Contents

Safety 1

Emergency 2

Controls 3

Driving 4

Maintenance 5

Information 6

Index 7 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 on this vehicle. This manual may also include a description of features and equipment which are no longer available or were not ordered on this vehicle. Please disregard any illustrations or descriptions relating to features or equipment which are not on this vehicle.

PACCAR reserves the right to discontinue, change specifications, or change the design of its vehicles at any time without notice 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 strictly prohibited without prior written authorization from PACCAR Inc. Truck Model Example

i

SAFETY

1 INTRODUCTION About this Manual...... 1-3 Safety Alerts ...... 1-3 Vehicle Safety ...... 1-5 Environmental Protection ...... 1-6 Data Recorder ...... 1-7 Repairs ...... 1-7 Greenhouse Gas Certification ...... 1-8 Additional Sources of Information ...... 1-9 CAB AND FRAME ACCESS Safety ...... 1-10 Door Lock and Keys ...... 1-14 Remote Keyless Entry (Option) ...... 1-14 GETTING TO YOUR ENGINE Hood Hold Downs...... 1-17 Hood Tilt ...... 1-17 Hood Lock ...... 1-18

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1 Hood Safety Cable ...... 1-19 SEATS AND RESTRAINTS Introduction ...... 1-20 Safety Restraint Belts ...... 1-21 Tether Belts ...... 1-24 Komfort-Latch® Feature ...... 1-26 During Pregnancy...... 1-27 Belt Damage and Repair ...... 1-27 Safety Restraint Tips ...... 1-28 Sleeper Bunks and Restraints ...... 1-29 START-UP Introduction ...... 1-33 Safe Vehicle Operation ...... 1-33 Vehicle Loading...... 1-34 Emergency Equipment ...... 1-35 Driver's Check List ...... 1-35

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INTRODUCTION Safety Alerts Your Kenworth may not have all the 1 About this Manual features or options mentioned in this Please read and follow all of the manual. Therefore, you should pay safety alerts contained in this manual. Congratulations! Your selection of a careful attention to the instructions that They are there for your protection Kenworth truck was a wise investment. pertain to just your vehicle. In addition, and information. These alerts can Kenworth trucks are recognized as if your vehicle is equipped with special help you avoid injury to yourself, your the industry standard for quality and equipment or options not discussed in passengers, and help prevent costly reliability. this manual, consult your dealer or the damage to the vehicle. Safety alerts manufacturer of the equipment. are highlighted by safety alert symbols Please take the time to get acquainted and signal words such as "WARNING", with your vehicle by reading this All information contained in this "CAUTION", or "NOTE". Please do not Operator’s Manual. We recommend manual is based on the latest ignore any of these alerts. that you read and understand this production information available at the manual from beginning to end before time of publication. Kenworth Truck you operate your truck. This manual Company reserves the right to make explains the safe, efficient operation changes at any time without notice. and maintenance of your Kenworth.

NOTE After you’ve read this manual, it should be stored in the cab for con- venient reference and remain with this truck when sold.

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1 WARNING CAUTION NOTE WARNING! CAUTION NOTE

The safety message following this The safety alert following this symbol The alert following this symbol and symbol and signal word provides a and signal word provides a caution signal word provides important warning against operating procedures against operating procedures which information that is not safety related which could cause injury or even death. could cause equipment or property but should be followed. The alert They could also cause equipment or damage. The alert will identify the will highlight things that may not be property damage. The alert will identify hazard, how to avoid it, and the obvious and is useful to your efficient the hazard, how to avoid it, and the probable consequence of not avoiding operation of the vehicle. probable consequence of not avoiding the hazard. the hazard. Example: Example: Example: NOTE CAUTION Pumping the accelerator will not as- WARNING! Continuing to operate your vehi- sist in starting the engine. Do not attempt repair work without cle with insufficient oil pressure will sufficient training, service manuals, cause serious engine damage. Fail- and the proper tools. You could be ure to comply may result in equip- killed or injured, or you could make ment or property damage. your vehicle unsafe. Do only those tasks you are fully qualified to do.

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Vehicle Safety Ratings Data Label on the driver's door Make sure your Kenworth is in top edge. 1 WARNING! working condition before heading out on the road, it is the responsible Safe driving is only possible with the Do not drive after drinking alcohol or driver's duty to do so. Inspect the proper concentration on the driving using other substances that may af- vehicle according to the Driver's Check task. Keep distraction to a minimum to fect the senses, including prescrip- List beginning on page 1-35. improve your concentration. Examples tion medications. Your reflexes, per- of distractions may include radio ceptions, and judgment can be af- Every new Kenworth vehicle is controls, GPS navigation controls, fected by even a small amount of al- designed to conform to all Federal cellular telephone calls, cellular text cohol or other substances, and can Motor Vehicle Safety Standards messages, reading or reaching for cause a serious or even fatal acci- applicable at the time of manufacture. something on the floor. Minimizing dent. Failure to comply may result in Even with these safety features, your distractions will improve safe death, personal injury, or equipment continued safe and reliable operation driving and will help avoid an accident and property damage. depends greatly upon regular vehicle involving death or personal injury. maintenance. Follow the maintenance WARNING! recommendations found in Preventive Be aware of local regulations that may Do not text while driving. Your re- Maintenance on page 5-7. This will prohibit the use of cellular telephones flexes, perceptions, and judgment help preserve your investment. while driving. In addition to being an can be affected while texting or unsafe practice, it may be against local Keep in mind that even a well using any other form of mobile mes- or federal ordinances to use cellular maintained vehicle must be operated saging while driving. Failure to com- devices while operating the vehicle. within the range of its mechanical ply may result in death, personal capabilities and the limits of its load This manual is not a training manual. injury, or equipment and property ratings. See the Tire, Rim and Weight It cannot tell you everything you need damage. to know about driving your Kenworth

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vehicle. For that you need a good Environmental Protection regulations can result in fines and/or jail 1 training program or truck driving terms. Contact your local government school. If you have not been trained, WARNING! agency for information concerning get the proper training before you Diesel engine exhaust and some proper disposal. drive. Only qualified drivers should of its constituents are known to the California Proposition 65 Warning drive this vehicle. State of California to cause cancer, birth defects, and other reproduc- • Diesel engine exhaust and some tive harm. Other chemicals in this of its constituents are known to vehicle are also known to the State the State of California to cause of California to cause cancer, birth cancer, birth defects, and other defects or other reproductive harm. reproductive harm. This warning requirement is man- dated by California law (Proposition • Other chemicals in this vehicle 65) and does not result from any are also known to the State of change in the manner in which vehi- California to cause cancer, birth cles are manufactured. defects or other reproductive harm. Some of the ingredients in engine • Battery posts, terminals, and oil, hydraulic oil, transmission and related accessories contain lead axle oil, engine coolant, diesel fuel, and lead compounds, chemicals air conditioning refrigerant (R12, known to the State of California R-134a and PAG oil), batteries, etc., to cause cancer and reproductive may contaminate the environment if harm. Wash hands after handling. spilled or not disposed of properly. Non-compliance with environmental

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Data Recorder Repairs Your dealer’s service center is the best 1 California Vehicle Code - Section WARNING! place to have your vehicle repaired. 9951- Disclosure of Recording Device You can find dealers all over the Do not attempt repair work without country with the equipment and trained sufficient training, service manuals, Your vehicle may be equipped with one personnel to get you back on the road and the proper tools. You could or more recording devices commonly quickly—and keep you there. referred to as “event data recorders make your vehicle unsafe. Do only (EDR)” or “sensing and diagnostic those tasks you are fully qualified to Your vehicle is a complex machine. modules (SDM)”. If you are involved in do. Failure to comply may result in Anyone attempting repairs on it needs an accident, the device(s) may have personal injury, death, or equipment good mechanical training and the the ability to record vehicle data that and property damage. proper tools. However, all warranty occurred just prior to and/or during the repairs must be performed by an accident. For additional information on WARNING! authorized service facility. If you aren’t your rights associated with the use of Modifying your vehicle can make an experienced mechanic, or don’t this data, contact it unsafe. Some modifications can have the right equipment, please affect your vehicle's electrical sys- leave all repairs to an authorized • the California Department of Motor service facility. They are the ones Vehicles - Licensing Operations tem, stability, or other important functions. Before modifying your best equipped to do the job safely and Division correctly. – or – vehicle, check with your dealer to make sure it can be done safely. To find a dealer near you, give us a • www.dmv.ca.gov Improper modifications may result in call toll-FREE at 1-800-KW-ASSIST death, personal injury, or equipment (1-800-592-7747) 24-7-365 days and property damage. a year or visit us online at www.kenworth.com and click on

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the "dealers" link. When it comes Greenhouse Gas 1 Emission Emissions Related time for service work, your Kenworth Certification Control Components Dealer will need your Vehicle Identifier Identification Number (VIN), see This vehicle may be equipped with VSL, VSLS, Engine Software Vehicle Identification on page 6-4. VSLE, or VSLD parameters that affect components that are identified as the Vehicle Speed Limiter Greenhouse Gas Certified components IRT5, IRTE Engine software Maintenance Manuals (GHG). A label on the door is printed parameters that affect the with codes that identify the components automatic engine shutdown timer If you do decide to do any manufactured on the vehicle that are complex repair work, you’ll need ATS Aerodynamic side skirts part of the GHG certification. The and/or fuel tank fairings the maintenance manuals. Order them codes are translated in the following ARF Aerodynamic roof fairing from your authorized dealer. Please table: ARFR Adjustable height provide your Chassis Serial Number aerodynamic roof fairing when you order, to be sure you get the TGR Gap reducing fairing (tractor correct manuals for your vehicle. Allow to trailer) LRRA, LRRD, Greenhouse Gas (GHG) about four weeks for delivery. There or LRRS Tires will be a charge for these manuals.

Final Chassis Bill of Material

A complete, non-illustrated computer printout listing of the parts used to custom-build your vehicle is available through the dealer from whom you purchased your vehicle.

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Additional Sources of Other Sources 1 Information Installed Equipment - Operator's Another place to learn more about Manuals trucking is from local truck driving schools. Contact one near you to learn Major component suppliers to about courses they offer. Kenworth also supply operation manuals specific to their products. Federal and state agencies such Additional manuals and other pieces as the department of licensing also of literature are included in the glove have information. The Interstate box literature package. Look for Commerce Commission can give information on products such as the you information about regulations engine, driver's seat, transmission, governing transportation across state axles, wheels, tires, ABS/ESP (if lines. applicable) and radio. If you are missing these pieces of literature, ask your Kenworth Dealer for copies.

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CAB AND FRAME steps and handholds provided, not • Use three points of contact 1 chain hooks, quarter fenders, etc. ACCESS (two feet one hand or one foot two hands) to grip the steps or • Do not climb onto and off the deck Safety handholds whenever possible and plate, use steps and grab handle look where you are going. provided. If there is no deck plate, The following cab and frame entry/exit or if proper steps and grab handles • Use even more care when steps procedure recommendations were are not provided, do not climb onto and handholds (or footwear) are prepared with personal safety foremost the area behind the cab. in mind. wet, coated with ice, snow, mud, oil, fuel, or grease. • Keep steps clean. Clean any fuel, WARNING! oil, or grease off the steps before WARNING! entering the cab. Do not jump out of the cab or get into the cab without proper caution. You Do not step on vehicle components WARNING! could slip or fall, possibly suffering a without anti-skid surfaces or use injury or death. You could slip and components not designed for en- Always reinstall the battery compart- fall if the steps are wet or icy, or if try-and-exit use. You could fall and ment cover (step) before entering you step in fuel, oil, or grease. injure or kill yourself if you step onto the cab. Without the battery and a slippery surface. or SCR compartment cover in place, To help avoid personal injury due to you could slip and fall, resulting in • Do not step onto the surface of a slip or fall: possible injury to yourself. a fuel tank. A fuel tank is not a • Always face the vehicle when step. The tank surface can get accessing or leaving the cab or very slippery, and you might not be frame access area. able to prevent a fall. Use only the

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NOTE 1 Any alteration (adding bulkheads, headache racks, tool boxes, etc.) behind the cab or sleeper that af- fects the utilization of grab handles, deck plates or frame access steps installed by Kenworth must comply with Federal Motor Carrier Safety Regulation 399.

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1

Hold handles as you step up on the frame/deck plate.

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1

Remember: Hold handle(s) as you step up. Always maintain three points of contact as you access and leave the deck plate area, hands on the grab handle and your feet on the steps.

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1 Door Lock and Keys Remote Keyless Entry WARNING! (Option) Doors can be locked from the inside by To lessen the chance and/or severity using the lock button. Close the door of personal injury in case of an ac- This vehicle may be equipped with a then push the button down to lock. cident, always lock the doors while Remote Keyless Entry (RKE) system Doors automatically unlock when you driving. Along with using the lap/ that adds security and convenience to open them from inside, and can be shoulder belts properly, locking the your Kenworth truck. The system will locked from the outside with the key doors helps prevent occupants from lock or unlock the driver's door and only. being thrown from the vehicle. Fail- passenger's door with the key fob and ure to comply may result in personal alert you with parking lights when the As standard equipment, two keys are injury or death. selected doors are locked or unlocked. provided for the doors and ignition. The system includes two key fobs that When necessary, additional locks provide secure rolling code technology and keys are provided for storage To lock or unlock the doors from outside the cab: that prevents someone from recording compartments. the entry signal. • Insert the key in the door lock. FCC ID: L2C0031T IC: 3432A-0031T • Turn the key toward the rear door frame to lock; forward to unlock. FCC ID: L2C0032R IC: 3432A-0032R

This device complies with Part 15 of the FCC Rules and with RSS-210 of Industry Canada. Operation is subject to the following two conditions: 1. This device may not cause harmful interference, and

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Operation 2. This device must accept any To Unlock the Driver's Door The range of the RKE system should 1 interference received, including be approximately 30 feet. This will interference that may cause Press the UNLOCK button once. The be reduced if it is operated close to undesired operation. driver's door will unlock and the parking other RF sources such as TV/radio lights will come on for 40 seconds. transmitters and cell towers. NOTE Changes or modifications not ex- To Unlock the Passenger's Door Batteries pressively approved by the party responsible for compliance could Press the UNLOCK button once and To Replace the Battery press again within 5 seconds. The void the user's authority to operate 1. Remove rear cover from key fob. the equipment. The term “IC:” be- passenger door will unlock. fore the radio certification number 2. Remove the battery. To Lock Both Doors only signifies that Industry Canada 3. Install new battery. technical specifications were met. Press the LOCK button. The doors will 4. Reinstall cover. lock and the parking lights will come on for 2 seconds. If the doors are open 5. Synchronize the key fob. they will not lock. The key fob uses one CR2032, NOTE 3V battery. Batteries should last approximately three years, depending If this system is retrofit on vehicles on use. Consistently reduced range built before March 2002, doors may is an indicator that the battery needs lock when open. replacement. Batteries are available at most discount, hardware and drug stores.

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Synchronization 1 See Remote Keyless Entry The key fob may need to be Troubleshooting on page 5-80, synchronized to the vehicle when the for more information. battery is replaced, or when the key fob has not been used for an extended period time.

To Synchronize a Key Fob 1. Hold the key fob near the center gauge area (middle of the instrument panel). 2. Press either the lock or unlock button twice within 2 seconds. ° When the key fob is resynchronized, the doors will lock or unlock. ° If the fob fails to synchronize, it could be programmed to a different vehicle or could have failed.

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GETTING TO YOUR Hood Tilt 1 ENGINE CAUTION If you do not latch your hood se- To open the hood, unlock the hood holddown by unlatching it. Put one Hood Hold Downs curely, it could open during opera- tion and cause vehicle damage. Be hand on the KW emblem, one foot sure to latch the hood securely. on the bumper, and one foot on the The hood is locked in position by two ground. Tilt the hood forward. external latches. These latches serve as hold downs and keep the hood from opening unexpectedly.

Pull up and over to unlatch

WARNING! Hood Latch: pull out to release A hood could hurt someone in the way of its descent. Before lowering the hood, be sure there are no peo- ple or objects in the way.

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Hood Lock 1 NOTE Hood Pivot Lock is automatic. To deactivate the hood lock, push on the rear portion of the cylinder until the magnet attached to the cylinder. This releases the lock mechanism and allows the hood to be closed.

With the lever in the open position, the Hood Lock keeps the hood from closing unexpectedly. If the Hood Lock malfunctions, have it repaired by an Authorized Service Center or 1 Hood Lock Kenworth Dealer.

NOTE • To close the hood, you must first push the lever against the cylinder Device automatically locks when to UNLOCK the Hood Lock. After hood is fully opened! Lock mecha- lowering the hood, fasten the Hood nism must be de-activated in order Latches on each side of the hood. to close hood.

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Hood Safety Cable WARNING! WARNING! 1 If the hood falls, anyone under it If the hood falls, anyone under it could be injured. Always attach the could be injured. Always attach the safety cable and/or hood stop when safety cable and/or hood stop when the hood is in its open position any the hood is in its open position any time anyone gets under the hood for time anyone gets under the hood for any reason. any reason. Attach safety cable here WARNING! CAUTION If the hood is not latched securely, Before lowering the hood, be sure it could open during operation and no objects or people are in the way. cause an accident. Be sure the hood Look on both sides of the engine is latched securely before moving and then yell “HOOD DOWN” prior the vehicle. Failure to comply may to closing the hood. result in personal injury, death, or equipment damage. WARNING! Attached cable If the hood is not latched securely, it could open during operation and cause an accident. Be sure the hood is latched securely before moving the vehicle.

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1 SEATS AND Seat Adjustment Standard Driver's Seat RESTRAINTS WARNING! The standard driver's seat can be adjusted forward and rearward as well Do not adjust the driver's seat while Introduction as up and down. The seat back angle the vehicle is moving. The seat can also be adjusted. These three could move suddenly and unexpect- This section covers the operation movements are each controlled by edly and can cause the driver to and safe use of your Kenworth seats. levers located either beneath or at the lose control of the vehicle. Make all For further information on features sides of the seat. and adjustment of the seat, see the adjustments to the seat while the manufacturer's Service and Operation vehicle is stopped. After adjusting Driver's Seat with Air Suspension Manual included with the vehicle. the seat and before driving off, al- ways check to ensure that the seat WARNING! is firmly latched in position. Failure to comply may result in death, per- Before driving or riding in vehi- sonal injury, equipment or property cle, ensure that there is adequate damage. head clearance at maximum upward travel of seat. Injury may occur if head clearance is not adequate. NOTE Failure to comply may result in per- After adjusting the seat and before sonal injury or death. driving off, always check to ensure that the seat is firmly latched in po- Reclining Seats sition. • Make sure the sleeper curtain is tied back.

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Safety Restraint Belts • Raise the seat all the way up 1 so that the seat will tilt back and Safety belts have proven to be completely clear objects behind the single most effective means you. available for reducing the potential for either injury or death in motor WARNING! vehicle accidents. Therefore, read Do not drive or ride with your seat the following instructions and always back in the reclined position. You observe user warnings pertaining to could be injured by sliding under the safety belts. Unbelted Person in Crash seat belts in a collision. Failure to comply may result in personal injury WARNING! Your vehicle may be equipped or death. Do not drive vehicle without your with a seat belt indicator in the seat belt and your riders belts fas- warning light display above the tened. Unbelted riders could be speedometer/tachometer (“Seat Belt, thrown into the windshield or other Fasten” “Seat Belt, Fasten” on page parts of the cab or could be thrown 3-45). It will turn on if the seat belt is out of the cab. Injuries can be much not fastened and the ignition key is worse when riders are unbelted. Al- turned on. ways fasten your seat belt and be sure anyone riding with you does the same. Failure to comply may result in personal injury or death.

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1 Lap/Shoulder Belt ° Pull shoulder section to make Proper Safety Belt Adjustment sure belt fits snugly across the The combination lap-shoulder belt is Your combination lap-shoulder belt chest. equipped with a locking mechanism. may need adjustment. Adjust safety The system adjusts automatically to a ° The shoulder belt must be belts properly. person's size and movements as long positioned over the shoulder, • The lap belt should be worn as low as the pull on the belt is slow. it must never rest against the and tight on the hips as possible. neck. Hard braking or a collision locks the Make sure any slack is taken up belt. The belt will also lock when ° Belts should fit snugly across by the belt mechanism. driving up or down a steep hill or in a the pelvis and chest. • The shoulder belt should fit snugly sharp curve. Make sure any slack is wound across your body. It should up on the retractor. To fasten the belt: be positioned midway over the To unfasten the belt: shoulder (that is next to the door); 1. Grasp the belt tongue. it should never rest against your • Push in the release button on the neck. 2. Pull belt in a continuous slow buckle. The belt will spring out of motion across your chest and lap. the buckle. 3. Insert belt tongue into buckle on • To release a locked belt, lean back inboard side of seat. to take the body pressure off of 4. Push down until the tongue is the belt. securely locked with an audible • To store a lap-shoulder belt, allow click. Pull belt to check for proper the belt to wind up on the retractor fastening. by guiding the belt tongue until the belt comes to a stop.

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Safety Restraint Belts 1

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 not • You can be injured if your too loose. A loose belt could allow WARNING! belt is buckled too high. In you to slide under it in an accident, Proper seat belt adjustment and use a crash, it would apply force and that could bring the belt up is important to maximize occupant to your abdomen, not your around your abdomen. safety. Failure to wear or adjust pelvic bones. This can result in the safety belt properly may result in • Ensure that you do not twist the internal injuries. death or personal injury. belt in the process of putting it on. • Do not drive with your seat belt A twisted belt will not work as well loose. A too-loose seat belt can to protect you.

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allow you to fall too far forward, Tether Belts 1 possibly causing head and neck WARNING! Tether belts are installed on suspension injuries. You could strike the Do not twist the belt in the process seats. They help secure the seat to the wheel or the windshield. Adjust of putting it on. A twisted belt will floor to restrain it in case of a sudden your belt so that there is no not work as well to protect you. In a stop or an accident. more than 1 in. (25mm) of slack. crash, the full width of the belt would not be protecting you. A twisted belt WARNING! could cut into your body and cause Do not wear the shoulder part of injuries. Straighten the belt before belt under your arm or otherwise out buckling it. If you are unable to wear of position. In a crash your body it without twisting it, have your dealer would move too far forward, increas- or service person repair it as soon ing the chance of head and neck in- as possible. Failure to comply may jury. Also, the belt would apply too result in personal injury or death. much force to the ribs, which are not as strong as your shoulder bones, and could cause you to suffer inter- nal injuries. Wear the shoulder belt over your shoulder (see Safety Re- straint Belts on page 1-23). Failure to comply may result in personal in- jury or death.

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Fixed Tethers Tether Adjustment WARNING! 1 If your Kenworth has been equipped • Make sure that the tether belt is Failure to adjust tether belts properly with fixed length tethers, no manual attached to the cab floor and seat can cause excessive movement of adjustment is required. The same frame. It should be routed through the seat in an accident. Tether belts inspection and replacement guidelines the buckle on each side. should be adjusted so that they are should be used as stated in Safety taut when the seat is in its most up- • Often the attachments are made Restraint System - Inspection on page ward and forward position. Failure using a split-type hook. Make sure 5-57. to comply may result in personal in- both halves of the hook are around jury or death. the anchor bracket. WARNING! Do not remove, modify, or replace • To lengthen the tether, turn the WARNING! the tether belt system with a differ- buckle to a right angle to the ent tether system. A failed or miss- Before driving or riding in a vehi- webbing. Then pull the buckle. ing tether belt could allow the seat cle, ensure that there is adequate To shorten the tether, pull on the base to fully extend in the event of head clearance at maximum upward strap. an accident. Failure to comply may travel of seat. Shorten the tether belt result in personal injury or death. as necessary to provide adequate head clearance. Injury or death may occur if head clearance is not ade- quate.

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Komfort-Latch® Feature 1 4. While seated appropriately, push the "on" button to engage the Your vehicle includes a feature Komfort-Latch. designed to eliminate cinching and provide improved safety and comfort. 5. Learn forward in the seat until you Cinching is the condition where a belt hear a "click." becomes continually tighter around you during a rough, bouncy ride. The 6. Return to normal driving position, need for this feature increases with and the Komfort-Latch maintains rough road conditions, particularly over the preset amount of tension relief. long distances. To disengage the mechanism: To eliminate cinching, simply activate 1. Unbuckle the seat belt the Komfort-Latch feature located on the seat belt webbing at the 2. Press the “OFF” button of the appropriate time: Komfort-Latch or tug on the shoulder strap. Komfort-Latch® 1. Adjust the seat to its proper driving position. WARNING! More information and video tutorials can be found at: 2. Latch the seat belt. Do not set the Komfort-Latch with www.clicktugsnug.com too much slack. Too much slack 3. If available, adjust the seat belt may reduce the effectiveness of the height adjuster to a comfortable seat belt. Failure to comply may re- driving position. sult in death or personal injury.

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During Pregnancy Belt Damage and Repair 1 Pregnant women should always wear Damaged belts in the cab must combination lap/shoulder belts. The be replaced. Belts that have been lap belt portion must be worn snugly stretched, cut, or worn out may not and as low as possible across the protect you in an accident. pelvis. To avoid pressure on the abdomen, the belt must never pass If any seat belt is not working properly, over the waist. Sometimes pregnant see an Authorized Service Center for women worry that in a crash the seat repair or replacement. belt could hurt the baby. But if a woman wears her belt properly, low For further information on seat belts over her pelvis, below her abdomen, and seat belt maintenance, see Safety the belt will not harm the baby, even in Restraint System - Inspection on page a crash. And remember, the best way Pregnant Woman with Belt Properly 5-57. to keep an unborn baby safe is to keep Worn the mother safe.

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Safety Restraint Tips (if equipped) while it is moving should be inspected for any loose 1 should wear a seat belt. (attaching) hardware or damaged • Anyone riding in your vehicle buckles. should wear a seat belt. A • A responsible operator sees to it responsible operator sees to it that everyone in the vehicle rides • If belts show damage to any part that everyone in the vehicle rides or sleeps safely. The operator of assembly, such as webbing, safely and that means with a seat is responsible to inform any bindings, buckles or retractors, belt. passengers or co-drivers how to they must be replaced. properly use the seat belts and • Do not wear a belt over rigid or bunk restraint in the vehicle. • Do not allow safety belts (seat breakable objects in or on your or bunk) to become damaged by clothing, such as eye glasses, • Do not strap in more than one getting caught in door, bunk or pens, keys, etc., as these may person with each belt. seat hardware, or rubbing against cause injury in an accident. sharp objects. • Keep seat belt and bunk restraint • Several layers of heavy clothing buckles free of any obstruction • All belts must be kept clean or the may interfere with proper that may prevent secure locking. retractors may not work properly. positioning of belts and reduce the overall effectiveness of the • Damaged or worn belts in the cab • Never bleach or dye seat or bunk system. or sleeper, subjected to excessive restraint belts: chemicals can stretch forces from normal wear, weaken them. Do, however, keep • Any authorized person sleeping must be replaced. They may them clean by following the care in your vehicle while it is moving not protect you if you have an label on the belts. Let them dry should use the bunk restraint. accident. completely before allowing them to retract or be stowed away. • Any authorized person sitting in • Any belts or restraints that have the sleeper area on the sofa bed been subjected to an accident

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• Make sure the seat belts and Sleeper Bunks and WARNING! 1 bunk restraint of the unoccupied Restraints passenger seat or bunk is fully Be sure the restraint system is wound up on its retractor or For Kenworth cabs equipped with a used when anyone is occupying the is stowed, so that the belt or sleeper, be sure to use the restraint sleeper while the vehicle is moving. restraint tongue is in its properly devices when the vehicle is in motion. In an accident, an unrestrained per- stowed position. This reduces the Your vehicle may have belts and/or a son lying in a sleeper bunk could be possibility of the tongue becoming net restraint system which are over the seriously injured. He or she could a striking object in case of a bunk or cover the opening. be thrown from the bunk. Failure sudden stop. to comply may result in personal If your vehicle has an upper and lower injury, death, equipment or property • Do not modify or disassemble the bunk, the upper bunk can be folded up damage. seat belts or bunk restraint in your out of the way to provide you with more vehicle. They will not be available room in the sleeper. Fold the upper to keep you and your passengers bunk up and insert the metal end of the safe. bunk retaining belts into the buckles. Check to be sure the lower bunk is in • If any seat belt or bunk restraint the down position. is not working properly, see an authorized dealer for repair or replacement.

(02/14) Y53-1203-1D1 1-29 SEATS AND RESTRAINTS

Lower: Upper: 1 NOTE WARNING! WARNING! Per FMCSR 392.60 - Unauthorized Always keep the lower bunk in its Be sure the latch that holds the up- Persons Not to be Transported. down position while the vehicle is per bunk in the folded position is Federal law prohibits the trans- moving. If left open, stored items working properly so the bunk will not portation of persons in commercial could become loose during an acci- fall down. Pull on the bunk to be sure vehicles unless they are specifically dent and strike you, causing serious it is latched securely. If the bunk authorized in writing by the motor damage or injury. falls, you could be injured. Failure to carrier. See the cited FMCSR for a comply may result in personal injury, complete description of the regula- death, equipment or property dam- tion and exemptions. age. • Be sure to stow away all loose WARNING! belongings before you move your vehicle. And do not store objects Be sure no one ever rides in the on the bunks—they could cause upper bunk. That person could be serious damage or injury in an thrown out in an accident and could accident. be very seriously injured. The up- per bunk is not equipped with a re- • Any authorized person sleeping straint system. Do not use the up- in your vehicle while it is moving per bunk while you are moving. Fail- should use the bunk restraint. ure to comply may result in personal injury, death, equipment or property • Any authorized person sitting in damage. the sleeper area on the sofa bed

1-30 Y53-1203-1D1 (02/14) SEATS AND RESTRAINTS

(if equipped) while it is moving • Keep seat belt and bunk restraint • All belts must be kept clean or the 1 should wear a seat belt. buckles free of any obstruction retractors may not work properly. that may prevent secure locking. • A responsible operator sees to it • Never bleach or dye seat or bunk that everyone in the vehicle rides • Damaged or worn belts in the cab restraint belts: chemicals can or sleeps safely -and that means or sleeper, subjected to excessive weaken them. Do, however, keep with a seat belt or bunk restraint. stretch forces from normal wear, them clean by following the care The operator is responsible must be replaced. They may label on the belts. Let them dry to inform any passengers or not protect you if you have an completely before allowing them co-drivers how to properly use the accident. to retract or be stowed away. seat belts and bunk restraint in the vehicle. • Any belts or restraints that have • Make sure the seat belts and been subjected to an accident bunk restraint of the unoccupied • Do not strap in more than one should be inspected for any loose passenger seat or bunk is fully person with each belt. (attaching) hardware or damaged wound up on its retractor or • Do not wear a belt over rigid or buckles. is stowed, so that the belt or restraint tongue is in its properly breakable objects in or on your • If belts show damage to any part clothing, such as eye glasses, stowed position. This reduces the of assembly, such as webbing, possibility of the tongue becoming pens, keys, etc., as these may bindings, buckles or retractors, cause injury in an accident. a striking object in case of a they must be replaced. sudden stop. • Several layers of heavy clothing • Do not allow safety belts (seat • Do not modify or disassemble the may interfere with proper or bunk) to become damaged by positioning of belts and reduce seat belts or bunk restraint in your getting caught in door, bunk or vehicle. They will not be available the overall effectiveness of the seat hardware, or rubbing against system. sharp objects.

(02/14) Y53-1203-1D1 1-31 SEATS AND RESTRAINTS

to keep you and your passengers 1 safe. CAUTION The shelf is not intended for person- • If any seat belt or bunk restraint nel use or storage of items weigh- is not working properly, see an ing over 75 pounds total. The upper authorized Kenworth Dealer for storage shelf is only intended for soft repair or replacement. lightweight items such as bedding, Upper Rear Sleeper Storage duffel bags and clothing. Storage of hard or heavy items may cause shelf Your Kenworth may be equipped with to collapse and/ or fall out in a sud- an upper storage shelf that extends den stop that could cause personal over the lower bunk and across the injury. rear of the sleeper. The following caution applies:

1-32 Y53-1203-1D1 (02/14) START-UP

START-UP Safe Vehicle Operation Regulation 392.7, which states that interstate commercial motor vehicles 1 Introduction For your safety, as well as those are not to be driven unless the driver is around you, be a responsible driver: sure that certain parts and accessories are in working order. The following section covers start-up • If you drink, do not drive. procedures for getting your Kenworth ready for the road. • Do not drive if you are tired, ill, or WARNING! under emotional stress. Do not drive after drinking alcohol or using other substances that may af- Much has gone into the manufacturing fect the senses, including prescrip- of your Kenworth, including advanced tion medications. Your reflexes, per- engineering techniques, rigid quality ceptions, and judgment can be af- control, and demanding inspections. fected by even a small amount of al- These manufacturing processes will cohol or other substances, and can be enhanced by you, the safe driver, cause a serious or even fatal acci- who observes the following: dent. Failure to comply may result in • knows and understands how to death, personal injury, or equipment operate the vehicle and all its and property damage. controls • maintains the vehicle properly • uses driving skills wisely

For more information, refer to Department of Transportation

(02/14) Y53-1203-1D1 1-33 START-UP

Vehicle Loading weight rating (GVWR), or the 1 WARNING! maximum front and rear gross Compare your vehicle's load capacity The use of alcohol, drugs, and cer- axle weight ratings (GAWRs). with the total load you are carrying. If tain medications will seriously im- (Axle weight ratings are listed adjustments need to be made, make pair perception, reactions, and driv- on the driver's door edge.) them, do not drive an overloaded ing ability. These circumstances can vehicle. If you are overloaded or your The following are some definitions of substantially increase the risk of an load has shifted, your vehicle may be weight you should know: accident. Failure to comply may re- unsafe to drive. sult in death, personal injury, equip- GVWR: is the Gross Vehicle Weight ment or property damage. WARNING! Rating. This is the MAXIMUM WEIGHT your vehicle is allowed to Do not exceed the specified load rat- WARNING! carry, including the weight of the empty ing. Overloading can result in loss vehicle, loading platform, occupants, Do not text while driving. Your re- of vehicle control, either by causing fuel, and any load. Never exceed the flexes, perceptions, and judgment component failures or by affecting GVWR of your vehicle. can be affected while texting or vehicle handling. Exceeding load using any other form of mobile mes- ratings can also shorten the service GCW: is the actual combined weight, saging while driving. Failure to com- life of the vehicle. Failure to com- or Gross Combination Weight (GCW), ply may result in death, personal ply may result in personal injury or of your vehicle and its load: vehicle, injury, or equipment and property death. plus trailer(s), plus cargo. damage. • The components of your GAWR: is the Gross Axle Weight vehicle are designed to provide Rating. This is the total weight that satisfactory service if the one axle is designed to transmit to the vehicle is not loaded in excess of either the gross vehicle

1-34 Y53-1203-1D1 (02/14) START-UP ground. You will find this number listed Emergency Equipment Driver's Check List on the driver's door edge. 1 It is good practice to carry an To keep your Kenworth in top shape Load Distribution: be sure any load emergency equipment kit in your and maintain a high level of safety you carry is distributed so that no axle vehicle. One day, if you have a for you, your passengers, and your has to support more than its GAWR. roadside emergency, you will be glad load, make a thorough inspection the following items are with you: every day before you drive. You will WARNING! save maintenance time later, and the • window scraper An unevenly distributed load or a safety checks could help prevent a load too heavy over one axle can af- • snow brush serious accident. Please remember, fect the braking and handling of your too, that Federal Motor Carrier Safety vehicle, which could result in an ac- • container or bag of sand or salt Regulation 392.7 requires a pre-trip inspection and so do commercial cident. Even if your load is under the • emergency light legal limits, be sure it is distributed trucking companies. evenly. Failure to comply may result • triangles You are not expected to become a in personal injury, death, equipment professional mechanic. The purpose or property damage. • small shovel of your inspections is to find anything • first aid kit that might interfere with the safe and efficient transportation of yourself, any • fire extinguisher passengers, and your load. If you do • vehicle recovery hitches (see find something wrong and cannot fix it Vehicle Recovery Guidelines on yourself, have an authorized Kenworth page 2-12 for details). Dealer or qualified mechanic repair your vehicle right away.

(02/14) Y53-1203-1D1 1-35 START-UP

Approaching Your Vehicle Daily Checks 1 The following operations are to be Engine Compartment Checks - Daily performed by the driver. Performing • Check the overall appearance and these checks and following the condition. Are windows, mirrors, 1. Engine Fluid Levels - add more if maintenance procedures in this and lights clean and unobstructed? necessary. manual will help keep your Kenworth ° Engine oil running properly. • Check beneath the vehicle. Are there signs of fuel, oil, or water ° Coolant (check while engine leaks? is cold) • Check for damaged, loose, or ° Power steering fluid level missing parts. Are there parts showing signs of excessive wear 2. Engine Belt - check tension and or lack of lubrication? Have a condition of belts. This is important qualified mechanic examine any to ensure proper air compressor questionable items and repair and engine operation. them without delay. ° Measure the belt tension • Check your load. Is it secured at the longest span of the properly? belt. See Accessory Drive Belts on page 5-92 for further information on checking belt tension.

1-36 Y53-1203-1D1 (02/14) START-UP

to springs or other suspension 6. Hood closed before entering cab. parts. 1 NOTE Is it latched properly? Deflection should be one belt thick- 5. Brake Components - check lines, Chassis and Cab Checks - Daily ness for each foot distance between linkages, chambers, parking and the pulley centers. Before entering the cab and operating service brake operation. the vehicle, check the following If breaks or tears are found, 6. Air System - are there leaks? ° equipment for proper maintenance: the belt should be replaced ° Air Tanks - drain water from before operating the vehicle. 1. Lights - do headlights, turn signals, all air tanks. Make sure the emergency flashers, and exterior 3. Fuel Filter/Water Separator drain cocks are closed. This lamps function and are they clean Draining - check and drain. procedure is also required for and adjusted properly? Depending on the fuel storage air suspension tanks equipped facility, more frequent draining 2. Windows and Mirrors - are they with automatic drain valves. may be required. clean and adjusted properly? ° For further details, see Using 4. Windshield washer reservoir fluid 3. Tires and Wheels - are they the Brake System on page level - fill if necessary. inflated properly? Are all wheel 4-16. cap nuts in place and torqued 5. Battery Cables - check the 7. Steps and Handholds - check properly - tighten if necessary. condition of the battery and for worn surfaces and loose or Check front wheel bearing oil alternator cables for signs of missing fasteners. levels. Inspect all tires and wheels chafing or rubbing. Make sure for damage - correct if found. 8. Fluid Tanks - check underneath that all clamps (straps) holding the the vehicle for signs of fluid leaks. cables are present and in good 4. Suspension - check for loose or If any are found, correct before working order. missing fasteners. Check damage operating the vehicle.

(02/14) Y53-1203-1D1 1-37 START-UP

of turn signals and emergency 9. Fuel Tank Caps - are they secure? ° Is the landing gear up and the 1 lights. handle secured? WARNING! 7. Instruments - check all 11. Check the fifth wheel. Is the instruments. Do not remove a fuel tank cap near kingpin locked? an open flame. Diesel fuel in the 8. Windshield - check operation of presence of an ignition source (such ° Is the sliding fifth wheel windshield wipers and washers. as a cigarette) could cause an ex- locked? 9. Horn - check operation of horn. plosion. A mixture of gasoline or Cab Interior - Daily alcohol with diesel fuel increases 10. Sleeper and Luggage this risk of explosion. Use only the 1. Seat - adjust the seat for easy Compartment - all loose items fuel and/or additives recommended reach of controls. stowed securely. for your engine. Failure to comply 2. Seat Belts - fasten and adjust may result in personal injury, death, ° Is the fire extinguisher fully safety restraint belts. equipment or property damage. See charged? Refueling on page 4-75, for more 3. Sleeper Restraints - check and information. inspect condition. ° Is your road emergency kit complete? 4. Steering Column - adjust for easy 10. Trailer Connections - are they ° Compartments closed? secure and the (Tractor) lines reach. clear? If they are not being used, 5. Mirrors - check and readjust 11. Fuel - check fuel. Is there enough are they stored properly? mirrors if necessary. fuel? ° Is the trailer spare wheel 6. Lights - turn ignition key to the ON 12. Diesel Exhaust Fluid (DEF) - secure and inflated? position and check for warning check level. Is there enough fluid? lights and buzzer. Check operation

1-38 Y53-1203-1D1 (02/14) START-UP

Weekly Operations NOTE • After Engine Warm-up. 1 1. Battery - check battery and The above items (Engine Com- terminals. ° Automatic Transmission partment, Chassis and Cab, and - check fluid level in the Prestart Checks) should be checked 2. Wheel Cap Nuts - are they all automatic transmission oil (if daily, as a minimum. They are in in place and torqued properly - equipped). addition to, not in place, of Fed- tighten if necessary. See Wheel eral Motor Carrier Safety Regula- Cap Nut Torque on page 5-128. tions. These regulations may be 3. Other Controls and Wiring - check purchased by writing to: Superinten- for condition and adjustment. dent of Documents, U.S. Govern- ment Printing Office, Washington, 4. Steering Components - check DC 20402 pitman arm, draglink, and power steering hoses, etc., for loose, broken, or missing parts. 5. Other Engine Compartment Checks. • Check condition and fastening of engine belt, hoses, clamps, and radiator. • Check the air cleaner, muffler, and exhaust pipes. Are they tight and secure?

(02/14) Y53-1203-1D1 1-39

EMERGENCY

WHAT TO DO IF... You Need Roadside Assistance...... 2-3 Low Air Alarm Turns On ...... 2-3 2 Stop Engine Lamp Turns On ...... 2-4 Engine Oil Pressure Lamp Turns On...... 2-4 Check Engine Lamp Turns On ...... 2-5 Engine is Overheating ...... 2-5 Fuse or Relay Blows ...... 2-7 JUMP STARTING VEHICLES Introduction ...... 2-9 VEHICLE RECOVERY AND SPRING BRAKES Introduction ...... 2-12 Vehicle Recovery Instructions ...... 2-12 Recovery Rigging ...... 2-14 Returning Vehicle to Service ...... 2-14 Spring Brakes - Manual Release ...... 2-15 Freeing the Vehicle from Sand, Mud, Snow and Ice 2-17

(02/14) Y53-1203-1D1 2-1

WHAT TO DO IF...

WHAT TO DO IF... Low Air Alarm Turns On • They can assist with jump and pull starts, tires, trailers, fines and 1. Slow down carefully. You Need Roadside permits, chains, towing, hazardous 2. Move a safe distance off the road Assistance clean-up, out of fuel (roadside), and stop. mechanical repairs and preventive 2 maintenance services. 3. Place the transmission in neutral (park with automatic • They have bilingual agents and transmissions, if equipped) and access to a translation service set the parking brake. (Refer Call toll-FREE 1-800-KW-ASSIST to ensure quality assistance to Parking Brake Valve on page (1-800-592-7747) to talk to someone for customers who speak any 3-102 and OPERATING THE at the PACCAR Customer Center. language. TRANSMISSION on page 4-65, • Open 24-7-365 days a year. • They can’t answer your warranty for transmission shifting and questions but can get you in parking brake information.) • They can help you get roadside contact with a Kenworth dealer assistance. 4. Turn OFF the engine. who can. • They have a custom mapping 5. Turn ON the emergency flasher • The PACCAR Customer Center system which locates Kenworth & and use other warning devices to service is FREE even if you don’t Peterbilt Dealers and Independent alert other motorists. drive a Kenworth. Service Providers (ISPs) near you and lists types of services offered, hours of operation and contact information.

(02/14) Y53-1203-1D1 2-3 WHAT TO DO IF...

Stop Engine Lamp Turns On Engine Oil Pressure Lamp WARNING! Turns On If the air pressure falls below 60 psi (414 kPa) the spring brakes 2 may stop the vehicle abruptly, which could cause an accident resulting in personal injury or death. Ob- WARNING! serve the red warning lamps on the 1. Slow down carefully. gauges. If one comes on, do not This should be considered an emer- continue to drive the vehicle until it gency. You should stop the vehi- 2. Move a safe distance off the road has been properly repaired or ser- cle as safely as possible and turn and stop. viced. OFF the ignition. The vehicle must 3. Place the transmission in park be serviced and the problem cor- and set the parking brake. (See If the light and alarm do not turn off rected before driving again. Failure Parking Brake Valve on page at startup, do not try to drive the to do so may cause severe engine or 3-102 and OPERATING THE vehicle until the problem is found and DPF damage, or cause an accident TRANSMISSION on page 4-65, fixed. (Refer to USING THE BRAKE which may result in personal injury for transmission shifting and SYSTEM on page 4-16, for more brake or death. parking brake information.) information.) 4. Turn OFF the engine. If the Stop Engine warning lamp illuminates, it means you have a 5. Turn ON the emergency flasher serious engine system problem. and use other warning devices to alert other motorists. 6. Wait a few minutes to allow oil to drain into the engine oil pan, and

2-4 Y53-1203-1D1 (02/14) WHAT TO DO IF...

then check the oil level. (See Oil Check Engine Lamp Turns Engine is Overheating Level Check on page 5-87, for On 1. Reduce engine speed and safely details on checking oil level.) stop the vehicle. When stopped, 7. Add oil if necessary. If the problem place the transmission in Neutral persists, contact an authorized and set the parking brake. (See 2 Kenworth dealer as soon as Parking Brake Valve on page possible. 3-102 and OPERATING THE Vehicle should be serviced to correct TRANSMISSION on page 4-65, CAUTION the problem but the situation should for transmission shifting and not be considered an emergency. The parking brake information.) Keep Continuing to operate your vehicle vehicle can still be safely driven. with insufficient oil pressure may the engine running. cause severe engine damage or 2. Check to ensure the Oil Pressure cause an accident which may result Gauge reads normal. (See Engine in equipment or property damage. Oil Pressure Gauge, on page 3-62, for further information.) It is important to maintain oil pressure 3. Make sure the engine fan is within acceptable limits. If oil pressure turning by switching the Engine drops below the minimum psi a Red Fan Switch from AUTO to MAN Warning Lamp on the oil pressure (Manual). gauge and the Stop Engine Lamp will come ON. 4. Increase the engine speed to about one-half of full operating speed, or 1,100 to 1,200 rpm, maximum.

(02/14) Y53-1203-1D1 2-5 WHAT TO DO IF...

° Carefully and slowly turn 5. Return the engine speed to normal WARNING! idle after 2 or 3 minutes. the cap one-quarter of a turn or until it reaches the To reduce the chance of death, 6. Monitor the engine temperature. first stop—allowing excess personal injury, fire and/or vehicle 2 After the temperature returns to pressure to escape—push damage from overheated engines, normal, allow the engine to idle down and turn for final never leave the engine idling without 3 to 5 minutes before shutting it removal. an alert driver present. If the en- off. This allows the engine to cool gine should overheat, as indicated gradually and uniformly. See Topping Up on page 5-61, for by the engine coolant temperature 7. If overheating came from instructions on checking and filling the light, immediate action is required severe operating conditions, the coolant expansion tank. to correct the condition. Continued temperature should have cooled unattended operation of the engine, by this time. If it has not, stop WARNING! even for a short time, may result the engine and let it cool before Do not remove the radiator fill cap in serious engine damage or a fire. checking to see if the coolant is while the engine is hot. Scalding Failure to comply may result in per- low. steam and fluid under pressure may sonal injury, death, equipment or escape. You could be badly burned. property damage. Wait until the coolant ° Failure to comply may result in per- temperature is below 122° F sonal injury or death. (50° C). ° Protect face, hands, and arms by covering the cap with a large, thick rag to protect against escaping fluid and steam.

2-6 Y53-1203-1D1 (02/14) WHAT TO DO IF...

Fuse or Relay Blows CAUTION NOTE Fuses, circuit breakers, and relays Before replacing a fuse, turn OFF all If a fuse of the same rating is not are located in the Power Distribution lights and accessories and remove available, a fuse of a lower rating Box to the left of the steering column the ignition key to avoid damaging may be temporarily substituted. You behind the clutch pedal. See Power 2 the electrical system. can also use a fuse from a circuit you Distribution Box on page 5-70. can do temporarily without (for ex- Additional fuses for the alternator, CAUTION ample an accessory circuit or radio). engine electronics and trailer battery Never patch fuses with tin foil or All the electrical circuits have fuses charge circuit may be located in the wire. This may cause serious dam- to protect them from a short circuit or Power Distribution Center (PDC) age elsewhere in the electrical cir- overload. If something electrical on inside the battery box and/ or on the cuit, and it may cause a fire. engine side of the cab firewall. See your chassis stops working, the first Power Distribution Center (PDC) on thing you should check for is a blown page 5-67. CAUTION fuse. If a circuit keeps blowing fuses, have 1. Turn OFF all lights and accessories WARNING! the electrical system inspected for a and remove the ignition key to Do not replace a fuse with a fuse of a short circuit or overload by an au- avoid damaging the electrical higher rating. Doing so may damage thorized Kenworth dealer as soon system. the electrical system and cause a as possible. Failure to do so could 2. Determine from the chart on the fire. Failure to comply may result in cause serious damage to the elec- fuse panel which fuse controls that personal injury, death, equipment or trical system and/or vehicle. component. property damage.

(02/14) Y53-1203-1D1 2-7 WHAT TO DO IF...

3. Remove that fuse and see if it is CAUTION blown. When replacing a failed circuit breaker, always use an approved 2 circuit breaker with a current rat- ing equal to or less than the circuit breaker being replaced. Only use the approved Type II modified re- 1 Blown set circuit breakers. NEVER use a Type I (automatic reset) or Type If a fuse is blown, replace it with a fuse III (manual reset) circuit breaker. A of the same rating. fuse with a current rating equal to or less than the circuit breaker being replaced can also be used.

2-8 Y53-1203-1D1 (02/14) JUMP STARTING VEHICLES JUMP STARTING VEHICLES WARNING! WARNING! Batteries contain acid that can burn Never remove or tamper with battery Introduction and gasses that can explode. Ignor- caps. Ignoring this could allow bat- ing safety procedures may result in tery acid to contact eyes, skin, fab- 2 Because of the various battery personal injury, death, equipment or rics, or painted surfaces. Failure to installations and electrical system property damage. comply may result in personal injury, options, Kenworth does not death, equipment or property dam- recommend that you attempt to WARNING! age. jump start your vehicle. If you have a Never jump start a battery near fire, battery problem, it is best to contact a • Be careful that metal tools (or flames, or electrical sparks. Bat- Kenworth Dealer or a reputable towing any metal in contact with the teries generate explosive gases service. positive terminal) do not contact that could explode. Keep sparks, the positive battery terminal and flame, and lighted cigarettes away However, if your battery is discharged any other metal on the vehicle from batteries. Failure to comply (dead), you may be able to start it at the same time. Remove metal may result in personal injury, death, by using energy from a good battery jewelry and avoid leaning over equipment or property damage. in another vehicle. This is termed the battery. jump starting. Be sure to follow the precautions and instructions below. • If metal jewelry or other metal comes in contact with electrical circuits, a short circuit may occur causing you to be injured, as well as electrical system failure and damage to the vehicle.

(02/14) Y53-1203-1D1 2-9 JUMP STARTING VEHICLES

To Jump Start Your Vehicle Preparing the vehicles: • Improper hook-up of jumper cables or not following these 1. Position the two vehicles together, WARNING! procedures can damage the but do not allow them to touch. The voltage of the booster bat- alternator or cause serious 2. Turn OFF all lights, heater, radio, 2 tery must have a 12 volt rating and damage to both vehicles. the capacity of the booster battery and any other accessory on both vehicles. should not be lower than that of the WARNING! discharged battery. Use of batteries To avoid personal injury and dam- 3. Set the parking brakes: pull out of different voltage or substantially age to the vehicle, heed all warnings the Yellow button located on the different capacity rating may cause and instructions of the jumper cable dash. an explosion. Failure to comply manufacturer. may result in personal injury, death, 4. Shift the transmission into park equipment or property damage. position or neutral for manual • The jumper cables must be long transmissions. (See OPERATING enough so that the vehicles do THE TRANSMISSION on page CAUTION not touch. 4-65 and Parking Brake Valve Applying a higher voltage booster on page 3-102, for transmission battery will cause expensive dam- shifting and parking brake age to sensitive electronic compo- information.) nents, such as relays, and the ra- 5. If either vehicle is equipped with dio. Failure to comply may result in battery disconnects ensure they equipment damage. are in the "OFF" position prior to connecting the two vehicles.

2-10 Y53-1203-1D1 (02/14) JUMP STARTING VEHICLES

Connect the batteries: Remove jumper cables: 6. Start the engine: 1. Attach one end of a jumper cable WARNING! to the positive (+) terminal of the • Start the vehicle that has the discharged (dead) battery. This good battery first. Let it run for 5 When disconnecting jumper cables, will have a large red + or P on the minutes. make sure they do not get caught 2 battery case, post, or clamp. • Then start the vehicle that has the in any moving parts in the engine compartment. You could be injured. 2. Attach the other end of the same discharged (dead) battery. If the engine fails to start, do not cable to the positive (+) terminal • Reverse the above procedure of the good (booster) battery. continue to crank the starter but contact the nearest authorized exactly when removing the jumper 3. Attach the remaining jumper cable Kenworth Dealer. cables. With engine running, FIRST to the negative (-) terminal disconnect jumper cables from (black or N) of the good battery. both vehicles in the exact reverse order (Steps 4-1), making sure 4. Attach the other end of the to first remove the negative negative cable to a bare metal part cable from the vehicle with the not bolted to the engine block. discharged battery. IMPORTANT: Always connect positive (+) to positive (+) and negative (-) to negative (-). 5. If either vehicle is equipped with battery disconnects, ensure that they are in the "ON" position.

(02/14) Y53-1203-1D1 2-11 VEHICLE RECOVERY AND SPRING BRAKES

VEHICLE RECOVERY Vehicle Recovery AND SPRING BRAKES Instructions CAUTION Remove the driveline and axle Introduction Refer to the instructions below when shafts or lift the driving wheels off 2 towing your vehicle: the ground before towing the ve- Your Kenworth may be equipped with a • Use proper towing equipment to hicle. See Driver Controlled Main Recovery Device(s) designed for short prevent damage to the vehicle. Differential Lock on page 4-55. All distance recovery purposes only. Use lubricating and clutch application only the original Kenworth recovery CAUTION oil pressure is provided by an en- device(s) and the instructions below. gine-driven pump, which will not If your vehicle does not have the Connect only to the Recovery De- work when the engine is stopped. proper device contact your authorized vice(s), as described on the follow- You could seriously damage your Kenworth Dealer. ing pages. Do not attach to bumpers vehicle by towing it with the driveline or brackets. Use only equipment de- connected and the drive wheels on signed for this purpose. Connec- the ground. tions to other structural parts could damage the vehicle.

2-12 Y53-1203-1D1 (02/14) VEHICLE RECOVERY AND SPRING BRAKES

• Do not tow vehicles at speeds in Technology & Maintenance Council CAUTION excess of 55 mph (90 km/h). 950 N. Glebe Road When vehicles are towed, either by (703) 838-1763 wrecker or piggy-back, the lubricant NOTE Arlington, VA 22203 Email: [email protected] in the top front of the drive axle will For additional information concern- www.trucking.org 2 drain to the rear. This will leave the ing heavy duty truck recovery, see top components dry. The resulting Technology & Maintenance Council friction may seriously damage them. (TMC). Always remove the main driveshaft and axle shafts before towing your • Recommended Practice #602–A vehicle. — “Front Towing Devices For Trucks and Tractors.” • See the following references: • Recommended Practice #602–B ° Recovery Rigging on page — “Recovery Attachment Points 2-14. For Trucks, Tractors, and ° Driver Controlled Main Combination Vehicles." Differential Lock on page • Recommended Practice #626 4-55. — “Heavy Duty Truck Towing • Use a safety chain system. Procedures.” • Disconnect driveline. Copies of these can be obtained from the following address: • Follow state/provincial and local laws that apply to vehicles in tow.

(02/14) Y53-1203-1D1 2-13 VEHICLE RECOVERY AND SPRING BRAKES

Recovery Rigging • Never loop a single chain or cable cable no closer than 6 ft. from the through both hitches (3). vehicle (2). To connect to the Kenworth, follow the suggested rigging methods below. • Use a spreader or equalizer bar to distribute the load on both hitches • Use a double chain or cable setup 2 (1). that distributes the load equally to both hitches. See 1 or 2 in the • If no spreader bar is available, following illustration. connect the main tow chain or

1. Spreader Bar or Equalizer 2. Minimum 6 FT. 3. NEVER USE SINGLE CHAIN OR CABLE Preferred Acceptable LOOPED THROUGH TOW DEVICES Returning Vehicle to Service will thoroughly circulate the lubricant After adding the specified type and through the assembly. Your vehicle may have lost lubricant amount of lubricant, drive the vehicle. while being towed. To prevent It should be unloaded. Drive 1 to damage, check the oil level and add 2 miles (1.5 to 3 km) at a speed oil if necessary. lower than 25 mph (40 km/h). This

2-14 Y53-1203-1D1 (02/14) VEHICLE RECOVERY AND SPRING BRAKES

Spring Brakes - Manual This could happen if the system air Release pressure does not reach operating WARNING! pressure because your engine or Do not operate a vehicle when the In order to tow a vehicle, if there is compressor is not working properly. spring brakes have been manu- insufficient air to release the parking You will have to release the spring ally released. Driving a vehicle 2 brake, the spring brakes can be brakes at the spring brake chambers. after its spring brakes are manu- manually released. ally released is extremely danger- WARNING! ous. The brakes may not func- WARNING! Do not disassemble a spring brake tion. Failure to comply may result Do not drive vehicle with malfunc- chamber. These chambers con- in personal injury, death, equip- tioning brakes. If one of the brake tain a powerful spring that is com- ment or property damage. circuits should become inoperative, pressed. Sudden release of this braking distances will increase sub- spring may result in personal injury WARNING! stantially and handling characteris- or death. tics while braking will be affected. Releasing the spring brakes on You could lose control of your vehi- an unsecured vehicle could lead cle or cause an accident. Have it to an accident. The vehicle could towed to the nearest dealer or qual- roll, which may result in per- ified repair facility for repair. Fail- sonal injury, death, equipment or ure to comply may result in personal property damage. Always secure injury, death, equipment or property the vehicle with wheel chocks, damage. chains, or other safe means to prevent rolling before manually releasing the spring brakes. You may sometimes have to release your vehicle's spring brakes by hand.

(02/14) Y53-1203-1D1 2-15 VEHICLE RECOVERY AND SPRING BRAKES

To move a vehicle immobilized by 4. Insert the release stud 6. With a wrench, through the opening in turn the release stud the spring brakes due to loss of the spring chamber assembly nut until the air pressure in the brake system, where the cap was compression spring is perform the following procedure: removed. Insert it into 90-95 percent caged. 2 the pressure plate. Turn While doing this, check 1. Remove the cap from the release stud 1/4 to make sure the push the spring chamber. turn clockwise in the rod (adapter push pressure plate. This rod or service push secures the cross pin rod) is retracting. Do into the cross pin area of not over-torque the the pressure plate and release stud assembly. locks it into the manual (S-Cam type maximum: release position. 50 lb-ft, Wedge type 2. Remove the release maximum: 30 lb-ft). stud assembly from the 5. Assemble the release The spring brake is now side pocket, and remove stud washer and nut on mechanically released. the release nut and the release stud. washer from the release stud.

3. Slide out the release stud.

2-16 Y53-1203-1D1 (02/14) VEHICLE RECOVERY AND SPRING BRAKES

Freeing the Vehicle from Be sure that transmission is fully WARNING! • Sand, Mud, Snow and Ice engaged in gear before releasing Do not spin the wheels faster than the clutch pedal (manual only). If the vehicle gets stuck in sand, 35 mph (55 km/h). Spinning a tire at mud, snow, or ice: speedometer readings faster than • Do not shift into reverse while the 2 35 mph (55 km/h) can be dangerous. vehicle is moving. Move the gearshift lever or • Tires can explode from spinning too selector from First to Reverse. • Do not permit the vehicle to be fast. Under some conditions, a tire towed for long distances without may be spinning at a speed twice • Apply light pressure on the removing the driveshaft. accelerator pedal while the that shown on the speedometer. transmission is in gear. Any resulting tire explosion could cause injury or death to a bystander • Remove your foot from the or passenger, as well as exten- accelerator while shifting. sive vehicle damage: including tire, transmission and/or rear axle mal- Do not race the engine. • function. • For best traction and safety, avoid spinning the wheels. Comply with the following instructions to avoid transmission damage: • Always start vehicle in motion with the shift lever in first gear.

