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Preventive Maintenance (PM) Interval (mi.

/km)
1 A
At the first 15.000 15,000/km
mi/ 24.000 24,000 Monthly
or at the first PM

SYSTEM COMPONENT
Fifth Wheel
Frame Fasteners
Frame Crossmembers and Mounting Brackets

Total Vehicle Alignment


Steering knuckle spindles, thrust bearings, kingpins, drawkeys, tie rod ends, steering stops, & bushings
Kingpin bushings, thrust bearings, & tie rod ball ends
Front Axle (Arvin Meritor)
Drawkeys

25-6 Maintenance

PM825001

(09/12)

SYSTEM COMPONENT
Total Vehicle Alignment
Kingpin bushings, thrust bearings, & tie rod ball ends (ON HIGHWAY)
Kingpin bushings, thrust bearings, & tie rod ball ends (OFF HIGHWAY AND VOCATIONAL)
Steering knuckle spindles, thrust bearings, kingpins, drawkeys, tie rod ends, steering stops, & bushings (ON HIGHWAY)
Front Axle (Dana) Steering knuckle spindles, thrust bearings, kingpins, drawkeys, tie rod ends, steering stops, & bushings (OFF HIGHWAY AND VOCATIO

Front Spring
Spring Pins & Shackles

Shock Absorbers
U-bolts (ON HIGHWAY)
Front Suspension U-bolts (OFF HIGHWAY)

Axle Housing

Air Shift Unit


Breather
Drive Axle (Dana) Lube Pump (ON HIGHWAY)
Lube Pump (OFF HIGHWAY)
Lube Filter (ON HIGHWAY)
Lube Filter (OFF HIGHWAY)
Magnetic drain plug and breather (ON HIGHWAY)
Drive Axle (Dana) Magnetic drain plug and breather (OFF HIGHWAY)

(09/12)
PM825001

Maintenance 25-7

SYSTEM COMPONENT

Axle Housing
Lubricant filter
Breather
Input shaft & pinion shaft
Axle shaft
Drive Axle (Meritor) Interaxle differential

Axle Housing
Breather
Lube Filter
Drive Axle (SISU) S-cam brakes

U-bolts
Frame & crossmember bolts
Rear Suspension Mounting brackets and fasteners

Slack adjusters
Brake camshaft bearing

Brake treadle valve

Brakes (All) Brake air system


Drum Brakes Brake lining
Disc Brakes Brake pads

25-8 Maintenance

PM825001

(09/12)

SYSTEM COMPONENT
Brake disc/rotor

Caliper sliding function


Disc Brakes All
Meritor Unitized Wheel Ends
Hubs (non-LMS)
Hub, Drum, & HubcapHubs (non-LMS) with outrunner seals
Hubs (non-LMS) with standard seals
Hub seals (all)
LMS Hubs (Dana)
LMS Hubs (Dana) with Synthetic Lubricant
LMS Hubs (Dana) with Mineral Lubricant
Brake drums
Hub, Drum, & HubcapHubcaps

Main & auxiliary transmission and transfer case


Mounting Brackets and Fasteners
Main & auxiliary transmission
Oil cooler
Main & aux.transmission
Main & auxiliary transmission (ON HIGHWAY)
Main & auxiliary transmission
Main & auxiliary
(except Freedom-
transmission
line)
(OFF HIGHWAY)

(09/12)

PM825001

Maintenance 25-9

SYSTEM COMPONENT

Cotta TR2205

Fabco TC142/ TC143/ TC170/TC270

Auxiliary transmissionMarmon-Harrington MVG2000/MVG2000SD

Air intake piping, mounting, and charge air cooler


Engine air intake tubing
Cold starting aids
Air Intake Air cleaner

Clutch pedal shaft


Clutch pedal
Clutch release linkage
Clutch release bearing
Clutch (linkage design)
Clutch release shaft
Clutch hydraulic fluid
Clutch release bearing
Clutch (hydraulic over air design)
Clutch (hydraulic overClutch
air design)
release shaft

25-10 Maintenance

PM825001

(09/12)

SYSTEM COMPONENT
Hoses

System (ELC)

System (Conv. Coolant)


Cooling Fan clutch housing

Tires
Disc wheels
Demountable rims

Tires & Wheels Wheel nuts and studs

(09/12)

PM825001

Maintenance 25-11

SYSTEM COMPONENT
Reservoir
Reservoir (ON HIGHWAY)
Reservoir (OFF HIGHWAY)

Steering gear
Power assist cylinder
Hoses and tubes
Steering linkage
Draglink tube clamp and ball socket

