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Sterling Trucks Acterra MX User's Manual

1. Filth Wheel Lubricating ssi nce eura ete me dats Frame Fastener Torque 0 Index Alphabetical MOP Number Acterra Maintenance Manual January 2007 Frame and Frame Components 31 01 Frame Fastener Torque Checking Because of bedding in or seating frame fasteners must be torqued at the recommended intervals These intervals apply to new vehicles and to frame fasteners that have been removed and installed NOTE For off highway operations retorque frame fasteners the first 1000 miles 1600 km then periodically depending on operating condi tions CAUTION Make sure frame fasteners are properly tightened Continued vehicle operation with loose fasteners could result in bracket or frame damage NOTE Engine supports on vehicles built from January 2007 do not require checking Typical frame fastener applications include front frame suspension and spring brackets fuel tank exhaust and engine supports frame crossmembers and gussets and fifth wheel mounting brackets For additional fastener and torque value information see Group 00 of the Acterra Workshop Manual Tighten all Freightliner AirLiner suspension fasteners to the torque values in Table 1 Also tighten all sus pension air line fittings and air lines Freightliner Airliner Torque Values e Torque Description Size N m Leveling Valve Adjustmen
2. 42 23 Brake Chamber Inspecting All 5 42 07 Brake INSPeClON susc ecc ye os hx eg Tea CE ORR 42 24 Brake Lines Checking Hydraulic Disc 42 18 Brake Lining Wear Checking Hydraulic Disc 42 17 Camshaft Bracket Bushing 0 42 08 Foot Brake Valve Actuator Lubricating Bendix 42 03 Power Booster Checking Bendix 9 42 19 Quick Release and Flipper Valves Checking 42 06 Relay Valve Checking d Eat ERROR 42 05 Acterra Maintenance Manual October 2007 Brakes 42 01 Air Dryer Inspecting Bendix AD 9 Check the reservoirs for moisture A small amount teaspoon or less is normal Larger amounts may mean that the desiccant needs to be replaced Check the mounting and connecting lines Tighten the fasteners that attach the air dryer to the vehicle Use the following torque values 28 Ibf ft 38 N m for SAE grade 5 3 8 16 fasteners e 135 183 N m for SAE grade 5 5 8 11 fasteners Check all air lines fittings and electric
3. z Wheel Torque dry threads Description Size Manufacturer Ibf ft N m Front Wheel Nut 5 and 7 6 Spoke 3 4 10 Gunite 200 225 270 305 Rear Wheel Nut 5 and 2 6 Spoke With Channel Spacer 3 4 10 Gunite 200 225 270 305 Rear Wheel Nut 5 and 6 Spoke With Corrugated 3 4 10 Gunite 240 260 325 350 Channel Spacer front axles with over 12 000 Ibs 5448 kg capacity tighten the wheel nuts 240 to 265 Ibf ft 325 to 359 N m Gunite part number W 854 nut with a phosphate and oil coating must be used Table 3 Spoke Type Wheel Fastener Torque 40 Acterra Maintenance Manual March 2000 40 1 40 Wheels and Tires 1 1 1 2 7j NW 3 3 4 5 NC gt 6 9 4 5 4 3 2 A B C D 05 27 93 1400057 A 8 Stud Disc Wheel C 6 Spoke Wheel B 10 Stud Disc Wheel D 5 Spoke Wheel Fig 1 Wheel Nut and Rim Nut Tightening Sequence 40 2 Acterra Maintenance Manual March 2000 Driveline Title of Maintenance Operation MOP Driveline Driveline Tuba eoa ted ac ota a Hate eur ma dra ae oot a 41 Index Alphabetical MOP Number Acterra Maintenance Manual March 2000 Driveline 41 01 Driveline Inspecting Inspecting 1 Check that the yoke strap capscrews see Fig 1 Ref 4 are tightened as follows Dana Spicer 1590 and 1610 50 to 60 Ibf ft 68 to 81 N m
4. 08 08 94 SS 1200290 1 System Sentry Fuse 4 Piston Friction Disc 2 Safeguard Hole 5 Air Chamber 3 Friction Facing Fig 5 Horton Advantage Fan Clutch 7 Connect the battery cables Start the engine and charge the air system to 120 psi 827 kPa Shut 10 Engine Cooling R adiator down the engine Separate the halves of the fan solenoid connector The fan clutch should en gage If the fan does not operate correctly see Group 20 of the Acterra Workshop Manual for trouble shooting and repair procedures With the air system charged to 120 psi 827 kPa and with the fan solenoid connector halves separated check the fan clutch for audible air leaks using a suitable listening device If a leak is detected remove the fan blade Using a soapy water solution check the fan clutch at the following locations to locate the source of the leak Install a new seal kit See Group 20 of the Acterra Workshop Manual for repair procedures 9 1 Check for a leak at the bleed hole on the fan pilot Air leakage means that the car tridge assembly see Fig 6 Ref 16 or face seal Ref 17 is damaged 9 2 Check for air leaks between the air cham ber and the piston friction disc Air leak age means that the large O ring Ref 14 is damaged 9 3 Check for air leaks around the safeguard hole on the piston friction disc Air leak age means the small O ring Ref 18 is damaged 9 4 Check for air leaking from
5. Dana Spicer 1710 125 to 135 Ibf ft 170 to 183 N m CAUTION Do not overtighten the yoke strap capscrews due to the extreme load occurring at high speed rota tion A loose or broken capscrew at any point in the driveline weakens the driveline connection which could eventually result in serious vehicle damage 2 Check each of the output and input end yokes see Fig 1 Refs 2 and 11 for cracks and looseness Replace cracked yokes 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 end yoke Check the drive component s shaft seal for leakage or other vis ible damage that may have been caused by the loose yoke Replace the seal if needed Tighten the end yoke nut to the value in Table 1 If the end yoke is still loose after tightening the yoke nut install a new yoke and yoke nut NOTE If the end yoke locknut was removed for any reason install a new one 3 Check the U joint assemblies for wear by at tempting to move the driveshaft up and down and from side to side If movement of the U joint trunnion in the bearings is greater than 0 006 inch 0 15 mm replace the U joint assembly 4 Check the midship bearing and bracket for loose ness and deterioration by attempting to move the driveshaft up and down and from side to side If the bearing is loose on its shaft or rattles re place it If the bearing bracket is loose on the fram
6. NOTE Numbers in this table are maintenance opera tion reference numbers matching those in the text of Acterra Maintenance Manual January 2007 00 15 00 M1 Maintenance Interval Operations Table 00 10 General Information oe M1 Maintenance Interval Operations 42 14 Air Brake Valve Leak Checking Bendix 6 42 17 Brake Lining Wear Checking Hydraulic Disc Brakes 42 18 Brake Lines Checking Hydraulic Disc Brakes 42 19 Power Booster Checking Bendix Hydro Max 42 21 Automatic Slack Adjuster Inspecting Gunite 42 24 Brake Inspection 83 01 Air Conditioner Inspecting 00 16 Acterra Maintenance Manual January 2007 General Information IMPORTANT After performing all operations listed in this table perform all daily weekly and monthly maintenance operations listed in the Pretrip and Post Trip Inspections and Maintenance chapter of the Acterra Driver s Manual Also perform all M1 Maintenance Interval Operations at the M2 Mainte nance Interval 00 M2 Maintenance Interval Operations Table 00 11 below M2 Maintenance Interval Operations Maint Oper No M2 Maintenance Interval Operations 00 10 Perform All M1 Operations 00 16 Lubrication and Fluid Level Check Two Speed Axle Shift Unit Oil Level Checking Camshaft Bracket Bushing Lubricating e Air Reservoir Automatic Drain Valve Disassembly Cleaning Inspect ing a
7. 0 1 26 04 Eaton Fuller TTC Transmission Fluid Changing and Magnetic Plug Glofl 2 25 chore oud dane Rd ONES D a Rusa Roa beds 26 02 Manual Transmission Fluid Level 26 01 Mercedes Benz Transmission Fluid Changing and Magnetic Plug 26 05 Mercedes Benz Transmission Leak 26 06 Acterra Maintenance Manual March 2005 Transmission 26 01 Manual Transmission Fluid Level Checking 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 With the transmission at operating temperature check the fluid level in the transmission 2 1 Clean the area around the fill plug then remove the plug from the side of the case 2 2 Using your finger or a bent pipe cleaner Y see if the fluid is level with the lower edge ff 2 of the fill opening See Fig 1 MM suem 10 05 94 A B A Full B Low XMS SSS 7 f260006b Fig 1 Transmission Fluid Level Checking If needed fill the transmission with fluid until level with the lower edge of the fill opening See Table 1 for approved lubricants Approved Manual Transmission Lubricants Lubricant Type Temperature SAE
8. 1 Shut off the engine apply the brakes and chock the rear tires Front Axle 2 Make sure the tires touch the ground Do notraise the vehicle 3 Clean off all grease fittings prior to lubrication IMPORTANT Meritor recognizes that industry trends are moving toward increased selection and usage of synthetic grease in vehicle mainte nance However some seals are known to ex pand when in contact with synthetic grease Consult your local Meritor representative for synthetic grease application references before using any synthetic grease when performing axle service and maintenance 4 Using a multipurpose grease NLGI grade 1 or 2 lubricate the kingpins through the grease fittings on the top and bottom of the knuckle See Fig 3 10 11 2001 1330184 Apply lubricant until new lubricant comes from these areas 1 Grease Fitting Fig 3 Sealed Easy Steer Plus Kingpin Lubrication 5 Force lubricant into the upper and lower kingpin grease fitting caps until new lubricant flows from between the upper axle beam end and the knuckle and between the lower axle beam end and the knuckle See Fig 3 6 Remove the chocks from the tires 33 02 Tie Rod End Inspecting IMPORTANT If the tie rod end boot is torn or missing replace the entire tie rod end Do not replace the boot only 33 2 Acterra Maintenance Manual September 2002 Front Axle 1 Shut off the engine apply the brakes a
9. 3 3 Using a clean lint free cloth wipe off any excess solvent 3 4 Reassemble the clutch valve solenoid air filter assembly and install on the vehicle 4 Visually check the fan for bent cracked or dam aged blades Replace if damaged Check for ad equate clearance between the fan and other components 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 the fan clutch from a dis tance 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 Acterra Workshop Manual for troubleshooting and repair procedures reservoir 8 With the air system charged to 120 psi 827 kPa check the fan clutch for audible air leaks using a suitable listening device 20 6 Acterra Maintenance Manual January 2007 Engine Cooling Radiator Check at the solenoid valve the air filter assem bly and the air hoses and fittings See Fig 8 Using a wet finger or a soapy water solu
10. 6 Remove the chocks from the tires 42 06 Quick Release and Flipper Valves Checking Midland 1 Park the vehicle on a level surface Chock the tires 2 Start the engine and run it long enough to pres surize the air system to at least 80 psi 550 kPa Turn off the engine Repeat as necessary to maintain 80 psi 550 kPa pressure during these checks Clean any road grime from the valves and material from the valves exhaust ports 4 Listen for air leakage around the fittings and ex haust ports Tighten the fittings as necessary Use two wrenches to avoid twisting the tubing 5 f any valve fails this check or is damaged repair or replace it For instructions see the Midland service manual 6 Remove the chocks from the tires 42 07 Brake Chamber Inspecting All Models A WARNING Do not loosen or remove the parking brake clamp ring for any purpose at any time See Fig 1 The parking emergency brake section is not intended to be serviced Serious injury or death may result from sudden release of the power spring Before doing any repairs or adjustments on a service parking brake chamber read the appli cable warnings and instructions in the applicable Brakes brake chamber section in Group 42 of the Acterra Workshop Manual 02 22 2000 A Do not remove the factory sealed clamp ring 1 Model TR T TR Series Brake Chamber 1421352 Fig 1 MGM Brake Chambe
11. 00 8 Acterra Maintenance Manual January 2007 General Information 00 Maintenance Interval Tables 00 07 Maintenance Intervals for Schedule Maint No Maintenance Interval Miles km Hours 1 IM and M1 1000 1600 100 2 M1 2000 3200 200 3 M1 3000 4800 300 4 1 M2 4000 6400 400 5 M1 5000 8000 500 6 M1 6000 9600 600 7 M1 7000 11 200 700 8 M1 M2 and M3 8000 12 800 800 9 M1 9000 14 400 900 10 M1 10 000 16 000 1000 11 M1 11 000 17 600 1100 12 M1 and M2 12 000 19 200 1200 13 M1 13 000 20 800 1300 14 M1 14 000 22 400 1400 15 M1 15 000 24 000 1500 16 M1 M2 M3 and M4 16 000 25 600 1600 17 M1 17 000 27 200 1700 18 M1 18 000 28 800 1800 19 M1 19 000 30 400 1900 20 M1 and M2 20 000 32 000 2000 21 M1 21 000 33 600 2100 22 M1 22 000 35 200 2200 23 M1 23 000 36 800 2300 24 M1 M2 and M3 24 000 38 400 2400 25 M1 25 000 40 000 2500 26 M1 26 000 41 600 2600 27 M1 27 000 43 200 2700 28 M1 and M2 28 000 44 800 2800 29 M1 29 000 46 400 2900 30 M1 30 000 48 000 3000 31 M1 31 000 49 600 3100 32 M1 M2 M3 M4 and M5 32 000 51 200 3200 Table 7 Maintenance Intervals for Schedule Acterra Maintenance Manual January 2007 00 9 00 General Information Maintenance Interval Tables 00 07 Maint
12. 42 19 Power Booster Checking Bendix Hydro Max 42 20 Automatic Slack Adjuster Lubricating Gunite fe 42 21 Automatic Slack Adjuster Inspecting Gunite 42 22 Automatic Slack Adjuster Lubricating Haldex 42 23 Bosch Rail Slide Hydraulic Brake Caliper Lubricating 42 24 Brake Inspection Table 10 Maintenance Operation Sets for Groups 33 through 42 Maintenance Operation Sets for Groups 46 through 83 REQUIRED MAINTENANCE OPERATION SET M1 M2 M3 M4 5 Maintenance Operation Number and Operation Description 46 01 Steering Driveline Lubricating 46 02 Drag Link Lubricating 46 03 Power Steering Reservoir Fluid Level Checking 46 04 Power Steering Reservoir Fluid and Filter Changing 46 05 Power Steering Gear Lubricating fe 47 01 Fuel Tank Draining and Vent Checking 49 01 Exhaust System Inspecting 54 01 Electrical System Checking 54 02 Coolant Level Sensor Cleaning 72 01 Weatherstrip Door Latch and Door Hinge Lubricating 83 01 Air Conditioner Inspecting 83 02 HVAC Air Filter Replacing Replace the HVAC filter every 6 months regardless of mileage Table 11 Maintenance Operation Sets for Groups 46 through 83 Acterra Maintenance Manual January 2007 00 13 00 General Information Initial Maintenance IM Operations Table 00 09 IMPORTANT After performing all operations in this NOTE
13. A 2 2 A fA 2 X P 22 2 2 10 05 94 B 12600060 Full Low Fig 11 Fluid Level Checking MBT Transmission Lubricant Types Manufacturer Type Mobil Mobiltrans SHC DC Table 5 MBT Lubricant Types MBT Transmission Lubricant Capacities Refill Capacity Transmission Model quarts liters MBT660S 60 9 5 9 0 MBT520S 6D 9 5 9 0 Quantities listed are approximate Fill the transmission until the lubricant is level with the bottom of the fill hole with the vehicle in normal operating position Table 6 MBT Lubricant Capacities Acterra Maintenance Manual March 2005 26 11 26 CAUTION Use only the approved Mobiltrans SHC DC fluid Do not mix fluid types Adding SHC 50 RN 2952 E 5 fluid used in Eaton and Meritor transmis sions could damage the radial seals 2 Clean the fill plug before installing it 3 Install the fill plug p n NO000908 020001 and new aluminum gasket p n N 00763 024105 Tighten the fill plug 42 57 N m 26 06 Mercedes Benz Transmission Leak Checking 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Check for signs of leakage at the breather See Fig 12 5 05 22 2001 8 7 6 1261101 NOTE The transmission is shown from the left hand side 1 Shift Lever Cap Seal Breather Output Shaft Radial Seal Countershaft Cover Plate Transmis
14. Table 8 Maintenance Intervals for Schedules and all models 00 10 Acterra Maintenance Manual January 2007 General Information 00 Maintenance Operation Sets Tables 00 08 IMPORTANT At each Maintenance Operation Set in NOTE Maintenance operations appearing in italics in addition to the maintenance operations listed in this this table are for noise emission control components table perform all daily weekly and monthly mainte Numbers in this table are maintenance operation ref nance operations listed in the Pretrip and Post trip erence numbers matching those in the text of this Inspections and Maintenance chapter of the manual Acterra Driver s Manual Maintenance Operation Sets for Groups 00 through 32 REQUIRED MAINTENANCE OPERATION SET 1 M2 M3 M4 5 Maintenance Operation Number and Operation Description 00 15 Lubrication and Fluid Level Check 00 16 Lubrication and Fluid Level Check 01 01 Engine Support Fasteners Checking 01 02 Engine Drive Belt Inspecting 01 03 Inspecting and Maintenance 09 01 Air Cleaner Element Inspecting and Replacing 13 01 Air Compressor Inspecting Bendix 13 02 Air Compressor Rebuilding Replacing Bendix 15 01 Alternator Battery and Starter Checking e o 20 01 Radiator Cap Checking 1 1 1 20 02 Radiator Press
15. 10 Automatic Slack Adjuster Lubricating Meritor IMPORTANT Perform MOP 42 24 before lubri cating the slack adjusters Lubricate the slack adjuster using high temperature waterproof grease NLGI Grade 1 Texaco Thermotex EP 1 Shell Darina No 1 Marathon 528 heavy duty Sunaplex No 1 EP Amdex No 1 EP or Philube B No 1 It should be smooth textured corrosion resistant grease free of fillers and abrasives 42 6 Acterra Maintenance Manual October 2007 Brakes 42 11 Automatic Slack Adjuster Inspecting Meritor IMPORTANT Perform MOP 42 24 before lubri cating the slack adjusters 1 Remove the pull pawl assembly See 2 Examine the pull pawl assembly for grease re tention and condition If the grease is in good condition install the pull pawl assembly Lube the slack adjuster through the grease fitting until lubricant is forced out through the inboard cam shaft splines and the pull pawl assembly If the grease is hardened or the pull pawl as sembly is dry and shows extreme wear remove the slack adjuster Disassemble and clean the slack adjuster Inspect the internal parts Install new seals and a new boot when assembling Install and lubricate the slack adjuster See Group 42 of the Acterra Workshop Manual 42 12 Air Dryer Checking Bendix AD 9 During cold weather operation check the operation of the end cover heater and thermostat assembly 1 With the ignition on check for voltag
16. 2 1 Remove the magnetic drain plug from the bottom of the gear case 2 2 Discard the aluminum gasket 2 3 Catch the transmission fluid in a suitable container and dispose of it properly 3 Clean the area around the fill plug 4 Remove the fill plug from the side of the case Discard the aluminum gasket NOTE Use piece of key stock or any other convenient steel slug to short the two magnetic poles and divert the magnetic field 5 Clean the magnetic drain plug before installing it 6 Install the drain plug p n A 124 997 01 32 and a new aluminum gasket p n N 00763 024105 Tighten the drain plug 42 57 N m Filling A CAUTION Operating a manual transmission with the fluid level higher or lower than recommended can re sult in transmission damage Do not overfill the transmission overfilling will force fluid out of the case through the main shaft openings Fluid over flow may also drain onto the clutch or clutch brake causing additional problems 1 Add transmission fluid until it is level with the lower edge of the fill opening See Fig 10 for location of the fill plug and Fig 11 for correct level See Table 5 for approved transmission lu bricants and Table 6 for lubricant capacities 05 22 2001 3 2 1261102 NOTE The transmission is shown from the left hand side 1 Transmission 2 Fill Plug 3 Drain Plug Fig 10 MBT Drain and Fill Plugs 2 Z
17. 4 Support the oil pan then remove the twenty one washer head screws that attach the oil pan to the transmission case Remove the pan and dis card the pan gasket 5 Clean the oil pan with mineral spirits Remove the washer head screw that attaches the internal fluid filter to the filter spacer then remove the filter and discard it See Fig 3 Re move the fluid intake tube then remove the seal ring from the intake tube and discard the seal ring 7 Remove clean and install the governor feed line screen located in the control valve body See Fig 4 8 Install a new seal ring in the fluid intake tube IMPORTANT Avoid twisting the intake tube when installing the internal fluid filter intake tube and seal ring the seal ring could be pinched cut or deformed An air tight seal must be maintained 9 Install the intake tube with the seal ring installed into the main housing Install the internal fluid filter on the intake tube making sure the grom met in the filter fits the intake tube snugly 10 Install the washer head screw to retain the fluid filter and tighten it 10 to 15 14 to 20 N m 26 4 Acterra Maintenance Manual March 2005 Transmission 10 05 94 1260133 1 Fluid Intake Tube 5 Governor Pressure 2 Filter Spacer Tube 3 Internal Fluid Filter 6 Governor Feed Tube 4 Washer Head Screw Fig 3 Allison AT Series Transmission Filter 11 Submerge a new oil p
18. Acterra Maintenance Manual January 2007 Engine 01 1 Belt Tension Engine Component Ibf kg Cummins ISB ISC ISM Refrigerant Compressor 100 45 Fan and Alternator 29 5 27 9 Mercedes Benz MBE900 Refrigerant Compressor 30 0 28 4 Table 1 Drive Belt Tensions 01 03 Pacbrake Inspecting and Maintenance With frequent use the Pacbrake Exhaust Brake will operate maintenance free If the vehicle is used in consistently or seasonally it will be necessary to per form preventative maintenance If the vehicle is ex posed to excess moisture or is used only for periodical or seasonal use perform the following steps 1 With the engine off use any oil free or non petroleum based high heat lubricant and spray or coat a sufficient amount on the restricter valve shaft and the attaching locations at each end of the actuation cylinder 2 With your hands or a pair of pliers motion the valve several times to distribute the lubricant down the shaft and the attaching locations NOTE Operation of the Pacbrake could be af fected by starting the engine and idling for short periods of time During a cold engine start up moisture occurs in the engine and the exhaust system that creates a corrosion hazard The brake housing may trap water in the valve shaft bore causing corrosion resulting in an improper or non functioning brake If it is necessary to periodically start the engine attain normal oper
19. 00 11 Perform All M2 Operations 00 12 Perform All M3 Operations 01 01 15 01 Engine Support Fasteners Checking Alternator Battery and Starter Checking 20 02 Radiator Pressure Flushing and Coolant Changing 26 02 Eaton Fuller and TTC Transmission Fluid Changing and Magnetic Plug Cleaning 31 01 Frame Fastener Torque Checking 33 04 All Axle Alignment Checking 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning 46 04 Power Steering Reservoir Fluid and Filter Changing NOTE Maintenance operations appearing in italics in this table are for noise emission control components Numbers in this table are maintenance operation ref erence numbers matching those in the text of this manual The M4 Maintenance consists of all M1 M2 and M3 Interval Operations plus the other operations Acterra Maintenance Manual January 2007 00 19 00 General Information M5 Maintenance Interval Operations Table 00 14 IMPORTANT After performing all operations listed in NOTE Numbers in this table are maintenance opera this table perform all daily weekly and monthly tion reference numbers matching those in the text of maintenance operations listed in the Pretrip and this manual The M5 Maintenance consists of all M1 Post Trip Inspections and Maintenance chapter of M2 M3 and M4 Interval Operations plus the other the Acterra Driver s Manual Also perform all M1 op
20. 66 89 1 2 13 64 87 68 92 55 75 91 123 1 2 20 72 98 77 104 65 88 102 138 96 12 92 125 98 133 80 108 130 176 9 16 18 103 140 110 149 90 122 146 198 5 8 11 128 173 136 184 110 149 180 244 5 8 18 145 197 154 209 130 176 204 277 3 4 10 226 306 241 327 200 271 320 434 3 4 16 253 343 269 365 220 298 357 484 7 8 9 365 495 388 526 320 434 515 698 7 8 14 402 545 427 579 350 475 568 770 1 8 582 789 1 12 637 863 1 14 652 884 Sterling recommends that all plated and unplated fasteners be coated with oil before installation t Use these torque values if either the bolt or nut is lubricated or plated zinc phosphate conversion coated cadmium plated or waxed Table 1 Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threads Acterra Maintenance Manual January 2007 00 3 00 Torque Specifications Tables 00 03 General Information Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threadst Regular Hex Flanged ee ee Grade 5 Bolt s odd B 8 2 or C 8 2 Grade G Nut Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m moms econ num 5 1 4 20 8 11 10 14 1 4 28 9 12 12 16 5 16 18 15 20 22 30 22 30 5 16 24 1
21. Air Brake Valve Inspecting and Leak Checking Bendix 1 42 02 Air Brake Valve Leak Checking Bendix 6 42 14 Air Brake Valve Operation 1 42 04 Air Dryer Checking Bendix 9 222 22 42 4594 dee beeen 42 12 Air Dryer Desiccant Replacing Bendix 9 42 13 Par Dryer Inspecting Bendix AD 9 uu secre ence Xx Oe eRe One OR eee 42 01 Air Reservoir Automatic Drain Valve Disassembly Cleaning Inspecting and Lubricating Bendix DV 2 ii xr mcm mk hao oe aes omg 42 15 Automatic Slack Adjuster Checking 42 09 Automatic Slack Adjuster Inspecting 42 21 Automatic Slack Adjuster Inspecting 42 11 Automatic Slack Adjuster Lubricating G hlte ox eee ened 42 20 Automatic Slack Adjuster Lubricating 42 22 Automatic Slack Adjuster Lubricating 42 10 Bosch Rail Slide Hydraulic Brake Caliper 0
22. Bendix E 8P e fe J 42 04 Air Brake Valve Operation Checking eo e we Je 42 05 Relay Valve Checking Midland 42 06 Quick Release and Flipper Valves Checking Midland e oe J 42 07 Brake Chamber Inspecting All Models 42 08 Camshaft Bracket Bushing Lubricating 21 14 1 42 09 Automatic Slack Adjuster Checking Meritor fe 42 10 Automatic Slack Adjuster Lubricating Meritor e fe J 42 11 Automatic Slack Adjuster Inspecting Meritor 42 12 Air Dryer Checking Bendix AD 9 n 00 12 Acterra Maintenance Manual January 2007 General Information 00 Maintenance Operation Sets Tables 00 08 Maintenance Operation Sets for Groups 33 through 42 REQUIRED MAINTENANCE OPERATION SET 1 M2 M3 5 Maintenance Operation Number and Operation Description 42 13 Air Dryer Desiccant Replacing Bendix AD 9 42 14 Brake Valve Leak Checking Bendix 6 42 15 Air Reservoir Automatic Drain Valve Disassembly Cleaning Inspecting and Lubricating Bendix DV 2 42 16 Air Brake Valve Disassembly Cleaning and Inspecting Bendix E 8P 12 14 SR 1 ST 3 TC 6 and TP 3DC 42 17 Brake Lining Wear Checking Hydraulic Disc Brakes 42 18 Brake Lines Checking Hydraulic Disc Brakes
