Maintenance Manual

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ACTERRA MAINTENANCE MANUAL

Models: MX

STI-403-1 (10/07P)

Published by

Freightliner LLC

4747 N. Channel Ave.

Portland, OR 97217

Printed in U.S.A.

Summary of content (134 pages)

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ACTERRA MAINTENANCE MANUAL Models: MX STI-403-1 (10/07P) Published by Freightliner LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
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Foreword When performed on a regular basis, lubricating the parts of your vehicle is the least costly way of obtaining safe and reliable vehicle operation. Added benefits and savings occur when you check that the engine, undercarriage, and noise emission control parts are in good working order during lubrication. This maintenance manual explains when you should lubricate parts and what to look for when checking for wear or damage. For daily and weekly checks, refer to the vehicle driver’s manual.
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Introduction Descriptions of Service Publications Freightliner LLC distributes the following major service publications. Workshop Manual Workshop manuals contain service and repair information for all vehicle systems and components, except for major components such as engines, transmissions, and rear axles. Each workshop manual section is divided into subjects that can include general information, principles of operation, removal, disassembly, assembly, installation, specifications, and troubleshooting.
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Introduction Page Description For a page example of the printed manual, see Fig. 1. A B C 31 Frame and Fifth Wheel 31−01 Frame Fastener Torque Checking CAUTION: 31−02 Fifth Wheel Inspecting and Lubricating HOLLAND FONTANE Acterra Trucks Maintenance Manual, April 2000 D 31/1 E f020103 02/11/2002 A. B. C. D. E. Maintenance Operation Number consists of the Group Number followed by the Sequence Number Group Title Group Number Release Date Group Number/Page Number Fig.
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Introduction Maintenance Manual Contents Group No. Group Title 00 . . . . . . . . . . . . . . . . . . . . . . General Information 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Intake 13 . . . . . . . . . . . . . . . . . . . . . . . . . Air Compressor 15 . . . . . . . . . . . . . . . . . . . Alternators and Starters 20 . . . . . . . . . . . . . . . . . . . Engine Cooling/Radiator 25 . . . . . . . . . . . . . . .
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General Information 00 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Initial Maintenance (IM) Operations Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–09 Lubrication and Fluid Level Check (M1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–15 Lubrication and Fluid Level Check (M2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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00 General Information Noise Emission Control Systems Maintenance: 00–01 General Information 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 degradation through
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00 General Information Verification of Inspections Log: 00–02 Verification of Inspections Log Verification of Inspections Log — Group 20 Verification of Inspections Log — Group 20 — Engine Cooling/Radiator Date Mileage Repair Description Cost Repair Facility Verification of Inspections Log — Group 49 Verification of Inspections Log — Group 49 — Exhaust Date 00/2 Mileage Repair Description Cost Repair Facility Acterra Maintenance Manual, January 2007
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00 General Information Torque Specifications Tables: 00–03 Torque Values for U.S. Customary Thread Fasteners With Lubricated* or Plated Threads† Regular Hex Thread Diameter– Pitch Grade 5 Bolt Grade 5 or B Nut Torque: lbf·ft (N·m) f230003 f230002 Flanged Grade 8 or 8.2 Bolt Grade 8 or C Nut Torque: lbf·ft (N·m) f230004 f230005 Grade 5 Bolt Grade B Nut Torque: lbf·ft (N·m) f230006 f230007 Grade 8 or 8.
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00 General Information Torque Specifications Tables: 00–03 Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated)* Plain (Unplated) Threads† Regular Hex Thread Diameter–Pitch Grade 5 Bolt Grade 5 or B Nut Torque: lbf·ft (N·m) Grade 8 or C Nut Torque: lbf·ft (N·m) f230003 f230002 Flanged Grade 8 or 8.2 Bolt f230004 Grade 8 or 8.
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00 General Information Torque Specifications Tables: 00–03 Torque Values for Metric Thread Fasteners With Lubricated* or Plated Threads† Class 8.8 Bolt Class 8 Nut Thread Diameter–Pitch Torque: lbf·ft (N·m) 8.8 Class 10 Nut Torque: lbf·ft (N·m) 10.9 8 f230010 Class 10.9 Bolt f230011 10 f230012 f230013 M6 5 (7) 7 (9) M8 12 (16) 17 (23) M8 x 1 13 (18) 18 (24) M10 24 (33) 34 (46) M10 x 1.25 27 (37) 38 (52) M12 42 (57) 60 (81) M12 x 1.
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00 General Information Metric/U.S. Customary Conversion Tables: 00–04 When You Know U.S. Customary Multiply By To Get Metric When You Know Metric Multiply By To Get U.S. Customary Length inches (in) 25.4 millimeters (mm) 0.03937 inches (in) inches (in) 2.54 centimeters (cm) 0.3937 inches (in) feet (ft) 0.3048 meters (m) 3.281 feet (ft) yards (yd) 0.9144 meters (m) 1.094 yards (yd) miles (mi) 1.609 kilometers (km) 0.6215 miles (mi) square inches (in2) 645.
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00 General Information Scheduled Maintenance Intervals, Description and Use: 00–05 Description Use Schedule I (severe service) applies to vehicles that annually travel up to 6000 miles (10 000 kilometers) or that operate under severe conditions.
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00 General Information Maintenance Schedule Table: 00–06 Maintenance Intervals Maintenance Schedule Models Maintenance Interval Operation Frequency Miles Km Hours Schedule I (Severe Service) vehicles that annually travel up to 6000 miles (10 000 km) All Initial Maintenance (IM) first 1000 1600 100 Maintenance 1 (M1) every 1000 1600 100 Maintenance 2 (M2) every 4000 6400 400 Maintenance 3 (M3) every 8000 12 800 800 Maintenance 4 (M4) every 16,000 25 600 1600 Maintenance
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00 General Information Maintenance Interval Tables: 00–07 Maintenance Intervals for Schedule I Maint. No.
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00 General Information Maintenance Interval Tables: 00–07 Maintenance Intervals for Schedules II and III (all models) Schedule II Schedule III Maint. No.
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00 General Information Maintenance Operation Sets Tables: 00–08 IMPORTANT: At each Maintenance Operation Set, in addition to the maintenance operations listed in this table, perform all daily, weekly, and monthly maintenance operations listed in the "Pretrip and Post-trip Inspections and Maintenance" chapter of the Acterra® Driver’s Manual. NOTE: Maintenance operations appearing in italics in this table are for noise emission control components.
