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freightliner PT126SLP Maintenance Manual

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NEW CASCADIA MAINTENANCE MANUAL
Models: PT126SLP
PT126DC
PE116SLP
PE116DC
STI-500-10 (02/03/2022)
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.
Published by

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  • Page 1 NEW CASCADIA MAINTENANCE MANUAL Models: PT126SLP PT126DC PE116SLP PE116DC STI-500-10 (02/03/2022) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
  • Page 3 Perform any maintenance operations listed at the intervals scheduled in those manuals. Your Freightliner Dealership has the qualified technicians and equipment to perform this maintenance for you. They can also set up a scheduled maintenance program tailored specifically to your needs. Optionally, they can assist you in learning how to perform these maintenance procedures.
  • Page 4 © 2016–2022 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.
  • Page 5 Introduction Descriptions of Service Publications Daimler Trucks North America LLC distributes the following major service publications in paper and electronic formats. Refer to www.DTNAConnect.com. Workshop/Service 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 6 ™ EZWiring EZWiring makes Freightliner, Sterling, Western Star, Thomas Built Buses, and Freightliner Custom Chassis Corporation products’ wiring drawings and floating pin lists available online for viewing and printing. EZWiring can also be ac- cessed from within PartsPro.
  • Page 7 Introduction Page Description For an example of a Maintenance Manual page, see Fig. 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−...
  • Page 8 Introduction Maintenance Manual Contents Group No. Group Title 00 ..... . General Information 09 ......Air Intake 13 .

  • Page 9: 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 11: Determining Scheduled Maintenance Intervals

    Maintenance Intervals 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 mainte- nance program can result in inefficient operation and unscheduled down time.
  • Page 12 General Information Service Schedule Table: 00–02 Maintenance Interval Service Schedule Maintenance Interval Operation Frequency Miles Initial Maintenance (IM) first 10,000 16 000 Schedule I Maintenance 1 (M1) every 10,000 16 000 (Short-Haul Transport) vehicles that annually travel less than 60,000 Maintenance 2 (M2) every 50,000...
  • Page 13 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule I Service Schedule I Maintenance Service Maint. No. Interval Date Miles IM and M1 10,000 16 000 20,000 32 000 30,000 48 000 40,000 64 000 M1 and M2 50,000 80 000 60,000...
  • Page 14 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule I Service Schedule I Maintenance Service Maint. No. Interval Date Miles 36th 360,000 576 000 37th 370,000 592 000 38th 380,000 608 000 39th 390,000 624 000 40th M1 and M2 400,000 640 000 41st...
  • Page 15 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule I Service Schedule I Maintenance Service Maint. No. Interval Date Miles 71st 710,000 1 143 000 72nd 720,000 1 159 000 73rd 730,000 1 175 000 74th 740,000 1 191 000 75th M1, M2, and M3 750,000...
  • Page 16 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule II Service Schedules II Service Maint. No. Maintenance Interval Date Miles IM and M1 25,000 40 000 50,000 80 000 75,000 121 000 M1 and M2 100,000 161 000 125,000 201 000 150,000...
  • Page 17 General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule II Service Schedules II Service Maint. No. Maintenance Interval Date Miles M1, M2, and M3 900,000 1 448 000 925,000 1 490 000 950,000 1 529 000 975,000 1 569 000 M1 and M2 1,000,000 1 609 000...

  • Page 18: Initial Maintenance (Im) Operations

    General Information Initial Maintenance (IM) Operations: 00–04 The Initial Maintenance table lists all maintenance tenance operations to be performed. All operations operations that are to be performed at the initial listed in the table, along with the operations listed in maintenance (IM) interval.

  • Page 19: M1 Maintenance Interval Operations

    General Information M1 Maintenance Interval Operations: 00–05 The M1 Maintenance Interval Operations tables list 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. Maintenance opera- maintenance operations listed in the "Pretrip and tion numbers are reference numbers used to help Post-Trip Inspections and Maintenance"...

  • Page 20: M2 Maintenance Interval Operations

    General Information M2 Maintenance Interval Operations: 00–06 The M2 Maintenance Interval Operations tables list you find detailed instructions in this manual on the all maintenance operations that are to be performed maintenance operations to be performed. Perform all at the M2 maintenance interval. Maintenance opera- M1 maintenance interval operations at the M2 main- tion numbers are reference numbers used to help tenance interval.
  • Page 21 General Information M3 Maintenance Interval Operations: 00–07 The M3 Maintenance Interval Operations table lists you find detailed instructions in this manual on the all maintenance operations that are to be performed maintenance operations to be performed. Perform all at the M3 maintenance interval. Maintenance opera- M1 and M2 maintenance interval operations at the tion numbers are reference numbers used to help M3 maintenance interval.

