Freightliner Cascadia 2016 Repair Manual

. ® CASCADIA Maintenance Manual Part Number STI 478 Publication Number STI-478-6. CASCADIA MAINTENANCE MANUAL Models: CA113DC CA113SLP CA125DC CA125SLP STI-478-6 (3/16) Published by Daimler Trucks North America LLC 4747 N.

UP to 75% Off Freightliner Heavy Duty Truck Repair Manuals and Scan tools. BEST BRANDS REPAIR MANUALS. Freightliner Cascadia Truck Factory Service Manual on.

Portland, OR 97217 Printed in U.S.A. Perform any maintenance operations listed at the intervals scheduled in those manuals. Your Freightliner Dealership has the qualified technicians and equipment to perform this mainte- nance for you. They can also set up a scheduled maintenance program tailored specifically to your needs. Introduction Descriptions of Service Publications Daimler Trucks North America LLC distributes the following major service publications in paper and electronic (via ServicePro®) formats. Workshop/Service Workshop/service manuals contain service and repair information for all vehicle Manual systems and components, except for major components such as engines, trans- missions, and rear axles. Descriptions of Service Publications EZWiring EZWiring ™ makes Freightliner, Sterling, Western Star, Thomas Built Buses, and Freightliner Custom Chassis Corporation products’ wiring drawings and floating pin lists available online for viewing and printing.

EZWiring can also be ac- cessed from within PartsPro. Introduction Page Description For an example of a Maintenance Manual page, see Fig. Driveline 41−01 Driveline Inspection 1.

Park the vehicle on a level surface, apply the parking brakes, and chock the tires. CAUTION Due to the extreme load occurring at high− speed rotation, a loose or broken capscrew at any point in the driveline will weaken the driveline connec−. Introduction Maintenance Manual Contents Group No. Group Title 00. General Information 09.Air Intake 13. General Information Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Determining Scheduled Maintenance Intervals.00–01 Initial Maintenance (IM) Operations. Maintenance Intervals intervals.

Freightliner Cascadia 2016 Repair Manual Pdf

Performing regular maintenance on your Freightliner vehicle will help ensure that your vehicle delivers safe reliable service and optimum performance for years to come. Failure to follow a regular mainte- nance program can result in inefficient operation and unscheduled down time. General Information Service Schedule Table: 00–02 Maintenance Interval Service Schedule Maintenance Interval Operation Frequency Miles Initial Maintenance (IM) first 10,000 16 000 Schedule I Maintenance 1 (M1) every 10,000 16 000 (Short-Haul Transport) vehicles that annually travel less than 60,000 Maintenance 2 (M2) every 50,000. General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule I Service Schedule I Maintenance Service Maint. Interval Date Miles IM and M1 10,000 16 000 20,000 32 000 30,000 48 000 40,000 64 000 M1 and M2 50,000 80 000 60,000. General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule I Service Schedule I Maintenance Service Maint. Interval Date Miles 36th 360,000 576 000 37th 370,000 592 000 38th 380,000 608 000 39th 390,000 624 000 40th M1 and M2 400,000 640 000 41st.

General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule I Service Schedule I Maintenance Service Maint. Interval Date Miles 71st 710,000 1 143 000 72nd 720,000 1 159 000 73rd 730,000 1 175 000 74th 740,000 1 191 000 75th M1, M2, and M3 750,000. General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule II Service Schedules II Service Maint. Maintenance Interval Date Miles IM and M1 25,000 40 000 50,000 80 000 75,000 121 000 M1 and M2 100,000 161 000 125,000 201 000 150,000. General Information Vehicle Maintenance Schedule Table: 00–03 Maintenance for Service Schedule II Service Schedules II Service Maint. Maintenance Interval Date Miles M1, M2, and M3 900,000 1 448 000 925,000 1 490 000 950,000 1 529 000 975,000 1 569 000 M1 and M2 1,000,000 1 609 000.

General Information Initial Maintenance (IM) Operations: 00–04 The Initial Maintenance table lists all maintenance tenance operations to be performed. All operations operations that are to be performed at the initial listed in the table, along with the operations listed in maintenance (IM) interval. General Information M1 Maintenance Interval Operations: 00–05 The M1 Maintenance Interval Operations tables list IMPORTANT: After performing all operations listed in all maintenance operations that are to be performed this table, perform all daily, weekly, and monthly at the M1 maintenance interval. Maintenance opera- maintenance operations listed in the 'Pretrip and tion numbers are reference numbers used to help Post-Trip Inspections and Maintenance'.