23. IMPORTANT Before using a particular service bulletin check the current service bulletin validity list to be sure the bulletin is valid These bulletins pertain to special situations that involve service work or replace ment of parts in connection with a recall notice Recall bulletins pertain to mat ters of vehicle safety All bulletins are distributed to dealers customers receive notices that apply to their vehicles This publication is concerned with non safety related service work or replace ment of parts All field service modifications are distributed to dealers custom ers receive notices that apply to their vehicles Acterra Maintenance Manual January 2003 Introduction Page Description For a page example of the printed manual see Fig 1 A B Y Y Frame and Fifth Wheel 31 31 01 Frame Fastener Torque Checking CAUTION lt 31 02 Fifth Wheel Inspecting and Lubricating HOLLAND FONTANE Acterra Trucks Maintenance Manual April 2000 31 1 A A D E 02 11 2002 1020103 A Maintenance Operation Number consists of the Group Number followed by the Sequence Number B Group Title C Group Number D Release Date E Group Number Page Number Fig 1 Page Example of the Printed Manual Acterra Maintenance Manual January 2003 Maintenance Manual Contents Group No Group Title D General Information Olas hd oh kas hi aad oa ead oe En
24. M2 Maintenance Interval Operations 00 11 Maintenance Interval Operations 00 12 M4 Maintenance Interval Operations 00 13 M5 Maintenance Interval Operations 00 14 Maintenance Interval Tables y yer yk Rok xen e xor d ved 00 07 Maintenance Operation Sets 00 08 Maintenance Schedule 00 06 Metric U S Customary Conversion 00 04 Noise Emission Control Systems 00 01 Scheduled Maintenance Intervals Description and 0 00 05 Torque Specifications Tables iss sodes EG RR Y d E XX REO erg Xe Wee eee A wa 00 03 Verification or INSPECUONS LOG 55 e aper eq 00 02 Acterra Maintenance Manual January 2007 General Information 00 Noise Emission Control Systems Maintenance 00 01 General Information Federal Law Part 205 Transportation Equipment Noise Emission Controls Part 205 Transportation Equipment Noise Emission Controls requir
25. Numbers in this table are maintenance opera table perform all daily and weekly maintenance op tion reference numbers matching those in the text of erations listed in the Pretrip Inspection and Daily this manual The Initial Maintenance consists of all Maintenance chapter of the vehicle driver s manual M1 Operations plus the other operations listed below Also perform all M1 Maintenance Interval Operations at the Initial Maintenance IM Initial Maintenance IM Operations Maint Oper No 00 10 Perform All M1 Operations 25 02 Clutch Pull Type Inspecting and Adjusting 26 02 Eaton Fuller and TTC Transmission Fluid Changing and Magnetic Plug Cleaning Initial Maintenance IM Operations 31 01 Frame Fastener Torque Checking 32 03 U Bolt Torque Checking 33 04 All Axle Alignment Checking 33 07 Draw Key Nut Inspecting 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning 35 04 Two Speed Axle Shift Unit Oil Level Checking M interval does not apply to vehicles with a factory fill of Eaton approved synthetic lubricant 00 14 Acterra Maintenance Manual January 2007 General Information IMPORTANT After performing all operations listed in this table perform all daily weekly and monthly 00 M1 Maintenance Interval Operations Table 00 10 maintenance operations listed in the Pretrip and this manual Post Trip Inspections and Maintenance chapter of
26. compressor clutch and the pulley to check the compressor clutch clearance Drive plate to pul ley clearance is 0 02 to 0 03 inch 0 6 to 0 8 mm If the clearance is not correct see Group 83 of the Acterra Workshop Manual 5 Inspect the compressor clutch coil wire Check that the connector is not damaged or loose Re place the wire if it is damaged 83 08 25 94 1830641 Fig 1 Drive Plate Clearance Inspection 6 Check the overall condition of the air conditioning hoses Look for cracks cuts and abrasions on the hoses Replace damaged hoses See Group 83 of the Acterra Workshop Manual for replace ment instructions Also check for loose fittings on all air conditioning components 7 Check for a buildup of road debris on the con denser fins See Group 83 of the Acterra Work shop Manual for cleaning instructions 83 02 HVAC Air Filter Replacing The air filter must be replaced every six months re gardless of mileage to permit proper operation of the HVAC system IMPORTANT When replacing the air filter use only a Sterling approved air filter 1 Turn off the engine apply the parking brakes and chock the tires 2 Open the hood 3 Remove the screws that attach the filter cover to the filter housing See Fig 2 Remove the filter from the housing Install a new filter in the housing 6 Using screws attach the filter cover to the hous ing 7 Close the hood 8 Remove the c
27. each of the control rod ends up down in and out If there is any movement examine the control rods for wear or damage Replace if necessary 2 Inspect the rubber bushings for cracks or cuts Acterra Maintenance Manual September 2002 32 3 32 3 Check for any shifting of the barpin 4 Check for cracks in the metal components and welds NOTE The AirLiner suspension is manufactured at numerous weight ratings up to 46 000 pounds The control rod on the 46 000 pound rated suspension is larger and is fastened dif ferently than on other applications see Group 32 of the Acterra Workshop Manual for re moval and installation information Freightliner TufTrac 1 Inspect the suspension spring assemblies for pitted cracked broken or abnormally bent leaves and extreme rust If any of these condi tions exist replace the spring assembly A WARNING Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring as sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Re placement of only the visibly damaged part s is no assurance that the spring is safe 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 IMPORTANT On multi leaf suspensions
28. use SAE 10 heavy duty engine oil API service classification SD sulfated ash content must not exceed 1 85 When the vehicle operating tempera tures are below 0 18 C use one part of kerosene to three parts of SAE 10 heavy duty engine oil API service classification SD sul fated ash content must not exceed 1 85 This cold weather mixture can be safely used up to 32 F 0 C Commercially available automatic transmission fluid may be used in place of SAE 10 engine oil Automatic transmission fluid can be used for all temperatures Do not mix kerosene with auto matic transmission fluid f350021a 3 Apply a small amount of Loctite 242 or equiva lent sealant to the threads of the fill hole plug Install the fill hole plug finger tight then using a wrench tighten the plug 1 1 2 turns more Acterra Maintenance Manual March 2000 35 3 35 35 05 Two Speed Axle Shift Unit Oil Changing 1 Remove the shift unit housing cover see Fig 2 and drain the old lubricant Discard the housing cover gasket and the old lubricant 2 Thoroughly wash the axle shift parts and housing cover and allow them to air dry 3 Install the housing cover and a new housing cover gasket Tighten the housing cover cap screws 90 to 110 Ibf in 1020 to 1240 then remove the oil fill hole plug from the cover 4 Fill the shift unit housing through the oil fill hole until the specified lubricant is leve
29. 00 General Information Verification of Inspections Log 00 02 Verification of Inspections Log Verification of Inspections Log Group 20 Verification of Inspections Log Group 20 Engine Cooling Radiator Date Mileage Repair Description Cost Repair Facility Verification of Inspections Log Group 49 Verification of Inspections Log Group 49 Exhaust Date Mileage Repair Description Cost Repair Facility 00 2 Acterra Maintenance Manual January 2007 General Information 00 Torque Specifications Tables 00 03 Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threadst Regular Hex Flanged M ci Grade 5 Grade 5 or Grade 8 or Grade 8 or Grade 5 Grade B Grade 8 or Grade G Pitch Bolt B Nut 8 2 Bolt C Nut Bolt Nut 8 2 Bolt Nut Torque N m Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m SHS X gt KA NL 2 LA 1230003 ht NE ca MED 5 SER st 1 4 20 7 9 8 11 6 8 10 14 1 4 28 8 11 9 12 7 9 12 16 5 16 18 15 20 16 22 13 18 21 28 5 16 24 16 22 17 23 14 19 23 31 3 8 16 26 35 28 38 23 31 37 50 3 8 24 30 41 32 43 25 34 42 57 7 16 14 42 57 45 61 35 47 60 81 7 16 20 47 64 50 68 40 54
30. 150 Ibf ft 170 to 203 N m 5 Use click type torque wrench to check that the two end nuts for each torque rod are tightened 400 to 450 Ibf ft 540 to 610 N m 6 Use click type torque wrench to check that spring retainer bolts are tightened 60 to 80 81 to 109 N m 32 02 Suspension Lubricating Suspension Sterling Spring Front Suspension Wipe all dirt from the grease fittings at the forward spring pin and the spring shackle pins then apply multipurpose chassis grease with a pressure gun until the old grease is forced out Sterling Spring Rear Suspension Single Axle Lubricate the spring pin by applying multipurpose chassis grease at the grease fitting See Fig 10 Lu bricate with a grease gun until grease appears at the base of the fitting Tandem Axle CAUTION If the equalizer cap and tube assembly is equipped with a nonrelief grease fitting excessive lubrication can damage the bushings Lubricate the equalizer cap and tube assembly bush ings by applying multipurpose chassis grease at the pressure relief grease fitting See Fig 11 Lubricate with a hand gun or pressure gun until grease is forced out from the base of the pressure relief fitting 22 10 05 94 f320268a Fig 10 Forward Spring Bracket Spring Pin Grease Fitting vehicles built before September 15 2002 05 27 93 A Lubricate here 320020a 1 Cap and Tube Assembly Bushing Fig 11
31. 2004 Steering Plastic Ventra Reservoir NOTE If the power steering reservoir in the ve hicle looks like the reservoir shown in Fig 4 use the following procedure 1 Turn off the engine apply the parking brakes and chock the tires 2 N 4 MAXHOT 2 1 MIN COLD A 10 19 2000 461917 1 Power Steering Reservoir 2 Retaining Ring 3 Filter Cover 4 Return Hose Fig 4 Power Steering Reservoir 2 Open the hood 3 With the engine cool the fluid level should be between the MIN COLD and MAX HOT lines with the engine off Add or remove fluid as necessary to bring the fluid level to the line between the MIN COLD and MAX HOT lines Use only Dexron III automatic transmission fluid 4 With the engine hot the fluid level should be at the MAX HOT line with the engine off Add or remove fluid as necessary to bring the fluid level to the MAX HOT line Use only Dexron auto matic transmission fluid 5 Close the hood and remove the chocks from the tires 46 46 04 Power Steering Reservoir Fluid and Filter Changing Metal Ventra Reservoir 1 Turn off the engine apply the parking brakes and chock the tires 2 Open the hood 3 Remove the fill cap nut and cover from the Steering reservoir 4 Disconnect the hose between the reservoir and the steering gear from the reservoir Then drain the reservoir in a drain pan and cap the reser voir port 5 Lift out the sprin
32. Check the terminals for tightness damage and corrosion or dirt 10 05 94 1540844 1 Electrical Connectors 2 Magnetic Switch Fig 2 Right Side of the Firewall 9 Check the seven way trailer cable plug at the back of the cab Make sure all the pins are tight and free of dirt and grease Chassis 1 Check the main wiring harness Check the wiring insulation for damage from chafing or heat Also check for kinks Reroute repair or replace the wires as needed 2 Check all the tie straps for breakage or damage Replace any broken or cracked tie straps A CAUTION Do not use flat strip aluminum tie straps for hold ing electrical wiring The sharp edges on these tie straps may cause breaks in the wire insulation allowing the aluminum tie strap to make contact with the wire This could cause a short circuit and damage to the wiring 3 Check the temperature sending units on the axles and transmission Check for damaged wires and loose connectors Acterra Maintenance Manual March 2000 54 1 54 Electrical Instruments and Controls 54 02 Coolant Level Sensor Cleaning 1 Drain enough coolant from the radiator to expose the coolant level sensor 2 Disconnect wire 173 from the sensor in the ra diator surge tank Remove the sensor from the surge tank 3 Using a fine grit sandpaper clean the sensor until the metal is exposed Clean the tapped hole with a wire brush 4 Install th
33. F Viscosity Eaton Fuller Transmissions MobilTrans SHC 50 RN All 50 2952 E 5 Synthetic transmission All 50 lubricant approved by Eaton Heavy duty engine oil API Above 10 12 40 or 50 service classification CD or SF Below 10 12 30 TTC Transmissions Heavy duty engine oil API Above 0 18 30 or 40 service classification CD or Above 15 30 SF 26 26 Approved Manual Transmission Lubricants Temperature SAE Lubricant Type F C Viscosity Straight mineral gear oil with Above 10 12 90 rust and oxidation inhibitor API GL 1 iio 3 20 Synthetic engine oil meeting All 50 MIL L 2104D MIL L 46152B API SF or API CD Mercedes Benz Transmissions MobilTrans SHC DC All 50 Lubricants listed in order of preference Do not mix types of oil t Call 1 800 826 4357 for a complete list of Eaton approved lubricants Table 1 Approved Manual Transmission Lubricants CAUTION Operating a manual transmission with the fluid level higher or lower than recommended can re sult in transmission damage Do not overfill the transmission overfilling will force fluid out of the case through the main shaft openings Fluid over flow may also drain onto the clutch or clutch brake causing additional problems IMPORTANT Do not mix types of fluid because of possible incompatibility Do not use fluid addi tives or fricti
34. Leakage Checking WARNING Do not loosen or remove the parking brake clamp ring for any purpose at any time See Fig 1 The parking emergency brake section is not intended to be serviced Serious injury or death may result from sudden release of the power spring Before doing any repairs or adjustments on a service parking brake chamber read the appli cable warnings and instructions in the applicable brake chamber section in Group 42 of the Acterra Workshop Manual 1 Park the vehicle on a level surface Chock the tires 2 Build the air pressure in the system to at least 100 psi 690 kPa and shut off the engine 3 Place the park control valve in the park position The brake should apply immediately Place the park control valve in the released position The brake should release immediately If the brakes do not apply or release as required see the air brake system troubleshooting guide in the applicable brake chamber section in Group 42 of the Acterra Workshop Manual for possible causes and corrections 42 Do not disconnect the pressurized parking brake hose If disconnected under pressure the parking brake hose will whip as air escapes from the line and the air stream can direct dirt or sludge toward persons in the area which could result in injury 4 Check the parking brake chambers for leakage 4 1 With the park control valve released apply soapy water around the parking brake diaphragm clamp ring
35. Workshop Manual 31 2 Acterra Maintenance Manual January 2007 Frame and Frame Components 8 Replace cracked worn or damaged parts with new parts Replace loose mounting bolts with 5 8 11 SAE grade 8 bolts grade nuts and hardened washers Do not reuse bolts nuts and washers on fifth wheel mountings Holland Disconnect the tractor from the trailer For instruc tions see Chapter 10 of the Acterra Driver s Manual Thoroughly steam clean the fifth wheel then inspect for 1 Loose nuts or broken bolts on the fifth wheel as sembly 2 Cracks or wear on the mounting bolts 3 Improper locking action cracks or wear on the jaw locking mechanism 4 Gouges or wear on the fifth wheel top plate 5 Fatigued or cracked welds 6 Replace cracked worn or damaged parts with new parts Replace loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C nuts and hardened washers Do not reuse bolts nuts and washers on fifth wheel mountings 7 f you observe any problems doing the previous Steps correct them immediately For instructions see Group 31 of the Acterra Workshop Manual 31 03 Fifth Wheel Lubricating Fontaine Use a multipurpose extreme pressure EP chassis grease and lubricate all moving parts on the fifth wheel When lubricating the top plate at the grease fittings for the bracket bearing area tilt the top plate forward and backward to evenly distribute the grease Using a pry too
36. and at the drain slots and exhaust breather on the body Disconnect the service brake hose at the service port and apply soapy water to check for piston O ring leakage A WARNING Read and follow all applicable warnings and in structions in the applicable brake chamber section in Group 42 of the Acterra Workshop Manual for repairs to the service parking brake chambers These chambers contain a power spring which if released could cause serious injury or death 4 2 If leakage is detected at either the clamp ring or the drain slots replace the parking brake section Slight leakage is permitted at the service port Any other leakage is not acceptable Using the instructions in the applicable brake chamber section in Group 42 of the Acterra Workshop Manual replace the parking brake section do not attempt to service the parking brake section Connect the air hose to the brake chamber mak ing sure that the fittings are clean and free of debris Tighten the nut finger tight Using a wrench further tighten the nut until you feel re sistance Then tighten the nut one sixth turn more Repeat the above steps for each parking brake chamber 7 Apply the parking brakes Remove the chocks from the tires Acterra Maintenance Manual October 2007 42 5 42 42 08 Camshaft Bracket Bushing Lubricating IMPORTANT Perform MOP 42 24 before lubri cating the camshaft brackets Pump multipurpose chassis
37. and improve grease distribution Lower the tires to the ground and regrease both top and bottom bushings until new grease is seen at the seal on the bushing opposite the fittings The grease seal will accept the grease pressure without damag ing the seal and is designed to have grease pumped 33 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 seal on the bushing opposite the grease fitting When lubricating knuckle pin bushings at M1 through M5 do not raise the front axle Wipe the lube fittings clean and apply multipurpose chassis grease until new grease is seen at the grease seal on the bush ing opposite the fittings The grease seal will accept the grease pressure without damaging the seal 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 seal on the bushing opposite the grease fitting Sealed and Easy Steer Axle Kingpins NOTE This procedure applies to the following axles e MFS 8 153B MFS 10 143A MFS 12 143A e MFS 13 143A MFS 14 143A MFS 16 143A MFS 18 133A e MFS 20 133A 975 Series Easy Steer sealed front axles Refer to the identification tag on the front of the axle beam On sealed and Easy Steer front axle the grease fittings are on the top and bottom kingpin
38. both spring assemblies to ensure even spring deflection Hendrickson Radius Rod Bushing Checking 1 Without detaching the torque arms attempt to move by hand each of the radius rod ends up Acterra Maintenance Manual September 2002 32 5 32 down in and out If there is any movement re place the torque arm 2 Inspect the rubber bushing ends Replace the torque arm if there are gaps between the rubber bushing and the pin or the outer steel sleeve if either bushing end contacts a torque arm pin mounting bolt if there are cracks in the bushing or if part of the rubber bushing extends beyond the outside diameter of the outer bushing sleeve Chalmers Suspension Checking Chock the front wheels to prevent the vehicle from moving Place the transmission in neutral and re lease the spring or driveline brakes before inspecting the rear suspension Power wash the Chalmers rear suspension or clean it with a hard bristle brush before performing a visual inspection 1 Inspect the rubber bushings for cracks or other damage Try to move the torque rod ends using your hands only and check for any free play If free play is felt replace the torque rod end bushing Do not use a pry bar to check for free play Use of a pry bar may lead to premature bushing re placement See Group 32 of the Acterra Work shop Manual for replacement instructions 2 f equipped with optional shock absorbers check for worn broke
39. caps of the knuckle 1 Shut off the engine apply the brakes and chock the rear tires 2 Make sure the tires touch the ground Do notraise the vehicle 3 Clean off all grease fittings prior to lubrication IMPORTANT Meritor recognizes that industry trends are moving toward increased selection and usage of synthetic grease in vehicle mainte nance However some seals are known to ex Acterra Maintenance Manual September 2002 33 1 33 when in contact with synthetic grease Consult your local Meritor representative for synthetic grease application references before using any synthetic grease when performing axle service and maintenance 4 Using a multipurpose grease NLGI grade 1 or 2 lubricate the kingpins through the grease fittings on the top and bottom of the knuckle See Fig 2 10 10 2001 1330185 Apply lubricant until new lubricant comes from these areas 1 Grease Fitting Fig 2 Sealed Easy Steer Kingpin Lubrication 5 Apply lubricant until new lubricant comes from the thrust bearing seal and the upper shim pack 6 Remove the chocks from the tires Easy Steer Plus Axles With Unitized Wheel Ends King Pins NOTE This procedure applies to Easy Steer Plus MFS 10 12 143D sealed front axles Refer to the identification tag on the front of the axle beam On Easy Steer Plus front axles the grease fittings are on the top and bottom kingpin caps of the knuckle
40. checking wheel nuts on a dual disc assembly remove one outer nut at a time tighten the inner nut CAUTION Too little wheel nut torque can cause wheel shimmy resulting in wheel damage stud break age and extreme tire tread wear Too much wheel nut torque can break studs damage threads and crack discs in the stud hole area then reinstall the outer nut Repeat this procedure for all of the inner wheel nuts in the sequence shown in Fig 1 then tighten all of the outer wheel nuts in the same sequence See Table 1 Table 2 or Table 3 for wheel nut torque specifications Fastener Torque for 10 Hole Disc Wheel With Inner and Outer Locknuts Description Nut Size Wheel Manufacturer Torque dry threads Ibf ft N m Front Wheel Nut 3 4 16 1 1 8 16 Accuride 450 500 610 680 Rear Wheel Inner Nut 3 4 16 Accuride 450 500 610 680 Rear Wheel Outer Nut 1 1 8 16 Accuride 450 500 610 680 Wheel Stud Retainer Nut 3 4 16 Accuride 175 200 235 270 Table 1 Fastener Torque for 10 Hole Disc Wheel With Inner and Outer Locknuts Fastener Torque for 8 Hole Disc Wheel With Cone Locknuts Description Front and Rear Wheel Nuts Nut Size M20 Torque lubricated threads Ibf ft N m 280 310 380 420 Table 2 Fastener Torque for 8 Hole Disc Wheel With Cone Locknuts Spoke Type Wheel Fastener Torque
41. stands 10 Start the engine and operate it at idle Turn the steering wheel from full left to full right several times until clean fluid starts flowing from the steering filter Add fluid to the reservoir to main tain the fluid level between the MIN COLD and MAX HOT lines 11 Shut down the engine and install the filter and filter cover in the reservoir Make sure that the gasket under the filter cover is not damaged If the gasket is damaged replace it Install the gas ket on the reservoir 12 Attach the retaining ring to the reservoir to se cure the filter and filter cover 13 Start the engine and check that the fluid level is between the MIN COLD and MAX HOT lines Add more fluid if needed 14 Raise the vehicle remove the jack stands and lower the vehicle 15 Close the hood and remove the chocks from the tires 46 05 Power Steering Gear Lubricating 1 Wipe off debris from the grease fitting See Fig 5 46 2 Using a hand type grease gun apply multipur pose chassis grease until the grease starts com ing out of the sector shaft dirt and water seal 04 13 93 1 Sector Shaft Grease Fitting f460515a Fig 5 Sector Shaft TRW TAS Series Acterra Maintenance Manual July 2004 46 5 Fuel 47 Index Alphabetical Title of Maintenance Operation MOP MOP Number Fuel Tank Draining and Vent Checking Racer dn boum RR Er wes deba vee 47 01 Acter
42. the Acterra Driver s Manual M1 Maintenance Interval Operations Maint Oper No M1 Maintenance Interval Operations 00 15 31 02 Lubrication and Fluid Level Check Clutch Release Bearing and Release Cross Shaft Lubricating Hydraulic Fluid Level Checking Manual Transmission Fluid Level Checking Fifth Wheel Lubricating Suspension Lubricating Knuckle Pin Lubricating Tie Rod End Lubricating All Wheel Drive Front Axle Oil Level Checking Axle Lubricant Level Checking Driveline Lubricating Foot Brake Valve Actuator Lubricating Bendix 8 Automatic Slack Adjuster Lubricating Meritor Automatic Slack Adjuster Lubricating Gunite Automatic Slack Adjuster Lubricating Haldex Drag Link Lubricating Power Steering Reservoir Fluid Level Checking Power Steering Gear Lubricating Ross TAS Series Weatherstrip Door Latch and Door Hinge Lubricating Fifth Wheel Inspecting 32 01 Suspension Inspecting 33 02 Tie Rod End Inspecting 35 02 Axle Breather Checking 41 01 Driveline Inspecting 42 01 Air Dryer Inspecting Bendix AD 9 42 02 Air Brake Valve Inspecting and Leak Checking Bendix 1 42 04 Air Brake Valve Operation Checking 42 05 Relay Valve Checking Midland 42 06 Quick Release and Flipper Valves Checking Midland 42 07 42 09 Brake Chamber Inspecting All Models Automatic Slack Adjuster Checking Meritor
43. the System Sentry fuse Leaking air means the clutch has gotten so hot the lead alloy in the fuse melted This released the clutch before the heat could damage the clutch bearings Before replacing the fuse find and repair the source of the heat If equipped with an override toggle switch on the dash check the fan clutch operation as follows 10 1 Connect the halves of the fan solenoid connector 10 2 Turn the air conditioner off 10 3 Start the engine and charge the air sys tem to 120 psi 827 kPa Tests must be performed with the engine temperature below 205 96 for Caterpillar en gines and below 200 F 93 C for Cum mins 10 4 Set the toggle switch to the ON position the fan clutch should engage 20 4 Acterra Maintenance Manual January 2007 Engine Cooling Radiator 20 03 30 95 ONO Ord ox Mounting Bracket 9 Rear Sheave Bearing 10 Bearing Spacer Inner and Outer Bearing 11 Splined Hub Spacers 12 Forward Hub Bearing Forward Sheave Bearing 13 Piston Friction Disc Sheave 14 Large O Ring Friction Facing 15 Locknut Journal Spacer 16 Cartridge Assembly Socket Head Capscrew 24 Rear Hub Bearing f200194a 17 Face Seal 18 Small O Ring 19 Air Chamber 20 Socket Head Capscrew 21 Stud Bolt 22 Lockwasher 23 Hexnut 24 Piston Assembly Fig 6 Horton Advantage Fan Clutch Components 10 5 Apply the foot brake and release the parking brakes 10
44. to be damaged remove the driveshaft and check the runout on the tube If the tube is not straight and cannot be straightened within 0 015 inch 0 38 mm on the slip joint seal surface of the splined shaft 0 020 inch 0 51 mm on the tube 3 inches 76 mm from the front and rear welds and 0 025 inch 0 635 mm at the center of the tube replace the tube See Fig 3 Acterra Maintenance Manual March 2000 41 1 41 Driveline 10 06 94 3 NOTE Not all fasteners are shown 1 Transmission 8 Slip Joint Assembly 13 Splined Shaft 2 Half Round End Yoke 9 Driveshaft Tube 14 Dust Seal 3 U Joint Assembly 10 Driveshaft Yoke 15 Sleeve Yoke 4 Yoke Strap and Capscrew 11 Input Shaft Half Round End 16 Full Round Yoke Lug 5 Coupling Shaft Yoke 17 U Joint Cross 6 Midship Bearing and Mount 12 Rear Axle 18 Lockplate and Capscrew 7 Bearing Cup 1410057 Fig 1 Driveline Assembly With Midship Bearing for Single Axle Installation If the driveshaft tube requires straightening or replacement balance the repaired driveshaft be fore installing it See Group 41 of the Acterra Workshop Manual 7 Check the driveshaft for missing balance weights and for debris build up Remove any build up If any balance weights are missing re move the driveshaft and have it balanced see Group 41 of the Acterra Workshop Manual 8 For driveshafts with slip joints check that the yoke plug is not loose or missing S
