CASCADIA MAINTENANCE MANUAL Models

CASCADIA MAINTENANCE MANUAL Models
CASCADIA MAINTENANCE MANUAL
Models: CA125DC
CA125SLP
STI-478-3 (11/10P)
Published by
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.
Foreword
Scheduled maintenance provides a key element for the safe operation of your vehicle. A proper
maintenance program also helps to minimize downtime and to safeguard warranties. This
maintenance manual provides information necessary for years of safe, reliable, and cost-efficient
vehicle operation.
IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also
refer to other component and body manufacturers’ instructions for specifi inspection
and maintenance instructions.
Perform the operations in this maintenance manual at scheduled intervals. Perform the pretrip
inspection and daily/weekly/monthly maintenance, as outlined in the vehicle driver’s manual.
Major components, such as engines, transmissions, and rear axles, are covered in their own
maintenance and operation manuals, that are provided with the vehicle. Perform any maintenance operations listed at the intervals scheduled in those manuals. Your Freightliner Dealership
has the qualifie technicians and equipment to perform this maintenance for you. They can also
set up a scheduled maintenance program tailored specificall to your needs. Optionally, they can
assist you in learning how to perform these maintenance procedures.
IMPORTANT: Descriptions and specification in this manual were in effect at the time of
printing. Freightliner Trucks reserves the right to discontinue models and to change
specification or design at any time without notice and without incurring obligation.
Descriptions and specification contained in this publication provide no warranty,
expressed or implied, and are subject to revision and editions without notice.
Refer to www.Daimler-TrucksNorthAmerica.com and www.FreightlinerTrucks.com for more
information, or contact Daimler Trucks North America LLC at the address below.
Environmental Concerns and Recommendations
Whenever you see instructions in this manual to discard materials, you should attempt to reclaim
and recycle them. To preserve our environment, follow appropriate environmental rules and
regulations when disposing of materials.
NOTICE: Parts Replacement Considerations
Do not replace suspension, axle, or steering parts (such as springs, wheels, hubs, and steering
gears) with used parts. Used parts may have been subjected to collisions or improper use and
have undetected structural damage.
© 2007–2010 Daimler Trucks North America LLC
All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced,
stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks
North America LLC. Daimler Trucks North America is a Daimler company.
Daimler Trucks North America LLC
Service Systems and Documentation (CVI-SSD)
P.O. Box 3849
Portland, OR 97208–3849
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. Each workshop/service manual section is divided into
subjects that can include general information, principles of operation, removal,
disassembly, assembly, installation, and specifications
Maintenance Manual
Maintenance manuals contain routine maintenance procedures and intervals for
vehicle components and systems. They have information such as lubrication
procedures and tables, flui replacement procedures, flui capacities, specifica
tions, and procedures for adjustments and for checking the tightness of fasteners. Maintenance manuals do not contain detailed repair or service information.
Troubleshooting Manual
Troubleshooting manuals contain diagnostic procedures for determining causes
of problems in vehicle components and systems. Information on multiplexing
diagnosis is included. These manuals are organized by functional systems,
such as cab, chassis, and powertrain. Troubleshooting manuals do not contain
repair or service information.
Driver’s/Operator’s
Manual
Driver’s/operator’s manuals contain information needed to enhance the driver’s
understanding of how to operate and care for the vehicle and its components.
Each manual contains a chapter that covers pre-trip and post-trip inspections,
and daily, weekly, and monthly maintenance of vehicle components.
Driver’s/operator’s manuals do not contain detailed repair or service information.
Service Bulletins
Service bulletins provide the latest service tips, fiel repairs, product improvements, and related information. Some service bulletins are updates to information in the workshop/service manual. These bulletins take precedence over
workshop/service manual information, until the latter is updated; at that time, the
bulletin is usually canceled. The service bulletins manual is available only to
dealers. When doing service work on a vehicle system or part, check for a valid
service bulletin for the latest information on the subject.
IMPORTANT: Before using a particular service bulletin, check the current
service bulletin validity list to be sure the bulletin is valid.
Parts Technical Bulletins
Parts technical bulletins provide information on parts. These bulletins contain
lists of parts and BOMs needed to do replacement and upgrade procedures.
Web-based repair, service, and parts documentation can be accessed using the following applications on the
AccessFreightliner.com website.
ServicePro
ServicePro® provides Web-based access to the most up-to-date versions of the
publications listed above. In addition, the Service Solutions feature provides diagnostic assistance with Symptoms Search, by connecting to a large knowledge
base gathered from technicians and service personnel. Search results for both
documents and service solutions can be narrowed by initially entering vehicle
identificatio data.
PartsPro
PartsPro® is an electronic parts catalog system, showing the specifie vehicle’s
build record.
Cascadia Maintenance Manual, May 2010
I–1
Introduction
Descriptions of Service Publications
EZWiring
EZWiring™ makes Freightliner, Sterling, Western Star, Thomas Built Buses, and
Freightliner Custom Chassis Corporation products’ wiring drawings and floatin
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.
Recall Campaigns
Recall campaigns cover situations that involve service work or replacement of
parts in connection with a recall notice. These campaigns pertain to matters of
vehicle safety. All recall campaigns are distributed to dealers; customers receive
notices that apply to their vehicles.
Field Service Campaigns
Field service campaigns are concerned with non-safety-related service work or
replacement of parts. All fiel service campaigns are distributed to dealers; customers receive notices that apply to their vehicles.
I–2
Cascadia Maintenance Manual, May 2010
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. Tighten bearing−cap capscrews or
yoke−strap capscrews to specif ed torque, being
careful to not overtighten.
2. For U−jointswith bearing caps,tighten bearing−
cap capscrews 43 lbf·ft (49 N·m). See Fig. 1.
For Arvin Meritor RPL series U−joints , tighten
bearing−capcapscrews 125 lbf·ft (169 N·m). See
Fig. 2.
For U−jointswith yoke straps, tighten yoke−strap
capscrews 125 lbf·ft (169 N·m). See Fig. 3.
12/09/97
f410182
Fig. 2, Arvin Meritor RPL Series U−Joint
If any end−yoke can be moved in or out on its
shaft, or can be rocked on its shaft, disconnect
the driveshaft and U−jointfrom the yoke, then
check the drive component’s shaft seal for leak−
age or other visible damage that may have been
caused by the loose yoke. Replace the seal if
needed, then tighten the yoke nut. Refer to
Group 41 of the Cascadia Workshop Manual
for torque specifications . If the yoke is still loose
after tightening the yoke nut, replace the end−
yoke and yoke nut.
TM
1
Replace the prevailing torque locknut (end−yoke
nut) if it was removed for yoke replacement, seal
replacement, or any other reason.
2
M
4. Check U−jointassemblies for wear by moving the
driveshaft up and down, and from side to side. If
any movement of the U−jointcross in the bear−
ings can be felt or seen, replace the U−joint as−
sembly.
I
E R T OR
1
1
f410155a
04/13/98
1. Self−Locking
Capscrew
2. Adhesive Band
Fig. 1, Arvin Meritor U−JointFasteners for Bearing
Caps
3. Check the driveline yokes for cracks, and check
end−yokes for looseness. See Fig. 3 .
Replace cracked yokes.
Cascadia
D
TM
5. Check if the midship bearing and mounting are
loose or have deteriorated, by attempting to
move the driveshaft up and down, and from side
to side. If the bearing is loose on its shaft, or
rattles, replace it. If the bearing mount is loose
on the frame, tighten the mounting fasteners to
the proper torque value. See Group 41 of the
CascadiaY Workshop Manual for torque specif−
cations. Replace the midship bearing assembly if
the rubber cushion is deteriorated or oil−soaked.
6. Check slip joints for spline wear by moving the
sleeve−yoke and splined shaft back and forth.
See Fig. 4. If the slip joint can be twisted in a
clockwise, or counterclockwise movement
Maintenance Manual, July 2007
E
41/1
F
06/11/2007
A.
B.
C.
D.
E.
F.
f020166
Maintenance Operation Number consists of the Group Number followed by the Sequence Number
Group Title
Group Number
Vehicle Name
Release Date
Group Number/Page Number
Fig. 1, Example of a Maintenance Manual Page
Cascadia Maintenance Manual, May 2010
I–3
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission
31 . . . . . . . . . . . . . Frame and Frame Components
32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension
33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle
35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle
40 . . . . . . . . . . . . . . . . . . . . . . . . Wheels and Tires
41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driveline
42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes
46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering
47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel
49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust
54 . . . . . . . . . . Electrical, Instruments, and Controls
60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab
83 . . . . . . . . . . . . . . . . . Heater and Air Conditioner
88 . . . . . . . . . . . . . . Hood, Grille, and Cab Fenders
I–4
Cascadia Maintenance Manual, May 2010
General Information
00
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Determining Scheduled Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–01
Initial Maintenance (IM) Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–04
M1 Maintenance Interval Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–05
M2 Maintenance Interval Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–06
M3 Maintenance Interval Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–07
Maintenance Operation Sets Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–08
Noise Emission Controls Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–09
Service Schedule Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–02
Vehicle Maintenance Schedule Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–03
Verificatio of Inspections Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–10
Cascadia Maintenance Manual, August 2010
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.
To determine the correct maintenance intervals for
your vehicle you must firs determine the type of service or conditions the vehicle will be operating in.
Generally, over-the-road vehicles operate under conditions that fall within one of the two types of service
described. Before placing your new vehicle in service, determine the type of service (Service Schedule
I or II) that applies to the intended use of the vehicle.
After determining the vehicle’s type of service, refer
to the service schedule table or the vehicle maintenance schedule table, to determine how often maintenance should be performed.
When the vehicle reaches the distance given for a
maintenance interval, see the Maintenance Interval
Operation Table for a list of the maintenance operations to be performed at that maintenance interval.
Use the maintenance operation reference numbers to
fin detailed instructions in the manual on each operation.
Types of Service
Service Schedule I (short-haul transport) applies to
vehicles that annually travel less than 60,000 miles
(100 000 kilometers) and operate under normal conditions. Examples of Schedule I usage are: operation
primarily in cities and densely populated areas; local
transport with infrequent freeway travel; or high percentage of stop-and-go travel.
Service Schedule II (long-haul transport) is for vehicles that annually travel more than 60,000 miles
(100 000 kilometers) with minimal city or stop-and-go
operation. Examples of Schedule II usage are: regional delivery that is mostly freeway miles; interstate
transport; or any road operation with high annual
mileage.
NOTE: Maintenance instructions in this manual
are based on average vehicle use and normal
Cascadia Maintenance Manual, August 2010
00/1
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)
firs
10,000
16 000
Maintenance 1 (M1)
every
10,000
16 000
Maintenance 2 (M2)
every
50,000
80 000
Maintenance 3 (M3)
every
150,000
240 000
Initial Maintenance (IM)
firs
25,000
40 000
Maintenance 1 (M1)
every
25,000
40 000
Maintenance 2 (M2)
every
100,000
161 000
Maintenance 3 (M3)
every
300,000
483 000
Table 1, Service Schedule
00/2
Cascadia Maintenance Manual, August 2010
00
General Information
Vehicle Maintenance Schedule Table: 00–03
Maintenance for Service Schedule I
Maint. No.
Maintenance
Interval
1st
Service
Date
Service Schedule I
Miles
km
IM and M1
10,000
16 000
2nd
M1
20,000
32 000
3rd
M1
30,000
48 000
4th
M1
40,000
64 000
5th
M1 and M2
50,000
80 000
6th
M1
60,000
96 000
7th
M1
70,000
112 000
8th
M1
80,000
128 000
9th
M1
90,000
144 000
10th
M1 and M2
100,000
160 000
11th
M1
110,000
176 000
12th
M1
120,000
192 000
13th
M1
130,000
208 000
14th
M1
140,000
224 000
15th
M1, M2, and M3
150,000
240 000
16th
M1
160,000
256 000
17th
M1
170,000
272 000
18th
M1
180,000
288 000
19th
M1
190,000
304 000
20th
M1 and M2
200,000
320 000
21st
M1
210,000
336 000
22nd
M1
220,000
352 000
23rd
M1
230,000
368 000
24th
M1
240,000
384 000
25th
M1 and M2
250,000
400 000
26th
M1
260,000
416 000
27th
M1
270,000
432 000
28th
M1
280,000
448 000
29th
M1
290,000
464 000
30th
M1, M2, and M3
300,000
480 000
31st
M1
310,000
496 000
32nd
M1
320,000
512 000
33rd
M1
330,000
528 000
34th
M1
340,000
544 000
35th
M1 and M2
350,000
560 000
Cascadia Maintenance Manual, August 2010
00/3
00
General Information
Vehicle Maintenance Schedule Table: 00–03
Maintenance for Service Schedule I
00/4
Maint. No.
Maintenance
Interval
36th
Service
Date
Service Schedule I
Miles
km
M1
360,000
576 000
37th
M1
370,000
592 000
38th
M1
380,000
608 000
39th
M1
390,000
624 000
40th
M1 and M2
400,000
640 000
41st
M1
410,000
656 000
42nd
M1
420,000
672 000
43rd
M1
430,000
688 000
44th
M1
440,000
704 000
45th
M1, M2, and M3
450,000
720 000
46th
M1
460,000
736 000
47th
M1
470,000
752 000
48th
M1
480,000
768 000
49th
M1
490,000
784 000
50th
M1 and M2
500,000
800 000
51st
M1
510,000
820 000
52nd
M1
520,000
837 000
53rd
M1
530,000
853 000
54th
M1
540,000
869 000
55th
M1 and M2
550,000
885 000
56th
M1
560,000
901 000
57th
M1
570,000
917 000
58th
M1
580,000
933 000
59th
M1
590,000
949 000
60th
M1, M2, and M3
600,000
965 000
61st
M1
610,000
982 000
62nd
M1
620,000
998 000
63rd
M1
630,000
1 014 000
64th
M1
640,000
1 030 000
65th
M1 and M2
650,000
1 046 000
66th
M1
660,000
1 062 000
67th
M1
670,000
1 078 000
68th
M1
680,000
1 094 000
69th
M1
690,000
1 110 000
70th
M1 and M2
700,000
1 127 000
Cascadia Maintenance Manual, August 2010
00
General Information
Vehicle Maintenance Schedule Table: 00–03
Maintenance for Service Schedule I
Maint. No.
Maintenance
Interval
71st
Service
Date
Service Schedule I
Miles
km
M1
710,000
1 143 000
72nd
M1
720,000
1 159 000
73rd
M1
730,000
1 175 000
74th
M1
740,000
1 191 000
75th
M1, M2, and M3
750,000
1 207 000
76th
M1
760,000
1 223 000
77th
M1
770,000
1 239 000
78th
M1
780,000
1 255 000
79th
M1
790,000
1 271 000
80th
M1 and M2
800,000
1 287 000
81st
M1
810,000
1 304 000
82nd
M1
820,000
1 320 000
83rd
M1
830,000
1 340 000
84th
M1
840,000
1 352 000
85th
M1 and M2
850,000
1 370 000
86th
M1
860,000
1 384 000
87th
M1
870,000
1 400 000
88th
M1
880,000
1 416 000
89th
M1
890,000
1 432 000
90th
M1, M2, and M3
900,000
1 448 000
91st
M1
910,000
1 465 000
92nd
M1
920,000
1 481 000
93rd
M1
930,000
1 500 000
94th
M1
940,000
1 513 000
95th
M1 and M2
950,000
1 530 000
96th
M1
960,000
1 550 000
97th
M1
970,000
1 561 000
98th
M1
980,000
1 577 000
99th
M1
990,000
1 593 000
M1 and M2
1,000,000
1 609 000
100th
Table 2, Maintenance for Service Schedule I
Cascadia Maintenance Manual, August 2010
00/5
00
General Information
Vehicle Maintenance Schedule Table: 00–03
Maintenance for Service Schedule II
00/6
Maint. No.
Maintenance Interval
1
Service
Date
Service Schedules II
Miles
km
IM and M1
25,000
40 000
2
M1
50,000
80 000
3
M1
75,000
121 000
4
M1 and M2
100,000
161 000
5
M1
125,000
201 000
6
M1
150,000
241 000
7
M1
175,000
281 000
8
M1 and M2
200,000
322 000
9
M1
225,000
362 000
10
M1
250,000
402 000
11
M1
275,000
443 000
12
M1, M2, and M3
300,000
483 000
13
M1
325,000
523 000
14
M1
350,000
563 000
15
M1
375,000
604 000
16
M1 and M2
400,000
644 000
17
M1
425,000
684 000
18
M1
450,000
724 000
19
M1
475,000
764 000
20
M1 and M2
500,000
805 000
21
M1
525,000
845 000
22
M1
550,000
885 000
23
M1
575,000
925 000
24
M1, M2, and M3
600,000
966 000
25
M1
625,000
1 005 800
26
M1
650,000
1 046 000
27
M1
675,000
1 086 000
28
M1 and M2
700,000
1 127 000
29
M1
725,000
1 167 000
30
M1
750,000
1 207 000
31
M1
775,000
1 248 000
32
M1 and M2
800,000
1 287 000
33
M1
825,000
1 328 000
34
M1
850,000
1 368 000
35
M1
875,000
1 408 000
Cascadia Maintenance Manual, August 2010
00
General Information
Vehicle Maintenance Schedule Table: 00–03
Maintenance for Service Schedule II
Maint. No.
Maintenance Interval
36
Service
Date
Service Schedules II
Miles
km
M1, M2, and M3
900,000
1 448 000
37
M1
925,000
1 490 000
38
M1
950,000
1 529 000
39
M1
975,000
1 569 000
40
M1 and M2
1,000,000
1 609 000
Table 3, Maintenance for Service Schedule II
Cascadia Maintenance Manual, August 2010
00/7
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
fin detailed instructions in this manual on the mainMaintenance
Operation Number
tenance operations to be performed. All operations
listed in the table, along with the operations listed in
the applicable M1 maintenance interval table, must
be performed to complete the initial maintenance
(IM).
Initial Maintenance (IM) Operations for Service Schedules I and II
00–05
Perform all M1 Operations
31–03
Frame Fastener Torque Check
32–02
Suspension U-Bolt Torque Check
33–04
All-Axle Alignment Check
47–03
Fuel Tank Band-Nut Tightening
Check
Table 4, Initial Maintenance (IM) Operations for Service Schedules I and II
00/8
Cascadia Maintenance Manual, August 2010
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 operaMaintenance
Operation Number
tion numbers are reference numbers used to help
you fin detailed instructions in this manual on the
maintenance operations to be performed.
M1 Maintenance Interval Operations for Service Schedules I and II
13–01
Bendix Air Compressor Inspection
25–01
Eaton Fuller Clutch Release Bearing Lubrication
31–01
Fifth Wheel Inspection
31–02
Fifth Wheel Lubrication
33–05
Knuckle Pin Lubrication, Dana Spicer Axles
33–06
Tie Rod Lubrication, Dana Spicer Axles
40–01
Wheel Nut Check
41–01
Driveline Inspection
41–02
Driveline Lubrication
42–02
Bendix Air Dryer Desiccant Replacement (with an oil-coalescing desiccant cartridge)*
42–05
Dana Spicer Camshaft Bracket Lubrication
42–06
Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication
49–01
Exhaust System Inspection (noise emission control)
83–03
ParkSmart™ Drain Tube Inspection
88–01
Hood Rear Support Lubrication
Check
* If equipped with an oil-coalescing desiccant cartridge, replace the cartridge once a year, regardless of mileage. Otherwise use the M3 maintenance interval.
