically. When draining coolant,capture old coolant and dispose of itproperly.

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Refilling

To refill the cooling system, followthe recommendations below:

1. Before refilling be sure the radiatorand engine block drains areclosed.

2. Move the heater control tomaximum heat position.

3. Remove the surge tank pressurecap.

4. Through the surge tank, fill thesystem with premixed coolant.Pour it in a steady flow until theradiator is full.

5. Start the engine and idle it at lowRPM.

6. Complete the filling as quicklyas possible. Idle the engineuntil it reaches normal operatingtemperature.

7. Fill the radiator as necessaryto raise the coolant level to theproper level.

8. Replace the surge tank pressurecap.

You may find the coolant level is notup to the correct level soon after youhave filled the radiator. This maybe because all the trapped air in thesystem has not yet been purged. Ittakes a little time for all the air to leavethe system after you fill the radiator.

For further details on coolant, coolantcapacities, water filters, and antifreezemixture see the Engine Operation andMaintenance Manual (supplied withthe vehicle).

Radiator Cap

CAUTIONWhen replacing the radiator cap al-ways use one with the correct ratedpressure. Failure to do so couldcause engine or cooling systemdamage.

All radiator caps are marked with therated pressure (psi) of the cap.

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Engine (Block) Heater

Regularly inspect the engine blockheater wiring and connector fordamaged or frayed wires. Contactyour authorized Kenworth Dealer orthe manufacturer of the heater if youare in need of repairs or information.

WARNING!

Do not use the heater if there areany signs of problems. Engine blockheaters can cause fires resulting inpersonal injury, death, equipmentor property damage if not properlymaintained and operated.

CAUTIONAlways unplug the block heater be-fore starting your engine. Damageto the cooling system could occur ifnot turned OFF (unplugged).

Use a solution of half ethylene glycolantifreeze and half water for best

heater performance. Do not usemore than 65 percent concentration ofantifreeze, as a shortened heater lifewill result.

After servicing the cooling system,operate the vehicle for a day or twobefore using the heater. Trappedair inside the engine needs time toescape.

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ELECTRICAL MAINTENANCE

ELECTRICALMAINTENANCE

Electrical System

WARNING!

Battery posts, terminals and relatedaccessories contain lead and leadcompounds, chemicals known to theState of California to cause cancerand reproductive harm. Wash handsafter handling.

CAUTION

Do not modify or improperly repairthe vehicles electrical system orpower distribution box. All electricalrepairs should be performed by anauthorized Kenworth dealer. Im-proper repair or modifications willvoid your warranty and/or cause se-rious damage to your vehicle.

Fuses, Circuit Breakers, andRelays

Fuses, circuit breakers, and relaysare located in the Power DistributionBox to the left of the steering columnbehind the clutch pedal. See PowerDistribution Box on page 5-67.Additional fuses for the alternator,engine electronics and trailer batterycharge circuit may be located in thePower Distribution Center (PDC) insidethe battery box and/ or on the engineside of the cab firewall. Power Distribution Center (shown

without fuse cover)

1. MEGA FUSE2. MIDI FUSE

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Adding Electrical Options

WARNING!

Do not add a fuse with a ratinghigher than 30 amps. Follow thecircuit protection size/type recom-mended by the component manu-facturer. Installing a fuse or circuitbreaker greater than designatedmay damage the electrical systemwhich could lead to equipment dam-age and/or personal injury.

WARNING!

Never install a circuit breaker in acircuit that is designated as “fuse-only” circuit(s). Circuit breaker cir-cuits are marked with an * on the re-verse side of the Power DistributionBox cover. Using a circuit breaker infuse-only circuits may cause the cir-cuit to overheat when a short existswhich could lead to equipment dam-age and/or personal injury.

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NOTEDo not install a circuit breaker inplace of a fuse for the following cir-cuits:

• ACC FEED

• BODY IGN

• CAB ABS - BATT

• CAB ABS - IGN

• CAB ACC

• CB PWR

• CECU - BATT (2 PLCS)

• CECU IGN

• DOOR IGN

• ENG AUX

• ENG SD

• FOG LMPS

• GAUGE CL

• HIGH BEAM SUP

• LH DR / DOOR LOCK

• LOW BEAM SUP

• PARK LMP SNSE

• RADIO MEM

• RADIO PWR

• RH DOOR

• SLPR ACC

• RKE

• TRLR ABS

• TURN MOD PWR

Power Distribution Box: Typical - Seereverse side of Power Distribution Boxcover for fuse and relay locations

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Power Distribution Box

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Turn Signal Flasher

If you have any problems with yourvehicle’s turn signals, take your vehicleto your nearest Kenworth dealer forrepair.

Batteries

Battery Access

The vehicle is originally equipped withthree or four batteries. Replacementbatteries must meet the followingspecifications: maintenance-free,group 31 size, threaded stud, 12V/ 650cold cranking ampere (CCA), and 160minutes of reserve capacity.

The battery compartment is located onthe left side of the vehicle, under thecab access steps.

1. Remove steps by removing 2 boltsfrom each step.

2. Remove 4 bolts and washers fromforward fairing.

3. Remove 2 bolts (A) from step strut.

4. Remove battery cover for access.

In-Cab Battery Box

Your vehicle may be equipped withOptima brand Absorbed Glass Mat(AGM) batteries located in the cabunder the passenger’s seat. The glassmat in AGM batteries is designed toabsorb the battery acid inside thebattery that can leak or spill out inconventional batteries. This designfeature allows Optima batteries to bepositioned in any orientation withoutrisk of leaking.

To access the batteries:

1. Remove 6 fasteners securing thepassenger side seat base to thebattery box assembly.

2. Remove the seat and seat baseas one unit to gain access to thebatteries.

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WARNING!

Replace only with Optima brandAGM (Group 31) batteries. Use ofother batteries could result in acidleaks causing personal injury in theevent of a vehicle accident.

WARNING!

Battery cables and air/electrical har-nesses are mounted to the bottom ofthe floor. Do not drill or screw intofloor pan without first checking thelocation of the cables, harnesses orany other component that might bedamaged. Damaging any compo-nent could result in electrical shockwhich could cause personal injuryand/or loss of a critical truck system.

WARNING!

Electrical damage or battery ex-plosion can occur when improperlycharging batteries. Refer to theoperation and service manual forappropriate charging instructions.

WARNING!

Batteries release gases that areflammable. Batteries are equippedwith vent tubes and flash arrestorswhich vent battery gases out of thecab. Ensure all vent tubes, flash ar-restors and grommets are properlyinstalled and ensure they are clearand functioning properly. Failure toreinstall or keep the vent tubes andgrommets clear or ensure the flasharrestor(s) are functioning properlycould result in personal injury orequipment damage.

CAUTIONDo not store other items in this bat-tery box. Failure to comply could re-sult in damage to the truck and/orbatteries.

CAUTIONProperly secure battery tie downsand battery box cover when rein-stalling batteries after service. Donot over tighten. Over tighteningcan crack the battery case which canlead to equipment damage.

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Replacing Parts Removed forAccess

1. Replace battery cover.

2. Install 2 bolts in step strut. Torqueto 24-32 lb-ft (33-43 Nm).

3. Install fairing and install 4 bolts.Torque to 6-7 lb-ft (8-9 Nm).

4. Install steps by installing 2 bolts ineach step. Torque to 24-32 lb-ft(33-43 Nm).

WARNING!

Always reinstall the steps before en-tering the cab. Without the steps youcould slip and fall, resulting in possi-ble injury to yourself.

WARNING!

Fairings not installed properly couldcome loose and cause other mo-torists to have an injury accident. Itis important that fairings be installedproperly. Failure to comply may re-sult in death, personal injury, equip-ment or property damage.

WARNING!

Before attempting any work on thebatteries or electrical system, re-move all jewelry. If metal jewelry orother metal comes in contact withelectrical circuits, a short circuit mayoccur causing you to be injured, aswell as electrical system failure anddamage.

Removing and Installing Batteries:

1. Be sure all switches on the vehicleare turned OFF.

2. Disconnect negative ground cablefirst.

3. Disconnect positive cable.

4. Unscrew bolt of holding plate withopen end wrench.

NOTEAlways dispose of automotive bat-teries in a safe and responsibleman-ner. Contact your authorized Ken-worth dealer for disposal standards.Call your local authorized recyclingcenter for information on recyclingautomotive batteries.

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Follow the procedure below to reinstallbatteries on the vehicle:

NOTEMake sure to reconnect the ground(negative) cable last.

1. Place batteries in vehicle andtighten bolt of holding plate.

2. Reconnect positive cable.

3. Reconnect ground (negative)ground cable.

Battery Care

Regular attention to the chargingsystem will help prolong the servicelife of the batteries. Here are somecommon causes of battery failure:

Overcharge: this condition resultsfrom improper voltage regulatoradjustment. It results in overheatingof the battery, warped plates, andevaporation of electrolyte.

Undercharge: the voltage regulatoris malfunctioning, the drive belt isslipping, or your vehicle has undergonelong periods of standing idle or shortdistance driving. These conditionsresult in battery plates becomingcovered with a hard coating.

Vibration: loose battery hold-downsmay cause battery plate failure.

Short Circuits: these discharge thebattery by draining electricity.

Dirty or Loose Connections:improper connections may stop theflow of electrical power to and from thebattery.

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Battery Charging

Except for using small trickle charges(as explained in Slow Battery Chargingon page 5-74) to maintain batterycondition, you should have yourvehicle's batteries charged by aqualified service facility.

WARNING!

Batteries can injure you severely.They contain acid, produce poi-sonous and explosive gases, andsupply levels of electric current highenough to cause burns. A sparkor flame near a battery on chargemay cause it to explode with greatforce. Never remove or tamper withthe battery caps. Failure to complymay result in death, personal injury,equipment or property damage.

To help reduce the risk of personalinjuries, follow these guidelinescarefully when recharging a battery:

• Before attempting any servicein the electrical installation,disconnect the battery negativecable.

• Allow no sparks or open flameanywhere near the charging area.

• Charge a battery only in awell-ventilated area, such asoutdoors or in a fully open garagewhich contains no pilot lights orother flames. Gases generatedduring the charging process mustbe allowed to escape.

• Always make sure the batterycharger is OFF before connectingor disconnecting the cable clamps.

• To avoid short circuits, damageto the vehicle, or personal injury,never place metal tools or jumpercables on the battery or nearby.Metal that accidentally comes incontact with the positive batteryterminal or any other metal on the

vehicle (that is in contact with thepositive terminal), could cause ashort circuit or an explosion.

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Battery Cables

WARNING!

Battery cables can cause fires re-sulting in death or serious personalinjury and/or property damage if notproperly maintained and located.Regularly inspect the battery ca-bles and connectors for damagedor compromised cable insulation.Contact your Authorized ServiceCenter if you are in need of repairsor information.

Turn off the ignition and disconnectthe negative battery cable. Batterycables have a protective insulationcovering the metal cable. Contact yourauthorized service center to have thecables replaced if you find any chafing,tears or breaks in the insulation andthe cable is visible through the tear orbreak.

Charging Reminders

• Use protective eyewear.

• Keep all batteries away fromchildren.

• Never reverse battery poles.

• Never attempt to place the vehiclein motion, or run the engine withbatteries disconnected.

• Keep the battery clean and dry.

• Look for any signs of damage.

• Battery terminals should notbe coated with impropergrease. Use petroleum jellyor commercially available,noncorrosive, nonconductiveterminal coatings.

• Never use a fast charger as abooster to start the engine. Thiscan seriously damage sensitiveelectronic components such

as relays, radio, etc., as wellas the battery charger. Fastcharging a battery is dangerousand should only be attempted bya competent mechanic with theproper equipment.

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Slow Battery Charging

NOTEFollow the instructions that comewith your battery charger.

• It is not necessary to remove thebattery from the compartment.

WARNING!

Charger cables must be connectedpositive to positive (+ to +) and neg-ative to negative (- to -). If con-nected improperly, batteries couldexplode. Failure to comply may re-sult in death, personal injury, equip-ment or property damage.

• Always make sure thebattery charger is OFF beforeconnecting or disconnectingthe cable clamps. To reducethe danger of explosions andresulting personal injury, do notconnect or disconnect charger

cables while the charger isoperating.

1. Disconnect the battery cables.

2. Connect charger cables.

3. Start charging the battery at a ratenot over 6 amperes. Normally, abattery should be charged at nomore than 10 percent of its ratedcapacity.

4. After charging, turn OFF chargerand disconnect charger cables.

Electrical and AlternatorPrecautions

Take the following precautions toavoid burning out alternator diodes:

• Do not start the enginewith alternator disconnected(connections removed) from thecircuit.

• Before welding, disconnect allelectronic connections to thevehicle batteries.

• Remove battery power cable andinsulate it from the vehicle.

• Do not run the engine with thebatteries disconnected.

• Do not disconnect the batterycables or alternator connectioncables with the engine running.

• Never turn the ignition switch fromthe ON position to the STARTposition with the engine running.

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• When charging the battery(installed in the vehicle) disconnectthe battery cables.

• Do not reverse the cables of thealternator, starter motor, or battery.

• Do not polarize the alternator. Thealternator should not be polarizedlike a generator. To ensure correctpolarity, use a test lamp or avoltmeter.

Remote Keyless EntryTroubleshooting

The remote keyless entry system maybecome non-operational due to failureof a key fob battery. If you have issueswith a key fob, replace the battery andre-synchronize the key fob. In somesituations, the key fob may need tobe replaced and in others, a fuse mayhave failed and may render both keyfobs inoperative.

Contact your dealer for more help, ifa key fob does not work and it is notbecause of a bad battery.

To Synchronize a Key Fob

1. Hold the key fob near the centergauge area (middle of theinstrument panel).

2. Press either the lock or unlockbutton twice within 2 seconds.

° When the key fob isresynchronized, the doorswill lock or unlock.

° If the fob fails to synchronize,it could be programmed to adifferent vehicle or could havefailed.

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Halogen/HID LampHeadlamp Servicing

A Halogen or HID (High IntensityDischarge) Projector headlampassembly comprises of a Halogenor HID projector low beam, acomplex reflector high beam, two sidemarker/turn signal lamps, housing andmounting/wiring hardware.

NOTEIt is normal for some fogging on theinside of the lens to occur. Thiscondensation may be removed bydriving the vehicle for an extendedperiod with the headlights turnedon. Servicing is required if waterdroplets or puddles of water form onthe inside of the headlamp.

Servicing

Access is gained from the rear of theassembly.

Rear Of Halogen/HID Housing

1 Low-beam Access Cover

Follow the procedure below to replaceHID bulbs.

Removing Ignition Device

1. Rotate low-beam access covercounter-clockwise and removecover.

Low-Beam Access Cover

2. Rotate Ignition Device 25°counter-clockwise.

° High-voltage line will beautomatically ejected as asafety precaution.

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Ignition Device

1 High-voltage cableejected

2 Ignition Device

3. Pull Ignition Device away frombulb.

Remove HID Bulb

1. Squeeze the two projector housingspring ends marked with arrowstowards each other and thendeflect away from bulb housing.

Projector Housing Spring Clips

2. Release spring ends and let hangfree.

CAUTIONThe spring clip cannot be displaced“upwards.” The arms of the springcan be moved only so far apart to re-move the bulb. Discharge bulbs arefilled with overpressure. The glassbulb may burst if improperly han-dled.

3. Carefully remove the bulb.

Cleaning or Disposal

NOTEDo not touch glass bulb with barefingers. Oil from your skin can dam-age the life of the bulb. If touched,the glass can be cleaned with de-na-tured alcohol and wiped clean witha lint-free cloth. Discharge bulbsmay be filled with a trace amount ofmercury. The bulb will be markedwith a Symbol indicating Mercury(Hg). Follow Hazardous Waste reg-ulations for disposal.

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Bulb

1 Symbol Indicating Mercury(Hg)

Bulb Installation

1. During installation of the bulb thewire with the ceramic insulationshould be pointed down.

Bulb Details

1 Ceramic Insulated Wire2 Indexing Grooves

2. Install bulb into the projectorhousing.

NOTEThere are two indexing grooves (12o’clock and 2 o’clock) located on thelargest diameter of the bulb. Theseindex the bulb only one way in theprojector housing.

3. Squeeze the two projector housingspring ends towards each otherand then make sure they engagein the grooves.

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Projector Housing Installation

1 Spring Grooves2 Index Points (12 o’clock

and 2 o’clock)3 White Tab

Ignition Device Installation

CAUTION

Care must be taken to NOT installthe High-voltage cable until after theIgnition device is fully installed, oth-erwise, damage may result to eitherthe Ignition Device or the HID Bulb.

1. Verify white ring alignment. Ifneeded, carefully rotate ring witha small blunt tool, so that the 4grooves in the housing and ringare aligned or the device cannotbe installed.

2. This tab indexes with white tab onprojector housing (see followingFig.).

Ignition Device

1 White Ring2 Tab

3. Push Ignition Device onto back ofprojector housing.

4. Rotate Ignition Device 25°clockwise until it locks into place.

5. Lastly, install the high-voltagecable to the ignition device.

Ignition Device Installed

Close Cover

1. Install and rotate low-beam accesscover clockwise.

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Close Low-Beam Access Cover

Final Checks

1. After everything is reconnected,turn on your headlamps and checkfor operation.

2. Have your headlamps periodicallychecked for proper alignment.Headlamps should be adjusted to-0.6° (-1.0%) Vertical.

3. Keep your headlamps clean. Adirty headlamp reduces headlampperformance and creates glare.

° Use only clean soap andwater.

° Your headlamp is coated witha special substance to resistchips and hazing. Harshchemicals and polishing canremove this coating.

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ENGINE MAINTENANCE

ENGINE MAINTENANCE

Engine Maintenance

WARNING!

Exhaust fumes from the engine con-tain carbon monoxide, a colorlessand odor less gas. Do not breathethe engine exhaust gas. A poorlymaintained, damaged or corrodedexhaust system can allow carbonmonoxide to enter the cab. Entry ofcarbon monoxide into the cab is alsopossible from other vehicles nearby.Failure to properly maintain your ve-hicle could cause carbon monoxideto enter the cab and cause illness ordeath.

WARNING!

Never idle your vehicle for prolongedperiods of time if you sense that ex-haust fumes are entering the cab.Investigate the cause of the fumesand correct it as soon as possible.If the vehicle must be driven underthese conditions, drive only with thewindows open. Failure to repair thesource of the exhaust fumes may re-sult in death, personal injury, equip-ment or property damage.

