Sterling Trucks Acterra MX User 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.
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 theengine, undercarriage, andnoise emission controlparts are ingood working order during lubrication.
This maintenance manual explains when you should lubricate parts and what to look for when checking for wear or damage. For daily and weekly checks, refer to the vehicle driver’s manual.
IMPORTANT:Descriptions and specificationsin this manual were in effectat the time of printing. Sterling Truck Corporation reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation. Descriptions and specifications contained in this publication provide no warranty, expressed or implied, and are subject to revision and editions without notice.
For additional information, please contact Freightliner LLC, Service Systems and Documenta­tion, P.O. Box 3849, Portland, OR 97208-3849, U.S.A. or refer to www.Freightliner.com and www.SterlingTrucks.com.
Environmental Concerns and Recommendations
Whenever you seeinstructions in this manual todiscard materials, youshould 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.
© 2000-2007 Freightliner LLC
All rights reserved. No partof this publication, in whole or inpart, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Freightliner LLC.
Freightliner LLC
Service Systems and Documentation (POC-SSD)
P.O. Box 3849
Portland, OR 97208–3849
Introduction
Descriptions of Service Publications
Freightliner LLC distributes the following major service publications. Workshop Manual Workshop manuals contain service and repair information for all vehicle sys-
tems and components, except for major components such as engines, transmis­sions, and rear axles. Each workshop manual section is divided into subjects that can include general information, principles of operation, removal, disassem­bly, assembly, installation, specifications, and troubleshooting.
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, procedures for adjustments and for checking the tightness of fasteners. Maintenance manuals do not contain detailed repair or service information.
Driver’s Manual Driver’s manuals contain information needed to enhance the driver’s under-
standing of how to operate and care for the vehicle and its components. Each manual contains a chapter that covers pretrip inspection and daily maintenance of vehicle components. Driver’s manuals do not contain detailed repair or ser­vice information.
Parts Technical Manual Freightliner LLC publishes this manual to aid in the identification of serviceable
replacement vehicle parts. This manual is used in conjunction with the parts book and the service parts catalog microfiche.
Service Bulletins 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 manual. These bulletins take precedence over workshop manual information, until the latter is updated; at that time, the bulletin is usually canceled. The service bulletins manual is available only to dealers. When doing service work on a vehicle system or part, check for a valid service bulletin for the latest information on the subject.
IMPORTANT: Before using a particular service bulletin, check the current service bulletin validity list to be sure the bulletin is valid.
Recall Bulletins These bulletins pertain to special situations that involve service work or replace-
ment of parts in connection with a recall notice. Recall bulletins pertain to mat­ters of vehicle safety. All bulletins are distributed to dealers; customers receive notices that apply to their vehicles.
Field Service Modifications
This publication is concerned with non-safety-related service work or replace­ment of parts. All field service modifications are distributed to dealers; custom­ers receive notices that apply to their vehicles.
Acterra Maintenance Manual, January 2003 I–1
Introduction
For a page example of the printed manual, see Fig. 1.
A
BC
Page Description
Frame and Fifth Wheel
31−01 Frame Fastener Torque
Checking
CAUTION:
31−02 Fifth Wheel Inspecting and
Lubricating
31
HOLLAND
FONTANE
Acterra Trucks Maintenance Manual, April 2000
D
02/11/2002
31/1
E
f020103
A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number B. Group Title C. Group Number D. Release Date E. Group Number/Page Number
Fig. 1, Page Example of the Printed Manual
I–2 Acterra Maintenance Manual, January 2003
Maintenance Manual Contents
Group No. Group Title
00...................... General Information
01................................ Engine
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
72................................ Doors
83................. Heater and Air Conditioner
Introduction
Acterra Maintenance Manual, January 2003 I–3
General Information 00
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Initial Maintenance (IM) Operations Table................................................00–09
Lubrication and Fluid Level Check (M1)..................................................00–15
Lubrication and Fluid Level Check (M2)..................................................00–16
M1 Maintenance Interval Operations Table...............................................00–10
M2 Maintenance Interval Operations Table ............................................... 00–11
M3 Maintenance Interval Operations Table...............................................00–12
M4 Maintenance Interval Operations Table...............................................00–13
M5 Maintenance Interval Operations Table...............................................00–14
Maintenance Interval Tables..........................................................00–07
Maintenance Operation Sets Tables....................................................00–08
Maintenance Schedule Table .........................................................00–06
Metric/U.S. Customary Conversion Tables................................................00–04
Noise Emission Control Systems Maintenance ............................................00–01
Scheduled Maintenance Intervals, Description and Use......................................00–05
Torque Specifications Tables..........................................................00–03
Verification of Inspections Log.........................................................00–02
Acterra Maintenance Manual, January 2007
General Information 00
Noise Emission Control Systems Maintenance: 00–01
General Information
Federal Law, Part 205: Transportation Equipment Noise Emission Controls
Part 205, Transportation Equipment Noise Emission Controls, 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 degradation throughout the life of the vehicle. In compliance with the law, the Noise Emis­sion Control Systems maintenance located in each applicable group within this manual, in conjunction with the vehicle workshop manual, provides these instructions to owners.