45. 038 M Engineering Standards B Ethylene glycol solution that has less than 0 1 anhydrous sodium metasili cate and meets either GM 1825 or GM 1899 M Engineering Standards Table 2 Approved Coolants 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 20 20 03 Fan Clutch Checking Noise Emission Control Eaton Viscous Fan Clutch CAUTION If the fan drive assembly is damaged replace the unit as soon as possible Operating a seized or otherwise damaged clutch reduces fuel economy and could cause serious engine damage See Group 20 of the Acterra Workshop Manual for replacement instructions 1 With the engine off rotate the fan at least one full turn by hand It should have a smooth steady drag If it does not replace the fan clutch 2 Check for physical damage to the fan or fan shroud 3 Atthe fan clutch mounting 3 1 Check for correct drive belt alignment and tension For specifications see Group 01 of this manual 3 2 Check for wear of the fan clutch bearings There should be no side to side or in and out movement of the fan clutch 3 3 Do all of the checks in Section 20 02 of the Acterra Workshop Manual Horton Advantage 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 Acterra Wo
46. 2 2 If the locknuts are loose tighten them For correct torque values see the appli cable brake chamber section in Group 42 of the Acterra Workshop Manual 3 Observe the piston rod engagement with the cle vis Engagement of at least 7 threads is required there should be 1 inch 25 mm clearance from the centerline of the clevis pin hole to the end of the piston rod See Fig 3 Adjust if needed 4 Check the tightness of the piston rod nut See Table 1 for torque values Tighten if needed 5 Seeif the chamber piston rod is in line with the slack adjuster Misalignment can cause the pis ton rod to rub on the non pressure chamber and cause a dragging brake Reposition the brake chamber on the mounting bracket if necessary 2 3 E A B i Y A 4 Y 5 08 20 93 A Minimum of 1 inch 25 mm clearance between centerline of clevis pin hole and piston rod end 1420225 Minimum of 7 threads engagement 1 Piston Rod 4 Cotter Pin 2 Piston Rod Nut 5 Clevis Pin 3 Clevis Fig 3 Piston Rod Engagement With the Clevis Piston Rod Nut Torque Values se Rod Size Torque inch Ibf ft N m MGM Tandem Chambers All 25 35 34 47 1 2 20 30 27 41 5 8 33 90 45 122 Table 1 Piston Rod Nut Torque Values Midland Service Chambers 6 Inspect the condition of the hose s to the brake chamber Check carefully for chafing restrictions such as kinking or bending and mak
47. 4 02 Electrical System OCIO 2 emcee oc Ret d p eee A ean p Ra ate 54 01 Acterra Maintenance Manual March 2000 Electrical Instruments and Controls 54 01 Electrical System Checking Cab 1 Uncover the electrical panel see Fig 1 by re moving the fasteners 10 05 94 1540843 1 Flasher Fig 1 Under Dash Electrical Panel 2 Check the wiring harness for movement that could strain the electrical connections Install more clamps on the harness if needed 3 Check all the wiring for chafing kinks and dis colored insulation Find the cause of any prob lems then repair replace or reroute the wires as needed 4 Check that all the relays are firmly seated in their mounting plates 5 Check the turn signal flasher if so equipped See Fig 1 Make sure that the two male and female connectors are firmly connected Check that the flasher fuse is firmly seated in its holder 6 Check the cigarette lighter Look inside the Socket for signs of overheating discoloration melting caused by misuse of the lighter socket 7 Test the electric horn If it does work check the adjustment screw on the horn unit Turn the screw in or out until the horn works If the horn 54 still does not work check the wiring to it If the wiring checks out okay replace the horn 8 Check connectors on the right side of the fire wall below the radiator surge tank See Fig 2
48. 6 Set the toggle switch to the AUTO or OFF position the air should exhaust and the fan clutch should disengage Replace the Switch if necessary Kysor K22RA Fan Clutch 1 Disconnect the electrical cables from the battery Drain all air from the air system If equipped with an air starter drain the air starter reservoir WARNING Make sure the batteries are disconnected and if applicable the air starter reservoir is drained be fore checking the fan clutch If the engine starts during this procedure the fan could engage which could result in serious personal injury 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 7 Ref A Disconnect the line from the air inlet of the air cylinder Connect a shop air hose to the inlet 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 the retaining plate to the forward most edge of the fan belt pulley Compare the two measurements if the difference between the two measurements exceeds 0 150 inches 3 8 mm the clutch lining is worn and Acterra Maintenance Manual January 2007 20 5 20 05 27 93 f200237a With the fan clutch engaged measure the distance at A measure it again with the fan clutch disengaged 5 Air Cylinder 6 F
49. 7 23 25 34 3 8 16 28 38 40 54 40 54 3 8 24 31 42 45 61 76 14 45 61 65 88 65 88 76 20 50 68 70 95 1 2 13 70 95 95 129 95 129 1 2 20 75 102 110 149 9 16 12 100 136 140 190 140 190 9 16 18 110 149 155 210 5 8 11 135 183 190 258 190 258 5 8 18 155 210 215 292 3 410 240 325 340 461 340 461 3 416 270 366 380 515 7 8 9 385 522 540 732 7 814 425 576 600 813 1 8 580 786 820 1112 1 12 635 861 900 1220 1 14 650 881 915 1241 Threads may have residual oil but will be dry to the touch t Male and female threads bolt and nut must both be unlubricated and unplated if either is plated or lubricated use Table 1 Sterling recommends that all plated and unplated fasteners be coated with oil before installation Table 2 Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threads 00 4 Acterra Maintenance Manual January 2007 General Information 00 Torque Specifications Tables 00 03 Torque Values for Metric Thread Fasteners With Lubricated or Plated Threadst Thread Class 8 8 Bolt Class 8 Nut Class 10 9 Bolt Class 10 Nut Diameter Pitch Torque Ibf ft N m Torque Ibf ft N m N N N P N uds a E 0 1230010 1230011 1230012 1230013 6 5 7 7 9 8 12 16 17 23 8 1 13 18 1
50. 8 24 10 24 33 34 46 M10 x 1 25 27 37 38 52 M12 42 57 60 81 M12 x 1 5 43 58 62 84 M14 66 89 95 129 M14 x 1 5 72 98 103 140 M16 103 140 148 201 M16 x 1 5 110 149 157 213 M18 147 199 203 275 M18 x 1 5 165 224 229 310 M20 208 282 288 390 M20 x 1 5 213 313 320 434 M22 283 384 392 531 M22 x 1 5 315 427 431 584 M24 360 488 498 675 M24 x 2 392 531 542 735 M27 527 715 729 988 M27 x 2 569 771 788 1068 M30 715 969 990 1342 M30 x 2 792 1074 1096 1486 Sterling recommends that all plated and unplated fasteners be coated with oil before installation t Use these torque values if either the bolt or nut is lubricated or plated zinc phosphate conversion coated cadmium plated or waxed Table 3 Torque Values for Metric Thread Fasteners With Lubricated or Plated Threads Acterra Maintenance Manual January 2007 00 5 00 Metric U S Customary Conversion Tables 00 04 General Information bia pee U S ur dd To Get Metric ri d To Get U S Customary Length inches in 25 4 millimeters mm 0 03937 inches in inches in 2 54 centimeters cm 0 3937 inches in feet ft 0 3048 meters m 3 281 feet ft yards yd 0 9144 meters m 1 094 yards yd miles mi 1 609 kilometers km 0 6215 miles mi Area square inches in 645 16 square millimeters mm 0 00155 square inches in square inches in 6 452 sq
51. 81 to 102 N m for Eaton Fuller transmissions with 1 1 4 inch pipe threads 26 03 Allison Transmission Breather Checking Transmission housing breathers must remain clear A plugged breather could result in pressure build up which could cause fluid leakage If the breather is plugged clean or replace it See Fig 2 Check more often if the vehicle is operating under very dusty conditions 05 27 93 1260007 Fig 2 Transmission Breather 26 26 04 Allison Transmission Fluid and Filter Changing 1000 2000 2400 Series 1 Park the vehicle on a level surface and apply the parking brakes 2 Run the engine until the transmission fluid reaches the operating temperature of 160 to 200 F 71 to 93 C Shift the transmission to neutral N and shut down the engine CAUTION To prevent dirt from entering the transmission use only clean containers and fillers for the trans mission fluid Do not use fillers or containers that have been used for water or antifreeze Dirt water or antifreeze could damage the transmission 3 Clean the area around the drain plug Place a drain pan under the transmission and remove the drain plug Examine the fluid while it drains If only the filter is being changed do not drain the fluid NOTE A lot of fluid will drain when the filter is removed 4 Using a standard strap type filter wrench remove the filter by turning it counterclockwise 5 Remove the
52. ACTERRA MAINTENANCE MANUAL Models MX STI 403 1 10 07P STERLING TRUCKS Published by Freightliner LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A Foreword When performed on a regular basis lubricating the parts of your vehicle is the least costly way of obtaining safe and reliable vehicle operation Added benefits and savings occur when you check that the engine undercarriage and noise emission control parts are in good working order during lubrication This maintenance manual explains when you should lubricate parts and what to look for when checking for wear or damage For daily and weekly checks refer to the vehicle driver s manual IMPORTANT Descriptions and specifications in this manual were in effect at the time of printing Sterling Truck Corporation reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation Descriptions and specifications contained in this publication provide no warranty expressed or implied and are subject to revision and editions without notice For additional information please contact Freightliner LLC Service Systems and Documenta tion Box 3849 Portland OR 97208 3849 U S A or refer to www Freightliner com and www Sterling Trucks com Environmental Concerns and Recommendations Whenever you see instructions in this manual to discard materials you should attempt to re
53. Allison Transmission Lubricants Allison Transmission Lubricant Capacities m Fill Capacity Transmission Model quarts liters On Highway Series 1000 2000 2400 15 0 14 2 AT Series 545 16 0 15 1 MT Series MT 643 15 0 14 2 653 MD Series MD 3060 19 0 18 0 MD 3560 Quantities listed are approximate Add the recommended amount of fluid as listed under fill capacity then perform a hot check and add fluid as needed Do not overfill Table 4 Allison Transmission Lubricant Capacities AT Series 1 Park the vehicle on a level surface and apply the parking brakes Transmission 2 Run the engine until the transmission fluid reaches the operating temperature of 160 to 200 F 71 to 93 C Shift the transmission to neutral N and shut down the engine CAUTION To prevent dirt from entering the transmission use only clean containers and fillers for the trans mission fluid Do not use fillers or containers that have been used for water or antifreeze Dirt water or antifreeze could damage the transmission 3 Clean the area around the drain plug While the transmission fluid is warm remove the drain plug and drain the fluid Disconnect the fill tube from the oil pan IMPORTANT Examine the used transmission fluid for dirt coolant or water and metal par ticles If any of these contaminants are present a problem may exist within the transmission system
54. Bd fa QUUD dod ees Goa dde odo d OUR 33 01 Tle Rod End Inspecting de por bote be do nT pr Oe dae eae daw datas 33 02 TMe Rod End LUDNCAING EM pm 33 03 Acterra Maintenance Manual September 2002 Front Axle 33 01 Knuckle Pin Lubricating Standard Meritor Axles Hold a pressure gun on each fitting until fresh grease appears See Fig 1 This will ensure that all the old contaminated grease has been forced out It is not necessary to exceed 4000 psi 27 560 kPa The best distribution of new lubricant and the best purg ing of old lubricant occurs when about 4000 psi 27 560 kPa pressure is applied at the grease gun nozzle Using a 40 to 1 booster the air should be limited to 100 psi 689 kPa using a 50 to 1 booster the air should be limited to 80 psi 551 kPa Higher or lower pressures are not recommended 09 06 96 1320032 A Pump lubricant into each grease fitting until fresh grease comes out here 1 Grease Fitting Fig 1 Meritor Front Axle When lubricating knuckle pin bushings for Initial Maintenance raise the front axle until the front tires are off the ground Wipe the lube fittings clean and slowly feed multipurpose chassis grease NLGI grade 1 or 2 into each bushing area while turning the wheels from extreme right to left and back again lock to lock This will eliminate small air pockets
55. Bleeding the Clutch See Fig 4 Bleeding the Clutch 1 Apply the parking brake and chock the tires 2 Prepare the pressure bleeding equipment ac cording to the manufacturer s instructions Use DOT 3 brake fluid Pressurize the bleeder unit to 15 psi 103 kPa CAUTION Do not spill clutch hydraulic fluid DOT 3 brake fluid on the cab paint Clean it off immediately if any is spilled DOT 3 brake fluid can damage paint 3 Remove the reservoir lid and install the pressure bleed adaptor on the reservoir 4 Remove the cap from the bleed valve Install a transparent drain hose on the bleed valve of the slave cylinder IMPORTANT The slave cylinder may not be mounted in a horizontal position If it isn t re move the slave cylinder and hold it in a horizon tal position to completely purge all air from the cylinder 5 Pressurize the reservoir filling the system Open the bleed valve on the bleed tank NOTE A pressure bleeder hose J 29532 and a bleeder adaptor J 35798 for the fluid reser voir are available through SPX Kent Moore Tools and may be used to complete the follow ing procedure To order these parts call Kent Moore at 1 800 328 6657 6 Press the clutch pedal all the way down and keep it down 25 pm F M 6 10 9g 11 B 4 5 12 13 16 15 CN 08 05 2002 1250594 1 Reservoir 11 Hose Connector 2 Reservoir Cap 12 Hydraulic Hose 3 Clutch Support Pl
56. Check the rubber helper spring if present for cracks 2 05 27 93 1820022 A Measure the change in gap at this point 1 Equalizer Bracket 3 Pry Bar 2 Equalizer Fig 2 Torque Arm Bushings Fig 3 Side View of the Equalizer 32 2 Acterra Maintenance Manual September 2002 Suspension 1 2 3 N 05 27 93 5 1320023a A 1 8 inch 3 mm Clearance 1 Frame Fasteners 4 Equalizer 2 Frame Rail 5 Equalizer Bracket 3 Pry Bar Fig 4 Top View of the Equalizer 60 Inch Taper Leaf Spring Component Check No lubrication is required on the 60 inch taper leaf spring rear suspension Inspect the rear shackle brackets for bushing wear or cracks Inspect the stabilizer bar if present for irregular bushing wear or cracks in the brackets Check the rubber helper spring if present for cracks Freightliner AirLiner Component Clearance Checking Check that the air line support brackets are posi tioned so the air lines do not rub against anything Reposition any configurations that could contact and result in friction and wear There must be at least 1 inch 25 mm clearance around the rubber air spring when inflated If the clearance is less than 1 inch 25 mm relocate the obstructing parts CAUTION Failure to relocate obstructing parts could result in damage to the air spring 32 Freightliner AirLiner Component Inspecting and Operation Che
57. Checking Do not remove or loosen the radiator 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 CAUTION The radiator cap currently installed may not be the same one installed when the vehicle was built If the radiator cap must be replaced make sure that it is the correct cap for the cooling system of the vehicle Because the radiator cap pressure rating affects the operating temperature of the engine installing an improperly rated radiator cap may have adverse effects on the cooling system and engine operating temperatures This could cause premature engine wear or damage 1 Using 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 2 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 3 Make sure that the cap seals properly on the coolant filler neck seat and that the radiator cap gasket is not damaged On
58. Equalizer Assembly Lubrication Hendrickson Equalizer Beam End Bushings and Rubber Center Bushings No lubrication is required for the equalizer beam end bushings or equalizer beam rubber center bushings 32 8 Acterra Maintenance Manual September 2002 Suspension Hendrickson Spring Eye Pins RT and RTE Series NOTE See Fig 7 for this procedure Apply multipurpose chassis grease at the spring eye pin grease fitting located on the inboard side of the spring eye pin until clean grease appears at both ends of the spring eye pin Freightliner TufTrac The TufTrac suspension is maintenance free and de signed so that lubrication is not required There are no provisions for lubrication and attempting to lubri cate the suspension could shorten component life 32 03 U Bolt Torque Checking Check the U bolt torque of both the front and rear axles where applicable 32 CAUTION Failure to retorque the U bolt nuts could result in spring breakage and abnormal tire wear 1 Park the vehicle on a flat surface and apply the parking brakes Chock the tires to prevent the vehicle from moving 2 Check the U bolt torque in a diagonal pattern Set a click type torque wrench to the highest torque value for the fastener being checked See Table 1 for U bolt torque specifications Turn the wrench in a clockwise motion looking up until the torque wrench clicks 3 Remove the chocks Description U Bolt Torq
59. Group 32 of the Acterra Workshop Manual Check all fasteners for tightness Check for distorted or frayed rubber at the beam end bushings If the bushings are damaged replace them Check that the ends of the equalizer beam are not lower in the beam hanger If the equalizer beam ends appear lower use a jack to raise each beam end and check for movement of the inner metal of the rubber end bushing see Fig 5 Movement cannot be corrected by tightening the fastener because parts could be damaged If there is movement replace the rubber end bushings and all connecting parts After repairs to the suspension check the fastener torque after the vehicle has been in service for 2500 miles 4000 km Tighten the adapter type beam end connection nut see Fig 6 210 to 240 Ibf ft 285 to 325 N m Do not over torque WARNING Insufficient beam end fastener torque could cause the beam to separate from the axle This will 32 4 Acterra Maintenance Manual September 2002 Suspension 32 2 3 05 27 93 1320039a 1 Beam Hanger 3 Jack 2 Equalizer Beam Fig 5 Raising the Beam End 5 2 Dine Aun DUUM D J sh s T 1 7 Ws CZ A V LA A 2 uz 7 2 lt lt HS 22272772 3 4 05 27 93 1320110a NOTE Do not use the three piece adapter without the intermediate tube 1 Nut 4 2 Adapter 3 Intermediate Tube Inner M
60. Heater and Air Conditioner 83 01 Air Conditioner Inspecting Wear eye protection gloves and protective cloth ing when working on the air conditioning system Leaking refrigerant from a damaged hose or line could cause blindness or serious skin burns Preliminary Checks 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 Visually inspect the refrigerant compressor drive belt for damage and check that the belt is set at the proper ten sion Also check the tightness of the compressor mounting fasteners For instructions and torque values see Group 01 of the Acterra Workshop Manual 3 Inspect the drive plate If the friction surface of the drive plate shows visible signs of damage due to excessive heat replace the drive plate and pulley assembly in Group 83 of the Acterra Workshop Manual for removal and in stallation procedures 4 Ona Sanden refrigerant compressor use a feeler gauge to check that the drive plate clutch clearance is 0 016 to 0 03 inch 0 4 to 0 8 mm See Fig 1 If the drive plate clutch requires ad justment see Group 83 of the Acterra Work shop Manual On a Climate Control refrigerant compressor place a feeler gauge between the air conditioner
61. Use a tension gauge at the belt s widest span and adjust the belt tension if needed See Group 01 for belt tension specifications Some Caterpillar engines are equipped with dual alter nator belts always check both belts for correct tension Check that the tensioner operates smoothly without binding Engines equipped with a serpentine or poly V belt have automatic belt tensioners and do not require belt tension in spection 3 Check that all electrical connections at the alter 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 4 Inspect the battery cables for wear and replace as needed Clean the cable connector terminals with a wire brush See Group 54 of the Acterra Workshop Manual for troubleshooting instruc tions and for adjustment repair or replacement instructions 4 1 Clean and tighten the battery ground cable terminal and clamps 15 4 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 Rinse with clean water and dry Paint the retainer assembly if needed to prevent rusting 4 3 Check that foreign objects such as stones bolts and nuts are removed from the battery box 4 4 After
62. a clamp is removed it must be replaced 2 1 On Caterpillar and Cummins engines check for leakage at the V type clamp that attaches the exhaust pipe to the tur bocharger exhaust outlet If leakage ex ists tighten the nut on the V type clamp 85 940 N cm If leakage persists install a new V band coupling 2 2 On Mercedes Benz MBE900 engines check the tightness of the fasteners that attach the exhaust pipe to the exhaust flange see Fig 1 If needed tighten the fasteners 33 45 N m for Mercedes Benz MBE900 engines 3 Check for leakage at each wide band exhaust clamp see Fig 2 If leakage exists tighten the nuts 40 to 60 Ibf ft 54 to 81 N m If leakage per sists install a new wide band exhaust clamp See Group 49 of the Acterra Workshop Manual for instructions 07 Exhaust System Inspecting IMPORTANT The Environmental Protection Agency s 2007 regulations require lower ex haust emissions thus requiring new exhaust system components See Fig 3 In particular 49 10 05 94 lt 1490032a A Check the Tightness of These Fasteners Fig 1 Typical Exhaust Pipe to Exhaust Flange Fasteners 10 05 94 f490005a Fig 2 Wide Band Exhaust Clamp the after treatment device ATD which is part of the after treatment system ATS requires special attention during regularly scheduled maintenance inspections If any discrepancies are discovered refer to th
63. a lithium based grease NLGI grade 2 sparingly to the universal joints and slip joint splines 46 02 Drag Link Lubricating 1 Using a clean rag wipe the dirt from both grease fittings on the drag link See Fig 2 46 2 Using a pressure gun apply multipurpose chas sis grease at the grease fittings until old grease is forced out of the socket NOTE Use multipurpose chassis grease NLGI grade 1 6 12 hydroxy lithium stearate grease or NLGI grade 2 8 12 hydroxy lithium stear ate grease Grade 2 chassis grease is pre ferred 6 10 05 94 1 Pinch Bolt 4 Boot 2 Universal Joint Shaft 5 Boot Retainer 3 Bushing 1460516 6 Prevailing Torque Locknut 7 Grease Fitting Fig 1 Steering Driveline Acterra Maintenance Manual July 2004 46 1 46 10 05 94 1 Grease Fitting 2 Drag Link pitman arm end shown 1460926 Fig 2 Steering Drag Link 46 03 Power Steering Reservoir Fluid Level Checking Metal Ventra Reservoir 1 Turn off the engine apply the parking brakes and chock the tires Open the hood Clean around the power steering reservoir fill cap with a clean rag then remove the dipstick WARNING Fill only with approved clean fluid Do not mix fluid types Any mixture or any unapproved fluid could lead to seal deterioration and leaks Fluid leakage could cause loss of power steering assist possibly resulting in personal injury
64. after the normal operating temperature 160 to 200 F 71 to 93 C has been reached Fig 9 MT Series Dipstick Markings 5 1 Inch Depth Oil Pan Hot Check 1 Park the vehicle on a flat level surface Apply the parking brakes and chock the rear tires 2 Shift the transmission to NEUTRAL 3 Operate the engine at idle 500 800 rpm until normal operating temperature is reached Check that the sump temperature is 160 to 200 F 71 to 93 C Check that the converter out temperature is 180 to 220 F 82 to 104 C 4 With the engine idling remove the dipstick from the tube and wipe it clean Insert the dipstick into the tube and remove it Check the fluid level reading and repeat the check procedure to verify the reading Safe oper ating level is within the HOT RUN band on the dipstick The HOT RUN band is between the HOT FULL and HOT ADD marks If the fluid level is not within the HOT RUN band add or drain fluid as needed to bring the fluid level within the HOT RUN band See Fig 8 for the AT and MD series and Fig 9 for the MT se ries 26 10 Acterra Maintenance Manual March 2005 Transmission 26 05 Mercedes Benz Transmission Fluid Changing and Magnetic Plug Cleaning 26 Draining 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires NOTE Drain the transmission fluid while the transmission is warm 2 Drain the transmission fluid See Fig 10
65. ak E Uneven Ribs F Cracks f150010a Fig 2 Drive Belt Replacement Conditions checked not the pulley to isolate the area from outside interference 8 Inspect all pulleys for foreign objects oil or grease in the grooves Belt Tension Inspection NOTE If engine drive belts require adjustment see Group 01 of the Acterra Workshop Manual for instructions Threaded Adjustment Type 1 Apply the parking brakes and chock the tires to prevent the vehicle from moving 2 Install a belt tension gauge at the center of the belt s longest free span Check belt tension See Table 1 for belt tension specifications 3 If belt tension is not correct see Group 01 of the Acterra Workshop Manual to adjust belt tension Spring Tension Type On belts equipped with a spring tensioner the belt tension is automatically adjusted Check that the ten sioner is holding tension on the belt by inserting the end of a breaker bar in the 1 2 inch square hole on the forward face of the tensioner and rotating the tensioner down away from the belt When the breaker bar is slowly released the tensioner should return to its original position If not see Group 01 of the Acterra Workshop Manual for replacement instructions NOTE Caterpillar engines are provided with automatic drive belt tensioners The following engines which appear in Table 1 are provided with automatic tensioners for the fan and alter nator belts 01 2