Power Steering
Pitman arm clamp bolt and nut
Steering intermediate shaft
Steering intermediate shaft U-joints (ON HIGHWAY)
Steering intermediate shaft U-joints (OFF HIGHWAY or CITY DELIVERY)
Draglink and tie rod arm ball sockets (ON HIGHWAY)
Power Steering Draglink and tie rod arm ball sockets ((OFF HIGHWAY or CITY DELIVERY)

Fuel tanks
Fuel tank breathers
Fuel & Tanks Fuel tank straps
Fuel & Tanks Fuel tank steps

Models 1610-1810 &SPL-90 slip member & U-joints


Model SPL-100 slip member & U-joints
Driveshafts Models SPL-140/140HD/ 170/170HD/250/250HD slip members & U-joints

25-12 Maintenance

PM825001

(09/12)

SYSTEM COMPONENT
Models SPL-140XL7 170XL/250XL slip members and U-joints (ON HIGHWAY & LINE HAUL)
Driveshafts Models SPL-140XL/ 170XL/250XL slip members and U-joints (OFF HIGHWAY & CITY)

Battery cables (ON HIGHWAY & LINE HAUL)


Battery cables (VOCATIONAL & SEVERE SERVICE)
Batteries (ON HIGHWAY & LINE HAUL)
Batteries (VOCATIONAL & SEVERE SERVICE)
Battery box and tray (ON HIGHWAY & LINE HAUL)
Battery box and tray (VOCATIONAL & SEVERE SERVICE)
Battery Boxes, Tool Boxes,
Battery
and
Cable
Steps
Fasteners

Headlamps
Warning lights in light bar
Turn signal
Stop lights
Reverse lights

Electrical & lights Alternator


Starter
ECM connector
Wheel sensors
Fuel tank sending unit
Power supply harnesses (engine, transmission, etc.)
Electrical & lights Power supply harnesses (engine, transmission, etc.)
(09/12)

PM825001

Maintenance 25-13

SYSTEM COMPONENT
Hood
Hinges and latch
Body & cab holddown bolts
Tilt pump
Cab structure, doors, Cab
& hoods
tilt system

Air conditioner

Heater & air conditioner


Heating & Air Conditioning
Cab air filter

System
Diesel exhaust fluid tank
Diesel exhaust fluid supply module
Exhaust / Aftertreatment
Diesel
system
Particulate Filter

Air compressor governor


Air lines
System
Inline filters
Air dryer
Air dryer (ON HIGHWAY)
Air Air dryer (OFF HIGHWAY)

Basic Engine
Fuel filter
Bypass oil filter
Block
Engine Crankcase breather

25-14 Maintenance

PM825001

(09/12)

SYSTEM COMPONENT
Manifold nuts
Oil pan Capscrew

Engine
Drive pulleys
Turbocharger
Radiator shutters
All lines and seals
Mounts
Engine Fan hub

(09/12)

PM825001

Maintenance 25-15

PM825001

(09/12)
B C D
30,000 /48.000 60,000 / 96,000120,000/
6 months192,000 Annually

Recommended PM Interval
MAINTENANCE TASK 1 A
Check the kingpin lock and plate for wear and function; lubricate (NLGI #2 grease). X
Check for tightness; tighten to the specified torque value as required (see Frame).
Inspect for cracks and loose fasteners. Replace or tighten to the specified torque value as required (see Frame).

Check and adjust as required (see Front Axle). X


Inspect for wear and damage and for endplay. Shim or replace as required.
Lubricate with approved grease.
Tighten nuts X

Recommended PM Interval
MAINTENANCE TASK 1 A
Check and adjust as required (see Front Axle). X
Lubricate with approved grease.
Lubricate with approved grease.
Inspect for wear and damage and for endplay. Shim or replace as required.
Inspect for wear and damage and for endplay. Shim or replace as required.

Inspect for cracked leaves, worn bushings, & excessive corrosion.


Inspect for worn parts and excessive joint clearance. Replace as required (see Front Suspension).
Inspect for leaking, body damage, and damaged or worn bushings. Replace as required. Check the shock mounting stud torque.
Check for proper function. X
Check general condition and tightness of the nuts; tighten to specified torque value as required (see Front
X Suspension).
Check general condition and tightness of the nuts; tighten to specified torque value as required (see Front Suspension).X

Visually inspect for damage or leaks.


