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.

CAT: 8030A June 2017 Page iii
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

Page viii CAT: 8030A June 2017
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

CAT: 8030A June 2017 Page ix
CONTENTS
FRONT AXLE AND SUSPENSION..............................191
Axle lubrication.............................................191
Suspension lubrication ......................................191
Visual inspection ...........................................192
U-BOLT TENSION FOR FRONT AND REAR AXLES..............192
WHEEL ALIGNMENT .........................................194
Front wheel alignment .......................................194
WHEEL BEARING ADJUSTMENT ..............................194
REAR AXLE AND SUSPENSION ...............................195
General maintenance ........................................195
Rear suspension fasteners ...................................195
Visual inspection ...........................................196
REAR AXLE LUBRICATION ...................................197
Dana rear axle..............................................197
Meritor rear axle ............................................197
Axle housing breather vent ...................................197
REAR AXLE ALIGNMENT .....................................198
REAR SUSPENSION ALIGNMENT .............................199
NOISE CONTROL SYSTEM....................................200
Tampering with noise control system prohibited .................200
Air system silencers ........................................201
Inspection and maintenance ..................................202
MAGNETIC DRAIN PLUGS ....................................205
TORQUE SPECIFICATIONS ...................................206
Grade 5 fasteners...........................................206
Grade 8 fasteners...........................................207
CONVERSION TABLES .......................................208
CUSTOMER INFORMATION & VEHICLE IDENTIFICATION .......210
VEHICLE IDENTIFICATION NUMBERS (VIN) ....................212
SERIAL NUMBERS AND CAPACITIES..........................213
EMERGENCY DEALER CONTACT NUMBERS...................214
AFTER HOURS AUSTRALIA WIDE BREAKDOWN ASSISTANCE .............216

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CONTENTS
SECTION THREE – MAINTENANCE AND LUBRICATION
SCHEDULES
INTRODUCTION..............................................221
CHANGE OF ADDRESS/OWNERSHIP..........................221
WARRANTY QUESTIONS .....................................222
CUSTOMER ASSISTANCE ....................................226
KENWORTH DEALER NETWORK..............................226
OWNER’S RESPONSIBILITY ..................................226
MASTER LUBRICATION CHART...............................227
T4 Series - MX Engine service schedule ........................228
First service: ..............................................230
A-Service: .................................................232
B-Service: .................................................234
C-Service: .................................................236
Chassis lubrication points ...................................238
Master lubrication chart .....................................243
Lubrication & uid capacities ................................245
MAINTENANCE SERVICE RECORDS ..........................246
Recommended Preventative Maintenance.......................246
A, B & C Service intervals ...................................247
SECTION FOUR – SERVICE RECORDS
FIRST SERVICE INSPECTION RECORD........................259
KM SERVICE INSPECTION RECORDS .........................261
INDEX.......................................................295

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CONTENTS
LIST OF TABLES
Operating Temperatures ...................................................................17
Operating Pressures .........................................................................17
UltraShift Fault Codes .......................................................................74
Brake Adjuster Application ............................................................146
Recommended Laden Tyre Pressures ..........................................155
Maximum Vehicle Load Rating ......................................................157
Wheel Nut Torques ..........................................................................159
Hydrometer Readings .....................................................................168
Transmission Service Intervals .....................................................184
Spring Suspension U-Bolts Grade 8 .............................................193
Front Wheel Alignment Specications ...........................................194
Rear Wheel Alignment ....................................................................198
Torque Requirements – Frame Fasteners .....................................199
Grade 5 Fastener Torques ..............................................................206
Grade 8 Fastener Torques ..............................................................207
Conversion Table .............................................................................208
Periodic Maintenance .....................................................................227
T4 Series - MX Engine Service Schedule ......................................228
Master lubrication chart .................................................................243
Lubrication and uid capacities ....................................................245
A, B & C Service intervals ..............................................................247

Page xii CAT: 8030A June 2017
CONTENTS
ABOUT THIS HANDBOOK
Your handbook contains important information for the safe, efcient
operation and service of your truck. We urge you to become familiar with
the handbook's contents and use it as a ready reference. All information
contained in this manual is based on the latest production information
available at the time of publication. Kenworth Trucks reserves the right to
make changes without notice.
Your Kenworth Dealer is only too pleased to go over the operation and
controls of your new vehicle with you, and to explain any queries you may
have.
The handbook is divided into four sections:
SECTION 1 - OPERATING INSTRUCTIONS includes routine checks and
operating instructions in a logical sequence, from walk-around inspection
to nal shut down.
SECTION 2 - PREVENTIVE MAINTENANCE will guide you through the
basic operations required to keep your vehicle in good operating condition.
More detailed technical information can be found on the Electronic
Customised Maintenance Manual.
SECTION 3 - MAINTENANCE & LUBRICATION SCHEDULES include
complete lubrication specications and schedules, recommended service
information and intervals, and the Kenworth Preventive Maintenance
Program for normal operating conditions.
SECTION 4 - SERVICE RECORDS Service Records for each 10,000 km
service inspection from the First Service Inspection Record through to
the 100,000 km service. These are to be retained by you, the owner, as a
record of the service history of the vehicle. After the 100,000 km service,
there are pages for each 10,000 km service to be recorded.
In addition, a Driver’s Check List is included for your convenience on
pages 11-16.
We strongly recommend any system covered by State or Federal
Regulations be inspected and serviced by an Authorised Kenworth
Dealer or the component manufacturer’s service facility. This would apply
particularly to safety, emission, lighting and noise control systems.
Kenworth Trucks are built to conform to all Australian Federal Standards
and Regulations applicable at the time of manufacture. Kenworth Trucks
cannot be held liable for any unapproved alterations to systems or
components, certied or otherwise.