Table 5, M1 Maintenance Interval Operations for Service Schedules I and II
Cascadia Maintenance Manual, August 2010
00/9
00
General Information
M2 Maintenance Interval Operations: 00–06
The M2 Maintenance Interval Operations tables list
all maintenance operations that are to be performed
at the M2 maintenance interval. Maintenance operation numbers are reference numbers used to help
Maintenance
Operation Number
you fin detailed instructions in this manual on the
maintenance operations to be performed. Perform all
M1 maintenance interval operations at the M2 maintenance interval.
M2 Maintenance Interval Operations for Service Schedules I and II
00–05
Perform All M1 Operations
15–01
Alternator, Battery, and Starter Check
20–01
Pressure Relief Cap Check
20–03
Fan Clutch Check (noise emission control)
26–02
Transmission Fluid Level Inspection
26–03
Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement
31–04
Fairing Bumper Wear Check
32–01
Suspension Inspection
32–02
Suspension U-Bolt Torque Check
33–01
Knuckle Pin Lubrication, Meritor Axles
33–02
Tie Rod Inspection
33–03
Tie Rod Lubrication, Meritor Axles
35–02
Axle Breather and Axle Lubricant Level Inspection
42–01
Air Brake System Valve Inspection
42–03
Air Dryer Inspection
42–04
Alcohol Evaporator Cleaning and Inspection
42–07
Meritor Camshaft Bracket Lubrication
42–08
Meritor Slack Adjuster Lubrication
46–01
Drag Link Inspection
46–03
Power Steering Fluid Level Inspection
46–04
Power Steering Gear Lubrication
46–05
Drag Link Lubrication
46–06
Rack and Pinion Steering Inspection
47–01
Fuel Filter Replacement
47–02
Fuel/Water Separator Element Checking and Replacement
54–01
Trailer Cable Inspection and Cleaning
60–01
Mirror Folding Check
83–01
Air Conditioner Inspection
83–02
Air Filter Replacement
Check
Table 6, M2 Maintenance Interval Operations for Service Schedules I and II
00/10
Cascadia Maintenance Manual, August 2010
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 fin 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.
M3 Maintenance Interval Operations for Service Schedules I and II
00–05
Perform All M1 Operations
00–06
Perform All M2 Operations
09–01
Air Cleaner Element Inspection and Replacement
20–02
Radiator Pressure-Flushing and Coolant Change
26–01
Manual Transmission Fluid Change, and Magnetic Plug Cleaning (synthetic lubricant)
35–01
Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning (synthetic lubricant)
42–02
Bendix Air Dryer Desiccant Replacement
42–09
Bendix E–6 Foot Control Valve Inspection and Lubrication
46–02
Power Steering Fluid and Filter Change
Check
Table 7, M3 Maintenance Interval Operations for Service Schedules I and II
Cascadia Maintenance Manual, August 2010
00/11
00
General Information
Maintenance Operation Sets Table: 00–08
Maintenance Operation Sets
Maint.
No.
Service Schedules I
and II
Operation Description
IM
09–01
Air Cleaner Element Inspection and Replacement
13–01
Bendix Air Compressor Inspection
15–01
M1
M2
M3
•
•
•
•
•
Alternator, Battery, and Starter Check
•
•
20–01
Pressure Relief Cap Check
•
•
20–02
Radiator Pressure-Flushing and Coolant Change
20–03
Fan Clutch Check (noise emission control)
25–01
Eaton Fuller Clutch Release Bearing Lubrication
26–01
Manual Transmission Fluid Change, and Magnetic Plug Cleaning (Synthetic Lubricant)
26–02
•
•
•
•
•
Transmission Fluid Level Inspection
•
•
26–03
Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement
•
•
31–01
Fifth Wheel Inspection
•
•
•
•
31–02
Fifth Wheel Lubrication
•
•
•
•
31–03
Frame Fastener Torque Check
•
31–04
Fairing Bumper Wear Check
•
•
32–01
Suspension Inspection
•
•
32–02
Suspension U-Bolt Torque Check
•
•
33–01
Knuckle Pin Lubrication, Meritor Axles
•
•
33–02
Tie Rod Inspection
•
•
33–03
Tie Rod Lubrication, Meritor Axles
•
•
33–04
All-Axle Alignment Check
•
33–05
Knuckle Pin Lubrication, Dana Spicer Axles
•
•
•
•
33–06
Tie Rod Lubrication, Dana Spicer Axles
•
•
•
•
35–01
Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning (synthetic lubricant)
35–02
Axle Breather and Axle Lubricant Level Inspection
•
•
40–01
Wheel Nut Check
•
•
•
•
41–01
Driveline Inspection
•
•
•
•
41–02
Driveline Lubrication
•
•
•
•
42–01
Air Brake System Valve Inspection
•
•
42–02
Bendix Air Dryer Desiccant Replacement*
•
•
•
42–03
Air Dryer Inspection
•
•
42–04
Alcohol Evaporator Cleaning and Inspection
•
•
42–05
Dana Spicer Camshaft Bracket Lubrication
•
•
•
•
42–06
Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication
•
•
•
•
42–07
Meritor Camshaft Bracket Lubrication
•
•
00/12
•
•
•
•
•
Cascadia Maintenance Manual, August 2010
00
General Information
Maintenance Operation Sets Table: 00–08
Maintenance Operation Sets
Maint.
No.
Operation Description
Service Schedules I
and II
IM
42–08
Meritor Slack Adjuster Lubrication
42–09
Bendix E–6 Foot Control Valve Inspection and Lubrication
46–01
Drag Link Inspection
46–02
Power Steering Fluid and Filter Change
46–03
M1
M2
M3
•
•
•
•
•
Power Steering Fluid Level Inspection
•
•
46–04
Power Steering Gear Lubrication
•
•
46–05
Drag Link Lubrication
•
•
46–06
Rack and Pinion Steering Inspection
•
•
47–01
Fuel Filter Replacement
•
•
47–02
Fuel/Water Separator Element Checking and Replacement
•
•
47–03
Fuel Tank Band-Nut Tightening
•
49–01
Exhaust System Inspection (noise emission control)
•
•
•
54–01
Trailer Cable Inspection and Cleaning
•
•
60–01
Mirror Folding Check
•
•
83–01
Air Conditioner Inspection
•
•
83–02
Air Filter Replacement
•
•
83–03
ParkSmart™ Drain Tube Inspection
•
•
•
88–01
Hood Rear Support Lubrication
•
•
•
•
•
* If equipped with an oil-coalescing desiccant cartridge, replace the cartridge once a year, regardless of mileage. Otherwise use the M3 maintenance interval.
Table 8, Maintenance Operation Sets
Cascadia Maintenance Manual, August 2010
00/13
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 degradation throughout the
life of the vehicle. In compliance with the law, the
noise emission controls maintenance information in
each applicable group of this manual, in conjunction
with the vehicle workshop manual, provides these
instructions to owners.
Recommendations for
Replacement Parts
Replacement parts used for maintenance or repair of
noise emission controls should be genuine Freightliner parts. If other than genuine Freightliner parts
are used for replacement or repair of components
affecting noise emission control, the owner should be
sure that such parts are warranted by their manufacturer to be equivalent to genuine Freightliner parts in
performance and durability.
Freightliner Noise Emission
Controls Warranty
the purpose of noise control, prior to its sale or
delivery to the ultimate purchaser, or while it is in
use.
2. The use of the vehicle after such device or element of design has been removed or rendered
inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
A. Removal of engine noise-deadening panels.
B. Removal of cab-tunnel or hood noisedeadening panels.
C. Removal of, or rendering inoperative, the engine speed governor so as to allow engine
speed to exceed manufacturer’s specifica
tions.
D. Removal of, or rendering inoperative, the fan
clutch, including bypassing the control on
any thermostatic fan drive to cause it to operate continuously.
E. Removal of the fan shroud.
F.
Removal of, or rendering inoperative, exhaust components, including exhaust pipe
clamping.
G. Removal of air intake components.
Maintenance Instructions
Scheduled intervals are in the maintenance tables in
this group. A "Verificatio of Inspections Log" for
Groups 20 and 49 follows, and should be fille in
each time noise emission controls on the vehicle are
maintained or repaired.
Refer to the vehicle owner’s warranty information
book for warranty information concerning noise emission controls.
Tampering with Noise Controls is
Prohibited
Federal law prohibits the following acts or the causing thereof:
1. The removal or rendering inoperative by any person (other than for purposes of maintenance,
repair, or replacement) of any device or element
of design incorporated into any new vehicle for
00/14
Cascadia Maintenance Manual, August 2010
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 2010
Item
Cost
Maintenance Facility
00/15
Air Intake
09
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Air Cleaner Element Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09–01
Cascadia Maintenance Manual, August 2009
09
Air Intake
09–01 Air Cleaner Element
Inspection and
Replacement
Restriction of air flo 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).
1. Inspect the air restriction indicator to see if air
restriction equals or exceeds the maximum allowable restriction. For instructions, see the Cascadia™ Driver’s Manual.
04/08/2005
f090431
Fig. 2, Manual-Reset Air Restriction Indicator, Go/
No-Go
2. If necessary, replace the air cleaner element. For
air cleaner element replacement instructions, see
Group 09 of the Cascadia™ Workshop Manual.
3. Inspect the air cleaner housing for cracks, leaks,
or any other damage. If the air cleaner housing
or element is damaged, replace it.
4. Reset the air restriction indicator.
5. Each time the air cleaner housing is replaced,
perform the procedures in MOP 13–01.
08/07/2007
f090452
Fig. 1, Manual-Reset Air Restriction Indicator,
Graduated
Cascadia Maintenance Manual, August 2009
09/1
Air Compressor
13
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Air Compressor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–01
Cascadia Maintenance Manual, August 2007
Air Compressor
13
13–01 Air Compressor
Inspection
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 intake-air adapter is loose, remove the
adapter, replace the adapter gaskets, and securely
install the adapter.
Check the cooling fin on the compressor crankcase,
if equipped. Clean the fin if they are clogged with
dirt or grease.
Cascadia Maintenance Manual, August 2007
13/1
Alternators and Starters
15
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Alternator, Battery, and Starter Connections Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–01
Cascadia Maintenance Manual, September 2008
15
Alternators and Starters
15–01 Alternator, Battery, and
Starter Connections
Check
WARNING
Batteries generate explosive gas as a by-product
of their chemical process. Do not smoke when
working around batteries. Put out all flames and
remove any source of sparks or intense heat in
the vicinity of the battery compartment. Make sure
the battery compartment has been completely
vented before disconnecting or connecting the
battery cables.
3.4
After cleaning, connect the cables to the
batteries and tighten them to the torque
specification listed on the battery, generally 10 to 15 lbf·ft (14 to 20 N·m).
3.5
Coat the battery terminals with dielectric
grease.
4. Check the alternator wiring for missing insulation,
kinks, and heat damage. Replace or repair as
needed.
5. Check the terminals on the battery shut-off
switch and the magnetic switch. Make sure the
terminal connections are clean and tight. Coat
the terminal connections with dielectric red
enamel after cleaning.
Battery acid is extremely harmful if splashed in
the eyes or on the skin. Always wear a face shield
and protective clothing when working around
batteries.
1. Check the tightness of the alternator bracket fasteners; tighten the fasteners as needed. For
torque values, see Group 15 of the Cascadia™
Workshop Manual.
2. Check that all electrical connections at the alternator and starter are clean. Clean and tighten all
charging system electrical connections, including
the connections at the starter B terminal and
ground terminal, and where the alternator charging cable terminates.
3. Inspect the battery cables for wear, and replace
them if they are damaged. Clean the cable connector terminals with a wire brush. See Group
54 of the Cascadia™ Workshop Manual for adjustment, repair, or replacement instructions.
3.1
Clean and tighten the battery ground
cable, terminal, and clamps.
3.2
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.
Flush with clean water, and dry. Paint the
retainer assembly if needed, to prevent
rusting.
3.3
Check that foreign objects, such as
stones, bolts, and nuts, are removed from
the battery box.
Cascadia Maintenance Manual, September 2008
15/1
Engine Cooling/Radiator
20
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Fan Clutch Check (Noise Emission Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–03
Pressure Relief Cap Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–01
Radiator Pressure-Flushing and Coolant Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–02
Cascadia Maintenance Manual, August 2007
20
Engine Cooling/Radiator
20–01 Pressure Relief Cap
Check
2. Place a suitable container under the elbow of the
radiator outlet pipe and the radiator. The container should hold at least 60 quarts (59 liters) of
fluid
WARNING
Do not remove or loosen the surge tank cap until
the engine and cooling system have completely
cooled. Use extreme care when removing the cap.
A sudden release of pressure from removing the
cap prior to the system cooling can result in a
surge of scalding coolant that could cause serious personal injury.
1. Remove the fil cap first to relieve the cooling
system pressure, then remove the SAE cap.
2. Using a radiator-cap tester, check the pressure
cap to see if it maintains pressure to within 10%
of the pressure rating marked on the cap. If it
doesn’t, replace the cap. Make sure that the replacement radiator cap is correctly rated for the
cooling system of the vehicle.
WARNING
Do not remove or loosen the surge tank cap until
the engine and cooling system have completely
cooled. Use extreme care when removing the cap.
A sudden release of pressure from removing the
cap prior to the system cooling can result in a
surge of scalding coolant that could cause serious personal injury.
3. Remove the surge tank cap.
4. Remove the drain plugs at the radiator side tank
and at the lower radiator outlet pipe elbow, if
equipped. See Fig. 1. Allow the coolant to drain.
3. There is a second valve in the radiator cap that
opens under vacuum. This prevents the collapse
of hoses and other parts that are not internally
supported when the system cools. Inspect the
vacuum-relief valve to be sure it is not stuck.
4. Make sure that the cap seals properly on the
coolant fille neck seat, and that the radiator cap
gasket is not damaged. On vehicles with
screw-on caps with O-rings, make sure that the
O-ring is not cracked or deteriorated. Replace
the cap if the gasket shows deterioration or damage.
20–02 Radiator PressureFlushing and Coolant
Change
NOTE: For additional instructions on cleaning
and flushin the engine cooling system, see the
applicable engine manufacturer’s maintenance
and operation manual.
1. Apply the vehicle parking brakes, then chock the
tires. Tilt the hood.
Cascadia Maintenance Manual, August 2007
1
1
06/29/95
f011008
NOTE: Cummins engine shown.
1. Coolant Drain Plug
Fig. 1, Coolant Drain Plug Location
5. Disconnect the radiator upper and lower hoses,
and install the surge tank cap and the radiator
side-tank drain plug. Attach the flushin gun
nozzle to the radiator at the lower radiator hose
opening. Run the water until the radiator is full.
20/1
20
Engine Cooling/Radiator
CAUTION
When flushing the radiator, do not apply more
than 15 psi (100 kPa) air pressure. Excessive pressure can damage the radiator.
6. Gradually, apply up to 15 psi (100 kPa) air pressure to help dislodge sediment that has built up
in the radiator core.
7. Shut off the air at the pressure gun nozzle and
allow the radiator to refil with water.
8. Repeat the previous two steps until clean water
flow from the radiator.
9. Remove the radiator side-tank drain plug and
allow the radiator to drain. Install and tighten the
side-tank drain plug and the radiator outlet pipe
drain plug after the radiator has been drained.
Do not overtighten the plugs.
10. Connect the hoses. Your hose clamps can be
either T-bolt clamps (see Fig. 2) or Breeze
Constant-Torque clamps (see Fig. 3).
f200326
02/28/96
Fig. 2, T-Bolt Type Hose Clamp
A
B
1
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).
When installing Breeze Constant-Torque hose
clamps, the clamps must be tightened to the correct torque. The screw tip of the clamp must extend about 1/4 inch (6 mm) from the clamp housing, and the Belleville washer stacks must be
collapsed almost flat Use a torque wrench to
install these clamps correctly. The correct installation torque is as follows:
For Breeze Constant-Torque clamps with a 5/16inch tightening screw hex: 55 lbf·in (620 N·cm).
For Breeze Constant-Torque clamps with a 3/8inch tightening screw hex: 90 lbf·in (1020 N·cm).
NOTE: All hose clamps will lose torque after
installation due to "compression set." However,
when correctly installed, Breeze ConstantTorque clamps will hold enough torque to automatically adjust and keep consistent sealing
pressure. During vehicle operation and shutdown, the screw tip may adjust according to
temperature and pressure changes. The torque
may need to be adjusted for individual applications.
20/2
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
Fig. 3, Breeze Constant-Torque Hose Clamp Installation
11. Place a pan under the coolant filte to catch engine coolant.
12. Remove the coolant filte with a strap or chain
wrench. Install a new coolant filte and tighten.
13. Fill the cooling system with new coolant. Certain
equipment such as fuel heaters, water filters and
auxiliary heaters may increase the coolant capacity and require additional coolant. The cooling
system is fille when the coolant level reaches
the MAX line on the surge tank. Freightliner recommends the use of a precharged and premixed
antifreeze when refillin the cooling system. See
Table 1 for a list of some of the precharged antifreeze available. Use of an equivalent antifreeze
to those listed in the table is also acceptable.
Always check that the antifreeze meets Freightliner’s specification and is at the proper concen-
Cascadia Maintenance Manual, August 2007
20
Engine Cooling/Radiator
tration for protection in the vehicle operating
area. Freightliner specifie that antifreeze must
be an ethylene glycol solution that meets GM
6038 M Engineering Standards or a ethylene glycol solution that has less than 0.1% anhydrous
sodium metasilicate, and meets either GM 1825
M or GM 1899 M Engineering Standards. If
supplemental coolant additives are being used,
add the supplements to the coolant as necessary. See the coolant additive manufacturer’s
instructions for the correct amount of additive
required. Don’t forget to consider the volume of
the supplemental coolant additive being added to
the system when determining the amount of
coolant required to refil the system.
NOTE: You can mix purple-pink coolant (precharged with a borate/nitrate-based additive)
with the common green coolant, although some
color change will be apparent.
14. Replace the surge tank cap(s).
15. Return the hood to the operating position.
16. Start the engine and turn on the cab heater.
Allow the engine to warm up to normal operating
temperature. Check the radiator and hoses for
leaks. Repair as needed.
17. Shut off the engine, then check the coolant level
in the surge tank. Add coolant if the level isn’t
between MIN and MAX lines on the surge tank.
20–03 Fan Clutch Check (Noise
Emission Control)
3
2
1
4
5
6
A
f200237a
05/27/93
With the fan clutch engaged, measure the distance at A;
measure it again with the fan clutch disengaged.
1.
2.
3.
4.
Bearing Housing
Retaining Plate
Fan Pulley
Air Inlet (from solenoid
valve)
5. Air Cylinder
6. Fan
Fig. 4, Kysor K26RA Fan Clutch Lining Wear Check
the retaining plate to the forward-most edge of
the fan belt pulley.
