NEW CASCADIA MAINTENANCE MANUAL Models: PT126SLP PT126DC PE116SLP PE116DC STI-500-10 (10/20/2021) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
Foreword Scheduled maintenance provides a key element for the safe operation of your vehicle. A proper maintenance program also helps to minimize downtime and to safeguard warranties. This maintenance manual provides information necessary for years of safe, reliable, and cost-efficient vehicle operation. IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also refer to other component and body manufacturers’ instructions for specific inspection and maintenance instructions.
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Introduction Descriptions of Service Publications Daimler Trucks North America LLC distributes the following major service publications in paper and electronic formats. Refer to www.DTNAConnect.com. Workshop/Service Manual Workshop/service manuals contain service and repair information for all vehicle systems and components, except for major components such as engines, transmissions, and rear axles.
Introduction Descriptions of Service Publications PartsPro PartsPro® is an electronic parts catalog system, showing the specified vehicle’s build record. EZWiring EZWiring™ makes Freightliner, Sterling, Western Star, Thomas Built Buses, and Freightliner Custom Chassis Corporation products’ wiring drawings and floating pin lists available online for viewing and printing. EZWiring can also be accessed from within PartsPro. Warranty-related service information available on the www.DTNAConnect.
Introduction Page Description For an example of a Maintenance Manual page, see Fig. 1. A B C 41 Driveline 41−01 Driveline Inspection 1. Park the vehicle on a level surface, apply the parking brakes, and chock the tires. CAUTION Due to the extreme load occurring at high−speed rotation, a loose or broken capscrew at any point in the driveline will weaken the driveline connec− tion, which could eventually result in serious ve− hicle damage.
Introduction Maintenance Manual Contents Group No. Group Title 00 . . . . . . . . . . . . . . . . . . . . . . General Information 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Intake 13 . . . . . . . . . . . . . . . . . . . . . . . . . Air Compressor 15 . . . . . . . . . . . . . . . . . . . Alternators and Starters 20 . . . . . . . . . . . . . . . . . . . Engine Cooling/Radiator 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch 26 . . . . . . . . . . . . . . .
General Information 00 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Determining Scheduled Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–01 Initial Maintenance (IM) Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–04 M1 Maintenance Interval Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
00 General Information Determining Scheduled Maintenance Intervals: 00–01 Determining Scheduled Maintenance Intervals operating conditions. Unusual vehicle operating conditions may require service at more frequent intervals. Performing regular maintenance on your Freightliner vehicle will help ensure that your vehicle delivers safe reliable service and optimum performance for years to come. Failure to follow a regular maintenance program can result in inefficient operation and unscheduled down time.
00 General Information Service Schedule Table: 00–02 Service Schedule Schedule I (Short-Haul Transport) vehicles that annually travel less than 60,000 miles (100 000 km) Schedule II (Long-Haul Transport) vehicles that annually travel over 60,000 miles (100 000 km) Maintenance Interval Operation Maintenance Interval Frequency Miles km Initial Maintenance (IM) first 10,000 16 000 Maintenance 1 (M1) every 10,000 16 000 Maintenance 2 (M2) every 50,000 80 000 Maintenance 3 (M3) every 150,00
00 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule I Maint. No.
00 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule I 00/4 Maint. No.
00 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule I Maint. No.
00 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule II 00/6 Maint. No.
00 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule II Maint. No.
00 General Information Initial Maintenance (IM) Operations: 00–04 The Initial Maintenance table lists all maintenance operations that are to be performed at the initial maintenance (IM) interval. Maintenance operation numbers are reference numbers used to help you find detailed instructions in this manual on the mainMaintenance Operation Number tenance operations to be performed.
00 General Information M1 Maintenance Interval Operations: 00–05 The M1 Maintenance Interval Operations tables list all maintenance operations that are to be performed at the M1 maintenance interval. Maintenance operation numbers are reference numbers used to help you find detailed instructions in this manual on the maintenance operations to be performed.
00 General Information M2 Maintenance Interval Operations: 00–06 The M2 Maintenance Interval Operations tables list all maintenance operations that are to be performed at the M2 maintenance interval. Maintenance operation numbers are reference numbers used to help Maintenance Operation Number you find detailed instructions in this manual on the maintenance operations to be performed. Perform all M1 maintenance interval operations at the M2 maintenance interval.
00 General Information M3 Maintenance Interval Operations: 00–07 The M3 Maintenance Interval Operations table lists all maintenance operations that are to be performed at the M3 maintenance interval. Maintenance operation numbers are reference numbers used to help Maintenance Operation Number you find detailed instructions in this manual on the maintenance operations to be performed. Perform all M1 and M2 maintenance interval operations at the M3 maintenance interval.
00 General Information Maintenance Operation Sets Table: 00–08 Maintenance Operation Sets Maint. No.
00 General Information Maintenance Operation Sets Table: 00–08 Maintenance Operation Sets Maint. No.
00 General Information Noise Emission Controls Maintenance: 00–09 Noise Emission Control Maintenance Federal Law, Part 205: Transportation Equipment Noise Emission Controls Part 205, Transportation Equipment Noise Emission Controls, requires the vehicle manufacturer to furnish, with each new vehicle, such written instructions for the proper maintenance, use, and repair of the vehicle by the ultimate purchaser to provide reasonable assurance of the elimination or minimization of noise-emission-control deg
00 General Information Verification of Inspections Log: 00–10 Verification of Inspections Log Verification of Inspections Log, Group 20 Verification of Inspections Log — Group 20 — Fan Clutch Date Mileage Item Cost Maintenance Facility Verification of Inspections Log, Group 49 Verification of Inspections Log — Group 49 — Exhaust System Components Date Mileage New Cascadia Maintenance Manual, October 2020 Item Cost Maintenance Facility 00/15
Air Intake 09 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
09 Air Intake 09–01 Air Cleaner Inspection Restriction of air flow through the air cleaner element is measured at the tap in the air cleaner outlet. Check the restriction indicator at the air cleaner or in the cab if the vehicle is equipped with a dashmounted restriction gauge. Vehicles may be equipped with either a manual-reset restriction indicator with graduations ( Fig. 1), or a go/no-go restriction indicator without graduations ( Fig. 2). NOTICE Do not use aftermarket air-cleaner elements.