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00 General Information Maintenance Operation Sets Tables: 00–08 Maintenance Operation Sets for Groups 00 through 32 REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 M4 M5 Maintenance Operation Number and Operation Description 32–03 U-Bolt Torque Checking • • • • * With frequent use, the Pacbrake Exhaust Brake will operate free of maintenance.
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00 General Information Maintenance Operation Sets Tables: 00–08 Maintenance Operation Sets for Groups 33 through 42 REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 M4 M5 Maintenance Operation Number and Operation Description 42–13 Air Dryer Desiccant Replacing, Bendix AD–9 • 42–14 Air Brake Valve Leak Checking, Bendix TC–6 42–15 Air Reservoir Automatic Drain Valve Disassembly, Cleaning, Inspecting, and Lubricating, Bendix DV–2 • • • • • • • • • • 42–16 Air Brake Valve Disassembly, Clea
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00 General Information Initial Maintenance (IM) Operations Table: 00–09 IMPORTANT: After performing all operations in this table, perform all daily and weekly maintenance operations listed in the "Pretrip Inspection and Daily Maintenance" chapter of the vehicle driver’s manual. Also, perform all M1 Maintenance Interval Operations at the Initial Maintenance (IM). NOTE: Numbers in this table are maintenance operation reference numbers matching those in the text of this manual.
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00 General Information M1 Maintenance Interval Operations Table: 00–10 IMPORTANT: After performing all operations listed in this table, perform all daily, weekly, and monthly maintenance operations listed in the "Pretrip and Post-Trip Inspections and Maintenance" chapter of the Acterra® Driver’s Manual. NOTE: Numbers in this table are maintenance operation reference numbers matching those in the text of this manual. M1 Maintenance Interval Operations Maint. Oper. No.
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00 General Information M1 Maintenance Interval Operations Table: 00–10 Maint. Oper. No.
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00 General Information M2 Maintenance Interval Operations Table: 00–11 IMPORTANT: After performing all operations listed in this table, perform all daily, weekly, and monthly maintenance operations listed in the "Pretrip and Post-Trip Inspections and Maintenance" chapter of the Acterra® Driver’s Manual. Also, perform all M1 Maintenance Interval Operations at the M2 Maintenance Interval. NOTE: Maintenance operations appearing in italics in this table are for noise emission control components.
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00 General Information M3 Maintenance Interval Operations Table: 00–12 IMPORTANT: After performing all operations listed in this table, perform all daily, weekly, and monthly maintenance operations listed in the "Pretrip and Post-Trip Inspections and Maintenance" chapter of the Acterra® Driver’s Manual. Also, perform all M1 and M2 Maintenance Interval Operations at the M3 Maintenance Interval.
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00 General Information M4 Maintenance Interval Operations Table: 00–13 IMPORTANT: After performing all operations listed in this table, perform all daily, weekly, and monthly maintenance operations listed in the "Pretrip and Post-Trip Inspections and Maintenance" chapter of the Acterra® Driver’s Manual. Also, perform all M1, M2, and M3 Maintenance Interval Operations at the M4 Maintenance Interval. NOTE: Maintenance operations appearing in italics in this table are for noise emission control components.
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00 General Information M5 Maintenance Interval Operations Table: 00–14 IMPORTANT: After performing all operations listed in this table, perform all daily, weekly, and monthly maintenance operations listed in the "Pretrip and Post-Trip Inspections and Maintenance" chapter of the Acterra® Driver’s Manual. Also, perform all M1, M2, M3, and M4 Maintenance Interval Operations at the M5 Maintenance Interval.
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00 General Information Lubrication and Fluid Level Check (M1): 00–15 Maintenance Operation 00–15 (see Table 12), summarizes all Lubrication and Fluid Level Check operations that must be performed at the M1 Maintenance Interval for Schedules I, II, and III Maintenance operation numbers given in the table are reference numbers used to help you find detailed instructions in the manual on the lubrication or fluid check. Maintenance Operation 00–15 M1 Lubrication and Fluid Level Check Maint. Oper. No.
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00 General Information Lubrication and Fluid Level Check (M2): 00–16 Maintenance Operation 00–16 (see Table 13), summarizes all Lubrication and Fluid Level Check operations that must be performed at the M2 Maintenance Interval for Schedules I, II, and III Maintenance operation numbers given in the table are reference numbers used to help you find detailed instructions in the manual on the lubrication or fluid check. Maintenance Operation 00–16 M2 Lubrication and Fluid Level Check Maint. Oper. No.
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Engine 01 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Engine Drive Belt Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–02 Engine-Support Fasteners Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–01 Pacbrake Inspecting and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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01 Engine 01–01 Engine-Support Fasteners Checking Front and rear engine supports for vehicles built from January 2007 require no periodic maintenance. Mounts should be inspected when the engine is removed for service. For vehicles manufactured prior to January 2007, perform the following check. Check the rear engine-support fasteners (see Fig. 1, Ref. 4) for tightness. Tighten the 3/4-inch fasteners 215 to 265 lbf·ft (292 to 359 N·m). Check the front engine-support fasteners for tightness.
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01 Engine A D B E C F 11/21/94 A. Glazing B. Separating Layers C. Streaked Sidewalls f150010a D. Tensile Break E. Uneven Ribs F. Cracks Fig. 2, Drive Belt Replacement Conditions checked, not the pulley, to isolate the area from outside interference. 8. Inspect all pulleys for foreign objects, oil, or grease in the grooves. Belt Tension Inspection NOTE: If engine drive belts require adjustment, see Group 01 of the Acterra® Workshop Manual for instructions. Threaded-Adjustment Type 1.
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01 Engine Engine Cummins ISB, ISC, ISM Mercedes-Benz MBE900 Component Refrigerant Compressor Belt Tension: lbf (kg) 100 (45) Fan and Alternator 29.5 (27.9) Refrigerant Compressor 30.0 (28.4) Table 1, Drive Belt Tensions 01–03 Pacbrake Inspecting and Maintenance With frequent use, the Pacbrake Exhaust Brake will operate maintenance-free. If the vehicle is used inconsistently or seasonally, it will be necessary to perform preventative maintenance.
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Air Intake 09 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Element Inspecting and Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Air Intake 09 09–01 Air Cleaner Element Inspecting and Replacing Method 1 Replace the air cleaner element at the recommended interval or when the air restriction indicator reaches 22 inH2O on a vehicle with an MBE engine, or 25 inH2O on a vehicle with a Caterpillar or Cummins engine, if equipped with an air restriction indicator. For replacement instructions, see Group 09 of the Acterra® Workshop Manual. Reset the air restriction indicator.