Normal Vehicle Use
The maintenance instructions contained in this manual are based on average vehicle use and nor­mal operating conditions. Unusual vehicle operating conditions may require service at more frequent in­tervals.
Recommendations for Replacement Parts
Replacement parts used for maintenance or for the repair of noise emission control systems should be genuine Sterling parts. If other than genuine Sterling parts are used for replacements or for the repair of components affecting noise emission control, the owner should be sure that such parts are warranted by their manufacturer to be equivalent to genuine Sterling parts in performance and durability.
Sterling Noise Emissions Warranty
Tampering With the Noise Control System 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, or (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 or rendering the engine speed gover-
nor inoperative so as to allow engine speed to exceed manufacturer’s specifications.
C. Removal of or rendering inoperative the fan
clutch, including by-passing the control on any thermostatic fan drive to cause it to operate con-
tinuously. D. Removal of the fan shroud. E. Removal of or rendering inoperative exhaust sys-
tem components, including exhaust pipe clamp-
ing. F. Removal of air intake system components. G. Removal of hood liners (noise-deadening pan-
els).
Maintenance Instructions
Scheduled intervals are in the maintenance tables in Group 00 of this manual. A "Verification of Inspec­tions Log" is contained in the following table, and should be filled in each time the noise emission con­trols on the vehicle are maintained or repaired.
See the vehicle owner’s warranty information book for warranty information concerning noise emission control systems.
Acterra Maintenance Manual, January 2007 00/1
General Information00
Verification of Inspections Log: 00–02
Verification of Inspections Log
Verification of Inspections Log — Group 20
Verification of Inspections Log — Group 20 — Engine Cooling/Radiator
Date Mileage Repair Description Cost Repair Facility
Verification of Inspections Log — Group 49
Verification of Inspections Log — Group 49 — Exhaust
Date Mileage Repair Description Cost Repair Facility
Acterra Maintenance Manual, January 200700/2
General Information 00
Torque Specifications Tables: 00–03
Torque Values for U.S. Customary Thread Fasteners With Lubricated*or Plated Threads
Regular Hex Flanged
Thread
Diameter–
Pitch
Grade 5
Bolt
Grade 5 or
BNut
Grade 8 or
8.2 Bolt
Grade 8 or
CNut
Grade 5
Bolt
Grade B
Nut
Grade 8 or
8.2 Bolt
Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)
f230002
f230003
f230004
f230005
f230006
f230007
f230008
1/4–20 7 (9) 8 (11) 6 (8) 10 (14)
1/4–28 8 (11) 9 (12) 7 (9) 12 (16) 5/16–18 15 (20) 16 (22) 13 (18) 21 (28) 5/16–24 16 (22) 17 (23) 14 (19) 23 (31)
3/8–16 26 (35) 28 (38) 23 (31) 37 (50)
3/8–24 30 (41) 32 (43) 25 (34) 42 (57) 7/16–14 42 (57) 45 (61) 35 (47) 60 (81) 7/16–20 47 (64) 50 (68) 40 (54) 66 (89)
1/2–13 64 (87) 68 (92) 55 (75) 91 (123)
1/2–20 72 (98) 77 (104) 65 (88) 102 (138) 9/16–12 92 (125) 98 (133) 80 (108) 130 (176) 9/16–18 103 (140) 110 (149) 90 (122) 146 (198)
5/8–11 128 (173) 136 (184) 110 (149) 180 (244)
5/8–18 145 (197) 154 (209) 130 (176) 204 (277)
3/4–10 226 (306) 241 (327) 200 (271) 320 (434)
3/4–16 253 (343) 269 (365) 220 (298) 357 (484)
7/8–9 365 (495) 388 (526) 320 (434) 515 (698)
7/8–14 402 (545) 427 (579) 350 (475) 568 (770)
1–8 582 (789) — 1–12 637 (863) — 1–14 652 (884)
*
Sterling recommends that all plated and unplated fasteners be coated with oil before installation.
Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed).
Table 1, Torque Values for U.S. Customary Thread Fasteners With Lubricated or Plated Threads
Grade G
Nut
f230009
Acterra Maintenance Manual, January 2007 00/3
Torque Specifications Tables: 00–03
General Information00
Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated)*Plain (Unplated) Threads
Regular Hex Flanged
Thread
Diameter–Pitch
Grade 5 Bolt
Grade5orB
Nut
Grade 8 or 8.2
Bolt
Grade8orC
Nut
Grade 8 or 8.2
Bolt
Grade G Nut
Torque: lbf·ft (N·m) Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)
f230002
f230003
f230004
f230005
f230008
1/4–20 8 (11) 10 (14)
1/4–28 9 (12) 12 (16) — 5/16–18 15 (20) 22 (30) 22 (30) 5/16–24 17 (23) 25 (34)
3/8–16 28 (38) 40 (54) 40 (54)
3/8–24 31 (42) 45 (61) — 7/16–14 45 (61) 65 (88) 65 (88) 7/16–20 50 (68) 70 (95)
1/2–13 70 (95) 95 (129) 95 (129)
1/2–20 75 (102) 110 (149) — 9/16–12 100 (136) 140 (190) 140 (190) 9/16–18 110 (149) 155 (210)
5/8–11 135 (183) 190 (258) 190 (258) 5/8–18 155 (210) 215 (292) — 3/4–10 240 (325) 340 (461) 340 (461) 3/4–16 270 (366) 380 (515)
7/8–9 385 (522) 540 (732)
7/8–14 425 (576) 600 (813)
1–8 580 (786) 820 (1112) — 1–12 635 (861) 900 (1220) — 1–14 650 (881) 915 (1241)
*
Threads may have residual oil, but will be dry to the touch.
