Freightliner CA113SLP, CA113DC Maintenance Manual
CASCADIA
®
Part Number STI 478
Publication Number STI-478-6
Maintenance Manual
CASCADIA MAINTENANCE MANUAL
Models: CA113DC
CA113SLP
CA125DC
CA125SLP
STI-478-6 (3/16)
Published by
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.
Foreword
Scheduled maintenance provides a key element for the safe operation of your vehicle. A proper maintenance
program also helps to minimize downtime and to safeguard warranties. This maintenance manual provides
information necessary for years of safe, reliable, and cost-efficient vehicle operation.
IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also refer to other
component and body manufacturers’ instructions for specific inspection and maintenance instructions.
Perform the operations in this maintenance manual at scheduled intervals. Perform the pretrip inspection and
daily/weekly/monthly maintenance, as outlined in the vehicle driver’s manual. Major components, such as
engines, transmissions, and rear axles, are covered in their own maintenance and operation manuals, that are
provided with the vehicle. Perform any maintenance operations listed at the intervals scheduled in those
manuals. Your Freightliner Dealership has the qualified technicians and equipment to perform this maintenance for you. They can also set up a scheduled maintenance program tailored specifically to your needs.
Optionally, they can assist you in learning how to perform these maintenance procedures.
IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing.
Freightliner Trucks reserves the right to discontinue models and to change specifications or design
at any time without notice and without incurring obligation. Descriptions and specifications contained
in this publication provide no warranty, expressed or implied, and are subject to revision and editions
without notice.
Refer to www.Daimler-TrucksNorthAmerica.com and www.FreightlinerTrucks.com for more information,
or contact Daimler Trucks North America LLC at the address below.
Environmental Concerns and Recommendations
Whenever you see instructions in this manual to discard materials, you should attempt to reclaim and recycle
them. To preserve our environment, follow appropriate environmental rules and regulations when disposing of
materials.
NOTICE: Parts Replacement Considerations
Do not replace suspension, axle, or steering parts (such as springs, wheels, hubs, and steering gears) with
used parts. Used parts may have been subjected to collisions or improper use and have undetected structural
damage.
© 2007–2016 Daimler Trucks North America LLC
All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a
retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or
otherwise, without the prior written permission of Daimler Trucks North America LLC. Daimler Trucks North
America is a Daimler company.
Daimler Trucks North America LLC
Service Systems and Documentation (CVI-SSD)
P.O. Box 3849
Portland, OR 97208–3849
Daimler Trucks North America LLC distributes the following major service publications in paper and electronic
(via ServicePro®) formats.
Workshop/Service
Manual
Workshop/service manuals contain service and repair information for all vehicle
systems and components, except for major components such as engines, transmissions, and rear axles. Each workshop/service manual section is divided into
subjects that can include general information, principles of operation, removal,
disassembly, assembly, installation, and specifications.
Maintenance Manual 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, specifications, and procedures for adjustments and for checking the tightness of fasteners. Maintenance manuals do not contain detailed repair or service information.
Troubleshooting Manual Troubleshooting manuals contain diagnostic procedures for determining causes
of problems in vehicle components and systems. Information on multiplexing
diagnosis is included. These manuals are organized by functional systems,
such as cab, chassis, and powertrain. Troubleshooting manuals do not contain
repair or service information.
Driver’s/Operator’s
Manual
Driver’s/operator’s manuals contain information needed to enhance the driver’s
understanding of how to operate and care for the vehicle and its components.
Each manual contains a chapter that covers pre-trip and post-trip inspections,
and daily, weekly, and monthly maintenance of vehicle components.
Driver’s/operator’s manuals do not contain detailed repair or service information.
Service Bulletins Service bulletins provide the latest service tips, field repairs, product improve-
ments, and related information. Some service bulletins are updates to information in the workshop/service manual. These bulletins take precedence over
workshop/service manual information, until the latter is updated; at that time, the
bulletin is usually canceled. The service bulletins manual is available only to
dealers. When doing service work on a vehicle system or part, check for a valid
service bulletin for the latest information on the subject.
IMPORTANT: Before using a particular service bulletin, check the current
service bulletin validity list to be sure the bulletin is valid.
Parts Technical Bulletins Parts technical bulletins provide information on parts. These bulletins contain
lists of parts and BOMs needed to do replacement and upgrade procedures.
Web-based repair, service, and parts documentation can be accessed using the following applications on the
AccessFreightliner.com website.