66. aks are allowed 1 Check for leakage at the clamp that attaches the anywhere in the system exhaust pipe to the turbocharger exhaust outlet 6 Check all sensors attached to the ATD for leaks If leakage exists tighten the nut on the clamp to or damaged wires No leaks are allowed the torque If leakage persists install a 7 Check the DPF exterior surface Ter dents or camp other damage See Item A of Fig 3 A dent over 2 Check the exhaust pipe bellows and each ex 3 inches 76 mm in diameter and 1 4 inch 6 haust seal clamp for leakage wear cracks or mm deep could cause internal damage to the damage Replace damaged components as DPF causing it to malfunction iara at 2 22 8 Check for heat discoloration on the surface of ns Ir S E 2 5 the ATD Heat discoloration may indicate internal Msta a NSW NOLTEUSE damage especially around the DPF seal clamps Once a seal clamp is loosened or removed it must be replaced 49 2 Acterra Maintenance Manual January 2007 Exhaust 49 9 Check any wires lines or hoses within 4 inches 10 cm of the exhaust system for heat damage Repair or reroute as needed Acterra Maintenance Manual January 2007 49 3 Electrical Instruments and Controls 54 Index Alphabetical Title of Maintenance Operation MOP MOP Number Coclantibevel Sensor Cleaning cha dace use Se doo M Bele et Saws eS eqs 5
67. al connec tions for damage leakage or looseness Replace damaged or leaking parts and tighten loose fittings or electrical connections 42 02 Air Brake Valve Inspecting and Leak Checking Bendix 1 Clean the valve exterior and inspect it for corro sion and damage Inspect the air lines connected to the valve for signs of wear or damage Replace the lines as needed Check the valve for leakage 3 1 Apply the service brakes and hold them on full line pressure of at least 80 psi 550 kPa 3 2 Check the air line fittings for leaks tighten or replace the fittings as needed 3 3 Coat the exhaust port and body of the valve with soapy water and check for leakage Leakage is excessive if it pro duces a 1 inch 25 mm bubble within 5 seconds If the brake valve does not function as described above or if leakage is exces sive replace it with a new or remanufac tured unit Repeat the leakage checks before placing the brake valve in service 42 42 03 Foot Brake Valve Actuator Lubricating Bendix E 8P 1 Clean any dirt gravel and other foreign debris from the plunger boot and brake base bracket 2 Check the brake plunger boot for cracks holes or deterioration Replace if necessary 3 Lift up the edge of the brake plunger boot and check the plunger for existing lubrication 3 1 If the plunger is dry remove it by remov ing the cotter pin from the clevis pin and pulling the clevis pin
68. an 1 Bearing Housing 2 Retaining Plate 3 Fan Pulley 4 Air Inlet from solenoid valve Fig 7 Kysor K22RA Fan Clutch Lining Wear Checking must be replaced See Group 20 of the Acterra Workshop Manual for clutch lining replacement instructions 6 Release the air pressure then disconnect the shop hose from the air inlet of the air cylinder Connect the vehicle air hose to the inlet 7 Connect the electrical cables to the battery 8 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 Acterra Workshop Manual 1 Disconnect the batteries at the negative termi nals Drain all air from the air system If equipped with an air starter drain the air starter Engine Cooling R adiator Make sure the batteries are disconnected and if applicable the air starter reservoir is drained be fore checking the fan clutch If the engine starts during this procedure the fan could engage which could result in serious personal injury 2 Inspect the electrical connections and wires to the fan clutch solenoid Secure the connection if loose replace wires and connectors if damaged 3 Clean the fan clutch air solenoid valve filter if equipped 3 1 Unscrew the fan clutch solenoid valve air filter assembly and remove the filter ele ment 3 2 Clean the filter element with cleaning sol vent
69. an gasket in transmission fluid for five minutes Then place the gasket on the pan do not use any substance as a gasket retainer IMPORTANT Do not use gasket sealing com pounds any place inside the transmission or where they might get washed into the transmis sion Also nonsoluble vegetable based cooking compounds or fibrous greases must not be used inside the transmission 12 Install the oil pan and gasket 12 4 Guide the pan and gasket carefully into place Guard against dirt or foreign mate rial entering the pan Retain the pan with four 5 16 18 washer head screws in stalled by hand into the corners of the pan 12 2 Install the remaining seventeen washer head screws by hand carefully threading each through the gasket and into the transmission Bottom all of the screws before tightening any of them 26 12 3 Evenly tighten all 21 of the screws 10 to 15 Ibf ft 14 to 20 N m Check the gasket fit while the screws are being tightened IMPORTANT The oil pan bolts must main tain a minimum torque of 60 Ibf in 680 N cm after the oil pan gasket has taken a set 13 Install the fill tube at the side of the pan Tighten the tube fitting 90 to 100 Ibf ft 122 to 136 N m 14 Install the drain plug and gasket and tighten the plug 15 to 20 20 to 27 N m 15 Replace the external auxiliary fluid filter 16 Clean the area around the fill tube and remove the dipstick Using a clean funnel in the fill tub
70. and property damage 4 With the power steering fluid at operating tem perature check the fluid level on the dipstick If below the ADD mark add enough fluid to bring the level up to the FULL mark on the dipstick Use Dexron automatic transmission fluid ATF in the power steering reservoir 5 Install the fill cap on the power steering reservoir Steering 6 Close the hood and remove the chocks from the tires Nelson Reservoir NOTE If the power steering reservoir in the ve hicle looks like the reservoir shown in Fig 3 use the following procedure 1 Turn off the engine apply the parking brakes and chock the tires 1 6 3 2 4 5 07 09 98 1461670 1 Fill Cap 4 Clamp 2 Filter Spring 5 Filter 3 Filter Top Plate 6 Reservoir Cover Fig 3 Nelson Power Steering Reservoir and Filter 2 Open the hood 3 With the engine cool the level should be be tween MIN COLD and MAX HOT lines with the engine off Add or remove fluid as necessary to bring the fluid level to the line between the MIN COLD and MAX HOT lines Use only Dexron III automatic transmission fluid 4 With the engine hot the fluid level should be at the MAX HOT line with the engine off 5 Add or remove fluid as necessary to bring the fluid level to the MAX HOT line Use only Dexron automatic transmission fluid 6 Close the hood and remove the chocks from the tires 46 2 Acterra Maintenance Manual July
71. anual for instructions Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring as sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Re placement of only the visibly damaged part s is no assurance that the spring is safe 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 IMPORTANT On multi leaf suspensions closely inspect each component of the leaf spring as semblies including the brackets U bolts and related parts Sterling Spring Rear Suspension Spring Brackets and Equalizer Brackets Inspecting Inspect the forward and rear spring brackets equal izer brackets and the wear pads for wear cracks and other damage If any of these conditions exist replace the damaged bracket s and wear pad s See Group 32 of the Acterra Workshop Manual for instructions WARNING Failure to replace the forward spring brackets equalizer brackets or rear spring brackets if they are worn cracked or otherwise damaged could result in progressive damage to and eventual breakage of the bracket This could cause a loss 32 of vehicle control resulting in property damage serious personal injury or death Sterling Spring Tandem Axle Suspension Cross
72. as been removed inspect the lower and upper isolators Refs 1 and 6 and replace them if they are worn See Group 01 of the Acterra Workshop Manual for instructions 2200474 4 3 4 10 Hexnut 5 Engine Mount 6 Upper Isolator 10 05 94 1 Lower Isolator 2 Engine Support Washer 3 3 4 10 Capscrew Fig 1 Engine Rear Mount 01 02 Engine Drive Belt Inspecting Worn or loose drive belts may cause premature bearing failure or engine overheating Excessive ten sion or too little tension on the belt may result in ex 01 cessive and premature belt wear Poly V belts or serpentine belts are retained by a belt tensioner that requires no tension adjustment Replace the engine drive belt if any conditions described in the visual description are found V belts are installed as indi vidual belts and as matched sets When replacing a matched set of belts always replace both belts at the same time Matched belts must be from the same manufacturer To inspect a belt gently twist the belt to view the belt sidewalls and bottom Inspect all drive belts for the following conditions then perform the belt tension inspection Belt Condition Inspection 1 Inspect the belt for glazing See Fig 2 Ref A Glazing is represented by shiny sidewalls and is caused by friction created when a loose belt slips in the pulleys It can also be caused by oil or grease contamination on the pulleys 2 Check the belt for pl
73. ate 13 Cushioned Clamp 4 Locking Capscrew M6 14 Clamp Mounting Bolt 5 Hardened Flatwasher 1 4 20 6 Clevis 15 Steel Plated Washer 7 Clevis Pin 16 Locknut 1 4 20 8 Master Cylinder 17 Shock Bracket 9 Elbow Connector Standoff Bracket 10 Reservoir Hose Fig 4 Clutch Master Cylinder 7 Open the slave cylinder bleed valve Observe the flow of clutch hydraulic fluid through the drain Acterra Maintenance Manual September 2002 25 3 25 10 11 12 hose When no bubbles appear in the fluid close the valve on the slave cylinder Release the clutch pedal and then close the valve at the bleeder unit Disconnect the bleeder unit and install the cap on the slave cylinder bleeder valve Check the fluid level in the reservoir If neces sary add or remove clutch hydraulic fluid to bring the fluid level to the MAX mark Install the reser voir cap Depress the clutch pedal a few times There should be resistance over the full pedal stroke Check the entire system for leaks Tighten con nections if necessary Check the fluid level in the reservoir again Remove the chocks from the tires Clutch 25 4 Acterra Maintenance Manual September 2002 Transmission 26 Index Alphabetical Title of Maintenance Operation MOP MOP Number Allison Transmission Breather Checking exer k x deen 26 03 Allison Transmission Fluid and Filter
74. ating temperatures before shutting down the en gine Acterra Maintenance Manual January 2007 01 3 Air Intake 09 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Cleaner Element Inspecting and 0 09 01 Acterra Maintenance Manual February 2004 Air Intake 09 01 Air Cleaner Element Inspecting and Replacing Method 1 Replace the air cleaner element at the recommended interval or when the air restriction indicator reaches 22 inH5O on a vehicle with an MBE engine or 25 on a vehicle with a Caterpillar or Cummins engine if equipped with an air restriction indicator For replacement instructions see Group 09 of the Acterra Workshop Manual Reset the air restriction indicator If the maximum restriction is not reached record the air restriction value If the value is higher than the previous recording reset the air restriction indicator If the value is lower than the previous recording in spect the air cleaner and air cleaner element of cracks leaks or any other damage If the air cleaner or air cleaner element is damaged replace it and reset the air restriction indicator Method 2 Replace the air cleaner element at the recommended interval or when the air restriction indicator reaches 22 inH5O on a vehicle with an MBE engine or 25 inH O on a vehicle with a Caterpillar or Cummins engine if equipped with an ai
75. ave a small tapped and plugged hole located near and below the housing oil fill hole This smaller hole is for the lubricant temperature sensor only and must not be used as a fill or level hole 2 With the vehicle on level ground lubricant must be level with the bottom of the oil fill hole If low add lubricant See Table 1 for approved axle lubricants and see Table 2 or Table 3 for axle capacities Meritor Drive Axle Recommended Lubricant Lubricant Type Ambient Temperature Viscosity Grade pectication 10 F 12 2 C and 85W 140 0 76 15 F 26 1 C 80W 140 0 76 Hypoid Gear Oil 15 F 26 1 C and 80W 90 0 76 D API Service Classification GL 5 40 F 40 C 75W 90 0 76 40 40 C to 35 F 2 75W 0 76 J 40 F 40 C and 75W 140 0 76 L Synthetic Gear Oil 40 F 40 C and 75W 90 0 76 40 F 40 C 75W 140 0 76 There is no upper limit on these ambient temperatures but axle sump temperature must never exceed 250 F 121 Table 1 Meritor Drive Axle Recommended Lubricant Meritor Drive Axle Lubricant Capacities Single Axles Axle Type Axle Model E Axle Type Axle Model 11 RS 13 120 16 7 6 5 19 220 31 14 7 5 15 120 16 7 6 RS 21 145 32 15 1 RS 15 210 16 7 6 RS 21 160 39 5 18 7 Singlet RS 17 140 31 14 7 Si
76. bc edat quide 25 04 Acterra Maintenance Manual September 2002 Clutch 25 01 Clutch Release Bearing and Release Cross Shaft Lubricating Clutch Release Bearing A 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 On clutches with a grease type release bearing see Fig 1 wipe the dirt from the grease fitting Using a pressure gun and high temperature grease only lu bricate the release bearing at the grease fitting until the grease starts coming out of the fitting Use only a lithium based grease that meets NLGI grade 1 or 2 specifications 05 27 93 f250081a Fig 1 Release Bearing Grease Fitting NOTE On clutches with a sealed release bear ing the release bearing is lubricated at the time of manufacture and requires no additional grease for the life of the bearing 25 On Sachs hydraulic clutches never lubricate the release bearing The release bearing is made of plastic with a kind of embedded grease Clutch Release Cross Shaft The clutch release cross shaft is equipped with two grease fittings one at each side of the transmission clutch housing Wipe the dirt from the grease fittings Using a pressure gun lubricate the cross shaft with multipurpose chassis grease 25 02 Clutch Pull Type Inspecting a
77. cants of this type that operate continuously at high tempera tures must be changed more frequently CAUTION Failure to change the axle lubricant at more fre quent intervals when adverse operating condi tions require could result in axle damage Axle Draining and Flushing 1 Remove the plug at the bottom of the housing and drain the lubricant while the unit is warm Allow enough time for all the old lubricant to drain completely 2 Flush the unit with clean flushing oil then drain it completely IMPORTANT Do not flush axles with solvent such as kerosene 3 Clean the drain plugs For magnetic drain plugs a piece of key stock or any other convenient steel slug may be used to short the two magnetic poles and divert the magnetic field 35 2 Acterra Maintenance Manual March 2000 Rear Axle NOTE Meritor recommends using magnetic plugs with elements having a minimum pickup capacity of 2 pounds 1 kg of low carbon steel in plate or bar form Magnets will rapidly lose effectiveness as collected material bridges the gap between the two poles Clean or change the plugs before this occurs It may be neces sary to clean or change the plugs one or more times between lubrication change intervals 4 After cleaning the drain plugs install and tighten them 35 47 N m Axle Filling 1 With the vehicle on a level surface fill the axle housings to the bottom of the oil fill hole in the carrier or
78. cking Inspect the components and check their operation as described below Failure to perform these in spections and checks could result in separation of worn suspension components and loss of vehicle control possibly causing personal injury or death or property damage 1 Chock the front tires Raise the rear of the ve hicle so the tires just clear the ground and the suspension is fully extended Place safety stands under the vehicle frame 2 Squeeze all air springs to check for complete deflation If any air springs remain partially or fully inflated see Group 32 of the Acterra Workshop Manual 3 Inspect each air spring for wear at its connection to its pedestal Replace any worn air springs for instructions see Group 32 of the Acterra Work shop Manual 4 Inspect the shock absorbers for oil leaks and worn rubber bushings Replace the shock ab sorbers and or rubber bushings if wear or dam age is noted For instructions see Group 32 of the Acterra Workshop Manual 5 Remove the safety stands and lower the rear of the vehicle to the ground Run the engine until air pressure of at least 100 psi 689 kPa is maintained throughout the system 6 Check that all air springs are inflated If the air springs do not inflate see Group 32 of the Acterra Workshop Manual for possible causes and corrections Freightliner AirLiner Control Rod Checking 1 Without disconnecting the control rods attempt to move by hand
79. claim 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 2000 2007 Freightliner 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 Freightliner LLC Freightliner LLC Service Systems and Documentation POC SSD P O Box 3849 Portland OR 97208 3849 Introduction Descriptions of Service Publications Freightliner LLC distributes the following major service publications Workshop Manual Maintenance Manual Driver s Manual Parts Technical Manual Service Bulletins Recall Bulletins Field Service Modifications Workshop manuals contain service and repair information for all vehicle sys tems and components except for major components such as engines transmis sions and rear axles Each workshop manual section is divided into subjects that can include general information principles of operation removal disassem bly assembly installation specificatio
80. cleaning connect the cables to the batteries and tighten them to the torque specifications listed on the battery gener ally 10 to 15 Ibf ft 14 to 20 N m 4 5 Spray each connection with dielectric red enamel and coat the battery terminals with dielectric grease see Table 1 Approved Dielectric Protectants Protectant Material Approved Brand Dielectric Grease Lubriplate FLP DS ES 3M 1602 IVI Spray Sealer order Dielectric Red Enamel from the PDC Spray On Application Spray On 6 665 Gyptal 1201EW Low VOC Red order at www glyptal com or 1 800 GLP 1201 Dielectric Red Enamel Brush On Application Table 1 Approved Dielectric Protectants 5 Check the alternator wiring for missing insulation kinks and heat damage Replace or repair as needed 6 Check the terminals on the battery shut off switch and the magnetic switch Make sure the terminal connections are clean and tight Coat the terminal connections with dielectric red enamel after cleaning Acterra Maintenance Manual January 2006 15 1 Engine Cooling Radiator Title of Maintenance Operation MOP Fan Clutch Checking Noise Emission Control Radiator Checking usu Stet ren ee gtr A ER RERO Radiator Pressure Flushing and Coolant Changing 20 Index Alphabetical MOP Number Acterra Maintenance Manual January 2007 Engine Cooling Radiator 20 01 Radiator Cap
81. closely inspect each component of the leaf spring as semblies including the brackets U bolts and related parts 2 Inspect the brackets for cracks in the castings Inspect the V rod tower welds for cracking or other signs of damage Also check for contact between the frame rail and the upper axle clamp brackets If contact exists check the V rod bush ing for wear Check the V rod fastener torques 3 Inspect the rubber center bearing and spring tip pads for excessive wear including de lamination of the rubber to metal shim interface and distor tion and degradation of rubber 4 Inspect the V rods and lower control rods for wear and looseness Suspension 4 1 Without disconnecting the control rods use your hand to attempt to move each of the control rod ends up down in and out If there is any movement examine the control rods for wear or damage Re place if necessary 4 2 Inspect the rubber bushings for cracks or cuts 4 3 Check for any shifting of the barpin 4 4 Check for cracks in the metal compo nents and welds Check all fasteners for looseness 6 Inspect the shock absorbers for oil leaks and worn rubber bushings Replace the shock ab sorbers and or rubber bushings if wear or dam age is noted Hendrickson Suspension Inspecting Inspect the suspension assembly for wear cracks and damage to its components Replace the compo nent s if any wear cracks or damage exists For instructions see
82. cylinder and bleed the clutch hydraulic system For detailed in structions see Group 25 9 3 If the slave cylinder fittings and or the hose are damaged replace them 9 4 Check the torque on the slave cylinder mounting capscrews Tighten them 15 Ibf ft 20 N m 9 5 If any leakage of clutch hydraulic fluid is found check the fluid level in the reser voir and add fluid if needed For detailed procedures see Group 25 NOTE There are two cover plates on the coun tershaft one at the front and one at the rear 10 Check for signs of leakage at the clutch bell housing If leakage is found check the radial seal on the input shaft the front cover plate on the countershaft inside the clutch bell housing and the rear radial seal on the crankshaft 10 1 If the radial seal on the input shaft is leaking replace the radial seal For pro cedures see Section 26 02 Subject 120 of the Acterra Workshop Manual 10 2 If the cover plate on the countershaft is leaking replace the cover plate Apply 10 3 26 liquid gasket Loctite 518 to the new cover plate when installing it If the rear radial seal on the engine crankshaft is leaking replace the rear ra dial seal For procedures see the engine manufacturer s manual 11 Remove the chocks from the tires Acterra Maintenance Manual March 2005 26 13 31 Frame and Frame Components Title of Maintenance Operation MOP Fifth Wheel 1
83. d right to adjust the fluid level and remove any existing air from the power steering pump and gear Check the fluid level again Add fluid as needed The sys tem is properly bled when the steering pump does not labor when turning the wheel 13 Check for leaks in the system and repair as needed Fill the reservoir as needed 14 Turn off the engine close the hood and remove the chocks from the tires Plastic Ventra Reservoir NOTE If the power steering reservoir in the ve hicle looks like the reservoir shown in Fig 4 use the following procedure 1 Turn off the engine apply the parking brakes and chock the tires 46 4 Acterra Maintenance Manual July 2004 Steering 2 Open the hood Place a drain pan under the power steering res ervoir 4 Remove the retaining ring from the reservoir See Fig 4 5 Remove the filter and filter cover from the reser voir Drain the fluid from the filter into the drain pan Leave the filter hanging over the drain pan 6 Remove the bolts nuts and washers that attach the reservoir to the mounting bracket Drain the fluid from the reservoir but do not remove the supply line to the reservoir 7 Using bolts nuts and washers attach the reser voir to the mounting bracket 8 Fill the reservoir with Dexron Ill automatic trans mission fluid to the line between the MIN COLD and MAX HOT lines See Fig 4 9 Raise the front of the vehicle and support it with jack
84. e add transmission fluid See Table 3 for approved transmission lubricants and Table 4 for lubricant capacities 17 Check and adjust the fluid level using the proce dure under Checking the Fluid Level MD Series When draining transmission fluid check for evidence of dirt or water contamination A small amount of condensation will appear in the fluid during operation Water contamination is normally characterized as a milky discoloration of the transmission fluid Obvious contamination of the transmission fluid indicates a leak between the water and fluid areas of the trans mission cooler Inspect and pressure test the cooler to confirm the leak replace leaking transmission coolers A CAUTION To prevent dirt from entering the transmission use only clean containers and fillers for the trans mission fluid Do not use fillers or containers that have been used for water or antifreeze Dirt water or antifreeze could damage the transmission 1 Park the vehicle on a level surface and apply the parking brakes 2 Operate the vehicle until the transmission reaches normal operating temperature 160 to 200 F 71 to 93 3 Clean the area around the drain plug and the transmission fluid pan Place a drain pan under Acterra Maintenance Manual March 2005 26 5 26 Transmission 10 05 94 Fluid Intake Tube Detent Spring Detent Spring 1 3 4 Bolt Filter Spacer 2 1 4 Bolt 16 qty First Revers
85. e Acterra Workshop Manual for repair and re placement instructions 09 27 95 1320432 Non Wear Area B Wear Area 1 Walking Beam Fig 8 Walking Beam End Wear Thickness 5 Rotate the restrictor cans 360 degrees and in spect the cans for cracks severe corrosion and distortion If any of these conditions are present or the restrictor can is missing replace the re strictor can See Group 32 of the Acterra Work shop Manual for replacement instructions 32 6 Acterra Maintenance Manual September 2002 Suspension Replace all cracked or missing restrictor cans Failure to do so could lead to loss of vehicle con trol which could result in property damage seri ous personal injury or death Vehicles with cracked or missing restrictor cans may be driven slowly to the nearest workshop for restrictor can replacement 6 Remove the jack stands then lower the vehicle Check that the spring or driveline brake is ap plied then remove the wheel chocks Reyco 79KB Suspension Visual Inspection The Reyco 79KB suspension requires minimal main tenance To provide trouble free operation in over the road applications do the following inspection 1 Park the vehicle on level ground Apply the park ing brakes and chock the tires 32 Check for elongated holes in the suspension components See Group 32 of the Acterra Workshop Manual for proper repair procedures Check bushing condition R
86. e or the bearing mount is loose on the bracket tighten the mounting bolt nuts 91 123 N m Replace the midship bearing assem bly if the rubber cushion is worn or oil soaked 41 End Yoke Nut Torque Specifications Description Thread Size ibe Nem Transmissions Allison AT 545 1 2 20 2 ED Allison MD Series 2 16 Ie HORS Single Axle Input Shaft Meritor RS 13 120 15 120 and 210 RS 17 140 and 20 740 920 5 19 145 and 220 M32 x 1 5 4990 1250 and 5 21 145 and 230 1000 1230 Meritor RS 23 160 M45 x 1 5 1355 1670 920 1130 Meritor 5 23 240 M39 x 1 5 1250 1530 Tandem Axle Input and Output Shafts Meritor RD and RR 17 145 of 34 145 and M39 x 1 5 4250 080 RD and RR 20 145 of 40 145 Coupling Shaft Midship Bearings Dana Spicer 1590 1610 1 1 4 18 475 525 and 1710 644 712 The Allison AT 545 transmission output shaft end yoke is retained by a 1 2 20 x 1 1 2 inch bolt and a 1 1 16 inch washer Both the bolt and the washer must be replaced each time they are removed Table 1 End Yoke Nut Torque Specifications 5 Check the slip joints for spline wear by trying to bend the sleeve yoke and splined shaft back and forth see Fig 2 If looseness is greater than 0 007 inch 0 18 mm replace both the sleeve yoke and the splined shaft 6 Check the driveshaft tubes for dents bends twists or other damage If any tube appears