09 Air Intake 2 1 2 1 3 3 1 A 06/02/2016 A. 1 2. 3. f090530 Check this connection. Air Cleaner Resonator Compressor Supply Line Fig. 5, Compressor Supply Line Quick Connect 6 4 7 8 5 04/25/2016 f090528 1. Air Cleaner Housing 2. Nut 3. Forward Mounting Isolator 4, Aft Mounting Isolator 5 6. 7. 8. Aft Mounting Bracket Clamp Intake Duct Clamp Fig. 3, Air Cleaner Assembly 1 2 01/17/2012 1. Steel Plate f090496 2. Rubber Fig.
Air Compressor 13 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–01 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Compressor 13 13–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death. 13–01 Air Compressor Inspection 1.
Alternators and Starters 15 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–01 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 Alternators and Starters 15–00 Safety Precautions 54 of the New Cascadia™ Workshop Manual for adjustment, repair, or replacement instructions. Safety Precautions in this section apply to all procedures within this group. 4.1 Clean and tighten the battery ground cable, terminal, and clamps. 4.2 Inspect the retainer assembly or battery hold-downs, and the battery box. Replace worn or damaged parts. Remove any corrosion with a wire brush, and wash with a weak solution of baking soda and water.
Engine Cooling/Radiator 20 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fan Clutch Check (Noise Emission Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–03 Pressure Relief Cap Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–01 Radiator Pressure-Flushing and Coolant Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 Engine Cooling/Radiator 20–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. 1 2 DANGER When working on the vehicle, shut down the engine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
20 Engine Cooling/Radiator WARNING Do not remove or loosen the surge tank cap until the engine and cooling system have completely cooled. Use extreme care when removing the cap. A sudden release of pressure from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause serious personal injury. install these clamps correctly.
20 Engine Cooling/Radiator 11. Place a pan under the coolant filter to catch engine coolant. 12. Remove the coolant filter with a strap or chain wrench. Install a new coolant filter and tighten. 13. Fill the cooling system with new coolant. The cooling system is filled when the coolant level reaches the MAX line on the surge tank. Refer to the engine manufacturer’s service literature for specific coolant information. 14. Replace the surge tank cap(s). 15. Return the hood to the operating position. 16.
20 Engine Cooling/Radiator 2. Inspect the electrical connections and wires to the fan clutch solenoid; see Fig. 6. Secure the connection if loose; replace wires and connectors if damaged. 3. Clean the fan clutch air solenoid valve filter, if equipped, as follows. 3.1 Unscrew the fan clutch solenoid valve air filter assembly and remove the filter element; see Fig. 7. 3.2 Clean the filter element with cleaning solvent. 3.3 Using a clean, lint-free cloth, wipe off any excess solvent. 3.
20 Engine Cooling/Radiator 10/05/2016 f200581 Fig. 8, Checking for Air Leaks (Horton DriveMaster) a leak inside the fan clutch. Any leak must be remedied. 11. Check the fan clutch bearings as follows. 11.1 Turn the fan in both directions and feel for worn hub bearings. 11.2 If possible, remove the drive belt and check for worn sheave bearings by turning the sheave in both directions. 11.
Clutch 25 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch Release Bearing Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–01 Fluid Change, Hydraulic Clutch Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–03 Fluid Level Check, Hydraulic Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 Clutch 25–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death. 25–01 Clutch Release Bearing Lubrication 06/22/2007 f250662 Fig.
25 Clutch age the rubber parts of the system, causing loss of clutch function and the risk of serious personal injury. Hydraulic clutch control fluid is hazardous. It may be a skin irritant and can cause blindness if it gets in your eyes. Always wear safety glasses when handling it or bleeding hydraulic lines. If you get it on your skin, wash it off as soon as possible. NOTICE Do not spill hydraulic clutch control fluid on the cab paint. Clean it off immediately if any is spilled.
25 Clutch tainer. Pressurize the bleeder system to 15 psi (103 kPa). 3. Remove the reservoir lid (see Fig. 3) and install the pressure bleed adaptor on the reservoir. 4. Bleed the hydraulic system as follows. 4.1 Open the bleed valve on the bleed tank to pressurize the reservoir. 4.2 Remove the cap from the bleed valve of the slave cylinder. See Fig. 4. On the valve, install a transparent drain hose connected to a catch bottle.
Transmission 26 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number ™ Detroit Automated Transmission Fluid Change and Magnetic Plug Cleaning. . . . . . . . . . . . . . . . . . . . . . 26–01 Detroit™ Automated Transmission Fluid Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–02 Eaton Fuller Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 Transmission 26–00 Safety Precautions 2 Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
26 Transmission NOTE: In all cases, the correct fluid level is established by checking at the fill opening. 6. Operate the engine for five minutes after filling the transmission, then check the fluid level again. 7. Install a new seal on the fill plug, then install the plug and tighten it 45 lbf·ft (60 N·m). 8. Operate the vehicle to check for correct operation.