ServicePro ServicePro® provides Web-based access to the most up-to-date versions of the
publications listed above. In addition, the Service Solutions feature provides diagnostic assistance with Symptoms Search, by connecting to a large knowledge
base gathered from technicians and service personnel. Search results for both
documents and service solutions can be narrowed by initially entering vehicle
identification data.
PartsPro PartsPro® is an electronic parts catalog system, showing the specified vehicle’s
build record.
Introduction
Descriptions of Service Publications
Cascadia Maintenance Manual, May 2011 I–1
EZWiring EZWiring™makes Freightliner, Sterling, Western Star, Thomas Built Buses, and
Freightliner Custom Chassis Corporation products’ wiring drawings and floating
pin lists available online for viewing and printing. EZWiring can also be accessed from within PartsPro.
Warranty-related service information available on the AccessFreightliner.com website includes the following
documentation.
Recall Campaigns Recall campaigns cover situations that involve service work or replacement of
parts in connection with a recall notice. These campaigns pertain to matters of
vehicle safety. All recall campaigns are distributed to dealers; customers receive
notices that apply to their vehicles.
Field Service Campaigns Field service campaigns are concerned with non-safety-related service work or
replacement of parts. All field service campaigns are distributed to dealers; customers receive notices that apply to their vehicles.
Introduction
Descriptions of Service Publications
I–2 Cascadia Maintenance Manual, May 2011
For an example of a Maintenance Manual page, see Fig. 1.
f020166
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41
CascadiaTMMaintenance Manual, July 2007
41/1
Driveline
1.
Self−Locking
A
06/11/2007
A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number
B. Group Title
C. Group Number
D. Vehicle Name
E. Release Date
F. Group Number/Page Number
Fig. 1, Example of a Maintenance Manual Page
Introduction
Page Description
Cascadia Maintenance Manual, May 2011 I–3
Group No. Group Title
00...................... General Information
09.............................. AirIntake
13 ......................... AirCompressor
15................... Alternators and Starters
20................... Engine Cooling/Radiator
25................................ Clutch
26........................... Transmission
31 ............. Frame and Frame Components
32............................ Suspension
33 ............................. Front Axle
35 ............................. Rear Axle
40........................ Wheels and Tires
41 .............................. Driveline
42................................ Brakes
46............................... Steering
47 ................................. Fuel
49............................... Exhaust
54.......... Electrical, Instruments, and Controls
60 .................................. Cab
83................. Heater and Air Conditioner
88.............. Hood, Grille, and Cab Fenders
Introduction
Maintenance Manual Contents
I–4 Cascadia Maintenance Manual, May 2011
Title of Maintenance Operation (MOP) MOP Number
Determining Scheduled Maintenance Intervals.............................................00–01
Initial Maintenance (IM) Operations.....................................................00–04
M1 Maintenance Interval Operations....................................................00–05
M2 Maintenance Interval Operations....................................................00–06
M3 Maintenance Interval Operations....................................................00–07
Maintenance Operation Sets Table ..................................................... 00–08
Noise Emission Controls Maintenance...................................................00–09
Service Schedule Table ............................................................. 00–02
Vehicle Maintenance Schedule Table ................................................... 00–03
Verification of Inspections Log.........................................................00–10
General Information 00
Index, Alphabetical
Cascadia Maintenance Manual, August 2015
Determining Scheduled
Maintenance Intervals
Performing regular maintenance on your Freightliner
vehicle will help ensure that your vehicle delivers
safe reliable service and optimum performance for
years to come. Failure to follow a regular maintenance program can result in inefficient operation and
unscheduled down time.
To determine the correct maintenance intervals for
your vehicle you must first determine the type of service or conditions the vehicle will be operating in.
Generally, over-the-road vehicles operate under conditions that fall within one of the two types of service
described. Before placing your new vehicle in service, determine the type of service (Service Schedule
I or II) that applies to the intended use of the vehicle.
After determining the vehicle’s type of service, refer
to the service schedule table or the vehicle maintenance schedule table, to determine how often maintenance should be performed.
When the vehicle reaches the distance given for a
maintenance interval, see the Maintenance Interval
Operation Table for a list of the maintenance operations to be performed at that maintenance interval.
Use the maintenance operation reference numbers to
find detailed instructions in the manual on each operation.
Types of Service
Service Schedule I (short-haul transport) applies to
vehicles that annually travel less than 60,000 miles
(100 000 kilometers) and operate under normal conditions. Examples of Schedule I usage are: operation
primarily in cities and densely populated areas; local
transport with infrequent freeway travel; or high percentage of stop-and-go travel.