87. e Clutch Feed Tube 3 Bolt 2 qty behind ooRON f260132a First Reverse Clutch Feed Tube Governor Screen in control valve body Governor Pressure Tube Governor Feed Tube Fig 4 Allison AT Series Transmission Governor the transmission and remove the drain plug Ex 7 Lubricate the new O rings with transmission fluid amine the fluid as it drains If only the filter is and install them on the cover assemblies being changed do not drain the fluid 8 Install a new square cut seal on each cover as 4 Remove the 12 mounting bolts six each from sembly and install the fluid filter elements on the the two filter covers cover assemblies NOTE A lot of fluid will drain when the filter 9 Install the filter and cover assemblies into the covers are removed filter compartment 5 Remove the filter covers O rings and two 10 Align each cover assembly with the holes in the square cut seals from the transmission See channel plate sump and push the cover assem Fig 5 blies in by hand to seat the seals 6 Remove the filters from the bottom of the control module 26 6 Acterra Maintenance Manual March 2005 Transmission aN a 1 f 1 YY MX SZ d N 2 2 v 3 3 4 3 4 1 1 08 25 95 1260317 1 Filter Cover 3 Filter Element O Ring 2 Filter Element 4 Square Cut Seal 26 12 Replace the drain plug O ring and install the drain plu
88. e Table shows three different schedules of vehicle usage For each schedule the appropriate distance interval is given for performing Initial Maintenance and for re peating each maintenance operation set M1 through 5 For Schedule the appropriate time interval is also given The tables under Maintenance Interval Tables show which maintenance operation set must be performed at the actual distances miles and kilometers for each maintenance schedule or the actual hours of operation for Schedule 1 The schedule of actual dis tances and hours is based on the intervals given in the Maintenance Schedule Table The tables under Maintenance Operation Sets Tables list in numerical order the text reference numbers and descriptions of a maintenance opera tions and indicates all maintenance operation sets at which each operation must be performed Each Maintenance Interval Operations Table IM through M5 lists the appropriate text reference numbers and descriptions of only those maintenance operations that must be performed at that mainte nance operation set Each maintenance operation set is listed in a separate Maintenance Operations Table Before placing your new vehicle in service determine the correct maintenance intervals that apply to your intended use of the vehicle Refer to the Mainte nance Schedule Table to determine the distance or hour interval at which each Maintenance Operation Set must be performed to comply
89. e engine manufactur er s service literature for repair instructions Definitions of ATS Components Refer to the following list of definitions of ATS com ponents e After Treatment System ATS the entire ex haust system from the turbocharger to the ex haust stack or tail pipe After Treatment Device ATD a muffler like canister that houses a DPF DOC and sensors Acterra Maintenance Manual January 2007 49 1 49 Exhaust 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 3 Typical After Treatment Device e Diesel Particulate Filter DPF a filter that col 3 If present check the condition of the insulation lects and holds particulate matter soot and material around the exhaust pipe between the ash turbocharger and the ATD Diesel Oxidation Catalyst DOC oxidizes hy 4 Check the ATD mounting bands for tightness drocarbons and reduces NOx Tighten to 30 Ibf ft 41 if needed Do not e Sensors detect temperatures and pressures in the ATS 5 Check for leaks around the clamps that attach the ATD in the ATS and around the clamps that Inspection retain the DPF in the ATD No le
90. e fill plug is too loose tighten it 42 Ibf ft 57 N m If the fill plug is too tight loosen it and tighten to 42 57 N m 7 Check for signs of leakage at the transmission fluid drain plug If leakage is found check the torque on the plug and check the aluminum gas ket for damage 7 1 If the gasket is damaged replace it 7 2 If the drain plug is too loose tighten it 42 Ibf ft 57 N m If the plug is too tight loosen it and tighten to 42 57 N m 8 Check for fluid dripping at the gear case seals If substantial leakage is found at either location replace the transmission NOTE Weeping or sweating seals are not cause for transmission replacement 26 12 Acterra Maintenance Manual March 2005 Transmission Clutch hydraulic fluid DOT 3 brake fluid is haz ardous It may be a skin irritant and can cause blindness if it gets in your eyes Always wear safety glasses when handling clutch hydraulic fluid or bleeding hydraulic lines If you get clutch hydraulic fluid on your skin wash it off as soon as possible 9 Check for signs of leakage at the clutch slave cylinder CAUTION Do not spill clutch hydraulic fluid DOT 3 brake fluid on the cab paint Clean it off immediately if any is spilled DOT 3 brake fluid can damage paint 9 1 If leakage is found on the slave cylinder body check the fittings and hose for dam age 9 2 If leakage is found on the piston seals replace the slave
91. e level teaspoon evenly on both sides of the key and spring After the caliper is installed pack any ac cumulation of grease at each end of the rail and along the top of the rail or key at the V way 13 Being careful not to get grease or dirt on the pad face install each brake pad 14 Grasp the caliper firmly rest the V ways on the forward anchor plate torque rail the large rail and swing the caliper into place Make sure that the brake hose is not twisted Do not get grease on the pad faces or rotor surfaces 15 With the caliper installed and firmly seated on the forward rail large rail position the key and spring between the caliper V way and the anchor rail from the inboard end of the anchor rail 16 Carefully drive the key and spring into place In stall the key retaining fastener and torque 12 to 18 16 to 24 N m 17 Install the wheels For instructions see Group 40 of the Acterra Workshop Manual 18 Before moving the vehicle press the brake pedal several times to bring the pistons back to the normal position 19 Raise the vehicle remove the jack stands and lower the vehicle to the ground 20 Remove the chocks from the tires 21 Test drive the vehicle and ensure that the brakes operate properly 42 24 Brake Inspection IMPORTANT This procedure should be per formed prior to lubrication of the brake compo nents Parking Brake Operational Check A CAUTION Perform the followin
92. e sensor do not seal the sensor threads with tape and reconnect wire 173 Fill the cool ing system to the proper level 5 Start the engine The LOW WTR light and warn ing buzzer should be off If the light and buzzer are off the sensor is okay If the light and buzzer are on replace the sensor 54 2 Acterra Maintenance Manual March 2000 Doors 72 Index Alphabetical Title of Maintenance Operation MOP MOP Number Weatherstrip Door Latch and Door Hinge 0 72 01 Acterra Maintenance Manual March 2000 Doors 72 01 Weatherstrip Door Latch and Door Hinge Lubricating Lightly coat door weatherstrips with a lubricant that is safe as recommended by the lubricant manufac turer on rubber Apply a few drops of light engine oil or spray a light coating of silicone lubricant on the door latch mecha nism This will help reduce noise and wear Wipe off any excess oil or silicone lubricant Lubricate door hinges by spraying them with a light coating of silicone lubricant Always lubricate new cab door hinges at installation 72 Acterra Maintenance Manual March 2000 72 1 Heater and Air Conditioner Title of Maintenance Operation MOP Air Conditioner 0 HVAC Air Filter 0 83 Index Alphabetical MOP Number Acterra Maintenance Manual March 2003
93. e sure the hoses are properly supported Replace a dam aged hose with the same size hose With the service brakes applied check for leaks at the hose to chamber connections Any leaks are probably caused by loose connections or by a damaged hose fitting Eliminate all leaks A WARNING Read and follow all applicable warnings and in structions in Group 42 of the Acterra Workshop Manual for repairs to the service parking brake chambers These chambers contain a power Acterra Maintenance Manual October 2007 42 3 42 spring which if released could cause serious in jury or death 7 Inspect the exterior surfaces of the chamber for damage Make sure the breather holes in the non pressure section s are open and free of de bris Using the instructions in Group 42 of the Acterra Workshop Manual replace any dam aged parts On parking brake chambers equipped with inte gral release bolts lubricate the bolt with thread anti seize compound Check the tightness of the bolt For torque values see the applicable brake chamber section in Group 42 of the Acterra Workshop Manual A CAUTION If the external breather tube is missing or incor rectly installed road dirt and debris can adversely affect the operation of the brake chamber Once inside the chamber dirt and debris cause the in ternal parts to deteriorate and shorten their lives 9 On brake chambers equipped with an external breather tube make sure
94. e to the heater and thermostat assembly Unplug the electrical connector at the air dryer and place the test leads of a voltmeter on each of the pins of the male connector If there is no voltage look for a blown fuse broken wires or corrosion in the vehicle wiring harness Check that a good ground path exists 2 Check the thermostat and heater operation Turn off the ignition switch and cool the end cover as sembly to below 40 F 4 C Using an ohmmeter check the resistance between the electrical pins in the female connector The resistance should be 1 5 to 3 0 ohms for the 12 volt heater assem bly Warm the end cover assembly to over 90 F 32 C and again check the resistance It should exceed 1000 ohms If it does the thermostat and heater assembly is operating properly If it does 42 not replace the purge valve housing assembly which includes the heater and thermostat assem bly 42 13 Air Dryer Desiccant Replacing Bendix AD 9 The desiccant change interval may vary from vehicle to vehicle Although typical desiccant cartridge life is three years many will perform adequately for a longer period of time To take maximum advantage of desiccant life and ensure that replacement occurs only when necessary disassemble clean and in spect the air dryer Replace the desiccant cartridge For instructions see Group 42 of the Acterra Work shop Manual 42 14 Air Brake Valve Leak Checking Bendix TC 6 Check f
95. earing and Release Cross Shaft Lubricating 25 03 Hydraulic Fluid Level Checking 26 01 Manual Transmission Fluid Level Checking 31 03 Fifth Wheel Lubricating 32 02 Suspension Lubricating 33 01 Knuckle Pin Lubricating 33 03 Tie Rod End Lubricating 33 05 All Wheel Drive Front Axle Oil Level Checking 35 01 Axle Lubricant Level Checking 41 02 Driveline Lubricating 42 03 Foot Brake Valve Actuator Lubricating Bendix E 8P 42 10 Automatic Slack Adjuster Lubricating Meritor 42 20 Automatic Slack Adjuster Lubricating Gunite 42 22 Automatic Slack Adjuster Lubricating Haldex 46 02 Drag Link Lubricating 46 03 Power Steering Reservoir Fluid Level Checking 46 05 Power Steering Gear Lubricating 72 01 Weatherstrip Door Latch and Door Hinge Lubricating Table 12 Maintenance Operation 00 15 M1 Lubrication and Fluid Level Check Acterra Maintenance Manual January 2007 00 21 00 General Information Lubrication and Fluid Level Check M2 00 16 Maintenance Operation 00 16 see Table 13 sum Maintenance operation numbers given in the table marizes all Lubrication and Fluid Level Check opera are reference numbers used to help you find detailed tions that must be performed at the M2 Maintenance instructions in the manual on the lubrication or fluid Interval for Schedules II and 111 check Maintenance Operation 00 16 M2 Lubrication and F
96. ee Fig 4 Ref 2 Replace the yoke plug if needed If the yoke plug is missing the splined shaft may be hitting the yoke plug and knocking it out check the driveshaft for proper length 41 02 Driveline Lubricating U Joint Lubricating 1 Wipe all old grease and dirt from each U joint grease fitting See Fig 4 Ref 8 Use a hand type grease gun or a high pressure gun with a low pressure adapter to lubricate the U joints 41 2 Acterra Maintenance Manual March 2000 Driveline MY 05 27 93 Y 1410012 Attempt to bend the sleeve yoke and splined shaft back and forth Fig 2 Slip Joint Spline Wear Checking A 06 13 96 Measurement 3 76 mm Measurement 0 015 0 38 mm Measurement 0 020 0 51 mm Measurement 0 025 0 635 mm f410110b com Fig 3 Driveshaft Runout Specifications NOTE If a low pressure adapter is not used with the high pressure gun the U joints may not receive enough lubricant 3 Using lithium 12 hydroxy stearate grease NLGI grade 1 or 2 with EP additives lubricate until new grease can be seen at all four U joint seals IMPORTANT Fresh lubricant must be seen es caping from all four bearing cup seals of each U joint On full round yokes if most of the grease being added to a U joint can be seen escaping from just one of the U joint seals bend the tabs of the lockstrap away from the heads of the bear ing cup cap
97. eel sleeve Acterra Maintenance Manual September 2002 32 1 32 e Either bushing end contacts a torque arm pin mounting bolt e There are cracks in the bushing e Part of the rubber bushing extends beyond the outside diameter of the outer bushing sleeve 10 05 94 1 Upper Mounting Bracket 2 Shock Absorber 3 Lower Mounting Bracket f320267a Fig 1 Front Shock Absorber Installation vehicles built before September 15 2002 N 05 27 93 f320021a Suspension Sterling Spring Tandem Equalizer Bushing Checking 1 Block the frame up enough to take the weight of the chassis off of the springs Attempt to move the equalizer up and down by using a pry bar between the top of the equalizer and the top of the equalizer bracket Apply hand pressure only See Fig 3 If movement at the center of the equalizer exceeds 1 8 inch 3 mm replace the equalizer bushings 2 With the vehicle unloaded attempt to move the equalizer side to side using a pry bar between the equalizer and frame rail Apply hand pressure only See Fig 4 If clearance between the equal izer assembly and any frame component or fas tener is less than 1 8 inch 3 mm replace the equalizer bushings 52 Inch Multi Leaf Spring Component Check No lubrication is required on the 52 inch multi leaf spring rear suspension Inspect the stabilizer bar if present for irregular bushing wear or cracks in the brackets
98. enance Intervals for Schedules II and III all models n ote oe 1 IM and M1 8000 12 000 10 000 16 000 2 M1 and M2 16 000 24 000 20 000 32 000 3 M1 24 000 36 000 30 000 48 000 4 M1 M2 and M3 32 000 48 000 40 000 64 000 5 M1 40 000 60 000 50 000 80 000 6 M1 and M2 48 000 72 000 60 000 96 000 7 M1 56 000 84 000 70 000 112 000 8 M1 M2 M3 and M4 64 000 96 000 80 000 128 000 9 M1 72 000 108 000 90 000 144 000 10 M1 and M2 80 000 120 000 100 000 160 000 11 M1 88 000 132 000 110 000 176 000 12 M1 M2 and M3 96 000 144 000 120 000 192 000 13 M1 104 000 156 000 130 000 208 000 14 M1 and M2 112 000 168 000 140 000 224 000 15 M1 120 000 180 000 150 000 240 000 16 M1 M2 M3 M4 and M5 128 000 192 000 160 000 256 000 17 M1 136 000 204 000 170 000 272 000 18 M1 and M2 144 000 216 000 180 000 288 000 19 M1 152 000 228 000 190 000 304 000 20 M1 M2 and M3 160 000 240 000 200 000 320 000 21 M1 168 000 252 000 210 000 336 000 22 M1 and M2 176 000 264 000 220 000 352 000 23 M1 184 000 276 000 230 000 368 000 24 M1 M2 M3 and M4 192 000 288 000 240 000 384 000 25 M1 200 000 300 000 250 000 400 000 26 M1 and M2 208 000 312 000 260 000 416 000 27 M1 216 000 324 000 270 000 432 000 28 M1 M2 and M3 224 000 336 000 280 000 448 000 29 M1 232 000 348 000 290 000 464 000 30 M1 and M2 240 000 360 000 300 000 480 000 31 M1 248 000 372 000 310 000 496 000 32 M1 M2 M3 M4 and M5 256 000 384 000 320 000 512 000
99. eplace any bushing that is worn cracked dry rotted or otherwise damaged See Group 32 of the Acterra Work shop Manual for removal and installation instruc tions Check tire condition If abnormal tire wear is found check and replace all worn or damaged components and check suspension alignment See Group 32 of the Acterra Workshop Manual for component removal and installation proce dures and for suspension alignment instructions Reyco 79KB Fastener Torque Check Check the U bolt nuts hanger mounting bolts torque rod clamp nuts and the spring retainer bolts for proper fastener torque 1 Park the vehicle on level ground Apply the park 2 Check that the torque rod clamps are directed ing brakes and chock the tires away from the spring to prevent possible interfer d ence during operation See Fig 9 Use a click type torque wrench to check that U bolt nuts are tightened 400 to 450 Ibf ft 540 to 3 Check the fit of springs to hangers to ensure 610 N m good ride characteristics FZ 2222227 2 7 1 WIN 1 K 2 gt gt 01 04 96 1320488 1 Torque Rod Clamp 2 Torque Rod Fig 9 Reyco 79KB Torque Rod Clamp Position Acterra Maintenance Manual September 2002 32 7 32 3 Use click type torque wrench to check that spring hanger bolts are tightened 190 Ibf ft 258 N m 4 Use click type torque wrench to check that the 5 8 inch torque rod clamp nuts are tightened 125 to
100. erations listed below M2 M3 and M4 Maintenance Interval Operations at the M5 Maintenance Interval M5 Maintenance Interval Operations Maint Oper No M5 Maintenance Interval Operations 00 10 Perform All M1 Operations 00 11 Perform All M2 Operations 00 12 Perform All M3 Operations 00 13 13 02 Perform All M4 Operations Air Compressor Rebuilding Replacing Bendix 25 04 Hydraulic Fluid Replacing 26 05 Mercedes Benz Transmission Fluid Changing and Magnetic Plug Cleaning 26 06 Mercedes Benz Transmission Leak Checking 42 13 Air Dryer Desiccant Replacing Bendix 9 42 16 Air Brake Valve Disassembly Cleaning and Inspecting Bendix 8 R 12 R 14 SR 1 ST 3 TC 6 and TP 3DC 54 02 Coolant Level Sensor Cleaning 00 20 Acterra Maintenance Manual January 2007 General Information 00 Lubrication and Fluid Level Check M1 00 15 Maintenance Operation 00 15 see Table 12 sum Maintenance operation numbers given in the table marizes all Lubrication and Fluid Level Check opera are reference numbers used to help you find detailed tions that must be performed at the M1 Maintenance instructions in the manual on the lubrication or fluid Interval for Schedules II and 111 check Maintenance Operation 00 15 M1 Lubrication and Fluid Level Check Maint Oper No Operation Description 25 01 Clutch Release B
101. es 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 degradation throughout the life of the vehicle In compliance with the law the Noise Emis sion Control Systems maintenance located in each applicable group within this manual in conjunction with the vehicle workshop manual provides these instructions to owners Normal Vehicle Use The maintenance instructions contained in this manual are based on average vehicle use and nor mal operating conditions Unusual vehicle operating conditions may require service at more frequent in tervals Recommendations for Replacement Parts Replacement parts used for maintenance or for the repair of noise emission control systems should be genuine Sterling parts If other than genuine Sterling parts are used for replacements or for the repair of components affecting noise emission control the owner should be sure that such parts are warranted by their manufacturer to be equivalent to genuine Sterling parts in performance and durability Sterling Noise Emissions Warranty See the vehicle owner s warranty information book for warranty information concerning noise emission control systems Tampering With the Noise Control System Is Prohibited Federal law prohibits the following acts o
102. etal of Beam End Bushing 5 Beam Hanger Fig 6 Three Piece Adapter Type Beam End Connection cause loss of vehicle control resulting in property damage serious personal injury or death Hendrickson Leaf Spring Assembly Inspecting NOTE See Fig 7 for this procedure 1 4 A EZ 2 3 05 27 93 1320112a A Minimum gap of 3 8 inch 9 5 mm 1 Forward no 1 Spring Hanger 2 Spring Eye Pin 3 Rear no 2 Spring Hanger 4 Rear no 3 Extension Fig 7 Unloaded RTE or UE Spring Suspension 1 Inspect the spring hangers for wear of the spring pin holes cams and the spring hanger legs 2 If equipped with the RTE or UE series the gap between the rear No 2 spring hanger and the top spring leaf should measure at least 3 8 inch 9 5 mm in an unloaded condition If the measurement is less than 3 8 inch 9 5 mm install new rear No 3 extension hangers Lubricate the bolt threads with SAE 20 oil Tighten the 1 2 13 locknuts with hardened washers 85 115 3 Inspect the spring leaves for cracks gouges wear or abnormal bends The no 1 main and no 2 wrapper spring leaves the top two spring leaves may be individually replaced If equipped with the RTE or UE series suspension the nos 1 2 and 3 spring leaves the top three spring leaves may be individually replaced If a spring leaf is damaged below these numbers in a pack replace the spring assembly In addition replace
103. f the Acterra Workshop Manual for wheel alignment procedures 33 05 All Wheel Drive Front Axle Oil Level Checking 1 On all front wheel drive vehicles check the oil level in the differential See Fig 6 NS 7 77 A lt lt 2 04 15 96 9 1350149 1 Vent Valve 2 Oil Level Check and Fill Plug 3 Oil Drain Plug Fig 6 All Wheel Drive Front Axle Differential 1 1 Remove the oil level check and fill plug and make sure the oil level is even with the bottom of the bore 1 2 If needed add oil until the differential is filled to the bottom of the bore 1 3 Install the oil level check and fill plug and tighten it firmly 33 4 Acterra Maintenance Manual September 2002 Front Axle 2 On front wheel drive vehicles equipped with MT 14 MT 17 and MT 22 axles check the oil level in the hubs 2 1 The oil drain bore must be at the bottom in order to check the oil level See Fig 7 1 A ta N 1 s 25 2 2 04 10 96 1350148 A Correct Oil Level 1 Oil Level Checking 2 Oil Drain Bore Bore Fig 7 All Wheel Drive Front Axle Hub MT 17 Axles 2 2 Remove the plug from the oil level check ing bore and make sure the oil is level with the bottom edge of the bore 2 3 If needed add oil until each axle hub is filled to the bottom of the bore 2 4 Install the plug in each oil level checking bore and tighten it firmly 33 06 All Wheel Drive Front A
104. for the 32nd con tinue this pattern for each successive Maintenance Number Acterra Maintenance Manual January 2007 00 7 00 Maintenance Schedule Table 00 06 General Information i Maintenance Intervals Maintenance Schedule Models Maintenance Operation Frequency Miles Km Hours Schedule I All Initial Maintenance IM first 1000 1600 100 _ Severe Service Maintenance 1 M1 every 1000 1600 100 vehicles that annually travel up to 6000 miles 10 000 km Maintenance 2 M2 every 4000 6400 400 Maintenance 3 M3 every 8000 12 800 800 Maintenance 4 M4 every 16 000 25 600 1600 Maintenance 5 M5 every 32 000 51 200 3200 Schedule II All Initial Maintenance IM first 8000 12 000 Short Haul Transport vehicles that annually travel up Maintenance 1 M1 every 8000 12 000 to 60 000 miles 100 000 km Maintenance 2 M2 every 16 000 24 000 Maintenance 3 M3 every 32 000 48 000 Maintenance 4 M4 every 64 000 96 000 Maintenance 5 M5 every 128 000 192 000 Schedule III All Initial Maintenance IM first 10 000 16 000 Long Haul Transport vehicles that annually travel Maintenance 1 M1 every 10 000 16 000 over 60 000 miles 100 000 Maintenance 2 M2 every 20 000 32 000 km Maintenance 3 M3 every 40 000 64000 Maintenance 4 M4 every 80 000 128 000 Maintenance 5 M5 every 160 000 256 000 Table 6 Maintenance Schedule Table
105. g Tighten the drain plug 18 to 24 Ibf ft 25 to 32 13 Refill the transmission with fresh transmission fluid see Table 3 and check the fluid level See Table 4 for lubricant capacities 14 Check and adjust the fluid level using the proce dures under Checking the Fluid Level MT Series 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Start the engine and check that the transmission fluid temperature is 160 to 200 F 71 to 93 C before draining the fluid Shift the gear selector to neutral and shut down the engine 3 Place a suitable container under the transmis sion then remove the drain plug and gasket from the transmission oil pan Allow the fluid to drain 4 Remove the nut that secures the oil filler tube to the transmission pan 5 Remove the 21 capscrews that secure the trans mission oil pan to the transmission housing then remove the transmission oil pan and gasket from the transmission Discard the gasket 6 Clean the oil pan of any debris and residual fluid in an approved cleaning tank 7 Remove the washer head capscrew that secures the filter to the transmission then remove the filter and the filter intake pipe from the transmis sion See Fig 6 8 Separate the filter intake pipe from the filter dis card the O ring then clean the tube 9 Install the filter intake pipe on the new filter In Fig 5 Allison MD Series Transmissi
106. g and filter element Thoroughly clean the reservoir with a lint free cloth 7 Install a new filter element and position the spring on top of the filter element 8 Fill the reservoir with Dexron II automatic trans mission fluid WARNING Fill only with approved clean fluid Do not mix fluid types Any mixture or any unapproved fluid could lead to seal deterioration and leaks Fluid leakage could cause loss of power steering assist possibly resulting in personal injury and property damage 9 Place the end of the hose in the drain pan Do not start the engine while draining the sys tem Raise the front of the vehicle with a floor jack and support it with jack stands Have some one turn the steering wheel to full lock left and right and capture the fluid flowing from the hose in the drain pan Add fluid to the reservoir as needed Continue turning the steering wheel until clean power steering fluid flows from the hose 10 Remove the plug from the reservoir and connect the hose to the reservoir Tighten the hose fitting nut finger tight Then with a wrench tighten until there is firm resistance Tighten one sixth turn more Do not overtighten Remove the jack stands and lower the vehicle Acterra Maintenance Manual July 2004 46 3 46 11 Fill the reservoir with ATF as needed Start the engine and let it idle Have someone turn the steering wheel from lock to lock until no bubbles are seen in the reser
107. g 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 Put the vehicle in the lowest gear and gently at tempt to move it forward The vehicle should not 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 Acterra 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 Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mechanical problem Adjustment is not repairing Before adjusting an automatic slack adjuster troubleshoot the foundation brake system and inspect it for worn or damaged com ponents Improperly maintaining the vehicle brak ing system may lead to brake failure resulting in property damage personal injury or death 2 With the engine off and 100 psi 689 kPa of air tank pressure have an assistant apply and hold an 80 to 90 psi 550 to 620 kPa brake applica tion 3 Check to see if the colored over stroke band on each brake chamber pushrod is exposed If a band shows the stroke is too long Check the foundation brake compo