  • Page 22: Maintenance Operation Sets Table

    General Information Maintenance Operation Sets Table: 00–08 Maintenance Operation Sets Maint. Service Schedules I Operation Description and II 09–01 Air Cleaner Inspection • 13–01 Air Compressor Inspection • • • • 15–01 Alternator, Battery, and Starter Connections Check • • 20–01 Pressure Relief Cap Check •...
  • Page 23 General Information Maintenance Operation Sets Table: 00–08 Maintenance Operation Sets Maint. Service Schedules I Operation Description and II 42–05 Brake Inspection • • • • 42–06 Haldex Slack Adjuster Lubrication • • • • 42–07 Meritor Camshaft Bracket Lubrication • •...

  • Page 24: Noise Emission Controls Maintenance

    Maintenance Instructions sure that such parts are warranted by their manufac- turer to be equivalent to genuine Freightliner parts in performance and durability. Scheduled intervals are in the maintenance tables in this group. A "Verification of Inspections Log" for Freightliner Noise Emission Groups 20 and 49 follows, and should be filled in...

  • Page 25: Verification Of Inspections Log

    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 Item...
  • Page 27 Air Intake Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Inspection ............. . 09–01 New Cascadia Maintenance Manual, January 2017...
  • Page 29 Air Intake 09–01 Air Cleaner Inspection NOTICE Restriction of air flow through the air cleaner element Do not use aftermarket air-cleaner elements. After- is measured at the tap in the air cleaner outlet. market air-cleaner elements may not seal the Check the restriction indicator at the air cleaner or in housing correctly, which can lead to engine dam- the cab if the vehicle is equipped with a dash-...
  • Page 30 Air Intake 06/02/2016 f090530 A. Check this connection. Air Cleaner 2. Resonator 3. Compressor Supply Line Fig. 5, Compressor Supply Line Quick Connect 04/25/2016 f090528 1. Air Cleaner Housing Aft Mounting Bracket 2. Nut 6. Clamp 3. Forward Mounting 7. Intake Duct Isolator 8.
  • Page 31 Air Compressor Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspection ............13–01 Safety Precautions .
  • Page 33 Air Compressor 13–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 35 Alternators and Starters Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Check ......... 15–01 Safety Precautions .
  • Page 37 Alternators and Starters 15–00 Safety Precautions ™ 54 of the New Cascadia Workshop Manual for adjustment, repair, or replacement instructions. Safety Precautions in this section apply to all Clean and tighten the battery ground cable, terminal, and clamps. procedures within this group. Inspect the retainer assembly or battery DANGER hold-downs, and the battery box.
  • Page 39 Engine Cooling/Radiator Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fan Clutch Check (Noise Emission Control) ..........20–03 Pressure Relief Cap Check.
  • Page 41 Engine Cooling/Radiator 20–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 42 Engine Cooling/Radiator install these clamps correctly. The correct instal- WARNING lation torque is as follows: For Breeze Constant-Torque clamps with a 5/16- Do not remove or loosen the surge tank cap until inch tightening screw hex: 55 lbf·in (620 N·cm). the engine and cooling system have completely cooled.
  • Page 43 Engine Cooling/Radiator 11. Place a pan under the coolant filter to catch en- gine coolant. 12. Remove the coolant filter with a strap or chain wrench. Install a new coolant filter and tighten. 13. Fill the cooling system with new coolant. The cooling system is filled when the coolant level reaches the MAX line on the surge tank.
  • Page 44 Engine Cooling/Radiator 2. Inspect the electrical connections and wires to the fan clutch solenoid; see Fig. 6. Secure the connection if loose; replace wires and connectors if damaged. 3. Clean the fan clutch air solenoid valve filter, if equipped, as follows. Unscrew the fan clutch solenoid valve air filter assembly and remove the filter ele- ment;...
  • Page 45 Engine Cooling/Radiator 10/05/2016 f200581 Fig. 8, Checking for Air Leaks (Horton DriveMaster) a leak inside the fan clutch. Any leak must be remedied. 11. Check the fan clutch bearings as follows. 11.1 Turn the fan in both directions and feel for worn hub bearings.
  • Page 47 Clutch Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch Release Bearing Lubrication........... . . 25–01 Fluid Change, Hydraulic Clutch Control.
  • Page 49 Clutch 25–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 50 Clutch age the rubber parts of the system, causing loss of clutch function and the risk of serious personal injury. Hydraulic clutch control fluid is hazardous. It may be a skin irritant and can cause blindness if it gets in your eyes. Always wear safety glasses when handling it or bleeding hydraulic lines.
  • Page 51 Clutch Manual Bleeding tainer. Pressurize the bleeder system to 15 psi (103 kPa). 1. Park the vehicle on a level surface, shut down 3. Remove the reservoir lid (see Fig. 3) and install the engine, and set the parking brake. Chock the the pressure bleed adaptor on the reservoir.
  • Page 53 Transmission Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number ™ Detroit Automated Transmission Fluid Change and Magnetic Plug Cleaning..... . 26–01 ™...