26 Transmission NOTE: For an Eaton Fuller transmission, the optional transmission fluid filter is a remotemount, spin-on type, and is located between the transmission and the fluid cooler. The filter bracket is attached to the frame rail or some other nearby location. The filter is mounted in a vertical position, and should be filled with fluid before installation to assure the proper fluid level. For optimum transmission performance, change the filter each time that the fluid is changed. 5.
26 Transmission Eaton Fuller Transmission Lubricant Capacities Transmission Model Refill Capacity: qt (L) MHP and MXP 14.0 (13.0) Table 2, Eaton Fuller Transmission Lubricant Capacities NOTE: In all cases, the correct fluid level is established by checking at the fill opening. Checking at the Fill Plug 1. Clean the area around the fill plug, and remove it from the side of the gear case. 2. Using your finger or a bent pipe cleaner, see if the fluid is level with the fill opening. See Fig. 2. 3.
26 Transmission 1. Drain Plug 2. Fill Plug 10/05/2016 3. Sight Glass f260037a Fig. 5, Air Filter/Regulator Location Fig. 3, Eaton Fuller Transmission With a Sight Glass 2 02/23/2015 A. Full A B f261461 B. Low Fig. 4, Transmission Fluid Level Sight Glass WARNING Drain the air supply; if the air supply is not drained before the air filter/regulator is serviced, serious injury and component damage could result. 2. Clean the outside of the air filter/regulator with cleaning solvent. See Fig. 5.
26 Transmission WARNING Wear safety goggles when using compressed air to clean parts, as permanent harm to eyes could result from flying debris. 4. Clean the filter element by dipping it in alcohol or other cleaning solvent. Blow compressed air through the element (inside to outside) to loosen surface dirt and to dry the element. If it is not damaged, the sintered metallic filter element will last the life of the vehicle. Wipe out the filter housing with a clean, dry, lintfree rag.
Frame and Frame Components 31 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fifth Wheel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–01 Fifth Wheel Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–02 Frame Fastener Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 Frame and Frame Components 31–00 Safety Precautions 2. Thoroughly steam clean all fifth wheel components before inspection. Safety Precautions in this section apply to all procedures within this group. 3. Check for cracks in the fifth wheel assembly, mounting brackets, and mounting parts. DANGER When working on the vehicle, shut down the engine or motor, set the parking brake, and chock the tires.
31 Frame and Frame Components 2. Thoroughly steam clean the fifth wheel. 3. Check for cracks in the fifth wheel assembly, mounting brackets, and mounting parts. 4. Ensure that both bracket pins are in place and secured by retainer pins and cotter pins. See Fig. 2. 5. For fifth wheels equipped with bracket liners, rock the fifth wheel. If it does not rock freely, remove the top plate and inspect the bracket liners. Replace liners that are broken or less than 0.
31 Frame and Frame Components 16 13 12 8 8 7 14 15 17 5 12 12 12 18 11 10 12 19 6 5 15 20 9 21 22 5 8 27 5 7 26 6 8 25 1 15 12 2 3 4 12/02/2010 12 24 23 2 f311134 NOTE: 6000 Series shown; 7000 Series fifth wheels use similar parts. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Wedge Stop Rod Nut Flat Washer, 5/8" Wedge Stop Rod Spring Wedge Stop Rod Grease Fitting Bracket Pin Bracket Retainer Pin Cotter Pin, 3/16" x 1" Bumper Spring Handle Spring 11. 12. 13. 14. 15. 16. 17. 18.
31 Frame and Frame Components C E D 09/01/2009 f311101 Fig. 3, Bracket Pin Bolt Locking Tabs nism several times to test. Repeat if necessary. See Fig. 5. If the lock is too loose, loosen the jam nut, turn the adjustment bolt counterclockwise one full turn, then reset the jam nut. Lock and unlock the mechanism several times to test. Repeat if necessary. See Fig. 5. A F 9. If the fifth wheel is equipped with a sliding mechanism, inspect and adjust it as follows. 9.
31 Frame and Frame Components WARNING Failure to properly lubricate the fifth wheel could result in a possible disengagement of the trailer from the tractor, which could result in personal injury or property damage. 1 Fontaine 2 3 1. Tilt the top plate forward (the front of the fifth wheel is down) and apply grease to each bearing area through the zerk fittings located on each side of the top plate just to the front of the bracket pins.
31 Frame and Frame Components Fig. 6. Open and close the fifth wheel several times to further distribute the grease. 1 Lightly oil other moving parts in the fifth wheel. 12/03/2010 f311136 Use a light oil (such as SAE 10W or 20W motor oil) to lubricate the cam track and pivot. 1. Cam Plate Fig. 7, Holland FW35 Fifth Wheel, Oil Lubrication 1. Pull Handle 2. Jaw 3. Wedge 1 2 Fig. 6, Fontaine Fifth Wheel 4. Apply grease to the top plate. Spread grease all over the mating surface of the top plate.
31 Frame and Frame Components • deck plates Jost Lubricate the kingpin lock using a hand pump grease gun through the grease zerk on the skirt of the fifth wheel; see Fig. 5. Apply a light oil to all moving parts. For sliding fifth wheels spray diesel fuel on the slide path of the base plate. NOTICE • equalizer brackets • exhaust brackets • fifth wheel legs • fifth wheel mountings • frame crossmembers and gussets • front frame brackets Do not use a power grease gun.
