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Maintenance Manual

CASCADIA

Part Number STI 478

Publication Number STI-478-6

Summary of content (147 pages)

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® CASCADIA Maintenance Manual Part Number STI 478 Publication Number STI-478-6
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CASCADIA MAINTENANCE MANUAL Models: CA113DC CA113SLP CA125DC CA125SLP STI-478-6 (3/16) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
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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 (via ServicePro®) formats. 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.
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Introduction Descriptions of Service Publications 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 AccessFreightliner.com website includes the following documentation.
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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.
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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 . . . . . . . . . . . . . . .
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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
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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
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00 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule I Maint. No.
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00 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule I 00/4 Maint. No.
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00 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule I Maint. No.
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00 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule II 00/6 Maint. No.
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00 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule II Maint. No.
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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.
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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.
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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 00/10 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.
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00 General Information M2 Maintenance Interval Operations: 00–06 Maintenance Operation Number 83–02 M2 Maintenance Interval Operations for Service Schedules I and II Check Air Filter Replacement * For Schedule I vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), whichever comes first. † The fuel cylinder should be inspected every year or 100,000 miles (160 900 km), whichever comes first.
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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.
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00 General Information Maintenance Operation Sets Table: 00–08 Maintenance Operation Sets Maint. No.
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00 General Information Maintenance Operation Sets Table: 00–08 Maintenance Operation Sets Maint. No.
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00 General Information Maintenance Operation Sets Table: 00–08 Maintenance Operation Sets Maint. No. Operation Description Service Schedules I and II IM M1 M2 M3 83–03 ParkSmart™ Inspection • • • • 88–01 Hood Rear Support Lubrication • • • • * On vehicles equipped with Detroit transmissions, the release bearing does not need to be lubricated. On vehicles equipped with Eaton Fuller UltraShift PLUS transmissions, lubricate the release bearing every 50,000 miles (80 000 km) or 3 months.
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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
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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 Cascadia Maintenance Manual, August 2015 Item Cost Maintenance Facility 00/17
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Air Intake 09 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
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09 Air Intake 6 5 4 7 2 2 3 2 1 08/08/2007 f090453 1. Forward Mounting Bracket 2. Nut 3. Forward Mounting Isolator 4, 5 6. 7. Air Cleaner Housing Aft Mounting Bracket Capscrews Aft Mounting Isolator Fig. 3, Air Cleaner Assembly 1 2 01/17/2012 1. Steel Plate f090496 2. Rubber Fig.
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Air Compressor 13 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–01 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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, 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 can not drop. Failure to follow these steps could result in serious personal injury or death. 13–01 Air Compressor Inspection 1.
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Alternators and Starters 15 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–01 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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15 Alternators and Starters 15–00 Safety Precautions 54 of the 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.
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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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20 Engine Cooling/Radiator 20–00 Safety Precautions 2 Safety Precautions in this section apply to all procedures within this group. 3 DANGER 4 When working on the vehicle, shut down the engine, 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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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20 Engine Cooling/Radiator 4. Remove the drain plugs at the radiator side tank and at the lower radiator outlet pipe elbow, if equipped. See Fig. 2. Allow the coolant to drain. 10. Connect the hoses. Your hose clamps can be either T-bolt clamps (see Fig. 3) or Breeze Constant-Torque clamps (see Fig. 4). When working with T-bolt hose clamps, tighten the clamps 55 lbf·in (620 N·cm). These clamps are now standard on hoses with an inside diameter greater than 2 inches (51 mm).
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20 Engine Cooling/Radiator A B 3 1 2 1 4 08/15/94 f200286 A. The screw tip must extend about 1/4 inch (6 mm). B. Belleville washers must collapse almost flat. 1. Tightening Screw Hex 5 Fig. 4, Breeze Constant-Torque Hose Clamp Installation 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.
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20 Engine Cooling/Radiator 1. Disconnect the batteries at the negative terminals. 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. 1 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.
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20 Engine Cooling/Radiator 05/30/2002 f200581 Fig. 8, Checking for Air Leaks (Horton DriveMaster) NOTE: The fan clutch may slip if the air supply pressure is below 70 psi (483 kPa) or if there is 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.
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Clutch 25 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch Release Bearing Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–01 Clutch Replacement, Detroit™ Automated Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–04 Fluid Change, Hydraulic Clutch Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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, 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 can not drop. Failure to follow these steps could result in serious personal injury or death. 25–01 Clutch Release Bearing Lubrication 06/22/2007 Fig.
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25 Clutch 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. Brake fluid can damage paint. Do not allow the fluid level in the reservoir to go below the MIN line.
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25 Clutch 3. Remove the reservoir lid (see Fig. 3) and install the pressure bleed adaptor on the reservoir. Manual Bleeding 4. Bleed the hydraulic system as follows. 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires and open the hood. 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.
