Home

CASCADIA MAINTENANCE MANUAL Models

1. Maintenance Operation Sets EE Operation Description decer E i IM M1 M2 M3 09 01 Air Cleaner Element Inspection and Replacement 13 01 Bendix Air Compressor Inspection 15 01 Alternator Battery and Starter Check 20 01 Pressure Relief Cap Check 20 02 Radiator Pressure Flushing and Coolant Change 20 03 Fan Clutch Check noise emission control 25 01 Eaton Fuller Clutch Release Bearing Lubrication 26 01 Manual Transmission Fluid Change and Magnetic Plug Cleaning Synthetic Lubricant 26 02 Transmission Fluid Level Inspection 26 03 Manual Transmission Air Filter Regulator Check Cleaning or Replacement 31 01 Fifth Wheel Inspection 31 02 Fifth Wheel Lubrication 31 03 Frame Fastener Torque Check 31 04 Fairing Bumper Wear Check 32 01 Suspension Inspection 32 02 Suspension U Bolt Torque Check 33 01 Knuckle Pin Lubrication Meritor Axles 33 02 Tie Rod Inspection 33 03 Tie Rod Lubrication Meritor Axles 33 04 All Axle Alignment Check 33 05 Knuckle Pin Lubrication Dana Spicer Axles 33 06 Tie Rod Lubrication Dana Spicer Axles e 35 01 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning synthetic lubricant 35 02 Axle Breather and Axle Lubricant Level Inspection 40 01 Wheel Nut Check 41 01 Driveline Inspecti
2. Table 6 M2 Maintenance Interval Operations for Service Schedules and II 00 10 Cascadia Maintenance Manual August 2010 General Information 00 M3 Maintenance Interval Operations 00 07 The M3 Maintenance Interval Operations table lists you fin 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 o Pen jedi rd idi M3 Maintenance Interval Operations for Service Schedules and II Check 00 05 Perform All M1 Operations 00 06 Perform All M2 Operations 09 01 Air Cleaner Element Inspection and Replacement 20 02 Radiator Pressure Flushing and Coolant Change 26 01 Manual Transmission Fluid Change and Magnetic Plug Cleaning synthetic lubricant 35 01 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning synthetic lubricant 42 02 Bendix Air Dryer Desiccant Replacement 42 09 Bendix E 6 Foot Control Valve Inspection and Lubrication 46 02 Power Steering Fluid and Filter Change Table 7 M3 Maintenance Interval Operations for Service Schedules and II Cascadia Maintenance Manual August 2010 00 11 00 General Information Maintenance Operation Sets Table 00 08
3. 18 Speed Autoshift AS2 all Quantities listed are approximate Fill transmission until lubricant is level with bottom of fll hole with vehicle in normal operating position Table 2 Eaton Fuller Transmission Lubricant Capacities Transmission NOTE In all cases the correct flui level is es tablished by checking at the fil opening 6 Operate the engine for fiv minutes after fillin the transmission then check the flui level again 7 Clean the fil plug then install it in the transmis sion Tighten the plug as follows e 25 to 35 Ibf ft 34 to 48 N m for plugs with 3 4 inch pipe threads e 60 to 75 Ibf ft 81 to 102 N m for plugs with 1 1 4 inch pipe threads 8 Operate the vehicle to check for correct opera tion 26 02 Transmission Fluid Level Inspection CAUTION Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion Overfilling will force fluid out of the case through the main shaft openings Do not mix types and brands of fluid because of possible incompatibility Do not use fluid addi 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 flui level in the transmission 1 Clean the area around the fil plug and remove it from the side of the gear case 2 Using yo
4. Maintenance Instructions Scheduled intervals are in the maintenance tables in this group A Verificatio of Inspections Log for Groups 20 and 49 follows and should be fille in each time noise emission controls on the vehicle are maintained or repaired 00 14 Cascadia Maintenance Manual August 2010 General Information Verification of Inspections Log Verification of Inspections Log Group 20 00 Verification of Inspections Log 00 10 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 Cost Maintenance Facility Cascadia Maintenance Manual August 2010 00 15 Air Intake 09 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Cleaner Element Inspection and Replacement ie EE cece eee 09 01 Cascadia Maintenance Manual August 2009 Air Intake 09 01 Air Cleaner Element Inspection and Replacement 09 Restriction of air flo through the air cleaner element is measured at the tap in the air cleaner outlet Check the restriction indicator at the air cleaner or in the cab if the vehicle is equipped with a dash mounted restri
5. To maintain proper fift wheel operation always lubri cate the fift wheel after an inspection has been performed 31 4 Cascadia Maintenance Manual August 2007 Frame and Frame Components IMPORTANT Lubricate the fift wheel e After power washing or steam cleaning e f the vehicle operates in harsh conditions such as salt spray from road surfaces or in ex tremely dusty environments e After any service that requires removal of lubri cant from the fift wheel head or components WARNING Failure to properly lubricate the fifth wheel could result in a possible disengagement of the trailer from the tractor which could result in personal injury or property damage Fontaine Use a multipurpose extreme pressure EP chassis grease to lubricate all moving parts on the fift wheel When lubricating the top plate at the grease fitting for the bracket bearing area tilt the top plate forward and backward to evenly distribute the grease Using a pry tool separate the jaw and wedge and lubricate the serrations using a brush to distribute the grease On slide mount applications lubricate the slide rail and tapered wedges for smooth operation Once the moving parts of the fift wheel are lubri cated apply a liberal coating of grease to the top plate and the trailer kingpin plate Holland Lubricate all moving parts with a multipurpose chas sis grease Lubricate the two grease fitting located on either side of the
6. ing brake and shut down the engine Chock the tires 2 Remove the sleeper HVAC access panel on the inboard side of the cabinet See Fig 8 The panel is held in place with four spring clips Pull straight out to remove it 3 Pull the filte out of the slot See Fig 10 ON e EE 05 27 2010 831858 1 Filter Fig 10 Removing the Filter 4 Install a new filte making sure that it is com pletely seated 5 Install the access panel 83 4 Cascadia Maintenance Manual August 2010 Heater and Air Conditioner 83 03 ParkSmart Drain Tube Inspection NOTICE The ParkSmart drain tube must be kept clear of debris Failure to do so will cause excessive water build up in the base of the unit and may cause damage to the control unit 1 Remove the battery cover step or forward side fairing as needed to improve access to the un derside of the ParkSmart unit 2 Remove the drain tube from the bottom of the unit See Fig 11 09 21 2010 1831857 Remove and clean the drain tube as needed 1 Drain Tube 2 Intake Duct Fig 11 Drain Tube Inspection 3 Check the drain tube for debris and clean as needed Install the drain tube 5 Install any components that were removed for access 83 Cascadia Maintenance Manual August 2010 83 5 Hood Grille and Cab Fenders 88 Index Alphabetical Title of Maintenance
7. 11 Inspect the condition of the O ring seals If they are cracked crimped or otherwise damaged replace them to ensure an airtight seal Clean the O ring grooves of any dirt or obstruction 12 Lubricate the O rings with silicone or lithium grease and install them in the end cover 13 Install the desiccant cartridge on the end cover Turn the cartridge clockwise until the desiccant cartridge makes contact with the end cover 14 Place the desiccant cartridge in a vise and turn the end cover clockwise an additional 180 to 225 degrees to fully tighten the desiccant cartridge to the end cover NOTE Desiccant cartridge torque should not exceed 50 Ibf ft 68 N m 15 Place the housing over the desiccant cartridge and align the mounting holes with the end cover IMPORTANT Replace do not reuse the Nylok nuts on the air dryer cover Cascadia Maintenance Manual January 2010 42 1 42 Brakes 08 09 95 1421383 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 Heater and Thermostat 4 5 16 Inch Nylok Nut 13 3 8 Inch Bolt long Housing 5 Upper Mounting Bracket 14 Check Valve Assembly 22 Return Spring 6 Housing 15 Purge Valve Assembly 23 Purge Piston 7 Nylok Nut 16 Purge Valve Capscrew
8. All fiel service campaigns are distributed to dealers cus tomers receive notices that apply to their vehicles Cascadia Maintenance Manual May 2010 Page Description For an example of a Maintenance Manual page see Fig 1 Introduction A Driveline 41 01 Driveline Inspection 1 Park the vehicle on a level surface apply the parking brakes and chock the tires A CAUTION Due to the extreme load occurring at high speed rotation a loose or broken capscrew at any point in the driveline will weaken the driveline connec tion which could eventually result in serious ve hicle damage Tighten bearing cap capscrews or yoke strap capscrews to specif ed torque being careful to not overtighten 2 For U jointswith bearing caps tighten bearing cap capscrews 43 Ibf ft 49 N m See Fig 1 For Arvin Meritor RPL series U joints tighten bearing capcapscrews 125 Ibf ft 169 N m See Fig 2 For U jointswith yoke straps tighten yoke strap capscrews 125 Ibf ft 169 N m See Fig 3 12 09 97 1410182 04 13 98 14101558 1 Self Locking 2 Adhesive Band Capscrew Fig 1 Arvin Meritor U JointFasteners for Bearing Caps 3 Check the driveline yokes for cracks and check end yokes for looseness See Fig 3 Replace cracked yokes Fig 2 Arvin Meritor RPL Series U Joint If any end yoke can be moved in or out on its shaft or can be rocked on its shaft discon
9. M2 Maintenance Interval Operations c so ecca aaa se Ee ER ee a ee 00 06 M3 Maintenance Interval Operations ooooocccocoo rn 00 07 Maintenance Operation Sets Table 0 6 ce n 00 08 Noise Emission Controls Maintenance 3 22 sched rra Gold a aa eee aes wee 00 09 Service schedule Table i a apte ees be AA de Re iE Ed dins RS 00 02 Vehicle Maintenance Schedule Table lille nh 00 03 Verni atio Of Inspections LOG can s ox uoce 9 SALE LE DOREM eee ER ED EE m RIEN dE 00 10 Cascadia Maintenance Manual August 2010 General Information 00 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 mainte nance program can result in inefficient operation and unscheduled down time To determine the correct maintenance intervals for your vehicle you must firs determine the type of ser vice or conditions the vehicle will be operating in Generally over the road vehicles operate under con ditions that fall within one of the two types of service described Before placing your new vehicle in ser vice determine the type of service Service Schedule or Il that applies to the intended use of the vehicle After determining the vehicle s type of service refer to the service
10. nator and starter are clean Clean and tighten all charging system electrical connections including the connections at the starter B terminal and ground terminal and where the alternator charg ing cable terminates 3 Inspect the battery cables for wear and replace them if they are damaged Clean the cable con nector terminals with a wire brush See Group 54 of the Cascadia Workshop Manual for ad justment repair or replacement instructions 3 1 Clean and tighten the battery ground cable terminal and clamps 3 2 Inspect the retainer assembly or battery hold downs and the battery box Replace worn or damaged parts Remove any cor rosion with a wire brush and wash with a weak solution of baking soda and water Flush with clean water and dry Paint the retainer assembly if needed to prevent rusting 3 3 Check that foreign objects such as stones bolts and nuts are removed from the battery box 15 3 4 After cleaning connect the cables to the batteries and tighten them to the torque specification listed on the battery gener ally 10 to 15 Ibf ft 14 to 20 N m 3 5 Coat the battery terminals with dielectric grease Check the alternator wiring for missing insulation kinks and heat damage Replace or repair as needed Check the terminals on the battery shut off switch and the magnetic switch Make sure the terminal connections are clean and tight Coat the terminal connections with dielectric red ena
11. t t 411 06 11 2007 Group Title Group Number Vehicle Name Release Date m mmoomg D E Group Number Page Number F Maintenance Operation Number consists of the Group Number followed by the Sequence Number f020166 Fig 1 Example of a Maintenance Manual Page Cascadia Maintenance Manual May 2010 Introduction Maintenance Manual Contents Group No Group Title A REEDE RA oe General Information D PTT RT Air Intake ee LE OE EE Air Compressor AE EE IRON TE Alternators and Starters Aa E ae Engine Cooling Radiator EE ar is alo te Clutch AE tae daa Transmission OF RE EO EE Frame and Frame Components de EE EES Suspension BA EER WERKERS EE bi it ER EA d d Front Axle dO Eos a a o SI HEAD E Rear Axle O EE Gee bi Ge Ee N Wheels and Tires T ART EE EE HE OE DES Driveline ESRA EDE EEU DEER DEE EE IN Brakes EER e aa Odo Steering MEET a die aa asa Fuel io ecc ARA Exhaust OU c surgat uid ae Electrical Instruments and Controls D uuu erue ON Cab BE OR NES Heater and Air Conditioner 88 soos eae ee Hood Grille and Cab Fenders 1 4 Cascadia Maintenance Manual May 2010 General Information 00 Index Alphabetical Title of Maintenance Operation MOP MOP Number Determining Scheduled Maintenance Intervals lilii 00 01 Initial Maintenance IM Operations ss dees EE RE xe RO ACE REEKSE BE ORE DER cR mE WE ales Re 00 04 M1 Maintenance Interval Operati0NS oooooccoccoo hrs 00 05
12. 83 1 Heater and Air Conditioner 05 15 2007 y f X 04 10 2007 1831716 Fig 3 Disengaging the Lock 5 Remove the filte from the tray Note the airflo directional arrow on the filte edge When prop erly installed the airflo arrow will point in the same direction as the marking on the front edge of the tray Both will point toward the cab See Fig 4 6 Puta new filte in the tray making sure the air flo arrow is correctly oriented and install the tray in the slot in the plenum Make sure the tray locks into position 7 Install the intake screen 8 Return the hood to the operating position A gt do D 7 A ae Eb pi 04 10 2007 f831717 1 Fo OES SOLOSZT sade j d aac SETHY 19008 Q XATUN Airflo Directional Arrow Orientation Fig 4 Airflow Directional Arrow Cab Recirculation Air Filter Replacement The recirculation air filte is located on the back side of the evaporator housing in the corner of the frontwall and the right side of the cab See Fig 5 It is accessed from the underside of the unit It is a coarse sponge or fibe filte IMPORTANT When replacing the air filte use only a Freightliner approved air filte NOTE Filter replacement is done blind 1 Park the vehicle on a level surface set th
13. Capacity Quarts liters Lubricant Type Axle Hubs Hubs Full Dry 80W 90 Gear Oil Forward 14 3 15 9 79W90 Synthetic Tandem 13 5 15 0 Gear Oil 80W 90 Gear Oil a Single amp Rear 10 6 12 2 73190 Synthetic Tandem 10 0 11 5 Gear Oil Table 3 Freightliner Rear Axle Approved Lubricant Type and Capacity NOTE Some Freightliner axles have a small tapped and plugged hole near and below the housing oil fil hole This smaller hole is for a lubricant temperature indicator only and should not be used as a fil or level hole 5 1 Fill the axle through the oil fil hole Lubri cant should be level with the bottom of the oil fil hole To check flui level see Fig 2 5 2 Install and tighten the fil plug 41 Ibf ft B5 N m Dana Spicer IMPORTANT The use of friction modifier is not approved in Dana drive axles 1 Park the vehicle on a level surface set the park ing brakes and chock the tires 2 Clean the fil plug and the area around it In the axle housing rear cover remove the plug from the oil fil hole or standpipe if installed in the oil fil hole See Fig 3 3 Place a drain pan under the rear axle drain plug See Fig 3 Drain the oil at normal operating temperature 150 to 200 F 65 to 93 C At this Cascadia Maintenance Manual August 2007 35 3 39 Rear Axle 05 27 93 1 Oil Fill Plug f350018a 2 Oil Drain Plug Fig 3 Axle Housing Drain and Fil
14. Check the steering I Shaft U joints for evidence of looseness or binding If any is found replace the I Shaft 3 Check the steering I Shaft slip joint for evidence of lateral movement looseness or binding If any is found replace the I Shaft 4 Jack up one axle end at a time and move the tire in and out by hand to check the tie rod ends for free play No free play is allowed If the outer tie rod ends are damaged or worn replace them 46 For repair procedures see Group 46 of the Cas cadia Workshop Manual 5 Check the rack and pinion gear mounting bolts for security 6 Check that the outer tie rod castellated nuts are tight and the cotter pins are properly installed IMPORTANT Do not remove the rack and pin ion bellows unless they are damaged and must be replaced or there is evidence of a loose inner tie rod or there is hydraulic flui leaking from the bellows 7 Check the rack tie rod bellows for holes or tears If any are found remove the bellows and check the rack for evidence of corrosion No corrosion is allowed If corrosion is found replace the rack and pinion unit If there is no corrosion replace the damaged bellows with a new one 8 Check the rack and pinion tie rod bellows for evi dence of leakage from the bellows If hydraulic flui is found to be leaking from within the bel lows replace the rack and pinion unit 9 Check the input shaft for any leakage around the on center cap If there
15. Clutch Inspection Plate NOTE For lubrication of the release bearing Eaton Fuller recommends a lithium base high temperature grease that meets the NLGI Grade 1 or 2 specification 3 Locate the grease fittin at the 9 o clock position on the left side of the bellhousing and wipe any dirt away from the grease fitting See Fig 2 Ay CAUTION Do not over lubricate the clutch release bearing Over lubrication could contaminate the clutch in ternally causing clutch slippage and premature failure Do not use chassis grease or multipurpose lubricants 25 1250663 05 07 2007 N 9 1 Grease Fitting 2 Left Engine Mount Fig 2 Release Bearing Grease Fitting 4 Using a pressure type grease gun equipped with the recommended grease lubricate the bearing until excess grease purges from the rear of the release bearing toward the transmission 5 Install the clutch inspection plate Cascadia Maintenance Manual August 2007 25 1 Transmission Title of Maintenance Operation MOP Manual Transmission Air Filter Regulator Check Cleaning or Replacement Manual Transmission Fluid Change and Magnetic Plug Cleaning Synthetic Lubricant Transmission Fluid Level Inspection 26 Index Alphabetical MOP Number Cascadia Maintenance Manual January 2008 Transmission 26 01 Manual Transmission Fluid Change and Magnetic Plug Cleaning Synthetic Lubricant 4h CAUTION Operat
16. EPA10 Exhaust System Definitions of Aftertreatment ATS Terms Refer to the following list of definition of ATS terms and components e Aftertreatment System ATS the entire ex haust system from the turbocharger to the ex haust stack or tail pipe Aftertreatment Device ATD a housing that contains the DOC and DPF also the SCR and the mixing tube in one box systems BlueTec Daimler s proprietary SCR technol ogy Diesel Oxidation Catalyst DOC a flow through device that oxidizes soot in the ATD Diesel Particulate Filter DPF a component in the ATD that traps soot from the exhaust gas 49 Diesel Exhaust Fluid DEF the chemical agent that reacts with the exhaust gases in the SCR to reduce NOx e DEF Pump filter and supplies DEF to the DEF metering unit e DEF Tank holds DEF and regulates its tem perature e DEF Metering Unit mixes DEF with com pressed air and meters this mixture into the exhaust flo via an injection nozzle e SCR Catalyst the housing containing a treated ceramic flow throug block where the DEF and exhaust gases undergo selective catalytic re duction SCR e Selective Catalytic Reduction SCR a process used to reduce NOx emissions Inspection To meet EPA10 emissions regulations for vehicles domiciled in the USA or Canada engines manufac tured after December 31 2009 are equipped with an emission aftertreatment system Vehicles domiciled outside of