Suspension 32 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–00 Suspension Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–01 Suspension U-Bolt Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 Suspension 32–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. 1. Check the rubber mounting bushings for cracks, cuts, swelling, dry rot, or missing pieces. If the shock absorber bushings are no longer serviceable, replace the shock absorber with a new one. DANGER When working on the vehicle, shut down the engine or motor, set the parking brake, and chock the tires.
32 Suspension exist, replace the damaged parts; see Group 32 of the New Cascadia™ Workshop Manual. 2. Mark the location of the front and rear tires on the floor. Visually check the air spring piston for cracks, chips, and broken areas. Check the air bag for rips, tears, and holes. Verify that the air spring assembly does not leak. If any of these conditions exist, replace the damaged parts; see Group 32 of the New Cascadia™ Workshop Manual.
32 Suspension Suspensions with Single-Leaf Springs: Measure between the top of the U-bolt pad and the bottom of the axle stop. 4. If the measurement is not within the acceptable range, refer to the New Cascadia™ Workshop Manual for adjustment instructions. If the distance is within the acceptable range, apply the parking brakes.
32 Suspension A A 02/21/2017 Measure Point A = Measure Here f320961a Suspension Height Measurement Min Target Max 2-3/8 inch (60 mm) 2-1/2 inch (64 mm) 2-7/8 inch (73 mm) Table 3, Suspension Ride-Height Measurement, Single-Leaf Spring, 40k Low and Mid Ride 02/21/2017 Measure Point A = Measure Here f321046a Suspension Height Measurement Min Target Max 2-3/4 inch (70 mm) 3 inch (76 mm) 3-1/4 inch (83 mm) Table 4, Suspension Ride-Height Measurement, DualLeaf Spring, 23k High Ride 32/4 N
32 Suspension 4 1 2 3 A 10/05/2016 f320783 Fig.
Front Axle 33 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–04 Knuckle Pin Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–01 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 Front Axle 33–00 Safety Precautions 1 Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
33 Front Axle 33–03 Tie Rod Lubrication 1 Detroit and Meritor Axles A 1 09/06/96 For any Detroit or Meritor axle that requires lubrication of the tie-rod ends, wipe the grease fittings clean, then pump multipurpose chassis grease, NLGI Grade 1 (6% 12-hydroxy lithium stearate grease) or NLGI Grade 2 (8% 12-hydroxy lithium stearate grease), into the tie-rod ends until all used grease is forced out and fresh grease is seen at the ball stud neck. See Fig. 4. f320032a A. Grease Exit 1.
33 Front Axle equipment manufacturer. Freightliner dealers must have proof of this calibration history. 1. Apply the parking brakes and chock the rear tires. 7. Place the trammel bar at the front of the tires (see Fig. 6) and adjust the scale end so that the pointers line up with the scribe lines. See Fig. 7. 2. Raise the front of the vehicle until the tires clear the ground. Place safety stands under the axle. 3. Using spray paint or a piece of chalk, mark the entire center rib of each front tire. 4.
33 Front Axle 33–05 Steer Axle Hub Cap Vent Plug Inspection General Information As a function of their design, hubcap vent plugs will on occasion exhibit signs of hub oil on their exterior surface. Depending on environmental conditions and/or age of the plug, the amount of oil present can vary. This is a normal result of the venting process due to pressure increase within the hub cavity. For an example of normal vent plug appearance, see Fig. 8. 09/01/2016 f330299 Fig.
Front Axle 33 clean before checking the oil. Do not use a pressure washer to clean the hub/plug area. The plug has a vent and this can contaminate the oil with water. 1. Park the vehicle on a level surface, shut down the engine and set the parking brakes. Chock the tires. 2. Inspect the axle hub cap and vent plug for evidence of excessive leakage. 3. Wipe the hub cap and vent plug clean with a rag. 4. Remove the vent plug and check the oil for evidence of water contamination.
Rear Axle 35 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Axle Breather and Axle Lubricant Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–02 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–01 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 Rear Axle 35–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
35 Rear Axle 3. Place a drain pan under the rear axle drain plug. Drain the oil when it is warm. At this temperature, the oil will run more freely and ensure that the axle is flushed. 4. Clean the fill and drain plugs. Change them if necessary. 4.1 For magnetic plugs, use a piece of key stock or any other convenient steel slug to short the two magnetic poles and divert the magnetic field. 4.2 Clean away the collected material deposited on each pole.
35 Rear Axle Detroit™ New Final Drive CAUTION 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 2. Clean the fill plug and the area around it. In the carrier housing, remove the plug from the oil fill hole. See Fig. 3 for the forward axle, and Fig. 4 for the rear axle . Be careful when draining the axle oil. It may be very hot, and could cause personal injury if it contacts the skin. 3. Place a drain pan under the rear axle drain plug.
35 Rear Axle New Final Drive Oil Capacity, New Final Drive Axle Type Oil in Hubs (2) Oil in Axle NFD Model 4 Forward Axle TP 1.8 L 9L NFD Model 4 Rear Rear Axle TP 1.8 L 7.5 L NFD Model 4 Forward Axle SP 1.8 L 14 L NFD Model 4 Rear Rear Axle SP 1.8 L 11 L NFD Model 6 TP 1.8 L 9.5 L NFD Model 6 SP 1.
35 Rear Axle contacts the base; do not overtighten. See Table 5 for recommended lubricants. Meritor Drive Axle Recommended Lubricant Recommended Lubricant Type Synthetic Gear Oil Lubricant SAE Viscosity Grade Ambient Temperature Meritor Specification –40°F (–40°C) and Up* 75W–90 0–76–N –40°F (–40°C) and Up* 75W–140 0–76–M * There is no upper limit on these outside temperatures, but axle sump temperature must never exceed 250°F (121°C). Table 5, Meritor Drive Axle Recommended Lubricant 5.