Service Schedule II (long-haul transport) is for vehicles that annually travel more than 60,000 miles
(100 000 kilometers) with minimal city or stop-and-go
operation. Examples of Schedule II usage are: regional delivery that is mostly freeway miles; interstate
transport; or any road operation with high annual
mileage.
NOTE: Maintenance instructions in this manual
are based on average vehicle use and normal
operating conditions. Unusual vehicle operating
conditions may require service at more frequent
intervals.
General Information 00
Determining Scheduled Maintenance Intervals: 00–01
Cascadia Maintenance Manual, August 2015 00/1
Service Schedule Maintenance Interval Operation
Maintenance Interval
Frequency Miles km
Schedule I
(Short-Haul Transport)
vehicles that annually travel less than 60,000
miles (100 000 km)
Initial Maintenance (IM) first 10,000 16 000
Maintenance 1 (M1) every 10,000 16 000
Maintenance 2 (M2) every 50,000 80 000
Maintenance 3 (M3) every 150,000 240 000
Schedule II
(Long-Haul Transport)
vehicles that annually travel over 60,000
miles (100 000 km)
Initial Maintenance (IM) first 25,000 40 000
Maintenance 1 (M1) every 25,000 40 000
Maintenance 2 (M2) every 100,000 161 000
Maintenance 3 (M3) every 300,000 483 000
Table 1, Service Schedule
General Information00
Service Schedule Table: 00–02
Cascadia Maintenance Manual, August 201500/2
Maintenance for Service Schedule I
Maint. No.
Maintenance
Interval
Service
Date
Service Schedule I
Miles km
1st IM and M1 10,000 16 000
2nd M1 20,000 32 000
3rd M1 30,000 48 000
4th M1 40,000 64 000
5th M1 and M2 50,000 80 000
6th M1 60,000 96 000
7th M1 70,000 112 000
8th M1 80,000 128 000
9th M1 90,000 144 000
10th M1 and M2 100,000 160 000
11th M1 110,000 176 000
12th M1 120,000 192 000
13th M1 130,000 208 000
14th M1 140,000 224 000
15th M1, M2, and M3 150,000 240 000
16th M1 160,000 256 000
17th M1 170,000 272 000
18th M1 180,000 288 000
19th M1 190,000 304 000
20th M1 and M2 200,000 320 000
21st M1 210,000 336 000
22nd M1 220,000 352 000
23rd M1 230,000 368 000
24th M1 240,000 384 000
25th M1 and M2 250,000 400 000
26th M1 260,000 416 000
27th M1 270,000 432 000
28th M1 280,000 448 000
29th M1 290,000 464 000
30th M1, M2, and M3 300,000 480 000
31st M1 310,000 496 000
32nd M1 320,000 512 000
33rd M1 330,000 528 000
34th M1 340,000 544 000
35th M1 and M2 350,000 560 000
General Information 00
Vehicle Maintenance Schedule Table: 00–03
Cascadia Maintenance Manual, August 2015 00/3
Maintenance for Service Schedule I
Maint. No.
Maintenance
Interval
Service
Date
Service Schedule I
Miles km
36th M1 360,000 576 000
37th M1 370,000 592 000
38th M1 380,000 608 000
39th M1 390,000 624 000
40th M1 and M2 400,000 640 000
41st M1 410,000 656 000
42nd M1 420,000 672 000
43rd M1 430,000 688 000
44th M1 440,000 704 000
45th M1, M2, and M3 450,000 720 000
46th M1 460,000 736 000
47th M1 470,000 752 000
48th M1 480,000 768 000
49th M1 490,000 784 000
50th M1 and M2 500,000 800 000
51st M1 510,000 820 000
52nd M1 520,000 837 000
53rd M1 530,000 853 000
54th M1 540,000 869 000
55th M1 and M2 550,000 885 000
56th M1 560,000 901 000
57th M1 570,000 917 000
58th M1 580,000 933 000
59th M1 590,000 949 000
60th M1, M2, and M3 600,000 965 000
61st M1 610,000 982 000
62nd M1 620,000 998 000
63rd M1 630,000 1 014 000
64th M1 640,000 1 030 000
65th M1 and M2 650,000 1 046 000
66th M1 660,000 1 062 000
67th M1 670,000 1 078 000
68th M1 680,000 1 094 000
69th M1 690,000 1 110 000
70th M1 and M2 700,000 1 127 000
General Information00
Vehicle Maintenance Schedule Table: 00–03
Cascadia Maintenance Manual, August 201500/4
Maintenance for Service Schedule I
Maint. No.
