Sterling Trucks MX manual

ACTERRA MAINTENANCE MANUAL Models: MX STI-403-1 (10/07P) 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 w[...]

Freightliner LLC distributes the following major service publications. Workshop Manual 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 informat[...]

For a page example of the printed manual, see Fig. 1 . 02/11/2002 f020103 A BC D E Frame and Fifth Wheel 31 31−01 Frame Fastener Torque Checking 31−02 Fifth Wheel Inspecting and Lubricating Acterra Trucks Maintenance Manual, April 2000 31/1 FONTANE HOLLAND CAUTION: A. Maintenance Operation Number consists of the Group Number followed by the Seq[...]

Group No. Group Title 0 0 ...................... General Information 0 1 ................................ Engine 0 9.............................. A i r Intake 1 3 ......................... A i r Compressor 1 5 ................... Alternators and Starters 2 0 ................... Engine Cooling/Radiator 2 5 ................................ Clutch 2 [...]

Title of Maintenance Operation (MOP) MOP Number Initial Maintenance (IM) Operations T able ................................................ 00–09 Lubrication and Fluid Level Check (M1) .................................................. 00–15 Lubrication and Fluid Level Check (M2) .................................................. 00–16 M1 Mai[...]

General Information Federal Law , Part 205: T ransportation Equipment Noise Emission Controls Part 205, T ransportation Equipment Noise Emission Controls, requires the vehicle manufacturer to fur- nish, with each new vehicle, such written instructions for the proper maintenance, use, and repair of the vehicle by the ultimate purchaser to provide re[...]

V erification of Inspections Log V erification of Inspections Log — Group 20 V erification of Inspections Log — Group 20 — Engine Cooling/Radiator Date Mileage Repair Description Cost Repair Facility V erification of Inspections Log — Group 49 V erification of Inspections Log — Group 49 — Exhaust Date Mileage Repair Description Cos[...]

T orque V alues for U.S. Customary Thread Fasteners With Lubricated * or Plated Threads † Thread Diameter– Pitch Regular Hex Flanged Grade 5 Bolt Grade 5 or BN u t Grade 8 or 8.2 Bolt Grade 8 or CN u t Grade 5 Bolt Grade B Nut Grade 8 or 8.2 Bolt Grade G Nut T orque: lbf·ft (N·m) T orque: lbf·ft (N·m) T orque: lbf·ft (N·m) T orque: lbf·f[...]

T orque V alues for U.S. Customary Thread Fasteners With Dry (Unlubricated) * Plain (Unplated) Threads † Thread Diameter–Pitch Regular Hex Flanged Grade 5 Bolt G r a d e5o rB Nut Grade 8 or 8.2 Bolt G r a d e8o rC Nut Grade 8 or 8.2 Bolt Grade G Nut T orque: lbf·ft (N·m) T orque: lbf·ft (N·m) T orque: lbf·ft (N·m) f230002 f230003 f230004 [...]

T orque V alues for Metric Thread Fasteners With Lubricated * or Plated Threads † Thread Diameter–Pitch Class 8.8 Bolt Class 8 Nut Class 10.9 Bolt Class 10 Nut T orque: lbf·ft (N·m) T orque: lbf·ft (N·m) f230010 8.8 f230011 8 f230012 10.9 f230013 10 M6 5 (7) 7 (9) M8 12 (16) 17 (23) M8 x 1 13 (18) 18 (24) M10 24 (33) 34 (46) M10 x 1.25 27 ([...]

When Y ou Know U.S. Customary Multiply By T o Get Metric When Y ou Know Metric Multiply By T o 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)[...]

Description Schedule I (severe service) applies to vehicles that annually travel up to 6000 miles (10 000 kilometers) or that operate under severe conditions. Examples of Schedule I 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 climat[...]

Maintenance Schedule Models Maintenance Interval Operation Maintenance Intervals Frequency Miles Km Hours Schedule I (Severe Service) vehicles that annually travel up to 6000 miles (10 000 km) All Initial Maintenance (IM) first 1000 1600 100 Maintenance 1 (M1) every 1000 1600 100 Maintenance 2 (M2) every 4000 6400 400 Maintenance 3 (M3) every 8000[...]

Maintenance Intervals for Schedule I 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 M1and M2 4000 6400 400 5 M1 5000 8000 500 6 M1 6000 9600 600 7 M1 7000 1 1 200 700 8 M1, M2, and M3 8000 12 800 800 9 M1 9000 14 400 900 10 M1 10,000 16 000 1000 1 1 M1 1 1,000 17 600 1 100 12 M1 and [...]