NOTEKeep the engine exhaust systemand the vehicles cab ventilation sys-tem properly maintained.

It is recommended that the vehiclesexhaust system and cab be inspected:

• By a competent technician every15,000 miles


• Whenever the exhaust system,underbody or cab is damaged

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ENGINE MAINTENANCE

Engine Lubrication

Refer to the engine manufacturer'sEngine Operation and MaintenanceManual supplied with your vehicle forinformation about draining and refillingengine oil, engine crank case capacity,engine oil type, and changing oil filters,etc.

WARNING!

Hot engine oil can be dangerous.You could be burned. Let the engineoil cool down before changing it.

Oil Level Check

• To check the engine oil level, parkthe vehicle on level ground andwait 15 minutes after shutting theengine OFF. This allows time forthe oil to drain to the oil pan.

• Remove the dipstick and wipe itoff with a clean, lint-free rag.

• Reinsert the dipstick all the way inand pull it out again to check oillevel. Correct oil level is betweenthe low (L) and high (H) marks onthe dipstick.

Pipe and Hose Clamps

Use the following table for torquespecifications to check pipe and hoseclamps.

Table 13 Pipe and Hose Clamp Torque Values

TORQUEAPPLICATION APPROVED CLAMPNm Lb-In

Radiator & Heat Exchanger Hoses Constant-Torque CT-L 10.2-12.5 90-110Heater Hoses Constant Tension not required not requiredAir Intake Pipes Hi-Torque HTM-L 11.3-14.2 100-125

Flex Seal 667 7.9-11.3 70-100Charge Air Intake HosesB9296 6-7 50-60

Fuel, Oil & Water Heat Exchangers (forhoses less than 9/16 diameter)

Miniature 3600L 1.1-1.7 10-15

Exhaust Clamps Breeze V-Band 54 480

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ENGINE MAINTENANCE

Master Lubrication IndexLubricant Symbol Key

ATF MD3 or MERCON®-approved automatic transmission fluidBB High temperature ball bearing grease. Chevron SRI Mobile Grease HP, Texaco Multifax 2 or equivalentCD50 SAE50W synthetic transmission fluidCJ-4 Engine oil for PACCAR MX and Cummins ISX enginesCL Multipurpose chassis greaseEP Extreme Pressure Lubricant (Lithium 12-hydroxystearate base NGLI 2)GL Straight mineral gear lubricantHD Hypoid Gear Oil, A.P.I. - GL-5, SAE 75W-90FE synthetic gear lubricantHT High Temperature grease (Timken Spec. 0-616)MP Multipurpose gear lubricant (MIL-L-2105B)DOT3 or DOT4 Brake Fluid

NOTEThe responsibility for meeting thesespecifications, the quality of theproduct, and its performance in ser-vice rests with the lubricant supplier.

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ENGINE MAINTENANCE

Component Lubrication IndexUniversal Joints EP*Drive Shaft Splines CL*Steering Column CLAlternator Bearing BB*Fan Hub BB*Power Steering Reservoir ATFSteering Drag Link CLSteering Knuckles CLSpring Pins CLClutch Release Bearings BBBrake Shoe Anchor Pins HTBrake Cam Bearings HTSlack Adjusters CLStarter Bearings CCTurbocharger Aneroid CCWater Pump BB*Suspension Fittings (other than threaded pins and bushings) EPSteering Axle: Grease Fittings on Steering Arm; Tie Rod Ends; DragLink; King Pins

EP

Steering Shaft Grease Fittings EPBrake Treadle Hinge and Roller Engine oilLock Cylinders Lock lubricantDoor Hinges Not required - Teflon bushingsDoor Latches and Striker Plates Polyethylene grease stickDoor Weatherstrip Silicone lubricantHub-piloted Aluminum Wheels Coat the wheel pilot or hub pads with Freylube #3 lubricant (light colored)

or Chevron Zinc lube. Do not get lubricant on the face of the wheel orthe hub.

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ENGINE MAINTENANCE

Component Lubrication IndexManual Transmission Hydraulic Clutch DOT3 or DOT4 (Brake Fluid)*Consult manufacturer or lubricant supplier for special details.

Fuel System

Please follow these recommendationswhen you are changing your fuel filtersor strainer elements. Your vehicle'sengine will run better and last longer ifyou do. See the engine manufacturer'srecommendations for proper water andmicron requirements.

Installing Fuel Filters

When removing filters, cover anyelectrical equipment and wiring thatmight get soaked with fuel. Diesel fuelmay permanently damage electricalinsulation.

When installing spin-on (throwaway)filters:

1. Pre-fill filter with fuel.

2. Moisten gasket with diesel fuel

3. Hand tighten them only to 1/2 - 2/3turn after gasket contact.Mechanical tightening of thesefilters may distort or crack the filterhead.

• When replacing a fuel filterelement, do not use a substitute.Install only filter elements designedfor fuel filtration. First clean and

inspect the shell. Then insert thenew element and fill the containerat least 2/3 full of clean fuel beforeinstalling the shell.

NOTETo expel air from density-typestrainer elements, soak them inclean fuel before installing them.

• Throw away old gaskets. Replacethem with new ones to ensure apositive seal.

• Position the shell and gasketproperly. Then tighten the covernut or bolt just enough to preventfuel leakage.

• After starting the engine, check forleaks around the filter.

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ENGINE MAINTENANCE

Filter Draining

1. Check fuel filter/water separatordaily. Check with engine OFF.Depending on the fuel storagefacility, more frequent drainingmay be required.

2. Open drain valve (by hand only):turn valve screw counter clockwiseapproximately 1- to 2 turns untildraining occurs. Drain filter sumpof water until clear fuel is visible.

3. If entrapped water exceeds sumpvolume, you can either:

4. Close valve and run engine untilsmooth idle is established, thenrepeat drain procedures.

5. Remove filter from mounting head,completely drain all fluid, andreassemble filter assembly. Besure to follow new filter assemblyinstructions.

6. Close drain valve by turning valvescrew clockwise approximately 1-to 2 turns.

CAUTION

Do not overtighten the valve. Overtightening can damage the threads.

Accessory Drive Belts

You can avoid costly downtime byperiodically checking belt wear andreplacing worn and damaged belts.Neglect could cause belt failure. Theresult could be the loss of the electricalor air system as well as possibleengine damage from overheating. So,it is a good idea to check the beltsfrequently and replace them as soonas you detect trouble.

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ENGINE MAINTENANCE

Engine FanThermatic (Clutch) Type Fan

WARNING!


To check the fan:

• Check the fan assembly mountingbolts for tightness. Inspect theblades for damage.

• Check the clutch operation bystarting the engine when it is cold.Then idle it at about 800 rpm.Listen for air leaks.

Fan Drive and Blade

Fan Blade Clearance: Around the fanshroud, the recommended distanceis 1 in. (25 mm) from front edge ofany fan blade-to-radiator side member.Minimum clearance is 3/4 in. (19 mm).

• Rear edge of any blade must beno closer than 3/8 in. (9 mm) tothe nearest engine component. Ifthis cannot be obtained, the fanspacer or fan is not correct.

• The leading edge of any fan blademust be 1 in. (25 mm) from theinside edge of the shroud.

Exhaust System

The exhaust system is part of thenoise control system. Periodicallycheck the exhaust for wear and looseor missing parts. For details see Noiseand Emission Control on page 5-101.

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ENGINE MAINTENANCE

Engine Mounting

Periodic Inspection: Inspect enginemounts every 60,000 miles (96,560km). Check for the following:

• Inspect both mount and legfasteners. Check for looseor broken bolts. Replace asnecessary.

• Check mount and leg for fractures,breaks or deformation. Replaceas necessary.

• Check for complete insertionof motor mount. Replace asnecessary.

• New leg to mount flange headbolts should be torqued to 210-230Lb-Ft (284-311 Nm).

CAUTIONDo not re-torque or reuse existingflange head bolts. These bolts arefactory set to the specified torque.If bolts are loose or damaged, theymust be replaced with the new bolts.Failure to comply may result inequipment or property damage.

All Models

Proper operation, driving techniquesand maintenance are key factors inobtaining the maximum service life ofthe muffler and/or converter. Someprecautions should be taken if theengine is equipped with a mufflerand converter. Avoid excess idling.Excessive idling or extended low loadperiods can cause the muffler andconverter to plug. A plugged mufflerand converter will lead to an increasein exhaust back pressure. Operatingthe engine in extremely cold conditionscan cause the muffler and converter toplug sooner. Use the procedure belowto clean out the muffler and converterif extended idle periods or extendedlow load periods are required.

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ENGINE MAINTENANCE

1. Operate the engine at ratedconditions for five to fifteenminutes.

2. Contact an authorized EngineService Center, if the enginecontinues to run at low poweror the engine does not respondproperly.

Multi-Function MessageDisplay

The Multi-function Display will displaydiagnostic messages that are intendedto alert you that trouble may bedeveloping in one of the systems, donot ignore these messages, they areimportant indicators that your vehicleshould be serviced immediately.

See your Kenworth Dealer for troubleshooting and diagnostic information.

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FRAME MAINTENANCE

FRAME MAINTENANCE

Introduction

WARNING!

Do not cut, splice or weld framerails or drill through the top or bot-tom flanges of the rails. Theseoperations could affect frame railstrength leading to a failure resultingin an accident. Rail failures re-sulting from such modifications arenot warrantable. Failure to complymay result in death, personal injury,equipment or property damage.

Medium Duty chassis has the followingframe rail options:

1. 10.5 inch rails; non- heat treatedsteel

2. 10.5 inch rails; non- heat treatedwith heat treated reinforcement

3. 10.62 inch rails; heat treated

4. 10.62 inch rails with insert; bothheat treated

Emergency Welding

Kenworth DOES NOT recommendframe welding. The high heat ofwelding nullifies the special heattreatment of the rails, greatly reducingthe tensile strength of the framerail. If a frame member becomescracked from overloading, fatigue,surface damage or a collision, the onlypermanent repair is to replace thedamaged frame member with a newpart. In an emergency, a temporaryrepair may be performed. Observethe following precautions to protectelectronic systems during weldingoperations.

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FRAME MAINTENANCE

Welding Precautions

In the event of emergency welding of aframe rail and when welding any otherpart of your truck or any componentattached to your truck, observe thefollowing precautions before welding:

• Disconnect all electronic devices.It is not possible to list all of theelectronics that could be affected,but a few examples include thefollowing: alternator, engineElectronic Control Unit (ECU),transmission ECU, ABS ECU,navigation devices, diagnosticdevices, and monitoring devices.

• Disconnect battery cables andinsulate them from the vehicle.

• Do not use the ECU or engineground stud for the ground of thewelding probe.

• Ensure that the ground connectionfor the welder is as close to the

weld point as possible. Thisensures maximum weld currentand minimum risk to damageof electrical components on thevehicle.

Painting

Do not electrostatically paint yourtruck or any component on yourtruck without first removing all ofthe electronic components from thetruck. It is not possible to list all ofthe electronics that could be affected,but a few examples include thealternator, engine Electronic ControlUnit (ECU), transmission ECU, ABSECU, navigation devices, diagnosticdevices, and monitoring devices.

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FRAME MAINTENANCE

Frame Fastener TorqueRequirements

• Tighten all frame fastenerswith a torque wrench. Torquespecifications apply to thefollowing fasteners with lightlylubricated threads.

NOTEWhenever possible, torque all framefasteners on the nut end, not the bolthead.

Table 14 Standard Grade 8 UNF or UNCand Metric

TORQUE *FASTENERSIZE Nm Lb-Ft5/16 22-30 16-223/8 41-54 30-407/16 75-88 55-651/2 109-122 80-909/16 156-190 115-1405/8 224-265 165-1953/4 394-462 290-3407/8 517-626 380-4601 952-1,129 700-830

1-1/8 1,346-1,591 990-1,1701-1/4 1,877-2,217 1,380-1,630

METRIC WITH NYLON INSERT NUTSM5 8-12 6-9M6 9-15 7-11M8 23-31 17-23M10 33-43 24-32M12 75-101 55-75M16 163-217 120-160M20 352-460 260-340

* ESNA Style Lock Nut, with nylon insert.Lubricate nylon insert nut lightly with SAE20/30 oil.

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FRONT AXLE AND SUSPENSION MAINTENANCE

FRONT AXLEAND SUSPENSIONMAINTENANCE

Axle Lubrication• Change bearing lubrication

when seals are replaced, orbrakes are relined. See Table6, Recommended LubricationIntervals on page 5-13.

• Thoroughly clean hubs andbearings with solvent and a stiffbristle brush, then dry and inspectcomponents for wear or damage.Re-lubricate with approved axlelubricant.

Kingpin Lubrication

• Lubricate with approved lubricant.Lubricate knuckle thrust bearings,knuckle pins, and tie rod ends.See Table 6, RecommendedLubrication Intervals on page5-13. Lack of lubrication causespremature wear and hard steering.Lubrication schedule may beshortened if necessary.

Suspension Lubrication

Each standard spring anchor pin hasa grease fitting. Pressure lubricatespring pins as specified. See Table 6,Recommended Lubrication Intervalson page 5-13.

• At regular intervals, the springleaves may be lubricated with arust-inhibiting oil applied with aspray gun or brush.

• Depending on your suspension,lubricate all spring pins untilgrease flows out of both ends ofthe bushing. Look for signs of rustor water in the flushed grease.If a pin will not accept grease, itshould be removed, cleaned, andinspected.

CAUTIONDo not spray the suspension withchemical products or mineral oil; itcan cause damage to the bushings.

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Inspection• For all vehicles, mandatory

maintenance procedures includeretightening all U-bolts andinspecting the suspension forloose fasteners, abnormal wear,or damage. However, even withproper maintenance, the servicelife of leaf springs is affected bymany factors, such as: fatigue,vehicle gross weight, type ofload, road conditions, and vehiclespeed.

• Check for cracks, wear marks,splits, or other defects on thesurface of the spring. Defectiveparts must be replaced. Becauserepaired springs cannot befully restored to their originalservice life, replace the completeassembly if cracks or other defectsare detected.

• Visually inspect shock absorbersand rubber bushings.

Wheel Alignment

For driving safety and comfort, andto prolong the life of your vehicle, itis important to have wheels correctlyaligned. Check tire wear frequently.Uneven tire wear is a sign that thewheels may be misaligned.

If you see uneven wear, take yourvehicle to a Kenworth Dealer familiarwith aligning wheels on Kenworthvehicles.

U-Bolt Torque

It is important that U-bolts remain tight.Severe use of your vehicle will causethem to loosen faster. But all vehiclesneed to have their U-bolts checked andtightened regularly. Be sure someonewith the proper training and the righttools checks and tightens the U-boltson your Kenworth.

New springs can settle in after service,relieving the tension on the U-bolts.Loose U-bolts can cause leaf springbreakage, axle misalignment, hardsteering and abnormal tire wear.

• All vehicles should havesuspension U-bolts tightenedafter the first 500 miles (800 km) ofoperation. And re-torque the frontspring pinch bolts and shacklepinch bolts.

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WARNING!

Do not operate the vehicle if theU-bolts are not properly tightened.Loose U-bolts will cause the axleto not be properly secured to thesuspension, which could cause lossof vehicle control and an accident.Loose U-bolts can also cause un-even tire wear and poor alignment.Failure to comply may result indeath, personal injury, equipment orproperty damage.

U-bolts are difficult to tighten unlessyou have the right equipment. If youcannot tighten them correctly yourself,be sure to have them checked andtightened regularly by an authorizedmechanic.

Tighten U-bolt nuts to the specifiedtorque value with the vehicle loaded toits normal gross weight. The followingtorque values apply to U-bolts andnuts with clean threads lubricated with

Chevron zinc lubricant (SAE 20 or 30oils acceptable but not preferred).

WARNING!

Do not replace U-bolts and nuts withcommon U-bolts or standard nuts.These parts are critical to vehiclesafety. If the wrong U-bolts or nutsare used, the axle could loosen orseparate from the vehicle and causea serious accident. Use only U-boltsand nuts of SAE Grade 8 specifi-cation or better. Failure to complymay result in death, personal injury,equipment or property damage.

Table 15 Front Spring Suspension U-Bolts,Grade 8

TORQUEU-BOLT SIZEDIAMETER(InchDimensions)

Nm Lb-Ft

3/4 333-408 245-3007/8 598-734 440-5401 925-1,060 680-780

1-1/8 1,470-1,660 1,080-1,2201-1/4 1,890-2,120 1,390-1,5601-1/2 3,130-3,860 2,300-2,840

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HEATER AND AIR CONDITIONER MAINTENANCE

HEATER AND AIRCONDITIONERMAINTENANCE

Introduction

The combination heater-air conditionerprovides comfort for those in the cabthrough accurate control of the cabenvironment in all weather conditions.Regular attention to the items belowwill help you keep the heater-airconditioner unit running well.

NOTEKeep the vehicles ventilation sys-tem, engine exhaust system and cabjoints properly maintained.

It is recommended that the vehiclesexhaust system and cab be servicedas follows:

• Inspected by a competenttechnician every 15,000 miles


• Whenever the exhaust system,underbody or cab is damaged

NOTETo allow for proper operation of thevehicle ventilation system, proceedas follows:

• Keep the inlet grille at the base ofthe windshield clear of snow, ice,leaves and other obstructions atall times.

• Keep the exhaust pipe area clearto help reduce the buildup ofexhaust gas under the vehicle.

Special Precautions

WARNING!

Excessive heat may cause the pres-surized components of the air con-ditioning system to explode. Neverweld, solder, steam clean, or use ablow torch near any part of the airconditioning system. Failure to com-ply may result in death, personal in-jury, equipment or property damage.

• If a refrigerant leak develops inthe presence of excessive heator an open flame, hazardousgases may be generated.These gases may causeunconsciousness or death.If you become aware of arefrigerant leak on your vehiclehave your system serviceimmediately and observe thefollowing precautions:

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° Stay away from the hotengine until the exhaustmanifold has cooled.

° Do not permit any openflame in the area. Even amatch or a cigarette lightermay generate a hazardousquantity of poisonous gas.

° Do not smoke in the area.Inhaling gaseous refrigerantthrough a cigarette maycause violent illness.

Heater• Check all heater controls for

full-range operation.

• Check hoses, connections, andheater core for condition andleaks.

• Check the drain tube of the freshair inlet for trapped water beforeassuming that there is a leak in theheating system. If the heater coreis leaking, a reliable radiator shopshould be able to repair it.