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25 Clutch 25–04 Clutch Replacement, Detroit™ Automated Transmissions Replace the clutch assembly for a Detroit Automated transmission at 750,000-mile (1 200 000-km) intervals. Follow the procedure published on the Detroit Diesel Customer Support Network (DDCSN): www.ddcsn.
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Transmission 26 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number ™ Detroit Automated Transmission Air Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–03 Detroit™ Automated Transmission Fluid Change and Magnetic Plug Cleaning. . . . . . . . . . . . . . . . . . . . . . 26–01 Detroit™ Automated Transmission Fluid Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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, 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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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26 Transmission cation, such as Detroit Synth 75W-90. Using lubricant that does not comply with this specification will result in damage to the transmission. The oil part number can be found in module 348 in PartsPro. 6. Add fluid until it is level with the lower edge of the fill opening; see Fig. 3. See Table 1 for approved transmission lubricants, and Table 2 for transmission lubricant capacities. NOTE: In all cases, the correct fluid level is established by checking at the fill opening. 7.
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26 Transmission 26–03 Detroit™ Automated Transmission Air Filter Replacement 5 NOTE: The information in this MOP only applies if the vehicle is equipped with a transmission air filter. 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 4 2. Drain the main air system and the isolated transmission reserve air tank. See Fig. 4. 2 3 3 4 2 1 1 01/08/2013 1. RH Frame Rail 2. Air Filter Canister 3. Air Inlet Hose f261450 4. Air Outlet Hose 5.
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26 Transmission clockwise motion to separate the filter from the mounting. Carefully spin the filter off the mount and remove it from the vehicle. sion. Overfilling will force fluid out of the case through the main shaft openings. Do not mix types or brands of fluid, because of possible incompatibility. Do not use fluid additives, friction modifiers, extreme-pressure gear fluids, or multiviscosity lubricants. IMPORTANT: Drain the transmission when the fluid is warm.
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26 Transmission Eaton Fuller Transmission Lubricant Capacities Transmission Model Refill Capacity: qt (L) RTLO Series 14.0 (13.2) 10-Speed Deep Reduction RTO–14908LL 14.0 (13.2) RTO–16908LL 10-Speed Advantage FA Series 8.0 (7.5) 10-Speed Automated Lightning Top 2 (all) 13.5 (12.8) 10-Speed Autoshift AS2 (all) 13.0 (12.3) 13-Speed RTLO Series All Models 14.0 (13.
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26 Transmission For more information and a complete listing of approved lubricants, refer to the Eaton website, www.roadranger.com. 1. Clean the oil level sight glass. See Fig. 6. 26–06 Eaton Fuller Manual Transmission Air Filter/ Regulator Check, Cleaning, or Replacement 1. Apply the parking brakes, and chock the rear tires. Drain the air reservoirs.
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26 Transmission 3. Remove the end cap, large O-ring, and filter element from the filter housing. See Fig. 9. Remove the small O-ring from the end cap. 2 4 3 5 6 7 CAUTION A leaking air filter or air lines can cause slow or hard shifting of the transmission, and eventual transmission damage. 7. Start the engine, and build pressure in the air system. Check for air leaks at the filter housing and air line connections; repair any leaks. 1 f260052a 10/17/2001 1. 2. 3. 4.
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Frame and Frame Components 31 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fairing Bumper Wear Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–04 Fifth Wheel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–01 Fifth Wheel Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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31 Frame and Frame Components 31–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER 3. Check the fifth wheel plate for cracks. Check for sharp edges on top; the chamfer should be 1/8 to 1/4 inch (3 to 6 mm). 4. When the wheel is locked, the safety latch must swing free and fall freely into position. See Fig. 1. 1 When working on the vehicle, shut down the engine, set the parking brake, and chock the tires.
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31 Frame and Frame Components 6. Check all cotter pins for cracking or damage. Replace any cotter pin that shows any signs of damage. 7. Check all mounting bolts for signs of fatigue, and tighten them to the proper torque. For torque specifications, see Group 00 of the vehicle Workshop Manual. Inspect all angles, plates, and brackets for cracks or other damage. A 8. Replace cracked, worn, or damaged parts with new parts.
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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.
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31 Frame and Frame Components 9. Check all springs to see if they are securely fastened, and are not deformed. WARNING Do not disassemble the fifth wheel to inspect the springs. The springs are under extreme pressure, and could cause serious injury. 10. Check the wedge adjustment. 10.1 Close the fifth wheel on a standard 2-inch (50-mm) kingpin or similar 2-inch (50-mm) diameter shaft so that it locks. 10.2 Push on the wedge stop rod with hand pressure.