17. Group 32 of the Cascadia Workshop Manual 32 05 24 2007 1321090 Fig 1 Direct Acting Shock Absorber front suspension shown Inspect the spring bushings for wear or other dam age If any of these conditions exist replace the damaged bushings A WARNING Replace worn cracked or damaged spring brackets Failure to do so could result in bracket breakage possibly leading to loss of vehicle con trol and resulting in personal injury or property damage Inspect the crossmember s and gussets for wear cracks and other damage If any of these conditions exist replace the damaged parts see Group 32 of the Cascadia Workshop Manual Visually check the air spring piston for cracks chips and broken areas Check the air bag for rips tears and holes Verify that the air spring assembly does not leak If any of these conditions exist replace the damaged parts see Group 32 of the Cascadia Workshop Manual Suspension Height Checking IMPORTANT Before checking the AirLiner sus pension height make sure there is no load on the chassis and the trailer is unhitched IMPORTANT To prevent voiding the warranty on Barksdale height control valves note the fol lowing Cascadia Maintenance Manual August 2010 32 1 32 e Do not overtighten the bolts in the Barksdale height control valve housing The bolts should not be loose and should not require tightening Only if necessary tighten the val
18. 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 Yoke Shaft 11 Lock Guard 17 Left Hand Release Handle 6 Yoke Sub Assembly 12 Pin 18 Secondary Lock Left Hand Fig 2 Holland Fifth Wheel 5 The lever bar and operating handle must be in proper alignment See Fig 4 Compare the lever bar and operating handle alignment to a new or a properly operating lever bar and operating handle Replace any bent or misaligned lever bar or operating rod 6 Check all cotter pins for cracking or damage Re place any cotter pin that shows any signs of damage Level the fift wheel plate to a horizontal posi tion Measure the height from a stationary mounting point see Fig 5 Item 3 such as the Cascadia Maintenance Manual August 2007 31 3 31 Frame and Frame Components 2 S gt NE 11 28 95 1310353b 1 Lubricant Grooves 3 Lock Control Handle 2 Safety Latch 4 Mount Fig 3 Simplex Series Fifth Wheel 09 15 95 1 Operating Handle 1310470 2 Lever Bar Fig 4 Lever Bar and Operating Handle Alignment frame rail to the top of the fift wheel plate Item 1 Pry up on the fift wheel plate Item 4 below the pin boss and measure the vertical move ment Item 5 The bracket connection provides a 9 32 inch 7 mm vertical clearance to
19. Manual for repair procedures 10 Check the fan drive for discoloration or any other signs of slipping or overheating NOTE The fan clutch may slip if the air supply pressure is below 70 psi 483 kPa or if there is a leak inside the fan clutch Any leak must be remedied 11 Check the fan clutch bearings as follows 20 4 Cascadia Maintenance Manual August 2007 Engine Cooling R adiator Turn the fan in both directions and feel for worn hub bearings If possible remove the drive belt and check for worn sheave bearings by turn ing the sheave in both directions If either the hub or sheave bearings are worn replace them using a Horton Drive Master Super Kit For instructions and kit part number see Group 20 of the Cascadia Workshop Manual 20 Cascadia Maintenance Manual August 2007 20 5 Clutch 25 Index Alphabetical Title of Maintenance Operation MOP MOP Number Eaton Fuller Clutch Release Bearing Lubrication llli 25 01 Cascadia Maintenance Manual August 2007 Clutch 25 01 Eaton Fuller Clutch Release Bearing Lubrication The standard clutch release bearing is not sealed and requires lubrication Lubricate the bearing as follows 1 Apply the parking brakes and chock the rear tires 2 Remove the clutch inspection plate so that you can see the release bearing while lubricating it See Fig 1 m c 06 22 2007 f250662 Fig 1
20. Operation MOP Fuel Filter Replacements 22325 2d ars es a OER Fuel Tank Band MNut Tidhitening criar ade Fuel Water Separator Element Checking and Replacement 47 Index Alphabetical MOP Number Cascadia Maintenance Manual April 2009 Fuel 47 01 Fuel Filter Replacement Refer to the engine manufacturer s service manual for removal and installation procedures 47 02 Fuel Water Separator Element Checking and Replacement Alliance The only maintenance necessary on an Alliance fuel water separator is to replace the filte element A WARNING Diesel fuel is flammable and can ignite if exposed to an open flame intense heat or other ignition source Do not drain fuel near or expose fuel vapor to open flame or intense heat Exposure to open flame or intense heat could start a fire pos sibly resulting in personal injury or property dam age When working on a fuel system have a fire extinguisher within easy reach 1 Drain off some fuel by loosening the vent plug and opening the drain valve 2 Disconnect the water sensor and heater connec tions if equipped 3 Remove the element and bowl together by turn ing counterclockwise 4 Remove the bowl from the element and clean the O ring land 5 Apply a coating of clean fuel or motor oil to the new O ring and element seal 6 Spin the bowl onto the new element then spin them both onto the filte head snugly by hand only IMPORTANT Do not use to
21. Operation MOP MOP Number Hood Rear Support LUDMNCATIOM xs edd SO ES rotas rs DERE Mer ENE a 88 01 Cascadia Maintenance Manual May 2010 Hood Grille and Cab Fenders 88 01 Hood Rear Support Lubrication Apply the parking brakes and chock the tires 2 Open the hood 3 Clean both the hood and cab mounted hood rear support components with a soapy water so lution 4 Cover all contact surfaces of the hood rear sup port brackets and isolators with an approved multi purpose lithium complex soap based grease see Table 1 5 Close the hood Approved Suppliers of Multi Purpose Lithium Grease Supplier Grease Chevron Delo Heavy Duty EP Exxon Unirex EP2 Mobil Mobil Grease XHP 222 Shell Retinax LC Grease Texaco Starplex 2 Table 1 Approved Suppliers of Multi Purpose Lithium Grease 88 Cascadia Maintenance Manual May 2010 88 1
22. Pin Screw 20 Bumper Grease Fitting 12 Step Jaw and Wedge 21 Flatwasher Lower Bracket Pin 13 Jaw Spring 22 5 16 Bumper Pivot Bushing Wedge Stop Rod 14 1 4 x 3 Cotter Pin 23 1 2 13 Locknut Flatwasher 15 Timer 24 7 16 Handle Pivot Bushing Wedge Stop Rod Spring 16 Wedge Spring 25 Operating Handle side release Wedge Stop Rod Nut Side Release Upper Assembly Leaf Spring 17 18 Pull Handle Bumper Handle Spring onl y 26 1 2 13 x 2 Handle Pivot Bolt Fig 1 Fontaine H5092 Series Fifth Wheel left side release shown 8 Inspect for fatigue or cracked welds Simplex Series 9 Replace cracked worn or damaged parts with f new parts Replace all loose mounting bolts with ui se Ee a oe p n 5 8 11 SAE grade 8 bolts grade C locknuts and SNCS S EH E SASCA CA EVES Manda hardened washers Do not re use bolts nuts Thoroughly steam clean the fift wheel and washers on fit wheel mountings Check the fift wheel plate for cracks Check for 10 After inspecting the fift wheel lubricate all mov sharp edges on top the chamfer should be 1 8 ing parts with a chassis or multipurpose grease to 1 4 inch 3 to 6 mm Sd e Operation 3150 for lubrica 4 When the wheel is locked the safety latch must S swing free and fall freely into position See Fig 3 31 2 Cascadia Maintenance Manual August 2007 Frame and Frame Components 31 17 16 14 14 11 12 4 08 29 95 3 13 1310472 1
23. See Group 41 of the Cascadia Workshop Manual for torque specifi cations Replace the midship bearing assembly if the rubber cushion is deteriorated or oil soaked 6 Check slip joints for spline wear by moving the sleeve yoke and splined shaft back and forth See Fig 4 If the slip joint can be twisted in a clockwise or counterclockwise movement Cascadia Maintenance Manual August 2007 41 1 41 Driveline 16 4 3 05 01 95 1410067b 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 U Joint Assembly 9 Slip Joint Assembly 15 Axle Input Shaft End Yoke 4 Bearing Cap Self Locking 10 Sleeve Yoke bearing cap type yoke strap type Capscrew 11 Dust Cap 16 Rear Axle 5 Bearing Cap Fig 3 Components of a Basic Driveline greater than 0 007 inch 0 18 mm replace both the sleeve yoke and the splined shaft Visually examine the driveshaft tubes for dents bends twists or other damage If any tube ap pears to be damaged refer to Group 41 of the Cascadia Workshop Manual for repair and re placement instructions 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
24. and M2 200 000 320 000 21st M1 210 000 336 000 22nd M1 220 000 352 000 23rd M1 230 000 368 000 24th M1 240 000 384 000 25th M1 and M2 250 000 400 000 26th M1 260 000 416 000 27th M1 270 000 432 000 28th M1 280 000 448 000 29th M1 290 000 464 000 30th M1 M2 and M3 300 000 480 000 31st M1 310 000 496 000 32nd M1 320 000 512 000 33rd M1 330 000 528 000 34th M1 340 000 544 000 35th M1 and M2 350 000 560 000 Cascadia Maintenance Manual August 2010 00 3 00 Vehicle Maintenance Schedule Table 00 03 General Information Maintenance for Service Schedule Maint No rico id series x 36th M1 360 000 576 000 37th M1 370 000 592 000 38th M1 380 000 608 000 39th M1 390 000 624 000 40th M1 and M2 400 000 640 000 41st M1 410 000 656 000 42nd M1 420 000 672 000 43rd M1 430 000 688 000 44th M1 440 000 704 000 45th M1 M2 and M3 450 000 720 000 46th M1 460 000 736 000 47th M1 470 000 752 000 48th M1 480 000 768 000 49th M1 490 000 784 000 50th M1 and M2 500 000 800 000 51st M1 510 000 820 000 52nd M1 520 000 837 000 53rd M1 530 000 853 000 54th M1 540 000 869 000 55th M1 and M2 550 000 885 000 56th M1 560 000 901 000 57th M1 570 000 917 000 58th M1 580 000 933 000 59th M1 590 000 949 000 60th M1 M2 and M3 600 000 965 000 61st M1 610 000 982 000 62nd M1 620 000 998 000 63rd M1 630 000 1 014 000 64th M1 64
25. and the area surrounding the fil plug on the side of the axle carrier Remove the plug Check lubricant level when the axle is cold or near room temperature NOTE Some Meritor axles have a small tapped and plugged hole near and below the housing oil fil hole This smaller hole is for a lubricant Rear Axle temperature indicator only and should not be used as a fil or level hole 3 Check that the lubricant is level with the bottom of the fil hole See Fig 2 If low check for oil leaks and correct as needed Add oil to the level of the fil plug using the lubricant recommended in Table 1 4 Install and tighten the fil plug 35 Ibf ft 47 N m IMPORTANT Always check the axle breather whenever checking lubricant level Check the breather more frequently under adverse operat ing conditions 5 Check the axle housing breather Make sure that it is open and unclogged See Fig 6 If the breather is plugged or damaged clean or re place it as needed 06 07 94 f350062a 1 Axle Housing 2 Carrier Oil Fill Plugs Breathers 3 Interaxle Differential Fig 6 Meritor Axle Housing Breathers 6 On non drive axles using oil lubricated wheel bearings check the oil level at the wheels and add oil if low Use the same lubricant recom mended for the drive axle NOTE When adding to or checking the oil level make certain the hub cap and plug are clean before removing the plug this will minimize the possibility of di
26. are missing re move the driveshaft and have it balanced 9 For driveshafts with slip joints check to be sure the yoke plug is not loose or missing See Fig 5 Repair or replace the yoke plug as needed If the yoke plug is missing the splined shaft may be hitting the plug and knocking it out contact your Regional Service Office for assistance in deter mining the correct driveshaft length 41 2 Cascadia Maintenance Manual August 2007 Driveline za HY MY 05 27 93 Y f410012a Attempt to move the sleeve yoke and splined shaft back and forth Fig 4 Slip Joint Spline Wear Checking 10 20 93 f410050a A After grease appears cover the pressure relief hole while continuing to lubricate Slip Joint Grease Fitting with grease gun attached Yoke Plug Grease Half Round Yoke Yoke Plug Pressure Relief Hole Slip Joint Seal Full Round Yoke U Joint Grease Fitting o xdOogiom Fig 5 Slip Joint and U Joint Lubrication 41 41 02 Driveline Lubrication Universal Joint Lubrication NOTE Vehicles equipped with Meritor RPL Se ries drivelines do not require periodic lubrication 1 Park the vehicle on a level surface apply the parking brakes and chock the tires 2 Wipe all old grease and dirt from each U joint grease fitting See Fig 5 3 Use a hand type grease gun or a high pressure gun with a low pressure adapter to lubricate U joints If a low pressure adapter is not use
27. chock the front tires 2 Remove the axle carrier fil plug Then remove the drain plug from the bottom of the housing Completely drain the lubricant while the unit is warm to allow the lubricant to drain faster On tandem drive axles it is also necessary to remove the plug at the bottom of the interaxle differential housing to drain that lubricant 3 If equipped with an oil pump remove the axle oil filte Use a suitable filte strap wrench See Fig 1 Discard the old filte 05 27 93 f350119a Fig 1 Meritor Axle Oil Filter Removal NOTE There may be about one pint 0 5 L of lubricant remaining in the filte Be careful not to spill it when removing the filte 4 Using the recommended drive axle lubricant coat the face of the gasket on the new oil filte if one was removed Install the filte over the adapter and tighten the filte one full turn after the gasket contacts the base do not overtighten See Table 1 for recommended lubricants Cascadia Maintenance Manual August 2007 35 1 39 Rear Axle Meritor Drive Axle Recommended Lubricant Lubricant SAE Viscosity Grade 40 F 40 C and Up 75W 90 40 F 40 C and Up 75W 140 There is no upper limit on these outside temperatures but axle sump temperature must never exceed 250 F 121 C Table 1 Meritor Drive Axle Recommended Lubricant Recommended Lubricant Type Ambient Temperature Meritor Specification 0 76
28. from a damaged hose or line could cause blindness or serious skin burns Preliminary Checks 1 Park the vehicle on a level surface apply the parking brakes and chock the tires 2 Check the appearance of the air conditioner compressor pulley assembly If the friction sur face of the pulley shows signs of excessive grooving due to belt slippage replace both the pulley and the drive plate Inspect the refrigerant compressor drive belt for damage and check that the belt is set at the proper tension Also check the tightness of the compressor mounting fasten ers For instructions and torque values see Group 01 of the Cascadia Workshop Manual 3 Inspect the drive plate If the drive plate shows visible signs of damage due to excessive heat replace the drive plate and pulley assembly For removal and installation procedures see Group 83 of the Cascadia Workshop Manual 4 Using a feeler gauge check that the drive plate clutch clearance is within limits See Table 1 for clearance specifications See Fig 1 for the checking method If the drive plate clutch re quires adjustment see Group 83 of the Casca dia Workshop Manual Compressor Drive Plate Clutch Clearance Manufacturer Clearance in mm Sanden 0 016 to 0 040 0 4 to 1 0 Denso 0 014 to 0 024 0 35 to 0 60 Table 1 Compressor Drive Plate Clutch Clearance 5 Inspect the compressor clutch coil wire Check that the connector is not damage
29. gasket under the filte cover is not damaged If the gasket is damaged re place it Install the gasket on the reservoir 14 Attach the retaining ring to the reservoir to se cure the filte and filte cover 15 Start the engine and check that the power steer ing flui level is between the MIN COLD and MAX HOT lines Add more power steering flui if needed 16 Raise the vehicle remove the jack stands and lower the vehicle 46 03 Power Steering Fluid Level Inspection 1 Apply the parking brakes and chock the tires 2 With the engine cool use a shop towel or a clean rag to clean the area around the power steering reservoir fil cap Twist the cap counter clockwise to remove it Check the cold power steering flui level The level should be between ADD COLD and FULL COLD with the engine off 3 Start the engine and run it at idle until it reaches operating temperature Remove the dipstick and check that power steering flui is between ADD HOT and FULL HOT If the flui level is low add enough flui to bring the level up to the FULL HOT mark on the dipstick See Table 1 for recommended power steering fluids 46 04 Power Steering Gear Lubrication TRW TAS and THP Series Sector Shaft A CAUTION Apply grease to the sector shaft with a hand type grease gun only Use of a high pressure power grease gun will supply grease too quickly and could affect the high pressure seal contaminating the hydraulic fluid Usin
30. is likely masking a mechanical problem Adjustment is not repairing Before adjusting an automatic slack adjuster troubleshoot the foundation brake system and inspect it for worn or damaged com ponents Improperly maintaining the vehicle brak ing system may lead to brake failure resulting in property damage personal injury or death 2 Brakes With the engine off and 100 psi 689 kPa of air tank pressure have an assistant apply and hold an 80 to 90 psi 550 to 620 kPa brake applica tion Check to see if the colored over stroke band on each brake chamber pushrod is exposed If a band shows the stroke is too long Check the foundation brake components for wear or damage and repair as needed See Group 42 of the Cascadia Workshop Manual for inspection and repair procedures Measure the applied chamber stroke See Table 1 for the proper stroke for the type of chamber being used If the stroke is too short the brakes may drag or will not fully apply Check for im proper operation or adjustment of the automatic slack adjuster See Group 42 of the Cascadia Workshop Manual or see the Cascadia Troubleshooting Manual for procedures Brake Chamber Stroke Specifications Chamber Max Applied Stroke inch mm Manufacturer Type Sizet 12 1 3 8 35 16 Standard Stroke 20 1 3 4 44 24 Haldex 2 1 2 Inch Extended Stroke 24 2 51 3 Inch Extended Strok
31. is evidence of leakage from inside the on center cap remove the on center cap and replace the input shaft seal See Group 46 of the Cascadia Workshop Manual for instructions Check the steering system pressure and return lines and fitting for leaks and damaged lines or hoses Repair or replace lines hoses and fit tings as necessary 10 Check the tube fitting on the hard transfer lines of the gear see Fig 4 Item 15 If there is leak age from either of the fittings replace the rack and pinion unit IMPORTANT Tightening the tube fitting can cause tearing of the O ring seal and increased flui leakage Cascadia Maintenance Manual November 2009 46 3 46 Steering 07 24 2009 Steering Tie Rod Arm Power Steering Fluid Lines Large Bellows Clamp Bellows Small Bellows Clamp Driver Side Outer Tie Rod Tie Rod Jam Nut Inner Tie Rod Flat Inner Tie Rod Ball Joint LAAIDARON 10 11 12 13 14 15 16 Input Shaft Seal Cover Shaft Upper Yoke Shaft Lower Yoke Boot Clamp I Shaft Lower Yoke Boot Shaft Lower End Yoke Transfer Line Tube Fittings Power Steering Fluid Line Fittings 17 18 19 21 22 23 1462151 I Shaft Slip Joint Transfer Lines Rack and Pinion Gear Pinch Bolt Tie Rod Clamp Tie Rod Clamp Nut Passenger Side Outer Tie Rod Fig 4 Rack and Pinion Steering System 46 4 Cascadia Maintenance Manual November 2009 Fuel Title of Maintenance
32. joint 7 Wipe the purged grease from the seals and any excess grease from the grease fitting Cascadia Maintenance Manual August 2007 41 3 41 Slip Joint Spline Lubrication NOTE Vehicles equipped with Meritor RPL Se ries drivelines do not require periodic lubrication 1 If equipped with a grease fitting wipe all old grease and dirt from the slip joint grease fitting See Fig 5 Use a hand type grease gun or a high pressure gun with a low pressure adapter to lubricate the slip joint Add multipurpose chassis grease lithium 12 hydroxy stearate NLGI Grade 1 or Grade 2 with EP additives until it appears at the pressure relief hole in the yoke plug Then cover the relief hole with your finge while continuing to apply gun pressure until new grease appears at the slip joint seal See Fig 5 This ensures complete lubrication of the splines Wipe the purged grease from the pressure relief hole and slip joint seal and any excess grease from the grease fitting Driveline 41 4 Cascadia Maintenance Manual August 2007 Brakes 42 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Brake System valve Inspecti s sas a e dai e 42 01 Air Dryer InspeciO eeter ERRADA A gh b dle quis Up ED IE hes 42 03 Alcohol Evaporator Cleaning and Inspection i i 42 04 Bendix Air Dryer Desiccant Replacement oo oooocooooo eene 42 02 Bendix E 6 Foot Control Valve Inspection and