General Information M2 Maintenance Interval Operations: 00–06 The M2 Maintenance Interval Operations tables list you find detailed instructions in this manual on the all maintenance operations that are to be performed maintenance operations to be performed. Perform all at the M2 maintenance interval. Maintenance opera- M1 maintenance interval operations at the M2 main- tion numbers are reference numbers used to help tenance interval. General Information M2 Maintenance Interval Operations: 00–06 Maintenance M2 Maintenance Interval Operations for Service Schedules I and II Check Operation Number 83–02 Air Filter Replacement For Schedule I vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), whichever comes first. General Information M3 Maintenance Interval Operations: 00–07 The M3 Maintenance Interval Operations table lists you find detailed instructions in this manual on the all maintenance operations that are to be performed maintenance operations to be performed. Perform all at the M3 maintenance interval. Maintenance opera- M1 and M2 maintenance interval operations at the tion numbers are reference numbers used to help M3 maintenance interval.

General Information Maintenance Operation Sets Table: 00–08 Maintenance Operation Sets Maint. Service Schedules I Operation Description and II 09–01 Air Cleaner Inspection. 13–01 Air Compressor Inspection. 15–01 Alternator, Battery, and Starter Check. 20–01 Pressure Relief Cap Check.

General Information Maintenance Operation Sets Table: 00–08 Maintenance Operation Sets Maint. Service Schedules I Operation Description and II 42–02 Bendix Air Dryer Desiccant Replacement. 42–03 Air Dryer Inspection. 42–04 Alcohol Evaporator Cleaning and Inspection. General Information Maintenance Operation Sets Table: 00–08 Maintenance Operation Sets Maint. Service Schedules I Operation Description and II ™ 83–03 ParkSmart Inspection. 88–01 Hood Rear Support Lubrication.

On vehicles equipped with Detroit transmissions, the release bearing does not need to be lubricated. On vehicles equipped with Eaton Fuller UltraShift PLUS transmissions, lubricate the release bearing every 50,000 miles (80 000 km) or 3 months. Maintenance Instructions sure that such parts are warranted by their manufac- turer to be equivalent to genuine Freightliner parts in performance and durability.

Scheduled intervals are in the maintenance tables in this group. A 'Verification of Inspections Log' for Freightliner Noise Emission Groups 20 and 49 follows, and should be filled in. General Information Verification of Inspections Log: 00–10 Verification of Inspections Log Verification of Inspections Log, Group 20 Verification of Inspections Log — Group 20 — Fan Clutch Date Mileage Item Cost Maintenance Facility Verification of Inspections Log, Group 49 Verification of Inspections Log — Group 49 — Exhaust System Components Date Mileage Item. Air Intake Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Inspection. 09–01 Cascadia Maintenance Manual, November 2014. Air Intake 09–01 Air Cleaner Inspection NOTICE Restriction of air flow through the air cleaner element Do not use aftermarket air-cleaner elements.

After- is measured at the tap in the air cleaner outlet. Market air-cleaner elements may not seal the Check the restriction indicator at the air cleaner or in housing correctly, which can lead to engine dam- the cab if the vehicle is equipped with a dash. Air Intake f090453 1.

Forward Mounting 4, Air Cleaner Housing Bracket Aft Mounting Bracket 2. Forward Mounting 7. Aft Mounting Isolator Isolator Fig. 3, Air Cleaner Assembly f090496 1.

Steel Plate 2. 4, Mounting Isolator 09/2 Cascadia Maintenance Manual, November 2014. Air Compressor Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspection.13–01 Safety Precautions. Air Compressor 13–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle can not drop.

Alternators and Starters Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Check. 15–01 Safety Precautions.

Alternators and Starters 15–00 Safety Precautions ™ 54 of the Cascadia Workshop Manual for ad- justment, repair, or replacement instructions. Safety Precautions in this section apply to all Clean and tighten the battery ground cable, terminal, and clamps. Procedures within this group.

Inspect the retainer assembly or battery DANGER hold-downs, and the battery box. Engine Cooling/Radiator Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fan Clutch Check (Noise Emission Control).20–03 Pressure Relief Cap Check. Engine Cooling/Radiator 20–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle can not drop. Engine Cooling/Radiator 4.

Remove the drain plugs at the radiator side tank 10. Connect the hoses. Your hose clamps can be and at the lower radiator outlet pipe elbow, if either T-bolt clamps (see Fig.

3) or Breeze equipped. Engine Cooling/Radiator 08/15/94 f200286 A. The screw tip must extend about 1/4 inch (6 mm). Belleville washers must collapse almost flat.

Tightening Screw Hex Fig. 4, Breeze Constant-Torque Hose Clamp Installation 12. Remove the coolant filter with a strap or chain f200237a 05/27/93 wrench. Engine Cooling/Radiator 1. Disconnect the batteries at the negative termi- nals. Inspect the electrical connections and wires to the fan clutch solenoid; see Fig. Secure the connection if loose; replace wires and connectors if damaged.

