KW T4 Series User manual

Driver’s HandbookDriver’s Handbook
T4 Series with PACCAR MX-13T4 Series with PACCAR MX-13

VEHICLE IDENTIFICATION
Owner’s Name: ........................Address: ...............................................
Suburb: ....................................State: .................Postcode: ................
Phone Number (Business): .....................................................................
Phone Number (Private): .........................................................................
Vehicle Registration Number: ..................................................................
Colour: .....................................................................................................
Model: ......................................................................................................
Engine Number: .......................................................................................
VlN (Vehicle Identication Number): ........................................................
Chassis Number: .....................................................................................
MAXIMUM VEHICLE WEIGHT
The maximum vehicle weight ratings are stamped on the Vehicle
Identication Plate attached to the body. Refer to 'Customer Information
and Vehicle Identication' for locations in Section Two.
Registered Tare Weight: ..........................................................................
GVM (Gross Vehicle Mass): ....................................................................
GCM (Gross Combination Mass): ...........................................................
Date of Acquisition: ..................................................................................
Date: .....................................
Stamp & Signature
of Selling Dealer:
The above information fully identies your vehicle. It will furnish all of the
necessary information in the event that warranty repairs are required. Be
certain it is completely and properly lled out and signed by your selling
dealer or his/her authorised representative. NOTE: Original ratings letter
is supplied by the selling dealer for every truck.

WELCOME TO THE KENWORTH FAMILY
We thank you for investing in your new Kenworth. Proudly engineered
and built inAustralia, this vehicle has been custom designed to meet your
exacting standards and the specic requirements of your application.
Advanced technology, pride in workmanship and a total commitment to
quality have been combined to produce a truck that is unequalled.
Our network of dealers will support your Kenworth with the same quality
andattentiontodetailthatwentintoitsmanufacture. AnywhereinAustralia,
New Zealand and Papua New Guinea, support for your investment is only
as far away as a phone call to your nearest Kenworth Dealer. Contact
information appears on pages 214 to 216.
Australian Kenworth or DAF owners in need of emergency roadside
assistance can simply call 1800 4 PACCAR (1800 4 72222). Trained
operators are available 24-7 to connect you with your nearest PACCAR
dealer for support.
Please take the time to read this handbook, as it contains information that
will assist you in getting the most from your new Kenworth. We know it
will provide many years of productive service, and we welcome you to the
family of Kenworth owners.

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CONTENTS
INTRODUCTION
List of tables................................................xi
About this Handbook.........................................xii
Safety symbols.............................................xiv
Vehicle safety ...............................................xv
Driver Information Pack (DIP) .................................xvi
SECTION ONE - OPERATING INSTRUCTIONS
GENERAL INFORMATION.......................................1
Vehicle access ...............................................1
Keys and locks ...............................................2
Remote keyless entry (RKE) ....................................3
Remote verication ...........................................3
Keypad transmitter............................................4
Programming ................................................4
Cab and frame access .........................................5
ENGINE ACCESS...............................................8
Conventional hood hold-downs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
SAFE VEHICLE OPERATION ...................................10
VEHICLE LOADING............................................10
EMERGENCY EQUIPMENT.....................................11
DRIVER’S CHECKLIST.........................................11
Approaching your vehicle.....................................12
DAILY CHECKS ...............................................13
Engine compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Chassis and cab.............................................13
PRE-START CHECKS ....................................15
Daily operations .......................................15
Weekly operations ...........................................16
INSTRUMENTS AND CONTROLS ...............................18
Instrument Panel ............................................18
Adjustable steering column ...................................18
Curved dash layout - T409 & T409SAR .........................19
Warning lights...............................................20
Power on test ...............................................21
Tachourmeter ...............................................22
Speedometer/Odometer.......................................23
Engine coolant temperature gauge .............................23
Engine oil pressure gauge.....................................24
Air system pressure gauges ...................................25