Maintenance Intervals for Schedules II and III (all models) Maint. No. Maintenance Interval Schedule II Schedule III Miles km Miles km 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 [...]

IMPORT ANT : At each Maintenance Operation Set, in addition to the maintenance operations listed in this table, perform all daily , weekly , and monthly mainte- nance operations listed in the "Pretrip and Post-trip Inspections and Maintenance" chapter of the Acterra ® Driver’s Manual . NOTE: Maintenance operations appearing in italics [...]

Maintenance Operation Sets for Groups 00 through 32 REQUIRED MAINTENANCE OPERA TION SET IM M1 M2 M3 M4 M5 Maintenance Operation Number and Operation Description 32–03 U-Bolt T orque Checking •• • • * With frequent use, the Pacbrake Exhaust Brake will operate free of maintenance. However , if the vehicle is used inconsistently , seasonally[...]

Maintenance Operation Sets for Groups 33 through 42 REQUIRED MAINTENANCE OPERA TION SET IM M1 M2 M3 M4 M5 Maintenance Operation Number and Operation Description 42–13 Air Dryer Desiccant Replacing, Bendix AD–9 • 42–14 Air Brake V alve Leak Checking, Bendix TC–6 •••••• 42–15 Air Reservoir Automatic Drain V alve Disassembly , [...]

IMPORT ANT : After performing all operations in this table, perform all daily and weekly maintenance op- erations listed in the "Pretrip Inspection and Daily Maintenance" chapter of the vehicle driver’s manual. Also, perform all M1 Maintenance Interval Operations at the Initial Maintenance (IM). NOTE: Numbers in this table are maintenan[...]

IMPORT ANT : After performing all operations listed in this table, perform all daily , weekly , and monthly maintenance operations listed in the "Pretrip and Post-T rip Inspections and Maintenance" chapter of the Acterra ® Driver’s Manual . NOTE: Numbers in this table are maintenance opera- tion reference numbers matching those in the [...]

Maint. Oper . No. M1 Maintenance Interval Operations 42–14 Air Brake V alve Leak Checking, Bendix TC–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?[...]

IMPORT ANT : After performing all operations listed in this table, perform all daily , weekly , and monthly maintenance operations listed in the "Pretrip and Post-T rip Inspections and Maintenance" chapter of the Acterra ® Driver’s Manual . Also, perform all M1 Maintenance Interval Operations at the M2 Mainte- nance Interval. NOTE: Mai[...]

IMPORT ANT : After performing all operations listed in this table, perform all daily , weekly , and monthly maintenance operations listed in the "Pretrip and Post-T rip Inspections and Maintenance" chapter of the Acterra ® Driver’s Manual . Also, perform all M1 and M2 Maintenance Interval Operations at the M3 Maintenance Interval. NOTE[...]

IMPORT ANT : After performing all operations listed in this table, perform all daily , weekly , and monthly maintenance operations listed in the "Pretrip and Post-T rip 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.[...]

IMPORT ANT : After performing all operations listed in this table, perform all daily , weekly , and monthly maintenance operations listed in the "Pretrip and Post-T rip Inspections and Maintenance" chapter of the Acterra ® Driver’s Manual . Also, perform all M1, M2, M3, and M4 Maintenance Interval Operations at the M5 Maintenance Inter[...]

Maintenance Operation 00–15 (see T able 12 ), sum- marizes all Lubrication and Fluid Level Check opera- tions that must be performed at the M1 Maintenance Interval for Schedules I, II, and III Maintenance operation numbers given in the table are reference numbers used to help you find detailed instructions in the manual on the lubrication or fl[...]

Maintenance Operation 00–16 (see T able 13 ), sum- marizes all Lubrication and Fluid Level Check opera- tions that must be performed at the M2 Maintenance Interval for Schedules I, II, and III Maintenance operation numbers given in the table are reference numbers used to help you find detailed instructions in the manual on the lubrication or fl[...]

Title of Maintenance Operation (MOP) MOP Number Engine Drive Belt Inspecting .......................................................... 01–02 Engine-Support Fasteners Checking .................................................... 01–01 Pacbrake Inspecting and Maintenance .................................................. 01–03 Engine 01 Index,[...]

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[...]

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 T ension Inspection NOTE: If engine drive belts require adjustment, see Group 01 of the Acterra ® Workshop Manual for instructions. Threaded-Adjustment T ype 1. Apply the parking brakes, and chock[...]