(02/14) Y53-1203-1D1 2-17 VEHICLE RECOVERY AND SPRING BRAKES

Tire Chains

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

2 CAUTION Chains on the tires of only one tan- dem axle can damage the driveline U-joints and the interaxle differen- tial. Repairs could be costly and time-consuming. Failure to comply may result in equipment damage.

2-18 Y53-1203-1D1 (02/14) CONTROLS

ACCESSORIES Introduction ...... 3-5 Radio (Option) ...... 3-6 Cigarette Lighter and Ashtray (Option) ...... 3-6 Clock ...... 3-7 Cab Storage ...... 3-10 3 HEATING AND AIR CONDITIONING Introduction ...... 3-12 Precautions ...... 3-13 Cab Controls ...... 3-16 Sleeper Heater - A/C Controls (option) ...... 3-19 AUDIBLE ALERTS Introduction ...... 3-21 INDICATORS Introduction ...... 3-27

(02/14) Y53-1203-1D1 3-1 CONTROLS

GAUGES AND DISPLAYS Introduction ...... 3-49 Multi-Function Display (Option) ...... 3-72 MULTI-FUNCTION DISPLAY Introduction ...... 3-77 3 Alarms, Warning Tones and Visual Indicator Lights 3-77 Warning and Information Alert Screens . . . . . 3-78 Wingman® ACB Warning Tone / Alert Screens . . 3-82 Multi-Function Display ...... 3-84 SWITCHES Introduction ...... 3-95 STEERING COLUMN Introduction ...... 3-112 Turn Signal/High Beam Switch ...... 3-112 Windshield Wipers/Washer...... 3-114 Trailer Brake Hand Valve...... 3-116 Stop/Turn Signal Lamp Operation ...... 3-116

3-2 Y53-1203-1D1 (02/14) CONTROLS

Adjustable Tilt/Telescoping Column ...... 3-117 Horn ...... 3-118 SmartWheel Multiplex Control System ...... 3-119 MIRRORS Introduction ...... 3-124 Power Mirror Switch ...... 3-124 Mirror Heat Button ...... 3-126 3

(02/14) Y53-1203-1D1 3-3

ACCESSORIES ACCESSORIES

Introduction

3

1. Radio 3. Ashtray (Option) 2. Glove Box 4. Cigarette Lighter (Option)

(02/14) Y53-1203-1D1 3-5 ACCESSORIES

Radio (Option) Cigarette Lighter and Ashtray (Option) WARNING! As an option, your vehicle has either Do not place paper or other com- an AM/FM Stereo Receiver or AM/FM NOTE bustible substances in an ashtray, it Stereo with CD. The cigarette lighter will operate with could cause a fire. Keep all burnable For instructions on how to operate your the ignition key in either the OFF, materials, besides smoking materi- particular radio, see the manufacturer's ACC (accessory), or ON position. als, out of the ashtray. Failure to Radio Operating Instructions. comply may result in personal injury, death, equipment or property dam- 3 To operate, push in on the knob end age. of the lighter. After a few moments, the lighter will automatically pop out, glowing hot and ready to use. After WARNING! use, insert the lighter back into the Do not exceed the voltage/amper- socket without pushing all the way in. age capacity of the cigarette lighter. It could result in a fire. Follow all The socket of the cigarette lighter may warnings and instructions in the op- be used to operate 12 volt, 15 ampere erator's manual for the appliance appliances, such as a hand spotlight you are using. Failure to comply or small vacuum cleaner. may result in personal injury, death, equipment or property damage.

3-6 Y53-1203-1D1 (02/14) ACCESSORIES

Clock • Depress right hand button to rotate Dash and Sleeper Clock clock hands clockwise. Analog Clock - Dash • Depress left hand button to rotate clock hands counter clockwise. • Continue to depress buttons for faster movement. 3

1 Counter Clockwise 2 Clockwise

Digital Clock - Sleeper

Quick Operating Instructions for Kenworth Digital Clock

Mode Display Functions Buttons to Use Clock Current time (flashing colon) • set time +, - (note PM in upper left corner) • silence alarm (hold down to change faster) Select or On/Off Date Date (MM/DD) • set date - for month, + for day Alarm Alarm setting (alarm symbol) • set alarm +, - (steady symbol = alarm On • turn alarm on/off On/Off Elapsed Elapsed time (ET displayed) • start & stop timer On/Off Time (steady ET = timer On) • reset elapsed time + or - when timer is off Auxiliary AUX in lower left corner • not used

(02/14) Y53-1203-1D1 3-7 ACCESSORIES

Clock Date Alarm

Set the time as follows: Press and Enter the date mode by pressing the Press the “Select” button twice to hold down either the “+” or “-” button to “Select” button once. Set the current switch to the alarm mode, which is change the time to the proper setting month using the “-” button, and the indicated by the alarm symbol on the (note “PM” indicator in upper left corner date by using the “+” button (the left side of the display. The alarm is of display). After holding down either display will automatically return to the set in the same manner as the time button for three seconds, the rate of clock mode after a few seconds). (again, be careful to note the status of change will increase from slow to fast. the “PM” indicator). Use the “On/Off” 3 The clock will start keeping time as button to turn the alarm on and off soon as either button is released. A while in this mode. The alarm symbol flashing display indicates that power flashes when the alarm is off, and turns has been interrupted to the clock, and to steady when the alarm is turned on. all functions will need to be reset. When the alarm is turned on, the alarm The clock mode is the default display, symbol is displayed while in the clock which means the display will return to mode. To silence the alarm, press this mode after a few seconds from either the “Select” or “On/Off” button. every other mode except from elapsed time mode.

3-8 Y53-1203-1D1 (02/14) ACCESSORIES

Elapsed Time Auxiliary Display

Press the “Select” button three times This mode has no function at this time The display is always on. The display to switch to the elapsed time mode, and should be ignored. can be set to four levels of brightness which is indicated by “ET” in the lower by pressing both the “+” and “-” buttons left corner of the display. Similar to at the same time. the alarm symbol, the “ET” flashes when the elapsed timer is turned off, and is steady while the timer is turned on. Turn the elapsed timer on and off 3 by using the “On/Off” button. When the elapsed timer is on, “ET” is also displayed while in the clock mode. To reset the elapsed time, press either the “+” or the “-” button while the timer is off. Unlike the other modes, the display will stay in elapsed time mode until the “Select” button is pressed.

(02/14) Y53-1203-1D1 3-9 ACCESSORIES

Cab Storage Interior Compartments Ashtray Glove Box You can choose from a variety of To open, pull on the upper side of A glove box is provided to store interior storage options to store your the panel. To close, push against the important documents, the vehicle personal supplies or small tools: panel. literature set (including this Operator's Manual) and other related materials. - center console WARNING! Do not place paper or other com- WARNING! - map pocket 3 bustible substances in an ashtray, it Do not drive with the glove box open, - overhead storage compartments could cause a fire. Keep all burnable it can be dangerous. In an accident materials, besides smoking materi- or sudden stop, you or a passenger - records holder, behind seat als, out of the ashtray. Failure to could be thrown against the cover comply may result in personal injury, and be injured. To reduce the risk WARNING! death, equipment or property dam- of personal injury during an accident age. Do not carry loose objects in your or sudden stop, keep the glove box cab, it can be dangerous. In a sud- closed when the vehicle is in motion. den stop, or even going over a bump in the road, they could fly through the air and strike you or a passenger. You could be injured or even killed. Secure all loose objects in the cab before moving the vehicle. Carry any heavy objects such as luggage in the exterior storage compartment and close it securely.

3-10 Y53-1203-1D1 (02/14) ACCESSORIES

Appliances

If your Kenworth is equipped with a television, refrigerator or other appliance, be sure they are compatible with your vehicle's electrical system. And secure them in the cab so they cannot come loose in a sudden stop.

WARNING! 3 In a sudden stop or collision a heavy object in your cab could strike you or anyone with you. You could be in- jured or even killed. Secure any ap- pliance (such as a radio, refrigerator or TV) you add to your cab.

(02/14) Y53-1203-1D1 3-11 HEATING AND AIR CONDITIONING HEATING AND AIR CONDITIONING

Introduction

3

1. Heating and Air Conditioning Controls

3-12 Y53-1203-1D1 (02/14) HEATING AND AIR CONDITIONING

The cab heater and A/C controls are Precautions located together in the center of the WARNING! dash just to the right of the steering WARNING! The air conditioning system is un- column. Additionally, the sleeper Do not drive with visibility reduced der pressure. If not serviced prop- compartment may also contain a by fog, condensation, or frost on the erly, it could explode and may result separate heater and A/C controls windshield. Your view may be ob- in personal injury, death or property located on the driver’s side sleeper scured, which may result in personal damage to your vehicle. Any servic- cabinet. Each control maintains injury, death, equipment or property ing that requires depressurizing and 3 separate temperature settings. damage. For clear visibility and safe recharging the air conditioning sys- driving it is extremely important for tem must be conducted by a quali- you to follow the instructions per- fied technician with the right facilities taining to the function and use of to do the job. the ventilation/heating and defog- ging/defrosting system. If in doubt, WARNING! consult your dealer. Maximum heat- Excessive heat may cause the pres- ing output and fast defrosting can be surized components of the air con- obtained only after the engine has ditioning system to explode. Never reached operating temperature. weld, solder, steam clean, or use a blow torch near any part of the air conditioning system. Failure to comply may result in personal injury, death, equipment or property dam- age.

(02/14) Y53-1203-1D1 3-13 HEATING AND AIR CONDITIONING

If a refrigerant leak develops in • WARNING! WARNING! the presence of excessive heat or an open flame, hazardous Exhaust fumes from the engine Never idle your vehicle for prolonged gases may be generated. contain carbon monoxide, a col- periods of time if you sense that ex- These gases may cause orless and odorless gas. Do not haust fumes are entering the cab unconsciousness or death. breathe the engine exhaust gas. or sleeper. Investigate the cause If you become aware of a A poorly maintained, damaged or of the fumes and correct it as soon refrigerant leak on your vehicle corroded exhaust system can allow as possible. If the vehicle must be 3 have your system serviced carbon monoxide to enter the cab driven under these conditions, drive immediately and observe the or sleeper. Entry of carbon monox- only with the windows open. Failure following precautions: ide into the cab or sleeper is also to repair the source of the exhaust possible from other vehicles nearby. fumes may result in personal injury, ° Stay away from the hot Failure to properly maintain your ve- death, equipment or property dam- engine until the exhaust hicle could cause carbon monoxide age. manifold has cooled. to enter the cab or sleeper, resulting in illness or death. ° Do not permit any open NOTE flame in the area. Even a Keep the engine exhaust system match or a cigarette lighter and the vehicles cab/sleeper venti- may generate a hazardous lation system properly maintained. quantity of poisonous gas. ° Do not smoke in the area. It is recommended that the vehicles Inhaling gaseous refrigerant exhaust system and cab/sleeper be through a cigarette may inspected: cause violent illness.

3-14 Y53-1203-1D1 (02/14) HEATING AND AIR CONDITIONING

• By a competent technician every NOTE 15,000 miles CAUTION Do not stay in the vehicle with the If you are required to idle your ve- • Whenever a change is noticed in engine running or idling for more hicle for long periods of time, install the sound of the exhaust system than 10 minutes with the vehicle's an auxiliary heater or automatic idle control. These auxiliary devices can • Whenever the exhaust system, Heater and A/C ventilation system reduce fuel consumption and save underbody, or cab or sleeper is in RECIRC or at LOW FAN SPEED. you money. damaged Even with the ventilation system on, running the engine while parked or 3 NOTE stopped for prolonged periods of NOTE time is not recommended. To allow for proper operation of the If you are parked next to idling ve- vehicle ventilation system, keep the hicles, move your vehicle or do not When idling for short periods of time: inlet grille at the base of the wind- stay in your vehicle for prolonged pe- shield clear of snow, ice, leaves and • Set the heating or cooling system riods of time. other obstructions at all times. to Heat or A/C • Set the fan to Medium or High speed • Set the controls to FRESH AIR

(02/14) Y53-1203-1D1 3-15 HEATING AND AIR CONDITIONING

Cab Controls

3

1 Fan Control Dial 9 Air Conditioner, Green 2 Temperature Control Dial Indicator Light (On) 3 Dash 10 Fresh Air/Recirculate, 4 Dash & Floor Amber Indicator Light (On) 5 Floor 11 Sleeper Enable Green 6 Air Flow Control Dial Indicator Light (On) 7 Floor & Defrost 8 Defrost

3-16 Y53-1203-1D1 (02/14) HEATING AND AIR CONDITIONING

What Each Control Does Temperature Control Dial NOTE Fan Control Dial Turn this dial clockwise for heat, On the Cab Control Unit, the Sleeper Turning this dial clockwise from the OFF counterclockwise for cool. Enable Switch must be pressed position turns the fan ON and increases the to turn ON power to the Sleeper fan speed. Control Unit. If air conditioning is Air Conditioner Switch Air Flow Control Dial requested in the sleeper, the A/C This dial directs the air flow through 5 primary This switch turns the air conditioner On and Switch on the Cab Control Unit and 3 sets of vents: Off. the fan in the Cab Heater and A/C Dash Vents Unit will be turned ON low (if it was NOTE OFF), automatically. Dash and Floor Vents Fan Control Dial must also be in the Floor Vents ON position for A/C to be on. Fresh Air/Recirculation Switch This switch controls the source of the air Floor and *Defrost Vents Sleeper Enable Switch flowing into the heater and air conditioner unit. This switch turns ON and OFF the sleeper *Defrost Vents Fresh Air mode = Air comes from control panel. Green light in center of dial *Fresh air and air conditioning are outside the cab. comes on when switch is enabled. automatically turned ON. As the dial is turned away from a primary position, the system Recirculation mode = Air comes directs an increasing amount of air flow from inside the cab. towards the next primary position.

(02/14) Y53-1203-1D1 3-17 HEATING AND AIR CONDITIONING

How to Use the System b) To cool using air conditioning: 3.) Adjust the Temperature Control Dial clockwise until the air temperature feels 1.) Turn ON the comfortable. The engine must be running for the Air Conditioning heater and air conditioner to generate Switch. To Dehumidify hot and cold air. 2.) Push the Fresh 1.) Push the Fresh to the Fresh Air to the Fresh Air Air/Recirculate Air/Recirculate To Cool mode. mode. Switch Switch There are 2 ways to cool: 3 3.) Turn ON the to the desired fan 2.) Turn ON the Air Conditioning Fan Control Dial speed. Switch. a) using cool outside air 4.) Turn the Air to Dash Vents. Flow Control Dial 3.) Turn ON the to the desired fan b) using air conditioning Fan Control Dial speed.

a) Outside air is cooler than the inside air: 5.) Adjust the Temperature Control Dial 4.) Adjust the Temperature Control Dial until counterclockwise until the air temperature 1.) Push the Fresh the air temperature feels comfortable. to the Fresh Air feels comfortable. Air/Recirculation mode. Switch To Heat The air conditioner removes moisture from the air while the heater heats the 2.) Turn ON the to the desired fan 1.) Turn ON the to the desired fan air. Fan Control Dial speed. Fan Control Dial speed. To Defog and Defrost the Windshield 3.) Turn the Air to Dash Vents. 2.) Turn the Air Flow Control Dial to Floor Vents. Flow Control Dial 1.) Turn the Fan clockwise to the Control Dial highest fan speed.

3-18 Y53-1203-1D1 (02/14) HEATING AND AIR CONDITIONING

Sleeper Heater - A/C 2.) Turn the Air to Defrost Vents. Flow Control Dial Controls (option)

Fresh air and air conditioning are NOTE automatically turned ON. On the Cab Control Unit, the Sleeper 3.) Adjust the Temperature Control Dial Enable Switch must be pressed to clockwise to full heat. turn ON power to the Sleeper Con- trol Unit. In addition, if air condition- Aerocab & Studio Sleeper Controls CAUTION ing is requested in the sleeper, the 3 During extreme cold weather, do not Air Conditioner Switch on the Cab Fan Control (1) blow hot defroster air onto cold wind- Control Unit will be turned ON and shields. This could crack the glass. the fan in the Cab Heater and Air Turning this dial controls fan speed. Turn the Air Flow Control Dial to De- Conditioning Unit will be turned ON Heat & A/C Control (2) (Aerocab & frost and adjust the fan speed ac- low (if it was OFF), automatically. Studio): cordingly while the engine warms. If the engine is already warm, move Allows you to select between, Max the Temperature Control Dial to cool, Heat, Max A/C, and Auto Heat - A/C. then gradually increase the temper- ature when you see that the wind- • Max Heat: Fully opens the valve shield is starting to warm up. Failure that allows hot engine coolant to to comply may result in equipment flow through the heater core. damage. Modular Sleeper Controls • Max A/C: Completely closes the engine coolant valve.

(02/14) Y53-1203-1D1 3-19 HEATING AND AIR CONDITIONING

• Auto Heat - A/C: Works together Temperature Control (3): NOTE with the Temperature Control (3) to maintain the temperature The temperature for the sleeper is The sensor is located on the sleeper automatically. controlled automatically. heater - A/C control panel and mea- sures the sleeper air temperature Heat & A/C Control (2) (Modular): Set the Heat & A/C Control to: at the panel. There will be a time delay between Temperature Control Allows you to select between Heat or • AutoHeat - A/C (for Aerocabs & adjustment and sleeper air tempera- 3 A/C. Studios) ture change. Also, be careful of any heat source which could affect the Heat: The fan cycles on/off to Heat or A/C (for Modulars) • • air temperature by the sensor. Avoid regulate temperature based on the hanging items (e.g. shirt, jacket, Temperature Control (3) setting. Adjust the Temperature Control and etc.) which could block the air flow a sensor will then control the sleeper to the sensor. • A/C: A refrigerant solenoid valve temperature. The Temperature Control cycles open/closed to regulate is not keyed to specific temperatures. the temperature based on the Turning counterclockwise means Temperature Control (3) setting. cooler than it is now. Clockwise means warmer than it is now. Once the desired temperature is reached, the system will maintain it automatically.

3-20 Y53-1203-1D1 (02/14) AUDIBLE ALERTS AUDIBLE ALERTS

Introduction

3

(02/14) Y53-1203-1D1 3-21 AUDIBLE ALERTS

Your vehicle's dash and instrumentation uses various WARNING! methods to indicate to you the status Do not ignore any type of tone or of various systems, or that one or lights. These signals tell you that more of your vehicle's systems may something is malfunctioning on your be malfunctioning. The method vehicle and provide you an indi- to communicate or alert you of a cation of what system is affected. particular condition is by: It could be a failure of an impor- 3 tant system, such as the brakes, • Audible alarm tone which could lead to an accident and • Audible warning tone may result in personal injury, death, equipment or property damage. • Indicator light(s) Please remember that each Kenworth In some cases, you may have both an is custom made. Your instrument alarm or warning tone accompanied by panel may not look exactly like the one an indicator light(s). in the illustration.

3-22 Y53-1203-1D1 (02/14) AUDIBLE ALERTS

Table 1 Indicator Symbols

Symbol Name Symbol Color Standard Option Page 1. Brakes, Air Pressure in Primary Air Red ● on page 3-24 System is Low

2. Brakes, Air Pressure in Secondary Air Red ● on page 3-24 System is Low 3 3. Engine, Low Coolant Level Yellow ● on page 3-41

4. Engine, Oil Pressure Yellow ● on page 3-41

5. Engine, Stop Engine Red ● on page 3-42

6. Fifth Wheel Slide Red ● on page 3-26

7. Park Brake Red ● on page 3-45

(02/14) Y53-1203-1D1 3-23 AUDIBLE ALERTS

The instrument cluster generates alert A. Alarm Tone screens and three distinct audible The Alarm tone is activated under the tones or sounds. • Series of clear bell tones, repeated following conditions. at a rate of 100 tones per minute. A. Alarm tone Stop Engine Alarm • Indicates that something is B. Warning tone seriously wrong with the vehicle that should be considered an 3 C. Alert screens Multi-Function emergency. Display WARNING! This alarm tone is active when the D. Turn signal/hazard sound Do not ignore an alarm tone. You Stop Engine light is active (turned should visually determine what sys- on by the engine). Examples of the The alert screens, tones and sound tem is affected by glancing at your conditions that would cause the alarm are described below. gauges and indicator lights, then be- to sound are low oil pressure or high gin to slow your vehicle down to a engine coolant temperature. stop as safely as possible. Turn off your ignition and take appropri- Primary or Secondary Low Air ate action. The vehicle must be ser- Warning Alarm viced and the problem corrected be- fore driving the vehicle again. Fail- ure to obey an Alarm tone may result in personal injury, death, equipment or property damage. This alarm tone is active when either the Primary or Secondary Low Air

3-24 Y53-1203-1D1 (02/14) AUDIBLE ALERTS

Warning lamp is active and the engine for approximately 4.5 minutes and the B. Warning tone (similar to the RPM is above 300. This occurs when park brake warning light will blink. Alarm tone) the primary or secondary air pressure drops below 65 psi, and stays active • Series of clear bell tones, repeated until it increases above 66.5 psi. The at a rate of 60 tones per minute. tone is only active when the engine is • Sounds when a problem exists, running (RPM above 300). but the vehicle can still be safely driven. Service the vehicle to Engine Oil Pressure Alarm correct the problem but the 3 situation should not be considered an emergency.

This alarm tone is active when the CAUTION Engine Oil Pressure light is active If a warning tone sounds, determine (turned on by the engine). the system affected by glancing at Park Brake Alarm your indicator lights. The warning tone indicates a problem exists, but the vehicle can still be safely driven. Service the vehicle at your earliest convenience to correct the problem, but the situation should not be con- sidered an emergency. With the park brake not set and the door open, the Alarm tone is activated The Warning tone is activated under the following conditions.

(02/14) Y53-1203-1D1 3-25 AUDIBLE ALERTS

Low Coolant Level Warning During the Instrumentation Power On Self Test (POST) - Two bell tones sound when the ignition is turned on.

All gauges, indicators and warning lights will turn on for a power-on Light is active (turned on by the self test. All gauge pointers will engine), and engine is running (RPM momentarily move to the maximum above 300). 3 limit, stay there for a short time, then move back to the "zero" position. Additionally, all indicator and warning lights will turn on together, then off together. Several different audible warnings will also be activated twice without break.

Fifth Wheel Slide Warning

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

3-26 Y53-1203-1D1 (02/14) INDICATORS INDICATORS

Introduction

3

Numbered items in illustration are standard or common indicators.

(02/14) Y53-1203-1D1 3-27 INDICATORS

NOTE In some cases, you may have both an Your vehicle includes both standard alarm or warning tone accompanied by and optional gauges in the instru- an indicator light(s). ment cluster display. Some optional warning light indicators will be inop- WARNING! erable unless that option was speci- Do not ignore any type of tone or fied with the vehicle. lights. These signals tell you that 3 something is malfunctioning on your Your vehicle's dash and vehicle and provide you an indi- instrumentation uses various cation of what system is affected. methods to indicate to you the status It could be a failure of an impor- of various systems, or that one or tant system, such as the brakes, more of your vehicles systems may which could lead to an accident and be malfunctioning. The method may result in personal injury, death, to communicate or alert you of a equipment or property damage. particular condition is by: • Audible alarm tone Please remember that each Kenworth is custom made. Your instrument • Audible warning tone panel may not look exactly like the one in the illustration. • Indicator light(s)

3-28 Y53-1203-1D1 (02/14) INDICATORS

Table 2 Warning Light/Indicator Symbols

Symbol Name Symbol Color Std Opt Page

1. Anti-Lock Brake System (ABS) Yellow ● on page 3-34

2. Anti-Lock Brake System (ABS), Trailer Yellow ● on page 3-34 3

3. Axle, Traction Control Yellow ● on page 3-36

4. Diesel Particulate Filter (DPF) Yellow ● on page 3-37

5. Dump Truck, Body Up Red ● on page 3-37

6. Engine BrakeSaver or Transmission Retarder Yellow ● on page 3-37

7. Engine, Check Engine Yellow ● on page 3-38

(02/14) Y53-1203-1D1 3-29 INDICATORS

Symbol Name Symbol Color Std Opt Page

8. Engine, Ether Start Green ● on page 3-38

9. Hill Hold Yellow ● on page 3-39

● 3 10. Lane Departure Warning (LDW) Yellow on page 3-39

11. Service Transmission Yellow ● on page 3-39

12. Worn brake Red ● on page 3-40

13. Engine, Fan Green ● on page 3-40

14. Engine, Heater Yellow ● on page 3-40

15. Engine, Low Coolant Level Yellow ● on page 3-41

3-30 Y53-1203-1D1 (02/14) INDICATORS

Symbol Name Symbol Color Std Opt Page

16. Engine, Overspeed Red ● on page 3-41

17. Engine, Overspeed Air Shutdown Red ● on page 3-41

18. Engine, Retarder (Brake) Green ● on page 3-42 3

19. Engine, Stop Engine Red ● on page 3-42

20. Engine, Wait To Start Yellow ● on page 3-42

21. High Exhaust System Temperature Yellow ● on page 3-43

22. Lights, High Beam Blue ● on page 3-43

23. Pump Mode Green ● on page 3-43

(02/14) Y53-1203-1D1 3-31 INDICATORS

Symbol Name Symbol Color Std Opt Page

24. Power Take-Off (PTO) Yellow ● on page 3-44

25. Inter Axle Lock Green ● on page 3-44

3 26. Trailer Body Up Red ● on page 3-44

27. Message Waiting Green ● on page 3-45

28. Park Brake Red ● on page 3-45

29. Seat Belt, Fasten Red ● on page 3-45

30. Transmission, Oil Temperature High Yellow ● on page 3-46

31. Turn Signal, Left Green ● on page 3-46

3-32 Y53-1203-1D1 (02/14) INDICATORS

Symbol Name Symbol Color Std Opt Page

32. Turn Signal, Right Green ● on page 3-46

33. Malfunction Indicator Lamp (MIL) Yellow ● on page 3-47

34. Water In Fuel (WIF) Yellow ● on page 3-47 3

35. Fifth Wheel Slide Unlocked Red ● on page 3-47

36. Fifth Wheel King Pin Lock Red ● on page 3-48

37. Check Transmission Red ● on page 3-48

38. Refrigerator Green ● on page 3-48

(02/14) Y53-1203-1D1 3-33 INDICATORS

1. Anti-Lock Brake System (ABS) to Operator's Manual for "Anti-Lock 2. Anti-Lock Brake System (ABS), Braking System" for more information.) Trailer

C. If your vehicle has the optional Wheel Spin Control feature, the ABS Warning Lamp turns on and stays A. It illuminates during the power-on on when a problem exists with the self test when the ignition is turned ATC system. This should be checked A. It illuminates during the power-on ON. It turns off after a few seconds if by a Kenworth dealer as soon as self test when the ignition is turned 3 no system problems are detected. possible. (Refer to Operator's Manual ON. It turns off after a few seconds if for "Anti-Lock Braking System" for no system problems are detected. The CAUTION more information.) bulb self-test is performed whenever If the ABS Warning Lamp does not the ignition is turned ON, regardless NOTE illuminate during the power-on self of whether you have Trailer ABS. If a test, there may be a problem with the After servicing the ABS, the lamp Trailer ABS system is detected, the light or wiring. You should have this stays on after the power-on self test. lamp will turn off after a few seconds if checked as soon as possible. Fail- This indicates that the ABS wheel no system problems are detected. ure to comply may result in equip- sensors have not been checked by ment or property damage. the ABS. As soon as the vehicle is CAUTION driven at speeds above 4 mph (6 If the Trailer ABS Warning Lamp km/h) the lamp turns off, indicating B. If it turns on and stays on at any does not turn on during the power-on that the wheel sensors have been other time, it is indicating that a self test, there may be a problem checked by the ABS. problem exists with the ABS. This with the light or wiring. You should should be checked by a Kenworth have this checked as soon as pos- dealer as soon as possible. (Refer sible.

3-34 Y53-1203-1D1 (02/14) INDICATORS

B. If it turns on at any other time, CAUTION NOTE it is indicating that a problem exists If the Trailer ABS Warning Lamp The Trailer ABS Warning Lamp with the Power Line Communication does not turn on during the power-on will not turn on when connected to (PLC) trailer ABS. This should be self test there may be a problem with trailers with ABS (but without PLC) checked by a Kenworth dealer as soon the light or wiring. You should have powered through the primary 7-way as possible. (Refer to "Trailer ABS" this checked as soon as possible. trailer light line. Use the lamp on the in the Operator's Manual for more driver's side of the trailer to identify information.) NOTE trailer ABS problems. 3 C. If your tractor and trailer have Tractors/Trucks and trailers built af- the "Special Trailer ABS (Without ter 3/1/01 must be able to turn on an NOTE PLC) Option", (Refer to "Special In-Cab Trailer ABS Warning Lamp For doubles or triples, the lamp does Trailer ABS (Without PLC) Option" (per U.S. FMVSS121). The industry not distinguish between trailers. An in the Operator's Manual for more chose PLC as the standard method ABS problem in any of the trailers information.) this lamp will turn on to turn it on. (Refer to "Trailer ABS" will activate the Trailer ABS Warning when the trailer ABS has a system in the Operator's Manual for more in- Lamp. problem. This should be checked by a formation.) Kenworth dealer as soon as possible. The Trailer ABS Warning Lamp will not turn on for the power-on self test when connected to these types of trailers.

(02/14) Y53-1203-1D1 3-35 INDICATORS

3. Axle, Traction Control Anti-Lock Braking System" for more (ATC or Automatic Traction information.) WARNING! Control) If this chassis is equipped with an NOTE electronic stability program (ESP) For vehicles equipped with Elec- and is modified (e.g. adding or re- tronic Stability Program, please refer moving an axle, converting from a to Bendix ABS Operator's Manual, truck to a tractor, converting from included in your glove box informa- a tractor to a truck, changing the 3 tional packet. body, lengthening of the wheelbase A. Illuminates during the power-on and/or frame, relocating frame com- self test when the ignition is turned ponents, or modifying pneumatic or ON. It turns off after a few seconds if electrical ABS/ESP harnesses) the no system problems are detected. If ESP must be disabled by a qual- an ATC problem is detected, the ATC ified technician. If you have any Warning lamp will turn on and stay on. questions, contact your authorized Kenworth Dealer. Failure to comply B. Flashes when the ATC is regulating may result in personal injury, death, wheel spin. (Refer to Operator’s equipment or property damage. Manual for "Automatic Traction Control" for more information.)

C. It blinks continuously when the Deep Snow & Mud switch is turned on, indicating that this feature is active. (Refer to Operator’s Manual "Deep Snow and Mud Switch (option)

3-36 Y53-1203-1D1 (02/14) INDICATORS

4. Diesel Particulate Filter (DPF) 5. Dump Truck, Body Up 6. Engine BrakeSaver or Transmission Retarder

Illuminates when Truck Dump Body is Illuminates when BrakeSaver (export Illuminates when diesel particulate up. filter needs regeneration (controlled only) or Transmission Retarder is by Engine Control Module (ECM)). active. 3 This warning lamp will illuminate even if the regeneration operation is disabled. (Refer to the Engine Manufacturer's Operator Manual and the PACCAR Engine After-treatment Control Operator Manual for additional information.)

NOTE Only for engines equipped with emissions aftertreatment.

(02/14) Y53-1203-1D1 3-37 INDICATORS

7. Engine, Check Engine 8. Engine, Ether Start NOTE Only for engines equipped with emissions aftertreatment.

Illuminates when a problem exists, but Illuminates when ether start switch is the vehicle can still be safely driven. on. Vehicle should be serviced to correct 3 the problem, but the situation should not be considered an emergency.

The Check Engine lamp will activate for several reasons. These include but are not limited to Water in Fuel and No-Idle Shutdown alert screens and the High Exhaust Temperature, Diesel Particulate Filter (DPF), Diesel Exhaust Fluid (DEF) warning lights. You may need to refer to your Engine Operator's Manual for additional information.

3-38 Y53-1203-1D1 (02/14) INDICATORS

9. Hill Hold 10. Lane Departure Warning (LDW) 11. Service Transmission (Eaton Ultrashift Plus)

Illuminates when optional LDW system Illuminates when Allison 1000/2000 Blinks when disabled by switch (once is not able to track the vehicle's transmission requires service. per second), or continuous with fault. position within the lane. 3 The hill stop aid prevents unwanted NOTE vehicle movement on steep grades when transitioning from the brake to For vehicles equipped with Lane throttle pedal. Departure Warning, please refer to Lane Departure Warning Driver's Guide for additional information.

(02/14) Y53-1203-1D1 3-39 INDICATORS

12. Worn Brake 13. Engine, Fan 14. Engine, Heater

Illuminates when fan is active. Illuminates when Engine Heater switch Illuminates when brake pads on is on. optional Brake Warning System 3 require replacement.

3-40 Y53-1203-1D1 (02/14) INDICATORS

15. Engine, Low Coolant Level 16. Engine, Overspeed 17. Engine, Overspeed Air Shutdown

Illuminates and an audible warning tone will sound when coolant level in Illuminates when engine RPM is the radiator is critically low. exceeded (Allison Transmissions). Illuminates when the Engine 3 Overspeed Air Shutdown system is CAUTION activated. The vehicle must be serviced to cor- rect the problem, but the situation should not be considered an emer- gency.

(02/14) Y53-1203-1D1 3-41 INDICATORS

18. Engine, Retarder (Brake) 19. Engine, Stop Engine 20. Engine, Wait to Start

Illuminates when the engine retarder (compression brake), BrakeSaver Illuminates and an audible alarm tone Illuminates when engine grid heater (export only), or exhaust brake is will sound when a major engine system is on. (PACCAR PX-6, PX-8, and 3 switch is on (Smartwheel only). problem exists. Cummins ISL engines)

WARNING! This should be considered an emer- gency. You should stop the vehicle as safely as possible and turn OFF the ignition. The vehicle must be serviced and the problem corrected before driving again. Failure to do so may cause severe engine dam- age or cause an accident which may result in personal injury or death.

3-42 Y53-1203-1D1 (02/14) INDICATORS

21. High Exhaust System 22. Lights, High Beam 23. Pump Mode Temperature

Illuminates when the high beams are Illuminates when optional pump switch on. is activated. Illuminates when exhaust temperature is high (controlled by The high beam indicator will flash and 3 Engine Control Module (ECM)). (Refer a tone will sound to indicate that the to the Engine Manufacturer's Operator head lamps are left on when: the head Manual and the PACCAR Engine lamp switch is ON, the driver's door is After-treatment Control Operator open, AND the key switch is OFF. Manual for additional information.)

(02/14) Y53-1203-1D1 3-43 INDICATORS

24. Power Take Off (PTO) 25. Inter Axle Lock 26. Trailer Body Up

Illuminates when optional PTO is It illuminates when the inter-axle Illuminates when optional trailer body active. 3 differential switch is ON thus locking up switch is activated. the inter-axle differential. This powers the forward rear and the rear rear differentials equally. When the switch is turned off (inter-axle differential unlocked) the engine power is allowed to flow to any of the 4 drive tires based on the differential effect (mostly to the forward rear differential). (This feature is standard on all tandem axles).

3-44 Y53-1203-1D1 (02/14) INDICATORS

27. Message Waiting 28. Park Brake 29. Seat Belt, Fasten

Illuminates with telematic equipped messaging. Illuminates when parking brakes are applied. Illuminates for 5 seconds whenever the ignition key is turned on, then it 3 The Park Brake lamp will flash and the turns off. The warning lamp may also warning tone will sound anytime the come on if the driver's seat belt is not Park Brake is not set and the driver's fastened (if the vehicle was ordered door is open. with a seat belt warning light option).

(02/14) Y53-1203-1D1 3-45 INDICATORS

30. Transmission, Oil Temperature 31. Turn Signal, Left 32. Turn Signal, Right High

Blinks when the left turn signal is Blinks when the right turn signal is Illuminates when transmission operating. operating. 3 lubricant temperature is too high.

CAUTION This should be considered an emer- gency. You should stop the vehicle as safely as possible and turn OFF the ignition. The vehicle must be serviced and the problem corrected before driving again. Failure to do so may cause severe transmission damage.

3-46 Y53-1203-1D1 (02/14) INDICATORS

33. Malfunction Indicator Lamp 34. Water In Fuel (WIF) 35. Fifth Wheel Slide (MIL)

Illuminates when water has been Illuminates when fifth wheel slide detected in the fuel. Illuminates when an engine emissions switch is activated. Indicates fifth failure has occurred. The vehicle wheel can move. 3 can be safely driven but should be serviced to correct the problem. The situation should not be considered an emergency. In some cases, the Malfunction Indicator Lamp will activate in conjunction with the High Exhaust Temperature, Diesel Particulate Filter (DPF) and Diesel Exhaust Fluid (DEF) Warning Lights.

NOTE Only for engines equipped with emissions aftertreatment.

(02/14) Y53-1203-1D1 3-47 INDICATORS

36. King Pin Lock 37. Check Transmission 38. Refrigerator

Illuminates when king pin lock switch A fault with transmission. is activated. Indicates the king pin is Indicates when the refrigerator is on. (Refer to transmission manual) 3 disengaged.

3-48 Y53-1203-1D1 (02/14) GAUGES AND DISPLAYS GAUGES AND DISPLAYS

Introduction

3

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 be inoperable unless that option was specified with the vehicle. See Indicators on page 3-27 for a complete list of standard and optional gauges and warning light indicators.

(02/14) Y53-1203-1D1 3-49 GAUGES AND DISPLAYS

Gauges

Table 3 Gauges Symbol

Symbol Name Symbol Std Opt Page 1. Air Filter Restriction Pressure ● on page 3-56

2. Ammeter ● on page 3-56 Front 3 Rear 3. Axle, Drive Oil Temperature ● on page 3-57 Center (Tridem)

4. Axle, Pusher Air Pressure, #1, #2, #3 ● on page 3-57

5. Axle, Tag Air Pressure ● on page 3-58

6. Brake, Application Air Pressure ● on page 3-58 7. BrakeSaver, Application Air Pressure (Export vehicles only) ● on page 3-59

3-50 Y53-1203-1D1 (02/14) GAUGES AND DISPLAYS

Symbol Name Symbol Std Opt Page 8. BrakeSaver, Oil Temperature (Export vehicles only) ● on page 3-59

9. Diesel Exhaust Fluid (DEF) ● on page 3-59

10. Engine, Coolant Temperature ● on page 3-60

11. Engine, Oil Pressure ● on page 3-62 12. Engine, Oil Temperature ● on page 3-63 13. Engine, Pyrometer (Export vehicles only) ● on page 3-63 3 14. Fuel Filter Restriction Pressure ● on page 3-64

Primary ●

15. Fuel Level, Primary and Secondary (if equipped) on page 3-65 Secondary ●

#1 16. General Air Pressure #1, #2 ● on page 3-66 #2

17. General Oil Temperature ● on page 3-66

18. Manifold Pressure (Turbo Boost) ● on page 3-67

(02/14) Y53-1203-1D1 3-51 GAUGES AND DISPLAYS

Symbol Name Symbol Std Opt Page Primary

19. Primary and Secondary Air Pressure ● on page 3-67 Secondary

#1

20. Suspension Load Air Pressure, #1, #2 ● on page 3-69 #2 3

21. Tractor Brake Application Air Pressure ● on page 3-70

22. Trailer Brake Application Air Pressure ● on page 3-70

23. Trailer Air Tank Air Pressure ● on page 3-70

24. Transfer Case Oil Temperature ● on page 3-71

25. Transmission Oil Temperature, Main ● on page 3-71

26. Transmission Oil Temperature, Auxiliary ● on page 3-71

27. Transmission Retarder Oil Temperature ● on page 3-72

28. Voltmeter ● on page 3-72

3-52 Y53-1203-1D1 (02/14) GAUGES AND DISPLAYS

Speedometer Odometer/Trip Meter distance that can be shown on the trip odometer is 9999.9 before it rolls over to zero.

NOTE 1 Odometer Pressing the trip odometer reset but- 2 Trip Meter ton 4 times in less than 4 seconds will change the odometer units. The LCD display in the lower part of the 3 The Speedometer indicates the vehicle speedometer contains the Odometer To reset the trip odometer, press and speed in miles per hour (mph) and and the Current Trip Meter. hold the button on the cluster. The in kilometers per hour (km/h). The numbers will reset to 0 and begin to The odometer displays the distance Speedometer cluster also includes count new miles/km traveled. your vehicle has traveled. It will display several warning and indicator lamps in miles on an English cluster or in (see Audible Alerts on page 3-21) and To select a different trip, refer to kilometers on a metric cluster. The an Odometer/Trip Meter. Kenworth Multi-Function Display maximum distance that can be shown Operator Manual. on the odometer is 999,999 before it rolls over to zero.

The current trip odometer displays how far the vehicle has gone on a particular trip. The trip odometer will display in miles on an English cluster or in kilometers on a metric cluster, in one tenth divisions. The maximum

(02/14) Y53-1203-1D1 3-53 GAUGES AND DISPLAYS

Tachometer Manual for "More Driving Tips and NOTE Techniques" for further instructions The Odometer/Trip Meter comes on on driving techniques and using the when the door is opened and when tachometer.) To avoid engine damage, the ignition key is in the ACC or ON do not let the pointer exceed maximum position. The Odometer/Trip Me- governed speed. (See your Engine ter will remain on for 3 seconds af- Operation and Maintenance Manual ter the door is closed or the igni- for RPM recommendations.) 3 tion switch is turned off. This allows driver and service personnel to read The Tachometer measures the engine the odometer without ignition switch speed in revolutions per minute (RPM). being turned on. The Tachometer cluster also includes several warning and indicator lamps (see Audible Alerts on page 3-21) and an Engine Hour Meter and Outside Temperature Display.

Watching the tachometer is important to driving efficiently. It will let you match driving speed and gear selection to the operating range of your engine. If the engine speed gets too high, you can select a higher gear to lower the RPM's. If the engine speed drops too low, you can select a lower gear to raise the RPM's. (Refer to Operator's

3-54 Y53-1203-1D1 (02/14) GAUGES AND DISPLAYS

Engine Hours/Outside Air displayed from -40° to 158° F or -40° Temperature to 70° C. NOTE The OAT will come on when the door The display will also alert the is open and when the ignition key is driver when the outside temperate in the ACC or ON position. The OAT approaches freezing (32° F or 0° C) display will turn off when the ignition by displaying a snowflake symbol. switch is turned off. The symbol will turn on when the temperature drops below 34° F or 11° 1 Hour Meter C and flash for the first 3 seconds, NOTE 3 2 Outside Air Temperature then stay on until the temperature goes 3 Snowflake Symbol The OAT uses a sensor (located at above 37° F or 28° C. the bottom of the driver's side mir- The LCD display in the lower part of the ror assembly) to measure outside air The OATs units (Fahrenheit or Celsius) tachometer contains the Engine Hour temperature only. It is not capable can be changed by pressing the reset Meter and the Outside Air Temperature of displaying the temperature of the button on the cluster 4 times in less display. road surface on either the tempera- than 4 seconds. ture display or the snowflake icon. The engine hour meter will display the Additionally, the OAT reading may total number of hours the engine has CAUTION be affected by exposure to direct been running. The maximum hours Modifying the sensor or its location sunlight. that can be shown are 99999.9 before can impact vehicle performance, the meter rolls over to zero. emissions, and/or reliability.

The Outside Air Temperature (OAT) will display the temperature outside the vehicle. The temperature can be

(02/14) Y53-1203-1D1 3-55 GAUGES AND DISPLAYS

1. Air Filter Restriction Pressure 2. Ammeter 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 replace if necessary. Holes in the paper el- ement render an air cleaner useless 3 and may cause the Air Filter Restric- The Air Filter Restriction Pressure tion Gauge to give a false reading, The ammeter tells you whether your gauge indicates the condition of the whether the element is clogged or vehicles electrical system is in balance engine air cleaner and is measured by not. Replace the element if it is dam- and operating normally. If not, it may inches of water (H2O). A clean filter aged. Failure to comply may result be drawing power from the alternator should register 7 in. H2O (may vary in equipment damage. (positive reading) or from the batteries with system design) and a filter whose (negative reading). life is over will register approximately 20 in. H2O. The red light will come on Under normal conditions the ammeter when it has reached a critical level. will read nearly "zero". If it begins This critical level is determined by to read noticeably above or below engine and air filter selections. the "zero" balance, have the system checked out immediately. If you do not, you could have a roadside breakdown.

3-56 Y53-1203-1D1 (02/14) GAUGES AND DISPLAYS

3. Axle, Drive Oil Temperature 4. Axle, Pusher Air Pressure

Center Drive Axle (for Tridem Axle Front Drive Axle configuration) Pusher Axle #1 3 The Drive Axle Oil Temperature gauges (front, rear, and center) indicate the temperature of the lubricant in your vehicle's axles. These temperatures will vary with the kind of load you are carrying and the driving conditions you encounter. The red light will come on Pusher Axle #2 Rear Drive Axle when the temperature has reached a critical level. This critical level is determined by axle type.

NOTE Very high temperatures signal a need to have the axle(s) lubrication checked.

(02/14) Y53-1203-1D1 3-57 GAUGES AND DISPLAYS

5. Axle, Tag Air Pressure 6. Brake, Application Air Pressure

Pusher Axle #3 3 The Pusher Axle Air Pressure gauge(s) The Tag Axle Air Pressure gauge The Brake Application air gauge indicate the air pressure in the pusher indicates the amount of air pressure in indicates how much air pressure is axle(s) suspension air bags. the tag axle suspension air bags. being applied from the foot brake valve or trailer brake hand valve to the air brakes.

3-58 Y53-1203-1D1 (02/14) GAUGES AND DISPLAYS

7. BrakeSaver, Application Air 8. BrakeSaver, Oil Temperature 9. Diesel Exhaust Fluid (DEF) Pressure (Export vehicles only) (Export vehicles only)

3 The Diesel Exhaust Fluid gauge The BrakeSaver Application Air The BrakeSaver Oil Temperature indicates the total (approximate) Pressure gauge indicates the gauge indicates the temperature in amount of DEF in the tank. In addition amount of air pressure applied to the the BrakeSaver. If the oil temperature to indicating empty and full, the BrakeSaver hand control valve. exceeds the maximum limits, a red gauge also indicates the DEF level in warning lamp in the gauge will turn on. graduated increments. When the DEF level in the tank reaches 10% full, a red CAUTION warning light in the gauge illuminates, This should be considered an emer- when the DEF level in the tank reaches gency. You should stop the vehicle 5%, the red light flashes. Refer to as safely as possible and turn OFF your PACCAR Engine After-Treatment the ignition. The vehicle must be Control Operator’s Manual for more serviced and the problem corrected information. before driving again. Failure to do so may cause severe BrakeSaver dam- age.

(02/14) Y53-1203-1D1 3-59 GAUGES AND DISPLAYS

10. Engine, Coolant Temperature Overheating Engine CAUTION This should be considered an emer- The cooling system may overheat if gency. You should stop the vehicle the coolant level is below normal or if as safely as possible and turn OFF there is sudden loss of coolant, such the ignition. The vehicle must be as a split hose. The system may also serviced and the problem corrected temporarily overheat during severe before driving again. Failure to do so operating conditions such as: 3 may cause severe engine damage. • Climbing a long hill on a hot day The Engine Coolant (water) Temperature gauge indicates the Under normal operating conditions, • Stopping after high-speed driving temperature of the engine coolant. the water temperature gauge should register between 165° and 205° F (74° NOTE If the coolant temperature exceeds and 90° C). Under certain conditions, If one of the following occurs, DO the maximum limits, a red warning somewhat higher temperatures may be NOT TURN OFF THE ENGINE un- lamp in the gauge will turn on and acceptable. The maximum allowable less: a) the Low Water warning an audible warning will sound. If the temperature is 220° F (104° C) with device indicates a loss of coolant, coolant temperature continues to rise, the cooling system pressurized, except b) the Red Warning lamp (on the the Check Engine and/or Stop Engine for certain engines. Check the engine gauge) and Check Engine lamp lights will also come on. manual to be sure. comes ON, c) the Audible Warning or Audible Alarm sounds showing an overheat condition, or d) you have any other reason to suspect the engine may be overheating, fol- low these steps.

3-60 Y53-1203-1D1 (02/14) GAUGES AND DISPLAYS

turn or until it reaches the 1. Reduce engine speed or stop. 6. Monitor the engine temperature. first stop—allowing excess When stopped, place the After the temperature returns to pressure to escape—push transmission in Neutral and set normal, allow the engine to idle down and turn for final the parking brake. (Refer to 3 to 5 minutes before shutting it removal. Operator’s Manualfor "Parking off. This allows the engine to cool Brake Valve" and "Putting the gradually and uniformly. For further information on engine Vehicle in Motion" for more 7. If overheating came from temperature and operating engines information.) properly, see the Engine Operation and severe operating conditions, the 3 2. Check to ensure the Oil Pressure temperature should have cooled Maintenance Manual and Operator's Gauge reads normal. (See the by this time. If it has not, stop Manual. Check the coolant level Engine Oil Pressure in Gauges the engine and let it cool before after each trip when the engine has and Displays on page 3-49, for checking to see if the coolant is cooled. The coolant level should be further information.) low. visible within the sight gauge (glass level indicator) on the surge tank; 3. Make sure the engine fan is ° Wait until the coolant add coolant if necessary. (Refer to turned on by switching the Engine temperature is below 122° F Operator's Manual for "Topping Up", Fan Switch from AUTO to MAN (50° C). for instructions on checking and filling (Manual). the coolant expansion tank.) ° Protect face, hands, and arms 4. Increase the engine speed to about by covering the cap with a one-half of full operating speed, or large, thick rag to protect 1,100 to 1,200, maximum. against escaping fluid and 5. Return the engine speed to normal steam. idle after 2 or 3 minutes. ° Carefully and slowly turn the cap one-quarter of a

(02/14) Y53-1203-1D1 3-61 GAUGES AND DISPLAYS

11. Engine, Oil Pressure WARNING! • Check the engine manufacturer's manual for the correct oil pressure Do not remove the radiator fill cap ranges for your vehicle's engine. while the engine is hot. Scalding steam and fluid under pressure may • If the oil pressure suddenly drops, escape. You could be badly burned. or the audible alarm and engine Failure to comply may result in per- oil pressure warning light come on sonal injury or death. while driving, do the following: 3 1. Slow down carefully. WARNING! It is important to maintain oil pressure within acceptable limits. If oil pressure 2. Move a safe distance off the road To reduce the chance of death, drops below the minimum psi a red and stop. personal injury, fire and/or vehicle warning light in the gauge will turn on, 3. Place the transmission in park and damage from overheated engines, the Stop Engine light will come on and set the parking brake. (Refer to never leave the engine idling without an audible alarm tone will sound. an alert driver present. If the en- Operator’s Manual for "Parking Brake Valve" and "Operating the gine should overheat, as indicated CAUTION by the engine coolant temperature Transmission" for transmission light, immediate action is required Continuing to operate your vehi- shifting and parking brake to correct the condition. Continued cle with insufficient oil pressure will information.) cause serious engine damage. unattended operation of the engine, 4. Turn OFF the engine. even for a short time, may result in serious engine damage or a fire. • If the oil pressure fails to rise within 5. Turn ON the emergency flasher Failure to comply may result in per- 10 seconds after the engine starts, and use other warning devices to sonal injury, death, equipment or stop the engine and determine the alert other motorists. property damage. cause.

3-62 Y53-1203-1D1 (02/14) GAUGES AND DISPLAYS

12. Engine, Oil Temperature 13. Engine, Pyrometer (Export 6. Wait a few minutes to allow oil to vehicles only) drain into the engine oil pan, and then check the oil level. (Refer to Operator’s Manual for "Oil Level Check" for details on checking oil level.) 7. Add oil if necessary. If the problem persists, contact an authorized 3 Kenworth Dealer. The Engine Oil Temperature gauge indicates the engine oil temperature. The Pyrometer Gauge indicates engine For further information on engine oil If the oil temperature exceeds the exhaust gas temperature. Since it and normal operating pressures, see maximum limits, a red warning responds almost immediately to the Engine Operation and Maintenance light in the gauge will turn on. Do changes in exhaust gas temperature, Manual. not exceed maximum engine oil the pyrometer is an excellent indicator temperature recommended by the of engine output. Monitor it in For further information on engine engine manufacturer. (See the Engine conjunction with the tachometer gauges and operating your engine Operation and Maintenance Manual and manifold pressure gauge. The properly, refer to Operator’s Manual for for details.) pyrometer can be a useful aid to "Engine Maintenance". operating your truck more efficiently and avoiding sudden changes in engine operating temperature.

See the Engine Operation and Maintenance Manual for maximum temperature recommendations.

(02/14) Y53-1203-1D1 3-63 GAUGES AND DISPLAYS

14. Fuel Filter Restriction Pressure To establish or test for the best NOTE operating (exhaust) temperatures on your vehicle, follow the procedure The maximum allowable restriction below: could vary according to the type or make of engine. Consult the en- Climb a grade at maximum operating gine manufacturers manual or en- RPM and full throttle for one minute. gine dealer for fuel restriction speci- Record the pyrometer reading at the fications. 3 end of this time. Then ease up on the throttle. This gauge tells you the condition of the fuel filter by indicating the Subtract 200º F (110º C) from the restriction from the fuel filter to the fuel recorded temperature reading. The pump. The restriction is measured by result is the optimum operating inches of mercury (Hg). Check the temperature. engine manual for proper restriction. Replace the filter with an approved This procedure is also useful as an filter only. Do not substitute the wrong occasional check of engine condition. micron element. Any large variation in the maximum temperature reading may be an early indication of possible engine problems.

Different size injectors or changes in altitude may affect engine operating temperatures.

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15. Fuel Level, Primary Secondary (if equipped) NOTE Kenworth manufactures vehicles The Primary Fuel gauge and that are built with different fuel sys- Secondary Fuel gauge (if equipped) tems and draw tube locations. Be- indicate the total (approximate) amount cause of this and the amount of road of fuel in each fuel tank. In addition to crown, it is recommended that you indicating empty and full, the gauge(s) Primary do not operate your vehicle with less also indicate the fuel level in graduated than one-quarter of your truck’s fuel increments. When the fuel level for 3 capacity. Allowing the fuel level to each tank is below 1/4 full, a red go below one-quarter of capacity warning light in the gauge will come on. could result in the lack of fuel to keep the engine running. In addition, you will want to keep the fuel tanks at least half-full to reduce condensa- tion of moisture in the tanks. This Secondary moisture can damage the engine.

NOTE WARNING! For Export vehicles, the fuel gauges Do not carry fuel containers or any will not state: ULTRA LOW SULFUR container used to store combustible DIESEL FUEL ONLY. liquids. Failure to comply may result in personal injury, death, equipment or property damage.

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16. General Air Pressure #1, #2 17. General Oil Temperature WARNING! Do not remove a fuel tank cap near an open flame. Fuel vapors may be hot and combustible and can cause an explosion or fire. Failure to comply may result in personal injury, death, equipment or property damage. 3 General Air Pressure #1 The General Oil Temperature gauge(s) are used for customer installed Refer to Operator’s Manual for component applications. "Refueling" for more information.

General Air Pressure #2

The General Air Pressure gauge(s) are used for customer installed component applications.

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18. Manifold Pressure (Turbo Boost) 19. Primary and Secondary Air amount of air pressure in each system Pressure in pounds per square inch (psi).

On vehicles equipped with metric air pressure gauges, the gauge face plate includes a kPa (major) scale and psi (minor) scale.

NOTE 3 The Manifold Pressure Gauge Be sure the air pressure registers Primary Air Pressure indicates the power your vehicles more than 100 psi in both service engine is putting out by showing the systems before you move the vehi- amount of turbo boost. If the pressure cle. indicated by the manifold pressure gauge goes down, there may be something wrong with the engine. NOTE Have it checked by a qualified service If the pressure in either or both cir- person. cuits falls below 65 psi, a red warn- ing light in the gauge will turn on Secondary Air Pressure and an audible alarm tone will sound when the engine is running. The Primary Air Pressure gauge indicates pressure in the rear braking system. The Secondary gauge indicates pressure in the front braking system. Each gauge indicates the

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Air Loss Emergency Procedure WARNING! WARNING! 1. Slow down carefully. If the air pressure falls below 60 psi The air pressure warning light and (414 kPa), the spring brakes may the audible alarm tone indicate a 2. Move a safe distance off the road stop the vehicle abruptly which could dangerous situation: there is not and stop. cause an accident resulting in per- enough air pressure in the air tanks 3. Place the transmission in sonal injury or death. Observe the for repeated braking and the brake neutral (park with automatic red warning lamps on the gauges. system has failed. Without the use transmissions, if equipped) and 3 If one comes on, do not continue of your service brakes your spring set the parking brake. (Refer to to drive the vehicle until it has been brakes could suddenly apply caus- Operator’s Manual for "Parking properly repaired or serviced. ing a wheel lock-up, loss of control, Brake Valve" and "Operating the or over-take by following vehicles. Transmission" for transmission This may cause an accident result- shifting and parking brake ing in personal injury or death. Bring information.) the vehicle to a safe stop right away, while you still have control of the 4. Turn OFF the engine. vehicle. Refer to the following pro- 5. Turn ON the emergency flasher cedure: and use other warning devices to alert other motorists.

If the light and alarm do not turn off at startup, do not try to drive the vehicle until the problem is found and fixed. (Refer to Operator’s Manual for "Using

3-68 Y53-1203-1D1 (02/14) GAUGES AND DISPLAYS the Brake System" for more brake 20. Suspension Load Air Pressure, gauge, the #1 gauge indicates the information.) #1, #2 air pressure in the driver's side air bags. The #2 gauge indicates the air pressure in the passenger's side air bags.

3 Suspension Load Air Pressure #1

Suspension Load Air Pressure #2

The Suspension Load Air Pressure gauge indicates the amount of air pressure in the air suspension air bags.

When the vehicle is equipped with a second Suspension Load Air pressure

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21. Tractor Brake Application Air 22. Trailer Brake Application Air 23. Trailer Air Tank Air Pressure Pressure Pressure

3 The Trailer Air Tank Air Pressure The Tractor Brake Application Air The Trailer Brake Application Air gauge indicates the amount of air Pressure gauge indicates the amount Pressure gauge indicates the amount pressure in the trailer brake air tank. of air pressure applied to the tractor of air pressure applied to the trailer brakes. brakes during brake foot valve and/or hand brake control valve applications. NOTE This gauge will be included when the Trailer Brake Application Air Pres- sure gauge is ordered.

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24. Transfer Case Oil Temperature 25. Transmission Oil Temperature, 26. Transmission Oil Temperature, Main Auxiliary

3 The Transfer Case Oil Temperature gauge indicates the temperature of The Main Transmission Oil The Auxiliary Transmission Oil the oil in the transfer case. If the oil Temperature Gauge indicates Temperature gauge indicates the temperature exceeds maximum limits, the temperature of the oil in the temperature of the oil in the auxiliary a red warning light in the gauge will transmission. transmission. turn on. Do not exceed maximum oil temperature recommended by the NOTE NOTE manufacturer. (See the Transfer Case Watch this gauge to know when the Watch this gauge to know when the Operation and Maintenance Manual transmission is overheating. transmission is overheating. for details.) Do not exceed maximum oil Do not exceed maximum oil temperature recommended by the temperature recommended by the manufacturer. (See the Transmission manufacturer. (See the Transmission Operation and Maintenance Manual Operation and Maintenance Manual for details.) for details.)

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27. Transmission Retarder Oil 28. Voltmeter Multi-Function Display Temperature (Option)

(Refer to Kenworth Multi-Function Display Operator Manual)

3 The Voltmeter displays the battery The Transmission Retarder Oil voltage. Normally, it should show 12 to Temperature gauge indicates 14V (volts). A red warning light in the the temperature of the oil in the gauge turns on when an out of range transmission retarder. condition exists. NOTE NOTE Watch this gauge to know when the Even with a healthy charge/start transmission is overheating. system, the voltmeter may fall well below 12V during engine cranking. Do not exceed maximum oil If voltage drops below 12V and stays temperature recommended by the there, have the electrical system manufacturer. (See the Transmission checked. Operation and Maintenance Manual for details.)