  • Page 55: Detroit Automated Transmission Fluid Change And Magnetic Plug Cleaning

    Transmission 26–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.

  • Page 56: Detroit Automated Transmission Fluid Level Inspection

    Transmission NOTE: In all cases, the correct fluid level is es- chure at http://dtna.info/DT12FluidsManual approved transmission lubricants. tablished by checking at the fill opening. 5. Clean the fill plug and install a new seal on it. 6. Operate the engine for five minutes after filling Install the plug in the side of the gear case, then the transmission, then check the fluid level again.
  • Page 57 Transmission NOTE: For an Eaton Fuller transmission, the Approved Manual Transmission Lubricants optional transmission fluid filter is a remote- Transmission Temp. Lubricant Type mount, spin-on type, and is located between the Model Range Viscosity transmission and the fluid cooler. The filter MobilTrans SHC 50 bracket is attached to the frame rail or some (RN 2952 E-5)

  • Page 58: Replacement

    Transmission Checking at the Fill Plug Eaton Fuller Transmission Lubricant Capacities Transmission Model Refill Capacity: qt (L) 1. Clean the area around the fill plug, and remove it MHP and MXP 14.0 (13.0) from the side of the gear case. Table 2, Eaton Fuller Transmission Lubricant 2.
  • Page 59 Transmission 10/05/2016 f260037a 1. Drain Plug 3. Sight Glass 2. Fill Plug Fig. 5, Air Filter/Regulator Location Fig. 3, Eaton Fuller Transmission With a Sight Glass 02/23/2015 f261461 A. Full B. Low f260052a 10/17/2001 1. Air Regulator 5. Small O-Ring Fig.
  • Page 60 Transmission WARNING Wear safety goggles when using compressed air to clean parts, as permanent harm to eyes could result from flying debris. 4. Clean the filter element by dipping it in alcohol or other cleaning solvent. Blow compressed air through the element (inside to outside) to loosen surface dirt and to dry the element.
  • Page 61 Frame and Frame Components Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fifth Wheel Inspection ............. . 31–01 Fifth Wheel Lubrication.

  • Page 63: Safety Precautions

    Frame and Frame Components 31–00 Safety Precautions 2. Thoroughly steam clean all fifth wheel compo- nents before inspection. Safety Precautions in this section apply to all 3. Check for cracks in the fifth wheel assembly, mounting brackets, and mounting parts. procedures within this group.
  • Page 64 Frame and Frame Components 2. Thoroughly steam clean the fifth wheel. 11. Replace cracked, worn, or damaged parts with new parts. Replace all loose mounting bolts with 3. Check for cracks in the fifth wheel assembly, 5/8–11 SAE grade 8 bolts, grade C locknuts, and mounting brackets, and mounting parts.
  • Page 65 Frame and Frame Components 12/02/2010 f311134 NOTE: 6000 Series shown; 7000 Series fifth wheels use similar parts. 1. Wedge Stop Rod Nut 11. Bolt, Secondary Safety Lock 19. Bumper 2. Flat Washer, 5/8" 12. Flat Washer 20. Timer Spring 3. Wedge Stop Rod Spring 13.
  • Page 66 Frame and Frame Components 09/01/2009 f311101 Fig. 3, Bracket Pin Bolt Locking Tabs nism several times to test. Repeat if necessary. Fig. If the lock is too loose, loosen the jam nut, turn the adjustment bolt counterclockwise one full turn, then reset the jam nut. Lock and unlock the mechanism several times to test.