33. must not exceed 1 85 This cold weather mixture can be safely used up to 32 F 0 C Cascadia Maintenance Manual August 2007 35 5 39 Commercially available automatic transmission flui may be used in place of SAE 10 engine oil Automatic transmission flui can be used for all temperatures do not mix it with kerosene To prevent component damage do not mix engine oil and automatic transmission fluid 4 Using the recommended lubricant fil the shift unit housing through the oil fil hole until the lubri cant is level with the bottom of the opening 5 Coat the threads of the fil plug with a small amount of Loctite 242 or equivalent sealant Install the fil plug finger tigh in the rear axle shift unit housing Using a wrench tighten it an addi tional 1 1 2 turns 35 02 Axle Breather and Axle Lubricant Level Inspection For all axles including tandem drive axles and two speed axles do the procedures under the heading All Axle Models For a two speed axle with a shift unit also check the shift unit lubricant See under the heading Two Speed Axles With Shift Unit All Axle Models Meritor A CAUTION Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage 1 Park the vehicle on level ground set the parking brakes and chock the tires IMPORTANT Oil level must be checked at each M1 interval on Meritor axles 2 Clean the fil plug
34. provide cushioning and to avoid downward pin loading while retaining minimum plate lift If the plate lift Ref A exceeds 5 16 inch 8 mm as a result of wear or rubber deterioration install new stan dard or oversized bracket shoe rubber pads see Group 31 of the Cascadia Workshop Manual for replacement instructions 08 31 95 A A Extended Top Plate Lift Height Fifth Wheel Top Plate Fifth Wheel Mounting Base Fifth Wheel Mounting Angle Lifting Point Static Top Plate Height 1310475 SUBO Fig 5 Measuring Fifth Wheel Top Plate Lift NOTE Do not measure plate lift immediately after a trailer has been uncoupled from the fift wheel The rubber may have taken a temporary set which will normally recover after being un coupled for a short period of time 8 Check all mounting bolts for signs of fatigue and tighten them to the proper torque For torque specifications see Group 31 of the Cascadia Workshop Manual Inspect all angles plates and brackets for cracks or other damage 9 Replace cracked worn or damaged parts with new parts Replace all loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and washers on fift wheel mountings 10 After inspecting the fift wheel lubricate all mov ing parts with a chassis or multipurpose grease See Maintenance Operation 31 02 for lubrica tion instructions 31 02 Fifth Wheel Lubrication
35. schedule table or the vehicle mainte nance schedule table to determine how often main tenance should be performed When the vehicle reaches the distance given for a maintenance interval see the Maintenance Interval Operation Table for a list of the maintenance opera tions to be performed at that maintenance interval Use the maintenance operation reference numbers to fin detailed instructions in the manual on each op eration Types of Service Service Schedule short haul transport applies to vehicles that annually travel less than 60 000 miles 100 000 kilometers and operate under normal con ditions Examples of Schedule usage are operation primarily in cities and densely populated areas local transport with infrequent freeway travel or high per centage of stop and go travel Service Schedule II long haul transport is for ve hicles that annually travel more than 60 000 miles 100 000 kilometers with minimal city or stop and go operation Examples of Schedule II usage are re gional delivery that is mostly freeway miles interstate transport or any road operation with high annual mileage NOTE Maintenance instructions in this manual are based on average vehicle use and normal operating conditions Unusual vehicle operating conditions may require service at more frequent intervals Cascadia Maintenance Manual August 2010 00 1 00 General Information Service Schedule Table 00 02
36. specification in this manual were in effect at the time of printing Freightliner Trucks reserves the right to discontinue models and to change specification or design at any time without notice and without incurring obligation Descriptions and specification contained in this publication provide no warranty expressed or implied and are subject to revision and editions without notice Refer to www Daimler TrucksNorthAmerica com and www FreightlinerTrucks com for more information or contact Daimler Trucks North America LLC at the address below Environmental Concerns and Recommendations Whenever you see instructions in this manual to discard materials you should attempt to reclaim and recycle them To preserve our environment follow appropriate environmental rules and regulations when disposing of materials NOTICE Parts Replacement Considerations Do not replace suspension axle or steering parts such as springs wheels hubs and steering gears with used parts Used parts may have been subjected to collisions or improper use and have undetected structural damage O 2007 2010 Daimler Trucks North America LLC All rights reserved No part of this publication in whole or in part may be translated reproduced stored in a retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Daimler Trucks North America LLC Daimler Trucks North A
37. the air inlet of the air cylinder Connect the vehicle air hose to the inlet 7 Connect the battery cables Start the engine Horton DriveMaster Fan Clutch NOTE If any part of the fan clutch needs to be repaired or replaced after performing the checks below see Group 20 of the Cascadia Work shop Manual 1 Disconnect the batteries at the negative termi nals Cascadia Maintenance Manual August 2007 20 3 20 Engine Cooling R adiator Approved Antifreeze Manufacturer Antifreeze Type F Contains supplement additives Available as a Caterpillar Caterpillar Diesel Engine Antifreeze Coolant premixed solution Cummins Fleetguard Compleat Premix Premixed solution with supplement additives Detroit Diesel Detroit Diesel Power Cool Old World Industries Fleet Charge Premixed solution with supplement additives With supplement additives Table 1 Approved Antifreeze 2 Inspect the electrical connections and wires to the fan clutch solenoid Secure the connection if loose replace wires and connectors if damaged 3 Clean the fan clutch air solenoid valve filte if equipped as follows 3 1 Unscrew the fan clutch solenoid valve air fille assembly and remove the filte ele ment 3 2 Clean the filte element with cleaning sol vent 3 3 Using a clean lint free cloth wipe off any excess solvent 3 4 Reassemble the clutch valve solenoid air filte then install it o
38. top plate with a multipurpose chassis grease Once the fift wheels moving parts are lubricated apply a heavy coat of grease to the top plate by di rect application On slide mount applications lubri cate the baseplate rails and the plungers for smooth operation Simplex Series Use a chassis or multipurpose grease to lubricate the two grease fitting located on either side of the fift wheel top plate Lubricate the two grease fitting lo cated in the grease grooves on the fift wheel top plate Lubricate the two grease fitting located below 31 the top plate mounting pins Lubricate the lock mechanism Once the fift wheels moving parts are lubricated apply a heavy coat of grease to the top plate either through the grease fitting located on the underside of the top plate or by direct application On slide mount applications lubricate the slider lock pockets and the slider bracket 31 03 Frame Fastener Torque Check Frame brackets and components secured with Huck bolt fasteners do not require a torque check how ever they should be inspected for damage Frame brackets and components secured with conventional bolts and nuts are to be checked at Initial Mainte nance IM Check the torque of frame fasteners to offset the effects of bedding in or seating When checking torque torque the nut not the bolt head whenever possible This will give a true torque read ing by eliminating bolt body friction When checking th
39. using compressed air to clean parts as permanent harm to eyes could result from flying debris 4 Clean the filte element by dipping it in alcohol or other cleaning solvent Blow compressed air through the element inside to outside to loosen surface dirt and to dry the element If it is not damaged the sintered metallic filte element will last the life of the vehicle 26 f260037a 05 27 93 Fig 2 Air Filter Regulator Location 10 17 2001 f260052a 1 Air Regulator 2 Housing 3 Large O Ring 4 Filter Element 5 Small O Ring 6 End Cap 7 Plug Fig 3 Eaton Fuller Transmission Air Filter Regulator Components Wipe out the filte housing with a clean dry lint free rag Clean and inspect the O rings and end cap Replace any parts that are damaged 5 Install the large O ring then the filte element small end first into the filte housing Install the small O ring in the end cap then in stall the end cap and tighten it until firm Cascadia Maintenance Manual January 2008 26 3 26 4h CAUTION A leaking air filter or air lines can cause slow or hard shifting of the transmission and eventual transmission damage 7 Start the engine and build pressure in the air system Check for air leaks at the filte housing and air line connections repair any leaks Transmission 26 4 Cascadia Maintenance Manual January 2008 Frame and Frame Components 31 Index Alphab
40. 0 000 1 030 000 65th M1 and M2 650 000 1 046 000 66th M1 660 000 1 062 000 67th M1 670 000 1 078 000 68th M1 680 000 1 094 000 69th M1 690 000 1 110 000 70th M1 and M2 700 000 1 127 000 00 4 Cascadia Maintenance Manual August 2010 General Information 00 Vehicle Maintenance Schedule Table 00 03 Maintenance for Service Schedule Maint No Haln nanes Servios oe ee 71st M1 710 000 1 143 000 72nd M1 720 000 1 159 000 73rd M1 730 000 1 175 000 74th M1 740 000 1 191 000 75th M1 M2 and M3 750 000 1 207 000 76th M1 760 000 1 223 000 77th M1 770 000 1 239 000 78th M1 780 000 1 255 000 79th M1 790 000 1 271 000 80th M1 and M2 800 000 1 287 000 81st M1 810 000 1 304 000 82nd M1 820 000 1 320 000 83rd M1 830 000 1 340 000 84th M1 840 000 1 352 000 85th M1 and M2 850 000 1 370 000 86th M1 860 000 1 384 000 87th M1 870 000 1 400 000 88th M1 880 000 1 416 000 89th M1 890 000 1 432 000 90th M1 M2 and M3 900 000 1 448 000 91st M1 910 000 1 465 000 92nd M1 920 000 1 481 000 93rd M1 930 000 1 500 000 94th M1 940 000 1 513 000 95th M1 and M2 950 000 1 530 000 96th M1 960 000 1 550 000 97th M1 970 000 1 561 000 98th M1 980 000 1 577 000 99th M1 990 000 1 593 000 100th M1 and M2 1 000 000 1 609 000 Table 2 Maintenance for Service Schedule I Cascadia Maintenance Manual August 2010 00 5
41. 00 Vehicle Maintenance Schedule Table 00 03 General Information Maintenance for Service Schedule II Maint No Maintenance Interval genna SCC Ra i ate Miles km 1 IM and M1 25 000 40 000 2 M1 50 000 80 000 3 M1 75 000 121 000 4 M1 and M2 100 000 161 000 5 M1 125 000 201 000 6 M1 150 000 241 000 7 M1 175 000 281 000 8 M1 and M2 200 000 322 000 9 M1 225 000 362 000 10 M1 250 000 402 000 11 M1 275 000 443 000 12 M1 M2 and M3 300 000 483 000 13 M1 325 000 523 000 14 M1 350 000 563 000 15 M1 375 000 604 000 16 M1 and M2 400 000 644 000 17 M1 425 000 684 000 18 M1 450 000 724 000 19 M1 475 000 764 000 20 M1 and M2 500 000 805 000 21 M1 525 000 845 000 22 M1 550 000 885 000 23 M1 575 000 925 000 24 M1 M2 and M3 600 000 966 000 25 M1 625 000 1 005 800 26 M1 650 000 1 046 000 27 M1 675 000 1 086 000 28 M1 and M2 700 000 1 127 000 29 M1 725 000 1 167 000 30 M1 750 000 1 207 000 31 M1 775 000 1 248 000 32 M1 and M2 800 000 1 287 000 33 M1 825 000 1 328 000 34 M1 850 000 1 368 000 35 M1 875 000 1 408 000 00 6 Cascadia Maintenance Manual August 2010 General Information 00 Vehicle Maintenance Schedule Table 00 03 Maintenance for Service Schedule Il Maint No Maintenance Interval e e BOUM ate Miles km 36 M1 M2 and M38 900 000 1 448 000 37 M1 925 0
42. 00 1 490 000 38 M1 950 000 1 529 000 39 M1 975 000 1 569 000 40 M1 and M2 1 000 000 1 609 000 Table 3 Maintenance for Service Schedule Il Cascadia Maintenance Manual August 2010 00 7 00 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 Maintenance operation the applicable M1 maintenance interval table must numbers are reference numbers used to help you be performed to complete the initial maintenance fin detailed instructions in this manual on the main IM Pcia uad r Initial Maintenance IM Operations for Service Schedules and II Check 00 05 Perform all M1 Operations 31 03 Frame Fastener Torque Check 32 02 Suspension U Bolt Torque Check 33 04 All Axle Alignment Check 47 03 Fuel Tank Band Nut Tightening Table 4 Initial Maintenance IM Operations for Service Schedules and Il 00 8 Cascadia Maintenance Manual August 2010 General Information The M1 Maintenance Interval Operations tables list all maintenance operations that are to be performed at the M1 maintenance interval Maintenance opera 00 M1 Maintenance Interval Operations 00 05 tion numbers are reference numbers used to help you fin detailed instructions in
43. 00 Ib 15 000 to 18 000 kg using synthetic lubricant Oil must be changed at least every four years and more often if the axle is exposed to high tem peratures and steep grades 1 Park the vehicle on a level surface set the park ing brakes and chock the tires IMPORTANT Freightliner rear axles do not re quire the use of friction modifiers 2 Clean the fil plug and the area around it In the axle housing rear cover remove the plug from the oil fil hole 3 Place a drain pan under the rear axle drain plug Drain the oil when it is warm At this tempera ture the oil will run more freely and ensure that the axle is flushed 4 Clean the fil and drain plugs Change them if necessary 4 1 For magnetic plugs use a piece of key stock or any other convenient steel slug to short the two magnetic poles and divert the magnetic field 4 2 Clean away the collected material depos ited on each pole Magnets will rapidly lose their effectiveness as collected mate rial bridges the gap between the two poles 4 3 After the firs oil is changed inspect the drain plug each time for large quantities of metal particles 35 4 4 After cleaning install the drain plug s and tighten to 41 Ibf ft 55 N m 5 Fill the axle with the recommended lubricant See Table 3 for recommended drive axle lubri cants and drive axle lubricant capacities Freightliner Rear Axle Approved Lubricant Type and Capacity Cil
44. 007 Front Axle 33 01 Knuckle Pin Lubrication Meritor Axles CAUTION Use regulated pressure when lubricating the knuckle assemblies otherwise damage could re sult to the knuckle caps When lubricating knuckle pin bushings do not raise the front axle Wipe the lube fitting clean and apply multipurpose chassis grease NLGI Grade 1 6 12 hydroxy lithium stearate grease or NLGI Grade 2 896 12 hydroxy lithium stearate grease until new grease is seen at the bushing grease seal opposite the fittings The grease seal will accept grease pres sure without damage and is designed to have grease pumped out through it during lubrication Even if grease leaks out around the top or bottom plate gasket continue pumping until new grease is seen at the bushing seal opposite the grease fitting See Fig 1 09 06 96 1 A Grease Exit 1 Grease Fitting f320032a Fig 1 Meritor Knuckle Pin Lubrication 33 02 Tie Rod Inspection Inspect the tie rod ends as follows 1 Shake the cross tube A loose fit or movement between the tapered shaft of the ball and the 33 cross tube socket members indicates that the tie rod end assembly must be replaced 2 The threaded portion of the tie rod end assembly must be inserted all the way into the cross tube split for adequate clamping See Fig 2 Replace the components if this cannot be done For in structions refer to Group 33 of the C
45. 2010 49 5 49 06 01 93 1 Flex Hose 4 Turbocharger Exhaust 2 V Band Coupling Outlet 3 Exhaust Pipe Fig 5 V Band Coupling and Flex Hose 6 Check the U bolt clamps for tightness and tighten as needed 7 Check the isolator at the base of the exhaust stack elbow s see Fig 6 for cracking dam age and dry rot Replace as needed Exhaust sealclamps If necessary install a new wide band exhaust clamp f490024a 05 28 93 f490025a 08 25 95 1 Exhaust Pipe 2 Exhaust Elbow Isolator 3 Mounting Nut 1490127 Fig 6 Exhaust Elbow Isolator 8 Check for leakage at all wide band exhaust clamps See Fig 7 If leakage exists tighten the nuts 40 to 60 Ibf ft 54 to 81 N m If leakage persists inspect the Fig 7 Donaldson Sealclamp Wide Band Exhaust Clamp 49 6 Cascadia Maintenance Manual August 2010 Electrical Instruments and Controls 54 Index Alphabetical Title of Maintenance Operation MOP MOP Number Trailer Cable Inspection and Cleanings sasie ks EERDER RD ra DEE DES ae dde 54 01 Cascadia Maintenance Manual August 2007 Electrical Instruments and Controls 54 01 Trailer Cable Inspection and Cleaning Disconnect the trailer electrical cables from the sockets at the cab Inspect the cables and sockets for evidence of corrosion and clean as necessary If a socket is too badly corroded to clean replace it Freight line
46. 24 3 8 Inch Bolt 8 3 8 Inch Special Washer 17 Exhaust Diaphragm 25 End Cover Fig 1 AD 9 Air Dryer exploded view 16 Install the 6 bolts 12 washers and 6 new Nylok strap Torque the upper mounting bracket strap 17 nuts Torque the Nylok nuts in a star pattern 17 to 24 Ibf ft 370 to 520 N m See Fig 2 Install the air dryer on the lower mounting bracket Install the two previously marked bolts four washers and two new Nylok nuts Torque the two remaining Nylok nuts 17 to 24 Ibf ft 370 to 520 N m Install the bolt two washers and a new Nylok nut in the upper mounting bracket Nylok nut 80 to 120 Ibf in 900 to 1360 N cm Connect and tighten the three air lines Connect the harness connector to the heater and thermo stat assembly until the lock tab snaps in place Start the engine build the air pressure and check the air brake system for leaks If any air leaks are present see Group 42 of the Casca dia Workshop Manual for diagnosis and repair information 42 2 Cascadia Maintenance Manual January 2010 Brakes 42 09 20 94 f420544a Fig 2 AD 9 End Cover to Housing Torgue Pattern AD IS 1 Park the vehicle on a level surface apply the parking brakes and chock the tires 2 Drain the air reservoirs 3 Using a strap wrench or equivalent loosen the desiccant cartridge Spin the cartridge off by hand and discard it See Fig 3 4 On the new desiccant cartr
47. 4 to 81 N m Cascadia Maintenance Manual August 2007 35 7 39 IMPORTANT Always check the axle breather whenever checking lubricant level Check the breather more freguently under adverse operat ing conditions 6 Check the axle housing breather Make sure that it is unclogged and free from corrosion See Fig 7 If the breather is plugged or damaged clean or replace it as needed Two Speed Axles With Shift Unit Dana Spicer and Meritor CAUTION Failure to keep lubricant at the specified level could cause damage to the axle shift unit 1 Clean the shift unit oil fil plug and the area sur rounding the plug See Fig 5 Turn the fil plug counterclockwise to remove it 2 Inserta finge or pipe cleaner into the fil plug hole and check the flui level The lubricant should be level with the bottom of the fil hole If low add the recommended lubricant 4h CAUTION Before adding additional lubricant make sure of the type currently in the shift unit To prevent component damage do not mix engine oil with automatic transmission fluid IMPORTANT When the ambient temperature is above O F 18 C use SAE 10 heavy duty en gine oil API service classificatio SD sulfated ash content must not exceed 1 85 When the ambient temperature is below O F 18 C use one part kerosene to three parts SAE 10 heavy duty engine oil API service classificatio SD sulfated ash content must not exceed 1 85 This cold w
48. 402 402 P 34 16 1 Ms NA PEDES 2 Speed dual ousing Cover Gaske ace DT451 P 39 18 5 t 2 Oil Fill Plug DT461 P 43 20 3 t 3 Shift Unit Housing Cover Double DP451 P 34 16 1 Fig 5 Two Speed Axle Shift Unit Reduction DESIT 43 20 3 1 2 Thoroughly wash the axle shift parts and housing Quantities listed are approximate Fill axle until lubricant is level with bot cover and allow them to air dry tom of fll hole with vehicle on level ground t Add 2 pints 1 L of additional lubricant to the power divider Table 5 Dana Spicer Drive Axle Lubricant Capacities NOTE Some Dana Spicer axles have a small tapped and plugged hole near and below the housing oil fil hole This smaller hole is for a lubricant temperature indicator only and should not be used as a fil or level hole 6 1 Fill the axle through the oil fil hole or standpipe opening Lubricant should be level with the bottom of the oil fil hole or 3 Install the housing cover and a new cover gas ket Tighten the housing cover capscrews 90 to 110 Ibf in 1020 to 1240 N cm then remove the oil fil plug from the cover IMPORTANT When the ambient temperature is above 0 F 18C use SAE 10 heavy duty en gine oil API service classificatio SD sulfated ash content must not exceed 1 85 When the ambient temperature is below O F 18 C use one part kerosene to three parts SAE 10 heavy duty engine oil API service classificatio SD sulfated ash content