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Air Compressor 13 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspecting, Bendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–01 Air Compressor Rebuilding/Replacing, Bendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Air Compressor 13 13–01 Air Compressor Inspecting, Bendix Inspect the air intake line, oil supply and return lines, and coolant supply and return hoses for tight connections and general condition. Tighten the connections, and replace the lines and hoses, as needed. If the compressor air-intake adapter is loose, remove the adapter, replace its gaskets, and securely install it. Check the cooling fins on the compressor crankcase. Clean the fins if they are clogged with debris.
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Alternators and Starters 15 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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15 Alternators and Starters 15–01 Alternator, Battery, and Starter Connections Checking 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. Rinse with clean water, and dry. Paint the retainer assembly, if needed, to prevent rusting. Batteries generate explosive gas as a by-product of their chemical process. Do not smoke when working around batteries.
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Engine Cooling/Radiator 20 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fan Clutch Checking (Noise Emission Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–03 Radiator Cap Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–01 Radiator Pressure Flushing and Coolant Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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20 Engine Cooling/Radiator 20–01 Radiator Cap Checking WARNING Do not remove or loosen the radiator 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.
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20 Engine Cooling/Radiator 1 f200326 02/28/96 2 Fig. 3, T-Bolt Type Hose Clamp A 11/19/94 B 1 f500108a 1. Radiator 2. Horn Fig. 2, Draining The Engine Coolant 4. Drain the radiator, and flush the radiator until clean water flows from the radiator. Remove the flushing gun. 5. Close the petcock at the bottom of the radiator. 6. Connect the hoses. Your hose clamps can be either T-bolt clamps (see Fig. 3) or Breeze Constant-Torque clamps (see Fig. 4).
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20 Engine Cooling/Radiator the coolant level is between the MIN and MAX lines on the surge tank. 7. Fill the radiator with coolant. Use a mixture of 50 percent water and 50 percent corrosion-inhibiting antifreeze to protect the engine to –34°F (–37°C) year round. 20–03 Fan Clutch Checking (Noise Emission Control) Eaton Viscous Fan Clutch See Table 1 for engine cooling system capacities. See Table 2 for approved antifreezes.
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20 Engine Cooling/Radiator during this procedure, the fan could engage, which could result in serious personal injury. 2. Inspect the electrical connections and wires to the fan clutch solenoid. Secure the connection, if loose; replace wires and connectors if damaged. 3. Clean the fan clutch air solenoid valve filter, if equipped. 3.1 Unscrew the fan clutch solenoid valve air filter assembly and remove the filter element. 3.2 Clean the filter element with cleaning solvent. 3.
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20 Engine Cooling/Radiator 8 7 6 19 5 20 18 4 17 3 1 14 2 21 22 23 15 13 16 12 11 9 10 24 03/30/95 f200194a 9. 10. 11. 12. 13. 14. 15. 16. 1. Mounting Bracket 2. Rear Sheave Bearing 3. Inner and Outer Bearing Spacers 4. Forward Sheave Bearing 5. Sheave 6. Friction Facing 7. Journal Spacer 8. Socket-Head Capscrew Rear Hub Bearing Bearing Spacer Splined Hub Forward Hub Bearing Piston Friction Disc Large O-Ring Locknut Cartridge Assembly 17. 18. 19. 20. 21. 22. 23. 24.
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20 Engine Cooling/Radiator WARNING 3 2 Make sure the batteries are disconnected, and if applicable, the air starter reservoir is drained before checking the fan clutch. If the engine starts during this procedure, the fan could engage, which could result in serious personal injury. 1 4 2. Inspect the electrical connections and wires to the fan clutch solenoid. Secure the connection if loose; replace wires and connectors if damaged. 3. Clean the fan clutch air solenoid valve filter, if equipped.
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20 Engine Cooling/Radiator Check at the solenoid valve, the air filter assembly, and the air hoses and fittings. See Fig. 8. Using a wet finger or a soapy water solution, check for a leak in the same areas. 05/30/2002 f200581 Fig. 8, Checking for Air Leaks (Horton DriveMaster) 9. If a leak is detected, remove the fan blade. Install a new seal kit. See Group 20 of the Acterra® Workshop Manual for repair procedures. 10. Check the fan drive for discoloration or any other signs of slipping or overheating.
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Clutch 25 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch (Pull-Type) Inspecting and Adjusting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–02 Clutch Release Bearing and Release Cross-Shaft Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–01 Hydraulic Fluid Level Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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25 Clutch 25–01 Clutch Release Bearing and Release Cross-Shaft Lubricating Clutch Release Bearing CAUTION Do not over-lubricate the clutch release bearing. Over-lubrication could contaminate the clutch internally, causing clutch slippage and premature failure. Do not use chassis grease or multipurpose lubricants. On clutches with a grease-type release bearing (see Fig. 1), wipe the dirt from the grease fitting.
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25 Clutch 2 1 1 2 3 4 3 5 4 10 7 6 9 8 7 5 06/17/2002 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 6 f250589 Clamp Mounting Bolt, 1/4–20 Steel-Plated Flatwasher Locknut, 1/4–20 Bell Housing Standoff Bracket Hydraulic Hose Bleed Valve Slave Cylinder Slave Cylinder Capscrew, M8 Flatwasher, M8 Cushioned Clamp Fig. 3, Clutch Slave Cylinder f250588 06/17/2002 1. 2. 3. 4. Reservoir Reservoir Cap Pedal Unit Master Cylinder 5. Hydraulic Hose 6. Slave Cylinder 7. Reservoir Hose WARNING procedures below.
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25 Clutch 4.3 Press down on the pedal several times, until no more fluid drains from the reservoir. 4.4 Cover the hose to avoid contamination of the clutch hydraulic fluid. 5. Connect the hydraulic hose to the slave cylinder. Install the clamp, as removed. 6. Fill the reservoir with approved DOT 3 brake fluid and bleed the system according to the procedures under the heading "Bleeding the Clutch." See Fig. 4. 2 3 1 6 Bleeding the Clutch 10 1. Apply the parking brake and chock the tires. 2.
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25 Clutch hose. When no bubbles appear in the fluid, close the valve on the slave cylinder. Release the clutch pedal and then close the valve at the bleeder unit. 8. Disconnect the bleeder unit, and install the cap on the slave cylinder bleeder valve. 9. Check the fluid level in the reservoir. If necessary, add or remove clutch hydraulic fluid to bring the fluid level to the MAX mark. Install the reservoir cap. 10. Depress the clutch pedal a few times.