35 Rear Axle Dana® Spicer® IMPORTANT: The use of friction modifiers is not approved in Dana drive axles. 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 2. Clean the fill plug and the area around it. In the axle housing rear cover, remove the plug from the oil fill hole (or standpipe, if installed in the oil fill hole). See Fig. 7. 2 1 1 10/05/2016 f350017a 1. Magnetic Strainer 2. Power Divider Fig.
35 Rear Axle 5.3 After the first oil is changed, inspect the drain plug each time for large quantities of metal particles. 5.4 After cleaning, install the drain plug(s) and tighten to 40 to 60 lbf·ft (54 to 81 N·m). 6. Fill the axle with the recommended lubricant. See Table 7 for recommended drive axle lubricants, and Table 8 for drive axle lubricant capacities.
35 Rear Axle IMPORTANT: When the ambient temperature is above 0°F (–18°C), use SAE 10 heavy-duty engine oil, API service classification SD (sulfated ash content must not exceed 1.85%). When the ambient temperature is below 0°F (–18°C), use one part kerosene to three parts SAE 10 heavyduty engine oil, API service classification SD (sulfated ash content must not exceed 1.85%). This cold-weather mixture can be safely used up to 32°F (0°C).
35 Rear Axle of the fill plug, using the lubricant recommended in Table 4. IMPORTANT: A lubricant level close enough to be seen or touched is not sufficient. It must be level with the bottom of the fill hole. 5. Install and tighten the fill plug 30 lbf·ft (41 N·m). IMPORTANT: Always check the axle breather whenever checking the lubricant level. Check the breather more frequently under adverse operating conditions. 6. Check the axle housing breather (see Fig. 1). Make sure that it is open and unclogged.
35 Rear Axle IMPORTANT: Always check the axle breather whenever checking the lubricant level. Check the breather more frequently under adverse operating conditions. Dana® Spicer® NOTICE Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage. 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 2. If the vehicle has just been driven, allow a few minutes for the lubricant to settle. 3.
Rear Axle 35 3. Coat the threads of the fill plug with a small amount of Loctite® 242, or equivalent sealant. Install the fill plug finger-tight in the rear axle shift unit housing. Using a wrench, tighten it an additional 1-1/2 turns.
Wheels and Tires 40 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Tire Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–02 Wheel Nut Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40 Wheels and Tires 40–01 Wheel Nut Check 40–02 Tire Check IMPORTANT: After a wheel has been installed, the wheel nut torque must be rechecked after 50 to 100 miles (80 to 160 km) of operation. Tires should be inspected closely during the first 3000 to 10,000 miles (5000 to 16 000 km) for abnormal wear. Check the torque on all wheel nuts. See Table 1 for torque specifications, and see Fig. 1 for the wheel nut tightening sequence.
Driveline 41 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–01 Driveline Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–02 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 Driveline 41–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. 1 DANGER 2 When working on the vehicle, shut down the engine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death. ME 1 41–01 Driveline Inspection 1.
41 Driveline 14 15 13 3 9 8 7 16 12 11 1 2 6 10 5 4 3 10/06/2016 f410067b NOTE: Not all fasteners are shown. 1. Transmission 2. Transmission Output-Shaft End-Yoke (yoke-strap type) 3. U-Joint Assembly 4. Bearing Cap Self-Locking Capscrew 5. Bearing Cap 6. 7. 8. 9. 10. 11. U-Joint Cross Bearing Cup (for yoke strap) Yoke Strap and Capscrew Slip-Joint Assembly Sleeve-Yoke (bearing-cap type) Dust Cap 12. 13. 14. 15.
41 Driveline 2 1 8. Examine the driveshaft for evidence of missing balance weights, and for buildup of foreign material. Remove any foreign material. If there is any evidence that balance weights are missing, remove the driveshaft and have it balanced. 3 4 5 9. For driveshafts with slip joints, check to be sure the yoke plug is not loose or missing. See Fig. 6. Repair or replace the yoke plug as needed.
41 Driveline 41–02 Driveline Lubrication Slip Joint Spline Lubrication Universal Joint Lubrication NOTE: Vehicles equipped with Meritor RPL Series drivelines do not require periodic lubrication. NOTE: Vehicles equipped with Meritor RPL Series drivelines do not require periodic lubrication. 1. Park the vehicle on a level surface, apply the parking brakes, and chock the tires. 2. Wipe all old grease and dirt from each U-joint grease fitting. See Fig. 6. 3.
Brakes 42 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Brake System Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–01 Air Dryer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–03 Alcohol Evaporator Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42 Brakes 42–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
42 Brakes 1 2 11 9 3 4 25 5 10 8 10 14 12 10 10 10 10 23 8 6 13 10 24 22 15 7 8 21 20 18 17 19 16 08/09/95 1. 5/16 x 4-1/2 Upper Mounting Bracket Bolt 2. Upper Mounting Bracket Strap 3. Lockwasher 4. 5/16-Inch Nylok Nut 5. Upper Mounting Bracket 6. Housing 7. Nylok Nut 8. 3/8-Inch Special Washer f421383 9. 10. 11. 12. 13. 14. 15. 16. 17.
42 Brakes 6 WARNING 2 4 5 Do not attempt to disassemble the desiccant cartridge assembly. Parts for the assembly are not available and the cartridge contains a 150 lb spring that cannot be mechanically caged. Disassembly could release the spring, resulting in personal injury. 4. Remove and discard both O-rings from the cartridge bolt. 1&9 3 7 09/20/94 8 f420544a Fig. 2, AD–9 End Cover to Housing Torque Pattern 17. Install the air dryer on the lower mounting bracket.