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31 Frame and Frame Components C 1 E 2 D 3 A F 09/02/2009 f311100 1. Jam Nut 2. Adjustment Bolt Fig. 7, Jost Fifth Wheel H G 9.3 Check the locking mechanism for proper operation. If the plungers will not release, check the air cylinder or plunger adjustment. B If the plungers are loose, check the plunger adjustment and the plunger springs for proper compression. Replace if needed. f311099 09/01/2009 A. B. C. D. E. F. G. H. 3. Grease Zerk Checking for fore/aft play.
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31 Frame and Frame Components hardened washers. Do not re-use bolts, nuts, and washers on fifth wheel mountings. 11. After inspecting the fifth wheel, lubricate all moving parts with a chassis or multipurpose grease. Apply a generous coating of grease to the top plate to fill the grooves, or depressions, on the top plate. See MOP 31–02 in this manual for lubrication instructions.
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31 Frame and Frame Components Grease #5213, Craftsman Chemical Co. #LTF 2, Mystic LP-200, or equivalent is recommended. 1 1 2 2 3 2 3 3 2 3 4 f310884 04/11/2011 1. Pull Handle 2. Jaw 3. Wedge 12/03/2010 f311135 1. Release Handle and Spring 2. Grease Fitting Fig. 8, Fontaine Fifth Wheel 1 3. Yoke Tip 4. Locks Fig. 10, Holland FW35 Fifth Wheel, Grease Lubrication Jost Lubricate the kingpin lock using a hand pump grease gun through the grease zerk on the skirt of the fifth wheel; see Fig.
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31 Frame and Frame Components 31–03 Frame Fastener Torque Check Frame brackets and components secured with Huckbolt® fasteners do not require a torque check, however, they should be inspected for damage. Frame brackets and components secured with conventional bolts and nuts are to be checked at Initial Maintenance (IM). Check the torque of frame fasteners to offset the effects of "bedding in" (or seating). When checking torque, torque the nut, not the bolt head whenever possible.
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Frame and Frame Components 03/13/2007 31 f311034 Fig.
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Suspension 32 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Lubrication of Front Suspensions with Grease Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–03 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–00 Suspension Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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32 Suspension 32–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine, 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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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32 Suspension not leak. If any of these conditions exist, replace the damaged parts; see Group 32 of the Cascadia™ Workshop Manual. Suspension Height Checking IMPORTANT: Before checking the AirLiner suspension height, make sure there is no load on the chassis, and the trailer is unhitched. as viewed from the side of the vehicle; see Fig. 2. The rod may be on the forward or aft side of the lever to get it to be vertical. 3.
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32 Suspension for adjustment instructions. If the distance is within the acceptable range, apply the parking brakes. 32–02 Suspension U-Bolt Torque Check CAUTION tern as shown in Fig. 3. Set a click-type torque wrench to the mid-point torque value for the fastener being checked. Turn the wrench in a clockwise motion (looking up) until the torque wrench clicks, then release pressure on the torque wrench, and turn the wrench again until it clicks.
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32 Suspension A A 09/24/2009 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, 10k/12k/15k/18k Mid Ride and 40k Low and Mid Ride 09/28/2005 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
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32 Suspension 32–03 Lubrication of Front Suspensions with Grease Fittings Wipe all dirt away from the grease fittings (if equipped) on the spring-eye bushings. Apply multipurpose chassis grease with a pressurized grease gun until the old grease is forced out.
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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, 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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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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.
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33 Front Axle equipment manufacturer. Freightliner dealers must have proof of this calibration history. 1. Apply the parking brakes and chock the rear tires. 2. Raise the front of the vehicle until the tires clear the ground. Place safety stands under the axle. 6. Place a trammel bar at the rear of the front tires; locate the trammel pointers at spindle height, and adjust the pointers to line up with the scribe lines on the center ribs of the front tires. See Fig. 6. Lock in place.
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33 Front Axle f400100a 08/30/94 Fig.
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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35 Rear Axle 35–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER 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. See Fig. 1. When working on the vehicle, shut down the engine, set the parking brake, and chock the tires.
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35 Rear Axle Detroit Drive Axle Lubricants* CAUTION 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. 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 4.2 4.3 4.
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35 Rear Axle 500,000 miles (800 000 km) for axles using synthetic lubricant with a pump and filter system. On single drive axles so equipped, the traction equalizer may slip or stick. When this happens, the driver will hear intervals of shrill noises when the vehicle is driven at low speed or makes sharp turns. Use a "limited-slip friction modifier" to correct this slip/stick condition. Add 1.6 ounces (35 mL) of additive for each pint (0.5 L) of lube capacity.
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35 Rear Axle to short the two magnetic poles and divert the magnetic field. 5.2 5.3 Check the drain plug for metal particles every 100,000 miles (160 000 km). Clean away the collected material deposited on each pole. Magnets will rapidly lose their effectiveness as collected material bridges the gap between the two poles. Each time the oil is changed, replace any magnetic drain plug that does not meet the minimum pickup capacity.