• Check the heater core for debrisblocking the air flow. If the blowerand air controls are functioningproperly, yet the heater is notoperating properly, the heatercore or the hot water valves maybe clogged or closed. Clean theheater core if necessary. If thecondition persists, take the vehicleto a Kenworth Dealer for properheater service or repair.

CAUTIONDuring extreme cold weather, do notblow hot defroster air onto cold wind-shields. This could crack the glass.Turn the air direction lever to Defrostand adjust the fan speed accordinglywhile the engine warms. If the en-gine is already warm, move the tem-perature selector to Cool, then grad-ually increase the temperature whenyou see that the windshield is start-ing to warm-up.

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Air Conditioner

WARNING!

The air conditioning system is underpressure. If not handled properlyduring servicing, it could explode.Any servicing that requires depres-surizing and recharging the air con-ditioning system must be conductedby a qualified technician with theright facilities to do the job. Failureto comply may result in death, per-sonal injury, equipment or propertydamage.

• Check the compressor and driveclutch for noise and vibration.If you find problems, have thesystem checked thoroughly. Amalfunctioning clutch usuallyindicates trouble elsewhere in thesystem.

• Check the evaporator core, filter,and condenser core for debrisrestricting air flow. Clean if

necessary. Small particles maybe removed with compressedair blown through the core in theopposite direction of normal airflow.

WARNING!

Wear eye protection any time youblow compressed air. Small parti-cles blown by compressed air couldinjure your eyes.

• Inspect and clean cab air filterelement every 3 - 6 monthsof service. Depending on theoperating environment, if air flowfrom the air conditioner and heateris less efficient or windows fogeasier, you may need to replacethe cab air filter.

• Check the compressor belt forcondition and proper tension.

• Check all hoses for kinks,deterioration, chafing, and leaks.

Adjust kinked or chafing hoses toeliminate restrictions and preventfurther wear.

• Check all components andconnections for refrigerant leaks.If you discover a leak, do not try totighten a connection. Tighteninga connection may cause a worseleak. Have a qualified techniciancorrect the problem.

NOTEA leaking evaporator or condensercore cannot be repaired; it must bereplaced.

Have the air conditioning system fullyserviced annually by your KenworthDealer. Qualified service technicianswill have to evacuate and recharge thesystem.

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NOISE AND EMISSION CONTROL MAINTENANCE

NOISE ANDEMISSION CONTROLMAINTENANCE

Noise Emission Warranty

Kenworth Truck Company warrantsto the first person who purchases thisvehicle (for purposes other than resale)and to each subsequent purchaser:that this vehicle, as manufacturedby Kenworth Truck Company, wasdesigned, built and equipped toconform, at the time it left Kenworth'scontrol, with all applicable U.S. EPANoise Control Regulations.

This warranty covers this vehicleas designed, built and equipped byKenworth, and is not limited to anyparticular part, component or system ofthe vehicle manufactured by Kenworth.Defects in design, assembly or in anypart, component or system of thevehicle as manufactured by Kenworth,

which at the time it left Kenworth'scontrol caused noise emissionsto exceed Federal standards, arecovered by this warranty for the life ofthe vehicle.

Tampering with Noise ControlSystem

Federal law prohibits the followingacts or the causing thereof:

1. The removal or renderinginoperative by any person otherthan for purposes of maintenance,repair, or replacement, of anydevice or element of designincorporated into any new vehiclefor the purpose of noise controlprior to its sale or delivery to theultimate purchaser or while it is inuse, or

2. The use of the vehicle after suchdevice or element of designhas been removed or renderedinoperative by any person.

Among those acts presumed toconstitute tampering are the acts listedbelow:

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Air Intake System

• Removing or rendering inoperativethe air cleaner/silencers or intakepiping.

Engine Cooling System

• Removing or rendering inoperativethe fan clutch.

• Removing the fan shroud.

Engine

• Removing or rendering enginespeed governor inoperative so asto allow engine speed to exceedmanufacturer's specifications.

• Modifying ECU parameters.

Exhaust System

• Removing or rendering inoperativeexhaust system components.

Fuel System

• Removing or rendering enginespeed governor inoperative,allowing engine speed to exceedmanufacturer's specifications.

• Removing of air signal attenuatoron engines equipped with thisdevice.

Inner Fender Shields and Cab Skirts

• Removing shield or skirts.

• Cutting away parts of shields,skirts or damaged or looseportions of shields or skirts.

Noise Insulating Blankets

• Removing noise insulators fromengine block or from around theoil pan.

• Cutting holes in, or cutting awaypart of noise insulators.

• Removing hood-mounted noiseinsulation.

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Inspection and MaintenanceInstructions

The following instructions are based oninspection of the noise control systemat regular intervals as indicated in theNoise Control System MaintenanceLog on page 5-108.

If, during periodic inspection andmaintenance of other systems andcomponents, it is found that parts of thenoise control system require attention,we recommend that those parts beinspected at more frequent intervalsto assure adequate maintenance andperformance.

Air Intake System

• Do all checks and maintenanceprocedures listed in this manualunder Engine Air Intake Systemand Air Cleaner. See Air Dryer onpage 4-17.

• Check the induction tubing, elbowconnections, clamps, brackets,and fasteners for deterioration,cracks, and security.

• If you find an air leak anywherebetween the air cleaner andthe engine, repair that leakimmediately.

CAUTIONAir leaks cause excessive noise andmay result in serious damage to theengine. If you do not repair them theengine damage will not be coveredby your warranty. Repair all air leaksas soon as you find them.

Engine Mounted Noise Insulators

• Check condition. Is the insulatorsecure? How you do this willdepend on the method of attachingthe noise insulators on the engineand around the oil pan (bolts,snap fasteners, or straps). Tightenloose fasteners and repair orreplace any worn or damagedfasteners.

• Check insulators around fastenersand stress points, especiallywhere they may be affected byengine vibration. Repair anycracked or damaged mountingpoints. Use suitable reinforcingplates to ensure that the insulatorswill remain in position.

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Exhaust System

• Check for exhaust leaks,which would indicate a leakingmanifold gasket; replace gasket ifnecessary.

• Check cap screws for tightness,including those at the flanges.Refer to the engine manufacturer'sservice manual for propertightening sequence and torquevalues.

Joints and Clamps

• Check for leaks, and tighten asnecessary. Check for deteriorationor dents in pipes and clamps whichcould allow exhaust to escape.

Piping

• Check exhaust piping for rust,corrosion, or damage. Replacedeteriorated piping before holesappear. If piping is perforated atany point, temporary patching orlagging is acceptable until you canhave permanent repairs made.On turbocharged engines, checkjoints at flanges and mountingbrackets for tightness.

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Diesel Particulate Filters (DPF)

• Check diesel particulate filter(DPF), clamps, and mountingbrackets. Tighten if necessary.Inspect diesel particulate filter(DPF) for signs of rust or corrosion.

• Check internal baffling. You cando this by listening for rattlingsounds while tapping on the dieselparticulate filter (DPF) with arubber mallet or revving the engineup and down through its normaloperating range.

Exhaust Tail Pipe

• Check the mounting. Tighten asnecessary. The miter cut at the tipof the pipe must be facing the rearof the vehicle. Do not modify theend of the pipe in any way.

Engine Fan and Shroud

WARNING!


• Check all fasteners for tightness.Check for stress cracks in theshroud. Make sure the shroud isadjusted so that it does not touchthe fan blades.

• Check to verify that the fan isdisengaged (not turning) withthe engine running at normaloperating temperatures (from coldto the point that the fan engages).

• Check fan blade mounting bolts.Inspect fan blades to be sure theyare not cracked or bent.

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Transmission and Driveline

• Substituting a different maintransmission or drivelinecomponents, other thandesign-specified units, mayresult in increased vehicle noiseemission.

Hood Insulation Blanket

• Check all fasteners for conditionand security. Repair or replaceany broken or defective fasteners.

Blanket

• Check for chafing or tears. Patchit if necessary. Find the cause ofthe damage. If any componentor accessory is causing wear ordamage and cannot be relocated,put reinforcing pads on the blanketat the site of wear.

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Inner Fender Shields and Cab Skirts

• Check all fasteners, especially theself-tapping hex head screws. Arethey secure? Remove and replaceany loose rivets.

Shields and Skirts

• Check shields and skirts for cracksat mounting and stress points.Check fender shields for tiremarks, worn spots, or damagefrom objects thrown from tiretreads. You can repair cracked ordamaged fiberglass fender shieldswith fiberglass and resin.

• If you find damage at a fasteningpoint, you can gain additionalstrength by installing a suitablereinforcing plate. This plateshould be drilled to accept a rivetand laminated to the shield withfiberglass and resin.

• Check cab skirts, sills, andbrackets for overall conditionand repair them as necessary.Damaged rubber fender shieldsor cab skirting cannot be repaired.You will need to replace it.

NOTEYour Kenworth Dealer can performall of these checks and repairs orreplacements.

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Noise Control System -Maintenance Log

To ensure your Kenworth's noisecontrol requirements are maintained,

record maintenance checks. Use thefollowing log sheet and retain copiesof documents regarding maintenanceservices performed and parts replacedon the vehicle.

Table 16 Noise Control System - Maintenance Log

ComponentRecom-mended In-terval (Miles)

Date & R.O. No. Repair Facility& Location

WorkPerformed Date & R.O. No. Repair Facility &

LocationWork

Performed

Exhaust SystemRouting Integrity

25,000

ShuttersShrouds

25,000

Hood InsulationBlanket

10,000

EngineMountedHose InsulatorsFasteners

10,000

Inner FenderShields

50,000

Cab SkirtsFasteners

50,000

Air IntakeSystem IntegrityElement

5,000

Clutch Type FanDrive

10,000

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5

REAR AXLE AND SUSPENSION MAINTENANCE

REAR AXLE ANDSUSPENSIONMAINTENANCE

General Maintenance

WARNING!

Do not work on the vehicle withoutthe parking brake set and wheelschocked securely. If the vehicle isnot secured to prevent uncontrolledvehicle movement, it could roll andmay result in personal injury, death,equipment or property damage.

NOTEUse wood blocks (4 in. X 4 in. orlarger) against the front and rear sur-faces of the tires. Be sure the vehi-cle cannot move.

Your vehicle's suspension, bydesign, requires a minimal amount ofmaintenance. However, suspensionsin over-the-road operations requireperiodic inspection to ensure trouble-free performance.

WARNING!


WARNING!

Failure to maintain the specifiedtorque values or to replace wornparts can cause component systemfailure, possibly resulting in an ac-cident. Improperly tightened (loose)suspension U-bolts can lead to un-safe vehicle conditions, including:hard steering, axle misalignment,spring breakage or abnormal tirewear. See Front Spring Suspen-sion U-bolts on page 5-97 for propertorque specifications. Failure tocomply may result in death, per-sonal injury, equipment or propertydamage.

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CAUTIONDo not spray the suspension withchemical products or mineral oil; itcan cause damage to the bushings.

NOTEFailure to follow these recommenda-tions could void warranty.

Visual Inspection

For all vehicles, mandatorymaintenance procedures includeretightening of U-bolts and completeinspection. However, even with propermaintenance, many factors affect theservice life of springs and suspensioncomponents, such as: fatigue, vehiclegross weight, type of load, roadconditions and vehicle speed.

It is important that U-bolts remain tight.Severe use of your vehicle can causethem to loosen faster. But all vehiclesneed to have their U-bolts checked andtightened regularly. Be sure someonewith the proper training and the righttools checks and tightens the U-boltson your Kenworth.

• After the first 500 miles (800 km) ofoperation, inspect the suspensionperiodically, as noted below:

• Visually check for loose or missingfasteners, cracks in hanger or axleconnection brackets.

• Check that springs are centered inhangers and in good condition.

• Check for cracks, wear marks,splits, or other defects on thesurface of the spring.

• Replace defective parts. Becauserepaired springs cannot befully restored to their originalservice life, replace the completeassembly if cracks or other defectsare detected.

• After replacement of any part ordiscovery of loose components,check the torque of all fasteners.

• New springs settle-in after thevehicle's initial service, causingthe U-bolts to become loose.

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Rear Suspension Fasteners

To maintain the performance of theair suspension, check fastener torquevalues after the first 2,000 miles (3,218km) of service and every 60,000 miles(96,000 km) thereafter.

Torque recommendations apply tofasteners supplied and installedby Kenworth. The values listed inTable 17 and Table 18 below, are forcadmium plated or phosphate and oilfasteners only.

U-bolts are difficult to tighten unlessyou have the right equipment. If youcannot tighten them correctly yourself,be sure to have them checked andtightened regularly by an authorizedmechanic.

U-Bolt Torque

NOTETo ensure an accurate torque read-ing, use properly maintained andcalibrated torque wrenches.

• Clean the nut and bolt. No dirt,grit, or rust should be present.

WARNING!


NOTETorque all fasteners on the nut end.

Table 17 Rear Suspension Fasteners(Metric & Standard)

TORQUE*SIZE/TYPENm LbFt

M16 nylon-insert nuts

163-217 120-160

M20 nylon-insert nuts

352-460 260-340

M20 all-metallock nuts

427-475 315-350

1/2 in. nut 109-122 80-903/4 in. nut 394-462 290-3401-1/4 in. nut 1,877-2,217 1,380-1,630* Torque requirements apply to Kenworthproprietary suspensions. All othersuspensions must refer and adhere tooriginal manufacturers shop manual.

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Table 18 Rear Suspension U-Bolts, Grade8 (lubricated*)

TORQUE**U-BOLT SIZEDIAMETERTHREAD Nm Lb-Ft

3/4 333-408 245-3007/8 598-734 440-5401 925-1,060 680-780

1-1/8 1,470-1,660 1,080-1,2201-1/4 1,890-2,120 1,390-1,5601-1/2 3,130-3,860 2,300-2,840

* Chevron Zinc Lubricant or SAE 20/30 oilshould be used on U-Bolt threads.** Torque requirements apply to manufacturerproprietary suspensions. All othersuspensions must refer and adhere tooriginal manufacturers shop manual.

• Load the vehicle to its normalgross weight before tighteningU-bolts. Loading the vehicleensures proper adjustment of theU-bolt and spring assembly.

WARNING!

Do not replace U-bolts and nuts withcommon U-bolts or standard nuts.These parts are critical to vehiclesafety. If the wrong U-bolts or nutsare used, the axle could loosen orseparate from the vehicle and causea serious accident. Use only U-boltsand nuts of SAE Grade 8 specifi-cation or better. Failure to complymay result in death, personal injury,equipment or property damage.

Rear Axle Lubrication• Check oil level with the vehicle

parked on level ground and thefluid warm. The level should beeven with the bottom of the fillerhole.

CAUTION

Do not mix lubricants of differentgrades; although, mixing differentbrands of the same grade lubricant(meeting miLL2105C), is accept-able. Lubricants of different gradesare not compatible and could dam-age the axle.

NOTEIn all cases, lubricant supplier as-sumes full responsibility for the per-formance of their product, and forproduct and patent liability.

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For recommended types and brandsof lubricants, contact your KenworthDealer.

Dana Spicer and Fabco

No initial drain is required on DanaSpicer axles that are factory filled withan Dana Spicer-approved syntheticlubricant.

• Petroleum-based lubricants mustbe drained within the first 5,000miles (8,000 km) if converting toan approved synthetic lubricant.

Initial Change: See Table 6,Recommended Lubrication Intervalson page 5-13 for standard rearaxle service intervals. Changemineral-based lubricant in other DanaSpicer and Fabco axle assemblies(new or rebuilt) within the first 3,000 to5,000 miles (4,800 to 8,000 km).

• For petroleum-based axles, uselubricants meeting miL L2105C/Dgrade specifications or approvedsynthetic lubrication. Do not useoil additives.

All Vehicles with Dana Spicerand Fabco Axles: See Table 6,Recommended Lubrication Intervalson page 5-13. Contact your KenworthDealer for approved synthetic lubricantbrands.

• Dana Spicer Axles with syntheticlubrication and Out Runner Seals:drain, flush, and refill at 500,000miles (804,000 km).

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Axle Housing Breather Vent

• Check and clean the axle housingbreather vent at each oil levelcheck.

Meritor

See Meritor Lubrication MaintenanceManual (MM1).

Rear Axle Alignment

Continual road shock and loadstresses may force the rear axlesout of alignment. If you detect rapidtire wear on the rear axles, you mayhave misaligned axles. If you suspectrapid tire wear, have your rear axlealignment checked and adjusted by aKenworth Dealer.

In addition to pre-delivery inspections,suspension alignment should bechecked when any one of the followingconditions exist:

• Discovery of loose suspensionfasteners. (Loose, defined as anytorque below the recommendedtorque value.)

• Discovery of elongated holes in asuspension component.

• Bushing replacement.

• Excessive or abnormal tire wear.

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5

STEERING AND DRIVELINE MAINTENANCE

STEERING ANDDRIVELINEMAINTENANCE

Power Steering

Oil (under low pressure) provides thepower to operate the steering gear. Italso serves to lubricate moving partsand remove heat. A loss of steeringefficiency will occur if too much heatbuilds up in the system.

WARNING!

Do not operate the vehicle if thesteering system is not working prop-erly. You could lose control of yourvehicle if the steering system is notin good working condition, whichcould result in a serious accident.For driving safety, visually checkthe steering gear and components.Frequent checks are important fordriving safety, especially after trav-eling over rough roads. Failure tocomply may result in death, per-sonal injury, equipment or propertydamage.

NOTEIf the steering feels unbalanced fromside-to-side while turning, check forthe following possible causes:

• unequal tire pressures

• vehicle overloaded or unevenlydistributed load

• wheels out of alignment

• wheel bearings improperlyadjusted

If you cannot correct the problem,check with an authorized KenworthDealer.

The Kenworth is equipped with integralpower steering. The system includesan engine-driven fluid pump, a fluidreservoir, the steering gear, andconnecting hoses. Because of thehydraulic power assist, little effort isrequired to turn the steering wheel.When no input is applied through thesteering wheel, the steering gear willreturn to the neutral position. If, forany reason, the power assist systemgoes out, steering the vehicle is stillpossible, yet it will require muchgreater effort.

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Visually check the following parts:

• Crosstube: Is it straight?

• Draglink tube clamp: Check forlooseness or interference.

• Ball joints and steering U-joints:Check for looseness.

• Steering wheel for excessivefree-play. Check the simplestprobable causes first:

° unequal tire pressures

° loose cap nuts

° bent crosstube

° lack of lubrication

• If these checks do not reveal theproblem, or if you correct themand still have a steering problem,take your truck to an authorizedKenworth Dealer for evaluation.