108. gine Ns dere EPICUREI ee aaah ee aed Air Intake Air Compressor Dic TP Alternators and Starters gedaan ee wen Game eden Engine Cooling Radiator Bg sca starts kha esd dubi es does Clutch aie Transmission 1 Frame and Frame Components ERNIE ATEEN FRLET PESTES eee Front Axle B Er E E E D EA EE Rear Axle MP FERE wr Wheels and Tires rr Sey A Sys atthe Driveline iniu ed Brakes at Re qus dedu dab dp dst d ya a Steering prac yes caren a de eee OR a Fuel HU d 8 2 29 3 3 BE AEE Exhaust DE on ede tend Electrical Instruments and Controls unt Doors Heater and Air Conditioner Introduction Acterra Maintenance Manual January 2003 General Information 00 Index Alphabetical Title of Maintenance Operation MOP MOP Number Initial Maintenance IM Operations 00 09 Lubrication and Fluid Level Check RR nou Renten n Seb RR a E EOD 00 15 Lubrication and Fluid Level Check 2 00 16 M1 Maintenance Interval Operations 00 10
109. grease NLGI Grade 1 or 2 into the chamber bracket until it appears at the slack adjuster end of the bracket See Fig 4 Use care that no grease enters the drum cavity If grease leaks out under the camhead the camshaft grease seal is worn or damaged or is installed backwards NOTE The use of meter type fittings having a maximum 40 psi 275 kPa pressure relief at shutoff is recommended 05 28 93 A Grease exit 1 Brake Chamber 2 Slack Adjuster 3 Grease Fitting 1420011a Fig 4 Camshaft Bracket Bushing Lubrication 42 09 Automatic Slack Adjuster Checking Meritor WARNING Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mechanical problem Adjustment is not repairing Before adjusting an automatic slack adjuster troubleshoot the foundation brake Brakes 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 1 Inspect the slack adjuster for structural damage Replace the slack adjuster if needed 2 Check the boot for cuts tears etc and replace it if necessary See Fig 5 10 20 93 1420012a Brake Chamber Clevis Actuator Rod Boot Pull Pawl Manual Adjusting Nut Grease Fitting or Lube Plug Fig 5 Meritor Automatic Slack Adjuster 42
110. he clamps for damage If a clamp is damaged replace the clamp Replace the entire cross tube assembly if either clamp is welded to the cross tube 7 Check for proper installation of the tie rod end clamp to the cross tube Make sure that the tie rod ends are threaded in the cross tube past the clamps and the slots at the cross tube ends See Fig 5 02 27 2007 NOTE Pinch bolt not shown to provide clarity 1 Cross Tube Split 1320033 Fig 5 Tie Rod End Adjustment 8 Check the zerk fittings for damage If a zerk fit ting is damaged replace it Some tie rod ends have no zerk fittings because they are not to be greased Do not install a zerk fitting on this type of tie rod end 9 Check that the cotter pin is in place If it is not tighten the tie rod end nut to one of the following specs depending on the size of the stud e 7 8 14 160 to 300 Ibf ft 217 to 406 N m e 1 14 250 to 450 Ibf ft 339 to 610 N m Acterra Maintenance Manual September 2002 33 3 33 1 1 8 12 350 to 650 475 to 881 N m 1 1 4 12 500 to 675 678 to 915 N m 10 Check the steering arm bolts for a minimum torque of 300 Ibf ft 406 N m If the steering arm bolt torque has fallen below this specification remove the bolt clean all the threads and apply new Loctite 680 Tighten the bolt 300 to 450 Ibf ft 406 to 610 N m 11 Remove the chocks f
111. he quick disconnect clamp that attaches the hydraulic hose to the slave cylinder Retain the clamp for later installation See Fig 3 06 17 2002 1250589 Clamp Mounting Bolt 1 4 20 Steel Plated Flatwasher Locknut 1 4 20 Bell Housing Standoff Bracket Hydraulic Hose Bleed Valve Slave Cylinder Slave Cylinder Capscrew M8 Flatwasher M8 0 Cushioned Clamp 1 2 3 4 5 6 7 8 9 1 Fig 3 Clutch Slave Cylinder Clutch hydraulic fluid DOT 3 brake fluid is haz ardous It may be a skin irritant and can cause blindness if it gets in your eyes Always wear safety glasses when handling clutch hydraulic fluid or bleeding hydraulic lines If you get clutch hydraulic fluid on your skin wash it off as soon as possible 4 Drain the hydraulic fluid 4 1 Using a drain pan or other suitable con tainer collect the fluid that drains from the reservoir not more than 0 3 quarts 0 3 liters 4 2 Allow the open end of the drain hose to remain over the drain pan 25 2 Acterra Maintenance Manual September 2002 Clutch 4 3 Press down on the pedal several times until no more fluid drains from the reser voir 4 4 Cover the hose to avoid contamination of the clutch hydraulic fluid 5 Connect the hydraulic hose to the slave cylinder Install the clamp as removed 6 Fill the reservoir with approved DOT 3 brake fluid and bleed the system according to the proce dures under the heading
112. hocks from the tires Acterra Maintenance Manual March 2003 83 1 83 1 KS 02 17 2003 2277 1831564 1 Screw 2 Filter Cover Fig 2 Air Filter Replacement 83 2 Heater and Air Conditioner Acterra Maintenance Manual March 2003
113. housing with lubricant See Table 1 for approved axle lubricants and see Table 2 or Table 3 for axle capacities NOTE Meritor axles have a small tapped and plugged hole located near and below the hous ing oil fill hole This smaller hole is for the lubri cant temperature sensor only and must not be used as a fill or level hole 2 Install the fill hole plug and tighten it 35 Ibf ft 47 N m 3 After filling the carrier and housing assembly with lubricant drive the vehicle unloaded for 1 or 2 miles 2 or 3 kilometers at speeds not to exceed 25 mph 40 km h to thoroughly circulate the lubricant throughout the assembly 35 04 Two Speed Axle Shift Unit Oil Level Checking CAUTION Failure to keep lubricant at the specified level could cause damage to the axle shift unit 1 Clean the oil fill hole plug in the shift unit housing cover and the area surrounding it See Fig 2 Remove the fill hole plug 2 The lubricant level should be maintained at the bottom of the fill hole If low add the specified lubricant 35 08 06 93 1 Housing Cover Gasket 2 Oil Fill Hole Plug 3 Shift Unit Housing Cover Fig 2 Two Speed Axle Shift Unit 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 vehicle operating tem peratures are above 0 F 18
114. ic system 5 Shift to NEUTRAL and allow the engine to idle at 500 800 rpm 6 With the engine running at idle remove the dip stick from the tube and wipe clean 7 Insert the dipstick into the tube and remove the dipstick 8 Check the fluid level reading and repeat the check procedure to verify the reading If the fluid level is within the COLD RUN band the transmission may be operated until the fluid is hot enough to perform a HOT RUN check If the fluid level is not within the COLD RUN band add or drain fluid as needed to adjust the fluid level to the middle of the COLD RUN band See Fig 8 for the AT and MD series and Fig 9 for the MT series Transmission 12 01 97 A Cold Run Band 270002a B Hot Run Band Q T gt Tx ES 5 B 01 22 97 5 1260395 Transmission Housing Oil Pan Split Line B Hot Run Band C Cold Run Band Fig 8 AT and MD Series Dipstick Markings A CAUTION Do not fill above the COLD RUN band if the trans mission fluid is below normal operating tempera ture As fluid temperature increases so does the fluid level Filling above the COLD RUN band when the transmission is below normal operating temperature may result in an overfilled transmis sion which causes fluid foaming and aeration Fluid foaming and aeration cause transmission overheating and erratic shifting NOTE Perform a hot check at the first opportu nity
115. l 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 fifth wheel are lubri cated apply a liberal coating of grease to the top plate and the trailer kingpin plate 31 Holland Lubricate all moving parts with a multipurpose chas sis grease Lubricate the two grease fittings located on either side of the top plate with a multipurpose chassis grease Once the fifth wheel s 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 Acterra Maintenance Manual January 2007 31 3 Suspension Title of Maintenance Operation MOP SUSPENSION SUSPENSION Lubricating aca eec rat reds U Bolt Torque 0 32 Index Alphabetical MOP Number Acterra Maintenance Manual September 2002 Suspension 32 01 Suspension Inspecting Sterling Front and Rear Suspension Spring Assemblies Inspecting Inspect the front and rear suspension spring assem blies for pitted cracked broken or abnormally bent leaves and extreme rust If any of these conditions exist replace the spring assembly See Group 32of the Acterra Workshop M
116. l with the bot tom of the opening IMPORTANT When the vehicle operating tem peratures are above 0 F 18 use SAE 10 heavy duty engine oil API service classification SD sulfated ash content must not exceed 1 8596 When the vehicle operating tempera tures are below 0 18 C use one part of kerosene to three parts of SAE 10 heavy duty engine oil API service classification SD sul fated ash content must not exceed 1 85 This cold weather mixture can be safely used up to 32 F 0 C Commercially available automatic transmission fluid may be used in place of SAE 10 engine oil Automatic transmission fluid can be used for all temperatures Do not mix kerosene with auto matic transmission fluid 5 Apply a small amount of Loctite 242 or an equivalent sealant to the threads of the oil fill hole plug Install the oil fill hole plug finger tight then using a wrench tighten the plug 1 1 2 turns more Rear Axle 35 4 Acterra Maintenance Manual March 2000 Wheels and Tires 40 Index Alphabetical Title of Maintenance Operation MOP MOP Number Wheel rat Ire ipio e ER xr LP ee Reseed i 40 01 Acterra Maintenance Manual March 2000 Wheels and Tires 40 01 Wheel Nut Checking IMPORTANT In addition to the maintenance interval in this manual check the wheel nut torque the first 50 to 100 miles 80 to 160 km of operation after a wheel has been removed and installed When
117. luid Level Check Maint Oper No 35 04 Two Speed Axle Shift Unit Oil Level Checking 42 08 Camshaft Bracket Bushing Lubricating 42 15 Air Reservoir Automatic Drain Valve Disassembly Cleaning Inspecting and Lubricating Bendix DV 2 42 23 Bosch Rail Slide Hydraulic Brake Caliper Lubricating 46 01 Steering Driveline Lubricating Table 13 Maintenance Operation 00 16 M2 Lubrication and Fluid Level Check Operation Description 00 22 Acterra Maintenance Manual January 2007 Engine Title of Maintenance Operation MOP Engine Drive Belt 0 Engine Support Fasteners 0 Pacbrake Inspecting and 01 Index Alphabetical MOP Number Acterra Maintenance Manual January 2007 Engine 01 01 Engine Support Fasteners Checking Front and rear engine supports for vehicles built from January 2007 require no periodic maintenance Mounts should be inspected when the engine is re moved for service For vehicles manufactured prior to January 2007 perform the following check Check the rear engine support fasteners see Fig 1 Ref 4 for tightness Tighten the 3 4 inch fasteners 215 to 265 Ibf ft 292 to 359 N m Check the front engine support fasteners for tight ness Tighten the 5 8 inch fasteners 125 Ibf ft 170 N m NOTE At engine overhaul and whenever the engine h
118. magnet from the filter attachment tube or from the top of the filter element 6 Clean any metal debris from the magnet Then install the magnet on the filter attachment tube 7 Using transmission fluid lubricate the gasket on the filter 8 Using your hand install the filter by turning it clockwise until the filter gasket contacts the con verter housing or cooler manifold Then turn the filter one more complete turn 9 Install the drain plug and sealing washer Tighten the plug 22 to 30 Ibf ft 30 to 40 10 Clean the area around the fill tube and remove the dipstick Using a clean funnel in the fill tube add transmission fluid See Table 3 for approved transmission lubricants and Table 4 for lubricant capacities Acterra Maintenance Manual March 2005 26 3 26 11 Check and adjust the fluid level using the proce dure under Checking the Fluid Level Approved Allison Transmission Lubricants Lubricant Type Temperature F C Vi EN All Allison Transmissions Castrol TranSynd u synthetic Above 22 30 On Highway Transmissions 1000 2000 2400 Series Dexron III Above 13 25 AT and MD Series Dexron 111 Above 13 25 MT Series Dexron 111 Above 13 25 Type C4 10 to 120 12 to 48 SAE 10W Type C4 32 to 120 0 to 48 SAE 30W Lubricants listed in order of preference Do not mix types of oil Table 3 Approved
119. member and Gussets Inpsecting Inspect the tandem axle frame crossmember and gussets for wear cracks and other damage If any of these conditions exist replace the damaged parts See Group 32 of the Acterra Workshop Manual for instructions Check all fasteners for tightness see Group 00 of this manual for torque values A CAUTION Failure to replace the suspension crossmember or gussets if they are cracked worn or otherwise damaged could result in damage to the vehicle chassis Sterling Spring Shock Absorber Checking Make sure that the shock absorber brackets are tight and that the shock absorber is not striking or rubbing on the frame or some other part of the chas sis See Fig 1 Check the rubber mounting bushings and replace if worn Inspect the shock absorber for oil leakage If the shock absorber is worn or damaged replace it with a new one Sterling Spring Tandem Radius Rod Bushing Checking 1 Without detaching the torque arms attempt to move by hand each of the radius rod ends up down in and out If there is any movement re place the torque arm 2 Inspect the weld seams between the torque arm tube and the shorter bushing tubes If there are cracks replace the torque arm Do not weld the torque arm for any reason Inspect the rubber bushing ends See Fig 2 Re place the torque arm for any of the following rea sons e There are gaps between the rubber bush ing and the pin or the outer st
120. mproperly maintaining the vehicle brak ing system may lead to brake failure resulting in property damage personal injury or death 1 Inspect the slack adjuster for structural damage Replace the slack adjuster if needed 2 Inspect the slack adjuster boot for cuts or tears If the boot is damaged replace it as follows See 2 1 Remove the two clevis pins 2 2 Rotate the worm shaft adjusting hexnut counterclockwise to move the link away from the clevis About 45 Ibf ft 60 N m is needed You will hear a clicking sound Remove the old boot from the link 2 3 Install a new boot on the link heavy sec tion down Be careful not to damage the boot 2 4 Seat the boot so that the bottom of the boot is in the boot insert and the top is in the groove of the link 2 5 Rotate the adjusting hexnut clockwise until the 1 4 inch hole in the clevis lines up with the hole in the link Install the 1 4 inch clevis pin and the cot ter pin 2 6 Tap the clevis upward or downward until the large hole in the slack adjuster lines up with one in the clevis Install the 1 2 inch clevis and the cotter pin Make sure both clevis pins are installed Failure to do so will cause the slack adjuster to work incor rectly which could lead to loss of braking control This could result in an accident causing personal injury or property damage 42 22 Automatic Slack Adjuster Lubricating Haldex IMPORTANT Perform MOP 42 24 before lubri cati
121. n or damaged shock bushings heavy corrosion on the shock absorber body or fluid leaking from the shock absorber Replace the shock absorbers if any of these conditions are found see Group 32 of the Acterra Work shop Manual 3 Lift the rear of the vehicle and support the frame on jack stands to unload the suspension compo nents The vehicle is lifted high enough when the beam ends are off of the saddles All jack stands must be of sufficient strength and rigidity to safely support the vehicle Do not perform any work on or around a vehicle that is supported solely by a lifting device Visually inspect the walking beam for cracks or other damage If damage is found see Group 32 of the Acterra Workshop Manual for replace ment instructions Keep the vehicle supported by the jack stands for the next operation Suspension 4 Manipulate the walking beam so that a microme ter vernier or dial caliper can be used to deter mine the wear area thickness on the bottom face See Fig 8 Measurements should be taken a minimum of 1 2 inch 13 mm from the beam flange edges to eliminate any edge wear that may have occurred Subtract the wear area thickness see Fig 8 Ref B from the non wear area see Fig 8 Ref A to determine the amount of wear If the beams show any wear greater than the allowable 0 062 inch 1 5 mm wear a Chalmers wear plate must be installed or the walking beam must be replaced See Group 32 of th
122. n tighten the capscrews to the above specifications and bend the tabs of the lockstrap against a flat side of each cap screw If the bearing will not take grease re place the U joint assembly see Group 41 of the Acterra Workshop Manual 4 Check the old grease If it appears rusty gritty or burned replace the U joint assembly See Group 41 of the Acterra Workshop Manual 5 Wipe any excess grease from the seals and grease fittings Slip Joint Spline Lubricating 1 Wipe all old grease and dirt from the slip joint grease fitting See Fig 4 Ref 1 2 Use a hand type grease gun or a high pressure gun with a low pressure adapter to lubricate the slip joint Using lithium 12 hydroxy stearate grease NLGI grade 1 or 2 with EP additives lubricate until fresh grease appears at the pressure relief hole in the yoke plug Then cover the relief hole with your finger while continuing to lubricate until fresh grease appears at the slip joint seal see Fig 4 Ref 6 This ensures com plete lubrication of the splines 3 Wipe any excess grease from the pressure relief hole slip joint seal and grease fitting Driveline 41 4 Acterra Maintenance Manual March 2000 Brakes 42 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Brake Valve Disassembly Cleaning and Inspecting Bendix E 8P R 12 R 14 SR 1 5 3 6 and 42 16
123. nd Adjusting See Group 25 of the Acterra Workshop Manual for clutch pull type inspection and adjustment 25 03 Hydraulic Fluid Level Checking Use only approved clutch hydraulic fluid DOT 3 brake fluid in the clutch hydraulic system Do not mix different types of brake fluid The wrong fluid will damage the rubber parts of the system caus ing loss of clutch function and the risk of serious personal injury CAUTION Do not allow the fluid level in the reservoir to go below the MIN line If too much air enters the hy draulic system will not operate correctly and the clutch could be damaged If the fluid level is below the MIN mark fill the reser voir with DOT 3 brake fluid until the level reaches the MAX mark See Fig 2 25 04 Hydraulic Fluid Replacing Replace the clutch hydraulic fluid every two years to ensure clutch function is reliable and correct Use the Acterra Maintenance Manual September 2002 25 1 25 Clutch 2 1 3 4 7 5 N 6 06 17 2002 1250588 1 Reservoir 5 Hyaraulic Hose 2 Reservoir Cap 6 Slave Cylinder 3 Pedal Unit 7 Reservoir Hose 4 Master Cylinder Fig 2 Clutch Components procedures below Fluid replacement must be done at an authorized Freightliner service facility Draining and Filling 1 Shut down the engine 2 Apply the parking brakes chock the front and rear tires and open the hood 3 Using a flat tip screwdriver remove t
124. nd Lubricating Bendix DV 2 Bosch Rail Slide Hydraulic Brake Caliper Lubricating Steering Driveline Lubricating 13 01 Air Compressor Inspecting Bendix 20 01 Radiator Cap Checking 20 03 Fan Clutch Checking 26 03 Allison Eaton Fuller and Meritor Transmission Breather Checking 42 11 Automatic Slack Adjuster Inspecting Meritor 49 01 Exhaust System Inspecting 83 02 HVAC Air Filter Replacing Replace the HVAC filter every 6 months regardless of mileage NOTE Maintenance operations appearing in italics in this table are for noise emission control components Numbers in this table are maintenance operation ref erence numbers matching those in the text of this manual The M2 Maintenance consists of all M1 In terval Operations plus the other operations listed Acterra Maintenance Manual January 2007 00 17 00 M3 Maintenance Interval Operations Table 00 12 IMPORTANT After performing all operations listed in this table perform all daily weekly and monthly maintenance operations listed in the Pretrip and Post Trip Inspections and Maintenance chapter of the Acterra Driver s Manual Also perform all M1 and M2 Maintenance Interval Operations at the M3 Maintenance Interval M3 Maintenance Interval Operations General Information NOTE Numbers in this table are maintenance opera tion reference numbers matching those in the text of this ma
125. nd chock the rear tires 2 Check the tie rod boot for cracks tears or other damage If the tie rod boot is damaged replace the entire tie rod end 3 Grasp by hand or use a pipe wrench with jaw protectors to avoid gouging the cross tube and slightly rotate the cross tube toward the front of the vehicle and then slightly toward the rear Then center the cross tube between the stop po sitions If the cross tube does not rotate in either direction replace both tie rod ends 4 Position yourself directly below the ball stud socket Using both hands grab the end as close to the socket as possible no more than 6 inches 15 2 cm from the end Firmly apply about 100 pounds of hand pressure in an up and down mo tion several times When moving the assembly check for any movement at both tie rod ends See Fig 4 If any movement is detected at one tie rod end replace both tie rod ends Always replace tie rod ends in pairs even if only one tie rod end is damaged 10 10 2001 V f330195 Fig 4 Check Movement of Tie Rod End CAUTION Do not attempt to straighten a bent cross tube Doing so could result in damage to the axle Be sure to replace the cross tube with an original equipment cross tube with the same length diam eter and thread size as the existing cross tube 33 5 Check the cross tube for cracks or other dam age If the cross tube is bent or damaged re place the cross tube 6 Check t
126. nents for wear or damage and repair as needed See Group 42 of Acterra Maintenance Manual October 2007 42 11 42 the Acterra Workshop Manual for inspection troubleshooting and repair procedures Brakes 5 Start the engine and build air pressure to at least 100 psi 689 kPa Shut down the engine 4 Measure the applied chamber stroke See 6 Check all of the foundation brake components for Table 3 for the proper stroke for the type of damage wear and loose or missing parts Re chamber being used If the stroke is too short pair as needed See Group 42 of the Acterra the brakes may drag or will not fully apply Check Workshop Manual for repair procedures for improper operation or adjustment of the auto matic slack adjuster See Group 42 of the Acterra Workshop Manual for inspection and troubleshooting procedures Brake Chamber Stroke Specifications Chamber Applied Stroke inch mm Manufacturer Type Sizet 9 1 3 8 35 12 16 Standard Stroke 20 1 3 4 44 24 30 2 51 Gunite 36t 2 1 4 57 16 20 2 51 24 2 1 2 inch rated Long Stroke stroke 24 3 inch rated stroke 2 1 2 64 30 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 Stroke 24 2 1 2 64 Standard Stroke 30 2 51 Long Stroke 30 2 1 2 64 42 12 Acterra Maintenance Manual Oc
127. ng the slack adjusters Acterra Maintenance Manual October 2007 42 9 42 Lubricate a Haldex automatic slack adjuster at the grease fitting with any extreme pressure NLGI Grade 1 or Grade 2 grease if the operating temperature is 20 F 29 and above If the operating tempera ture is below 20 29 C use a low temperature extreme pressure grease 42 23 Bosch Rail Slide Hydraulic Brake Caliper Lubricating NOTE This procedure is only for vehicles equipped with Bosch rail slide hydraulic brake calipers IMPORTANT After the vehicle is put into ser vice lubricate the calipers every 6 months or every 18 000 miles 28 800 km whichever comes first 1 Park the vehicle on a level surface Shut down the engine set the parking brake and chock the front or the rear tires depending on which axle you are working on 2 Raise the vehicle off of the ground and securely support it with jack stands 3 Remove the wheel from each wheel end For instructions see Group 40 of the Acterra Work shop Manual 4 Place a stool near the axle to rest the caliper upon after the caliper is removed 5 Remove the key retaining fastener from the an chor plate See Fig 7 6 Using a hammer and drift carefully drive out the key and spring See Fig 8 Be careful not to nick the anchor plate rail 7 Insert a large flat bladed screwdriver through the caliper vent window and into the rotor fins Pry the calipe
128. nglet RS 21 230 39 18 5 RS 17 145 33 6 15 9 RS 23 160 42 19 9 RS 17 220 31 14 7 RS 23 240 45 21 3 RS 19 145 34 4 16 3 Quantities listed are approximate and include 1 pint 0 5 liter for each wheel end and with the drive pinion at 3 degrees t Single drive axles equipped with traction equalizers may require a friction modifier to correct a slip stick condition as described in the vehicle driver s manual Meritor s experience shows that the following additives perform adequately Add Elco No 2 Friction Modifier 1 ounce 30 ml of additive for each 1 pint 0 5 liter of lube capacity or Lubrizol No 797 or 762 1 ounce 30 mL of additive for each 1 pint 0 5 liter of lube capacity Table 2 Meritor Drive Axle Lubricant Capacities Single Axles Acterra Maintenance Manual March 2000 35 1 35 Meritor Drive Axle Lubricant Capacities Tandem Axles Axle Model Capacity pints liters IA Forward 29 8 14 1 RT 94 144 Rear 34 16 1 An Forward 30 4 14 4 RT 40 145 Rear 34 4 16 3 Quantities listed are approximate and include 1 pint 0 5 liter for each wheel end and with the drive pinion at 3 degrees Table 3 Meritor Drive Axle Lubricant Capacities Tandem Axles 3 Install the fill hole plug and tighten it 35 47 N m 35 02 Axle Breather Checking The axle housing breather see Fig 1 must remain clean Whenever the axle lubricant le
129. not use gasket type sealing com pounds or cement anywhere inside the trans mission or where they might get washed into the transmission Non soluble vegetable base cooking compounds or fibrous grease must not be used inside the transmission 12 Install the oil pan and gasket onto the transmis sion Check that no dirt or debris enters the pan Secure the pan to the transmission housing with four 5 16 18 washer head capscrews installed into the corners of the oil pan but do not tighten 13 Install the remaining 17 washer head capscrews by hand Check that all of the capscrews are hand tight 14 Using a click type torque wrench tighten each capscrew 5 7 See Fig 7 for the pat tern needed to distribute the torque evenly When all the capscrews are tightened to the first stage repeat this procedure This time torque all the capscrews 15 to 20 20 to 27 N m 15 Install the oil filler tube on the oil pan Tighten the tube fitting 90 to 100 Ibf ft 122 to 136 N m then install the drain plug and gasket Tighten the drain plug 15 to 20 Ibf ft 20 to 27 N m 16 Pour approximately 15 quarts 14 liters of trans mission fluid into the transmission Start the en gine and allow the transmission fluid to circulate With the transmission in NEUTRAL check the fluid level Check for fluid leaks Correct any leak with the engine OFF Checking the Fluid Level CAUTION Operating a transmission with the fl