Maintenance
Interval
Service
Date
Service Schedule I
Miles km
71st M1 710,000 1 143 000
72nd M1 720,000 1 159 000
73rd M1 730,000 1 175 000
74th M1 740,000 1 191 000
75th M1, M2, and M3 750,000 1 207 000
76th M1 760,000 1 223 000
77th M1 770,000 1 239 000
78th M1 780,000 1 255 000
79th M1 790,000 1 271 000
80th M1 and M2 800,000 1 287 000
81st M1 810,000 1 304 000
82nd M1 820,000 1 320 000
83rd M1 830,000 1 340 000
84th M1 840,000 1 352 000
85th M1 and M2 850,000 1 370 000
86th M1 860,000 1 384 000
87th M1 870,000 1 400 000
88th M1 880,000 1 416 000
89th M1 890,000 1 432 000
90th M1, M2, and M3 900,000 1 448 000
91st M1 910,000 1 465 000
92nd M1 920,000 1 481 000
93rd M1 930,000 1 500 000
94th M1 940,000 1 513 000
95th M1 and M2 950,000 1 530 000
96th M1 960,000 1 550 000
97th M1 970,000 1 561 000
98th M1 980,000 1 577 000
99th M1 990,000 1 593 000
100th M1 and M2 1,000,000 1 609 000
Table 2, Maintenance for Service Schedule I
General Information 00
Vehicle Maintenance Schedule Table: 00–03
Cascadia Maintenance Manual, August 2015 00/5
Maintenance for Service Schedule II
Maint. No. Maintenance Interval
Service
Date
Service Schedules II
Miles km
1 IM and M1 25,000 40 000
2 M1 50,000 80 000
3 M1 75,000 121 000
4 M1 and M2 100,000 161 000
5 M1 125,000 201 000
6 M1 150,000 241 000
7 M1 175,000 281 000
8 M1 and M2 200,000 322 000
9 M1 225,000 362 000
10 M1 250,000 402 000
11 M1 275,000 443 000
12 M1, M2, and M3 300,000 483 000
13 M1 325,000 523 000
14 M1 350,000 563 000
15 M1 375,000 604 000
16 M1 and M2 400,000 644 000
17 M1 425,000 684 000
18 M1 450,000 724 000
19 M1 475,000 764 000
20 M1 and M2 500,000 805 000
21 M1 525,000 845 000
22 M1 550,000 885 000
23 M1 575,000 925 000
24 M1, M2, and M3 600,000 966 000
25 M1 625,000 1 005 800
26 M1 650,000 1 046 000
27 M1 675,000 1 086 000
28 M1 and M2 700,000 1 127 000
29 M1 725,000 1 167 000
30 M1 750,000 1 207 000
31 M1 775,000 1 248 000
32 M1 and M2 800,000 1 287 000
33 M1 825,000 1 328 000
34 M1 850,000 1 368 000
35 M1 875,000 1 408 000
General Information00
Vehicle Maintenance Schedule Table: 00–03
Cascadia Maintenance Manual, August 201500/6
Maintenance for Service Schedule II
Maint. No. Maintenance Interval
Service
Date
Service Schedules II
Miles km
36 M1, M2, and M3 900,000 1 448 000
37 M1 925,000 1 490 000
38 M1 950,000 1 529 000
39 M1 975,000 1 569 000
40 M1 and M2 1,000,000 1 609 000
Table 3, Maintenance for Service Schedule II
General Information 00
Vehicle Maintenance Schedule Table: 00–03
Cascadia Maintenance Manual, August 2015 00/7
The Initial Maintenance table lists all maintenance
operations that are to be performed at the initial
maintenance (IM) interval. Maintenance operation
numbers are reference numbers used to help you
find detailed instructions in this manual on the main-
tenance operations to be performed. All operations
listed in the table, along with the operations listed in
the applicable M1 maintenance interval table, must
be performed to complete the initial maintenance
(IM).
Maintenance
Operation Number
Initial Maintenance (IM) Operations for Service Schedules I and II Check
00–05 Perform all M1 Operations
31–03 Frame Fastener Torque Check
32–02 Suspension U-Bolt Torque Check
33–04 All-Axle Alignment Check
47–03 Fuel Tank Band-Nut Tightening
Table 4, Initial Maintenance (IM) Operations for Service Schedules I and II
General Information00
Initial Maintenance (IM) Operations: 00–04
Cascadia Maintenance Manual, August 201500/8
The M1 Maintenance Interval Operations tables list
all maintenance operations that are to be performed
at the M1 maintenance interval. Maintenance operation numbers are reference numbers used to help
you find detailed instructions in this manual on the
maintenance operations to be performed.