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CONTENTS
AIR LOSS EMERGENCY PROCEDURE..........................26
Low air audible alarm .......................................26
Parking brake valve ..........................................27
Fuel level gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Voltmeter...................................................28
Transmission low oil warning light..............................29
Headlight switch.............................................30
Emergency left hand headlight.................................30
High beam..................................................30
Emergency asher switch.....................................30
Panel light knob (dimmer switch)...............................31
ID and clearance lights switch .................................31
Fog lights switch ............................................31
Mirrors.....................................................32
Power Windows ............................................32
Air suspension deate switch (dump valve) ......................33
iPod & MP3 connectivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Windshield wipers/washers control.............................34
Cab mounted power supply socket .............................35
Cruise control...............................................36
Smartwheel mounted controls .................................37
Smartwheel mounted engine brake controls .....................37
Dash mounted engine brake controls ...........................39
Turbo timer .................................................40
Engine management/diagnostic fault codes .....................41
System warning lights .......................................41
Shift pattern display..........................................42
Engine control unit (ECU) self test lights ........................42
HEATING AND AIRCONDITIONING .............................43
Cab heater/airconditioner .....................................44
CAB STORAGE ...............................................48
Interior compartments........................................48
Glove compartment ..........................................48
Toolboxes .................................................48
SEATS........................................................49
Seat adjustment .............................................49
SAFETY RESTRAINT BELTS ...................................50
Lap and shoulder belt ........................................51
Sleeper, bunks and restraints..................................52
OPERATING THE ENGINE......................................53
Normal starting procedure ....................................53
Engine warm-up .............................................54
Idling the engine ............................................57
Engine speed control (ESP) ..................................57

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CONTENTS
ENGINE AFTERTREATMENT SYSTEMS (EAS) ...............58
Selective Catalytic Reduction (SCR) ............................58
PACCAR MX-13 engine ......................................58
AdBlue low level warning and inducement ......................58
EAS Tampering .............................................59
Diesel Exhaust Fluid (DEF) - AdBlue Level .......................59
“Engine Derate” Means: Engine Power Limiting ..................60
Diesel Exhaust Fluid (DEF) - AdBlue ............................60
AdBlue lling ..............................................61
OPERATING THE TRANSMISSION..............................62
Transmission oil pressure ....................................62
PUTTING THE VEHICLE IN MOTION ............................63
Shifting gears in a new vehicle ................................64
Clutch brake and travel .......................................64
Double clutching ............................................65
CLUTCH OPERATION .........................................66
Starting ....................................................66
Transmission oil temperature gauge ............................68
Manual transmission shift pattern ..............................68
EATON FULLER TRANSMISSIONS..............................69
Driving the UltraShift transmissions ............................69
UltraShift driving tips .........................................71
Retrieving fault codes .......................................73
Clearing fault codes ..........................................73
UltraShift fault codes ........................................74
UltraShift Plus transmissions ..................................75
Start-up & power down .......................................76
UltraShift transmission shift pattern ...........................78
USING THE BRAKE SYSTEM...................................79
Air supply system ...........................................80
Brake operation .............................................80
USING THE PARKING BRAKE .................................81
Before you leave the cab .....................................81
To release the truck parking brakes ONLY .......................81
To release the full combination of brakes ........................82
TRUCK/TRAILER AIR SUPPLY VALVE ..........................82
TRAILER PARK BRAKE RELEASE VALVE ......................84
SYSTEM TRUCK PARK ........................................85
BRAKE SAFETY AND EMERGENCY ............................85
EMERGENCY BRAKING .......................................85
FOR NON ABS VEHICLES .....................................86
DISC BRAKES ...............................................86
ELECTRONIC BRAKING SAFETY SYSTEMS ....................87
Anti-Lock Braking System (ABS) ..............................87

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CONTENTS
ABS warning lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Automatic Traction Control (ATC) ..............................88
Drag Torque Control (DTC) ....................................89
Electronic Stability Program (ESP) .............................89
Trailer Response Management (TRM) ...........................89
Active Cruise with Brakes (ACB) ...............................89
OFF-ROAD FUNCTION ........................................90
ABS off-road function switch ..................................90
HILL START ASSIST (HSA) ....................................91
TRAILER BRAKE HAND VALVE ................................91
DRIVING BOBTAIL OR WITH AN UNLOADED TRAILER ..........92
VEHICLE RETARDERS ........................................92
Engine compression and exhaust brake .........................93
OPERATING THE REAR/DRIVE AXLE...........................94
Driver controlled differential lock...............................94
Inter-axle differential lock (Power divider)........................95
Inter-axle differential lock operation ............................95
TOWING WITH AXLES FITTED WITH DCDL......................97
DCDL Dual range rear axle..................................97
Dual range axle operation .....................................98
Starting up ................................................98
DRIVE AXLE TEMPERATURE GAUGE..........................100
DRIVING TIPS AND TECHNIQUES .............................101
INSTRUCTIONS TO PREVENT JACKKNIFING...................104
ECONOMICAL DRIVING.......................................106
Safe driving................................................108
AIR SUSPENSION............................................110
FIFTH WHEEL................................................111
Fifth wheel jaw lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Hook up...................................................111
Air activated 5th wheel release procedure (Jost) ................111
Fifth wheel lubrication.......................................112
TOW HITCH .................................................112
Towing....................................................112
Returning vehicle to service .................................113
VEHICLE RECOVERY AND SPRING BRAKES ..................113
SPRING BRAKES - MANUAL RELEASE........................114
SHUT DOWN.................................................117
Before stopping the engine ..................................117
Turbocharger ..............................................117
Final stopping procedures ...................................118
REFUELLING ................................................119
Location of fuel shut-off valves ...............................119