5. Compare the two measurements; if the difference
between the two measurements exceeds 0.150
inches (3.8 mm), the clutch lining is worn and
must be replaced. See Group 20 of the Cascadia™ Workshop Manual for clutch lining replacement instructions.
Borg Warner (Kysor) K26RA Fan
Clutch
6. Release the air pressure, then disconnect the
shop hose from the air inlet of the air cylinder.
Connect the vehicle air hose to the inlet.
1. Disconnect the batteries at the negative terminals. Drain all air from the air system.
7. Connect the battery cables. Start the engine.
2. Measure the distance from the back surface of
the fan clutch retaining plate to the forward-most
edge of the fan belt pulley. See Fig. 4, Ref. A.
3. Disconnect the line from the air inlet of the air
cylinder. Connect a shop air hose to the inlet.
4. Apply a minimum of 100 psi (690 kPa) air pressure to the air cylinder—the bearing housing will
move backwards, disengaging the clutch. Again,
measure the distance from the back surface of
Cascadia Maintenance Manual, August 2007
Horton DriveMaster® Fan Clutch
NOTE: If any part of the fan clutch needs to be
repaired or replaced after performing the checks
below, see Group 20 of the Cascadia™ Workshop Manual.
1. Disconnect the batteries at the negative terminals.
20/3
20
Engine Cooling/Radiator
Approved Antifreeze
Manufacturer
Antifreeze
Type
Caterpillar
Caterpillar Diesel Engine Antifreeze/Coolant
Contains supplement additives. Available as a
premixed solution.
Cummins
Fleetguard® Compleat Premix
Premixed solution with supplement additives.
Detroit Diesel
Detroit Diesel Power Cool
Premixed solution with supplement additives.
Old World Industries Fleet
With supplement additives.
Charge™
Table 1, Approved Antifreeze
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 filte , if
equipped, as follows.
3.1
Unscrew the fan clutch solenoid valve air
filte assembly and remove the filte element.
3.2
Clean the filte element with cleaning solvent.
3.3
Using a clean, lint-free cloth, wipe off any
excess solvent.
3.4
Reassemble the clutch valve solenoid air
filte , then install it on the vehicle.
8. With the air system charged to 120 psi (827
kPa), check the fan clutch for audible air leaks,
using a suitable listening device.
Check at the solenoid valve, the air filte assembly, and the air hoses and fittings See Fig. 5.
Using a wet finge or a soapy water solution,
check for a leak in the same areas.
4. Check the fan for bent, cracked, or damaged
blades. Replace if damaged. Check for adequate
clearance between the fan and other components.
5. Check the fan belt for wear, tension, and alignment. Correct if necessary.
6. Check for wear on the friction facing. Replace
the friction facing if it is worn to a 3/16-inch (4.8mm) thickness or less. Also check the facing for
signs of oil contamination or burn marks. If evidence of oil or burn marks are found, replace the
friction facing.
7. Connect the battery cables. Start the engine, and
charge the air system to 120 psi (827 kPa).
Manually engage and disengage the fan clutch.
Check the fan and fan clutch from a distance.
Look for vibration, fan blade contact, fan clutch
slippage, and overall fan clutch operation.
If the fan clutch does not operate correctly, see
Group 20 of the Cascadia™ Workshop Manual
for troubleshooting and repair procedures.
20/4
05/30/2002
f200581
Fig. 5, 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 Cascadia™ Workshop Manual for repair procedures.
10. Check the fan drive for discoloration or any other
signs of slipping or overheating.
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.
Cascadia Maintenance Manual, August 2007
Engine Cooling/Radiator
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.
11.3
If either the hub or sheave bearings are
worn, replace them, using a Horton DriveMaster Super Kit.
20
For instructions and kit part number, see
Group 20 of the Cascadia™ Workshop
Manual.
Cascadia Maintenance Manual, August 2007
20/5
Clutch
25
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Eaton Fuller Clutch Release Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–01
Cascadia Maintenance Manual, August 2007
25
Clutch
25–01 Eaton Fuller Clutch
Release Bearing
Lubrication
The standard clutch release bearing is not sealed,
and requires lubrication. Lubricate the bearing, as
follows.
2
1
1. Apply the parking brakes, and chock the rear
tires.
2. Remove the clutch inspection plate so that you
can see the release bearing while lubricating it.
See Fig. 1.
05/07/2007
1. Grease Fitting
f250663
2. Left Engine Mount
Fig. 2, Release Bearing Grease Fitting
4. Using a pressure-type grease gun equipped with
the recommended grease, lubricate the bearing
until excess grease purges from the rear of the
release bearing (toward the transmission).
5. Install the clutch inspection plate.
06/22/2007
f250662
Fig. 1, Clutch Inspection Plate
NOTE: For lubrication of the release bearing,
Eaton Fuller recommends a lithium-base hightemperature grease that meets the NLGI Grade
1 or 2 specification
3. Locate the grease fittin at the 9-o’clock position
on the left side of the bellhousing, and wipe any
dirt away from the grease fitting See Fig. 2.
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.
Cascadia Maintenance Manual, August 2007
25/1
Transmission
26
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement . . . . . . . . . . . . . . . . . . . . . . . 26–03
Manual Transmission Fluid Change, and Magnetic Plug Cleaning (Synthetic
Lubricant)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–01
Transmission Fluid Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–02
Cascadia Maintenance Manual, January 2008
26
Transmission
26–01 Manual Transmission
Fluid Change, and
Magnetic Plug Cleaning
(Synthetic Lubricant)
formance, change the filte each time that the
flui is changed.
4. For a transmission equipped with a transmission
flui filter(s) replace the flui filter(s as follows:
4.1
Place a drain pan under the transmission
flui filte .
CAUTION
Operating a transmission with the fluid level
higher or lower than recommended can result in
transmission damage. Do not overfill the transmission. Overfilling will force fluid out of the case
through the main shaft openings.
Do not mix types and brands of fluid, because of
possible incompatibility. Do not use fluid additives, friction modifiers, extreme-pressure gear
fluids, or multiviscosity lubricants.
NOTE: Fluid change intervals are extended to
500,000 miles (800 000 km) on any vehicles
fille with synthetic transmission fluid
IMPORTANT: Drain the transmission when the
flui is warm. If not already warm, run the engine until the transmission flui reaches operating temperature. Shift the transmission to neutral (N) and shut down the engine.
CAUTION
To prevent skin burns from hot transmission fluid,
wear protective gloves when removing the filter.
4.2
Place a strap or chain wrench around the
filte canister, and rotate it in a counterclockwise motion to separate the filte
from the mounting. Carefully spin the filte
off the mount and remove it from the vehicle.
4.3
Apply a light coat of transmission flui to
the O-ring gasket on the new filte . See
Fig. 1. Fill the filte with specifie transmission fluid and spin the filte onto the
mount.
NOTE: The filte fill slowly, so be patient to
ensure the proper flui level has been set.
4.4
1. Apply the parking brakes, and chock the rear
tires. Place a large drain pan under the transmission.
2. Clean the area around the fil plug, and remove it
from the side of the gear case. Remove each
drain plug from the bottom of the case.
3. Clean the fil and drain plugs. 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
Once the filte makes contact with the
mount, use a strap wrench to rotate the
canister an additional 180 to 270 degrees
to firml tighten the filte . Wipe the filte
clean of any flui after it is tightened.
5. Add flui until it is level with the lower edge of
the fil opening. See Fig. 1. If the transmission
has two fil openings, add flui to the level of
both openings. See Table 1 for approved transmission lubricants. See Table 2 for transmission
lubricant capacities.
Install and tighten each drain plug 50 lbf·ft (68
N·m).
NOTE: The optional transmission flui filte is a
remote-mount, spin-on type, and is located between the transmission and the flui cooler. The
filte bracket is attached to the frame rail or
some other nearby location. The filte is
mounted in a vertical position, and should be
fille with flui before installation to assure the
proper flui level. For optimum transmission per-
Cascadia Maintenance Manual, January 2008
05/27/93
A. Full
B
A
f260006a
B. Low
Fig. 1, Checking Transmission Fluid Level
26/1
26
Transmission
Approved Manual Transmission Lubricants
Transmission
Model
All Eaton
Fuller
Temp.
SAE
Range Viscosity
Lubricant Type*
MobilTrans SHC 50
(RN 2952 E-5)
All
50W
Synthetic transmission
lubricant approved by
Eaton
All
50W
* Do not mix types or brands of fluid Multi-weight and extreme-pressure
gear fluid are not recommended. Call 1-800-826-4357 for a complete list of
Eaton approved lubricants.
Table 1, Approved Manual Transmission Lubricants
NOTE: In all cases, the correct flui level is established by checking at the fil opening.
6. Operate the engine for fiv minutes after fillin
the transmission, then check the flui level again.
7. Clean the fil plug, then install it in the transmission. Tighten the plug as follows:
• 25 to 35 lbf·ft (34 to 48 N·m) for plugs with
3/4-inch pipe threads.
• 60 to 75 lbf·ft (81 to 102 N·m) for plugs
with 1-1/4-inch pipe threads.
8. Operate the vehicle to check for correct operation.
Eaton Fuller Transmission Lubricant Capacities
Transmission Model
Refill Capacity:* qt (L)
7-Speed T Series
All Models
18.0 (17.0)
All 9-Speed Series
All Models
13.5 (12.8)
All 10-Speed Manual (except deep reduction)
FR and FRO Series
11.75 (11.0)
RT and RTX Series
13.0 (12.3)
RTLO Series
14.0 (13.2)
10-Speed Deep Reduction
RTO–14908LL
14.0 (13.2)
RTO–16908LL
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 (13.2)
15-Speed RTO Series
All Models
14.0 (13.2)
All 18-Speed Series
RTLO Series
18-Speed Autoshift AS2 (all)
14.0 (13.2)
26–02 Transmission Fluid
Level Inspection
CAUTION
Operating a transmission with the fluid level
higher or lower than recommended can result in
transmission damage. Do not overfill the transmission. Overfilling will force fluid out of the case
through the main shaft openings.
Do not mix types and brands of fluid, because of
possible incompatibility. Do not use fluid additives, friction modifiers, extreme-pressure gear
fluids, or multiviscosity lubricants.
With the transmission at operating temperature, and
the vehicle on a level surface, check the flui level in
the transmission.
1. Clean the area around the fil plug, and remove it
from the side of the gear case.
2. Using your finge or a bent pipe cleaner, see if
the flui is level with the fil opening. See Fig. 1.
3. If the flui level is low, check the transmission for
leaks, and correct as needed.
4. If needed, add the recommended fluid until it is
level with the lower edge of the fil opening. See
Table 1 for approved transmission lubricants.
* Quantities listed are approximate. Fill transmission until lubricant is level
with bottom of f ll hole with vehicle in normal operating position.
Table 2, Eaton Fuller Transmission Lubricant
Capacities
26/2
Cascadia Maintenance Manual, January 2008
26
Transmission
5. Clean the fil plug, then install it. Tighten the plug
as follows:
• 25 to 35 lbf·ft (34 to 48 N·m) for transmissions with 3/4-inch pipe threads.
• 60 to 75 lbf·ft (81 to 102 N·m) for transmissions with 1-1/4-inch pipe threads.
26–03 Manual Transmission Air
Filter/Regulator Check,
Cleaning, or
Replacement
Eaton Fuller
1. Apply the parking brakes, and chock the rear
tires. Drain the air reservoirs.
WARNING
f260037a
05/27/93
Drain the air supply; if the air supply is not
drained before the air filter/regulator is serviced,
serious injury and component damage could result.
Fig. 2, Air Filter/Regulator Location
2. Clean the outside of the air filter/regulato with
cleaning solvent. See Fig. 2.
2
3
4
5
6
7
3. Remove the end cap, large O-ring, and filte element from the filte housing. See Fig. 3. Remove
the small O-ring from the end cap.
NOTE: Do not remove, disassemble, or adjust
the air regulator. If the air regulator is not keeping air pressure between 58 and 63 psi (400
and 435 kPa), replace the air filter/regulato . It
cannot be repaired.
WARNING
Wear safety goggles when using compressed air
to clean parts, as permanent harm to eyes could
result from flying debris.
4. Clean the filte element by dipping it in alcohol or
other cleaning solvent. Blow compressed air
through the element (inside to outside) to loosen
surface dirt and to dry the element. If it is not
damaged, the sintered metallic filte element will
last the life of the vehicle.
Cascadia Maintenance Manual, January 2008
1
f260052a
10/17/2001
1.
2.
3.
4.
Air Regulator
Housing
Large O-Ring
Filter Element
5. Small O-Ring
6. End Cap
7. Plug
Fig. 3, Eaton Fuller Transmission Air Filter/Regulator
Components
Wipe out the filte housing with a clean, dry, lintfree rag. Clean and inspect the O-rings and end
cap. Replace any parts that are damaged.
5. Install the large O-ring, then the filte element
(small end first into the filte housing.
6. Install the small O-ring in the end cap, then install the end cap and tighten it until firm
26/3
26
Transmission
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 filte housing
and air line connections; repair any leaks.
26/4
Cascadia Maintenance Manual, January 2008
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–02
Frame Fastener Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–03
Cascadia Maintenance Manual, August 2007
31
Frame and Frame Components
31–01 Fifth Wheel Inspection
WARNING
All fifth wheel maintenance, adjustment, and rebuilding must be done only by a qualified mechanic. Improper or incomplete procedures could
result in a possible disengagement of the trailer
from the tractor, which could result in personal
injury or property damage.
Parts are under spring compression. Wear safety
goggles while servicing the fifth wheel. Failure to
do so can result in personal injury, due to parts
ejecting with force.
Fontaine
1. Disconnect the tractor from the trailer. For instructions, see Chapter 10 of the Cascadia™
Driver’s Manual.
2. Thoroughly steam clean the fift wheel.
3. Look for cracks in the fift wheel assembly,
mounting brackets, and mounting parts.
4. Check the jaw and stationary jaw for mushrooming, and check that the serrations at the jaw and
wedge are in good condition.
5. Test the safety lock latch for ease of operation.
NOTE: The safety lock latch is located at the
front of the fift wheel on the top plate.
6. Check for loose nuts or bolts (see Fig. 1) on the
fift wheel and the mounting. Set a torque
wrench to the maximum torque value for the bolt
being checked, and confir that the torque is to
specification Do not loosen the bolt to check the
torque. See Group 31 of the Cascadia™ Workshop Manual for bolt torque specifications
7. Check all springs to see if they are securely fastened, and are not deformed.
WARNING
8.2
Release the lock by tripping the release
latch at the bottom of the throat.
8.3
Adjust the wedge stop at the end of the
wedge to approximately 1/4-inch (6-mm)
clearance by turning the wedge stop rod
located on the right side of the top plate.
9. Replace cracked, worn, or damaged parts with
new parts. Replace all loose mounting bolts with
5/8–11 SAE grade 8 bolts, grade C locknuts, and
hardened washers. Do not re-use bolts, nuts,
and washers on fift wheel mountings.
10. After inspecting the fift wheel, lubricate all moving parts with a chassis or multipurpose grease.
Apply a generous coating of grease to the top
plate to fil the grooves, or depressions, on the
top plate. See Maintenance Operation 31–02
for lubrication instructions.
Holland
1. Disconnect the tractor from the trailer. For instructions, see the Cascadia™ Driver’s Manual.
2. Thoroughly steam clean the fift wheel.
3. Check for loose nuts or broken bolts on the fift
wheel assembly.
4. Inspect for cracks or wear on the mounting bolts.
5. Inspect for improper locking action and for cracks
or wear on the jaw locking mechanism.
6. Check the depth of the grease grooves. If the
depth of the grooves is 1/8 inch or less, replace
the fift wheel top plate. See Group 31 of the
Cascadia™ Workshop Manual.
7. Check the condition of the X-pattern cast into the
underside of the fift wheel top plate. See Fig. 2.
The fift wheel top plate must be removed to
check the X-pattern.
7.1
Remove the roll pins from the bushing
pins. Remove the bushing pins from the
slide mount. Using a hoist, lift the fift
wheel top plate off of the vehicle.
7.2
Turn the fift wheel top plate over with
the locks open. Check the condition of
the X-pattern in the pockets. If the
X-pattern is worn away, replace the fift
wheel top plate.
7.3
Install the fift wheel top plate, bushing
pins, and roll pins.
Do not disassemble the fifth wheel to inspect the
springs. The springs are under extreme pressure,
and could cause serious injury.
8. Check wedge adjustment.
8.1
Open the kingpin lock, and vertically insert a two-inch (50-mm) diameter shaft.
Cascadia Maintenance Manual, August 2007
31/1
31
Frame and Frame Components
13
14
10
15
11
1
12
3
2
16
14
9
4
17
18
1
1
21
22
19
2
3
20
4
21
23
25
5
1
6
7
6
21
8
23
24
26
f310476
09/18/95
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
3/16" x 1" Cotter Pin
Lower Bracket Retainer Pin
Grease Fitting
Lower Bracket Pin
Wedge Stop Rod
Flatwasher
Wedge Stop Rod Spring
Wedge Stop Rod Nut
Side Release Upper Assembly
Leaf Spring
11. 1/4–20 x 3/8" Thread-Cutting
Screw
12. Step Jaw and Wedge
13. Jaw Spring
14. 1/4" x 3" Cotter Pin
15. Timer
16. Wedge Spring
17. Pull Handle
18. Bumper Handle Spring
19.
20.
21.
22.
23.
24.
25.
1/2–13 x 2" Bumper Pivot Bolt
Bumper
Flatwasher
5/16" Bumper Pivot Bushing
1/2–13 Locknut
7/16" Handle Pivot Bushing
Operating Handle (side-release
only)
26. 1/2–13 x 2" Handle Pivot Bolt
Fig. 1, Fontaine H5092 Series Fifth Wheel (left-side-release shown)
8. Inspect for fatigue or cracked welds.
9. Replace cracked, worn, or damaged parts with
new parts. Replace all loose mounting bolts with
5/8–11 SAE grade 8 bolts, grade C locknuts, and
hardened washers. Do not re-use bolts, nuts,
and washers on fift wheel mountings.
10. After inspecting the fift wheel, lubricate all moving parts with a chassis or multipurpose grease.
See Maintenance Operation 31–02 for lubrication instructions.
31/2
Simplex Series
1. Disconnect the tractor from the trailer. For instructions, see the Cascadia™ Driver’s Manual.
2. Thoroughly steam clean the fift wheel.
3. Check the fift 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.
3.
Cascadia Maintenance Manual, August 2007
31
Frame and Frame Components
1
2
3
18
4
17
5
15
6
10
7
16
8
9
15
14
08/29/95
1.
2.
3.
4.
5.
6.
Locknut, 3/4–16
Washer
Rubber Washer
Lock Adjustment Tag
Yoke Shaft
Yoke Sub-Assembly
14
11
13
12
13
7.
8.
9.
10.
11.
12.
f310472
Torsion Spring
Roll Pin
Secondary Lock, Right-Hand
Cam Plate
Lock Guard
Pin
13.
14.
15.
16.
17.
18.
Lock Pin
Lock Jaw
Washer
Right-Hand Release Handle
Left-Hand Release Handle
Secondary Lock, Left-Hand
Fig. 2, Holland Fifth Wheel
5. The lever bar and operating handle must be in
proper alignment. See Fig. 4. Compare the lever
bar and operating handle alignment to a new, or
a properly operating lever bar and operating
handle. Replace any bent or misaligned lever bar
or operating rod.