Fluid Level and Refill

Have the power steering fluid andfilters changed at an authorizedKenworth Dealer.

• Check and completely changethe fluid level according to Table6, Recommended LubricationIntervals on page 5-13. Use thefollowing procedure:

NOTEBefore removing reservoir cover,wipe outside of cover so that no dirtcan fall into the reservoir.

• Maximum/Minimum level isindicated on the reservoir. Thesesame levels are also indicated bytwo lines on the dipstick in thereservoir.

• There are two ways to checkwhether the power steering fluid

is at its proper level. Both checksare with the engine NOT running.

1. If you check the fluid with theengine and steering systemCOLD, the fluid level should beat/or above the Minimum indicatorlevel and should generally notexceed the middle point betweenMaximum and Minimum levelindicators.

2. If you check the fluid with theengine and steering systemWARM, the fluid should NOTexceed the Maximum levelindicator and should generallynot drop below the middle pointbetween the Maximum andMinimum level indicators.

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Fluid Refill

The following recommendations arefor general purpose steering systems,commonly installed on Kenworthvehicles.

• For normal temperatures, useAutomatic Transmission Fluid(ATF) Type E or F or Dexron® II.

• For cold temperatures of -22º F(-30º C) and above use ATF TypeA.

• For extremely cold temperaturesbetween -22º F (-30º C) and -40ºF (-40º C) use ATF Type B.

Steering Driveline

The following are common torquespecifications for most drivelines.

• Torque on U–joint pinch bolt andnut (7/16 in) 74–81 Nm (55 to 60lb-ft), lubricated.

• Torque on Pitman arm clamp boltand nut (3/4 in): 406–433 Nm (300to 320 lb-ft), lubricated.

• For off–highway vehicles, tightenthe U–bolts after the first day ortwo of operation. Then checkweekly.

WARNING!

If this chassis is equipped with anelectronic stability system (ESP) andany part of the steering system (e.g.linkage, steering driveline, column,front-end alignment, etc) is repaired,removed, or disassembled in anyway, or if the steering angle sen-sor is replaced, the steering anglesensor must be recalibrated. Fail-ure to do so could cause loss of ve-hicle control. Any repairs or adjust-ments to any part of the steering sys-tem must be performed by an au-thorized Kenworth Dealer. Failure tocomplymay result in death, personalinjury, equipment or property dam-age. Failure to comply may result indeath, personal injury, equipment orproperty damage.

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Driveshaft

The slip joints and universal joints ofthe drive shaft should be lubricatedperiodically.

• Use a good qualitylithium-soap-base or equivalentextreme pressure (E.P.) grease:NLGI Grade 2.

For Towing Guidelines and Returning aTowed Vehicle to Service see VehicleRecovery Guidelines on page 2-12.

U-Joints

• The slip joints and universaljoints of the drive shaft shouldbe lubricated according to Table6, Recommended LubricationIntervals on page 5-13.

Use a good quality lithium-soap-baseor equivalent extreme pressure (E.P.)grease: NLGI Grade 2.

WARNING!

Improper lubrication of U-joints cancause them to fail prematurely. Thedriveshaft could separate from thevehicle and result in an accident.Make sure lubricant is purged at allfour ends of each U-joint and loosencaps if necessary. Also, regularlyinspect U-joints for excessive wearor movement, and repair or replaceas necessary. Failure to complymay result in death, personal injury,equipment or property damage.

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5

TIRES AND WHEEL MAINTENANCE

TIRES AND WHEELMAINTENANCE

Introduction

Keeping the tires in good condition isessential to the safe, efficient operationof your Kenworth. Regular, frequentinspection and the right care will giveyou the assurance of safe and reliabletire operation.

General SafetyRequirements• Each mounting system is

engineered only for use with itscorrect mating part. Be sure thatproperly matched componentsare used for each type ofmounting. The comparisonchart, Comparing Hub-pilotedand Ball-seat Wheels onpage 5-130, illustrates thedifferences between parts usedin hub-piloted mount and ballseat mount applications. OnlyOEM supplied hub-piloted orball-seat mounted wheels maybe used on this vehicle.

WARNING!

Use only original equipment manu-factured (OEM) components. Use ofnon-original equipment could causewheel breakage and wheel separa-tion from vehicle. Failure to complymay result in personal injury, death,equipment or property damage.

• If you are not fully qualified andnot equipped with the propertools and equipment, do notattempt to raise the vehicle orremove or install the damagedtire and wheel assembly. Obtainexpert help. A person can beinjured and/or damage canresult from using the wrongservice methods. Truck tiresand wheels should be servicedonly by trained personnel usingproper equipment.

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Do not reinflate a tire that hasbeen run flat or is low on airwithout first removing the tirefrom the rim and inspecting fordamage.

• Follow OSHA regulations persection 1910.177.

• Do not exceed the speed ratingof tires. Exceeding the speedrating may result in suddentire failure and loss of vehiclecontrol.

• Follow all warnings andcautions contained within thetire and wheel manufacturersliterature.

• Only properly trained personnelshould service tire and rimassemblies.

WARNING!

Always support the vehicle with ap-propriate safety stands if it is neces-sary to work underneath the vehicle.A jack is not adequate for this pur-pose.

Speed Restricted Tires

WARNING!

This vehicle may be equipped withspeed restricted tires. Check eachtires sidewall for maximum ratedspeed. Vehicle should not be oper-ated at sustained speed in excessof maximum rated speed. Failureto comply with these speed restric-tions could cause sudden tire failurewhich may result in death, personalinjury, equipment or property dam-age.

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Tire Inspection andReplacement

Visually inspect your tires frequentlyfor any abnormal conditions such asscrapes, bulges, and uneven wear.This must be done immediately afterknown or suspected contact with anobject in the road, with a pothole,road irregularity or after severebraking. Refer these conditions to anAuthorized Tire Service Center forrepair or replacement. Never drive ona tire if such conditions appear.

If the tire looks under-inflated, standoff to the side and check for damageto the wheel assembly. This can bedone by visually comparing the wheelin question to other wheels on thevehicle. For dual wheel assemblies,check between the wheels for damage.If any damage is found, or you suspectdamage, do not attempt further repair.Call for expert tire service.

Tire Inflation and Loading

Low pressure is a tire's worst enemy.Under-inflation allows tires to fleximproperly, causing high temperaturesto build up. Heat causes early tiredamage such as flex break, radialcracks, and ply separation. And lowpressure may affect control of yourvehicle, especially at the front wheels.

WARNING!

Do not operate vehicle with under-inflated tires. The extra heat causedby under-inflation can cause suddentire failure such as a tire fire or blowout. Low pressure may affect controlat the front wheels, which could re-sult in an accident. Keep your tiresinflated to the manufacturer's rec-ommended air pressure. Failure tocomplymay result in death, personalinjury, equipment or property dam-age.

Tire Inflation

Most tire wear problems are causedby under-inflation as the result ofslow leaks. So you will want to checktire pressure regularly. Give the tiresa visual test every day, and checkinflation with a gauge every week.

When checking tire pressure, inspecteach tire for damage to sidewalls,cuts, cracks, uneven wear, rocksbetween dual wheels (tires), etc. If atire appears under-inflated, check fordamage to the wheel assembly. Do notforget to check between dual wheels.If you find wheel damage, have anexpert tire service repair it.

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WARNING!

Do not repair damaged tires unlessyou are fully qualified and equippedto do so. Wheel and tire assem-blies cannot be worked on withoutproper tools and equipment, suchas: safety cages or restraining de-vices. Have all tire repairs per-formed by an expert. And standaway from the tire assembly whilethe expert is working. Failure tocomply may result in death or per-sonal injury.

CAUTIONPressure should be checked whenthe tires are cool. Warm or hot tirescause pressure buildup and will giveyou an inaccurate reading. So neverdeflate a warm tire to the specifiedpressure. Failure to comply may re-sult in equipment damage.

Under-inflated tires will adverselyaffect the operation of the vehicleand tires:

• making steering difficult

• causing extra strain on the tiresidewalls

• reducing the tread life of tiresdue to the high temperaturesgenerated from excess flexing ofthe tire

• Inflate tires to the manufacturer'scold air pressure specificationmolded into the tire side wall.

Lower tire pressure does not giveyou more traction on ice or snow.under-inflation actually reducestraction and steering control. See thetire manufacturer's Driver's Handbookfor more information on properoperation and use of tires.

1

TREAD CONTACTWITH ROAD

Proper-Inflation: thecorrect profile for fullcontact with the road.

2


Under-Inflation:causes abnormal tiredeflection, which buildsup excessive heat,running the risk offailure. It also causesirregular wear.

3


Over-Inflation:reduces the treadcontact area withthe road surface,concentrating all ofthe vehicle weighton the center of thetread. This causespremature wear of thetire.

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• Too much air pressure reduces thetire tread contact area and resultsin rapid wear in the center of thetire. It also causes tires to run hardand makes them more vulnerableto impact and other road hazarddamage.

WARNING!

Over-inflated tires can cause acci-dents. They wear more quickly thanproperly inflated tires and are moresubject to punctures, cracks, andother damage. They could fail andcause you to lose control of your ve-hicle resulting in an accident. Besure all tires are inflated correctlyaccording to the manufacturer's rec-ommendations. Failure to complymay result in death, personal injury,equipment or property damage.

If over-inflation is noted during travel,do not deflate tires. The increasedpressure is caused by temperature

build-up during operation. Thiscondition has been taken into accountduring manufacturing of the tires.Allow tires to cool, then recheck andadjust if necessary.

Tire Loading

WARNING!

Do not exceed the load rating of yourtires (molded on the side wall of yourtire) or the maximum vehicle loadrating, whichever is less. Overload-ing could result in premature tire fail-ure causing you to loose control ofyour vehicle and result in an acci-dent. The maximum vehicle loadrating (GVWR) is found on the Tireand Rim Data label on the driver'sdoor. Failure to comply may resultin death, personal injury, equipmentor property damage.

Overloading your vehicle is asdamaging to the tires as under-inflation.It significantly affects the expectedlife (total mileage of a tire). Thefollowing chart shows how neglect ordeliberate abuse can affect the life ofyour vehicle's tires.

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Table 19 Effect of Load Pressure on Tire Life

Vehicle Load Normal 20% Over 40% Over 60% Over 80% Over 100% OverTire Pressure Normal 20% Low 30% Low 35% Low 45% Low 55% LowExpected TotalTire Mileage

Normal 70% 50% 40% 30% 25%

Wheel Mounting andFastening

After the vehicle travels about 50 to 100miles (80 to 160 km), wheel mountingsseat in and will lose some initial torque.Check hub/wheel mountings after thisinitial period and retighten.

Wheel Cap Nut Torque

At the first scheduled lube interval,have all wheel cap nuts torqued to theirspecified value. See Table 20, WheelCap Nut Torque on page 5-126. Afterthat, check wheel cap nuts at leastonce a week. Contact an authorizedKenworth Dealer for information on theproper installation procedure for thewheels on your truck. This is a job youmay not be able to do yourself. Youneed the right torquing equipment todo it.

WARNING!

Never use oil or grease on studs ornuts; improper torque readings willresult, which could cause improperwheel clamping and could lead toa wheel failure resulting in an acci-dent. Failure to comply may resultin death, personal injury, equipmentor property damage.

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Wheel Bearing Adjustment

For safe, reliable operation andadequate service life, your wheelbearings must be adjusted properly atthe recommended intervals. See Table9, Maintenance Schedule on page5-19 and Steering Axle Wheel Bearing- End Play Adjustment and Inspectionon page 5-19. Contact your authorizedKenworth Dealer to make sure thewheel bearings are properly adjusted.

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Table 20 Wheel Cap Nut Torque

TORQUE FOR INNER & OUTER CAP NUTS & RIM CLAMP NUTSWHEEL & NUT CONFIGURATION STUD SIZENm Lb-Ft

3/4-16 610-680 450-500Steel or Aluminum Disc-TypeWheel; Double Cap Nut Mounting;Standard 7/8 Radius Ball Seat

1-1/8-16 610-680 450-500

15/16-12 1,020-1,220 750-9001-1/8-16 1,020-1,220 750-900

Heavy-Duty Steel Disc-Type Wheel;Double Cap Nut Mounting;1-3/16 Radius Ball Seat: 1-15/16-12 1,020-1,220 750-900Hub-Piloted Disc-Type Wheelw/Two Piece Flanged Cap Nuts:Steel or Aluminum Wheel

M22-1.5 610-680 450-500

3/4-16 240-270 175-200Stud Backnuts (when used)1-14 240-410 175-300

Threads should be clean and dry. Donot lubricate wheel nuts or studs.

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Proper Torque and Sequence

Proper wheel torque can best beobtained on level ground. Install lugnuts and finger-tighten in the numericalsequence as shown below, see NutTightening Sequence for Hub PilotedDisc Wheels on page 5-127 or NutTightening Sequence for Stud PilotedDisc Wheels on page 5-127. Thisprocedure will ensure that the wheel isdrawn evenly against the hub. Torqueeach nut to the torque value listed inTable 20, Wheel Cap Nut Torque.

WARNING!

Tighten wheel cap nuts properly.If they are not tightened properly,wheel nuts could eventually causethe wheel to become loose, to fail,and/or to come off while the vehicleis moving, possibly causing loss ofcontrol and may result in death, per-sonal injury, equipment or propertydamage.

Nut Tightening Sequence for HubPiloted Disc Wheels

Nut Tightening Sequence for StudPiloted Disc Wheels

Wheel Replacement withDisc Brake Option

Use only the wheel brand, size andpart number originally installed byKenworth. Use of a different wheelbrand or size could cause valve stemto interfere with a brake componentwhich could lead to loss of vehiclecontrol and may lead to personal injury.

Vehicles equipped with front discbrakes are fitted with wheels designedspecifically for disc brake applications.If it ever becomes necessary toreplace an original equipment wheel,the replacement wheel must be thesame brand and size as the take-offwheel. On vehicles equipped with 22.5in. disc wheels, installing the wrongreplacement wheel could result in thewheel valve stem making contact withthe disc brake assembly.

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When installing any replacementwheel, always inspect the tires/wheelsto ensure there is adequate clearancebetween other vehicle components.

With the hood open, check forclearance between the wheel and discbrake assembly. Use a hydraulic jackto raise the front of the vehicle offthe ground to allow the wheel to spinfreely. While rotating the wheel, checkto ensure there is adequate clearancebetween the wheel and disc brakeassembly

WARNING!

If the hood falls, anyone under itcould be injured. Always attach thesafety cable and/or hood stop whenthe hood is in its open position anytime anyone gets under the hoodfor any reason. Failure to complymay result in personal injury, death,equipment or property damage.

WARNING!

Always support the vehicle with ap-propriate safety stands if it is neces-sary to work underneath the vehicle.A jack is not adequate for this pur-pose.

WARNING!

Improperly mounting and demount-ing tire and rim assemblies is dan-gerous. Failure to observe properprecautions could cause the tire-rimassembly to burst explosively, caus-ing serious injury or death. See thewheel manufacturer's literature forthe proper way to mount and de-mount your tires and rims. Followtheir precautions exactly.

Wheel and Tire Replacementfor Trucks with HydraulicBrakesGeneral Safety Requirements

WARNING!

Do not replace wheels or tires witha different size than originally in-stalled. The Anti- Lock Brake Sys-tem (ABS) is calibrated for the spe-cific tire revolutions per mile. Useof a different tire and/or wheel sizemay cause the ABS system to notfunction during a hard braking event.This could cause an accident or per-sonal injury. Use the table below todetermine the acceptable range oftire rev/mile.

For proper ABS operation all tire sizesmust be within the appropriate rangelisted below.

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A change of tire size may require thatthe ABS ECU be changed based onthe listed range of compatible tirerevolutions per mile (RPM). Consultyour Kenworth dealer before using adifferent tire and/or wheel size.

CAUTIONNo indication will be given via thedashboard warning lights or buzzerif tires of the wrong size are installedon your vehicle. See the warningabove for consequences of tires ofthe wrong size.

Table 21 Acceptable Rev per Mile

Frame-mountedECU

Nominal TireRev/Mile

AcceptableRange/Rev/Mile

478 407 079 0 572 460-658

Disc Wheels

WARNING!

Use the correct components andtools when working on wheels.Grooves in the wheel disc or otherdamage to the disc can weaken thewheel and cause it to eventuallycome off. This could cause you tolose control of your vehicle, andmay result in an accident. Failureto comply may result in death, per-sonal injury, equipment or propertydamage.

The end of the wheel wrench mustbe smooth. Burrs on the end of thewrench can tear grooves in the disc.These grooves may lead to cracks inthe disc, and can cause it to fail.

Comparing Hub Piloted andBall Seat Parts

WARNING!

Do not mismatch wheel compo-nents. Equipment that does not ex-actly match original specifications orthat is mismatched could cause thewheels to break and separate fromthe vehicle. The resulting accidentcould be very serious. Each mount-ing system is engineered for useonly with its correct mating part. Besure properly matched componentsare used for each type of mount-ing. Failure to comply may result indeath, personal injury, equipment orproperty damage.

The following comparison (Table 22,Comparing Hub-piloted and Ball-seatWheels), shows the differencebetween parts used in hub pilot mountand ball seat mount applications.

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Table 22 Comparing Hub-piloted and Ball-seat Wheels

HUB-PILOTED MOUNT BALLSEAT MOUNT

Hub, Drum, and Stud AssemblyHub-piloted mountings use M22 x 1.5 metric threads (about 7/8 in.diameter). The stud stands out at least 1.94 in. beyond the brake drum.All studs are right-hand threads. Pilot bosses (machined surfaces) on thehub, fit tightly to the wheel center bore.

Ball-seat (stud-piloted) mountings use 3/4x16 or 1-1/8x16 threads. Thedual mounting studs provide 1.30 in. 1.44 in. standout. Right-hand andleft-hand threads are required. Inner and outer wheel nuts center thewheels by seating against wheel ball seats.

WheelsHub-piloted wheels have stud holes reamed straight through (no ballseats). Center bore diameter is 8-21/32 in.

Ball-seat wheels have spherical chamfers machined on each stud hole.Center bore diameter is 8-23/32 in.

Wheel NutsHub-piloted wheel nuts have a hex body and a flange for clampingagainst wheel face. Hex size is 1-5/16 in. (33 mm).

Ball-seat inner and outer wheel nuts mate with spherical chamfers onwheels. The inner nut has 13/16 in. square end. The outer nut hasa 1-1/2 in. hex.