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Transmission 26 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Allison Transmission Breather Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–03 Allison Transmission Fluid and Filter Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–04 Eaton Fuller and TTC Transmission Fluid Changing and Magnetic Plug Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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26 Transmission 26–01 Manual Transmission Fluid Level Checking Approved Manual Transmission Lubricants 1. Park the vehicle on a level surface. Apply the parking brakes and chock the rear tires. 2. With the transmission at operating temperature, check the fluid level in the transmission. 2.1 2.2 Temperature: SAE °F (°C) Viscosity Lubricant Type* Clean the area around the fill plug, then remove the plug from the side of the case.
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26 Transmission • 42 lbf·ft (57 N·m) for all Mercedes-Benz transmissions. 26–02 Eaton Fuller and TTC Transmission Fluid Changing and Magnetic Plug Cleaning 1. Park the vehicle on a level surface. Apply the parking brakes and chock the rear tires. 2. Drain the fluid while the transmission is warm. 3. Clean the area around the fill plug and the drain plug(s). 4. Remove the fill plug from the side of the gear case. Remove the drain plug(s) from the bottom of the gear case. 5.
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26 Transmission fected component must be thoroughly drained. Switching to a synthetic lubricant, when a petroleum-based lubricant has been used for 50,000 miles (80 000 km) or longer, may affect transmission performance. Monitor all seal areas for the first 10,000 miles (16 000 km) after changing to a synthetic from a petroleumbased lubricant. NOTE: The correct fluid capacity is established by the fill plug opening. 2. Clean the fill plug, then install it in the transmission.
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26 Transmission 11. Check and adjust the fluid level using the procedure under "Checking the Fluid Level.
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26 Transmission 12.3 Evenly tighten all 21 of the screws 10 to 15 lbf·ft (14 to 20 N·m). Check the gasket fit while the screws are being tightened. IMPORTANT: The oil pan bolts must maintain a minimum torque of 60 lbf·in (680 N·cm) after the oil pan gasket has taken a set. 13. Install the fill tube at the side of the pan. Tighten the tube fitting 90 to 100 lbf·ft (122 to 136 N·m). 6 5 1 15. Replace the external (auxiliary) fluid filter. 2 16.
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26 Transmission 1 8 2 3 4 9 10 7 5 6 f260132a 10/05/94 1. 2. 3. 4. 5. 6. Fluid Intake Tube Detent Spring Detent Spring 1-3/4" Bolt Filter Spacer 2-1/4" Bolt (16 qty.) First/Reverse Clutch Feed Tube 3" Bolt (2 qty., behind) 7. 8. 9. 10. First/Reverse Clutch Feed Tube Governor Screen (in control valve body) Governor Pressure Tube Governor Feed Tube Fig. 4, Allison AT Series Transmission Governor the transmission and remove the drain plug. Examine the fluid as it drains.
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26 Transmission 12. Replace the drain plug O-ring, and install the drain plug. Tighten the drain plug 18 to 24 lbf·ft (25 to 32 N·m). 1 1 13. Refill the transmission with fresh transmission fluid (see Table 3) and check the fluid level. See Table 4 for lubricant capacities. 14. Check and adjust the fluid level using the procedures under "Checking the Fluid Level." MT Series 1. Park the vehicle on a level surface. Apply the parking brakes and chock the rear tires. 2.
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26 Transmission 1 13 15 2 14 7 12 11 8 3 4 6 5 10 9 08/30/96 f260369 1. Transmission Housing 2. Transmission Oil Pan Gasket 3. 5/16–18 Washer-Head Capscrew 4. Plug 5. Transmission Oil Pan 6. 7. 8. 9. 10. Magnet Drain Plug Gasket Drain Plug 5/16–18 x 5/8 Capscrew Flatwasher 11. 12. 13. 14. 15. Transmission Fluid Filter Fluid-Filter Spacer O-Ring Fluid-Filter Tube Plug Fig.
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26 Transmission vented from contacting areas of the oil pan flange that are inside the raised bead of the flange. NOTE: Do not use gasket-type sealing compounds or cement anywhere inside the transmission or where they might get washed into the transmission. Non-soluble vegetable-base cooking compounds or fibrous grease must not be used inside the transmission. 1 4 6 12. Install the oil pan and gasket onto the transmission. Check that no dirt or debris enters the pan.
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26 Transmission 3. Run the engine for at least one minute. CH 4. Shift from DRIVE to NEUTRAL, and then shift to REVERSE to fill the hydraulic system. EC K IN NE 5. Shift to NEUTRAL and allow the engine to idle at 500–800 rpm. UTR A AL AT 6. With the engine running at idle, remove the dipstick from the tube and wipe clean. E I DL B 8. Check the fluid level reading and repeat the check procedure to verify the reading. UN T R HO 7. Insert the dipstick into the tube and remove the dipstick.
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26 Transmission 26–05 Mercedes-Benz Transmission Fluid Changing and Magnetic Plug Cleaning 1 Draining 1. Park the vehicle on a level surface. Apply the parking brakes and chock the rear tires. NOTE: Drain the transmission fluid while the transmission is warm. 2. Drain the transmission fluid. See Fig. 10. 2.1 Remove the magnetic drain plug from the bottom of the gear case. 2.2 Discard the aluminum gasket. 2.3 Catch the transmission fluid in a suitable container and dispose of it properly.
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26 Transmission CAUTION Use only the approved Mobiltrans SHC® DC fluid. Do not mix fluid types. Adding SHC 50 RN 2952 E-5 fluid (used in Eaton and Meritor transmissions) could damage the radial seals. 2. Clean the fill plug before installing it. 3. Install the fill plug (p/n N000908 020001) and a new aluminum gasket (p/n N 00763 024105). Tighten the fill plug 42 lbf·ft (57 N·m). 26–06 Mercedes-Benz Transmission Leak Checking If leakage is found, check the breather for a missing cap.
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26 Transmission liquid gasket (Loctite 518) to the new cover plate when installing it. WARNING Clutch hydraulic fluid (DOT 3 brake 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 clutch hydraulic fluid or bleeding hydraulic lines. If you get clutch hydraulic fluid on your skin, wash it off as soon as possible. 10.3 If the rear radial seal on the engine crankshaft is leaking, replace the rear radial seal.
