freightliner Run Smart ECASCADIA PE116DC 2022 Maintenance Manual
  1. Manuals
  2. Brands
  3. freightliner Manuals
  4. Trucks
  5. Run Smart ECASCADIA PE116DC 2022
  6. Maintenance manual
freightliner Run Smart ECASCADIA PE116DC 2022 Maintenance Manual

freightliner Run Smart ECASCADIA PE116DC 2022 Maintenance Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
ECASCADIA MAINTENANCE MANUAL
Models: PE116DC
STI-511-1 (11/01/2022)
Published by
Daimler Truck North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Run Smart ECASCADIA PE116DC 2022 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for freightliner Run Smart ECASCADIA PE116DC 2022

Summary of Contents for freightliner Run Smart ECASCADIA PE116DC 2022

  • Page 1 ECASCADIA MAINTENANCE MANUAL Models: PE116DC STI-511-1 (11/01/2022) Published by Daimler Truck North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
  • Page 3 IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Freightliner Trucks reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation. Descriptions and specifications contained in this publication provide no warranty, expressed or implied, and are subject to revision and editions without notice.
  • Page 4 © 2016–2023 Daimler Truck 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 Truck North America LLC.
  • Page 5 Introduction Descriptions of Service Publications Daimler Truck North America LLC distributes the following major service publications in paper and electronic formats. Refer to www.DTNAPortal.com. Workshop/Service Workshop/service manuals contain service and repair information for all vehicle Manual systems and components, except for major components such as motors, transmissions, 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 accessed from within PartsPro. Warranty-related service information available on the www.DTNAPortal.com...
  • 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 13 ......Air Compressor 20 .

  • 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

    General Information Determining Scheduled Maintenance Intervals: 00–01 Determining Scheduled Maintenance 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.
  • 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) Maintenance 2 (M2) every 50,000 80 000 vehicles that annually travel less than 60,000 miles (100 000 km) Maintenance 3 (M3)
  • 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, M2, and M3 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 M4 750,000...

  • Page 16: Initial Maintenance (Im) Operations

    General Information Initial Maintenance (IM) Operations: 00–04 The Initial Maintenance table lists all maintenance maintenance operations to be performed. All operations that are to be performed at the initial operations listed in the table, along with the maintenance (IM) interval. Maintenance operation operations listed in the applicable M1 maintenance numbers are reference numbers used to help you interval table, must be performed to complete the...

  • Page 17: 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 maintenance operations listed in the ’Pretrip and operation numbers are reference numbers used to Post-Trip Inspections and Maintenance’...

  • Page 18: M2 Maintenance Interval Operations

    General Information M2 Maintenance Interval Operations: 00–06 The M2 Maintenance Interval Operations tables list help you find detailed instructions in this manual on all maintenance operations that are to be performed the maintenance operations to be performed. at the M2 maintenance interval. Maintenance Perform all M1 maintenance interval operations at operation numbers are reference numbers used to the M2 maintenance interval.

  • Page 19: M3 Maintenance Interval Operations

    General Information M3 Maintenance Interval Operations: 00–07 The M3 Maintenance Interval Operations table lists help you find detailed instructions in this manual on all maintenance operations that are to be performed the maintenance operations to be performed. at the M3 maintenance interval. Maintenance Perform all M1 and M2 maintenance interval operation numbers are reference numbers used to operations at the M3 maintenance interval.

  • Page 20: M4 Maintenance Interval Operations

    General Information M4 Maintenance Interval Operations: 00–08 The M4 Maintenance Interval Operations table lists help you find detailed instructions in this manual on all maintenance operations that are to be performed the maintenance operations to be performed. at the M4 maintenance interval. Maintenance Perform all M1 and M2 maintenance interval operation numbers are reference numbers used to operations at the M4 maintenance interval.

  • Page 21: Maintenance Operation Sets Table

    General Information Maintenance Operation Sets Table: 00–09 Maintenance Operation Sets Maint. Operation Description Service Schedule I 08–01 High Voltage Electrical Component Inspection • • • 08–02 High Voltage Wiring Check • • • 08–03 Cable Gland Protection Inspection • • •...
  • Page 22 General Information Maintenance Operation Sets Table: 00–09 Maintenance Operation Sets Maint. Operation Description Service Schedule I 60–02 Cab Shock Absorber Bracket Torque Check • • • • • 60–03 Aerodynamic Component Inspection • • • • • 83–01 Air Conditioner Inspection •...