Clean the fan clutch air solenoid valve filter, if equipped, as follows. Engine Cooling/Radiator f200581 Fig. 8, Checking for Air Leaks (Horton DriveMaster) 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. Clutch Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch Release Bearing Lubrication. Clutch 25–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle can not drop. Clutch Hydraulic clutch control fluid is hazardous.

It may be a skin irritant and can cause blindness if it gets in your eyes. Always wear safety glasses when handling it or bleeding hydraulic lines. If you get it on your skin, wash it off as soon as possible. NOTICE Do not spill hydraulic clutch control fluid on the cab paint. Clutch Manual Bleeding 3. Remove the reservoir lid (see Fig. 3) and install the pressure bleed adaptor on the reservoir.

Park the vehicle on a level surface, shut down 4. Bleed the hydraulic system as follows. The engine, and set the parking brake.

Chock the Open the bleed valve on the bleed tank tires and open the hood. Clutch 25–04 Clutch Replacement, ™ Detroit Automated Transmissions Replace the clutch assembly for a Detroit Automated transmission at 750,000-mile (1 200 000-km) inter- vals.

Follow the procedure published on the Detroit Diesel Customer Support Network (DDCSN): www.ddcsn.com 25/4 Cascadia Maintenance Manual, August 2015. Transmission Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number ™ Detroit Automated Transmission Air Filter Replacement.26–03 ™.

Transmission 26–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle can not drop. Transmission ™ 26–02 Detroit Automated cation, such as Detroit Synth 75W-90.

Using lubri- cant that does not comply with this specification Transmission Fluid will result in damage to the transmission. The oil part number can be found in module 348 in Level Inspection PartsPro. Transmission ™ 26–03 Detroit Automated Transmission Air Filter Replacement NOTE: The information in this MOP only applies if the vehicle is equipped with a transmission air filter. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. Transmission sion.

Overfilling will force fluid out of the case clockwise motion to separate the filter through the main shaft openings. From the mounting.

Carefully spin the filter off the mount and remove it from the ve- Do not mix types or brands of fluid, because of hicle. Transmission 26–05 Eaton Fuller Eaton Fuller Transmission Lubricant Capacities Transmission Fluid Transmission Model Refill Capacity: qt (L) RTLO Series 14.0 (13.2) Level Inspection 10-Speed Deep Reduction RTO–14908LL NOTICE 14.0 (13.2) RTO–16908LL Operating a transmission with the fluid level 10-Speed Advantage higher or lower than recommended can result in FA Series 8.0 (7.5). Transmission 1. Clean the oil level sight glass. For more information and a complete listing of approved lubricants, refer to the Eaton website, www.roadranger.com.

26–06 Eaton Fuller Manual Transmission Air Filter/ Regulator Check, Cleaning, or Replacement 1. Apply the parking brakes, and chock the rear tires. Transmission 3. Remove the end cap, large O-ring, and filter ele- CAUTION ment from the filter housing.

Remove the small O-ring from the end cap. A leaking air filter or air lines can cause slow or hard shifting of the transmission, and eventual transmission damage. Frame and Frame Components Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fairing Bumper Wear Check.31–04 Fifth Wheel Inspection. Frame and Frame Components 31–00 Safety Precautions 3. Check the fifth wheel plate for cracks. Check for sharp edges on top; the chamfer should be 1/8 to 1/4 inch (3 to 6 mm). Safety Precautions in this section apply to all 4.

Frame and Frame Components 6. Check all cotter pins for cracking or damage. Re- place any cotter pin that shows any signs of damage.

Check all mounting bolts for signs of fatigue, and tighten them to the proper torque. For torque specifications, see Group 00 of the vehicle Workshop Manual. Frame and Frame Components f311134 NOTE: 6000 Series shown; 7000 Series fifth wheels use similar parts. Wedge Stop Rod Nut 11. Bolt, Secondary Safety Lock 19. Flat Washer, 5/8' 12. Flat Washer 20.

Timer Spring 3. Wedge Stop Rod Spring 13. Frame and Frame Components 9. Check all springs to see if they are securely fas- tened, and are not deformed. WARNING Do not disassemble the fifth wheel to inspect the springs.

The springs are under extreme pressure, and could cause serious injury. Frame and Frame Components f311100 1. Grease Zerk 2. Adjustment Bolt Fig. 7, Jost Fifth Wheel Check the locking mechanism for proper operation. If the plungers will not release, check the air cylinder or plunger adjustment.