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Frame and Frame Components 31 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fifth Wheel Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–02 Fifth Wheel Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–03 Frame Fastener Torque Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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31 Frame and Frame Components 31–01 Frame Fastener Torque Checking Tighten Hendrickson suspension fasteners to the torque values given in Table 2. Hendrickson Suspension Torque Values Because of "bedding in" (or seating), frame fasteners must be torqued at the recommended intervals. These intervals apply to new vehicles, and to frame fasteners that have been removed and installed.
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31 Frame and Frame Components Check the drive-axle-flange fasteners (see Fig. 2) for tightness. Tighten the fasteners as follows: Tighten 1/2-inch drive-axle stud nuts (with or without dowels) 75 to 115 lbf·ft (102 to 156 N·m), and tighten 5/8-inch drive-axle stud nuts 150 to 230 lbf·ft (203 to 312 N·m). 31–02 Fifth Wheel Inspecting 5 2 WARNING All fifth wheel maintenance, adjustment, and rebuilding must be done only by a qualified mechanic.
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31 Frame and Frame Components 8. Replace cracked, worn, or damaged parts with new parts. Replace loose mounting bolts with 5/8–11 SAE grade 8 bolts, grade C nuts, and hardened washers. Do not reuse bolts, nuts, and washers on fifth wheel mountings. Holland Disconnect the tractor from the trailer. For instructions, see Chapter 10 of the Acterra® Driver’s Manual Thoroughly steam clean the fifth wheel, then inspect for: Holland Lubricate all moving parts with a multipurpose chassis grease.
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Suspension 32 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Suspension Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–01 Suspension Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–02 U-Bolt Torque Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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32 Suspension 32–01 Suspension Inspecting of vehicle control resulting in property damage, serious personal injury or death. Sterling Front and Rear Suspension Spring Assemblies Inspecting Sterling Spring Tandem-Axle Suspension Crossmember and Gussets Inpsecting Inspect the front and rear suspension spring assemblies for pitted, cracked, broken, or abnormally bent leaves and extreme rust. If any of these conditions exist, replace the spring assembly.
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32 Suspension • Either bushing end contacts a torque arm pin mounting bolt. • There are cracks in the bushing. • Part of the rubber bushing extends beyond the outside diameter of the outer bushing sleeve. 1 Sterling Spring (Tandem) Equalizer Bushing Checking 1. Block the frame up enough to take the weight of the chassis off of the springs. Attempt to move the equalizer up and down, by using a pry bar between the top of the equalizer and the top of the equalizer bracket. Apply hand pressure only.
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32 Suspension Freightliner AirLiner Component Inspecting and Operation Checking 2 1 A WARNING 3 4 5 05/27/93 A. 1. 2. 3. f320023a 1/8-inch (3-mm) Clearance Frame Fasteners 4. Equalizer Frame Rail 5. Equalizer Bracket Pry Bar Fig. 4, Top View of the Equalizer 60-Inch Taper-Leaf Spring Component Check No lubrication is required on the 60-inch taper-leaf spring rear suspension. Inspect the rear shackle brackets for bushing wear or cracks.
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32 Suspension 3. Check for any shifting of the barpin. 4.1 Without disconnecting the control rods, use your hand to attempt to move each of the control rod ends up, down, in, and out. If there is any movement, examine the control rods for wear or damage. Replace if necessary. 4.2 Inspect the rubber bushings for cracks or cuts. 4.3 Check for any shifting of the barpin. 4.4 Check for cracks in the metal components and welds. 4. Check for cracks in the metal components and welds.
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32 Suspension 4 1 1 A 2 2 3 3 f320039a 05/27/93 1. Beam Hanger 2. Equalizer Beam 3. Jack 05/27/93 A. 1. 2. 3. 4. Fig. 5, Raising the Beam End f320112a Minimum gap of 3/8 inch (9.5 mm). Forward (no. 1) Spring Hanger Spring Eye Pin Rear (no. 2) Spring Hanger Rear (no. 3) Extension Fig. 7, Unloaded RTE or UE Spring Suspension 1. Inspect the spring hangers for wear of the spring pin holes, cams, and the spring hanger legs. 5 2 1 2.
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32 down, in, and out. If there is any movement, replace the torque arm. 2. Inspect the rubber bushing ends. Replace the torque arm if there are gaps between the rubber bushing and the pin or the outer steel sleeve, if either bushing end contacts a torque arm pin mounting bolt, if there are cracks in the bushing, or if part of the rubber bushing extends beyond the outside diameter of the outer bushing sleeve. Chalmers Suspension Checking Chock the front wheels to prevent the vehicle from moving.
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32 Suspension WARNING Replace all cracked or missing restrictor cans. Failure to do so could lead to loss of vehicle control, which could result in property damage, serious personal injury or death. Vehicles with cracked or missing restrictor cans may be driven slowly to the nearest workshop for restrictor can replacement. 6. Remove the jack stands, then lower the vehicle. Check that the spring, or driveline brake is applied, then remove the wheel chocks.
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32 Suspension 3. Use a click-type torque wrench to check that spring hanger bolts are tightened 190 lbf·ft (258 N·m). 4. Use a click-type torque wrench to check that the 5/8-inch torque rod clamp nuts are tightened 125 to 150 lbf·ft (170 to 203 N·m). 5. Use a click-type torque wrench to check that the two end-nuts for each torque rod are tightened 400 to 450 lbf·ft (540 to 610 N·m). 6. Use a click-type torque wrench to check that spring retainer bolts are tightened 60 to 80 lbf·ft (81 to 109 N·m).
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32 Suspension Hendrickson Spring-Eye Pins, RT and RTE Series NOTE: See Fig. 7 for this procedure. Apply multipurpose chassis grease at the spring eye pin grease fitting (located on the inboard side of the spring eye pin) until clean grease appears at both ends of the spring eye pin. Freightliner TufTrac The TufTrac suspension is maintenance-free and designed so that lubrication is not required.
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32 01/05/99 Suspension 4 1 2 3 f320783 Fig.
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Front Axle 33 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–04 All-Wheel-Drive Front Axle Oil Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–06 All-Wheel-Drive Front Axle Oil Level Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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33 Front Axle 33–01 Knuckle Pin Lubricating Standard Meritor Axles out through it during lubrication. Even if grease leaks out around the top or bottom plate gasket, continue pumping until new grease is seen at the seal on the bushing opposite the grease fitting. Hold a pressure gun on each fitting until fresh grease appears. See Fig. 1. This will ensure that all the old contaminated grease has been forced out. It is not necessary to exceed 4000 psi (27 560 kPa).