  • Page 23: Noise Emission Controls Maintenance

    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.
  • Page 25 Electric Drive Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Cable Gland Protection Inspection ........... . . 08–03 High Voltage Electrical Component Inspection.
  • Page 27 Electric Drive 08–00 Safety Precautions 4. Inspect the component protective cover for proper fit and function. Inspect the cover for cracks, broken mounting, missing sealing Safety Precautions in this section apply to all surfaces, and warped or bulged surfaces. The procedures within this group.
  • Page 28 Electric Drive inverter housing located in multple areas Daimler Safety Training. Failure to do so could cause severe personal injury or death. throughout the vehicle. 1. Park the vehicle on a level surface, shut down 1. Inspect all cable glands to make sure corrosion the vehicle, and apply the parking brake.
  • Page 29 Electric Drive 09/15/2022 f080439 1. Frontbox 4. Inverters 6. Charge Ports 2. Charging Fuse 5. eAxles 7. DC Boxes 3. High Voltage Batteries Fig. 1, HV Cable Routing 08/3 eCascadia Maintenance Manual, 10/03/2022...
  • Page 30 Electric Drive 09/12/2022 f080440 1. DC/DC Converter 4. Positive Temperature 5. eRC 2. Air Compressor Coefficient Heating Element 3. Auxiliary PDU Fig. 2, HV Frontbox Cable Routing 06/22/2022 f080427 Fig. 3, Cable Gland Protection 08/4 eCascadia Maintenance Manual, 10/03/2022...
  • Page 31 Air Compressor Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspection ............13–01 Air Compressor Oil and Filter Change.
  • Page 33 Air Compressor 13–00 Safety Precautions 6. Drain the air compressor oil using one of the following methods. • Place a drain pan under the air Safety Precautions in this section apply to all compressor and remove the drain plug. procedures within this group. •...
  • Page 35 Engine Cooling/Radiator Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Radiator Pressure-Flushing and Coolant Change......... . . 20–02 Safety Precautions .
  • Page 37 Engine Cooling/Radiator 20–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER Electric vehicles are equipped with a high-voltage system. Do not attempt any type of electrical work on the vehicle unless you have completed HV3 Daimler Safety Training.
  • Page 38 Engine Cooling/Radiator may need to be adjusted for individual 7. Shut off the air at the pressure gun nozzle and allow the radiator to refill with water. applications. 8. Repeat the previous two steps until clean water 11. Refill the radiator with coolant. flows from the radiator.
  • Page 39 Frame and Frame Components Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fifth Wheel Inspection ............. . 31–01 Fifth Wheel Lubrication.

  • Page 41: Fifth Wheel Inspection

    Frame and Frame Components 31–00 Safety Precautions and nuts as needed. Replace missing or damaged bolts. Safety Precautions in this section apply to all 5. Inspect the fifth wheel for bent, worn, damaged, and missing parts; replace them as needed with procedures within this group.
  • Page 42 Frame and Frame Components 4. Ensure that both bracket pins are in place and 12. After inspecting the fifth wheel, lubricate all secured by retainer pins and cotter pins. See moving parts with a chassis or multipurpose Fig. grease. Apply a generous coating of grease to the top plate to fill the grooves, or depressions, 5.
  • Page 43 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 44 Frame and Frame Components 09/01/2009 f311101 Fig. 3, Bracket Pin Bolt Locking Tabs mechanism several times to test. Repeat if necessary. See Fig. 9. If the fifth wheel is equipped with a sliding mechanism, inspect and adjust it as follows. Check the bracket for any cracks or missing and damaged parts.

  • Page 45: Fifth Wheel Lubrication

    Frame and Frame Components 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 bracket pins.
  • Page 46 Frame and Frame Components 12/03/2010 f311136 Use a light oil (such as SAE 10W or 20W motor oil) to 1. Pull Handle 3. Wedge lubricate the cam track and pivot. 2. Jaw 1. Cam Plate Fig. 6, Fontaine Fifth Wheel Fig.

  • Page 47: Frame Fastener Torque Check

    Frame and Frame Components • front suspension spring brackets NOTICE • high-voltage battery mounts Do not use a power grease gun. The pressure will • impact structure damage the lube line. • radius rods If the fifth wheel is not equipped with low-lube plates, •...
  • Page 49 Suspension Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Safety Precautions ..............32–00 Suspension Inspection .