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Bendix Wingman® Active Cruise driver. They are not to be solely with Braking (ACB) relied upon to operate a vehicle NOTE and should be used in conjunction Before operating the system, read • Your vehicle may be equipped with with rear view mirrors, windows and understand the Bendix Wing- a Bendix Wingman® Active Cruise and any other applicable device or man® Active Cruise with Braking with Braking (ACB) system. This method to operate the vehicle in a (ACB) Operator’s Manual provided system is an integrated feature of safe manner. with your vehicle. In addition, ob- the vehicle cruise control which serve all Warnings, Cautions, and will slow the vehicle to maintain a • The Bendix Wingman® Active Notes in the Operator’s Manual and set following distance. The speed Cruise with Braking (ACB) system 3 listed below. reduction may be accomplished by includes a front sensor and an engine de-throttle, application single RH side sensor along with of engine retarder, and application driver and side displays. This WARNING! of foundation brakes. option provides Active Cruise with Ultimate responsibility for the safe Braking and side object detection. • Driver alerts and stationary object operation of the vehicle remains with Side object detection is an optional the driver at all times. Even with alerts are a feature of the Bendix add-on to Bendix Wingman® Wingman® Active Cruise with Bendix Wingman® Active Cruise Active Cruise with Braking (ACB) with Braking (ACB), you must re- Braking (ACB) system and are and may not be present. always active regardless of the main alert, react appropriately and vehicle’s cruise control status. in a timely manner, and use good These alerts are intended solely driving practices. Failure to comply as a supplement to the existing may result in personal injury, death, windows and mirrors of your equipment or property damage. vehicle and should strictly be used as an aid for an attentive and conscientious professional

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WARNING! WARNING! WARNING! Bendix Wingman® Active Cruise The Bendix Wingman® Active The Bendix Wingman® Active with Braking (ACB) reacts to vehi- Cruise with Braking (ACB) driver Cruise with Braking (ACB) system cles moving in the same direction alerts will not warn of all potential should never be used on roads as your vehicle. The system does hazards. Do not assume “all is clear” where you cannot drive safely at a not attempt to brake the vehicle if no warning signals are indicated. steady speed including city streets, when approaching stopped vehi- This system is intended solely as winding roads and sharp curves, 3 cles, side-to-side moving traffic, or a driver aid and supplement to ex- downhill grades, poor road con- oncoming traffic. Failure to comply isting visual aids, and should not ditions such as gravel, dirt, ice may result in personal injury, death, be relied upon to operate a vehicle. or wet surfaces, or in fog, heavy equipment or property damage. Use the Bendix Wingman® Active rain, or snowy conditions. In cer- Cruise with Braking (ACB) system in tain situations Bendix Wingman® conjunction with rear view mirrors, Active Cruise with Braking (ACB) windows and any other applicable should not be used including in- device or method to operate the ve- clement weather, dense traffic or hicle in a safe manner. Failure to where smaller vehicles such as mo- comply may result in personal injury, torcycles are ahead in the same death, equipment or property dam- lane, construction zones, off-road age. use, downhill grades, when enter- ing turning lanes, entering or exiting highways, or similar situations. Fail- ure to comply may result in personal injury, death, equipment or property damage.

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Vehicle Configuration Changes–Limitations and WARNING! WARNING! Guidelines The addition of SAE J1939 data The front radar has been aligned per bus communication equipped de- • The positioning of the various Bendix’s installation guidelines. If vices have the potential to disrupt components of the Bendix you are in an accident that involves the other SAE J1939 data compo- Wingman® Active Cruise with the front bumper or the radar’s align- nents, including but not limited to Braking (ACB) system has been ment, the radar needs to be checked engine controls, transmissions and designed for your vehicle. Prior to and adjusted prior to placing the ve- Bendix Wingman® Active Cruise adding any SAE J1939 equipped hicle into service. Kenworth strongly 3 with Braking (ACB). Do not add devices, or changing the vehicle’s recommends that if your vehicle was any additional SAE J1939 equipped frame height or relocating the involved in a frontal accident, you devices. Any unauthorized or uncer- Bendix Wingman® Active Cruise have the system checked by an au- tified SAE J1939 equipped devices with Braking (ACB) sensors, thorized Kenworth dealer. Failure to added to the vehicle may result in please contact your nearest do so may result in the degradation the SAE J1939 communication link Kenworth authorized dealer to of system performance. Failure to to not perform as designed. Failure ensure that your planned changes comply may result in personal injury, to comply may result in personal do not effect the operation of death, equipment or property dam- injury, death, equipment or property performance of the Bendix age. damage. Wingman® Active Cruise with Braking (ACB) system. For further information, you can contact the Bendix Tech Team at 1-800-AIR-BRAK (247-2725).

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WARNING! The location and height of the Bendix Wingman® Active Cruise with Braking (ACB) front radar and side sensor position was specifically designed for your vehicle per Bendix requirements. The elevation and 3 location of the radar and side sen- sor are critical for proper operation of the system. Any changes to the vehicle frame height or side sensor location, including but not limited to tire radius changes must be ap- proved by Bendix. Any changes that affect the location of the radar and/or side sensor may result in the degradation of system performance. Failure to comply may result in per- sonal injury, death, equipment or property damage.

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MULTI-FUNCTION Alarms, Warning Tones and DISPLAY Visual Indicator Lights WARNING! Introduction Do not ignore any type of tone or Introduction lights. These signals tell you that Your vehicle's dash and something is malfunctioning on your This section explains the location and instrumentation uses various vehicle and provide you an indi- function of the various instruments and methods to indicate to you the status cation of what system is affected. controls on your vehicle. of various systems, or that one or It could be a failure of an impor- more of your vehicle's systems may tant system, such as the brakes, 3 Please remember that each Kenworth be malfunctioning. The method which could lead to an accident and is custom made. Your instrument panel to communicate or alert you of a may result in personal injury, death, may not look exactly like the one in particular condition is by: equipment or property damage. the illustration below. Described below • Audible alarm tone are the most common instruments and controls available. • Audible warning tone • Indicator light(s)

In some cases, you may have both an alarm or warning tone accompanied by an indicator light(s).

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Warning and Information Alert Screens The Cruise Control Rationality screen is displayed when attempting to The Multi-Function display has various activate the cruise control prior to alert screens that are either warnings, depressing both the service brake or informational. pedal and the clutch pedal. For vehicles with automated transmissions Lamp Faults - Low/High Beam and no clutch pedal, only the service brake pedal needs to be depressed. The Lamp Faults screen is displayed 3 when an error is detected in the headlamp circuits.

No Idle Shutdown

The No-Idle Shutdown screen is activated upon engine shutdown due Park Brake On While Moving to extended idle time while not moving. The Park Brake On While Moving Regen Inhibited warning screen is displayed when the Park Brake is on and the vehicle The Regen Inhibited due to speed is greater than zero and/or the Switch screen is displayed when accelerator pedal position is greater a regeneration is required and the DPF than 10%. switch is in the inhibit positiion. Cruise Control Rationality (Brake/Clutch)

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The Exhaust (SCR/DEF) Service Required screen is displayed when either the SCR system has been tampered with or the DEF quality is below standards. It may be DEF (Low Diesel Exhaust Fluid) suppressed by pushing enter on the Low Voltage Disconnect MCS (Menu Control Switch). See The DEF Warning screen is displayed Menu Control Switch on page 3-86. The Low Voltage Disconnect (LVD) when the DEF Fluid level has reached This warning may be accompanied screen is displayed when the system 3 a critically low level. It may be by the DEF Lamp flashing, the Check voltage falls to 12.1 volts. suppressed by pushing enter on the Engine lamp, the Stop Engine lamp, MCS (Menu Control Switch). See the MIL lamp, and/or engine de-rate. Menu Control Switch on page 3-86. This warning may be accompanied by the DEF Level in the low range, DEF Lamp on solid or flashing, the Check Engine lamp, the Stop Engine lamp, Over-Crank Protection the MIL lamp, and/or engine de-rate. Trailer Fault Over-Crank Protection screen is displayed when the starter motor is The Trailer Fault screen is displayed being protected from over heat or from when an error is detected in the trailer being engaged while the engine is circuits. running.

SCR/DEF

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The Cruise Control Set screen is The Circuit Failure screen is displayed displayed when the Cruise Control is when a circuit fault is detected. This active and the Set/Resume switch is screen is accompanied with the hazard used. The current cruise control speed indicators and low beam headlamps. will be displayed. Alarm Clock Active

The Alarm Clock Active screen is 3 displayed when the Alarm is on and the Alarm time equals clock/local time. The Alarm Clock Active screen will Hydrocarbon Burn be displayed for approximately 10 Water In Fuel minutes and may be suppressed by The “Do Not Drive 10 Minute Parked pressing MCS (Menu Control Switch) The Water In Fuel (WIF) screen Regen Required” is displayed when enter, which turns off the alarm. See is displayed when the WIF sensor unburned hydrocarbons or water vapor Menu Control Switch on page 3-86. detects water in the fuel. are trapped in the Diesel Particular Filter (DPF). These need to be burned off before the vehicle is driven. This warning may be accompanied by the DPF lamp on or flashing, the Check Engine Lamp, the Stop Engine Lamp and/or engine derate. An audible alarm Cruise Control Screen Circuit Failure will engage when the vehicle starts moving while this warning is active.

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guarantee that the Air Inlet Valve will shut for overspeed conditions. It may be suppressed by pushing on the MCS (Menu Control Switch). See Menu Control Switch on page 3-86. There is an accompanying audio alarm, which Engine Protection Shutdown Timer Front Drive Axle Speed Warning will continue to sound as long as the conditions are true even if the pop-up The “Shutdown” is displayed when the The “Attention Front Axle Is Engaged” has been suppressed. engine has derated and the situation is displayed when the front drive 3 requires the engine to turn off. The axle is engaged and the vehicle has time to shutdown is displayed. This exceeded a pre-determined speed. warning may be accompanied by the An audible alert will sound when the Check Engine Lamp, the Stop Engine warning is displayed. Lamp and/or engine derate. A restart of the engine is possible with minimal function to ensure safe operation. It may be suppressed by pushing on the MCS (Menu Control Switch). See Menu Control Switch on page 3-86. Engine Over-Speed Shutdown Low Air Warning

The “Overspeed Shutdown May not work due to low-air” is displayed when the system air pressure is to low to

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What You Should Do Wingman® ACB Warning ACB system. This is the least severe Tone / Alert Screens of all the ACB warning tones. The high If an alert screen comes on while pitched ring will have a single beep driving, do the following: • Series of high pitched rings that repeating at a rate of 42 tones per repeat at different rates. See the 1. Slow down carefully. minute. following warning descriptions and 2. Move a safe distance off the road corresponding number of tones and stop. per minute. 3 3. Set the parking brake. (Refer to • Indicates one of the following Operator’s Manual for "Operating scenarios; your vehicle is too close the Transmission" and "Operating to the vehicle ahead, a stationary Level 2 Following Distance Alert the Brake System".) object has been detected, or there 4. If the engine is overheating do is an active fault in the Wingman® This Wingman® ACB warning tone is not turn it off (see “Overheating ACB system. active when the following distance is Engine” in the Operator’s Manual); less than what is set in the Wingman® otherwise, for other conditions turn ACB system. This ACB warning the engine OFF. tone is more severe than the Level 3 Following Distance Alert. The high 5. Turn on the emergency flasher pitched ring will have a double beep and use other warning devices to repeating at a rate of 80 tones per alert other motorists. Level 3 Following Distance Alert minute (40 double beeps per minute).

This Wingman® ACB warning tone is active when the following distance is less than what is set in the Wingman®

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is active when the driver must take immediate evasive action by applying more braking power and/or steering clear of the vehicle ahead to avoid a potential collision. The high pitched ring will have a solid tone for a 3 Level 1 Following Distance Alert second duration. Stationary Object Alert

This Wingman® ACB warning tone is This Wingman® ACB warning tone active when the following distance is is active when the system detects a 3 less than what is set in the Wingman® sizable stationary object with reflective ACB system. This ACB warning tone surfaces in your lane of travel. The is the most severe following distance high pitched ring will have a continuous alert. The high pitched ring will have a Fault Alert beep repeating at a rate of 188 tones continuous beep repeating at a rate of per minute. 188 tones per minute. This Wingman® ACB warning tone is active when there is a fault in the WARNING! Wingman® ACB system. The high The Wingman® ACB sensor may pitched ring will have a single beep not be able to detect vehicles and that is not repeating. objects with limited metal surfaces (such as recreational vehicles, horse-drawn buggies, motorcycles, Impact Alert logging trailers, etc.). Failure to un- derstand the system limitation may This is the most severe warning issued result in death, serious injury, and/or by Wingman® ACB. The warning tone property damage.

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ACB system. It is also used as the Multi-Function Display brake overuse alert when the system is intervening and using the foundation brakes excessively.

Disabled Alert

This Wingman® ACB is able to use 3 the vehicle’s foundation brakes as a 1 Multi-Function Display last resort in attempt to keep the set following distance. This alert screen is WARNING! active once the system stops applying the foundation brakes because cruise Do not look at the Multi-Function control is disabled. Display for prolonged periods while the vehicle is moving. Only glance at the monitor briefly while driving. Failure to do so can result in the driver not being attentive to the vehi- cle's road position, which could lead to an accident involving personal Not Available Alert injury, death or vehicle damage.

This Wingman® ACB alert screen The Multi-Function Display integrates is active after a cruise set/resume the following list of functions (menu switch activation with a fault in the items) into one display.

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• Blank Screen (for night driving) whenever one of the following are Menu Navigation & Definitions activated: • Engine RPM Display Table 4 Menu Item Accessibility • Ignition key is in ON or ACC Access Access • Fuel Economy Display positions Menu Items while while Driving Parked Ignition Timer Ignition timer is ON (active) • • Blank Screen Yes Yes Trip Information Display • MCS button is pushed Fuel Economy Yes No • RPM Detail Yes Yes (independent of ignition key • Truck Information Display Ignition Timer No Yes 3 switch position) Trip Information Yes Yes • On-Board Diagnostic Display Truck Information No Yes • Clock alarm sounds Diagnostic No Yes • Transmission Gear Display Display • Driver or passenger door is Transmission Yes Yes (automated transmissions only) opened Gear Display Clock Display Yes Yes • Clock Display Collision • Hazard warning lamp switch is ON Yes Yes Avoidance • Collision Avoidance • Head lamp switch is ON Settings Screen No Yes • Settings Screen • Dome lamp switch is ON The Multi-Function Display, located • Service Brake switch is ON above the primary instrument cluster will display important vehicle information through a constant monitor of systems. The display will turn on

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Right Hand Status Bar and Left Hand Menu Bar Definitions NOTE This gear display will only be dis- played in the right-hand status bar if the operator has not selected the Transmission Display. If the Trans- mission Display is selected, a larger gear icon and the current gear num- Right Hand Status Bar The left hand menu bar (menu bullets) 3 ber will be displayed while driving. gives the status of the current menu Cruise Control Active - Icon (See Transmission Display on page item. Scroll through the menu items will indicate when cruise control 3-90 for additional information.) by rotating the Menu Control Switch ● is active or the cruise set speed will be displayed (optional). Icon (MCS) clockwise (down the menu) looks like a clock dial face. Shift Indicator (option) or counterclockwise (up the menu). ● -Prompts the driver when to shift up on manual transmissions for Select a menu item by pressing the Alarm On Indicator - The right MCS. Some menu items require hand status bar is equipped fuel economy. with a clock warning bell. If the the MCS to be pressed to access ● alarm has been set, the bell will Submenu information. be displayed with no animation. When the alarm is active, the bell shows animation.

Gear Display (for automatic ● transmissions only) - Displays present gear.

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1. Bar graph - Indicates D. Ignition Timer instantaneous fuel economy. 2. Trip Econ. - Indicates trip fuel economy.

C. RPM Detail

1 Menu Control Switch (MCS) Ignition Timer 2 Heater and Air Conditioning 3 Controls Ignition timer is set from this menu. To set the timer, push the MCS on Menu Items the ignition timer menu (bullet). Then RPM rotate the MCS to the desired time (0 A. Blank Screen - No information or to 30 minutes). After the time expires, graphics displayed. RPM reading of actual engine RPM. the vehicles ignition (switched) power Engine RPM within the bar graph B. Fuel Economy will be shut off (if the ignition key is in chevrons (in range zone) indicates the the OFF position). engine is operating in the most efficient RPM range.

Fuel Economy

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Odometer Reset Button on the 2. Average Speed (Accessible when E. Trip Information main gauge instrument cluster. driving) - Indicates trip average NOTE speed (not including idling). 3. PTO Trip (%) (Accessible when parked) - Indicates total trip PTO When accessing the trip information Trip Result percentage. menu, push the MCS on this menu (bullet). To exit, push the MCS 1. Trip Distance - Indicates total trip 4. PTO Trip Fuel - Indicates total trip again. To reset the trip values, press distance. PTO fuel. the Trip Odometer Reset Button on 2. Trip Engine Hours - Indicates total 5. PTO Trip Economy - Indicates 3 the main gauge instrument cluster. trip engine hours. total trip PTO economy.

Idle Info NOTE 1. Trip Engine Hours - Indicates total Display functions for PTO hours, trip engine hours. PTO Trip Hours and PTO Trip Per- 2. Trip Idle Percentage (%) - centage will only be available if sup- ported by the engine installed. If the Trip Information Indicates total trip idle percentage. truck has a factory-installed PTO, Trip Info (submenu): PTO Info (Optional) these fields will appear in the Trip Information screen. If the engine Instant Info 1. PTO Hours - Indicates total vehicle does not support the data, dashes PTO operation hours. will be shown. 1. Trip Economy (Accessible when driving) - Indicates trip fuel 2. PTO Trip Hours - Indicates total economy. trip PTO operation hours. To reset the Trip Values, press the Trip

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F. Truck Information 1. Chassis Number 2. ABS Model 2. Fleet ID Number (Optional) 3. ABS Software Version NOTE 3. Cab Electronic Control Unit G. Diagnostic Display Only available truck information (CECU) Software Version will be shown (i.e., manual trans- NOTE missions do not have a software Engine Info version). "Faults Found" will only be active if 1. Engine Make a red or yellow warning lamp is il- 3 NOTE 2. Engine Model luminated and additional information is available. When accessing the truck informa- 3. Engine Software Version tion menu, push the MCS on this menu (bullet). To exit, push the MCS 4. Governed Speed Limit (Optional) again. Transmission Info (Automated Transmissions only) 1. Transmission Make Diagnostic Display 2. Transmission Model The diagnostic display menu (bullet) 3. Transmission Software Version will indicate a fault that is present. Truck Information ABS Info While on this menu item the display Truck Info (submenu): will either indicate "No Faults Found" 1. ABS (Anti-Lock Braking System) or "Faults Found". If "Faults Found" Make Chassis Info is active, pushing the MCS on this

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menu item will show "Exit", "Engine", "Transmission", "ABS", "Truck", and/or I. Speed Control Management J. Clock Display "Soot Filter". Exit will take you back to Display (Automated Transmissions the diagnostic menu bullet and clicking only) on any of the other items will display an active vehicle diagnostic message.

H. Transmission Display (Automated Transmissions only) 3 Clock Display NOTE Upshift Indicator while on Transmission Shows Local or Home time as selected by the driver. The time can also be Refer to the Automated Transmis- Gear Screen with Autoshift or Ultrashift set to show 12 hour time (AM/PM) or sion Operator's Manual for complete Transmissions 24 hour time (military). Refer to the description of arrow symbols. The “Shift for fuel econ.” is displayed "Settings Menu" section for additional when the current screen is information covering clock/alarm and Transmission Display And the formatting options. engine requests an upshift for better fuel economy.

Transmission Display

Shows gear number that coincides with the current transmission gear selected. Can also indicate to driver to shift up or down.

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K. Settings Menu To Set Clock Home/Local Time:

The Settings menu screen allows 1. Scroll through the list of menu items the driver to view and/or change the to Time: Home or Local. Press the following menu items: MCS to toggle between Home or Local time. • Clock Display Format 12 Hour Settings Menu (AM/PM) or 24 Hour (military) To Set Clock Display Format: 3 • Clock Home/Local Time 1. When in the settings menu, scroll • Clock Alarm ON/OFF through the list of menu items to "Format". • Clock Local Time (Set) 2. Press the MCS to display either 12 Clock Home/Local Time hour (AM/PM) or 24 hour (military • Clock Alarm Time (Set) 2. To change the selected time (Home time). • Trailer Detect or Local), rotate the MCS to the Settings screen. Press the MCS to • Headlamps With Wipers select it.

• Units Standard or Metric 3. When in the menu settings, scroll through the list of menu items to Set • Language English, Spanish or Clock Time (for home time) or Set French Clock Display Format Local Time. Press the MCS to select it. • Pre-Trip Lamp Test • Exit

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

4. To exit the screen, rotate the MCS to Exit, then press the MCS.

Set Clock Time Exit

4. Rotate the MCS to change the hour. To Set Alarm Time: 3 Press the MCS. Rotate the MCS again to change the minutes. Press the MCS 1. Rotate the MCS to the "Settings" menu. Press the MCS. to set the new time. Set Alarm Hour/Minutes 2. When in the Settings menu, scroll To Turn Alarm ON/OFF: through the list of menu items to "Set Alarm Time". Press the MCS to select 1. Rotate the MCS to the "Settings" it. menu. Press the MCS. 2. When in the setting menu, scroll Set Hour/Minutes through the list of menu items to "Alarm". 5. To exit the screen, rotate the MCS to Exit, then press the MCS. 3. Press the MCS to turn the alarm ON or OFF. Set Alarm Time

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

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NOTE To Activate Trailer Detect:

Unless there is a loss of battery The trailer outputs on your vehicle power, the display will always main- may be able to detect whether or not tain the last screen from key off after a trailer is attached. Should a trailer the key is turned back to the on posi- connection be detected and later lost Trailer Detect tion and the POST cycle completes. while driving the driver will be notified of the error. Errors will be presented To Activate Headlamps with Wipers: 4. To exit the screen, rotate the MCS to the driver as either intermittent or 3 to Exit, then press the MCS. 1. Scroll to HL + Wiper and select by persistent depending on the duration pressing the MCS. of the error. All notifications may be NOTE suppressed by the driver 2. Press MCS to toggle to the desired A bell icon appears in the clock dis- ON/OFF setting. play when the alarm has been set to 1. Scroll to TRLR Detect and select 3. When set to 'ON' the Low Beam ON. by pressing the MCS. Lamps will be active when the 2. Scroll to the desired ON/OFF ignition switch is in the 'ON' setting. position and the Wiper Control 3. When set to 'ON' Trailer Detect will Switch is 'ON'. be active when the ignition switch is in the 'ON' position. Alarm "On"

Headlamps with Wipers

(02/14) Y53-1203-1D1 3-93 MULTI-FUNCTION DISPLAY

periodically while the test is active. The To Set Standard or Metric Units: test will illuminate the following lamps: Asterisks (*) indicate that dash switch 1. Rotate the MCS to the "Settings" must be ON for the Pre-trip Self Test to Lamp Sequence operate these lamps. menu. Press the MCS. Marker* 1, 2 Clearance* 1, 2 2. When in the Settings menu, scroll Headlamp low-beam 1 through the list of menu items to Headlamp high-beam 2 "Units". Press the MCS to display Auxiliary (fog or driving) 1, 2 either Standard or Metric units. Stop 2 3 Park* 1, 2 Hazard/Turn lamps 1 To Set Language: Pre-trip Lamp Test 1. Rotate the MCS knob to the All lamps with sequence #1 will "Settings" menu. Press the MCS. illuminate simultaneously for 10 2. When in the Settings menu, scroll seconds. All lamps with sequence through the list of menu items to #2 will illuminate simultaneously for "Language". Press the MCS to 10 seconds immediately following display either English, Spanish or sequence #1. Each sequence will French. illuminate lamps for 10 seconds. With the default settings and without L. Pre-trip Lamp Test intervention the Pre-trip Lamp Test will deactivate after 10 minutes. Sequence When activated with the MCS, ‘Pre-trip time can vary from 10 seconds with a Lamp Test Active’ appears on the 10 minute duration up to 30 seconds Multi-function display and will reappear and a 30 minute duration.

3-94 Y53-1203-1D1 (02/14) SWITCHES SWITCHES

Introduction

3

Numbered items in illustration are standard or common indicators.

(02/14) Y53-1203-1D1 3-95 SWITCHES

Table 5 Dash Switches

Symbol Name Symbol Color Standard Option Page See Axle, Automatic Traction Control on page 1. Axle, Automatic Traction Control None ● 3-101.

2. Axle, Diff-Lock - Dual Amber ● See Axle, Diff-Lock - Dual on page 3-101.

See Axle, Diff-Lock - Forward Rear on page 3. Axle, Diff-Lock - Forward Rear Amber 3 ● 3-101. 4. Axle, Diff-Lock - Front Amber ● See Axle, Diff-Lock - Front on page 3-101.

5. Axle, Diff-Lock - Rear Rear Amber ● See Axle, Diff-Lock - Rear Rear on page 3-101.

See Axle, Diff-Lock - Single Rear on page 6. Axle, Diff-Lock - Single Rear Amber ● 3-101. See Axle, Inter-Axle Differential Locked 7. Axle, Inter-Axle Differential Locked (Tandem) Amber ● (Tandem) on page 3-44. 8. Axle, Two Speed Green ● See Axle, Two Speed on page 3-101.

9. Back Up Alarm Mute Amber ● See Back Up Alarm Mute on page 3-101. See Batteries, Low Voltage Disconnect (LVD) 10. Batteries, Low Voltage Disconnect (LVD) None ● on page 3-101 11. Brakes, ABS Off-Road Amber ● See Brakes, ABS Off-Road on page 3-102.

See Brakes, Parking Brake Valve on page 12. Brakes, Parking Brake Valve Red ● 3-102

3-96 Y53-1203-1D1 (02/14) SWITCHES

Symbol Name Symbol Color Standard Option Page 13. Dump Truck Gate Red ● See Dump Truck Gate on page 3-102.

14. Engine, Brake Level None ● See Engine, Brake Level on page 3-102.

15. Engine, Brake On/Off Green ● See Engine, Brake On/Off on page 3-102. See Engine, Cruise Control On/Off on page 16. Engine, Cruise Control On/Off Green ● 3-103. SET See Engine, Cruise Control Set/Resume on 17. Engine, Cruise Control Set/Resume None ● page 3-103. 3 RESUME 18. Engine, Ether Start None ● See Engine, Ether Start on page 3-103.

19. Engine, Fan Override Green ● See Engine, Fan Override on page 3-103.

20. Engine, Heater Green ● See Engine, Heater on page 3-104

21. Engine, Remote Throttle Amber ● See Engine, Remote Throttle on page 3-104.

See Engine, Overspeed Air Shutdown (Manual) 22. Engine, Overspeed Air Shutdown (Manual) Red ● on page 3-104.

See Engine, Overspeed Air Shutdown (Test) 23. Engine, Overspeed Air Shutdown (Test) None ● on page 3-104.

24. Engine, Start None ● See Engine, Start on page 3-104. 25. Exhaust, Diesel Particulate Filter (DPF) See Exhaust, Diesel Particulate Filter (DPF) None ● Regeneration Regeneration on page 3-104.

26. Fifth Wheel Slide Red ● See Fifth Wheel Slide on page 3-104.

(02/14) Y53-1203-1D1 3-97 SWITCHES

Symbol Name Symbol Color Standard Option Page 27. Fuel Heater Amber ● See Fuel Heater on page 3-105. 28. Generic Air, Accessory Green ● See Generic Air, Accessory on page 3-105. 29. Generic, Spare SPARE Green ● See Generic, Spare on page 3-105 30. Ignition Key Switch None ● See Ignition Key on page 3-105.

31. Lights, Auxiliary Green ● See Lights, Auxiliary on page 3-106.

32. Lights, Beacon Green ● See Lights, Beacon on page 3-106. 3 33. Lights, Daytime Running (Override) Green ● See Lights, Daytime Running on page 3-106.

34. Lights, Dome None ● See Lights, Dome on page 3-107. 35. Lights, Flood Amber ● See Lights, Flood on page 3-107. See Lights, Flood ISO 3732 Spare on page 36. Lights, Flood ISO 3732 Spare Amber ● 3-107.

37. Lights, Fog Green ● See Lights, Fog on page 3-107.

38. Lights, Hazard Red ● See Lights, Hazard on page 3-107

39. Lights, Headlight None ● See Lights, Headlight on page 3-107.

40. Lights, Marker/Clearance None ● See Lights, Marker/Clearance on page 3-108. See Lights, Marker/Clearance/Cab on page 41. Lights, Marker/Clearance/Cab None ● 3-109. See Lights, Marker/Clearance/Trailer on page 42. Lights, Marker/Clearance/Trailer None ● 3-109.

3-98 Y53-1203-1D1 (02/14) SWITCHES

Symbol Name Symbol Color Standard Option Page 43. Lights, Panel Dimmer None ● See Lights, Panel Dimmer on page 3-109.

44. Lights, Park Light None ● See Lights, Park Light on page 3-109.

45. Lights, Spot Green ● See Lights, Spot on page 3-109.

46. Power Take-off (PTO) Amber ● See Power Take-off (PTO) on page 3-109.

See Power Take-off (PTO), Forward on page 47. Power Take-off (PTO), Forward Amber ● 3-109. 3 48. Power Take-off (PTO), Rear Amber ● See Power Take-off (PTO), Rear on page 3-109

49. Power Take-off (PTO), Brake/Clutch See Power Take-off (PTO), Brake/Clutch Amber ● Kickout Kickout on page 3-110.

50. Roofdenser Green ● See Roofdenser on page 3-110.

51. Suspension, Air Retention Amber ● See Suspension, Air Retention on page 3-110.

52. Suspension, Axle, Pusher Green ● See Suspension, Axle, Pusher on page 3-110.

53. Suspension, Axle, Tag Green ● See Suspension, Axle, Tag on page 3-110.

54. Suspension, Dump Amber ● See Suspension, Dump on page 3-110.

55. Suspension, Lift Amber ● See Suspension, Lift on page 3-110.

56. Suspension, Third Axle Lift Green ● See Suspension, Third Axle Lift on page 3-110.

(02/14) Y53-1203-1D1 3-99 SWITCHES

Symbol Name Symbol Color Standard Option Page 57. Tow Hook Green ● See Tow Hook on page 3-110. See Vehicle/Trailer Air Supply Valve on page 58. Trailer Air Supply Red ● 4-23 59. Trailer, Axle (3rd Axle) Lift Green ● See Trailer, Axle (3rd Axle) Lift on page 3-110. 60. Trailer, Axle Lift Forward Green ● See Trailer, Axle Lift Forward on page 3-110.

61. Trailer, Axle Lift Rear Green ● See Trailer, Axle Lift Rear on page 3-110. 3 62. Trailer, Belly Dump Red ● See Trailer, Belly Dump on page 3-110. 63. Trailer, Dump Gate Red ● See Trailer, Dump Gate on page 3-110. 64. Trailer, Dump Gate Center Red ● See Trailer, Dump Gate Center on page 3-111. 65. Trailer, Dump Gate Front Red ● See Trailer, Dump Gate Front on page 3-111. 66. Trailer, Dump Gate Rear Red ● See Trailer, Dump Gate Rear on page 3-111. 67. Trailer, Hotline Green ● See Trailer, Hotline on page 3-111. See Trailer, Suspension Air Dump on page 68. Trailer, Suspension Air Dump Amber ● 3-111

69. Winch Clutch Green ● See Winch Clutch on page 3-111. 70. Trip Odometer Reset Button ● Odometer/Trip Meter on page 3-53.

3-100 Y53-1203-1D1 (02/14) SWITCHES

1. Axle, Automatic Traction 8. Axle, Two Speed Control NOTE If equipped, the two speed axle Momentarily push switch in to engage switch allows you to select axle high 86 in. Aerocab Sleepers have an Traction Control (TC). and low ranges. The low range additional LVD located either behind (Off) provides maximum torque for the sleeper fuse panel or inside the 2. Axle Diff-Lock - Dual operating off-highway. The high Turn switch on to engage Front and range (On) is a faster ratio for sleeper tool-box. Rear Axle Diff Lock. highway speeds. Purpose 3. Axle Diff-Lock - Forward Rear 9. Back Up Alarm Mute 3 Turn switch on to engage Forward Turn switch on to mute Back Up Rear Axle Diff Lock. Alarm. The LVD may increase battery life and prevent unnecessary jump 4. Axle Diff Lock - Front start conditions by ensuring that an NOTE Turn switch on to engage Front Axle unattended load does not deplete Diff Lock. Kenworth discourages the use of the the battery charge to a level that will mute function. Only use mute when 5. Axle Diff-Lock Rear Rear prevent you from starting your vehicle. Turn switch on to engage Rear Rear legally required. Axle Diff Lock. Operation 10. Batteries, Low Voltage 6. Axle Diff Lock - Single Rear Disconnect (LVD) The LVD will disconnect non-vital Turn switch on to engage Single Rear battery loads when battery voltage Axle Diff Lock. If your vehicle is equipped with a Low drops below 12.3V for 3 minutes and Voltage Disconnect (LVD) feature, 7. Axle, Inter-Axle Differential the key switch is in the ACC or OFF Locked (Tandem) the LVD module is located inside the position. During the last 2 minutes Turn switch on to engage Inter-Axle driver's side kick panel. the LVD will emit a slow audible beep. Differential Lock. 30 seconds before disconnecting

(02/14) Y53-1203-1D1 3-101 SWITCHES

loads the alarm will change to a fast beep. Turning the key switch to the WARNING! 11. Brakes, ABS Off-Road Turn switch on to engage ABS ON position at anytime will reconnect Do not use the Spare Battery A & Off-Road mode. See Anti-Lock Braking System on page 3-34. loads disconnected by the LVD. B circuits or other circuits that are controlled by the LVD to power elec- See an authorized Kenworth Dealer if 12. Brakes, Parking Brake Valve tronic engine controls, ABS circuits, the LVD fails to reconnect loads during Pull yellow knob to activate parking or safety/work-related lighting. Be- brakes. See Parking Brake Valve on normal operation. fore adding any device to the vehi- page 3-102. cle's electrical system, consult your 3 Circuits Disconnected by LVD 13. Dump Truck Gate nearest authorized Kenworth Dealer Turn switch on to open Dump Truck • Cab Dome Lamps or read the contents of TMC RP-136. Gate. Failure to do so may cause equip- • Cab Accessories ment damage or lead to personal in- 14. Engine, Brake Level jury. In the up position there will be 100% • Spare Battery A & B engine retarding. In the middle position there will be 60% engine • Sleeper Dome Lamps retarding. In the down position there NOTE will be 33% engine retarding. • Sleeper Accessories The determination of what cir- cuits/loads that were connected to For more information on when and NOTE the LVD was based upon the rec- how to use the engine brake in your All LVD circuits are color-coded blue ommendation from Technology and vehicle, see the engine brake owner’s on the central electrical panel cover Maintenance Council (TMC) of the manual for additional engine brake label. American Trucking Association. To information. review the recommended practice, see TMC RP-136.

3-102 Y53-1203-1D1 (02/14) SWITCHES

15. Engine, Brake On/Off WARNING! 19. Engine Fan Override Turn switch on to activate Engine The engine fan switch allows you Brake system. Do not operate the cruise control to control the engine fan manually or automatically. With the ignition when operating on road surfaces key switch ON and the fan switch in For more information on when and with poor traction (wet, icy, or snow the MANUAL position, the engine how to use the engine brake in your covered roads) or in heavy traffic. fan will be on regardless of engine vehicle, see the engine brake owner’s Accelerations caused by the normal temperature. With the engine fan switch in the AUTOMATIC position, manual for additional engine brake operation of the cruise control could the engine fan will automatically turn information. cause you to lose control of the ve- on when the engine coolant reaches 3 hicle resulting in an injury accident. a temperature of about 200°F (93°C) 16. Engine, Cruise Control On/Off or when the air conditioning system Turn switch on to activate Cruise has reached setpoint pressure. Control System. 18. Engine, Ether Start With an electronic engine, the fan Momentarily push switch in to activate may also be activated by air intake SET 17. Engine, Cruise Control the Ether Start system. temperature, oil temperature and Set/Resume compression brake usage. The Cruise Control Set/Resume RESUME switch allows you to SET the desired speed or RESUME the desired speed after the cruise control function has been interrupted.

(02/14) Y53-1203-1D1 3-103 SWITCHES

23. Engine, Overspeed Air WARNING! CAUTION Shutdown (Test) Do not work on or near the fan with Do not operate the engine fan in Set the park brake. Hold down switch and increase engine RPM the engine running. Anyone near the the MANUAL position for extended to test that Engine Overspeed Air engine fan when it turns on could be periods of time. The fan hub was Shutdown system functions correctly. seriously injured. If it is set at MAN- designed for intermittent operation. A system reset will be required before UAL, the fan will turn on any time the Sustained operation will shorten the re-starting engine. ignition key switch is turned to the fan hub’s service life as well as re- 24. Engine, Start 3 ON position. In AUTO, it could en- duce fuel economy. This switch replaces an engine start gage suddenly without warning. Be- switch. Momentarily push switch in fore turning on the ignition or switch- 20. Engine Heater to start engine. Release switch after engine has started. ing from AUTO to MANUAL, be sure Turn switch on to activate the Engine Heater. no workers are near the fan. 25. Exhaust, Diesel Particulate 21. Engine, Remote Throttle Filter (DPF) Regeneration Switch Manually controls the diesel CAUTION Turn switch on to activate Remote Throttle Control. particulate filter regeneration process. The fan or equipment near it could Refer to Engine After-treatment Controls Operator's Manual for be damaged if the fan turns on sud- 22. Engine, Overspeed Air additional information. denly when you do not expect it. Shutdown (Manual) Turn switch on to engage the Engine Keep all tools and equipment away Overspeed Air Shutdown system. A 26. Fifth Wheel Slide from the fan. system reset will be required before Turn switch on to “Unlock” Fifth re-starting engine Wheel Slide mechanism.

3-104 Y53-1203-1D1 (02/14) SWITCHES

NOTE WARNING! 30. Ignition Key Switch Vehicles having an air slide fifth Do not move the fifth wheel while the wheel have a fifth wheel slider lock tractor-trailer is in motion. Your load The ignition key switch (located to the controlled by a switch on the instru- could shift suddenly, causing you to left of the steering column) has four ment panel. By placing the switch lose control of the vehicle. Never positions: ACC (Accessories), OFF, in the unlock position you can slide operate the vehicle with the switch ON, and START. the fifth wheel to various positions in the UNLOCK position. Always in- to adjust weight distribution. spect the fifth wheel after you lock OFF: In this position all accessories 3 the switch to be sure the fifth wheel are OFF (except those listed below) The switch is guarded to protect slide lock is engaged. Failure to and you can remove the key. comply may result in personal injury, you from accidentally activating or • The following lights and releasing the lock. death, equipment or property dam- age. accessories have power when the key is in the OFF position: 27. Fuel Heater brake lights Turn switch on to activate Fuel ° Heater. ° emergency hazard flasher 28. Generic, Air, Accessory dome and courtesy lamps (on Provides accessory air to the end ° of frame connection when switch is doors) turned on. ° electric horn SPARE 29. Generic, Spare Turn switch on to power customer ° cigarette lighter installed accessory. ° tail lights

(02/14) Y53-1203-1D1 3-105 SWITCHES

° marker lamps 64 psi (441 kPa). In this position, the headlamp life). For T660's the front ignition key cannot be removed. turn signals are used as DRL’s at full ° headlights intensity. START: Turn the key to this position ° radio station memory to start your engine: it energizes the Three controls (or conditions) will affect starter and retracts the solenoid valve whether the system is ON or OFF: ° instrument lights to allow fuel supply to the engine. • headlight (master) switch ° auxiliary power Release the key after the engine has started. If your Kenworth is equipped • engine cranking 3 ° multi-function display memory with the optional push button starter switch, use it to engage the starter. For • parking brake NOTE complete engine starting procedures, In the OFF position, fuel is cut off by see OPERATING THE ENGINE on If the headlight switch is turned OFF, a solenoid valve. page 4-40. the DRL system engages automatically after the engine starts and you release 30. Lights, Auxiliary the parking brake. If the headlight ACC (Accessory): With the key in this Turn switch on for Auxiliary Lights. switch is ON, the DRL system is position you can play the radio, defrost overridden, and headlights operate mirrors (if equipped with mirror heat) 31. Lights, Beacon normally. Also, during engine cranking or use other accessories. Turn switch on for Beacon Light(s). the DRL is temporarily turned off. ON: In the ON position all circuits are 32. Lights, Daytime Running Lights energized. Panel warning lights will (DRL) (with optional over-ride switch) light and the buzzer will sound until (1) the engine is started, (2) normal oil For C500, T800 and W900 models, operating pressure is reached, and (3) the low beam headlamps are used as air brake system pressure is above DRL’s at reduced intensity (to conserve

3-106 Y53-1203-1D1 (02/14) SWITCHES

WARNING! NOTE WARNING! Do not use daytime running lights Across the U.S.A. and Canada, Use your Hazard Warning Light Sys- (DRL) during periods of darkness or State/Provincial requirements vary tem any time you have to stop off the reduced visibility. Do not use DRL as as to when high beams and fog lights road or on the side of the road, day a substitute for headlights or other can and cannot be used together. or night. A hard-to-see vehicle can lights during operations that require Some states allow only four lights to result in an injury accident. Another lighting of your vehicle. Failure to be used together, while some allow vehicle could run into you if you do comply may result in personal injury, more. How your lights are arranged not set your flashers and follow the 3 death, equipment or property dam- will affect whether you can operate placement of emergency signals per age. headlights and fog lights concur- FMCSR 392.22. rently—always comply with the state 34. Lights, Dome or provincial requirements where 39. Lights, Headlight Turn switch on for Cab Dome Lights. you are driving. Turn switch on for headlights. When the Headlights are ON, the dash 35. Lights, Flood lights, side, and tail lights are also on. Turn switch on for cab mounted Flood 38. Lights, Hazard Lights. The four-way Hazard Warning light switch is located directly above the Your Kenworth vehicle uses an Heater / A/C Control Panel. With 36. Lights, Flood ISO 3732 Spare electronic control unit to interface the switch in the ON position, the lighting functions from the dash Turn switch on for trailer mounted emergency flasher makes all four Flood Lights. turn signals (front and rear) flash switches and turn signal stalk to the simultaneously. The flasher works turn/stop lamps on the vehicle and 37. Lights, Fog independently of the ignition switch. turn signals only on the trailer. This Turn switch on for Fog Lights. You should always use the flasher if the vehicle is disabled or parked electronic unit has control functions under emergency conditions. designed to protect the system from

(02/14) Y53-1203-1D1 3-107 SWITCHES

failures and keep your exterior lighting beams, but the headlamps operate at system operating reliably. a reduced intensity. After 1 second CAUTION of detecting a fault, the control unit If you have confirmed there is a In the event the vehicle's lighting will attempt to activate the low beam problem in the low beam wiring cir- system defaults to protection mode, headlamps again. If the fault is cuit, proceed with caution to the follow the steps below to assist in not cleared after five attempts, the next available exit/turnoff and safely determining the lighting system's headlamps will remain on high beam pull your vehicle completely off the condition. (reduced intensity) until the headlamp road and call for assistance. Driv- switch is turned off. ing your vehicle with the headlamps 3 NOTE on high beam (at reduced intensity) Correction: Check both low beam Stop your vehicle before diagnosing for a prolonged period could lead headlamp fuses in the power the system. to an injury accident. Contact your distribution box. nearest Kenworth dealer to have Switch Position: Headlamps On, Low • If you find a blown fuse, replace it the problem corrected as soon as Beam Selected with the same amperage fuse and possible. try the headlamps again. Symptom: High beam indicator lamp 40. Lights, Marker/Clearance in dash is illuminated. Headlamps • If the fuse continues to blow, Turn switch on to control Cab and momentarily flashed several times, but contact your nearest Kenworth Vehicle Marker/Clearance lights. otherwise appear to operate okay. dealer for service. A separate switch next to the headlight Cause: The electronic control unit switch turns on the marker lights for has detected a short in the right or both the cab and trailer. These are left low beam wiring circuit. Under the five amber lights on top of the this condition, the system controller cab, front trailer lights, and red rear automatically activates the high truck/trailer lights.

3-108 Y53-1203-1D1 (02/14) SWITCHES

PTO disengagement may not have 44. Lights, Park Light NOTE occurred. Turn switch on for Park Lights. When An interrupt switch for the trailer the Park Lights are on the dash lights, marker lights is mounted on the end side and tail lights are also on. NOTE of the turn signal lever. Do not drive vehicle with PTO en- 45. Lights, Spot Turn switch on for Spot Light. gaged. 41. Lights, Marker/Clearance/Cab Turn switch on to control Cab Marker/Clearance lights separately 46. Power Take-off (PTO) NOTE from the trailer. Turn switch on to engage PTO. 3 Actual PTO engagement / disen- 42. Lights, Marker/Clearance/ Your Kenworth vehicle may be gagement may be delayed momen- Trailer equipped with a dash mounted tarily since it is controlled by the air Turn switch on to control Trailer system and mechanical movement. Marker/Clearance lights separately air switch that controls PTO from the vehicle marker/clearance engagement/disengagement. lights. CAUTION When the operator activates the switch 43. Lights, Panel Dimmer Increasing engine RPM before the for the PTO, the status indicator Rotate thumb wheel up to brighten PTO is actually engaged could pre- lamp (located on the switch) will panel lights. Rotate thumb wheel vent the PTO from engaging and/or down to dim panel lights. immediately illuminate even though cause PTO damage. PTO engagement may not have occurred. NOTE 47. Power Take-off (PTO), Forward The Headlight Switch must be in one Turn switch on to engage forward If the PTO is engaged and the operator PTO. of two ON positions for the panel turns the switch OFF, the PTO status lights to operate. indicator lamp (located on the switch) will go out immediately even though

(02/14) Y53-1203-1D1 3-109 SWITCHES

48. Power Take-off (PTO), Rear 54. Suspension, Dump 55. Suspension, Lift Turn switch on to engage Rear PTO. Turn switch on to deflate suspension Turn switch on to over-inflate air bags. The switch is guarded suspension air bags. Turn switch off to protect you from accidentally for normal suspension height. 49. Power Take-off (PTO), deflating the suspension. Brake/Clutch Kickout Turn switch on to disable PTO when 56. Suspension Third Axle Lift brake pedal or clutch pedal are WARNING! Turn switch on to raise Third Axle. depressed. Do not operate the Air Suspension 57. Tow Hook 3 50. Roofdenser Deflate Switch (Dump Valve) while Turn switch on to remove the slack Turn switch on for roof mounted driving. Sudden deflation while your from the Tow Hook. condenser fan. vehicle is moving can affect han- 58. Trailer Air Supply 51. Suspension, Air Retention dling and control. Failure to comply The red octagon knob controls the air The Air Retention Switch keeps may result in personal injury, death, supply to the trailer. the air suspension bags from equipment or property damage. losing air pressure when used with 59. Trailer, Axle (3rd Axle) Lift vehicle outriggers. Depress the Air Turn switch on to lift 3rd Trailer Axle. Retention Switch prior to deploying CAUTION the outriggers. While outriggers are 60. Trailer, Axle Lift Forward deployed axle stability is maintained. Operating a vehicle with air suspen- Turn switch on to lift Forward Trailer sion bags either overinflated or un- Axle. 52. Suspension, Axle, Pusher derinflated may cause damage to Turn switch on to lower Single or driveline components. If a vehicle 61. Trailer, Axle Lift Rear Forward Pusher Axle. must be operated under such condi- Turn switch on to lift Rear Trailer Axle. 53. Suspension, Axle, Tag tions, do not exceed 5 mph (8 km/h). Turn switch on to lower tag axle. 62. Trailer, Belly Dump Turn switch on to open Trailer Belly Dump.

3-110 Y53-1203-1D1 (02/14) SWITCHES

63. Trailer Dump Gate Turn switch on to open Trailer Dump Gate.

64. Trailer, Dump Gate Center Turn switch on to open Trailer Center Dump Gate.

65. Trailer, Dump Gate Front Turn switch on to open Trailer Front Dump Gate. 3

66. Trailer, Dump Gate Rear Turn switch on to open Trailer Rear Dump Gate.

67. Trailer Hotline Turn switch on to supply electrical power to trailer accessories.

68. Trailer, Suspension Air Dump Turn switch on to deflate Trailer Air Suspension.

69. Winch Clutch Turn switch on to engage Winch Clutch.

(02/14) Y53-1203-1D1 3-111 STEERING COLUMN

STEERING COLUMN Turn Signal/High Beam Turn Signals Switch • To signal a right turn, push the Introduction lever forward (clockwise). NOTE The ignition key must be turned to • To signal a left turn, pull the lever ON for the signal/switch to operate. back (counterclockwise). • Each time the turn indicator is The lever-action turn signal/high beam activated the audible warning 3 switch is located on the left side of the emits a short beep. steering column.. Each time a turn indicator is activated the buzzer emits a short beep.

Steering Column Controls

1. Turn Signal Lever 2. Trailer Brake Hand Valve (optional) 3. Tilt Steering Column Lever (optional) 4. Wiper switch

3-112 Y53-1203-1D1 (02/14) STEERING COLUMN

High Beam NOTE CAUTION If the vehicle turn signals and turn After you complete a turn, shut NOTE signal indicators in the dash gauge the system off by returning the The headlights must be ON for the cluster ever begin flashing at an lever to the “OFF” (center) position. high beam switch to operate. accelerated rate (115 cycles per The switch's lever action is NOT minute) when the turn signal lever self-canceling. Failure to shut off • To switch your headlights to lower is in the OFF (center) position, or a turn signal could confuse other or higher beam, gently pull the turn when a Right/Left turn has been se- drivers and result in an injury ac- signal lever, toward the steering 3 lected, the problem may be related cident. An indicator light in the wheel, until you hear the switch to a failed turn signal switch or turn instrument panel will flash until the click and the beam changes. signal module. In either case, the turn signal is turned off. The blue indicator light in the problem is not a failed bulb. Contact instrument panel will be ON when your nearest authorized Kenworth the high beam is being used. Dealer to have the problem cor- rected as soon as possible. • To return to previous beam: pull the lever towards the steering wheel again. • To momentarily flash your headlights (illuminating the high-beams), push the turn signal lever forward.

(02/14) Y53-1203-1D1 3-113 STEERING COLUMN

Windshield Wipers/Washer NOTE Your Kenworth is equipped with a • You cannot momentarily flash two-speed, intermittent windshield headlights when high beams are wiper system. A seven-position rotary on. The headlights will flash on if wiper switch (located on the turn-signal they are off, if headlamps are on lever) operates the windshield wipers as low beams, headlamps dim to and washer. Rotate the end of the turn 25%. 1 Press in for washer pump signal lever to change the wiper mode. 2 Rotate to change wiper 3 • Headlight flash is not available mode on models with high intensity NOTE 3 Press button for Marker / ID discharge (HID) headlight option. The ignition key must be turned to Lamp flash • Check your local state’s ON or ACC for the wiper/washer The first position after OFF is the regulations for any restriction on switches to operate. intermittent #1 cycle. The next the use of the high-beam flashing positions are intermittent #2, #3 and function. #4. The last two positions are wiper low speed and wiper high speed. See the wiper switch settings table for intermittent delay times.

NOTE The ignition key must be turned to ON or ACC for the wiper/washer switch to operate.

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Wiper Switch Settings To Wash the Windshield WARNING! Push the rotary wash/wipe knob in Do not drive with worn or dirty wiper (towards steering column), hold for blades. They can reduce visibility, more than 0.8 seconds and then making driving hazardous. Clean release. Hold the knob in to extend blades regularly to remove road film the washing cycle. After the lever and wax build-up. Use an alco- is released, the wipers will shut off hol based cleaning solution and a automatically or resume the wiper’s lint-free cloth, and wipe along the 3 setting speed. blades. Wiper Switch Wiper Speed Position To activate the wipers for one swipe Off Off without activating the washer (“mist” CAUTION Intermittent #1 20 Second Delay function), push the turn signal lever If the electric pump is operated for a Intermittent #2 17 Second Delay in (towards the steering column) and long period (more than 15 seconds) Intermittent #3 7 Second Delay release in less than 0.5 seconds. The with a dry reservoir, the pump rotor Intermittent #4 4 Second Delay wipers will perform a single swipe and Low Low Speed may be damaged. High High Speed then resume the wiper’s setting speed. Clean all inside and outside windows The windshield washer reservoir is regularly. Use an alcohol- based located inside the engine compartment cleaning solution and wipe dry with on the left side of the steering column. either a lint free or a chamois cloth. Check the windshield washing fluid Avoid running the wiper blades over a level daily. If necessary, fill to top. dry windshield to prevent scratching the glass. Spray on washer fluid first.

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Trailer Brake Hand Valve Stop/Turn Signal Lamp Maximum Number of Lamps Operation Allowed per Circuit This hand valve, mounted on the Vehicle Stop/Turn Signal Circuit steering wheel column, provides air Your Kenworth vehicle uses combined • pressure to apply the trailer brakes stop/turn signal lamps at the rear of The lighting control unit is limited only. It operates independently of the vehicle, using the same bulb to to 5 amps total, or two (2) 25 watt the foot treadle valve. See Using the perform both functions. This means a incandescent bulbs per side. Do not Brake System on page 4-16, for more single bulb is used for the brake lamp wire more than two incandescent bulbs instructions on proper use of the Trailer as well as the turn signal lamp. This per side to the vehicle tail lamp fixtures. 3 Brake Hand Valve. bulb will burn steadily with the brakes If more than two bulbs are required applied. The same bulb will flash with for each tail lamp fixture, install LED the turn signal activated, even with the type lamps, or contact your nearest brakes applied. Kenworth dealer for other options. • Trailer Turn and Vehicle Forward Side Facing Turn Lamp Circuit

The lighting control unit is limited to 20 amps or nine (9) 25 watt incandescent bulbs total (per side) for the combination of trailer turn lamps and vehicle forward side facing turn lamps. Do not wire more than nine incandescent bulbs per side for the combination of trailer turn lamps and vehicle forward side facing turn lamps.

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If more than nine bulbs per side are you experience intermittent turn signal Adjustable Tilt/Telescoping required, install LED type lamps, or operation, the problem is either a Column contact your nearest Kenworth dealer short in the turn signal circuit or the for other options. maximum number of bulbs has been The Adjustable Tilt/Telescoping exceeded for the circuit. Column is an option on your CAUTION Kenworth. Depending on your If you experience any vehicle stop/turn Before installing additional vehicle vehicle’s configuration, you may signal issues, contact your nearest stop/turn lamps, trailer turn lamps or have a Tilt/Telescoping steering Kenworth dealer. additional forward side facing turn column or Fixed steering column. 3 lamps on the vehicle, make sure the The tilt feature allows forward and lighting circuit limits described above rearward movement of the wheel. are not exceeded. Exceeding the The telescoping feature allows you number of lamps designated above to move the wheel up and down. To can/will cause the electronic control activate these features, locate the unit to default to a protection mode, Tilt/Telescoping pedal at the base of causing the lamps to not function the steering column. properly.

Similar to the headlamp system, if a problem is detected with the electronic control unit, the control unit will cycle the turn signals off once every 9 seconds. You can detect that this is occurring if the turn signal indicators in the dash operate intermittently. If

(02/14) Y53-1203-1D1 3-117 STEERING COLUMN

To tilt, raise or lower the Telescoping Horn WARNING! steering wheel: Do not adjust the Tilt-Telescoping Your vehicle may be equipped with • Push the pedal down fully. Move Steering Wheel while the vehicle is air horns. To operate, pull on the the wheel to the desired height in motion, it could cause loss of con- lanyard extending from the overhead and angle, then release the pedal trol. You would not be able to steer header panel. Your vehicle may also to lock the wheel at the desired properly and could have an acci- have an electric horn. To sound the position. dent. Make all adjustments to the electric horn, press the button in the center of the steering wheel, which 3 steering column while the vehicle is stopped. Failure to comply may re- is the standard location for electric sult in personal injury, death, equip- horns (optional horn locations may be ment or property damage. requested).

1 Tilt / Telescoping Steering Column Lever (optional)

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SmartWheel Multiplex System Description and horn are still located in the truck Control System power distribution box. The electronics The multiplex steering wheel system module is located between the dash CAUTION consists of the steering wheel mounted switches and the relays, so that it can controls, the multiplex electronics control them. Under no circumstances should module, the clockspring in the steering you attempt to service the steering column and the interconnecting wire The clockspring in the steering wheel, clockspring, or any of the harnesses. column is a rotating electrical contact electrical wiring in the multiplex sys- containing a wound electrical ribbon tem, or any steering components The steering wheel mounted controls that lets "multiplexed" electrical signals 3 (steering column, steering driveline tell the multiplex electronics module to get from the steering wheel hub or steering gear). Tampering with (located behind the dash) which to the electronics module and still these components may result in an electrical circuit to turn on or off. allow the steering wheel to turn. The inoperable multiplex system. The controls are connected to the clockspring is located at the top of the electronics module with two wires, steering column directly beneath the using a "multiplexed" electronic signal. steering wheel. This multiplexed signal allows more than one switch to use the same pair of wires.

The multiplex electronics module contains relays and electronics to activate the circuits controlled by the steering wheel controls. These relays are not replaceable. The relays that control the headlights, marker lights

(02/14) Y53-1203-1D1 3-119 STEERING COLUMN

Operating the System A. Horn WARNING! The engine retarder is NOT intended Depressing the bottom center bar as the primary brake for the vehicle, activates the electric horn. nor is it an emergency brake. The B. Engine Retarder engine retarder only helps the ser- vice brakes by using engine pres- These controls are located on the sure to slow the drivetrain. Use the 3 right-hand side of the steering wheel service brakes for quick stops. Fail- hub. ure to comply may result in personal injury, death, equipment or property WARNING! damage. 1. Marker Light "Flash" The service brakes must be used in 2. Engine Retarder "Off" WARNING! 3. Engine Retarder "Medium" an emergency. The engine or re- 4. Engine Retarder "High" tarder alone might not stop you fast Do not operate the engine retarder 5. Engine Retarder "Low" enough to prevent an accident. Re- when driving/operating your vehicle 6. Cruise Control "Coast" lying only on the engine retarder, bobtail or with a loaded or unloaded 7. Cruise Control "Resume" may result in personal injury, death, trailer on road surfaces with poor 8. Cruise Control "Set" equipment or property damage. traction (wet, icy, or snow covered 9. Cruise Control "Off" roads) or in heavy traffic. Braking 10. Headlamp Flash caused by the normal operation of the engine retarder could cause you to lose control of the vehicle and may result in personal injury, death, equipment or property damage.

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NOTE NOTE WARNING! The exhaust brake and engine brake Your engine may only have 2 engine Do not operate the cruise control are two types of engine retarders. retarder settings, LOW and HIGH. when operating on road surfaces Refer also to the Engine Manufac- If so, the MEDIUM button is non- with poor traction (wet, icy, or snow turer’s Operator Manual and to the operational. covered roads) or in heavy traffic. Engine Retarder manual for addi- Accelerations caused by the normal tional instructions. • To Turn Off: operation of the cruise control could cause you to lose control of the ve- 3 • To Activate: Press for OFF. hicle resulting in an injury accident. To activate the desired engine retarder setting: C. Cruise Control

These controls are located on the Press for LOW. left-hand side of the steering wheel hub. Press for MEDIUM.

Press for HIGH.