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35 Rear Axle 4.2 Wash the strainer in solvent, and blow it dry with compressed air to remove oil and metal particles. 4.3 Install and tighten the magnetic strainer 40 to 60 lbf·ft (54 to 81 N·m). 1 5. Clean the fill and drain plugs. Change them if necessary. 5.1 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. 5.2 Clean away the collected material deposited on each pole.
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35 Rear Axle Dana Spicer Drive Axle Lubricant Capacities Axle Type Single Reduction Axle Model Capacity:* Pints (liters) 23080S, 23080D 40 (18.9) 23105S, 23105D 48 (22.7) 1 Tandem Drive Axle Installation Single Reduction 2-Speed (dualrange) Double Reduction DD404, DD404–P 31 (14.7)† DS404, DS404–P 39 (18.5)† DS461–P 43 (20.3)† DT402, 402–P 34 (16.1)† DT451–P 39 (18.5)† DT461–P 43 (20.3)† DP451–P 34 (16.1)† DP461–P 43 (20.3)† * Quantities listed are approximate.
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35 Rear Axle 35–02 Axle Breather and Axle Lubricant Level Inspection For all axles, including tandem drive axles and twospeed axles, perform the applicable procedures under the heading, "All Axle Models." For a twospeed axle with a shift unit, also check the shift unit lubricant; see under the heading, "Two-Speed Axles With Shift Unit." All Axle Models Detroit™ NOTICE of the fill plug, using the lubricant recommended in Table 2.
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35 Rear Axle leaks, and correct as needed. Add oil to the level of the fill plug, using the lubricant recommended in Table 3. Dana® Spicer® NOTICE 4. Install and tighten the fill plug 35 lbf·ft (47 N·m). IMPORTANT: Always check the axle breather whenever checking the lubricant level. Check the breather more frequently under adverse operating conditions. 5. Check the axle housing breather. Make sure that it is open and unclogged. See Fig. 7.
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35 Rear Axle 5. Install and tighten the fill plug 40 to 60 lbf·ft (54 to 81 N·m). Automatic transmission fluid can be used for all temperatures; do not mix it with kerosene. IMPORTANT: Always check the axle breather whenever checking the lubricant level. Check the breather more frequently under adverse operating conditions. 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.
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Wheels and Tires 40 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Tire Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–02 Wheel Nut Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
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Driveline 41 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–01 Driveline Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–02 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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, 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 can not drop. Failure to follow these steps could result in serious personal injury or death. ME 41–01 Driveline Inspection 1.
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41 Driveline 14 15 13 3 9 8 7 16 12 11 1 2 10 6 5 4 3 05/01/95 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.
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41 Driveline 5 1 2 f410012a 05/27/93 7 3 4 3 6 Attempt to move the sleeve-yoke and splined shaft back and forth. 8 Fig. 4, Slip Joint Spline Wear Checking 3 evidence that balance weights are missing, remove the driveshaft and have it balanced. 9. For driveshafts with slip joints, check to be sure the yoke plug is not loose or missing. See Fig. 5. Repair or replace the yoke plug as needed.
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41 Driveline screws to the correct torque specifications. If the bearing will not take grease, replace the U-joint. Refer to Group 41 of the vehicle Workshop Manual for replacement instructions. 6. Check the purged grease. If it appears rusty, gritty, or burned, replace the U-joint. 7. Wipe the purged grease from the seals, and any excess grease from the grease fitting. Slip Joint Spline Lubrication NOTE: Vehicles equipped with Meritor RPL Series drivelines do not require periodic lubrication. 1.
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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, 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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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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.
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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.
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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.
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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.
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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.
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42 Brakes Brake Chamber Stroke Specifications Chamber Type* Manufacturer Gunite Standard Stroke Size† 9 Max Applied Stroke: inch (mm) 1-3/8 (35) 12 16 20 1-3/4 (44) 24 Long Stroke 30 2 (51) 36‡ 2-1/4 (57) 16 2 (51) 20 24 (2-1/2 inch rated stroke) 24 (3 inch rated stroke) 2-1/2 (64) 30 Haldex Standard Stroke 12 1-3/8 (35) 16 1-3/4 (44) 20 24 2-1/2-Inch Extended Stroke Meritor 24 2 (51) 3-Inch Extended Stroke 24 2-1/2 (64) Standard Stroke 30 2 (51) Long Stroke 30 2-1/2 (64
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42 Brakes Brake Chamber Stroke Specifications Chamber Type* Manufacturer Dana Spicer Long Stroke Size† Max Applied Stroke: inch (mm) 16L 2 (51) 20L 24L 24LS 2-1/2 (64) 30LS * Long stroke design is indicated by a tag, or embossing, on the brake chamber. † Specifications are relative to a brake application with 80 to 90 psi (550 to 620 kPa) air pressure in the brake chambers. ‡ If type 36 chamber is used, slack length should be less than 6 inches. Table 1, Brake Chamber Stroke Specifications 5.