If the plungers are loose, check the f311099. Frame and Frame Components hardened washers. Do not re-use bolts, nuts, 2.

Inspect the trailer kingpin plate and top surface and washers on fifth wheel mountings. Of the fifth wheel to make sure each is properly greased. A liberal coating of grease should be 11.

Frame and Frame Components Grease #5213, Craftsman Chemical Co. #LTF 2, Mystic LP-200, or equivalent is recommended. Pull Handle 3.

Jaw f311135 Fig. 8, Fontaine Fifth Wheel 1. Release Handle and 3. Yoke Tip Spring 4. Frame and Frame Components 31–03 Frame Fastener Torque vehicle vehicle Workshop Manual for repair or re- placement information.

Check 31–04 Fairing Bumper Wear Frame brackets and components secured with Huck- Check bolt® fasteners do not require a torque check, how- ever, they should be inspected for damage. Frame and Frame Components f311034 Fig.

12, Bumper Location 31/9 Cascadia Maintenance Manual, March 2016. Suspension Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Lubrication of Front Suspensions with Grease Fittings.32–03 Safety Precautions. Workshop Manual. Visible damage (cracks or breaks) to one leaf causes hidden damage to other leaves. Re- Freightliner AirLiner Rear placement of only the visibly damaged part(s) is Suspension Check no assurance that the spring is safe. Suspension as viewed from the side of the vehicle; see Fig.

If any of these conditions exist, replace the ™ damaged parts; see Group 32 of the Cascadia 2. The rod may be on the forward or aft side of Workshop Manual. Suspension for adjustment instructions.

If the distance is tern as shown in Fig. Set a click-type torque within the acceptable range, apply the parking wrench to the mid-point torque value for the fas- brakes. Tener being checked. Turn the wrench in a clock- wise motion (looking up) until the torque wrench clicks, then release pressure on the torque 32–02 Suspension U-Bolt.

Suspension f320961a Suspension Height Measurement Measure Point Target 2-3/8 inch 2-1/2 inch 2-7/8 inch A = Measure Here (60 mm) (64 mm) (73 mm) Table 3, Suspension Ride-Height Measurement, f321046a Single-Leaf Spring, 10k/12k/15k/18k Mid Ride and 40k Low and Mid Ride Suspension Height Measurement Measure Point Target. Suspension 32–03 Lubrication of Front Suspensions with Grease Fittings Wipe all dirt away from the grease fittings (if equipped) on the spring-eye bushings. Apply multi- purpose chassis grease with a pressurized grease gun until the old grease is forced out. F320962a Suspension Height Measurement.

Front Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Check.33–04 Knuckle Pin Lubrication. Front Axle 33–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires.

Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle can not drop. Front Axle 33–03 Tie Rod Lubrication Detroit and Meritor Axles For any Detroit or Meritor axle that requires lubrica- tion of the tie-rod ends, wipe the grease fittings clean, then pump multipurpose chassis grease, NLGI Grade 1 (6% 12-hydroxy lithium stearate grease) or NLGI Grade 2 (8% 12-hydroxy lithium stearate grease), into the tie-rod ends until all used grease is forced out and fresh grease is seen at the ball stud. Front Axle equipment manufacturer. Freightliner dealers must 6. Place a trammel bar at the rear of the front tires; have proof of this calibration history. Locate the trammel pointers at spindle height, and adjust the pointers to line up with the scribe 1.

Front Axle f400100a 08/30/94 Fig. 8, Setting Trammel Bar Pointers 33/4 Cascadia Maintenance Manual, August 2015. Rear Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Axle Breather and Axle Lubricant Level Inspection. 35–02 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning. Rear Axle 35–00 Safety Precautions 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake.

Chock the tires. Safety Precautions in this section apply to all 2. Clean the fill plug and the area around it. In the procedures within this group. Rear Axle Detroit Drive Axle Lubricants CAUTION IMPORTANT: Lubricant used in Detroit rear axles must Be careful when draining the axle oil. It may be meet Mercedes-Benz specification 235.20 (mineral) or very hot, and could cause personal injury if it con- 235.8 (synthetic). Rear Axle 500,000 miles (800 000 km) for axles using syn- On tandem drive axles, it is also necessary to remove the plug at the bottom of the interaxle thetic lubricant with a pump and filter system.

Repair

Differential housing to drain that lubricant. On single drive axles so equipped, the traction equal- 3. Rear Axle to short the two magnetic poles and divert Meritor Drive Axle Lubricant Capacities the magnetic field. Axle Model Capacity: pt (L) Check the drain plug for metal particles Forward 39.1 (18.5) every 100,000 miles (160 000 km). Clean RT–46–160, RT–46–160P Rear 34.4 (16.3).