  • Page 51: Safety Precautions

    Workshop Manual. two top leaves, a loss of vehicle control could Freightliner AirLiner Rear occur. Failure to replace a damaged spring assembly could cause an accident resulting in...
  • Page 52 Suspension tightening the nuts without holding the studs can WARNING back the studs out, causing a separation of the two halves of the valve body, and possibly a leak. Replace worn, cracked, or damaged spring 1. Park the vehicle on a level surface, using a light brackets.
  • Page 53 Suspension 02/21/2017 f320961a Suspension Height Measurement Measure Point Target 2-3/8 inch 2-5/8 inch 2-7/8 inch A = Measure Here (60 mm) (67 mm) (73 mm) Table 1, Suspension Ride-Height Measurement, 10/05/2016 f320562a Single-Leaf Spring, 21k/40k, High Ride 1. Valve Mounting Bracket 2.
  • Page 54 Suspension ™ Group 32 of the eCascadia Workshop Manual for bolt replacement procedures. 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) 5/8–18 180–230 (245–313) 3/4–16 270–330 (367–449) 7/8–14 420–500 (571–680) 1–14 520–600 (707–816)
  • Page 55 Front Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Check ............33–04 Knuckle Pin Lubrication .
  • Page 57 Front Axle 33–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER Electric vehicles are equipped with a high-voltage system. Do not attempt any type of electrical work on the vehicle unless you have completed HV3 Daimler Safety Training.
  • Page 58 Freightliner dealers must have proof of this calibration history. 1. Apply the parking brakes and chock the rear tires.
  • Page 59 Front Axle 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. NOTE: If turn-plates or turntables are not available, lower the vehicle.
  • Page 60 Front Axle due to pressure increase within the hub cavity. For an example of normal vent plug appearance, see Fig. 09/01/2016 f330299 09/01/2016 f330298 Fig. 9, Excessive Leakage Fig. 8, Normal Oil Venting A vent plug can wear or be damaged and cause excessive leakage, or allow water to enter the hub and contaminate the oil.
  • Page 61 Front Axle 4. Remove the vent plug and check the oil for evidence of water contamination. If there is evidence of water contaminated oil in the hub, disassemble the effected axle end, clean, inspect, and reassemble the axle end. For instructions, refer to Group 33 of the eCascadia...
  • Page 63 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 65 Rear Axle 35–00 Safety Precautions temperature, the oil will run more freely and ensure that the axle is flushed. Safety Precautions in this section apply to all 4. Clean the fill and drain plugs. Change them if necessary. procedures within this group. For magnetic plugs, use a piece of key DANGER stock or any other convenient steel slug...
  • Page 66 Rear Axle 09/16/2022 f350828 A. Top View B. Rear View 1. eCarrier Breather Hose 3. Axle Housing Fill Plug 5. Temperature Sensor Port 2. Axle Housing Breather Hose 4. eCarrier Breather Fig. 1, Detroit eAxle Tandem Axle (forward axle shown) Detroit Rear Axle Lubricant Capacity, eAxle (Hubs Full) Oil Capacity:...
  • Page 67 Rear Axle All Axle Models 35–03 eCarrier Oil Filter and Fluid Change Detroit® eAxle 1. Park the vehicle on a level surface, shut down NOTICE the vehicle, and set the parking brakes. Chock the tires. Failure to keep the rear axle filled to the proper 2.
  • Page 68 Rear Axle eCarrier Lubricant Capacity Oil Capacity: Axle Quarts (liters) Front-Rear and Single 6.7 (7.1) Rearmost Tandem 10.4 (11.0) Table 2, eCarrier Lubricant Capacity 09/ 8/20 f350826 Fig. 4, Oil Mesh Filter 09/ 8/20 f350827 Fig. 5, eCarrier Fluid Fill Plug IMPORTANT: The lubricant used in eCarrier (eMotor) must meet Detroit Fluids Specification (DFS) 93K230.
  • Page 69 Wheels and Tires Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Tire Check ............... 40–02 Wheel Nut Check.
  • Page 71 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 the wheel nut torque must be rechecked after abnormal wear.
  • Page 73 Brakes Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Brake System Valve Inspection ........... . . 42–01 Bendix E-6 Foot Control Valve Inspection and Lubrication .