Engine Component Belt T ension: lbf (kg) Cummins ISB, ISC, ISM Refrigerant Compressor 100 (45) Mercedes-Benz MBE900 Fan and Alternator 29.5 (27.9) Refrigerant Compressor 30.0 (28.4) T able 1, Drive Belt T ensions 01–03 Pacbrake Inspecting and Maintenance With frequent use, the Pacbrake Exhaust Brake will operate maintenance-free. If the vehicle i[...]

Title of Maintenance Operation (MOP) MOP Number Air Cleaner Element Inspecting and Replacing ............................................ 09–01 Air Intake 09 Index, Alphabetical Acterra Maintenance Manual, February 2004[...]

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 inH 2 O on a vehicle with an MBE engine, or 25 inH 2 O on a vehicle with a Caterpillar or Cummins engine, if equipped with an air restriction indicator . For replacement instructi[...]

Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspecting, Bendix ..................................................... 13–01 Air Compressor Rebuilding/Replacing, Bendix ............................................. 13–02 Air Compressor 13 Index, Alphabetical Acterra Maintenance Manual, March 2000[...]

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. T ighten 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 secu[...]

Title of Maintenance Operation (MOP) MOP Number Alternator , Battery , and Starter Connections Checking ....................................... 15–01 Alternators and Starters 15 Index, Alphabetical Acterra Maintenance Manual, January 2006[...]

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 com[...]

Title of Maintenance Operation (MOP) MOP Number Fan Clutch Checking (Noise Emission Control) ............................................ 20–03 Radiator Cap Checking .............................................................. 20–01 Radiator Pressure Flushing and Coolant Changing ......................................... 20–02 Engine Coolin[...]

20–01 Radiator Cap Checking WARNING 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 . CAUTI[...]

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 the hoses. Y our hose clamps can be either T -bolt clamps (see Fig. 3 ) or Breeze Constant-T orque clamps (see Fig. 4 ). T ighten T -bolt type hose clamps 55 lbf·in ([...]

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°F (–37°C) year round. See T able 1 for engine cooling system capaci- ties. See T able 2 for approved antifreezes. Coolant Capac[...]

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[...]

10.5 Apply the foot brake, and release the parking brakes. 10.6 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 sta[...]

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 C[...]

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 solution, check for a leak in the same areas. 9. If a 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 d[...]

Title of Maintenance Operation (MOP) MOP Number Clutch (Pull-T ype) Inspecting and Adjusting ............................................... 25–02 Clutch Release Bearing and Release Cross-Shaft Lubricating ................................. 25–01 Hydraulic Fluid Level Checking ........................................................ 25–03 Hydr[...]

25–01 Clutch Release Bearing and Release Cross-Shaft Lubricating Clutch Release Bearing 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 b[...]

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 the quick- disconnect clamp that attaches the hydraulic hose to the slave cylinder [...]

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 proc[...]

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. 8. Disconnect the bleeder unit, and install the cap on the slave cylinder bleeder valve. 9. Check the fluid level in the reservoir . If neces- sary , add or remove clutch hydraulic fluid to bri[...]

Title of Maintenance Operation (MOP) MOP Number Allison T ransmission Breather Checking ................................................. 26–03 Allison T ransmission Fluid and Filter Changing ............................................ 26–04 Eaton Fuller and TTC Transmission Fluid Changing and Magnetic Plug Cleaning ...........................[...]

26–01 Manual T ransmission 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 o[...]

• 42 lbf·ft (57 N·m) for all Mercedes-Benz transmissions. 26–02 Eaton Fuller and TTC T ransmission Fluid Changing and Magnetic Plug Cleaning Draining 1. Park the vehicle on a level surface. Apply the parking brakes and chock the rear tires. 2. Drain the fluid while the transmission is warm. 3. Clean the area around the fill plug and the dra[...]

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 correc[...]

1 1. Check and adjust the fluid level using the proce- dure under "Checking the Fluid Level." Approved Allison T ransmission Lubricants Lubricant T ype * T emperature: °F (°C) SAE Viscosity All Allison T ransmissions Castrol T ranSynd ™ (synthetic) Above –22 (–30) — On-Highway T ransmissions (1000/2000/2400 Series) Dexron ® II[...]

1 1. Submerge a new oil pan gasket in transmission fluid for five minutes. Then place the gasket on the pan; do not use any substance as a gasket retainer . IMPORT ANT : 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[...]

the transmission and remove the drain plug. Ex- amine the fluid as it drains. If only the filter is being changed, do not drain the fluid. 4. Remove the 12 mounting bolts (six each) from the two filter covers. NOTE: A lot of fluid will drain when the filter covers are removed. 5. Remove the filter covers, O-rings, and two square-cut seals fr[...]