Rear Axle Wash the strainer in solvent, and blow it dry with compressed air to remove oil and metal particles. Install and tighten the magnetic strainer 40 to 60 lbfft (54 to 81 Nm). Clean the fill and drain plugs.

Change them if necessary. Rear Axle Dana Spicer Drive Axle Lubricant Capacities Capacity: Axle Type Axle Model Pints (liters) 23080S, 23080D 40 (18.9) Single Reduction 23105S, 23105D 48 (22.7) Tandem Drive Axle Installation † DD404, DD404–P 31 (14.7) Single † DS404, DS404–P 39 (18.5) Reduction †.

Rear Axle 35–02 Axle Breather and Axle of the fill plug, using the lubricant recommended Table Lubricant Level IMPORTANT: A lubricant level close enough to Inspection be seen or touched is not sufficient. It must be level with the bottom of the fill hole. For all axles, including tandem drive axles and two- 5. Rear Axle leaks, and correct as needed.

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Add oil to the level Dana® Spicer® of the fill plug, using the lubricant recommended Table NOTICE 4. Install and tighten the fill plug 35 lbfft (47 Nm). Failure to keep the rear axle filled to the proper IMPORTANT: Always check the axle breather level with the recommended lubricant can result in whenever checking the lubricant level.

Rear Axle Automatic transmission fluid can be used for all 5. Install and tighten the fill plug 40 to 60 lbfft (54 to 81 Nm). Temperatures; do not mix it with kerosene. IMPORTANT: Always check the axle breather 3. Coat the threads of the fill plug with a small whenever checking the lubricant level. Wheels and Tires Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Tire Check. 40–02 Wheel Nut Check.

Wheels and Tires 40–01 Wheel Nut Check 40–02 Tire Check Tires should be inspected closely during the first IMPORTANT: After a wheel has been installed, 3000 to 10,000 miles (5000 to 16 000 km) for abnor- the wheel nut torque must be rechecked after mal wear. Driveline Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspection.41–01 Driveline Lubrication.

Driveline 41–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle can not drop.

Driveline 05/01/95 f410067b NOTE: Not all fasteners are shown. Transmission 6. U-Joint Cross 12. Splined Stub Shaft 2. Transmission Output-Shaft 7.

Bearing Cup (for yoke strap) 13. Driveshaft Tube End-Yoke (yoke-strap type) 8. Yoke Strap and Capscrew 14. Tube-Yoke (bearing-cap type) 3. Driveline 05/27/93 f410012a Attempt to move the sleeve-yoke and splined shaft back and forth. 4, Slip Joint Spline Wear Checking evidence that balance weights are missing, re- move the driveshaft and have it balanced. For driveshafts with slip joints, check to be sure the yoke plug is not loose or missing.

Driveline screws to the correct torque specifications. If the bearing will not take grease, replace the U-joint. Refer to Group 41 of the vehicle Workshop Manual for replacement instructions. Check the purged grease. If it appears rusty, gritty, or burned, replace the U-joint. Brakes Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Brake System Valve Inspection.

42–01 Air Dryer Inspection. Brakes 42–00 Safety Precautions NOTE: The compressor discharge line may still contain residual air pressure, open the line slowly. Safety Precautions in this section apply to all procedures within this group. Identify, tag, and disconnect the three air lines from the end cover. Brakes 08/09/95 f421383 1. 5/16 x 4-1/2 Upper Mounting 9. Desiccant Cartridge 18.

Purge Valve Bracket Bolt 10. 1/4-Inch Tapping Screw 2.

Upper Mounting Bracket Strap 11. Safety Valve 20. Purge Valve Housing 3. Lockwasher 12.

Lower Mounting Bracket 21. Brakes WARNING Do not attempt to disassemble the desiccant car- tridge assembly. Parts for the assembly are not available and the cartridge contains a 150 lb spring that cannot be mechanically caged. Disas- sembly could release the spring, resulting in per- sonal injury.

Brakes IMPORTANT: Only use the silicone grease sup- 12.3 Fan the service brakes to reduce system air pressure to governor cut-in. Note that plied with Bendix replacement kits. The system once again builds to full pres- 5. Screw the desiccant cartridge onto the body by sure and is followed by a purge at the hand until the seal makes contact with the body. Brakes Group 42 of the vehicle Workshop Manual for 9. Remove the heater/thermostat assembly and mounting instructions.