Check oil level. Check cold. Torque the drain plug.
Drain the lubricant while warm. Flush each unit with clean flushing oil. Change the lubricant. See information on page 25-4
Check the lubricant level.
Remove the housing cover and drain the lubricant. Wash the parts thoroughly and dry in air.
Clean or replace.
Remove the magnetic strainer and inspect for wear particles. Wash in solvent and dry in air.
Remove the magnetic strainer and inspect for wear particles. Wash in solvent and dry in air.
Change.
Change.
Clean or replace.
Clean or replace.
Recommended PM Interval
MAINTENANCE TASK 1 A

Check the cold fill level at the differential carrier plug for a pinion angle of less than 7 degrees, or at the axle bowl plug for a pinion angle of greater than 7 de
Visually inspect for damage or leaks.
Drain and replace the lubricant. See information on page 25-4
Change the filter.
Check the operation. If the cap doesnt rotate freely, replace.
Check and adjust the endplay.
Tighten the rear axle flange nuts to the specified torque value.
Check the operation.
Change the oil in the differential carrier and the hubs, and clean the magnetic oil drain plugs. X
Check the wheel bearing hubs and adjust if necessary. X
Visually inspect for damage or leaks. X
Check the oil level in the differential carrier and hubs. X
Check the breather for proper operation.
Clean the suction filter for the optional pressure lubrication system
Overhaul the brakes; degrease all moving parts; check the bushings and seals for wear.

Check the torque. Tighten to specified torque value as required (see Rear Suspension). X
Check the torque. Tighten to specified torque value as required (see Frame).
Check the condition and the fastener torque. Tighten to the specified torque value as required (see Rear X
Suspension).

Check the push rod travel and check the control arm for cracks. Adjust at reline. X
Lubricate (NLGI #2 grease). X
Lubricate (NLGI #2 grease).
Clean the area around the treadle, boot, and mounting plate. Check the pivot and mounting plate for integrity. Check the plunger boot for cracks. Lubricate rol
Rebuild through an authorized Peterbilt service facility.
Check air lines and fittings for leaks. Adjust routing as required to reduce chafing. Check tank mounting and condition. X
Clean or replace the inline filters.
Inspect; replace as required (see Brakes).
Inspect; replace as required (see Brakes).

Recommended PM Interval
MAINTENANCE TASK 1 A
Inspect for visible cracks, heat checking, galling, or scoring of surface. Check for runout [maximum allowable 0.02 in. (0.51 mm)].
Ensure caliper slides freely with no obstructions or excessive play (see manufacturers service literature in Brakes for measuring procedure and maximum a
Inspect protection caps and rubber boots of the slide pins for damage or cracking.
Check operation; inspect as per manufacturers service literature (see Brakes).
Check the bearing endplay (see Meritor TP-0251)
Check the bearing endplay and adjust as required.
Clean the components and check for excessive wear or damage. Change the oil and seal (see page 25-5).
Clean the components and check for excessive wear or damage. Change the oil and seal (see page 25-5).
Check for leaks; replace as required.
Check the bearing endplay and adjust as required.
Clean the components and check for excessive wear or damage. Change the oil and seal (see page 25-5).
500.000 miles/ 800.000 km
Clean the components and check for excessive wear or damage. Change the oil and seal (see page 25-5).
350.000 miles/ 560.000 km
Inspect for visible cracks, heat checking, galling or scoring of the braking surface, and for severe corrosion on the outside surface. Check for out-of-round or o
Clean the sight window. Check the center plug, mounting flange, and fill plug for leaks and for proper installation. ReplaceXbroken or damaged parts. Check th

Inspect for visible damage, signs of overheating, and leaks. X X


Check the drain plugs for tightness.
Check the condition of the fasteners and their torque. Tighten to the specified torque value as required.
Clean the fins (air-to-oil type) and body. Check the hose condition and for leaks; replace as required.
Check the oil level; refill as required (see page 25-2).
Drain lubricant while warm. Flush each unit with clean flushing oil. 500.000 miles/ 800.000 km
Drain lubricant while warm. Flush each unit with clean flushing oil. X

Recommended PM Interval
MAINTENANCE TASK 1 A
Inspect: Check oil level; inspect for leaks and any visible damage X
Initial oil change: Drain oil while warm; flush case with gear oil-compatible fluid; clean magnetic drain plug;X refill. Do not flush the case with any solvent.
Change oil.
Inspect: Check oil level; inspect for leaks and any visible damage X
Initial oil change: Drain oil while warm; flush case with gear oil-compatible fluid; clean magnetic drain plug;X refill. Do not flush the case with any solvent.
Change oil. X
Inspect: Check oil level; inspect for leaks and any visible damage X
Initial oil change: Drain oil while warm; flush case with gear oil-compatible fluid; clean magnetic drain plug;X refill. Do not flush the case with any solvent.
Change oil. X