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• Tap the brake pedal. • To Turn On: NOTE Press the ON button. Cruise Control may not hold the set • Tap the clutch pedal. speed going down hills. If the speed • Press the "OFF" button. • To Turn Off: increases going down a hill, use the brakes to slow down. This will can- Resuming Cruise Control Press the OFF button. Any previous cel Cruise Control. speed settings are cleared. 1. If you tapped the brake or Changing the Cruise Set Speed clutch pedal, the cruise control 3 Using Cruise Control While Driving remembered the previously set • To increase the cruise set speed: cruise speed. To resume that Setting Cruise Speed set speed, accelerate above the 1. Ensure that the vehicle speed is Press the "SET" button until the minimum cruise control speed and above the minimum cruise control desired speed is achieved, then press the "RESUME" button. release the button. speed (15 mph for Caterpillar 2. If you pressed the "OFF" button or engines, 30 mph for the Cummins • To decrease the cruise set speed: turned the ignition key OFF, this engines) and the engine speed is cleared the system memory and above 1100 rpm. Press the "RESUME" button and you will need to set a new cruise 2. Press the "ON" button. coast to the desired lower speed, then speed. release the button. 3. Accelerate the vehicle to the desired cruise speed. Cancelling Cruise Control 4. Press the "SET" button to set the You can cancel cruise control in any cruise speed. of these ways:

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D. Headlight/Marker Lamp Flash Using Cruise Control for Stationary PTO Operation • Headlight Flash:

Setting Idle Speed Press located on the upper left corner of the steering wheel 1. Ensure parking brakes are applied. hub. The headlights will flash on if they are off, if 2. Ensure transmission is in Neutral. headlamps are on as low beams, headlamps dim to 3. Engage PTO per the 25%. This function is disabled on T660 with HID headlamp 3 manufacturer's operating option. If headlamps are on instructions. high beams, high beams are deactivated, low beams are 4. Press the "ON" button. lit 25%. Headlamps return to low beam, not high beam. 5. Press the "SET" button to obtain the desired engine rpm. • Marker Lamp Flash:

Cancelling Cruise Control Press to flash on the marker lamps if they are off, or blink off if they are on while the button is You can cancel cruise control in any held down. This feature works of these ways: with the marker lamp switch on the dash in either position. • Tap the brake pedal. The button controls the trailer marker lamps (and the tractor • Tap the clutch pedal. marker lamps if they are on the same switch). • Press the "OFF" button.

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MIRRORS Power Mirror Switch WARNING! If your vehicle is equipped with power Introduction Convex mirrors can distort images mirrors, the directional controls for and make objects appear smaller both mirrors are located near the top of Your vehicle comes equipped with two and farther away than they really the driver side door trim pad. outside rear view mirrors that enable are. You could have an accident you to see to the sides and behind if you are too close to another ve- your vehicle. Be sure both mirrors are hicle or other object. Keep plenty 3 adjusted properly before you begin of space between your vehicle and driving. others when you turn or change lanes. Remember that other objects WARNING! are closer than they may appear. Adjust all mirrors before driving. Ad- Failure to comply may result in per- justing the mirrors while driving can sonal injury, death, equipment or cause you to take your eyes off the property damage. 1. Power Mirror & Heated road, which could result in an acci- Mirror Controls dent. Failure to do so could lead to serious injury or equipment damage.

To provide good visibility, adjust the mirror so the side of your vehicle appears in the inboard part of the mirror.

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NOTE 2. Depress the mirror directional control pad towards the arrows After mirror adjustments have been pointing left or right to adjust the completed, return the mirror selec- mirror in/out. tor switch back to the center (neu- tral) position to prevent unintentional NOTE adjustments to the mirrors. Because the Moto mirrors have only 2- way adjustment, the mirror direc- To Adjust Moto Mirrors tional control pad is also restricted in 3 1. For in/out mirror adjustment: Move its movement to left or right ONLY. 1. Mirror Directional Control the mirror selector switch to the Pad right or left from the neutral center 2. Mirror Selector Switch NOTE position to select the desired mirror for adjustment. After mirror adjustments have been To Adjust Kenworth Aerodynamic completed, return the mirror selec- Style Mirrors NOTE tor switch back to the center (neu- 1. Move the mirror selector switch tral) position to prevent unintentional If the mirror is fixed (non-motorized) to the right or left from the neutral adjustments to the mirrors. on the left side, then the mirror se- center position to select the lector switch will ONLY allow selec- desired mirror for adjustment. tion of the neutral and right mirror 2. Depress the mirror directional switch positions. control pad in one of its four arrow directions to adjust the mirror in/out or up/down.

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Mirror Heat Button

Your Kenworth vehicle may be equipped with optional heated mirrors. Mirror heat is controlled by the mirror heat switch button, which is part of the mirror switch module located on the driver side door pad. 3

1. Mirror Heat Switch Button 2. Mirror Heat Indicator Light

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DRIVING TIPS AND TECHNIQUES Introduction ...... 4-5 Coasting ...... 4-5 Descending a Grade ...... 4-6 Economical Driving ...... 4-6 Fuel - Excess Consumption ...... 4-8 Safe Driving ...... 4-9 Cruise Control ...... 4-11 Air Suspension Height/Air Pressure ...... 4-12 4 Fifth Wheel...... 4-14 OPERATING THE BRAKE SYSTEM Introduction ...... 4-16 Air Supply System ...... 4-17 Using the Parking Brake ...... 4-19 European Air System Parking Brake Option for Export Vehicles ...... 4-22 Vehicle/Trailer Air Supply Valve ...... 4-23

(02/14) Y53-1203-1D1 4-1 DRIVING

Brake Safety and Emergency...... 4-27 Anti-Lock Braking System ...... 4-29 Trailer Brake Hand Valve...... 4-34 Driving with an Unloaded Trailer ...... 4-34 Engine Retarders ...... 4-35 Exhaust Brake ...... 4-36 Engine Brakes ...... 4-37 Brake Components ...... 4-37 OPERATING THE ENGINE 4 Introduction ...... 4-40 Starting Procedure - Normal Temperature . . . . 4-41 Starting Procedure - Cold Weather ...... 4-42 Engine Block and Oil Pan Heater (Option) . . . . 4-42 Engine Warm-up ...... 4-43 Ether Metering Equipment ...... 4-46 Cruise Control ...... 4-47 Engine Fan Control ...... 4-49 Engine Control Display ...... 4-50

4-2 Y53-1203-1D1 (02/14) DRIVING

Engine Shutdown System ...... 4-50 OPERATING THE REAR/DRIVE AXLE Introduction ...... 4-52 Inter-Axle Differential Lock ...... 4-52 Driver Controlled Main Differential Lock . . . . . 4-55 Dual Range (Two-Speed) Rear Axle ...... 4-56 Auxiliary Axles - Pusher or Tag ...... 4-58 OPERATING THE TRANSMISSION Introduction ...... 4-65 4 Transmission Warm-Up ...... 4-65 Operating Manual Transmissions ...... 4-66 Putting the Vehicle in Motion ...... 4-66 More Transmission Tips ...... 4-69 Operating Automatic Transmissions ...... 4-71 Auxiliary Transmissions ...... 4-72 Steerable Drive Axle ...... 4-72

(02/14) Y53-1203-1D1 4-3 DRIVING

SHUT-DOWN Introduction ...... 4-73 Final Stopping Procedures ...... 4-73 Before Stopping the Engine ...... 4-74 Refueling ...... 4-75 Sleeper Bunk...... 4-76

4

4-4 Y53-1203-1D1 (02/14) DRIVING TIPS AND TECHNIQUES

DRIVING TIPS AND Coasting TECHNIQUES Besides being illegal and dangerous, Do not coast with the transmission coasting is also expensive. It causes in neutral or with the clutch pedal premature failure or damage to the Introduction depressed. clutch and transmission and overloads the brake system. This section covers driving tips and WARNING! techniques on how to drive your Coasting with the transmission Do not coast with the transmission Kenworth efficiently. For further in neutral also prevents proper in neutral or with the clutch pedal information on driving techniques, read transmission component lubrication. depressed, it is a dangerous prac- the Truck Driver Handbook included During coasting the transmission is tice. Without the use of the retarding in your glove box literature package. driven by the rear wheels, and the power of the drivetrain, your vehicle It will give you more tips on starting, countershaft gear (which lubricates can reach dangerous speeds. At shifting, and driving your vehicle. the transmission components by oil 4 very high speeds you may not be splash) will only be turning at idle able to put the transmission in any speed. gear. At high speeds you could seri- ously damage your vehicle or cause an accident when you put the trans- mission in gear. The engine speed could exceed the maximum gov- erned speed and cause a serious accident due to mechanical failures. Failure to comply may result in per- sonal injury, death, equipment or property damage.

(02/14) Y53-1203-1D1 4-5 DRIVING TIPS AND TECHNIQUES

Descending a Grade Economical Driving Engine Overspeed - RPM

WARNING! The following section includes • Operate the engine within the recommendations for best engine optimum engine RPM range and Do not hold the brake pedal down performance and economy: do not allow the RPM's to exceed too long or too often while going the maximum governed speed. down a steep or long grade. This See your Engine Operation could cause the brakes to overheat and Maintenance manual for and reduce their effectiveness. As information regarding engine a result, the vehicle will not slow RPM. down at the usual rate. To reduce the risk of personal injury and/or an • When the engine is used as a accident, before going down a steep brake to control vehicle speed 4 or long grade, reduce speed and (e.g., while driving down a grade), shift the transmission into a lower do not allow the engine RPM gear to help control your vehicle to exceed maximum governed speed. Failure to follow procedures speed. for proper downhill operation could result in loss of vehicle control and • Under normal load and road may result in personal injury, death, conditions operate the engine in equipment or property damage. the lower end of the range.

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Use of Tachometer has no control over the engine RPM NOTE when it is being driven by the vehicle's Often these recommendations are The tachometer is an instrument that transmission, for example, on steep secondary to maintaining an ade- aids in obtaining the best performance downgrades. Apply service brakes or quate and safe speed relative to the of the engine and manual transmission, shift to a higher gear. surrounding traffic and road condi- serving as a guide for shifting gears. tions. Refer to the Engine Operation and Maintenance manual for optimum engine RPM. CAUTION To avoid engine damage, do not let • If the engine RPM moves beyond the engine RPM go beyond the max- the maximum governed speed, imum governed RPM valve damage indicating an overspeed condition, could result if overspeed conditions apply the service brake or shift to 4 occur. a higher gear to bring engine RPM within the optimum speed range. • When driving downhill: shift to a lower gear, use the engine brake (if so equipped), and use the service brake, keeping the engine speed below 2,100 rpm.

When the engine speed reaches its maximum governed speed, the injection pump governor cuts off fuel to the engine. However, the governor

(02/14) Y53-1203-1D1 4-7 DRIVING TIPS AND TECHNIQUES

Fuel economy and engine Fuel - Excess Consumption • improperly inflated tires performance are also directly related to driving habits: The vehicle's fuel consumption is • wheel bearings improperly connected to three important factors: adjusted • The best results in trip time and maintenance, driving habits, and fuel economy are obtained while general condition of the road, traffic • clutch improperly adjusted or worn driving the vehicle at a steady conditions, and vehicle load. (slipping) speed. Maintenance • fuel leaks • Shift into higher or lower gears (or apply the service brake) to keep Proper maintenance will keep the engine RPM near the lower end of vehicle running like new even after the optimum operating range. long periods of use. The driver must 4 • Avoid rapid acceleration and perform the daily and weekly checks braking. of the vehicle. Maintenance factors affecting fuel consumption: • air and/or fuel filters clogged • engine valves out of adjustment • injection pump improperly synchronized • injection nozzles defective or uncalibrated

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Driving Habits General Condition Safe Driving

Wrong driving habits must be Other factors affecting fuel NOTE corrected and the recommendations consumption are related to loads The following recommendations are on economic driving should be and type of roads on which the vehicle merely informative and do not cover followed. operates. It is not always possible to all safety precautions. Safe driving choose the most adequate road, but is, above all, the responsibility of the Driving factors affecting fuel it must be kept in mind that the ideal driver. consumption: road is the one that allows a steady speed in high gear, without requiring • excessive speed and unnecessary frequent braking and acceleration. The safe operation of a vehicle is fast acceleration not just following the established traffic rules, but should also include: • long periods of idling The following general conditions can affect fuel consumption: maintaining the vehicle in good 4 • driving with foot resting on the mechanical condition, and proper (manual transmission) clutch • overload operation of the engine, transmission, and brakes. pedal • unbalanced load • very high load • inadequate roads • traffic conditions

(02/14) Y53-1203-1D1 4-9 DRIVING TIPS AND TECHNIQUES

The following guidelines will help Checks and Adjustments on page you to drive the vehicle safely: 5-46. WARNING! Do not exceed the specified load rat- • Make a thorough inspection of the • Obey speed limits and all traffic ing. Overloading can result in loss vehicle, daily and weekly. See signals. of vehicle control and personal in- Driver's Check List on page 1-35. • When driving downhill, select one jury, either by causing component • Ensure that windows, mirrors, and gear lower than the up-hill gear. failures or by affecting vehicle han- lights are clean. And use the brakes properly, do dling. Exceeding load ratings can not ride them. also shorten the service life of the • Check all tires for damage and vehicle. Failure to comply may re- correct inflation pressure. • Do not exceed maximum governed sult in personal injury, death, equip- speed (as specified in the Engine ment or property damage. • Adjust the seat to a comfortable Operation and Maintenance 4 driving position, for easy access to Manual). The components of your pedals and vehicle controls. • vehicle are designed to provide • Adjust rear view mirrors. satisfactory service if the vehicle is not loaded in excess of either • Always use the safety belts. the gross vehicle weight rating (GVWR), or the maximum front • Do not exceed the GVWR. and rear gross axle weight ratings • Proportionally distribute loads on (GAWRs). (Axle weight ratings are the frame. listed on the driver's door edge.) • Always keep the brakes adjusted and in proper condition. See

4-10 Y53-1203-1D1 (02/14) DRIVING TIPS AND TECHNIQUES

Cruise Control NOTE NOTE For your safety and the safety of For SmartWheel Cruise Control, others, follow routine and periodic see SmartWheel Control System on maintenance schedules for all com- page 3-119. For dash cruise control ponents on your vehicle. See Table This feature can improve fuel mileage switch operation, see Cruise Control 9, Maintenance Schedule on page and can reduce driver fatigue by on page 4-47. 5-18. maintaining a constant vehicle speed. NOTE WARNING! Cruise Control will not function until Do not operate the cruise control the operator has depressed both the when operating on road surfaces service brake pedal and the clutch 4 with poor traction (wet, icy, or snow pedal at least one time after each covered roads) or in heavy traffic. start-up. For vehicles with auto- Accelerations caused by the normal mated transmissions and no clutch operation of the cruise control could pedal, only the service brake pedal cause you to lose control of the needs to be depressed. vehicle and may result in personal injury, death, equipment or property damage.

(02/14) Y53-1203-1D1 4-11 DRIVING TIPS AND TECHNIQUES

Air Suspension Height/Air Suspension Air Pressure Gauge Pressure CAUTION Operating a vehicle with air sus- The Suspension Air Pressure gauge pension bags either overinflated or (option), see Optional Gauges on under-inflated may cause damage page 3-69, indicates the amount of air to driveline components. If a vehi- pressure in the air suspension springs Your vehicle may have an air cle must be operated under such in pounds per square inch (psi). Air suspension and a deflation switch conditions, do not exceed 5 mph (8 pressure in the spring is related to which allows the air in the suspension km/h). Failure to comply may result the rear axle load. The greater the to be exhausted from a switch on the in equipment damage. rear axle load, the greater the air dash. The normal purpose of this pressure in the air bags. Therefore, feature is to allow you to lower the the air pressure displayed will vary, depending upon the rear axle load. 4 vehicle for loading. On tractors, the deflate switch allows you to lower the fifth wheel to slide under a trailer.

A guard on the switch prevents you from accidentally deflating the suspension.

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Driving with Deflated Air Springs To get to a repair facility, do the following: WARNING! If an air spring ruptures, there will Low air pressure could make brakes be enough air pressure to drive the 1. Remove the height control link connected to the axle and to unsafe for driving by not provid- vehicle to a safe stop off the highway ing sufficient air brake application to investigate the problem. the suspension air valve control arm. This will cause the air valve pressure in an emergency, which control arm to center in the closed could lead to an accident. Before position. driving the vehicle, make sure the air pressure pumps up to over 100 2. The air system can then be psi for normal brake operation. If it pumped up to normal pressure for does not reach 100 psi, do not try to continued operation. move the vehicle. Failure to comply may result in personal injury, death, 4 equipment or property damage.

(02/14) Y53-1203-1D1 4-13 DRIVING TIPS AND TECHNIQUES

Fifth Wheel Fifth Wheel Jaw Lock Air-Controlled Sliding Fifth Wheel To unlock the fifth wheel lock: The following applies to tractor configurations: • Pull out on the lever (usually located on the left-hand side of the Vehicles having an air-controlled fifth wheel) until it remains in an WARNING! sliding fifth wheel have a fifth wheel over center position. Ensure that all fifth wheel mainte- slider lock controlled by a switch on the nance, adjustments, and rebuilding Hook Up: accessory switch panel. To operate are done only by a qualified me- this type of lock, move the switch to chanic. An improperly maintained • After connecting your tractor to the the appropriate position. By placing fifth wheel can cause a trailer to sep- trailer, always inspect the jaws to the switch in the UNLOCK position, arate from a tractor. This could lead be sure they have locked on the you can slide the fifth wheel to various kingpin before driving. 4 to a serious accident. Failure to positions to adjust weight distribution. comply may result in personal injury, There is a guard on this switch to death, equipment or property dam- protect you against accidentally age. activating or releasing the lock.

Your Kenworth T700 is equipped with either a Fixed or an Air-Controlled Sliding Fifth Wheel. Either type should self lock when a trailer king pin trips the locking dogs as the tractor is backed under a trailer.

4-14 Y53-1203-1D1 (02/14) DRIVING TIPS AND TECHNIQUES

Fifth Wheel Lubrication WARNING! • Frequently operate and lubricate Do not move the fifth wheel while the movable or sliding fifth wheels to tractor-trailer is in motion. Your load prevent corrosion. could shift suddenly, causing you to lose control of the vehicle, which can CAUTION result in an accident. Never operate the vehicle with the switch in the UN- Both the fifth wheel plate and the LOCK position. Always inspect the slide tracks (if a slider) should be fifth wheel after you lock the switch cleaned and lubricated periodically to be sure the fifth wheel lock is en- to ensure smooth turning and slid- gaged. Failure to comply may result ing action. Failure to keep these sur- in personal injury, death, equipment faces lubricated can lead to frame or 4 or property damage. driveline damage.

See Frame and Fifth Wheel on page 5-95, for maintenance information.

(02/14) Y53-1203-1D1 4-15 OPERATING THE BRAKE SYSTEM

OPERATING THE is why, when you push down on the BRAKE SYSTEM brake pedal, you do not feel the same WARNING! amount of pressure on the pedal that Never drive your vehicle with the you do when you apply the brakes on Introduction parking brake applied. Always re- your car. All you are doing on your lease the parking brakes prior to truck is opening an air valve to allow The operation of the vehicle's braking moving the vehicle. Failure to dis- air to flow into the brake chambers. system and many vehicle accessories engage the parking brakes prior to depends upon the storage and moving your vehicle could result in WARNING! application of a high-pressure air excessive heat buildup in the brake supply. The brake system is a critical vehicle system, resulting in a fire. Failure safety system. For the safety of you to comply may result in personal This air brake system is of the dual and others around you, have the ve- injury, death, equipment or property 4 circuit type: it has a circuit for the front hicle submitted for periodic preven- damage. wheels, a separate circuit for the rear tive maintenance checks as well as wheels, and one for the trailer. The having any suspected problems im- NOTE system is supplied by an engine-driven mediately checked by an authorized compressor. The vehicle's compressor Kenworth Dealer. Failure to prop- Today's diesel electronic engines takes outside air and compresses it, erly maintain your brake system can have significant torque and starta- usually to 100-130 psi (690-896 kPa). lead to serious accidents. Failure to bility power at low RPM. Combina- The compressor air then goes to the comply may result in personal injury, tions of engine speed and available air tanks to be stored until needed. death, equipment or property dam- torque may over-power the vehicles age. parking brakes. When you operate your air brakes, the stored compressed air flows into the chambers where it is used to apply your truck and trailer brakes. That

4-16 Y53-1203-1D1 (02/14) OPERATING THE BRAKE SYSTEM

Air Supply System Air Dryer Your Kenworth vehicle may be Contamination of the air supply system Bendix AD-IS Series Air Dryers equipped with a Bendix AD-IS series is the major cause of problems in air dryer. Any air dryer replacement air-operated components such as WARNING! should be made with an identical brake valves and suspension height If a different air dryer brand or model component. control valves. To keep contaminants is installed on the vehicle other than The AD-IS Series air dryer has to the lowest possible level, follow all what was originally installed, it could incorporated into its design various maintenance procedures. cause the air system to not perform components that have typically been correctly unless the full air system installed separately on the vehicle (see design is reviewed and modifica- below for components/ areas affected). tions made to comply with Federal Motor Vehicle Safety Standards • Pressure protection valves 4 (FMVSS 121 - Air Brake Systems) or, in the case of chassis equipped • Safety valve with the European air system, ECE • Governor and plumbing R13. Failure to abide by this warning and maintain compliance to FMVSS • Plumbing of the front and rear 121 or ECE R13 could cause loss service air tanks of vehicle control and may lead to personal injury or death. • Plumbing to accessory systems

(02/14) Y53-1203-1D1 4-17 OPERATING THE BRAKE SYSTEM

Brake Operation Front Brake System These components are required to meet the Federal Motor Vehicle WARNING! When the brake pedal is depressed, Safety Standards (FMVSS 121 - Air the front circuit portion of the treadle Do not drive through water deep Brake Systems) or, in the case of valve delivers air from the front enough to wet brake components, chassis equipped with the European service air tank to the front axle brake as it may cause the brakes to work air system, ECE R13. As the Warning chambers via a quick-release valve. above states, any other type of air less efficiently than normal. The dryer installed in the place of an vehicle's stopping distance may be Simultaneously (on full truck AD-IS Series will require changes, longer than expected, and the vehi- configurations), air is also supplied modifications, and/or additions to cle may pull to the left or right when to the modulating valve control port. your vehicle’s air system to maintain brakes are applied, which could In the event of a rear service circuit compliance with FMVSS 121 or ECE contribute to an accident. Failure failure, the modulating valve will 4 R13. Kenworth strongly recommends to comply may result in personal exhaust air from the spring brake that if the air dryer is changed from an injury, death, equipment or property chambers, applying the spring brakes AD-IS series, you consult your nearest damage. in proportion to the front circuit authorized Kenworth dealer. application. To rectify this condition, check the rear and both sides of the vehicle for clear traffic, then apply the brakes gently, releasing and gently reapplying until the brakes dry out, restoring normal operation. Always check brakes after driving through deep water to help reduce the possibility of personal injury or an accident.

4-18 Y53-1203-1D1 (02/14) OPERATING THE BRAKE SYSTEM

Rear Brake System Using the Parking Brake

When the brake pedal is depressed, The yellow diamond-shaped knob on the rear circuit portion of the treadle the dash controls the vehicle parking valve delivers air from the rear service brakes. These are spring brakes that air tank to the service brake relay you activate by releasing air pressure valve control port. The relay valve from their chambers. When they are then delivers air directly from the not in use, air pressure compresses Combination ( Vehicle/Trailer) Parking rear service air tank to the rear brake the springs and releases the brakes. Brake Control Valves chambers in proportion to the treadle Pulling the valve OUT applies the pressure. parking brake, which exhausts air from 1 Parking Brake Control the chambers and allows the springs (Yellow) On tractors without ABS, the relay to extend and apply the brakes. 2 Trailer Air Supply Control valve is part of the BP-R1 brake (Red) 4 valve, which automatically proportions WARNING! the drive axle brake application Do not leave the cab without apply- pressure when driving bobtail (without ing the parking brake. The vehicle a trailer connected). The proportioning could roll and cause an accident. Al- BP-R1 brake valve allows full use ways apply the parking brake before of the steer axle (front) brakes and you leave the cab. Failure to comply reduces the chance that the drive axle may result in personal injury, death, brakes will lockup. The bobtail brake equipment or property damage. proportioning system is automatically turned off when a trailer is connected.

(02/14) Y53-1203-1D1 4-19 OPERATING THE BRAKE SYSTEM

Before you leave the cab: To release the vehicle parking WARNING! brakes ONLY: 1. Apply all parking brakes. Pull Do not pull out the parking brake out the Yellow Parking Brake • Push IN the Yellow knob on the valve while the vehicle is moving. Control knob (1) located on the dash. Your trailer will remain Stopping with the parking brake con- dash. The Red (octagon-shaped) parked. Trailer Air Supply Control knob will trols can cause a sudden wheel lock- automatically pop out. (A dash up, loss of control, or over-take by • Below 60 psi (414 kPa) the Yellow warning light will indicate when the following vehicles. Failure to comply parking brake valve remains OUT brake is ON.) may result in personal injury, death, (ON position). If air pressure is not equipment or property damage. restored above 60 psi (414 kPa), 2. Shift the transmission into PARK the knob will automatically return position: The parking brakes act on the rear to the OUT position if you attempt 4 ° manual transmission, select wheels only. They are spring-applied, to push it in. See Primary and First or Reverse gear. with air pressure used to release them. Secondary Air Pressure on page Release air is supplied by both the 3-67. ° automatic transmission, select front and rear circuit air tanks through Neutral. a double check valve. 3. Turn the key to OFF. 4. Remove the key.

4-20 Y53-1203-1D1 (02/14) OPERATING THE BRAKE SYSTEM

To release the trailer brakes ONLY: To release the full combination of brakes: WARNING! • Push IN the Red knob on the dash. The vehicle will remain parked. • Push IN BOTH knobs on the dash. If the air pressure falls below 60 psi (414 kPa) the spring brakes • In the event that air pressure is may stop the vehicle abruptly, which reduced below a safe level: the could result in an accident. Ob- low air warning light will come on serve the red warning lamps on the first; if air pressure continues to gauges. If one comes on, do not drop, the parking brake valve will continue to drive the vehicle until it pop OUT, automatically applying has been properly repaired or ser- the spring brakes. viced. Failure to comply may result in personal injury, death, equipment CAUTION or property damage. 4 Do not try to put the vehicle in mo- tion before pressure in the system reaches 100 psi (689 kPa) because the wheels are locked by the spring brake action. Unnecessary stress and possible brake malfunction could occur if the vehicle is forced to move before the air system reaches 100 psi (689 kPa). Failure to comply may result in equipment damage.

(02/14) Y53-1203-1D1 4-21 OPERATING THE BRAKE SYSTEM

European Air System WARNING! Parking Brake Option for NOTE Do not use the trailer hand brake or Export Vehicles Today’s electronic diesel engines service brakes to park and hold an have significant torque and starta- unattended vehicle, use the parking Parking Brake Operation bility power at low RPM. Combina- brakes. Because service brakes tions of engine speed and available work with air pressure, these brakes WARNING! torque may over-power the vehicle’s could slowly release. Your vehicle Never drive your vehicle with the parking brake. could roll, causing a serious ac- parking brake applied. Always re- cident. Never rely on the service lease the parking brake prior to mov- WARNING! brakes to hold a parked vehicle. ing the vehicle. Failure to disen- Do not leave the cab without apply- Failure to comply may result in per- gage the parking brake prior to mov- ing the parking brake. The truck 4 sonal injury, death, equipment or ing your vehicle could result in ex- could roll and cause an injury ac- property damage. cessive heat build-up in the brake cident. Always apply the parking system, resulting in a fire. Failure to brake before you leave the cab. Fail- comply may result in personal injury, ure to comply may result in personal death, equipment or property dam- injury, death, equipment or property age. damage.

4-22 Y53-1203-1D1 (02/14) OPERATING THE BRAKE SYSTEM

Vehicle/Trailer Air Supply WARNING! Valve The brake system is a critical vehicle Initial Charge safety system. For the safety of you and others around you, have the ve- The red octagon knob controls the air hicle submitted for periodic preven- supply to the trailer. With the system tive maintenance checks as well as completely discharged, both the Red having any suspected problems im- (trailer air supply) and the Yellow mediately checked by an Authorized (parking brake) knobs are OUT; thus, Service Center. Failure to properly vehicle and the trailer parking (spring) maintain your brake system can lead brakes are applied. to serious injury accidents. 1. Top view To supply air to the trailer system 2. Front view and release the trailer parking 4 3. Parking Brake ON: Handle brakes: in left position 4. Parking Brake OFF: Handle 1. Allow the vehicle air system in right position pressure to build up to operating level. To engage parking brake: 2. When system pressure reaches Move handle to left until locked. 50 psi (345 kPa) the Red knob may be pushed IN. To disengage parking brake: 3. Hold the Red knob IN by hand until the trailer air pressure builds Move handle out and move to the right. to a pre-set level, about 45 psi. At

(02/14) Y53-1203-1D1 4-23 OPERATING THE BRAKE SYSTEM

this point it will remain in, charging Normal Run Position the trailer system and releasing only the trailer brakes. • The Yellow knob (system park) may now be pushed IN, which will 4. The Yellow knob will remain OUT supply air to the vehicle spring (vehicle brakes ON). brakes, releasing them.

4

1. Normal Run Position 2. Trailer Park with Vehicle Released 3. System Park or Trailer Charge with Vehicle Parked

4-24 Y53-1203-1D1 (02/14) OPERATING THE BRAKE SYSTEM

Trailer Park or Emergency Brake System Park Application Only WARNING! Do not use the trailer hand brake or With both knobs pushed in for normal If you ever have a failure or disconnect service brakes to park and hold an operating modes, the parking brakes the air supply hose to the trailer, the unattended vehicle, use the parking of both the vehicle and the trailer trailer parking brakes will set. The Red brakes. Because service brakes may be applied by pulling the Yellow knob will automatically pop OUT and work with air pressure, these brakes knob OUT. This will exhaust the air seal off the vehicle air tanks to protect could slowly release. Your vehicle from the vehicle spring brakes, and the vehicle air system pressure. could roll, causing a serious ac- simultaneously cause the Red knob to cident. Never rely on the service pop OUT, which will apply the trailer To apply the trailer brakes only: brakes to hold a parked vehicle. brakes. This complies with the Federal Failure to comply may result in per- Motor Vehicle Safety Standards Pull OUT the Red knob. This will (FMVSS) 121 requirement that one exhaust air from the trailer supply line, sonal injury, death, equipment or 4 property damage. control should apply all the parking causing the vehicle protection valve to brakes on the vehicle. close and the trailer spring brakes to apply. The trailer is now in emergency or park. This mode would be used to uncouple from the trailer (running without a trailer connected).

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Trailer Charge Trailer Unload Air Assist System Due to the variation in tank trailers, If both knobs are OUT (combination If your vehicle is equipped with a trailer please consult the trailer manufacturer vehicle is parked), and it is desired to unload air assist system, Kenworth for air assist unloading information. recharge the trailer, the Red knob may has provided the air supply and the Follow the basic operating instructions be pushed IN repressurizing the trailer vehicle’s portion of the controls for the listed below: supply line. The vehicle will remain system. Please read and understand parked. For more information on air the operating instructions below and General Operating Instructions: supply pressure requirements, see provided by the trailer manufacturer 1. Apply parking brakes. Initial Charge on page 4-23. before operating the system. 2. Open trailer unload air assist CAUTION system. 4 This vehicle is equipped with a trailer 3. Apply trailer unload air assist air assist system. Do not exceed the pressure. trailer manufacturers recommended air pressure or apply air pressure be- NOTE fore the trailer unload mechanism is Kenworth has installed a parking in the open position. Failure to com- brake interlock device on the ve- ply could result in inability to unload hicle. The parking brake must be your trailer or cause damage to the engaged for the system to operate. unload system. Contact the trailer air assist manufacturer for further in- formation, operating settings and in- The vehicle’s portion of the trailer structions. unload air assist system is equipped with a pressure limiting valve set at 20 psi. Please review the trailer

4-26 Y53-1203-1D1 (02/14) OPERATING THE BRAKE SYSTEM manufacturer’s instructions for the Brake Safety and Emergency • If air pressure is lost in the operating pressure required to operate trailer supply/park circuit, and the the trailer unload system. WARNING! pressure drops below 60 psi (414 Do not operate the vehicle in the kPa), the trailer spring brakes are event of a malfunction in any air cir- automatically applied, and the cuit. The vehicle should not be op- vehicle air pressure circuits are erated until the system is repaired unaffected. and both braking circuits, including all pneumatic and mechanical com- • If air pressure is lost in the trailer ponents, are working properly. Loss brake service circuit, and the of system air can cause the service pressure in the vehicle front and brakes to not function resulting in rear circuits drops below 60 psi the sudden application of the spring (414 kPa), the vehicle and trailer 4 brakes causing wheel lock-up, loss spring brakes are automatically of control, or overtake by following applied. vehicles. Failure to comply may re- sult in personal injury, death, equip- ment or property damage.

• If pressure is lost in the vehicle front or rear circuit, the “check” valves isolate the unaffected circuit, allowing this circuit to continue normal operation. The trailer brakes are still functional.

(02/14) Y53-1203-1D1 4-27 OPERATING THE BRAKE SYSTEM

Emergency Braking Overheated Brakes To prevent drums from distortion while they cool down: WARNING! Under normal braking conditions, the energy generated will bring the internal • Park the vehicle on level surface Unless you have an anti-lock brak- brake drum temperature to about 500˚ and block the wheels. ing system (ABS), always avoid F (260˚ C). This is well within the safe completely depressing the service • Release the parking brake and zone: the maximum safe temperature brake pedal, if possible, even dur- allow the brakes to cool down. of lining for drum type brakes is usually ing emergency braking. Depressing See Parking Brake Valve on page about 800˚ F (427˚ C). the brake pedal too aggressively 3-102. can cause the wheels to lock, which If service brakes are used for can lead to an uncontrolled skid and emergency braking, used improperly, can result in an accident. Failure or for prolonged periods, internal brake 4 to comply may result in personal drum temperatures may exceed 800˚ injury, death, equipment or property F (427˚ C). Such brake overheating damage. may be detected by a burning smell or smoke coming from a drum. If this For Non-ABS Vehicles: to stop your occurs, you should immediately stop vehicle in an emergency, vary the and check for cracked brake drums or service brake application pressure lining fires. If neither exists, continue to provide maximum braking force driving and resume a slow speed as without locking the wheels. Use engine soon as possible to cool the brakes. If compression to assist the service the vehicle was to remain stopped, the brakes by not depressing the clutch heat transfer could destroy the linings pedal until the engine reaches idle and distort the brake drum. speed.

4-28 Y53-1203-1D1 (02/14) OPERATING THE BRAKE SYSTEM

Anti-Lock Braking System corner too fast or making a sudden Introduction NOTE lane change. Always drive at a If your ABS lamp goes on while safe, prudent speed for the road North American on-highway Kenworths you are driving or stays on after the and weather conditions. have anti-lock braking system (ABS) power-on test, your anti-lock system as standard equipment. The ABS • ABS cannot prevent a loss of might not be working. The ABS may reduces the possibility of wheel lock-up stability. Always steer moderately not function in an emergency. You during hard braking. If a wheel is about when you are braking hard. will still have conventional brakes, to lock during braking, the ABS will Severe or sharp steering wheel but not anti-lock brakes. If the lamp automatically adjust air pressure to the movement can still cause your indicates a problem, have the ABS brake chambers on the appropriate vehicle to veer into oncoming checked wheel(s) to prevent wheel lock-up. traffic or off the road. The ABS is automatically turned on when the ignition switch is turned on. NOTE 4 See Anti-Lock Brake System (ABS) on Important Safety Reminders page 3-34. • ABS does not reduce the time WARNING! or distance it takes to stop the Do not rely on an anti-lock brake sys- vehicle, it only helps with steering tem that is functioning improperly. control during braking. You should You could lose control of the vehicle always maintain a safe following resulting in a severe accident. Fail- distance from other vehicles. ure to comply may result in personal ABS will not prevent a skid that injury, death, equipment or property • results from changing direction damage. abruptly, such as trying to take a

(02/14) Y53-1203-1D1 4-29 OPERATING THE BRAKE SYSTEM

Wheel Spin Control (option) feature. If drive wheels spin during Deep Snow and Mud Switch (option) acceleration, the ASR Warning Lamp Your ABS may have the optional comes on, indicating wheel spin control A deep snow and mud switch is Acceleration Slip Regulation is active. included with Wheel Spin Control. The (ASR)/Automatic Traction Control Deep Snow and Mud feature is helpful (ATC) feature. This feature is Do not allow the ASR Warning Lamp during acceleration This function monitored by a wheel spin control ASR to remain on continuously for an increases available traction on extra Warning Lamp. See the appropriate extended length of time. Extended, soft surfaces like snow, mud or gravel, vehicle section in this manual for continuous use of the ASR/ATC can by slightly increasing the permissible details. This feature helps improve cause overheating of the drive wheel wheel spin. When this function is in traction when vehicles are on slippery brakes. use, the ASR Warning Lamp blinks surfaces by reducing drive wheel continuously. overspin. Wheel spin control works 4 automatically in two different ways: • If a drive wheel starts to spin, wheel spin control applies air pressure to brake the wheel. This transfers engine torque to the wheels with better traction. • If all drive wheels spin, wheel spin control reduces engine torque to provide improved traction.

Wheel spin control turns itself on and off, you do not have to select this

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Off-Road ABS Function Switch • Allows retarders to function (option) independently of the ABS function. WARNING! While the off-road mode can im- Your Kenworth vehicle may be • If your vehicle does not have an prove vehicle control and shorten equipped with a separate switch to engine retarder, the Off- Road stopping distances, some steering activate an Off-Road ABS function. ABS switch will function the same. ability may be reduced on certain This function is NOT to be used surfaces resulting from the momen- for On-Highway driving but is CAUTION tarily sliding tires. Always oper- intended to be used to improve Never drive your vehicle on im- ate your vehicle at safe operating stopping performance in Off-Highway proved roads/highways with the speeds. Failure to do so may cause conditions (e. g. loose gravel and Off-Road ABS function turned on. you to lose control of the vehicle mud). The Off-Road ABS function is When you drive your vehicle onto an and could result in an accident or accomplished by allowing a “wedge” improved road surface or highway, personal injury. of material to build-up in front of 4 immediately turn off the Off-Road momentarily locked wheels. ABS switch. Failure to do so will How the Off-Road ABS Function Features and Benefits cause the ABS system to not func- Works tion properly in an ABS event under • Changes the ABS control limits to 25 mph and could result in an acci- • The ABS lamp flashes slowly allow for a more aggressive ABS dent or personal injury. during off-road mode engagement. function while off-road. This is done to alert you of a modification to the ABS control • Improves vehicle control and software. helps reduce stopping distances in off-road conditions or on poor • At speeds above 25 mph, the ABS traction surfaces such as loose controller operates in the normal gravel, sand and dirt. on-highway mode.

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• At speeds between 10 and 25 Trailer ABS CAUTION mph, the ABS control software is Power Line Communication (PLC) modified to allow short periods Do not splice into the non-switchable North American on-highway Kenworths (0.25 seconds) of locked-wheel Auxiliary circuit on the primary 7-way are equipped with a separate electrical cycles. trailer light line. Doing so may cause circuit to power the anti-lock brake the trailer ABS to malfunction. This • At speeds below 10 mph, the ABS system (ABS) on towed vehicle(s). circuit is dedicated for trailer ABS control software is turned off to In most cases, the ABS power will power. To add a switchable auxiliary allow locked wheels. be supplied through the Auxiliary circuit, contact a Kenworth Dealer- circuit on the primary 7- way trailer ship. • When the Off-Road ABS function light line connector. If the vehicle is enabled, the Retarder Disable was manufactured with a switchable Vehicles and trailers built after output is turned off. That is, Auxiliary circuit for trailer accessories, 3/1/01 must be able to turn on an 4 the engine retarders are left to an additional 7-way connector would In-Cab Trailer ABS Warning Lamp function without ABS intervention. have been provided for trailer ABS (per Federal Motor Vehicle Safety For additional information, see the power. In either case, the ABS Standards (FMVSS) 121). The industry Off-Road ABS pamphlet in your power line on the vehicle will be PLC chose Power Line Communication vehicle’s glove box. equipped. (PLC) as the standard method to turn it on.

4-32 Y53-1203-1D1 (02/14) OPERATING THE BRAKE SYSTEM

Special Trailer ABS (Without PLC) NOTE NOTE Option Trailers not equipped with PLC can If you change the intended service in If a trailer does not have PLC, but not turn on the In-Cab Trailer ABS anyway (i.e. number of axles, mul- it does have ABS that is powered Warning Lamp.(There is one option tiple trailers, add switchable trailer through an optional second trailer that is an exception to this rule. See accessories, etc.) from the date connector (ISO 3731) and that trailer Special Trailer ABS (Without PLC) the vehicle was manufactured, you ABS is designed to control the Trailer Option in the Anti-lock Braking Sys- should contact your trailer manufac- ABS Warning Lamp in the cab and tem section on page 4-29 for de- turer and/or trailer anti-lock brake the vehicle has been ordered with the tails.) manufacturer to determine if the option to turn on this lamp for these power available at the 7-way trailer types of trailers, then this lamp will turn light line is adequate. Failure to do NOTE on when that trailer ABS has a system so might result in insufficient power problem. This should be checked by a 4 For doubles or triples, the lamp does to the trailer ABS system which may Kenworth Dealer as soon as possible. not distinguish between trailers. An affect its operation. ABS problem in any of the trailers The Trailer ABS Warning Lamp will will activate the Trailer ABS Warning not turn on for the power-on test when Lamp. CAUTION connected to these types of trailers. The center pin of the 7-way trailer light line may be constantly powered NOTE for ABS. Make sure it will not acci- Very few trailers built before 3/1/01 dentally turn on trailer equipment. have this option. Trailers built after 3/1/01 are built with PLC technology.

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Trailer Brake Hand Valve Driving with an Unloaded WARNING! Trailer This hand valve provides air pressure Do not use the trailer hand brake or to apply the trailer brakes only. It service brakes to park and hold an Do not use the engine retarder (such operates independently of the foot unattended vehicle, use the parking as an exhaust brake) to slow the treadle valve. brakes. Because service brakes vehicle down when you are pulling an empty trailer. To operate the trailer brake hand work with air pressure, these brakes valve: could slowly release. Your vehicle could roll, causing a serious ac- WARNING! • Pull down on the lever under the cident. Never rely on the service Do not use an engine retarder when right side of the steering wheel. brakes to hold a parked vehicle. you are driving with an unloaded See Steering Column And Mirrors Failure to comply may result in per- trailer. Using engine retarders with 4 on page 3-112. sonal injury, death, equipment or an unloaded trailer can cause a property damage. wheel lockup resulting in less con- • The valve is self-returning. When trol and/or jackknife. When you pressure is removed from the are unloaded, you can have a se- valve lever, it will return to the OFF rious accident if your wheels lock position. suddenly during braking. Failure to comply may result in personal injury, NOTE death, equipment or property dam- The trailer brake is not to be used as age. a substitute for the service brakes. Using this brake frequently, instead of using the foot brake, will cause the trailer brakes to wear out sooner.

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Engine Retarders an option) to create a braking effect WARNING! on the drive wheels. These devices WARNING! Do not operate the engine retarder use your engine's power to slow your The engine retarder is NOT intended when driving/operating your vehicle vehicle down. Because they can as the primary brake for the vehi- on road surfaces with poor traction help keep your vehicle's brakes from cle, nor is it an emergency brake. (wet, icy, or snow covered roads) overheating, they save wear and tear The engine retarder only helps the or in heavy traffic. Braking caused on the service brakes. However, the service brakes by using pressure to by the normal operation of the en- retarder is not an emergency brake. slow the drivetrain. Use the service gine retarder could cause you to lose Ideally (on normal road surfaces), brakes for quick stops. DO NOT rely control of the vehicle resulting in an you should slow your vehicle with only on the engine retarder. Fail- accident. Failure to comply may re- the retarder (where permitted by law) ure to comply may result in personal sult in personal injury, death, equip- and use the service brakes only for injury, death, equipment or property ment or property damage. stopping completely. Operating this 4 damage. way will greatly prolong the life of the NOTE brakes. The exhaust brake and engine brake are two types of engine retarders. See your Engine Operation and Maintenance Manual and Engine Retarder or Engine Brake Operation Manual for further details on using these types of engine retarders.

A variety of engine retarders or exhaust brakes may be installed (as

(02/14) Y53-1203-1D1 4-35 OPERATING THE BRAKE SYSTEM

Exhaust Brake WARNING! WARNING! With the exhaust brake switch ON, the Do not use an engine retarder when Do not use the engine retarder when brake automatically creates its braking you are driving with an unloaded operating on road surfaces with poor effect when you remove your foot from trailer. Using engine retarders with traction (such as wet, icy, or snow the accelerator pedal. an unloaded trailer can cause a covered roads or gravel). Retarders wheel lockup resulting in less con- can cause the wheels to skid on The brake switch is located on the trol and/or jackknife. When you a slippery surface. You could lose accessory dash panel. It controls are unloaded, you can have a se- control of the vehicle and/or jack- whether the brake is ON (ready to slow rious accident if your wheels lock knife if the wheels begin to skid, re- the vehicle down) or OFF (no braking suddenly during braking. Failure to sulting in an accident. Failure to action). comply may result in personal injury, comply may result in personal injury, 4 • Do not use the engine retarder death, equipment or property dam- death, equipment or property dam- (such as an exhaust brake) to age. age. slow the vehicle down when you are pulling an empty trailer. See • Make sure the brake is OFF before If your vehicle is equipped with Engine Brakes for further details. starting the engine. anti-lock brakes (ABS), the operation of the exhaust brake (if turned ON) • After the engine is started, warmed will be controlled by the ABS. For up, and you are ready to get under further details on how to use the way, turn the exhaust brake switch exhaust brake, see the exhaust brake ON for added braking effect. manufacturers Owner's Manual.

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Engine Brakes Brake Components Depending on the engine, your vehicle may be equipped with either The following is a brief description of a 2-position or 3-position Retardation the air/brake system. It is intended to Level Switch. If your vehicle has the supply you with general information on two-speed system, you can select how the system works. On/Off Switch Symbol FULL or HALF. If it has the three-speed system, you can select LOW (1), Compressor: supplies air to the MEDIUM (2), or HIGH (3) retarding. system. System pressure is controlled by the governor. See your Engine Operation and Maintenance Manual or Engine Brake Governor: controls the air pressure Operation Manual for further details on in the system by actuating the using engine retarders. compressor discharge mechanism. Its 4 Retardation Level Switch Symbol cut-out pressure is 115 to 125 psi (793 to 862 kPa). Its preset cut-in pressure There are two switches that control is set to between 13 to 25 psi (90 to your vehicle's engine brake. One 172 kPa) below the cut-out pressure switch turns the system On/Off setting (cut-out and cut-in interval is and the second switch controls the not adjustable). retardation level. These are located in the right-hand switch panel. With Safety Valve: installed on the supply the engine brake switch ON, the brake air tank outlet. It should vent off at 150 automatically creates its braking effect psi (1034 kPa) permitting air to escape. when you remove your foot from the accelerator pedal.

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exhausting back through the treadle Air Dryer: collects and removes Modulating Valve (SR-1): used only valve. moisture and contaminants from the on full trucks, not tractors, performs air as it travels from the compressor four functions: Single Check Valve: allows air flow in to the wet tank. one direction only. • Limits spring brake hold-off air Compressed Air Tanks: The wet pressure delivered to the spring Parking Brake Valve: Yellow tank receives air from the air dryer and brake chambers. diamond-shaped knob. It controls the cools it somewhat, allowing moisture • Provides a quick release of air application and release of the parking to condense for draining. Relatively pressure from the spring brake (spring) brakes of the vehicle or of the dry air is then supplied to the two chambers to speed spring brake vehicle-trailer combinations. If the air service air tanks for distribution to their application. system is being charged from zero respective brake circuits. The service pressure, the parking brake valve will 4 air tanks are isolated from each other • Modulates spring brake application not hold in the release position until the by check valves. in proportion to front service system pressure exceeds 60 psi (414 application in the event of a rear kPa), which is the pressure required to Dual Service Brake Treadle Valve: service failure. override the load of this valve's plunger delivers air to the two service brake return spring. circuits. • Prevents compounding of service and spring applications. Trailer Supply Valve: The Red Double Check Valve: directs the octagonal-shaped knob protects higher air pressure from either the rear Quick-Release Valve: speeds the the vehicle system; it functions in (primary) or front (secondary) service release of air from the brake chambers. conjunction with the parking brake air tank to the modulating valve. When air is released, the air in the valve (yellow). The trailer supply brake chambers is exhausted at valve is responsible for synchronizing the quick-release valve, rather than the vehicle and trailer parking and

4-38 Y53-1203-1D1 (02/14) OPERATING THE BRAKE SYSTEM emergency brakes. If the air system is being charged from zero pressure, the trailer supply valve will not hold in the applied position until the system pressure exceeds 50 psi (345 kPa). It automatically pops out and exhausts air if supply air pressure drops below 60 psi (414 kPa).

Vehicle Protection Valve: The functions of this valve are to (1) receive all pneumatic signals pertinent to the operation of the trailer brake system, (2) transmit these signals to the trailer, 4 and (3) protect the vehicle air supply in case of separation of the air lines connecting the vehicle to the trailer.

(02/14) Y53-1203-1D1 4-39 OPERATING THE ENGINE OPERATING THE ENGINE This section includes instructions for WARNING! both Normal Temperature starting and Do not use ether or starting fluid in Cold Weather starting. The engine conjunction with flame-start air in- Introduction type (brand) and size determines what take heating systems. Flame-start type of cold weather starting aid is systems use an open flame inside For detailed information on starting installed in your vehicle. Refer to your the manifold to heat the air/fuel mix- and operating the engine, refer to the Engine Operation and Maintenance ture for cold weather starting. If Engine Operation and Maintenance Manual to learn what precautions ether is also used with flame-start, Manual provided with your Kenworth. you should take before starting the the air/fuel will ignite inside the man- engine. Many new electronic engines Because each vehicle is ifold, which could cause an explo- cannot use ether or other starting custom-equipped, all engine operation sion. Failure to comply may result fluids. These engines are equipped instructions presented in this section in personal injury, death, equipment 4 with a flame-start air intake heating are general. You will want to consult or property damage. system. See Starting Procedure - Cold the engine manual to find out details Weather on page 4-42. about your vehicle's specific engine CAUTION needs. You may need to use a slightly WARNING! different procedure from the one Do not park or operate the vehicle in outlined here. Do not start or let the engine run in areas where the hot exhaust system an enclosed, unventilated area. Ex- may come in contact with dry grass, Also, read the American Trucking haust fumes from the engine contain brush, spilled fuel or other material Association's (ATA) Truck Driver's carbon monoxide, a colorless and that can cause a fire. Handbook. It will give you tips on odorless gas. Carbon monoxide can starting, shifting, and driving your be fatal if inhaled. Failure to com- vehicle. ply may result in personal injury or death.

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Starting Procedure - Normal manual for the right pressure for Temperature NOTE your engine. If the oil pressure Some starters are equipped with doesn’t rise within a few seconds, When the outside temperature is overcrank protection. Check the stop the engine. Find out what above 50° F (10° C), you can use the “Engine Operation and Maintenance is wrong before restarting the following procedure: Manual” for details. engine. 1. Set the parking brake. 7. Slowly engage (release) the clutch 5. Turn the ignition key to the START after the engine has started. 2. Put your main transmission in position. If the engine does not Neutral. start within 30 seconds, release 8. Wait for the oil pressure gauge to the ignition switch. To avoid reach normal operating pressure 3. Disengage (depress) the clutch before operating the vehicle or (with manual transmission). overtaxing the starter motor or the batteries, don’t use the starter idling faster than 1000 rpm. 4 4. Turn the key switch to ON. for more than 30 seconds. Let the starter motor cool and the CAUTION batteries recover for two minutes Never operate the starter motor before trying again. while the engine is running. The If the engine still won’t start after a starter and flywheel gears could couple of tries, check the fuel lines clash or jam, severely damaging for possible fuel starvation or air them. leaks. Starting failure may mean fuel isn’t reaching the injectors. 6. As soon as the engine starts, begin to watch the oil pressure gauge. Check your engine manufacturer’s

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Starting Procedure - Cold Engine Block and Oil Pan Weather Heater (Option) CAUTION Always unplug heater before starting In cold weather, fast engine starting To preheat the engine before starting, the engine. Damage to the cooling helps relieve the loads on the electrical plug the optional engine block heater system could occur if the heater is system and cranking motor. Using the into a properly grounded AC electrical not turned OFF (unplugged). special cold starting equipment will source. Do not start the engine with help starting. If you follow a few simple the heater plugged in. Depending on engine make, when the guidelines, you will extend the service temperature falls below -10° F (-24° life of your engine: WARNING! C), the block heater is recommended. • Keep the electrical system in top Engine block and oil pan heaters • Use a solution of half ethylene condition. can cause fires which may result in 4 death, injury and/or property dam- glycol antifreeze and half water for • Use the best quality fuel of the age if not properly maintained and best heater performance. Do not recommended grade. operated. Regularly inspect the en- exceed 65 percent concentration gine block heater wiring and connec- of antifreeze, as a shortened • Use recommended engine tor for damaged or frayed wires. Do heater life will result. See Engine lubricating oil. not use the heater if there are any Cooling System on page 5-61, for more information. • For manual transmissions and signs of problems. Contact your au- thorized dealer or the manufacturer auxiliary transmissions, leave the • After servicing the cooling system, of the heater if you are in need of re- transmission in neutral and allow operate the vehicle for a day or two pairs or information. the transmission lubricating oil before using the heater. Trapped to warm up (approximately 3-5 air inside the engine needs time minutes) before operating vehicle. to escape.

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Engine Warm-up slowly and evenly. In extremely Engine cold temperatures, you may have WARNING! to increase idle speed. Exhaust fumes from the engine The purpose of engine warm-up is to contain carbon monoxide, a color- allow oil film to be established between NOTE less and odorless gas. A poorly pistons and liners, shafts and bearings In colder climates where the tem- maintained, damaged, or corroded while your engine gradually reaches perature is often below freezing, the exhaust system can allow car- operating temperature. warm-up for turbocharged engines bon monoxide to enter the cab or sleeper. Failure to properly main- Warm-up Procedure is especially important. Chilled ex- ternal oil lines leading to the tur- tain your vehicle could cause car- 1. After you’ve started your engine, bocharger will slow the oil flow until bon monoxide to enter the cab and idle it at approximately 600 RPM the oil warms, reducing oil available cause death or personal injury. while you check: for the bearings. Watch the engine 4 a. oil pressure oil temperature or pressure gauge WARNING! for a warming trend before increas- Never idle your vehicle for prolonged b. air pressure ing engine idle speed (RPM). periods of time if you sense that ex- c. alternator output 3. Continue the engine warm-up until haust fumes are entering the cab. 2. After a few minutes of idling at the coolant temperature reaches Investigate the cause of the fumes 600 RPM, increase your idle at least 130° F (54° C). At this and correct it as soon as possible. speed to 900 or 1000 RPM. temperature, you can use partial If the vehicle must be driven under Continue your warm-up. This throttle. Wait until the coolant these conditions, drive only with the procedure allows oil to warm and temperature is at least 160° F (71° windows slightly open. Failure to re- flow freely while pistons, liners, C) before operating at full throttle. pair the source of the exhaust fumes shafts, and bearings expand may lead to death or personal injury.

(02/14) Y53-1203-1D1 4-43 OPERATING THE ENGINE

CAUTION NOTE NOTE The use of a winterfront can result Keep the engine exhaust system • Do not stay in the vehicle with in excessive engine coolant, oil, and and the vehicle’s cab/sleeper venti- the engine running or idling charge air (intake) temperatures, lation system properly maintained. for more than 10 minutes with which can lead to overheating and It is recommended that the vehicle’s the vehicle’s Heater and A/C possible engine damage. If you exhaust system and cab/sleeper be ventilation system in RECIRC must use a winterfront: inspected: or at LOW FAN SPEED. Even with the ventilation system On, • Refer to the “Engine Operation • By a competent technician every running the engine while parked and Maintenance Manual” 15,000 miles, or stopped for prolonged periods for operating restrictions and • Whenever a change is noticed in of time is not recommended. recommendations. the sound of the exhaust system, 4 • If other vehicles are parked next • Use only a winterfront available • Whenever the exhaust system, to you idling, move your vehicle from your dealer that is underbody, cab or sleeper is or do not stay in your vehicle for compatible with an EPA-compliant damaged. prolonged periods of time. engine cooling system. These winterfronts are specifically designed for use with new grill Idling the Engine snap patterns. Under most circumstances, idling your engine for long periods merely wastes fuel. In severe arctic weather conditions, however, you may need longer idling to be sure all parts of your engine are fully lubricated.

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Transmission WARNING! CAUTION In cold weather [below 32° F (0° To reduce the chance of death or Do not allow your engine to idle, C)], you may find shifting sluggish personal injury and/or vehicle dam- at low rpm's (400–600 rpm), longer when you first start up. Transmission age from overheated engines, which than five minutes. Long peri- warm-up is especially important at can result in a fire, never leave the ods of idling after the engine has this time, but it is always a good engine idling without an alert driver reached operating temperatures idea to warm-up your transmission present. If the engine should over- can decrease engine temperature before starting out on the road. To heat, as indicated by the engine and cause gummed piston rings, warm-up the transmission, follow these coolant temperature light, immedi- clogged injectors, and possible en- procedures. ate action is required to correct the gine damage from lack of lubrica- condition. Continued unattended tion. The normal torsional vibrations To warm-up the transmission operation of the engine, even for generated can also cause transmis- lubricating oil during engine warm-up, 4 a short time, may result in serious sion wear. with a single transmission (manual and engine damage or a fire. automatic): 1. Put the transmission in Neutral. 2. Release the clutch pedal (manual only) and operate the transmission in neutral for 3 to 5 minutes prior to operating the transmission in either forward or reverse range. 3. If you have a two-transmission combination:

(02/14) Y53-1203-1D1 4-45 OPERATING THE ENGINE

Ether Metering Equipment a. Put the main transmission in WARNING! gear. WARNING! Do not store the spare cylinder in the b. Put the auxiliary transmission Ether starting fluid is flammable cab. Failure to comply may result in in Neutral. This will allow and poisonous. Do not smoke near death, personal injury, equipment or the transmission countershaft ether or ether equipment, do not property damage. to turn, agitating the oil and ingest ether fluid and wear safety warming it. goggles when handling ether fluid. Do not smoke when testing, installing, Follow all safety literature provided or servicing an ether starting unit. with your ether equipment. Failure Service it in a well-ventilated area away to take these precautions may result from heat, open flames, or sparks. in death, personal injury. 4 If swallowed, do not induce vomiting. Call a physician immediately. WARNING! Do not move or relocate the ether Wear goggles to avoid getting fluid in cylinder or tubing from its original in- your eyes. Avoid getting it on your skin stallation. It must be mounted to pro- and avoid breathing the fumes. If fluid tect it from engine exhaust heat and does get in your eyes or fumes irritate from moving parts which could dam- your eyes, flush for 15 minutes with age it. Failure to comply may result large amounts of clean water. Contact in death, personal injury, equipment an eye specialist. or property damage. In warm weather, when you will not need the ether starting system, remove the ether bottle from your truck and

4-46 Y53-1203-1D1 (02/14) OPERATING THE ENGINE store it safely. Return the protective Cruise Control cap to the bottle mounting connector. If your vehicle is equipped with cruise For more helpful starting information, control dash switches, follow the refer to the engine manual that came operating instructions below. with your vehicle. WARNING! Ether injected into the engine cylinder Do not operate the cruise control during cold weather startup will help when driving on road surfaces with the engine start faster. Using ether poor traction (wet, icy, or snow during cold weather startup will result covered roads) or in heavy traffic. in reduced demands on the batteries Accelerations caused by the normal and the starter motor. operation of the cruise control could On/Off Switch, Set/Resume Switch 4 When you turn the ignition switch to the cause you to lose control of the ve- START position, the cranking motor hicle resulting in an injury accident. and the ether system are engaged. Failure to comply may result in per- When needed, starting fluid is released sonal injury, death, equipment or from a pressurized cylinder, flows property damage. through a valve and tubing, and sprays from a nozzle in you engine’s air intake system.

(02/14) Y53-1203-1D1 4-47 OPERATING THE ENGINE

Using Cruise Control While Driving: Changing the Cruise Set Speed Resuming Cruise Control Setting Cruise Speed • To increase the cruise set speed; 1. If you tapped the brake or 1. Ensure that the vehicle speed is Hold the SET/ RESUME switch in clutch pedal, the cruise/idle above the minimum cruise control the "SET" position until the desired control remembered the speed (30 mph for Cummins speed is achieved then release previously set cruise speed. engines) and the engine speed is the switch. To resume that set speed, above 1100 rpm. accelerate above the minimum • To decrease the cruise set speed; cruise control speed and; 2. Move the ON/OFF switch to the Hold the SET/ RESUME switch in Toggle the SET/RESUME switch "ON" position. the "RESUME" position and coast to the "RESUME" position. to the desired lower speed then 3. Accelerate the vehicle to the 2. If you moved the ON/OFF switch release the switch. 4 desired cruise speed. to the "OFF" position or turned the 4. Toggle the SET/RESUME switch Cancelling Cruise Control ignition key OFF, this cleared the to the "SET" position to set the system memory and you will need cruise speed. You can cancel cruise control in any to set a new cruise speed. of these ways: NOTE • Tap the brake pedal. Cruise Control may not hold the set speed going down hills. If the speed • Tap the clutch pedal. increases going down a hill, use the brakes to slow down. This will can- • Move the ON/OFF switch to the cel Cruise Control. "OFF" position.