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42 Brakes NOTE: If equipped with an extendedmaintenance Q Plus™ brake system, the camshaft bracket will not have a grease fitting. These camshafts use a special NLGI Grade synthetic polyurea grease and do not require lubrication for 3 years or 500,000 miles (800 000 km), whichever comes first. The extendedmaintenance camshaft bushings are lubricated during the brake reline service interval. For service and lubrication instructions, see Group 42 of the vehicle Workshop Manual.
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42 Brakes 5. Check the brake pedal mounting plate adapter for signs of wear or cracks at the bosses (the area from which the pivot pin was removed). Replace it if necessary. 1 2 6. Check the brake pedal rollers for signs of wear or cracks. Replace the rollers as needed. 7. If the rollers are replaced, replace the roller pin, install a new cotter pin, bend it to 90 degrees and apply Torque Seal (OPG F900 White) to the cotter pin. 3 4 8. Remove the plunger from the valve.
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42 Brakes this may result in contamination and malfunctioning of downstream air system components. Refer to Fig. 9 for cartridge replacement. 1. Drain the air system. 42–11 Versajust Slack Adjuster Inspection and Lubrication IMPORTANT: Perform the Brake Inspection maintenance operation before lubricating the slack adjusters. 1. Visually check for physical damage, such as broken air lines and broken or missing parts. 2.
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42 Brakes Actuator Stroke–Standard Stroke Brake Actuator Size Recommended Maximum Operating Stroke (Inches) 20 1-3/4 16 1-3/4 12 1-3/8 Table 2, Actuator Stroke–Standard Stroke Actuator Stroke–Long Stroke Brake Actuator Size Recommended Maximum Operating Stroke (Inches) 30 Long Stroke 2-1/2 24 Long 2 24 Long Stroke 2-1/2 20 Long 2 16 Long 2 Table 3, Actuator Stroke–Long Stroke 42/12 Cascadia Maintenance Manual, November 2015
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Steering 46 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Bellows Replacement, Rack and Pinion Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–07 Drag Link Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–01 Drag Link Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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, 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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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46 the drain pan. Leave the filter hanging over the drain pan. 5. Remove the nuts, bolts, and washers that attach the power steering reservoir to the mounting bracket, but do not remove the supply line to the reservoir. Drain the power steering fluid from the reservoir. Steering 46–03 Power Steering Fluid Level Inspection 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 6.
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46 Steering Inspect the rack and pinion steering system as described below, and repair or replace any components that are worn or damaged. Figure 4 shows the components of the rack and pinion steering system. 1 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 2. Check the steering I-shaft U-joints for evidence of looseness or binding. If any is found, replace the I-shaft. 3.
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46 Steering 16 11 12 15 13 10 7 8 9 14 6 17 2 3 4 5 21 19 9 8 20 22 23 18 5 1 3 f462151 07/24/2009 1. 2. 3. 4. 5. 6. 7. 8. 9. 4 Steering Tie Rod Arm Power Steering Fluid Lines Large Bellows Clamp Bellows Small Bellows Clamp Driver-Side Outer Tie Rod Tie Rod Jam Nut Inner Tie Rod Flat Inner Tie Rod Ball Joint 10. 11. 12. 13. 14. 15. 16.
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46 Steering 46–07 Bellows Replacement, Rack and Pinion Steering Gear 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. the teeth of the rack shaft. Do not apply grease to the shaft on the passenger side. 10. Turn the wheels all the way to the right to fully expose the driver-side rack. Without applying grease to the teeth of the rack shaft, evenly apply a light film of Renolit CX-FO 20 grease to the metal surfaces covered by the driver-side bellows.
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46 Steering 14.1 Rotate the ears of the large Oetiker clamp forward on the bellows to avoid pinching the clamp in the next step. 14.2 Ensure the large Oetiker clamp is properly seated in the clamp groove on the bellows. Align the large Oetiker clamp ear with the small clamp ear. Both clamp ears should be aligned with the rack housing casting rib. See Fig. 7. 3 1 2 5 4 09/09/2009 11/30/2011 f462214 1. Inner Tie Rod 2. Small Oetiker Clamp 3. Bellows 4. Large Oetiker Clamp 5.
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46 Steering 2 07/24/2009 f580473 2 Fig. 8, Oetiker Clamp Tool, P/N 14100037 or 14100082 A 1 5 08/25/2009 f462172 A. Crimp the clamp ears until the ear width is 0.08 to 0.16 inch (2 to 4 mm). 1. Bellows 2. Large Oetiker Clamp 3 1 07/21/2009 4 2 1. Outer Tie Rod 2. Small Oetiker Clamp 3. Bellows Fig. 10, Oetiker Clamp Ear Width f462165 4. Large Oetiker Clamp 5. Oetiker Clamp Tool Fig. 9, Oetiker Clamp Installation 16.