Tire Replacement

Front: Replace front tires when lessthan 4/32 in. of tread remains. Checkat three places equally spaced aroundthe tire.

Drive Axles or Trailers: Replace tireson drive axles or trailers when less than2/32 in. of tread depth remains in anymajor groove. Check at three placesequally spaced around the tire. See

the next illustration for recommendedmeasuring points for tread depth.

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Steer Tire Points (left), Drive TirePoints (right)

WARNING!

Do not install regrooved or rein-forcement- repaired tires on steeringaxles. They could fail unexpectedlyand cause you to lose control ofyour vehicle resulting in an acci-dent. Failure to comply may resultin death, personal injury, equipmentor property damage.

WARNING!

Do not replace original equipmenttires with load ratings less than theoriginal tires. Doing so could lead tounintentional overloading of the tire,which could cause a failure resultingin loss of vehicle control and an ac-cident. Failure to comply may resultin death, personal injury, equipmentor property damage.

NOTETo prolong the tires' life and makethem safer, have their radial andlateral run-out checked at your Ken-worth Dealer. And of course havethe tires balanced any time youchange a tire.

Greenhouse Gas Certified Tires

Replacing a tire that is greenhousegas certified.

NOTEThe tires installed on this vehicleat the factory as original equipmentmay be certified for GreenhouseGas and Fuel Efficiency regula-tions. Replacement tires must beof equal or lower rolling resistancelevel (TRRL or Crr). Consult withyour tire supplier(s) for appropriatereplacement tires.

Verify if your vehicle is equipped withGreenhouse Gas certified tires bychecking the Vehicle Emission Controllabel on the driver's side door frame. Ifthese tires were installed at the factory,Lower Rolling Resistance codes (LRR)identify which tires are certified.

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Maintaining a greenhouse gascertified tire.

In order to limit the rolling resistance ofthe tires and optimize fuel economy,the maintenance procedures specifiedby the tire manufacture must befollowed.

For warranty information, SeeGreenhouse Gas Tires on page 6-10.

Matching Tires

Be sure to buy matched tires foryour vehicle, especially on the rearaxles. Mismatched tires can causestress between axles and cause thetemperature of the axle lubricant to gettoo hot. Matched tires will help thedriveline last longer and will give youbetter tire mileage.

WARNING!

Do not mismatch tires, it can be dan-gerous. Never mix tires of differ-ent design such as steel belted ra-dials and bias ply tires, etc. Mixingtire types and sizes will adversely af-fect the road-holding ability of bothtypes of tires and can lead to lossof vehicle control. Failure to complymay result in death, personal injury,equipment or property damage.

Make sure, too, that you use the rightsize tires on each wheel. Some trucksrequire different sizes on front and rearwheels. For safety, always use therecommended size and type of tires.

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TRANSMISSION AND CLUTCH MAINTENANCE

TRANSMISSIONAND CLUTCHMAINTENANCE

Introduction

Follow the procedures below toensure parts are properly lubricated:

• Maintain oil level, check it regularly

• Change oil regularly

• Use the correct grade and type ofoil

• Buy oil from a reputable dealer

All Transmissions

Initial Change: drain and replaceaccording to Table 6, RecommendedLubrication Intervals on page 5-13; forsome transmissions this may not berequired.

Oil Change

Change fluid according to changeprocedures specified in theTransmission Service Manual.Use the recommended types of oilas specified in the Operation andService Manual (included with vehicle).Select from the appropriate lubricantfor varying ambient (outside air)temperatures.

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Transmission Lubricants

CAUTIONWhen adding oil, types and brandsof oil should not be intermixed be-cause of possible incompatibility,which could decrease the effec-tiveness of the lubrication or causecomponent failure.

Manual Transmission

Manual transmissions are designed sothat the internal parts operate in a bathof oil circulated by the motion of gearsand shafts.

Service Intervals

For recommended types and brandsof all lubricants, see the transmissionmanufacturer's Service Manual andTable 6, Recommended LubricationIntervals on page 5-13.

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Standard Transmission Oil Level

NOTEThe vehicle must be parked on levelground.See the Transmission Op-erator's Manual for information onchecking the transmission oil level.

Automatic TransmissionsService Intervals

Check daily with engine idling. SeeTable 6, Recommended LubricationIntervals on page 5-13 for serviceintervals.

Automatic Transmission Oil Level

NOTEThe vehicle must be parked on levelground.

See the Transmission Operator'sManual for information on checking thetransmission oil level.

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Clutch System Introduction

Free pedal is the distance the clutchpedal moves by applying only slightpressure. During free pedal therelease yoke in the transmissionmoves until its bearing pads contactthe release bearing. This movement ofthe release yoke is called free travel.Thus, free pedal and free travel aredirectly related to each other.

As the clutch pedal is depressedfurther, with harder pressure, therelease yoke moves the releasebearing away from the engine. Thiscauses the clutch plate to release fromthe driven disks in the clutch. This iscalled release travel. And finally, as thepedal is pushed to the last 1/2 to 1 inchof travel, the release bearing contactsand engages the clutch brake. Thisis called clutch brake squeeze. Whenthe clutch wears, the release bearinggradually moves toward the engine,decreasing free pedal and free travel.

When all free pedal and free travel aregone, the clutch requires adjustment.

The clutch is adjusted by turning anadjustment ring that is built into theclutch. When the ring is turned, therelease bearing moves back towardthe transmission, restoring free pedaland clutch free travel. Under normalclutch wear this is the only adjustmentneeded. Do not attempt to change anyother component.

Clutch Linkage

Have your authorized KenworthDealer service the clutch accordingto the clutch manufacturer's serviceguidelines.

• The Kenworth is equipped with arod and lever mechanical clutchlinkage. Lubricate each pivot pointon the clutch linkage.

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Clutch Adjustment - NormalWear

See the clutch manufacturer's ServiceManual for the proper adjustmentprocedures.

NOTEThis procedure is all that is requiredfor normal clutch adjustment. Ad-justment of any other components isnot required.

External Linkage Adjustment

1. Adjust clutch to clutchmanufacturer's specification.

2. Verify 1/8 in. free travel (distancethe release yoke moves before therelease yoke bearing pads contactthe release bearing).

3. Verify free pedal of 1.75 in. (44mm ± 6 mm).

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INFORMATION

CONSUMER INFORMATION AND VEHICLE IDENTIFICATIONIntroduction . . . . . . . . . . . . . . . . . . 6-3Reporting Safety Defects . . . . . . . . . . . . 6-3Vehicle Identification . . . . . . . . . . . . . . 6-4Certification Labels . . . . . . . . . . . . . . . 6-5Component Identification. . . . . . . . . . . . . 6-8How to Order Parts . . . . . . . . . . . . . . . 6-9

VEHICLE EMISSIONS LIMITED EXPRESS WARRANTYOriginal Equipment Tires . . . . . . . . . . . . 6-10Greenhouse Gas (GHG) Components Other ThanTires . . . . . . . . . . . . . . . . . . . 6-11

Your Warranty Rights and Obligations . . . . . . 6-11Manufacturer's Warranty Coverage . . . . . . . 6-12Owner's Warranty Responsibilities . . . . . . . 6-12Replacement Parts . . . . . . . . . . . . . . 6-13PACCAR Responsibilities . . . . . . . . . . . 6-14Warranty Limitations. . . . . . . . . . . . . . 6-14

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CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

CONSUMERINFORMATIONAND VEHICLEIDENTIFICATION

Introduction

WARNING!

This vehicle contains materialknown by the State of California tocause cancer and/or birth defectsor other reproductive harm. Thiswarning requirement is mandatedby California law (Proposition 65)and does not result from any changein the manner in which Kenworthtrucks are manufactured.

Reporting Safety Defects

United States

If you believe that your vehicle hasa defect which could cause a crashor could cause injury or death, youshould immediately inform the NationalHighway Traffic Safety Administration(NHTSA) in addition to notifyingKenworth Truck Company.

If NHTSA receives similar complaints,it may open an investigation, andif it finds that a safety defect existsin a group of vehicles, it may ordera recall and remedy campaign.However, NHTSA cannot get involvedin individual problems between you,your Kenworth Dealer, and KenworthTruck Company.

To contact NHTSA, you may eithercall the Auto Safety Hotline toll-free at(888) 327-4236 or write to: Office ofDefects Investigations/CRD NVS-216

1200 New Jersey Ave SE Washington,DC 20590. You can also get otherinformation about auto safety from theHotline.

Canada

Canadian customers whowish to reporta safety-related defect to TransportCanada, Defect Investigations andRecalls, may telephone the toll freehotline 1-800-333-0510, or contactTransport Canada bymail at: TransportCanada, ASFAD, Place de Ville TowerC, 330 Sparks Street, Ottawa ON K1A0N5.

For additional road safety information,please visit the Road Safety websiteat: www.tc.gc.ca/roadsafety

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Vehicle Identification

The 17-digit Vehicle IdentificationNumber (VIN) is used to registeryour vehicle for warranty, license andinsurance.

1 Manufacturer Identifier2 Vehicle Attributes3 Reserved Space4 Model Year5 Assembly Plant (Chassis

Number)6 Serial Number (Chassis

Number)

Table 23 Model Year Designations

CODE YEAR9 2009A 2010B 2011C 2012D 2013E 2014F 2015G 2016H 2017I 2018

Assembly Plant Code

F = KENMEX

M = Ste. Therese

R = Renton

J = Chillicothe

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VIN Location

The full, 17-digit VIN is exclusivelylocated on the Weight Rating DataLabel. The label is located on thedriver's side door edge or on thedriver's side door frame.

Chassis Number

The Chassis Number refers to thelast seven characters of the VIN.This number will allow your KenworthDealer to identify your vehicle. You willbe asked for this number when youbring it in for service.

Chassis Number Locations

• Right frame rail, top flange, about3 ft. from the front end

• Cab back, left-hand rear panel,lower edge

• Tire, Rim, and Weight Rating Datalabel (truck)

• Components and Weights label

• Noise Emission label

• Paint Identification label

Certification Labels

Vehicle information and specificationsfor your Kenworth are documented onlabels. As noted below, each labelcontains specific information pertainingto vehicle capacities and specificationsthat you should be aware of.

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Components and Weights Label

The Components and Weights Labelis located on either the driver's sidedoor edge or on the door frame. Itincludes chassis weight and grossweight, plus model and serial numbersfor the vehicle, engine, transmission,and axles.

Tire, Rim and Weight Rating DataLabel

The Tire, Rim and Weight RatingData Label is located on the driver'sside door edge or on the driver's sidedoor frame. It contains the followinginformation:

• GVWR - Gross Vehicle WeightRating

• GAWR FRONT and REAR - GrossAxle Weight Ratings for Front andRear Axle

• TIRE/RIM SIZES AND INFLATIONPRESSURES - Tire/Rim Sizesand Cold Pressure Minimums

• CHASSIS NUMBER

WARNING!

Do not exceed the specified load rat-ing. Overloading can result in lossof vehicle control and personal in-jury, either by causing componentfailures or by affecting vehicle han-dling. Exceeding load ratings canalso shorten the service life of thevehicle.

The components of your vehicleare designed to provide satisfactoryservice if the vehicle is not loadedin excess of either the gross vehicleweight rating (GVWR), or the maximumfront and rear gross axle weight ratings(GAWRs). (Axle weight ratings arelisted on the driver's door edge.)

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NOTEGVW is the TOTAL SCALEWEIGHTthe vehicle is designed to carry. Thisincludes the weight of the empty ve-hicle, loading platform, occupants,fuel, and any load.

Noise Emission Label

The Noise Emission Label is locatedin the driver's side door frame. Itcontains information regarding U.S.noise emission regulations, chassisnumber, and date of manufacture.

Paint Identification Label

The Paint Identification Label containsthe paint colors used by the factoryto paint your vehicle. It lists frame,wheels, cab interior and exteriorcolors. This label is located inside theglove box.

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Federal Safety StandardCertification Label

The NHTSA regulations require a labelcertifying compliance with FederalSafety Standard, for United Statesand U.S. Territories, be affixed toeach motor vehicle and prescribewhere such label may be located.This certification label, which indicatesthe date of manufacture and otherpertinent information, is located on thedriver's side door frame and on the cabaperture door frame.

Component Identification

Each of the major components onyour vehicle has an identification labelor tag. For easy reference, recordcomponent numbers such as, model,serial, and assembly number. Seethe Vehicle Component Register (lastpage of this manual).

Engine: For further information,please refer to the Engine Operationand Maintenance Manual.

Transmission: For both manualand automatic transmissions, theidentification number is stamped on atag affixed to the right rear side of thetransmission case.

Clutch: Enclosed in clutch housing.Location depends on manufacturer.

Steer Axle: The front axle serialnumber is stamped on a plate locatedon the center of the axle beam.

Drive Axles: The drive axle numberingsystem includes three labels or stamps:

1. Axle Specification Number, usuallystamped on the right rear side ofthe axle housing. This numberidentifies the complete axle.

2. Axle Housing Number Tag, usuallylocated on the left forward sideof the housing arm. This tagidentifies the axle housing.

3. Axle Differential CarrierIdentification, usually locatedon the top side of the differentialcarrier. The following informationis either stamped, or marked with ametal tag: Model No., ProductionAssembly No., Serial No., GearRatio, and Part Number.

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How to Order Parts

Replacement parts may be obtainedfrom an authorized dealership.

When you order, it is IMPORTANTthat you have the following informationready:

• Your name and address.

• Serial number of the truck.

• The name of the part you need.

• The name and number of thecomponent for which the part isrequired.

• The quantity of parts you need.

• How you want your order shipped.

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VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY

VEHICLE EMISSIONSLIMITED EXPRESSWARRANTY

Original Equipment Tires

PACCAR Inc warrants the tiresinstalled as original equipment onthis vehicle only against defects inmaterials and workmanship whichcause the vehicle to fail to complywith applicable U.S. and Canadiangreenhouse gas emission limits(“Warrantable Emissions Failures”).This vehicle emissions limited expresswarranty relating to original equipmenttires is valid for two (2) years or 24,000miles, whichever occurs first.

YOUR SOLE AND EXCLUSIVEREMEDY AGAINST PACCAR IncIS LIMITED TO THE REPAIR ORREPLACEMENT OF ORIGINALEQUIPMENT TIRES, SUBJECT TOPACCAR’S TIME AND MILEAGE

LIMITATIONS LISTED ABOVE. ThisVehicle Emissions Limited ExpressWarranty relating to original equipmenttires begins on the date of delivery ofthe vehicle to the first purchaser orlessee and accrued time andmileage iscalculated when the vehicle is broughtin for correction of the WarrantableEmissions Failures relating to theoriginal equipment tires.

PACCAR MAKES NO OTHERVEHICLE EMISSIONS WARRANTIESRELATING TO THE ORIGINALEQUIPMENT TIRES, EXPRESSOR IMPLIED. WHERE PERMITTEDBY LAW, PACCAR EXPRESSLYDISCLAIMS ANY WARRANTY OFMERCHANTABILITY OR FITNESSFOR A PARTICULAR PURPOSERELATING TO VEHICLE EMISSIONS.PACCAR AND THE SELLINGDEALER SHALL NOT BE LIABLE FORINCIDENTAL OR CONSEQUENTIALDAMAGES INCLUDING, BUT NOTLIMITED TO: LOSS OF INCOME

OR LOST PROFITS; VEHICLEDOWNTIME; COMMUNICATIONEXPENSES; LODGING AND/ORMEAL EXPENSES; FINES;APPLICABLE TAXES OR BUSINESSCOSTS OR LOSSES; ATTORNEY’SFEES; AND ANY LIABILITY YOU MAYHAVE IN RESPECT TO ANY OTHERPERSON OR ENTITY RELATINGTO WARRANTABLE EMISSIONSFAILURES.

This Vehicle Emissions LimitedExpress Warranty relating tooriginal equipment tires is limitedto emissions compliance only.The tires are separately warrantedby their manufacturer for defects inmaterials and workmanship other thanthose which cause non-compliancewith U.S. and Canadian GHGregulations, subject to limitations andconditions contained within the tiremanufacturer’s warranty agreement.You are responsible for the safeoperation and maintenance of the

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vehicle and its tires. PACCAR doesnot warrant wear and tear of the tires.

Greenhouse Gas (GHG)Components Other ThanTires

This GHG vehicle Warranty applies tothe vehicle (hereafter, vehicle) certifiedwith the US Environmental ProtectionAgency.

Your Warranty Rights andObligations

This vehicle is warranted forcomponents that directly impact themanufacturers greenhouse gas (GHG)certification with the US EnvironmentalProtection Agency. PACCAR mustwarrant these components for theperiods of time listed below providedthere has been no abuse, neglect orimproper maintenance of the vehicle.

If a GHG-related part on your vehicleis found to have a defect in material orassembly, the part will be repaired orreplaced by PACCAR.

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Manufacturer's WarrantyCoverage

This warranty coverage is provided forfive years or 100,000 miles (160,000)km, whichever first occurs, from thedate of delivery of the vehicle tothe first purchaser or first lessee.Where a Warrantable Condition exists,PACCAR will diagnose and repairthe vehicle, parts and labor included,at no cost to the first purchaser orfirst lessee and each subsequentpurchaser or lessee. This warrantydoes not override any extendedwarranty purchased to cover specificvehicle components.

Owner's WarrantyResponsibilities

The vehicle owner is responsible forperforming required maintenance thatis listed in your engine and vehicleOperator’s Manuals. The owner isresponsible for presenting the vehicleto a service location as soon as aproblem exists. Any warranty repairsshould be completed in a reasonableamount of time.

Retain all receipts coveringmaintenance on this equipment.PACCAR cannot deny warranty solelyfor the lack of receipts or for thefailure to ensure the performance of allscheduled maintenance.

PACCAR may deny warranty coverageif a vehicle component has failed due toabuse, neglect, improper maintenance,unapproved modifications (bothphysical components and computer

programming) or using non-OriginalEquipment replacement parts.

If there are any questionsregarding these warranty rightsand responsibilities, please contactthe vehicle OEM manufacturer at thecustomer center telephone numberprovided with the vehicle operatinginstructions.

Prior to the expiration of the applicablewarranty, Owner must give notice ofany warranted failure to an authorizedPACCAR dealer and deliver the vehicleto such facility for repair.

Owner is responsible for incidentalcosts such as: communicationexpenses, meals, lodging incurred byOwner or employees of Owner as aresult of a Warrantable Condition.