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Using Cruise Control for Stationary Engine Fan Control point, or 3) the Engine Control Unit PTO Operation: detects that air intake temperature, oil temperature, or compression Setting Idle Speed brake usage requires it. 1. Ensure parking brakes are applied. WARNING! 2. Ensure transmission is in Neutral. The engine fan can be turned ON Do not work on or near the fan with 3. Engage PTO per the using a switch that is mounted on the the engine running. Anyone near the manufacturer's operating accessory switch panel. This lets you engine fan when it turns on could instructions. set the fan to manual or automatic be injured. If it is set at MANUAL, operation. the fan will turn on any time the ig- 4. Move the ON/OFF switch to the nition key switch is turned to the ON "ON" position. • With the ignition key turned ON position. In AUTO, it could engage and the fan switch in the MANUAL 4 5. Toggle the SET/RESUME switch suddenly without warning. Before position, the engine fan will be ON to obtain the desired engine rpm. turning on the ignition or switching regardless of engine temperature. from AUTO to MANUAL, be sure no • With the engine fan switch in workers are near the fan. Failure to the AUTO position, the engine comply may result in personal injury, fan will automatically turn ON death, equipment or property dam- when any one of the following age. conditions occur: 1) the engine coolant temperature reaches 200º F (93º C) approximately, 2) the Air Conditioning system is turned ON or has reached a set pressure

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Engine Control Display Engine Shutdown System CAUTION Your Kenworth may come with This system is an option with each The fan or equipment near it could an optional Engine and Driver engine. The engine shutdown system be damaged if the fan turns on sud- Information Display. This instrument continually monitors oil pressure and denly when you do not expect it. records information on engine engine temperature. If either condition Keep all tools and equipment away diagnostics, scheduled maintenance, changes beyond the normal range of from the fan. driving conditions, and general trip oil pressure or temperature readings, information. The specific features the engine shuts down automatically, NOTE of your display may vary depending sounding the alarm and turning a Do not operate the engine fan in on engine make. For complete warning light on. The buzzer will sound the MANUAL position for extended information on the display see the continuously as long as Stop Engine engine manufacturer's manual. indicator is on. 4 periods of time. The fan hub was designed for intermittent operation. Sustained operation will shorten the After the engine starts, and until oil fan hub's service life as well as re- pressure reaches normal operating duce fuel economy. pressures, a warning alarm will sound. As soon as oil pressure increases, the buzzer turns off automatically. If the engine shuts down automatically or if the buzzer and light turn on while the engine is running, have your engine serviced at an authorized Kenworth Dealer.

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Each shutdown system is engine specific; therefore to learn how this system works on your vehicle, you should consult the engine manufacturer's manual.

4

(02/14) Y53-1203-1D1 4-51 OPERATING THE REAR/DRIVE AXLE

OPERATING THE Inter-Axle Differential Lock When to Use the Differential Lock REAR/DRIVE AXLE In the LOCK position, an air operated clutch positively locks both sets of Introduction axles together, providing greater traction on slippery road surfaces; This section covers the operation however, steering around corners of your Rear/Drive Axle. These and on dry pavement is more difficult. instructions apply to the most common Continuous operation on a paved, dry features of drive axles. Refer to the surface stresses the tandem axles, manufacturers instructions for further possibly causing internal damage. information on the operation of your The inter-axle differential allows each axle to turn independently, which axle. Only use this feature when driving on relieves stress on the rear axles and 4 surfaces with poor traction, such as reduces tire wear. A switch on the heavy mud or snow, or loose gravel. accessory switch panel locks the And do not use it when going downhill inter-axle differentials, which gives you or at speeds greater than 25 mph (40 better traction for slippery surfaces. km/h). You will notice that the switch has a guard to protect you from activating it Lock the differential when you accidentally. encounter road conditions such as these: • Ice or snow, with or without tire chains. • Dirt roads.

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Inter-Axle Differential Lock • Loose sand, mud, or other off-road WARNING! Operation conditions. Do not operate the vehicle on WARNING! WARNING! dry pavement with the differential locked, this could lead to an acci- Do not use the differential lock dur- Do not put the differential lock in the dent. On dry pavement, you will not ing downhill operation or at speeds LOCK position while the wheels are be able to steer well with the differ- above 25 mph (40 km/h). When it spinning freely (slipping), you could ential locked. Lock the differential is engaged under these conditions, lose control of the vehicle or cause only when operating on surfaces your vehicle will exhibit understeer axle damage. Switch to LOCK only with poor traction, such as wet, slip- handling characteristics. This un- when the wheels are not spinning. pery roads or loose gravel. Failure dersteer condition will cause your Failure to comply may result in per- to comply may result in personal vehicle to not turn as quickly and sonal injury, death, equipment or injury, death, equipment or property more steering effort will be required, property damage. 4 damage. which can cause an accident. Fail- ure to comply may result in personal • Look ahead for wet, muddy, or icy injury, death, equipment or property patches on the road, stop your damage. vehicle and switch to LOCK ahead of time.

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indicating that the differential is locked (engaged). NOTE 3. If you LOCK or UNLOCK the If your vehicle has an automatic differential while moving, let up transmission, it may be necessary to momentarily on the accelerator shift the transmission to the Neutral Understeer Condition pedal to relieve torque on the position momentarily to allow the 1 Turning Radius When gearing and allow full engagement main differential lock splines to fully Unlocked (Disengaged) of the clutch (mechanism that engage or disengage. 2 Turning Radius When locks the wheels). Locked (Engaged) 4. Drive the vehicle through the poor NOTE traction area, keeping your speed To LOCK the inter-axle differential: under 25 mph (40 km/h). The Meritor main differential lock or 4 1. Anticipate when you might need Dana Spicer wheel differential lock To UNLOCK the inter-axle increased traction, slow down to a is controlled by the switch labeled differential: steady speed under 25 mph (40 WHEEL DIFFERENTIAL. By mov- 1. When you reach dry pavement km/h) or stop the vehicle. Do not ing the switch you can LOCK or UN- lock the differential while going or better road conditions where LOCK the main differential when the the differential lock is not needed, down steep grades or traveling vehicle is moving or stopped. faster than 25 mph, or while switch the differential lock to wheels are spinning or traction is UNLOCK. minimal; lock the differential before 2. Let up momentarily on the you encounter these conditions. accelerator pedal to relieve torque 2. Put the inter-axle differential lock and allow the clutch to disengage. switch in the LOCK position. A 3. When you unlock the differential, light on the switch will turn on, normal vehicle handling will

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resume and the light on the switch Driver Controlled Main will turn off. Differential Lock

If your Kenworth has a Meritor axle with a Driver Controlled Main Differential Lock, install the caging bolt before removing the axles for towing. Installation of the caging bolt prevents damage by locking internal axle components in position. Use the procedure below to lock the Meritor differential. Driver Controlled Main Differential 1. Remove the air line. Lock 4 2. Remove the caging bolt from its 1 Air Line - Remove to Install storage hole. Caging Bolt 2 Caging Bolt Storage 3. Screw the caging bolt all the way Location into the air line hole. This locks the differential by pushing a piston into lock position.

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Dual Range (Two-Speed) Dual Range Axle Operation Rear Axle CAUTION Important tips on operating a Dual If you shift the axle range with the Your vehicle may be equipped with a Range Axle with Interaxle Differential: inter-axle differential in LOCK, you two-speed or dual range axle (option). 1. Shift the axle with the inter-axle could seriously damage the axles. You can select two rear axle ratios for differential in the unlocked position Never shift the axle range with the operating under heavy loads or rough only. differential locked. terrain as well as for over the road hauling. 2. When you are driving with poor traction, lock the differential. When The Low Range provides maximum you have the differential locked, torque for hauling heavy loads or drive with the axle in LOW range traveling over rough terrain. The High only. 4 Range is a faster ratio for highway 3. When you are driving on a surface speeds and general over the road with good traction, keep the conditions. A switch on the accessory interaxle differential unlocked. You switch panel controls the Dual Range can drive with the axle in the LOW Rear Axle. You will notice that the or HIGH range. switch has a guard to protect you from activating it accidentally. Always park 4. Always UNLOCK the inter-axle your vehicle with the range selector in differential before shifting the axle LOW. speed range.

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Starting-Up WARNING! When going down hill the wheels will 1. Unlock the inter-axle differential not slow down, but will tend to speed Never shift the axle when moving before starting. up, which makes gear synchronization down hill. Engine driveline disen- almost impossible. As a result, the 2. Put the Range Selector in the gagement may occur, eliminating axle is neither in HIGH nor LOW range LOW range. Shift the transmission engine retardation and allowing the and all engine/driveline retardation is to start the vehicle moving. wheels to spin faster than the cur- lost. Without engine retardation it is rent speed of the engine. This may 3. When you are driving on rough more difficult to slow the vehicle down require severe braking to slow the terrain and secondary roads, or and greater stress is put on the brake vehicle down and can result in an ac- under a very heavy load, keep the system. axle in the LOW range. Shift the cident. Failure to comply may result in personal injury, death, equipment transmission to maintain proper CAUTION road speed. or property damage. To avoid damaging your vehicle shift 4 Proper shifting of the axle depends on the axle at slower travel speeds until the synchronization of engine/driveline you are used to driving with a dual and wheel speed. When you shift range axle. the axle, the connection between the engine and wheels is momentarily disengaged while the gearing is synchronized. Normally when the axle is shifted the speed of the engine, axle, and wheels adjust, allowing for proper gear engagement.

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LOW to HIGH (Cruising) HIGH to LOW (Rough Terrain) Auxiliary Axles - Pusher or Tag When you go from rough terrain to If you need to downshift the axle for highway driving, shift the axle to the more power or you are driving on Adjustable auxiliary axles can add HIGH range following this procedure: rough terrain: to the productivity of your vehicle. It 1. Be sure the differential is 1. Maintain your vehicle speed is important to recognize that when UNLOCKED. (accelerator depressed) and move adjustable auxiliary axles are not the Range Selector lever to LOW. deployed while the vehicle is carrying 2. Maintain your vehicle speed a load, excessive loads may be forced (accelerator depressed) and move 2. Keep driving with the accelerator onto other vehicle components (frame, the Range Selector lever to HIGH. depressed until you want the axle axles, suspension, brakes, steering, to downshift. 3. Keep driving with the accelerator tires, etc.). This overload condition 4 depressed until you want the axle 3. To make the axle downshift, may reduce the service life of these to shift. release and depress the vehicle components. Acceptable accelerator quickly to increase the service life is maintained through 4. To make the axle shift, release the engine RPM. The axle will shift to careful operation, proper maintenance accelerator until the axle shifts. LOW range. and proper adherence to the vehicles You are now in the HIGH axle and auxiliary axle manufacturers range for highway speeds. Shift 4. You are now in the LOW axle operating limits. the transmission normally to reach range for rough terrain and heavy your desired cruising speed. loads. Shift the transmission If your vehicle is equipped with normally to maintain the desired factory-installed pusher or tag speed. axle(s), or you have a third-party (i.e. body-builder) install these axles, it is your responsibility to ensure that the axle lift controls or air-dump valve (if

4-58 Y53-1203-1D1 (02/14) OPERATING THE REAR/DRIVE AXLE equipped) are calibrated prior to putting Functionality of Auxiliary Axles the vehicle into service. The reason installed by Kenworth WARNING! for doing this important calibration is to Do not operate or park the ve- • Any liftable steerable auxiliary obtain the proper axle load distribution hicle with auxiliary axles in the axles installed by Kenworth will for the entire vehicles axles. As with down/loaded position when vehicle raise when the parking brake is the entire vehicles axles, the pusher is unladen, or is being unloaded. engaged. or tag axle load cannot exceed the Raise or dump air into driver-con- certified GAWR and/or the legal load • Any liftable steerable auxiliary trolled auxiliary axle(s) prior to un- limit of the axle assembly and its axles installed by Kenworth will loading vehicle. Failure to do so can related components. raise when the vehicle is placed result in loss of vehicle control or into reverse. rollaway that may result in personal There are three types of pusher or tag injury, death, equipment or property axles: • Liftable/non-steerable axles do damage. not raise when parking brake is 4 • Liftable/steerable (axle lift engaged or if vehicle is in reverse. calibration required) • Liftable/non-steerable (axle lift calibration required) • Non-liftable (some suspensions require dump valve calibration)

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Axle Creep Rating Definition ratings are generally limited to the CAUTION Creep Ratings following: Never exceed the manufacturers Low speed, off-highway (work site) • Tandem rear axles only assigned gross axle weight ratings axle loads, which exceed the standard (GAWR) of each axle when the aux- • Straight trucks only gross axle weight rating (GAWR) of a iliary axles are downloaded. Never particular axle. exceed the manufacturers creep • Maximum spring mount ratings when operating with a load centers per axle manufacturers Operator's using vehicles equipped specifications when the auxiliary axles are un- with liftable auxiliary axles must loaded. Refer to your vehicles com- consider creep ratings when any • Maximum tire static loaded radius pliance decals located on the LH liftable axle is unloaded or in the raised (SLR) per axle manufacturers doorjamb for the maximum allow- position. Liftable auxiliary axles should specifications 4 able load for each axle. Exceeding only be raised (or unloaded) to improve the specified weight rating of any maneuverability in an off-road use or CAUTION axle can cause equipment damage. when vehicle is unloaded. Always lower the axles as soon as possible after receiving a load. NOTE NOTE Never exceed 5 miles per hour when Axle Creep Ratings are assigned Axle Creep ratings MUST NOT be driving with a load with the auxil- by the axle manufacturer and are exceeded. iary axle(s) raised/unloaded. Failure based on axle model and intended to lower the axle(s) can overload service of the vehicle. To find out Contact your Kenworth Dealer or the frame and remaining axles, and what the allowable creep rating is axle manufacturer to determine what could cause equipment damage. for your vehicle, contact the nearest the creep rating is for your particular authorized Kenworth Dealer or axle axle(s) and configuration. Creep representative.

4-60 Y53-1203-1D1 (02/14) OPERATING THE REAR/DRIVE AXLE

Liftable/Steerable or WARNING! CAUTION Liftable/Non-Steerable Pusher Never operate the vehicle with more A change in tire size on either the and/or Tag Axle Calibration pressure in the lift axles than is nec- auxiliary axles or the drive/steer Procedure essary to carry the load, as deter- axles can change the calibration Below are some general instructions mined by the calibration procedure of the auxiliary axles. If tires are on how to adjust and calibrate the air described. Failure to do so can re- installed with a different loaded ra- control valve for the auxiliary axles to sult in loss of traction and stability at dius, the calibration procedure must obtain the proper load distribution of the steer and/or drive axles and can be repeated. Failure to do so can the axle(s). For additional operating result in increased braking distance cause equipment damage. and maintenance instructions, see the which could cause loss of vehicle pusher or tag suspension manufacturer control resulting in an accident. Fail- literature in the glove box or contact ure to comply may result in personal them directly. 4 injury, death, equipment or property damage. NOTE This procedure must be performed CAUTION prior to placing the vehicle into ser- Do not modify the air system and/or vice. control functionality on a factory in- stalled auxiliary axle(s). Modifying Setting the Pressure-to-Load Ratio the factory operation of the pusher and/or tag axle(s) will void your war- To obtain the desired axle load ranty, and can cause equipment distribution, you must correlate the damage. suspension air gauge pressure to the actual axle load by scaling the axle

(02/14) Y53-1203-1D1 4-61 OPERATING THE REAR/DRIVE AXLE

weight(s) and adjusting the pressure General Calibration Guidelines 4. Adjust the amount of load on to obtain the desired load. Once the each axle by turning the pressure desired load or load range is achieved, These instructions are general in regulator clockwise to increase document the pressure-to-load ratio or nature. For more specific instructions, the load or counterclockwise setting for future use. review the pusher or tag suspension to decrease the load. (The manufacturers maintenance manual or suspension manufacturer contact the nearest authorized dealer. may publish pre-established Pressure-to- Load Ratio Pressure NOTE Settings to assist you in achieving Perform this procedure at or near a an estimated ground load.) weight scale. Procedure can be per- formed while parked on the weight 5. After setting the pressure to obtain scale if scale is available. the desired axle load, verify proper 4 ground loading with the weight 1. Park loaded vehicle on level scale. surface with wheels blocked. NOTE 2. Release vehicles spring brakes. (Do not release for Exceeding local, state or federal Liftable/Non-Steerable pusher or weight limits may result in cita- tag axles). tions. Contact your local commercial weight enforcement office for limits 3. Lower the pusher/tag axles with in your area. the axle lift control flip valve. (For some non-liftable axles, inflate air suspension).

4-62 Y53-1203-1D1 (02/14) OPERATING THE REAR/DRIVE AXLE

Operation Guidelines Maximizing Drive Axle Traction Coupling to a Loaded Trailer

NOTE Adjust the pressure regulator control Inflate air springs of the auxiliary axles knob to a lower pressure until desired to the desired pressure after coupling Steerable-pusher and/or tag axle(s) traction is obtained. By reducing air to a loaded trailer while still maintaining will raise when the transmission is pressure at pusher or tag axle, load proper traction of the drive axles. shifted into reverse or when the will be transferred to drive axles. Do parking brakes are applied. not overload drive axles.

4

(02/14) Y53-1203-1D1 4-63 OPERATING THE REAR/DRIVE AXLE

Unloading Operation Non-liftable (Non-steerable) Axles

Always deflate air springs of the Some suspensions require dump valve auxiliary axles before attempting to calibration. unload vehicle. This allows maximum traction of the drive axles to control the Example: Neway dead axles do not vehicle. lift, but the air can be dumped out of them to unload them when empty. Air pressure is controlled via an adjustable regulator. These axles need to be calibrated for load.

Contact your authorized Kenworth 4 Dealer or axle/suspension manufacturer for dump valve calibration procedures.

4-64 Y53-1203-1D1 (02/14) OPERATING THE TRANSMISSION

OPERATING THE in the transmission manufacturer's Transmission Warm-Up TRANSMISSION Driver/Operator's Instruction Manual. In cold weather (below 32° F (0° You will find a shift pattern diagram C), you may find shifting sluggish Introduction in the cab. Check to be sure you when you first start up. Transmission know the correct sequence for your warm-up is especially important at Your Kenworth is equipped with either a particular transmission. this time, but it is always a good manual or automatic transmission with idea to warm-up your transmission special features and gearing to meet before starting out on the road. To your particular needs. It is important warm-up the transmission, follow these for you, the driver, to understand procedures. how your particular transmission is operated. To do this, you have two To warm-up the transmission sources: this Operator's Manual lubricating oil during engine warm-up, 4 and the transmission manufacturer's with a single transmission (manual and Driver/Operator's Instruction Manual. automatic): Because of the wide variety of different transmissions installed in Kenworth 1. Put the transmission in Neutral. vehicles, operating procedures for 2. Release the clutch pedal (manual your particular transmission are not only) and operate the transmission included in this manual; therefore, in neutral for 3 to 5 minutes prior you should read and understand both to operating the transmission in manuals. Read the general guidelines either forward or reverse range. and instructions that follow and read the specific instructions contained 3. If you have a two-transmission combination:

(02/14) Y53-1203-1D1 4-65 OPERATING THE TRANSMISSION

Operating Manual Putting the Vehicle in Motion ° Put the main transmission in Transmissions gear. After making sure the vehicle's oil ° Put the auxiliary transmission The transmission shift pattern for your and air pressure are correct and all in Neutral. This will allow vehicle may be located on the driver’s other parts and systems are in proper the transmission countershaft sun visor and shift control knob. In working condition: to turn, agitating the oil and addition to understanding the shift 1. Fully depress the clutch pedal (for warming it. pattern and its location, you should manual transmission) until the read the transmission manufacturer’s clutch brake makes contact. The manual provided with your vehicle contact will occur at about 1 inch before operating the vehicle. or less from the floorboard. ° The total stroke of the clutch 4 pedal is about 10 inches. The first 1-½ inches is free travel. After the free travel comes the release stroke, which is the part that fully releases the clutch. The last 1 inch engages the clutch brake. ° Always start out in a low gear. Starting in higher gears, even with a light load, will cause a very jumpy start and excessive wear.

4-66 Y53-1203-1D1 (02/14) OPERATING THE TRANSMISSION

engagement. If you need to are obtained. For further information, CAUTION start up on an incline, apply your see MORE DRIVING TIPS AND Always use first gear or a low speed service brakes before you release TECHNIQUES on page 4-5. range to start the vehicle in motion. the parking brake. Then release The use of a higher gear or speed your service brakes as you engage range forces undue strain on the the clutch and apply throttle. engine, clutch, other transmission For further instructions on components, and may cause dam- operating your transmission, see age. the transmission manufacturer's 2. Evaluate the road surface Driver/Operator's Instruction Manual. conditions and terrain your vehicle If you have a misaligned gear condition is on. Select a gear low enough to in your vehicle's transmission and 4 let your vehicle start forward with cannot start, gradually release the the throttle at idle. clutch, allowing the drive gear teeth to 3. Push the parking brake valve line up properly. Then the drive gear handle (Yellow) against the dash can roll enough to allow the teeth to panel to release the brakes. line up properly and complete the shift.

4. Release the clutch pedal (manual The best engine performance and only), then gradually accelerate to maximum economy is obtained if gears permit smooth starting. are properly selected. This efficiency 5. Do not allow your vehicle is achieved by always selecting gears to roll (even a little) in the within optimum engine RPM, which opposite direction during clutch is where maximum torque and power

(02/14) Y53-1203-1D1 4-67 OPERATING THE TRANSMISSION

Shifting Gears in a New Vehicle Clutch Brake and Travel During Normal Driving

Shift carefully in a new vehicle. The The clutch brake is used for stopping If you want to shift directly into any gear transmission may be a little stiff at transmission gears, allowing you to other than first or reverse, depress the first. Avoid gear clashing, by closely easily shift into first gear or reverse clutch pedal only far enough to release following these procedures. without grinding gears. Approximately the clutch. Pushing the clutch to the the last one inch of clutch pedal travel floor applies the clutch brake and could When you are operating a new vehicle activates the clutch brake. cause gear hang-up. or one that has been exposed to cold weather, you want the transmission • To apply the clutch brake (while CAUTION lubricant (fluid) to circulate and coat the vehicle is stopped) fully Be careful not to apply the clutch the contacting surfaces of the gears. depress the clutch pedal to the brake while the vehicle is moving. Metal contacting metal in moving floorboard to stop the gears. With The purpose of the clutch brake is 4 parts may seriously damage your the throttle at idle, select first gear to stop the transmission so that you transmission, do not drive in one then release the clutch pedal to let can shift into a starting gear without gear for long periods of time until the the vehicle start forward, until the grinding gears. Applying the clutch transmission lubricant has a chance to clutch is fully engaged. See the brake when the vehicle is moving coat all contacting surfaces. Carefully manufacturer's Driver/Operator's causes a braking effect on the drive- observe the free travel in the clutch Instruction Manual for further train and shortens the service life of for the first few hundred miles. As the details. the clutch brake. clutch lining wears and high spots get worn smooth, you will get less free If the transmission has a butt-tooth travel. condition and you cannot engage a gear, gradually release the clutch. Then the drive gear can roll enough to allow the teeth to line up properly and complete the shift.

4-68 Y53-1203-1D1 (02/14) OPERATING THE TRANSMISSION

Double Clutching ° Downshifts: press accelerator, More Transmission Tips increase engine and gear Riding the Clutch Whether you are upshifting or down speed to the RPM required in shifting, it is best to double clutch. The clutch is not a footrest. Do not the lower gear. Double clutching is easier on the drive with your foot resting on the transmission and on the engine, 4. Now, quickly press the pedal to clutch pedal. It will allow your clutch to helping your vehicle match engine disengage the clutch and move slip, causing excessive heat and wear, speed with driveline speed and the gear shift lever to the next gear damage could result. achieving clash-free shifts. speed position.

To Double Clutch: 5. Release the pedal to engage the clutch. 1. Push the clutch pedal down to disengage the clutch. 4 2. Move the gear shift lever to neutral. 3. Release the pedal to engage the clutch. This lets you control the RPM of the mainshaft gears, allowing you to match the RPM of the mainshaft gears to those of the output shaft. ° Upshifts: let the engine and gears slow down to the RPM required for the next gear.

(02/14) Y53-1203-1D1 4-69 OPERATING THE TRANSMISSION

Release Bearing Wear Clutch Adjustment • To provide smooth gear engagements while shifting, When you must idle your engine for any Inspect manual clutches according to use proper coordination between period of time, shift your transmission the manufacturer's recommendations. shift lever and clutch. to neutral and disengage the clutch Regular maintenance should be (take your foot OFF of the pedal). This followed to maintain correct clutch helps prevent unnecessary wear to adjustment. Have your dealer's your clutch release bearing, and it is Service Department perform any less tiring for you, too. adjustment necessary.

Tips • Always use the clutch when 4 making upshifts or downshifts. • Always select a starting gear that will provide sufficient gear reduction for the load and terrain. • Never downshift when the vehicle is moving too fast. • Never slam or jerk the shift lever to complete gear engagement. • Never coast with the transmission in neutral and the clutch disengaged.

4-70 Y53-1203-1D1 (02/14) OPERATING THE TRANSMISSION

Transmission Oil Temperature Operating Automatic brake before leaving the cab. See Gauge Transmissions Using the Parking Brake on page 4-19. The Transmission Temperature An automatic transmission makes Gauge (option), see Transmission Oil shifting much easier, of course. But WARNING! Temperature Gauge on page 3-71, because your truck pulls a heavy Do not leave the cab without apply- indicates the temperature of the oil in load, it is important to use it efficiently. ing the parking brake. The truck the transmission. Watch this gauge For correct automatic transmission could roll and cause an accident. Al- to know when the transmission is operation, see the manufacturer's ways apply the parking brake before overheating: if it is, have it checked by Driver/Operator's Instruction Manual. you leave the cab. Failure to comply an authorized service representative. may result in personal injury, death, WARNING! equipment or property damage. If your vehicle has a Freedomline 4 transmission, be aware that it can roll backwards when stopped on a hill or grade, or when starting from a stop on a hill or grade. Failure to comply may result in personal injury, death, equipment or property dam- age. Observe the following guide- lines:

• On most automatic transmissions there is no PARK position, so you will need to apply the parking

(02/14) Y53-1203-1D1 4-71 OPERATING THE TRANSMISSION

Auxiliary Transmissions Steerable Drive Axle

If you have an auxiliary transmission CAUTION installed on your Kenworth , see The customer cannot change axle the transmission manufacturer's ratios or tires without Kenworth En- Driver/Operator's Instruction Manual to gineering approval. learn how to operate it correctly.

If you have a Steerable Drive Axle installed on your Kenworth, refer to the auxiliary transmission/transfer case manufacturer's Driver/Operator's Instruction Manual to learn how to 4 operate correctly.

4-72 Y53-1203-1D1 (02/14) SHUT-DOWN

SHUT-DOWN Final Stopping Procedures WARNING! 1. Set the parking brake before Introduction leaving the driver's seat. Do not use the trailer hand brake To hold your vehicle while it or service brakes to park and hold After you have parked in a safe place is parked, DO NOT rely on the an unattended vehicle, use the park- check your vehicle to make sure it will following: ing brakes. Because service brakes be ready for the next trip. To make work with air pressure, these brakes sure your vehicle is ready to go after a ° air brakes could slowly release. Your vehicle long stop (such as overnight), please could roll, causing a serious acci- ° hand control valve for trailer follow the suggestions below. Your dent. Always set the parking brakes. brakes vehicle will be easier to get going when Never rely on the service brakes to you are ready, and it will be safer for ° engine compression hold a parked vehicle. Failure to everyone who might be around it. Always use your parking comply may result in personal injury, 4 brakes! death, equipment or property dam- Please remember, too, that in some age. states it is illegal to leave the engine running and the vehicle unattended. 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 supply system are still warm, drain moisture from the air tanks. Open the tank drains just enough to drain the moisture. Do not deplete the entire air supply.

(02/14) Y53-1203-1D1 4-73 SHUT-DOWN

Turbocharger 5. Secure the vehicle, close all the Before Stopping the Engine windows, and lock all doors. Do not shut off the engine immediately. This cooling-down practice is A hot engine stores a great amount especially important for a turbocharged of heat and it does not cool down engine. The turbocharger on your immediately after you shut if off. vehicle contains bearings and seals Always cool the engine down before that are subjected to hot exhaust shutting it off. You will greatly increase gases. While the engine is operating, its service life. heat is carried away by circulating oil. If you stop the engine suddenly after Idle the engine at 1,000 rpm for five a hard run, the temperature of the minutes. Then low idle for thirty turbocharger could rise to as much as seconds before shutdown. This will 100° F (55° C) above the temperature 4 allow circulating coolant and lubricating reached during operation. A sudden oil to carry away heat from the cylinder rise in temperature like this could head, valves, pistons, cylinder liners, cause the bearings to seize or the oil Blocked Wheels turbocharger, and bearings. This way seals to loosen. you can prevent engine damage that may result from uneven cooling.

4-74 Y53-1203-1D1 (02/14) SHUT-DOWN

Refueling Location of Fuel Shut-Off Valves WARNING! Air inside the fuel tanks allows water If your vehicle is equipped with shut-off Do not remove a fuel tank cap near to condense in the tank. To prevent valves for the take-off and return lines, an open flame. Diesel fuel in the this condensation while the vehicle is they are located on the fuel lines presence of an ignition source (such parked for extended periods of time, entering the top of the fuel tank. Fuel as a cigarette) could cause an ex- fill the tanks to 95 percent of capacity. shut-off valves for the fuel crossover plosion. A mixture of gasoline or Never fill to more than 95 percent line are on the bottom of the fuel tank, alcohol with diesel fuel increases capacity as this provides room for at the crossover line connection. this risk of explosion. Use only the expansion resulting from temperature fuel and/or additives recommended extremes. When refueling, add for your engine. Failure to comply approximately the same amount to may result in personal injury, death, each fuel tank on vehicles with more equipment or property damage. than one tank. 4

WARNING! Specification: Use only Ultra Low Sulfur Diesel (ULSD) Fuel, Do not carry additional fuel contain- as recommended by engine ers in your vehicle. Fuel containers, manufacturers. If you need further either full or empty, may leak, ex- information on fuel specifications, plode, and cause or feed a fire. Do consult the Engine Operation and not carry extra fuel containers, even Maintenance Manual. empty ones are dangerous. Failure to comply may result in personal in- jury, death, equipment or property damage.

(02/14) Y53-1203-1D1 4-75 SHUT-DOWN

Sleeper Bunk WARNING! WARNING! If your vehicle has an upper and lower Always keep the lower bunk in its Be sure the restraint system is bunk, the upper bunk can be folded up down (latched) position while the ve- used when anyone is occupying the out of the way to provide you with more hicle is moving. If left open, stored sleeper while the vehicle is moving. dressing area in the sleeper cab. The items could become loose during an In an accident, an unrestrained per- lower bunk has storage underneath accident and strike you. Failure to son lying in a sleeper bunk could it to stow your luggage and other comply may result in personal injury be injured. He or she could be belongings. or death. thrown from the bunk. Failure to comply may result in personal injury WARNING! To Lower Upper Bunk: pull on the or death. Be sure the restraint system is lanyard in the upper left corner of the 4 used when anyone is occupying the bunk to release the bunk. This will free WARNING! sleeper while the vehicle is moving. it from the anchored position and allow Be sure to stow away all loose be- In an accident, an unrestrained per- you to lower the bunk. son lying in a sleeper bunk could be longings before you move your vehi- cle. And do not store objects on the injured. He or she could be thrown To Raise Upper Bunk: fold the bunks, they could cause damage or from the bunk. upper bunk up and push it against the injury in an accident. retaining latch until you hear a click. Pull on the bunk to be sure it is latched securely.

4-76 Y53-1203-1D1 (02/14) SHUT-DOWN

Sleeper Occupant Restraint the buckles on the forward edge WARNING! of the bunk. The sleeper restraint is stored in a Be sure the latch that holds the up- compartment on the rear sleeper cab 3. Start with the buckle nearest to per bunk in the folded position is wall. your feet and progress to the working properly so the bunk will not buckle near your head. fall down. If the bunk falls, you could WARNING! be injured. Failure to comply may re- 4. Adjust the tenting straps to the sult in personal injury or death. Failure to properly use the sleeper desired tension. restraint when an individual is lo- cated in the sleeper bunk and the ve- NOTE WARNING! hicle is moving can result in injury or For partial stowage of the sleeper Be sure no one ever rides in the death. restraint the tenting straps may re- upper bunk. That person could be main attached and the front buckles 4 thrown out in an accident and could To Fasten the Sleeper Restraint released. This allows entrance and be injured. Do not use the upper exit to and from the sleeper bunk. bunk while you are moving. Failure 1. Locate the tenting straps on each to comply may result in personal in- side of the sleeper restraint and 5. For complete stowage, disconnect jury or death. attach them to the buckle-latch all buckles and replace the plate located on the sides of the restraint into the stowage sleeper cab (above the lower bunk compartment. See Sleeper Bunks mattress). and Restraints on page 1-29, 2. Enter the sleeper bunk, and attach for more information on cab/seat the latch plates (on the forward restraint systems. edge of the sleeper restraint) to

(02/14) Y53-1203-1D1 4-77

MAINTENANCE

PREVENTIVE MAINTENANCE Introduction ...... 5-7 Safety Precautions ...... 5-7 Environmental Protection and Material Hazards . . . 5-8 MAINTENANCE SCHEDULE AND LUBRICATION Introduction ...... 5-10 Preventive Maintenance Intervals and Schedule . 5-10 Lubrication Specifications ...... 5-30 Oil Reservoirs ...... 5-30 Lubrication Chart ...... 5-31 AIR SYSTEM MAINTENANCE 5 Introduction ...... 5-34 Scheduled Maintenance ...... 5-35 Air Tanks ...... 5-36 Air Gauges and Air Leaks ...... 5-37 Air Compressor ...... 5-38 Air Dryer ...... 5-40

(02/14) Y53-1203-1D1 5-1 MAINTENANCE

Air Intake System ...... 5-42 Turbocharger...... 5-43 Air Cleaners and Filter Replacement ...... 5-43 BRAKE SYSTEM MAINTENANCE Introduction ...... 5-44 Checks and Adjustments...... 5-46 Anti-Lock Braking System (ABS) ...... 5-49 CAB MAINTENANCE Exterior Maintenance ...... 5-51 Cleaning, Protecting and Weather Stripping . . . 5-52 Pendleton® Limited Edition Interior Cleaning 5 Instructions ...... 5-55 Safety Restraint System - Inspection ...... 5-57 Windshield Wiper/Washer ...... 5-60 COOLING SYSTEM MAINTENANCE Topping Up...... 5-61 Adding Coolant ...... 5-63 Change and Refilling ...... 5-65

5-2 Y53-1203-1D1 (02/14) MAINTENANCE

Radiator Cap ...... 5-66 Engine (Block) Heater ...... 5-66 ELECTRICAL MAINTENANCE Electrical System ...... 5-67 Fuses, Circuit Breakers, and Relays ...... 5-67 Fuse Inspection and Replacement ...... 5-68 Adding Electrical Options ...... 5-69 Batteries ...... 5-74 Battery Care ...... 5-77 Battery Charging ...... 5-77 Electrical and Alternator Precautions ...... 5-79 Remote Keyless Entry ...... 5-80 5 Halogen/HID Lamp Headlamp Servicing . . . . . 5-81 ENGINE MAINTENANCE Engine Maintenance ...... 5-86 Engine Lubrication ...... 5-87 Fuel System ...... 5-90 Accessory Drive Belts ...... 5-92

(02/14) Y53-1203-1D1 5-3 MAINTENANCE

Engine Fan ...... 5-92 Engine Mounting ...... 5-93 Exhaust System ...... 5-93 All Models ...... 5-94 Multi-Function Message Display ...... 5-94 FRAME MAINTENANCE Introduction ...... 5-95 FRONT AXLE AND SUSPENSION MAINTENANCE Axle Lubrication ...... 5-98 Inspection ...... 5-99 Wheel Alignment ...... 5-99 5 U-Bolt Torque ...... 5-99 HEATER AND AIR CONDITIONER MAINTENANCE Introduction ...... 5-101 Heater...... 5-102 Air Conditioner ...... 5-103

5-4 Y53-1203-1D1 (02/14) MAINTENANCE

NOISE AND EMISSION CONTROL MAINTENANCE Noise Emission Warranty ...... 5-104 Inspection and Maintenance Instructions . . . . . 5-106 Noise Control System - Maintenance Log . . . . 5-112 REAR AXLE AND SUSPENSION MAINTENANCE General Maintenance ...... 5-113 Visual Inspection ...... 5-114 Rear Suspension Fasteners ...... 5-114 Rear Axle Lubrication ...... 5-116 Rear Axle Alignment ...... 5-118 STEERING AND DRIVELINE MAINTENANCE Power Steering ...... 5-119 5 Fluid Level and Refill ...... 5-120 Steering Driveline ...... 5-121 Driveshaft ...... 5-122 TIRES AND WHEEL MAINTENANCE Introduction ...... 5-123

(02/14) Y53-1203-1D1 5-5 MAINTENANCE

General Safety Requirements ...... 5-123 Speed Restricted Tires ...... 5-124 Tire Inspection and Replacement ...... 5-125 Tire Inflation and Loading ...... 5-125 Wheel Mounting and Fastening ...... 5-128 Wheel Replacement with Disc Brake Option . . . 5-131 Disc Wheels ...... 5-132 Comparing Hub Piloted and Ball Seat Parts . . . 5-132 Tire Replacement ...... 5-134 TRANSMISSION AND CLUTCH MAINTENANCE Introduction ...... 5-137 5 All Transmissions ...... 5-137 Transmission Lubricants ...... 5-138 Automatic Transmissions ...... 5-139 Clutch System Introduction ...... 5-140 Clutch Linkage ...... 5-140 Clutch Adjustment - Normal Wear ...... 5-141

5-6 Y53-1203-1D1 (02/14) PREVENTIVE MAINTENANCE

PREVENTIVE Safety Precautions WARNING! MAINTENANCE • Before attempting any It can be dangerous to attempt procedures in the engine maintenance work without sufficient Introduction compartment, stop the engine training, service manuals, and the and let it cool down. Hot proper tools. You could be injured, This section will help you keep your components can burn skin on or you could make your vehicle un- Kenworth in good running condition. contact. There are a number of checks you safe. Do only those tasks you are can do, and you may be able to do fully trained and equipped to do. • Be alert and cautious around some of the service work yourself. But Failure to comply may result in per- the engine at all times while the please, let your Kenworth Dealer do sonal injury, death, equipment or engine is running. any work you do not have the tools property damage. • If work has to be done with the or skill to perform. Authorized service engine running, always (1) set mechanics are trained in the proper the parking brake, (2) chock technical and safety procedures to the wheels, and (3) ensure that maintain your Kenworth correctly. the shift lever or selector is in 5 Good driving practices, daily Neutral. and weekly driver maintenance • Exercise extreme caution to inspections, and periodic service prevent neckties, jewelry, long inspections by an authorized Kenworth hair, or loose clothing from Dealer, will help keep your Kenworth in getting caught in moving engine good working order and provide many parts. years of dependable service.

(02/14) Y53-1203-1D1 5-7 PREVENTIVE MAINTENANCE

• Disconnect the battery ground • Never start or let the engine run Environmental Protection strap whenever you work on in an enclosed, unventilated and Material Hazards the fuel system or the electrical area. Exhaust fumes from system. When you work around the engine contain carbon Some of the ingredients in engine fuel, do not smoke or work monoxide, a colorless and oil, hydraulic oil, transmission and near heaters or other fire odorless gas. Carbon monoxide axle oil, engine coolant, diesel fuel, hazards. Keep an approved fire can be fatal if inhaled. air conditioning refrigerant (R12, extinguisher handy. R-134a and PAG oil), batteries, etc., Incomplete or improper servicing may contaminate the environment if • Always support the vehicle with may cause problems in the operation spilled or not disposed of properly. appropriate safety stands if it is of the vehicle. If in doubt about Non-compliance with environmental necessary to work underneath any servicing, have it done by your regulations can result in fines and/or jail the vehicle. A jack is not authorized Kenworth Dealer. Improper terms. Contact your local government adequate for this purpose. maintenance during the warranty agency for information concerning period may also affect the warranty proper disposal. • When working underneath the coverage. vehicle without appropriate 5 safety stands but with the Modifying your vehicle can make wheels on the ground (not it unsafe. Some modifications can supported), make sure that (1) affect your vehicle's electrical system, the vehicle is on hard level stability, or other important functions. ground, (2) the parking brake Before modifying your vehicle, check is applied, (3) all wheels are with your Kenworth Dealer to make chocked (front and rear) and (4) sure it can be done safely and correctly. the engine cannot be started. Remove the ignition key.

5-8 Y53-1203-1D1 (02/14) PREVENTIVE MAINTENANCE

WARNING! This vehicle contains material known by the State of California to cause cancer and/or birth defects or other reproductive harm. This warning requirement is mandated by California law (Proposition 65) and does not result from any change in the manner in which Kenworth Truck Company vehicles are manu- factured.

CAUTION Handle lubricants carefully. Vehi- cle lubricants (oil and grease) can be poisonous and cause sickness. 5 They can also damage the paint on the vehicle.

(02/14) Y53-1203-1D1 5-9 MAINTENANCE SCHEDULE AND LUBRICATION

MAINTENANCE Preventive Maintenance SCHEDULE AND Intervals and Schedule WARNING! LUBRICATION It can be dangerous to attempt main- Your preventive maintenance program tenance work without sufficient train- begins with daily checks you perform. ing, service manuals, and the proper Introduction See Driver's Check List on page 1-35. tools. You could be injured, or you If your Kenworth is serviced regularly, could make your vehicle unsafe. Do The following section summarizes you can avoid many large, expensive, only those tasks you are fully trained preventive maintenance and lubrication and time-consuming repairs, as well and equipped to do. requirements for the maintenance of as ensuring many years of safe and your Kenworth. In addition, supporting smooth operation. Also, be advised In severe operating conditions such manuals and literature are included in that neglect of recommended service the glove box literature package. as earth moving, you will need to may in some cases void your vehicle's perform maintenance checks and warranty. For your safety and life of services more frequently. Other your vehicle, please follow Table 9, severe operating conditions to be Maintenance Schedule on page 5-18. aware of are: where the vehicle is 5 Remember, there may be maintenance consistently operated under conditions operations that demand skills and of extreme temperature; conditions equipment you do not have. If so, where heavy loads are being hauled; please take your Kenworth to an expert and contaminated environments, or mechanic, for your safety and your steep grades. Consult the component vehicle's performance. manufacturer's maintenance manuals for further information on maintenance procedures specific to these conditions.

5-10 Y53-1203-1D1 (02/14) MAINTENANCE SCHEDULE AND LUBRICATION

Maintenance and Lubrication vehicles. All intervals shown are for Intervals normal and heavy-duty operations. NOTE Different lubricants or service inter- The following table (Table 6 vals than those listed below may be Recommended Lubrication Intervals) required. shows service intervals for Kenworth

Table 6 Recommended Lubrication Intervals

ITEM INTERVALS COMMENTS Hood Pivot None Front Brake Camshaft 10,000-15,000 Synthetic Grease with Special Fittings Front Brake Camshaft 120,000 With LMS Tie-Rod Ends 10,000-15,000 Power Steering Reservoir - Check Fluid Level 10,000-15,000 - 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-operated gun only Steering Gear Box Trunnion 10,000-15,000 #2 NLGI extreme pressure, lithium-based, moly-filled, heavy duty grease with 5 hand-operated gun only

Steering U-joints 10,000-15,000 #2 NLGI extreme pressure, lithium-based, moly-filled, heavy duty grease with hand-operated gun only Steering Slip Joint 10,000-15,000 #2 NLGI extreme pressure, lithium-based, moly-filled, heavy duty grease with hand-operated gun only Brake Treadle 10,000-15,000 Clutch Pedal Shaft None

(02/14) Y53-1203-1D1 5-11 MAINTENANCE SCHEDULE AND LUBRICATION

ITEM INTERVALS COMMENTS Main and Aux. Transmission Kenworth is Standard with Synthetic Lube (mineral gear lube optional) - Check Fluid Level See Transmission Manufacturers Specifications and Recommendations - Contact - Drain and Refill your Kenworth Dealer for Preventive Maintenance Specifications/Schedule Rear Wheel Bearings - 12 mo./100,000 See www.conmet.com for maintenance details Standard Rear Wheel Bearings - LMS 12 mo./100,000 - Inspect Inspect for leaks and check for end-play: 12 mo.\100,000 miles. 3 years/350,000 - Service See hub manufacturer's service manual for details: www.conmet.com/pdfs/preset_service_manual.pdf If no oil leaks, then no need for service prior to 3 years/350,000 miles. Rear Axle Kenworth is Standard with Synthetic Lube (mineral gear lube optional) - Check Fluid Level See Axle Manufacturer's Specifications and Recommendations - Contact your - (Rear Axle) Drain, Flush, Refill Kenworth Dealer for Preventive Maintenance Specifications/Schedule Rear Brake Camshafts 10,000-15,000 Synthetic Grease with Special Fittings Rear Brake Camshafts 120,000 With LMS Spring Pins 10,000-15,000 With Rubber Bushed Pins - No Service Front & Rear Slack Adjusters 10,000-15,000 Synthetic Grease with Special Fittings King Pins 10,000-15,000 Fifth Wheel 10,000-15,000 40,000 to 60,000 miles for Adjustment Front Wheel Bearings - 12 mo./100,000 See www.conmet.com for maintenance details 5 Standard Front Wheel Bearings - LMS 12 mo./100,000 - Inspect Inspect for leaks and check for end-play: 12 mo.\100,000 miles. 3 years/350,000 - Service See hub manufacturer's service manual for details: www.conmet.com/pdfs/preset_service_manual.pdf If no oil leaks, then no need for service prior to 3 years/350,000 miles. Engine Lubricating Oil - Check Fluid Level Daily Trip Check See Engine Manufacturer's Recommendations - Change Oil 10,000-15,000 Must Meet Engine Manufacturer's Specifications Spring Shackle Pins 10,000-15,000 No Service with Rubber Bushed Spring Pins Clutch Linkage 10,000-15,000 Clutch Release Bearing 10,000-15,000 Extended Grease Fittings

5-12 Y53-1203-1D1 (02/14) MAINTENANCE SCHEDULE AND LUBRICATION

ITEM INTERVALS COMMENTS Clutch Cross Shaft 10,000-15,000 Extended Grease Fittings Door Weatherstrip 100,000 or As Required Lock Cylinders 100,000 or As Required Door Hinges 100,000 or As Required Teflon Bushing Door Latches and Striker Plate 100,000 or As Required Driveshaft (all) See Table 7 and 8. Center Bearing None Suspension Per Specifications AG380 AG400 None No Lube Required Chalmers None No Lube Required Hendrickson See Suspension Manufacturer's Specifications & Recommendations - Contact your Neway Kenworth Dealer for Preventive Maintenance Specifications/Schedule Reyco

For additional Air System Scheduled Maintenance information, see Air System Scheduled Maintenance on 5 page 5-35.

(02/14) Y53-1203-1D1 5-13 MAINTENANCE SCHEDULE AND LUBRICATION

Table 7 Spicer Driveshaft Lubrication Intervals*

SERIES CITY ON-HWY LINEHAUL ON/OFF-HWY 10-Series 5,000/8,000 mi 10,000/15,000 mi 10,000/15,000 mi 5,000/8,000 mi (1480 thru 1810 & SPL-90) (8,000/12,800 km) (16,000/24,000 km) (16,000/24,000 km) (8,000/12,800 km) Slip member also requires or 3 Months (whichever or 3 Months (whichever or 30 Days (whichever or 3 Months (whichever lubrication. comes first) comes first) comes first) comes first) Spicer Life Series® - 25,000 mi 25,000 mi 25,000 mi 25,000 mi Medium Duty (40,000 km) (40,000 km) (40,000 km) (40,000 km) (SPL-55, 70 & 100) or 6 Months (whichever or 6 Months (whichever or 6 Months (whichever or 6 Months (whichever Booted & permanently comes first) comes first) comes first) comes first) lubricated slip member. Spicer Life Series® - 25,000 mi 100,000 mi 100,000 mi 25,000 mi Heavy Duty (40,000 km) (160,000 km) (160,000 km) (40,000 km) (SPL-140, 140HD, 170, 170 or 6 Months (whichever or 6 Months (whichever or 6 Months (whichever or 6 Months HD, 250 & 250 HD) comes first) comes first) comes first) Standard Spicer Life Series u-joint Booted & permanently lubricated slip 5 member. * Spicer Driveshaft Division recommends re-lubrication with Chevron Ulta-Duty EP-2 or a compatible grease meeting N.L.G.I. Grade 2 specifications with 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-joints have a plastic fitting cover attached prior to the required initial 350,000 mile re-lubrication. Standard Spicer Life Series u-joints have a hard plastic 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.

5-14 Y53-1203-1D1 (02/14) MAINTENANCE SCHEDULE AND LUBRICATION

Table 8 XL Lubrication Cycles

SERIES CITY ON-HWY LINEHAUL ON/OFF-HWY SPICER LIFE XL - FIRST LUBRICATION CYCLE* SPICER LIFE XL** - HEAVY 100,000 mi 350,000 mi 350,000 mi 100,000 mi DUTY (160,000 km) (560,000 km) (560,000 km) (160,000 km) (SPL-140XL, 170XL & or 1 year (whichever comes or 3 years (whichever comes or 3 years (whichever comes or 1 year (whichever comes 250XL) first) first) first) first) Extended Lubrication u-joints. Booted & permanently lubricated slip member. After initial miles (kilometers) or time is reached, the plastic grease fitting cover must be removed and the joints re-lubricated.

5

(02/14) Y53-1203-1D1 5-15 MAINTENANCE SCHEDULE AND LUBRICATION

SERIES CITY ON-HWY LINEHAUL ON/OFF-HWY SPICER LIFE XL - RE-LUBRICATION CYCLE* SPICER LIFE XL** - HEAVY 25,000 mi 100,000 mi 100,000 mi 25,000 mi DUTY (40,000 km) (160,000 km) (160,000 km) (40,000 km) (SPL-140XL, 170XL & or 6 Months (whichever or 6 Months (whichever or 6 Months (whichever or 6 Months (whichever 250XL) comes first) comes first) comes first) comes first) Extended Lubrication u-joints. Booted & permanently lubricated slip member. Once the greased fitting cover has been removed, this relubrication interval must be followed. * Spicer Driveshaft Division recommends re-lubrication with Chevron Ulta-Duty EP-2 or a compatible grease meeting N.L.G.I. Grade 2 specifications with 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-joints have a plastic fitting cover attached prior to the required initial 350,000 mile relubrication. Standard Spicer Life Series u-joints have a hard plastic 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. 5 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.

5-16 Y53-1203-1D1 (02/14) MAINTENANCE SCHEDULE AND LUBRICATION

Maintenance Schedule

Depending on the service package built into your Kenworth, use Table 9, Maintenance Schedule on page 5-18, as a guide to plan service work for Non-ESI and ESI vehicles. Be sure and follow the frequency recommendations for your vehicle.

Maintenance Interval

Perform the listed operation in the shortest interval indicated. For example, if there is an “I” for Inspect listed under 15,000 mi, 60,000 mi and 120,000 mi, the shortest interval indicated is 15,000 mi; therefore, you 5 should inspect the operation listed every 15,000 miles. It just so happens that both 60,000 and 120,000 miles are multiples of 15,000 and the table indicates that a 15,000 mile interval will also occur at 60,000 and 120,000 miles.

(02/14) Y53-1203-1D1 5-17 MAINTENANCE SCHEDULE AND LUBRICATION

TABLE KEY

A Part of Federal Annual Inspection Every 120,000 Miles (192,000 km) I Inspect R Replace G2 Synthetic Lube Required - 500,000 Drain

Table 9 Maintenance Schedule

INTERVALS COMMENTS OPERATION \ FREQUENCY 7,500 mi 15,000 mi 60,000 mi 120,000 mi (12,000 (24,000 (96,000 km) (193,000 km) km) km) Annually INITIAL DRIVE-IN A B C D Clutch Brake Operation I I I Clutch Pedal Free Travel _____ inches I I I Glass for Cracks or Chips I I I A Door Window Operation 5 Interior Lights Replace as Required Interior Appearance:/Condition: Check for Tears, Stains, Wear Seats I I I I Floor Mats I I I I Door Panels I I I I Headliner I I I I Dash I I I I Sleeper I I I I Covers I I I I Wiper Operation I I I A

5-18 Y53-1203-1D1 (02/14) MAINTENANCE SCHEDULE AND LUBRICATION

INTERVALS COMMENTS OPERATION \ FREQUENCY 7,500 mi 15,000 mi 60,000 mi 120,000 mi (12,000 (24,000 (96,000 km) (193,000 km) km) km) Annually Wiper Blade Condition I I I A Horns (Electric and Air) I I I A Mirrors I I I A SAFETY EQUIPMENT A B C D Drain Water from Air Tanks I I I I Daily Air Tank Check Valve I I I A Emergency Operation of Spring Brakes I I I A Air Press. Build-up time: ______min. I A Governed Air Pressure: ______psi I A Air Press. Drop-Brakes not Applied: ___ I A Air Press. Drop-Brakes Applied: ___ I A Fire Extinguisher Charge Replace or Recharge per Extinguisher Manufacturer Recommendations Flare Kit/Reflectors A CIRCLE INSPECTION A B C D Physical Damage: 5 Exterior Sheet Metal I I I I Grille and Radiator I I I I Trailer Light Cord and Connectors I I I A Air Lines and Gladhands I I I A Pintle - Hook/Eye Condition I I I A 5th Wheel Mounting and Condition I I I A Headlights - High and Low Beams I I I A Road Lights I I I A Marker Lights I I I A

(02/14) Y53-1203-1D1 5-19 MAINTENANCE SCHEDULE AND LUBRICATION

INTERVALS COMMENTS OPERATION \ FREQUENCY 7,500 mi 15,000 mi 60,000 mi 120,000 mi (12,000 (24,000 (96,000 km) (193,000 km) km) km) Annually Turn Signals I I I A Emergency Flasher I I I A Brake Lights I I I A Backup/Loading Lights I I I A License Plates: Permits and Mounting I I I A Mud Flaps/Serviceable I I I A Fuel Tank Mounting I I I A Exhaust System-Condition and Mounting I I I A Bolts Frame Fastener Torque: I A See Table Key on page 5-18. Lubricate: I I Door Hinges and Latches Body Mounts (Straight Truck Only) I I Body Sides and Roof Panels I I (Straight trucks) 5 Cab and Sleeper Air Suspension Mounts I I See Manufacturer's Recommendations Hood: Replace if Damaged I I Hold Down Latches Safety Lock I I Replace as Required Front Pivot Assembly I I

5-20 Y53-1203-1D1 (02/14) MAINTENANCE SCHEDULE AND LUBRICATION

INTERVALS COMMENTS OPERATION \ FREQUENCY 7,500 mi 15,000 mi 60,000 mi 120,000 mi (12,000 (24,000 (96,000 km) (193,000 km) km) km) Annually ENGINE SERVICE A B C D Engine Oil - Change See Engine Manufacturer's Operator Engine Oil Level Manual provided with this chassis Oil Filters Fuel Filters Diesel Particulate Filter (DPF) Drain Water from Fuel System Engine Tune-up Cooling: Check Supplemental Additive/Conditioner to Manufacturer Specifications______% Coolant Level I I I I Coolant Protection: ______degrees I I Pressure Test I I I Check at Time of Coolant Replacement Replace Water Filter R New Release at 100-120K - per Engine Filter Manufacturer Recommendations 5 Hose Condition and Connections I I I Radiator Mounting I I Fan Shroud I I Ring Shroud I I Fan Assembly and Idler Pulley I I No Service Required on ESI Units Check 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 this chassis

(02/14) Y53-1203-1D1 5-21 MAINTENANCE SCHEDULE AND LUBRICATION

INTERVALS COMMENTS OPERATION \ FREQUENCY 7,500 mi 15,000 mi 60,000 mi 120,000 mi (12,000 (24,000 (96,000 km) (193,000 km) km) km) Annually Charge Air Cooler Piping (CAC) * Tighten clamps after the first 500 miles (800 km). * See Pipe and Hose Clamp Torque Values on page 5-90. Air Cleaner: R Replace Annually/Air Cleaner Restriction: Replace if Greater Than 20 Air Intake Pipe Clamps * Tighten clamps after the first 500 miles (800 km). * See Pipe and Hose Clamp Torque Values on page 5-90. Contaminant Accumulation I I Check Every 15,000 Miles (24,000 km) in Dirty Conditions Air Cleaner Restriction ___ I I I (replace if greater than 20) Vacuator Valve-Operation & Condition I I 5 Mounting Bolts I I Leaks I I Interference I I Hose Condition and Connections I I I Check for Leaks and Cracking Power Steering - Reservoir Level I I I I Power Steering Fluid - Replace Service 2 Times per Year - 60,000 Mile R R Intervals Power Steering Filter - Replace R R See Table Key on page 5-18 Fan and Accessory Drive Belt(s) Condition For details on belt replacement see the I I I Engine Operator's Manual included with this chassis.

5-22 Y53-1203-1D1 (02/14) MAINTENANCE SCHEDULE AND LUBRICATION

INTERVALS COMMENTS OPERATION \ FREQUENCY 7,500 mi 15,000 mi 60,000 mi 120,000 mi (12,000 (24,000 (96,000 km) (193,000 km) km) km) Annually Air Conditioner Compressor Mounting I I Cold Start Aids I I I Governor and Pump Security Seals OK A High Idle: ______RPM A Emergency Shutdown I I I Vibration Damper Condition I I Cranking System: I I I Check Harness/Cables For Loose A To ensure proper inspection it may be Connections, Chafing, Broken Retention necessary to inspect under and inside frame Clips rails and unclip harness/cable bundles. Starter Draw: ______volts Alternator/Charging System: I I I To ensure proper inspection it may be Check Harness/Cables For Loose I A necessary to inspect under and inside frame Connections, Chafing, Broken Retention rails and unclip harness/cable bundles. Clips Output Voltage: ______volts 5 Exhaust System I Check for leaks and proper support. Inspect engine mounts every 60,000 miles (96,560 km) (shown on page 5-93). Contact Engine Mounting I an authorized vehicle OEM dealership if engine mounts need servicing. FRONT COMPONENTS A B C D Steering Components Condition: I I I I Steering Gear I A Steering Shaft Splines and Joint(s) I I I A Pitman Arm I I A

(02/14) Y53-1203-1D1 5-23 MAINTENANCE SCHEDULE AND LUBRICATION

INTERVALS COMMENTS OPERATION \ FREQUENCY 7,500 mi 15,000 mi 60,000 mi 120,000 mi (12,000 (24,000 (96,000 km) (193,000 km) km) km) Annually Drag Link I I A Steering Arms I I A Tie Rod Arms I I A Tie Rod Ends I I A Radius Rods/Torque Arms I I A Chassis Frame Cracks or Breaks I I I A Spring Shackles and Hanger Brackets I A No Service Required on ESI Units Spring Pins I I A No Service Required on ESI Units King Pin Wear I Steering Axle Wheel Bearing - End Play I I I I Inspect for leaks and check for end-play: Adjustment and Inspection 12 mo.\100,000 miles. See hub manufacturer's service manual for details: www.conmet.com/ If no oil leaks, then no need for service prior 5 to 3 years/350,000 miles. Front Hub Lubricant Level I I A Spring Leaves I A Air Springs - AG130 I I A See for Front Suspension U-Bolt torque. on page 5-100 U-Bolt and Suspension Fastener Torque I I I Tighten U-bolts after the first 500 miles (800 km). See Table Key on page 5-18.