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46 Steering NOTICE Maximum wheel cut is not to exceed 46 degrees. Excessive wheel cut may damage the inner tie rod. 1 20.10 Verify that wheel cut does not exceed 46 degrees. Adjust wheel cut if needed. A 21. Install both wheels on the steer axle. 2 22. Remove the jack stands and lower the vehicle. 05/31/2007 f462071 A. Align the pointers. 1. Input Shaft Seal Cover 2. Input Shaft Housing Fig. 11, Rack and Pinion Pointer Alignment 20.5 Loosen the passenger-side tie rod clamp nut. 20.
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Fuel 47 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number CNG Fuel Cylinder Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–08 CNG Fuel System Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–06 CNG High-Pressure Fuel Filter Element Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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47 Fuel 47–00 Safety Precautions 2. Disconnect the water sensor and heater connections if equipped. Safety Precautions in this section apply to all procedures within this group. 3. Remove the element and bowl together, by turning counterclockwise. DANGER When working on the vehicle, shut down the engine, 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 can not drop.
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47 Fuel The drain valve has a 1/2-inch (12.7-mm) pipe; use a hose with a 1/2-inch pipe thread to fit correctly. 2 3 1 4. Remove the vent cap ( Fig. 2, Item 4) and open the drain valve ( Fig. 2, Item 1) to drain the fuel completely, then close the drain valve. 4 4 11 3 5 5 10 2 9 6 7 6 8 06/25/97 1. 2. 3. 4. 5. 6. f470147 Mounting Head Fuel Primer Pump Vent Plug Bowl O-Ring Bowl Gasket Bowl Probe Plug 7. 8. 9. 10. 11.
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47 Fuel to be hand-tightened only, not tightened with a wrench. Use part number 482017 on Fuel Pro 482 units; part number 380134 on Fuel Pro 382 units. 6. Remove the filter, cover O-ring, and vent cap O-ring. Dispose of them in an environmentally acceptable manner. See Fig. 4 or Fig. 5. 11 10 9 7. Clean all threads and sealing surfaces very thoroughly. Even a small amount of dirt will prevent the fuel/water separator from sealing, and an air leak may result. 8 8.
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47 Fuel cooled. Draining it when the engine is hot could cause severe personal injury due to scalding. 10 If returning fuel is released into the atmosphere, its vapors can ignite in the presence of any ignition source. Do not expose the fuel to, or work with the fuel system near, open flame or intense heat. To do so could cause fire, possibly resulting in serious personal injury or property damage. 9 8 1. Shut down the engine, apply the parking brake, and chock the tires. 2.
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47 Fuel 13. Start the engine. When the lubricating oil reaches its normal operating pressure, increase engine speed to high idle for one to two minutes to purge air from the system. 14. Check for leaks and shut down the engine. 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).
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47 Fuel 7 6 8 10 9 5 11 4 3 2 12 1 02/04/2014 1. 2. 3. 4. 5. 6. f470617 7. 8. 9. 10. 11. 12. Pressure Control Regulator Vapor Shutoff Valve Fuel Fill Hose Secondary Relief Valve (red cap) Fuel Fill Fitting Fuel Level Sender Box Primary Relief Valve Tank Pressure Gauge Fill Vent Fitting Excess Flow Valve Fuel Shutoff Valve (liquid) Fill Check Valve Fig. 6, LNG Tank Plumbing Components Plumbing Components Inspecting See Fig. 6 for plumbing component locations.
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47 Fuel 3. Inspect all connectors and wiring for signs of loose connections, damage, or chafing. 4. Turn the ignition switch to the ON position and check for fuel gauge response. 5. Repair or replace any damaged fuel gauge components. Vaporizer Inspecting See Fig. 6 for plumbing component locations. 1. Ensure that the vaporizer is secured to its mounting brackets and that the mounting brackets are secured to the frame. Inspect for any signs of looseness. 2.
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47 Fuel Vacuum Integrity Test Results Pressure Increase Over EightHour Period More than 50 psi (345 kPa) Remedy Remove vehicle from service and evacuate the tank per the tank manufacturer’s instructions Table 1, Vacuum Integrity Test Results 47–06 CNG Fuel System Inspecting WARNING As with all pressure vessels, CNG/LNG storage and fuel delivery systems are inherently dangerous and should be treated as such.
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47 Fuel 47–08 CNG Fuel Cylinder Inspecting Have a qualified inspector inspect compressed natural gas (CNG) fuel cylinders for damage or deterioration. Note cuts, cracks, gouges, abrasions, discoloration, broken fibers, loose brackets, damaged gaskets or isolators, heat damage, or other problems. 2 4 3 Refer to the Compressed Gas Association’s (CGA) pamphlet C-6.