Cascadia Maintenance Manual, August 2007
6. Check all cotter pins for cracking or damage. Replace any cotter pin that shows any signs of
damage.
7. Level the fift wheel plate to a horizontal position. Measure the height from a stationary
mounting point (see Fig. 5, Item 3), such as the
31/3
31
Frame and Frame Components
A
1
2
3
5
1
4
2
3
4
11/28/95
f310353b
1. Lubricant Grooves
2. Safety Latch
3. Lock Control Handle
4. Mount
Fig. 3, Simplex Series Fifth Wheel
1
08/31/95
A.
1.
2.
3.
4.
5.
f310475
Extended Top Plate Lift Height
Fifth Wheel Top Plate
Fifth Wheel Mounting Base
Fifth Wheel Mounting Angle
Lifting Point
Static Top Plate Height
Fig. 5, Measuring Fifth Wheel Top Plate Lift
NOTE: Do not measure plate lift immediately
after a trailer has been uncoupled from the fift
wheel. The rubber may have taken a temporary
set, which will normally recover after being uncoupled for a short period of time.
8. Check all mounting bolts for signs of fatigue, and
tighten them to the proper torque. For torque
specifications see Group 31 of the Cascadia™
Workshop Manual. Inspect all angles, plates, and
brackets for cracks or other damage.
2
f310470
09/15/95
1. Operating Handle
2. Lever Bar
Fig. 4, Lever Bar and Operating Handle Alignment
frame rail to the top of the fift wheel plate (Item
1). Pry up on the fift wheel plate (Item 4) below
the pin boss, and measure the vertical movement (Item 5). The bracket connection provides a
9/32-inch (7-mm) vertical clearance to provide
cushioning and to avoid downward pin-loading
while retaining minimum plate lift. If the plate lift
(Ref. A) exceeds 5/16 inch (8 mm) as a result of
wear or rubber deterioration, install new, standard or oversized bracket-shoe rubber pads; see
Group 31 of the Cascadia™ Workshop Manual
for replacement instructions.
31/4
9. Replace cracked, worn, or damaged parts with
new parts. Replace all loose mounting bolts with
5/8–11 SAE grade 8 bolts, grade C locknuts, and
hardened washers. Do not re-use bolts, nuts,
and washers on fift wheel mountings.
10. After inspecting the fift wheel, lubricate all moving parts with a chassis or multipurpose grease.
See Maintenance Operation 31–02 for lubrication instructions.
31–02 Fifth Wheel Lubrication
To maintain proper fift wheel operation, always lubricate the fift wheel after an inspection has been
performed.
Cascadia Maintenance Manual, August 2007
31
Frame and Frame Components
IMPORTANT: Lubricate the fift wheel:
• After power washing, or steam cleaning.
• If the vehicle operates in harsh conditions such
as salt spray from road surfaces, or in extremely dusty environments.
• After any service that requires removal of lubricant from the fift wheel head or components.
WARNING
Failure to properly lubricate the fifth wheel could
result in a possible disengagement of the trailer
from the tractor, which could result in personal
injury or property damage.
Fontaine
Use a multipurpose extreme pressure (EP) chassis
grease to lubricate all moving parts on the fift
wheel. When lubricating the top plate at the grease
fitting for the bracket bearing area, tilt the top plate
forward and backward to evenly distribute the
grease. Using a pry tool, separate the jaw and
wedge and lubricate the serrations using a brush to
distribute the grease. On slide-mount applications,
lubricate the slide rail and tapered wedges for
smooth operation.
Once the moving parts of the fift wheel are lubricated, apply a liberal coating of grease to the top
plate and the trailer kingpin plate.
Holland
Lubricate all moving parts with a multipurpose chassis grease. Lubricate the two grease fitting located
on either side of the top plate with a multipurpose
chassis grease.
Once the fift wheel’s moving parts are lubricated,
apply a heavy coat of grease to the top plate by direct application. On slide-mount applications, lubricate the baseplate rails and the plungers for smooth
operation.
the top plate mounting pins. Lubricate the lock
mechanism.
Once the fift wheel’s moving parts are lubricated,
apply a heavy coat of grease to the top plate, either
through the grease fitting located on the underside
of the top plate, or by direct application. On slidemount applications, lubricate the slider lock pockets
and the slider bracket.
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. This will give a true torque reading by eliminating bolt-body friction. When checking
the torque of frame fasteners, inspect the frame for
cracks and other damage. Set a click-type torque
wrench to the maximum torque of the fastener you
are checking. Apply pressure until the torque wrench
clicks. Do not loosen the bolt to check the torque.
See the applicable torque table in the Cascadia™
Workshop Manual for torque specifications
CAUTION
Make sure frame fasteners are properly tightened.
Continued vehicle operation with loose fasteners
could result in bracket or frame damage.
Check the fasteners at the following locations:
• Axle Stops
• Deck Plates
• Equalizer Brackets
• Exhaust Brackets
Simplex Series
• Fifth Wheel Legs
Use a chassis or multipurpose grease to lubricate the
two grease fitting located on either side of the fift
wheel top plate. Lubricate the two grease fitting located in the grease grooves on the fift wheel top
plate. Lubricate the two grease fitting located below
• Frame Crossmembers and Gussets
Cascadia Maintenance Manual, August 2007
• Fifth Wheel Mountings
• Front Frame Extension and Brackets
• Front Suspension Spring Brackets
31/5
31
Frame and Frame Components
• Fuel Tank Brackets
• Radius Rods
A
• Rear Suspension Spring Brackets
• Shock Absorbers
• All Other Frame Fasteners
3
Any component that shows signs of cracking or other
damage must be repaired or replaced. Refer to the
Cascadia™ Workshop Manual for repair or replacement information in the respective section for the
component in question.
31–04 Fairing Bumper Wear
Check
Vehicles equipped with chassis side fairings, and forward mounted battery boxes, have latched front panels. The bumpers on these fairings provide the tension for the latch mechanism. These bumpers will
wear over time, and will not properly hold the fairings
in place.
2
1
03/09/2007
f311032
A. Wear Area
1. Metal Cup
2. Mounting Stud
3. Rubber Bumper
Fig. 6, Fairing Bumper
1. Open the latched section of the fairing panel.
2. Inspect the rubber bumpers for wear. See Fig. 6
for the bumper wear area, and Fig. 7 for the
bumper location.
If the bumper rubber is worn down even with the
top of the metal cup, or if there are signs of the
metal cup coming in contact with the surface of
the brace that the bumper makes contact with,
replace the bumper.
3. Tighten the fastener 10 to 13 lbf·ft (14 to 18
N·m).
4. Close and latch the fairing.
31/6
Cascadia Maintenance Manual, August 2007
Frame and Frame Components
03/13/2007
31
f311034
Fig. 7, Bumper Location
Cascadia Maintenance Manual, August 2007
31/7
Suspension
32
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Suspension Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–01
Suspension U-Bolt Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–02
Cascadia Maintenance Manual, August 2010
32
Suspension
32–01 Suspension Inspection
WARNING
Do not replace individual leaves of a damaged leaf
spring assembly; replace the complete spring assembly. Visible damage (cracks or breaks) to one
leaf causes hidden damage to other leaves. Replacement of only the visibly damaged part(s) is
no assurance that the spring is safe. On front
spring assemblies, if cracks or breaks exist in the
two top leaves, a loss of vehicle control could
occur. Failure to replace a damaged spring assembly could cause an accident resulting in property
damage, serious personal injury, or death.
Front Suspension Check
Inspect the front spring assemblies for cracked, broken, or abnormally bent leaves. If any of these conditions exist, replace the spring assembly; see Group
32 of the Cascadia™ Workshop Manual.
Front and Rear Suspension
Shock Absorber Check
Make sure the shock absorber brackets are tight,
and the shock absorber is not striking or rubbing the
frame or some other part of the chassis. Striking or
rubbing the frame is characterized by chafe marks on
the shock absorber body and the frame rail; see
Fig. 1. Check the rubber mounting bushings for
cracks, cuts, swelling, dry rot, or missing pieces. If
the shock absorber bushings are no longer serviceable, replace the shock absorber with a new one.
Inspect the shock absorber for oil leakage. Some
misting of the oil is normal, and does not mean the
shock is leaking. If the shock absorber is damaged
or leaking, replace it with a new one; see Group
32of the Cascadia™ Workshop Manual.
Freightliner AirLiner Rear
Suspension Check
Components Checking
Inspect the forward spring brackets for wear, cracks,
and other damage. If any of these conditions exist,
replace the damaged bracket(s); see Group 32 of
the Cascadia™ Workshop Manual.
Cascadia Maintenance Manual, August 2010
05/24/2007
f321090
Fig. 1, Direct-Acting Shock Absorber (front suspension
shown)
Inspect the spring bushings for wear or other damage. If any of these conditions exist, replace the
damaged bushings.
WARNING
Replace worn, cracked, or damaged spring
brackets. Failure to do so could result in bracket
breakage, possibly leading to loss of vehicle control and resulting in personal injury or property
damage.
Inspect the crossmember(s) and gussets for wear,
cracks, and other damage. If any of these conditions
exist, replace the damaged parts; see Group 32 of
the Cascadia™ Workshop Manual.
Visually check the air spring piston for cracks, chips,
and broken areas. Check the air bag for rips, tears,
and holes. Verify that the air spring assembly does
not leak. If any of these conditions exist, replace the
damaged parts; see Group 32 of the 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.
IMPORTANT: To prevent voiding the warranty
on Barksdale height-control valves, note the following:
32/1
32
Suspension
• Do not overtighten the bolts in the Barksdale
height-control valve housing. The bolts should
not be loose, and should not require tightening.
Only if necessary, tighten the valve housing
bolts 45 lbf·in (500 N·cm). Any damage to the
valve housing will void the warranty.
2
1
3
• Do not attempt to disassemble the Barksdale
valve body or the control lever. There are no
serviceable parts in the valve, and any disassembly will void the warranty.
NOTICE
When removing or loosening a Barksdale heightcontrol valve from a mounting bracket, always
hold the valve-side mounting studs in place with
an Allen wrench while loosening or tightening the
nuts that attach the valve to the bracket. Because
the mounting studs are threaded into the valve
body, loosening the nuts without holding the
studs can tighten the studs, which can crush the
valve body and damage the valve. Conversely,
tightening the nuts without holding the studs can
back the studs out, causing a separation of the
two halves of the valve body, and possibly a leak.
1. Park the vehicle on a level surface, using a light
application of the brakes. Do not apply the parking brakes. Shift the transmission into neutral,
and build the secondary air pressure to at least
100 psi (690 kPa). Shut down the engine. Have
an assistant chock the tires on one axle only.
2. Mark the location of the front and rear tires on
the floo .
NOTE: The stud bolt that fastens the valve’s
height-control lever to the vertical linkage is oriented correctly when the linkage rod is vertical,
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.
4
5
f320562a
01/12/2000
1.
2.
3.
4.
5.
Valve Mounting Bracket
Height-Control Valve
Stud Bolt
Linkage Rod
Axle
Fig. 2, Barksdale Height-Control Valve Installation (side
view) (typical)
Suspensions with Single-Leaf Springs: Measure between the top of the U-bolt pad and the
bottom of the axle stop.
4. If the measurement is not within the acceptable
range, refer to the Cascadia™ Workshop Manual
for adjustment instructions.
If the distance is within the acceptable range,
apply the parking brakes.
3. Measure the distance between the left forwardmost axle stop and the suspension as indicated;
see Table 1, Table 2, Table 3, Table 4, and
Table 5 for an acceptable range of heights for
each suspension.
IMPORTANT: Suspensions with Dual-Leaf
Springs: Measure between the top of the U-bolt
and the bottom of the axle stop.
32/2
Cascadia Maintenance Manual, August 2010
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)
2-5/8 inch
(67 mm)
2-7/8 inch
(73 mm)
Table 2, Suspension Ride-Height Measurement,
Single-Leaf Spring, 20k/40k, High Ride
12/20/2005
Measure Point
A = Measure Here
f320838b
Suspension Height Measurement
Min
Target
Max
2-3/8 inch
(60 mm)
2-5/8 inch
(67 mm)
2-7/8 inch
(73 mm)
Table 1, Suspension Ride-Height Measurement, DualLeaf Spring, 20k/40k High Ride
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
Cascadia Maintenance Manual, August 2010
32/3
32
Suspension
wrench, and turn the wrench again until it clicks.
If the nut turns on the second application, the
bolt is stretching and must be replaced. See
Group 32 of the Cascadia™ Workshop Manual
for bolt replacement procedures.
A
A
01/25/2006
09/28/2005
Measure Point
A = Measure Here
f321046a
Measure Point
Suspension Height Measurement
Min
Target
Max
2-3/4 inch
(70 mm)
3 inch
(76 mm)
3-1/4 inch
(83 mm)
Table 4, Suspension Ride-Height Measurement, DualLeaf Spring, 23k/46k/69k High Ride
A = Measure Here
f320962a
Suspension Height Measurement
Min
Target
Max
2-1/8 inch
(54 mm)
2-9/32 inch
(58 mm)
2-5/8 inch
(67 mm)
Table 5, Suspension Ride-Height Measurement,
Single-Leaf Spring, 10k/12k/15k Low and Extra-Low
Ride
32–02 Suspension U-Bolt
Torque Check
4
1
2
3
CAUTION
Failure to retorque the U-bolt nuts could result in
spring breakage and abnormal tire wear.
1. Park the vehicle on a level surface and apply the
parking brakes. Chock the tires.
2. Check the U-bolt torque. See Table 6 for U-bolt
torque specifications Tighten in a diagonal pattern 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
32/4
01/05/99
f320783
Fig. 3, Tightening Pattern for U-Bolt High Nuts
Spring U-Bolt High Nut Torque Values
Size
Torque: lbf·ft (N·m)
5/8–18
180–230 (245–313)
3/4–16
270–330 (367–449)
7/8–14
420–500 (571–680)
Cascadia Maintenance Manual, August 2010
32
Suspension
Spring U-Bolt High Nut Torque Values
Size
Torque: lbf·ft (N·m)
1–14
520–600 (707–816)
Table 6, Spring U-Bolt High Nut Torque Values
Cascadia Maintenance Manual, August 2010
32/5
Front Axle
33
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
All-Axle Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–04
Knuckle Pin Lubrication, Meritor Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–01
Tie Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–02
Tie Rod Lubrication, Meritor Axles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–03
Cascadia Maintenance Manual, August 2007
33
Front Axle
33–01 Knuckle Pin Lubrication,
Meritor Axles
CAUTION
Use regulated pressure when lubricating the
knuckle assemblies, otherwise damage could result to the knuckle caps.
cross-tube socket members indicates that the
tie-rod end assembly must be replaced.
2. The threaded portion of the tie-rod end assembly
must be inserted all the way into the cross-tube
split for adequate clamping. See Fig. 2. Replace
the components if this cannot be done. For instructions, refer to Group 33 of the Cascadia™
Workshop Manual.
When lubricating knuckle pin bushings, do not raise
the front axle. Wipe the lube fitting clean, and apply
multipurpose chassis grease, NLGI Grade 1 (6% 12hydroxy lithium stearate grease) or NLGI Grade 2
(8% 12-hydroxy lithium stearate grease) until new
grease is seen at the bushing grease seal opposite
the fittings The grease seal will accept grease pressure without damage, and is designed to have
grease pumped out through it during lubrication.
Even if grease leaks out around the top, or bottomplate gasket, continue pumping until new grease is
seen at the bushing seal opposite the grease fitting
See Fig. 1.
OK
1
OK
1
f320033a
02/27/2007
NOTE: Shown without pinch bolt to provide clarity.
A
1. Cross-Tube Split
Fig. 2, Tie-Rod End Adjustment
33–03 Tie Rod Lubrication,
Meritor Axles
1
09/06/96
f320032a
A. Grease Exit
1. Grease Fitting
Fig. 1, Meritor Knuckle Pin Lubrication
33–02 Tie Rod Inspection
For any Meritor axle that requires lubrication of the
tie-rod ends, wipe the grease fitting 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.
Inspect the tie-rod ends as follows:
1. Shake the cross-tube. A loose fit or movement
between the tapered shaft of the ball and the
Cascadia Maintenance Manual, August 2007
33/1
33
Front Axle
33–04 All-Axle Alignment
Check
Drive Axle Alignment Checking
Check the axle alignment, parallelism, and thrust
angle measurements for the rear drive axles. Use the
applicable procedure and specification in Group 35
of the Cascadia™ Workshop Manual.
Toe-In Inspection
For vehicle alignment to be accurate, the shop floo
must be level in every direction. The turn plates for
the front wheels must rotate freely without friction,
and the alignment equipment must be calibrated
every three months by a qualifie technician from the
equipment manufacturer. Freightliner dealers must
have proof of this calibration history.
1. Apply the parking brakes and chock the rear
tires.
04/26/2007
f330239
Align the pointers to center the steering.
2. Raise the front of the vehicle until the tires clear
the ground. Place safety stands under the axle.
Fig. 3, Centering the Rack and Pinion Steering Gear
3. Using spray paint or a piece of chalk, mark the
entire center rib of each front tire.
A
4. Place a scribe or pointed instrument against the
marked center rib of each tire, and turn the tires.
The scribe must be held firml in place so that a
single straight line is scribed all the way around
each front tire.
5. Place a turn-plate or turntable under both front
tires. Remove the safety stands and lower the
vehicle. Remove the lock-pins from the gauges;
make sure the tires are exactly straight ahead.
On vehicles with rack and pinion steering, center
the rack using the pointers on the front of the
input shaft housing. See Fig. 3.
B
f330082a
08/29/94
NOTE: B minus A equals toe-in.
NOTE: If turn-plates or turntables are not available, lower the vehicle. Remove the chocks
from the rear tires and release the parking
brakes. Move the vehicle backward, then forward about six feet (two meters).
7. Place the trammel bar at the front of the tires
(see Fig. 5) and adjust the scale end so that the
pointers line up with the scribe lines. See Fig. 6.
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. 4. Lock in place. Check that the scale is set
on zero.
8. Read the toe-in from the scale, and compare it to
the toe-in specificatio in Group 33 of the Cascadia™ Workshop Manual. If corrections are
needed, refer to Group 33 of the Cascadia™
Workshop Manual for instructions on adjusting
the toe-in.
33/2
Fig. 4, Wheel Toe-In (overhead view)
Cascadia Maintenance Manual, August 2007
33
Front Axle
f330014a
08/30/94
Fig. 5, Trammel Bar Positioning
f400100a
08/30/94
Fig. 6, Setting Trammel Bar Pointers
Cascadia Maintenance Manual, August 2007
33/3
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 (Synthetic
Lubricant)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–01
Cascadia Maintenance Manual, August 2007
35
Rear Axle
35–01 Axle Lubricant and Filter
Change, and Magnetic
Strainer Cleaning
(Synthetic Lubricant)
CAUTION
Failure to change the axle lubricant at more frequent intervals, when adverse operating conditions require, could result in axle damage.