42 Brakes 12.3 Fan the service brakes to reduce system air pressure to governor cut-in. Note that the system once again builds to full pressure and is followed by a purge at the AD-IP air dryer exhaust. 12.4 Check for excessive leakage around the head of the desiccant cartridge where it contacts the end cover. With the compressor in loaded mode (compressing air), apply a soapy solution to these areas, and observe that any leakage does not exceed a 1-inch bubble in 1 second.
42 Brakes 6. Connect a voltmeter to circuit 94 on the air dryer’s harness connector and to a body ground point. Check for battery voltage. If voltage is not found, check and repair the open or short to ground in wire 94. 9. Remove the heater/thermostat assembly and place it in a freezer for about five minutes to cool it below 40°F (5°C). Remove the cold heater/thermostat assembly and check resistance between the heater/thermostat terminals. Resistance should be 1.5 to 3.0 ohms.
42 Brakes 8. Install the reservoir on the cover and tighten the capscrews. 9. Fill the reservoir with 40 ounces (1183 mL) of methyl alcohol, then install the filler cap. 42–05 Brake Inspection Parking Brake Operational Check IMPORTANT: This procedure should be performed prior to lubrication of the brake components. CAUTION Perform the following check in a clear safe area. If the parking brakes fail to hold the vehicle, personal injury or property damage may result. 1.
42 Brakes Torque Check with 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005 Angle View Extension Angle (degrees) Target Torque [lbf·ft (N·m)] Tool Setting [lbf·ft (N·m)] 0° 11/28/2016 0 296 (401) 45 310 (420) 60 320 (434) f422613 45° 11/28/2016 f422614 60° 11/06/2018 f422668 90 350 (475) 350 (475) 90° 11/28/2016 f422615 120 386 (523) 135 402 (545) 120° 11/06/2018 f422669 135° 11/28/2016 f422616 Table 1, Torque Check with 47 Inch (119 cm) Torque Wrench and Tool DDC DSN
42 Brakes D D C C B A 5 1 2 6 4 4 6 5 3 3 10/31/2018 2 1 f422663a A. Right-hand brake (viewed from below). B. Left-hand brake (viewed from below). C. Sheer sleeve above in this location. D. Shelf above in this location. Fig. 7, Bendix Radial Mounted Caliper Tightening Pattern (viewed from below) 5. Install the wheel assemblies. For instructions, see Group 40 of the New Cascadia Workshop Manual. 5. Install the wheel assemblies.
42 Brakes 4 4 3 3 2 2 1 1 A B 07/30/2018 f422655 Tighten the fasteners in the order indicated. A. Left Hand, Bottom View B. Right Hand, Bottom View Fig. 8, Meritor Radial Mounted Caliper Tightening Pattern 5. Install the wheel assemblies. For instructions, see Group 40 of the New Cascadia Workshop Manual. ponents. Improperly maintaining the vehicle braking system may lead to brake failure, resulting in property damage, personal injury, or death. 6.
42 Brakes 4 4 3 3 2 2 1 1 A B 07/30/2018 f422657 Tighten the fasteners in the order indicated. A. Left Hand, Bottom View B. Right Hand, Bottom View Fig. 9, Wabco Maxxus Radial Mounted Caliper Tightening Pattern for improper operation or adjustment of the automatic slack adjuster. See Group 42 of the New Cascadia Workshop Manual for inspection, troubleshooting, and repair procedures. pair as needed.
42 Brakes Brake Chamber Stroke Specifications Chamber Type* Manufacturer Size† Max Applied Stroke: inch (mm) 9 1-3/8 (35) 12 16 Standard Stroke 20 1-3/4 (45) 24 Gunite 30 2 (51) 36‡ 2-1/4 (57) 16 20 Long Stroke 2 (51) 24 24 2-1/2 (64) 30 12 Standard Stroke Haldex 1-3/8 (35) 16 20 1-3/4 (44) 24 2-1/2-Inch Extended Stroke 24 2 (51) 3-Inch Extended Stroke 24 2-1/2 (64) Standard Stroke 30 2 (51) Long Stroke 30 2-1/2 (64) 9 12 Standard Stroke 16 20 Meritor 24 Long Stroke 2
42 Brakes 42–06 Haldex Slack Adjuster Lubrication 42–07 Meritor Camshaft Bracket Lubrication Automatic slack adjusters that have a grease fitting must be lubricated periodically to ensure proper brake operation. IMPORTANT: Perform a brake inspection before lubricating the camshaft bracket. WARNING Failure to lubricate slack adjusters could lead to dragging brakes or a brake failure, resulting in property damage, personal injury, or death. CAUTION Do not use moly-disulfide-loaded grease or oil.
42 Brakes grease seal replacement instructions. If this seal is not replaced, the brake linings could become contaminated with grease. The stopping distance of the vehicle will be increased, which could result in personal injury or property damage. Steer Axle S-cam Tube Greasing 1. Park the vehicle on a level surface, shut down the engine, and set the park brake. 2. Chock the drive-axle tires. 3. Chock steer-axle tires. 4. Grease the S-cam tubes. Drive Axle S-cam Tube Greasing 1.