49. 9 97 f410182 04 13 98 f410155a 1 Self Locking 2 Adhesive Band Capscrew Fig 1 Arvin Meritor U Joint Fasteners for Bearing Caps 3 Check the driveline yokes for cracks and check end yokes for looseness See Fig 3 Replace cracked yokes Fig 2 Arvin Meritor RPL Series U Joint If any end yoke can be moved in or out on its shaft or can be rocked on its shaft disconnect the driveshaft and U joint from the yoke then check the drive component s shaft seal for leak age or other visible damage that may have been caused by the loose yoke Replace the seal if needed then tighten the yoke nut Refer to Group 41 of the Cascadia Workshop Manual for torque specifications If the yoke is still loose after tightening the yoke nut replace the end yoke and yoke nut Replace the prevailing torque locknut end yoke nut if it was removed for yoke replacement seal replacement or any other reason 4 Check U joint assemblies for wear by moving the driveshaft up and down and from side to side If any movement of the U joint cross in the bear ings can be felt or seen replace the U joint as sembly 5 Check if the midship bearing and mounting are loose or have deteriorated by attempting to move the driveshaft up and down and from side to side If the bearing is loose on its shaft or rattles replace it If the bearing mount is loose on the frame tighten the mounting fasteners to the proper torque value
50. Connectors Port 9 Exhaust Inlet 14 DPF Outlet Pressure Sensor 3 DOC Inlet Temperature Sensor 10 SCR Outlet Temperature Port 4 Front Heat Shield Sensor 15 SCR Inlet Temperature Sensor 5 DEF Nozzle Fig 1 One Box ATS Sensor Locations 49 2 Cascadia Maintenance Manual August 2010 Exhaust 49 09 16 2009 1 DEF Metering Unit 5 2 DEF Nozzle 6 3 SCR Outlet Temperature 7 Sensor 8 4 SCR Inlet Temperature Sensor DOC Inlet Temperature Sensor DOC Inlet Pressure Sensor DPF Inlet Temperature Sensor DPF Outlet Pressure Sensor f490353 9 DPF Outlet Temperature Sensor 10 DPF Outlet NOx Sensor 11 SCR Outlet NOx Sensor Fig 2 2V2 Two Box ATS Sensor Locations Diesel Exhaust Fluid DEF Filter Replacement The Environmental Protection Agency s 2010 regula tions require lower nitrogen oxide NOx exhaust emissions Selective catalytic reduction SCR uses diesel exhaust flui DEF to lower NOx emissions in the vehicle exhaust A filte in the DEF pump pre vents clogging of the DEF metering unit injection nozzle See the engine manufacturer s maintenance manual for filte replacement instructions and maintenance intervals EPAO7 Exhaust System Definitions of ATS Terms Refer to the following list of definition of ATS com ponents e Aftertreatment System ATS the entire ex haust system from the turbocharger to the ex haust stack or tail pipe e Aftert
51. Disconnect the tractor from the trailer For in structions see the Cascadia Driver s Manual 2 Thoroughly steam clean the fift wheel 3 Check for loose nuts or broken bolts on the fift wheel assembly 4 Inspect for cracks or wear on the mounting bolts 5 Inspect for improper locking action and for cracks or wear on the jaw locking mechanism 6 Check the depth of the grease grooves If the depth of the grooves is 1 8 inch or less replace the fift wheel top plate See Group 31 of the Cascadia Workshop Manual 7 Check the condition of the X pattern cast into the underside of the fift wheel top plate See Fig 2 The fift wheel top plate must be removed to check the X pattern 7 1 Remove the roll pins from the bushing pins Remove the bushing pins from the slide mount Using a hoist lift the fift wheel top plate off of the vehicle L 2 Turn the fift wheel top plate over with the locks open Check the condition of the X pattern in the pockets If the X pattern is worn away replace the fift wheel top plate 7 3 Install the fift wheel top plate bushing pins and roll pins Cascadia Maintenance Manual August 2007 31 1 31 Frame and Frame Components 2 3 4 5 6 7 8 9 1 0 11 1 p z f 09 18 95 2 3 4 X AN 25 5 D a 21 23 26 24 1 1310476 3 16 x 1 Cotter Pin 11 1 4 20 x 3 8 Thread Cutting 19 1 2713 x 2 Bumper Pivot Bolt Lower Bracket Retainer
52. Drain Tube Inspection 88 01 Hood Rear Support Lubrication If equipped with an oil coalescing desiccant cartridge replace the cartridge once a year regardless of mileage Otherwise use the M3 maintenance interval Table 8 Maintenance Operation Sets Cascadia Maintenance Manual August 2010 00 13 00 General Information Noise Emission Controls Maintenance 00 09 Noise Emission Control Maintenance Federal Law Part 205 Transportation Equipment Noise Emission Controls Part 205 Transportation Equipment Noise Emission Controls requires the vehicle manufacturer to fur nish with each new vehicle such written instructions for the proper maintenance use and repair of the vehicle by the ultimate purchaser to provide reason able assurance of the elimination or minimization of noise emission control degradation throughout the life of the vehicle In compliance with the law the noise emission controls maintenance information in each applicable group of this manual in conjunction with the vehicle workshop manual provides these instructions to owners Recommendations for Replacement Parts Replacement parts used for maintenance or repair of noise emission controls should be genuine Freight liner 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
53. FREIGHTLINER Run Smart CASCADIA MAINTENANCE MANUAL Models CA125DC CA125SLP STI 478 3 11 10P Published by Daimler Trucks North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A Foreword Scheduled maintenance provides a key element for the safe operation of your vehicle A proper maintenance program also helps to minimize downtime and to safeguard warranties This maintenance manual provides information necessary for years of safe reliable and cost efficient vehicle operation IMPORTANT The maintenance operations in this manual are not all inclusive Also refer to other component and body manufacturers instructions for specifi inspection and maintenance instructions Perform the operations in this maintenance manual at scheduled intervals Perform the pretrip inspection and daily weekly monthly maintenance as outlined in the vehicle drivers manual Major components such as engines transmissions and rear axles are covered in their own maintenance and operation manuals that are provided with the vehicle Perform any mainte nance operations listed at the intervals scheduled in those manuals Your Freightliner Dealership has the qualifie technicians and equipment to perform this maintenance for you They can also set up a scheduled maintenance program tailored specificall to your needs Optionally they can assist you in learning how to perform these maintenance procedures IMPORTANT Descriptions and
54. Lubrication ii EE EE EE ee eee 42 09 Brake Inspectiofi ss22cd2ced0hnecasetedatcadetatecamde te Versa d nt bu usd adie ad ae EN 42 05 Haldex Slack Adjuster LUBHGSHOR ss a iva a id a is a ii 42 06 Meritor Camshaft Bracket Eubricatlol 2 BRIEKE SEDEER ER REEDE RE DEAR ED SE ORR EG EE 42 07 Meritor Slack Adjuster Lubrication llli rn 42 08 Cascadia Maintenance Manual January 2010 Brakes 42 01 Air Brake System Valve Inspection NOTE There is no scheduled air valve mainte nance on vehicles equipped with Bendix air valves and a Bendix air dryer if the air dryer desiccant is replaced at 350 000 miles 563 000 km If the desiccant is not changed at 350 000 miles 563 000 km or if the vehicle is equipped with another air dryer maintenance will have to be performed to the air brake valves See Group 42 of the Cascadia Workshop Manual for procedures IMPORTANT For vehicles equipped with an oil coalescing air dryer desiccant cartridge replace the cartridge once a year regardless of mileage 42 02 Bendix Air Dryer Desiccant Replacement IMPORTANT For vehicles equipped with an oil coalescing air dryer desiccant cartridge replace the cartridge once a year regardless of mileage AD 9 1 Park the vehicle on a level surface apply the parking brakes and chock the tires 2 Completely drain all air reservoirs Air pressure gauges should read O psi 0 kPa NOTE The compressor discharge li
55. Maintenance Interval Service Schedule Maintenance Interval Operation Frequency Miles km Initial Maintenance IM firs 10 000 16 000 Schedule I Short Haul Transport Maintenance 1 M1 every 10 000 16 000 vehicles that annually travel less than 60 000 Maintenance 2 M2 every 50 000 80 000 miles 100 000 km Maintenance 3 M3 every 150 000 240 000 Initial Maintenance IM firs 25 000 40 000 Schedule Il Long Haul Transport Maintenance 1 M1 every 25 000 40 000 vehicles that annually travel over 60 000 Maintenance 2 M2 every 100 000 161 000 miles 100 000 km Maintenance 3 M3 every 300 000 483 000 Table 1 Service Schedule 00 2 Cascadia Maintenance Manual August 2010 General Information 00 Vehicle Maintenance Schedule Table 00 03 Maintenance for Service Schedule Maint No Melntenance sene oe ee 1st IM and M1 10 000 16 000 2nd M1 20 000 32 000 3rd M1 30 000 48 000 4th M1 40 000 64 000 5th M1 and M2 50 000 80 000 6th M1 60 000 96 000 7th M1 70 000 112 000 8th M1 80 000 128 000 9th M1 90 000 144 000 10th M1 and M2 100 000 160 000 11th M1 110 000 176 000 12th M1 120 000 192 000 13th M1 130 000 208 000 14th M1 140 000 224 000 15th M1 M2 and M3 150 000 240 000 16th M1 160 000 256 000 17th M1 170 000 272 000 18th M1 180 000 288 000 19th M1 190 000 304 000 20th M1
56. Manual Adjusting Nut Grease Fitting or plug NAS No Fig 7 Meritor Automatic Slack Adjuster 2 Remove the roll pin from the brake pedal pivot pin See Fig 8 3 Remove the brake pedal pivot pin Remove the brake pedal 5 Check the brake pedal mounting plate adapter for signs of wear or cracks at the bosses the area from which the pivot pin was removed Re place it if necessary 6 Check the brake pedal rollers for signs of wear or cracks Replace the rollers as needed 7 If the rollers are replaced replace the roller pin install a new cotter pin bend it to 90 degrees and apply Torque Seal OPG F900 White to the cotter pin 8 Remove the plunger from the valve Using alco hol clean the existing grease from the plunger Check the plunger for signs of wear or cracks Replace it if necessary 9 Lubricate the plunger with barium grease BW 246671 10 Insert the plunger in the valve 42 8 Cascadia Maintenance Manual January 2010 Brakes 09 10 2004 7 1430405 1 E 6 Foot Control Valve 5 Roll Pin 2 Mounting Plate 6 Roller 3 Nut and Washer 7 Roller Pin 4 Pivot Pin 8 Pedal Fig 8 Brake Pedal and Valve Assembly 11 Install the brake pedal with the pivot pin Install a new roll pin and apply Torque Seal OPG F900 White to the roll pin Install the brake valve assembly See Section 42 08 Subject 110 of the Cascadia Workshop Manual for instruc
57. Meritor Camshaft Bracket Lubrication NOTE If equipped with an extended maintenance Q Plus brake system the cam shaft bracket will not have a grease fitting These camshafts use a special NLGI Grade synthetic polyurea grease and do not require lubrication for 3 years or 500 000 miles 800 000 km whichever comes first The extended maintenance camshaft bushings are lubricated during the brake reline service interval For ser vice and lubrication instructions see Group 42 of the Cascadia Workshop Manual For camshaft brackets with grease fittings use an NLGI Grade 1 or Grade 2 multipurpose chassis grease Lubricate the camshaft bushings through the 42 06 26 2007 f422363c Fig 5 Haldex Automatic Slack Adjuster Grease Fitting grease fittin on the camshaft bracket or the spider until new grease flow from the inboard seal See Fig 6 A 05 28 93 f420011a A Grease Exit 1 Brake Chamber 2 Slack Adjuster 3 Non Pressure Relief Grease Fitting Fig 6 Camshaft Bracket Lubrication Cascadia Maintenance Manual January 2010 42 7 42 If grease leaks out under the camhead the cam shaft bracket grease seal is worn or damaged See Group 42 in the Cascadia Workshop Manual for grease seal replacement instructions If this seal is not replaced the brake linings could become contaminated with grease The stopping distance of the vehicle will be increased which could resul
58. N 0 76 M Synthetic Gear Oil 5 Clean the fil and drain plugs Change them if necessary 5 1 For magnetic plugs use a piece of key stock or any other convenient steel slug to short the two magnetic poles and divert the magnetic field 5 2 Check the drain plug for metal particles i every 100 000 miles 160 000 km Clean mE A away the collected material deposited on each pole Magnets will rapidly lose their effectiveness as collected material 08 17 2009 f350061a bridges the gap between the two poles 5 8 Each time the oil is changed replace any magnetic drain plug that does not meet the minimum pickup capacity NOTE Meritor recommends plugs with ele ments having a minimum pickup capacity of 1 5 pounds 0 7 kg of low carbon steel 5 4 After cleaning install the drain plug s and tighten to 35 Ibf ft 47 N m 6 Fill the axle with recommended lubricant See Table 2 for drive axle lubricant capacities NOTE Some Meritor axles have a small tapped and plugged hole near and below the housing lubricant fil hole This smaller hole is for a lubricant temperature indicator only and should not be used as a fil or level hole 6 1 With the vehicle on a level surface fil the axle through the oil fil hole Lubricant should be level with the bottom of the oil fil hole To check flui level see Fig 2 A Correct lube level at bottom of fil hole B Incorrect lube level below fil hole F
59. and general condition Tighten the connections and replace the lines and hoses as needed If the compressor intake air adapter is loose remove the adapter replace the adapter gaskets and securely install the adapter Check the cooling fin on the compressor crankcase if equipped Clean the fin if they are clogged with dirt or grease 13 Cascadia Maintenance Manual August 2007 13 1 Alternators and Starters 15 Index Alphabetical Title of Maintenance Operation MOP MOP Number Alternator Battery and Starter Connections ChecCk oooo oooocooooca eee 15 01 Cascadia Maintenance Manual September 2008 Alternators and Starters 15 01 Alternator Battery and Starter Connections Check A WARNING Batteries generate explosive gas as a by product of their chemical process Do not smoke when working around batteries Put out all flames and remove any source of sparks or intense heat in the vicinity of the battery compartment Make sure the battery compartment has been completely vented before disconnecting or connecting the battery cables Battery acid is extremely harmful if splashed in the eyes or on the skin Always wear a face shield and protective clothing when working around batteries 1 Check the tightness of the alternator bracket fas teners tighten the fasteners as needed For torque values see Group 15 of the Cascadia Workshop Manual 2 Check that all electrical connections at the alter
60. ascadia Workshop Manual 02 27 2007 NOTE Shown without pinch bolt to provide clarity 1 Cross Tube Split f320033a Fig 2 Tie Rod End Adjustment 33 03 Tie Rod Lubrication Meritor Axles For any Meritor axle that requires lubrication of the tie rod ends wipe the grease fitting clean then pump multipurpose chassis grease NLGI Grade 1 696 12 hydroxy lithium stearate grease or NLGI Grade 2 896 12 hydroxy lithium stearate grease into the tie rod ends until all used grease is forced out and fresh grease is seen at the ball stud neck Cascadia Maintenance Manual August 2007 33 1 33 33 04 All Axle Alignment Check Drive Axle Alignment Checking Check the axle alignment parallelism and thrust angle measurements for the rear drive axles Use the applicable procedure and specification in Group 35 of the Cascadia Workshop Manual Toe In Inspection For vehicle alignment to be accurate the shop floo must be level in every direction The turn plates for the front wheels must rotate freely without friction and the alignment equipment must be calibrated every three months by a qualifie technician from the equipment manufacturer Freightliner dealers must have proof of this calibration history 1 Apply the parking brakes and chock the rear tires 2 Raise the front of the vehicle until the tires clear the ground Place safety stands under the
61. ate 6 Check for loose nuts or bolts see Fig 1 on the fift wheel and the mounting Set a torque wrench to the maximum torque value for the bolt being checked and confir that the torque is to specification Do not loosen the bolt to check the torque See Group 31 of the Cascadia Work shop Manual for bolt torque specifications 7 Check all springs to see if they are securely fas tened and are not deformed WARNING Do not disassemble the fifth wheel to inspect the springs The springs are under extreme pressure and could cause serious injury 8 Check wedge adjustment 8 1 Open the kingpin lock and vertically in sert a two inch 50 mm diameter shaft 31 8 2 Release the lock by tripping the release latch at the bottom of the throat 8 3 Adjust the wedge stop at the end of the wedge to approximately 1 4 inch 6 mm clearance by turning the wedge stop rod located on the right side of the top plate 9 Replace cracked worn or damaged parts with new parts Replace all loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and washers on fift wheel mountings 10 After inspecting the fift wheel lubricate all mov ing parts with a chassis or multipurpose grease Apply a generous coating of grease to the top plate to fil the grooves or depressions on the top plate See Maintenance Operation 31 02 for lubrication instructions Holland 1
62. 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 The scribe must be held firml in place so that a single straight line is scribed all the way around each front tire 5 Place a turn plate or turntable under both front tires Remove the safety stands and lower the vehicle Remove the lock pins from the gauges make sure the tires are exactly straight ahead On vehicles with rack and pinion steering center the rack using the pointers on the front of the input shaft housing See Fig 3 NOTE If turn plates or turntables are not avail able lower the vehicle Remove the chocks from the rear tires and release the parking brakes Move the vehicle backward then for ward about six feet two meters 6 Place a trammel bar at the rear of the front tires locate the trammel pointers at spindle height and adjust the pointers to line up with the scribe lines on the center ribs of the front tires See Fig 4 Lock in place Check that the scale is set on zero Front Axle 04 26 2007 1330239 Align the pointers to center the steering Fig 3 Centering the Rack and Pinion Steering Gear 4 A gt D B gt 08 29 94 f330082a NOTE B minus A equals toe in Fig 4 Wheel Toe In overhead view 7 Place the trammel bar a
63. capscrews and reservoir from the cover Remove the cover tetraseal 5 Drain the air tank and disconnect the line from the evaporator outlet Remove the check valve retainer spring and disc 6 Install the disc spring and check valve retainer and connect the line to the evaporator outlet Install the cover tetraseal Install the reservoir on the cover and tighten the capscrews 9 Fill the reservoir with 40 ounces 1183 mL of methyl alcohol then install the fille cap 42 05 Brake Inspection Parking Brake Operational Check CAUTION Perform the following check in a clear safe area If the parking brakes fail to hold the vehicle per sonal injury or property damage may result 1 With the engine running and air pressure at cut out pressure set the parking brake 2 Putthe vehicle in the lowest gear and gently at tempt to move it forward The vehicle should not Cascadia Maintenance Manual January 2010 42 5 42 move If the vehicle moves the parking brakes are not operating correctly and must be repaired before the vehicle is returned to service See Group 42 of the Cascadia Workshop Manual for repair procedures Brake Component Inspection 1 Park the vehicle on a level surface set the park ing brake and chock the tires Once the tires are chocked release the parking brake A WARNING Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits
64. ce the heater thermostat 9 Remove the heater thermostat assembly and place it in a freezer for about fiv minutes to cool it below 40 F 5 C Remove the cold heater thermostat assembly and check resis tance between the heater thermostat terminals Resistance should be 1 5 to 3 0 ohms As the temperature of the heater thermostat assembly increases the ohm reading will increase When the temperature goes above 45 F 7 C mea sured resistance should be infinit ohms If the heater thermostat does not operate as outlined replace it If it does operate as outlined install it 42 04 Alcohol Evaporator Cleaning and Inspection Maintenance is required during both the freeze sea son and the off season to keep the alcohol evapora tor in good working order 42 Off Season During the off season drain the unit of alcohol At regular engine service intervals open the drain cock to remove moisture from the alcohol evaporator Be fore reactivating the evaporator for the next freeze season drain disassemble inspect and steam clean the unit of any sludge that may have accumu lated It is advisable to replace any rubber parts when assembling the alcohol evaporator Perform this service just before the freeze season Freeze Season Reactivation 1 Park the vehicle on a level surface and apply the parking brakes Shut down the engine Chock the tires 2 Remove the fille cap and check the cap tet raseal 3 Remove the
65. ction gauge Vehicles may be equipped with either a manual reset restriction indicator with graduations Fig 1 or a go no go restriction indicator without graduations Fig 2 1 Inspect the air restriction indicator to see if air restriction equals or exceeds the maximum al lowable restriction For instructions see the Cas cadia Driver s Manual 2 If necessary replace the air cleaner element For air cleaner element replacement instructions see Group 09 of the Cascadia Workshop Manual 3 Inspect the air cleaner housing for cracks leaks or any other damage If the air cleaner housing or element is damaged replace it Reset the air restriction indicator 5 Each time the air cleaner housing is replaced perform the procedures in MOP 13 01 04 08 2005 f090431 FILTER PUSH BUTTON TO RESET 08 07 2007 f090452 Fig 1 Manual Reset Air Restriction Indicator Graduated Fig 2 Manual Reset Air Restriction Indicator Go No Go Cascadia Maintenance Manual August 2009 09 1 Air Compressor 13 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Compressor Inspecioni irc diarrea ra ci ai Pe 13 01 Cascadia Maintenance Manual August 2007 Air Compressor 13 01 Air Compressor Inspection Inspect the air intake line oil supply and return lines and coolant supply and return hoses for tight connec tions
66. d U joints may not receive enough grease Using lithium 12 Hydroxy stearate grease NLGI Grade 1 or Grade 2 with EP additives lubricate until new grease can be seen at all four U joint seals Fresh grease must be seen escaping from all four bearing cap seals of each U joint On yokes equipped with a yoke bearing cap if most of the grease being added to a U joint can be seen escaping from just one of the U joint seals check the torque on the capscrews at that seal 4 Tighten the bearing cap capscrews 43 Ibf ft 49 N m If the capscrews were already tight or all of the U joint seals still do not purge remove the bearing cap at that seal and examine the seal for damage If the seal is damaged replace the complete U joint 5 If grease does not appear at one seal use a pry ing tool to pry the U joint trunnion away from the non purging seal or tap the driveshaft or yoke with a plastic or rawhide mallet on the side oppo site the dry seal while continuing to lubricate If grease still does not appear loosen the cap screws at the bearing with the dry seal to relieve seal tension Lubricate the U joint until new grease is seen at the seal then tighten the cap screws to the correct torque specifications If the bearing will not take grease replace the U joint Refer to Group 41 of the Cascadia Workshop Manual for replacement instructions 6 Check the purged grease If it appears rusty gritty or burned replace the U
67. d or loose Re place the wire if it is damaged 6 Check the overall condition of the air conditioning hoses Look for cracks cuts and abrasions on the hoses Replace damaged hoses For re 83 p E 08 25 94 830641 Check clearance in three equally spaced places Fig 1 Drive Plate Clearance Inspection placement instructions see Group 83 of the Cascadia Workshop Manual Also check for loose fitting on all of the air conditioning compo nents 7 Check for a buildup of road debris on the con denser fins For cleaning instructions see Group 83 of the Cascadia Workshop Manual 83 02 Air Filter Replacement The HVAC system has three filter that must be re placed periodically to maintain proper system opera tion The cabin fresh air intake filte is accessed from under the hood and the recirculation filte is ac cessed from inside the cab The sleeper air filte is accessed through an access panel on the cabinet behind the driver s seat Cab Fresh Air Filter Replacement IMPORTANT When replacing the air filte use only a Freightliner approved air filte 1 Park the vehicle on a level surface set the park ing brake and shut down the engine Chock the tires Open the hood Remove the intake screen See Fig 2 4 Lightly press on the filte tray handle to disen gage the lock see Fig 3 and slide the tray out of the slot in the plenum Cascadia Maintenance Manual August 2010
68. e 1 for a list of some of the precharged anti freeze available Use of an equivalent antifreeze to those listed in the table is also acceptable tions Always check that the antifreeze meets Freight liners specification and is at the proper concen 20 2 Cascadia Maintenance Manual August 2007 Engine Cooling Radiator tration for protection in the vehicle operating area Freightliner specifie that antifreeze must be an ethylene glycol solution that meets GM 6038 M Engineering Standards or a ethylene gly col solution that has less than 0 1 anhydrous sodium metasilicate and meets either GM 1825 M or GM 1899 M Engineering Standards If supplemental coolant additives are being used add the supplements to the coolant as neces sary See the coolant additive manufacturer s instructions for the correct amount of additive required Don t forget to consider the volume of the supplemental coolant additive being added to the system when determining the amount of coolant required to refil the system NOTE You can mix purple pink coolant pre charged with a borate nitrate based additive with the common green coolant although some color change will be apparent 14 Replace the surge tank cap s 15 Return the hood to the operating position 16 Start the engine and turn on the cab heater Allow the engine to warm up to normal operating temperature Check the radiator and hoses for leaks Repair as needed 17 Shut off the engine
69. e 24 2 1 2 64 Standard Stroke 30 2 51 Long Stroke 30 2 1 2 64 9 Less than 1 1 2 38 12 Standard Stroke 16 Less than 1 3 4 44 Meritor 20 24 Less than 1 7 8 48 Long Stroke 24 Less than 2 51 Standard Stroke 30 Long stroke design is indicated by a tag or embossing on the brake chamber t Specification are relative to a brake application with 80 to 90 psi 550 to 620 kPa air pressure in the brake chambers Table 1 Brake Chamber Stroke Specifications 42 6 Cascadia Maintenance Manual January 2010 Brakes 5 Start the engine and build air pressure to at least 100 psi 689 kPa Shut down the engine 6 Check all of the foundation brake components for damage wear and loose or missing parts Re pair as needed See Group 42 of the Cascadia Workshop Manual for repair procedures 42 06 Haldex Slack Adjuster Lubrication Automatic slack adjusters that have a grease fittin must be lubricated periodically to ensure proper brake operation WARNING Failure to lubricate slack adjusters could lead to dragging brakes or a brake failure resulting in property damage personal injury or death CAUTION Do not use moly disulfide loaded grease or oil Both the life and reliability of the slack adjuster will be reduced if this type of grease is used Lubricate the automatic slack adjuster at the grease fitting See Fig 5 Use standard chassis lubricant for Haldex slack adjusters 42 07
70. e lever to get it to be vertical 3 Measure the distance between the left forward most axle stop and the suspension as indicated see Table 1 Table 2 Table 3 Table 4 and Table 5 for an acceptable range of heights for each suspension IMPORTANT Suspensions with Dual Leaf Springs Measure between the top of the U bolt and the bottom of the axle stop Suspension 01 12 2000 f320562a Valve Mounting Bracket Height Control Valve Stud Bolt Linkage Rod Axle Qu ect Fig 2 Barksdale Height Control Valve Installation side view typical Suspensions with Single Leaf Springs Mea sure between the top of the U bolt pad and the bottom of the axle stop 4 fthe measurement is not within the acceptable range refer to the Cascadia Workshop Manual for adjustment instructions If the distance is within the acceptable range apply the parking brakes 32 2 Cascadia Maintenance Manual August 2010 Suspension 32 7 l J 12 20 2005 f320838b 09 24 2009 f320961a Suspension Height Measurement Measure Point Min Target Max 5 2 3 8 inch 2 5 8 inch 2 7 8 inch MEE ae Here 60 mm 67 mm 73 mm Table 2 Suspension Ride Height Measurement Single Leaf Spring 20k 40k High Ride Suspension Height Measurement Measure Point Min Target Max _ 2 3 8
71. e 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 o Res kr er M2 Maintenance Interval Operations for Service Schedules and II Check 00 05 Perform All M1 Operations 15 01 Alternator Battery and Starter Check 20 01 Pressure Relief Cap Check 20 03 Fan Clutch Check noise emission control 26 02 Transmission Fluid Level Inspection 26 03 Manual Transmission Air Filter Regulator Check Cleaning or Replacement 31 04 Fairing Bumper Wear Check 32 01 Suspension Inspection 32 02 Suspension U Bolt Torque Check 33 01 Knuckle Pin Lubrication Meritor Axles 33 02 Tie Rod Inspection 33 03 Tie Rod Lubrication Meritor Axles 35 02 Axle Breather and Axle Lubricant Level Inspection 42 01 Air Brake System Valve Inspection 42 03 Air Dryer Inspection 42 04 Alcohol Evaporator Cleaning and Inspection 42 07 Meritor Camshaft Bracket Lubrication 42 08 Meritor Slack Adjuster Lubrication 46 01 Drag Link Inspection 46 03 Power Steering Fluid Level Inspection 46 04 Power Steering Gear Lubrication 46 05 Drag Link Lubrication 46 06 Rack and Pinion Steering Inspection 47 01 Fuel Filter Replacement 47 02 Fuel Water Separator Element Checking and Replacement 54 01 Trailer Cable Inspection and Cleaning 60 01 Mirror Folding Check 83 01 Air Conditioner Inspection 83 02 Air Filter Replacement
72. e park ing brake and shut down the engine Chock the tires Loosen the passenger side kick panel tilt it out and carefully twist and remove the light bulb socket from the lens on the back of the panel Move the panel out of the way See Fig 6 Remove the door step plate and then pull the door seal loose from the bottom of the door opening to just above the filte area Remove the A pillar trim panel remove the screw located under the step plate and dis engage the spring clips by pushing the panel to wards the center of the cab 83 2 Cascadia Maintenance Manual August 2010 Heater and Air Conditioner 04 18 2007 f831719 1 Filter Fig 5 Cab Recirculation Air Filter shown out of the vehicle for clarity f831718 04 17 2007 1 Kick Panel 2 Side Trim Panel 3 Step Plate 4 Door Seal Fig 6 Panels 4 Remove the filte from the intake recess in the back of the plenum Pull it loose along the bot 83 tom edge of the recess and slide it straight down See Fig 7 f831720 04 25 2007 1 Filter Fig 7 Removing the Filter 5 Slide a new filte up into the recess slots of the plenum Be sure that it fully seats into the slot all the way around the opening 6 Install the A pillar trim panel and then the door seal and finall the door step plate 7 Position the passenger side kick panel and in stall the li
73. e the U bolt nuts could result in spring breakage and abnormal tire wear 1 Park the vehicle on a level surface and apply the parking brakes Chock the tires 2 Check the U bolt torque See Table 6 for U bolt torque specifications Tighten in a diagonal pat tern as shown in Fig 3 Set a click type torque wrench to the mid point torque value for the fas tener being checked Turn the wrench in a clock wise motion looking up until the torque wrench clicks then release pressure on the torque 01 05 99 2 3 1320783 Fig 3 Tightening Pattern for U Bolt High Nuts Spring U Bolt High Nut Torque Values Size Torque Ibf ft N m 5 8 18 180 230 245 313 3 4 16 270 330 367 449 7 8 14 420 500 571 680 32 4 Cascadia Maintenance Manual August 2010 Suspension Size Spring U Bolt High Nut Torque Values Torque Ibf ft N m 1 14 520 600 707 816 Table 6 Spring U Bolt High Nut Torque Values 32 Cascadia Maintenance Manual August 2010 32 5 Front Axle 33 Index Alphabetical Title of Maintenance Operation MOP MOP Number All Axle Alighmebb Check avatars ADDR RR 2 A do a reta drive 33 04 Knuckle Pin Lubrication Meritor Axles o o ooooo o Es SE RR RR ee ee 33 01 Tie Rod Inspections ass aed greater dei bee ad A A A RU Re BO ED BEE 33 02 Tie Rod Lubrication Meritor Axles o 33 03 Cascadia Maintenance Manual August 2
74. e torque of frame fasteners inspect the frame for cracks and other damage Set a click type torque wrench to the maximum torque of the fastener you are checking Apply pressure until the torque wrench clicks Do not loosen the bolt to check the torque See the applicable torque table in the Cascadia Workshop Manual for torque specifications CAUTION Make sure frame fasteners are properly tightened Continued vehicle operation with loose fasteners could result in bracket or frame damage Check the fasteners at the following locations e Axle Stops e Deck Plates Equalizer Brackets Exhaust Brackets Fifth Wheel Legs Fifth Wheel Mountings e Frame Crossmembers and Gussets Front Frame Extension and Brackets Front Suspension Spring Brackets Cascadia Maintenance Manual August 2007 31 5 31 e Fuel Tank Brackets e Radius Rods e Rear Suspension Spring Brackets e Shock Absorbers e All Other Frame Fasteners Any component that shows signs of cracking or other damage must be repaired or replaced Refer to the Cascadia Workshop Manual for repair or replace ment information in the respective section for the component in question 31 04 Fairing Bumper Wear Check Frame and Frame Components Vehicles equipped with chassis side fairings and for ward mounted battery boxes have latched front pan els The bumpers on these fairings provide the ten sion for the latch mechanism These bumpers will wea
75. eather mixture can be safely used up to 32 F 0 C Commercially available automatic transmission flui may be used in place of SAE 10 engine oil Automatic transmission flui can be used for all temperatures do not mix it with kerosene 3 Coat the threads of the fil plug with a small amount of Loctite 242 or equivalent sealant Install the fil plug Rear Axle finger tigh in the rear axle shift unit housing Using a wrench tighten it an addi tional 1 1 2 turns 35 8 Cascadia Maintenance Manual August 2007 Wheels and Tires 40 Index Alphabetical Title of Maintenance Operation MOP MOP Number Wheel NALE heck usina ti a a aa EA EE ES GEGEE 40 01 Cascadia Maintenance Manual August 2007 Wheels and Tires 40 01 Wheel Nut Check IMPORTANT After a wheel has been installed the wheel nut torque must be rechecked after 50 to 100 miles 80 to 160 km of operation Check the torque on all wheel nuts See Table 1 for torque specifications and see Fig 1 for the wheel nut tightening sequence NOTE Torque values are given for lubricated threads Apply 2 drops of SAE 30W oil to a point between the nuts and flanges Ay CAUTION Insufficient wheel nut torque can cause wheel shimmy resulting in wheel damage stud break age and extreme tire tread wear Excessive wheel nut torque can break studs damage threads and crack discs in the stud hole area Use the recom mended torque values and follow the ti
76. ect the bolt paying attention to the threads and O ring grooves IMPORTANT Use only the grease supplied with Bendix replacement kits 8 Lubricate the O rings bolt O ring grooves seal ing rings and cartridge grooves Lubricate the end cover bore for the bolt Cascadia Maintenance Manual January 2010 42 3 42 9 Install both O rings on the cartridge bolt then using a twisting motion insert the assembled desiccant cartridge bolt in the end cover 10 Install the desiccant cartridge on the end cover making sure the cartridge is properly seated and flus on the end cover NOTE It may be necessary to rotate the car tridge slightly until the anti rotation lugs are properly aligned and allow the cartridge to rest flus against the end cover 11 Using a wrench or socket tighten the desiccant cartridge bolt 70 Ibf ft 95 N m Do not over torque 12 Before placing the vehicle in service perform the test below 12 1 Close all reservoir drain cocks 12 2 Build system pressure to governor cut out and note that the AD IP air dryer purges with an audible escape of air 12 3 Fan the service brakes to reduce system air pressure to governor cut in Note that the system once again builds to full pres sure and is followed by a purge at the AD IP air dryer exhaust 12 4 Check for excessive leakage around the head of the desiccant cartridge where it contacts the end cover With the com pressor in loaded mode c
77. ehicles with screw on caps with O rings make sure that the O ring is not cracked or deteriorated Replace the cap if the gasket shows deterioration or dam age 20 02 Radiator Pressure Flushing and Coolant Change NOTE For additional instructions on cleaning and flushin the engine cooling system see the applicable engine manufacturer s maintenance and operation manual 1 Apply the vehicle parking brakes then chock the tires Tilt the hood 20 2 Place a suitable container under the elbow of the radiator outlet pipe and the radiator The con tainer should hold at least 60 quarts 59 liters of fluid Do not remove or loosen the surge tank cap until the engine and cooling system have completely cooled Use extreme care when removing the cap A sudden release of pressure from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause seri ous personal injury 3 Remove the surge tank cap 4 Remove the drain plugs at the radiator side tank and at the lower radiator outlet pipe elbow if equipped See Fig 1 Allow the coolant to drain Va 06 29 95 1011008 NOTE Cummins engine shown 1 Coolant Drain Plug Fig 1 Coolant Drain Plug Location 5 Disconnect the radiator upper and lower hoses and install the surge tank cap and the radiator side tank drain plug Attach the flushin gun nozzle to the radiator at the lower radiator hose opening Run the wa
78. etical Title of Maintenance Operation MOP MOP Number Falling Bumper Wear heel ses rd ars eii idea va aya 31 04 Filth Wheel Inpec vf quee tirade Pa MEE duh QUE dele dem awh GE ER ed d gne bee de 31 01 Fifth Wheel LUDNICA uoo ket ee e uem Rey Xe owe o wes EN REOR X eg ee ea 31 02 Frame Fastener Torque Check oe todos titer Eur odor E a GA ie EER Rd e d ronde adum anes 31 03 Cascadia Maintenance Manual August 2007 Frame and Frame Components 31 01 Fifth Wheel Inspection All fifth wheel maintenance adjustment and re building must be done only by a qualified me chanic Improper or incomplete procedures could result in a possible disengagement of the trailer from the tractor which could result in personal injury or property damage Parts are under spring compression Wear safety goggles while servicing the fifth wheel Failure to do so can result in personal injury due to parts ejecting with force Fontaine 1 Disconnect the tractor from the trailer For in structions see Chapter 10 of the Cascadia Driver s Manual 2 Thoroughly steam clean the fift wheel Look for cracks in the fift wheel assembly mounting brackets and mounting parts 4 Check the jaw and stationary jaw for mushroom ing and check that the serrations at the jaw and wedge are in good condition 5 Test the safety lock latch for ease of operation NOTE The safety lock latch is located at the front of the fift wheel on the top pl
79. g a hand type grease gun apply NLGI Grade 2 or 3 multipurpose chassis grease until it starts to come out past the sector shaft seal Fig 2 11 28 95 1461071 1 Sector Shaft Grease Fitting Fig 2 TRW TAS Series Sector Shaft Lubrication 46 05 Drag Link Lubrication 1 Using a clean rag wipe all dirt from both drag link grease fittings See Fig 3 46 2 Cascadia Maintenance Manual November 2009 Steering 2 Using a pressure gun apply clean grease at the grease fitting until old grease is forced out of the socket Use multipurpose chassis grease NLGI Grade 2 8 12 hydroxy lithium stearate grease or NLGI Grade 1 6 12 hydroxy lithium stearate grease Grade 2 is preferred Wl 2 1 11 27 95 1461072 1 Grease Fitting at Pitman Arm 2 Grease Fitting at Axle Steering Arm Fig 3 Drag Link 46 06 Rack and Pinion Steering Inspection All steering system components are critical for safe operation of the vehicle Failure to maintain the steering system as specified may result in loss of steering control which could lead to per sonal injury and property damage The rack and pinion steering system is designed to be maintenance free Inspect the system as de scribed below and repair or replace any components that are worn or damaged Figure 4 shows the com ponents of the rack and pinion steering system 1 Park the vehicle on a level surface and chock the rear tires 2