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 Cascadia
™
Driver’s Manual.
Maintenance
Operation Number
M1 Maintenance Interval Operations for Service Schedules I and II Check
13–01 Air Compressor Inspection
25–01 Clutch Release Bearing Lubrication
*
31–01 Fifth Wheel Inspection
31–02 Fifth Wheel Lubrication
32–03 Lubrication of Front Suspensions with Grease Fittings
40–01 Wheel Nut Check
40–02 Tire Check
41–01 Driveline Inspection
41–02 Driveline Lubrication
42–02 Bendix Air Dryer Desiccant Replacement (with an oil-coalescing desiccant cartridge)
†
42–05 Brake Inspection
42–06 Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication
42–07 Meritor Camshaft Bracket Lubrication
42–10 WABCO System Saver Air Dryer Desiccant Cartridge Replacement
42–11 Versajust Slack Adjuster Inspection and Lubrication
‡
47–04 LNG Fuel System Inspecting
47–06 CNG Fuel System Inspecting
47–07 CNG High-Pressure Fuel Filter Element Replacing
§
49–01 Exhaust System Inspection (noise emission control)
60–02 Cab Shock Absorber Bracket Torque Check
60–03 Aerodynamic Component Inspection
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.
†
If equipped with an oil-coalescing desiccant cartridge, replace the cartridge once a year, regardless of mileage. Otherwise use the M3 maintenance interval.
‡
Complete this procedure every 25,000 miles (40 225 km), 3 months, or 500 operating hours, whichever comes first.
§
M1 maintenance interval should be used as a general guideline; the actual frequency of filter element replacement will vary depending on cleanliness ofthe
fuel station system.
Table 5, M1 Maintenance Interval Operations for Service Schedules I and II
General Information 00
M1 Maintenance Interval Operations: 00–05
Cascadia Maintenance Manual, August 2015 00/9
The M2 Maintenance Interval Operations tables list
all maintenance operations that are to be performed
at the M2 maintenance interval. Maintenance operation numbers are reference numbers used to help
you find detailed instructions in this manual on the
maintenance operations to be performed. Perform all
M1 maintenance interval operations at the M2 maintenance interval.
Maintenance
Operation Number
M2 Maintenance Interval Operations for Service Schedules I and II Check
00–05 Perform All M1 Operations
15–01 Alternator, Battery, and Starter Check
20–01 Pressure Relief Cap Check
20–03 Fan Clutch Check (noise emission control)
25–02 Fluid Level Check, Hydraulic Clutch Control
26–02 Detroit™Automated Transmission Fluid Level Inspection
26–03 Detroit™Automated Transmission Air Filter Replacement
26–05 Eaton Fuller Transmission Fluid Level Inspection
26–06 Eaton Fuller Manual Transmission Air Filter/Regulator Check, Cleaning, or
Replacement
31–04 Fairing Bumper Wear Check
32–01 Suspension Inspection
32–02 Suspension U-Bolt Torque Check
33–01 Knuckle Pin Lubrication
*
33–02 Tie Rod Inspection
33–03 Tie Rod Lubrication
*
35–02 Axle Breather and Axle Lubricant Level Inspection
42–01 Air Brake System Valve Inspection
42–03 Air Dryer Inspection
42–04 Alcohol Evaporator Cleaning and Inspection
42–08 Meritor Slack Adjuster Lubrication
46–01 Drag Link Inspection
46–03 Power Steering Fluid Level Inspection
46–04 Power Steering Gear Lubrication
46–05 Drag Link Lubrication
46–06 Rack and Pinion Steering Gear Inspection
47–01 Fuel Filter Replacement
47–02 Fuel/Water Separator Element Checking and Replacement
47–08 CNG Fuel Cylinder Inspecting
†
54–01 Trailer Cable Inspection and Cleaning
60–01 Mirror Folding Check
60–04 Baggage Door and Sleeper Access Door Release Cable and Latch Lubrication
83–01 Air Conditioner Inspection
General Information00
M2 Maintenance Interval Operations: 00–06
Cascadia Maintenance Manual, August 201500/10
Maintenance
Operation Number
M2 Maintenance Interval Operations for Service Schedules I and II Check
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.
†
The fuel cylinder should be inspected every year or 100,000 miles (160 900 km), whichever comes first.