42 Brakes 2. Remove the roll pin from the brake pedal pivot pin. See Fig. 13. 1 2 2 5 3 6 1 4 3 4 7 8 5 7 10/20/93 6 f420012a 1. 2. 3. 4. 5. Brake Chamber Clevis Actuator Rod Boot Pressure-Relief Capscrew, Gasket, Pawl Spring, and Pawl 6. Manual Adjusting Nut 7. Grease Fitting (or plug) Fig. 12, Meritor Automatic Slack Adjuster 4. Cage the drive-tire park-brake chamber opposite of the tire that is chocked. 5. Grease the slack adjuster on the caged brake side only. 11/01/2016 1. 2. 3. 4.
42 Brakes 12. Install a new roll pin and apply Torque Seal (OPG F900 White) to the roll pin. 13. Install the brake valve assembly; see Group 42, of the vehicle Workshop Manual. 14. Test the brakes before returning the vehicle to service. 42–10 WABCO System Saver Air Dryer Desiccant Cartridge Replacement 2 3 1 NOTE: The following instructions apply to the System Saver 1200, 1200 Plus, and Twin air dryers.
42 Brakes full released position. Observe the looseness that exists between the clevis and adapter bushing and the yoke and link pins and their mating parts (clevis, body, link). Replace these parts if looseness appears excessive. Make certain the brake actuator pushrod jam nut is tightened securely. 2. Inspect the slack adjuster for physical damage, paying attention to the link, boot, and clevis. If any components are damaged, repair or replace them as necessary. 3.
Steering 46 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Drag Link Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–01 Drag Link Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–04 Power Steering Fluid and Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46 Steering 46–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
46 Steering needed to maintain the fluid level between the MIN COLD and MAX HOT lines. 2 1 16. Shut down the engine. 17. Raise the vehicle, remove the jack stands, and lower the vehicle. 46–03 Power Steering Gear Lubrication 3 4 NOTICE 3. Pressure Line 4. Return Hose Apply grease to the sector shaft with a hand-type grease gun only. Use of a high-pressure power grease gun will supply grease too quickly and could affect the high pressure seal, contaminating the hydraulic fluid.
46 Steering 2. Using a clean rag, wipe all dirt from the drag link grease fittings. See Fig. 3. 3. Using a pressure gun and NLGI Grade 2 (8% 12-hydroxy lithium stearate grease) or NLGI Grade 1 (6% 12-hydroxy lithium stearate grease) chassis grease, apply clean grease at the grease fittings until old grease is forced out of the socket. 1 2 10/07/2016 f461072 1. Grease Fitting at Pitman Arm 2. Grease Fitting at Axle Steering Arm Fig.
Fuel 47 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–01 Fuel Tank Band-Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–03 Fuel/Water Separator Element Checking and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47 Fuel 47–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. 1 DANGER When working on the vehicle, shut down the engine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
47 Fuel 9. Connect the water sensor and heater connectors if equipped. 4. Remove the vent cap, shown in Fig. 2, to drain the fuel completely, then close the drain valve. 10. If equipped with a primer pump, prime the fuel/water separator as follows. 5. Using a DAVCO Collar Wrench, shown in Fig. 3, remove the clear cover and collar. 10.1 Loosen the vent plug. Then operate the primer pump until the fuel purges at the vent plug. 10.2 Close the vent plug. 11. Start the engine and check for fuel leaks.
47 VENT CAP Fuel FOR REMOVAL OF TOP COLLAR ONLY 02/16/2009 f470277 Fig. 3, DAVCO Collar Wrench 1. Arrow (on the endplate) 2. Keyway 3. Separator Plate 4. Key 5. Endplate Fig. 4, Positioning the Filter Element 1. 2. 3. 4. 5. 6. 7. Lower Housing Drain Valve Inlet Port/Check Valve 12VDC Pre-Heater 120VAC Pre-Heater Bypass Valve Filter Element 8. 9. 10. 11. 12. 13. Spring Cover O-Ring Clear Cover Vent Cap O-Ring Vent Cap Collar 10.
47 Fuel 47–03 Fuel Tank Band-Nut Tightening Hold each fuel tank band retention nut with a wrench while backing off its jam nut, then tighten the retention nuts 30 to 35 lbf·ft (41 to 46 N·m). After the retention nuts have been tightened, hold each retention nut with a wrench while tightening its jam nut 30 lbf·ft (41 N·m). IMPORTANT: Do not overtighten.
Exhaust 49 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Exhaust System Inspection (noise emission control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–01 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49 Exhaust 49–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
49 Vehicles domiciled outside of the U.S. and Canada may not have aftertreatment equipment, depending upon local statutory emissions guidelines. IMPORTANT: The aftertreatment device (ATD), which is part of the aftertreatment system (ATS), requires special attention during regularly scheduled maintenance inspections. No leaks are allowed anywhere in the system. If any discrepancies are discovered, refer to the engine manufacturer’s service literature for repair instructions. Exhaust 8.
49 Exhaust 4 5 3 2 1 6 12 7 13 8 14 9 11 10 06/28/2016 16 15 f490520 NOTE: The sensor box (item 11) contains the SCR outlet NOx and PM sensors, and the Aftertreatment Control Module (ACM). 1. 2. 3. 4. 5. 6. 7. 8. DOC Inlet NOx Sensor DOC Inlet Pressure Sensor DOC Inlet NOx Sensor Port Exhaust Inlet 18-Pin Connectors Particular Matter Sensor Port SCR Outlet Temperature Sensor SCR Outlet NOx Sensor Port 9. 10. 11. 12. 13. 14. 15. 16.