  • Page 67: Fifth Wheel Lubrication

    Frame and Frame Components WARNING Failure to properly lubricate the fifth wheel could result in a possible disengagement of the trailer from the tractor, which could result in personal injury or property damage. Fontaine 1. Tilt the top plate forward (the front of the fifth wheel is down) and apply grease to each bearing area through the zerk fittings located on each side of the top plate just to the front of the...
  • Page 68 Frame and Frame Components Fig. 6. Open and close the fifth wheel several times to further distribute the grease. Lightly oil other moving parts in the fifth wheel. 12/03/2010 f311136 Use a light oil (such as SAE 10W or 20W motor oil) to lubricate the cam track and pivot.

  • Page 69: Frame Fastener Torque Check

    Frame and Frame Components • deck plates Jost • equalizer brackets Lubricate the kingpin lock using a hand pump grease • exhaust brackets gun through the grease zerk on the skirt of the fifth wheel; see Fig. 5. Apply a light oil to all moving •...
  • Page 71 Suspension Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Safety Precautions ..............32–00 Suspension Inspection .

  • Page 73: Safety Precautions

    ™ of the New Cascadia Workshop Manual. spring assemblies, if cracks or breaks exist in the Freightliner AirLiner Rear two top leaves, a loss of vehicle control could occur. Failure to replace a damaged spring assem- Suspension Check bly could cause an accident resulting in property damage, serious personal injury, or death.
  • Page 74 Suspension exist, replace the damaged parts; see Group 32 of 2. Mark the location of the front and rear tires on ™ the New Cascadia Workshop Manual. the floor. NOTE: The stud bolt that fastens the valve’s Visually check the air spring piston for cracks, chips, and broken areas.
  • Page 75 Suspension Suspensions with Single-Leaf Springs: Mea- sure between the top of the U-bolt pad and the bottom of the axle stop. 4. If the measurement is not within the acceptable range, refer to the New Cascadia ™ Workshop Manual for adjustment instructions. If the dis- tance is within the acceptable range, apply the parking brakes.
  • Page 76 Suspension 02/21/2017 f320961a Suspension Height Measurement Measure Point 02/21/2017 f321046a Target Suspension Height Measurement 2-3/8 inch 2-1/2 inch 2-7/8 inch A = Measure Here Measure Point (60 mm) (64 mm) (73 mm) Target Table 3, Suspension Ride-Height Measurement, 2-3/4 inch 3 inch 3-1/4 inch A = Measure Here...
  • Page 77 Suspension 10/05/2016 f320783 Fig. 3, Tightening Pattern for U-Bolt High Nuts Spring U-Bolt High Nut Torque Values Size Torque: lbf·ft (N·m) 06/29/2016 f321234 5/8–18 180–230 (245–313) Suspension Height Measurement 3/4–16 270–330 (367–449) Measure Point Target 7/8–14 420–500 (571–680) 2-3/4 inch 3 inch 3-1/4 inch 1–14...
  • Page 79 Front Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Check ............33–04 Knuckle Pin Lubrication .
  • Page 81 Front Axle 33–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 82 Front Axle 33–03 Tie Rod Lubrication Detroit and Meritor Axles For any Detroit or Meritor axle that requires lubrica- tion of the tie-rod ends, wipe the grease fittings clean, then pump multipurpose chassis grease, NLGI Grade 1 (6% 12-hydroxy lithium stearate grease) or NLGI Grade 2 (8% 12-hydroxy lithium stearate grease), into the tie-rod ends until all used grease is forced out and fresh grease is seen at the ball stud...
  • Page 83 Front Axle equipment manufacturer. Freightliner dealers must 7. Place the trammel bar at the front of the tires have proof of this calibration history. (see Fig. 6) and adjust the scale end so that the pointers line up with the scribe lines. See Fig.
  • Page 84 Front Axle 33–05 Steer Axle Hub Cap Vent Plug Inspection General Information As a function of their design, hubcap vent plugs will on occasion exhibit signs of hub oil on their exterior surface. Depending on environmental conditions and/or age of the plug, the amount of oil present can vary.
  • Page 85 Front Axle clean before checking the oil. Do not use a pres- sure washer to clean the hub/plug area. The plug has a vent and this can contaminate the oil with water. 1. Park the vehicle on a level surface, shut down the engine and set the parking brakes.
  • Page 87 Rear Axle 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.
  • Page 89 Rear Axle 35–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 90 75W-90 meets this specification. For more product stock or any other convenient steel slug information, see http://bevo.mercedes-benz.com or to short the two magnetic poles and divert https://ddcsn-ddc.freightliner.com/cps/rde/xchg/ddcsn/hs/ the magnetic field. 5931.htm. Detroit rear axles do not require the use of friction modifiers.