Owner is responsible for downtimeexpenses, cargo damage, fines, allapplicable taxes, all business costs,

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and other losses resulting from aWarrantable Condition.

Owner is responsible for maintainingall emissions related engine andvehicle computer program settingsin accordance with manufacturerspecifications. This responsibilityincludes GHG specific settingsthat may not be altered before theGHG-related expiration mileage hasbeen reached for each system.

Owner is responsible for maintainingall physical parts related toGHG-regulations in the as-builtconfiguration and in proper workingorder for the full regulatory useful lifeof 435,000 miles for Class 8 vehicles,185,000 miles for Class 6-7, and110,000 for Class 5.

Replacement Parts

PACCAR recommends that anyservice parts used for maintenance,repair or replacement of GHGcomponents be new or genuineapproved rebuilt parts and assemblies.The use of non-genuine engine orvehicle replacement parts that are notequivalent to the PACCAR engine orOEM vehicle manufacturer’s originalpart specification as built from thefactory may impair the engine andvehicle emissions control system fromworking or functioning effectively, andmay jeopardize your GHG warrantycoverage.

In addition, genuine vehicle or engineparts must be replaced with the samematerial and function as the partassembled on the vehicle from thefactory.

The owner may elect to havemaintenance, replacement or repair of

the emission control parts performedby a facility other than an authorizedPACCAR dealer and may elect touse parts other than new or genuineapproved rebuilt parts and assembliesfor such maintenance, replacementor repair; however, the cost of suchservice or parts and subsequentfailures resulting from such serviceor parts may not be fully warrantedif the manufacturer determines thatthe replacement part is not of similarmaterial and function as the OEM partassembled to the vehicle at the factory.

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PACCAR Responsibilities

The warranty coverage begins whenthe vehicle is delivered to the firstpurchaser or first lessee. Repairsand service will be performed by anyauthorized PACCAR dealer usingnew or genuine approved rebuilt partsand assemblies PACCAR will utilizereplacement parts that are selectedand installed to support the GHGcompliance certification. PACCARwill repair parts found by PACCAR tobe defective without charge for partsor labor (including diagnosis whichresults in determination that there hasbeen a failure of a warranted part).

Warranty Limitations

Sole and exclusive remedy againstPACCAR and the Selling Dealerarising from the purchase and useof this vehicle is limited to the repairor replacement of “warrantablefailures”, for replacement parts thatare similar in material and functionto OEM specifications and subject toPACCAR’s time, mileage, and hourlimitations of the greenhouse gaswarranty. The maximum time, mileageand hour limitations of the warrantybegin with the Date of Delivery to thefirst purchaser or first lessee. Theaccrued time, mileage, or hours iscalculated when the vehicle is broughtin for correction of warrantable failures.

PACCAR is not responsible forfailures or damage resulting from whatPACCAR determines to be abuse,neglect or uncontrollable acts of nature,including, but not limited to: damagedue to accident; operation without

adequate coolants or lubricants;overfueling; overspeeding; lack ofmaintenance of cooling, lubricatingor intake systems; improper storage,starting, warm-up, run-in or shutdownpractices; unauthorized modificationsto the vehicle and its components.PACCAR is also not responsible forfailures caused by incorrect oil, fuelor diesel exhaust fluid or by water,dirt or other contaminants in the fuel,oil or diesel exhaust fluid. Failureof replacement parts used in repairsdue to the above non-warrantableconditions is not warrantable.

This warranty is void if the vehicle isaltered with parts that do not meet thematerial and functional specificationsas manufactured from the factory.Any alterations to vehicle or enginecomputer settings will void GHGwarranty and potentially cause thevehicle to become non-compliantwith the GHG regulation of the EPAClean Air Act. Any alterations to

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GHG specific settings prior to theGHG related expiration mileage foreach system will void GHG warrantyand potentially cause the vehicleto become non-compliant with theGHG regulation of the EPA Clean AirAct. This warranty is void if certainGHG components are not properlymaintained and thus cannot perform totheir designed capability.

PACCAR is not responsible for failuresresulting from improper repair or theuse of parts which are not genuineapproved parts.

PACCAR is not responsible for thematerial and labor costs of emissioncontrol parts and assemblies replacedduring Scheduled Maintenance ofthe engine as specified in PACCAROperator’s Manuals.

THIS WARRANTY, TOGETHERWITH THE EXPRESS COMMERCIALWARRANTIES ARE THE SOLE

WARRANTIES MADE BY PACCAR INREGARD TO THIS VEHICLE.

THIS LIMITED GHG WARRANTYIS THE SOLE WARRANTY MADEBY PACCAR AND THE SELLINGDEALER. EXCEPT FOR THE ABOVELIMITED WARRANTY, PACCAR ANDTHE SELLING DEALER MAKE NOOTHER WARRANTIES, EXPRESSOR IMPLIED. PACCAR AND THESELLING DEALER EXPRESSLYDISCLAIM ANY WARRANTY OFMERCHANTABILITY OR WARRANTYOF FITNESS FOR A PARTICULARPURPOSE.

PACCAR AND THE SELLINGDEALER SHALL NOT BE LIABLE FORINCIDENTAL OR CONSEQUENTIALDAMAGES INCLUDING, BUT NOTLIMITED TO: LOSS OF INCOMEOR LOST PROFITS; ENGINE ORVEHICLE DOWNTIME; THIRD PARTYDAMAGE, INCLUDING DAMAGEOR LOSS TO OTHER ENGINES,

VEHICLES OR PROPERTY,ATTACHMENTS, TRAILERS ANDCARGO; LOSS OR DAMAGETO PERSONAL CONTENTS;COMMUNICATION EXPENSES;LODGING AND/OR MEALEXPENSES; FINES; APPLICABLETAXES OR BUSINESS COSTS ORLOSSES; ATTORNEYS’ FEES; ANDANY LIABILITY YOU MAY HAVE INRESPECT TO ANY OTHER PERSONOR ENTITY.

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Index

Index

AAbout this Manual. . . . . . . . . . . . . . . . . . . .1-3Accessoriescigarette lighter . . . . . . . . . . . . . . . . . . . .3-6radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Adding Coolant. . . . . . . . . . . . . . . . . . . . . 5-61Adding electrical options . . . . . . . . . . 5-67Additional sources of information. . .1-9installed equipment - operator's

manuals . . . . . . . . . . . . . . . . . . . . . . .1-9other sources . . . . . . . . . . . . . . . . . . . . . .1-9

Adjustable auxiliary axles . . . . . . . . . 4-58liftable/non-steerable pusher

calibration. . . . . . . . . . . . . . . . . . . 4-62liftable/steerable calibration . . . . 4-62tag axle calibration . . . . . . . . . . . . . . 4-62

Adjustable Tilt/TelescopingColumn .. . . . . . . . . . . . . . . . . . . . . . . 3-92

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . 5-46Air cleaner and filter . . . . . . . . . . . . . . . 5-43Air cleaner restriction gauge . . . . . . 5-43

Air compressor . . . . . . . . . . . . . . . . . . . . . 5-38Air dryer. . . . . . . . . . . . . . . . . . . . . . .4-17, 5-40Air dryer (Bendix AD-IS series) . . . 5-41Air dryer overhaul . . . . . . . . . . . . . . . . . . 5-41Air filter restriction pressure

gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48Air gaugesair filter restriction pressure . . . . 3-48air pressure - air suspension air

bags . . . . . . . . . . . . . . . . . . . . . . . . . 3-55air pressure #1 & #2 . . . . . . . . . . . . 3-53brake application air pressure. . 3-50tractor air brake pressure -

primary/secondary . . . . . . . . . 3-54Air intake system.. . . . . . . . . . . . . . . . . . 5-42Air Supply System .. . . . . . . . . . . . . . . . 4-17Air Suspension Height/Air

Pressure . . . . . . . . . . . . . . . . . . . . . . . 4-12Air systemair cleaner. . . . . . . . . . . . . . . . . . . . . . . . 5-43air compressor. . . . . . . . . . . . . . . . . . . 5-38

air dryer . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40air gauges and air leaks . . . . . . . . 5-37air intake system .. . . . . . . . . . . . . . . 5-42draining air tanks . . . . . . . . . . . . . . . . 5-36filter elements. . . . . . . . . . . . . . . . . . . . 5-43primary air pressure gauge. . . . . 5-37scheduled maintenance . . . . . . . . 5-35scheduled maintenance table . . 5-35secondary air pressure gauge . 5-37turbocharger . . . . . . . . . . . . . . . . . . . . . 5-43

Air system maintenance. . . . . . . . . . . 5-34Air tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57engine oil pressure . . . . . . . . . . . . . . 3-24fifth wheel slide . . . . . . . . . . . . . . . . . . 3-24low air warning alarm - primary 3-24low air warning alarm -

secondary. . . . . . . . . . . . . . . . . . . 3-24low coolant level. . . . . . . . . . . . . . . . . 3-25park brake. . . . . . . . . . . . . . . . . . . . . . . . 3-24stop engine alarm .. . . . . . . . . . . . . . 3-23

(02/14) Y53-1212-1B1 Index-1

7

Index

turn signal/hazard . . . . . . . . . . . . . . . 3-25Alert screensalarm clock active . . . . . . . . . . . . . . . 3-60circuit failure . . . . . . . . . . . . . . . . . . . . . 3-60cruise control . . . . . . . . . . . . . . . . . . . . 3-60cruise control rationality . . . . . . . . 3-58DEF.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59disabled alert . . . . . . . . . . . . . . . . . . . . 3-64engine over-speed shutdown low air

warning. . . . . . . . . . . . . . . . . . . . . . 3-61engine protection shutdown

timer . . . . . . . . . . . . . . . . . . . . . . . . . 3-61fault alert . . . . . . . . . . . . . . . . . . . . . . . . . 3-63front drive axle speed warning . 3-61hydrocarbon burn . . . . . . . . . . . . . . . 3-60impact alert . . . . . . . . . . . . . . . . . . . . . . 3-63lamp faults . . . . . . . . . . . . . . . . . . . . . . . 3-58level 1 following distance alert . 3-63level 2 following distance alert . 3-62level 3 following distance alert . 3-62low voltage disconnect. . . . . . . . . . 3-59no-idle shutdown .. . . . . . . . . . . . . . . 3-58not available alert . . . . . . . . . . . . . . . 3-64over-crank protection . . . . . . . . . . . 3-59park brake on while moving . . . . 3-58SCR/DEF .. . . . . . . . . . . . . . . . . . . . . . . 3-59

stationary object alert . . . . . . . . . . . 3-63trailer detect. . . . . . . . . . . . . . . . . . . . . . 3-59water in fuel (WIF). . . . . . . . . . . . . . . 3-60Wingman® ACB alert screens . 3-62

Anti-Lock Brake System (ABS)Indicator . . . . . . . . . . . . . . . . . . . . . . . 3-32

Anti-lock brakes . . . . . . . . . . . . . . . . . . . . 4-27trailer ABS .. . . . . . . . . . . . . . . . . . . . . . 4-30trailer ABS (without PLC) . . . . . . . 4-31wheel spin control . . . . . . . . . . . . . . . 4-28

Appliances. . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Audible alerts. . . . . . . . . . . . . . . . . . . . . . . 3-20Automatic transmissionsauxiliary transmission . . . . . . . . . . . 4-72oil level . . . . . . . . . . . . . . . . . . . . . . . . . .5-135operation . . . . . . . . . . . . . . . . . . . . . . . . . 4-71service intervals . . . . . . . . . . . . . . . .5-135

Auxiliary axles . . . . . . . . . . . . . . . . . . . . . . 4-58AxleSteerable Drive Axle . . . . . . . . . . . . 4-72

BBatteriesbattery access . . . . . . . . . . . . . . . . . . . 5-70battery care . . . . . . . . . . . . . . . . . . . . . . 5-73

battery charging . . . . . . . . . . . . . . . . . 5-74jump starting vehicles . . . . . . . . . . . . .2-9removing and installing

batteries. . . . . . . . . . . . . . . . . . . . . 5-72Battery Cables . . . . . . . . . . . . . . . . . . . . . 5-75Beltstether belts . . . . . . . . . . . . . . . . . . . . . . . 1-22

Brake air pressure gauge . . . . . . . . . 3-50Brake gaugesbrake pedal or trailer brake hand

valve pressure. . . . . . . . . . . . . . 3-50tractor primary/secondary air brake

pressure. . . . . . . . . . . . . . . . . . . . . 3-54Brake system.. . . . . . . . . . . . . . . . . . . . . . 4-15air supply system.. . . . . . . . . . . . . . . 4-17anti-lock brakes. . . . . . . . . . . . . . . . . . 4-27anti-lock braking system (ABS) 5-49automatic (slack) adjusters . . . . . 5-47brake adjuster stroke. . . . . . . . . . . . 5-48brake and slack adjuster

lubrication. . . . . . . . . . . . . . . . . . . 5-46brake component descriptions . 4-35brake linings . . . . . . . . . . . . . . . . . . . . . 5-46cam-actuated component

lubrication. . . . . . . . . . . . . . . . . . . 5-45emergency braking. . . . . . . . . . . . . . 4-26

Index-2 Y53-1212-1B1 (02/14)

7

Index

engine brake. . . . . . . . . . . . . . . . . . . . . 4-35engine retarders . . . . . . . . . . . . . . . . . 4-33exhaust brake. . . . . . . . . . . . . . . . . . . . 4-34front brakes . . . . . . . . . . . . . . . . . . . . . . 4-19hydraulic brakes . . . . . . . . . . . . . . . . . 4-16modulating valve . . . . . . . . . . . . . . . . 4-19overheated brakes . . . . . . . . . . . . . . 4-26parking brake system .. . . . . . . . . . 4-19parking brake valve . . . . . . . . . . . . . 4-19releasing combination of brakes 4-21releasing trailer brakes. . . . . . . . . . 4-21releasing truck or tractor parking

brakes . . . . . . . . . . . . . . . . . . . . . . . 4-21safety - tractor/trailer . . . . . . . . . . . . 4-25system park tractor. . . . . . . . . . . . . . 4-24tractor/trailer air supply valve. . . 4-22trailer brake hand valve. . . . . . . . . 4-32trailer charge. . . . . . . . . . . . . . . . . . . . . 4-25trailer emergency brake

application . . . . . . . . . . . . . . . . . . 4-24trailer parking brake . . . . . . . . . . . . . 4-24treadle valve - front circuit . . . . . . 4-19treadle valve - rear circuit. . . . . . . 4-19wet brake components. . . . . . . . . . 4-18

Brake system maintenance . . . . . . . 5-44

Brake System MalfunctionIndicator . . . . . . . . . . . . . . . . . . . . . . . 3-35

CCab and frame access . . . . . . . . . . . . 1-10Cab maintenance . . . . . . . . . . . . . . . . . . 5-51Cab Status Indicator . . . . . . . . . . . . . . . 3-36Cab storage . . . . . . . . . . . . . . . . . . . . . . . . 3-10glove box. . . . . . . . . . . . . . . . . . . . . . . . . 3-10interior compartments. . . . . . . . . . . 3-10

Cablesbattery . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-75

Certification labelscomponents and weights label . . .6-6federal safety standard certification

label . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8noise emission label . . . . . . . . . . . . . .6-7part identification label . . . . . . . . . . . .6-7tire, rim data and weight rating data

label . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18Check Engine Indicator. . . . . . . . . . . . 3-36Checks and adjustments . . . . . . . . . . 5-46Cigarette lighter . . . . . . . . . . . . . . . . . . . . . .3-6Clock

Analog clock - dash . . . . . . . . . . . . . . .3-7clock display . . . . . . . . . . . . . . . . . . . . . 3-71clock settings menu .. . . . . . . . . . . . 3-71Digital clock - sleeper . . . . . . . . . . . . .3-7lamp test . . . . . . . . . . . . . . . . . . . . . . . . . 3-74Quick operating instructions. . . . . .3-7to set alarm time.. . . . . . . . . . . . . . . . 3-72to set clock display . . . . . . . . . . . . . . 3-71to set clock home/local time . . . . 3-71to turn alarm ON/OFF.. . . . . . . . . . 3-73

Clutchclutch adjustment. . . . . . . . . . . . . . . . 4-70clutch brake . . . . . . . . . . . . . . . . . . . . . . 4-66clutch linkage . . . . . . . . . . . . . . . . . . .5-136clutch linkage adjustment. . . . . .5-137clutch linkage lubrication

(non-ESI). . . . . . . . . . . . . . . . . . . . 5-32clutch pedal shaft lubrication . . . 5-32clutch release bearing

lubrication. . . . . . . . . . . . . . . . . . . 5-33clutch ring adjustment. . . . . . . . . .5-136clutch travel . . . . . . . . . . . . . . . . . . . . . . 4-66double clutching . . . . . . . . . . . . . . . . . 4-69identification . . . . . . . . . . . . . . . . . . . . . . .6-8introduction . . . . . . . . . . . . . . . . . . . . .5-136riding the clutch. . . . . . . . . . . . . . . . . . 4-69

(02/14) Y53-1212-1B1 Index-3

7

Index

Clutch Adjustment . . . . . . . . . . . . . . . . . 4-70Component identification reference 6-8Consumer information . . . . . . . . . . . . . . .6-3how to order parts . . . . . . . . . . . . . . . . .6-9reporting safety defects. . . . . . . . . . .6-3

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6indicators. . . . . . . . . . . . . . . . . . . . . . . . . 3-26

Cooling systemadding coolant . . . . . . . . . . . . . . . . . . . 5-61additives. . . . . . . . . . . . . . . . . . . . . . . . . . 5-62coolant change and refilling . . . . 5-63engine (block) heater . . . . . . . . . . . 5-65fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89fan clutch. . . . . . . . . . . . . . . . . . . . . . . . . 5-89radiator cap . . . . . . . . . . . . . . . . . . . . . . 5-64topping up. . . . . . . . . . . . . . . . . . . . . . . . 5-60

Cruise control . . . . . . . . . . . . . . . . . . . . . . 4-11Cruise Control . . . . . . . . . . . . . . . . . . . . . . 4-47

DDaily checks . . . . . . . . . . . . . . . . . . . . . . . . 1-33Data recorder. . . . . . . . . . . . . . . . . . . . . . . . .1-7Deep Snow and Mud Switch. . . . . . 4-28Diesel Emission Fluid (DEF)

Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 3-50

Diesel Particulate Filter (DPF)Indicator . . . . . . . . . . . . . . . . . . . . . . . 3-39