Male and female threads (bolt and nut) must both be unlubricated and unplated; if either is plated or lubricated, use Table 1. Sterling recommends that all
plated and unplated fasteners be coated with oil before installation.
Table 2, Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated) Plain (Unplated) Threads
f230009
Acterra Maintenance Manual, January 200700/4
General Information 00
Torque Specifications Tables: 00–03
Torque Values 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
Torque: lbf·ft (N·m) Torque: lbf·ft (N·m)
8.8
f230010
8
f230011
10.9
f230012
10
f230013
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 (37) 38 (52) M12 42 (57) 60 (81) M12 x 1.5 43 (58) 62 (84) M14 66 (89) 95 (129) M14 x 1.5 72 (98) 103 (140) M16 103 (140) 148 (201) M16 x 1.5 110 (149) 157 (213) M18 147 (199) 203 (275) M18 x 1.5 165 (224) 229 (310) M20 208 (282) 288 (390) M20 x 1.5 213 (313) 320 (434) M22 283 (384) 392 (531) M22 x 1.5 315 (427) 431 (584) M24 360 (488) 498 (675) M24 x 2 392 (531) 542 (735) M27 527 (715) 729 (988) M27 x 2 569 (771) 788 (1068) M30 715 (969) 990 (1342) M30 x 2 792 (1074) 1096 (1486)
*
Sterling recommends that all plated and unplated fasteners be coated with oil before installation.
Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated,
cadmium-plated, or waxed).
Table 3, Torque Values for Metric Thread Fasteners With Lubricated or Plated
Threads
Acterra Maintenance Manual, January 2007 00/5
Metric/U.S. Customary Conversion Tables: 00–04
General Information00
When You Know U.S.
Customary
Multiply
By
To Get Metric
When You
Know Metric
Multiply
By
To Get U.S. Customary
Length
inches (in) 25.4 millimeters (mm) 0.03937 inches (in) inches (in) 2.54 centimeters (cm) 0.3937 inches (in) feet (ft) 0.3048 meters (m) 3.281 feet (ft) yards (yd) 0.9144 meters (m) 1.094 yards (yd) miles (mi) 1.609 kilometers (km) 0.6215 miles (mi)
Area
square inches (in square inches (in square feet (ft
2
) 645.16 square millimeters (mm2) 0.00155 square inches (in2)
2
) 6.452 square centimeters (cm2) 0.155 square inches (in2)
2
) 0.0929 square meters (m2) 10.764 square feet (ft2)
Volume
3
cubic inches (in cubic inches (in cubic inches (in
) 16387.0 cubic millimeter (mm3) 0.000061 cubic inches (in3)
3
) 16.387 cubic centimeters (cm3) 0.06102 cubic inches (in3)
3
) 0.01639 liters (L) 61.024 cubic inches (in3) fluid ounces (fl oz) 29.54 milliliters (mL) 0.03381 fluid ounces (fl oz) pints (pt) 0.47318 liters (L) 2.1134 pints (pt) quarts (qt) 0.94635 liters (L) 1.0567 quarts (qt) gallons (gal) 3.7854 liters (L) 0.2642 gallons (gal) cubic feet (ft cubic feet (ft
3
) 28.317 liters (L) 0.03531 cubic feet (ft3)
3
) 0.02832 cubic meters (m3) 35.315 cubic feet (ft3)
Weight/Force
ounces (av) (oz) 28.35 grams (g) 0.03527 ounces (av) (oz) pounds (av) (lb) 0.454 kilograms (kg) 2.205 pounds (av) (lb) U.S. tons (t) 907.18 kilograms (kg) 0.001102 U.S. tons (t) U.S. tons (t) 0.90718 metric tons (t) 1.1023 U.S. tons (t)
Torque/Work Force
inch–pounds (lbf·in) 11.298 Newton–centimeters (N·cm) 0.08851 inch–pounds (lbf·in) foot–pounds (lbf·ft) 1.3558 Newton–meters (N·m) 0.7376 foot–pounds (lbf·ft)
Pressure/Vacuum
inches of mercury (inHg) 3.37685 kilo Pascals (kPa) 0.29613 inches of mercury (inHg) pounds per square inch (psi) 6.895 kilo Pascals (kPa) 0.14503 pounds per square inch (psi)
Table 4, Metric/U.S. Customary Conversion
When You Know Subtract
Then
Divide By
To Get
When You
Know
Multiply
By
Then
Add
To Get
degrees Fahrenheit (°F) 32 1.8 degrees Celsius (°C) 1.8 32 degrees Fahrenheit (°F)
Table 5, Temperature Conversion
Acterra Maintenance Manual, January 200700/6
General Information 00
Scheduled Maintenance Intervals, Description and
Use: 00–05
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 accumula­tion; constant exposure to extreme hot, cold, salt-air, or other extreme climates; frequent short-distance travel; construction-site operation; city operation (fire truck, garbage truck); or farm operation.