  • Page 91 Rear Axle ™ Detroit New Final Drive CAUTION 1. Park the vehicle on a level surface, shut down Be careful when draining the axle oil. It may be the engine, and set the parking brake. Chock the very hot, and could cause personal injury if it con- tires.
  • Page 92 Rear Axle New Final Drive Oil Capacity, New Final Drive Axle Type Oil in Hubs (2) Oil in Axle NFD Model 4 Forward Axle TP 1.8 L NFD Model 4 Rear Rear Axle TP 1.8 L 7.5 L NFD Model 4 Forward Axle SP 1.8 L 14 L NFD Model 4 Rear Rear Axle SP...
  • Page 93 Rear Axle contacts the base; do not overtighten. See Table for recommended lubricants. Meritor Drive Axle Recommended Lubricant Recommended Lubricant SAE Ambient Temperature Meritor Specification Lubricant Type Viscosity Grade –40°F (–40°C) and Up 75W–90 0–76–N Synthetic Gear Oil –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).
  • Page 94 Rear Axle Dana® Spicer® IMPORTANT: The use of friction modifiers is not approved in Dana drive axles. 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 2. Clean the fill plug and the area around it. In the axle housing rear cover, remove the plug from the oil fill hole (or standpipe, if installed in the oil fill hole).
  • Page 95 Rear Axle NOTE: Some Dana Spicer axles have a After the first oil is changed, inspect the drain plug each time for large quantities small tapped and plugged hole near and of metal particles. below the housing oil fill hole. This smaller hole is for a lubricant temperature indicator After cleaning, install the drain plug(s) only, and should not be used as a fill or level...
  • Page 96 Rear Axle IMPORTANT: When the ambient temperature is 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the above 0°F (–18°C), use SAE 10 heavy-duty en- tires. gine oil, API service classification SD (sulfated ash content must not exceed 1.85%).
  • Page 97 Rear Axle of the fill plug, using the lubricant recommended leaks, and correct as needed. Add oil to the level Table of the fill plug, using the lubricant recommended Table IMPORTANT: A lubricant level close enough to 4. Install and tighten the fill plug 35 lbf·ft (47 N·m). be seen or touched is not sufficient.
  • Page 98 Rear Axle IMPORTANT: Always check the axle breather Dana® Spicer® whenever checking the lubricant level. Check the breather more frequently under adverse op- NOTICE erating conditions. Failure to keep the rear axle filled to the proper 6. Check the axle housing breather. Make sure that level with the recommended lubricant can result in it is unclogged and free from corrosion.
  • Page 99 Rear Axle 3. Coat the threads of the fill plug with a small amount of Loctite® 242, or equivalent sealant. Install the fill plug finger-tight in the rear axle shift unit housing. Using a wrench, tighten it an addi- tional 1-1/2 turns. 35/11 New Cascadia Maintenance Manual, February 2019...
  • Page 101 Wheels and Tires Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Tire Check ............... 40–02 Wheel Nut Check.
  • Page 103 Wheels and Tires 40–01 Wheel Nut Check 40–02 Tire Check Tires should be inspected closely during the first IMPORTANT: After a wheel has been installed, 3000 to 10,000 miles (5000 to 16 000 km) for abnor- the wheel nut torque must be rechecked after mal wear.
  • Page 105 Driveline Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspection ..............41–01 Driveline Lubrication.
  • Page 107 Driveline 41–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 108 Driveline 10/06/2016 f410067b NOTE: Not all fasteners are shown. 1. Transmission 6. U-Joint Cross 12. Splined Stub Shaft 2. Transmission Output-Shaft 7. Bearing Cup (for yoke strap) 13. Driveshaft Tube End-Yoke (yoke-strap type) 8. Yoke Strap and Capscrew 14. Tube-Yoke (bearing-cap type) 3.
  • Page 109 Driveline 8. Examine the driveshaft for evidence of missing balance weights, and for buildup of foreign mate- rial. Remove any foreign material. If there is any evidence that balance weights are missing, re- move the driveshaft and have it balanced. 9.
  • Page 110 Driveline 41–02 Driveline Lubrication Slip Joint Spline Lubrication NOTE: Vehicles equipped with Meritor RPL Se- Universal Joint Lubrication ries drivelines do not require periodic lubrication. NOTE: Vehicles equipped with Meritor RPL Se- 1. If equipped with a grease fitting, wipe all old ries drivelines do not require periodic lubrication.
  • Page 111 Brakes Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Brake System Valve Inspection ........... . . 42–01 Air Dryer Inspection .