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47 Fuel 2 2 3 6 4 5 2 3 1 02/25/2014 f470619 1. CNG Fuel Cylinder, Frame Rail Mounted 2. Top Plate Bolts (qty 6 per side) 3. Frame Rail 4. Mounting Bracket 5. Gussett Bolts (qty 2 per side) 6. Bracket to Frame Nuts and Bolts (qty 8 per side) Fig.
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47 Fuel 2 1 H IG H PRESS UR E RE LOW PRES S U CYLINDERS INSPECT CYLINDERS EVERY 36 MONTHS OR 36000 MILES WHICHEVER OCCURS FIRST REGULATOR INSPECT PRESSURE RELIEF DEVICE EVERY 2000 MILES NATURAL GAS VEHICLE 110 PSIG FILTER ON DRAIN HOUSING EVERY 1500 MILES REPLACE ELEMENT EVERY 3000 MILES 3 M SH AN U U VA T O AL LV FF E 3600 PSIG MAX. SERVICE PRESSURE OPEN VALVE SLOWLY 4 04/30/2010 1. 2. 3. 4.
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Exhaust 49 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number CAT CGI Bellows Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–02 Exhaust System Inspection (Noise Emission Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–01 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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, 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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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49 1. Check for leakage at the clamp that attaches the exhaust pipe to the turbocharger exhaust outlet. If leakage exists, tighten the nut on the clamp to the required torque. If leakage persists, install a new clamp. 2. Check the exhaust pipe, bellows, and each exhaust seal clamp for leakage, wear, cracks, or damage. Replace damaged components as needed. If leakage exists at a clamp, tighten the nuts to the required torque. If leakage persists, install a new exhaust seal clamp. Do not reuse seal clamps.
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49 Exhaust 13 14 12 9 9 1 2 8 3 7 11 10 6 4 15 5 08/20/2009 f490355 NOTE: The sensor box (item 8) contains the SCR inlet and outlet NOx sensors, DPF outlet pressure sensor, and the DOC inlet pressure sensor. 1. DOC Outlet Temperature Sensor 2. DOC Inlet Pressure Sensor Port 3. DOC Inlet Temperature Sensor 4. Front Heat Shield 5. DEF Nozzle 6. 7. 8. 9. 10. Exhaust Outlet DEF Metering Unit Sensor Box (see note above) Exhaust Inlet SCR Outlet Temperature Sensor 11. 12. 13. 14.
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49 Exhaust 1 2 11 10 3 9 8 4 10 8 9 7 6 5 09/16/2009 1. DEF Metering Unit 2. DEF Nozzle 3. SCR Outlet Temperature Sensor 4. SCR Inlet Temperature Sensor f490353 5. 6. 7. 8. DOC Inlet Temperature Sensor DOC Inlet Pressure Sensor DPF Inlet Temperature Sensor DPF Outlet Pressure Sensor 9. DPF Outlet Temperature Sensor 10. DPF Outlet NOx Sensor 11. SCR Outlet NOx Sensor Fig. 2, 2V2 Two-Box ATS Sensor Locations 4.
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49 Exhaust 1 11 10 2 9 3 7 4 8 5 6 09/16/2009 1. 2. 3. 4. 5. DPF Inlet Temperature Sensor DOC Inlet Temperature Sensor DOC Inlet Pressure Sensor DPF Sensor Box DPF Outlet Pressure Sensor f490354 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. 3, 2HV Two-Box ATS Sensor Locations Pre-EPA07 Exhaust System 5. Inspect the turbo outlet pipe, and replace it as needed. 1.
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49 Exhaust 6 5 3 2 1 2 4 7 5 8 9 3 A 10/20/2006 A. 1. 2. 3. 4. 5. Inspect this area of the canister for dents. Marmon Fitting at Inlet from Turbocharger DOC Temperature Sensor ATD Mounting Band DPF Intake Pressure Sensor DPF V-Band Mounting Clamps 6. 7. 8. 9. f490283 Sensor Housing DPF Outlet Temperature Sensor Exhaust Outlet Marmon Fitting DPF Outlet Pressure Sensor Fig. 4, Typical EPA07 Aftertreatment Device 1 2 3 4 5 6 5 3 7 8 9 3 10 02/24/2011 1. 2. 3. 4.
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49 Exhaust 2 1 3 4 06/01/93 f490024a 1. Flex Hose 2. V-Band Coupling 3. Exhaust Pipe 4. Turbocharger Exhaust Outlet 05/28/93 f490025a Fig. 8, Donaldson Sealclamp Wide-Band Exhaust Clamp Fig. 6, V-Band Coupling and Flex Hose NOTICE A leak in the CGI piping, including the bellows, will allow unfiltered air and contaminants into the engine intake, and can cause serious engine damage. 1. Park the vehicle, set the parking brake, chock the wheels. 2. Open the hood. 1 3.