Schedule II (short-haul transport) applies to vehicles
up to
that annually travel meters) and operate under normal conditions. Ex­amples of Schedule II usage are: operation primarily in cities and densely populated areas; local transport with infrequent freeway travel; or high percentage of stop-and-go travel.
Schedule III (long-haul transport) is for vehicles that annually travel meters), with minimal city or stop-and-go operation. Examples of Schedule III usage are: regional delivery that is mostly freeway miles; interstate transport; or any road operation with high annual mileage.
The table under Maintenance Schedule Table shows three different schedules of vehicle usage. For each schedule the appropriate distance interval is given for performing Initial Maintenance and for re­peating each maintenance operation set (M1 through M5). For Schedule I, the appropriate time interval is also given.
The tables under Maintenance Interval Tables show which maintenance operation set must be performed at the actual distances (miles and kilometers) for each maintenance schedule (or the actual hours of operation for Schedule I). The schedule of actual dis­tances (and hours) is based on the intervals given in the Maintenance Schedule Table.
The tables under Maintenance Operation Sets
Tables list, in numerical order, the text reference
numbers and descriptions of tions, and indicates all maintenance operation sets at which each operation must be performed.
Each Maintenance Interval Operations Table (IM through M5) lists the appropriate text reference
numbers and descriptions of only those maintenance operations that must be performed at that mainte­nance operation set. Each maintenance operation set is listed in a separate Maintenance Operations Table.
more than
60,000 miles (100 000 kilo-
60,000 miles (100 000 kilo-
all
maintenance opera-
Use
Before placing your new vehicle in service, determine the correct maintenance intervals that apply to your intended use of the vehicle. Refer to the Mainte­nance Schedule Table to determine the distance (or hour) interval at which each Maintenance Operation Set must be performed to comply with your vehicle’s schedule. For Schedule I vehicles equipped with an hourmeter, use hours to determine maintenance in­tervals, rather than distance traveled.
When the vehicle reaches the actual distance (or hours) given for an interval, refer to the Maintenance Interval Tables to find the Maintenance Operation Set that applies to that interval. Then perform the mainte­nance operations listed in the applicable Mainte­nance Interval Operation Table. Use the maintenance operation reference numbers to find instructions in the manualfor completion of each operation.
Complete each Maintenance Operation Set at the required interval. Then, when you have completed Maintenance Operation Set M5 under the 32nd Main­tenance Number listed in the Maintenance Interval Table, repeat the pattern. The 33rd Maintenance Number will begin at Maintenance Operation Set M1, under the 1st Maintenance Number listed in the Maintenance Interval Table.
NOTE: When performing operations for the 33rd Maintenance Number, complete the M1 opera­tions only, not the Initial Maintenance opera­tions.
To determine the distance/hours for the 33rd Mainte­nance Number, add your schedule’s distance/hours for the 1st Maintenance Number to the distance/hours for the 32nd Maintenance Number, then perform the operations listed in the applicable table in the Maintenance Operations Tables. For the 34th Maintenance Number, add the distance/hours for the 2nd to the distance/hours for the 32nd; con­tinue this pattern for each successive Maintenance Number.
Acterra Maintenance Manual, January 2007 00/7
Maintenance Schedule Table: 00–06
General Information00
Maintenance Schedule Models
Schedule I
(Severe Service)
vehicles that annually travel up
to 6000 miles (10 000 km)
Schedule II
(Short-Haul Transport)
vehicles that annually travel up
to 60,000 miles (100 000 km)
Schedule III
(Long-Haul Transport) vehicles that annually travel over 60,000 miles (100 000
km)
Maintenance Interval
Operation
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 12 800 800 Maintenance 4 (M4) every 16,000 25 600 1600 Maintenance 5 (M5) every 32,000 51 200 3200
All Initial Maintenance (IM) first 8000 12 000
Maintenance 1 (M1) every 8000 12 000 Maintenance 2 (M2) every 16,000 24 000 Maintenance 3 (M3) every 32,000 48 000 Maintenance 4 (M4) every 64,000 96 000 Maintenance 5 (M5) every 128,000 192 000
All Initial Maintenance (IM) first 10,000 16 000
Maintenance 1 (M1) every 10,000 16 000 Maintenance 2 (M2) every 20,000 32 000 Maintenance 3 (M3) every 40,000 64 000 Maintenance 4 (M4) every 80,000 128 000 Maintenance 5 (M5) every 160,000 256 000
Table 6, Maintenance Schedule Table
Frequency Miles Km Hours
Maintenance Intervals
Acterra Maintenance Manual, January 200700/8
General Information 00
Maintenance Interval Tables: 00–07
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 11 200 700 8 M1, M2, and M3 8000 12 800 800
9 M1 9000 14 400 900 10 M1 10,000 16 000 1000 11 M1 11,000 17 600 1100 12 M1 and M2 12,000 19 200 1200 13 M1 13,000 20 800 1300 14 M1 14,000 22 400 1400 15 M1 15,000 24 000 1500 16 M1, M2, M3, and M4 16,000 25 600 1600 17 M1 17,000 27 200 1700 18 M1 18,000 28 800 1800 19 M1 19,000 30 400 1900 20 M1 and M2 20,000 32 000 2000 21 M1 21,000 33 600 2100 22 M1 22,000 35 200 2200 23 M1 23,000 36 800 2300 24 M1, M2, and M3 24,000 38 400 2400 25 M1 25,000 40 000 2500 26 M1 26,000 41 600 2600 27 M1 27,000 43 200 2700 28 M1 and M2 28,000 44 800 2800 29 M1 29,000 46 400 2900 30 M1 30,000 48 000 3000 31 M1 31,000 49 600 3100 32 M1, M2, M3, M4, and M5 32,000 51 200 3200
Table 7, Maintenance Intervals for Schedule I
Acterra Maintenance Manual, January 2007 00/9
General Information00
Maintenance Interval Tables: 00–07
Maintenance Intervals for Schedules II and III (all models)
Maint.