49 Exhaust 1 2 11 10 9 8 3 7 6 8 9 10 5 4 06/28/2016 1. DEF Metering Unit 2. SCR Outlet Temperature Sensor 3. SCR Inlet Temperature Sensor 4. DOC Inlet Temperature Sensor f490521 5. 6. 7. 8. DOC Inlet Pressure Sensor DPF Inlet Temperature Sensor Particulate Matter Sensors DPF Outlet Pressure Sensor 9. DPF Outlet Temperature Sensor 10. DPF Outlet NOx Sensor 11. SCR Outlet NOx Sensor Fig.
49 Exhaust 1 11 10 2 9 3 7 4 8 5 6 09/16/2009 1. 2. 3. 4. 5. f490354 DPF Inlet Temperature Sensor DOC Inlet Temperature Sensor DOC Inlet Pressure Sensor DPF Sensor Box DPF Outlet Pressure Sensor 6. DPF Outlet Temperature Sensor 7. DPF Outlet NOx Sensor 8. SCR Inlet Temperature Sensor 9. SCR Outlet Temperature Sensor 10. SCR Sensor Box 11. SCR Outlet NOx Sensor Fig.
Electrical, Instruments, and Controls 54 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Electrical Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54–02 Trailer Cable Inspection and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical, Instruments, and Controls 54–01 Trailer Cable Inspection and Cleaning 1. Inspect the cables for cuts, abrasion, or other damage. If internal wiring is exposed, replace the cables. 2. Disconnect the trailer electrical cables from the sockets at the cab. 3. Inspect the cables and sockets for evidence of corrosion, and clean as necessary. If a socket is too badly corroded to clean, replace it. If corrosion has gotten into the wires and connectors inside the socket, replace the cable.
54 Electrical, Instruments, and Controls remove connectors and terminals, scrub and clean as needed using a nylon brush. Clean debris with vacuum or electrical contact cleaner such as CRC QD® Electronic Cleaner, inspect terminals and mating contact terminal plating. If the terminal plating exhibits signs of unrecoverable corrosion, the component and terminal will need to be replaced. 10.
Cab 60 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Aerodynamic Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60–03 Baggage Door and Sleeper Access Door Release Cable and Latch Lubrication . . . . . . . . . . . . . . . . . . . . 60–04 Cab Shock Absorber Bracket Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60–02 Mirror Folding Check . . . . . . .
60 Cab 60–01 Mirror Folding Check For vehicles with folding main mirrors, make sure that the mirrors fold freely on the pivot points. Pivot each mirror fully forward and backward two times to break loose any debris that may affect the fold-away feature of the mirror. 60–02 Cab Shock Absorber Bracket Torque Check 1. Apply the parking brake and chock the tires. 2. Check the torque on the upper bolt that attaches the shock absorber upper bracket to the cab. If loose, tighten the bolt 34 lbf·ft (46 N·m).
60 Cab 1 A A C C E S S B A G G A G E 2 05/07/2012 f602471 NOTE: Baggage door latch shown. Sleeper access door latch is similar. A. Lubricate the latch jaws and the exposed length of cable. 03/31/2016 f720773 1. Sleeper Access Door Handle 2. Baggage Door Handle Fig. 3, Baggage Door Latch Fig. 2, Sleeper Door Release Handles length of cable. See Fig. 3. Repeat for the sleeper access door, if equipped. Removal of trim panels is not required.
Heater and Air Conditioner 83 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–01 Air Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–02 Battery-Powered HVAC System (BPHS) Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83 Heater and Air Conditioner 83–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. clearance specifications. See Fig. 1 for the checking method. If the drive plate clutch requires adjustment, see Group 83 of the New Cascadia™ Workshop Manual. DANGER When working on the vehicle, shut down the engine or motor, set the parking brake, and chock the tires.
83 Heater and Air Conditioner Cab Fresh-Air Filter Replacement IMPORTANT: When replacing the air filter, use only a Freightliner-approved air filter. 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 2. Open the hood. 3. Remove the self tapping screw. 4. Remove the intake filter access panel. Slide it down until it comes loose. See Fig. 2. 04/13/2016 f090526 1. Airflow Directional Arrow Orientation Fig. 3, Airflow Directional Arrow 1 6.
83 Heater and Air Conditioner In vehicles with 48-inch sleepers, raise the lower bunk, and lift the access panel. See Fig. 6. 04/13/2016 f090523 05/15/2007 1. Filter Fig. 4, Cab Recirculation Air Filter f831713 Fig. 5, Sleeper HVAC Access Panel, 60- and 72-inch Sleepers 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 2. Remove the dash front right-hand access panel. 3. Remove the filter. 4. Install the new filter. 5. Install the access panel.
83 Heater and Air Conditioner Battery-Powered HVAC System (BPHS) Air Filter Replacement 1 The BPHS air filter is located on the inboard side of the blower fan housing, under the cabinet, directly behind the driver’s seat. IMPORTANT: When replacing the air filter, use only a Freightliner-approved air filter. 1. Park the vehicle on a level surface, set the parking brake, and shut down the engine. Chock the tires. 2. Remove the sleeper HVAC access panel on the inboard side of the cabinet. See Fig. 5.
83 Heater and Air Conditioner 83–03 Battery-Powered HVAC System (BPHS) Inspection Fuel-Operated Heater Check 1. Start the BPHS and set the control knob to maximum heat. Run the heater for 15 minutes to achieve operating temperature, and clear old fuel from the lines. 2. Verify that the unit completes the start-up cycle, and continues to produce warm exhaust. 3. Check the drain tube(s) for debris, and clean as needed. 4. Install the drain tube(s). 5. Install any components that were removed for access.
83 Heater and Air Conditioner Remove the condenser cover. Fig.