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33 Front Axle pand when in contact with synthetic grease. Consult your local Meritor representative for synthetic grease application references before using any synthetic grease when performing axle service and maintenance. 4. Using a multipurpose grease, NLGI grade 1 or 2, lubricate the kingpins through the grease fittings on the top and bottom of the knuckle. See Fig. 2. 1 2. Make sure the tires touch the ground. Do notraise the vehicle. 3. Clean off all grease fittings prior to lubrication.
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33 Front Axle 1. Shut off the engine, apply the brakes, and chock the rear tires. 2. Check the tie rod boot for cracks, tears, or other damage. If the tie rod boot is damaged, replace the entire tie rod end. 3. Grasp by hand (or use a pipe wrench with jaw protectors to avoid gouging the cross tube) and slightly rotate the cross tube toward the front of the vehicle and then slightly toward the rear. Then center the cross tube between the stop positions.
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33 Front Axle • 1-1/8–12, 350 to 650 lbf·ft (475 to 881 N·m) • 1-1/4–12, 500 to 675 lbf·ft (678 to 915 N·m) 10. Check the steering arm bolts for a minimum torque of 300 lbf·ft (406 N·m). If the steering arm bolt torque has fallen below this specification, remove the bolt, clean all the threads, and apply new Loctite® 680. Tighten the bolt 300 to 450 lbf·ft (406 to 610 N·m).
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33 Front Axle 2. On front-wheel-drive vehicles equipped with MT14, MT-17, and MT-22 axles, check the oil level in the hubs. 2.1 The oil drain bore must be at the bottom in order to check the oil level. See Fig. 7. MH On vehicles equipped with an MT-14, MT-17, or MT-22 front axle, drain the oil from the differential and the hubs. 3.1 Remove the oil-drain plug from the differential, and allow the oil to drain. See Fig. 6. 3.
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33 Front Axle 10/11/2001 f330186 Fig.
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Rear Axle 35 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Axle Breather Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–02 Axle Lubricant Changing and Magnetic Plug Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–03 Axle Lubricant Level Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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35 Rear Axle 35–01 Axle Lubricant Level Checking NOTE: Some Meritor axles have a small tapped and plugged hole located near and below the housing oil fill hole. This smaller hole is for the lubricant temperature sensor only, and must not be used as a fill or level hole. CAUTION 2. With the vehicle on level ground, lubricant must be level with the bottom of the oil fill hole. Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage.
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35 Rear Axle Meritor Drive Axle Lubricant Capacities, Tandem Axles Capacity*: pints (liters) Axle Model RT–34–144 Forward 29.8 (14.1) Rear 34 (16.1) RT–40–145 Forward 30.4 (14.4) Rear 34.4 (16.3) * Quantities listed are approximate and include 1 pint (0.5 liter) for each wheel end and with the drive pinion at 3 degrees. Table 3, Meritor Drive Axle Lubricant Capacities, Tandem Axles 3. Install the fill hole plug, and tighten it 35 lbf·ft (47 N·m).
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35 Rear Axle NOTE: Meritor recommends using magnetic plugs with elements having a minimum pickup capacity of 2 pounds (1 kg) of low-carbon steel, in plate or bar form. Magnets will rapidly lose effectiveness as collected material bridges the gap between the two poles. Clean or change the plugs before this occurs. It may be necessary to clean or change the plugs one or more times between lubrication change intervals. 1 4. After cleaning the drain plugs, install and tighten them 35 lbf·ft (47 N·m).
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35 Rear Axle 35–05 Two-Speed-Axle Shift Unit Oil Changing 1. Remove the shift unit housing cover (see Fig. 2), and drain the old lubricant. Discard the housing cover gasket, and the old lubricant. 2. Thoroughly wash the axle shift parts and housing cover, and allow them to air dry. 3. Install the housing cover and a new housing cover gasket. Tighten the housing cover capscrews 90 to 110 lbf·in (1020 to 1240 N·cm), then remove the oil fill hole plug from the cover. 4.
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Wheels and Tires 40 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Wheel Nut Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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40 Wheels and Tires 40–01 Wheel Nut Checking CAUTION IMPORTANT: In addition to the maintenance interval in this manual, check the wheel nut torque the first 50 to 100 miles (80 to 160 km) of operation after a wheel has been removed and installed. Too little wheel nut torque can cause wheel shimmy, resulting in wheel damage, stud breakage, and extreme tire tread wear. Too much wheel nut torque can break studs, damage threads, and crack discs in the stud hole area.
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40 Wheels and Tires 2 1 10 7 4 5 6 8 3 A 1 1 1 8 3 3 6 5 4 6 3 5 7 4 9 2 B 5 2 2 C D f400057 05/27/93 A. 8-Stud Disc Wheel B. 10-Stud Disc Wheel 4 C. 6-Spoke Wheel D. 5-Spoke Wheel Fig.
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Driveline 41 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–01 Driveline Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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41 Driveline 41–01 Driveline Inspecting End-Yoke Nut Torque Specifications Description Inspecting 1. Check that the yoke-strap capscrews (see Fig. 1, Ref. 4) are tightened as follows: • Dana Spicer 1590 and 1610: 50 to 60 lbf·ft (68 to 81 N·m) • Dana Spicer 1710: 125 to 135 lbf·ft (170 to 183 N·m) CAUTION Do not overtighten the yoke-strap capscrews, due to the extreme load occurring at high-speed rotation.
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41 Driveline 12 2 6 5 4 3 1 10 11 2 9 8 4 13 7 14 7 17 15 16 18 3 10/06/94 f410057a NOTE: Not all fasteners are shown. 1. 2. 3. 4. 5. 6. 7. Transmission Half-Round End Yoke U-Joint Assembly Yoke Strap and Capscrew Coupling Shaft Midship Bearing and Mount Bearing Cup 8. 9. 10. 11. Slip-Joint Assembly Driveshaft Tube Driveshaft Yoke Input Shaft Half-Round End Yoke 12. Rear Axle 13. 14. 15. 16. 17. 18.
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41 Driveline 5 1 2 f410012a 05/27/93 7 3 4 3 6 Attempt to bend the sleeve yoke and splined shaft back and forth. 8 Fig. 2, Slip-Joint Spline Wear Checking 3 1 A A A B C D C f410110b 06/13/96 A. B. C. D. Measurement: Measurement: Measurement: Measurement: 3" (76 mm) 0.015" (0.38 mm) 0.020" (0.51 mm) 0.025" (0.635 mm) Fig. 3, Driveshaft Runout Specifications NOTE: If a low-pressure adapter is not used with the high-pressure gun, the U-joints may not receive enough lubricant. 3.