130. ns and troubleshooting Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems They have information such as lubrication procedures and tables fluid replacement procedures fluid capacities specifica tions procedures for adjustments and for checking the tightness of fasteners Maintenance manuals do not contain detailed repair or service information Driver s manuals contain information needed to enhance the driver s under standing of how to operate and care for the vehicle and its components Each manual contains a chapter that covers pretrip inspection and daily maintenance of vehicle components Driver s manuals do not contain detailed repair or ser vice information Freightliner LLC publishes this manual to aid in the identification of serviceable replacement vehicle parts This manual is used in conjunction with the parts book and the service parts catalog microfiche Service bulletins provide the latest service tips field repairs product improve ments and related information Some service bulletins are updates to informa tion in the workshop manual These bulletins take precedence over workshop 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
131. nual The M3 Maintenance consists of all M1 and M2 Interval Operations plus the other operations listed below Maint Oper No M3 Maintenance Interval Operations 00 10 Perform All M1 Operations 00 11 Perform All M2 Operations 01 02 Engine Drive Belt Inspecting 09 01 25 02 Air Cleaner Element Inspecting and Replacing Clutch Pull Type Inspecting and Adjusting 26 04 Allison Transmission Fluid and Filter Changing 32 03 U Bolt Torque Checking 33 06 All Wheel Drive Front Axle Oil Changing 33 07 Draw Key Nut Inspecting 35 05 Two Speed Axle Shift Unit Oil Changing 40 01 Wheel Nut Checking 42 12 Air Dryer Checking Bendix 9 47 01 Fuel Tank Draining and Vent Checking 54 01 Electrical System Checking 00 18 Acterra Maintenance Manual January 2007 General Information IMPORTANT After performing all operations listed in this table perform all daily weekly and monthly maintenance operations listed in the Pretrip and Post Trip Inspections and Maintenance chapter of the Acterra Driver s Manual Also perform all M1 M2 and M3 Maintenance Interval Operations at the M4 Maintenance Interval 00 M4 Maintenance Interval Operations Table 00 13 listed below M4 Maintenance Interval Operations Maint Oper No M4 Maintenance Interval Operations 00 10 Perform All M1 Operations
132. o 230 Ibf ft 203 to 312 N m 31 02 Fifth Wheel Inspecting WARNING 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 Disconnect the tractor from the trailer For instruc tions see Chapter 10 of the Acterra Driver s Manual Thoroughly steam clean the fifth wheel then make the following checks 1 Look for cracks in the fifth wheel assembly mounting brackets and mounting parts 2 Check moving parts for wear or damage 3 Test the safety lock latch for operation 4 Check for loose nuts and bolts in the fifth wheel and in the mounting 5 Check that all springs are securely fastened and not deformed 6 Check wedge adjustment 6 1 Open the kingpin lock and insert a 2 inch 51 mm diameter shaft vertically 6 2 Release the lock by tripping the release latch at the bottom of the throat 6 3 Adjust the wedge stop at the end of the wedge to approximately 1 4 inch 6 mm clearance 7 f you observe any problems doing the previous steps correct them immediately For instructions see Group 31 of the Acterra
133. on Filter Locations and Components A CAUTION Do not use the bolts to draw the filter covers to the sump This can damage the covers seals or sump 11 Install six bolts in each cover and torque the bolts 38 to 44 Ibf ft 51 to 61 N m 10 11 stall a new O ring on the filter intake tube then lubricate the O ring with a light coat of transmis sion fluid Insert the filter intake pipe into the orifice on the bottom of the transmission then secure the filter with the 5 16 18 x 5 8 inch washer head cap screw Tighten the capscrew 10 to 15 14 to 20 N m Place a new oil pan gasket on the oil pan If de sired a sealant may be used on the gasket but it must be applied carefully sealant must be pre Acterra Maintenance Manual March 2005 26 7 26 Transmission 08 30 96 1 Transmission Housing 2 Transmission Oil Pan Gasket 3 5 16 18 Washer Head Capscrew 4 Plug 5 Transmission Oil Pan odo X 15 2 14 7 8 6 Magnet Drain Plug Gasket Drain Plug 5 16 18 x 5 8 Capscrew Flatwasher 13 10 1260369 11 Transmission Fluid Filter 12 Fluid Filter Spacer 13 O Ring 14 Fluid Filter Tube 15 Plug Fig 6 Allison MT Series Transmission Filter Removal 26 8 Acterra Maintenance Manual March 2005 Transmission vented from contacting areas of the oil pan flange that are inside the raised bead of the flange NOTE Do
134. on modifiers Do not use multivis cosity fluids or EP Extreme Pressure gear flu ids If switching from a petroleum based lubricant to a synthetic all areas of each af fected component must be thoroughly drained Switching to a synthetic lubricant when a petroleum based lubricant has been used for 50 000 miles 80 000 km or longer may affect transmission performance Monitor all seal areas for the first 10 000 miles 16 000 km after changing to a synthetic from a petroleum based lubricant 4 Clean the fill plug then install it in the transmis sion Tighten the plug as follows e 25 to 35 34 to 48 N m for Eaton Fuller transmissions with 3 4 inch pipe threads 60 to 75 Ibf ft 81 to 102 N m for Eaton Fuller transmissions with 1 1 4 inch pipe threads Acterra Maintenance Manual March 2005 26 1 26 42 57 N m for all Mercedes Benz transmissions 26 02 Eaton Fuller and TTC Transmission Fluid Changing and Magnetic Plug Cleaning Draining 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires Drain the fluid while the transmission is warm Clean the area around the fill plug and the drain plug s 4 Remove the fill plug from the side of the gear case Remove the drain plug s from the bottom of the gear case 5 Clean the magnetic plug s before installation Use a piece of key stock or any other conve nient steel slug to short the t
135. or leakage For instructions see Group 42 of the Acterra Workshop Manual 42 15 Air Reservoir Automatic Drain Valve Disassembly Cleaning Inspecting and Lubricating Bendix DV 2 Disassemble the drain valve clean the parts with mineral spirits and inspect the parts Replace all rub ber parts and any worn or damaged parts Use only genuine Bendix replacement parts or kits Assemble and install the valve Check for proper operation and leakage For instructions see Group 42 of the Acterra Workshop Manual Acterra Maintenance Manual October 2007 42 7 42 42 16 Air Brake Valve Disassembly Cleaning and Inspecting Bendix 8 R 12 R 14 SR 1 ST 3 TC 6 and TP 3DC Disassemble each brake valve clean the parts with mineral spirits and inspect the parts Replace all rub ber parts and any worn or damaged parts Use only genuine Bendix replacement parts or kits Assemble and install the valves Check for proper operation and leakage For instructions see Group 42 of the Acterra Workshop Manual 42 17 Brake Lining Wear Checking Hydraulic Disc Brakes Before checking lining wear with the wheel removed review the following brake lining exposure warnings Breathing brake lining dust asbestos or non asbestos could cause lung cancer or lung dis ease Unless exposure can be reduced below legal limits wear an air purifying respirator approved by MSHA or NIOSH at all times when ser
136. or proper operation For instructions see Group 42 of the Acterra Workshop Manual 42 20 Automatic Slack Adjuster Lubricating Gunite IMPORTANT Perform 42 24 before lubri cating the slack adjusters Lubricate the slack adjuster until grease flows from the grease relief opening See Fig 6 For tempera tures to 40 F 40 use Lubriplate Aero for tem peratures to 20 F 29 C use Texaco Multifak EP 2 or Mobil Grease No 77 The newest Gunite slack adjusters are produced without a grease relief During lubrication with a grease gun lubricant is forced through the drilled worm wheel onto the camshaft Lubricate the slack 42 8 Acterra Maintenance Manual October 2007 Brakes adjuster at the grease fitting until grease appears on the camshaft 10 10 27 93 1420653 1 7 6 Inch Adjusting 6 Clevis Hexnut 7 1 2 Inch Clevis Pin 2 Grease Fitting 8 1 4 Inch Clevis Pin 3 Boot 9 Grease Relief 4 Link Opening 5 Brake Chamber Piston 10 Slack Adjuster Spline Rod Fig 6 Gunite Automatic Slack Adjuster 42 21 Automatic Slack Adjuster Inspecting Gunite Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mechanical problem Adjustment is not repairing Before adjusting an automatic slack adjuster troubleshoot the foundation brake system and inspect it for worn or damaged com 42 ponents I
137. out Remove the pis ton rod and boot Lift out the plunger Lu bricate the plunger and the tip of the pis ton rod with barium grease part number BW 246671 or Penzoil Adhezoplex EP 2 Install the piston rod boot clevis pin and cotter pin 3 2 If the plunger has grease on it lift the edge of the brake plunger boot enough to apply 2 to 4 drops of light oil around the brake plunger Do not over oil Install the plunger boot 4 Lubricate the clevis pin with light oil 5 Check for leakage For instructions see Group 42 of the Acterra Workshop Manual 42 04 Air Brake Valve Operation Checking Check for proper operation of the brake air valves For instructions see Group 42 of the Acterra Work shop Manual 42 05 Relay Valve Checking Midland 1 Parkthe vehicle on a level surface Chock the tires 2 Start the engine and run it long enough to pres surize the air system to at least 80 psi 550 kPa Turn off the engine Repeat as necessary to maintain 80 psi 550 kPa pressure during this check Acterra Maintenance Manual October 2007 42 1 42 3 Clean any road grime from the relay valve and any debris from the valve exhaust port 4 Listen for air leakage around the fittings or ex haust port Tighten the fittings as necessary Use two wrenches to avoid twisting the tubing 5 If the valve fails this check or is damaged repair or replace it For instructions see the Midland service manual
138. oval of the filter pliers could cause metal chips to enter the steering system Clean the inside of the reservoir using a lint free cloth Steering IMPORTANT Do not start the engine while draining the system 6 Place the disconnected end of the steering gear to reservoir hose in a drain pan Raise the front of the vehicle with a floor jack and support it with jack stands Have someone turn the steering wheel to full lock left and right Capture the fluid flowing from the hose in a drain pan Add fluid to the reservoir as needed When clean fluid flows from the hose into the drain pan remove the plug from the reservoir and reconnect the steer ing gear to reservoir hose to the reservoir Re move the jack stands and lower the vehicle 7 With the larger opening at the top install a new filter in the reservoir 8 Clean the reservoir cover and gasket Inspect the O ring and the cover for cracks deformities or damage Replace the gasket seal or cover as needed 9 Install the reservoir cover along with the spring and the top plate Make sure the center of the top plate fits into the opening at the top of the filter 10 Place the clamp over the flanges of the cover and shell assembly then tighten the clamp 25 to 30 Ibf ft 35 to 40 N m 11 Fill the reservoir with Dexron III automatic trans mission fluid to the FULL COLD mark 12 Start the engine and operate it at idle Turn the steering wheel to full lock left an
139. p 15 20 Fore and Aft Torque __ 95 130 Rod Mount Nut Table 2 Hendrickson Suspension Torque Values All Hendrickson beam end fasteners must maintain their torque values to firmly clamp the rubber bushing inner metal tubes to the beam hanger legs Insufficient beam end fastener torque could cause the beam to separate from the axle This will cause loss of vehicle control resulting in property damage serious personal injury or death Tighten the nut see Fig 1 to the torque value in Table 2 Do not over torque Acterra Maintenance Manual January 2007 31 1 31 Check the drive axle flange fasteners see Fig 2 for tightness Tighten the fasteners as follows 5 y 2 4i TES ITI LLL LL ELLIO ys GN 144444 E LL ZL gt Zz Pe 222222222 3 4 05 27 93 1320110a NOTE Do not use the three piece adapter without the intermediate tube 1 Nut 4 Inner Metal of Beam 2 Adapter End Bushing 3 Intermediate Tube 5 Beam Hanger Fig 1 Three Piece Adapter Type Beam End Connection 06 09 94 NOTE Spoke wheel shown 1 Drive Axle Flange Studs and Nuts f400090b 2 Drive Axle Flange Fig 2 Drive Axle Flange Frame and Frame Components Tighten 1 2 inch drive axle stud nuts with or without dowels 75 to 115 Ibf ft 102 to 156 N m and tighten 5 8 inch drive axle stud nuts 150 t
140. placement parts or kits Test the operation of the unloader mechanism See Group 13 of the Acterra Workshop Manual for re build or replacement instructions and test opera tions NOTE Bendix factory rebuilt air compressors are available from authorized Bendix distribu tors and carry a new compressor warranty 13 Acterra Maintenance Manual March 2000 13 1 Alternators and Starters 15 Index Alphabetical Title of Maintenance Operation MOP MOP Number Alternator Battery and Starter Connections 0 10 15 01 Acterra Maintenance Manual January 2006 Alternators and Starters 15 01 Alternator Battery and Starter Connections Checking 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 Acterra Workshop Manual 2 Check the belt tension of the alternator drive belt
141. r WARNING Do not operate the vehicle with the front brakes backed off or disconnected Backing off or discon necting the front brakes will not improve vehicle handling and may lead to loss of vehicle control resulting in property damage or personal injury NOTE Vehicles operating under severe or ad verse conditions should be checked more fre quently If the brake chamber requires disas sembly see Group 42 of the Acterra Workshop Manual for instructions 1 With the slack adjuster properly adjusted check the angle formed by the centerline of the piston rod and slack adjuster This angle should be greater than 90 degrees in the released position and approach 90 degrees in the applied position See Fig 2 At angles less than 90 degrees brake chamber force is reduced which reduces braking efficiency 42 2 Acterra Maintenance Manual October 2007 Brakes 42 07 27 94 A Brakes Released B Brakes Applied 1 Brake Chamber 2 Piston Rod 1420009 C Greater than 90 degree angle 3 Slack Adjuster Fig 2 Angle Between Piston Rod and Slack Adjuster 2 Check each brake chamber for correct installa tion 2 1 Check each mounting stud for the pres ence of prevailing torque locknuts and hardened flatwashers Make sure that the hardened flatwashers are installed be tween the mounting bracket and the lock nuts Do not install flatwashers touching the service non pressure chamber
142. r outward this will push the pistons back slightly into the caliper making removal easier 8 Grasp the caliper swing it out and lift it from the anchor plate Rest the caliper on the stool For ease of removal swing the caliper on the for ward anchor plate torque rail the large one op posite the key and spring rail Brakes 3 4 2 7 5 1 6 10 28 94 bo 1420565 1 Caliper 4 Fastener 2 Wear Shim 5 Key 3 Spring 6 Anchor Plate Fig 7 Anchor Plate and Key Fastener 3 2 5 s 6 08 11 93 1420546 1 Key 4 Rotor 2 Spring 5 Outboard Brake Pad 3 Anchor Plate Upper 6 Caliper Housing Rail Fig 8 Drive Out the Key and Spring 9 Carefully remove the brake pads to avoid dam aging or getting grease on the pad faces Set them aside 10 Using brake cleaner or alcohol remove old grease from the caliper V ways the anchor plate rails and the shoe slots See Fig 7 and Fig 9 Also clean the key and spring 11 Using a wire brush or wire wheel remove any remaining debris from the V ways rails shoe slots key and spring 4210 Acterra Maintenance Manual October 2007 42 Brakes A gt NS 2 2 1 10 28 94 1420595 1 V Ways 2 Bleeder Fitting Fig 9 Caliper V Ways 12 Apply two level teaspoons of Aeroshell Grade 5 ES1246 grease on each side of the assembly Apply it evenly along the full length of the V way groove and anchor plate rail and apply on
143. r restriction indicator For replacement instructions see Group 09 of the Acterra Workshop Manual Reset the air restriction indicator If the maximum restriction is not reached inspect the air cleaner and air cleaner element for cracks leaks or any other damage If the air cleaner or air cleaner element is damaged replace it and reset the air re striction indicator 09 Acterra Maintenance Manual February 2004 09 1 Air Compressor Title of Maintenance Operation MOP Air Compressor Inspecting Air Compressor Rebuilding Replacing Bendix 13 Index Alphabetical MOP Number Acterra Maintenance Manual March 2000 Air Compressor 13 01 Air Compressor Inspecting Bendix Inspect the air intake line oil supply and return lines and coolant supply and return hoses for tight connec tions and general condition Tighten the connections and replace the lines and hoses as needed If the compressor air intake adapter is loose remove the adapter replace its gaskets and securely install it Check the cooling fins on the compressor crankcase Clean the fins if they are clogged with debris 13 02 Air Compressor Rebuilding Replacing Bendix Disassemble clean and inspect the air compressor Replace all seals gaskets springs and all parts that are worn or damaged beyond re use Replace the air compressor unloader mechanism components Use only genuine Bendix re
144. r the caus ing thereof 1 the removal or rendering inoperative by any person other than for purposes of mainte nance repair or replacement of any device or ele ment of design incorporated into any new vehicle for the purpose of noise control prior to its sale or deliv ery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or ele ment of design has been removed or rendered inop erative by any person Among those acts presumed to constitute tampering are the acts listed below A Removal of engine noise deadening panels B Removal of or rendering the engine speed gover nor inoperative so as to allow engine speed to exceed manufacturer s specifications C Removal of or rendering inoperative the fan clutch including by passing the control on any thermostatic fan drive to cause it to operate con tinuously Removal of the fan shroud Removal of or rendering inoperative exhaust sys tem components including exhaust pipe clamp ing F Removal of air intake system components G Removal of hood liners noise deadening pan els Maintenance Instructions Scheduled intervals are in the maintenance tables in Group 00 of this manual A Verification of Inspec tions Log is contained in the following table and should be filled in each time the noise emission con trols on the vehicle are maintained or repaired Acterra Maintenance Manual January 2007 00 1
145. ra Maintenance Manual March 2000 Fuel 47 47 01 Fuel Tank Draining and Vent Checking Remove the plug or open the drain valve at the bot tom of the fuel tank and allow the tank to drain until all traces of water and sediment have disappeared install the plug or close the drain valve On earlier vehicles with a screw on fuel cap remove the fuel cap and clean it with solvent Make sure the fuel cap vent is open Install the cap On vehicles with a quarter turn fuel cap check to be sure the vent line at the inboard side of the fuel tank is clean and not plugged Acterra Maintenance Manual March 2000 47 1 Exhaust 49 Index Alphabetical Title of Maintenance Operation MOP MOP Number Exhaust System Inspecting Noise Emission 5 49 01 Acterra Maintenance Manual January 2007 Exhaust 49 01 Exhaust System Inspecting Noise Emission Controls NOTE In addition to the maintenance interval in this manual inspect the exhaust system if the vehicle has a noticeable increase in noise level at any time Replace parts that show leakage wear or damage Pre EPAO7 Exhaust System Inspecting 1 Check the muffler body muffler outlet stack muf fler shield and inlet tubes for leakage dents corrosion or holes in the muffler 2 Inspect the exhaust pipe for leakage wear or damage replace with new parts if needed Do not reuse wide band clamps Once
146. ring This can distort the flange sealing surface or the clamp ring itself 3 2 Using soapy water coat the service chamber clamp ring Leakage is exces sive if it produces a 1 inch 25 mm bubble within 5 seconds See Fig 1 On Bendix service chambers tighten the clamp ring enough to stop the leakage but do not exceed the maximum torque limits in Table 2 Do not overtighten On other service chamber makes if leak age is detected tighten the clamp ring but do not exceed the maximum torque limits in Group 42 of the Acterra Work shop Manual Clamp Ring Torque Values Bendix Chambers Torque Description Ibf in N cm 5 16 24 Nut 130 150 1460 1700 3 8 16 Nut 140 180 1580 2040 Table 2 Clamp Ring Torque Values Bendix Chambers 42 4 Acterra Maintenance Manual October 2007 Brakes 3 3 If leakage persists use the instructions in Group 42 of the Acterra Workshop Manual to replace the service brake dia phragm 3 4 Using soapy water coat the area around the piston rod bore On some Bendix ser vice chambers loosen the boot if neces sary No leakage is permitted If there is leakage use the instructions in the appli cable brake chamber section in Group 42 of the Acterra Workshop Manual and replace the service brake diaphragm NOTE On weatherproof Bendix chambers the leakage check can be performed at the cross drilled mounting stud Parking Brake Operation and
147. rkshop Manual 1 Disconnect the the batteries at the negative ter minals Drain all air from the air system If equipped with an air starter drain the air starter reservoir Make sure the batteries are disconnected and if applicable the air starter reservoir is drained be fore checking the fan clutch If the engine starts Acterra Maintenance Manual January 2007 20 3 20 during this procedure the fan could engage which could result in serious personal injury 2 Inspect the electrical connections and wires to the fan clutch solenoid Secure the connection if loose replace wires and connectors if damaged 3 Clean the fan clutch air solenoid valve filter if equipped 3 1 Unscrew the fan clutch solenoid valve air filter assembly and remove the filter ele ment 3 2 Clean the filter element with cleaning sol vent 3 3 Reassemble the clutch valve solenoid air filter assembly and install on the vehicle 4 Check the fan for bent cracked or damaged blades Replace if damaged Check for ad equate clearance between the fan and other componenis 5 Check the fan belt for wear tension and align ment Correct if necessary 6 Check for wear on the friction facing See Fig 5 Replace the friction facing if it is worn to a 1 16 inch 1 6 mm thickness or less Also check the facing for signs of oil contamination or burn marks If evidence of oil or burn marks are found replace the friction facing
148. rom the tires 33 03 Tie Rod End Lubricating This procedure applies to all tie rod ends on Meritor nondrive steering axles 1 Park the vehicle with the wheels in the straight ahead position Turn off the engine apply the brakes and chock the rear tires 2 Wipe the zerk fitting and the seal or boot clean NOTE Synthetic lubricants are not approved for tie rod end lubrication 3 Using a grease gun apply a multipurpose grease NLGI grade 1 or 2 to the zerk fitting until all the old grease is purged from the boot Dis colored old grease should come out of the purge holes near the boot crimp or bellows area Apply grease until all the old grease is purged from the boot NOTE If using an air pressure grease gun do not exceed 150 psi 1035 kPa 4 If the tie rod end is designed for lube service and it does not accept grease perform the following substeps 4 1 Remove the zerk fitting 4 2 Inspect the threaded zerk fitting hole in the tie rod end and remove any obstruc tions 4 3 Install a new zerk fitting 4 4 Apply lubrication to the new zerk fitting 5 Remove the chocks from the tires Front Axle 33 04 All Axle Alignment Checking Drive Axle Alignment Checking Check the axle alignment parallelism and thrust angle measurements for the rear drive axles Use the applicable procedure and specifications in Group 35 of the Acterra Workshop Manual Toe In Checking Front Axle See Group 33 o
149. rque may need to be adjusted for individual applica tions IMPORTANT On vehicles with EPAO7 compliant engines the coolant capacity varies depending on the engine and accessory installation After servicing the cooling system always verify that 20 2 Acterra Maintenance Manual January 2007 Engine Cooling Radiator the coolant level is between the MIN and MAX lines on the surge tank 7 Fill the radiator with coolant Use a mixture of 50 percent water and 50 per cent corrosion inhibiting antifreeze to protect the engine to 34 37 year round See Table 1 for engine cooling system capaci ties See Table 2 for approved antifreezes Coolant Capacities pre EPA07 engines Radiator Core and System Capacity 2 Row 3 Row quarts liters quarts liters Engine Make and Model Caterpillar 3126 Series 28 26 5 m Cummins B Series 30 5 28 9 31 0 29 3 Cummins C Series 31 2 29 5 _ 11 System capacity includes all hoses fittings and the heater Table 1 Coolant Capacities pre EPA07 engines Approved Coolants Coolant Coolant Engine Type Manufacturer Designation Texaco JC04 Antifreeze Diesel Van Waters and Diesel Antifreeze Rogers Ltd No 6038 Canada Gasoline Chrysler Mopar Sterling approved antifreeze must meet one of the following conditions A Ethylene glycol solution that meets GM 6
150. screws then check the torque on the bearing cup capscrews at that seal Tighten the bearing cup capscrews as follows 10 20 93 A After grease appears cover the pressure relief hole while continuing to lubricate 1 Slip Joint Grease 5 Yoke Plug Pressure 1410050 Fitting with grease Relief Hole gun attached 6 Slip Joint Seal 2 Yoke Plug 7 Full Round Yoke 3 Grease 8 U Joint Grease Fitting 4 Half Round Yoke Fig 4 Slip Joint and U Joint Lubricating 5 16 24 capscrews 24 Ibf ft 32 e 3 8 24 capscrews 37 Ibf ft 50 N m Bend the lockstrap tabs up against a flat side of each capscrew If the capscrews were already tight or all of the U joint seals still do not purge remove the bearing cup at that seal and exam ine the seal for damage If the seal is damaged replace the complete U joint assembly If grease does not appear at one of the seals use a screwdriver to pry the U joint trunnion away from the non purging seal or tap the driveshaft or yoke with a plastic or rawhide mal let on the side opposite the dry seal while continuing to apply gun pressure If grease still does not appear bend the tabs of the lockstrap away from the heads of the bearing cup cap Acterra Maintenance Manual March 2000 41 3 41 screws then loosen the bearing cup capscrews at the bearing with the dry seal to relieve seal tension Lubricate the U joint until the old grease is purged the