Table 6, M2 Maintenance Interval Operations for Service Schedules I and II
General Information 00
M2 Maintenance Interval Operations: 00–06
Cascadia Maintenance Manual, August 2015 00/11
The M3 Maintenance Interval Operations table lists
all maintenance operations that are to be performed
at the M3 maintenance interval. Maintenance operation numbers are reference numbers used to help
you find detailed instructions in this manual on the
maintenance operations to be performed. Perform all
M1 and M2 maintenance interval operations at the
M3 maintenance interval.
Maintenance
Operation Number
M3 Maintenance Interval Operations for Service Schedules I and II Check
00–05 Perform All M1 Operations
00–06 Perform All M2 Operations
09–01 Air Cleaner Inspection
20–02 Radiator Pressure-Flushing and Coolant Change
25–03 Fluid Change, Hydraulic Clutch Control
25–04 Clutch Replacement, Detroit™Automated Transmissions
*
26–01 Detroit™Automated Transmission Fluid Change and Magnetic Plug Cleaning
†
26–04 Eaton Fuller Transmission Fluid Change and Magnetic Plug Cleaning
‡
35–01 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning
42–02 Bendix Air Dryer Desiccant Replacement
42–09 Bendix E–6 Foot Control Valve Inspection and Lubrication
42–10 WABCO System Saver Air Dryer Desiccant Cartridge Replacement
46–02 Power Steering Fluid and Filter Change
46–07 Bellows Replacement, Rack and Pinion Steering Gear
47–05 LNG Vacuum Integrity Testing
49–02 CAT CGI Bellows Replacement
*
Replace the clutch assembly for Detroit automated transmissions at 750,000-mile (1 200 000-km) intervals.
†
For Schedule II vehicles with Detroit automated transmissions spec’d to haul more than 80,000 lb (36 000 kg), change the transmission fluid at 200,000-mile
(322 000-km) intervals.
‡
For Eaton Fuller transmissions, fluid change intervals are extended to 500,000 miles (800 000 km) on vehicles filled with synthetic transmission fluid.
Table 7, M3 Maintenance Interval Operations for Service Schedules I and II
General Information00
M3 Maintenance Interval Operations: 00–07
Cascadia Maintenance Manual, August 201500/12
Maintenance Operation Sets
Maint.
No.
Operation Description
Service Schedules I
and II
IM M1 M2 M3
09–01 Air Cleaner Inspection •
13–01 Air Compressor Inspection • • • •
15–01 Alternator, Battery, and Starter Check • •
20–01 Pressure Relief Cap Check ••
20–02 Radiator Pressure-Flushing and Coolant Change •
20–03 Fan Clutch Check (noise emission control) • •
25–01 Clutch Release Bearing Lubrication
*
••••
25–02 Fluid Level Check, Hydraulic Clutch Control • •
25–03 Fluid Change, Hydraulic Clutch Control •
25–04 Clutch Replacement, Detroit™Automated Transmissions
†
•
26–01 Detroit™Automated Transmission Fluid Change and Magnetic Plug Cleaning
‡
•
26–02 Detroit™Automated Transmission Transmission Fluid Level Inspection • •
26–03 Detroit™Automated Transmission Air Filter Replacement • •
26–04 Eaton Fuller Transmission Fluid Change and Magnetic Plug Cleaning
§
•
26–05 Eaton Fuller Transmission Transmission Fluid Level Inspection • •
26–06 Eaton Fuller Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement • •
31–01 Fifth Wheel Inspection • • • •
31–02 Fifth Wheel Lubrication • • • •
31–03 Frame Fastener Torque Check •
31–04 Fairing Bumper Wear Check ••
32–01 Suspension Inspection ••
32–02 Suspension U-Bolt Torque Check • • •
32–03 Lubrication of Front Suspensions with Grease Fittings • • • •
33–01 Knuckle Pin Lubrication
¶
••
33–02 Tie Rod Inspection ••
33–03 Tie Rod Lubrication
¶
••
33–04 All-Axle Alignment Check •
35–01 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning •
35–02 Axle Breather and Axle Lubricant Level Inspection • •
40–01 Wheel Nut Check ••••
40–02 Tire Check ••••
41–01 Driveline Inspection ••••
41–02 Driveline Lubrication ••••
42–01 Air Brake System Valve Inspection • •
General Information 00
Maintenance Operation Sets Table: 00–08
Cascadia Maintenance Manual, August 2015 00/13
Maintenance Operation Sets
Maint.
No.