Check the system for broken pipes, leaks, joint integrity, cleanliness, and proper support (see Cooling System and Air Intake System).
Disassemble, clean, check for cracks, leaks, and joint integrity.
Check for leaks and proper operation.
Replace the element as indicated (see Air Intake System). When required by the air restriction indicator

Check for excessive looseness and lubricate (NLGI #2 grease). X


Check for proper free pedal (see Clutch) X
Check for excessive looseness and lubricate (NLGI #2 grease). X
Lubricate. X
Lubricate. X
Replace fluid and bleed system
Lubricate. X
Lubricate. X

Recommended PM Interval
MAINTENANCE TASK 1 A
Check the radiator and heater hoses for leaks. X
Check the freeze point.
Check for contamination using test strips.
Replace blank water filter if applicable.
Do lab analysis of coolant to determine suitability for continued use.
Flush, drain, and refill with new coolant if analysis shows coolant is unsuitable for continued use.
Add ELC extender if analysis of coolant is suitable for continued use.
Flush, drain, and refill with new coolant.
Check the freeze point.
Check inhibitor (nitrite) concentration using test strips.
Replace water filter if applicable.
Flush, drain, and refill with new coolant.
Check for leaks. X
Check inflation pressure. Weekly cold using calibrated gauge
Inspect for cuts, irregular wear, missing lugs, sidewall damage, etc. X
Inspect the wheel disc for any cracks or surface irregularities. Inspect the rim edge and bead seat area for damage. Replace
X any damaged wheels - DO NOT
Inspect the mounting ring, rim gutter, side ring, and lock ring for damage; replace as required (see Wheels & Tires). X
Check the tightness of the fasteners and tighten the fasteners to the specified torque as required. X
Inspect for damaged hex corners, stripped or damaged threads, and excessive corrosion; clean or replace as required. X

Recommended PM Interval
MAINTENANCE TASK 1 A
Check the fluid level (see page 25-5). X
Drain, replace the filter, and refill (see page 25-5). X
Drain, replace the filter, and refill (see page 25-5). X
Check the lash of the sector shaft; adjust as required.
Grease the trunnion bearing (EP NLGI #2 lithium-based, moly-filled, HD grease).
Grease the input shaft seal (EP NLGI #2 lithium-based, moly-filled, HD grease).
Lubricate the ball joints. Inspect for leaking rod seals, damaged ball joint boots, and damage to cylinder rod or barrel. X
Check for leaks and chafing.
Check all joints for excessive lash; replace as required.
Check the torque; tighten to specified torque value as required. X
Check the torque; tighten to specified torque value as required. X
Check the torque on the pinch bolt and nut. X
Lubricate [EP NLGI #2 HD grease, +325 F to -10 F (+163C to -23C) range]. X
Lubricate [EP NLGI #2 HD grease, +325 F to -10 F (+163C to -23C) range]. X
Lubricate (EP NLGI #2 lithium-based, moly-filled, HD grease). X
Lubricate (EP NLGI #2 lithium-based, moly-filled, HD grease). X X

Inspect tanks, brackets, hoses, and fittings for correct location, tightness, abrasion damage, and leaks; repair or replace as required.
Check for proper function; clean the drain hoses.
Check the strap tightness; tighten to proper torque value as required: -Aluminum tank: 30 Lb. ft. (41 N.m.)X-Cylindrical Steel tank: 8 Lb. ft. (11 N.m.) -Model 38
Check for snug fit of side plates against tank and tank straps. Check for damaged or broken steps, missing bolts, and missing
X grommet between tank and sid

Lubricate (see Driveshafts). X X


Lubricate.
Lubricate.

Recommended PM Interval
MAINTENANCE TASK 1 A
Lubricate. 350.000 miles/ 560.000 km 1 st interval and then
Lubricate.

Check the condition of the cables, cushion clamps, and routing. Replace a cushion clamp if the rubber has deteriorated. Repair or tighten terminals, and secu
Check the condition of the cables, cushion clamps, and routing. Replace a cushion clamp if the rubber has deteriorated. Repair
X or tighten terminals, and secu
Check for cracks and damage, electrolyte level, condition of terminals, and tightness of holddowns.
Check for cracks and damage, electrolyte level, condition of terminals, and tightness of holddowns. X
Check the box integrity. Clean the drain tube and check for acid leaks. Check condition of all equipment mounted under the box.
Check the box integrity. Clean the drain tube and check for acid leaks. Check condition of all equipment mounted under the
X box.
Check battery cable fasteners and tighten as necessary to 10 -15 Lb. ft. (13.6 - 20.3 N.m.) as specified on the battery label.
X

Check the aim and adjust as required (see Electrical).