Differential lock (driver controlled) 4-55Displays/menu screensclock display . . . . . . . . . . . . . . . . . . . . . 3-71clock home/local time . . . . . . . . . . . 3-71clock settings menu .. . . . . . . . . . . . 3-71diagnostic display . . . . . . . . . . . . . . . 3-70fuel economy .. . . . . . . . . . . . . . . . . . . 3-67ignition timer . . . . . . . . . . . . . . . . . . . . . 3-67lamp test . . . . . . . . . . . . . . . . . . . . . . . . . 3-74left hand menu bar . . . . . . . . . . . . . . 3-66multi-function display. . . . . . . . . . . . 3-64multi-function menu items .. . . . . 3-65outside air temperature display 3-47RPM detail . . . . . . . . . . . . . . . . . . . . . . . 3-67speed control management

display. . . . . . . . . . . . . . . . . . . . . . . 3-70to set language . . . . . . . . . . . . . . . . . . 3-74to set standard or metric units. . 3-74transmission display . . . . . . . . . . . . 3-70trip information. . . . . . . . . . . . . . . . . . . 3-68trip meter . . . . . . . . . . . . . . . . . . . . . . . . . 3-46truck information. . . . . . . . . . . . . . . . . 3-69

Door lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11key fob synchronization. . .1-13, 5-77

key fob troubleshooting . . . . . . . . . 5-77remote keyless entry (RKE)

system .. . . . . . . . . . . . . . . . . . . . . 1-12Double Clutching. . . . . . . . . . . . . . . . . . . 4-69Drive axle(s) oil temperature

gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49Drive axlesidentification . . . . . . . . . . . . . . . . . . . . . . .6-8

Driver controlled main differentiallock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55

Driver'sdaily checks. . . . . . . . . . . . . . . . . . . . . . 1-33weekly checks . . . . . . . . . . . . . . . . . . . 1-37

Driver's check list . . . . . . . . . . . . . . . . . . 1-32Driving tips. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5coasting . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5descending a grade . . . . . . . . . . . . . . .4-6economy .. . . . . . . . . . . . . . . . . . . . . . . . . .4-6engine RPM.. . . . . . . . . . . . . . . . . . . . . . .4-6using the tachometer. . . . . . . . . . . . . .4-7

Dual range (two-speed) rear axle 4-56

EElectrical and alternator

precautions. . . . . . . . . . . . . . . . . . . . 5-76

Index-4 Y53-1212-1B1 (02/14)

7

Index

Electrical gaugesvoltmeter . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

Electrical systemadding electrical options . . . . . . . . 5-67batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 5-70battery care . . . . . . . . . . . . . . . . . . . . . . 5-73battery charging . . . . . . . . . . . . . . . . . 5-74electrical and alternator

precautions . . . . . . . . . . . . . . . . . 5-76fuses, circuit breakers, and

relays. . . . . . . . . . . . . . . . . . . . . . . . 5-66jump starting vehicles . . . . . . . . . . . . .2-9removing and installing

batteries. . . . . . . . . . . . . . . . . . . . . 5-72turn signal flasher . . . . . . . . . . . . . . . 5-70

Electrical system maintenance . . . 5-66Emergencybattery connections . . . . . . . . . . . . . 2-11emergency equipment kit . . . . . . . 1-32jump starting vehicles . . . . . . . . . . . . .2-9

Emergency Braking. . . . . . . . . . . . . . . . 4-26Emergency equipment . . . . . . . . . . . . 1-32Emergency Flasher Switch . . . . . . . 3-88Enginedrive belts . . . . . . . . . . . . . . . . . . . . . . . . 5-88engine fan. . . . . . . . . . . . . . . . . . . . . . . . 5-89

engine mounting. . . . . . . . . . . . . . . . . 5-90exhaust system.. . . . . . . . . . . . . . . . . 5-89fuel filters. . . . . . . . . . . . . . . . . . . . . . . . . 5-87identification . . . . . . . . . . . . . . . . . . . . . . .6-8lubrication . . . . . . . . . . . . . . . . . . . . . . . . 5-84oil level check. . . . . . . . . . . . . . . . . . . . 5-84pipe and hose clamp torque

values . . . . . . . . . . . . . . . . . . . . . . . 5-84Engine (block) heater. . . . . . . . . . . . . . 5-65Engine block heater . . . . . . . . . . . . . . . 4-40Engine Brakes. . . . . . . . . . . . . . . . . . . . . . 4-35Engine Control Display . . . . . . . . . . . . 4-50Engine Coolant Temperature

Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 3-50Engine Fan Control . . . . . . . . . . . . . . . . 4-49Engine lubrication. . . . . . . . . . . . . . . . . . 5-84Engine maintenance. . . . . . . . . . . . . . . 5-83Engine Mounting . . . . . . . . . . . . . . . . . . . 5-90Engine Oil Pressure Alarm.. . . . . . . 3-24Engine Oil Pressure Gauge. . . . . . . 3-51Engine operation. . . . . . . . . . . . . . . . . . . 4-38cruise control . . . . . . . . . . . . . . . . . . . . 4-47engine block heater . . . . . . . . . . . . . 4-40engine control display. . . . . . . . . . . 4-50engine fan control . . . . . . . . . . . . . . . 4-49engine idling . . . . . . . . . . . . . . . . . . . . . 4-45

engine shutdown system .. . . . . . 4-50shut-down .. . . . . . . . . . . . . . . . . . . . . . . 4-73

Engine retarders . . . . . . . . . . . . . . . . . . . 4-33Engine Shutdown System.. . . . . . . . 4-50Engine Shutdown System (ESS) . 4-46Engine warm-up. . . . . . . . . . . . . . . . . . . . 4-41Environmental Protection . . . . . . . . . . .1-6Environmental Protection and Material

Hazards. . . . . . . . . . . . . . . . . . . . . . . . 5-10Ether metering equipment . . . . . . . . 4-44Exhaust Brake. . . . . . . . . . . . . . . . . . . . . . 4-34

FFan clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 5-89Fan Indicator . . . . . . . . . . . . . . . . . . . . . . . 3-37Fasten Seat Belt Indicator . . . . . . . . 3-41Fifth Wheel Slide Warning . . . . . . . . 3-24Frame fastener torque

requirements . . . . . . . . . . . . . . . . . . 5-94Freeing the vehicle from sand, mud,

snow and ice . . . . . . . . . . . .2-17–2-18Front axle and suspension

maintenance . . . . . . . . . . . . . . . . . . 5-95Fuel economydriving habits. . . . . . . . . . . . . . . . . . . . . . .4-8

(02/14) Y53-1212-1B1 Index-5

7

Index

fuel consumption . . . . . . . . . . . . . . . . . .4-8Fuel Filter Restriction Pressure

Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 3-52Fuel filtersdraining. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-88installing. . . . . . . . . . . . . . . . . . . . . . . . . . 5-87

Fuel gaugesfuel filter restriction pressure . . . 3-52fuel tank(s) level . . . . . . . . . . . . . . . . . 3-52

Fuel shut-off valve . . . . . . . . . . . . . . . . . 4-75Fuel specification . . . . . . . . . . . . . . . . . . 4-75Fuses, circuit breakers and relays 5-66

GGauge panel. . . . . . . . . . . . . . . . . . . . . . . . 3-43A - Panel . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

Gauge symbolsair brake application pressure. . 3-44air filter restriction pressure . . . . 3-44diesel emission fluid (DEF) . . . . . 3-44drive axle(s) oil temperature. . . . 3-44engine coolant temperature . . . . 3-44engine oil pressure . . . . . . . . . . . . . . 3-44fuel filter restriction pressure . . . 3-44

fuel level (primary andsecondary) . . . . . . . . . . . . . . . . . . 3-45

primary and secondary airpressure. . . . . . . . . . . . . . . . . . . . . 3-45

suspension load air pressure. . . 3-45symbols table . . . . . . . . . . . . . .3-43–3-44transmission oil temperature . . . 3-45voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . 3-45

Gaugesair filter restriction pressure . . . . 3-48air pressure - primary . . . . . . . . . . . 3-54air pressure - secondary. . . . . . . . 3-54brake application air pressure. . 3-50diesel emission fluid (DEF) . . . . . 3-50drive axle(s) oil temperature. . . . 3-49engine coolant (water)

temperature. . . . . . . . . . . . . . . . . 3-50engine hour meter. . . . . . . . . . . . . . . 3-47engine oil pressure . . . . . . . . . . . . . . 3-51fuel filter restriction pressure . . . 3-52fuel tank(s) level . . . . . . . . . . . . . . . . . 3-52general air pressure. . . . . . . . . . . . . 3-53odometer . . . . . . . . . . . . . . . . . . . . . . . . . 3-46primary air pressure. . . . . . . . . . . . . 5-37secondary air pressure . . . . . . . . . 5-37speedometer. . . . . . . . . . . . . . . . . . . . . 3-46

suspension load air pressure. . . 3-55tachometer . . . . . . . . . . . . . . . . . . 4-7, 3-47transmission oil temperature . . . 3-55transmission temperature . . . . . . 4-71voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

GAWR - Gross Axle WeightRating. . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

GCW - Gross CombinationWeight . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

Generic Air Pressure Gauge. . . . . . 3-53Glove box. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Greenhouse Gas (GHG) Components

Other Than Tires. . . . . . . . . . . . . . 6-11Greenhouse Gas Certification . . . . . .1-8Greenhouse gas certified tires. . .5-131GVWR - Gross Vehicle Weight

Rating. . . . . . . . . . . . . . . . . . . . . . . . . . 1-31

HHeadlampshalogen/hid lamp servicing . . . . . 5-78

Headlamps with Wipersto activate headlamps with

wipers . . . . . . . . . . . . . . . . . . . . . . . 3-74Headlight switch. . . . . . . . . . . . . . . . . . . . 3-85

Index-6 Y53-1212-1B1 (02/14)

7

Index

Heater and air conditioner . . . . . . . . 5-98air conditioner. . . . . . . . . . . . . . . . . . .5-100heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99

Heater and air conditionermaintenance . . . . . . . . . . . . . . . . . . 5-98

Heating and air conditioningair flow control dial . . . . . . . . . . . . . . 3-17cab controls . . . . . . . . . . . . . . . . . . . . . . 3-16cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18dash and floor vents . . . . . . . . . . . . 3-17dash vents . . . . . . . . . . . . . . . . . . . . . . . 3-17defrost vents . . . . . . . . . . . . . . . . . . . . . 3-17dehumidify . . . . . . . . . . . . . . . . . . . . . . . 3-18fan control dial . . . . . . . . . . . . . . . . . . . 3-17floor and defrost vents . . . . . . . . . . 3-17floor vents . . . . . . . . . . . . . . . . . . . . . . . . 3-17fresh air mode . . . . . . . . . . . . . . . . . . . 3-17fresh air/recirculation switch. . . . 3-17heating . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18precautions . . . . . . . . . . . . . . . . . . . . . . 3-13recirculation switch . . . . . . . . . . . . . . 3-17temperature control dial . . . . . . . . 3-17what each control does . . . . . . . . . 3-17windshield defog and defrost. . . 3-19

High Beam Indicator . . . . . . . . . . . . . . . 3-39

High Exhaust System TemperatureIndicator . . . . . . . . . . . . . . . . . . . . . . . 3-39

Hood hold downs . . . . . . . . . . . . . . . . . . 1-15Hood latch . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15Hood safety lock . . . . . . . . . . . . .1-16, 5-59Hood tiltinghood hold downs . . . . . . . . . . . . . . . . 1-15hood latch . . . . . . . . . . . . . . . . . . . . . . . . 1-15

How to order parts . . . . . . . . . . . . . . . . . . .6-9

IIdling the engine . . . . . . . . . . . . . . . . . . . 4-43Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26Installed Equipment - Operator's

Manuals . . . . . . . . . . . . . . . . . . . . . . . . .1-9Instrument panelA - Panel . . . . . . . . . . . . . . . . . . . . . . . . . 3-20alert screens . . . . . . . . . . . . . . . . . . . . . 3-58audible warning or alarm tone. . 3-57indicator light(s) . . . . . . . . . . . . . . . . . 3-57Multi-function message display 5-91warning and information

screens. . . . . . . . . . . . . . . . . . . . . . 3-58Wingman® ACB alert screens . 3-62

Wingman® ACB warning tone . 3-62Instrumentation. . . . . . . . . . . . . . . . . . . . . 3-43A - Panel . . . . . . . . . . . . . . . . . . . . . . . . . 3-20heater/air conditioner controls. . . .3-5radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5tractor/trailer brake control

valves . . . . . . . . . . . . . . . . . . . . . . . . .3-5wiper switch. . . . . . . . . . . . . . . . . . . . . . . .3-5

Inter-Axle Differential Lock . . . . . . . . 4-52Interior compartments . . . . . . . . . . . . . 3-10

JJump starting vehicles. . . . . . . . . . . . . . .2-9

KKeysRemote Keyless Entry (RKE) . . 1-11

Kingpin lubrication . . . . . . . . . . . . . . . . . 5-95Komfort-Latch® Feature . . . . . . . . . . 1-24

LLap/Shoulder belt . . . . . . . . . . . . . . . . . . 1-20Load distribution . . . . . . . . . . . . . . . . . . . 1-31

(02/14) Y53-1212-1B1 Index-7

7

Index

Loadingvehicle loading. . . . . . . . . . . . . . . . . . . 1-31

Lockhood safety . . . . . . . . . . . . . . . . . . . . . . 1-16

Low Coolant Level Indicator . . . . . . 3-37Low Coolant Level Warning. . . . . . . 3-25Lubricant specifications . . . . . . . . . . . 5-30Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . 5-85

MMaintenanceacceptable rev per mile . . . . . . . .5-129air conditioner. . . . . . . . . . . . . . . . . . .5-100air system .. . . . . . . . . . . . . . . . . . . . . . . 5-34anti-lock braking system (ABS) 5-49brake system .. . . . . . . . . . . . . . . . . . . 5-44cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51chrome and aluminum surfaces 5-52cleaning vinyl and upholstery . . 5-55driver's check list . . . . . . . . . . . . . . . . 1-32electrical system.. . . . . . . . . . . . . . . . 5-66emergency welding . . . . . . . . . . . . . 5-92engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-83environmental protection . . . . . . . 5-10exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51

frame fastener torquerequirements . . . . . . . . . . . . . . . 5-94

frame fastener torque table. . . . . 5-94front axle and suspension

lubrication. . . . . . . . . . . . . . . . . . . 5-95heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-99hood safety lock . . . . . . . . . . . . . . . . . 5-59inspection . . . . . . . . . . . . . . . . . . . . . . . . 5-96introduction . . . . . . . . . . . . . . . . . . . . . . . .5-9lubricant specifications. . . . . . . . . . 5-30lubricant specifications table . . . 5-32maintenance schedule table

key. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19noise and emission control

standards . . . . . . . . . . . . . . . . . .5-101oil reservoir levels . . . . . . . . . . . . . . . 5-31painted surfaces. . . . . . . . . . . . . . . . . 5-51rear axle alignment. . . . . . . . . . . . . 5-114rear axle and suspension. . . . . .5-109rear axle housing breather

vent. . . . . . . . . . . . . . . . . . . . . . . . . 5-114rear axle lubrication . . . . . . . . . . . . 5-112rear suspension fasteners torque

table . . . . . . . . . . . . . . . . . . . . . . . . 5-111rear suspension U-bolt torque

table . . . . . . . . . . . . . . . . . . . . . . . . 5-112

recommended lubricationintervals . . . . . . . . . . . . . . . . . . . . . 5-13

safety precautions. . . . . . . . . . . . . . . . .5-9safety restraint system -

inspection . . . . . . . . . . . . . . . . . . . 5-55safety restraint system - inspection

guidelines . . . . . . . . . . . . . . . . . . . 5-57spicer driveshaft lubrication cycle

table . . . . . . . . . . . . . . . . . . . . . . . . . 5-17spicer driveshaft lubrication interval

table . . . . . . . . . . . . . . . . . . . . . . . . . 5-16stainless steel. . . . . . . . . . . . . . . . . . . . 5-52steering and driveline . . . . . . . . . . 5-115tire and wheel. . . . . . . . . . . . . . . . . . . 5-119transmission and clutch. . . . . . . .5-133U-bolt torque. . . . . . . . . . . . . . . . . . . . . 5-96U-bolt torque table . . . . . . . . . . . . . . 5-97vehicle cleaning . . . . . . . . . . . . . . . . . 5-53washing chassis . . . . . . . . . . . . . . . . . 5-55washing exterior . . . . . . . . . . . . . . . . . 5-54wheel alignment . . . . . . . . . . . . . . . . . 5-96windshield wiper/washer. . . . . . . . 5-59

Maintenance and lubrication . . . . . . 5-13Maintenance schedule . . . . . . . . . . . . 5-18Maintenance schedule and lubricationintroduction . . . . . . . . . . . . . . . . . . . . . . 5-12

Index-8 Y53-1212-1B1 (02/14)

7

Index

Malfunction Indicator Lamp (MIL) 3-40Manual transmission. . . . . . . . . . . . . . . 4-66clutch adjustment. . . . . . . . . . . . . . . . 4-70clutch brake . . . . . . . . . . . . . . . . . . . . . . 4-68clutch travel . . . . . . . . . . . . . . . . . . . . . . 4-68double clutching . . . . . . . . . . . . . . . . . 4-69release bearing wear. . . . . . . . . . . . 4-70riding the clutch. . . . . . . . . . . . . . . . . . 4-69shifting gears . . . . . . . . . . . . . . . . . . . . 4-68

Manufacturer's WarrantyCoverage . . . . . . . . . . . . . . . . . . . . . . 6-12

Master lubrication index . . . . . . . . . . . 5-85Message Waiting Indicator . . . . . . . . 3-40Mirror Heat Button . . . . . . . . . . . . . . . . . 3-96Mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-94mirror heat button . . . . . . . . . . . . . . . 3-96power mirror switch . . . . . . . . . . . . . 3-94

Multi-function display . . . . . . . . . . . . . . 3-64display panel. . . . . . . . . . . . . . . . . . . . . 3-65left hand menu bar . . . . . . . . . . . . . . 3-66left handmenu bar - menu items 3-67menu items .. . . . . . . . . . . . . . . . . . . . . 3-65right hand status bar . . . . . . . . . . . . 3-66