5-24 Y53-1203-1D1 (02/14) MAINTENANCE SCHEDULE AND LUBRICATION

INTERVALS COMMENTS OPERATION \ FREQUENCY 7,500 mi 15,000 mi 60,000 mi 120,000 mi (12,000 (24,000 (96,000 km) (193,000 km) km) km) Annually REAR COMPONENTS A B C D Rear Suspension Components - Condition I I I For Kenworth Non-Proprietary Track/Torque Rods I I I Suspensions, see your Kenworth Suspension Brackets & Welds - Cracks I I I Dealer for Preventive Maintenance Springs, Hangers & Shackles I I I Specifications/Schedule Walking Beams I I I Bushings - Worn I I I Air Springs & Mounts I I I Lubrication I I I Suspension Air Fittings - Leaks I I I U-Bolt and Suspension Fastener Torque For other suspension, "see manufacturer's recommendations". Rear suspension I fasteners: re-torque after first 2,000 miles (3,218 km). See Rear Suspension U-Bolt torque on page 5-115. Leaks: 5 Coolant I I I I Engine Oil I I I A Power Steering I I I I Fuel I I I I Transmission I I I I Axles I I I I Inner and Outer Hub Seals I I I I Engine and Transmission Mounts I I Drivelines - U-joints and Slip Yokes I I Rear Axle Lubricant Level I I I

(02/14) Y53-1203-1D1 5-25 MAINTENANCE SCHEDULE AND LUBRICATION

INTERVALS COMMENTS OPERATION \ FREQUENCY 7,500 mi 15,000 mi 60,000 mi 120,000 mi (12,000 (24,000 (96,000 km) (193,000 km) km) km) Annually Rear Axle Lubricant Flush & Refill Non-ESI - 250,000 Miles/ESI - 500,000 Miles. See Table Key on page 5-18. Rear Axle Breathers - Clear I I I I Vehicle Protection Valve Breakaway Test I I I I Brake Chamber Mounting Bolt Torque I I A Brake Hoses for Cracks and Chafing I I I A Adjust Brakes I I A Front & Rear Brake Camshaft Tube Synthetic Grease Required - Special Fitting I A Lubrication Clutch Pedal Shaft I I No Service Required on ESI Units Clutch Linkage I I Suspension Air Fittings I I I Clutch Release Bearing A Required Extended Fittings Driveline Center Bearing I I No Service Required on ESI Units 5 Automatic Slack Adjusters I I I I Standard (non-LMS) Automatic Slack Adjusters I With LMS, Synthetic Lube Required - Special Fitting Brakes: Lining Remaining (replace as I I A required) RF ______RRF ______RRR ______LF ______LRF ______LRR ______

5-26 Y53-1203-1D1 (02/14) MAINTENANCE SCHEDULE AND LUBRICATION

INTERVALS COMMENTS OPERATION \ FREQUENCY 7,500 mi 15,000 mi 60,000 mi 120,000 mi (12,000 (24,000 (96,000 km) (193,000 km) km) km) Annually Drum Condition: I A RF ______RRF ______RRR ______LF ______LRF ______LRR ______Chassis Lubrication Transmission Lubricant Level See Transmission Manufacturer's Specifications and Recommendations Supplied 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 D Check Harness/Cables For Loose To ensure proper inspection it may be 5 Connections, Chafing, Broken Retention I I I necessary to inspect under and inside frame Clips rails and unclip harness/cable bundles. Signs of Over-Charging I I Remove Corrosion and Seal Terminals I I Hold-down and Box - Mounting Bolts I I Load Test Batteries A Sealed Type - Condition: I I I I (Color of charge indicator for each battery) I I I I 1 ______2 ______3 ______I I

(02/14) Y53-1203-1D1 5-27 MAINTENANCE SCHEDULE AND LUBRICATION

INTERVALS COMMENTS OPERATION \ FREQUENCY 7,500 mi 15,000 mi 60,000 mi 120,000 mi (12,000 (24,000 (96,000 km) (193,000 km) km) km) Annually TIRES AND WHEELS A B C D Missing Valve Caps and Stem Locks I I I I Cracks or Loose Wheel lugs I I I A Tandem Mating I I I I Irregular Wear I I I A Tire Pressure (Record below) I I I I Remaining Tread (Record below) I I I A Tires & Wheels Inspection I I I A Right

5 Left

Air Pressure Adjusted to: ______I I I I ALIGNMENT A B C D Toe-in: ______in (mm) I I Caster: L ______R ______I I Rear Axle Alignment I A

5-28 Y53-1203-1D1 (02/14) MAINTENANCE SCHEDULE AND LUBRICATION

INTERVALS COMMENTS OPERATION \ FREQUENCY 7,500 mi 15,000 mi 60,000 mi 120,000 mi (12,000 (24,000 (96,000 km) (193,000 km) km) km) Annually ROAD TEST A B C D Steering/Steering Play I I I I Shifting I I I Brakes I I I Engine Operation (noises, surging, black I I I smoke) Throttle Linkage I I I I Engine Brake Operation I I I Seat Belts I I I Air Seat Operation I I I Cab Heater I I I Air Conditioner I I Instruments and Gauges: Speedometer/odometer I I I Tachometer I I I Oil Pressure I I I 5 Engine Temperature I I I Illumination I I I SRS Warning I I ABS Warning I I Low Brake Pressure Warning Devices I I I A

(02/14) Y53-1203-1D1 5-29 MAINTENANCE SCHEDULE AND LUBRICATION

Lubrication Specifications manufacturer's specification and Oil Reservoirs requirements take precedence over You will find a complete Engine other specifications. For oil reservoirs with side filler plugs Lubrication Service Guide in the Engine (transmissions, axles, steering gear Operation and Maintenance Manual. CAUTION boxes, transfer cases, etc.), the oil There, the engine manufacturer must be level with the filler opening. Handle lubricants carefully. Vehi- explains more fully all the maintenance cle lubricants (oil and grease) can operations you and a qualified service NOTE be poisonous and cause sickness. mechanic will need. And please They can also damage the paint on Use care when checking the oil level remember: one key to keeping your the vehicle. with a finger. Just because you can Kenworth running at top economy reach the oil level with a finger, does and in prolonging its life is proper not mean the oil level is correct. lubrication servicing. Neglecting this CAUTION essential aspect of vehicle care can Do not mix different types of lubri- NOTE cost time and money in the long run. cants. Mixing lubricants (oil and grease) of different brands or types Factory oil level may be above this Below you will find basic information 5 could damage vehicle components; level because it is measured as a needed to perform routine vehicle therefore, drain (or remove) old lu- volume and not as a specific oil level. lubrication. Of course you will want bricants from the unit before refilling This is acceptable to the axle man- to schedule service more frequently it. ufacturers; however, refill should be if operating in severe conditions per the Proper Oil Level as shown in such as extreme heat or cold, with the figure below. very heavy loads, off-road, etc. For any special service requirements, consult your service manuals and your lubricant supplier. The component

5-30 Y53-1203-1D1 (02/14) MAINTENANCE SCHEDULE AND LUBRICATION

Lubrication Chart

The following lubrication specifications (Table 10) are for an ambient operating temperature range of -15° to 100° 1 Improper Oil Level F (-26° to 38° C). For extreme 2 Proper Oil Level temperature operations, consult the component manufacturers manuals.

Table 10 Recommended Lubrication Types * Non-ESI Units

COMPONENTS RECOMMENDED LUBRICANT Power Steering Gear ATF Dexron® II Manual Steering Gear SAE 80W-90 CP gear oil, MIL-L-2105D, API GL5. Driveline U-Joints EP chassis grease, lithium 12-hydroxystearate or lithium complex base, Slip-Joint Splines NLGI 2. Hood Pivots Fan Drive Clutch Pedal Shaft Clutch Linkage 5 Fifth Wheel Components Other chassis grease fittings not covered below. Wheel Bearings-Non-Driving Axles OIL LUBRICATED: SAE 80W-90 EP gear oil, MIL-L-2105D, API GL5; or Including Steerable Pushers and Tag Axles SAE 50 Synthetic Transmission Oil (CD50). GREASE LUBRICATED: EP chassis grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2. Wheel Bearings-Non-Steerable Pushers and Tag Axles OIL LUBRICATED: SAE 80W-90EP gear oil, MIL-L-2105D, API GL5; or SAE 75W-90 Synthetic Oil GREASE LUBRICATED: EP chassis grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2.

(02/14) Y53-1203-1D1 5-31 MAINTENANCE SCHEDULE AND LUBRICATION

COMPONENTS RECOMMENDED LUBRICANT Threaded Pins & Bushings (e.g., spring pins & bushings) EP grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2, with 3% molybdenum additive: Mobil Grease Special (Mobil), Molygrease EP (Chevron), or equal. Suspension Fittings (other than threaded pins & bushings) EP chassis grease, lithium 12-hydroxystearate or lithium complex base, NLGI 2. Steering Axle: Grease Fittings on Steering Arm; Tie Rod Ends; Drag EP chassis grease, lithium 12-hydroxystearate base, NLGI 2. Link; King Pins Clutch Release Bearing (remove inspection plate for access); Driveshaft High temperature ball bearing grease. Chevron SRI Mobil Grease HP, Center Bearing Texaco Multifax 2, or equivalent. Manual Slack Adjusters EP chassis grease, lithium 12-hydroxystearate base, NLGI 2. Automatic Slack Adjusters; Wedge Brake Components; Disc Brake High temperature EP grease; Texaco Thermotex EP-1, Shell Darina Caliper EP-1, Mobilith AW-1, Meritor 0-616A, or equivalent. Cam Brake Camshaft Splines; Disc Brake Shaft Splines and Slide Pin Anti-seize type grease, Meritor specification 0-637. Retainers; Brake Clevis Pins Brake Camshaft Bushings EP Chassis grease, lithium 12-hydroxystearate base, NLGI 2.

CAUTION Do not contaminate brake linings with grease. 5 Steering Shaft Grease Fittings EP chassis grease, lithium 12-hydroxystearate base, NLGI 2. Brake Treadle Hinge and Roller Engine oil Lock Cylinders Lock lubricant. Door Hinges Not required - Teflon bushings Door Latches & Striker Plates Polyethylene grease stick. Door Weatherstrip Silicone lubricant. 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

5-32 Y53-1203-1D1 (02/14) MAINTENANCE SCHEDULE AND LUBRICATION

COMPONENTS RECOMMENDED LUBRICANT 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 or the hub. Other Items Use manufacturers manuals. Deviations from the above list of lubricants should be based on specifications published in the component manufacturer's manuals or otherwise approved by the manufacturer.

5

(02/14) Y53-1203-1D1 5-33 AIR SYSTEM MAINTENANCE

AIR SYSTEM you are certain all system MAINTENANCE pressure has been depleted. WARNING! • Never exceed recommended Do not release the parking brake or Introduction air pressure and always wear attempt to move the vehicle until air safety glasses when working pressure in both circuits is at least WARNING! with air pressure. Never look 100 psi (690 kPa), the level required for normal brake operation. Failure Prior to the removal of any air sys- into air jets or direct them at anyone. to comply may result in personal in- tem component, always block and jury, death, equipment or property hold the vehicle by a secure means • Never attempt to disassemble a damage. other than the vehicle's own brakes. component until you have read Depleting air system pressure may and understood recommended • Do not use the trailer hand brake cause vehicle to roll unexpectedly procedures. Some components control to hold vehicle while resulting in an accident. Keep hands contain powerful springs and parked. This control utilizes air away from chamber push rods and injury or death can result if not pressure for brake application. slack adjusters, they may apply as properly disassembled. Use Because acceptable air leakage 5 system pressure drops. Failure to only proper tools and observe levels cause all truck air comply may result in personal injury, all precautions pertaining to the systems to gradually lose death, equipment or property dam- use of those tools. pressure, vehicle rollaway age. could occur, resulting in an accident, injuries or death. • Never connect or disconnect a hose or line containing air • Always apply the vehicle and pressure. It may whip as air trailer parking brakes when the escapes. Never remove a vehicle is unattended. component or pipe plug unless

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and suspension height control Scheduled Maintenance Contamination of the air supply valves. To keep contaminants to the system is the major cause of problems lowest possible level, follow these Use the following table to schedule in air-operated components such maintenance procedures. service operations and air system as brake valves, wiper motors, tests.

Table 11 Air System Scheduled Maintenance

MAXIMUM INTERVALS TEST EACH WEEK EACH MONTH THREE MONTHS SIX MONTHS ANNUALLY (10,000 mi) (25,000 mi) (50,000 mi) (100,000 mi) (16,000 km) (40,000 km) (80,000 km) (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 ● 5 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 INTERVALS TEST EACH WEEK EACH MONTH THREE MONTHS SIX MONTHS ANNUALLY (10,000 mi) (25,000 mi) (50,000 mi) (100,000 mi) (16,000 km) (40,000 km) (80,000 km) (160,000 km) Automatic Drain Valve ● Safety Valve ● Quick Release Valve ● Manual Drain Valve ● Air System Function Test Air Tanks Periodically: Clean filter screens Scheduled maintenance should be ahead of the valves by removing the performed on the Kenworth's air screens and soaking them in solvent. system, as outlined in Table 11. In Blow them dry with pressurized air addition, perform an Air System before reinstalling them. Function Test at least every 3 months or if there is any indication of a potential WARNING! problem. To eject moisture from the air system If the supply and service air tanks 5 tanks, pull the line which is connected are not drained at the recommended to the moisture ejection valve. frequency, water could enter the Continue pulling until the air comes out air lines and valves. This could free of water. cause corrosion or blockage, which could compromise the brake system Daily: The supply and service air safety and potentially cause an ac- tanks, must be drained on a daily cident. Failure to comply may result basis. Operate air devices daily to in personal injury, death, equipment circulate lubricants within the unit. or property damage.

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Air Gauges and Air Leaks until the problem is found and fixed. If CAUTION the pressure in either or both systems Your Kenworth comes with two Do not use penetrating oil, brake is too low for normal brake operation, separate air pressure gauges for fluid, or wax-based oils in the air sys- i.e., the pointer of one gauge falls two separate systems, Primary and tem. These fluids may cause severe below 60 psi (414 kPa), a warning light Secondary: the Primary gauge damage to air system components. on the gauge will glow and the audible indicates pressure in the rear braking alarm will sound. system; the Secondary gauge • Maintain the air compressor to indicates pressure in the front braking prevent excessive oil bypass. system. Each gauge indicates the • Replace worn seals in valves and amount of air pressure in pounds per air motors as they are needed. square inch (psi). Your Kenworth Dealer carries Primary Air Pressure Gauge rebuild kits for most units. WARNING! Do not operate the vehicle if leak- age in the air system is detected. Failure to check the brakes or follow 5 these procedures could cause a sys- tem failure, increasing the risk of an accident and may result in personal Secondary Air Pressure Gauge injury, death, equipment or property damage.

If the light and alarm do not turn off at start-up, do not try to drive the vehicle

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exceed 3.0 psi (21 kPa) per Air Compressor Follow the procedure below to minute. Operation check the compressed air system for leaks: 7. If you detect excessive leakage All compressors, regardless of make (air pressure loss greater than 1. Periodically, or after maintenance or model, run continuously while the 3.0 psi after five minutes of brake engine is running. System pressure or replacement of air system application), a leakage test should components: is controlled by the governor. The be made at the air line connections governor acts in conjunction with 2. Build up air pressure in the system and at all air brake control units. the unloading mechanism in the to the governor cutout point or until These tests should determine compressor cylinder block to start 120 psi (827 kPa) is reached. where air is escaping. and stop compression of air. The 3. Stop the engine and release the compressor is unloaded when the service brakes. system pressure reaches 120 psi (827 kPa) and compression is reestablished 4. Without applying the brake pedal, when system pressure falls to 100 psi observe the rate of air pressure (690 kPa). drop. This rate should not exceed 5 2.0 psi (14 kPa) per minute. 5. Start the engine and build up the air pressure again. 6. Stop the engine, and apply the brakes fully. Apply the brake pedal and hold it down for five minutes. The pressure drop should not

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Preventive Maintenance • Remove compressor discharge CAUTION valve cap nuts and check for The following service checks are presence of excessive carbon. If When draining the engine cooling provided for your information only excessive carbon is found, clean system is required, to prevent dam- and should be performed by a or replace the compressor cylinder age from freezing, the compressor certified mechanic. Contact your head. Also, check compressor must also be drained at the cylin- Kenworth Dealer or the engine discharge line for carbon, and der head and block. Engine dam- manufacturer's Maintenance Manual clean or replace the discharge line age could occur if the cooling sys- for further information on servicing air if necessary. tem is not periodically drained and compressors. maintained. See Cooling System on • Disassemble compressor and page 5-61 for further information. After completing any repairs to the air thoroughly clean and inspect system, always test for air leaks, and all parts. Repair or replace check the brakes for safe operation all worn or damaged parts, or before putting the vehicle in service. replace compressor with a factory exchange unit. According to Table 11, Air System Scheduled Maintenance on page 5-35: 5 • Inspect compressor air filter element, if so equipped, and replace element if clogged. Check compressor mounting and drive for alignment and belt tension. Adjust if necessary.

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Air Dryer valves and checking for presence of and non-compressing cycle) in a water. normal fashion or it may be due to The function of the air dryer is to collect excessive leaks in the air system. and remove air system contaminants in NOTE solid, liquid and vapor form before they • In areas where more than a 30° A small amount of oil in the system enter the brake system. It provides F (17° C) range of temperature may be normal and should not, in it- clean, dry air to the components of occurs in one day, small amounts self, be considered a reason to re- the brake system, which increases of water can accumulate in place the desiccant cartridge. Oil the life of the system and reduces the air brake system due to stained desiccant can function ade- maintenance costs. condensation. Under these quately. conditions, the presence of small NOTE amounts of moisture is normal A tablespoon of water found in the and should not be considered as Because no two vehicles operate air tank would point to the need for a an indication that the dryer is not under identical conditions, mainte- desiccant cartridge change. However, performing properly. nance and maintenance intervals the following conditions can also will vary. Experience is a valuable cause water accumulation and should • An outside air source has been 5 guide in determining the best main- be considered before replacing the used to charge the air system. tenance interval for any one partic- desiccant cartridge. This air did not pass through the ular operation. drying bed. • Air usage is exceptionally high Every 900 operating hours or 25,000 and not normal for a highway miles or every three (3) months check vehicle. This may be due to for moisture in the air brake system accessory air demands or some by opening air tanks, drain cocks, or unusual air requirement that does not allow the compressor to load and unload (compressing

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Overhaul Bendix AD-IS Series Air Dryer NOTE Maintenance intervals typical for Your Kenworth vehicle may be The AD-IS Series air dryer has incor- on-highway operation would be 2 - 3 equipped with a Bendix AD-IS series porated into its design various com- years, 350,000 miles or 10,800 hours. air dryer. Any air dryer replacement ponents that have typically been in- should be made with an identical stalled separately on the vehicle. Maintenance intervals typical for high component. duty cycle usage such as transit bus, refuse hauler, dump truck, cement WARNING! See below for components/areas mixers and off-highway operation affected. If a different air dryer brand or model would be 1 year, 100,000 miles or is installed on the vehicle other than • Pressure protection valves 3,600 hours. what was originally installed, it could cause the air system to not perform • Safety valve NOTE correctly unless the full air system • Governor and plumbing Review the warranty policy before design is reviewed and modifica- performing any maintenance proce- tions made to comply with Federal • Plumbing of the front and rear dures. An extended warranty may Motor Vehicle Safety Standards service air tanks 5 be voided if unauthorized mainte- (FMVSS 121 - Air Brake Systems) nance is performed during this pe- or, in the case of chassis equipped • Plumbing to accessory systems riod. with the European air system, ECE These components are required R13. Failure to abide by this warning to meet the Federal Motor Vehicle and maintain compliance to FMVSS Safety Standards (FMVSS 121 - Air 121 or ECE R13 could cause loss Brake Systems) or, in the case of of vehicle control and may lead to chassis equipped with the European personal injury or death. air system, ECE R13. As the Warning

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above states, any other type of air Air Intake System dryer installed in the place of an CAUTION Engine heat, vibration, and age AD-IS Series will require changes, Do not use air intake pipes and con- combine to loosen air intake modifications, and/or additions to nections as a step or to pull your- connections and cause cracks in your vehicle’s air system to maintain self up. This could loosen the con- the tubing and elbows. Leaks in the compliance with FMVSS 121 or ECE nections and open the system to un- intake system allow abrasive dust to R13. Kenworth strongly recommends filtered air which could damage the enter the engine and quickly cause that if the air dryer is changed from an engine. AD-IS series, you consult your nearest expensive damage. During your daily authorized Kenworth dealer. walk-around inspection, carefully check all tubing, elbows, clamps supports and fasteners for condition and tightness. • Check the Charge-Air-Cooler for air leaks annually. The air leaks can be caused by cracked tubes 5 or header. For service see your authorized Kenworth Dealer.

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Turbocharger Air Cleaners and Filter Manifold: With the engine operating, Replacement When servicing the air intake and check for leaking manifold or flange exhaust systems on a turbocharged gaskets. The following service information is engine, check the items listed below. basic to all air cleaner makes and High Frequency Vibration: Vibration models. Service the filter elements WARNING! may indicate turbo rotor imbalance. as soon as reasonably possible when Have your Kenworth Dealer investigate Do not operate engine with tur- the Air Cleaner Restriction indicator this immediately. If you detect any bocharger intake piping discon- or gauge indicates that service is deficiencies, take the vehicle to nected. A suction is created when required. Have the element serviced an authorized Kenworth Dealer for the engine is running. This suction at a Kenworth Dealer. Paper elements servicing. Delay could lead to severe could draw your hand or anything require care and proper handling, and expensive damage to your vehicle. else near it into the impeller fan. You because they are critical to engine could be injured. Always keep the service life. intake piping connected when you will be running the engine. Failure Service the air cleaner periodically. to comply may result in personal If the vehicle operates in areas with 5 injury, death, equipment or property heavy dust, maintenance should be damage. more frequent.

Lubricating System: Check the oil lines, housing, and connections. Look for leaks, damage, or deterioration. Leaks could mean you have damaged oil lines or oil seals.

(02/14) Y53-1203-1D1 5-43 BRAKE SYSTEM MAINTENANCE BRAKE SYSTEM • brake linings MAINTENANCE Once a brake system is set to • brake chambers specifications, changing any one of its components or any combination of Introduction • slack adjusters components may cause the system not to work as well. All parts have to work To operate your vehicle safely, you NOTE together to perform as they should. need some understanding of its brake The air brake system of this vehi- systems. Brake adjustment and brake Because your brake system is air cle was configured for ONE of the balance must be set carefully to allow operated, see Air System Maintenance following operations, TRACTOR or equal stopping forces at all wheels. on page 5-34 for more information on TRUCK, and complies with the re- Tires are also a very important part of checking your brakes. the whole system. How fast you can spective portions of Federal Motor stop depends on how much friction Vehicle Safety Standards (FMVSS Any replacement components in there is between the road and your 121 - Air Brake Systems) or, in the the brake system should be the tires. case of chassis equipped with the same or better than the original European air system, ECE R13. components. Any changes from the 5 All of the following areas are A tractor shall not be operated or original specifications can affect the interrelated and must conform to configured as a truck, nor shall a performance of the entire system. original specifications: truck be operated or configured as a tractor without significant • tire size modifications to the air brake system in order to retain compli- • cam radius ance with FMVSS 121 or ECE R13. • wedge angle Contact your Kenworth dealer for instructions. • drum radius

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Lubrication WARNING! WARNING! Cam-actuated brake components Do not use any replacement part in Do not work on the brake system such as anchor pins and brake the brake system unless it conforms without the parking brake set and camshafts are subjected to high exactly to original specifications. A wheels chocked securely. If the temperatures, and must be lubricated nonconforming part in your vehi- vehicle is not secured to prevent with non-melting, water resistant brake cle's brake system could cause a uncontrolled vehicle movement, it grease meeting R-S Specification malfunction resulting in an injury could roll and may result in personal 0-616 (NLGI-Grade 1). accident. Sizes and types are so injury, death, equipment or property related to one another that a seem- damage. • Lubricate according to Table ingly unimportant change in one 6, Recommended Lubrication may result in a change in how well CAUTION Intervals on page 5-11. the brakes work for you on the road. If parts do not work together prop- Use wood blocks (4 in. X 4 in. or WARNING! erly, you could lose control of your larger) against the front and rear sur- vehicle, which could cause a se- faces of the tires. Be sure the vehi- Do not apply too much lubricant rious accident. Failure to comply cle cannot move. to brake components, lubricate 5 may result in personal injury, death, sparingly. Excessive amounts of equipment or property damage. lubricant could contaminate brake linings, which could reduce brake effectiveness and cause an acci- dent. Failure to comply may result in personal injury, death, equipment or property damage.

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Brake and Slack Adjuster Checks and Adjustments Brake Linings Lubrication All vehicle Operator's should check the WARNING! According to the interval, pressure brakes regularly. Always adjust the Do not use brake linings with a thick- lubricate the slack adjuster and brake brakes when they are cool. ness below the specified minimum. camshaft (bracket/tube). Two grease Such linings will have lining rivets fittings are provided for both the slack • Park the vehicle on a level surface exposed that can damage the brake adjuster and camshaft bracket/tube. and block the wheels before attempting any brake checks or drum and reduce brake efficiency, • Use standard chassis lubricant adjustments. which could cause an accident or (meeting No. 1 grade high system failure. Failure to comply temperature, water proof may result in personal injury, death, specifications). equipment or property damage.

• Do not use moly-disulfide loaded • Brake linings should be inspected grease or oil (they may shorten the by a qualified mechanic at an service life of the slack adjuster). authorized Kenworth Dealer for wear. See Table 9, Maintenance 5 • Do not use pressure-release Schedule on page 5-18. In severe grease fittings when lubricating service applications inspect the the slack adjuster. linings more frequently.

NOTE Depending on your vehicles service package (ESI or Non-ESI), brake service requirements will vary.

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Automatic Slack Adjusters 1. Check brakes when the temperature of the service Your Kenworth is equipped with brake linings are cool and the automatic brake (slack) adjusters. system air pressure at 100 psi WARNING! (690 kPa) minimum. Do not work on the brake system NOTE without the parking brake set and/or Chock the tires before proceeding. the wheels chocked securely. If the vehicle is not secured to prevent 2. Release the parking brakes to uncontrolled vehicle movement, it allow the slack adjusters to retract. could roll and may result in personal Measuring Pushrod Travel injury, death, equipment or property 3. Measure the retracted pushrod damage. length from the face of the brake 1 Short as Possible Without chamber to the center of the Brakes Dragging "Applied Stroke" CAUTION pushrod pin. 2 Released Position 5 Use wood blocks (4 in. X 4 in. or 4. Apply 80 to 90 psi brake application 3 Applied Position larger) against the front and rear sur- and measure the same distance. faces of the tires. Be sure the vehi- 5. The difference is the pushrod cle cannot move. travel distance (applied stroke). 6. Verify that the result is within the Periodically, brake adjustment correct range. See the following should be checked using the Brake Adjuster Stroke table for following procedure: acceptable limits.

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WARNING! Table 12 Brake Adjuster Stroke NOTE Automatic slack adjusters should not 80-90 PSI (552 - 621 KPA) BRAKE The automatic brake adjuster alone be manually adjusted to correct ex- APPLICATION does not ensure proper brake op- cessive pushrod travel/stroke. Ex- AIR BRAKE PUSHROD eration. Inspect all brake compo- cessive pushrod travel indicates a CHAMBER TRAVEL nents. All brake components work TYPE (Size) (Applied problem in either the automatic slack Stroke) together and must be checked peri- adjuster itself, the adjuster installa- 20-24 Front 1 to 1-3/4 in. odically to ensure the brake system tion or with related foundation brake (25-44mm) works properly. components. Improperly adjusting 16 Front 3/4 in. to 1-1/2 in.(19-38mm) the slack adjuster(s) could reduce 30 Rear 1-1/2 to 2 in. brake effectiveness and lead to an (38-51mm) accident. Failure to comply may re- sult in personal injury, death, equip- • If the pushrod travel exceeds ment or property damage. the above specifications, have your Kenworth dealer inspect the 5 Correctly installed and functioning slack adjuster and all other brake automatic slack adjusters will produce related components for excessive the pushrod travel for each chamber wear and/or damage. Replace type listed in the following table. components that are damaged or show signs of excessive wear.

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Anti-Lock Braking System (ABS) CAUTION If, due to operating conditions, a brake application causes either wheel on the Never detach the ECU connector same axle to begin skidding, wheel Below are some general notes on your with the ignition turned on. Failure speed sensors immediately signal the Kenworth anti-lock braking system. All to comply may result in equipment anti-lock controller in the modulator service work should be performed by damage. a qualified technician at an authorized assembly. The controller responds Kenworth Dealer. The foundation instantly by signaling the solenoids in brake system must be in proper NOTE the modulator which activate the air working order to ensure the best ABS Check ABS wiring harnesses and valves, reducing application pressure performance. piping periodically for chafing or as needed to prevent the wheels from other problems. No regular main- locking up. If this over-riding correction CAUTION tenance is required on the ABS is effective, application pressure is allowed to build up to the original input. Before welding anywhere on the components. vehicle, detach the ABS Electronic Any malfunction of the anti-lock Control Unit (ECU) connector and all NOTE system on one or more axles will other electronic control units. Fail- During wheel balancing, dyno test- cause the system to fail-safe, and 5 ure to comply may result in equip- ing, or any time the ignition is on the panel-mounted amber warning ment damage. with part of the ABS disconnected, a light will come on, indicating both a failure code will be recorded. Con- malfunction, and automatic shut-down sult with your authorized Kenworth of the system. If the air system is intact Dealer for information on clearing (indicated by the pressure gauges), the failure code. the service brakes will continue to function normally, but without benefit of the anti-lock feature.

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NOTE WARNING! WARNING! If one wheel on any driven axle con- Do not attempt to recycle the Do not operate the vehicle in the tinues to slip or spin for approxi- anti-lock system by turning the key event of a malfunction in any air cir- mately 4 seconds, this will cause the switch OFF and ON until the vehicle cuit. Such a malfunction may pre- anti-lock controller for that axle to has been brought to a full stop and vent the brake system from operat- go into the fail-safe mode, and the the parking brakes set. Failure to do ing properly, and could result in an warning light will give a shutdown so could adversely affect steering injury accident. The vehicle should signal. and braking control, and may result not be operated until the system is in loss of vehicle control and an ac- repaired and both braking circuits, • In this case, the anti-lock system cident. Failure to comply may result including all pneumatic and mechan- can be turned back on, and the in personal injury, death, equipment ical components, are working prop- warning light extinguished, by or property damage. erly. Failure to comply may result in turning the key switch OFF and personal injury, death, equipment or ON, after the vehicle has been property damage. brought to a full stop. When the 5 key switch is turned back on, the warning light will illuminate and remain on for 3 to 5 seconds. This is a built-in function test of the warning light.

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CAB MAINTENANCE Chrome and Aluminum Surfaces • Under corrosive conditions, such as driving on salted roads, clean To prevent rust, keep chromed parts Exterior Maintenance aluminum parts with steam or high clean and protected with wax at all Painted Surfaces pressure water from a hose. A times, especially in winter conditions mild soap solution will help. Rinse where the roads are salted. Wash painted surfaces frequently to thoroughly. remove grime and caustic deposits • If necessary, use a commercial which may stain the finish. See chrome cleaner to remove light Cleaning, Protecting, and Weather rust. Stripping on page 5-52. • Chrome surfaces are best cleaned with fresh water. Wipe dry to preserve their luster. A commercial chrome cleaner will remove light rust. After cleaning, wax flat surfaces and apply a thin coat of rust preventive lubricant 5 around bolts or other fasteners. • Clean aluminum wheels and bumpers with warm water. Tar remover will get rid of heavy deposits of road grime. To prevent spotting, wipe aluminum surfaces dry after washing.

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Tail Pipe Surface Cleaning Stainless Steel Cleaning, Protecting and Weather Stripping To maintain your quality finish, wash Even high quality stainless steel parts with a soft cloth, mild soap and water can rust under prolonged exposure Frequent washings of the vehicle or glass cleaner. A non-abrasive to salt water, especially when the are required to remove grime and chrome polish can be used sparingly salt-laden moisture is held against contaminants that can stain and on hard to clean areas. Do Not clean the metal surface by road grime. It oxidize paint and accelerate corrosion your high heat chrome using scouring is, therefore, important to frequently of plated and polished metal surfaces. pads, abrasive chrome polish, highly clean salty moisture and grime from acidic chemical cleaners or any other stainless steel surfaces. Waxing offers added protection against abrasive cleaners. staining and oxidation. But to allow If surface rust is encountered, • enough time for your truck's finish to wash the surface and use a CAUTION cure, wait about 30 days after the date commercial polishing compound of manufacture before waxing. Do not Using improper cleaning agents can to clean off the rust, followed by apply wax in the hot sun and do not harm your high heat chrome and in- a coating of wax (do not apply friction burn the paint with a buffing validate your warranty. wax to hot parts, such as exhaust machine. 5 pipes). • Never use steel wool when Occasionally spray weather-stripping cleaning stainless steel because on doors and windows with silicone minute particles of the steel wool compound to help preserve resiliency. can embed in the surface of the This is especially useful in freezing stainless steel and cause rust weather to prevent doors and windows staining. from sticking shut with ice.

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Vehicle Cleaning beauty and the value of your • Do not use gasoline, kerosene, vehicle. Precautions naphtha, nail polish remover or other volatile cleaning fluids. Your Kenworth Dealer has a number of WARNING! They may be toxic, flammable or vehicle-care products and can advise hazardous in other ways. Handle cleaning agents carefully. you on which ones to use for cleaning Cleaning agents may be poisonous. • Do not clean the underside of the exterior and interior of your vehicle. Keep them out of the reach of chil- chassis, fenders wheel covers, dren. etc. without protecting your hands CAUTION and arms. You may cut yourself Do not aim the water jet directly at • Observe all caution labels. on sharp-edged metal parts. door locks or latch. Tape the key holes to prevent water from seeping • Always read directions on the • Moisture, ice, and road salt into the lock cylinders. Water in lock container before using any on brakes may affect braking cylinders should be removed with product. efficiency. Test the brakes compressed air. To prevent locks carefully after each vehicle wash. • Do not use any solution that can from freezing in the winter, squirt damage the body paint. • Any vehicle is subjected to glycerin or lock deicer into the lock 5 deterioration from industrial cylinders. • Most chemical cleaners are fumes, ice, snow, corrosive road concentrates which require salt, etc., to name just a few dilution. causes. A well-cared-for vehicle can look like new many years • Only use spot removing fluids in later. Regular and correct care well ventilated areas. will contribute to maintaining the

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Washing the Exterior might scratch the finishes during the washing operation. NOTE 1. Begin by spraying water over the dry surface to remove all loose dirt 4. Wipe everything dry with a To allow enough time for your truck's before applying the car wash and chamois to avoid water spots. finish to cure, wait at least thirty days wax solution. To prevent water spotting, dry off after the date of manufacture before Do not wash the vehicle in direct the cosmetic surfaces with a clean waxing. sunshine. cloth or chamois. Do not spray water directly into the 5. Remove road tar with an cab and sleeper vents. automotive type tar remover or 2. Using soapy water, wash the mineral spirits. vehicle with a clean soft cloth or 6. After cleaning and drying, apply a a soft brush made for automotive quality automotive wax. cleaning. Use cool or warm water and a ° Do not apply wax in the hot mild, household type soap. Strong sun. industrial detergents and cleaning 5 agents are not recommended. ° Never dust off dry surfaces Do not use stiff brushes, paper with a cloth because it will towels, steel wool, or abrasive scratch the finishes. cleaning compounds because they will scratch painted, plated, and polished metal surfaces. 3. Rinse surfaces frequently while washing to flush away dirt that

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Cleaning the Chassis Cleaning Interior Vinyl and Pendleton® Limited Upholstery Edition Interior Cleaning • Hose dirt and grime from the entire chassis. Then, if an oil • Wipe vinyl upholstery and lining Instructions leak develops, you will be able to with a good commercial upholstery Sofa-Bed Ultra-Suede detect it easier. cleaner. Do not use acetone or lacquer thinner. General Maintenance: Dust regularly • Corrosive materials used for ice with a soft brush or vacuum cleaner. and snow removal and dust control • Clean fabric upholstery with Wipe with a damp cloth. For a deeper can collect on the underbody. If upholstery shampoo specially cleaning, spray and rub with a dry foam these materials are not removed, formulated for this purpose. Follow cleaner specific for stuffed furniture. accelerated corrosion (rust) can instructions on the container. occur on underbody parts such as Stain Removal: For cleaning fuel lines, frames, floor pan, and recommendations, refer to the table exhaust system, even though they below. Whatever the stain may be, you have been provided with corrosion will have to: protection. 1. Act quickly. 5 At least every spring, flush these 2. Start cleaning from the outside materials from the under body with of the stain towards its center to plain water. Be sure to clean any avoid a “halo” effect. area where mud and other debris can 3. If using solvent, do not pour collect. Sediment packed in closed directly onto the material but onto areas of the frame should be loosened a clean white rag. before being flushed. If desired, your Kenworth Dealer can do this service for you.

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Ink Remove as much as Wool Wall Lining (rear wall & upper Cleaning Recommendations possible by blotting Drinks, alcohol, Remove as much as with paper. Clean bunk) spirits, wine possible by blotting with 20% methylated with paper, then spirit and shampoo General Maintenance: Dust regularly shampoo with mild with soapy water. with vacuum cleaner. soapy water. Then Shoe polish Clean with clean with diluted perchloroethylene, methylated spirit trichloroethylene or Stain Removal: (10%). diluted ammonia Coffee, tea, milk Remove as much as (10% max). For most stains: possible by blotting Jam, syrup, fruit juice Remove most of with paper then the food/drink then 1. Blot (do not rub) with a damp rag. shampoo with mild shampoo with warm soapy water. If stain does not come out, move water (max 40ºC). to step 2. Chocolate, sweets Sponge with warm Oil, grease Sprinkle the stain water (max 40ºC). with talcum powder, 2. Blot (do not rub) with a stain Paint Clean with turpentine then brush away the then shampoo with talcum and clean with remover formulated for wool soapy water. trichloroethylene. (proper PH & no bleach). Cosmetics Shampoo with mild Nail polish Sponge with nail soapy water. In case polish remover then For oil based stains: 5 of persistent stain use shampoo with warm perchloroethylene or water (max 40ºC). trichloroethylene. 1. Use baby powder to soak up oil. Grass, vegetables Sponge with warm 2. If more cleaning is required, blot water (max 40ºC) then shampoo with with dry cleaning solvent such as mild soapy water. Carbona® brand products.

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Brown Leather and Vinyl Safety Restraint System - Inspection Factors contributing to reduced General Maintenance: Occasionally seat belt life: wipe with a clean damp cloth. The seat belt system, including • High mileage heavy trucks, often Clean spills with an absorbent cloth webbing, buckles, latches, and accumulate mileage in excess of and distilled water. DO NOT use mounting hardware, endures heavy 500,000 total miles (800,000 km) detergents, saddle soap, cleaning use in heavy-duty vehicles, much more during the vehicle lifetime. This agents, solvents, oils or ammonia. than seat belt systems in passenger is much greater than a typical cars. All users should be aware of the passenger car, which frequently Stain Removal: For tough stains, use a factors contributing to this heavy use will not exceed 125,000 total miles commercial leather/vinyl care product and reduced belt life. suitable for the stain type. Try a small (200,000 km). out of sight area first to minimize WARNING! • Seat and cab movement in possible damages. Failure to properly inspect and main- trucks, there is almost constant tain restraint systems can lead to in- movement of the belt due to ride jury or loss of life. Without periodic characteristics and seat design. inspection and maintenance to de- The constant movement of the belt 5 tect unsafe conditions, seat restraint inside the restraint hardware and components can wear out or not pro- the potential for the belt to come tect you in an accident. Failure to in contact with the cab and other comply may result in personal injury, vehicle parts, contributes to the death, equipment or property dam- wear of the entire system. age. • Environmental conditions, such as dirt and ultraviolet rays from the

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sun, will reduce the life of the seat Inspection Guidelines belt system. WARNING! It is important to remember that any Follow these guidelines when Due to these factors, the three-point time a vehicle is involved in an ac- inspecting for cuts, fraying, extreme safety belt system installed in your cident, the entire seat belt system or unusual wear of the webbing, vehicle requires thorough inspection must be replaced. Unexposed dam- and damage to the buckle, retractor, every 20,000 miles (32,000 km). If age caused by the stress of an acci- hardware, or other factors. Damage to the vehicle is exposed to severe dent could prevent the system from these areas indicates that belt system environmental or working conditions, functioning properly the next time it replacement is necessary. more frequent inspections may be is needed. Failure to comply may re- necessary. sult in personal injury or death. WARNING! Replace the entire belt system (re- Any seat belt system that shows cuts, tractor and buckle side) if replace- fraying, extreme or unusual wear, ment of any one part is necessary. significant discoloration due to UV Unexposed damage to one or more (ultraviolet) exposure, abrasion to the components could prevent the sys- seat belt webbing, or damage to the tem from functioning properly the 5 buckle, latch plate, retractor hardware next time it is needed. Failure to or any other obvious problem should comply may result in personal injury be replaced immediately, regardless or death. of mileage. 1. Check the web wear in the system. The webbing must be closely examined to determine if it is coming into contact with any sharp or rough surfaces on the seat or

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other parts of the cab interior. occupant restraint system and can the sun's ultraviolet rays. Replace These areas are typical places often be damaged if abused, even the system. where the web will experience unintentionally. Check operation cutting or abrasion. Cuts, fraying, to ensure that it is not locked up or excessive wear would indicate and that it spools out and retracts the need for replacement of the webbing properly. seat belt system. 6. If tethers are used, be sure they 2. The pillar web guide (D-loop) is are properly attached to the the area where almost constant seat and, if adjustable, that they movement of the seat belt are adjusted in accordance with webbing occurs because of installation instructions. Tethers relative movement between the must also be inspected for web seat and cab. wear and proper tightness of mounting hardware. 3. Check the Comfort Clip for cracks or possible damage and check for 7. Mounting hardware should be proper operation. evaluated for corrosion, and for tightness of bolts and nuts. 5 4. Check buckle and latch for proper Seat Belt Inspection Points operation and to determine if 8. Check web in areas exposed to 1. Web cut or frayed or latch plate is worn, deformed, or ultraviolet rays from the sun. If the extremely worn at latch damaged. color of the web in these areas is area. gray to light brown, the physical 5. Inspect the retractor web storage 2. Web cut or frayed at D-loop strength of the web may have device, which is mounted on the web guide. deteriorated due to exposure to floor of the vehicle, for damage. 3. Comfort Clip cracked or The retractor is the heart of the damaged.

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4. Buckle casting broken. be certain it is only replaced with Windshield Wiper/Washer 5. Retractor Web Storage for an authorized PACCAR Parts damage. (located behind replacement seat belt. The windshield wiper system is trim panel) maintenance free. Check wiper 6. Tethers for web wear and If the inspection indicates that any blades annually or every 60,000 miles proper tightness of mounting part of the seat belt system requires (96,000 km). Anco wiper blades hardware. replacement, the entire system must are recommended. See Windshield 7. Mounting hardware for be replaced. An installation guide is Wipers/Washer on page 3-114, for corrosion, proper tightness attached to every replacement belt. more information. of bolts and nuts. Utilize the proper guide for your type 8. Web for deterioration, due of seat, and follow the instructions Washer Reservoir to exposure to the sun. very closely. It is vitally important that all components be reinstalled CAUTION WARNING! in the same position as the original Do not use antifreeze or engine components that were removed and Failure to adjust tether belts properly coolant in the windshield washer that the fasteners be torqued to can cause excessive movement of reservoir, damage to seals and other specification. This will maintain the the seat in an accident. Tether belts components will result. 5 design integrity of the mounting points should be adjusted so that they are for the seat belt assembly. Contact taut when the seat is in its most up- Daily: Check reservoir water level, your Authorized Kenworth Dealer if ward and forward position. Failure located in the engine compartment. If you have any questions concerning to comply may result in personal in- necessary, refill to the proper level. seat belt replacement. jury or death.

Once the need for replacement of the seat belt has been determined,

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COOLING SYSTEM Topping Up MAINTENANCE Kenworth Trucks are standard with Air-to-Air cooling systems. These Check the coolant level after each cooling systems incorporate a radiator trip when the engine has cooled. The WARNING! to cool engine jacket water, a Charge coolant level should be visible within Do not remove the radiator cap on Air Cooler to cool turbo-charged engine the sight gauge (glass level indicator) a hot engine. It can cause scalding intake air, and a refrigerant condenser on the surge tank. Add coolant as coolant to spray out and you could to provide cab air conditioning. necessary (see Adding Coolant on be burned. If the engine has been page 5-63). operated within the last 30 minutes, be very careful in removing the radi- With the engine cold, top up with ator cap. Failure to comply may re- premixed coolant. Add the coolant sult in personal injury, death, equip- through the pressure cap neck on the ment or property damage. surge tank. The surge tank is located on the cooling module mounted on top WARNING! of the radiator. Do not work on the fan with the en- With the engine cold, the coolant level 5 gine running. The engine fan can should be at the full cold coolant level. engage at any time without warning. Use caution not to overfill the system Anyone near the fan when it turns with coolant. An overfilled cooling on could be injured. Before turning system will cause loss of coolant on the ignition be sure that no one through the radiator cap as the coolant is near the fan. Failure to comply expands during heating. Replacement may result in personal injury, death, or make-up coolant should have equipment or property damage. the same antifreeze concentration

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and corrosion inhibitor content as cap very slowly and carefully. Be the original coolant in the cooling WARNING! ready to back off if any steam or system. Never add 100% antifreeze Do not remove the radiator cap on coolant begins to escape. to the cooling system. Always dilute a hot engine. It can cause scalding antifreeze to the correct concentration coolant to spray out and you could WARNING! based on freeze protection prior to be burned. If the engine has been Handle coolant and antifreeze care- adding it to the cooling system. Adding operated within the last 30 minutes, fully. Ethylene glycol antifreeze is or using 100% antifreeze in a cooling be very careful in removing the radi- poisonous. Store in original fluid system may result in cooling system ator cap. Failure to comply may re- container only, and always keep plugging and overheating problems. sult in personal injury, death, equip- out of reach of children. Failure to ment or property damage. comply may result in personal injury, NOTE death, equipment or property dam- If frequent topping up is necessary • Protect face, hands, and arms age. and there are not visible signs of against escaping fluid and coolant leaks when the engine is steam by covering the cap with WARNING! cold, check for leaks with the engine a large, thick rag. 5 operating at normal operating tem- Never remove the cap on the surge perature. • Carefully and slowly turn cap (on tank while the engine is still hot. Wait expansion surge tank) one quarter until the coolant temperature is be- of a turn to allow excess pressure low 120º F (50º C). Scalding steam to escape before completely and fluid under pressure may es- removing cap. If you see any cape and cause personal injuries. steam or coolant escaping, do not even try to remove it until the radiator cools down. If you see nothing escaping, still remove the

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Adding Coolant Coolant Conditioner WARNING! A mixture of water and low silicate A variety of test methods are available Do not work on the fan with the en- antifreeze should be used for for measuring coolant conditioner gine running. The engine fan can coolant. Water must be clean and levels. Test strips provide convenient engage at any time without warning. free of corrosive and scale-forming and consistent results with minimal Anyone near the fan when it turns chemicals. Drinking water may not be training. Other test methods can be on could be injured. Before turning good for your vehicle. New vehicles used when appropriate training is on the ignition, be sure that no one come premixed with antifreeze and provided. The actual test (i.e. test is near the fan. Failure to comply corrosion inhibitor. Be sure different strips, etc.) and coolant conditioner may result in personal injury, death, types of coolant are not mixed. Stay maintenance schedule should be equipment or property damage. with the same coolant until a complete done in accordance with the actual Replacement is performed. coolant conditioner manufacturer recommendations.

The coolant conditioner should be recharged according to Table 6, Recommended Lubrication Intervals 5 on page 5-11, unless otherwise specified in the Engine Manufacturers Maintenance Manual.

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Additives recommendations check with your Kenworth Dealer or check the CAUTION If you add supplemental coolant manufacturer's Engine Operation Do not mix inhibitor types. Improper additives to the radiator, maintain them and Maintenance Manual. mixing of coolant may damage the at the recommended levels. Read engine. the label carefully. Too much additive • Antifreeze solutions containing could harm your vehicle. anti-leak additives will quickly restrict the water filter. If this • For coolant conditioner recharge Approved additives help neutralize happens, the filter will not work. intervals see the Engine Operation the water's harmful effects on your So stay away from anti-leak and Maintenance Manual. vehicle's cooling system. Ask your additives. dealer to recommend the best ones for you. CAUTION • Do not add rust inhibitors, Do not add inhibitor if the engine has radiator sealants, or water pump a Dry Charge Additive (DCA4) water lubricants containing soluble oil to filter cartridge containing corrosion 5 the coolant. These additives can inhibitor, engine damage from over cause the anti-corrosion chemicals concentration of silicates may occur. not to work. • The water filter cartridge • If the cooling system in your truck containing DCA4 inhibitor must has a treated spin-on water filter, be periodically changed. Refer install the service filter on all B or E to the Engine Operation and scheduled service intervals. See Maintenance Manual for details. Table 9, Maintenance Schedule on page 5-18. For more detailed

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Refilling Change and Refilling 7. Fill the radiator as necessary to raise the coolant level to the The coolant must be changed To refill the cooling system, follow proper level. periodically. When draining coolant, the recommendations below: capture old coolant and dispose of it 8. Replace the surge tank pressure 1. Before refilling be sure the radiator properly. cap. and engine block drains are closed. You may find the coolant level is not 2. Move the heater control to up to the correct level soon after you maximum heat position. have filled the radiator. This may be because all the trapped air in the 3. Remove the surge tank pressure system has not yet been purged. It cap. takes a little time for all the air to leave 4. Through the surge tank, fill the the system after you fill the radiator. system with premixed coolant. Pour it in a steady flow until the For further details on coolant, coolant radiator is full. capacities, water filters, and antifreeze mixture see the Engine Operation and 5 5. Start the engine and idle it at low Maintenance Manual (supplied with RPM. the vehicle). 6. Complete the filling as quickly as possible. Idle the engine until it reaches normal operating temperature.

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Radiator Cap Engine (Block) Heater heater performance. Do not use more than 65 percent concentration of CAUTION Regularly inspect the engine block antifreeze, as a shortened heater life heater wiring and connector for When replacing the radiator cap al- will result. damaged or frayed wires. Contact ways use one with the correct rated your authorized Kenworth Dealer or After servicing the cooling system, pressure. Failure to do so could the manufacturer of the heater if you operate the vehicle for a day or two cause engine or cooling system are in need of repairs or information. before using the heater. Trapped damage. air inside the engine needs time to WARNING! escape. All radiator caps are marked with the rated pressure (psi) of the cap. Do not use the heater if there are any signs of problems. Engine block heaters can cause fires resulting in personal injury, death, equipment or property damage if not properly maintained and operated. 5 CAUTION Always unplug the block heater be- fore starting your engine. Damage to the cooling system could occur if not turned OFF (unplugged).

Use a solution of half ethylene glycol antifreeze and half water for best

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ELECTRICAL Fuses, Circuit Breakers, and MAINTENANCE Relays

Electrical System Fuses, circuit breakers, and relays are located in the Power Distribution Box to the left of the steering column WARNING! behind the clutch pedal. See Power Battery posts, terminals and related Distribution Box on page 5-70. accessories contain lead and lead Additional fuses for the alternator, compounds, chemicals known to the engine electronics and trailer battery State of California to cause cancer charge circuit may be located in the and reproductive harm. Wash hands Power Distribution Center (PDC) inside after handling. Failure to comply the battery box and/ or on the engine may result in personal injury, death, side of the cab firewall. Power Distribution Center (shown equipment or property damage. without fuse cover) 1. MEGA FUSE CAUTION 2. MIDI FUSE 5 Do not modify or improperly repair the vehicles electrical system or power distribution box. All electrical repairs should be performed by an authorized Kenworth dealer. Im- proper repair or modifications will void your warranty and/or cause se- rious damage to your vehicle.

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Fuse Inspection and thing you should check for is a blown Replacement CAUTION fuse. If a circuit keeps blowing fuses, have 1. Turn OFF all lights and accessories WARNING! the electrical system inspected for a and remove the ignition key to short circuit or overload by an au- Do not replace a fuse with a fuse of a avoid damaging the electrical thorized Kenworth dealer as soon higher rating. Doing so may damage system. as possible. Failure to do so could the electrical system and cause a cause serious damage to the elec- 2. Determine from the chart on the fire. Failure to comply may result in trical system and/or vehicle. fuse panel which fuse controls that personal injury, death, equipment or component. property damage. NOTE 3. Remove that fuse and see if it is CAUTION If a fuse of the same rating is not blown. available, a fuse of a lower rating Before replacing a fuse, turn OFF all may be temporarily substituted. You lights and accessories and remove can also use a fuse from a circuit you the ignition key to avoid damaging can do temporarily without (for ex- 5 the electrical system. ample an accessory circuit or radio). If a fuse is blown, replace it with a fuse of the same rating. CAUTION See the Kenworth Shop Manual for 1 Blown Never patch fuses with tin foil or instructions on fuse replacement. wire. This may cause serious dam- age elsewhere in the electrical cir- All the electrical circuits have fuses cuit, and it may cause a fire. to protect them from a short circuit or overload. If something electrical on your chassis stops working, the first

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Adding Electrical Options NOTE WARNING! WARNING! If you are unfamiliar with proper Never install a circuit breaker in a Do not add a fuse with a rating electrical repair practices and pro- circuit that is designated as “fuse- higher than 30 amps. Follow the cedures, see your authorized Ken- only” circuit(s). Fuse-only circuits circuit protection size/type recom- worth dealer for assistance. are marked with an * on the reverse mended by the component manu- side of the Power Distribution Box facturer. Installing a fuse or circuit NOTE cover. Using a circuit breaker in breaker greater than designated those fuse-only circuits may cause Easy addition of circuits is provided may damage the electrical system the circuit to overheat when a short by plug-in connectors that have a which could lead to equipment dam- exists which could lead to equipment ground and a power wire. age and/or personal injury. damage and/or personal injury.

For proper electrical system NOTE CAUTION performance, refer to a wiring Follow all manufacturers' circuit pro- diagram for your chassis before adding Do not install a circuit breaker in tection recommendations for the electrical options. place of a fuse for the following cir- 5 components and wires being added. cuits: Failure to comply may result in equipment damage. • ACC FEED • BODY IGN • CAB ABS - BATT • CAB ABS - IGN

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• CAB ACC • RH DOOR • CB PWR • SLPR ACC • CECU - BATT (2 PLCS) • RKE • CECU IGN • TRLR ABS • DOOR IGN • TURN MOD PWR • ENG AUX • ENG SD • FOG LMPS • GAUGE CL • HIGH BEAM SUP 5 Power Distribution Box: Typical - See • LH DR / DOOR LOCK reverse side of Power Distribution Box cover for fuse and relay locations. • LOW BEAM SUP 1. Clutch Pedal • PARK LMP SNSE • RADIO MEM • RADIO PWR

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5

Power Distribution Box

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5 Chassis Load Center Fuse Box (MX)

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5 Chassis Load Center Fuse Box (Cummins)

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Batteries In-Cab Battery Box Battery Access WARNING! Your vehicle may be equipped with Replace only with Optima brand The vehicle is originally equipped with Optima brand Absorbed Glass Mat AGM (Group 31) batteries. Use of three or four batteries. Replacement (AGM) batteries located in the cab other batteries could result in acid batteries must meet the following under the passenger’s seat. The glass leaks causing personal injury in the specifications: maintenance-free, mat in AGM batteries is designed to event of a vehicle accident. Failure group 31 size, threaded stud, 12V/ 650 absorb the battery acid inside the to comply may result in personal cold cranking ampere (CCA), and 160 battery that can leak or spill out in injury, death, equipment or property minutes of reserve capacity. conventional batteries. This design damage. feature allows Optima batteries to be The battery compartment is located on positioned in any orientation without the left side of the vehicle, under the risk of leaking. WARNING! cab access steps. Battery cables and air/electrical har- To access the batteries: 1. Remove steps by removing 2 bolts nesses are mounted to the bottom of from each step. 1. Remove 6 fasteners securing the the floor. Do not drill or screw into passenger side seat base to the floor pan without first checking the 5 2. Remove 4 bolts and washers from battery box assembly. location of the cables, harnesses or forward fairing. any other component that might be 2. Remove the seat and seat base 3. Remove 2 bolts (A) from step strut. damaged. Damaging any compo- as one unit to gain access to the nent could result in electrical shock 4. Remove battery cover for access. batteries. which could cause personal injury and/or loss of a critical truck sys- tem. Failure to comply may result in personal injury, death, equipment or property damage.

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Replacing Parts Removed for WARNING! WARNING! Access Batteries release gases that are Electrical damage or battery ex- 1. Replace battery cover. flammable. Batteries are equipped plosion can occur when improperly with vent tubes and flash arrestors charging batteries. Refer to the 2. Install 2 bolts in step strut. Torque which vent battery gases out of the operation and service manual for to 24-32 lb-ft (33-43 Nm). cab. Ensure all vent tubes, flash ar- appropriate charging instructions. 3. Install fairing and install 4 bolts. restors and grommets are properly Failure to comply may result in per- Torque to 6-7 lb-ft (8-9 Nm). installed and ensure they are clear sonal injury, death, equipment or and functioning properly. Failure to property damage. 4. Install steps by installing 2 bolts in reinstall or keep the vent tubes and each step. Torque to 24-32 lb-ft (33-43 Nm). grommets clear or ensure the flash CAUTION arrestor(s) are functioning properly could result in personal injury or Do not store other items in this bat- WARNING! equipment damage. Failure to com- tery box. Failure to comply could re- Always reinstall the steps before en- ply may result in personal injury, sult in damage to the truck and/or tering the cab. Without the steps you death, equipment or property dam- batteries. could slip and fall, resulting in pos- 5 age. sible injury to yourself. Failure to CAUTION comply may result in personal injury, Properly secure battery tie downs death, equipment or property dam- and battery box cover when rein- age. stalling batteries after service. Do not over tighten. Over tightening can crack the battery case which can lead to equipment damage.

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Removing and Installing Batteries: WARNING! NOTE 1. Be sure all switches on the vehicle Fairings not installed properly could are turned OFF. Make sure to reconnect the ground come loose and cause other mo- (negative) cable last. torists to have an injury accident. It 2. Disconnect negative ground cable is important that fairings be installed first. 1. Place batteries in vehicle and properly. Failure to comply may re- 3. Disconnect positive cable. tighten bolt of holding plate. sult in personal injury, death, equip- 2. Reconnect positive cable. ment or property damage. 4. Unscrew bolt of holding plate with open end wrench. 3. Reconnect ground (negative) ground cable. WARNING! NOTE Before attempting any work on the Always dispose of automotive bat- WARNING! batteries or electrical system, re- teries in a safe and responsible man- Battery replacement may alter or move all jewelry. If metal jewelry or ner. Contact your authorized Ken- disturb battery cable routing. Check other metal comes in contact with worth dealer for disposal standards. to insure battery cables are free electrical circuits, a short circuit may 5 Call your local authorized recycling from any point of chaffing. Failure occur causing you to be injured, as center for information on recycling to comply may result in personal well as electrical system failure and automotive batteries. injury, death, equipment or property damage. damage. Follow the procedure below to reinstall batteries on the vehicle:

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Battery Care Battery Charging Dirty or Loose Connections: Regular attention to the charging improper connections may stop the Except for using small trickle charges system will help prolong the service flow of electrical power to and from the (as explained in Slow Battery Charging life of the batteries. Here are some battery. on page 5-77) to maintain battery common causes of battery failure: condition, you should have your vehicle's batteries charged by a Overcharge: this condition results qualified service facility. from improper voltage regulator adjustment. It results in overheating WARNING! of the battery, warped plates, and Batteries can injure you severely. evaporation of electrolyte. They contain acid, produce poi- Undercharge: the voltage regulator sonous and explosive gases, and is malfunctioning, the drive belt is supply levels of electric current high slipping, or your vehicle has undergone enough to cause burns. A spark long periods of standing idle or short or flame near a battery on charge distance driving. These conditions may cause it to explode with great 5 result in battery plates becoming force. Never remove or tamper with covered with a hard coating. the battery caps. Failure to comply may result in personal injury, death, Vibration: loose battery hold-downs equipment or property damage. may cause battery plate failure.