80. g the following applications on the ServicePro provides Web based access to the most up to date versions of the publications listed above In addition the Service Solutions feature provides di agnostic assistance with Symptoms Search by connecting to a large knowledge base gathered from technicians and service personnel Search results for both documents and service solutions can be narrowed by initially entering vehicle identificatio data PartsPro is an electronic parts catalog system showing the specifie vehicle s build record Cascadia Maintenance Manual May 2010 Introduction EZWiring Descriptions of Service Publications EZWiring makes Freightliner Sterling Western Star Thomas Built Buses and Freightliner Custom Chassis Corporation products wiring drawings and floatin pin lists available online for viewing and printing EZWiring can also be ac cessed from within PartsPro Warranty related service information available on the AccessFreightliner com website includes the following documentation Recall Campaigns Field Service Campaigns Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice These campaigns pertain to matters of vehicle safety All recall campaigns are distributed to dealers customers receive notices that apply to their vehicles Field service campaigns are concerned with non safety related service work or replacement of parts
81. ght bulb socket in the lens then fasten the panel Sleeper Air Filter Replacement The sleeper air filte is located on the forward side of the blower fan housing under the cabinet directly behind the driver s seat IMPORTANT When replacing the air filte use only a Freightliner approved air filte 1 Park the vehicle on a level surface set the park ing brake and shut down the engine Chock the tires Cascadia Maintenance Manual August 2010 83 3 83 2 Remove the sleeper HVAC access panel on the inboard side of the cabinet See Fig 8 The panel is held in place with four spring clips Pull straight out to remove it lcs OoOo 3 Sog0d0lo0lo 62008990808 020809 29808009 0908 080809 26080 pu 808 3989898 8 Gua ur D D N 05 15 2007 1831713 Fig 8 Sleeper HVAC Access Panel 3 Liftthe filte out of the slot See Fig 9 04 26 2007 f831721 1 Filter Fig 9 Removing the Filter 4 Install a new filte in the slot making sure that it is completely seated in the slot Heater and Air Conditioner 5 Install the access panel ParkSmart Air Filter Replacement The ParkSmart air filte is located on the inboard side of the blower fan housing under the cabinet directly behind the driver s seat IMPORTANT When replacing the air filte use only a Freightliner approved air filte 1 Park the vehicle on a level surface set the park
82. ghtening sequence shown in Fig 1 Disc Wheel Fastener Torque Torque Ibf ft N m Oiled Nut Size M22 x 1 5 450 500 610 678 NOTE If using specialty fasteners consult the manufacturer for recommended torque levels Table 1 Disc Wheel Fastener Torque 10 8 03 06 2000 1400157 Fig 1 Wheel Nut Tightening Sequence 40 Cascadia Maintenance Manual August 2007 40 1 Driveline Title of Maintenance Operation MOP Driveline Inspector ceci dae oe Driveline Lubrication o ooooooo ooo 41 Index Alphabetical MOP Number Cascadia Maintenance Manual August 2007 Driveline 41 01 Driveline Inspection 41 1 Park the vehicle on a level surface apply the parking brakes and chock the tires Ah CAUTION Due to the extreme load occurring at high speed rotation a loose or broken capscrew at any point in the driveline will weaken the driveline connec tion which could eventually result in serious ve hicle damage Tighten bearing cap capscrews or yoke strap capscrews to specified torque being careful to not overtighten 2 For U joints with bearing caps tighten bearing cap capscrews 43 Ibf ft 49 N m See Fig 1 For Arvin Meritor RPL series U joints tighten bearing cap capscrews 125 Ibf ft 169 N m See Fig 2 For U joints with yoke straps tighten yoke strap capscrews 125 Ibf ft 169 N m See Fig 3 12 0
83. hanged inspect the drain plug each time for large quantities of metal particles After cleaning install the drain plug s and tighten to 40 to 60 Ibf ft 54 to 81 N m Fill the axle with the recommended lubricant See Table 4 for recommended drive axle lubri cants and Table 5 for drive axle lubricant ca pacities 35 4 Cascadia Maintenance Manual August 2007 Rear Axle 35 Dana Spicer Drive Axle Recommended Lubricant the top of the standpipe opening To check flui level see Fig 2 Lubricant SAE Lubricant Type Condition Viscosity 6 2 Install and tighten the fil plug 40 to 60 Grade Ibf ft 54 to 81 N m Roada Sie 79w9 9 Two Speed Axles With Shift Unit Roadranger Service WO opee xles l l NI Synthetic Drive Axle Lubricants or Off Highway Dana Spicer and Meritor i i Equipment or i ie eee ane Extra 80W 140 1 Remove the shift unit housing cover See Fig 5 MIL L 2105D Heavy Loads Drain and discard the old lubricant Discard the housing cover gasket Table 4 Dana Spicer Drive Axle Recommended Lubricant Dana Spicer Drive Axle Lubricant Capacities Capacity Axle Type Axle Model Pints liters Single Drive Axle Installation Single 230805 23080D 40 18 9 Reduction 231058 23105D 48 22 7 d Tandem Drive Axle Installation DD404 DD404 P 31 14 7 1 Single z edici n DS404 DS404 P 39 18 5 DS461 P 43 20 3 t DT
84. he filte is mounted in a vertical position and should be fille with flui before installation to assure the proper flui level For optimum transmission per 26 formance change the filte each time that the flui is changed 4 Fora transmission equipped with a transmission flui filter s replace the flui filter s as follows 4 1 Place a drain pan under the transmission flui filte CAUTION To prevent skin burns from hot transmission fluid wear protective gloves when removing the filter 4 2 Place a strap or chain wrench around the filte canister and rotate it in a counter clockwise motion to separate the filte from the mounting Carefully spin the filte off the mount and remove it from the ve hicle 4 3 Apply a light coat of transmission flui to the O ring gasket on the new filte See Fig 1 Fill the filte with specifie trans mission fluid and spin the filte onto the mount NOTE The filte fill slowly so be patient to ensure the proper flui level has been set 4 4 Once the filte makes contact with the mount use a strap wrench to rotate the canister an additional 180 to 270 degrees to firml tighten the filte Wipe the filte clean of any flui after it is tightened 5 Add flui until it is level with the lower edge of the fil opening See Fig 1 If the transmission has two fil openings add flui to the level of both openings See Table 1 for approved trans mission lubricants See Table 2 for transmission
85. hed to the ATS for leaks or damaged wires No leaks are allowed See Fig 1 Fig 2 or Fig 3 for Detroit Diesel ATS sensor locations Check the DPF exterior surface for dents or other damage A dent over 3 inches 76 mm in diameter and 1 4 inch 6 mm deep could cause internal damage to the DPF causing it to malfunction Exhaust 8 Check the SCR catalyst for dents and other damage 9 Check for heat discoloration on the surface of the ATD Heat discoloration may indicate internal damage especially around the DPF NOTE Diesel exhaust flui creeps causing white crystals to form around the line fittings The presence of crystals does not mean the system has a leak Replacing fitting or trouble shooting components is not necessary unless there is a system failure or a fault code 10 Check the DEF tank pump metering unit and lines for leaks See Section 49 02 of the Casca dia Workshop Manual for repair procedures 11 Check any wires lines or hoses within 4 inches 10 cm of the exhaust system for heat damage Repair or reroute as needed 08 20 2009 NOTE The sensor box item 8 contains the SCR inlet and outlet NOx sensors DPF outlet pressure sensor and the DOC inlet pressure sensor 1490355 1 DOC Outlet Temperature 6 Exhaust Outlet 11 SCR Outlet NOx Sensor Port Sensor 7 DEF Metering Unit 12 SCR Inlet NOx Sensor Port 2 DOC Inlet Pressure Sensor 8 Sensor Box see note above 13 14 Pin
86. idge lubricate the sealing rings with silicone grease IMPORTANT Only use the silicone grease sup plied with Bendix replacement kits 5 Screw the desiccant cartridge onto the body by hand until the seal makes contact with the body Rotate the cartridge clockwise about one full turn Tighten the cartridge firml AD IP 1 With the vehicle parked on a level surface apply the parking brakes and chock the tires 2 Using a wrench or a socket loosen the desiccant cartridge bolt Then separate the desiccant car tridge from the end cover 3 Pull the cartridge bolt out of the cover and re move the cartridge 04 16 98 1 Desiccant Cartridge 2 Cartridge Sealing Ring 3 Threaded Base Post 1421910 Fig 3 AD IS Desiccant Cartridge Replacement A WARNING Do not attempt to disassemble the desiccant car tridge assembly Parts for the assembly are not available and the cartridge contains a 150 Ib spring that cannot be mechanically caged Disas sembly could release the spring resulting in per sonal injury 4 Remove and discard both O rings from the car tridge bolt 5 Using a clean rag wipe clean the inside of the end cover Clean the cartridge bolt bore in the end cover and the sealing surfaces for the large and small diameter desiccant cartridge sealing rings 6 Inspect the end cover for physical damage then inspect all air line fitting for corrosion replace as necessary 7 Clean and insp
87. ig 2 Axle Lubricant Level Inspection Meritor Drive Axle Lubricant Capacities Axle Model Capacity pt L Single Drive Single Reduction RS 21 160 39 5 18 7 RS 23 160 39 5 18 7 RS 23 161 37 2 17 6 RS 23 185 47 3 22 4 RS 25 160 37 2 17 6 Tandem Drive Single Reduction RT 40 145 RT 40 145A Forward 30 2 14 3 RT 40 145P Rear 25 8 12 2 RT 44 145 RT 44 145P RON EX Rear 25 1 11 9 Forward 39 1 18 5 RT 46 160 RT 46 160P Rear 34 4 16 3 Quantities listed are approximate Fill axle until lubricant is level with bot tom of f Il hole with vehicle on level ground t See Traction Equalizer Additives in the text Table 2 Meritor Drive Axle Lubricant Capacities 35 2 Cascadia Maintenance Manual August 2007 Rear Axle 6 2 Install and tighten the fil plug 35 Ibf ft 47 N m 7 Whenever the interaxle differential housing has been drained add an additional 2 pints 0 9 L of the recommended lubricant directly into the inter axle differential housing 8 Remove the chocks then drive the vehicle un loaded for 1 or 2 miles 2 or 3 km at speeds not to exceed 25 mph 40 km h to thoroughly circulate lubricant throughout the carrier and housing assemblies Freightliner IMPORTANT On Freightliner axles the oil change interval for Schedule III vehicles is ex tended to 500 000 miles 800 000 km for axles with weight ratings of 34 000 to 40 0
88. inch 2 5 8 inch 2 7 8 inch A Measure Here co mm 67 mm 73 mm Table 1 Suspension Ride Height Measurement Dual Leaf Spring 20k 40k High Ride 09 24 2009 Suspension Height Measurement f320961a Measure Point Min Target Max B 2 3 8 inch 2 1 2 inch 2 7 8 inch A Measure Here 60 mm 64 mm 73 mm Table 3 Suspension Ride Height Measurement Single Leaf Spring 10k 12k 15k 18k Mid Ride and 40k Low and Mid Ride Cascadia Maintenance Manual August 2010 32 3 32 Suspension wrench and turn the wrench again until it clicks If the nut turns on the second application the bolt is stretching and must be replaced See Group 32 of the Cascadia Workshop Manual for bolt replacement procedures 09 28 2005 f821046a Suspension Height Measurement Measure Point Min Target Max A Meas re Here 2 3 4 inch 3 inch 3 1 4 inch 70 mm 76 mm 83 mm 01 25 2006 1320962a Suspension Height Measurement Measure Point Min Target Max H 2 1 8 inch 2 9 82 inch 2 5 8 inch A Measure Here 54 mm 58 mm 67 mm Table 4 Suspension Ride Height Measurement Dual Leaf Spring 23k 46k 69k High Ride 32 02 Suspension U Bolt Torque Check Table 5 Suspension Ride Height Measurement Single Leaf Spring 10k 12k 15k Low and Extra Low Ride A CAUTION Failure to retorqu
89. ing a transmission with the fluid level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion Overfilling will force fluid out of the case through the main shaft openings Do not mix types and brands of fluid because of possible incompatibility Do not use fluid addi tives friction modifiers extreme pressure gear fluids or multiviscosity lubricants NOTE Fluid change intervals are extended to 500 000 miles 800 000 km on any vehicles fille with synthetic transmission fluid IMPORTANT Drain the transmission when the flui is warm If not already warm run the en gine until the transmission flui reaches operat ing temperature Shift the transmission to neu tral N and shut down the engine 1 Apply the parking brakes and chock the rear tires Place a large drain pan under the transmis sion 2 Clean the area around the fil plug and remove it from the side of the gear case Remove each drain plug from the bottom of the case 3 Clean the fil and drain plugs For magnetic plugs use a piece of key stock or any other con venient steel slug to short the two magnetic poles and divert the magnetic field Install and tighten each drain plug 50 Ibf ft 68 N m NOTE The optional transmission flui filte is a remote mount spin on type and is located be tween the transmission and the flui cooler The filte bracket is attached to the frame rail or some other nearby location T
90. ing oil lubricated wheel bearings check the oil level at the wheels and add oil if low Use the same lubricant recom mended for the drive axle NOTE When adding to or checking the oil level make certain the hub cap and plug are clean before removing the plug this will minimize the possibility of dirt and road grime entering the assembly 35 Dana Spicer 4h CAUTION Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage 1 Park the vehicle on level ground set the parking brakes and chock the tires 2 If the vehicle has just been driven allow a few minutes for the lubricant to settle 3 Clean the oil fil plug and the area surrounding it See Fig 7 Remove the plug from the fil hole or standpipe if installed in the oil fil hole 06 07 94 f350002a 1 Axle Housing Breather 2 Fill Plug 3 Temperature Indicator Plug Fig 7 Dana Spicer Axle Housing Breather IMPORTANT A lubricant level close enough to be seen or touched is not sufficient It must be level with the bottom of the fil hole or the top of the standpipe opening 4 Check that the lubricant is level with the bottom of the fil hole or with the top of the standpipe opening See Fig 2 If low check for oil leaks and correct as needed Add oil to the level of the fil plug using the lubricant recommended in Table 4 5 Install and tighten the fil plug 40 to 60 Ibf ft 5
91. ing on a fuel system have a fire extinguisher within easy reach 1 Drain the fuel below the collar level See Fig 2 2 Using Davco wrench 380134 or 382002 remove the filte collar Then remove the filte cover 3 Remove the element and dispose of it properly Install a new element Make sure the grommet is in place on the bottom of the filte element and seats completely on the filte stud 5 Install a new cover seal on the filte cover 6 Using the collar attach the filte cover with the spring to the base IMPORTANT Tighten the collar by hand only 7 Remove the filte vent Then fil the fuel water separator with fuel until the fuel level is 1 inch 2 5 cm above the collar 8 Install the filte vent on the fuel water separator 9 Start the engine and raise the rpm for one minute to purge air 47 03 Fuel Tank Band Nut Tightening Hold each fuel tank band retention nut with a wrench while backing off its jam nut Then tighten the reten tion nuts 30 to 35 Ibf 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 Ibf ft 41 N m IMPORTANT Do not overtighten Fuel 47 2 Cascadia Maintenance Manual April 2009 Fuel 47 04 30 2007 1470505 1 Filter Collar 6 Cover Seal 10 Fluid Heater Bottom Plate 2 Filter Vent and Vent Seal 7 Body 11 Mounting Capscrews 3 Filter Cover 8 Check Valve Fuel Inle
92. ir to the mounting bracket Fill the reservoir with an approved power steer ing flui to the line between the MIN COLD and MAX HOT lines See Fig 1 See Table 1 for ap proved power steering fluids dent resulting in personal injury or property dam age Wear eye protection when changing the fluid Approved Power Steering Fluids and filter Fluid Type Approved Fluid 1 Park the vehicle on a level surface shut down Automatic Transmission Fluid TES 389 the engine apply the parking brakes and chock the rear tires Table 1 Approved Power Steering Fluids Cascadia Maintenance Manual November 2009 46 1 46 Steering 8 Raise the front of the vehicle and support it with jack stands 9 Start the engine and operate it at idle Turn the steering wheel from full left to full right several times until clean flui starts flowin from the power steering filte Add flui to the reservoir to maintain the flui level between the MIN COLD and MAX HOT lines 10 Shut down the engine NOTE Always install a new power steering res ervoir filte when changing the fluid 11 Disconnect the filte from the filte cover and dis card the filte 12 Apply a thin fil of power steering flui on the gasket of the new filte Then attach the filte to the filte cover Hand tighten the filte then turn it an additional 1 4 turn 13 Install the filte and filte cover in the reservoir Make sure that the
93. ith a 5 16 inch tightening screw hex 55 Ibf in 620 N cm For Breeze Constant Torque clamps with a 3 8 inch tightening screw hex 90 Ibf in 1020 N cm NOTE All hose clamps will lose torque after installation due to compression set However when correctly installed Breeze Constant Torque clamps will hold enough torque to auto matically adjust and keep consistent sealing pressure During vehicle operation and shut down the screw tip may adjust according to temperature and pressure changes The torque may need to be adjusted for individual applica Engine Cooling R adiator VA 02 28 96 f200326 Fig 2 T Bolt Type Hose Clamp EN 08 15 94 1200286 A The screw tip must extend about 1 4 inch 6 mm B Belleville washers must collapse almost flat 1 Tightening Screw Hex Fig 3 Breeze Constant Torque Hose Clamp Installation 11 Place a pan under the coolant filte to catch en gine coolant 12 Remove the coolant filte with a strap or chain wrench Install a new coolant filte and tighten 13 Fill the cooling system with new coolant Certain equipment such as fuel heaters water filters and auxiliary heaters may increase the coolant ca pacity and require additional coolant The cooling System is fille when the coolant level reaches the MAX line on the surge tank Freightliner rec ommends the use of a precharged and premixed antifreeze when refillin the cooling system See Tabl
94. l Plugs temperature the oil will run more freely and en sure that the axle is flushed NOTE Some tandem drive axles are equipped with a cylindrical magnetic strainer located below the lube pump on the front of the power divider cover All rear axles are fitte with mag netic drain and fil plugs 4 At each axle oil change remove and clean the magnetic strainer if equipped See Fig 4 4 1 A WARNING Remove the magnetic strainer from the power divider cover Always wear eye protection when using com pressed air to clean parts as flying debris could cause permanent damage to unprotected eyes Do not point the air stream in the direction of other persons 4 2 4 3 Wash the strainer in solvent and blow it dry with compressed air to remove oil and metal particles Install and tighten the magnetic strainer 40 to 60 Ibf ft 54 to 81 N m 5 Clean the fil and drain plugs Change them if necessary 05 27 93 1 Magnetic Strainer AO 2 Power Divider f350017a Fig 4 Dana Spicer Tandem Drive Axle Magnetic 5 1 5 2 5 3 5 4 Strainer For magnetic plugs use a piece of key stock or any other convenient steel slug to short the two magnetic poles and divert the magnetic field Clean away the collected material depos ited on each pole Magnets will rapidly lose their effectiveness as collected mate rial bridges the gap between the two poles After the firs oil is c