NNoise and emission control

maintenance . . . . . . . . . . . . . . . . .5-101Noise control inspections . . . . . . . .5-103air intake system .. . . . . . . . . . . . . .5-103blanket . . . . . . . . . . . . . . . . . . . . . . . . . .5-106diesel particulate filters . . . . . . . .5-105engine fan and shroud . . . . . . . . .5-105engine mounted noise

insulators. . . . . . . . . . . . . . . . . . .5-103exhaust system.. . . . . . . . . . . . . . . .5-104exhaust tail pipe . . . . . . . . . . . . . . . .5-105hood insulation blanket . . . . . . . .5-106inner fender shields and cab

skirt . . . . . . . . . . . . . . . . . . . . . . . . .5-107joints and clamps. . . . . . . . . . . . . . .5-104maintenance log. . . . . . . . . . . . . . . .5-108piping . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-104shields and skirts . . . . . . . . . . . . . . .5-107transmission or driveline. . . . . . .5-106

OOdometer/Trip Meter . . . . . . . . . . . . . . 3-46Off-Road ABS Function Switch . . . 4-29Oil gauges

drive axle(s) oil temperature. . . . 3-49engine oil pressure . . . . . . . . . . . . . . 3-51transmission oil temperature . . . 3-55

Oil level check. . . . . . . . . . . . . . . . . . . . . . 5-84Oil pan heater . . . . . . . . . . . . . . . . . . . . . . 4-40Operating the transmission . . . . . . . 4-65cold weather warm-up . . . . . . . . . . 4-65

Original Equipment Tires . . . . . . . . . . 6-10Overheated Brakes . . . . . . . . . . . . . . . . 4-26Overspeed Shut Down Indicator. . 3-37Owner's Warranty Coverage. . . . . . 6-12

PPACCAR Responsibilities . . . . . . . . . 6-14Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-93Park Brake Alarm .. . . . . . . . . . . . . . . . . 3-24Park Brake Indicator . . . . . . . . . . . . . . . 3-35Parking braketractor/trailer brake control

valves . . . . . . . . . . . . . . . . . . . . . . . . .3-5Parking brake system .. . . . . . . . . . . . 4-19Pipe and hose clamp torque

values. . . . . . . . . . . . . . . . . . . . . . . . . . 5-84Power Mirror Switch . . . . . . . . . . . . . . . 3-94Power Take-off (PTO) Indicator. . . 3-40

(02/14) Y53-1212-1B1 Index-9

7

Index

Pressure gaugesengine oil pressure . . . . . . . . . . . . . . 3-51

Preventive maintenance. . . . . . . . . . . 5-12Preventive Maintenance Intervals 5-12Primary or Secondary Low Air Warning

Alarm .. . . . . . . . . . . . . . . . . . . . . . . . . 3-24

RRadio. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5–3-6Range Inhibit Indicator . . . . . . . . . . . . 3-41Rear axle - dual range

(two-speed). . . . . . . . . . . . . . . . . . . . 4-56Rear axle and suspension

maintenance . . . . . . . . . . . . . . . . .5-109rear suspension fasteners . . . . . 5-111visual inspection. . . . . . . . . . . . . . . . 5-110

Rear/Drive axle. . . . . . . . . . . . . . . . . . . . . 4-52inter-axle differential lock . . . . . . . 4-52inter-axle differential lock -

locking. . . . . . . . . . . . . . . . . . . . . . . 4-54inter-axle differential lock -

unlocking. . . . . . . . . . . . . . . . . . . . 4-55Recommended lubrication

intervals. . . . . . . . . . . . . . . . . . . . . . . . 5-13Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Recovery Rigging . . . . . . . . . . . . . . . . . . 2-14Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75fuel specification. . . . . . . . . . . . . . . . . 4-75

Release Bearing Wear . . . . . . . . . . . . 4-70Remote Keyless Entry (RKE)key fob operation . . . . . . . . . . . . . . . . 1-12key fob synchronization. . . . . . . . . 1-13troubleshooting . . . . . . . . . . . . . . . . . . 5-77

Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7Replacement Parts . . . . . . . . . . . . . . . . 6-13Retarder (Brake) Indicator . . . . . . . . 3-38Riding the Clutch. . . . . . . . . . . . . . . . . . . 4-69

SSafe vehicle operation. . . . . . . . . . . . . 1-28Safetyabout this manual . . . . . . . . . . . . . . . . .1-3air suspension height/air

pressure. . . . . . . . . . . . . . . . . . . . . 4-12cab and frame access . . . . . . . . . . 1-10cruise control . . . . . . . . . . . . . . . . . . . . 4-11deflated air springs . . . . . . . . . . . . . . 4-13driver's check list . . . . . . . . . . . . . . . . 1-32emergency equipment kit . . . . . . . 1-32introduction . . . . . . . . . . . . . . . . . . . . . . . .1-3

safe operation and driving . . . . . . 4-10safe vehicle operation. . . . . . . . . . . 1-28safety alerts . . . . . . . . . . . . . . . . . . . . . . . .1-3suspension air pressure gauge 4-13vehicle loading. . . . . . . . . . . . . . . . . . . 1-31vehicle safety . . . . . . . . . . . . . . . . . . . . . .1-5

Safety alerts . . . . . . . . . . . . . . . . . . . . . . . . . .1-3Safety Lockhood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

Safety restraint belts. . . . . . . . . . . . . . . 1-19belt damage and repair . . . . . . . . . 1-25during pregnancy. . . . . . . . . . . . . . . . 1-25inspection . . . . . . . . . . . . . . . . . . . . . . . . 5-55proper safety belt adjustment . . 1-20safety restraint tips . . . . . . . . . . . . . . 1-26

Seat adjustment. . . . . . . . . . . . . . . . . . . . 1-18driver's seat with air suspension 1-18reclining seats . . . . . . . . . . . . . . . . . . . 1-19standard driver's seat . . . . . . . . . . . 1-18

Seat Belt Indicator . . . . . . . . . . . . . . . . . 3-41Seat belts . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18adjustments . . . . . . . . . . . . . . . . . . . . . . 1-18belt damage and repair . . . . . . . . . 1-25during pregnancy. . . . . . . . . . . . . . . . 1-25Komfort-Latch feature. . . . . . . . . . . 1-24lap/shoulder belt . . . . . . . . . . . . . . . . . 1-20

Index-10 Y53-1212-1B1 (02/14)

7

Index

proper safety belt adjustment . . 1-20safety restraint tips . . . . . . . . . . . . . . 1-26

Seatsadjustments . . . . . . . . . . . . . . . . . . . . . . 1-18Komfort-Latch feature. . . . . . . . . . . 1-24tether adjustment. . . . . . . . . . . . . . . . 1-23tether belts . . . . . . . . . . . . . . . . . . . . . . . 1-22

Seats and restraints . . . . . . . . . . . . . . . 1-18Service application - 8,000 lb. or

10,000 lb. front axles . . . . . . . . . 1-29Service Transmission Indicator . . . 3-41Shut-downbefore stopping the engine . . . . . 4-74final stopping procedures. . . . . . . 4-73fuel specification. . . . . . . . . . . . . . . . . 4-75introduction . . . . . . . . . . . . . . . . . . . . . . 4-73location of fuel shut-off valves. . 4-75refueling . . . . . . . . . . . . . . . . . . . . . . . . . . 4-75turbocharger cool down.. . . . . . . . 4-74

Speedometer . . . . . . . . . . . . . . . . . . . . . . . 3-46Spring brakes - manual release . . 2-15Starting procedurecold temperature . . . . . . . . . . . . . . . . 4-40engine warm-up . . . . . . . . . . . . . . . . . 4-41ether metering . . . . . . . . . . . . . . . . . . . 4-44normal temperature . . . . . . . . . . . . . 4-39

Steer axleidentification . . . . . . . . . . . . . . . . . . . . . . .6-8

Steerable Drive Axle. . . . . . . . . . . . . . . 4-72Steering and driveline

maintenance . . . . . . . . . . . . . . . . . 5-115driveshaft. . . . . . . . . . . . . . . . . . . . . . . . 5-118fluid level and refill . . . . . . . . . . . . . 5-116steering driveline . . . . . . . . . . . . . . . 5-117

Steering column.. . . . . . . . . . . . . . . . . . . 3-87adjustable tilt and telescoping. . 3-92emergency flasher switch . . . . . . 3-88trailer brake hand valve. . . . . . . . . 3-91turn signal/high beam switch . . . 3-87

Stop Engine Alarm.. . . . . . . . . . . . . . . . 3-23Stop Engine Indicator. . . . . . . . . . . . . . 3-38Stop/Turn Signal Lamp Operation 3-91Suspension Load Air Pressure

Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 3-55Suspension lubrication . . . . . . . . . . . . 5-95Switchesaccessory air switch. . . . . . . . . . . . . 3-79air conditioner switch. . . . . . . . . . . . 3-17auxiliary light switch . . . . . . . . . . . . . 3-79axle switch, de-clutch, front . . . . 3-77axle switch, diff-lock - dual . . . . . 3-77

axle switch, diff-lock - forwardrear . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77

axle switch, diff-lock - rear rear 3-77axle switch, diff-lock - single

rear . . . . . . . . . . . . . . . . . . . . . . . . . . 3-77axle switch, inter axle differential

locked (tandem) . . . . . . . . . . . . 3-77axle switch, two speed. . . . . . . . . . 3-78back up alarm mute switch . . . . . 3-78beacon light switch . . . . . . . . . . . . . . 3-79brake level switch . . . . . . . . . . . . . . . 3-78brake on/off switch . . . . . . . . . . . . . . 3-78cruise control on/off switch . . . . . 3-78cruise control set/resume

switch . . . . . . . . . . . . . . . . . . . . . . . 3-78cruise control switch . . . . . . . . . . . . 4-11dash panel (dimmer) switch . . . . 3-85diesel particulate filter (DPF)

regeneration switch . . . . . . . . 3-79dual range rear axle switch. . . . . 4-56dump truck gate switch . . . . . . . . . 3-78emergency flasher switch . . . . . . 3-88engine fan override switch. . . . . . 3-78engine fan switch. . . . . . . . . . . . . . . . 4-49engine heater switch . . . . . . . . . . . . 3-79exhaust brake switch. . . . . . . . . . . . 4-34

(02/14) Y53-1212-1B1 Index-11

7

Index

flood light switch. . . . . . . . . . . . . . . . . 3-80fresh air/recirculation switch. . . . 3-17headlight switch . . . . . . . . . . .3-80, 3-85heater/air conditioner control . . . . .3-5inter-axle differential lock switch 4-52off-road ABS function switch

(option) . . . . . . . . . . . . . . . . . . . . . . 4-29optional deep snow and mud

switch . . . . . . . . . . . . . . . . . . . . . . . 4-28overspeed air shutdown

(manual) . . . . . . . . . . . . . . . . . . . . 3-79overspeed air shutdown (test). . 3-79panel dimmer switch . . . . . . . . . . . . 3-80park light switch . . . . . . . . . . . . . . . . . 3-80parking brake valve . . . . . . . . . . . . . 3-78power take-off (PTO) switch. . . . 3-80spare switch . . . . . . . . . . . . . . . . . . . . . 3-79suspension dump switch . . . . . . . 3-80trailer air supply valve. . . . . . . . . . . 3-80trailer marker light interrupter

switch . . . . . . . . . . . . . . . . . . . . . . . 3-87turn signal/high beam switch . . . 3-87two speed transfer case switch 3-80wheel differential switch . . . . . . . . 4-54wiper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

TTachometer . . . . . . . . . . . . . . . . . . . . . . . . . 3-47Temperature gaugesdrive axle(s) oil temperature. . . . 3-49water temperature (engine

coolant) . . . . . . . . . . . . . . . . . . . . . 3-50Tether belts . . . . . . . . . . . . . . . . . . . . . . . . . 1-22Tire and wheel maintenance . . . . . 5-119Tire chains . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18Tiresgreenhouse gas certified tires.5-131

Tires and wheelscomparing hub-piloted and ball-seat

wheels. . . . . . . . . . . . . . . . . . . . . .5-129inspection and replacement . . .5-121matched tires . . . . . . . . . . . . . . . . . . .5-132speed restricted tires. . . . . . . . . . .5-120tire inflation and loading . . . . . . .5-121tire replacement . . . . . . . . . . . . . . . .5-130wheel cap nut torque

sequence . . . . . . . . . . . . . . . . . .5-127wheel cap nut torque table . . . .5-126wheel mounting and fastening 5-124

Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12Traction Control Indicator . . . . . . . . . 3-32Trailer ABS .. . . . . . . . . . . . . . . . . . . . . . . . 4-30

Trailer Anti-Lock Brake System (ABS)Indicator . . . . . . . . . . . . . . . . . . . . . . . 3-33

Trailer brake hand valve. . . . . . . . . . . 4-32Trailer Brake Hand Valve. . . . . . . . . . 3-91Trailer Detectto activate trailer detect . . . . . . . . . 3-73

Transmissionauxiliary . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72identification . . . . . . . . . . . . . . . . . . . . . . .6-8lubricants. . . . . . . . . . . . . . . . . . . . . . . .5-134maintenance . . . . . . . . . . . . . . . . . . . .5-133oil change . . . . . . . . . . . . . . . . . . . . . . .5-133operation . . . . . . . . . . . . . . . . . . . . . . . . . 4-65shifting gears in a new vehicle . 4-68temperature gauge . . . . . . . . . . . . . . 4-71transmission tips . . . . . . . . . . . . . . . . 4-69warm-up. . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

Transmission and clutchmaintenance . . . . . . . . . . . . . . . . .5-133

Transmission Oil TemperatureGauge . . . . . . . . . . . . . . . . . . . . . . . . . 3-55

Transmission temperature gauge 4-71Transmission temperature gaugestransmission oil temperature . . . 3-55

Transmission, Oil Temperature HighIndicator . . . . . . . . . . . . . . . . . . . . . . . 3-42

Index-12 Y53-1212-1B1 (02/14)

7

Index

Turbocharger . . . . . . . . . . . . . . . . .5-43, 4-74Turn signal flasher . . . . . . . . . . . . . . . . . 5-70Turn Signal Indicator (Left). . . . . . . . 3-42Turn Signal Indicator (Right) . . . . . . 3-42Turn Signal/High Beam Switch . . . 3-87

VVehicle identificationassembly plant code . . . . . . . . . . . . . .6-4chassis number. . . . . . . . . . . . . . . . . . . .6-5chassis number locations. . . . . . . . .6-5model year designations table . . .6-4vehicle information and specification

label locations . . . . . . . . . . . . . . . .6-5VIN number . . . . . . . . . . . . . . . . . . . . . . . .6-4VIN number location . . . . . . . . . . . . . .6-5

Vehicle loading . . . . . . . . . . . . . . . . . . . . . 1-31GAWR.. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31GCW.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31GVWR.. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31load distribution. . . . . . . . . . . . . . . . . . 1-31

Vehicle recovery . . . . . . . . . . . . . . . . . . . 2-12recovery rigging . . . . . . . . . . . . . . . . . 2-14returning vehicle to service . . . . . 2-15spring brakes . . . . . . . . . . . . . . . . . . . . 2-15

tire chains . . . . . . . . . . . . . . . . . . . . . . . . 2-18Vehicle safety . . . . . . . . . . . . . . . . . . . . . . . .1-5repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7

Vehicle/Trailer air supply valve . . . 4-22Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56

WWait To Start Indicator . . . . . . . . . . . . . 3-38Warning light/indicator symbolsalarm on indicator . . . . . . . . . . . . . . . 3-66anti-lock brake system (ABS) . . 3-32anti-lock brake system (ABS),

trailer . . . . . . . . . . . . . . . . . . . . . . . . 3-33axle, stability control . . . . . . . . . . . . 3-32brake system malfunction . . . . . . 3-35cab status . . . . . . . . . . . . . . . . . . . . . . . . 3-36cruise control active icon . . . . . . . 3-66diesel particulate filter (DPF) . . . 3-39engine, check engine . . . . . . . . . . . 3-36engine, fan . . . . . . . . . . . . . . . . . . . . . . . 3-37engine, low coolant level . . . . . . . 3-37engine, retarder (brake) . . . . . . . . 3-38engine, stop engine . . . . . . . . . . . . . 3-38engine, wait to start . . . . . . . . . . . . . 3-38gear display . . . . . . . . . . . . . . . . . . . . . . 3-66

high exhaust systemtemperature. . . . . . . . . . . . . . . . . 3-39

lights, high beam .. . . . . . . . . . . . . . . 3-39malfunction indicator lamp.. . . . . 3-40message waiting . . . . . . . . . . . . . . . . 3-40overspeed shut down .. . . . . . . . . . 3-37park brake. . . . . . . . . . . . . . . . . . . . . . . . 3-35power take-off (PTO). . . . . . . . . . . . 3-40range inhibit. . . . . . . . . . . . . . . . . . . . . . 3-41seat belt, fasten . . . . . . . . . . . . . . . . . 3-41shift indicator. . . . . . . . . . . . . . . . . . . . . 3-66transmission, oil temperature

high. . . . . . . . . . . . . . . . . . . . . . . . . . 3-42transmission, service. . . . . . . . . . . . 3-41turn signal, left . . . . . . . . . . . . . . . . . . . 3-42turn signal, right . . . . . . . . . . . . . . . . . 3-42

WarrantyGreenhouse Gas (GHG)

Components Other ThanTires . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

Limitations . . . . . . . . . . . . . . . . . . . . . . . 6-14Manufacturer's warranty

coverage . . . . . . . . . . . . . . . . . . . . 6-12Original equipment tires . . . . . . . . 6-10Owner's warranty coverage . . . . 6-12PACCAR responsibilities . . . . . . . 6-14

(02/14) Y53-1212-1B1 Index-13

7

Index

Replacement parts . . . . . . . . . . . . . . 6-13Rights and obligations . . . . . . . . . . 6-11

Warranty Limitations . . . . . . . . . . . . . . . 6-14Warranty Rights and Obligations . 6-11Weekly checks . . . . . . . . . . . . . . . . . . . . . 1-37Welding (emergency). . . . . . . . . . . . . . 5-92What to do if.... . . . . . . . . . . . . . . . . . . . . . . .2-3check engine lamp turns on . . . . . .2-5engine is overheating . . . . . . . . . . . . .2-5engine oil pressure lamp turns

on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4fuse or relay blows . . . . . . . . . . . . . . . .2-7low air alarm turns on . . . . . . . . . . . . .2-3stop engine lamp turns on . . . . . . . .2-4you need roadside assistance . . .2-3

Wheel Spin Control . . . . . . . . . . . . . . . . 4-28Windshield wiper/washer. . . . . . . . . . 5-59Windshield wipers/washer switch 3-89

Index-14 Y53-1212-1B1 (02/14)

7