Short Circuits: these discharge the battery by draining electricity.

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cables on the battery or nearby. Charging Reminders To help reduce the risk of personal Metal that accidentally comes in injuries, follow these guidelines contact with the positive battery • Use protective eyewear. carefully when recharging a battery: terminal or any other metal on the • Keep all batteries away from vehicle (that is in contact with the • Before attempting any service children. positive terminal), could cause a in the electrical installation, short circuit or an explosion. • Never reverse battery poles. disconnect the battery negative cable. • Never attempt to place the vehicle in motion, or run the engine with • Allow no sparks or open flame batteries disconnected. anywhere near the charging area. • Keep the battery clean and dry. • Charge a battery only in a well-ventilated area, such as • Look for any signs of damage. outdoors or in a fully open garage which contains no pilot lights or • Battery terminals should not other flames. Gases generated be coated with improper 5 during the charging process must grease. Use petroleum jelly be allowed to escape. or commercially available, noncorrosive, nonconductive • Always make sure the battery terminal coatings. charger is OFF before connecting or disconnecting the cable clamps. • Never use a fast charger as a booster to start the engine. This • To avoid short circuits, damage can seriously damage sensitive to the vehicle, or personal injury, electronic components such never place metal tools or jumper

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as relays, radio, etc., as well Electrical and Alternator • Always make sure the as the battery charger. Fast battery charger is OFF before Precautions charging a battery is dangerous connecting or disconnecting and should only be attempted by Take the following precautions to the cable clamps. To reduce a competent mechanic with the avoid burning out alternator diodes: the danger of explosions and proper equipment. resulting personal injury, do not • Do not start the engine Slow Battery Charging connect or disconnect charger with alternator disconnected cables while the charger is (connections removed) from the NOTE operating. circuit. Follow the instructions that come 1. Disconnect the battery cables. • Before welding, disconnect all with your battery charger. 2. Connect charger cables. electronic connections to the vehicle batteries. • It is not necessary to remove the 3. Start charging the battery at a rate battery from the compartment. not over 6 amperes. Normally, a • Remove battery power cable and battery should be charged at no insulate it from the vehicle. WARNING! more than 10 percent of its rated • Do not run the engine with the 5 Charger cables must be connected capacity. batteries disconnected. positive to positive (+ to +) and neg- 4. After charging, turn OFF charger ative to negative (- to -). If con- and disconnect charger cables. • Do not disconnect the battery nected improperly, batteries could cables or alternator connection explode. Failure to comply may re- cables with the engine running. sult in personal injury, death, equip- ment or property damage. • Never turn the ignition switch from the ON position to the START position with the engine running.

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• When charging the battery Remote Keyless Entry To Synchronize a Key Fob Troubleshooting (installed in the vehicle) disconnect 1. Hold the key fob near the center the battery cables. The remote keyless entry system may gauge area (middle of the instrument panel). • Do not reverse the cables of the become non-operational due to failure alternator, starter motor, or battery. of a key fob battery. If you have issues 2. Press either the lock or unlock with a key fob, replace the battery and button twice within 2 seconds. • Do not polarize the alternator. The re-synchronize the key fob. In some alternator should not be polarized situations, the key fob may need to ° When the key fob is like a generator. To ensure correct be replaced and in others, a fuse may resynchronized, the doors polarity, use a test lamp or a have failed and may render both key will lock or unlock. voltmeter. fobs inoperative. ° If the fob fails to synchronize, Contact your dealer for more help, if it could be programmed to a a key fob does not work and it is not different vehicle or could have because of a bad battery. failed. 5

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Halogen/HID Lamp Servicing Headlamp Servicing Low-Beam Access Cover Access is gained from the rear of the A Halogen or HID (High Intensity assembly. Discharge) Projector headlamp assembly comprises of a Halogen Rear Of Halogen/HID Housing or HID projector low beam, a complex reflector high beam, two side marker/turn signal lamps, housing and mounting/wiring hardware.

NOTE It is normal for some fogging on the 2. Rotate Ignition Device 25° inside of the lens to occur. This counter-clockwise. condensation may be removed by ° High-voltage line will be driving the vehicle for an extended automatically ejected as a 1 Low-beam Access Cover period with the headlights turned safety precaution. 5 on. Servicing is required if water droplets or puddles of water form on Follow the procedure below to replace the inside of the headlamp. HID bulbs. Removing Ignition Device 1. Rotate low-beam access cover counter-clockwise and remove cover.

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Cleaning or Disposal Ignition Device Projector Housing Spring Clips NOTE Do not touch glass bulb with bare fingers. 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 with a lint-free cloth. Discharge bulbs may be filled with a trace amount of mercury. The bulb will be marked with a Symbol indicating Mercury 1 High-voltage cable 2. Release spring ends and let hang (Hg). Follow Hazardous Waste reg- ejected free. ulations for disposal. 2 Ignition Device CAUTION 3. Pull Ignition Device away from 5 bulb. The spring clip cannot be displaced “upwards.” The arms of the spring Remove HID Bulb can be moved only so far apart to re- 1. Squeeze the two projector housing move the bulb. Discharge bulbs are spring ends marked with arrows filled with overpressure. The glass towards each other and then bulb may burst if improperly han- deflect away from bulb housing. dled.

3. Carefully remove the bulb.

5-82 Y53-1203-1D1 (02/14) ELECTRICAL MAINTENANCE

Bulb Bulb Details NOTE There are two indexing grooves (12 o’clock and 2 o’clock) located on the largest diameter of the bulb. These index the bulb only one way in the projector housing.

3. Squeeze the two projector housing spring ends towards each other and then make sure they engage in the grooves. 1 Symbol Indicating Mercury (Hg) Bulb Installation 1. During installation of the bulb the 5 wire with the ceramic insulation 1 Ceramic Insulated Wire should be pointed down. 2 Indexing Grooves 2. Install bulb into the projector housing.

(02/14) Y53-1203-1D1 5-83 ELECTRICAL MAINTENANCE

Projector Housing Installation 1. Verify white ring alignment. If 3. Push Ignition Device onto back of needed, carefully rotate ring with projector housing. a small blunt tool, so that the 4 4. Rotate Ignition Device 25° grooves in the housing and ring clockwise until it locks into place. are aligned or the device cannot be installed. 5. Lastly, install the high-voltage cable to the ignition device. 2. This tab indexes with white tab on projector housing (see following Ignition Device Installed Fig.).

Ignition Device 1 Spring Grooves 2 Index Points (12 o’clock and 2 o’clock) 3 White Tab 5 Ignition Device Installation

CAUTION Care must be taken to NOT install Close Cover the High-voltage cable until after the Ignition device is fully installed, oth- 1. Install and rotate low-beam access 1 White Ring erwise, damage may result to either cover clockwise. 2 Tab the Ignition Device or the HID Bulb.

5-84 Y53-1203-1D1 (02/14) ELECTRICAL MAINTENANCE

° Use only clean soap and Close Low-Beam Access Cover water. ° Your headlamp is coated with a special substance to resist chips and hazing. Harsh chemicals and polishing can remove this coating.

Final Checks 1. After everything is reconnected, turn on your headlamps and check for operation. 5 2. Have your headlamps periodically checked for proper alignment. Headlamps should be adjusted to -0.6° (-1.0%) Vertical. 3. Keep your headlamps clean. A dirty headlamp reduces headlamp performance and creates glare.

(02/14) Y53-1203-1D1 5-85 ENGINE MAINTENANCE ENGINE MAINTENANCE WARNING! • By a competent technician every 15,000 miles Engine Maintenance Never idle your vehicle for prolonged periods of time if you sense that ex- • Whenever a change is noticed in WARNING! haust fumes are entering the cab the sound of the exhaust system or sleeper. Investigate the cause Exhaust fumes from the engine • Whenever the exhaust system, of the fumes and correct it as soon contain carbon monoxide, a col- underbody or cab or sleeper is as possible. If the vehicle must be orless and odor less gas. Do not damaged driven under these conditions, drive breathe the engine exhaust gas. only with the windows open. Failure A poorly maintained, damaged or to repair the source of the exhaust corroded exhaust system can allow fumes may result in personal injury, carbon monoxide to enter the cab or death, equipment or property dam- sleeper. Entry of carbon monoxide age. into the cab is also possible from other vehicles nearby. Failure to properly maintain your vehicle could NOTE 5 cause carbon monoxide to enter Keep the engine exhaust system the cab/sleeper and cause illness or and the vehicles cab/sleeper venti- death. lation system properly maintained.

It is recommended that the vehicles exhaust system and cab/sleeper be inspected:

5-86 Y53-1203-1D1 (02/14) ENGINE MAINTENANCE

Engine Lubrication WARNING! Refer to the engine manufacturer's Hot engine oil can be dangerous. Engine Operation and Maintenance You could be burned. Let the en- Manual supplied with your vehicle for gine oil cool down before changing information about draining and refilling it. Failure to comply may result in engine oil, engine crank case capacity, personal injury, death, equipment or engine oil type, and changing oil filters, property damage. etc.

Lubricant Symbol Key ATF MD3 or MERCON®-approved automatic transmission fluid BB High temperature ball bearing grease. Chevron SRI Mobile Grease HP, Texaco Multifax 2 or equivalent CD50 SAE50W synthetic transmission fluid CJ-4 Engine oil for PACCAR MX and Cummins ISX engines CL Multipurpose chassis grease EP Extreme Pressure Lubricant (Lithium 12-hydroxystearate base NGLI 2) GL Straight mineral gear lubricant HD Hypoid Gear Oil, A.P.I. - GL-5, SAE 75W-90FE synthetic gear lubricant 5 HT High Temperature grease (Timken Spec. 0-616) MP Multipurpose gear lubricant (MIL-L-2105B) DOT3 or DOT4 Brake Fluid

(02/14) Y53-1203-1D1 5-87 ENGINE MAINTENANCE

Inspection of the Engine Oil Level 4. Wipe the dipstick clean with a lint-free cloth. NOTE It takes approximately 15 minutes 5. Place the dipstick back into the for all the oil to run into the sump holder. when the engine is ‘warm.’ If the 6. Pull the dipstick out again and level is checked immediately after check the oil level. The oil level switching off the engine, the dipstick should always be between the 2 will show a low oil level. marks on the dipstick. 1. Make sure that the vehicle frame 7. Reinstall the dipstick and twist to rail is standing on a flat and level lock it in place. surface.

2. Make sure that the vehicle is 1. Engine Oil High Level horizontal, both lengthwise and 2. Engine Oil Low Level crosswise. Check this carefully 5 on a vehicle with air suspension. Note that the engine may be inclined up to 4° depending on the vehicle model and wheelbase. 3. Twist the dipstick handle to unlock it, then pull the dipstick out of the holder.

5-88 Y53-1203-1D1 (02/14) ENGINE MAINTENANCE

Topping Up the Engine Oil Pipe and Hose Clamps

1. Top up with oil, if necessary, via Use the following table for torque the filler opening. Use the correct specifications to check pipe and hose grade in the correct quantity. For clamps. oil replacement, please see engine Operator’s Manual included with this chassis. 2. After topping up, wait 1 minute and check the oil level again. 3. Reinstall the oil fill cap and twist to lock it in place.

5

(02/14) Y53-1203-1D1 5-89 ENGINE MAINTENANCE

Table 13 Pipe and Hose Clamp Torque Values

APPLICATION APPROVED CLAMP TORQUE Nm Lb-In Radiator & Heat Exchanger Hoses Constant-Torque CT-L 10.2-12.5 90-110 Heater Hoses Constant Tension not required not required Air Intake Pipes Hi-Torque HTM-L 11.3-14.2 100-125 Charge Air Intake Hoses Flex Seal 667 7.9-11.3 70-100 B9296 6-7 50-60 Fuel, Oil & Water Heat Exchangers (for Miniature 3600L 1.1-1.7 10-15 hoses less than 9/16 diameter) Exhaust Clamps Breeze V-Band 54 480 Installing Fuel Filters Fuel System 3. Hand tighten them only to 1/2 - 2/3 turn after gasket contact. Please follow these recommendations When removing filters, cover any Mechanical tightening of these when you are changing your fuel filters electrical equipment and wiring that filters may distort or crack the filter or strainer elements. Your vehicle's might get soaked with fuel. Diesel fuel head. 5 engine will run better and last longer if may permanently damage electrical you do. See the engine manufacturer's insulation. • When replacing a fuel filter recommendations for proper water and element, do not use a substitute. micron requirements. When installing spin-on (throwaway) Install only filter elements designed filters: for fuel filtration. First clean and 1. Pre-fill filter with fuel. inspect the shell. Then insert the new element and fill the container 2. Moisten gasket with diesel fuel. at least 2/3 full of clean fuel before installing the shell.

5-90 Y53-1203-1D1 (02/14) ENGINE MAINTENANCE

Filter Draining NOTE 6. Close drain valve by turning valve 1. Check fuel filter/water separator screw clockwise approximately 1 To expel air from density-type daily. Check with engine OFF. to 2 turns. strainer elements, soak them in Depending on the fuel storage clean fuel before installing them. facility, more frequent draining CAUTION may be required. • Throw away old gaskets. Replace Do not overtighten the valve. Over them with new ones to ensure a 2. Open drain valve (by hand only): tightening can damage the threads. positive seal. turn valve screw counter clockwise approximately 1 to 2 turns until • Position the shell and gasket draining occurs. Drain filter sump properly. Then tighten the cover of water until clear fuel is visible. nut or bolt just enough to prevent fuel leakage. 3. If entrapped water exceeds sump volume, you can either: • After starting the engine, check for 4. Close valve and run engine until leaks around the filter. smooth idle is established, then repeat drain procedures. 5 5. Remove filter from mounting head, completely drain all fluid, and reassemble filter assembly. Be sure to follow new filter assembly instructions.

(02/14) Y53-1203-1D1 5-91 ENGINE MAINTENANCE

Accessory Drive Belts Engine Fan Fan Drive and Blade Thermatic (Clutch) Type Fan You can avoid costly downtime by Fan Blade Clearance: Around the fan periodically checking belt wear and WARNING! shroud, the recommended distance replacing worn and damaged belts. is 1 in. (25 mm) from front edge of Do not work on the fan with the en- Neglect could cause belt failure. The any fan blade-to-radiator side member. gine running. The engine fan can result could be the loss of the electrical Minimum clearance is 3/4 in. (19 mm). engage at any time without warning. or air system as well as possible Anyone near the fan when it turns engine damage from overheating. So, • Rear edge of any blade must be on could be injured. Before turning it is a good idea to check the belts no closer than 3/8 in. (9 mm) to on the ignition, be sure that no one frequently and replace them as soon the nearest engine component. If is near the fan. Failure to comply as you detect trouble. this cannot be obtained, the fan may result in personal injury, death, spacer or fan is not correct. equipment or property damage. • The leading edge of any fan blade To check the fan: must be 1 in. (25 mm) from the inside edge of the shroud. 5 • Check the fan assembly mounting bolts for tightness. Inspect the blades for damage. • Check the clutch operation by starting the engine when it is cold. Then idle it at about 800 rpm. Listen for air leaks.

5-92 Y53-1203-1D1 (02/14) ENGINE MAINTENANCE

Engine Mounting Exhaust System CAUTION Periodic Inspection: Inspect engine Do not re-torque or reuse existing The exhaust system is part of the mounts every 60,000 miles (96,560 flange head bolts. These bolts are noise control system. Periodically km). Check for the following: factory set to the specified torque. check the exhaust for wear and loose If bolts are loose or damaged, they or missing parts. For details see Noise • Inspect both mount and leg and Emission Control on page 5-104. fasteners. Check for loose must be replaced with the new bolts. or broken bolts. Replace as Failure to comply may result in necessary. equipment or property damage. • Check mount and leg for fractures, breaks or deformation. Replace as necessary. • Check for complete insertion of motor mount. Replace as necessary. 5 • New leg to mount flange head bolts should be torqued to 210-230 Lb-Ft (284-311 Nm).

(02/14) Y53-1203-1D1 5-93 ENGINE MAINTENANCE

All Models continues to run at low power Multi-Function Message or the engine does not respond Display Proper operation, driving techniques properly. and maintenance are key factors in The Multi-function Display will display obtaining the maximum service life of diagnostic messages that are intended the muffler and/or converter. Some to alert you that trouble may be precautions should be taken if the developing in one of the systems, do engine is equipped with a muffler not ignore these messages, they are and converter. Avoid excess idling. important indicators that your vehicle Excessive idling or extended low load should be serviced immediately. periods can cause the muffler and converter to plug. A plugged muffler See your Kenworth Dealer for trouble and converter will lead to an increase shooting and diagnostic information. in exhaust back pressure. Operating the engine in extremely cold conditions can cause the muffler and converter to plug sooner. Use the procedure below 5 to clean out the muffler and converter if extended idle periods or extended low load periods are required. 1. Operate the engine at rated conditions for five to fifteen minutes. 2. Contact an authorized Engine Service Center, if the engine

5-94 Y53-1203-1D1 (02/14) FRAME MAINTENANCE

FRAME MAINTENANCE Emergency Welding • Disconnect all electronic devices. It is not possible to list all of the Kenworth DOES NOT recommend Introduction electronics that could be affected, frame welding. The high heat of but a few examples include the welding nullifies the special heat WARNING! following: alternator, engine treatment of the rails, greatly reducing Electronic Control Unit (ECU), Do not cut, splice or weld frame the tensile strength of the frame transmission ECU, ABS ECU, rails or drill through the top or bot- rail. If a frame member becomes navigation devices, diagnostic tom flanges of the rails. These cracked from overloading, fatigue, devices, and monitoring devices. operations could affect frame rail surface damage or a collision, the only strength leading to a failure resulting permanent repair is to replace the • Disconnect battery cables and in an accident. Rail failures re- damaged frame member with a new insulate them from the vehicle. sulting from such modifications are part. In an emergency, a temporary not warrantable. Failure to comply repair may be performed. Observe • Do not use the ECU or engine may result in personal injury, death, the following precautions to protect ground stud for the ground of the equipment or property damage. electronic systems during welding welding probe. operations. • Ensure that the ground connection 5 Welding Precautions for the welder is as close to the weld point as possible. This In the event of emergency welding of a ensures maximum weld current frame rail and when welding any other and minimum risk to damage part of your truck or any component of electrical components on the attached to your truck, observe the vehicle. following precautions before welding:

(02/14) Y53-1203-1D1 5-95 FRAME MAINTENANCE

Painting Frame Fastener Torque Fifth Wheel Maintenance Requirements Do not electrostatically paint your Proper preventive maintenance is truck or any component on your • Tighten all frame fasteners essential to trouble-free service and truck without first removing all of with a torque wrench. Torque safe operation of the fifth wheel. the electronic components from the specifications apply to the truck. It is not possible to list all of following fasteners with lightly Every 2 Months or 25,000 Miles: the electronics that could be affected, lubricated threads. • Refer to specific manufacturer's but a few examples include the literature for any special alternator, engine Electronic Control NOTE instructions. Unit (ECU), transmission ECU, ABS Whenever possible, torque all frame ECU, navigation devices, diagnostic fasteners on the nut end, not the bolt • Steam clean the fifth wheel. devices, and monitoring devices. head. • Check lock guard operation using a commercial lock tester. • Clean and oil all moving parts. 5 • Lubricate the following part with a lithium-base grease. ° Lock mechanism • All grease fittings (especially those which grease the top surface of the fifth wheel).

5-96 Y53-1203-1D1 (02/14) FRAME MAINTENANCE

Sliding Fifth Wheels FASTENER TORQUE * Every 6 Months or 50,000 Miles: SIZE Nm Lb-Ft • Lubricate bearing surface of 1-1/4 1,877-2,217 1,380-1,630 • Refer to specific manufacturer's support bracket through the METRIC WITH NYLON INSERT NUTS literature for any special grease fittings on the side of the M5 8-12 6-9 instructions. M6 9-15 7-11 fifth wheel plate. Use a water M8 23-31 17-23 • Remove fifth wheel from vehicle. resistant lithium-base grease. M10 33-43 24-32 Refer to the Kenworth Shop M12 75-101 55-75 NOTE M16 163-217 120-160 Manual, “Fifth Wheel Removal.” M20 352-460 260-340 The plate must be lifted up slightly * ESNA Style Lock Nut, with nylon insert. • Steam clean the fifth wheel and to relieve the weight of the bracket Lubricate nylon insert nut lightly with SAE mounting brackets. while applying grease. 20/30 oil. • Check all moving parts for excessive wear or damage. Table 14 Standard Grade 8 UNF or UNC and Metric Replace all worn or broken parts. FASTENER TORQUE * • Complete two-month service SIZE Nm Lb-Ft 5 procedure. 5/16 22-30 16-22 3/8 41-54 30-40 • Install fifth wheel. Refer to the 7/16 75-88 55-65 Kenworth Shop Manual, “Fifth 1/2 109-122 80-90 Wheel Installation.” 9/16 156-190 115-140 5/8 224-265 165-195 3/4 394-462 290-340 7/8 517-626 380-460 1 952-1,129 700-830 1-1/8 1,346-1,591 990-1,170

(02/14) Y53-1203-1D1 5-97 FRONT AXLE AND SUSPENSION MAINTENANCE

FRONT AXLE Kingpin Lubrication Suspension Lubrication AND SUSPENSION • Lubricate with approved lubricant. Each standard spring anchor pin has MAINTENANCE Lubricate knuckle thrust bearings, a grease fitting. Pressure lubricate knuckle pins, and tie rod ends. spring pins as specified. See Table 6, Axle Lubrication See Table 6, Recommended Recommended Lubrication Intervals Lubrication Intervals on page on page 5-11. • Change bearing lubrication 5-11. Lack of lubrication causes when seals are replaced, or premature wear and hard steering. • At regular intervals, the spring brakes are relined. See Table Lubrication schedule may be leaves may be lubricated with a 6, Recommended Lubrication shortened if necessary. rust-inhibiting oil applied with a Intervals on page 5-11. spray gun or brush. • Thoroughly clean hubs and • Depending on your suspension, bearings with solvent and a stiff lubricate all spring pins until bristle brush, then dry and inspect grease flows out of both ends of components for wear or damage. the bushing. Look for signs of rust 5 Re-lubricate with approved axle or water in the flushed grease. lubricant. If a pin will not accept grease, it should be removed, cleaned, and inspected.

CAUTION Do not spray the suspension with chemical products or mineral oil; it can cause damage to the bushings.

5-98 Y53-1203-1D1 (02/14) FRONT AXLE AND SUSPENSION MAINTENANCE

Inspection Wheel Alignment U-Bolt Torque

• For all vehicles, mandatory For driving safety and comfort, and It is important that U-bolts remain tight. maintenance procedures include to prolong the life of your vehicle, it Severe use of your vehicle will cause retightening all U-bolts and is important to have wheels correctly them to loosen faster. But all vehicles inspecting the suspension for aligned. Check tire wear frequently. need to have their U-bolts checked and loose fasteners, abnormal wear, Uneven tire wear is a sign that the tightened regularly. Be sure someone or damage. However, even with wheels may be misaligned. with the proper training and the right proper maintenance, the service tools checks and tightens the U-bolts life of leaf springs is affected by If you see uneven wear, take your on your Kenworth. many factors, such as: fatigue, vehicle to a Kenworth Dealer familiar vehicle gross weight, type of with aligning wheels on Kenworth New springs can settle in after service, load, road conditions, and vehicle vehicles. relieving the tension on the U-bolts. speed. Loose U-bolts can cause leaf spring breakage, axle misalignment, hard • Check for cracks, wear marks, steering and abnormal tire wear. splits, or other defects on the surface of the spring. Defective • All vehicles should have 5 parts must be replaced. Because suspension U-bolts tightened repaired springs cannot be after the first 500 miles (800 km) of fully restored to their original operation. And re-torque the front service life, replace the complete spring pinch bolts and shackle assembly if cracks or other defects pinch bolts. are detected. • Visually inspect shock absorbers and rubber bushings.

(02/14) Y53-1203-1D1 5-99 FRONT AXLE AND SUSPENSION MAINTENANCE

Chevron zinc lubricant (SAE 20 or 30 WARNING! oils acceptable but not preferred). Table 15 Front Spring Suspension U-Bolts, Grade 8 Do not operate the vehicle if the U-bolts are not properly tightened. WARNING! U-BOLT SIZE TORQUE Loose U-bolts will cause the axle Do not replace U-bolts and nuts with DIAMETER Nm Lb-Ft to not be properly secured to the (Inch common U-bolts or standard nuts. Dimensions) suspension, which could cause loss These parts are critical to vehicle 3/4 373-433 275-320 of vehicle control and an accident. safety. If the wrong U-bolts or nuts 7/8 502-563 370-415 Loose U-bolts can also cause un- are used, the axle could loosen or 1 925-1,060 680-780 even tire wear and poor alignment. separate from the vehicle and cause 1-1/8 1,470-1,660 1,080-1,220 1,890-2,120 1,390-1,560 Failure to comply may result in per- a serious accident. Use only U-bolts 1-1/4 1-1/2 3,130-3,860 2,300-2,840 sonal injury, death, equipment or and nuts of SAE Grade 8 specifi- property damage. cation or better. Failure to comply may result in personal injury, death, U-bolts are difficult to tighten unless equipment or property damage. you have the right equipment. If you 5 cannot tighten them correctly yourself, be sure to have them checked and tightened regularly by an authorized mechanic.

Tighten U-bolt nuts to the specified torque value with the vehicle loaded to its normal gross weight. The following torque values apply to U-bolts and nuts with clean threads lubricated with

5-100 Y53-1203-1D1 (02/14) HEATER AND AIR CONDITIONER MAINTENANCE

HEATER AND AIR Special Precautions • Inspected by a competent CONDITIONER technician every 15,000 miles MAINTENANCE WARNING! • Whenever a change is noticed in Excessive heat may cause the pres- the sound of the exhaust system surized components of the air con- Introduction ditioning system to explode. Never • Whenever the exhaust system, weld, solder, steam clean, or use The combination heater-air conditioner underbody or cab or sleeper is a blow torch near any part of the provides comfort for those in the cab damaged air conditioning system. Failure to through accurate control of the cab comply may result in personal injury, environment in all weather conditions. NOTE death, equipment or property dam- Regular attention to the items below To allow for proper operation of the age. will help you keep the heater-air vehicle ventilation system, proceed conditioner unit running well. as follows: WARNING! NOTE • Keep the inlet grille at the base of If a refrigerant leak develops in the Keep the vehicles ventilation sys- the windshield clear of snow, ice, presence of excessive heat or an 5 tem, engine exhaust system and leaves and other obstructions at open flame, hazardous gases may cab/sleeper joints properly main- all times. be generated. These gases may tained. cause unconsciousness or death. • Keep the exhaust pipe area clear to help reduce the buildup of It is recommended that the vehicles exhaust gas under the vehicle. exhaust system and cab/sleeper be serviced as follows:

(02/14) Y53-1203-1D1 5-101 HEATER AND AIR CONDITIONER MAINTENANCE

Heater • If you become aware of a CAUTION refrigerant leak on your vehicle • Check all heater controls for During extreme cold weather, do not have your system service full-range operation. immediately and observe the blow hot defroster air onto cold wind- following precautions: • Check hoses, connections, and shields. This could crack the glass. heater core for condition and Turn the air direction lever to Defrost ° Stay away from the hot leaks. and adjust the fan speed accordingly engine until the exhaust while the engine warms. If the en- manifold has cooled. • Check the drain tube of the fresh gine is already warm, move the tem- air inlet for trapped water before perature selector to Cool, then grad- ° Do not permit any open assuming that there is a leak in the ually increase the temperature when flame in the area. Even a heating system. If the heater core you see that the windshield is start- match or a cigarette lighter is leaking, a reliable radiator shop ing to warm-up. may generate a hazardous should be able to repair it. quantity of poisonous gas. • Check the heater core for debris ° Do not smoke in the area. blocking the air flow. If the blower 5 Inhaling gaseous refrigerant and air controls are functioning through a cigarette may properly, yet the heater is not cause violent illness. operating properly, the heater core or the hot water valves may be clogged or closed. Clean the heater core if necessary. If the condition persists, take the vehicle to a Kenworth Dealer for proper heater service or repair.

5-102 Y53-1203-1D1 (02/14) HEATER AND AIR CONDITIONER MAINTENANCE

Air Conditioner necessary. Small particles may Adjust kinked or chafing hoses to be removed with compressed eliminate restrictions and prevent WARNING! air blown through the core in the further wear. The air conditioning system is under opposite direction of normal air flow. • Check all components and pressure. If not handled properly connections for refrigerant leaks. during servicing, it could explode. WARNING! If you discover a leak, do not try to Any servicing that requires depres- tighten a connection. Tightening surizing and recharging the air con- Wear eye protection any time you a connection may cause a worse ditioning system must be conducted blow compressed air. Small parti- leak. Have a qualified technician by a qualified technician with the cles blown by compressed air could correct the problem. right facilities to do the job. Failure injure your eyes. to comply may result in personal NOTE injury, death, equipment or property • Inspect and clean cab air filter damage. element every 3 - 6 months A leaking evaporator or condenser of service. Depending on the core cannot be repaired; it must be • Check the compressor and drive operating environment, if air flow replaced. clutch for noise and vibration. from the air conditioner and heater 5 If you find problems, have the is less efficient or windows fog Have the air conditioning system fully system checked thoroughly. A easier, you may need to replace serviced annually by your Kenworth malfunctioning clutch usually the cab air filter. Dealer. Qualified service technicians indicates trouble elsewhere in the will have to evacuate and recharge the system. • Check the compressor belt for system. condition and proper tension. • Check the evaporator core, filter, and condenser core for debris • Check all hoses for kinks, restricting air flow. Clean if deterioration, chafing, and leaks.

(02/14) Y53-1203-1D1 5-103 NOISE AND EMISSION CONTROL MAINTENANCE

NOISE AND which at the time it left Kenworth's Tampering with Noise Control EMISSION CONTROL control caused noise emissions System to exceed Federal standards, are MAINTENANCE covered by this warranty for the life of Federal law prohibits the following the vehicle. acts or the causing thereof: Noise Emission Warranty 1. The removal or rendering inoperative by any person other Kenworth Truck Company warrants than for purposes of maintenance, to the first person who purchases this repair, or replacement, of any vehicle (for purposes other than resale) device or element of design and to each subsequent purchaser: incorporated into any new vehicle that this vehicle, as manufactured for the purpose of noise control by Kenworth Truck Company, was prior to its sale or delivery to the designed, built and equipped to ultimate purchaser or while it is in conform, at the time it left Kenworth's use, or control, with all applicable U.S. EPA Noise Control Regulations. 2. The use of the vehicle after such 5 device or element of design This warranty covers this vehicle has been removed or rendered as designed, built and equipped by inoperative by any person. Kenworth, and is not limited to any particular part, component or system of Among those acts presumed to the vehicle manufactured by Kenworth. constitute tampering are the acts listed Defects in design, assembly or in any below: part, component or system of the vehicle as manufactured by Kenworth,

5-104 Y53-1203-1D1 (02/14) NOISE AND EMISSION CONTROL MAINTENANCE

Air Intake System Fuel System • Removing hood-mounted noise • Removing or rendering inoperative • Removing or rendering engine insulation. the air cleaner/silencers or intake speed governor inoperative, piping. allowing engine speed to exceed manufacturer's specifications. Engine Cooling System • Removing of air signal attenuator • Removing or rendering inoperative on engines equipped with this the fan clutch. device. • Removing the fan shroud. Inner Fender Shields and Cab Skirts Engine • Removing shield or skirts. • Removing or rendering engine • Cutting away parts of shields, speed governor inoperative so as skirts or damaged or loose to allow engine speed to exceed portions of shields or skirts. manufacturer's specifications. Noise Insulating Blankets 5 • Modifying ECU parameters. • Removing noise insulators from Exhaust System engine block or from around the • Removing or rendering inoperative oil pan. exhaust system components. • Cutting holes in, or cutting away part of noise insulators.

(02/14) Y53-1203-1D1 5-105 NOISE AND EMISSION CONTROL MAINTENANCE

Inspection and Maintenance Air Intake System Engine Mounted Noise Insulators Instructions • Do all checks and maintenance • Check condition. Is the insulator procedures listed in this manual secure? How you do this will The following instructions are based on under Engine Air Intake System depend on the method of attaching inspection of the noise control system and Air Cleaner. See Air Dryer on the noise insulators on the engine at regular intervals as indicated in the page 4-17. and around the oil pan (bolts, Noise Control System Maintenance snap fasteners, or straps). Tighten Log on page 5-112. • Check the induction tubing, elbow loose fasteners and repair or connections, clamps, brackets, If, during periodic inspection and replace any worn or damaged and fasteners for deterioration, fasteners. maintenance of other systems and cracks, and security. components, it is found that parts of the • Check insulators around fasteners noise control system require attention, • If you find an air leak anywhere and stress points, especially we recommend that those parts be between the air cleaner and where they may be affected by inspected at more frequent intervals the engine, repair that leak engine vibration. Repair any to assure adequate maintenance and immediately. cracked or damaged mounting 5 performance. points. Use suitable reinforcing CAUTION plates to ensure that the insulators Air leaks cause excessive noise and will remain in position. may result in serious damage to the engine. If you do not repair them the engine damage will not be covered by your warranty. Repair all air leaks as soon as you find them.

5-106 Y53-1203-1D1 (02/14) NOISE AND EMISSION CONTROL MAINTENANCE

Exhaust System Joints and Clamps Selective Catalyst Reduction (SCR) • Check for exhaust leaks, • Check for leaks, and tighten as • Check SCR canister filter, clamps which would indicate a leaking necessary. Check for deterioration and mounting brackets. Tighten if manifold gasket; replace gasket if or dents in pipes and clamps which necessary. Inspect SCR canister necessary. could allow exhaust to escape. for signs of rust or corrosion. • Check cap screws for tightness, including those at the flanges. Refer to the engine manufacturer's service manual for proper tightening sequence and torque values.

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(02/14) Y53-1203-1D1 5-107 NOISE AND EMISSION CONTROL MAINTENANCE

Piping Diesel Particulate Filters (DPF) Mufflers • Check exhaust piping for rust, • Check diesel particulate filter • Check muffler, clamps, and corrosion, or damage. Replace (DPF), clamps, and mounting mounting brackets. Tighten if deteriorated piping before holes brackets. Tighten if necessary. necessary. Inspect muffler for appear. If piping is perforated at Inspect diesel particulate filter signs of rust or corrosion. any point, temporary patching or (DPF) for signs of rust or corrosion. lagging is acceptable until you can • Check internal baffling. You can have permanent repairs made. • Check internal baffling. You can do this by listening for rattling On turbocharged engines, check do this by listening for rattling sounds while tapping the muffler joints at flanges and mounting sounds while tapping on the diesel with a rubber mallet or revving the brackets for tightness. particulate filter (DPF) with a engine up and down through its rubber mallet or revving the engine normal operating range. up and down through its normal operating range.

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5-108 Y53-1203-1D1 (02/14) NOISE AND EMISSION CONTROL MAINTENANCE

Exhaust Tail Pipe Engine Fan and Shroud • Check fan blade mounting bolts. Inspect fan blades to be sure they • Check the mounting. Tighten as WARNING! necessary. The miter cut at the tip are not cracked or bent. of the pipe must be facing the rear Do not work on the fan with the en- of the vehicle. Do not modify the gine running. The engine fan can end of the pipe in any way. engage at any time without warning. Anyone near the fan when it turns on could be injured. Before turning on the ignition, be sure that no one is near the fan. Failure to comply may result in personal injury, death, equipment or property damage.

• Check all fasteners for tightness. Check for stress cracks in the shroud. Make sure the shroud is adjusted so that it does not touch 5 the fan blades. • Check to verify that the fan is disengaged (not turning) with the engine running at normal operating temperatures (from cold to the point that the fan engages).

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Transmission and Driveline Hood Insulation Blanket Blanket • Substituting a different main • Check all fasteners for condition • Check for chafing or tears. Patch transmission or driveline and security. Repair or replace it if necessary. Find the cause of components, other than any broken or defective fasteners. the damage. If any component design-specified units, may or accessory is causing wear or result in increased vehicle noise damage and cannot be relocated, emission. put reinforcing pads on the blanket at the site of wear.

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5-110 Y53-1203-1D1 (02/14) NOISE AND EMISSION CONTROL MAINTENANCE

Inner Fender Shields and Cab Skirts Shields and Skirts NOTE • Check all fasteners, especially the • Check shields and skirts for cracks Your Kenworth Dealer can perform self-tapping hex head screws. Are at mounting and stress points. all of these checks and repairs or they secure? Remove and replace Check fender shields for tire replacements. any loose rivets. marks, worn spots, or damage from objects thrown from tire treads. You can repair cracked or damaged fiberglass fender shields with fiberglass and resin. • If you find damage at a fastening point, you can gain additional strength by installing a suitable reinforcing plate. This plate should be drilled to accept a rivet and laminated to the shield with fiberglass and resin. 5 • Check cab skirts, sills, and brackets for overall condition and repair them as necessary. Damaged rubber fender shields or cab skirting cannot be repaired. You will need to replace it.

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Noise Control System - record maintenance checks. Use the Maintenance Log following log sheet and retain copies of documents regarding maintenance To ensure your Kenworth's noise services performed and parts replaced control requirements are maintained, on the vehicle.

Table 16 Noise Control System - Maintenance Log

Recom- Repair Facility Work Repair Facility & Work Component mended In- Date & R.O. No. Date & R.O. No. & Location Location terval (Miles) Performed Performed Exhaust System 25,000 Routing Integrity Shutters 25,000 Shrouds Hood Insulation 10,000 Blanket Engine Mounted 10,000 Hose Insulators Fasteners 5 Inner Fender 50,000 Shields Cab Skirts 50,000 Fasteners Air Intake 5,000 System Integrity Element Clutch Type Fan 10,000 Drive

5-112 Y53-1203-1D1 (02/14) REAR AXLE AND SUSPENSION MAINTENANCE

REAR AXLE AND in over-the-road operations require SUSPENSION periodic inspection to ensure trouble- WARNING! MAINTENANCE free performance. Do not operate the vehicle if the U-bolts are not properly tightened. WARNING! Loose U-bolts will cause the axle General Maintenance Failure to maintain the specified to not be properly secured to the torque values or to replace worn suspension, which could cause loss WARNING! parts can cause component system of vehicle control and an accident. Do not work on the vehicle without failure, possibly resulting in an ac- Loose U-bolts can also cause un- the parking brake set and wheels cident. Improperly tightened (loose) even tire wear and poor alignment. chocked securely. If the vehicle is suspension U-bolts can lead to un- Failure to comply may result in per- not secured to prevent uncontrolled safe vehicle conditions, including: sonal injury, death, equipment or vehicle movement, it could roll and hard steering, axle misalignment, property damage. may result in personal injury, death, spring breakage or abnormal tire equipment or property damage. wear. See Front Spring Suspension CAUTION U-bolts on page 5-100 for proper Do not spray the suspension with NOTE torque specifications. Failure to 5 comply may result in personal injury, chemical products or mineral oil; it Use wood blocks (4 in. X 4 in. or death, equipment or property dam- can cause damage to the bushings. larger) against the front and rear sur- age. faces of the tires. Be sure the vehi- NOTE cle cannot move. Failure to follow these recommenda- tions could void warranty. Your vehicle's suspension, by design, requires a minimal amount of maintenance. However, suspensions

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Visual Inspection • Visually check for loose or missing Rear Suspension Fasteners fasteners, cracks in hanger or axle For all vehicles, mandatory To maintain the performance of the connection brackets. maintenance procedures include air suspension, check fastener torque retightening of U-bolts and complete • Check that springs are centered in values after the first 2,000 miles (3,218 inspection. However, even with proper hangers and in good condition. km) of service and every 60,000 miles maintenance, many factors affect the (96,000 km) thereafter. service life of springs and suspension • Check for cracks, wear marks, components, such as: fatigue, vehicle splits, or other defects on the Torque recommendations apply to gross weight, type of load, road surface of the spring. fasteners supplied and installed conditions and vehicle speed. by Kenworth. The values listed in • Replace defective parts. Because Table 17 and Table 18 below, are for It is important that U-bolts remain tight. repaired springs cannot be cadmium plated or phosphate and oil Severe use of your vehicle can cause fully restored to their original fasteners only. them to loosen faster. But all vehicles service life, replace the complete need to have their U-bolts checked and assembly if cracks or other defects U-bolts are difficult to tighten unless tightened regularly. Be sure someone are detected. you have the right equipment. If you cannot tighten them correctly yourself, 5 with the proper training and the right • After replacement of any part or be sure to have them checked and tools checks and tightens the U-bolts discovery of loose components, tightened regularly by an authorized on your Kenworth. check the torque of all fasteners. mechanic. • After the first 500 miles (800 km) of • New springs settle-in after the operation, inspect the suspension vehicle's initial service, causing periodically, as noted below: the U-bolts to become loose.

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U-Bolt Torque NOTE Table 18 Rear Suspension U-Bolts, Grade 8 (lubricated*) NOTE Torque all fasteners on the nut end. To ensure an accurate torque read- U-BOLT SIZE TORQUE** DIAMETER ing, use properly maintained and Table 17 Rear Suspension Fasteners Nm Lb-Ft (Metric & Standard) THREAD calibrated torque wrenches. AG380 441- 508 380- 375 • Clean the nut and bolt. No dirt, SIZE/TYPE TORQUE* AG400L 508- 644 375- 475 grit, or rust should be present. Nm Lb-Ft 1 925-1,060 680-780 M16 nylon- 163-217 120-160 1-1/8 1,470-1,660 1,080-1,220 insert nuts 1-1/4 1,890-2,120 1,390-1,560 WARNING! M20 nylon- 352-460 260-340 1-1/2 3,130-3,860 2,300-2,840 insert nuts *Chevron Zinc Lubricant or SAE 20/30 oil Do not operate the vehicle if the M20 all-metal 427-475 315-350 should be used on U-Bolt threads U-bolts are not properly tightened. lock nuts **Torque requirements apply to manufacturer Loose U-bolts will cause the axle 1/2 in. nut 109-122 80-90 proprietary suspensions. All other 3/4 in. nut 394-462 290-340 suspensions must refer and adhere to to not be properly secured to the 1-1/4 in. nut 1,877-2,217 1,380-1,630 original manufacturers shop manual. suspension, which could cause loss * Torque requirements apply to Kenworth of vehicle control and an accident. proprietary suspensions. All other • Load the vehicle to its normal 5 Loose U-bolts can also cause un- suspensions must refer and adhere to gross weight before tightening original manufacturers shop manual. even tire wear and poor alignment. U-bolts. Loading the vehicle Failure to comply may result in per- ensures proper adjustment of the sonal injury, death, equipment or U-bolt and spring assembly. property damage.

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Rear Axle Lubrication WARNING! For recommended types and brands • Check oil level with the vehicle Do not replace U-bolts and nuts with of lubricants, contact your Kenworth parked on level ground and the common U-bolts or standard nuts. Dealer. fluid warm. The level should be These parts are critical to vehicle even with the bottom of the filler safety. If the wrong U-bolts or nuts hole. are used, the axle could loosen or separate from the vehicle and cause CAUTION a serious accident. Use only U-bolts and nuts of SAE Grade 8 specifi- Do not mix lubricants of different cation or better. Failure to comply grades; although, mixing different may result in personal injury, death, brands of the same grade lubricant equipment or property damage. (meeting MIL-L-2105C), is accept- able. Lubricants of different grades are not compatible and could dam- age the axle. 5 NOTE In all cases, lubricant supplier as- sumes full responsibility for the per- formance of their product, and for product and patent liability.

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Dana Spicer and Fabco Axle Housing Breather Vent All Vehicles with Dana Spicer No initial drain is required on Dana and Fabco Axles: See Table 6, • Check and clean the axle housing Spicer axles that are factory filled with Recommended Lubrication Intervals breather vent at each oil level an Dana Spicer-approved synthetic on page 5-11. Contact your Kenworth check. lubricant. Dealer for approved synthetic lubricant brands. • Petroleum-based lubricants must be drained within the first 5,000 • Dana Spicer Axles with synthetic miles (8,000 km) if converting to lubrication and Out Runner Seals: an approved synthetic lubricant. drain, flush, and refill at 500,000 miles (804,000 km). Initial Change: See Table 6, Recommended Lubrication Intervals on page 5-11 for standard rear axle service intervals. Change mineral-based lubricant in other Dana Spicer and Fabco axle assemblies 5 (new or rebuilt) within the first 3,000 to 5,000 miles (4,800 to 8,000 km). • For petroleum-based axles, use lubricants meeting MIL-L-2105C/D grade specifications or approved synthetic lubrication. Do not use oil additives.

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Meritor Clark Rear Axle Alignment

See Meritor Lubrication Maintenance Initial Change: See Table 6, Continual road shock and load Manual (MM1). Recommended Lubrication Intervals stresses may force the rear axles on page 5-11 for standard rear axle out of alignment. If you detect rapid service intervals. Change standard tire wear on the rear axles, you may lubricant in Clark axle assemblies have misaligned axles. If you suspect within the first 3,000 to 5,000 miles rapid tire wear, have your rear axle (4800 to 8000 km). alignment checked and adjusted by a Kenworth Dealer. All Vehicles with Clark Axles: Check Clark axles every 5,000 miles (8,000 In addition to pre-delivery inspections, km). suspension alignment should be checked when any one of the following • Change lubricant every 25,000 conditions exist: miles (40,000 km) thereafter or yearly whichever occurs first. • Discovery of loose suspension 5 fasteners. (Loose, defined as any On–Off Highway: Check every 250 torque below the recommended hours of operation. torque value.) • Change every 2,500 hours of • Discovery of elongated holes in a operation thereafter or yearly suspension component. whichever occurs first. • Bushing replacement. • Excessive or abnormal tire wear.

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STEERING AND vehicle overloaded or unevenly WARNING! • DRIVELINE distributed load MAINTENANCE Do not operate the vehicle if the steering system is not working prop- • wheels out of alignment erly. You could lose control of your • wheel bearings improperly Power Steering vehicle if the steering system is not adjusted in good working condition, which Oil (under low pressure) provides the could result in a serious accident. If you cannot correct the problem, power to operate the steering gear. It For driving safety, visually check also serves to lubricate moving parts check with an authorized Kenworth the steering gear and components. Dealer. and remove heat. A loss of steering Frequent checks are important for efficiency will occur if too much heat driving safety, especially after trav- builds up in the system. The Kenworth is equipped with integral eling over rough roads. Failure to power steering. The system includes comply may result in personal injury, an engine-driven fluid pump, a fluid death, equipment or property dam- reservoir, the steering gear, and age. connecting hoses. Because of the hydraulic power assist, little effort is 5 NOTE required to turn the steering wheel. When no input is applied through the If the steering feels unbalanced from steering wheel, the steering gear will side-to-side while turning, check for return to the neutral position. If, for the following possible causes: any reason, the power assist system goes out, steering the vehicle is still • unequal tire pressures possible, yet it will require much greater effort.

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Fluid Level and Refill is at its proper level. Both checks Visually check the following parts: are with the engine NOT running. Have the power steering fluid and • Crosstube: Is it straight? filters changed at an authorized 1. If you check the fluid with the engine and steering system • Draglink tube clamp: Check for Kenworth Dealer. COLD, the fluid level should be looseness or interference. • Check and completely change at/or above the Minimum indicator • Ball joints and steering U-joints: the fluid level according to Table level and should generally not Check for looseness. 6, Recommended Lubrication exceed the middle point between Intervals on page 5-11. Use the Maximum and Minimum level • Steering wheel for excessive following procedure: indicators. free-play. Check the simplest 2. If you check the fluid with the probable causes first: NOTE engine and steering system ° unequal tire pressures Before removing reservoir cover, WARM, the fluid should NOT wipe outside of cover so that no dirt exceed the Maximum level ° loose cap nuts can fall into the reservoir. indicator and should generally ° bent crosstube not drop below the middle point 5 • Maximum/Minimum level is between the Maximum and ° lack of lubrication indicated on the reservoir. These Minimum level indicators. same levels are also indicated by • If these checks do not reveal the two lines on the dipstick in the problem, or if you correct them reservoir. and still have a steering problem, take your truck to an authorized • There are two ways to check Kenworth Dealer for evaluation. whether the power steering fluid

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Fluid Refill Steering Driveline WARNING! The following recommendations are The following are common torque If this chassis is equipped with an for general purpose steering systems, specifications for most drivelines. electronic stability system (ESP) and commonly installed on Kenworth any part of the steering system (e.g. vehicles. • Torque on U–joint pinch bolt and nut (7/16 in) 74–81 Nm (55 to 60 linkage, steering driveline, column, • For normal temperatures, use lb-ft), lubricated. front-end alignment, etc) is repaired, Automatic Transmission Fluid removed, or disassembled in any (ATF) Type E or F or Dexron® II. • Torque on Pitman arm clamp bolt way, or if the steering angle sensor and nut (3/4 in): 406–433 Nm (300 is replaced, the steering angle sen- • For cold temperatures of -22º F to 320 lb-ft), lubricated. sor must be recalibrated. Failure to (-30º C) and above use ATF Type do so could cause loss of vehicle A. • For off–highway vehicles, tighten control. Any repairs or adjustments the U–bolts after the first day or to any part of the steering system • For extremely cold temperatures two of operation. Then check must be performed by an authorized between -22º F (-30º C) and -40º weekly. Kenworth Dealer. Failure to comply F (-40º C) use ATF Type B. may result in personal injury, death, 5 equipment or property damage.

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Driveshaft U-Joints

The slip joints and universal joints of • The slip joints and universal the drive shaft should be lubricated joints of the drive shaft should periodically. be lubricated according to Table 6, Recommended Lubrication • Use a good quality Intervals on page 5-11. lithium-soap-base or equivalent extreme pressure (E.P.) grease: Use a good quality lithium-soap-base NLGI Grade 2. or equivalent extreme pressure (E.P.) grease: NLGI Grade 2. For Towing Guidelines and Returning a Towed Vehicle to Service see Vehicle WARNING! Recovery Guidelines on page 2-12. Improper lubrication of U-joints can cause them to fail prematurely. The driveshaft could separate from the vehicle and result in an accident. 5 Make sure lubricant is purged at all four ends of each U-joint and loosen caps if necessary. Also, regularly inspect U-joints for excessive wear or movement, and repair or replace as necessary. Failure to comply may result in personal injury, death, equipment or property damage.

5-122 Y53-1203-1D1 (02/14) TIRES AND WHEEL MAINTENANCE

TIRES AND WHEEL General Safety MAINTENANCE WARNING! Requirements Always support the vehicle with ap- • Each mounting system is propriate safety stands if it is neces- Introduction engineered only for use with its sary to work underneath the vehicle. correct mating part. Be sure that A jack is not adequate for this pur- Keeping the tires in good condition is properly matched components pose. Failure to comply may result essential to the safe, efficient operation are used for each type of in personal injury, death, equipment of your Kenworth. Regular, frequent mounting. The comparison or property damage. inspection and the right care will give chart, Comparing Hub-piloted you the assurance of safe and reliable and Ball-seat Wheels on tire operation. page 5-133, illustrates the differences between parts used WARNING! in hub-piloted mount and ball Use only original equipment manu- seat mount applications. Only factured (OEM) components. Use of OEM supplied hub-piloted or non-original equipment could cause ball-seat mounted wheels may wheel breakage and wheel separa- be used on this vehicle. 5 tion from vehicle. Failure to comply may result in personal injury, death, • If you are not fully qualified and equipment or property damage. not equipped with the proper tools and equipment, do not attempt to raise the vehicle or remove or install the damaged tire and wheel assembly. Obtain expert help. A person can be

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injured and/or damage can Speed Restricted Tires • Only properly trained personnel result from using the wrong should service tire and rim service methods. Truck tires WARNING! assemblies. and wheels should be serviced This vehicle may be equipped with only by trained personnel using speed restricted tires. Check each proper equipment. Do not tires sidewall for maximum rated reinflate a tire that has been run speed. Vehicle should not be oper- flat or is low on air without first ated at sustained speed in excess removing the tire from the rim of maximum rated speed. Failure and inspecting for damage. to comply with these speed restric- • Follow OSHA regulations per tions could cause sudden tire failure section 1910.177. which may result in personal injury, death, equipment or property dam- • Do not exceed the speed rating age. of tires. Exceeding the speed rating may result in sudden 5 tire failure and loss of vehicle control. • Follow all warnings and cautions contained within the tire and wheel manufacturers literature.

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Tire Inspection and Tire Inflation and Loading Tire Inflation Replacement Low pressure is a tire's worst enemy. Most tire wear problems are caused Visually inspect your tires frequently Under-inflation allows tires to flex by under-inflation as the result of for any abnormal conditions such as improperly, causing high temperatures slow leaks. So you will want to check scrapes, bulges, and uneven wear. to build up. Heat causes early tire tire pressure regularly. Give the tires This must be done immediately after damage such as flex break, radial a visual test every day, and check known or suspected contact with an cracks, and ply separation. And low inflation with a gauge every week. object in the road, with a pothole, pressure may affect control of your road irregularity or after severe vehicle, especially at the front wheels. When checking tire pressure, inspect braking. Refer these conditions to an each tire for damage to sidewalls, Authorized Tire Service Center for WARNING! cuts, cracks, uneven wear, rocks between dual wheels (tires), etc. If a repair or replacement. Never drive on Do not operate vehicle with under- tire appears under-inflated, check for a tire if such conditions appear. inflated tires. The extra heat caused damage to the wheel assembly. Do not by under-inflation can cause sudden forget to check between dual wheels. If the tire looks under-inflated, stand tire failure such as a tire fire or blow If you find wheel damage, have an off to the side and check for damage out. Low pressure may affect control expert tire service repair it. 5 to the wheel assembly. This can be at the front wheels, which could re- done by visually comparing the wheel sult in an accident. Keep your tires in question to other wheels on the inflated to the manufacturer's rec- vehicle. For dual wheel assemblies, ommended air pressure. Failure to check between the wheels for damage. comply may result in personal injury, If any damage is found, or you suspect death, equipment or property dam- damage, do not attempt further repair. age. Call for expert tire service.

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WARNING! Under-inflated tires will adversely 1 affect the operation of the vehicle Do not repair damaged tires unless Proper-Inflation: the you are fully qualified and equipped and tires: correct profile for full contact with the road. to do so. Wheel and tire assem- • making steering difficult blies cannot be worked on without TREAD CONTACT proper tools and equipment, such • causing extra strain on the tire WITH ROAD as: safety cages or restraining de- sidewalls vices. Have all tire repairs per- 2 formed by an expert. And stand • reducing the tread life of tires away from the tire assembly while due to the high temperatures Under-Inflation: generated from excess flexing of causes abnormal tire the expert is working. Failure to deflection, which builds comply may result in personal injury the tire up excessive heat, or death. running the risk of Inflate tires to the manufacturer's cold TREAD CONTACT failure. It also causes WITH ROAD air pressure specification molded into irregular wear. CAUTION the tire side wall. 3 5 Pressure should be checked when the tires are cool. Warm or hot tires Lower tire pressure does not give Over-Inflation: cause pressure buildup and will give you more traction on ice or snow. reduces the tread under-inflation actually reduces contact area with you an inaccurate reading. So never the road surface, traction and steering control. See the deflate a warm tire to the specified TREAD CONTACT concentrating all of pressure. Failure to comply may re- tire manufacturer's Driver's Handbook WITH ROAD the vehicle weight for more information on proper on the center of the sult in equipment damage. tread. This causes operation and use of tires. premature wear of the tire.

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build-up during operation. This Tire Loading • Too much air pressure reduces the condition has been taken into account tire tread contact area and results during manufacturing of the tires. WARNING! in rapid wear in the center of the Allow tires to cool, then recheck and tire. It also causes tires to run hard Do not exceed the load rating of your adjust if necessary. and makes them more vulnerable tires (molded on the side wall of your to impact and other road hazard tire) or the maximum vehicle load damage. rating, whichever is less. Overload- ing could result in premature tire fail- WARNING! ure causing you to loose control of your vehicle and result in an acci- Over-inflated tires can cause acci- dent. The maximum vehicle load dents. They wear more quickly than rating (GVWR) is found on the Tire properly inflated tires and are more and Rim Data label on the driver's subject to punctures, cracks, and door. Failure to comply may result other damage. They could fail and in personal injury, death, equipment cause you to lose control of your ve- or property damage. hicle resulting in an accident. Be sure all tires are inflated correctly 5 according to the manufacturer's rec- Overloading your vehicle is as ommendations. Failure to comply damaging to the tires as under-inflation. may result in personal injury, death, It significantly affects the expected equipment or property damage. life (total mileage of a tire). The following chart shows how neglect or deliberate abuse can affect the life of If over-inflation is noted during travel, your vehicle's tires. do not deflate tires. The increased pressure is caused by temperature

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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% Over Tire Pressure Normal 20% Low 30% Low 35% Low 45% Low 55% Low Expected Total Normal 70% 50% 40% 30% 25% Tire Mileage Wheel Mounting and Wheel Cap Nut Torque Fastening WARNING! At the first scheduled lube interval, Never use oil or grease on studs or have all wheel cap nuts torqued to their After the vehicle travels about 50 to 100 nuts; improper torque readings will specified value. See Table 20, Wheel miles (80 to 160 km), wheel mountings result, which could cause improper Cap Nut Torque on page 5-130. After seat in and will lose some initial torque. wheel clamping and could lead to that, check wheel cap nuts at least Check hub/wheel mountings after this a wheel failure resulting in an acci- once a week. Contact an authorized initial period and retighten. dent. Failure to comply may result Kenworth Dealer for information on the in personal injury, death, equipment proper installation procedure for the or property damage. 5 wheels on your truck. This is a job you may not be able to do yourself. You need the right torquing equipment to do it.

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Wheel Bearing Adjustment

For safe, reliable operation and adequate service life, your wheel bearings must be adjusted properly at the recommended intervals. See Table 9, Maintenance Schedule on page 5-18 and Steering Axle Wheel Bearing - End Play Adjustment and Inspection on page 5-18. Contact your authorized Kenworth Dealer to make sure the wheel bearings are properly adjusted.