Place it in a freezer for about five minutes to cool it below 40°F (5°C). Remove the cold 4. Turn on the ignition switch, but do not start the heater/thermostat assembly and check resis- engine. Install the reservoir on the cover and tighten the WARNING capscrews. Fill the reservoir with 40 ounces (1183 mL) of Manually adjusting an automatic slack adjuster to methyl alcohol, then install the filler cap. Bring the pushrod stroke within legal limits is likely masking a mechanical problem. Brakes Brake Chamber Stroke Specifications Chamber Max Applied Stroke: inch (mm) † Manufacturer Type Size Gunite Standard Stroke 1-3/8 (35) 1-3/4 (44) 2 (51) ‡ 2-1/4 (57) Long Stroke 2 (51) 24 (2-1/2 inch rated stroke) 24 (3 inch rated 2-1/2 (64) stroke) Haldex.

Brakes Brake Chamber Stroke Specifications Chamber Max Applied Stroke: inch (mm) † Manufacturer Type Size Dana Spicer Long Stroke 2 (51) 24LS 2-1/2 (64) 30LS Long stroke design is indicated by a tag, or embossing, on the brake chamber. † Specifications are relative to a brake application with 80 to 90 psi (550 to 620 kPa) air pressure in the brake chambers.

Brakes NOTE: If equipped with an extended- 42–08 Meritor Slack Adjuster maintenance Q Plus ™ brake system, the cam- Lubrication shaft bracket will not have a grease fitting. These camshafts use a special NLGI Grade IMPORTANT: Perform a brake inspection follow- synthetic polyurea grease and do not require ing the instructions in this group before lubricat- lubrication for 3 years or 500,000 miles (800. Check the brake pedal mounting plate adapter for signs of wear or cracks at the bosses (the area from which the pivot pin was removed). Re- place it if necessary.

Check the brake pedal rollers for signs of wear or cracks. Brakes 42–11 Versajust Slack Adjuster this may result in contamination and malfunction- ing of downstream air system components.

Inspection and Refer to Fig. 9 for cartridge replacement. Lubrication 1.

Drain the air system. IMPORTANT: Perform the Brake Inspection maintenance operation before lubricating the slack adjusters.

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Brakes Actuator Stroke–Standard Stroke Recommended Maximum Brake Actuator Size Operating Stroke (Inches) 1-3/4 1-3/4 1-3/8 Table 2, Actuator Stroke–Standard Stroke Actuator Stroke–Long Stroke Recommended Maximum Brake Actuator Size Operating Stroke (Inches) 30 Long Stroke 2-1/2 24 Long 24 Long Stroke 2-1/2 20 Long 16 Long. Steering Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Bellows Replacement, Rack and Pinion Steering Gear.46–07 Drag Link Inspection. Steering 46–00 Safety Precautions tions. If there is 1/8-inch (3-mm) movement or more, do not drive the vehicle until the drag link is replaced.

Safety Precautions in this section apply to all procedures within this group. 46–02 Power Steering Fluid DANGER and Filter Changing When working on the vehicle, shut down the en. Steering 46–03 Power Steering Fluid the drain pan. Leave the filter hanging over the drain pan. Level Inspection 5. Remove the nuts, bolts, and washers that attach the power steering reservoir to the mounting 1. Park the vehicle on a level surface, shut down bracket, but do not remove the supply line to the the engine, and set the parking brake.

Steering Inspect the rack and pinion steering system as de- scribed below, and repair or replace any components that are worn or damaged. Figure 4 shows the com- ponents of the rack and pinion steering system. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Steering f462151 1. Steering Tie Rod Arm 10. Input Shaft Seal Cover 17. I-shaft Slip Joint 2.

Power Steering Fluid Lines 11. I-shaft Upper Yoke 18. Transfer Lines 3. Large Bellows Clamp 12. I-shaft Lower Yoke Boot Clamp 19. Rack and Pinion Gear 4. Steering 46–07 Bellows Replacement, the teeth of the rack shaft.

Do not apply grease to the shaft on the passenger side. Rack and Pinion 10. Turn the wheels all the way to the right to fully Steering Gear expose the driver-side rack. Without applying grease to the teeth of the rack shaft, evenly 1. Steering 14.1 Rotate the ears of the large Oetiker clamp forward on the bellows to avoid pinching the clamp in the next step.

14.2 Ensure the large Oetiker clamp is prop- erly seated in the clamp groove on the bellows. Align the large Oetiker clamp ear with the small clamp ear. Steering f580473 Fig. 8, Oetiker Clamp Tool, P/N 14100037 or 14100082 f462172 A.

Crimp the clamp ears until the ear width is 0.08 to 0.16 inch (2 to 4 mm). Large Oetiker Clamp Fig. 10, Oetiker Clamp Ear Width NOTE: Use a calibrated, computerized, f462165. Steering NOTICE Maximum wheel cut is not to exceed 46 degrees. Excessive wheel cut may damage the inner tie rod.