151. sed to excess moisture it will be necessary to perform preventative maintenance as instructed in Maintenance Operation 01 03 interval does not apply to vehicles with a factory fill of Eaton approved synthetic lubricant Table 9 Maintenance Operation Sets for Groups 00 through 32 Maintenance Operation Sets for Groups 33 through 42 REQUIRED MAINTENANCE OPERATION SET M2 Maintenance Operation Number and Operation Description 33 01 Knuckle Pin Lubricating eo e we Je 33 02 Tie Rod End Inspecting eo e Je 33 03 Tie Rod End Lubricating eo e 33 04 Alignment Checking 33 05 All Wheel Drive Front Axle Oil Level Checking 33 06 A All Wheel Drive Front Axle Oil Changing 33 07 Draw Key Nut Inspecting 35 01 Axle Lubricant Level Checking 35 02 Axle Breather Checking eo e Je 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning 35 04 Two Speed Axle Shift Unit Level Checking 35 05 Two Speed Axle Shift Unit Oil Changing 1 1 40 01 Wheel Nut Checking 41 01 Driveline Inspecting 41 02 Driveline Lubricating 42 01 Air Dryer Inspecting Bendix AD 9 42 02 Air Brake Valve Inspecting and Leak Checking Bendix 1 42 03 Foot Brake Valve Actuator Lubricating
152. sion Fluid Fill Plug Transmission Fluid Drain Plug Gear Case Seals Clutch Slave Cylinder Input Shaft Radial Seal Fig 12 Leak Check Transmission 2 1 If leakage is found check the breather for a missing cap Replace the cap if neces sary 2 2 Check the fluid level at the fill plug If the level is too high correct the fluid level 3 Check for signs of leakage at the cap seal on the shift lever If the cap seal is damaged replace it 4 Check for signs of leakage at the radial seal on the output shaft If leakage is found remove the output yoke end yoke and replace the seal For procedures see Section 26 02 Subject 120 of the Acterra Workshop Manual NOTE There are two cover plates on the coun tershaft one at the front and one at the rear 5 Check for signs of leakage at the rear cover plate on the countershaft next to the output yoke If leakage is found check the torque on the cover plate bolts and check the flat seal for damage 5 1 If the flat seal is damaged replace it 5 2 If the cover plate bolts are too loose tighten them 18 Ibf ft 25 N m If the cover plate bolts are too tight replace the flat seal and tighten to 18 Ibf ft 25 N m 6 Check for signs of leakage at the transmission fluid fill plug If leakage is found check the torque on the plug and check the aluminum gas ket for damage 6 1 If the gasket is damaged replace it 6 2 If th
153. t degrees Fahrenheit F 32 1 8 degrees Celsius C 1 8 32 degrees Fahrenheit F Table 5 Temperature Conversion 00 6 Acterra Maintenance Manual January 2007 General Information 00 Scheduled Maintenance Intervals Description and Description Use 00 05 Use Schedule severe service applies to vehicles that annually travel up to 6000 miles 10 000 kilometers or that operate under severe conditions Examples of Schedule usage include operation on extremely poor roads or where there is heavy dust accumula tion constant exposure to extreme hot cold salt air or other extreme climates frequent short distance travel construction site operation city operation fire truck garbage truck or farm operation Schedule short haul transport applies to vehicles that annually travel up to 60 000 miles 100 000 kilo meters and operate under normal conditions Ex amples of Schedule II usage are operation primarily in cities and densely populated areas local transport with infrequent freeway travel or high percentage of stop and go travel Schedule 111 long haul transport is for vehicles that annually travel more than 60 000 miles 100 000 kilo meters with minimal city or stop and go operation Examples of Schedule usage are regional delivery that is mostly freeway miles interstate transport or any road operation with high annual mileage The table under Maintenance Schedul
154. t Nut 1 4 20 5 7 Leveling Valve Mounting Nuts 5 16 18 14 1 9 3 4 16 45 61 Air Spring Upper Locknuts 1 Air Spring Lower Locknuts 1 2 13 55 75 1 2 13 23 3 Leaf Spring Eye Locknuts 3 4 16 Shock Absorber Upper Bracket 5 8 11 125 170 Locknuts Air Spring Upper Bracket 5 8 11 125 170 Spring Hanger Locknuts 3 4 10 210 285 Lateral Control Rod Nut 5 8 11 185 136 Table 1 Freightliner AirLiner Torque Values 31 Tighten Hendrickson suspension fasteners to the torque values given in Table 2 Hendrickson Suspension Torque Values Torque Ibf ft N m Description Size Top Pad to Spring Aligning Setscrew RT RTE Top Pad Nut RT RTE 100 150 135 200 275 400 375 542 U Bolt Locknut U UE 7 8 14 237 302 321 409 Spring Pin Locknut 1 2 13 45 63 61 85 Torque Rod Straddle Mount Nut 5 8 11 190 260 Torque Rod Stud E eom 1 1 4 12 175 225 235 305 7 8 14 Saddle Cap Stud 55 65 75 90 3 4 16 Saddle Locknut E RT RTE 7 8 14 225 275 305 373 Saddle Locknut T _ U UE 3 4 16 125 145 169 197 Adapter Type Beam End Locknut aaa 210 240 285 325 7 16 20 1 2 20 50 60 70 80 Spring Center Bolt 65 75 90 100 1 2 13 Rebound Spacer E _ Locknut 1 2 13 38 45 51 61 Spring Alignment Cli
155. th the bottom of the fill hole with the vehicle in normal operating position Table 2 Eaton Fuller and TTC Transmission Lubricant Capacities CAUTION Operating a manual transmission with the fluid level higher or lower than recommended can re sult in transmission damage Do not overfill the transmission overfilling will force fluid out of the case through the main shaft openings Fluid over flow may also drain onto the clutch or clutch brake causing additional problems IMPORTANT Do not mix types of fluid because of possible incompatibility Do not use multivis cosity fluids or EP Extreme Pressure gear flu ids Do not use fluid additives or friction modifi ers If switching from a petroleum based lubricant to a synthetic all areas of each af 26 2 Acterra Maintenance Manual March 2005 Transmission fected component must be thoroughly drained Switching to a synthetic lubricant when a petroleum based lubricant has been used for 50 000 miles 80 000 km or longer may affect transmission performance Monitor all seal areas for the first 10 000 miles 16 000 km after changing to a synthetic from a petroleum based lubricant NOTE The correct fluid capacity is established by the fill plug opening 2 Clean the fill plug then install it in the transmis sion Tighten the plug as follows e 25 to 35 34 to 48 N m for Eaton Fuller transmissions with 3 4 inch pipe threads 60 to 75 Ibf ft
156. the flexible elbows are in place and the connector tube is inserted into each elbow 1 2 inch 13 mm 10 On all parking brake installations check for pres ence of an end cover cap or dust plug and make sure the cap or plug is securely snapped into place Service Brake Operation and Leakage Checking WARNING Do not loosen or remove the parking brake clamp ring for any purpose at any time See Fig 1 The parking emergency brake section is not intended to be serviced Serious injury or death may result from sudden release of the power spring Before doing any repairs or adjustments on a service parking brake chamber read the appli cable warnings and instructions in the applicable brake chamber section in Group 42 of the Acterra Workshop Manual Brakes 1 Apply the service brakes and check that the pis ton rods move out promptly without binding 2 Release the service brakes and check that the piston rods return to the released positions promptly without binding WARNING Read and follow all applicable warnings and in structions in Group 42 of the Acterra Workshop Manual for repairs to the service parking brake chambers These chambers contain a power spring which if released could cause serious in jury or death 3 Check the service brake chambers for leakage 3 1 Apply the service brakes and hold them on full line pressure of at least 80 psi 550 kPa CAUTION Do not overtighten the clamp
157. the hoses Your hose clamps can be either T bolt clamps see Fig 3 or Breeze Constant Torque clamps see Fig 4 Tighten T bolt type hose clamps 55 Ibf in 620 N cm These clamps are now standard on hoses with an inside diameter greater than 2 inches 51 mm Breeze Constant Torque hose clamps must be tightened to the correct torque The screw tip of the clamp must extend about 1 4 inch 6 mm from the clamp housing and the belleville washer stacks must be collapsed almost flat Use a torque wrench to install these clamps Correct installation torque is as follows For Breeze Constant Torque hose clamps with a 5 16 inch tightening screw hex 55 620 N cm For Breeze Constant Torque hose clamps with a 3 8 inch tightening screw hex 90 Ibf in 1020 N cm VA 02 28 96 1200326 Fig 3 T Bolt Type Hose Clamp EN 08 15 94 8 1200286 screw tip must extend about 1 4 inch 6 B The belleville washer stacks must be collapsed almost flat 1 Tightening Screw Hex Fig 4 Breeze Constant Torque Hose Clamp Installation 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 to
158. tion check for a leak in the same areas 05 30 2002 i f f200581 Fig 8 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 Acterra Workshop Manual for repair procedures 10 Check the fan drive for discoloration or any other signs of slipping or overheating NOTE The fan clutch may slip if the air supply pressure is below 70 psi 483 kPa or if there is a leak inside the fan clutch Any leak must be remedied 11 Check the fan clutch bearings 11 1 Turn the fan in both directions and feel for worn hub bearings 11 2 If possible remove the drive belt and check for worn sheave bearings by turn ing the sheave in both directions 11 3 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 Acterra Workshop Manual 20 Acterra Maintenance Manual January 2007 20 7 Clutch 25 Index Alphabetical Title of Maintenance Operation MOP MOP Number Clutch Pul Type Inspecting and Adjusting sse een bake mmm i 25 02 Clutch Release Bearing and Release Cross Shaft 0 25 01 Hydraulic Fluid Level Ghecking ze ye o RR REI EX EROR Y 25 03 Hydraulic Fluid 2 opos m Side agat t
159. tober 2007 Brakes 42 Brake Chamber Stroke Specifications Chamber Max Applied Stroke inch mm Manufacturer Type Sizet 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 1 Specifications are relative to a brake application with 80 to 90 psi 550 to 620 kPa air pressure in the brake chambers t If type 36 chamber is used slack length should be less than 6 inches Table 3 Brake Chamber Stroke Specifications Acterra Maintenance Manual October 2007 42 13 Steering 46 Index Alphabetical Title of Maintenance Operation MOP MOP Number Drag Link ER prm 46 02 Power steenng Gear LUDICO ERROR i 46 05 Power Steering Reservoir Fluid Level 0 1 46 03 Power Steering Reservoir Fluid and Filter 46 04 Steering Driveline E bricalig a ascen Aq ATE RULe d RR REAd ERG RARE 46 01 Acterra Maintenance Manual July 2004 Steering 46 01 Steering Driveline Lubricating Wipe the grease fittings clean See Fig 1 Using a pressure gun apply
160. uare centimeters cm 0 155 square inches in square feet ft 0 0929 square meters m 10 764 square feet ft Volume cubic inches 3 16387 0 cubic millimeter mm3 0 000061 cubic inches cubic inches in 16 387 cubic centimeters 0 06102 cubic inches in cubic inches in 0 01639 liters L 61 024 cubic inches in fluid ounces fl oz 29 54 milliliters mL 0 03381 fluid ounces fl oz pints pt 0 47318 liters L 2 1134 pints pt quarts 0 94635 liters L 1 0567 quarts qt gallons gal 3 7854 liters L 0 2642 gallons gal cubic feet ft3 28 317 liters L 0 03531 cubic feet ft3 cubic feet ft3 0 02832 cubic meters m 35 315 cubic feet 3 Weight Force ounces av oz 28 35 grams g 0 03527 ounces av oz pounds av Ib 0 454 kilograms kg 2 205 pounds av Ib U S tons t 907 18 kilograms kg 0 001102 U S tons t U S tons t 0 90718 metric tons t 1 1023 U S tons t Torque Work Force inch pounds lbf in 11 298 Newton centimeters 0 08851 inch pounds lbf in foot pounds Ibf ft 1 3558 Newton meters 0 7376 foot pounds Pressure Vacuum inches of mercury inHg 3 37685 kilo Pascals kPa 0 29613 inches of mercury inHg pounds per square inch psi 6 895 kilo Pascals kPa 0 14503 pounds per square inch psi Table 4 Metric U S Customary Conversion Then When You Multiply Then When You Know Subtract Divide By To Get Know By Add To Ge
161. ue Values Torque Size Ibf ft N m Spring Assembly U Bolt High Nuts Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 180 to 230 245 to 313 Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 270 to 330 367 to 449 5 8 18 3 4 16 Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 420 to 500 571 to 680 7 8 14 Stage 1 Hand tighten Stage 2 60 81 Stage 3 200 271 Stage 4 520 to 600 707 to 816 1 14 Tighten in a diagonal pattern as shown in Fig 12 Table 1 U Bolt Torque Values Acterra Maintenance Manual September 2002 32 9 32 Suspension 4 1 LK A F4 bog 01 05 99 2 3 1320783 Fig 12 Tightening Pattern for U Bolt High Nuts 32 10 Acterra Maintenance Manual September 2002 Front Axle 33 Index Alphabetical Title of Maintenance Operation MOP MOP Number AIFA Alignment Checking a x8 2 5 EARS abet dob ape se de gas 33 04 All Wheel Drive Front Axle Oil 33 06 All Wheel Drive Front Axle Oil Level 0 33 05 Draw Key Nut Inspec adatta ost ed E dated ede dace Ic S BUS ee E Du Ud e utes 33 07 Fin LUD CaM 52 agi ae od Get od Roe Gude Bde
162. uid level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion 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 26 1 4 6 10 8 13 12 17 16 19 20 15 21 18 11 14 9 7 3 5 2 09 24 96 1260396 NOTE Torque the oil pan bolts with a click type torque wrench following this torque pattern Tighten the bolts 5 7 N m then repeat the torque pattern with a click type torque wrench 15 to 20 Ibf ft 20 to 27 N m Fig 7 Allison MT Series Transmission Oil Pan Torque Pattern Cold Check Clean all dirt away from around the end of the fluid fill tube before removing the dipstick CAUTION Do not allow foreign matter to enter the transmis sion Dirt or foreign matter in the hydraulic system may cause undue wear of transmission parts make valves stick and clog passages It is important to check the fluid level cold to deter mine if the transmission has a sufficient amount of fluid to be safely operated until a hot check can be performed 1 Park the vehicle on a flat level surface 2 Apply the parking brakes and chock the rear tires Acterra Maintenance Manual March 2005 26 9 26 3 Run the engine for at least one minute Shift from DRIVE to NEUTRAL and then shift to REVERSE to fill the hydraul
163. und Then remove the chocks from the rear tires 33 07 Draw Key Nut Inspecting Axles With Unitized Wheel Ends Check the torque of the nut that holds the draw key on the side of the knuckle The torque should be 30 to 45 Ibf ft 41 to 61 N m See Fig 8 Acterra Maintenance Manual September 2002 33 5 33 Front Axle 10 11 2001 1330186 Fig 8 Draw Key Nut 33 6 Acterra Maintenance Manual September 2002 Rear Axle 35 Index Alphabetical Title of Maintenance Operation MOP MOP Number Axle Breather Oeo NIFI Exod tri eue dinin eue d dte vb dE ROSE ravens rs d qu d RS 4 35 02 Axle Lubricant Changing and Magnetic Plug 35 03 Axle Lubricant Level Ghiecking pesa ee ad UR EON rd eR ee rede RR d 35 01 Two Speed Axle Shift Unit Oil 0 35 05 Two Speed Axle Shift Unit Oil Level 35 04 Acterra Maintenance Manual March 2000 Rear Axle 35 01 Axle Lubricant Level Checking CAUTION Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage 1 Clean the oil fill hole plug located in the carrier or the side of the axle housing and the area sur rounding it see Fig 1 Remove the plug 35 NOTE Some Meritor axles h
164. ure Flushing and Coolant Changing 20 03 Fan Clutch Checking e e o o 25 01 Clutch Release Bearing and Release Cross Shaft Lubricating e e Joe 25 02 Clutch Pull Type Inspecting and Adjusting 25 03 Hydraulic Fluid Level Checking 25 04 Hydraulic Fluid Replacing 26 01 Manual Transmission Fluid Level Checking 26 02 Eaton Fuller and TTC Transmission Fluid Changing and Magnetic Plug Cleaning et 26 03 Allison Eaton Fuller and Meritor Transmission Breather Checking 26 04 Allison Transmission Fluid and Filter Changing 26 05 Mercedes Benz Transmission Fluid Changing and Magnetic Plug Cleaning 26 06 Mercedes Benz Transmission Leak Checking 31 01 Frame Fastener Torque Checking 31 02 Fifth Wheel Inspecting 31 03 Fifth Wheel Lubricating 32 01 Suspension Inspecting 32 02 Suspension Lubricating e o Acterra Maintenance Manual January 2007 00 11 00 Maintenance Operation Sets Tables 00 08 General Information Maintenance Operation Sets for Groups 00 through 32 REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 M4 5 Maintenance Operation Number and Operation Description 32 03 U Bolt Torque Checking With frequent use the Pacbrake Exhaust Brake will operate free of maintenance However if the vehicle is used inconsistently seasonally or is expo
165. vehicles with screw on caps with O rings make sure that the O ring is not cracked or deteriorated Replace the cap if the gasket shows deterioration or damage 20 20 02 Radiator Pressure Flushing and Coolant Changing NOTE For additional instructions on cleaning and flushing the cooling system see the engine manufacturer s maintenance and operation manual 1 Drain the radiator 1 1 Remove the surge tank cap See Fig 1 11 19 94 v d 1 Surge Tank 1500107a Fig 1 Surge Tank and Cap 1 2 Open the petcock at the bottom of the radiator to drain the engine coolant See Fig 2 2 Disconnect the radiator inlet and outlet hose con nections 3 Flush the radiator 3 1 Attach a flushing gun nozzle to the radia tor outlet 3 2 Run water in until the radiator is full 3 3 Apply no more than 20 psi 138 kPa air pressure intermittently to help dislodge sediment buildup in the core CAUTION When flushing the radiator do not apply more than 20 psi 138 kPa air pressure Excessive pres sure can damage the radiator or heater core Acterra Maintenance Manual January 2007 20 1 20 Engine Cooling R adiator 11 19 94 1 Radiator 1500108 2 Horn Fig 2 Draining The Engine Coolant 4 Drain the radiator and flush the radiator until clean water flows from the radiator Remove the flushing gun 5 Close the petcock at the bottom of the radiator 6 Connect
166. vel is checked check that the axle breather is open Check more often under poor operating conditions If the breather is plugged clean or replace it as needed 1 7 K 5 al Go 2 3 06 07 94 1350062 1 Axle Housing 2 Carrier Oil Fill Plugs Breathers 3 Interaxle Differential Fig 1 Fill Hole Plug and Axle Housing Breather Locations Rear Axle 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning A regular schedule for changing the axle lubricant in a particular vehicle and operation can be accurately determined by analyzing oil samples taken from the axle at specified intervals or mileages Lubricant sup pliers frequently make their laboratory facilities avail able for determining the useful life of their product under actual service conditions The final schedule that is recommended may for economic reasons be correlated with lubricant changes that are governed by climatic conditions and magnetic plug mainte nance Change lubricant type and viscosity as cli matic temperatures demand regardless of vehicle mileage or established change schedule The normal operating temperature of compounded lubricants during the summer season is about 160 to 220 F 71 to 104 C The chemicals and addi tives that give these lubricants increased load carrying capacity oxidize faster at temperatures above 220 F 104 C contributing to more rapid lu bricant deterioration For this reason lubri
167. vicing the brakes starting with removal of the wheels and continuing through assembly To minimize the possibility of creating airborne brake lining dust clean the dust from the brake rotor brake caliper and brake assembly using an industrial type vacuum cleaner equipped with a high efficiency filter System Then using a rag soaked in water and wrung until nearly dry remove any remaining dust Do not use compressed air or dry brushing to clean the brake assembly 1 Check lining wear 1 1 Apply the parking brakes Chock the tires to prevent vehicle movement 1 2 Remove one or more of the lining inspec tion plugs and measure brake lining thickness Brakes 1 3 On front and rear axles replace linings worn to less than 1 16 inch 1 6 mm 1 4 Make sure that the brake rotor and linings are free of oil and grease 1 5 Install the inspection plug s 2 If the wheel and hub assembly is removed from the axle check lining wear Replace the linings on all brake assemblies if worn to less than 1 16 inch 1 6 mm at the thinnest point NOTE To replace the brake linings see the ap plicable foundation brake section in Group 42 of the Acterra Workshop Manual 42 18 Brake Lines Checking Hydraulic Disc Brakes Check all hydraulic lines and fittings for damage leakage or looseness Replace damaged or leaking components and tighten loose fittings 42 19 Power Booster Checking Bendix Hydro Max Check f
168. voir Turn off the engine 12 Install a new cover gasket the cover and nut Tighten the nut 28 38 N m Install the cap 13 Start the engine and check the power steering reservoir fluid level If the fluid level is low add ATF to bring the level up to the FULL mark on the dipstick 14 Close the hood and remove the chocks from the tires Nelson Reservoir 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 dent resulting in personal injury or property dam age Wear eye protection when changing the fluid and filter NOTE If the power steering reservoir in the ve hicle looks like the reservoir shown in Fig 3 use the following procedure 1 Turn off the engine apply the parking brakes and chock the tires Open the hood Place a drain pan under the reservoir and re move the steering gear to reservoir return hose at the reservoir Drain the steering fluid into the drain pan and dispose of the fluid properly Plug the return line fitting on the reservoir 4 Loosen the clamp and remove the cover along with the filter spring and the filter top plate See Fig 3 NOTE Always replace the reservoir filter when changing the fluid 5 Remove the filter It may be necessary to wiggle the filter to remove it from its base Do not use pliers to aid in rem
169. with your vehicle s schedule For Schedule 1 vehicles equipped with an hourmeter use hours to determine maintenance in tervals rather than distance traveled When the vehicle reaches the actual distance or hours given for an interval refer to the Maintenance Interval Tables to find the Maintenance Operation Set that applies to that interval Then perform the mainte nance operations listed in the applicable Mainte nance Interval Operation Table Use the maintenance operation reference numbers to find instructions in the manualfor completion of each operation Complete each Maintenance Operation Set at the required interval Then when you have completed Maintenance Operation Set M5 under the 32nd Main tenance Number listed in the Maintenance Interval Table repeat the pattern The 33rd Maintenance Number will begin at Maintenance Operation Set M1 under the 1st Maintenance Number listed in the Maintenance Interval Table NOTE When performing operations for the 33rd Maintenance Number complete the M1 opera tions only not the Initial Maintenance opera tions To determine the distance hours for the 33rd Mainte nance Number add your schedule s distance hours for the 1st Maintenance Number to the distance hours for the 32nd Maintenance Number then perform the operations listed in the applicable table in the Maintenance Operations Tables For the 34th Maintenance Number add the distance hours for the 2nd to the distance hours
170. wo magnetic poles and divert the magnetic field 6 Install and tighten the drain plug s 50 68 N m Filling 1 Add fluid until it is level with the lower edge of the fill opening See Fig 1 If the transmission has two fill openings add fluid to the level of both fill openings See Table 1 for approved transmission lubri cants and Table 2 for lubricant capacities Eaton Fuller and TTC Transmission Lubricant Capacities Transmission Model Eaton Fuller 5 Speed FS Series FS 4205A B 6 25 5 9 FS 5205A B 6 25 5 9 FS 6305A B 9 75 9 2 Eaton Fuller 6 Speed FS FSO Series 5 5406 9 75 9 2 Transmission Eaton Fuller and TTC Transmission Lubricant Capacities Refill Capacity Transmission Model quarts liters FS 6406A 9 75 9 2 FSO 6406A FSO 8406A 9 75 9 2 6 Speed Autoshift all 10 4 9 8 Eaton Fuller 7 Speed T Series T 14607A B 18 0 17 0 7 Speed Autoshift all 18 0 17 0 TTC 7 Speed ES Series ESO66 7B 11 0 10 4 Eaton Fuller 9 Speed RT RTF Series RT 6609A 6 0 5 7 RT 8709B 13 0 12 3 RTF 8709B RT 8608L 13 5 12 8 Eaton Fuller 10 Speed FR FRO and RT Series 10 Speed FR FRO all 11 75 11 1 RT 9710B 13 0 12 3 RT 8908LL 14 0 13 2 10 Speed Autoshift AS2 all 13 0 12 3 Quantities listed are approximate Fill the transmission until the lubricant is level wi
171. xle Oil Changing 1 Drive the vehicle until the axle oil is warmed then park it and chock the rear tires 2 Jack up the front axle until the wheels are off the ground then secure the axle on jack stands 3 On vehicles equipped with an MT 8 MT 10 or MT 11 front axle drain the oil from the differen tial 33 On vehicles equipped with an MT 14 MT 17 or MT 22 front axle drain the oil from the differential and the hubs 3 1 Remove the oil drain plug from the differ ential and allow the oil to drain See Fig 6 3 2 If applicable rotate each wheel until the oil drain bore is at the bottom then re move the drain bore plugs and allow the oil to drain into a suitable container See Fig 7 If needed use a bent piece of sheet metal to direct the draining oil so it doesn t splash on the tires 4 Fill the differential and hubs if applicable with new oil 4 1 Install the drain bore plugs in each hub and the differential then tighten the plugs firmly 4 2 Remove the plug from the oil level check bore in each hub and from the fill and check bore in the differential 4 3 Fill the hubs and differential until the oil level within each is even with the bottom of the fill and check bore 4 4 Install the check bore plug in each hub and install the fill and check plug in the differential Tighten all the plugs firmly 5 Lift the front axle off the jack stands remove the stands and lower the vehicle to the gro
172. y separation See Fig 2 Ref B Oil grease or belt dressing can cause the belt to fall apart in layers Repair any oil or coolant leaks that are affecting the belts before replacing the drive belts Do not use belt dress ing on any belt 3 Check the belt for a jagged or streaked sidewall See Fig 2 Ref C Jagged or streaked sidewalls are the result of foreign objects such as sand or gravel in the pulley or a rough pulley surface 4 Check for tensile breaks breaks in the cord body See Fig 2 Ref D Cuts in a belt are usu ally caused by foreign objects in the pulley or by prying or forcing the belt during removal or instal lation 5 Check for uneven ribs on serpentine poly V belts See Fig 2 Ref E Foreign objects in the pulley will erode the undercord ribs causing the belt to lose its gripping power 6 Check the drive belts for cracks See Fig 2 Ref F Small irregular cracks are usually the signs of an old belt 7 Inspect the pulleys for excessive play or wobble Excessive play or wobble indicates a failure of the pulley bearing Check for belt squealing or squeaking Replace the bearings as necessary NOTE If it is difficult to distinguish the location of a supposed bearing noise obtain a stetho scope and place it on the component being Acterra Maintenance Manual January 2007 01 1 01 Engine 11 21 94 A Glazing B Separating Layers C Streaked Sidewalls D Tensile Bre

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