  • Page 113: Air Brake System Valve Inspection

    Brakes 42–00 Safety Precautions NOTE: The compressor discharge line may still contain residual air pressure, open the line slowly. Safety Precautions in this section apply to all procedures within this group. 3. Identify, tag, and disconnect the three air lines from the end cover.
  • Page 114 Brakes 08/09/95 f421383 1. 5/16 x 4-1/2 Upper Mounting 9. Desiccant Cartridge 18. Purge Valve Bracket Bolt 10. O-Ring 19. 1/4-Inch Tapping Screw 2. Upper Mounting Bracket Strap 11. Safety Valve 20. Purge Valve Housing 3. Lockwasher 12. Lower Mounting Bracket 21.
  • Page 115 Brakes WARNING Do not attempt to disassemble the desiccant car- tridge assembly. Parts for the assembly are not available and the cartridge contains a 150 lb spring that cannot be mechanically caged. Disas- sembly could release the spring, resulting in per- sonal injury.

  • Page 116: Air Dryer Inspection

    Brakes IMPORTANT: Only use the silicone grease sup- 12.3 Fan the service brakes to reduce system air pressure to governor cut-in. Note that plied with Bendix replacement kits. the system once again builds to full pres- 5. Screw the desiccant cartridge onto the body by sure and is followed by a purge at the hand until the seal makes contact with the body.

  • Page 117: Alcohol Evaporator Cleaning And Inspection

    Brakes Group 42 of the vehicle Workshop Manual for 9. Remove the heater/thermostat assembly and mounting instructions. place it in a freezer for about five minutes to cool it below 40°F (5°C). Remove the cold 4. Turn on the ignition switch, but do not start the heater/thermostat assembly and check resis- engine.
  • Page 118 5. If they do not nents. turn, no further work is needed. If they turn, take the vehicle to an authorized Freightliner dealer to CAUTION have all of the caliper bolts on that wheel end replaced. Due to limited caliper bolt access, it Perform the following check in a clear safe area.
  • Page 119 If they turn, take 1. Park the vehicle on a level surface, shut down the vehicle to an authorized Freightliner dealer to the engine, and set the parking brake. Chock the have all of the caliper bolts on that wheel end tires.
  • Page 120 If they turn, take turn, no further work is needed. If they turn, take the vehicle to an authorized Freightliner dealer to the vehicle to an authorized Freightliner dealer to have all of the caliper bolts on that wheel end have all of the caliper bolts on that wheel end replaced.
  • Page 121 Brakes 07/30/2018 f422655 Tighten the fasteners in the order indicated. A. Left Hand, Bottom View B. Right Hand, Bottom View Fig. 8, Meritor Radial Mounted Caliper Tightening Pattern 5. Install the wheel assemblies. For instructions, ponents. Improperly maintaining the vehicle brak- see Group 40 of the New Cascadia Workshop ing system may lead to brake failure, resulting in Manual.
  • Page 122 Brakes 07/30/2018 f422657 Tighten the fasteners in the order indicated. A. Left Hand, Bottom View B. Right Hand, Bottom View Fig. 9, Wabco Maxxus Radial Mounted Caliper Tightening Pattern for improper operation or adjustment of the auto- pair as needed. See Group 42 of the New Cas- matic slack adjuster.
  • Page 123 Brakes Brake Chamber Stroke Specifications Chamber Max Applied Stroke: inch (mm) † Manufacturer Type Size 1-3/8 (35) Standard Stroke 1-3/4 (45) 2 (51) Gunite ‡ 2-1/4 (57) 2 (51) Long Stroke 2-1/2 (64) 1-3/8 (35) Standard Stroke 1-3/4 (44) Haldex 2-1/2-Inch Extended Stroke 2 (51) 3-Inch Extended Stroke...