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CONTENTS
SECTION TWO - PREVENTIVE MAINTENANCE
INTRODUCTION..............................................123
SAFETY PRECAUTIONS ......................................124
LUBRICATION SPECIFICATIONS - ENGINE ....................126
Lubrication system ........................................126
FUEL SYSTEM ...............................................132
Fuel specications ..........................................132
Fuel system priming ........................................133
Dual fuel tank pick-ups & return ...............................134
Fuel tank strap tension ......................................134
AIR CLEANER SYSTEMS .....................................135
Air cleaners and lter replacement.............................135
AIR INTAKE SYSTEM.........................................135
ACCESSORY DRIVE BELTS...................................136
Serpentine Belts ...........................................136
Replacing serpentine belts ..................................136
COOLING SYSTEM...........................................139
Standard system rell .......................................141
BRAKE SYSTEM .............................................143
Brake linings ...............................................144
AUTOMATIC SLACK ADJUSTERS.............................145
Free stroke measurement ....................................145
Adjusted chamber stroke ....................................146
ANTI-LOCK BRAKING SYSTEM (ABS) .........................147
ABS fault codes ............................................147
AIR SUPPLY SYSTEM ........................................149
Air system function test......................................150
Air tanks .................................................150
Water ejection valves........................................150
AIR COMPRESSOR...........................................151
Operation..................................................151
Air gauges and air leaks .....................................152
TURBOCHARGER............................................153
TYRES ......................................................154
Tyre ination and loading ....................................154
Tyre inspection and replacement ..............................154
Tyre ination ...............................................155
Replacing tyres.............................................158
Matching tyres .............................................158
WHEEL CAP NUT TORQUE ...................................159
Wheel mounting and fastening................................159

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CONTENTS
VEHICLE JACKING...........................................160
20 Tonne hydraulic bottle jack ................................160
JACK OPERATING INSTRUCTIONS............................161
To raise the load ............................................161
To lower the load ...........................................162
General care of your jack.....................................162
Storage of the vehicle jack ...................................163
Vehicle jacking points .......................................163
BATTERIES..................................................164
Battery charging ............................................165
Maintenance free batteries ...................................168
Electrical systems - 24 volt ..................................169
Jump starting ..............................................169
WELDING PRECAUTIONS ....................................171
For vehicles with electronic instrumentation ....................171
For vehicles with electronic engines ...........................171
CHASSIS & CAB – FINISH, APPEARANCE & CLEANING ........172
Chassis and cab ............................................172
Engine ....................................................175
STEERING WHEEL ...........................................175
Care & maintenance ........................................175
Cleaning ..................................................175
CAB HEATER/AIR CONDITIONING.............................176
Special precautions .........................................177
Cab-heater/air conditioner....................................177
AIR CONDITIONER ..........................................178
SAFETY RESTRAINT SYSTEM ................................179
Inspection guidelines........................................180
TRANSMISSION AND CLUTCH ................................183
All transmissions ...........................................183
Transmission service intervals ...............................184
CLUTCH SYSTEM ............................................185
Clutch linkage ..............................................185
Clutch adjustment - normal wear ..............................186
Clutch lubrication ..........................................187
STEERING...................................................188
Understeer and oversteer ...................................188
Axle stops .................................................189
HYDRAULIC POWER STEERING ..............................189
Filter service and parts – reservoir assembly ....................189
STEERING DRIVELINE........................................189
Driveshaft .................................................189
U-Joints ...................................................190