For all axles, including tandem drive axles and twospeed axles, do the procedures under the heading,
"All Axle Models." For a two-speed axle with a shift
unit, also change the shift unit lubricant. See under
the heading, "Two-Speed Axles With Shift Unit."
All Axle Models
changed at the Maintenance 2 (M2) interval,
instead of the Maintenance 3 (M3) interval recommended in the Maintenance Operation Chart
for axles that require only those lubricants recommended in Table 1.
1. Park the vehicle on a level surface, set the parking brakes, and chock the front tires.
2. Remove the axle carrier fil plug. Then remove
the drain plug from the bottom of the housing.
Completely drain the lubricant while the unit is
warm, to allow the lubricant to drain faster.
On tandem drive axles, it is also necessary to
remove the plug at the bottom of the interaxle
differential housing to drain that lubricant.
3. If equipped with an oil pump, remove the axle oil
filte . Use a suitable filte strap wrench. See Fig.
1. Discard the old filte .
Meritor®
IMPORTANT: On Meritor axles, the oil change
interval for Schedule III vehicles is extended to
500,000 miles (800 000 km) for axles using synthetic lubricant with a pump and filte system.
On single drive axles so equipped, the traction equalizer may slip or stick. When this happens, you will
hear intervals of shrill noises when the vehicle operates at low speed, or when the vehicle 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.
For all GL-5 oils, add one of the following limited-slip
friction modifiers
• Lubrizol No. 6178 (Lubrizol Corporation)
• DSL-178 (Guardsman Products)
• Equa-Torque No. 2411 (Sta-Lube Corporation)
• Equa-Torque No. 2414 (Sta-Lube Corporation)
IMPORTANT: These friction modifier generally
deteriorate faster than conventional extremepressure additives, so the lubricant change
schedule must be shortened when using these
additives. The traction equalizer additive (and
recommended drive axle lubricant) must be
Cascadia Maintenance Manual, August 2007
f350119a
05/27/93
Fig. 1, Meritor Axle Oil Filter Removal
NOTE: There may be about one pint (0.5 L) of
lubricant remaining in the filte . Be careful not to
spill it when removing the filte .
4. Using the recommended drive axle lubricant,
coat the face of the gasket on the new oil filte , if
one was removed. Install the filte over the
adapter, and tighten the filte one full turn after
the gasket contacts the base; do not overtighten.
See Table 1 for recommended lubricants.
35/1
35
Rear Axle
Meritor Drive Axle Recommended Lubricant
Recommended
Lubricant Type
Synthetic Gear Oil
Lubricant SAE
Viscosity Grade
Ambient Temperature
Meritor Specification
–40°F (–40°C) and Up*
75W–90
0–76–N
–40°F (–40°C) and Up*
75W–140
0–76–M
* There is no upper limit on these outside temperatures, but axle sump temperature must never exceed 250°F (121°C).
Table 1, Meritor Drive Axle Recommended Lubricant
5. Clean the fil 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
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.
5.3
Each time the oil is changed, replace any
magnetic drain plug that does not meet
the minimum pickup capacity.
NOTE: Meritor recommends plugs with elements having a minimum pickup capacity of
1.5 pounds (0.7 kg) of low-carbon steel.
A
B
f350061a
08/17/2009
A. Correct (lube level at bottom of fil hole)
B. Incorrect (lube level below fil hole)
Fig. 2, Axle Lubricant Level Inspection
Meritor Drive Axle Lubricant Capacities
Capacity:* pt (L)
Axle Model
Single Drive, Single Reduction†
After cleaning, install the drain plug(s)
and tighten to 35 lbf·ft (47 N·m).
RS–21–160
39.5 (18.7)
RS–23–160
39.5 (18.7)
6. Fill the axle with recommended lubricant. See
Table 2 for drive axle lubricant capacities.
RS–23–161
37.2 (17.6)
RS–23–185
47.3 (22.4)
RS–25–160
37.2 (17.6)
5.4
NOTE: Some Meritor axles have a small
tapped and plugged hole near and below the
housing lubricant fil hole. This smaller hole
is for a lubricant temperature indicator only,
and should not be used as a fil or level
hole.
6.1
With the vehicle on a level surface, fil the
axle through the oil fil hole. Lubricant
should be level with the bottom of the oil
fil hole. To check flui level, see Fig. 2.
Tandem Drive, Single Reduction
RT–40–145, RT–40–145A,
RT–40–145P
RT–44–145, RT–44–145P
RT–46–160, RT–46–160P
Forward
30.2 (14.3)
Rear
25.8 (12.2)
Forward
29.3 (13.9)
Rear
25.1 (11.9)
Forward
39.1 (18.5)
Rear
34.4 (16.3)
* Quantities listed are approximate. Fill axle until lubricant is level with bottom of f ll hole with vehicle on level ground.
† See "Traction Equalizer Additives" in the text.
Table 2, Meritor Drive Axle Lubricant Capacities
35/2
Cascadia Maintenance Manual, August 2007
35
Rear Axle
6.2
Install and tighten the fil plug 35 lbf·ft (47
N·m).
7. Whenever the interaxle differential housing has
been drained, add an additional 2 pints (0.9 L) of
the recommended lubricant directly into the interaxle differential housing.
8. Remove the chocks, then drive the vehicle, unloaded, for 1 or 2 miles (2 or 3 km) at speeds
not to exceed 25 mph (40 km/h), to thoroughly
circulate lubricant throughout the carrier and
housing assemblies.
Freightliner
IMPORTANT: On Freightliner axles, the oil
change interval for Schedule III vehicles is extended to 500,000 miles (800 000 km) for axles
with weight ratings of 34,000 to 40,000 lb (15
000 to 18 000 kg) using synthetic lubricant. Oil
must be changed at least every four years, and
more often if the axle is exposed to high temperatures and steep grades.
1. Park the vehicle on a level surface, set the parking brakes, and chock the tires.
IMPORTANT: Freightliner rear axles do not require the use of friction modifiers
2. Clean the fil plug and the area around it. In the
axle housing rear cover, remove the plug from
the oil fil hole.
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 fil and drain plugs. Change them if
necessary.
4.1
For magnetic plugs, use a piece of key
stock or any other convenient steel slug
to short the two magnetic poles and divert
the magnetic field
4.2
Clean away the collected material deposited on each pole. Magnets will rapidly
lose their effectiveness as collected material bridges the gap between the two
poles.
4.3
After the firs oil is changed, inspect the
drain plug each time for large quantities
of metal particles.
Cascadia Maintenance Manual, August 2007
4.4
After cleaning, install the drain plug(s)
and tighten to 41 lbf·ft (55 N·m).
5. Fill the axle with the recommended lubricant.
See Table 3 for recommended drive axle lubricants and drive axle lubricant capacities.
Freightliner Rear Axle Approved Lubricant Type and
Capacity
Lubricant Type
80W/90 Gear Oil
75W/90 Synthetic
Gear Oil
80W/90 Gear Oil
75W/90 Synthetic
Gear Oil
Axle
Oil Capacity:
Quarts (liters)
Hubs
Full
Hubs
Dry
Forward
Tandem
14.3
(13.5)
15.9
(15.0)
Single & Rear
Tandem
10.6
(10.0)
12.2
(11.5)
Table 3, Freightliner Rear Axle Approved Lubricant
Type and Capacity
NOTE: Some Freightliner axles have a small
tapped and plugged hole near and below the
housing oil fil hole. This smaller hole is for a
lubricant temperature indicator only, and
should not be used as a fil or level hole.
5.1
Fill the axle through the oil fil hole. Lubricant should be level with the bottom of
the oil fil hole. To check flui level, see
Fig. 2.
5.2
Install and tighten the fil plug 41 lbf·ft (55
N·m).
Dana® Spicer®
IMPORTANT: The use of friction modifier is not
approved in Dana drive axles.
1. Park the vehicle on a level surface, set the parking brakes, and chock the tires.
2. Clean the fil plug and the area around it. In the
axle housing rear cover, remove the plug from
the oil fil hole (or standpipe, if installed in the oil
fil hole). See Fig. 3.
3. Place a drain pan under the rear axle drain plug.
See Fig. 3. Drain the oil at normal operating
temperature, 150 to 200°F (65 to 93°C). At this
35/3
35
Rear Axle
1
2
2
05/27/93
1
f350018a
1. Oil Fill Plug
2. Oil Drain Plug
Fig. 3, Axle Housing Drain and Fill Plugs
temperature, the oil will run more freely and ensure that the axle is flushed
NOTE: Some tandem drive axles are equipped
with a cylindrical magnetic strainer, located
below the lube pump on the front of the power
divider cover. All rear axles are fitte with magnetic drain and fil plugs.
05/27/93
1. Magnetic Strainer
Remove the magnetic strainer from the
power divider cover.
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. Magnets will rapidly
lose their effectiveness as collected material bridges the gap between the two
poles.
5.3
After the firs oil is changed, inspect the
drain plug each time for large quantities
of metal particles.
5.4
After cleaning, install the drain plug(s)
and tighten to 40 to 60 lbf·ft (54 to 81
N·m).
WARNING
Always wear eye protection when using compressed air to clean parts, as flying debris could
cause permanent damage to unprotected eyes. Do
not point the air stream in the direction of other
persons.
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).
2. Power Divider
Fig. 4, Dana Spicer Tandem Drive Axle Magnetic
Strainer
4. At each axle oil change, remove and clean the
magnetic strainer, if equipped. See Fig. 4.
4.1
f350017a
6. Fill the axle with the recommended lubricant.
See Table 4 for recommended drive axle lubricants, and Table 5 for drive axle lubricant capacities.
5. Clean the fil and drain plugs. Change them if
necessary.
35/4
Cascadia Maintenance Manual, August 2007
35
Rear Axle
the top of the standpipe opening. To
check flui level, see Fig. 2.
Dana Spicer Drive Axle Recommended Lubricant
Lubricant Type
Condition
Dana Spicer
Roadranger®
Synthetic Drive Axle
Lubricants, or
Equivalent with
Military Specificatio
MIL–L–2105D
Lubricant SAE
Viscosity
Grade
Over-the-Road
Service
75W–90
6.2
Install and tighten the fil plug 40 to 60
lbf·ft (54 to 81 N·m).
Two-Speed Axles With Shift Unit
Dana Spicer and Meritor
Off-Highway
Equipment, or
Under Extra
Heavy Loads
80W–140
Table 4, Dana Spicer Drive Axle Recommended
Lubricant
1. Remove the shift unit housing cover. See Fig. 5.
Drain and discard the old lubricant. Discard the
housing cover gasket.
Dana Spicer Drive Axle Lubricant Capacities
Axle Type
Axle Model
Capacity:*
Pints (liters)
1
Single Drive Axle Installation
Single
Reduction
23080S, 23080D
40 (18.9)
23105S, 23105D
48 (22.7)
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. Fill axle until lubricant is level with bot-
tom of f ll hole with vehicle on level ground.
† Add 2 pints (1 L) of additional lubricant to the power divider.
Table 5, Dana Spicer Drive Axle Lubricant Capacities
NOTE: Some Dana Spicer axles have a
small tapped and plugged hole near and
below the housing oil fil hole. This smaller
hole is for a lubricant temperature indicator
only, and should not be used as a fil or level
hole.
6.1
Fill the axle through the oil fil hole or
standpipe opening. Lubricant should be
level with the bottom of the oil fil hole, or
Cascadia Maintenance Manual, August 2007
3
2
08/06/93
f350021a
1. Housing Cover Gasket
2. Oil Fill Plug
3. Shift Unit Housing Cover
Fig. 5, Two-Speed-Axle Shift Unit
2. Thoroughly wash the axle shift parts and housing
cover, and allow them to air dry.
3. Install the housing cover and a new cover gasket. Tighten the housing cover capscrews 90 to
110 lbf·in (1020 to 1240 N·cm), then remove the
oil fil plug from the cover.
IMPORTANT: When the ambient temperature is
above 0°F (–18°C), use SAE 10 heavy-duty engine oil, API service classificatio SD (sulfated
ash content must not exceed 1.85%). When the
ambient temperature is below 0°F (–18°C), use
one part kerosene to three parts SAE 10 heavyduty engine oil, API service classificatio SD
(sulfated ash content must not exceed 1.85%).
This cold-weather mixture can be safely used
up to 32°F (0°C).
35/5
35
Rear Axle
Commercially available automatic transmission
flui may be used in place of SAE 10 engine oil.
Automatic transmission flui can be used for all
temperatures; do not mix it with kerosene. To
prevent component damage, do not mix engine
oil and automatic transmission fluid
4. Using the recommended lubricant, fil the shift
unit housing through the oil fil hole until the lubricant is level with the bottom of the opening.
5. Coat the threads of the fil plug with a small
amount of Loctite® 242, or equivalent sealant.
Install the fil plug finger-tigh in the rear axle shift
unit housing. Using a wrench, tighten it an additional 1-1/2 turns.
35–02 Axle Breather and Axle
Lubricant Level
Inspection
temperature indicator only, and should not be
used as a fil or level hole.
3. Check that the lubricant is level with the bottom
of the fil hole. See Fig. 2. If low, check for oil
leaks, and correct as needed. Add oil to the level
of the fil plug, using the lubricant recommended
in Table 1.
4. Install and tighten the fil plug 35 lbf·ft (47 N·m).
IMPORTANT: Always check the axle breather
whenever checking 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. 6. If the
breather is plugged or damaged, clean or replace it as needed.
1
For all axles, including tandem drive axles and twospeed axles, do the procedures under the heading,
"All Axle Models." For a two-speed axle with a shift
unit, also check the shift unit lubricant. See under the
heading, "Two-Speed Axles With Shift Unit."
All Axle Models
Meritor®
CAUTION
Failure to keep the rear axle filled to the proper
level with the recommended lubricant can result in
rear axle damage.
1. Park the vehicle on level ground, set the parking
brakes, and chock the tires.
IMPORTANT: Oil level must be checked at each
M1 interval on Meritor axles.
2. Clean the fil plug and the area surrounding the
fil plug on the side of the axle carrier. Remove
the plug. Check lubricant level when the axle is
cold, or near room temperature.
NOTE: Some Meritor axles have a small tapped
and plugged hole near and below the housing
oil fil hole. This smaller hole is for a lubricant
35/6
2
3
06/07/94
f350062a
1. Axle Housing
Breathers
2. Carrier Oil Fill Plugs
3. Interaxle Differential
Fig. 6, Meritor Axle Housing Breathers
6. On non-drive axles using oil-lubricated wheel
bearings, check the oil level at the wheels, and
add oil if low. Use the same lubricant recommended for the drive axle.
NOTE: When adding to or checking the oil level,
make certain the hub cap and plug are clean
before removing the plug; this will minimize the
possibility of dirt and road grime entering the
assembly.
Cascadia Maintenance Manual, August 2007
35
Rear Axle
Dana® Spicer®
Freightliner
CAUTION
CAUTION
Failure to keep the rear axle filled to the proper
level with the recommended lubricant can result in
rear axle damage.
Failure to keep the rear axle filled to the proper
level with the recommended lubricant can result in
rear axle damage.
1. Park the vehicle on level ground, set the parking
brakes, and chock the tires.
1. Park the vehicle on level ground, set the parking
brakes, and chock the tires.
IMPORTANT: After 300,000 miles (500 000 km),
oil level must be checked at each M1 interval on
Freightliner axles.
2. If the vehicle has just been driven, allow a few
minutes for the lubricant to settle.
2. Clean the fil plug and the area surrounding the
fil plug on the side of the axle carrier. Remove
the plug. Check lubricant level when the axle is
cold, or near room temperature.
3. Clean the oil fil plug and the area surrounding it.
See Fig. 7. Remove the plug from the fil hole (or
standpipe, if installed in the oil fil hole).
NOTE: Some Freightliner axles have a small
tapped and plugged hole near and below the
housing oil fil hole. This smaller hole is for a
lubricant temperature indicator only, and should
not be used as a fil or level hole.
1
3. Check that the lubricant is level with the bottom
of the fil hole. See Fig. 2. If low, check for oil
leaks, and correct as needed. Add oil to the level
of the fil plug, using the lubricant recommended
in Table 3.
2
3
4. Install and tighten the fil plug 41 lbf·ft (55 N·m).
IMPORTANT: Always check the axle breather
whenever checking 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. If the breather is
plugged or damaged, clean or replace it as
needed.
6. On non-drive axles using oil-lubricated wheel
bearings, check the oil level at the wheels, and
add oil if low. Use the same lubricant recommended for the drive axle.
NOTE: When adding to or checking the oil level,
make certain the hub cap and plug are clean
before removing the plug; this will minimize the
possibility of dirt and road grime entering the
assembly.
Cascadia Maintenance Manual, August 2007
06/07/94
f350002a
1. Axle Housing Breather
2. Fill Plug
3. Temperature Indicator Plug
Fig. 7, Dana Spicer Axle Housing Breather
IMPORTANT: A lubricant level close enough to
be seen or touched is not sufficient. It must be
level with the bottom of the fil hole, or the top of
the standpipe opening.
4. Check that the lubricant is level with the bottom
of the fil hole, or with the top of the standpipe
opening. See Fig. 2. If low, check for oil leaks,
and correct as needed. Add oil to the level of the
fil plug, using the lubricant recommended in
Table 4.
5. Install and tighten the fil plug 40 to 60 lbf·ft (54
to 81 N·m).
35/7
35
Rear Axle
IMPORTANT: Always check the axle breather
whenever checking lubricant level. Check the
breather more frequently under adverse operating conditions.
Install the fil plug finger-tigh in the rear axle shift
unit housing. Using a wrench, tighten it an additional 1-1/2 turns.
6. Check the axle housing breather. Make sure that
it is unclogged and free from corrosion. See Fig.
7. If the breather is plugged or damaged, clean
or replace it as needed.
Two-Speed Axles With Shift Unit
Dana Spicer and Meritor
CAUTION
Failure to keep lubricant at the specified level
could cause damage to the axle shift unit.
1. Clean the shift unit oil fil plug, and the area surrounding the plug. See Fig. 5. Turn the fil plug
counterclockwise to remove it.
2. Insert a finge or pipe cleaner into the fil plug
hole and check the flui level. The lubricant
should be level with the bottom of the fil hole. If
low, add the recommended lubricant.
CAUTION
Before adding additional lubricant, make sure of
the type currently in the shift unit. To prevent
component damage, do not mix engine oil with
automatic transmission fluid.
IMPORTANT: When the ambient temperature is
above 0°F (–18°C), use SAE 10 heavy-duty engine oil, API service classificatio SD (sulfated
ash content must not exceed 1.85%). When the
ambient temperature is below 0°F (–18°C), use
one part kerosene to three parts SAE 10 heavyduty engine oil, API service classificatio SD
(sulfated ash content must not exceed 1.85%).
This cold-weather mixture can be safely used
up to 32°F (0°C).
Commercially available automatic transmission
flui may be used in place of SAE 10 engine oil.
Automatic transmission flui can be used for all
temperatures; do not mix it with kerosene.
3. Coat the threads of the fil plug with a small
amount of Loctite® 242, or equivalent sealant.
35/8
Cascadia Maintenance Manual, August 2007
Wheels and Tires
40
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Wheel Nut Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–01
Cascadia Maintenance Manual, August 2007
40
Wheels and Tires
40–01 Wheel Nut 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.
Check the torque on all wheel nuts. See Table 1 for
torque specifications and see Fig. 1 for the wheel
nut tightening sequence.
NOTE: Torque values are given for lubricated
threads. Apply 2 drops of SAE 30W oil to a
point between the nuts and flanges
CAUTION
Insufficient wheel nut torque can cause wheel
shimmy, resulting in wheel damage, stud breakage, and extreme tire tread wear. Excessive wheel
nut torque can break studs, damage threads, and
crack discs in the stud hole area. Use the recommended torque values, and follow the tightening
sequence shown in Fig. 1.
Disc Wheel Fastener Torque
Nut Size
Torque: lbf·ft (N·m)
Oiled
M22 x 1.5
450–500 (610–678)
NOTE: If using specialty fasteners, consult the
manufacturer for recommended torque levels.
Table 1, Disc Wheel Fastener Torque
10
1
8
3
6
5
4
7
2
9
03/06/2000
f400157
Fig. 1, Wheel Nut Tightening Sequence
Cascadia Maintenance Manual, August 2007
40/1
Driveline
41
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Driveline Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–01
Driveline Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–02
Cascadia Maintenance Manual, August 2007
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 connection, which could eventually result in serious vehicle damage. Tighten bearing-cap capscrews or
yoke-strap capscrews to specified torque, being
careful to not overtighten.
2. For U-joints with bearing caps, tighten bearingcap capscrews 43 lbf·ft (49 N·m). See Fig. 1.
For Arvin Meritor RPL series U-joints, tighten
bearing-cap capscrews 125 lbf·ft (169 N·m). See
Fig. 2.
For U-joints with yoke straps, tighten yoke-strap
capscrews 125 lbf·ft (169 N·m). See Fig. 3.
1
1
f410155a
04/13/98
1. Self-Locking
Capscrew
2. Adhesive Band
Fig. 1, Arvin Meritor U-Joint Fasteners for Bearing
Caps
3. Check the driveline yokes for cracks, and check
end-yokes for looseness. See Fig. 3.
Replace cracked yokes.
Cascadia Maintenance Manual, August 2007
Fig. 2, Arvin Meritor RPL Series U-Joint
If any end-yoke can be moved in or out on its
shaft, or can be rocked on its shaft, disconnect
the driveshaft and U-joint from the yoke, then
check the drive component’s shaft seal for leakage or other visible damage that may have been
caused by the loose yoke. Replace the seal if
needed, then tighten the yoke nut. Refer to
Group 41 of the Cascadia™ Workshop Manual
for torque specifications If the yoke is still loose
after tightening the yoke nut, replace the endyoke and yoke nut.
4. Check U-joint assemblies for wear by moving the
driveshaft up and down, and from side to side. If
any movement of the U-joint cross in the bearings can be felt or seen, replace the U-joint assembly.
R I T OR
1
f410182
Replace the prevailing torque locknut (end-yoke
nut) if it was removed for yoke replacement, seal
replacement, or any other reason.
2
ME
12/09/97
5. Check if the midship bearing and mounting are
loose or have deteriorated, by attempting to
move the driveshaft up and down, and from side
to side. If the bearing is loose on its shaft, or
rattles, replace it. If the bearing mount is loose
on the frame, tighten the mounting fasteners to
the proper torque value. See Group 41 of the
Cascadia™ Workshop Manual for torque specifi
cations. Replace the midship bearing assembly if
the rubber cushion is deteriorated or oil-soaked.
6. Check slip joints for spline wear by moving the
sleeve-yoke and splined shaft back and forth.
See Fig. 4. If the slip joint can be twisted in a
clockwise, or counterclockwise movement
41/1
41
Driveline
14
15
13
3
9
8
7
16
12
11
1
2
6
10
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.
Splined Stub Shaft
Driveshaft Tube
Tube-Yoke (bearing-cap type)
Axle Input-Shaft End-Yoke
(yoke-strap type)
16. Rear Axle
Fig. 3, Components of a Basic Driveline
greater than 0.007 inch (0.18 mm), replace both
the sleeve-yoke and the splined shaft.
7. Visually examine the driveshaft tubes for dents,
bends, twists, or other damage. If any tube appears to be damaged, refer to Group 41 of the
Cascadia™ Workshop Manual for repair and replacement instructions.
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. If the
yoke plug is missing, the splined shaft may be
hitting the plug and knocking it out; contact your
Regional Service Office for assistance in determining the correct driveshaft length.
8. Examine the driveshaft for evidence of missing
balance weights, and for buildup of foreign material. Remove any foreign material. If there is any
evidence that balance weights are missing, remove the driveshaft and have it balanced.
41/2
Cascadia Maintenance Manual, August 2007
41
Driveline
41–02 Driveline Lubrication
Universal Joint Lubrication
NOTE: Vehicles equipped with Meritor RPL Series drivelines do not require periodic lubrication.
1. Park the vehicle on a level surface, apply the
parking brakes, and chock the tires.
2. Wipe all old grease and dirt from each U-joint
grease fitting See Fig. 5.
f410012a
05/27/93
Attempt to move the sleeve-yoke and splined shaft back
and forth.
Fig. 4, Slip Joint Spline Wear Checking
Using lithium 12-Hydroxy stearate grease (NLGI
Grade 1 or Grade 2, with EP additives), lubricate
until new grease can be seen at all four U-joint
seals. Fresh grease must be seen escaping from
all four bearing-cap seals of each U-joint. On
yokes equipped with a yoke-bearing cap, if most
of the grease being added to a U-joint can be
seen escaping from just one of the U-joint seals,
check the torque on the capscrews at that seal.
5
1
2
7
3
4
3
4. Tighten the bearing-cap capscrews 43 lbf·ft (49
N·m). If the capscrews were already tight, or all
of the U-joint seals still do not purge, remove the
bearing cap at that seal, and examine the seal
for damage. If the seal is damaged, replace the
complete U-joint.
6
8
3
1
A
f410050a
10/20/93
3. Use a hand-type grease gun, or a high-pressure
gun with a low-pressure adapter, to lubricate
U-joints. If a low-pressure adapter is not used,
U-joints may not receive enough grease.
A. After grease appears, cover the pressure-relief hole
while continuing to lubricate.
1. Slip Joint Grease Fitting (with grease gun attached)
2. Yoke Plug
3. Grease
4. Half-Round Yoke
5. Yoke Plug Pressure-Relief Hole
6. Slip Joint Seal
7. Full-Round Yoke
8. U-Joint Grease Fitting
5. If grease does not appear at one seal, use a prying tool to pry the U-joint trunnion away from the
non-purging seal, or tap the driveshaft or yoke
with a plastic or rawhide mallet on the side opposite the dry seal, while continuing to lubricate. If
grease still does not appear, loosen the capscrews at the bearing with the dry seal, to relieve
seal tension. Lubricate the U-joint until new
grease is seen at the seal, then tighten the capscrews to the correct torque specifications If the
bearing will not take grease, replace the U-joint.
Refer to Group 41 of the Cascadia™ 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
Fig. 5, Slip Joint and U-Joint Lubrication
Cascadia Maintenance Manual, August 2007
41/3
41
Driveline
Slip Joint Spline Lubrication
NOTE: Vehicles equipped with Meritor RPL Series drivelines do not require periodic lubrication.
1. If equipped with a grease fitting wipe all old
grease and dirt from the slip joint grease fitting
See Fig. 5.
2. Use a hand-type grease gun or a high-pressure
gun with a low-pressure adapter, to lubricate the
slip joint. Add multipurpose chassis grease
(lithium 12-hydroxy stearate, NLGI Grade 1 or
Grade 2, with EP additives) until it appears at the
pressure-relief hole in the yoke plug. Then cover
the relief hole with your finge , while continuing
to apply gun pressure until new grease appears
at the slip joint seal. See Fig. 5. This ensures
complete lubrication of the splines.
3. Wipe the purged grease from the pressure-relief
hole and slip joint seal, and any excess grease
from the grease fitting
41/4
Cascadia Maintenance Manual, August 2007
Brakes
42
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Air Brake System Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–01
Air Dryer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–03
Alcohol Evaporator Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–04
Bendix Air Dryer Desiccant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–02
Bendix E-6 Foot Control Valve Inspection and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–09
Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–05
Haldex Slack Adjuster Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–06
Meritor Camshaft Bracket Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–07
Meritor Slack Adjuster Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–08
Cascadia Maintenance Manual, January 2010
42
Brakes
42–01 Air Brake System Valve
Inspection
NOTE: There is no scheduled air valve maintenance on vehicles equipped with Bendix air
valves and a Bendix air dryer if the air dryer
desiccant is replaced at 350,000 miles (563 000
km). If the desiccant is not changed at 350,000
miles (563 000 km), or if the vehicle is equipped
with another air dryer, maintenance will have to
be performed to the air brake valves. See
Group 42 of the Cascadia™ Workshop Manual
for procedures.
8. Place the air dryer on a bench and remove the
remaining 6 bolts, 12 washers, 6 Nylok nuts, and
the air dryer housing. See Fig. 1. Discard the
Nylok nuts. Remove the end-cover-to-housing
O-ring.
9. Clamp the desiccant cartridge in a vise.
WARNING
Clamping the end cover or housing in a vise could
seriously compromise the air dryer’s ability to
hold air pressure, which could cause a failure in
the brake system, resulting in property damage,
personal injury, or death.
IMPORTANT: For vehicles equipped with an oilcoalescing air dryer desiccant cartridge, replace
the cartridge once a year, regardless of mileage.
10. Twist the end cover counterclockwise to release
the cartridge from the end cover. Rotate the end
cover until it completely separates from the desiccant cartridge.
42–02 Bendix Air Dryer
Desiccant Replacement
NOTE: A substantial torque, up to 50 lbf·ft (68
N·m), may be necessary to remove the desiccant cartridge.
IMPORTANT: For vehicles equipped with an oilcoalescing air dryer desiccant cartridge, replace
the cartridge once a year, regardless of mileage.
AD–9
1. Park the vehicle on a level surface, apply the
parking brakes, and chock the tires.
2. Completely drain all air reservoirs. Air pressure
gauges should read 0 psi (0 kPa).
NOTE: The compressor discharge line may still
contain residual air pressure, open the line
slowly.
3. Identify, tag, and disconnect the three air lines
from the end cover.
4. Disconnect the harness connector from the
heater and thermostat assembly.
5. Loosen the bolt that secures the upper mounting
bracket strap.
6. Remove the two bolts and Nylok® nuts that secure the air dryer to the lower mounting bracket.
Mark the position of the mounting bracket to the
end cover and mark the bolts to ease installation.
7. Remove the upper mounting bracket strap fasteners, then remove the strap and the air dryer.
Cascadia Maintenance Manual, January 2010
NOTICE
Dirt or obstructions in the O-ring grooves can
cause an O-ring failure that will result in an air
leak.
11. Inspect the condition of the O-ring seals. If they
are cracked, crimped, or otherwise damaged,
replace them to ensure an airtight seal. Clean
the O-ring grooves of any dirt or obstruction.
12. Lubricate the O-rings with silicone or lithium
grease and install them in the end cover.
13. Install the desiccant cartridge on the end cover.
Turn the cartridge clockwise until the desiccant
cartridge makes contact with the end cover.
14. Place the desiccant cartridge in a vise, and turn
the end cover clockwise an additional 180 to 225
degrees to fully tighten the desiccant cartridge to
the end cover.
NOTE: Desiccant cartridge torque should not
exceed 50 lbf·ft (68 N·m).
15. Place the housing over the desiccant cartridge
and align the mounting holes with the end cover.
IMPORTANT: Replace, do not reuse the Nylok
nuts on the air dryer cover.
42/1
42
Brakes
1
2
11
3
9
4
25
5
10
14
12
10
13
10
24
10
10
10
23
8
6
8
10
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.
Desiccant Cartridge
O-Ring
Safety Valve
Lower Mounting Bracket
3/8-Inch Bolt (long)
Check Valve Assembly
Purge Valve Assembly
Purge Valve Capscrew
Exhaust Diaphragm
18.
19.
20.
21.
22.
23.
24.
25.
Purge Valve
1/4-Inch Tapping Screw
Purge Valve Housing
Heater and Thermostat
Housing
Return Spring
Purge Piston
3/8-Inch Bolt
End Cover
Fig. 1, AD–9 Air Dryer (exploded view)
16. Install the 6 bolts, 12 washers, and 6 new Nylok
nuts. Torque the Nylok nuts in a star pattern 17
to 24 lbf·ft (370 to 520 N·m). See Fig. 2.
17. Install the air dryer on the lower mounting
bracket. Install the two previously marked bolts,
four washers, and two new Nylok nuts. Torque
the two remaining Nylok nuts 17 to 24 lbf·ft (370
to 520 N·m). Install the bolt, two washers, and a
new Nylok nut in the upper mounting bracket
42/2
strap. Torque the upper mounting bracket strap
Nylok nut 80 to 120 lbf·in (900 to 1360 N·cm).
18. Connect and tighten the three air lines. Connect
the harness connector to the heater and thermostat assembly until the lock tab snaps in place.
19. Start the engine, build the air pressure, and
check the air brake system for leaks. If any air
leaks are present, see Group 42 of the Cascadia™ Workshop Manual for diagnosis and repair
information.
Cascadia Maintenance Manual, January 2010
42
Brakes
6
2
4
5
1
1&9
3
2
3
7
09/20/94
8
f421910
04/16/98
f420544a
1. Desiccant Cartridge
2. Cartridge Sealing Ring
3. Threaded Base Post
Fig. 2, AD–9 End Cover to Housing Torque Pattern
AD–IS
1. Park the vehicle on a level surface, apply the
parking brakes and chock the tires.
2. Drain the air reservoirs.
3. Using a strap wrench or equivalent, loosen the
desiccant cartridge. Spin the cartridge off by
hand and discard it. See Fig. 3.
4. On the new desiccant cartridge, lubricate the
sealing rings with silicone grease.
IMPORTANT: Only use the silicone grease supplied with Bendix replacement kits.
5. Screw the desiccant cartridge onto the body by
hand until the seal makes contact with the body.
Rotate the cartridge clockwise about one full
turn. Tighten the cartridge firml .
Fig. 3, AD–IS Desiccant Cartridge Replacement
WARNING
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.
5. Using a clean rag, wipe clean the inside of the
end cover. Clean the cartridge bolt bore in the
end cover, and the sealing surfaces for the largeand small-diameter desiccant cartridge sealing
rings.
AD–IP
6. Inspect the end cover for physical damage, then
inspect all air line fitting for corrosion; replace
as necessary.
1. With the vehicle parked on a level surface, apply
the parking brakes and chock the tires.
7. Clean and inspect the bolt, paying attention to
the threads and O-ring grooves.
2. Using a wrench or a socket, loosen the desiccant
cartridge bolt. Then separate the desiccant cartridge from the end cover.
IMPORTANT: Use only the grease supplied with
Bendix replacement kits.
3. Pull the cartridge bolt out of the cover and remove the cartridge.
Cascadia Maintenance Manual, January 2010
8. Lubricate the O-rings, bolt O-ring grooves, sealing rings, and cartridge grooves. Lubricate the
end cover bore for the bolt.
42/3
42
Brakes
9. Install both O-rings on the cartridge bolt, then,
using a twisting motion, insert the assembled
desiccant cartridge bolt in the end cover.
shop Manual for troubleshooting procedures. The
following conditions could cause small amounts
of moisture to be found in the air system:
10. Install the desiccant cartridge on the end cover,
making sure the cartridge is properly seated and
flus on the end cover.
• An outside air source has been used to
charge the air brake system. This air did
not pass through the drying bed.
NOTE: It may be necessary to rotate the cartridge slightly until the anti-rotation lugs are
properly aligned and allow the cartridge to rest
flus against the end cover.
• Air usage is unusually high and not normal.
This may be due to accessory air demands
or some unusual air requirement that does
not allow the compressor to load and unload in a normal fashion. Check for air system leaks.
11. Using a wrench or socket, tighten the desiccant
cartridge bolt 70 lbf·ft (95 N·m). Do not overtorque.
12. Before placing the vehicle in service, perform the
test below.
12.1
Close all reservoir drain cocks.
12.2
Build system pressure to governor cutout, and note that the AD-IP air dryer
purges with an audible escape of air.
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. If leakage exceeds this measure,
remove and re-install the desiccant cartridge.
42–03 Air Dryer Inspection
1. Park the vehicle on a level surface and apply the
parking brakes. Shut down the engine. Chock
the tires.
2. Check for moisture in the air brake system by
opening the reservoir drain cocks. Examine the
discharge. Some trace of water in the discharge
is normal. A discharge of a milky gray liquid indicates excessive moisture is present in the air
system and the desiccant cartridge needs to be
replaced. See Group 42 of the Cascadia™ Work-
42/4
• The air dryer has been installed on a system that had previously been operated
without an air dryer. This type of system
will be saturated with moisture, and several
weeks of operation may be needed to fully
dry the system.
• The temperature range in your area fluctu
ates more than 30 degrees in one day.
Small amounts of water can accumulate in
the air brake system due to condensation.
Under these conditions, the presence of
moisture is normal and should not be considered an indication of poor air dryer performance.
3. Inspect the air dryer for external damage, and
check that the unit is tightly mounted on the
frame. If the air dryer mounting is loose, See
Group 42 of the Cascadia™ Workshop Manual
for mounting instructions.
4. Turn on the ignition switch, but do not start the
engine.
5. Disconnect the harness connector from the air
dryer.
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.
7. Connect a voltmeter between the two terminals
on the air dryer’s harness connector. If voltage is
not found, repair the open in the ground circuit
wiring.
8. Use an ohmmeter to check resistance between
the terminals on the end cover. See Fig. 4. The
end cover contains the heater/thermostat. If the
heater/thermostat is between 40 and 90°F (5 and
Cascadia Maintenance Manual, January 2010
42
Brakes
Off Season
During the off season, drain the unit of alcohol. At
regular engine service intervals, open the drain cock
to remove moisture from the alcohol evaporator. Before reactivating the evaporator for the next freeze
season, drain, disassemble, inspect, and steamclean the unit of any sludge that may have accumulated. It is advisable to replace any rubber parts
when assembling the alcohol evaporator. Perform
this service just before the freeze season.
Freeze Season Reactivation
1. Park the vehicle on a level surface and apply the
parking brakes. Shut down the engine. Chock
the tires.
1
2. Remove the fille cap, and check the cap tetraseal.
2
f421384
06/04/96
1. End Cover Assembly
2. Heater/Thermostat Terminals
Fig. 4, End Cover Terminals Location
3. Remove the capscrews and reservoir from the
cover.
4. Remove the cover tetraseal.
5. Drain the air tank, and disconnect the line from
the evaporator outlet. Remove the check-valve
retainer, spring, and disc.
32°C), the heater/thermostat measured resistance will be infinit ohms. If the measured resistance is less than infinit , replace the
heater/thermostat.
6. Install the disc, spring, and check-valve retainer,
and connect the line to the evaporator outlet.
9. Remove the heater/thermostat assembly and
place it in a freezer for about fiv 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. As the
temperature of the heater/thermostat assembly
increases, the ohm reading will increase. When
the temperature goes above 45°F (7°C) measured resistance should be infinit ohms. If the
heater/thermostat does not operate as outlined,
replace it. If it does operate as outlined, install it.
8. Install the reservoir on the cover and tighten the
capscrews.
42–04 Alcohol Evaporator
Cleaning and Inspection
Maintenance is required during both the freeze season and the off season to keep the alcohol evaporator in good working order.
Cascadia Maintenance Manual, January 2010
7. Install the cover tetraseal.
9. Fill the reservoir with 40 ounces (1183 mL) of
methyl alcohol, then install the fille cap.
42–05 Brake Inspection
Parking Brake Operational Check
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. With the engine running, and air pressure at cutout pressure, set the parking brake.
2. Put the vehicle in the lowest gear and gently attempt to move it forward. The vehicle should not
42/5
42
Brakes
move. If the vehicle moves, the parking brakes
are not operating correctly and must be repaired
before the vehicle is returned to service. See
Group 42 of the Cascadia™ Workshop Manual
for repair procedures.
Brake Component Inspection
1. Park the vehicle on a level surface, set the parking brake, and chock the tires. Once the tires are
chocked, release the parking brake.
WARNING
Manually adjusting an automatic slack adjuster to
bring the pushrod stroke within legal limits is
likely masking a mechanical problem. Adjustment
is not repairing. Before adjusting an automatic
slack adjuster, troubleshoot the foundation brake
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.
2. With the engine off, and 100 psi (689 kPa) of air
tank pressure, have an assistant apply and hold
an 80 to 90 psi (550 to 620 kPa) brake application.
3. Check to see if the colored over-stroke band on
each brake chamber pushrod is exposed.
If a band shows, the stroke is too long. Check
the foundation brake components for wear or
damage, and repair as needed. See Group 42 of
the Cascadia™ Workshop Manual for inspection
and repair procedures.
4. Measure the applied chamber stroke. See Table
1 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. See Group 42 of the Cascadia™
Workshop Manual, or see the Cascadia™
Troubleshooting Manual for procedures.
Brake Chamber Stroke Specifications
Chamber
Manufacturer
Type*
Size†
Max Applied Stroke: inch (mm)
12
Standard Stroke
Haldex
1-3/8 (35)
16
20
1-3/4 (44)
24
2-1/2-Inch Extended Stroke
24
2 (51)
3-Inch Extended Stroke
24
2-1/2 (64)
Standard Stroke
30
2 (51)
Long Stroke
30
2-1/2 (64)
9
12
Standard Stroke
16
20
Meritor
24
Long Stroke
24
Standard Stroke
30
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.
† Specification are relative to a brake application with 80 to 90 psi (550 to 620 kPa) air pressure in the brake chambers.
Table 1, Brake Chamber Stroke Specifications
42/6
Cascadia Maintenance Manual, January 2010
42
Brakes
5. Start the engine and build air pressure to at least
100 psi (689 kPa). Shut down the engine.
6. Check all of the foundation brake components for
damage, wear, and loose or missing parts. Repair as needed. See Group 42 of the Cascadia™
Workshop Manual for repair procedures.
42–06 Haldex Slack Adjuster
Lubrication
Automatic slack adjusters that have a grease fittin
must be lubricated periodically to ensure proper
brake operation.
WARNING
Failure to lubricate slack adjusters could lead to
dragging brakes or a brake failure, resulting in
property damage, personal injury, or death.
CAUTION
Do not use moly-disulfide-loaded grease or oil.
Both the life and reliability of the slack adjuster
will be reduced if this type of grease is used.
Lubricate the automatic slack adjuster at the grease
fitting See Fig. 5. Use standard chassis lubricant for
Haldex slack adjusters.
06/26/2007
f422363c
Fig. 5, Haldex Automatic Slack Adjuster Grease Fitting
grease fittin on the camshaft bracket or the spider
until new grease flow from the inboard seal. See
Fig. 6.
42–07 Meritor Camshaft
Bracket Lubrication
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 Cascadia™ Workshop Manual.
For camshaft brackets with grease fittings use an
NLGI Grade 1 or Grade 2 multipurpose chassis
grease. Lubricate the camshaft bushings through the
1
3
2
A
05/28/93
A. Grease Exit
1. Brake Chamber
2. Slack Adjuster
f420011a
3. Non-Pressure-Relief
Grease Fitting
Fig. 6, Camshaft Bracket Lubrication
Cascadia Maintenance Manual, January 2010
42/7
42
Brakes
WARNING
1
If grease leaks out under the camhead, the camshaft bracket grease seal is worn or damaged. See
Group 42 in the Cascadia™ Workshop Manual for
grease seal replacement instructions. If this seal
is not replaced, the brake linings could become
contaminated with grease. The stopping distance
of the vehicle will be increased, which could result
in personal injury or property damage.
2
3
4
5
42–08 Meritor Slack Adjuster
Lubrication
NOTE: If equipped with an extendedmaintenance Q Plus™ brake system, the slack
adjuster will not have a grease fitting These
slack adjusters 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 slack adjusters are lubricated during the brake reline service interval. For service
and lubrication instructions, see Group 42 of
the Cascadia™ Workshop Manual.
For slack adjusters with grease fitting and for operating temperatures above –40°F (–40°C), use an
NLGI Grade 1 clay-base grease, or an NLGI Grade 1
or 2 lithium-base grease.
For slack adjusters with grease fitting and for operating temperatures below –40°F (–40°C) and above
–65°F (–54°C), use an NLGI Grade 2 synthetic oil,
clay-base grease.
Lubricate the slack adjuster at the grease fittin until
grease is forced past the pressure-relief capscrew or
past the gear splines around the inboard snap ring.
See Fig. 7.
42–09 Bendix E-6 Foot Control
Valve Inspection and
Lubrication
1. Remove the brake valve from the vehicle. See
Section 42.08, Subject 110, of the Cascadia™
Workshop Manual for instructions.
42/8
7
6
10/20/93
f420012a
1.
2.
3.
4.
5.
Brake Chamber
Clevis
Actuator Rod
Boot
Pressure-Relief Capscrew, Gasket, Pawl Spring,
and Pawl
6. Manual Adjusting Nut
7. Grease Fitting (or plug)
Fig. 7, Meritor Automatic Slack Adjuster
2. Remove the roll pin from the brake pedal pivot
pin. See Fig. 8.
3. Remove the brake pedal pivot pin.
4. Remove the brake pedal.
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.
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.
8. Remove the plunger from the valve. Using alcohol, clean the existing grease from the plunger.
Check the plunger for signs of wear or cracks.
Replace it if necessary.
9. Lubricate the plunger with barium grease (BW
246671).
10. Insert the plunger in the valve.
Cascadia Maintenance Manual, January 2010
42
Brakes
2
5
6
1
3
4
7
8
09/10/2004
1.
2.
3.
4.
E-6 Foot Control Valve
Mounting Plate
Nut and Washer
Pivot Pin
f430405
5.
6.
7.
8.
Roll Pin
Roller
Roller Pin
Pedal
Fig. 8, Brake Pedal and Valve Assembly
11. Install the brake pedal with the pivot pin.
12. Install a new roll pin and apply Torque Seal
(OPG F900 White) to the roll pin.
13. Install the brake valve assembly. See Section
42.08, Subject 110, of the Cascadia™ Workshop
Manual for instructions.
14. Test the brakes before returning the vehicle to
service.
Cascadia Maintenance Manual, January 2010
42/9
Steering
46
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Drag Link Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–01
Drag Link Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–05
Power Steering Fluid Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–03
Power Steering Fluid and Filter Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–02
Power Steering Gear Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–04
Rack and Pinion Steering Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–06
Cascadia Maintenance Manual, November 2009
46
Steering
46–01 Drag Link Inspection
WARNING
2. Place a drain pan under the power steering reservoir.
3. Remove the retaining ring from the reservoir.
See Fig. 1.
All steering system components are critical for
safe operation of the vehicle. Failure to maintain
the steering system as specified may result in
loss of steering control, which could lead to personal injury and property damage.
Have someone turn the steering wheel from left to
right. Check for movement between the ball stud end
and the pitman arm, and between the ball stud end
and the steering arm. Also check if the ball stud nut
is loose.
2
3
4
1
If the ball stud end is loose, replace the drag link. If
the ball stud nut is loose, replace the nut and cotter
key. See Group 46 of the Cascadia™ Workshop
Manual for proper torque specifications
Inspect the boot of the drag link at both the pitman
arm and the steering arm end for cracks, splits, or
other damage. Replace the boot as needed. See
Group 46 of the Cascadia™ Workshop Manual for
drag link removal and installation instructions.
Grasp the drag link near the pitman arm end, then
push and pull laterally to check for axial movement in
the ball stud end. If it is loose, replace the drag link.
See Group 46 of the Cascadia™ Workshop Manual
for replacement instructions. If there is 1/8-inch (3mm) movement or more, do not drive the vehicle
until the drag link is replaced.
46–02 Power Steering Fluid
and Filter Changing
WARNING
Fill only with approved clean fluid. Failure to use
the proper fluid could cause seal deterioration and
leaks. Fluid leaks could eventually cause loss of
power steering assist. This could lead to an accident resulting in personal injury or property damage. Wear eye protection when changing the fluid
and filter.
1. Park the vehicle on a level surface, shut down
the engine, apply the parking brakes, and chock
the rear tires.
Cascadia Maintenance Manual, November 2009
10/19/2001
1.
2.
3.
4.
f461917
Power Steering Reservoir
Retaining Ring
Filter Cover
Return Hose
Fig. 1, Power Steering Reservoir
4. Remove the filte , filte cover, and gasket from
the reservoir. Drain the flui from the filte into
the drain pan. Leave the filte 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 flui from the
reservoir.
6. Using bolts, nuts, and washers, attach the reservoir to the mounting bracket.
7. Fill the reservoir with an approved power steering flui to the line between the MIN COLD and
MAX HOT lines. See Fig. 1. See Table 1 for approved power steering fluids
Approved Power Steering Fluids
Fluid Type
Automatic Transmission Fluid
Approved Fluid
TES-389
Table 1, Approved Power Steering Fluids
46/1
46
8. Raise the front of the vehicle and support it with
jack stands.
9. Start the engine and operate it at idle. Turn the
steering wheel from full left to full right several
times until clean flui starts flowin from the
power steering filte . Add flui to the reservoir to
maintain the flui level between the MIN COLD
and MAX HOT lines.
10. Shut down the engine.
NOTE: Always install a new power steering reservoir filte when changing the fluid
11. Disconnect the filte from the filte cover, and discard the filte .
Steering
bring the level up to the FULL HOT mark on the
dipstick. See Table 1 for recommended power
steering fluids
46–04 Power Steering Gear
Lubrication
TRW TAS and THP Series
Sector Shaft
CAUTION
12. Apply a thin fil of power steering flui on the
gasket of the new filte . Then attach the filte to
the filte cover. Hand-tighten the filte , then turn it
an additional 1/4 turn.
Apply grease to the sector shaft with a hand-type
grease gun only. Use of a high-pressure power
grease gun will supply grease too quickly and
could affect the high pressure seal, contaminating
the hydraulic fluid.
13. Install the filte and filte cover in the reservoir.
Make sure that the gasket under the filte cover
is not damaged. If the gasket is damaged, replace it. Install the gasket on the reservoir.
Using a hand-type grease gun, apply NLGI Grade 2
or 3 multipurpose chassis grease until it starts to
come out past the sector shaft seal. Fig. 2.
14. Attach the retaining ring to the reservoir to secure the filte and filte cover.
1
15. Start the engine and check that the power steering flui level is between the MIN COLD and
MAX HOT lines. Add more power steering flui if
needed.
16. Raise the vehicle, remove the jack stands, and
lower the vehicle.
46–03 Power Steering Fluid
Level Inspection
1. Apply the parking brakes and chock the tires.
2. With the engine cool, use a shop towel or a
clean rag to clean the area around the power
steering reservoir fil cap. Twist the cap counterclockwise to remove it. Check the cold power
steering flui level. The level should be between
ADD COLD and FULL COLD with the engine off.
3. Start the engine and run it at idle until it reaches
operating temperature.
Remove the dipstick, and check that power
steering flui is between ADD HOT and FULL
HOT. If the flui level is low, add enough flui to
46/2
11/28/95
f461071
1. Sector Shaft Grease Fitting
Fig. 2, TRW TAS Series Sector Shaft Lubrication
46–05 Drag Link Lubrication
1. Using a clean rag, wipe all dirt from both drag
link grease fittings See Fig. 3.
Cascadia Maintenance Manual, November 2009
46
Steering
2. Using a pressure gun, apply clean grease at the
grease fitting until old grease is forced out of
the socket. Use multipurpose chassis grease
NLGI Grade 2 (8% 12-hydroxy lithium stearate
grease) or NLGI Grade 1 (6% 12-hydroxy lithium
stearate grease). Grade 2 is preferred.
For repair procedures, see Group 46 of the Cascadia™ Workshop Manual.
5. Check the rack and pinion gear mounting bolts
for security.
6. Check that the outer tie rod castellated nuts are
tight, and the cotter pins are properly installed.
IMPORTANT: Do not remove the rack and pinion bellows unless they are damaged, and must
be replaced, or there is evidence of a loose
inner tie rod, or there is hydraulic flui leaking
from the bellows.
11/27/95
1
2
f461072
1. Grease Fitting at Pitman Arm
2. Grease Fitting at Axle Steering Arm
Fig. 3, Drag Link
46–06 Rack and Pinion
Steering Inspection
WARNING
All steering system components are critical for
safe operation of the vehicle. Failure to maintain
the steering system as specified may result in
loss of steering control, which could lead to personal injury and property damage.
The rack and pinion steering system is designed to
be maintenance-free. Inspect the 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. Park the vehicle on a level surface, and chock
the rear tires.
2. Check the steering I-Shaft U-joints for evidence
of looseness or binding. If any is found, replace
the I-Shaft.
7. Check the rack tie rod bellows for holes or tears.
If any are found, remove the bellows and check
the rack for evidence of corrosion. No corrosion
is allowed. If corrosion is found, replace the rack
and pinion unit. If there is no corrosion, replace
the damaged bellows with a new one.
8. Check the rack and pinion tie rod bellows for evidence of leakage from the bellows. If hydraulic
flui is found to be leaking from within the bellows, replace the rack and pinion unit.
9. Check the input shaft for any leakage around the
on-center cap. If there is evidence of leakage
from inside the on-center cap, remove the oncenter cap and replace the input shaft seal. See
Group 46 of the Cascadia™ Workshop Manual
for instructions.
Check the steering system pressure and return
lines and fitting for leaks and damaged lines or
hoses. Repair or replace lines, hoses, and fit
tings as necessary.
10. Check the tube fitting on the hard transfer lines
of the gear, see Fig. 4, Item 15. If there is leakage from either of the fittings replace the rack
and pinion unit.
IMPORTANT: Tightening the tube fitting can
cause tearing of the O-ring seal and increased
flui leakage.
3. Check the steering I-Shaft slip joint for evidence
of lateral movement, looseness, or binding. If any
is found, replace the I-Shaft.
4. Jack up one axle end at a time, and move the
tire in and out by hand to check the tie rod ends
for free play. No free play is allowed. If the outer
tie rod ends are damaged or worn, replace them.
Cascadia Maintenance Manual, November 2009
46/3
46
Steering
16
11
12
7
8
15
13
10
9
14
6
17
5
4
2
3
19
9
8
20
21
22 23
18
5
1
3
f462151
07/24/2009
1.
2.
3.
4.
5.
6.
7.
8.
9.
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
4
10.
11.
12.
13.
14.
15.
16.
Input Shaft Seal Cover
I-Shaft Upper Yoke
I-Shaft Lower Yoke Boot Clamp
I-Shaft Lower Yoke Boot
I-Shaft Lower End Yoke
Transfer Line Tube Fittings
Power Steering Fluid Line
Fittings
17.
18.
19.
20.
21.
22.
23.
I-Shaft Slip Joint
Transfer Lines
Rack and Pinion Gear
Pinch Bolt
Tie Rod Clamp
Tie Rod Clamp Nut
Passenger-Side Outer Tie Rod
Fig. 4, Rack and Pinion Steering System
46/4
Cascadia Maintenance Manual, November 2009
Fuel
47
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–01
Fuel Tank Band-Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–03
Fuel/Water Separator Element Checking and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–02
Cascadia Maintenance Manual, April 2009
47
Fuel
47–01 Fuel Filter Replacement
Refer to the engine manufacturer’s service manual
for removal and installation procedures.
8.1
Loosen the vent plug. Then operate the
primer pump until the fuel purges at the
vent plug. See Fig. 1.
8.2
Close the vent plug.
2
47–02 Fuel/Water Separator
Element Checking and
Replacement
3
1
Alliance
4
The only maintenance necessary on an Alliance
fuel/water separator is to replace the filte element.
11
WARNING
5
Diesel fuel is flammable and can ignite if exposed
to an open flame, intense heat, or other ignition
source. Do not drain fuel near, or expose fuel
vapor to open flame or intense heat. Exposure to
open flame or intense heat could start a fire, possibly resulting in personal injury or property damage. When working on a fuel system, have a fire
extinguisher within easy reach.
1. Drain off some fuel by loosening the vent plug
and opening the drain valve.
2. Disconnect the water sensor and heater connections if equipped.
3. Remove the element and bowl together, by turning counterclockwise.
4. Remove the bowl from the element and clean
the O-ring land.
10
9
6
7
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.
Water Sensor Probe
Heater Connector
Drain Plug
Sight Bowl
Filter Element
Fig. 1, Alliance Fuel/Water Separator
5. Apply a coating of clean fuel or motor oil to the
new O-ring and element seal.
9. Start the engine and check for fuel leaks.
6. Spin the bowl onto the new element, then spin
them both onto the filte head, snugly, by hand
only.
Davco Fuel Pro® 382
IMPORTANT: Do not use tools to tighten the
bowl and element.
Replace the fuel/water separator element only when
the filte element is completely covered.
7. Connect the water sensor and heater connectors
if equipped.
8. If equipped with a primer pump, prime the
fuel/water separator.
Cascadia Maintenance Manual, April 2009
10. Shut down the engine and correct any fuel leaks.
Check the level of fuel in the fuel filte .
NOTE: In the event of an emergency, when the
filte needs replacement but a Davco filte is not
available, a temporary filte can be used. For
instructions, see Chapter 24 of the Cascadia™
Driver’s Manual.
47/1
47
Fuel
WARNING
Diesel fuel is flammable and can ignite if exposed
to an open flame, intense heat, or other ignition
source. Do not drain fuel near, or expose fuel
vapor to open flame or intense heat. Exposure to
open flame or intense heat could start a fire, possibly resulting in personal injury or property damage. When working on a fuel system, have a fire
extinguisher within easy reach.
1. Drain the fuel below the collar level. See Fig. 2.
2. Using Davco wrench 380134 or 382002, remove
the filte collar. Then remove the filte cover.
3. Remove the element and dispose of it properly.
4. Install a new element. Make sure the grommet is
in place on the bottom of the filte element, and
seats completely on the filte stud.
5. Install a new cover seal on the filte cover.
6. Using the collar, attach the filte cover, with the
spring, to the base.
IMPORTANT: Tighten the collar by hand only.
7. Remove the filte vent. Then fil the fuel/water
separator with fuel until the fuel level is 1 inch
(2.5 cm) above the collar.
8. Install the filte vent on the fuel/water separator.
9. Start the engine and raise the rpm for one
minute to purge air.
47–03 Fuel Tank Band-Nut
Tightening
Hold each fuel tank band retention nut with a wrench
while backing off its jam nut. Then tighten the retention nuts 30 to 35 lbf·ft (41 to 46 N·m). After the retention nuts have been tightened, hold each retention
nut with a wrench while tightening its jam nut 30 lbf·ft
(41 N·m).
IMPORTANT: Do not overtighten.
47/2
Cascadia Maintenance Manual, April 2009
47
Fuel
1
2
6
7
3
4
8
9
10
5
12
11
13
04/30/2007
1.
2.
3.
4.
5.
Filter
Filter
Filter
Filter
Filter
f470505
Collar
Vent and Vent Seal
Cover
Spring
Element
6.
7.
8.
9.
Cover Seal
Body
Check Valve Fuel Inlet
Bottom Plate Seal
10.
11.
12.
13.
Fluid Heater/Bottom Plate
Mounting Capscrews
Drain
Electric Heater (optional)
Fig. 2, Davco Fuel Pro 382
Cascadia Maintenance Manual, April 2009
47/3
Exhaust
49
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Exhaust System Inspection (Noise Emission Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–01
Cascadia Maintenance Manual, August 2010
49
Exhaust
49–01 Exhaust System
Inspection (Noise
Emission Control)
• Diesel Exhaust Fluid (DEF)—the chemical agent
that reacts with the exhaust gases in the SCR
to reduce NOx.
In addition to inspecting the exhaust system at the
scheduled maintenance interval, inspect the exhaust
system if the noise level of the vehicle has increased. Freightliner Trucks recommends replacing
parts that show leakage, wear, or damage, with
genuine Freightliner parts.
• DEF Tank—holds DEF and regulates its temperature.
The exhaust system must be free of leaks, binding,
grounding, and excessive vibrations. These conditions are usually caused by loose, broken, or misaligned clamps, brackets, or pipes. If any of these
conditions exist, check the exhaust system components and alignment. Align or replace as necessary;
see Group 49 of the Cascadia™ Workshop Manual,
or take the vehicle to an authorized Freightliner
dealer.
It is a violation of US federal law to alter exhaust
plumbing or aftertreatment in any way that would
bring the engine out of compliance with certificatio
requirements. (Ref: 42 U.S.C. S7522(a) (3).) It is the
owner’s responsibility to maintain the vehicle so that
it conforms to EPA regulations.
EPA10 Exhaust System
Definitions of Aftertreatment (ATS)
Terms
Refer to the following list of definition of ATS terms
and components.
• Aftertreatment System (ATS)—the entire exhaust system from the turbocharger to the exhaust stack or tail pipe.
• Aftertreatment Device (ATD)—a housing that
contains the DOC and DPF (also the SCR and
the mixing tube in one-box systems).
• BlueTec®—Daimler’s proprietary SCR technology.
• Diesel Oxidation Catalyst (DOC)—a flow
through device that oxidizes soot in the ATD.
• Diesel Particulate Filter (DPF)—a component in
the ATD that traps soot from the exhaust gas.
Cascadia Maintenance Manual, August 2010
• DEF Pump—filter and supplies DEF to the
DEF metering unit.
• DEF Metering Unit—mixes DEF with compressed air, and meters this mixture into the
exhaust flo via an injection nozzle.
• SCR Catalyst—the housing containing a treated
ceramic flow-throug block where the DEF and
exhaust gases undergo selective catalytic reduction (SCR).
• Selective Catalytic Reduction (SCR)—a process
used to reduce NOx emissions.
Inspection
To meet EPA10 emissions regulations for vehicles
domiciled in the USA or Canada, engines manufactured after December 31, 2009 are equipped with an
emission aftertreatment system. Vehicles domiciled
outside of the USA and Canada may not have aftertreatment equipment, depending upon local statutory
emissions guidelines.
IMPORTANT: The aftertreatment device (ATD),
which is part of the aftertreatment system (ATS),
requires special attention during regularly
scheduled maintenance inspections. No leaks
are allowed anywhere in the system. If any discrepancies are discovered, refer to the engine
manufacturer’s service literature for repair instructions.
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. Once a seal clamp is loosened or
removed, it must be replaced.
49/1
49
Exhaust
3. If present, check the condition of the insulation
material around the exhaust pipe between the
turbocharger and the ATD.
8. Check the SCR catalyst for dents and other
damage.
9. Check for heat discoloration on the surface of
the ATD. Heat discoloration may indicate internal
damage; especially around the DPF.
4. Check the ATD mounting bands for tightness.
Tighten to 30 lbf·ft (41 N·m) if needed. Do not
overtighten.
NOTE: Diesel exhaust flui creeps, causing
white crystals to form around the line fittings
The presence of crystals does not mean the
system has a leak. Replacing fitting or troubleshooting components is not necessary unless
there is a system failure or a fault code.
5. Check for leaks around the clamps that attach
the ATD in the ATS, and around the clamps that
retain the DPF in the ATD.
6. Check all sensors attached to the ATS for leaks
or damaged wires. No leaks are allowed. See
Fig. 1, Fig. 2, or Fig. 3 for Detroit Diesel ATS
sensor locations.
10. Check the DEF tank, pump, metering unit, and
lines for leaks. See Section 49.02 of the Cascadia™ Workshop Manual for repair procedures.
7. Check the DPF exterior surface for dents or
other damage. A dent over 3 inches (76 mm) in
diameter and 1/4-inch (6-mm) deep could cause
internal damage to the DPF, causing it to
malfunction.
13
14
11. Check any wires, lines, or hoses within 4 inches
(10 cm) of the exhaust system for heat damage.
Repair or reroute as needed.
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.
SCR Outlet NOx Sensor Port
SCR Inlet NOx Sensor Port
14-Pin Connectors
DPF Outlet Pressure Sensor
Port
15. SCR Inlet Temperature Sensor
Fig. 1, One-Box ATS Sensor Locations
49/2
Cascadia Maintenance Manual, August 2010
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
Diesel Exhaust Fluid (DEF) Filter
Replacement
The Environmental Protection Agency’s 2010 regulations require lower nitrogen oxide (NOx) exhaust
emissions. Selective catalytic reduction (SCR) uses
diesel exhaust flui (DEF) to lower NOx emissions in
the vehicle exhaust. A filte in the DEF pump prevents clogging of the DEF metering unit injection
nozzle.
See the engine manufacturer’s maintenance manual
for filte replacement instructions and maintenance
intervals.
Cascadia Maintenance Manual, August 2010
EPA07 Exhaust System
Definitions of ATS Terms
Refer to the following list of definition of ATS components.
• Aftertreatment System (ATS)—the entire exhaust system from the turbocharger to the exhaust stack or tail pipe.
• Aftertreatment Device (ATD)—a muffler-like canister that houses a DPF, DOC, and sensors.
• Diesel Particulate Filter (DPF)—a filte that collects and holds particulate matter (soot and
ash).
49/3
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
• Diesel Oxidation Catalyst (DOC)—oxidizes hydrocarbons and reduces NOx.
• Sensors—detect temperatures and pressures in
the ATS.
Inspection
To meet EPA07 emissions regulations for vehicles
domiciled in the USA or Canada, engines manufactured after December 31, 2006 are equipped with an
emission aftertreatment system. Vehicles domiciled
outside of the USA and Canada may not have aftertreatment equipment, depending upon local statutory
emissions guidelines.
IMPORTANT: The aftertreatment device (ATD),
which is part of the aftertreatment system (ATS),
requires special attention during regularly
scheduled maintenance inspections; see Fig. 4.
No leaks are allowed anywhere in the system. If
49/4
any discrepancies are discovered, refer to the
engine manufacturer’s service literature for repair instructions.
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. Once a seal clamp is loosened or
removed, it must be replaced.
Cascadia Maintenance Manual, August 2010
49
Exhaust
6
1
2
3
4
2
5
5
7
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
3. If present, check the condition of the insulation
material around the exhaust pipe between the
turbocharger and the ATD.
9. Check any wires, lines, or hoses within 4 inches
(10 cm) of the exhaust system for heat damage.
Repair or reroute as needed.
4. Check the ATD mounting bands for tightness. If
needed, tighten the mounting bands on horizontally and vertically mounted ATDs to 30 lbf·ft (41
N·m); on step-mounted ATDs, tighten the mounting bands to 15 lbf·ft (20 N·m). Do not overtighten.
Pre-EPA07 Exhaust System
5. Check for leaks around the clamps that attach
the ATD in the ATS, and around the clamps that
retain the DPF in the ATD.
6. Check all sensors attached to the ATD for leaks
or damaged wires. No leaks are allowed.
7. Check the DPF exterior surface for dents or
other damage. See Ref. A of Fig. 4. A dent over
3 inches (76 mm) in diameter or 1/4-inch (6-mm)
deep could cause internal damage to the DPF,
causing it to malfunction.
8. Check for heat discoloration on the surface of
the ATD. Heat discoloration may indicate internal
damage; especially around the DPF.
Cascadia Maintenance Manual, August 2010
1. On all vehicles, check the condition of the muffler
body and the top stack. Check the inlet/outlet
tubes for leakage, dents, and corrosion, and
check for holes in the muffler. Replace parts as
required. Use new parts, equivalent to parts
originally installed on the vehicle.
2. Inspect the exhaust fle hose (see Fig. 5) for
leakage, wear, or damage. Replace with new
parts if replacement is needed.
3. Check for leakage at the V-band coupling, which
attaches the exhaust pipe to the turbocharger
exhaust outlet. See Fig. 5.
4. If leakage exists, tighten the nut on the V-band
coupling 85 lbf·in (940 N·cm). If leakage persists,
install a new V-band coupling.
5. Inspect the turbo outlet pipe, and replace it as
needed.
49/5
49
Exhaust
sealclamps. If necessary, install a new wide-band
exhaust clamp.
2
1
3
4
06/01/93
f490024a
1. Flex Hose
2. V-Band Coupling
3. Exhaust Pipe
4. Turbocharger Exhaust
Outlet
Fig. 5, V-Band Coupling and Flex Hose
6. Check the U-bolt clamps for tightness, and
tighten as needed.
05/28/93
f490025a
Fig. 7, Donaldson Sealclamp Wide-Band Exhaust
Clamp
7. Check the isolator at the base of the exhaust
stack elbow(s) (see Fig. 6), for cracking, damage, and dry rot. Replace as needed.
1
2
3
08/25/95
f490127
1. Exhaust Pipe
2. Exhaust Elbow Isolator
3. Mounting Nut
Fig. 6, Exhaust Elbow Isolator
8. Check for leakage at all wide-band exhaust
clamps. See Fig. 7.
If leakage exists, tighten the nuts 40 to 60 lbf·ft
(54 to 81 N·m). If leakage persists, inspect the
49/6
Cascadia Maintenance Manual, August 2010
Electrical, Instruments, and Controls
54
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Trailer Cable Inspection and Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54–01
Cascadia Maintenance Manual, August 2007
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.
IMPORTANT: If using a spray cleaner to remove
corrosion, be careful to protect any surrounding
painted surfaces.
3. Coat the inside of the sockets with a lithiumbased dielectric grease such as Lubriplate FLP
DS–ES.
4. Connect the cables.
Cascadia Maintenance Manual, August 2007
54/1
Cab
60
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Mirror Folding Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60–01
Cascadia Maintenance Manual, August 2010
Cab
60
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.
Cascadia Maintenance Manual, August 2010
60/1
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™ Drain Tube Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–03
Cascadia Maintenance Manual, August 2010
83
Heater and Air Conditioner
83–01 Air Conditioner
Inspection
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. If the friction surface of the pulley shows signs of excessive
grooving due to belt slippage, replace both the
pulley and the drive plate. Inspect the refrigerant
compressor drive belt for damage and check that
the belt is set at the proper tension. Also check
the tightness of the compressor mounting fasteners. For instructions and torque values, see
Group 01 of the Cascadia™ Workshop Manual.
3. Inspect the drive plate. If the drive plate shows
visible signs of damage due to excessive heat,
replace the drive plate and pulley assembly. For
removal and installation procedures, see Group
83 of the Cascadia™ Workshop Manual.
4. Using a feeler gauge, check that the drive plate
clutch clearance is within limits. See Table 1 for
clearance specifications See Fig. 1 for the
checking method. If the drive plate clutch requires adjustment, see Group 83 of the Cascadia™ Workshop Manual.
Compressor Drive-Plate Clutch Clearance
Manufacturer
Clearance: in (mm)
Sanden
0.016 to 0.040 (0.4 to 1.0)
Denso
0.014 to 0.024 (0.35 to 0.60)
Table 1, Compressor Drive-Plate Clutch Clearance
5. Inspect the compressor clutch coil wire. Check
that the connector is not damaged or loose. Replace the wire if it is damaged.
6. Check the overall condition of the air conditioning
hoses. Look for cracks, cuts, and abrasions on
the hoses. Replace damaged hoses. For re-
Cascadia Maintenance Manual, August 2010
f830641
08/25/94
Check clearance in three equally spaced places.
Fig. 1, Drive-Plate Clearance Inspection
placement instructions, see Group 83 of the
Cascadia™ Workshop Manual. Also check for
loose fitting on all of the air conditioning components.
7. Check for a buildup of road debris on the condenser fins For cleaning instructions, see Group
83 of the Cascadia™ Workshop Manual.
83–02 Air Filter Replacement
The HVAC system has three filter that must be replaced periodically to maintain proper system operation. The cabin fresh-air-intake filte is accessed from
under the hood, and the recirculation filte is accessed from inside the cab. The sleeper air filte is
accessed through an access panel on the cabinet
behind the driver’s seat.
Cab Fresh-Air Filter
Replacement
IMPORTANT: When replacing the air filte , use
only a Freightliner-approved air filte .
1. Park the vehicle on a level surface, set the parking brake, and shut down the engine. Chock the
tires.
2. Open the hood.
3. Remove the intake screen. See Fig. 2.
4. Lightly press on the filte tray handle to disengage the lock (see Fig. 3), and slide the tray out
of the slot in the plenum.
83/1
83
Heater and Air Conditioner
1
f831714
05/15/2007
Fig. 2, Intake Screen
f831717
04/10/2007
1. Airflo
Directional Arrow Orientation
Fig. 4, Airflow Directional Arrow
Cab Recirculation Air Filter
Replacement
f831716
04/10/2007
Fig. 3, Disengaging the Lock
5. Remove the filte from the tray. Note the airflo
directional arrow on the filter’ edge. When properly installed, the airflo 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.
6. Put a new filte in the tray, making sure the airflo arrow is correctly oriented, and install the
tray in the slot in the plenum. Make sure the tray
locks into position.
7. Install the intake screen.
8. Return the hood to the operating position.
The recirculation air filte is located on the "back"
side of the evaporator housing, in the corner of the
frontwall and the right side of the cab. See Fig. 5. It
is accessed from the underside of the unit. It is a
coarse sponge, or fibe , filte .
IMPORTANT: When replacing the air filte , use
only a Freightliner-approved air filte .
NOTE: Filter replacement is done "blind".
1. Park the vehicle on a level surface, set the parking brake, and shut down the engine. Chock the
tires.
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. Remove the door step plate, and then pull the
door seal loose from the bottom of the door
opening to just above the filte area.
Remove the A-pillar trim panel; remove the
screw (located under the step plate) and disengage the spring clips by pushing the panel towards the center of the cab.
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Cascadia Maintenance Manual, August 2010
83
Heater and Air Conditioner
tom edge of the recess, and slide it straight
down. See Fig. 7.
1
1
04/18/2007
f831719
1. Filter
Fig. 5, Cab Recirculation Air Filter (shown out of the
vehicle for clarity)
04/25/2007
f831720
1. Filter
Fig. 7, Removing the Filter
5. Slide a new filte up into the recess slots of the
plenum. Be sure that it fully seats into the slot all
the way around the opening.
6. Install the A-pillar trim panel, and then the door
seal, and finall , the door step plate.
4
2
7. Position the passenger side kick panel, and install the light bulb socket in the lens, then fasten
the panel.
1
3
04/17/2007
1. Kick Panel
2. Side Trim Panel
Sleeper Air Filter Replacement
f831718
3. Step Plate
4. Door Seal
Fig. 6, Panels
4. Remove the filte from the intake recess in the
back of the plenum. Pull it loose along the bot-
Cascadia Maintenance Manual, August 2010
The sleeper air filte is located on the forward side of
the blower fan housing, under the cabinet, directly
behind the driver’s seat.
IMPORTANT: When replacing the air filte , use
only a Freightliner-approved air filte .
1. Park the vehicle on a level surface, set the parking brake, and shut down the engine. Chock the
tires.
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83
Heater and Air Conditioner
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.
5. Install the access panel.
ParkSmart Air Filter Replacement
The ParkSmart air filte is located on the inboard
side of the blower fan housing, under the cabinet,
directly behind the driver’s seat.
IMPORTANT: When replacing the air filte , use
only a Freightliner-approved air filte .
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 filte out of the slot. See Fig. 10.
05/15/2007
f831713
Fig. 8, Sleeper HVAC Access Panel
3. Lift the filte out of the slot. See Fig. 9.
1
1
05/27/2010
f831858
1. Filter
04/26/2007
f831721
1. Filter
Fig. 9, Removing the Filter
4. Install a new filte in the slot, making sure that it
is completely seated in the slot.
83/4
Fig. 10, Removing the Filter
4. Install a new filte , making sure that it is completely seated.
5. Install the access panel.
Cascadia Maintenance Manual, August 2010
83
Heater and Air Conditioner
83–03 ParkSmart™ Drain Tube
Inspection
NOTICE
The ParkSmart drain tube must be kept clear of
debris. Failure to do so will cause excessive water
build-up in the base of the unit and may cause
damage to the control unit.
1. Remove the battery cover/step or forward side
fairing, as needed, to improve access to the underside of the ParkSmart unit.
2. Remove the drain tube from the bottom of the
unit. See Fig. 11
1
2
09/21/2010
f831857
Remove and clean the drain tube as needed.
1. Drain Tube
2. Intake Duct
Fig. 11, Drain Tube Inspection
3. Check the drain tube for debris, and clean as
needed.
4. Install the drain tube.
5. Install any components that were removed for
access.
Cascadia Maintenance Manual, August 2010
83/5
Hood, Grille, and Cab Fenders
88
Index, Alphabetical
Title of Maintenance Operation (MOP)
MOP Number
Hood Rear Support Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88–01
Cascadia Maintenance Manual, May 2010
Hood, Grille, and Cab Fenders
88
88–01 Hood Rear Support
Lubrication
1. Apply the parking brakes and 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.
Approved Suppliers of Multi-Purpose Lithium Grease
Supplier
Grease
Chevron
Delo Heavy Duty EP
Exxon
Unirex EP2
Mobil
Mobil Grease XHP 222
Shell
Retinax LC Grease
Texaco
Starplex 2
Table 1, Approved Suppliers of Multi-Purpose Lithium
Grease
Cascadia Maintenance Manual, May 2010
88/1
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