20.10 Verify that wheel cut does not exceed 46 degrees. Adjust wheel cut if needed. Install both wheels on the steer axle. Fuel Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number CNG Fuel Cylinder Inspecting.47–08 CNG Fuel System Inspecting. Fuel 47–00 Safety Precautions 2. Disconnect the water sensor and heater connec- tions if equipped. Safety Precautions in this section apply to all 3.

Remove the element and bowl together, by turn- ing counterclockwise. Procedures within this group. Remove the bowl from the element and clean DANGER the O-ring land. Fuel The drain valve has a 1/2-inch (12.7-mm) pipe; use a hose with a 1/2-inch pipe thread to fit cor- rectly. Remove the vent cap ( Fig. 2, Item 4) and open the drain valve ( Fig.

2, Item 1) to drain the fuel completely, then close the drain valve. Fuel to be hand-tightened only, not tightened with a wrench. Use part number 482017 on Fuel Pro 482 units; part number 380134 on Fuel Pro 382 units.

Remove the filter, cover O-ring, and vent cap O-ring. Dispose of them in an environmentally acceptable manner. Fuel cooled. Draining it when the engine is hot could cause severe personal injury due to scalding. If returning fuel is released into the atmosphere, its vapors can ignite in the presence of any igni- tion source. Do not expose the fuel to, or work with the fuel system near, open flame or intense heat.

Start the engine. When the lubricating oil taminants into the threads of the fittings and dam- reaches its normal operating pressure, increase age the sealants. Engine speed to high idle for one to two minutes Gas detection sensors are located on the cab to purge air from the system. Fuel f470617 1. Pressure Control Regulator 7. Primary Relief Valve 2. Vapor Shutoff Valve 8.

Tank Pressure Gauge 3. Fuel Fill Hose 9. Fill Vent Fitting 4. Secondary Relief Valve (red cap) 10. Excess Flow Valve 5.

Fuel Fill Fitting 11. Fuel 47–05 LNG Vacuum Integrity 3. Inspect all connectors and wiring for signs of loose connections, damage, or chafing.

Turn the ignition switch to the ON position and check for fuel gauge response. Repair or replace any damaged fuel gauge components. Fuel Vacuum Integrity Test Results Pressure Increase Over Eight- Remedy Hour Period Remove vehicle from service and evacuate the tank per the tank manufacturer’s More than 50 psi (345 kPa) instructions Table 1, Vacuum Integrity Test Results 47–06 CNG Fuel System Harsh chemicals and extremely high temperatures may damage the sensor.

Fuel 47–08 CNG Fuel Cylinder Inspecting Have a qualified inspector inspect compressed natu- ral gas (CNG) fuel cylinders for damage or deteriora- tion. Note cuts, cracks, gouges, abrasions, discolor- ation, broken fibers, loose brackets, damaged gaskets or isolators, heat damage, or other prob- lems. Fuel f470619 1. CNG Fuel Cylinder, Frame Rail Mounted 4.

Mounting Bracket 2. Top Plate Bolts (qty 6 per side) 5. Gussett Bolts (qty 2 per side) 3. Frame Rail 6. Bracket to Frame Nuts and Bolts (qty 8 per side) Fig. Fuel CYLINDERS INSPECT CYLINDERS EVERY 36 MONTHS OR 36000 MILES WHICHEVER OCCURS FIRST REGULATOR INSPECT PRESSURE NATURAL RELIEF DEVICE EVERY 2000 MILES VEHICLE 110 PSIG OPEN VALVE FILTER SLOWLY DRAIN HOUSING EVERY 1500 MILES 3600 PSIG MAX. REPLACE ELEMENT SERVICE PRESSURE EVERY 3000 MILES f470556.

Exhaust Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number CAT CGI Bellows Replacement.49–02 Exhaust System Inspection (Noise Emission Control). Group 49 of the Cascadia ™ Workshop Manual, Inspection or take the vehicle to an authorized Freightliner To meet EPA10 emissions regulations for vehicles dealer.

Domiciled in the USA or Canada, engines manufac- It is a violation of US federal law to alter exhaust. Check for leakage at the clamp that attaches the 11. Check any wires, lines, or hoses within 4 inches exhaust pipe to the turbocharger exhaust outlet. (10 cm) of the exhaust system for heat damage.

If leakage exists, tighten the nut on the clamp to Repair or reroute as needed. Exhaust f490355 NOTE: The sensor box (item 8) contains the SCR inlet and outlet NOx sensors, DPF outlet pressure sensor, and the DOC inlet pressure sensor. DOC Outlet Temperature 6. Exhaust Outlet 11. SCR Outlet NOx Sensor Port Sensor 7.