Operation Description
Service Schedules I
and II
IM M1 M2 M3
42–02 Bendix Air Dryer Desiccant Replacement
**
••••
42–03 Air Dryer Inspection ••
42–04 Alcohol Evaporator Cleaning and Inspection • •
42–05 Brake Inspection ••••
42–06 Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication • • • •
42–07 Meritor Camshaft Bracket Lubrication • • • •
42–08 Meritor Slack Adjuster Lubrication • •
42–09 Bendix E–6 Foot Control Valve Inspection and Lubrication •
42–10 WABCO System Saver Air Dryer Desiccant Cartridge Replacement
**
••••
42–11 Versajust Slack Adjuster Inspection and Lubrication
††
•••
46–01 Drag Link Inspection ••
46–02 Power Steering Fluid and Filter Change •
46–03 Power Steering Fluid Level Inspection • •
46–04 Power Steering Gear Lubrication • •
46–05 Drag Link Lubrication ••
46–06 Rack and Pinion Steering Gear Inspection • •
46–07 Bellows Replacement, Rack and Pinion Steering Gear •
47–01 Fuel Filter Replacement ••
47–02 Fuel/Water Separator Element Checking and Replacement • •
47–03 Fuel Tank Band-Nut Tightening •
47–04 LNG Fuel System Inspecting • • •
47–05 LNG Vacuum Integrity Testing •
47–06 CNG Fuel System Inspecting • • •
47–07 CNG High-Pressure Fuel Filter Element Replacing • • •
47–08 CNG Fuel Cylinder Inspecting •
49–01 Exhaust System Inspection (noise emission control) • • • •
49–02 CAT CGI Bellows Replacement •
54–01 Trailer Cable Inspection and Cleaning • •
60–01 Mirror Folding Check ••
60–02 Cab Shock Absorber Bracket Torque Check • • • •
60–03 Aerodynamic Component Inspection • • • •
60–04 Baggage Door and Sleeper Access Door Release Cable and Latch Lubrication • •
83–01 Air Conditioner Inspection ••
83–02 Air Filter Replacement ••
General Information00
Maintenance Operation Sets Table: 00–08
Cascadia Maintenance Manual, August 201500/14
Maintenance Operation Sets
Maint.
No.
Operation Description
Service Schedules I
and II
IM M1 M2 M3
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.
†
Replace the clutch assembly for Detroit automated transmissions at 750,000-mile (1 200 000-km) intervals.
‡
For Schedule II vehicles with Detroit automated transmissions spec’d to haul more than 80,000 lb (36 000 kg), change the transmission fluid at 200,000-mile
(322 000-km) intervals.
§
For Eaton Fuller transmissions, fluid change intervals are extended to 500,000 miles (800 000 km) on vehicles filled with synthetic transmission fluid.
¶
For Schedule I vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), whichever comes first.
**
If equipped with an oil-coalescing desiccant cartridge, replace the cartridge once a year, regardless of mileage. Otherwise use the M3 maintenance interval.
††
Complete this procedure every 25,000 miles (40 225 km), 3 months, or 500 operating hours, whichever comes first.
Table 8, Maintenance Operation Sets
General Information 00
Maintenance Operation Sets Table: 00–08
Cascadia Maintenance Manual, August 2015 00/15
Noise Emission Control
Maintenance
Federal Law, Part 205:
Transportation Equipment Noise
Emission Controls
Part 205, Transportation Equipment Noise Emission
Controls, requires the vehicle manufacturer to furnish, with each new vehicle, such written instructions
for the proper maintenance, use, and repair of the
vehicle by the ultimate purchaser to provide reasonable assurance of the elimination or minimization of
noise-emission-control degradation throughout the
life of the vehicle. In compliance with the law, the
noise emission controls maintenance information in
each applicable group of this manual, in conjunction
with the vehicle workshop manual, provides these
instructions to owners.
Recommendations for
Replacement Parts
Replacement parts used for maintenance or repair of
noise emission controls should be genuine Freightliner parts. If other than genuine Freightliner parts
are used for replacement or repair of components
affecting noise emission control, the owner should be
sure that such parts are warranted by their manufacturer to be equivalent to genuine Freightliner parts in
performance and durability.
Freightliner Noise Emission
Controls Warranty
Refer to the vehicle owner’s warranty information
book for warranty information concerning noise emission controls.
Tampering with Noise Controls is
Prohibited
Federal law prohibits the following acts or the causing thereof:
1. The removal or rendering inoperative by any person (other than for purposes of maintenance,
repair, or replacement) of any device or element
of design incorporated into any new vehicle for
the purpose of noise control, prior to its sale or
delivery to the ultimate purchaser, or while it is in
use.