No.
1 IM and M1 8000 12 000 10,000 16 000 2 M1 and M2 16,000 24 000 20,000 32 000 3 M1 24,000 36 000 30,000 48 000 4 M1, M2, and M3 32,000 48 000 40,000 64 000 5 M1 40,000 60 000 50,000 80 000 6 M1 and M2 48,000 72 000 60,000 96 000 7 M1 56,000 84 000 70,000 112 000 8 M1, M2, M3, and M4 64,000 96 000 80,000 128 000
9 M1 72,000 108 000 90,000 144 000 10 M1 and M2 80,000 120 000 100,000 160 000 11 M1 88,000 132 000 110,000 176 000 12 M1, M2, and M3 96,000 144 000 120,000 192 000 13 M1 104,000 156 000 130,000 208 000 14 M1, and M2 112,000 168 000 140,000 224 000 15 M1 120,000 180 000 150,000 240 000 16 M1, M2, M3, M4, and M5 128,000 192 000 160,000 256 000 17 M1 136,000 204 000 170,000 272 000 18 M1 and M2 144,000 216 000 180,000 288 000 19 M1 152,000 228 000 190,000 304 000 20 M1, M2, and M3 160,000 240 000 200,000 320 000 21 M1 168,000 252 000 210,000 336 000 22 M1 and M2 176,000 264 000 220,000 352 000 23 M1 184,000 276 000 230,000 368 000 24 M1, M2, M3, and M4 192,000 288 000 240,000 384 000 25 M1 200,000 300 000 250,000 400 000 26 M1 and M2 208,000 312 000 260,000 416 000 27 M1 216,000 324 000 270,000 432 000 28 M1, M2, and M3 224,000 336,000 280,000 448 000 29 M1 232,000 348 000 290,000 464 000 30 M1 and M2 240,000 360 000 300,000 480 000 31 M1 248,000 372 000 310,000 496 000 32 M1, M2, M3, M4, and M5 256,000 384 000 320,000 512 000
Maintenance Interval
Table 8, Maintenance Intervals for Schedules II and III (all models)
Schedule II Schedule III
Miles km Miles km
Acterra Maintenance Manual, January 200700/10
General Information 00
Maintenance Operation Sets Tables: 00–08
IMPORTANT: At each Maintenance Operation Set, in addition to the maintenance operations listed in this table, perform all daily, weekly, and monthly mainte­nance operations listed in the "Pretrip and Post-trip Inspections and Maintenance" chapter of the
Acterra®Driver’s Manual
Maintenance Operation Number and Operation Description
00–15 Lubrication and Fluid Level Check •••••• 00–16 Lubrication and Fluid Level Check •••• 01–01 Engine-Support Fasteners Checking •• 01–02 Engine Drive Belt Inspecting ••• 01–03 Pacbrake Inspecting and Maintenance 09–01 Air Cleaner Element Inspecting and Replacing ••• 13–01 Air Compressor Inspecting, Bendix ••• 13–02 Air Compressor Rebuilding/Replacing, Bendix 15–01 Alternator, Battery, and Starter Checking •• 20–01 Radiator Cap Checking •••• 20–02 Radiator Pressure Flushing and Coolant Changing •• 20–03 25–01 Clutch Release Bearing and Release Cross-Shaft Lubricating •••••• 25–02 Clutch (Pull-Type) Inspecting and Adjusting •• 25–03 Hydraulic Fluid Level Checking ••••• 25–04 Hydraulic Fluid Replacing 26–01 Manual Transmission Fluid Level Checking ••• 26–02 Eaton Fuller and TTC Transmission Fluid Changing and Magnetic Plug Cleaning 26–03 Allison, Eaton Fuller, and Meritor Transmission Breather Checking •••• 26–04 Allison Transmission Fluid and Filter Changing ••• 26–05 Mercedes-Benz Transmission Fluid Changing and Magnetic Plug Cleaning 26–06 Mercedes-Benz Transmission Leak Checking 31–01 Frame Fastener Torque Checking •• 31–02 Fifth Wheel Inspecting •••••• 31–03 Fifth Wheel Lubricating •••••• 32–01 Suspension Inspecting •••••• 32–02 Suspension Lubricating ••••••
Fan Clutch Checking
.