  • Page 124: Haldex Slack Adjuster Lubrication

    Brakes 42–06 Haldex Slack Adjuster 42–07 Meritor Camshaft Lubrication Bracket Lubrication Automatic slack adjusters that have a grease fitting IMPORTANT: Perform a brake inspection before must be lubricated periodically to ensure proper lubricating the camshaft bracket. brake operation. NOTE: If equipped with an extended- ™...

  • Page 125: Meritor Slack Adjuster Lubrication

    Brakes grease seal replacement instructions. If this seal WARNING is not replaced, the brake linings could become contaminated with grease. The stopping distance Failure to lubricate slack adjusters could lead to of the vehicle will be increased, which could result dragging brakes or a brake failure, resulting in in personal injury or property damage.
  • Page 126 Brakes 2. Remove the roll pin from the brake pedal pivot pin. See Fig. f420012a 10/20/93 1. Brake Chamber 2. Clevis 3. Actuator Rod 4. Boot 5. Pressure-Relief Capscrew, Gasket, Pawl Spring, 11/01/2016 f430405 and Pawl 1. E-6 Foot Control Valve 5.

  • Page 127: Versajust Slack Adjuster Inspection And Lubrication

    Brakes 12. Install a new roll pin and apply Torque Seal (OPG F900 White) to the roll pin. 13. Install the brake valve assembly; see Group 42, of the vehicle Workshop Manual. 14. Test the brakes before returning the vehicle to service.
  • Page 128 Brakes 42–12 Bendix Automatic Drain full released position. Observe the looseness that exists between the clevis and adapter bushing Valve Operating and and the yoke and link pins and their mating parts (clevis, body, link). Replace these parts if loose- Leakage Tests ness appears excessive.
  • Page 129 Steering Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Drag Link Inspection..............46–01 Drag Link Lubrication .
  • Page 131 Steering 46–00 Safety Precautions Cascadia Workshop Manual for replacement in- structions. If there is 1/8-inch (3-mm) movement or more, do not drive the vehicle until the drag Safety Precautions in this section apply to all link is replaced. procedures within this group. 46–02 Power Steering Fluid DANGER and Filter Change...
  • Page 132 Steering needed to maintain the fluid level between the MIN COLD and MAX HOT lines. 16. Shut down the engine. 17. Raise the vehicle, remove the jack stands, and lower the vehicle. 46–03 Power Steering Gear Lubrication NOTICE Apply grease to the sector shaft with a hand-type grease gun only.
  • Page 133 Steering 2. Using a clean rag, wipe all dirt from the drag link grease fittings. See Fig. 3. Using a pressure gun and NLGI Grade 2 (8% 12-hydroxy lithium stearate grease) or NLGI Grade 1 (6% 12-hydroxy lithium stearate grease) chassis grease, apply clean grease at the grease fittings until old grease is forced out of the socket.
  • Page 135 Fuel Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fuel Filter Replacement ............. 47–01 Fuel Tank Band-Nut Tightening.
  • Page 137 Fuel 47–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 138 Fuel 9. Connect the water sensor and heater connectors 4. Remove the vent cap, shown in Fig. 2, to drain if equipped. the fuel completely, then close the drain valve. 10. If equipped with a primer pump, prime the 5. Using a DAVCO Collar Wrench, shown in Fig.
  • Page 139 Fuel FOR REMOVAL OF TOP COLLAR ONLY 02/16/2009 f470277 Fig. 3, DAVCO Collar Wrench 1. Arrow (on the 3. Separator Plate endplate) 4. Key 2. Keyway 5. Endplate Fig. 4, Positioning the Filter Element 10.5 While the engine is running, and after the air is purged from the system, loosen the vent cap until the fuel level falls to just above the collar, then hand-tighten the...
  • Page 140 Fuel 47–03 Fuel Tank Band-Nut Tightening Hold each fuel tank band retention nut with a wrench while backing off its jam nut, then tighten the reten- tion nuts 30 to 35 lbf·ft (41 to 46 N·m). After the re- tention nuts have been tightened, hold each retention nut with a wrench while tightening its jam nut 30 lbf·ft (41 N·m).
  • Page 141 Exhaust Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Exhaust System Inspection (noise emission control) ........49–01 Safety Precautions .
  • Page 143 • Diesel Exhaust Fluid (DEF)—the chemical agent system if the noise level of the vehicle has in- that reacts with the exhaust gases in the SCR creased. Freightliner Trucks recommends replacing to reduce NOx. parts that show leakage, wear, or damage, with •...