95. lly and vertically mounted ATDS to 30 Ibf ft 41 1 On all vehicles check the condition of the muffler N m on step mounted ATDs tighten the mount body and the top stack Check the inlet outlet ing bands to 15 Ibf ft 20 N m Do not over tubes for leakage dents and corrosion and tighten check for holes in the muffler Replace parts as 5 Check for leaks around the clamps that attach required Use new parts equivalent to parts the ATD in the ATS and around the clamps that originally installed on the vehicle retain the DPF in the ATD 2 Inspect the exhaust fle hose see Fig 5 for 6 Check all sensors attached to the ATD for leaks leakage wear or damage Replace with new or damaged wires No leaks are allowed parts if replacement is needed 7 Check the DPF exterior surface for dents or 3 Check for leakage at the V band coupling which other damage See Ref A of Fig 4 A dent over attaches the exhaust pipe to the turbocharger 3 inches 76 mm in diameter or 1 4 inch 6 mm exhaust outlet See Fig 5 deep could cele internal damage to the DPF 4 If leakage exists tighten the nut on the V band causing it to malfunction coupling 85 Ibf in 940 N cm If leakage persists 8 Check for heat discoloration on the surface of install a new V band coupling the ATD Heat discoloration may indicate internal 5 Inspect the turbo outlet pipe and replace it as damage especially around the DPF needed Cascadia Maintenance Manual August
96. lubricant See under the heading Two Speed Axles With Shift Unit All Axle Models Meritor IMPORTANT On Meritor axles the oil change interval for Schedule Ill vehicles is extended to 500 000 miles 800 000 km for axles using syn thetic lubricant with a pump and filte system On single drive axles so equipped the traction equal izer may slip or stick When this happens you will hear intervals of shrill noises when the vehicle oper ates at low speed or when the vehicle makes sharp turns Use a limited slip friction modifier to correct this slip stick condition Add 1 6 ounces 35 mL of additive for each pint 0 5 L of lube capacity For all GL 5 oils add one of the following limited slip friction modifiers e Lubrizol No 6178 Lubrizol Corporation e DSL 178 Guardsman Products e Equa Torque No 2411 Sta Lube Corporation e Equa Torque No 2414 Sta Lube Corporation IMPORTANT These friction modifier generally deteriorate faster than conventional extreme pressure additives so the lubricant change schedule must be shortened when using these additives The traction equalizer additive and recommended drive axle lubricant must be 35 changed at the Maintenance 2 M2 interval instead of the Maintenance 3 M3 interval rec ommended in the Maintenance Operation Chart for axles that require only those lubricants rec ommended in Table 1 1 Park the vehicle on a level surface set the park ing brakes and
97. lubricant capacities PA Zo Ys gt d N j v V 7 A A V J 7 d A j O fA A 7 2 j E OZILI BARRIEI DIAL DA dd XIII LIE 05 27 93 A Full 1260006a B Low Fig 1 Checking Transmission Fluid Level Cascadia Maintenance Manual January 2008 26 1 26 Approved Manual Transmission Lubricants Transmission x Temp SAE Model PHbneanprype Range Viscosity MobilTrans SHC 50 RN 2952 E 5 A S All Eaton Fuller Synthetic transmission lubricant approved by All 50W Eaton Do not mix types or brands of fluid Multi weight and extreme pressure gear fluid are not recommended Call 1 800 826 4357 for a complete list of Eaton approved lubricants Table 1 Approved Manual Transmission Lubricants Eaton Fuller Transmission Lubricant Capacities Transmission Model Refill Capacity qt L 7 Speed T Series All Models 18 0 17 0 All 9 Speed Series All Models 13 5 12 8 All 10 Speed Manual except deep reduction FR and FRO Series 11 75 11 0 RT and RTX Series 13 0 12 3 RTLO Series 14 0 13 2 10 Speed Deep Reduction RTO 14908LL RTO 16908LL 14 0 13 2 10 Speed Automated Lightning Top 2 all 13 5 12 8 10 Speed Autoshift AS2 all 13 0 12 3 13 Speed RTLO Series All Models 14 0 13 2 15 Speed RTO Series All Models 14 0 13 2 All 18 Speed Series RTLO Series 14 0 13 2
98. m ATS requires special attention during regularly scheduled maintenance inspections see Fig 4 No leaks are allowed anywhere in the system If If leakage exists tighten the nut on the clamp to the required torque If leakage persists install a new clamp 2 Check the exhaust pipe bellows and each ex haust seal clamp for leakage wear cracks or damage Replace damaged components as needed If leakage exists at a clamp tighten the nuts to the required torque If leakage persists install a new exhaust seal clamp Do not reuse seal clamps Once a seal clamp is loosened or removed it must be replaced 49 4 Cascadia Maintenance Manual August 2010 Exhaust 49 10 20 2006 1490283 A Inspect this area of the canister for dents 1 Marmon Fitting at Inlet from Turbocharger 6 Sensor Housing 2 DOC Temperature Sensor 7 DPF Outlet Temperature Sensor 3 ATD Mounting Band 8 Exhaust Outlet Marmon Fitting 4 DPF Intake Pressure Sensor 9 DPF Outlet Pressure Sensor 5 DPF V Band Mounting Clamps Fig 4 Typical EPAO7 Aftertreatment Device 3 If present check the condition of the insulation 9 Check any wires lines or hoses within 4 inches material around the exhaust pipe between the 10 cm of the exhaust system for heat damage turbocharger and the ATD Repair or reroute as needed 4 Check the ATD mounting bands for tightness If needed tighten the mounting bands on horizon Pre EPAO7 Exhaust System ta
99. manufac turer to be equivalent to genuine Freightliner parts in performance and durability Freightliner Noise Emission Controls Warranty Refer to the vehicle owner s warranty information book for warranty information concerning noise emis sion controls Tampering with Noise Controls is Prohibited Federal law prohibits the following acts or the caus ing thereof 1 The removal or rendering inoperative by any per son other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use 2 The use of the vehicle after such device or ele ment of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tam pering are the acts listed below A Removal of engine noise deadening panels B Removal of cab tunnel or hood noise deadening panels C Removal of or rendering inoperative the en gine speed governor so as to allow engine speed to exceed manufacturer s specifica tions D Removal of or rendering inoperative the fan clutch including bypassing the control on any thermostatic fan drive to cause it to op erate continuously Removal of the fan shroud Removal of or rendering inoperative ex haust components including exhaust pipe clamping G Removal of air intake components
100. mel after cleaning Cascadia Maintenance Manual September 2008 15 1 Engine Cooling Radiator Title of Maintenance Operation MOP Fan Clutch Check Noise Emission Control Pressure Relief Cap Check Radiator Pressure Flushing and Coolant Change 20 Index Alphabetical MOP Number Cascadia Maintenance Manual August 2007 Engine Cooling Radiator 20 01 Pressure Relief Cap Check Do not remove or loosen the surge tank cap until the engine and cooling system have completely cooled Use extreme care when removing the cap A sudden release of pressure from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause seri ous personal injury 1 Remove the fil cap first to relieve the cooling system pressure then remove the SAE cap 2 Using a radiator cap tester check the pressure cap to see if it maintains pressure to within 10 of the pressure rating marked on the cap If it doesn t replace the cap Make sure that the re placement radiator cap is correctly rated for the cooling system of the vehicle 3 There is a second valve in the radiator cap that opens under vacuum This prevents the collapse of hoses and other parts that are not internally supported when the system cools Inspect the vacuum relief valve to be sure it is not stuck 4 Make sure that the cap seals properly on the coolant fille neck seat and that the radiator cap gasket is not damaged On v
101. merica is a Daimler company Daimler Trucks North America LLC Service Systems and Documentation CVI SSD P O Box 3849 Portland OR 97208 3849 Introduction Descriptions of Service Publications Daimler Trucks North America L via ServicePro9 formats Workshop Service Manual Maintenance Manual Troubleshooting Manual Driver s Operator s Manual Service Bulletins Parts Technical Bulletins Web based repair service and AccessFreightliner com website ServicePro PartsPro LC distributes the following major service publications in paper and electronic Workshop service manuals contain service and repair information for all vehicle systems and components except for major components such as engines trans missions and rear axles Each workshop service manual section is divided into subjects that can include general information principles of operation removal disassembly assembly installation and specifications Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems They have information such as lubrication procedures and tables flui replacement procedures flui capacities specifica tions and procedures for adjustments and for checking the tightness of fasten ers Maintenance manuals do not contain detailed repair or service information Troubleshooting manuals contain diagnostic procedures for determining causes of problems in vehicle components and sys
102. n the vehicle 4 Check the fan for bent cracked or damaged blades Replace if damaged Check for adequate clearance between the fan and other compo nents 5 Check the fan belt for wear tension and align ment Correct if necessary 6 Check for wear on the friction facing Replace the friction facing if it is worn to a 3 16 inch 4 8 mm thickness or less Also check the facing for signs of oil contamination or burn marks If evi dence of oil or burn marks are found replace the friction facing 7 Connect the battery cables Start the engine and charge the air system to 120 psi 827 kPa Manually engage and disengage the fan clutch Check the fan and fan clutch from a distance Look for vibration fan blade contact fan clutch slippage and overall fan clutch operation If the fan clutch does not operate correctly see Group 20 of the Cascadia Workshop Manual for troubleshooting and repair procedures 8 With the air system charged to 120 psi 827 kPa check the fan clutch for audible air leaks using a suitable listening device Check at the solenoid valve the air filte assem bly and the air hoses and fittings See Fig 5 Using a wet finge or a soapy water solution check for a leak in the same areas LS 05 30 2002 1200581 Fig 5 Checking for Air Leaks Horton DriveMaster 9 Ifa leak is detected remove the fan blade In stall a new seal kit See Group 20 of the Casca dia Workshop
103. ne may still contain residual air pressure open the line slowly 3 Identify tag and disconnect the three air lines from the end cover 4 Disconnect the harness connector from the heater and thermostat assembly 5 Loosen the bolt that secures the upper mounting bracket strap 6 Remove the two bolts and Nylok nuts that se cure the air dryer to the lower mounting bracket Mark the position of the mounting bracket to the end cover and mark the bolts to ease installation 7 Remove the upper mounting bracket strap fas teners then remove the strap and the air dryer 42 8 Place the air dryer on a bench and remove the remaining 6 bolts 12 washers 6 Nylok nuts and the air dryer housing See Fig 1 Discard the Nylok nuts Remove the end cover to housing O ring 9 Clamp the desiccant cartridge in a vise Clamping the end cover or housing in a vise could seriously compromise the air dryer s ability to hold air pressure which could cause a failure in the brake system resulting in property damage personal injury or death 10 Twist the end cover counterclockwise to release the cartridge from the end cover Rotate the end cover until it completely separates from the des iccant cartridge NOTE A substantial torque up to 50 Ibf ft 68 N m may be necessary to remove the desic cant cartridge NOTICE Dirt or obstructions in the O ring grooves can cause an O ring failure that will result in an air leak
104. nect the driveshaft and U jointfrom the yoke then check the drive component s shaft seal for leak age or other visible damage that may have been caused by the loose yoke Replace the seal if needed then tighten the yoke nut Refer to Group 41 of the Cascadia Workshop Manual for torque specifications If the yoke is still loose after tightening the yoke nut replace the end yoke and yoke nut Replace the prevailing torque locknut end yoke nut if it was removed for yoke replacement seal replacement or any other reason 4 Check U jointassemblies for wear by moving the driveshaft up and down and from side to side If any movement of the U jointcross in the bear ings can be felt or seen replace the U joint as sembly 5 Check if the midship bearing and mounting are loose or have deteriorated by attempting to move the driveshaft up and down and from side to side If the bearing is loose on its shaft or rattles replace it If the bearing mount is loose on the frame tighten the mounting fasteners to the proper torque value See Group 41 of the Cascadia Workshop Manualfor torque specif cations Replace the midship bearing assembly if the rubber cushion is deteriorated or oil soaled 6 Check slip joints for spline wear by moving the sleeve yoke and splined shaft back and forth See Fig 4 If the slip joint can be twisted in a clockwise or counterclockwise movement Cascadia Maintenance Manual July 2007
105. ols to tighten the bowl and element 7 Connect the water sensor and heater connectors if equipped 8 If equipped with a primer pump prime the fuel water separator 47 8 1 Loosen the vent plug Then operate the primer pump until the fuel purges at the vent plug See Fig 1 8 2 Close the vent plug 2 1 3 4 11 0 d 5 10 9 Sea 6 7 8 06 25 97 1470147 1 Mounting Head 7 Water Sensor Probe 2 Fuel Primer Pump 8 Heater Connector 3 Vent Plug 9 Drain Plug 4 Bowl O Ring 10 Sight Bowl 5 Bowl Gasket 11 Filter Element 6 Bowl Probe Plug Fig 1 Alliance Fuel Water Separator 9 Start the engine and check for fuel leaks 10 Shut down the engine and correct any fuel leaks Davco Fuel Pro 382 Check the level of fuel in the fuel filte Replace the fuel water separator element only when the filte element is completely covered NOTE In the event of an emergency when the filte needs replacement but a Davco filte is not available a temporary filte can be used For instructions see Chapter 24 of the Cascadia Driver s Manual Cascadia Maintenance Manual April 2009 47A 47 Diesel fuel is flammable and can ignite if exposed to an open flame intense heat or other ignition source Do not drain fuel near or expose fuel vapor to open flame or intense heat Exposure to open flame or intense heat could start a fire pos sibly resulting in personal injury or property dam age When work
106. ompressing air apply a soapy solution to these areas and observe that any leakage does not exceed a 1 inch bubble in 1 second If leakage exceeds this measure remove and re install the desiccant car tridge 42 03 Air Dryer Inspection 1 Park the vehicle on a level surface and apply the parking brakes Shut down the engine Chock the tires 2 Check for moisture in the air brake system by opening the reservoir drain cocks Examine the discharge Some trace of water in the discharge is normal A discharge of a milky gray liquid indi cates excessive moisture is present in the air system and the desiccant cartridge needs to be replaced See Group 42 of the Cascadia Work Brakes shop Manual for troubleshooting procedures The following conditions could cause small amounts of moisture to be found in the air system e An outside air source has been used to charge the air brake system This air did not pass through the drying bed Air usage is unusually high and not normal This may be due to accessory air demands or some unusual air requirement that does not allow the compressor to load and un load in a normal fashion Check for air sys tem leaks The air dryer has been installed on a sys tem that had previously been operated without an air dryer This type of system will be saturated with moisture and several weeks of operation may be needed to fully dry the system The temperature range in your area fluctu ate
107. on e 41 02 Driveline Lubrication 42 01 Air Brake System Valve Inspection 42 02 Bendix Air Dryer Desiccant Replacement 42 03 Air Dryer Inspection 42 04 Alcohol Evaporator Cleaning and Inspection 42 05 Dana Spicer Camshaft Bracket Lubrication 42 06 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication 42 07 Meritor Camshaft Bracket Lubrication 00 12 Cascadia Maintenance Manual August 2010 General Information 00 Maintenance Operation Sets Table 00 08 Maintenance Operation Sets go Operation Description ues l IM M1 M2 M3 42 08 Meritor Slack Adjuster Lubrication 42 09 Bendix E 6 Foot Control Valve Inspection and Lubrication 46 01 Drag Link Inspection 46 02 Power Steering Fluid and Filter Change 46 03 Power Steering Fluid Level Inspection 46 04 Power Steering Gear Lubrication 46 05 Drag Link Lubrication 46 06 Rack and Pinion Steering Inspection 47 01 Fuel Filter Replacement 47 02 Fuel Water Separator Element Checking and Replacement e 47 03 Fuel Tank Band Nut Tightening 49 01 Exhaust System Inspection noise emission control e 54 01 Trailer Cable Inspection and Cleaning 60 01 Mirror Folding Check 83 01 Air Conditioner Inspection 83 02 Air Filter Replacement e 83 03 ParkSmart
108. r over time and will not properly hold the fairings in place 1 Open the latched section of the fairing panel 2 Inspect the rubber bumpers for wear See Fig 6 for the bumper wear area and Fig 7 for the bumper location If the bumper rubber is worn down even with the top of the metal cup or if there are signs of the metal cup coming in contact with the surface of the brace that the bumper makes contact with replace the bumper 3 Tighten the fastener 10 to 13 Ibf ft 14 to 18 N m 4 Close and latch the fairing 03 09 2007 A Wear Area 1 Metal Cup 2 Mounting Stud al NE f311032 3 Rubber Bumper Fig 6 Fairing Bumper 31 6 Cascadia Maintenance Manual August 2007 31 Frame and Frame Components 1311034 TWO Kee Be qw e Ae C fp NC Ve E n WA dd 03 13 2007 Fig 7 Bumper Location 31 7 Cascadia Maintenance Manual August 2007 Suspension Title of Maintenance Operation MOP Suspension INSPECHON ico 2 as Suspension U Bolt Torque Check 32 Index Alphabetical MOP Number Cascadia Maintenance Manual August 2010 Suspension 32 01 Suspension Inspection 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
109. r recommends also replacing the socket s harness as well if the corrosion has gotten into the wires and connectors inside the socket IMPORTANT If using a spray cleaner to remove corrosion be careful to protect any surrounding painted surfaces 3 Coat the inside of the sockets with a lithium based dielectric grease such as Lubriplate FLP DS ES Connect the cables 94 Cascadia Maintenance Manual August 2007 54 1 Cab 60 Index Alphabetical Title of Maintenance Operation MOP MOP Number Miror FOldING Gees codon isa pira aida ia ias E eene Sud 60 01 Cascadia Maintenance Manual August 2010 Cab 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 60 Cascadia Maintenance Manual August 2010 60 1 83 Heater and Air Conditioner Title of Maintenance Operation MOP Air Conditioner Inspection ee EE EE ER RE Ed Air Filter Replacement su 3 9 SEKER e AA EUR ParkSmart Drain Tube Inspecti0N Index Alphabetical MOP Number Cascadia Maintenance Manual August 2010 Heater and Air Conditioner 83 01 Air Conditioner Inspection Wear eye protection gloves and protective cloth ing when working on the air conditioning system Leaking refrigerant
110. reatment Device ATD a muffler like can ister that houses a DPF DOC and sensors e Diesel Particulate Filter DPF a filte that col lects and holds particulate matter soot and ash Cascadia Maintenance Manual August 2010 49 3 49 Exhaust 09 16 2009 1490354 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 SCR Inlet Temperature Sensor 11 SCR Outlet NOx Sensor 5 DPF Outlet Pressure Sensor Fig 3 2HV Two Box ATS Sensor Locations e Diesel Oxidation Catalyst DOC oxidizes hy any discrepancies are discovered refer to the drocarbons and reduces NOx engine manufacturer s service literature for re e Sensors detect temperatures and pressures in pair instructions the ATS 1 Check for leakage at the clamp that attaches the exhaust pipe to the turbocharger exhaust outlet Inspection A To meet EPAO7 emissions regulations for vehicles domiciled in the USA or Canada engines manufac tured after December 31 2006 are equipped with an emission aftertreatment system Vehicles domiciled outside of the USA and Canada may not have after treatment equipment depending upon local statutory emissions guidelines IMPORTANT The aftertreatment device ATD which is part of the aftertreatment syste