Maintenance Operation Sets for Groups 00 through 32
REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 M4 M5
*
NOTE: Maintenance operations appearing in italics in this table are for noise emission control components. Numbers in this table are maintenance operation ref­erence numbers matching those in the text of this manual.
•••
••••
••
Acterra Maintenance Manual, January 2007 00/11
General Information00
Maintenance Operation Sets Tables: 00–08
Maintenance Operation Sets for Groups 00 through 32
REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 M4 M5
Maintenance Operation Number and Operation Description
32–03 U-Bolt Torque Checking ••
*
With frequent use, the Pacbrake Exhaust Brake will operate free of maintenance. However, if the vehicle is used inconsistently, seasonally, or is exposed to
excess moisture, it will be necessary to perform preventative maintenance as instructed in Maintenance Operation 01–03.
IM interval does not apply to vehicles with a factory fill of Eaton approved synthetic lubricant.
Table 9, Maintenance Operation Sets for Groups 00 through 32
Maintenance Operation Sets for Groups 33 through 42
REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 M4 M5
Maintenance Operation Number and Operation Description
33–01 Knuckle Pin Lubricating •••••• 33–02 Tie-Rod End Inspecting •••••• 33–03 Tie-Rod End Lubricating •••••• 33–04 All-Axle Alignment Checking •• 33–05 All-Wheel-Drive Front Axle Oil Level Checking ••• 33–06 All-Wheel-Drive Front Axle Oil Changing ••• 33–07 Draw Key Nut Inspecting •• 35–01 Axle Lubricant Level Checking ••• 35–02 Axle Breather Checking •••••• 35–03 Axle Lubricant Changing and Magnetic Plug Cleaning •• 35–04 Two-Speed-Axle Shift Unit Oil Level Checking •• 35–05 Two-Speed-Axle Shift Unit Oil Changing ••• 40–01 Wheel Nut Checking ••• 41–01 Driveline Inspecting •••••• 41–02 Driveline Lubricating •••••• 42–01 Air Dryer Inspecting, Bendix AD–9 •••••• 42–02 Air Brake Valve Inspecting and Leak Checking, Bendix BP–R1 •••••• 42–03 Foot Brake Valve Actuator Lubricating, Bendix E–8P •••••• 42–04 Air Brake Valve Operation Checking •••••• 42–05 Relay Valve Checking, Midland •••••• 42–06 Quick Release and Flipper Valves Checking, Midland •••••• 42–07 Brake Chamber Inspecting (All Models) •••••• 42–08 Camshaft Bracket Bushing Lubricating •••• 42–09 Automatic Slack Adjuster Checking, Meritor •••••• 42–10 Automatic Slack Adjuster Lubricating, Meritor •••••• 42–11 Automatic Slack Adjuster Inspecting, Meritor •••• 42–12 Air Dryer Checking, Bendix AD–9 •••
Acterra Maintenance Manual, January 200700/12
General Information 00
Maintenance Operation Sets Tables: 00–08
Maintenance Operation Sets for Groups 33 through 42
REQUIRED MAINTENANCE OPERATION 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 Valve Leak Checking, Bendix TC–6 ••••••
42–15
42–16 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 42–20 Automatic Slack Adjuster Lubricating, Gunite •••••• 42–21 Automatic Slack Adjuster Inspecting, Gunite •••••• 42–22 Automatic Slack Adjuster Lubricating, Haldex •••••• 42–23 Bosch Rail-Slide Hydraulic Brake Caliper Lubricating •••• 42–24 Brake Inspection ••••••
Air Reservoir Automatic Drain Valve Disassembly, Cleaning, Inspecting, and Lubricating, Bendix DV–2
Air Brake Valve Disassembly, Cleaning, and Inspecting, Bendix E–8P, R–12, R–14, SR–1, ST–3, TC–6, and TP–3DC
®
Table 10, Maintenance Operation Sets for Groups 33 through 42
••••••
••••
Maintenance Operation Sets for Groups 46 through 83
REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 M4 M5
Maintenance Operation Number and Operation Description
46–01 Steering Driveline Lubricating •••• 46–02 Drag Link Lubricating •••••• 46–03 Power Steering Reservoir Fluid Level Checking •••• 46–04 Power Steering Reservoir Fluid and Filter Changing •• 46–05 Power Steering Gear Lubricating •••••• 47–01 Fuel Tank Draining and Vent Checking ••• 49–01 54–01 Electrical System Checking ••• 54–02 Coolant Level Sensor Cleaning 72–01 Weatherstrip, Door Latch, and Door Hinge Lubricating •••••• 83–01 Air Conditioner Inspecting •••••• 83–02 HVACAir Filter Replacing
*
Replace the HVAC filter every 6 months regardless of mileage.