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49 Exhaust NOTICE When the CGI pipes and bellows are installed, there should be approximately 3/4 inch (19 mm) clearance from the main bellows. Contact between the bellows could result in an exhaust leak, which in this case may allow ingestion of contaminants into the engine causing engine damage. 6.3 Use a straightedge to align the pipes so that the pipe ends that attach to the bellows are parallel and concentric. 8. Using a yellow paint pen, mark the pipes 1.
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49 Exhaust 13. Install the slip clamp with the retaining ring and graphite gasket ring onto the forward CGI pipe. See Fig. 12 for proper installation. 1 2 3 02/08/2010 1. CGI Bellows 2. Slip Clamp 3. Retaining Ring 4 5 f490417 4. Graphite Gasket 5. Forward CGI Pipe Fig. 12, Forward Facing Slip Clamp Installation 14. Slide the end of the forward CGI pipe into the bellows, and properly align the pipe. 15. Secure the forward CGI pipe to the engine and any CGI pipe support brackets. 16.
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Electrical, Instruments, and Controls 54 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Trailer Cable Inspection and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Electrical, Instruments, and Controls 54 54–01 Trailer Cable Inspection and Cleaning 1. Disconnect the trailer electrical cables from the sockets at the cab. 2. Inspect the cables and sockets for evidence of corrosion, and clean as necessary. If a socket is too badly corroded to clean, replace it. Freightliner recommends also replacing the socket’s harness as well, if the corrosion has gotten into the wires and connectors inside the socket.
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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 . . . . . . .
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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).
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60 Cab 1 A 2 3 05/11/2012 f720661a 1. Sleeper Access Door Handle 2. Baggage Door Handle 3. Cab Door Frame, Driver Side Fig. 2, Baggage Door and Sleeper Access Door Release Handles sleeper access door, if equipped. Removal of trim panels is not required. NOTE: Removal of trim panels is not required. 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. Fig.
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Heater and Air Conditioner 83 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–01 Air Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–02 ParkSmart™ Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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83 Heater and Air Conditioner 83–00 Safety Precautions quires adjustment, see Group 83 of the Cascadia™ Workshop Manual. Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine, 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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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83 Heater and Air Conditioner Cab Fresh-Air Filter Replacement IMPORTANT: When replacing the air filter, use only a Freightliner-approved air filter. erly installed, the airflow arrow will point in the same direction as the marking on the front edge of the tray. Both will point toward the cab. See Fig. 4. 1. Park the vehicle on a level surface, set the parking brake, and shut down the engine. Chock the tires. 2. Open the hood. 1 3. Remove the intake screen. See Fig. 2. f831717 04/10/2007 1.
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83 Heater and Air Conditioner 1 4 2 1 3 04/17/2007 04/18/2007 f831719 1. Filter f831718 1. Kick Panel 2. Side Trim Panel 3. Step Plate 4. Door Seal Fig. 6, Panels Fig. 5, Cab Recirculation Air Filter (shown out of the vehicle for clarity) 2. Loosen the passenger-side kick panel, tilt it out, and carefully twist and remove the light bulb socket from the lens on the back of the panel. Move the panel out of the way. See Fig. 6. 3.
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83 Heater and Air Conditioner Sleeper Air Filter Replacement In vehicles with 60-inch and 72-inch sleepers, the sleeper air filter is located on the forward side of the blower fan housing, under the cabinet, directly behind the driver’s seat. In vehicles with 48-inch sleepers, the sleeper air filter is located on the forward side of the blower fan housing, under the bunk, directly behind the driver’s seat. IMPORTANT: When replacing the air filter, use only a Freightliner-approved air filter. 1.
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83 Heater and Air Conditioner 2 1 1 02/14/2012 1. Bunk Frame Upper Surface f831900 2. Filter Fig. 11, Removing the Filter, 48-inch Sleeper 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. 8. The panel is held in place with four spring clips. Pull straight out to remove it. 3. Pull the filter out of the slot. See Fig. 12. 4.
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83 Heater and Air Conditioner 1. Remove the inspection plate on the bottom of the condenser module. See Fig. 15. 1 2 09/21/2010 f831857 Remove and clean the drain tube. 1. Drain Tube 2. Intake Duct 06/10/2011 Fig. 13, Drain Tube Inspection (pre-July 2011) f831879 Remove the inspection plate. Fig. 15, Condenser Cleaning NOTE: If the condenser core has a build up of fine debris, an A/C core cleaner, approved for copper and aluminum cores, and a low pressure water can be use to clean it. 2.
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Hood, Grille, and Cab Fenders 88 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Hood Rear Support Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Hood, Grille, and Cab Fenders 88 88–01 Hood Rear Support Lubrication 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. Clean both the hood- and cab-mounted hood rear support components with a soapy water solution. 4. Cover all contact surfaces of the hood rear support brackets and isolators with an approved multi-purpose, lithium-complex, soap-based grease; see Table 1. 5. Close the hood.