2. The use of the vehicle after such device or element of design has been removed or rendered
inoperative 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 cab-tunnel or hood noise-
deadening panels.
C. Removal of, or rendering inoperative, the en-
gine speed governor so as to allow engine
speed to exceed manufacturer’s specifications.
D. Removal of, or rendering inoperative, the fan
clutch, including bypassing the control on
any thermostatic fan drive to cause it to operate continuously.
E. Removal of the fan shroud.
F. Removal of, or rendering inoperative, ex-
haust components, including exhaust pipe
clamping.
G. Removal of air intake components.
Maintenance Instructions
Scheduled intervals are in the maintenance tables in
this group. A "Verification of Inspections Log" for
Groups 20 and 49 follows, and should be filled in
each time noise emission controls on the vehicle are
maintained or repaired.
General Information00
Noise Emission Controls Maintenance: 00–09
Cascadia Maintenance Manual, August 201500/16
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 Cost Maintenance Facility
General Information 00
Verification of Inspections Log: 00–10
Cascadia Maintenance Manual, August 2015 00/17
Title of Maintenance Operation (MOP) MOP Number
Air Cleaner Inspection .............................................................. 09–01
Air Intake 09
Index, Alphabetical
Cascadia Maintenance Manual, November 2014
09–01 Air Cleaner Inspection
Restriction of air flow through the air cleaner element
is measured at the tap in the air cleaner outlet.
Check the restriction indicator at the air cleaner or in
the cab if the vehicle is equipped with a dashmounted restriction gauge.
Vehicles may be equipped with either a manual-reset
restriction indicator with graduations (
Fig. 1), or a
go/no-go restriction indicator without graduations
(
Fig. 2).
1. Inspect the air restriction indicator to see if air
restriction equals or exceeds the maximum allowable restriction. For instructions, see Group
09 of the Cascadia Workshop Manual.
NOTICE
Do not use aftermarket air-cleaner elements. Aftermarket air-cleaner elements may not seal the
housing correctly, which can lead to engine damage and potentially the loss of warranty. When replacing an air-cleaner element, use only the part
listed in PartsPro for the serial number of the vehicle.
2. If necessary, replace the air cleaner element. For
air cleaner element replacement instructions, see
Group 09 of the Cascadia Workshop Manual.
3. Inspect the air cleaner housing for cracks, leaks,
or any other damage. If the air cleaner housing
or element is damaged, replace it.
4. Inspect the forward and rear mounting isolators
for damage. See
Fig. 3. Ensure the bonds be-
tween the rubber and the steel plates are completely intact. See
Fig. 4.
If a mounting isolator is damaged, replace it. For
isolator replacement instructions, see Section
09.01 of the Cascadia Workshop Manual.
5. Remove the pre-cleaners (if so equipped) from
the hood plenum, then clean them with compressed air.
6. Reset the air restriction indicator.
7. Each time the air cleaner housing is replaced,
perform the procedures in
MOP 13–01.
08/07/2007 f090452
Fig. 1, Manual-Reset Air Restriction Indicator,
Graduated
04/08/2005 f090431
Fig. 2, Manual-Reset Air Restriction Indicator, Go/
No-Go
Air Intake 09
Cascadia Maintenance Manual, November 2014 09/1
08/08/2007 f090453
1
2
2
3
4
5
6
2
7
1. Forward Mounting
Bracket
2. Nut
3. Forward Mounting
Isolator
4, Air Cleaner Housing
5 Aft Mounting Bracket
6. Capscrews
7. Aft Mounting Isolator
Fig. 3, Air Cleaner Assembly
01/17/2012 f090496
1
2
1. Steel Plate 2. Rubber
Fig. 4, Mounting Isolator
Air Intake09
Cascadia Maintenance Manual, November 201409/2
Title of Maintenance Operation (MOP) MOP Number
Air Compressor Inspection ...........................................................13–01
Safety Precautions .................................................................13–00
Air Compressor 13
Index, Alphabetical
Cascadia Maintenance Manual, August 2015
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 engine, 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. Failure to follow these steps
could result in serious personal injury or death.
13–01 Air Compressor
Inspection
1. Inspect the air compressor intake hoses and
connections at the air intake and air compressor
for physical damage. If needed, change the
hoses, and/or tighten or replace the connections.
2. Inspect the coolant supply and return lines for
tight connections. Tighten the connections and
replace the lines and fasteners if needed.
3. For the air governor, inspect the piping and connections for leaks. Replace gaskets and faulty
components as needed.
Air Compressor 13
Cascadia Maintenance Manual, August 2015 13/1
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