Exhaust System Inspecting
Table 11, Maintenance Operation Sets for Groups 46 through 83
••••
*
Acterra Maintenance Manual, January 2007 00/13
Initial Maintenance (IM) Operations Table: 00–09
General Information00
IMPORTANT: After performing all operations in this table, perform all daily and weekly maintenance op­erations 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).
Initial Maintenance (IM) Operations
Maint.
Oper. No.
00–10 Perform All M1 Operations 25–02 Clutch (Pull-Type) Inspecting and Adjusting 26–02 Eaton Fuller and TTC Transmission Fluid Changing and Magnetic Plug
31–01 Frame Fastener Torque Checking 32–03 U-Bolt Torque Checking 33–04 All-Axle Alignment Checking 33–07 Draw Key Nut Inspecting 35–03 Axle Lubricant Changing and Magnetic Plug Cleaning 35–04 Two-Speed-Axle Shift Unit Oil Level Checking
*
IM interval does not apply to vehicles with a factory fill of Eaton approved synthetic lubricant.
Cleaning
*
Initial Maintenance (IM) Operations
NOTE: Numbers in this table are maintenance opera­tion reference numbers matching those in the text of this manual. The Initial Maintenance consists of all M1 Operations plus the other operations listed below.
Acterra Maintenance Manual, January 200700/14
General Information 00
M1 Maintenance Interval Operations Table: 00–10
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
Acterra®Driver’s Manual
the
M1 Maintenance Interval Operations
Maint.
Oper. No.
00–15 Lubrication and Fluid Level Check:
31–02 Fifth Wheel Inspecting 32–01 Suspension Inspecting 33–02 Tie-Rod End Inspecting 35–02 Axle Breather Checking 41–01 Driveline Inspecting 42–01 Air Dryer Inspecting, Bendix AD–9 42–02 Air Brake Valve Inspecting and Leak Checking, Bendix BP–R1 42–04 Air Brake Valve Operation Checking 42–05 Relay Valve Checking, Midland 42–06 Quick Release and Flipper Valves Checking, Midland 42–07 Brake Chamber Inspecting (All Models) 42–09 Automatic Slack Adjuster Checking, Meritor
.
M1 Maintenance Interval Operations
Clutch Release Bearing and Release Cross-Shaft Lubricating
Hydraulic Fluid Level Checking
Manual Transmission Fluid Level Checking
Fifth Wheel Lubricating
Suspension Lubricating
Knuckle Pin Lubricating
Tie-Rod End Lubricating
All-Wheel-Drive Front Axle Oil Level Checking
Axle Lubricant Level Checking
Driveline Lubricating
Foot Brake Valve Actuator Lubricating, Bendix E–8P
Automatic Slack Adjuster Lubricating, Meritor
Automatic Slack Adjuster Lubricating, Gunite
Automatic Slack Adjuster Lubricating, Haldex
Drag Link Lubricating
Power Steering Reservoir Fluid Level Checking
Power Steering Gear Lubricating (Ross TAS Series)
Weatherstrip, Door Latch, and Door Hinge Lubricating
NOTE: Numbers in this table are maintenance opera­tion reference numbers matching those in the text of this manual.
Acterra Maintenance Manual, January 2007 00/15
M1 Maintenance Interval Operations Table: 00–10
General Information00
Maint.
Oper. No.
42–14 Air Brake Valve 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 83–01 Air Conditioner Inspecting
M1 Maintenance Interval Operations
®
Acterra Maintenance Manual, January 200700/16
General Information 00
M2 Maintenance Interval Operations Table: 00–11
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
Acterra®Driver’s Manual
the
. Also, perform all M1 Maintenance Interval Operations at the M2 Mainte­nance Interval.
M2 Maintenance Interval Operations
Maint.
Oper. No.
00–10 Perform All M1 Operations 00–16 Lubrication and Fluid Level Check:
Two-Speed-Axle Shift Unit Oil Level Checking
Camshaft Bracket Bushing Lubricating
Air Reservoir Automatic Drain Valve Disassembly, Cleaning, Inspect-
ing, and Lubricating, Bendix DV–2
Bosch Rail-Slide Hydraulic Brake Caliper Lubricating
Steering Driveline Lubricating
13–01 Air Compressor Inspecting, Bendix 20–01 Radiator Cap Checking 20–03 26–03 Allison, Eaton/Fuller, and Meritor Transmission Breather Checking 42–11 Automatic Slack Adjuster Inspecting, Meritor 49–01 83–02 HVAC Air Filter Replacing
*
Replace the HVAC filter every 6 months regardless of mileage.
Fan Clutch Checking
Exhaust System Inspecting
M2 Maintenance Interval Operations
*
NOTE: Maintenance operations appearing in italics in this table are for noise emission control components. Numbers in this table are maintenance operation ref­erence numbers matching those in the text of this manual. The M2 Maintenance consists of all M1 In­terval Operations plus the other operations listed below.
Acterra Maintenance Manual, January 2007 00/17
M3 Maintenance Interval Operations Table: 00–12
General Information00
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
Acterra®Driver’s Manual
the
. Also, perform all M1 and M2 Maintenance Interval Operations at the M3 Maintenance Interval.