  • Page 75 If they turn, take IMPORTANT: This procedure should be the vehicle to an authorized Freightliner dealer to have all of the caliper bolts on that wheel end performed prior to lubrication of the brake replaced.
  • Page 76 Brakes 03/26/2020 f422665 Fig. 1, Axial Bolt Tightening Pattern 09/28/2018 f580518 Fig. 2, DDC DSNCHA018005 30mm Air Disc Brake Caliper Brake Bolt Torque Adaptor 42/2 eCascadia Maintenance Manual, 10/03/2022...
  • Page 77 Brakes Torque Check with 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005 Extension Angle Target Torque Tool Setting Angle View (degrees) [lbf·ft (N·m)] [lbf·ft (N·m)] 0° 296 (401) 11/28/2016 f422613 310 (420) 45° 11/28/2016 f422614 320 (434) 60° 11/06/2018 f422668 350 (475)
  • Page 78 Brakes 14. Test the brakes before returning the vehicle to service. 42–04 EAPU (Electronic Air Processing Unit) Air Dryer Desiccant Cartridge Replacement NOTE: The following instructions apply to the 1200, 1200 Plus, and Twin air dryers. NOTICE The EAPU air dryers can use either a standard or oil coalescing desiccant cartridge.
  • Page 79 Brakes 10/07/2016 f421292 1. Seal 3. Air Dryer Base 2. O-Ring Fig. 4, Desiccant Cartridge Replacement 42/5 eCascadia Maintenance Manual, 10/03/2022...
  • Page 81 Steering Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Drag Link Inspection..............46–01 Drag Link Lubrication .
  • Page 83 Steering 46–00 Safety Precautions 4. 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 if Safety Precautions in this section apply to all needed.
  • Page 84 Steering • For filter caps with a separate retaining ring, hand-tighten the filter, then turn it an additional 1/4 turn. • For one-piece filter caps, the filter is not threaded. 13. With the vehicle off, turn the steering wheel from full left to full right three times.
  • Page 85 Steering 09/28/2021 f462459 1. Sector Shaft Grease Fitting Fig. 2, Steering Gear Lubrication fittings until old grease is forced out of the socket. 10/07/2016 f461072 1. Grease Fitting at Pitman Arm 2. Grease Fitting at Axle Steering Arm Fig. 3, Drag Link 46/3 eCascadia Maintenance Manual, March 2022...
  • Page 87 Electrical, Instruments, and Controls Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Electrical Component Inspection ............54–02 Gas Detection System Sensor Testing.
  • Page 89 Electrical, Instruments, and Controls 54–01 Trailer Cable Inspection prevent moisture and debris from entering the components protected area. Missing, leaking, or and Cleaning damaged covers will result in moisture and debris entering the component and will result in 1. Inspect the cables for cuts, abrasion, or other component failure.
  • Page 90 Electrical, Instruments, and Controls discoloration, high amperage heating or gas detection systems should be tested three times discoloring. If needed, remove connectors and per year at equal intervals. The testing procedure terminals, scrub and clean as needed using a should simulate the same operating environment in nylon brush.
  • Page 91 Electrical, Instruments, and Controls Control Module Functions Item Display Function Action Required Illuminated System is on. None required. Ensure the batteries are connected and replace any Green Power Light Detection system is Unlit blown fuses. If the gas detection system is still not not functioning.
  • Page 93 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Aerodynamic Component Inspection ........... . 60–03 Cab Shock Absorber Bracket Torque Check .
  • Page 95 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 97 Heater and Air Conditioner Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspection............83–01 Air Filter Replacement .
  • Page 99 When working on the vehicle, shut down the IMPORTANT: When replacing the air filter, use engine or motor, set the parking brake, and chock only a Freightliner-approved air filter. the tires. Before working on the vehicles, always place jack stands under the frame rails to ensure 1.
  • Page 100 Heater and Air Conditioner 04/13/2016 f090526 01/23/2019 f090524 1. Airflow Directional Arrow Orientation 1. Self Tapping Screw Fig. 2, Airflow Directional Arrow Fig. 1, Intake Filter Access Panel 2. Remove the dash front right-hand access panel. 3. Remove the filter. 4.

Table of Contents