CAT: 8030A June 2017 Page xiii
CONTENTS
Some equipment described in this manual is optional and not included
in the base price of the vehicle. Kenworth Trucks undertake a continual
product improvement program, therefore specications and data contained
in this handbook are subject to change without notice.
If there are any doubts about the safe operation of your Kenworth Truck,
pleasecontact yournearestAuthorisedKenworth Dealer. Alistis contained
at the rear of this book on pages 214-216.
To ensure optimum performance and safe operation of your vehicle,
Kenworth recommends it is regularly inspected and serviced by an
Authorised Kenworth Dealer.

Page xiv CAT: 8030A June 2017
CONTENTS
SAFETY SYMBOLS
Anumber of alerting messages are used in this manual. Please read and
followthem.They arefor yourprotection andinformation.These messages
can help you avoid personal injury and costly damage to your vehicle.
WARNING!
This symbol shows that the information that follows is important. This
signals anything that can cause serious injury or death. The message
will tell you what the hazard is, what can happen if you don’t heed
the warning and how to avoid it.
CAUTION:
This symbol signals something that could damage your vehicle or may
cause personal injury.
NOTE:
Gives you information we feel you would like to have. It could have to do
with care of your vehicle or with driving it more efciently.
Please take the time to read these messages when you see them.

CAT: 8030A June 2017 Page xv
CONTENTS
VEHICLE SAFETY
Makesureyour KenworthTruck isintop workingcondition before heading
out on the road - it is the responsible driver’s duty to do so. Inspect the
vehicle according to the “Daily Checks” beginning on page 13.
Please remember, this handbook is not a training manual. It cannot tell
you everything you need to know about driving your Kenworth Truck. For
that you need a good training program or driving school. If you have not
been trained, get proper training before you drive. Only qualied drivers
should drive this vehicle.
Everynew KenworthTruck isdesignedto conformto allAustralian Federal
StandardsandRegulationsapplicableatthetimeofmanufacture.However,
even with these safety features, continued safe and reliable operation
depends greatly upon regular vehicle maintenance.
The vehicle should only be operated within the range of its mechanical
capabilities and the limits of its load ratings. See the tyre placard located
in the cabin (page 210).

Page xvi CAT: 8030A June 2017
CONTENTS
DRIVER INFORMATION PACK (DIP)
Inaddition tothisDriver’sHandbook,therearemany otherpublications that
are supplied with your new Kenworth Truck. Please take the time to read
them. Electronic Customised Maintenance Manual (eCMM) is included in
this Driver Information Pack an Electronic Customised Parts Catalogue
(eCPC) is an optional item and is available in hard copy or CD-Rom as
an aftermarket purchasable item. This is an option and is specied at the
time of purchase of your new vehicle.
ELECTRONICCUSTOMISEDMAINTENANCEMANUAL(eCMM)
The Electronic Customised Maintenance Manual (eCMM) undergo
constant revision and reect the components installed when your truck
was manufactured.
ELECTRONIC CUSTOMISED PARTS CATALOGUE (eCPC)
Acomplete listing of the parts used to custom build your Kenworth Truck.
This is sent to you via your selling dealer approximately two weeks after
youtake delivery ofyour newKenworth truck.This canbe orderedthrough
the Dealer network. This same information is available electronically to
all Authorised Kenworth Dealers through the PACCAR Parts Electronic
Catalogue (eCAT) system.
PACCAR CUSTOMER SUPPORT DIRECTORY
Thisis apocketsizeddirectoryof allAuthorised KenworthandDAF Dealers
coveringParts, Service andSales. Itcontains the fulladdress ofall current
Dealers with phone and fax numbers, including after hours numbers. As
the directory undergoes continued change, you can in the future purchase
updated copies from your Authorised Kenworth Dealer.
AFTER HOURS AUSTRALIA WIDE ROADSIDE ASSISTANCE
In the event you need roadside assistance, Kenworth and DAF have an
Australia Wide Roadside Assistance number, this will direct you to the
nearest AuthorisedKenworth Dealershipfor emergencyService andParts
support. The number is: 1800 4 PACCAR
1800 472 222

CASTROL MASTER SERVICE CHART
Lists all Kenworth recommended lubricants for use in all your major and
auxiliary components.
Also in the Driver Information Pack you will nd the operating instructions
for the radio/s, etc.
Finally, there is a reminder for you to present your new Kenworth Truck to
any of our Authorised Kenworth Dealers for its First Service at 10,000km
or 30 days. This Service includes free labour and inspection, you only pay
for the lubricants and lters used.
It is the owner’s responsibility to maintain the vehicle and have the
recommended services carried out at the intervals specified in the
Maintenance Manual.
Should you have any difculty obtaining service, or require further details,
please contact:
Customer Service Department
Kenworth Trucks
A DIVISION OF PACR AUSTRALIA PTY. LTD.
A.B.N. 43 004 669 667
20-64 Canterbury Road
Bayswater, Vic, 3153. Australia
Telephone: [phone]
Fax No: [phone]
Cat. 8030A Revised June 2017
Printed in Australia Published by Kenworth Trucks