Check at the ignition start position to verify bulbs function. X
Visual check. X
Visual check. X
Visual check. X
Check operation and output.
Check tightness of the pulley nut.
Check the tension of the drive belt.
Check tightness of the terminal hex nuts.
Check torque on hex nuts.
Check the tightness of the ECM connector.
Check for damaged sensors and connectors, and worn or frayed wires.
Check the mounting screws and electrical connections for worn or damaged wires and connectors. X
Check for worn or damaged insulation, corroded terminals, frayed wires, and oil or fluid leaks on the connectors or wiring.X
Wash to remove excess grease.
Recommended PM Interval
MAINTENANCE TASK 1 A
Lubricate the lower hood pivot (only if lube fittings are present) (see Hood).
Lubricate with silicone spray.
Check the condition and tightness.
Check the oil level; refill as required.
Check for hydraulic leaks.

Operate the system (see Heating & Air Conditioning). (NOTE: The air conditioning system is active when the Defrost/Defog
X mode is selected.)
Perform the checks listed in the vehicles operators manual.
Full operational and diagnostic check.
Clean; replace after a maximum of three cleanings.

Check for leaks and proper support.t X


Inspect the tank, straps, brackets, hoses and fittings for abrasion damagge, leaks, tightness and fully engaged connectors
Replace filter Refer to the engine maintenance manual
Refer to the engine maintenance manual

Replace air strainer.


Check condition and routing to prevent chafing.
Lubricate.
Replace elements or clean with solvent.
Check for moisture (see Air System).
Overhaul. 360.000 miles/ 576.000 km
Overhaul.

The maintenance and service interval recommendations for the specific engine are the maintenance requirements specified in the engine manufacturers Ope
Drain, clean, and refill or replace as required. X
Clean filter and change element (see Engine). X
Clean with steam or solvent.
Clean.

Recommended PM Interval
MAINTENANCE TASK 1 A
Tighten to specified torque.
Tighten to specified torque.
Check for tightness.
Check manifold and mounting.
Check controls (see Cooling System).
Check for leaks.
Check for tightness.
Lubricate; check for air leaks. If vehicle is not equipped with an air filter/dryer, check the inline filter to the fan hub (see Cooling System).
E
240.000 / 384.000

PM Interval
B c D E

X
X

X
X
X
X

PM Interval
B C D E
X
X
X
X
X

X
X
X

X
X
on page 25-4
X
X
X
X
X
X
X
X
X
PM Interval
B c D E

r a pinion angle of greater than 7Xdegrees. Tighten the plug to 35 - 50 Lb. ft. (47 - 68 N.m.)
X
on page 25-4
X
X
X
X
X
X
X
X
X
X
X
X

X
X
X

X
lunger boot for cracks. Lubricate Xroller pin, pivot pin, and plunger (NLGI #2 grease).
X

X
X
X

PM Interval
B c D E
X
easuring procedure and maximumX allowable play).
X
X
X
X
X
X
X
X
800.000 km
560.000 km
X

X
X
X
X
800.000 km
X

PM Interval
B c D E

X
X
X
y the air restriction indicator

X
PM Interval
B c D E
X
X
X
X
X
X
X
X
X
X
X
X
X
ing calibrated gauge

PM Interval
B c D E

X
X
X
X
X

X
X
X
X
X
X
X
X

X
X
X

X
X

PM Interval
B c D E
560.000 km 1 st interval and then every 100.000 miles / 160.000 km after that
X

epair or tighten terminals, and secure


X cables to prevent chafing. Replace damaged cables (cuts, cracks, or excessive wear).

X
X
X
X
X
X
X
X

X
PM Interval
B c D E
X
X
X
X
X

X
X
X

X
ne maintenance manual

X
X
X
X
X
576.000 km
X

ed in the engine manufacturers Operations and Maintenance Manual included with the vehicle. Strict adherence to these recommendations is required to maintain warranty c

X
X

PM Interval
B c D E
X
X
X
X
X
X
X
X
s is required to maintain warranty coverage. The maintenance and service interval recommendations for the engines vary significantly, depending on the manufacturer and th
ding on the manufacturer and the model of the engine. As a minimum, perform the operations listed below: