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Sterling Trucks L7500 Maintenance Manual

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L-LINE AND A-LINE MAINTENANCE MANUAL
Models: L7500
L7501
L8500
L8511
L8513
L9500
L9501
L9511
L9513
L9522
A9500
A9522
STI-383-1 (10/08P)
https://www.besttruckmanuals.com/
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.
Published by

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i need to know what the cab gauges are for and what they operate 2009 Sterling L7500

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Summary of Contents for Sterling Trucks L7500

  • Page 1 L-LINE AND A-LINE MAINTENANCE MANUAL Models: L7500 L7501 L8500 L8511 L8513 L9500 L9501 L9511 L9513 L9522 A9500 A9522 STI-383-1 (10/08P) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A. https://www.besttruckmanuals.com/...
  • Page 2 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.
  • Page 3 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 Workshop/service manuals contain service and repair information for all vehicle Manual systems and components, except for major components such as engines, trans- missions, and rear axles.
  • Page 4 Introduction Descriptions of Service Publications Warranty-related service information available on the AccessSterling.com website includes the following docu- mentation. 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.
  • Page 5 Introduction Page Description For an example of an L-Line and A-Line Maintenance Manual page, see Fig. 08/25/98 f020080 A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number B. Group Title C. Group Number D. Release Date E.
  • Page 6 Introduction Maintenance Manual Contents Group No. Group Title 00 ..... . General Information 01 ....... . Engine 09 .

  • Page 7: Table Of Contents

    General Information Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Determining Scheduled Maintenance Intervals..........00–01 Initial Maintenance (IM) Operations.

  • Page 8: Determining Scheduled Maintenance Intervals

    General Information Determining Scheduled Maintenance Intervals: 00–01 Determining Scheduled Service Schedule III (long-haul transport) is for ve- hicles that annually travel more than 60,000 miles Maintenance Intervals (100 000 kilometers) with minimal city or stop-and-go operation. Examples of Schedule III (long-haul trans- Performing regular maintenance on your Sterling ve- port) usage are: regional delivery that is mostly free- hicle will help ensure that your Sterling vehicle deliv-...
  • Page 9 General Information Maintenance Service Table: 00–02 Maintenance Service Table Maintenance Intervals Maintenance Interval Service Schedule Operation Frequency Miles Hours Initial Maintenance (IM) first 1000 1600 Maintenance 1 (M1) every 1000 1600 Schedule I — (severe service) vehicles that annually travel up to 6000 miles Maintenance 2 (M2) every 5000...
  • Page 10 General Information Vehicle Maintenance Schedule Tables: 00–03 1st through 35th Vehicle Maintenance Intervals for Service Schedule I Service I Maint. Required Maintenance Operation Service Date Number Interval Miles Hours Initial Maintenance (IM) and M1 1000 1600 2000 3200 3000 4800 4000 6400 M1 and M2...
  • Page 11 General Information Vehicle Maintenance Schedule Tables: 00–03 1st through 35th Vehicle Maintenance Intervals for Service Schedule I Service I Maint. Required Maintenance Operation Service Date Number Interval Miles Hours 35th M1 and M2 35,000 56 000 3500 Table 2, 1st through 35th Vehicle Maintenance Intervals for Service Schedule I 36th through 70th Vehicle Maintenance Intervals for Service Schedule I Service I Maint.
  • Page 12 General Information Vehicle Maintenance Schedule Tables: 00–03 36th through 70th Vehicle Maintenance Intervals for Service Schedule I Service I Maint. Required Maintenance Operation Service Date Number Interval Miles Hours 65th M1 and M2 65,000 104 600 6500 66th 66,000 106 200 6600 67th 67,000...
  • Page 13 General Information Vehicle Maintenance Schedule Tables: 00–03 71st through 100th Vehicle Maintenance Intervals for Service Schedule I Service I Maint. Required Maintenance Operation Service Date Number Interval Miles Hours 95th M1 and M2 95,000 153 000 9500 96th 96,000 155 000 9600 97th 97,000...
  • Page 14 General Information Vehicle Maintenance Schedule Tables: 00–03 Vehicle Maintenance Intervals for Service Schedule III Maint. Required Maintenance Operation Interval Service Date Miles Number 62,000 100 000 75,000 120 000 87,000 140 000 M1, M2 and M3 100,000 160 000 112,000 180 000 10th 125,000...
  • Page 15 General Information Lubrication and Fluid Level Check: 00–04 Table 7 summarizes all operations that must be per- Maintenance operation numbers given in the table formed to complete lubrication and fluid level checks are reference numbers used to help you find detailed in the M1 maintenance interval for all service sched- instructions in the manual on the lubrication or fluid ules.
  • Page 16 General Information Maintenance Operation Sets Table: 00–05 IMPORTANT: At each maintenance operation set, in vides detailed instructions on the maintenance opera- addition to the maintenance operations listed in this tions to be performed. table, perform all daily, weekly, and monthly mainte- NOTE: Maintenance operations appearing in italics in nance operations listed in Chapter 11, "Pretrip and this table are for noise emission control components.
  • Page 17 General Information Maintenance Operation Sets Table: 00–05 Maintenance Operation Sets Maintenance Maintenance Interval Operation Operation Description IM M1 M2 M3 M4 Number 40–01 Wheel Nut and Rim Nut Checking • • • 41–01 Driveline Inspecting • • • • • 41–02 Driveline Lubricating •...

  • Page 18: Initial Maintenance (Im) Operations

    General Information Initial Maintenance (IM) Operations: 00–06 IMPORTANT: After performing all operations listed in The "Maintenance Operation Number" is a reference this table, perform all daily, weekly, and monthly number matching the text in this manual which pro- maintenance operations listed in Chapter 11, "Pre- vides detailed instructions on the maintenance opera- trip and Post-Trip Inspections and Maintenance"...

  • Page 19: M1 Maintenance Interval Operations Table

    General Information M1 Maintenance Interval Operations Table: 00–07 The "M1 Maintenance Interval Operations" table lists IMPORTANT: After performing all operations listed in all maintenance operations that are to be performed this table, perform all daily, weekly, and monthly at the M1 maintenance interval. The "Maintenance maintenance operations listed in Chapter 11, "Pre- Operation Number"...

  • Page 20: M2 Maintenance Interval Operations Table

    General Information M2 Maintenance Interval Operations Table: 00–08 The "M2 Maintenance Interval Operations" table lists formed. All M1 maintenance interval operations must all maintenance operations that are to be performed be completed before performing M2 maintenance at the M2 maintenance interval. The "Maintenance interval operations.

  • Page 21: M3 Maintenance Interval Operations Table

    General Information M3 Maintenance Interval Operations Table: 00–09 The "M3 Maintenance Interval Operations" table lists IMPORTANT: After performing all operations listed in all maintenance operations that are to be performed this table, perform all daily, weekly, and monthly at the M3 maintenance interval. The "Maintenance maintenance operations listed in Chapter 11, "Pre- Operation Number"...

  • Page 22: M4 Maintenance Interval Operations Table

    General Information M4 Maintenance Interval Operations Table: 00–10 The "M4 Maintenance Interval Operations" table lists IMPORTANT: After performing all operations listed in all maintenance operations that are to be performed this table, perform all daily, weekly, and monthly at the M4 maintenance interval. The "Maintenance maintenance operations listed in Chapter 11, "Pre- Operation Number"...
  • Page 23 General Information Noise Emission Controls Maintenance: 00–11 General Information 2. The use of the vehicle after such device or ele- ment of design has been removed or rendered inoperative by any person. Federal Law, Part 205: Among those acts presumed to constitute tam- Transportation Equipment Noise pering are the acts listed below: Emission Controls...
  • Page 24 General Information Verification of Inspections Log: 00–12 Verification of Inspections Log Verification of Inspections Log, Groups 01 and 20 Date Mileage Item Cost Maintenance Facility Group 01 — Engine Rear Supports and Engine Noise Panels Group 20 — Fan Drive Table 14, Verification of Inspections Log, Groups 01 and 20 00/17 L-Line and A-Line Maintenance Manual, January 2007...
  • Page 25 General Information Verification of Inspections Log: 00–12 Verification of Inspections Log, Group 49 Date Mileage Item Cost Maintenance Facility Group 49 — Exhaust System Components Table 15, Verification of Inspections Log, Group 49 00/18 L-Line and A-Line Maintenance Manual, January 2007 https://www.besttruckmanuals.com/...
  • Page 26 General Information Metric/U.S. Customary Conversion Tables: 00–13 When You Know U.S. Multiply When You Multiply To Get Metric To Get U.S. Customary Customary Know Metric Length inches (in) 25.4 millimeters (mm) 0.03937 inches (in) inches (in) 2.54 centimeters (cm) 0.3937 inches (in) feet (ft) 0.3048...

  • Page 27: Metric/U.s. Customary Conversion Tables

    General Information Metric/U.S. Customary Conversion Tables: 00–13 Temperature Conversion Then When You Multiply Then When You Know Subtract To Get To Get Divide By Know degrees Fahrenheit (°F) degrees Celsius (°C) degrees Fahrenheit (°F) Table 17, Temperature Conversion 00/20 L-Line and A-Line Maintenance Manual, January 2007 https://www.besttruckmanuals.com/...

  • Page 28: Torque Specifications Tables

    General Information Torque Specifications Tables: 00–14 † Torque Values for U.S. Customary Thread Fasteners With Lubricated or Plated Threads Regular Hex Flanged Thread Grade 5 Grade 5 or Grade 8 or Grade 8 or Grade 5 Grade B Grade 8 or Grade G Diameter–...
  • Page 29 General Information Torque Specifications Tables: 00–14 † Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated) Plain (Unplated) Threads Regular Hex Flanged Thread Grade 5 or B Grade 8 or 8.2 Grade 8 or C Grade 8 or 8.2 Grade 5 Bolt Grade G Nut Diameter–Pitch...
  • Page 30 General Information Torque Specifications Tables: 00–14 † Torque Values for Metric Thread Fasteners With Lubricated or Plated Threads Class 8.8 Bolt Class 8 Nut Class 10.9 Bolt Class 10 Nut Thread Diameter–Pitch Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) 10.9 f230010 f230012 f230011 f230013...
  • Page 31 Engine Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Engine Drive Belt Inspecting............01–04 Engine Noise Panel Inspecting (Noise Emission Control).
  • Page 32 Engine 01–01 Engine Rear-Support Assembly Checking (Noise Emission Control) Front and rear engine supports for vehicles built from January 2007 require no periodic maintenance. Mounts should be inspected when the engine is re- moved for service. For vehicles manufactured prior to January 2007, perform the following check.
  • Page 33 Engine 05/27/93 f010647a NOTE: Caterpillar 3406E engines do not have right-side noise panels. 1. Right-Side Noise Panel 2. Oil Pan Noise Panel 3. Left-Side Noise Panel Fig. 2, Caterpillar Engine Noise Panels 01–03 Jacobs Engine Brake Wiring Inspecting Inspect the wiring from the dash switches to the en- gine brake housings for breaks and for broken or chafed insulation.
  • Page 34 Engine in the pulleys. It can also be caused by oil or 6. Check the drive belts for cracks. See Fig. 4, Ref. grease contamination on the pulleys. F. Small irregular cracks are usually the signs of an old belt. 2.
  • Page 35 Engine Belt Tension Inspection Spring-Tension Type On belts equipped with a spring tensioner, the belt NOTE: If engine drive belts require adjustment, tension is automatically adjusted. Check that the ten- see Group 01 of the L-Line and A-Line Work- sioner is holding tension on the belt by inserting the shop Manual .
  • Page 36 Air Intake Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Element Inspecting and Replacing ..........09–01 L-Line and A-Line Maintenance Manual, February 2004 https://www.besttruckmanuals.com/...
  • Page 37 Air Intake 09–01 Air Cleaner Element Inspecting and Replacing Method 1 Replace the air cleaner element at the recommended interval or when the air restriction indicator reaches 20 inH O on a vehicle with a Detroit Diesel engine, 22 inH O on a vehicle with an M-B engine, or 25 O on a vehicle with a Caterpillar or Cummins engine.
  • Page 38 Air Compressor Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Bendix Air Compressor Inspecting............13–01 L-Line and A-Line Maintenance Manual, October 1999 https://www.besttruckmanuals.com/...
  • Page 39 Air Compressor 13–01 Bendix Air Compressor Inspecting Inspect the air intake line, oil supply and return lines, and coolant supply and return hoses for tight connec- tions and general condition. Tighten the connections and replace the lines and hoses as needed. If the compressor air-intake adapter is loose, remove the adapter, replace the adapter gaskets, and securely install the adapter.
  • Page 40 Alternators and Starters Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Check ......... 15–01 L-Line and A-Line Maintenance Manual, October 2008 https://www.besttruckmanuals.com/...
  • Page 41 Alternators and Starters 15–01 Alternator, Battery, and weak solution of baking soda and water. Rinse with clean water, and dry. Paint the Starter Connections retainer assembly, if needed to prevent rusting. Check Be sure there are no foreign objects, such as stones, bolts, and nuts, in the WARNING battery box.
  • Page 42 Engine Cooling/Radiator Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fan Drive and Fan Clutch Checking (Noise Emission Control) ....... . . 20–03 Radiator Cap Checking.
  • Page 43 Engine Cooling/Radiator 20–01 Radiator Cap Checking cable engine manufacturer’s maintenance and operation manual. 1. If necessary, remove the aerodynamic cover WARNING from the front bumper. Do not remove or loosen the radiator cap until the 2. Drain the radiator as follows: engine and cooling system have completely For a low-flow cooling system, disconnect the cooled.
  • Page 44 Engine Cooling/Radiator matically adjust and keep consistent sealing stallation torque for Breeze Constant-Torque hose clamps is as follows: pressure. During vehicle operation and shut- down, the screw tip may adjust according to For clamps with a 5/16-inch tightening screw temperature and pressure changes. The torque hex: 55 lbf·in (620 N·cm).
  • Page 45 Engine Cooling/Radiator Cooling System Capacity (pre-EPA07 engines) Radiator Core and System Capacity : quarts (liters) Engine Make Engine Model Standard 1050 sq. inch 1300 sq. inch All, Except 3306C/3406E 31.0 (29.4) 32.9 (31.2) 34.2 (32.4) Caterpillar 3306C 39.2 (37.2) 41.1 (39.0) 42.4 (40.2) 3406E 45.7 (43.3)
  • Page 46 Engine Cooling/Radiator Maximum Coolant Protection in °F (°C) at Various Antifreeze Concentrations Cooling ETHYLENE-GLYCOL BASE ANTIFREEZE REQUIRED gallons (liters) System Capacity: 2 (8) 3 (11) 4 (15) 5 (19) 6 (23) 7 (26) 8 (30) 9 (34) 10 (38) 11 (42) 12 (45) gal (L) –4...
  • Page 47 Engine Cooling/Radiator could fly out at high speeds. Do not direct the air- stream at anyone. Do not disconnect pressurized hoses, since they may whip as air escapes. Fail- ure to take all necessary precautions could result in personal injury. If the fan clutch does not engage, see if compressed air is in the fan clutch actuat- ing air line: With the ignition on, but the...
  • Page 48 Engine Cooling/Radiator 03/30/95 f200194a 1. Mounting Bracket 9. Rear Hub Bearing 17. Face Seal 2. Rear Sheave Bearing 10. Bearing Spacer 18. Small O-Ring 3. Inner and Outer Bearing 11. Splined Hub 19. Air Chamber Spacers 12. Forward Hub Bearing 20.
  • Page 49 Engine Cooling/Radiator 05/27/93 f500006a 1. Capscrew 8. Panhead Screw 14. O-Ring Seal 2. Mounting Bracket 9. Retaining Washer 15. Piston Assembly 3. Hexnut 10. Rotary Air Union 16. Friction Facing 4. Washer 11. O-Ring Seal 17. Capscrew 5. Drive Sleeve 12.
  • Page 50 Engine Cooling/Radiator 2. Inspect the electrical connections and wires to the fan clutch solenoid. Secure the connection if loose; replace wires and connectors if damaged. 3. Clean the fan clutch air solenoid valve filter, if equipped. Unscrew the fan clutch solenoid valve air filter assembly and remove the filter ele- ment.
  • Page 51 Engine Cooling/Radiator 05/30/2002 f200581 Fig. 8, Checking for Air Leaks (Horton DriveMaster) 9. If a leak is detected, remove the fan blade. In- stall a new seal kit. See Group 20 of the L-Line and A-Line Workshop Manual for repair proce- dures.
  • Page 52 Clutch Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch Release Bearing Lubricating........... . . 25–01 L-Line and A-Line Maintenance Manual, October 1999 https://www.besttruckmanuals.com/...
  • Page 53 Clutch 25–01 Clutch Release Bearing outside the bell housing, lubricate the bearing with the engine running. Lubricating Using a pressure gun and high-temperature grease only, lubricate the release bearing at the grease fit- NOTE: For a clutch with a sealed release bear- ting until grease starts coming out of the fitting.
  • Page 54 Transmission Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Allison Transmission Fluid and Filter Changing ..........26–01 Manual Transmission Magnetic Plug Cleaning and Oil Changing .

  • Page 55: Allison Transmission Fluid And Filter Changing

    Transmission 26–01 Allison Transmission Fluid and Filter Changing When draining transmission fluid, check for evidence of dirt or water contamination. A small amount of condensation will appear in the fluid during operation. Water contamination is normally characterized as a milky discoloration of the transmission fluid. Obvious contamination of the transmission fluid indicates a leak between the water and fluid areas of the trans- mission cooler.

  • Page 56: Manual Transmission Magnetic Plug Cleaning And Oil Changing

    Transmission 12. Replace the drain plug O-ring, and install the build-up, which could cause oil leakage. If the drain plug. Tighten the drain plug 18 to 24 lbf·ft breather is plugged, clean or replace it. See (25 to 32 N·m). Fig.
  • Page 57 Transmission Transmission Lubricant Capacities Capacity: Transmission Make and Model pt (L) Allison AT–542 30 (14.2) AT–545 40 (18.9) MT–600 34 (16.1) 05/27/93 f260006a MT–700 60 (28.4) A. Full B. Low MD Series 58 (27.4) Fig. 3, Checking Transmission Oil Level HD Series 102 (48.2) CAUTION...

  • Page 58: Transmission Air Filter/Regulator Checking And Cleaning, Or Replacing

    Transmission Approved Transmission Lubricants Transmission Lubricant Type Temperature SAE Viscosity ® Allison Dexron Above -17°F (–27°C) — Heavy-Duty Engine Oil meeting MIL–L–2104B, C, or D, or API Above +10°F (–12°C) 50 or 40 Service Classification SF or CD (previous API designations Below +10°F (–12°C) are acceptable) Fuller...
  • Page 59 Transmission 7. Start the engine, and build pressure in the air system. Check for air leaks at the filter housing and air line connections; repair any leaks. CAUTION A leaking air filter or air lines can cause slow or hard shifting of the transmission, and eventual transmission damage.

  • Page 60: Transmission Breather And Oil Level Checking

    Transmission 2. Clean the outside of the air filter/regulator with WARNING cleaning solvent, then let it air dry. 3. Remove the end cap from the air filter/regulator Wear eye protection when using compressed air assembly, then inspect the O-rings in the end to clean parts, as permanent harm to eyes could cap.
  • Page 61 Transmission Do not mix types and brands of fluid, because of possible incompatibility. Do not use fluid addi- tives, friction modifiers, extreme-pressure gear fluids, or multiviscosity lubricants. Cold Check Clean all dirt from around the end of the fluid fill tube before removing the dipstick.
  • Page 62 Transmission tives, friction modifiers, extreme-pressure gear fluids, or multiviscosity lubricants. With the transmission at operating temperature, and the vehicle on a level surface, check the fluid level in the transmission. 1. Clean the area around the fill plug, and remove it from the side of the case.
  • Page 63 Frame and Fifth Wheel Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fifth Wheel Inspecting ............. . 31–01 Fifth Wheel Lubricating.

  • Page 64: Fifth Wheel Inspecting

    Frame and Fifth Wheel 31–01 Fifth Wheel Inspecting Release the lock by tripping the release latch at the bottom of the throat. Adjust the wedge stop at the end of the WARNING wedge to approximately 1/4-inch (6-mm) clearance by turning the wedge stop rod All fifth wheel maintenance, adjustment, and re- located on the right side of the top plate.

  • Page 65: Fifth Wheel Lubricating

    Frame and Fifth Wheel 09/18/95 f310476 1. 3/16" x 1" Cotter Pin 11. 1/4–20 x 3/8 Thread-Cutting 19. 1/2–13 x 2 Bumper Pivot Bolt 2. Lower Bracket Retainer Pin Screw 20. Bumper 3. Grease Fitting 12. Step Jaw and Wedge 21.
  • Page 66 Frame and Fifth Wheel 08/29/95 f310472 1. Locknut, 3/4–16 7. Torsion Spring 13. Lock Pin 2. Washer 8. Roll Pin 14. Lock Jaw 3. Rubber Washer 9. Secondary Lock, Right-Hand 15. Washer 4. Lock Adjustment Tag 10. Cam Plate 16. Right-Hand Release Handle 5.

  • Page 67: Frame Fastener Torque Checking

    Frame and Fifth Wheel from the tractor, which could result in personal See the applicable torque table in Group 00 injury or property damage. torque specifications. Fontaine CAUTION Use a multipurpose extreme pressure (EP) chassis Make sure frame fasteners are properly tightened. grease, and lubricate all moving parts on the fifth Continued vehicle operation with loose fasteners wheel.

  • Page 68: Trailer Electrical Connector Lubricating

    Frame and Fifth Wheel 11/21/95 f310371 1. Rack 3. Pocket 2. Plunger 4. Plunger Adjusting Bolt Fig. 3, Locking Plungers 2. Disengage and engage the locking plungers. Check that the plungers are securely seated without binding. If the locking plungers do not operate properly, see Group 31 of the L-Line and A-Line Workshop Manual for adjustment pro- cedures.
  • Page 69 Suspension Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Suspension Inspecting ............. . 32–01 Suspension Lubricating.
  • Page 70 Suspension 32–01 Suspension Inspecting Front Suspension Check WARNING Do not replace individual leaves of a damaged leaf spring assembly; replace the complete spring as- sembly. Visible damage (cracks or breaks) to one leaf causes hidden damage to other leaves. Re- placement of only the visibly damaged part(s) is no assurance that the spring is safe.
  • Page 71 Suspension radius rod. If a radius rod needs to be replaced, see Group 32 of the L-Line and A-Line Work- shop Manual for instructions. 4. Inspect the weld seams between the radius rod tube and the shorter bushing tubes. If there are cracks, replace the radius rod.
  • Page 72 Suspension tions exist, replace the damaged bracket(s). See tube-type beam end connection (see Fig. Group 32 of the L-Line and A-Line Workshop tighten the nut 375 to 425 lbf·ft (508 to 576 N·m). Manual for instructions. Do not overtorque. 2. Check for distorted or frayed rubber at the beam end bushings.
  • Page 73 Suspension IMPORTANT: Before checking the AirLiner sus- pension height, make sure there is no load on the chassis, and the trailer is unhitched. 1. Park the vehicle on a level surface, using a light application of the brakes. Do not apply the park- ing brakes.
  • Page 74 Suspension the L-Line and A-Line Workshop Manual rod needs to be replaced, see Group 32 of the for the overtravel lever length for the rear L-Line and A-Line Workshop Manual for instruc- axle installed in your vehicle. tions. 5. On single-drive rear axle configurations, measure 8.
  • Page 75 Suspension Reyco Suspension, 79KB and 179 of a pry bar may lead to premature bushing re- placement. Park the vehicle on level ground and chock the front 2. Lift the rear of the vehicle and support the frame tires to prevent the vehicle from moving. Place the on jack stands to unload the suspension compo- transmission in neutral, and release the parking nents.
  • Page 76 Suspension 01/04/96 f320488 1. Torque Rod Clamp 2. Torque Rod Fig. 11, Reyco 79KB Torque Rod Clamp Position 01/16/96 f320503 1. Torque Rod Clamp 2. Torque Rod Fig. 12, Reyco 179 Torque Rod Clamp Position WARNING Be sure that fasteners are torqued correctly. Fas- teners that do not provide a tightly clamped joint 09/27/95 f320432...
  • Page 77 Suspension 2. Visually inspect each frame hanger for any evi- dence of cracks in the vertical mounting flange. Fig. 09/15/95 f320420 1. Crack In Inspection Area 09/15/95 f320419 1. Frame Rail Fig. 15, Hendrickson RS Series Horizontal Mounting 2. Crack In Inspection Area Flange Fig.
  • Page 78 Suspension and loss of vehicle control. This could result in serious personal injury or property damage. 4. Visually inspect the cam surface of the number- two spring hanger for wear due to operating mileage. Also, inspect the outside legs for wear which can be caused by worn spring eye bush- ings.
  • Page 79 Suspension ment is observed, the bushing and pin should be Check all other nuts and bolts for proper torque. replaced. This also could indicate that a broken Group 00 of this manual for torque specifi- spring eye and spring are connected to the cations.
  • Page 80 Suspension 09/15/95 f320423 1. Frame Rail 3. Axle Centerline 2. Axle Housing 4. Suspension Ride Height Fig. 20, Neway Ride Height Inspection 1. Park the vehicle on a level surface, apply the parking brakes, and chock the front tires. 2. Raise the rear of the vehicle until the rear wheels are suspended in the air, then support the ve- hicle with safety stands.
  • Page 81 Suspension 2. Check the U-bolt torque in a diagonal pattern. Set a click-type torque wrench to the highest torque value for the fastener being checked. Turn the wrench in a clockwise motion until the torque wrench clicks. See Table 1 of this manual for U-bolt torque specifications.
  • Page 82 Front Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Checking ............33–03 Knuckle Pin Lubricating .
  • Page 83 Front Axle 33–01 Knuckle Pin Lubricating plate gasket, continue pumping until new grease is seen at the bushing seal opposite the grease fitting. Fig. CAUTION Use regulated pressure when lubricating the knuckle assemblies, otherwise damage could re- sult to the knuckle caps. Dana Spicer Park the vehicle on a level surface, apply the parking brakes, and chock the wheels.
  • Page 84 Front Axle support the combined weight of the cab, axle, and frame. Place safety stands under the axle. 3. Using spray paint or a piece of chalk, mark the entire center rib of each front tire. 4. Place a scribe or pointed instrument against the marked center rib of each tire, and turn the tires.
  • Page 85 Front Axle f330014a 08/30/94 Fig. 5, Trammel Bar Positioning 08/30/94 f400100a Fig. 6, Setting the Trammel Bar Pointers and A-Line Workshop Manual . If corrections are needed, see Group 33 of the L-Line and A-Line Workshop Manual for instructions on adjusting the toe-in.
  • Page 86 Rear Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Axle Breather and Lubricant Level Checking ..........35–01 Axle Lubricant Changing, Oil Filter Replacing and Magnetic Strainer Cleaning .
  • Page 87 Rear Axle 35–01 Axle Breather and temperature indicator only, and should not be used as a fill or level hole. Lubricant Level 3. With the vehicle on level ground, lubricant should Checking be level with the bottom of the fill hole. If low, check for oil leaks, correct as needed, then add Meritor Axle Lubricant Level specified lubricant.
  • Page 88 Rear Axle Meritor Drive Axle Recommended Lubricant Recommended Lubricant SAE Ambient Temperature Meritor Specification Lubricant Type Viscosity Grade +10°F (–12.2°C) and up 85W–140 0–76–A –15°F (–26.1°C) and up 80W–140 0–76–B Hypoid Gear Oil API –15°F (–26.1°C) and up 80W–90 0–76–D Service Classification –40°F (–40°C) and up 75W–90...
  • Page 89 Rear Axle Dana Spicer Drive Axle Lubricant Capacities Capacity Axle Type Axle Model pints (liters) † DP451–P 34 (16.1) Double Reduction † DP461–P 43 (20.3) Quantities listed are approximate. Fill axle until lubricant is level with bot- tom of fill hole with vehicle on level ground. †...
  • Page 90 Rear Axle • Elco No. 2 Friction Modifier (Elco Corpora- 35–02 Axle Lubricant tion) Changing, Oil Filter • Lubrizol No. 6178 (Lubrizol Corporation) Replacing and Magnetic • Hi–Tec E–336 (Edwin Cooper, Inc.) Strainer Cleaning • Equa–Torque No. 2411 (Sta-Lube Corpora- tion) Meritor Axle Lubricant Change •...
  • Page 91 Rear Axle the filter cover. Do not remove the cap- screws. See Fig. 05/27/93 f350118a Fig. 7, Axle Oil Filter Adapter Removal and Installation 05/27/93 f350090a Place the oil filter adapter in its bore. In- stall the washers and capscrews, then Fig.
  • Page 92 Rear Axle sary to clean or change the plugs one or more pump on the front of the power divider cover, times between lubrication change intervals. that must be removed and cleaned at each axle oil change. All rear axle assemblies are fitted 6.
  • Page 93 Rear Axle short the two magnetic poles and divert the mag- netic field. IMPORTANT: Magnets will rapidly lose effective- ness as collected material bridges the gap be- tween the two poles. Clean or change the plugs before this occurs. It may be necessary to clean or change the plugs one or more times between lubrication change intervals.
  • Page 94 Rear Axle 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 gas- ket. Tighten the housing cover capscrews 7.5 to 9.2 lbf·ft (10.2 to 12.5 N·m), then remove the oil fill plug from the cover.
  • Page 95 Wheels and Tires Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Wheel Nut and Rim Nut Checking............40–01 L-Line and A-Line Maintenance Manual, October 1999 https://www.besttruckmanuals.com/...
  • Page 96 Wheels and Tires 40–01 Wheel Nut and Rim Nut breakage, and extreme tire tread wear. Excessive wheel nut torque can break studs, damage Checking threads, and crack discs in the stud hole area. Use the recommended torque values, and follow IMPORTANT: In addition to the maintenance the sequence shown in Fig.
  • Page 97 Driveline Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspecting ..............41–01 Driveline Lubricating.
  • Page 98 Driveline 41–01 Driveline Inspecting 3. Check U-joint assemblies for wear by attempting to move the driveshaft up and down, and from side-to-side. If movement of the U-joint cross in Before lubricating driveline U-joints and slip joints, the bearings can be felt or seen, replace the proceed as follows: complete U-joint.
  • Page 99 Driveline 05/27/93 f410032a NOTE: Not all fasteners are shown. 1. Full-Round End Yoke 9. Driveshaft Yoke (Full-Round) 2. Bearing Cap 10. Input Shaft End Yoke (Half-Round) 3. Lockplate and Capscrew 11. Splined Shaft 4. Main Transmission 12. Slip Joint Seal Assembly 5.
  • Page 100 Driveline 05/27/93 f410012a Attempt to bend the sleeve yoke and splined shaft back and forth. Fig. 2, Slip Joint Spline Wear Checking 10/20/93 f410050a A. After grease appears, cover the pressure-relief hole while continuing to lubricate. 1. Slip Joint Grease Fitting (with grease gun attached) 2.
  • Page 101 Driveline 3. Check the purged grease. If it appears rusty, gritty, or burned, replace the U-joint. 4. Wipe the purged grease from the seals, and any excess grease from the grease fitting. Slip Joint Spline Lubrication 1. Wipe all old grease and dirt from the slip joint grease fitting.
  • Page 102 Brakes Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Automatic Slack Adjuster Lubricating and Checking......... 42–02 Bendix Air Brake Valve Disassembly, Cleaning, Inspecting, and Lubricating (DV–2 and Single Check Valve) .

  • Page 103: Automatic Slack Adjuster Lubricating And Checking

    Brakes 42–01 Camshaft Bracket 42–02 Automatic Slack Bushing Lubricating Adjuster Lubricating and Checking IMPORTANT: Perform MOP 42–10 before lubri- cating the camshaft bracket. WARNING Pump grease into the camshaft bracket until it ap- pears at the slack adjuster end of the bracket. See Manually adjusting an automatic slack adjuster to Fig.
  • Page 104 Brakes WARNING Make sure both clevis pins are installed. Failure to do so will cause the slack adjuster to work incor- rectly, which could lead to loss of braking control. This could result in an accident causing personal injury or property damage. 42–03 Bendix Air Dryer Checking (AD–IP or AD–9)

  • Page 105: Bendix Air Brake Valve Disassembly, Cleaning, Inspecting, And Lubricating

    Brakes 42–04 Bendix Air Dryer Assemble and install the valves, then check for proper operation and for leakage. Desiccant Replacing (AD–9) 42–07 Bendix Air Brake Valve Disassembly, Cleaning, Disassemble, clean, and inspect the Bendix air dryer. Replace the desiccant cartridge. See Group 42 of Inspecting, and the L-Line and A-Line Workshop Manual for instruc- Lubricating (DV–2 and...

  • Page 106: Bendix Foot Brake Valve Actuator Lubricating And Leak Testing (E-12)

    Brakes 42–09 Bendix Foot Brake Valve E-12 Brake Valve Service Parts List Actuator Lubricating and Description Part Number Leak Testing (E–12) Gasket 12–15695–000 Table 1, E-12 Foot Brake Valve Service Parts List NOTE: You may need to remove tie straps and 5.
  • Page 107 Brakes are not operating correctly and must be repaired 3. Check to see if the colored over-stroke band on before the vehicle is returned to service. See each brake chamber pushrod is exposed. Group 42 of the L-Line and A-Line Workshop If a band shows, the stroke is too long.
  • Page 108 Brakes Brake Chamber Stroke Specifications Chamber Max Applied Stroke: inch (mm) † Manufacturer Type Size 1-3/8 (35) Standard Stroke 1-3/4 (44) Haldex 2-1/2-Inch Extended Stroke 2 (51) 3-Inch Extended Stroke 2-1/2 (64) Standard Stroke 2 (51) Long Stroke 2-1/2 (64) Less than 1-1/2 (38) Standard Stroke Less than 1-3/4 (44)
  • Page 109 Steering Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Drag Link and Power Steering Cylinder Lubricating ......... 46–02 Power Steering Reservoir Fluid Level Checking.
  • Page 110 Steering 46–01 Steering Driveline Lubricating Wipe the steering driveline grease fittings clean. See Fig. Fig. 2, and Fig. 3. Using a pressure gun, apply multipurpose chassis grease sparingly to the universal joints and slip-joint splines. 06/28/99 f460006b Fig. 2, Intermediate Shaft U-Joint Grease Fitting 05/28/93 f460005a 1.
  • Page 111 Steering 46–03 Power Steering Reservoir Fluid Level Checking Metal Ventra Reservoir 1. Turn off the engine, apply the parking brakes, and chock the tires. 2. Open the hood. 3. Clean around the power steering reservoir fill cap with a clean rag, then remove the dipstick. WARNING Fill only with approved clean fluid.
  • Page 112 Steering 4. Disconnect the hose, between the reservoir and the steering gear, from the reservoir. Then drain the reservoir in a drain pan, and cap the reser- voir port. 5. Remove the filter element. 6. Thoroughly clean the reservoir with a lint-free cloth.
  • Page 113 Steering Nelson Reservoir 7. With the larger opening at the top, install a new filter in the reservoir. 8. Clean the reservoir cover and gasket. Inspect the WARNING O-ring and the cover for cracks, deformities, or damage. Replace the gasket seal or cover as Fill only with approved clean fluid.
  • Page 114 Fuel Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fuel Separator Sight Bowl Cleaning and Element Replacing ........47–03 Fuel Tank Band Nut Tightening.
  • Page 115 Fuel 47–01 Fuel Tank Vent Checking On vehicles with a screw-on fuel cap, remove the fuel cap and clean it with solvent. Make sure the fuel cap vent is open. Install the cap. On vehicles with a quarter-turn fuel cap, check to be sure the vent line at the inboard side of the fuel tank is clean and not plugged.
  • Page 116 Fuel 5. Lightly lubricate the threads on the sight bowl, with oil, then thread the sight bowl into the bot- tom of the fuel separator. 6. Hand-tighten until the gasket is in full contact with the fuel separator, then tighten an additional 1/4 to 1/3 turn.
  • Page 117 Fuel 5. Remove and discard the bowl O-ring; then clean the bowl of debris using diesel fuel only. Clean the bowl O-ring seat with a shop cloth. 6. Lubricate the new bowl O-ring with clean diesel fuel or motor oil; then seat it in the collection bowl.
  • Page 118 Fuel 8. Hand-tighten the collection bowl to a new filter element. Do not use tools. 9. Lubricate the new filter element square-cut gas- ket with clean diesel fuel or motor oil. 10. Spin the filter and bowl assembly onto the mounting head until the gasket contacts the head base.
  • Page 119 Fuel age. When working on a fuel system, have a fire 6. By hand only, spin the bowl onto the new ele- extinguisher within easy reach. ment, then snugly spin them both onto the filter head. 1. Drain some fuel by loosening the vent plug and opening the drain valve.
  • Page 120 Fuel 1. Disconnect the water sensor probe connector and bowl heater connector, if equipped. See Fig. 05/28/97 f470183 1. T-Handle 3. Lid Gasket 2. Lid 4. Filter Element Fig. 6, Racor 900FG Fuel Heater/Water Separator (1000FG similar) Racor 6400 06/26/97 f470190 1.
  • Page 121 Fuel the fuel heater/water separator by opening the drain valve. 3. Remove the filter element and collection bowl together, by turning the filter element off of the mounting head. 4. Remove the filter element from the collection bowl by turning the collection bowl. Discard the filter element.
  • Page 122 Fuel 8. Start the engine, then raise the rpm for one to WARNING two minutes to purge air from the system, and check for fuel leaks. Diesel fuel is flammable and can ignite if exposed 9. Shut down the engine and correct any fuel leaks. to an open flame, intense heat, or other ignition source.
  • Page 123 Fuel 7. Install the filter element, filter cover and cover seal, and filter collar. Hand-tighten the filter col- lar. 8. Remove the filter vent. Fill with fuel until fuel is about one inch above the collar. Replace the fil- ter vent. 9.
  • Page 124 Exhaust Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Exhaust System Inspecting (Noise Emission Control)........49–01 L-Line and A-Line Maintenance Manual, January 2007 https://www.besttruckmanuals.com/...
  • Page 125 Exhaust 49–01 Exhaust System Inspecting (Noise Emission Control) In addition to inspecting the exhaust system at the scheduled maintenance interval, inspect the exhaust system if the noise level of the vehicle has in- creased. Replace parts that show leakage, wear, or damage, with genuine Sterling parts.
  • Page 126 Exhaust 06/01/93 f490024a 05/28/93 f490023a 1. Flex Hose Fig. 4, Riker Tru-Seal Wide-Band Exhaust Clamp 2. V-Band Coupling 3. Exhaust Pipe 4. Turbocharger Exhaust Outlet Fig. 2, V-Band Coupling and Flex Hose 10/05/94 f490005a Fig. 5, Torca Torctite Wide-Band Exhaust Clamp •...
  • Page 127 Exhaust seal clamps. Once a seal clamp is loosened or 8. Check for heat discoloration on the surface of removed, it must be replaced. the ATD. Heat discoloration may indicate internal damage; especially around the DPF. 3. If present, check the condition of the insulation material around the exhaust pipe between the 9.
  • Page 128 Electrical, Instruments, and Controls Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Electrical System Checking............54–01 L-Line and A-Line Maintenance Manual, October 1999 https://www.besttruckmanuals.com/...
  • Page 129 Electrical, Instruments, and Controls 54–01 Electrical System Checking Cab Interior Inspect the wiring and electrical connections at the electrical mounting plate, cab-to-chassis interface connectors, cab-to-engine interface connectors, main cab-power and cab-ground studs, and electrical junc- tion blocks. Check all wiring for chafing, kinks, and discolored insulation.
  • Page 130 Doors Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Door Latch and Door Hinge Lubricating..........72–01 L-Line and A-Line Maintenance Manual, October 1999 https://www.besttruckmanuals.com/...
  • Page 131 Doors 72–01 Door Latch and Door Hinge Lubricating Apply a few drops of light engine oil to the door latch mechanism to reduce noise and wear. Wipe off ex- cess oil. This includes baggage doors, ventilator doors, and the oil-check door. Lubricate door hinges every six months.
  • Page 132 Heater and Air Conditioner Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspecting............83–01 Air Filter Replacing.
  • Page 133 Heater and Air Conditioner 83–01 Air Conditioner Inspecting WARNING Wear eye protection, gloves, and protective cloth- ing when working on the air conditioning system. Leaking refrigerant from a damaged hose or line could cause blindness or serious skin burns. Preliminary Checks 08/25/94 f830641 1.
  • Page 134 Heater and Air Conditioner 8. Remove the chocks from the tires. f831564 02/17/2003 1. Screw 2. Filter Cover Fig. 2, Air Filter Replacement 83/2 L-Line and A-Line Maintenance Manual, January 2008 https://www.besttruckmanuals.com/...
  • Page 135 Hood Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Hood Hinge Bushings Lubricating ............88–01 L-Line and A-Line Maintenance Manual, October 1999 https://www.besttruckmanuals.com/...
  • Page 136 Hood 88–01 Hood Hinge Bushings Lubricating Lubricate the hood hinge bushings at the zerk fit- tings, using multi-purpose chassis grease. Use a hand-type grease gun, or a high-pressure gun with a low-pressure adapter. 88/1 L-Line and A-Line Maintenance Manual, October 1999 https://www.besttruckmanuals.com/...

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