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41 Driveline screws, then loosen the bearing cup capscrews (at the bearing with the dry seal) to relieve seal tension. Lubricate the U-joint until the old grease is purged, then tighten the capscrews to the above specifications, and bend the tabs of the lockstrap against a flat side of each capscrew. If the bearing will not take grease, replace the U-joint assembly; see Group 41 of the Acterra® Workshop Manual. 4. Check the old grease. If it appears rusty, gritty, or burned, replace the U-joint assembly.
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Brakes 42 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Brake Valve Disassembly, Cleaning, and Inspecting, Bendix E–8P, R–12, R–14, SR–1, ST–3, TC–6, and TP–3DC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–16 Air Brake Valve Inspecting and Leak Checking, Bendix BP–R1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–02 Air Brake Valve Leak Checking, Bendix TC–6 . . . . . . . . . . . . . . . . . . . . . . . .
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42 Brakes 42–01 Air Dryer Inspecting, Bendix AD–9 1. Check the reservoirs for moisture. A small amount (teaspoon or less) is normal. Larger amounts may mean that the desiccant needs to be replaced. Check the mounting and connecting lines. 2. Tighten the fasteners that attach the air dryer to the vehicle. Use the following torque values: • 28 lbf·ft (38 N·m) for SAE grade 5, 3/8–16 fasteners 42–03 Foot Brake Valve Actuator Lubricating, Bendix E–8P 1.
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42 Brakes 3. Clean any road grime from the relay valve and any debris from the valve exhaust port. brake chamber section in Group 42 of the Acterra® Workshop Manual. 4. Listen for air leakage around the fittings or exhaust port. Tighten the fittings as necessary. Use two wrenches to avoid twisting the tubing. 1 5. If the valve fails this check or is damaged, repair or replace it. For instructions, see the Midland service manual. A 6. Remove the chocks from the tires.
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42 Brakes A 1 B 2 2 3 C B 1 A 3 07/27/94 A. B. 1. 2. Brakes Released Brakes Applied Brake Chamber Piston Rod C. Greater than 90 degree angle 3. Slack Adjuster Fig. 2, Angle Between Piston Rod and Slack Adjuster 2. Check each brake chamber for correct installation. 2.1 2.2 4 f420009a Check each mounting stud for the presence of prevailing torque locknuts and hardened flatwashers. Make sure that the hardened flatwashers are installed between the mounting bracket and the locknuts.
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42 Brakes spring which, if released, could cause serious injury or death. 1. Apply the service brakes and check that the piston rods move out promptly without binding. 7. Inspect the exterior surfaces of the chamber for damage. Make sure the breather holes in the non-pressure section(s) are open and free of debris. Using the instructions in Group 42 of the Acterra® Workshop Manual, replace any damaged parts. 2.
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42 Brakes 3.3 3.4 If leakage persists, use the instructions in Group 42 of the Acterra® Workshop Manual to replace the service brake diaphragm. Using soapy water, coat the area around the piston-rod bore. On some Bendix service chambers loosen the boot, if necessary. No leakage is permitted. If there is leakage, use the instructions in the applicable brake chamber section in Group 42 of the Acterra® Workshop Manual and replace the service brake diaphragm.
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42 Brakes 42–08 Camshaft Bracket Bushing Lubricating system and inspect it for worn or damaged components. Improperly maintaining the vehicle braking system may lead to brake failure, resulting in property damage, personal injury, or death. IMPORTANT: Perform MOP 42–24 before lubricating the camshaft brackets. Pump multipurpose chassis grease (NLGI Grade 1 or 2) into the chamber bracket until it appears at the slack adjuster end of the bracket. See Fig. 4. Use care that no grease enters the drum cavity.
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Brakes 42–11 Automatic Slack Adjuster Inspecting, Meritor IMPORTANT: Perform MOP 42–24 before lubricating the slack adjusters. 1. Remove the pull-pawl assembly. See . 2. Examine the pull-pawl assembly for grease retention and condition. If the grease is in good condition, install the pull-pawl assembly. Lube the slack adjuster through the grease fitting until lubricant is forced out through the inboard camshaft splines and the pull-pawl assembly.
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42 Brakes 42–16 Air Brake Valve Disassembly, Cleaning, and Inspecting, Bendix E–8P, R–12, R–14, SR–1, ST–3, TC–6, and TP–3DC Disassemble each brake valve, clean the parts with mineral spirits, and inspect the parts. Replace all rubber parts and any worn or damaged parts. Use only genuine Bendix replacement parts or kits. Assemble and install the valves. Check for proper operation and leakage. For instructions, see Group 42 of the Acterra® Workshop Manual.
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42 Brakes adjuster at the grease fitting until grease appears on the camshaft. ponents. Improperly maintaining the vehicle braking system may lead to brake failure, resulting in property damage, personal injury, or death. 1. Inspect the slack adjuster for structural damage. Replace the slack adjuster if needed. 2. Inspect the slack adjuster boot for cuts or tears. 4 5 6 7 3 If the boot is damaged, replace it as follows. See . 2.1 Remove the two clevis pins. 2.
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42 Lubricate a Haldex automatic slack adjuster at the grease fitting with any extreme-pressure NLGI Grade 1 or Grade 2 grease if the operating temperature is –20°F (–29°C) and above. If the operating temperature is below –20°F (–29°C), use a low-temperature extreme-pressure grease. Brakes 3 2 5 1 42–23 Bosch Rail-Slide Hydraulic Brake Caliper Lubricating NOTE: This procedure is only for vehicles equipped with Bosch rail-slide hydraulic brake calipers.
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42 Brakes 42–24 Brake Inspection IMPORTANT: This procedure should be performed prior to lubrication of the brake components. 2 Parking Brake Operational Check CAUTION 1 f420595a 10/28/94 1. V-Ways 2. Bleeder Fitting Fig. 9, Caliper V-Ways 12. Apply two level teaspoons of Aeroshell Grade 5 (ES1246) grease on each side of the assembly. Apply it evenly along the full length of the V-way groove and anchor plate rail, and apply one level teaspoon evenly on both sides of the key and spring.
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42 Brakes the Acterra® Workshop Manual for inspection, troubleshooting, and repair procedures. 5. Start the engine and build air pressure to at least 100 psi (689 kPa). Shut down the engine. 4. Measure the applied chamber stroke. See Table 3 for the proper stroke for the type of chamber being used. If the stroke is too short, the brakes may drag or will not fully apply. Check for improper operation or adjustment of the automatic slack adjuster.