CAUTION Do not use the bolts to draw the filter covers to the sump. This can damage the covers, seals, or sump. 1 1. Install six bolts in each cover , and torque the bolts 38 to 44 lbf·ft (51 to 61 N·m). 12. Replace the drain plug O-ring, and install the drain plug. T ighten the drain plug 18 to 24 lbf·ft (25 to 32 N·m). 13. Refill the transm[...]

08/30/96 f260369 1 2 3 4 5 6 7 8 9 10 11 12 15 13 14 1. T ransmission Housing 2. T ransmission Oil Pan Gasket 3. 5/16–18 W asher-Head Capscrew 4. Plug 5. T ransmission Oil Pan 6. Magnet 7. Drain Plug Gasket 8. Drain Plug 9. 5/16–18 x 5/8 Capscrew 10. Flatwasher 1 1. Transmission Fluid Filter 12. Fluid-Filter Spacer 13. O-Ring 14. Fluid-Filter T[...]

vented from contacting areas of the oil pan flange that are inside the raised bead of the flange. NOTE: Do 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 transmissi[...]

3. Run the engine for at least one minute. 4. Shift from DRIVE to NEUTRAL, and then shift to REVERSE to fill the hydraulic 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[...]

26–05 Mercedes-Benz T ransmission Fluid Changing and Magnetic Plug Cleaning 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 . 2.1 Remove the magnetic drain plug from the bottom of th[...]

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 N000908 020001) and a new aluminum gasket (p/n N 00763 024105). T ighten the fil[...]

WARNING 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 [...]

Title of Maintenance Operation (MOP) MOP Number Fifth Wheel Inspecting .............................................................. 31–02 Fifth Wheel Lubricating .............................................................. 31–03 Frame Fastener T orque Checking ...................................................... 31–01 Frame and Frame Co[...]

31–01 Frame Fastener T orque 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 of f-highway operations, retorque frame fasteners the first 1000 miles (1600 km), then pe[...]

Check the drive-axle-flange fasteners (see Fig. 2 ) for tightness. T ighten the fasteners as follows: T ighten 1/2-inch drive-axle stud nuts (with or without dowels) 75 to 1 15 lbf·ft (102 to 156 N·m), and tighten 5/8-inch drive-axle stud nuts 150 to 230 lbf·ft (203 to 312 N·m). 31–02 Fifth Wheel Inspecting WARNING All fifth wheel maintenan[...]

8. Replace cracked, worn, or damaged parts with new parts. Replace loose mounting bolts with 5/8–1 1 SAE grade 8 bolts, grade C 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 Thorou[...]

Title of Maintenance Operation (MOP) MOP Number Suspension Inspecting .............................................................. 32–01 Suspension Lubricating .............................................................. 32–02 U-Bolt T orque Checking ............................................................. 32–03 Suspension 32 Index, [...]

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 32 of the Acterra ® Workshop Manual for instructio[...]

• Either bushing end contacts a torque arm pin mounting bolt. • There are cracks in the bushing. • Part of the rubber bushing extends beyond the outside diameter of the outer bushing sleeve. Sterling Spring (T andem) Equalizer Bushing Checking 1. Block the frame up enough to take the weight of the chassis off of the springs. Attempt to move t[...]

60-Inch T aper-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 AirL[...]

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 ® Works[...]

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. 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 bet[...]

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 exte[...]

WARNING 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. V ehicles with cracked or missing restrictor cans may be driven slowly to the nearest workshop for restrictor can replacement. 6. Remove the jack stands, then lo[...]

3. Use a click-type torque wrench to check that spring hanger bolts are tightened 190 lbf·ft (258 N·m). 4. Use a click-type torque wrench to check that the 5/8-inch torque rod clamp nuts are tightened 125 to 150 lbf·ft (170 to 203 N·m). 5. Use a click-type torque wrench to check that the two end-nuts for each torque rod are tightened 400 to 450[...]

Hendrickson Spring-Eye Pins, R T and R TE 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 T ufT rac The T ufTrac suspension is maintenance-free and de- si[...]

01/05/99 f320783 1 2 3 4 Fig. 12, Tightening Pattern for U-Bolt High Nuts Suspension 32 Acterra Maintenance Manual, September 2002 32/10[...]

Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Checking .......................................................... 33–04 All-Wheel-Drive Front Axle Oil Changing ................................................. 33–06 All-Wheel-Drive Front Axle Oil Level Checking ............................................. 33–05 Draw Key [...]

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 whe[...]

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.[...]

1. Shut off the engine, apply the brakes, and 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 vehic[...]

• 1-1/8–12, 350 to 650 lbf·ft (475 to 881 N·m) • 1-1/4–12, 500 to 675 lbf·ft (678 to 915 N·m) 10. Check the steering arm bolts for a minimum torque of 300 lbf·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. T ighten the bolt 300 t[...]

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 . 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 [...]

10/11/2001 f330186 Fig. 8, Draw Key Nut Front Axle 33 Acterra Maintenance Manual, September 2002 33/6[...]

Title of Maintenance Operation (MOP) MOP Number Axle Breather Checking ............................................................. 35–02 Axle Lubricant Changing and Magnetic Plug Cleaning ....................................... 35–03 Axle Lubricant Level Checking ........................................................ 35–01 T wo-Speed-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. NOTE: Some Meritor axles have a[...]

Meritor Drive Axle Lubricant Capacities, T andem Axles Axle Model Capacity * : pints (liters) RT–34–144 Forward 29.8 (14.1) Rear 34 (16.1) RT–40–145 Forward 30.4 (14.4) 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. T able 3, Meritor Drive Axle L[...]

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 ef fectiveness 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 pl[...]

35–05 T wo-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. T ighten the [...]

Title of Maintenance Operation (MOP) MOP Number Wheel Nut Checking ................................................................ 40–01 Wheels and Tires 40 Index, Alphabetical Acterra Maintenance Manual, March 2000[...]

40–01 Wheel Nut Checking IMPORT ANT : 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 checking wheel nuts on a dual disc assembly , remove one outer nut at a time, tighten the inner nut, then reinstall the o[...]

1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 34 5 f400057 05/27/93 1 2 3 4 5 6 7 8 AB CD A. 8-Stud Disc Wheel B. 10-Stud Disc Wheel C. 6-Spoke Wheel D. 5-Spoke Wheel Fig. 1, Wheel Nut and Rim Nut Tightening Sequence Wheels and Tires 40 Acterra Maintenance Manual, March 2000 40/2[...]

Title of Maintenance Operation (MOP) MOP Number Driveline Inspecting ................................................................ 41–01 Driveline Lubricating ................................................................ 41–02 Driveline 41 Index, Alphabetical Acterra Maintenance Manual, March 2000[...]

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 lbf·ft (68 to 81 N·m) • Dana Spicer 1710: 125 to 135 lbf·ft (170 to 183 N·m) CAUTION Do not overtighten the yoke-strap capscrews, due to the extreme load occurring at high-speed[...]

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; se[...]

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. IMPORT ANT : Fresh lubricant must be seen es- caping from all four bearing cup se[...]

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, then 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-joi[...]

Title of Maintenance Operation (MOP) MOP Number Air Brake V alve Disassembly , Cleaning, and Inspecting, Bendix E–8P , R–12, R–14, SR–1, ST–3, TC–6, and TP–3DC ................................................. 42–16 Air Brake V alve Inspecting and Leak Checking, Bendix BP–R1 ................................ 42–02 Air Brake V alv[...]

42–01 Air Dryer Inspecting, Bendix AD–9 1. 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. 2. T ighten the fasteners that attach the air dryer to the vehicle. Use the following torque values: • 28 lbf·ft ([...]

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. T ighten 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 servic[...]

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 . 2.2 If th[...]

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. 8. On parking brake chambers equi[...]

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- c[...]

42–08 Camshaft Bracket Bushing Lubricating IMPORT ANT : Perform MOP 42–24 before lubri- cating the camshaft brackets. Pump multipurpose chassis 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[...]

42–1 1 Automatic Slack Adjuster Inspecting, Meritor IMPORT ANT : 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 gre[...]

42–16 Air Brake V alve Disassembly , Cleaning, and Inspecting, Bendix E–8P , 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 ins[...]

adjuster at the grease fitting until grease appears on the camshaft. 42–21 Automatic Slack Adjuster Inspecting, Gunite 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 , troublesh[...]

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°C) and above. If the operating tempera- ture is below –20°F (–29°C), use a low-temperature extreme-pressure grease. 42–23 Bosch Rail-Slide Hydraulic Brake Caliper Lubric[...]