  • Page 144 Exhaust Vehicles domiciled outside of the U.S. and Canada 8. Check the SCR catalyst for dents and other may not have aftertreatment equipment, depending damage. upon local statutory emissions guidelines. 9. Check for heat discoloration on the surface of the ATD. Heat discoloration may indicate internal IMPORTANT: The aftertreatment device (ATD), damage;...
  • Page 145 Exhaust 06/28/2016 f490520 NOTE: The sensor box (item 11) contains the SCR outlet NOx and PM sensors, and the Aftertreatment Control Module (ACM). 1. DOC Inlet NOx Sensor 9. Exhaust Outlet 2. DOC Inlet Pressure Sensor 10. DEF Metering Unit 3.
  • Page 146 Exhaust 9 10 06/28/2016 f490521 1. DEF Metering Unit 5. DOC Inlet Pressure Sensor 9. DPF Outlet Temperature 2. SCR Outlet Temperature 6. DPF Inlet Temperature Sensor Sensor Sensor 7. Particulate Matter Sensors 10. DPF Outlet NOx Sensor 3. SCR Inlet Temperature Sensor 8.
  • Page 147 Exhaust 09/16/2009 f490354 1. DPF Inlet Temperature Sensor 6. DPF Outlet Temperature 9. SCR Outlet Temperature 2. DOC Inlet Temperature Sensor Sensor Sensor 3. DOC Inlet Pressure Sensor 7. DPF Outlet NOx Sensor 10. SCR Sensor Box 4. DPF Sensor Box 8.
  • Page 149 Electrical, Instruments, and Controls Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Electrical Component Inspection ............54–02 Trailer Cable Inspection and Cleaning.
  • Page 151 Electrical, Instruments, and Controls 54–01 Trailer Cable Inspection ponents protected area. Missing, leaking, or damaged covers will result in moisture and de- and Cleaning bris entering the component and will result in component failure. When it is determined that a 1.
  • Page 152 Electrical, Instruments, and Controls remove connectors and terminals, scrub and clean as needed using a nylon brush. Clean de- bris with vacuum or electrical contact cleaner such as CRC QD® Electronic Cleaner, inspect terminals and mating contact terminal plating. If the terminal plating exhibits signs of unrecover- able corrosion, the component and terminal will need to be replaced.
  • Page 153 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Aerodynamic Component Inspection ........... . 60–03 Baggage Door and Sleeper Access Door Release Cable and Latch Lubrication .
  • Page 155 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.
  • Page 156 05/07/2012 f602471 NOTE: Baggage door latch shown. Sleeper access door latch is similar. A. Lubricate the latch jaws and the exposed length of cable. 03/31/2016 f720773 Fig. 3, Baggage Door Latch 1. Sleeper Access Door Handle 2. Baggage Door Handle Fig.
  • Page 157 Heater and Air Conditioner Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspection............83–01 Air Filter Replacement .
  • Page 159 Heater and Air Conditioner 83–00 Safety Precautions clearance specifications. See Fig. 1 for the checking method. If the drive plate clutch re- quires adjustment, see Group 83 of the New Safety Precautions in this section apply to all ™ Cascadia Workshop Manual.
  • Page 160 Heater and Air Conditioner Cab Fresh-Air Filter Replacement IMPORTANT: When replacing the air filter, use only a Freightliner-approved air filter. 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
  • Page 161 IMPORTANT: When replacing the air filter, use Fig. 6, Sleeper HVAC Access Panel, 48-inch Sleeper only a Freightliner-approved air filter. 3. Lift the filter out of the slot. See Fig. 7 for 60- 1. Park the vehicle on a level surface, set the park- and 72-inch sleepers, or Fig.
  • Page 162 IMPORTANT: When replacing the air filter, use only a Freightliner-approved air filter. 1. Park the vehicle on a level surface, set the park- ing brake, and shut down the engine. Chock the tires.
  • Page 163 Heater and Air Conditioner 83–03 Battery-Powered HVAC 3. Check the drain tube(s) for debris, and clean as needed. System (BPHS) 4. Install the drain tube(s). Inspection 5. Install any components that were removed for access. Fuel-Operated Heater Check External A/C Condenser 1.
  • Page 164 Heater and Air Conditioner Remove the condenser cover. Fig. 12, Condenser Cover Fasteners (compact style condenser) 83/6 New Cascadia Maintenance Manual, November 2019...

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