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42 Brakes Brake Chamber Stroke Specifications Chamber Type* Manufacturer Size† 9 12 Standard Stroke 16 20 Meritor 24 Long Stroke 24 Standard Stroke 30 Max Applied Stroke: inch (mm) Less than 1-1/2 (38) Less than 1-3/4 (44) Less than 1-7/8 (48) Less than 2 (51) * 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.
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Steering 46 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Drag Link Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–02 Power Steering Gear Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–05 Power Steering Reservoir Fluid Level Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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46 Steering 46–01 Steering Driveline Lubricating 2. Using a pressure gun, apply multipurpose chassis grease at the grease fittings until old grease is forced out of the socket. Wipe the grease fittings clean. See Fig. 1. Using a pressure gun, apply a lithium-based grease (NLGI grade 2) sparingly to the universal joints and slip-joint splines. NOTE: Use multipurpose chassis grease NLGI grade 1 (6% 12-hydroxy lithium stearate grease) or NLGI grade 2 (8% 12-hydroxy lithium stearate grease).
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46 Steering 6. Close the hood, and remove the chocks from the tires. Nelson Reservoir NOTE: If the power steering reservoir in the vehicle looks like the reservoir shown in Fig. 3, use the following procedure. 1. Turn off the engine, apply the parking brakes, and chock the tires. 2 1 1 6 10/05/94 3 f460926 4 1. Grease Fitting 2. Drag Link (pitman arm end shown) 5 Fig. 2, Steering Drag Link 46–03 Power Steering Reservoir Fluid Level Checking Metal Ventra Reservoir 1.
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46 Steering Plastic Ventra Reservoir NOTE: If the power steering reservoir in the vehicle looks like the reservoir shown in Fig. 4, use the following procedure. 1. Turn off the engine, apply the parking brakes, and chock the tires. 2 46–04 Power Steering Reservoir Fluid and Filter Changing Metal Ventra Reservoir 1. Turn off the engine, apply the parking brakes, and chock the tires. 3 4 2. Open the hood. 3. Remove the fill cap, nut, and cover from the steering reservoir. 4.
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46 Steering 11. Fill the reservoir with ATF as needed. Start the engine and let it idle. Have someone turn the steering wheel from lock to lock until no bubbles are seen in the reservoir. Turn off the engine. 12. Install a new cover gasket, the cover, and nut. Tighten the nut 28 lbf·ft (38 N·m). Install the fill cap. 13. Start the engine and check the power steering reservoir fluid level. If the fluid level is low, add ATF to bring the level up to the FULL mark on the dipstick. 14.
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46 Steering 2. Open the hood. 3. Place a drain pan under the power steering reservoir. 2. Using a hand-type grease gun, apply multipurpose chassis grease until the grease starts coming out of the sector shaft dirt and water seal. 4. Remove the retaining ring from the reservoir. See Fig. 4. 5. Remove the filter and filter cover from the reservoir. Drain the fluid from the filter into the drain pan. Leave the filter hanging over the drain pan. 6.
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Fuel 47 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fuel Tank Draining and Vent Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Fuel 47 47–01 Fuel Tank Draining and Vent Checking Remove the plug or open the drain valve at the bottom of the fuel tank, and allow the tank to drain until all traces of water and sediment have disappeared; install the plug or close the drain valve. On earlier vehicles with a screw-on fuel cap, remove the fuel cap and clean it with solvent. Make sure the fuel cap vent is open. Install the cap.
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Exhaust 49 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Exhaust System Inspecting (Noise Emission Controls). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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49 Exhaust 49–01 Exhaust System Inspecting (Noise Emission Controls) A NOTE: In addition to the maintenance interval in this manual, inspect the exhaust system if the vehicle has a noticeable increase in noise level at any time. Replace parts that show leakage, wear, or damage. Pre-EPA07 Exhaust System Inspecting 1. Check the muffler body, muffler outlet stack, muffler shield, and inlet tubes, for leakage, dents, corrosion, or holes in the muffler. f490032a 10/05/94 A.
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49 Exhaust 6 5 1 2 3 4 2 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.
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Exhaust 49 9. Check any wires, lines, or hoses within 4 inches (10 cm) of the exhaust system for heat damage. Repair or reroute as needed.
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Electrical, Instruments, and Controls 54 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Coolant Level Sensor Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54–02 Electrical System Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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54 Electrical, Instruments, and Controls 54–01 Electrical System Checking still does not work, check the wiring to it. If the wiring checks out okay, replace the horn. Cab 1. Uncover the electrical panel (see Fig. 1) by removing the fasteners. 8. Check connectors on the right side of the firewall, below the radiator surge tank. See Fig. 2. Check the terminals for tightness, damage, and corrosion or dirt. 1 1 1 2 10/05/94 1. Electrical Connectors f540843 10/05/94 1. Flasher Fig.
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54 Electrical, Instruments, and Controls 54–02 Coolant Level Sensor Cleaning 1. Drain enough coolant from the radiator to expose the coolant level sensor. 2. Disconnect wire 173 from the sensor in the radiator surge tank. Remove the sensor from the surge tank. 3. Using a fine-grit sandpaper, clean the sensor until the metal is exposed. Clean the tapped hole with a wire brush. 4. Install the sensor (do not seal the sensor threads with tape), and reconnect wire 173.
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Doors 72 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Weatherstrip, Door Latch, and Door Hinge Lubricating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Doors 72 72–01 Weatherstrip, Door Latch, and Door Hinge Lubricating Lightly coat door weatherstrips with a lubricant that is safe (as recommended by the lubricant manufacturer) on rubber. Apply a few drops of light engine oil, or spray a light coating of silicone lubricant on the door latch mechanism. This will help reduce noise and wear. Wipe off any excess oil or silicone lubricant. Lubricate door hinges by spraying them with a light coating of silicone lubricant.
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Heater and Air Conditioner 83 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–01 HVAC Air Filter Replacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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83 Heater and Air Conditioner 83–01 Air Conditioner Inspecting WARNING Wear eye protection, gloves, and protective clothing when working on the air conditioning system. Leaking refrigerant from a damaged hose or line could cause blindness or serious skin burns. Preliminary Checks 1. Park the vehicle on a level surface, apply the parking brakes, and chock the tires. 2. Check the appearance of the air conditioner compressor pulley assembly.
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83 1 Heater and Air Conditioner 1 2 f831564 02/17/2003 1. Screw 2. Filter Cover Fig.