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Table 20 Wheel Cap Nut Torque

WHEEL & NUT CONFIGURATION STUD SIZE TORQUE FOR INNER & OUTER CAP NUTS & RIM CLAMP NUTS Nm Lb-Ft Steel or Aluminum Disc-Type 3/4-16 610-680 450-500 Wheel; Double Cap Nut Mounting; 1-1/8-16 610-680 450-500 Standard 7/8 Radius Ball Seat Heavy-Duty Steel Disc-Type Wheel; 15/16-12 1,020-1,220 750-900 Double Cap Nut Mounting; 1-1/8-16 1,020-1,220 750-900 1-3/16 Radius Ball Seat: 1-15/16-12 1,020-1,220 750-900 Hub-Piloted Disc-Type Wheel M22-1.5 610-680 450-500 w/Two Piece Flanged Cap Nuts: Steel or Aluminum Wheel Stud Backnuts (when used) 3/4-16 240-270 175-200 1-14 240-410 175-300

Threads should be clean and dry. Do Proper Torque and Sequence drawn evenly against the hub. Torque not lubricate wheel nuts or studs. each nut to the torque value listed in 5 Proper wheel torque can best be Table 20, Wheel Cap Nut Torque. obtained on level ground. Install lug nuts and finger-tighten in the numerical sequence as shown below, see Nut Tightening Sequence for Hub Piloted Disc Wheels on page 5-131 or Nut Tightening Sequence for Stud Piloted Disc Wheels on page 5-131. This procedure will ensure that the wheel is

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Wheel Replacement with ensure there is adequate clearance WARNING! Disc Brake Option between other vehicle components. Tighten wheel cap nuts properly. If they are not tightened properly, Use only the wheel brand, size and With the hood open, check for wheel nuts could eventually cause part number originally installed by clearance between the wheel and disc the wheel to become loose, to fail, Kenworth. Use of a different wheel brake assembly. Use a hydraulic jack and/or to come off while the vehicle brand or size could cause valve stem to raise the front of the vehicle off is moving, possibly causing loss of to interfere with a brake component the ground to allow the wheel to spin control and may result in personal which could lead to loss of vehicle freely. While rotating the wheel, check injury, death, equipment or property control and may lead to personal injury. to ensure there is adequate clearance damage. between the wheel and disc brake Vehicles equipped with front disc assembly brakes are fitted with wheels designed specifically for disc brake applications. WARNING! If it ever becomes necessary to If the hood falls, anyone under it replace an original equipment wheel, could be injured. Always attach the the replacement wheel must be the safety cable and/or hood stop when 5 Nut Tightening Sequence for Hub same brand and size as the take-off the hood is in its open position any Piloted Disc Wheels wheel. On vehicles equipped with 22.5 time anyone gets under the hood in. disc wheels, installing the wrong for any reason. Failure to comply replacement wheel could result in may result in personal injury, death, the wheel valve stem making contact equipment or property damage. with the disc brake assembly. When installing any replacement wheel, always inspect the tires/wheels to Nut Tightening Sequence for Stud Piloted Disc Wheels

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Disc Wheels Comparing Hub Piloted and WARNING! Ball Seat Parts Always support the vehicle with ap- WARNING! propriate safety stands if it is neces- Use the correct components and WARNING! sary to work underneath the vehicle. tools when working on wheels. Do not mismatch wheel compo- A jack is not adequate for this pur- Grooves in the wheel disc or other nents. Equipment that does not ex- pose. Failure to comply may result damage to the disc can weaken the actly match original specifications or in personal injury, death, equipment wheel and cause it to eventually that is mismatched could cause the or property damage. come off. This could cause you to wheels to break and separate from lose control of your vehicle, and the vehicle. The resulting accident WARNING! may result in an accident. Failure could be very serious. Each mount- to comply may result in personal ing system is engineered for use Improperly mounting and demount- injury, death, equipment or property only with its correct mating part. Be ing tire and rim assemblies is dan- damage. sure properly matched components gerous. Failure to observe proper are used for each type of mount- precautions could cause the tire-rim The end of the wheel wrench must ing. Failure to comply may result in assembly to burst explosively, caus- 5 be smooth. Burrs on the end of the personal injury, death, equipment or ing serious injury or death. See the wrench can tear grooves in the disc. property damage. wheel manufacturer's literature for These grooves may lead to cracks in the proper way to mount and de- the disc, and can cause it to fail. mount your tires and rims. Follow The following comparison (Table 21, their precautions exactly. Failure to Comparing Hub-piloted and Ball-seat comply may result in personal injury, Wheels), shows the difference death, equipment or property dam- between parts used in hub pilot mount age. and ball seat mount applications.

5-132 Y53-1203-1D1 (02/14) TIRES AND WHEEL MAINTENANCE

Table 21 Comparing Hub-piloted and Ball-seat Wheels

HUB-PILOTED MOUNT BALLSEAT MOUNT

Hub, Drum, and Stud Assembly Hub-piloted mountings use M22 x 1.5 metric threads (about 7/8 in. Ball-seat (stud-piloted) mountings use 3/4x16 or 1-1/8x16 threads. The diameter). The stud stands out at least 1.94 in. beyond the brake drum. dual mounting studs provide 1.30 in. 1.44 in. standout. Right-hand and All studs are right-hand threads. Pilot bosses (machined surfaces) on the left-hand threads are required. Inner and outer wheel nuts center the hub, fit tightly to the wheel center bore. wheels by seating against wheel ball seats. Wheels Hub-piloted wheels have stud holes reamed straight through (no ball Ball-seat wheels have spherical chamfers machined on each stud hole. seats). Center bore diameter is 8-21/32 in. Center bore diameter is 8-23/32 in. Wheel Nuts Hub-piloted wheel nuts have a hex body and a flange for clamping Ball-seat inner and outer wheel nuts mate with spherical chamfers on against wheel face. Hex size is 1-5/16 in. (33 mm). wheels. The inner nut has 13/16 in. square end. The outer nut has 5 a 1-1/2 in. hex.

(02/14) Y53-1203-1D1 5-133 TIRES AND WHEEL MAINTENANCE

Tire Replacement WARNING! NOTE Front: Replace front tires when less Do not install regrooved or rein- To prolong the tires' life and make than 4/32 in. of tread remains. Check forcement- repaired tires on steering them safer, have their radial and at three places equally spaced around axles. They could fail unexpectedly lateral run-out checked at your Ken- the tire. and cause you to lose control of worth Dealer. And of course have your vehicle resulting in an accident. Drive Axles or Trailers: Replace tires the tires balanced any time you Failure to comply may result in per- on drive axles or trailers when less than change a tire. sonal injury, death, equipment or 2/32 in. of tread depth remains in any property damage. major groove. Check at three places equally spaced around the tire. See the next illustration for recommended WARNING! measuring points for tread depth. Do not replace original equipment tires with load ratings less than the original tires. Doing so could lead to unintentional overloading of the tire, 5 which could cause a failure resulting in loss of vehicle control and an ac- cident. Failure to comply may result in personal injury, death, equipment or property damage. Steer Tire Points (left), Drive Tire Points (right)

5-134 Y53-1203-1D1 (02/14) TIRES AND WHEEL MAINTENANCE

Matching Tires require different sizes on front and rear Greenhouse Gas Certified Tires wheels. For safety, always use the Be sure to buy matched tires for recommended size and type of tires. Replacing a tire that is greenhouse your vehicle, especially on the rear gas certified. axles. Mismatched tires can cause stress between axles and cause the NOTE temperature of the axle lubricant to get The tires installed on this vehicle too hot. Matched tires will help the at the factory as original equipment driveline last longer and will give you are certified for Greenhouse Gas better tire mileage. and Fuel Efficiency regulations. Re- placement tires must be of equal or WARNING! lower rolling resistance level (TRRL Do not mismatch tires, it can be dan- or Crr). Consult with your tire sup- gerous. Never mix tires of differ- plier(s) for appropriate replacement ent design such as steel belted ra- tires. dials and bias ply tires, etc. Mixing tire types and sizes will adversely af- Verify if your vehicle is equipped with 5 fect the road-holding ability of both Greenhouse Gas certified tires by types of tires and can lead to loss checking the Vehicle Emission Control of vehicle control. Failure to comply label on the driver's side door frame. If may result in personal injury, death, these tires were installed at the factory, equipment or property damage. Lower Rolling Resistance codes (LRR) identify which tires are certified. Make sure, too, that you use the right size tires on each wheel. Some trucks

(02/14) Y53-1203-1D1 5-135 TIRES AND WHEEL MAINTENANCE

Maintaining a greenhouse gas certified tire.

In order to limit the rolling resistance of the tires and optimize fuel economy, the maintenance procedures specified by the tire manufacture must be followed.

For warranty information, See Original Equipment Tires on page 6-10.

5

5-136 Y53-1203-1D1 (02/14) TRANSMISSION AND CLUTCH MAINTENANCE

TRANSMISSION All Transmissions Oil Change AND CLUTCH Initial Change: drain and replace Change fluid according to change MAINTENANCE according to Table 6, Recommended procedures specified in the Lubrication Intervals on page 5-11; for Transmission Service Manual. Introduction some transmissions this may not be Use the recommended types of oil required. as specified in the Operation and Follow the procedures below to Service Manual (included with vehicle). ensure parts are properly lubricated: Select from the appropriate lubricant for varying ambient (outside air) • Maintain oil level, check it regularly temperatures. • Change oil regularly • Use the correct grade and type of oil • Buy oil from a reputable dealer 5

(02/14) Y53-1203-1D1 5-137 TRANSMISSION AND CLUTCH MAINTENANCE

Transmission Lubricants Manual Transmission Service Intervals

CAUTION Manual transmissions are designed so For recommended types and brands that the internal parts operate in a bath of all lubricants, see the transmission When adding oil, types and brands of oil circulated by the motion of gears manufacturer's Service Manual and of oil should not be intermixed be- and shafts. Table 6, Recommended Lubrication cause of possible incompatibility, Intervals on page 5-11. which could decrease the effec- tiveness of the lubrication or cause component failure.

5

5-138 Y53-1203-1D1 (02/14) TRANSMISSION AND CLUTCH MAINTENANCE

Standard Transmission Oil Level Automatic Transmissions Automatic Transmission Oil Level Service Intervals NOTE NOTE Check daily with engine idling. See The vehicle must be parked on level The vehicle must be parked on level Table 6, Recommended Lubrication ground. See the Transmission Op- ground. Intervals on page 5-11 for service erator's Manual for information on intervals. checking the transmission oil level. See the Transmission Operator's Manual for information on checking the transmission oil level.

5

(02/14) Y53-1203-1D1 5-139 TRANSMISSION AND CLUTCH MAINTENANCE

Clutch System Introduction When all free pedal and free travel are Clutch Linkage gone, the clutch requires adjustment. Free pedal is the distance the clutch Have your authorized Kenworth pedal moves by applying only slight The clutch is adjusted by turning an Dealer service the clutch according pressure. During free pedal the adjustment ring that is built into the to the clutch manufacturer's service release yoke in the transmission clutch. When the ring is turned, the guidelines. moves until its bearing pads contact release bearing moves back toward the release bearing. This movement of the transmission, restoring free pedal • The Kenworth is equipped with a the release yoke is called free travel. and clutch free travel. Under normal rod and lever mechanical clutch Thus, free pedal and free travel are clutch wear this is the only adjustment linkage. Lubricate each pivot point directly related to each other. needed. Do not attempt to change any on the clutch linkage. other component. As the clutch pedal is depressed further, with harder pressure, the release yoke moves the release bearing away from the engine. This causes the clutch plate to release from 5 the driven disks in the clutch. This is called release travel. And finally, as the pedal is pushed to the last 1/2 to 1 inch of travel, the release bearing contacts and engages the clutch brake. This is called clutch brake squeeze. When the clutch wears, the release bearing gradually moves toward the engine, decreasing free pedal and free travel.

5-140 Y53-1203-1D1 (02/14) TRANSMISSION AND CLUTCH MAINTENANCE

Clutch Adjustment - Normal External Linkage Adjustment Wear 1. Adjust clutch to clutch manufacturer's specification. See the clutch manufacturer's Service Manual for the proper adjustment 2. Verify 1/8 in. free travel (distance procedures. the release yoke moves before the release yoke bearing pads contact NOTE the release bearing). This procedure is all that is required 3. Verify free pedal of 1.75 in. (44 for normal clutch adjustment. Ad- mm ± 6 mm). justment of any other components is not required.

5

(02/14) Y53-1203-1D1 5-141

INFORMATION

CONSUMER INFORMATION AND VEHICLE IDENTIFICATION Introduction ...... 6-3 Reporting Safety Defects ...... 6-3 Vehicle Identification ...... 6-4 Certification Labels ...... 6-5 Component Identification...... 6-8 How to Order Parts ...... 6-9 VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY Original Equipment Tires...... 6-10 Greenhouse Gas (GHG) Components Other Than Tires ...... 6-11 Your Warranty Rights and Obligations ...... 6-11 Manufacturer's Warranty Coverage ...... 6-12 Owner's Warranty Responsibilities ...... 6-12 6 Replacement Parts ...... 6-13 PACCAR Responsibilities ...... 6-14 Warranty Limitations...... 6-14

(02/14) Y53-1203-1D1 6-1

CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

CONSUMER Reporting Safety Defects Administrator, NHTSA, 400 Seventh INFORMATION Street, S.W., Washington, D.C. 20590. United States You can also get other information AND VEHICLE about auto safety from the Hotline. IDENTIFICATION If you believe that your vehicle has a defect which could cause a crash Canada or could cause injury or death, you Introduction should immediately inform the National Canadian customers who wish to report Highway Traffic Safety Administration a safety-related defect to Transport WARNING! (NHTSA) in addition to notifying Canada, Defect Investigations and This vehicle contains material Kenworth Truck Company. Recalls, may telephone the toll free known by the State of California to hotline 1-800-333-0510, or contact cause cancer and/or birth defects If NHTSA receives similar complaints, Transport Canada by mail at: Transport or other reproductive harm. This it may open an investigation, and Canada, ASFAD, Place de Ville Tower warning requirement is mandated if it finds that a safety defect exists C, 330 Sparks Street, Ottawa ON K1A by California law (Proposition 65) in a group of vehicles, it may order 0N5. and does not result from any change a recall and remedy campaign. in the manner in which Kenworth However, NHTSA cannot get involved For additional road safety information, trucks are manufactured. in individual problems between you, please visit the Road Safety website your Kenworth Dealer, and Kenworth at: www.tc.gc.ca/roadsafety Truck Company. 6 To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (366-0123 in Washington, D.C.) or write to:

(02/14) Y53-1203-1D1 6-3 CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Vehicle Identification Assembly Plant Code Table 22 Model Year Designations The 17-digit Vehicle Identification F = KENMEX CODE YEAR Number (VIN) is used to register 9 2009 your vehicle for warranty, license and A 2010 M = Ste. Therese insurance. B 2011 C 2012 R = Renton D 2013 E 2014 J = Chillicothe F 2015 G 2016 1 Manufacturer Identifier H 2017 2 Vehicle Attributes I 2018 3 Reserved Space 4 Model Year 5 Assembly Plant (Chassis Number) 6 Serial Number (Chassis Number)

6

6-4 Y53-1203-1D1 (02/14) CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

VIN Location Chassis Number Certification Labels

The full, 17-digit VIN is exclusively The Chassis Number refers to the Vehicle information and specifications located on the Weight Rating Data last seven characters of the VIN. for your Kenworth are documented on Label. The label is located on the This number will allow your Kenworth labels. As noted below, each label driver's side door edge or on the Dealer to identify your vehicle. You will contains specific information pertaining driver's side door frame. be asked for this number when you to vehicle capacities and specifications bring it in for service. that you should be aware of.

Chassis Number Locations • Right frame rail, top flange, about 3 ft. from the front end • Cab back, left-hand rear panel, lower edge • Tire, Rim, and Weight Rating Data label (truck) • Components and Weights label • Noise Emission label 6 • Paint Identification label

(02/14) Y53-1203-1D1 6-5 CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Components and Weights Label Tire, Rim and Weight Rating Data Label WARNING! The Components and Chassis Weight Do not exceed the specified load rat- Label is located on either the driver's The Tire, Rim and Weight Rating ing. Overloading can result in loss side door edge or on the driver's Data Label is located on the driver's of vehicle control and personal in- side door frame. It includes chassis side door edge or on the driver's side jury, either by causing component number, chassis weight and gross door frame. It contains the following failures or by affecting vehicle han- weight, plus model information for the information: dling. Exceeding load ratings can vehicle, engine, transmission, and also shorten the service life of the axles. • GVWR - Gross Vehicle Weight Rating vehicle. Failure to comply may re- sult in personal injury, death, equip- • GAWR FRONT, INTERMEDIATE ment or property damage. and REAR - Gross Axle Weight Ratings for Front, Intermediate The components of your vehicle and Rear Axle are designed to provide satisfactory service if the vehicle is not loaded • TIRE/RIM SIZES AND INFLATION in excess of either the gross vehicle PRESSURES - Tire/Rim Sizes weight rating (GVWR), or the maximum and Cold Pressure Minimums front and rear gross axle weight ratings • VIN including CHASSIS NUMBER (GAWRs). 6

6-6 Y53-1203-1D1 (02/14) CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Noise Emission Label Paint Identification Label NOTE GVW is the TOTAL SCALE WEIGHT The Noise Emission Label is located The Paint Identification Label contains the vehicle is designed to carry. This in the driver's side door frame. It the paint colors used by the factory includes the weight of the empty ve- contains information regarding U.S. to paint your vehicle. It lists frame, hicle, loading platform, occupants, noise emission regulations, chassis wheels, cab interior and exterior fuel, and any load. number, and date of manufacture. colors. This label is located inside the glove box.

6

(02/14) Y53-1203-1D1 6-7 CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

Federal Safety Standard Component Identification 1. Axle Specification Number, usually Certification Label stamped on the right rear side of Each of the major components on the axle housing. This number The NHTSA regulations require a label your vehicle has an identification label identifies the complete axle. certifying compliance with Federal or tag. For easy reference, record Safety Standards, for United States component numbers such as, model, 2. Axle Housing Number Tag, usually and U.S. Territories, be affixed to serial, and assembly number. located on the left forward side each motor vehicle and prescribe of the housing arm. This tag where such label may be located. Engine: For further information, identifies the axle housing. This certification label, which indicates please refer to the Engine Operation the date of manufacture and other and Maintenance Manual. 3. Axle Differential Carrier pertinent information, is located on Identification, usually located the driver's side door edge or on the Transmission: For both manual on the top side of the differential driver's side door frame. and automatic transmissions, the carrier. The following information identification number is stamped on a is either stamped, or marked with a tag affixed to the right rear side of the metal tag: Model No., Production transmission case. Assembly No., Serial No., Gear Ratio, and Part Number. Clutch: Enclosed in clutch housing. Location depends on manufacturer. 6 Steer Axle: The front axle serial number is stamped on a plate located on the center of the axle beam.

Drive Axles: The drive axle numbering system includes three labels or stamps:

6-8 Y53-1203-1D1 (02/14) CONSUMER INFORMATION AND VEHICLE IDENTIFICATION

How to Order Parts

Replacement parts may be obtained from an authorized dealership.

When you order, it is IMPORTANT that you have the following information ready: • Your name and address. • Serial number of the truck. • The name of the part you need. • The name and number of the component for which the part is required. • The quantity of parts you need. • How you want your order shipped. 6

(02/14) Y53-1203-1D1 6-9 VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY

VEHICLE EMISSIONS LIMITATIONS LISTED ABOVE. This OR LOST PROFITS; VEHICLE LIMITED EXPRESS Vehicle Emissions Limited Express DOWNTIME; COMMUNICATION Warranty relating to original equipment EXPENSES; LODGING AND/OR WARRANTY tires begins on the date of delivery of MEAL EXPENSES; FINES; the vehicle to the first purchaser or APPLICABLE TAXES OR BUSINESS Original Equipment Tires lessee and accrued time and mileage is COSTS OR LOSSES; ATTORNEY’S calculated when the vehicle is brought FEES; AND ANY LIABILITY YOU MAY PACCAR Inc warrants the tires in for correction of the Warrantable HAVE IN RESPECT TO ANY OTHER installed as original equipment on Emissions Failures relating to the PERSON OR ENTITY RELATING this vehicle only against defects in original equipment tires. TO WARRANTABLE EMISSIONS materials and workmanship which FAILURES. cause the vehicle to fail to comply PACCAR MAKES NO OTHER with applicable U.S. and Canadian VEHICLE EMISSIONS WARRANTIES This Vehicle Emissions Limited greenhouse gas emission limits RELATING TO THE ORIGINAL Express Warranty relating to (“Warrantable Emissions Failures”). EQUIPMENT TIRES, EXPRESS original equipment tires is limited This vehicle emissions limited express OR IMPLIED. WHERE PERMITTED to emissions compliance only. warranty relating to original equipment BY LAW, PACCAR EXPRESSLY The tires are separately warranted tires is valid for two (2) years or 24,000 DISCLAIMS ANY WARRANTY OF by their manufacturer for defects in miles, whichever occurs first. MERCHANTABILITY OR FITNESS materials and workmanship other than FOR A PARTICULAR PURPOSE those which cause non-compliance YOUR SOLE AND EXCLUSIVE RELATING TO VEHICLE EMISSIONS. with U.S. and Canadian GHG 6 REMEDY AGAINST PACCAR Inc PACCAR AND THE SELLING regulations, subject to limitations and IS LIMITED TO THE REPAIR OR DEALER SHALL NOT BE LIABLE FOR conditions contained within the tire REPLACEMENT OF ORIGINAL INCIDENTAL OR CONSEQUENTIAL manufacturer’s warranty agreement. EQUIPMENT TIRES, SUBJECT TO DAMAGES INCLUDING, BUT NOT You are responsible for the safe PACCAR’S TIME AND MILEAGE LIMITED TO: LOSS OF INCOME operation and maintenance of the

6-10 Y53-1203-1D1 (02/14) VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY vehicle and its tires. PACCAR does Greenhouse Gas (GHG) Your Warranty Rights and not warrant wear and tear of the tires. Components Other Than Obligations Tires This vehicle is warranted for This GHG vehicle Warranty applies to components that directly impact the the vehicle (hereafter, vehicle) certified manufacturers greenhouse gas (GHG) with the US Environmental Protection certification with the US Environmental Agency. Protection Agency. PACCAR must warrant these components for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of the vehicle.

If a GHG-related part on your vehicle is found to have a defect in material or assembly, the part will be repaired or replaced by PACCAR.

6

(02/14) Y53-1203-1D1 6-11 VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY

Manufacturer's Warranty Owner's Warranty programming) or using non-Original Coverage Responsibilities Equipment replacement parts.

This warranty coverage is provided for The vehicle owner is responsible for If there are any questions five years or 100,000 miles (160,000) performing required maintenance that regarding these warranty rights km, whichever first occurs, from the is listed in your engine and vehicle and responsibilities, please contact date of delivery of the vehicle to Operator’s Manuals. The owner is the vehicle OEM manufacturer at the the first purchaser or first lessee. responsible for presenting the vehicle customer center telephone number Where a Warrantable Condition exists, to a service location as soon as a provided with the vehicle operating PACCAR will diagnose and repair problem exists. Any warranty repairs instructions. the vehicle, parts and labor included, should be completed in a reasonable at no cost to the first purchaser or amount of time. Prior to the expiration of the applicable first lessee and each subsequent warranty, Owner must give notice of purchaser or lessee. This warranty Retain all receipts covering any warranted failure to an authorized does not override any extended maintenance on this equipment. PACCAR dealer and deliver the vehicle warranty purchased to cover specific PACCAR cannot deny warranty solely to such facility for repair. vehicle components. for the lack of receipts or for the failure to ensure the performance of all Owner is responsible for incidental scheduled maintenance. costs such as: communication expenses, meals, lodging incurred by PACCAR may deny warranty coverage Owner or employees of Owner as a 6 if a vehicle component has failed due to result of a Warrantable Condition. abuse, neglect, improper maintenance, unapproved modifications (both Owner is responsible for downtime physical components and computer expenses, cargo damage, fines, all applicable taxes, all business costs,

6-12 Y53-1203-1D1 (02/14) VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY and other losses resulting from a Replacement Parts the emission control parts performed Warrantable Condition. by a facility other than an authorized PACCAR recommends that any PACCAR dealer and may elect to Owner is responsible for maintaining service parts used for maintenance, use parts other than new or genuine all emissions related engine and repair or replacement of GHG approved rebuilt parts and assemblies vehicle computer program settings components be new or genuine for such maintenance, replacement in accordance with manufacturer approved rebuilt parts and assemblies. or repair; however, the cost of such specifications. This responsibility The use of non-genuine engine or service or parts and subsequent includes GHG specific settings vehicle replacement parts that are not failures resulting from such service that may not be altered before the equivalent to the PACCAR engine or or parts may not be fully warranted GHG-related expiration mileage has OEM vehicle manufacturer’s original if the manufacturer determines that been reached for each system. part specification as built from the the replacement part is not of similar factory may impair the engine and material and function as the OEM part Owner is responsible for maintaining vehicle emissions control system from assembled to the vehicle at the factory. all physical parts related to working or functioning effectively, and GHG-regulations in the as-built may jeopardize your GHG warranty configuration and in proper working coverage. order for the full regulatory useful life of 435,000 miles for Class 8 vehicles, In addition, genuine vehicle or engine 185,000 miles for Class 6-7, and parts must be replaced with the same 110,000 for Class 5. material and function as the part assembled on the vehicle from the 6 factory.

The owner may elect to have maintenance, replacement or repair of

(02/14) Y53-1203-1D1 6-13 VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY

PACCAR Responsibilities Warranty Limitations adequate coolants or lubricants; overfueling; overspeeding; lack of The warranty coverage begins when Sole and exclusive remedy against maintenance of cooling, lubricating the vehicle is delivered to the first PACCAR and the Selling Dealer or intake systems; improper storage, purchaser or first lessee. Repairs arising from the purchase and use starting, warm-up, run-in or shutdown and service will be performed by any of this vehicle is limited to the repair practices; unauthorized modifications authorized PACCAR dealer using or replacement of “warrantable to the vehicle and its components. new or genuine approved rebuilt parts failures”, for replacement parts that PACCAR is also not responsible for and assemblies PACCAR will utilize are similar in material and function failures caused by incorrect oil, fuel replacement parts that are selected to OEM specifications and subject to or diesel exhaust fluid or by water, and installed to support the GHG PACCAR’s time, mileage, and hour dirt or other contaminants in the fuel, compliance certification. PACCAR limitations of the greenhouse gas oil or diesel exhaust fluid. Failure will repair parts found by PACCAR to warranty. The maximum time, mileage of replacement parts used in repairs be defective without charge for parts and hour limitations of the warranty due to the above non-warrantable or labor (including diagnosis which begin with the Date of Delivery to the conditions is not warrantable. results in determination that there has first purchaser or first lessee. The been a failure of a warranted part). accrued time, mileage, or hours is This warranty is void if the vehicle is calculated when the vehicle is brought altered with parts that do not meet the in for correction of warrantable failures. material and functional specifications as manufactured from the factory. PACCAR is not responsible for Any alterations to vehicle or engine 6 failures or damage resulting from what computer settings will void GHG PACCAR determines to be abuse, warranty and potentially cause the neglect or uncontrollable acts of nature, vehicle to become non-compliant including, but not limited to: damage with the GHG regulation of the EPA due to accident; operation without Clean Air Act. Any alterations to

6-14 Y53-1203-1D1 (02/14) VEHICLE EMISSIONS LIMITED EXPRESS WARRANTY

GHG specific settings prior to the WARRANTIES MADE BY PACCAR IN VEHICLES OR PROPERTY, GHG related expiration mileage for REGARD TO THIS VEHICLE. ATTACHMENTS, TRAILERS AND each system will void GHG warranty CARGO; LOSS OR DAMAGE and potentially cause the vehicle THIS LIMITED GHG WARRANTY TO PERSONAL CONTENTS; to become non-compliant with the IS THE SOLE WARRANTY MADE COMMUNICATION EXPENSES; GHG regulation of the EPA Clean Air BY PACCAR AND THE SELLING LODGING AND/OR MEAL Act. This warranty is void if certain DEALER. EXCEPT FOR THE ABOVE EXPENSES; FINES; APPLICABLE GHG components are not properly LIMITED WARRANTY, PACCAR AND TAXES OR BUSINESS COSTS OR maintained and thus cannot perform to THE SELLING DEALER MAKE NO LOSSES; ATTORNEYS’ FEES; AND their designed capability. OTHER WARRANTIES, EXPRESS ANY LIABILITY YOU MAY HAVE IN OR IMPLIED. PACCAR AND THE RESPECT TO ANY OTHER PERSON PACCAR is not responsible for failures SELLING DEALER EXPRESSLY OR ENTITY. resulting from improper repair or the DISCLAIM ANY WARRANTY OF use of parts which are not genuine MERCHANTABILITY OR WARRANTY approved parts. OF FITNESS FOR A PARTICULAR PURPOSE. PACCAR is not responsible for the material and labor costs of emission PACCAR AND THE SELLING control parts and assemblies replaced DEALER SHALL NOT BE LIABLE FOR during Scheduled Maintenance of INCIDENTAL OR CONSEQUENTIAL the engine as specified in PACCAR DAMAGES INCLUDING, BUT NOT Operator’s Manuals. LIMITED TO: LOSS OF INCOME 6 OR LOST PROFITS; ENGINE OR THIS WARRANTY, TOGETHER VEHICLE DOWNTIME; THIRD PARTY WITH THE EXPRESS COMMERCIAL DAMAGE, INCLUDING DAMAGE WARRANTIES ARE THE SOLE OR LOSS TO OTHER ENGINES,

(02/14) Y53-1203-1D1 6-15

Index Index

5th wheel Air cleaner restriction trailer air brake pressure...... 3-70 fifth wheel lubrication...... 5-31 indicator/gauge ...... 5-43 trailer air tank pressure ...... 3-70 maintenance ...... 5-96 Air compressor ...... 5-38 Air intake system...... 5-42 Air dryer...... 4-17, 5-40 Air system A Air dryer (Bendix AD-IS series)... 5-41 air cleaner...... 5-43 Air dryer overhaul ...... 5-41 air compressor...... 5-38 About this Manual...... 1-3 Air filter restriction pressure air dryer ...... 5-40 Accessories gauge ...... 3-56 air gauges and air leaks ...... 5-37 cigarette lighter ...... 3-6 Air gauges air intake system ...... 5-42 radio ...... 3-6 air filter restriction pressure .... 3-56 draining air tanks ...... 5-36 Adding electrical options ...... 5-69 air pressure - air suspension air filter elements...... 5-43 Additional sources of information...1-9 bags #1 & #2 ...... 3-69 primary air pressure gauge..... 5-37 installed equipment - operator's air pressure #1 & #2 ...... 3-66 scheduled maintenance ...... 5-35 manuals...... 1-9 brake application air pressure.. 3-58 scheduled maintenance table .. 5-35 other sources ...... 1-9 brakesaver application air secondary air pressure gauge . 5-37 Adjustable auxiliary axles ...... 4-58 pressure...... 3-59 turbocharger ...... 5-43 liftable/non-steerable pusher pusher axle(s) air pressure ..... 3-57 Air system maintenance...... 5-34 calibration...... 4-61 tag axle air pressure ...... 3-58 Air tanks ...... 5-36 liftable/steerable calibration .... 4-61 tractor air brake pressure...... 3-70 Alarms ...... 3-77 tag axle calibration ...... 4-61 tractor air brake pressure - engine oil pressure ...... 3-25 Adjustments ...... 5-46 primary/secondary ...... 3-67 fifth wheel slide ...... 3-26 7 Air cleaner and filter ...... 5-43

(02/14) Y53-1203-1D1 Index-1 Index

low air warning alarm - primary 3-24 low voltage disconnect...... 3-79 B low air warning alarm - no-idle shutdown ...... 3-78 Batteries secondary...... 3-24 not available alert ...... 3-84 battery access ...... 5-74 low coolant level...... 3-26 over-crank protection ...... 3-79 battery care ...... 5-77 park brake...... 3-25 park brake on while moving .... 3-78 battery charging ...... 5-77 power on self test (POST) ...... 3-26 SCR/DEF ...... 3-79 jump starting vehicles...... 2-9 stop engine alarm ...... 3-24 stationary object alert ...... 3-83 remote keyless entry (RKE) Alert screens trailer detect...... 3-79 system ...... 1-15 alarm clock active ...... 3-80 water in fuel (WIF)...... 3-80 removing and installing circuit failure ...... 3-80 Wingman® ACB alert screens . 3-82 batteries...... 5-76 cruise control ...... 3-80 Ammeter ...... 3-56 Bendix Wingman® Active Cruise with cruise control rationality ...... 3-78 Anti-lock brakes ...... 4-29 Braking (ACB)...... 3-73 DEF...... 3-79 trailer ABS ...... 4-32 Brake air pressure gauge ...... 3-58 disabled alert ...... 3-84 trailer ABS (without PLC) ...... 4-33 Brake gauges engine over-speed shutdown low air wheel spin control ...... 4-30 brake pedal or trailer brake hand warning...... 3-81 Appliances...... 3-11 valve pressure...... 3-58 engine protection shutdown Audible alerts...... 3-21 brakesaver application air timer ...... 3-81 Automatic transmissions pressure...... 3-59 fault alert ...... 3-83 auxiliary transmission ...... 4-72 tractor air brake pressure...... 3-70 front drive axle speed warning . 3-81 oil level ...... 5-139 tractor primary/secondary air brake hydrocarbon burn ...... 3-80 operation ...... 4-71 pressure...... 3-67 impact alert ...... 3-83 service intervals ...... 5-139 trailer air brake pressure...... 3-70 lamp faults ...... 3-78 Auxiliary axles...... 4-58 trailer air tank pressure ...... 3-70 level 1 following distance alert . 3-83 Axle Brake system...... 4-16 7 level 2 following distance alert . 3-82 Steerable Drive Axle ...... 4-72 air supply system...... 4-17 level 3 following distance alert . 3-82 anti-lock brakes...... 4-29

Index-2 Y53-1203-1D1 (02/14) Index

anti-lock braking system (ABS) 5-49 tractor/trailer air supply valve... 4-23 Chains ...... 2-18 automatic (slack) adjusters ..... 5-47 trailer brake hand valve...... 4-34 Checks and adjustments ...... 5-46 brake adjuster stroke...... 5-48 trailer charge...... 4-26 Cigarette lighter ...... 3-6 brake and slack adjuster trailer emergency brake Clock lubrication...... 5-46 application ...... 4-25 Analog clock - dash ...... 3-7 brake component descriptions . 4-37 trailer parking brake...... 4-25 clock display ...... 3-90 brake linings ...... 5-46 treadle valve - front circuit ...... 4-18 clock settings menu ...... 3-91 cam-actuated component treadle valve - rear circuit...... 4-19 Digital clock - sleeper ...... 3-7 lubrication...... 5-45 wet brake components...... 4-18 lamp test ...... 3-94 emergency braking...... 4-28 Brake system maintenance ...... 5-44 Quick operating instructions...... 3-7 engine brake...... 4-37 Brakesaver air pressure gauge... 3-59 to set alarm time...... 3-92 engine retarders ...... 4-35 to set clock display ...... 3-91 european air system parking to set clock home/local time .... 3-91 brake ...... 4-22 C to turn alarm ON/OFF...... 3-92 exhaust brake...... 4-36 Cab and frame access ...... 1-10 Clutch front brakes ...... 4-18 Cab storage ...... 3-10 clutch adjustment...... 4-70 modulating valve ...... 4-18 glove box...... 3-10 clutch brake...... 4-66 overheated brakes ...... 4-28 interior compartments...... 3-10 clutch linkage ...... 5-140 parking brake system ...... 4-19 Certification labels clutch linkage adjustment...... 5-141 parking brake valve ...... 4-19 components and weights label...6-6 clutch linkage lubrication releasing combination of brakes 4-21 federal safety standard certification (non-ESI)...... 5-31 releasing trailer brakes...... 4-21 label ...... 6-8 clutch pedal shaft lubrication ... 5-31 releasing truck or tractor parking noise emission label ...... 6-7 clutch release bearing brakes ...... 4-20 part identification label ...... 6-7 lubrication...... 5-32 safety - tractor/trailer ...... 4-27 tire, rim data and weight rating clutch ring adjustment...... 5-140 7 system park tractor...... 4-25 datalabel ...... 6-6 clutch travel ...... 4-66

(02/14) Y53-1203-1D1 Index-3 Index

double clutching ...... 4-69 Differential lock (driver controlled) 4-55 remote keyless entry (RKE) identification ...... 6-8 Displays/menu screens system ...... 1-14 introduction ...... 5-140 clock display ...... 3-90 Drive axle(s) oil temperature riding the clutch...... 4-69 clock home/local time ...... 3-91 gauge ...... 3-57 Component identification reference 6-8 clock settings menu ...... 3-91 Drive axles Consumer information...... 6-3 diagnostic display ...... 3-89 identification ...... 6-8 how to order parts ...... 6-9 fuel economy ...... 3-87 Driver controlled main differential reporting safety defects...... 6-3 ignition timer ...... 3-87 lock...... 4-55 Controls...... 3-6 lamp test ...... 3-94 Driver's indicators...... 3-27 left hand menu bar ...... 3-86 check list ...... 1-35 Cooling system multi-function display...... 3-84 daily checks...... 1-36 adding coolant ...... 5-63 multi-function menu items ...... 3-85 weekly checks ...... 1-39 additives...... 5-64 outside air temperature display 3-55 Driving tips...... 4-5 coolant change and refilling .... 5-65 RPM detail ...... 3-87 coasting ...... 4-5 engine (block) heater ...... 5-66 speed control management descending a grade ...... 4-6 fan ...... 5-92 display...... 3-90 economy ...... 4-6 fan clutch...... 5-92 to set language ...... 3-94 engine RPM...... 4-6 radiator cap ...... 5-66 to set standard or metric units.. 3-94 using the tachometer...... 4-7 topping up...... 5-61 transmission display ...... 3-90 Dual range (two-speed) rear axle 4-56 Cruise control ...... 4-11 trip information...... 3-88 trip meter ...... 3-53 truck information...... 3-89 E D Door lock ...... 1-14 Electrical and alternator Daily checks ...... 1-36 key fob synchronization...1-16, 5-80 precautions...... 5-79 7 Data recorder...... 1-7 key fob troubleshooting ...... 5-80 Electrical gauges Daytime running light (DRL) .....3-106 ammeter...... 3-56

Index-4 Y53-1203-1D1 (02/14) Index

voltmeter ...... 3-72 pipe and hose clamp torque Exhaust temperature gauge Electrical system values ...... 5-89 engine exhaust gas temperature adding electrical options ...... 5-69 Engine (block) heater...... 5-66 (pyrometer) ...... 3-63 batteries ...... 5-74 Engine block heater ...... 4-42 battery care ...... 5-77 Engine lubrication...... 5-87 battery charging ...... 5-77 Engine maintenance...... 5-86 F electrical and alternator Engine Mounting ...... 5-93 Fan clutch ...... 5-92 precautions ...... 5-79 Engine operation...... 4-40 Fifth wheel ...... 4-14 fuses, circuit breakers, and cruise control ...... 4-47 air-controlled sliding...... 4-14 relays...... 5-67 engine block heater ...... 4-42 fifth wheel lubrication...... 5-31 jump starting vehicles...... 2-9 engine control display...... 4-50 jaw lock...... 4-14 removing and installing engine fan control ...... 4-49 maintenance ...... 5-96 batteries...... 5-76 engine shutdown system ...... 4-50 Frame fastener torque Electrical system maintenance ... 5-67 shut-down ...... 4-73 requirements ...... 5-96 Emergency starting procedure - cold Freeing the vehicle from sand, mud, battery connections ...... 2-11 weather ...... 4-42 snow and ice ...... 2-17–2-18 emergency equipment kit...... 1-35 starting procedure - normal Front axle and suspension jump starting vehicles...... 2-9 temperature...... 4-41 maintenance ...... 5-98 Engine Engine retarders ...... 4-35 Fuel economy drive belts ...... 5-92 Engine temperature gauge driving habits...... 4-8 engine fan...... 5-92 engine (overheating) ...... 3-60 fuel consumption ...... 4-8 engine mounting...... 5-93 Engine warm-up...... 4-43 Fuel filters exhaust system...... 5-93 Environmental Protection ...... 1-6 draining...... 5-91 fuel filters...... 5-90 Ether metering equipment ...... 4-46 installing...... 5-90 identification ...... 6-8 European Air System Parking Fuel gauges 7 lubrication ...... 5-87 Brake ...... 4-22 fuel filter restriction pressure ... 3-64

(02/14) Y53-1203-1D1 Index-5 Index

fuel tank(s) level ...... 3-65 fuel level (primary and air pressure - primary ...... 3-67 Fuel shut-off valve ...... 4-75 secondary)...... 3-51 air pressure - secondary...... 3-67 Fuel specification ...... 4-75 general air pressure #1 & #2 ... 3-51 ammeter...... 3-56 Fuses, circuit breakers and relays 5-67 general oil temperature ...... 3-51 auxiliary transmission oil main transmission oil temperature...... 3-71 temperature...... 3-52 brake application air pressure.. 3-58 G manifold boost pressure ...... 3-51 brakesaver application air Gauge panel primary and secondary air pressure...... 3-59 A - Panel ...... 3-21 pressure...... 3-52 brakesaver oil temperature ..... 3-59 Gauge symbols pusher axles #1, #2 & #3 air diesel exhaust fluid (DEF) ...... 3-59 air brake application pressure.. 3-50 pressure...... 3-50 drive axle(s) oil temperature.... 3-57 air filter restriction pressure .... 3-50 suspension load air pressure, #1 & engine coolant (water) ammeter...... 3-50 #2...... 3-52 temperature...... 3-60 auxiliary transmission oil symbols table ...... 3-49–3-50 engine hour meter...... 3-55 temperature...... 3-52 tag axle air pressure ...... 3-50 engine oil pressure ...... 3-62 brakesaver air brake application tractor brake application air engine oil temperature ...... 3-63 pressure...... 3-50 pressure...... 3-52 engine pyrometer...... 3-63 brakesaver oil temperature ..... 3-51 trailer air tank pressure ...... 3-52 fuel filter restriction pressure ... 3-64 diesel exhaust fluid (DEF) ...... 3-51 trailer brake application air fuel tank(s) level ...... 3-65 drive axle(s) oil temperature.... 3-50 pressure...... 3-52 general air pressure #1 ...... 3-66 engine coolant temperature .... 3-51 transfer case oil temperature... 3-52 general air pressure #2 ...... 3-66 engine exhaust temperature transmission retarder oil general oil temperature ...... 3-66 (pyrometer) ...... 3-51 temperature...... 3-52 main transmission oil engine oil pressure ...... 3-51 voltmeter ...... 3-52 temperature...... 3-71 7 engine oil temperature ...... 3-51 Gauges manifold pressure (turbo boost) 3-67 fuel filter restriction pressure ... 3-51 air filter restriction pressure .... 3-56 odometer ...... 3-53

Index-6 Y53-1203-1D1 (02/14) Index

primary air pressure...... 5-37 Greenhouse Gas (GHG) Components defrost vents ...... 3-17 pusher axle(s) air pressure ..... 3-57 Other Than Tires...... 6-11 dehumidify ...... 3-18 secondary air pressure ...... 5-37 Greenhouse Gas Certification ...... 1-8 fan control dial ...... 3-17 speedometer...... 3-53 Greenhouse gas certified tires...5-135 floor and defrost vents ...... 3-17 suspension load air pressure GVWR - Gross Vehicle Weight floor vents ...... 3-17 #1...... 3-69 Rating...... 1-34 fresh air mode ...... 3-17 suspension load air pressure fresh air/recirculation switch.... 3-17 #2...... 3-69 heating ...... 3-18 tachometer ...... 4-7, 3-54 H precautions ...... 3-13 tag axle air pressure ...... 3-58 Headlamps recirculation switch ...... 3-17 tractor brake application air halogen/hid lamp servicing ..... 5-81 sleeper heater - A/C controls... 3-19 pressure...... 3-70 Headlamps with Wipers temperature control dial ...... 3-17 trailer air tank air pressure...... 3-70 to activate headlamps with what each control does ...... 3-17 trailer brake application air wipers ...... 3-93 windshield defog and defrost... 3-18 pressure...... 3-70 Headlight switch...... 3-107 Hood hold downs ...... 1-17 transfer case oil temperature... 3-71 Heater and air conditioner ...... 5-101 Hood tilting ...... 1-17 transmission retarder oil air conditioner...... 5-103 hood lock...... 1-18 temperature...... 3-72 heater ...... 5-102 How to order parts ...... 6-9 transmission temperature ...... 4-71 Heater and air conditioner voltmeter ...... 3-72 maintenance ...... 5-101 I GAWR - Gross Axle Weight Heating and air conditioning Rating...... 1-34 air flow control dial ...... 3-17 Idling the engine ...... 4-44 GCW - Gross Combination cab controls...... 3-16 Ignition key switch ...... 3-105 Weight ...... 1-34 cooling...... 3-18 Indicators ...... 3-27 Glove box...... 3-10 dash and floor vents ...... 3-17 Installed Equipment - Operator's 7 dash vents ...... 3-17 Manuals ...... 1-9

(02/14) Y53-1203-1D1 Index-7 Index

Instrument panel L front axle and suspension A - Panel ...... 3-21 lubrication...... 5-98 Lap/Shoulder belt ...... 1-22 alert screens ...... 3-78 heater ...... 5-102 Load distribution ...... 1-35 audible warning or alarm tone.. 3-77 inspection ...... 5-99 Low voltage disconnect (LVD) ...3-101 indicator light(s) ...... 3-77 introduction ...... 5-7 Lubricant specifications ...... 5-30 Multi-function message display 5-94 lubricant specifications...... 5-30 warning and information lubricant specifications table ... 5-31 screens...... 3-78 M maintenance schedule table Wingman® ACB alert screens . 3-82 key...... 5-18 Wingman® ACB warning tone . 3-82 Maintenance noise and emission control Instrumentation 5th wheel...... 5-96 standards ...... 5-104 A - Panel ...... 3-21 air conditioner...... 5-103 oil reservoir levels ...... 5-30 Interior compartments ...... 3-10 air system ...... 5-34 painted surfaces...... 5-51 anti-lock braking system (ABS) 5-49 pendleton® limited edition interior brake system ...... 5-44 cleaning instructions ...... 5-55 J chrome and aluminum surfaces 5-51 rear axle alignment...... 5-118 Jump starting vehicles...... 2-9 cleaning vinyl and upholstery .. 5-55 rear axle and suspension...... 5-113 driver's check list ...... 1-35 rear axle housing breather electrical system...... 5-67 vent...... 5-117 K emergency welding ...... 5-95 rear axle lubrication ...... 5-116 Keys engine ...... 5-86 rear suspension fasteners torque Remote Keyless Entry (RKE) .. 1-14 environmental protection ...... 5-8 table ...... 5-115 Kingpin lubrication ...... 5-98 exterior ...... 5-51 rear suspension U-bolt torque Komfort-Latch® Feature ...... 1-26 frame fastener torque table ...... 5-115 requirements ...... 5-96 recommended lubrication 7 frame fastener torque table..... 5-97 intervals ...... 5-11

Index-8 Y53-1203-1D1 (02/14) Index

safety precautions...... 5-7 Maintenance schedule and lubrication N safety restraint system - introduction ...... 5-10 Noise and emission control inspection ...... 5-57 Manual transmission...... 4-66 maintenance ...... 5-104 safety restraint system - inspection clutch adjustment...... 4-70 Noise control inspections ...... 5-106 guidelines ...... 5-58 clutch brake...... 4-68 air intake system ...... 5-106 spicer driveshaft lubrication cycle clutch travel ...... 4-68 blanket ...... 5-110 table ...... 5-15 double clutching ...... 4-69 diesel particulate filters ...... 5-108 spicer driveshaft lubrication interval release bearing wear...... 4-70 engine fan and shroud ...... 5-109 table ...... 5-14 riding the clutch...... 4-69 engine mounted noise stainless steel...... 5-52 shifting gears ...... 4-68 insulators...... 5-106 steering and driveline ...... 5-119 Manufacturer's Warranty exhaust system...... 5-107 tail pipe surface cleaning ...... 5-52 Coverage ...... 6-12 exhaust tail pipe ...... 5-109 tire and wheel...... 5-123 Mirrors ...... 3-124 hood insulation blanket ...... 5-110 transmission and clutch...... 5-137 mirror heat button ...... 3-126 inner fender shields and cab U-bolt torque...... 5-99 power mirror switch ...... 3-124 skirt ...... 5-111 U-bolt torque table ...... 5-100 Multi-function display ...... 3-72, 3-84 joints and clamps...... 5-107 vehicle cleaning ...... 5-53 Bendix Wingman® Active Cruise maintenance log...... 5-112 washing chassis ...... 5-55 with Braking (ACB)...... 3-73 mufflers and exhaust tail pipe .5-108 washing exterior ...... 5-54 display panel...... 3-85 piping ...... 5-108 wheel alignment ...... 5-99 left hand menu bar ...... 3-86 selective catalyst reduction windshield wiper/washer...... 5-60 left hand menu bar - menu items 3-87 (SCR) ...... 5-107 Maintenance and lubrication ...... 5-11 menu items ...... 3-85 shields and skirts ...... 5-111 Maintenance Procedures right hand status bar ...... 3-86 transmission or driveline...... 5-110 inspection of the engine oil level 5-88 vehicle configuration changes.. 3-75 topping up the engine oil ...... 5-89 Maintenance schedule ...... 5-17 7

(02/14) Y53-1203-1D1 Index-9 Index

O Pipe and hose clamp torque fuel specification...... 4-75 values...... 5-89 Remote Keyless Entry (RKE) Oil gauges Pressure gauges batteries ...... 1-15 auxiliary transmission oil engine oil pressure ...... 3-62 key fob operation ...... 1-14 temperature...... 3-71 manifold pressure (turbo boost) 3-67 key fob synchronization...... 1-16 brakesaver oil temperature ..... 3-59 Preventive maintenance...... 5-10 troubleshooting ...... 5-80 drive axle(s) oil temperature.... 3-57 Pusher axle(s) air pressure gauge 3-57 Repairs...... 1-7 engine oil pressure ...... 3-62 Replacement Parts ...... 6-13 engine oil temperature ...... 3-63 general oil temperature ...... 3-66 R main transmission oil S temperature...... 3-71 Rear axle - dual range transfer case oil temperature... 3-71 (two-speed)...... 4-56 Safe vehicle operation...... 1-33 transmission retarder oil Rear axle and suspension Safety temperature...... 3-72 maintenance ...... 5-113 about this manual ...... 1-3 Oil pan heater ...... 4-42 rear suspension fasteners ..... 5-114 air suspension height/air Operating the transmission ...... 4-65 visual inspection...... 5-114 pressure...... 4-12 cold weather warm-up ...... 4-65 Rear/Drive axle...... 4-52 cab and frame access ...... 1-10 Original Equipment Tires ...... 6-10 inter-axle differential lock ...... 4-52 cruise control ...... 4-11 Overheating engine...... 3-60 inter-axle differential lock - deflated air springs ...... 4-13 Owner's Warranty Coverage...... 6-12 locking...... 4-54 driver's check list ...... 1-35 inter-axle differential lock - emergency equipment kit...... 1-35 unlocking...... 4-54 introduction ...... 1-3 P Recommended lubrication safe operation and driving ...... 4-9 PACCAR Responsibilities ...... 6-14 intervals...... 5-11 safe vehicle operation...... 1-33 7 Painting ...... 5-96 Recovery ...... 2-12 safety alerts...... 1-3 Parking brake system ...... 4-19 Refueling ...... 4-75 suspension air pressure gauge 4-12

Index-10 Y53-1203-1D1 (02/14) Index

vehicle loading...... 1-34 Seats and restraints ...... 1-20 fluid level and refill ...... 5-120 vehicle safety ...... 1-5 Shut-down steering driveline ...... 5-121 Safety alerts ...... 1-3 before stopping the engine ..... 4-74 Steering column...... 3-112 Safety restraint belts...... 1-21 final stopping procedures...... 4-73 adjustable tilt and telescoping. 3-117 belt damage and repair ...... 1-27 fuel specification...... 4-75 trailer brake hand valve...... 3-116 during pregnancy...... 1-27 introduction ...... 4-73 turn signal/high beam switch .. 3-112 inspection ...... 5-57 location of fuel shut-off valves.. 4-75 Suspension lubrication ...... 5-98 proper safety belt adjustment .. 1-22 refueling ...... 4-75 Switches safety restraint tips ...... 1-28 sleeper bunk ...... 4-76 ABS off-road switch ...... 3-96 Seat adjustment...... 1-20 turbocharger cool down...... 4-74 accessory air switch...... 3-98 driver's seat with air suspension 1-20 Sleeper bunk ...... 4-76 air conditioner switch...... 3-17 reclining seats ...... 1-20 sleeper restraint ...... 4-77 air-controlled sliding fifth wheel standard driver's seat ...... 1-20 SmartWheel control system...... 3-119 switch ...... 4-14 Seat belts ...... 1-20 Spring brakes - manual release .. 2-15 auxiliary light switch...... 3-98 adjustments...... 1-20 Starting procedure axle switch, diff-lock - dual ..... 3-96 belt damage and repair ...... 1-27 engine warm-up ...... 4-43 axle switch, diff-lock - forward during pregnancy...... 1-27 ether metering ...... 4-46 rear ...... 3-96 Komfort-Latch feature...... 1-26 Starting procedure (cold weather) 4-42 axle switch, diff-lock - front ..... 3-96 lap/shoulder belt...... 1-22 Starting procedure (normal axle switch, diff-lock - rear rear 3-96 proper safety belt adjustment .. 1-22 temperature) ...... 4-41 axle switch, diff-lock - single safety restraint tips ...... 1-28 Steer axle rear ...... 3-96 Seats identification ...... 6-8 axle switch, inter axle differential adjustments...... 1-20 Steerable Drive Axle...... 4-72 locked (tandem) ...... 3-96 Komfort-Latch feature...... 1-26 Steering and driveline axle switch, pusher...... 3-99 tether adjustment...... 1-25 maintenance ...... 5-119 axle switch, tag ...... 3-99 tether belts ...... 1-24 driveshaft...... 5-122 axle switch, two speed...... 3-96 7

(02/14) Y53-1203-1D1 Index-11 Index

back up alarm mute switch ..... 3-96 ether start switch ...... 3-97 optional deep snow and mud beacon light switch ...... 3-98 exhaust brake switch...... 4-36 switch ...... 4-30 brake level switch ...... 3-97 fifth wheel slide switch ...... 3-97 overspeed air shutdown brake on/off switch ...... 3-97 flood light switch...... 3-98 (manual) ...... 3-97 brake/clutch kickout power take-off fog light switch...... 3-98 overspeed air shutdown (test).. 3-97 (PTO) switch...... 3-99 forward power take-off (PTO) panel dimmer switch ...... 3-99 cruise control on/off switch ..... 3-97 switch ...... 3-99 park light switch ...... 3-99 cruise control set/resume forward trailer axle lift switch ..3-100 parking brake valve ...... 3-96 switch ...... 3-97 fresh air/recirculation switch.... 3-17 power take-off (PTO) switch.... 3-99 cruise control switch ...... 4-11 fuel heater switch...... 3-98 rear power take-off (PTO) dash panel (dimmer) switch ...3-109 hazard light switch ...... 3-98 switch ...... 3-99 daytime running light switch .... 3-98 headlight flash switch ...... 3-123 rear trailer axle lift switch ...... 3-100 diesel particulate filter (DPF) headlight switch ...... 3-98, 3-107 remote throttle switch ...... 3-97 regeneration switch ...... 3-97 ignition key switch ...... 3-98, 3-105 roofdenser switch ...... 3-99 dome light switch ...... 3-98 inter-axle differential lock switch 4-52 sleeper enable switch...... 3-17 dual range rear axle switch..... 4-56 low voltage disconnect (LVD) ..3-96, spare switch ...... 3-98 dump truck gate switch ...... 3-97 3-101 spot light switch ...... 3-99 engine fan override switch...... 3-97 marker lamp flash switch ...... 3-123 suspension air retention switch 3-99 engine fan switch...... 4-49 marker light switch ...... 3-98 suspension dump switch ...... 3-99 engine heater switch ...... 3-97 marker/clearance/cab light suspension lift switch ...... 3-99 engine retarder - high switch ..3-121 switch ...... 3-98 third axle lift switch ...... 3-99 engine retarder - low switch ...3-121 marker/clearance/trailer light tow hook switch ...... 3-100 engine retarder - medium switch ...... 3-98 trailer air supply valve...... 3-100 switch ...... 3-121 off-road ABS function switch trailer axle (3rd axle) lift switch 3-100 engine retarder - off switch ....3-121 (option)...... 4-31 trailer belly dump switch ...... 3-100 7 engine start switch ...... 3-97 trailer center dump gate switch 3-100

Index-12 Y53-1203-1D1 (02/14) Index

trailer dump gate switch ...... 3-100 Tether belts ...... 1-24 oil change ...... 5-137 trailer front dump gate switch .3-100 Tire and wheel maintenance.....5-123 operation ...... 4-65 trailer hotline switch ...... 3-100 Tire chains...... 2-18 shifting gears in a new vehicle . 4-68 trailer marker light interrupter Tires temperature gauge ...... 4-71 switch ...... 3-112 greenhouse gas certified tires.5-135 transmission tips ...... 4-69 trailer rear dump gate switch ..3-100 Tires and wheels warm-up...... 4-65 trailer suspension air dump comparing hub-piloted and ball-seat Transmission and clutch switch ...... 3-100 wheels...... 5-132 maintenance ...... 5-137 turn signal/high beam switch .. 3-112 inspection and replacement ...5-125 Transmission temperature gauge 4-71 wheel differential switch ...... 4-54 matched tires ...... 5-135 Transmission temperature gauges winch clutch switch...... 3-100 speed restricted tires...... 5-124 auxiliary transmission oil tire inflation and loading ...... 5-125 temperature...... 3-71 tire replacement ...... 5-134 main transmission oil T wheel cap nut torque temperature...... 3-71 Tag axle air pressure gauge ...... 3-58 sequence ...... 5-130 Turbocharger ...... 5-43, 4-74 Temperature gauges wheel cap nut torque table ....5-130 wheel mounting and fastening 5-128 brakesaver oil temperature ..... 3-59 V drive axle(s) oil temperature.... 3-57 Towing ...... 2-12 engine (overheating) ...... 3-60 Trailer brake hand valve...... 4-34 Vehicle Configuration engine exhaust gas temperature Trailer Detect Changes–Limitations and (pyrometer) ...... 3-63 to activate trailer detect ...... 3-93 Guidelines engine oil temperature ...... 3-63 Transmission limitations and guidelines...... 3-75 transmission retarder oil auxiliary ...... 4-72 Vehicle identification temperature...... 3-72 identification ...... 6-8 assembly plant code ...... 6-4 water temperature (engine lubricants...... 5-138 chassis number...... 6-5 7 coolant) ...... 3-60 maintenance ...... 5-137 chassis number locations...... 6-5

(02/14) Y53-1203-1D1 Index-13 Index

model year designations table ...6-4 anti-lock brake system (ABS), king pin lock...... 3-48 vehicle information and specification trailer ...... 3-34 lane departure warning (LDW) . 3-39 label locations ...... 6-5 axle, traction control...... 3-36 lights, high beam ...... 3-43 VIN number ...... 6-4 check transmission...... 3-48 malfunction indicator lamp VIN number location ...... 6-5 cruise control active icon ...... 3-86 (MIL)...... 3-47 Vehicle loading ...... 1-34 diesel particulate filter (DPF) ... 3-37 message waiting ...... 3-45 GAWR ...... 1-34 dump truck, body up ...... 3-37 park brake...... 3-45 GCW...... 1-34 engine brakesaver or transmission power take off (PTO)...... 3-44 GVWR...... 1-34 retarder...... 3-37 pump mode ...... 3-43 load distribution...... 1-35 engine, check engine ...... 3-38 refrigerator ...... 3-48 Vehicle recovery ...... 2-12 engine, ether start ...... 3-38 seat belt, fasten ...... 3-45 recovery rigging ...... 2-14 engine, fan ...... 3-40 service transmission ...... 3-39 returning vehicle to service ..... 2-14 engine, heater ...... 3-40 shift indicator...... 3-86 spring brakes ...... 2-15 engine, low coolant level ...... 3-41 trailer body up ...... 3-44 tire chains ...... 2-18 engine, overspeed ...... 3-41 transmission, oil temperature Vehicle safety ...... 1-5 engine, overspeed air high...... 3-46 repairs ...... 1-7 shutdown...... 3-41 turn signal, left ...... 3-46 Vehicle/Trailer air supply valve ... 4-23 engine, retarder (brake) ...... 3-42 turn signal, right ...... 3-46 Voltmeter ...... 3-72 engine, stop engine ...... 3-42 water in fuel (WIF)...... 3-47 engine, wait to start ...... 3-42 worn brake ...... 3-40 fifth wheel slide ...... 3-47 Warranty W gear display...... 3-86 Greenhouse Gas (GHG) Warning light/indicator symbols high exhaust system Components Other Than alarm on indicator ...... 3-86 temperature...... 3-43 Tires ...... 6-11 anti-lock brake system (ABS) .. 3-34 hill hold ...... 3-39 Limitations ...... 6-14 7 inter axle lock ...... 3-44

Index-14 Y53-1203-1D1 (02/14) Index

Manufacturer's warranty coverage ...... 6-12 Original equipment tires ...... 6-10 Owner's warranty coverage .... 6-12 PACCAR responsibilities ...... 6-14 Replacement parts ...... 6-13 Rights and obligations ...... 6-11 Warranty Limitations...... 6-14 Warranty Rights and Obligations . 6-11 Weekly checks ...... 1-39 Welding (emergency)...... 5-95 What to do if...... 2-3 check engine lamp turns on ...... 2-5 engine is overheating ...... 2-5 engine oil pressure lamp turns on...... 2-4 fuse or relay blows ...... 2-7 low air alarm turns on ...... 2-3 stop engine lamp turns on ...... 2-4 you need roadside assistance ...2-3 Windshield wiper/washer...... 5-60 Windshield wipers/washer switch ...... 3-114

7

(02/14) Y53-1203-1D1 Index-15