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 one 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 alo[...]

the Acterra ® Workshop Manual for inspection, troubleshooting, and repair procedures. 4. Measure the applied chamber stroke. See T able 3 for the proper stroke for the type of chamber being used. If the stroke is too short, the brakes may drag or will not fully apply . Check for improper operation or adjustment of the auto- matic slack adjuster . [...]

Brake Chamber Stroke Specifications Chamber Max Applied Stroke: inch (mm) Manufacturer T ype * Size † Meritor Standard Stroke 9 Less than 1-1/2 (38) 12 16 Less than 1-3/4 (44) 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 . † Specifi[...]

Title of Maintenance Operation (MOP) MOP Number Drag Link Lubricating ............................................................... 46–02 Power Steering Gear Lubricating ....................................................... 46–05 Power Steering Reservoir Fluid Level Checking ............................................ 46–03 Power Steerin[...]

46–01 Steering Driveline Lubricating Wipe the grease fittings clean. See Fig. 1 . Using a pressure gun, apply 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 . 2. Using a pressu[...]

46–03 Power Steering Reservoir Fluid Level Checking Metal V entra Reservoir 1. T urn off the engine, apply the parking brakes, and chock the tires. 2. Open the hood. 3. Clean around the power steering reservoir fill cap with a clean rag, then remove the dipstick. WARNING Fill only with approved clean fluid. Do not mix fluid types. Any mixture [...]

Plastic V entra Reservoir NOTE: If the power steering reservoir in the ve- hicle looks like the reservoir shown in Fig. 4 , use the following procedure. 1. T urn off the engine, apply the parking brakes, and chock the tires. 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 [...]

1 1. Fill the reservoir with A TF 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 reservoir . T urn off the engine. 12. Install a new cover gasket, the cover , and nut. T ighten the nut 28 lbf·ft (38 N·m). Install the fill cap. 13. Start the engine and check the[...]

2. Open the hood. 3. 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 at[...]

Title of Maintenance Operation (MOP) MOP Number Fuel T ank Draining and V ent Checking .................................................. 47–01 Fuel 47 Index, Alphabetical Acterra Maintenance Manual, March 2000[...]

47–01 Fuel T ank Draining and V ent 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 sur[...]

Title of Maintenance Operation (MOP) MOP Number Exhaust System Inspecting (Noise Emission Controls) ....................................... 49–01 Exhaust 49 Index, Alphabetical Acterra Maintenance Manual, January 2007[...]

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-EP A07 Exhaust System Inspecting 1. Check the muff ler body , muffler outlet [...]

• Diesel Particulate Filter (DPF)—a filter that col- lects and holds particulate matter (soot and ash). • Diesel Oxidation Catalyst (DOC)—oxidizes hy- drocarbons and reduces NOx. • Sensors—detect temperatures and pressures in the A TS. Inspection 1. Check for leakage at the clamp that attaches the exhaust pipe to the turbocharger exhau[...]

9. Check any wires, lines, or hoses within 4 inches (10 cm) of the exhaust system for heat damage. Repair or reroute as needed. Exhaust 49 Acterra Maintenance Manual, January 2007 49/3[...]

Title of Maintenance Operation (MOP) MOP Number Coolant Level Sensor Cleaning ........................................................ 54–02 Electrical System Checking ........................................................... 54–01 Electrical, Instruments, and Controls 54 Index, Alphabetical Acterra Maintenance Manual, March 2000[...]

54–01 Electrical System Checking Cab 1. Uncover the electrical panel (see Fig. 1 )b yr e - moving the fasteners. 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-[...]

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. In[...]

Title of Maintenance Operation (MOP) MOP Number Weatherstrip, Door Latch, and Door Hinge Lubricating ....................................... 72–01 Doors 72 Index, Alphabetical Acterra Maintenance Manual, March 2000[...]

72–01 W eatherstrip, 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 [...]

Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspecting ............................................................ 83–01 HV AC Air Filter Replacing ............................................................ 83–02 Heater and Air Conditioner 83 Index, Alphabetical Acterra Maintenance Manual, March 2003[...]

83–01 Air Conditioner Inspecting WARNING Wear eye protection, gloves, and protective cloth- ing when working on the air conditioning system. Leaking refrigerant from a damaged hose or line could cause blindness or serious skin burns. Preliminary Checks 1. Park the vehicle on a level surface, apply the parking brakes, and chock the tires. 2. Check[...]

02/17/2003 f831564 1 1 2 1. Screw 2. Filter Cover Fig. 2, Air Filter Replacement Heater and Air Conditioner 83 Acterra Maintenance Manual, March 2003 83/2[...]