111. rt and road grime entering the assembly 35 6 Cascadia Maintenance Manual August 2007 Rear Axle Freightliner 4h CAUTION Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage 1 Park the vehicle on level ground set the parking brakes and chock the tires IMPORTANT After 300 000 miles 500 000 km oil level must be checked at each M1 interval on Freightliner axles 2 Clean the fil plug and the area surrounding the fil plug on the side of the axle carrier Remove the plug Check lubricant level when the axle is cold or near room temperature NOTE Some Freightliner axles have a small tapped and plugged hole near and below the housing oil fil hole This smaller hole is for a lubricant temperature indicator only and should not be used as a fil or level hole 3 Check that the lubricant is level with the bottom of the fil hole See Fig 2 If low check for oil leaks and correct as needed Add oil to the level of the fil plug using the lubricant recommended in Table 3 4 Install and tighten the fil plug 41 Ibf ft 55 N m IMPORTANT Always check the axle breather whenever checking lubricant level Check the breather more frequently under adverse operat ing conditions 5 Check the axle housing breather Make sure that it is open and unclogged If the breather is plugged or damaged clean or replace it as needed 6 On non drive axles us
112. s more than 30 degrees in one day Small amounts of water can accumulate in the air brake system due to condensation Under these conditions the presence of moisture is normal and should not be con sidered an indication of poor air dryer per formance Inspect the air dryer for external damage and check that the unit is tightly mounted on the frame If the air dryer mounting is loose See Group 42 of the Cascadia Workshop Manual for mounting instructions Turn on the ignition switch but do not start the engine Disconnect the harness connector from the air dryer Connect a voltmeter to circuit 94 on the air dry er s harness connector and to a body ground point Check for battery voltage If voltage is not found check and repair the open or short to ground in wire 94 Connect a voltmeter between the two terminals on the air dryer s harness connector If voltage is not found repair the open in the ground circuit wiring Use an ohmmeter to check resistance between the terminals on the end cover See Fig 4 The end cover contains the heater thermostat If the heater thermostat is between 40 and 90 F 5 and 42 4 Cascadia Maintenance Manual January 2010 Brakes 06 04 96 1421384 1 End Cover Assembly 2 Heater Thermostat Terminals Fig 4 End Cover Terminals Location 32 C the heater thermostat measured resis tance will be infinit ohms If the measured resis tance is less than infinit repla
113. t in personal injury or property damage 42 08 Meritor Slack Adjuster Lubrication NOTE If equipped with an extended maintenance Q Plus brake system the slack adjuster will not have a grease fitting These slack adjusters use a special NLGI Grade syn thetic polyurea grease and do not require lubri cation for 3 years or 500 000 miles 800 000 km whichever comes first The extended maintenance slack adjusters are lubricated dur ing the brake reline service interval For service and lubrication instructions see Group 42 of the Cascadia Workshop Manual For slack adjusters with grease fitting and for oper ating temperatures above 40 F 40 C use an NLGI Grade 1 clay base grease or an NLGI Grade 1 or 2 lithium base grease For slack adjusters with grease fitting and for oper ating temperatures below 40 F 40 C and above 65 F 54 C use an NLGI Grade 2 synthetic oil clay base grease Lubricate the slack adjuster at the grease fittin until grease is forced past the pressure relief capscrew or past the gear splines around the inboard snap ring See Fig 7 42 09 Bendix E 6 Foot Control Valve Inspection and Lubrication 1 Remove the brake valve from the vehicle See Section 42 08 Subject 110 of the Cascadia Workshop Manual for instructions Brakes 10 20 93 f420012a Brake Chamber Clevis Actuator Rod Boot Pressure Relief Capscrew Gasket Pawl Spring and Pawl
114. t 12 Drain 4 Filter Spring 9 Bottom Plate Seal 13 Electric Heater optional 5 Filter Element Fig 2 Davco Fuel Pro 382 Cascadia Maintenance Manual April 2009 47 3 Exhaust 49 Index Alphabetical Title of Maintenance Operation MOP MOP Number Exhaust System Inspection Noise Emission Control is ee se Se eee 49 01 Cascadia Maintenance Manual August 2010 Exhaust 49 01 Exhaust System Inspection 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 Freightliner Trucks recommends replacing parts that show leakage wear or damage with genuine Freightliner parts The exhaust system must be free of leaks binding grounding and excessive vibrations These condi tions are usually caused by loose broken or mis aligned clamps brackets or pipes If any of these conditions exist check the exhaust system compo nents and alignment Align or replace as necessary see Group 49 of the Cascadia Workshop Manual or take the vehicle to an authorized Freightliner dealer It is a violation of US federal law to alter exhaust plumbing or aftertreatment in any way that would bring the engine out of compliance with certificatio requirements Ref 42 U S C S7522 a 3 It is the owner s responsibility to maintain the vehicle so that it conforms to EPA regulations
115. t the front of the tires see Fig 5 and adjust the scale end so that the pointers line up with the scribe lines See Fig 6 8 Read the toe in from the scale and compare it to the toe in specificatio in Group 33 of the Cas cadia Workshop Manual If corrections are needed refer to Group 33 of the Cascadia Workshop Manual for instructions on adjusting the toe in 33 2 Cascadia Maintenance Manual August 2007 Front Axle 33 Sk 08 30 94 f330014a Fig 5 Trammel Bar Positioning N 08 30 94 f400100a Fig 6 Setting Trammel Bar Pointers Cascadia Maintenance Manual August 2007 33 3 Rear Axle 35 Index Alphabetical Title of Maintenance Operation MOP MOP Number Axle Breather and Axle Lubricant Level Inspection oooooooocorrrcrro errar 35 02 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning Synthetic ubican 2 3 06 2 Gea 2h ER ada eN ETT IM 35 01 Cascadia Maintenance Manual August 2007 Rear Axle 35 01 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning Synthetic Lubricant 4h CAUTION Failure to change the axle lubricant at more fre quent intervals when adverse operating condi tions require could result in axle damage For all axles including tandem drive axles and two speed axles do the procedures under the heading All Axle Models For a two speed axle with a shift unit also change the shift unit
116. tems Information on multiplexing diagnosis is included These manuals are organized by functional systems such as cab chassis and powertrain Troubleshooting manuals do not contain repair or service information Driver s operator s manuals contain information needed to enhance the driver s understanding of how to operate and care for the vehicle and its components Each manual contains a chapter that covers pre trip and post trip inspections and daily weekly and monthly maintenance of vehicle components Driver s operator s manuals do not contain detailed repair or service information Service bulletins provide the latest service tips fiel repairs product improve ments and related information Some service bulletins are updates to informa tion in the workshop service manual These bulletins take precedence over workshop service manual information until the latter is updated at that time the bulletin is usually canceled The service bulletins manual is available only to dealers When doing service work on a vehicle system or part check for a valid service bulletin for the latest information on the subject IMPORTANT Before using a particular service bulletin check the current service bulletin validity list to be sure the bulletin is valid Parts technical bulletins provide information on parts These bulletins contain lists of parts and BOMs needed to do replacement and upgrade procedures parts documentation can be accessed usin
117. ter until the radiator is full Cascadia Maintenance Manual August 2007 20 1 20 4h CAUTION When flushing the radiator do not apply more than 15 psi 100 kPa air pressure Excessive pres sure can damage the radiator 6 10 Gradually apply up to 15 psi 100 kPa air pres sure to help dislodge sediment that has built up in the radiator core Shut off the air at the pressure gun nozzle and allow the radiator to refil with water Repeat the previous two steps until clean water flow from the radiator Remove the radiator side tank drain plug and allow the radiator to drain Install and tighten the side tank drain plug and the radiator outlet pipe drain plug after the radiator has been drained Do not overtighten the plugs Connect the hoses Your hose clamps can be either T bolt clamps see Fig 2 or Breeze Constant Torque clamps see Fig 3 When working with T bolt hose clamps tighten the clamps 55 Ibf in 620 N cm These clamps are now standard on hoses with an inside diam eter greater than 2 inches 51 mm When installing Breeze Constant Torque hose clamps the clamps must be tightened to the cor rect torque The screw tip of the clamp must ex tend about 1 4 inch 6 mm from the clamp hous ing and the Belleville washer stacks must be collapsed almost flat Use a torque wrench to install these clamps correctly The correct instal lation torque is as follows For Breeze Constant Torque clamps w
118. that the spring is safe On front spring assemblies if cracks or breaks exist in the two top leaves a loss of vehicle control could occur Failure to replace a damaged spring assem bly could cause an accident resulting in property damage serious personal injury or death Front Suspension Check Inspect the front spring assemblies for cracked bro ken or abnormally bent leaves If any of these condi tions exist replace the spring assembly see Group 32 of the Cascadia Workshop Manual Front and Rear Suspension Shock Absorber Check Make sure the shock absorber brackets are tight and the shock absorber is not striking or rubbing the frame or some other part of the chassis Striking or rubbing the frame is characterized by chafe marks on the shock absorber body and the frame rail see Fig 1 Check the rubber mounting bushings for cracks cuts swelling dry rot or missing pieces If the shock absorber bushings are no longer service able replace the shock absorber with a new one Inspect the shock absorber for oil leakage Some misting of the oil is normal and does not mean the shock is leaking If the shock absorber is damaged or leaking replace it with a new one see Group 320f the Cascadia Workshop Manual Freightliner AirLiner Rear Suspension Check Components Checking Inspect the forward spring brackets for wear cracks and other damage If any of these conditions exist replace the damaged bracket s see
119. the USA and Canada may not have after treatment equipment depending upon local statutory emissions guidelines IMPORTANT The aftertreatment device ATD which is part of the aftertreatment system ATS requires special attention during regularly scheduled maintenance inspections No leaks are allowed anywhere in the system If any dis crepancies are discovered refer to the engine manufacturer s service literature for repair in structions 1 Check for leakage at the clamp that attaches the exhaust pipe to the turbocharger exhaust outlet If leakage exists tighten the nut on the clamp to the required torque If leakage persists install a new clamp 2 Check the exhaust pipe bellows and each ex haust seal clamp for leakage wear cracks or damage Replace damaged components as needed If leakage exists at a clamp tighten the nuts to the required torque If leakage persists install a new exhaust seal clamp Do not reuse seal clamps Once a seal clamp is loosened or removed it must be replaced Cascadia Maintenance Manual August 2010 49 1 49 If present check the condition of the insulation material around the exhaust pipe between the turbocharger and the ATD Check the ATD mounting bands for tightness Tighten to 30 Ibf ft 41 N m if needed Do not overtighten Check for leaks around the clamps that attach the ATD in the ATS and around the clamps that retain the DPF in the ATD Check all sensors attac
120. then check the coolant level in the surge tank Add coolant if the level isn t between MIN and MAX lines on the surge tank 20 03 Fan Clutch Check Noise Emission Control Borg Warner Kysor K26RA Fan Clutch 1 Disconnect the batteries at the negative termi nals Drain all air from the air system 2 Measure the distance from the back surface of the fan clutch retaining plate to the forward most edge of the fan belt pulley See Fig 4 Ref A 3 Disconnect the line from the air inlet of the air cylinder Connect a shop air hose to the inlet 4 Apply a minimum of 100 psi 690 kPa air pres sure to the air cylinder the bearing housing will move backwards disengaging the clutch Again measure the distance from the back surface of 20 05 27 93 N f200237a With the fan clutch engaged measure the distance at A measure it again with the fan clutch disengaged 1 Bearing Housing 5 Air Cylinder 2 Retaining Plate 6 Fan 3 Fan Pulley 4 Air Inlet from solenoid valve Fig 4 Kysor K26RA Fan Clutch Lining Wear Check the retaining plate to the forward most edge of the fan belt pulley 5 Compare the two measurements if the difference between the two measurements exceeds 0 150 inches 3 8 mm the clutch lining is worn and must be replaced See Group 20 of the Casca dia Workshop Manual for clutch lining replace ment instructions 6 Release the air pressure then disconnect the shop hose from
121. this manual on the maintenance operations to be performed o ke ar M1 Maintenance Interval Operations for Service Schedules and II Check 13 01 Bendix Air Compressor Inspection 25 01 Eaton Fuller Clutch Release Bearing Lubrication 31 01 Fifth Wheel Inspection 31 02 Fifth Wheel Lubrication 33 05 Knuckle Pin Lubrication Dana Spicer Axles 33 06 Tie Rod Lubrication Dana Spicer Axles 40 01 Wheel Nut Check 41 01 Driveline Inspection 41 02 Driveline Lubrication 42 02 Bendix Air Dryer Desiccant Replacement with an oil coalescing desiccant cartridge 42 05 Dana Spicer Camshaft Bracket Lubrication 42 06 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication 49 01 Exhaust System Inspection noise emission control 83 03 ParkSmart Drain Tube Inspection 88 01 Hood Rear Support Lubrication If equipped with an oil coalescing desiccant cartridge replace the cartridge once a year regardless of mileage Otherwise use the M3 maintenance interval Table 5 M1 Maintenance Interval Operations for Service Schedules and II Cascadia Maintenance Manual August 2010 00 9 00 General Information M2 Maintenance Interval Operations 00 06 The M2 Maintenance Interval Operations tables list you fin detailed instructions in this manual on the all maintenance operations that are to be performed maintenanc
122. tions Test the brakes before returning the vehicle to service 42 Cascadia Maintenance Manual January 2010 42 9 Steering 46 Index Alphabetical Title of Maintenance Operation MOP MOP Number Brad Link InSpeci n RI ras dub o id ab e 2 ELE EE 4 46 01 Drag Link Luca cs dt qi MB cde ene Se AN Ab dees Gees 46 05 Power Steering Fluid Level Inspection llli rh 46 03 Power Steering Fluid and Filter Changing lille 46 02 Power Steering Gear Lubrication lille 46 04 Rack and Pinion Steering Inspection usse bre eme I eR ede denne A AU nea d e ed 46 06 Cascadia Maintenance Manual November 2009 Steering 46 01 Drag Link Inspection 2 46 Place a drain pan under the power steering res ervoir Remove the retaining ring from the reservoir See Fig 1 All steering system components are critical for safe operation of the vehicle Failure to maintain the steering system as specified may result in loss of steering control which could lead to per sonal injury and property damage Have someone turn the steering wheel from left to right Check for movement between the ball stud end and the pitman arm and between the ball stud end and the steering arm Also check if the ball stud nut is loose If the ball stud end is loose replace the drag link If the ball stud nut is loose replace the nut and cotter key See Group 46 of the Cascadia Workshop Manual for proper
123. torque specifications Inspect the boot of the drag link at both the pitman arm and the steering arm end for cracks splits or other damage Replace the boot as needed See Group 46 of the Cascadia Workshop Manual for drag link removal and installation instructions 10 19 2001 1 Power Steering Reservoir 2 Retaining Ring 3 Filter Cover 4 Return Hose 1461917 Grasp the drag link near the pitman arm end then push and pull laterally to check for axial movement in the ball stud end If it is loose replace the drag link See Group 46 of the Cascadia Workshop Manual for replacement instructions If there is 1 8 inch 3 mm movement or more do not drive the vehicle until the drag link is replaced 46 02 Power Steering Fluid and Filter Changing WARNING Fill only with approved clean fluid Failure to use the proper fluid could cause seal deterioration and leaks Fluid leaks could eventually cause loss of power steering assist This could lead to an acci Fig 1 Power Steering Reservoir Remove the filte fille cover and gasket from the reservoir Drain the flui from the filte into the drain pan Leave the filte hanging over the drain pan Remove the nuts bolts and washers that attach the power steering reservoir to the mounting bracket but do not remove the supply line to the reservoir Drain the power steering flui from the reservoir Using bolts nuts and washers attach the reser vo
124. ur finge or a bent pipe cleaner see if the flui is level with the fil opening See Fig 1 3 If the flui level is low check the transmission for leaks and correct as needed 4 f needed add the recommended fluid until it is level with the lower edge of the fil opening See Table 1 for approved transmission lubricants 26 2 Cascadia Maintenance Manual January 2008 Transmission 5 Clean the fil plug then install it Tighten the plug as follows e 25 to 35 Ibf ft 34 to 48 N m for transmis sions with 3 4 inch pipe threads e 60 to 75 Ibf ft 81 to 102 N m for transmis sions with 1 1 4 inch pipe threads 26 03 Manual Transmission Air Filter Regulator Check Cleaning or Replacement Eaton Fuller 1 Apply the parking brakes and chock the rear tires Drain the air reservoirs A WARNING Drain the air supply if the air supply is not drained before the air filter regulator is serviced serious injury and component damage could re sult 2 Clean the outside of the air filter regulato with cleaning solvent See Fig 2 3 Remove the end cap large O ring and filte ele ment from the filte housing See Fig 3 Remove the small O ring from the end cap NOTE Do not remove disassemble or adjust the air regulator If the air regulator is not keep ing air pressure between 58 and 63 psi 400 and 435 kPa replace the air filter regulato It cannot be repaired A WARNING Wear safety goggles when
125. ve housing bolts 45 Ibf in 500 N cm Any damage to the valve housing will void the warranty e Do not attempt to disassemble the Barksdale valve body or the control lever There are no serviceable parts in the valve and any disas sembly will void the warranty NOTICE When removing or loosening a Barksdale height control valve from a mounting bracket always hold the valve side mounting studs in place with an Allen wrench while loosening or tightening the nuts that attach the valve to the bracket Because the mounting studs are threaded into the valve body loosening the nuts without holding the studs can tighten the studs which can crush the valve body and damage the valve Conversely tightening the nuts without holding the studs can back the studs out causing a separation of the two halves of the valve body and possibly a leak 1 Park the vehicle on a level surface using a light application of the brakes Do not apply the park ing brakes Shift the transmission into neutral and build the secondary air pressure to at least 100 psi 690 kPa Shut down the engine Have an assistant chock the tires on one axle only 2 Mark the location of the front and rear tires on the floo NOTE The stud bolt that fastens the valve s height control lever to the vertical linkage is ori ented correctly when the linkage rod is vertical as viewed from the side of the vehicle see Fig 2 The rod may be on the forward or aft side of th

CASCADIA MAINTENANCE MANUAL Models

Contents

Download Pdf Manuals

Related Search

Related Contents