Exhaust f490353 1. DEF Metering Unit 5. DOC Inlet Temperature Sensor 9. DPF Outlet Temperature 2. DEF Nozzle 6.

DOC Inlet Pressure Sensor Sensor 3. SCR Outlet Temperature 7. DPF Inlet Temperature Sensor 10. DPF Outlet NOx Sensor Sensor 8.

Exhaust f490354 1. DPF Inlet Temperature Sensor 6. DPF Outlet Temperature 9. SCR Outlet Temperature 2.

DOC Inlet Temperature Sensor Sensor Sensor 3. DOC Inlet Pressure Sensor 7. DPF Outlet NOx Sensor 10. SCR Sensor Box 4. DPF Sensor Box 8.

Exhaust f490283 A. Inspect this area of the canister for dents. 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. Exhaust 06/01/93 f490024a 05/28/93 f490025a 1. Turbocharger Exhaust Fig.

8, Donaldson Sealclamp Wide-Band Exhaust 2. V-Band Coupling Outlet Clamp 3. Exhaust Pipe Fig. 6, V-Band Coupling and Flex Hose NOTICE A leak in the CGI piping, including the bellows, will allow unfiltered air and contaminants into the engine intake, and can cause serious engine damage. Using a yellow paint pen, mark the pipes 1.5 NOTICE inches (38 mm) in from the end of each pipe. These two marks will be used to center the bel- When the CGI pipes and bellows are installed, lows between the two pipes. Exhaust 13.

Install the slip clamp with the retaining ring and graphite gasket ring onto the forward CGI pipe. 12 for proper installation. CGI Bellows 4. Graphite Gasket 2. Slip Clamp 5.

Forward CGI Pipe 3. Retaining Ring Fig. Electrical, Instruments, and Controls Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Trailer Cable Inspection and Cleaning. 54–01 Cascadia Maintenance Manual, August 2007.

Electrical, Instruments, and Controls 54–01 Trailer Cable Inspection and Cleaning 1. Disconnect the trailer electrical cables from the sockets at the cab.

Inspect the cables and sockets for evidence of corrosion, and clean as necessary. If a socket is too badly corroded to clean, replace it. Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Aerodynamic Component Inspection. 60–03 Baggage Door and Sleeper Access Door Release Cable and Latch Lubrication.

60–01 Mirror Folding Check For vehicles with folding main mirrors, make sure that the mirrors fold freely on the pivot points. Pivot each mirror fully forward and backward two times to break loose any debris that may affect the fold-away feature of the mirror. f720661a 1. Sleeper Access Door Handle 2. Baggage Door Handle 3.

Cab Door Frame, Driver Side Fig. 2, Baggage Door and Sleeper Access Door Release Handles sleeper access door, if equipped. Removal of trim panels is not required. F602471 NOTE: Removal of trim panels is not required. Heater and Air Conditioner Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspection.83–01 Air Filter Replacement. Heater and Air Conditioner 83–00 Safety Precautions quires adjustment, see Group 83 of the Casca- ™ Workshop Manual.

Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Both will point toward the cab. IMPORTANT: When replacing the air filter, use only a Freightliner-approved air filter. Park the vehicle on a level surface, set the park- ing brake, and shut down the engine.

Chock the tires. Heater and Air Conditioner f831718 1. Kick Panel 3. Step Plate f831719 2. Side Trim Panel 4. 6, Panels Fig.

5, Cab Recirculation Air Filter (shown out of the vehicle for clarity) 2. Loosen the passenger-side kick panel, tilt it out, and carefully twist and remove the light bulb socket from the lens on the back of the panel. IMPORTANT: When replacing the air filter, use only a Freightliner-approved air filter.

Park the vehicle on a level surface, set the park- ing brake, and shut down the engine. Chock the tires. Heater and Air Conditioner f831900 1. Bunk Frame Upper 2. Filter Surface Fig.

11, Removing the Filter, 48-inch Sleeper 1. Park the vehicle on a level surface, set the park- f831858 ing brake, and shut down the engine. Heater and Air Conditioner 1. Remove the inspection plate on the bottom of the condenser module.

F831857 Remove and clean the drain tube. Drain Tube 2. Intake Duct f831879 Fig.

13, Drain Tube Inspection (pre-July 2011) Remove the inspection plate. Hood, Grille, and Cab Fenders Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Hood Rear Support Lubrication.88–01 Cascadia Maintenance Manual, November 2014. Hood, Grille, and Cab Fenders 88–01 Hood Rear Support Lubrication 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. Open the hood.

Clean both the hood- and cab-mounted hood rear support components with a soapy water so- lution.