M3 Maintenance Interval Operations
Maint.
Oper. No.
00–10 Perform All M1 Operations
00–11 Perform All M2 Operations 01–02 Engine Drive Belt Inspecting 09–01 Air Cleaner Element Inspecting and Replacing 25–02 Clutch (Pull-Type) Inspecting and Adjusting 26–04 Allison Transmission Fluid and Filter Changing 32–03 U-Bolt Torque Checking 33–06 All-Wheel-Drive Front Axle Oil Changing 33–07 Draw Key Nut Inspecting 35–05 Two-Speed-Axle Shift Unit Oil Changing 40–01 Wheel Nut Checking 42–12 Air Dryer Checking, Bendix AD–9 47–01 Fuel Tank Draining and Vent Checking 54–01 Electrical System Checking
M3 Maintenance Interval Operations
NOTE: Numbers in this table are maintenance opera­tion reference numbers matching those in the text of this manual. The M3 Maintenance consists of all M1 and M2 Interval Operations plus the other operations listed below.
Acterra Maintenance Manual, January 200700/18
General Information 00
M4 Maintenance Interval Operations Table: 00–13
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
Acterra®Driver’s Manual
the
. Also, perform all M1, M2, and M3 Maintenance Interval Operations at the M4 Maintenance Interval.
M4 Maintenance Interval Operations
Maint.
Oper. No.
00–10 Perform All M1 Operations 00–11 Perform All M2 Operations 00–12 Perform All M3 Operations 01–01 Engine-Support Fasteners Checking 15–01 Alternator, Battery, and Starter Checking 20–02 Radiator Pressure Flushing and Coolant Changing 26–02 Eaton Fuller and TTC Transmission Fluid Changing and Magnetic Plug
Cleaning
31–01 Frame Fastener Torque Checking 33–04 All-Axle Alignment Checking 35–03 Axle Lubricant Changing and Magnetic Plug Cleaning 46–04 Power Steering Reservoir Fluid and Filter Changing
M4 Maintenance Interval Operations
NOTE: Maintenance operations appearing in italics in this table are for noise emission control components. Numbers in this table are maintenance operation ref­erence numbers matching those in the text of this manual. The M4 Maintenance consists of all M1, M2, and M3 Interval Operations plus the other operations listed below.
Acterra Maintenance Manual, January 2007 00/19
M5 Maintenance Interval Operations Table: 00–14
General Information00
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
Acterra®Driver’s Manual
the
. Also, perform all M1, M2, M3, and M4 Maintenance Interval Operations at the M5 Maintenance Interval.
M5 Maintenance Interval Operations
Maint.
Oper. No.
00–10 Perform All M1 Operations
00–11 Perform All M2 Operations 00–12 Perform All M3 Operations 00–13 Perform All M4 Operations 13–02 Air Compressor Rebuilding/Replacing, Bendix 25–04 Hydraulic Fluid Replacing 26–05 Mercedes-Benz Transmission Fluid Changing and Magnetic Plug Cleaning 26–06 Mercedes-Benz Transmission Leak Checking 42–13 Air Dryer Desiccant Replacing, Bendix AD–9 42–16 Air Brake Valve Disassembly, Cleaning, and Inspecting, Bendix E–8P,
R–12, R–14, SR–1, ST–3, TC–6, and TP–3DC
54–02 Coolant Level Sensor Cleaning
M5 Maintenance Interval Operations
NOTE: Numbers in this table are maintenance opera­tion reference numbers matching those in the text of this manual. The M5 Maintenance consists of all M1, M2, M3, and M4 Interval Operations plus the other operations listed below.
Acterra Maintenance Manual, January 200700/20
General Information 00
Lubrication and Fluid Level Check (M1): 00–15
Maintenance Operation 00–15 (see Table 12), sum- marizes all Lubrication and Fluid Level Check opera­tions that must be performed at the M1 Maintenance Interval for Schedules I, II, and III
Maintenance Operation 00–15
M1 Lubrication and Fluid Level Check
Maint.
Oper. No.
25–01 Clutch Release Bearing and Release Cross-Shaft Lubricating 25–03 Hydraulic Fluid Level Checking 26–01 Manual Transmission Fluid Level Checking 31–03 Fifth Wheel Lubricating 32–02 Suspension Lubricating 33–01 Knuckle Pin Lubricating 33–03 Tie-Rod End Lubricating 33–05 All-Wheel-Drive Front Axle Oil Level Checking 35–01 Axle Lubricant Level Checking 41–02 Driveline Lubricating 42–03 Foot Brake Valve Actuator Lubricating, Bendix E–8P 42–10 Automatic Slack Adjuster Lubricating, Meritor 42–20 Automatic Slack Adjuster Lubricating, Gunite 42–22 Automatic Slack Adjuster Lubricating, Haldex 46–02 Drag Link Lubricating 46–03 Power Steering Reservoir Fluid Level Checking 46–05 Power Steering Gear Lubricating 72–01 Weatherstrip, Door Latch, and Door Hinge Lubricating
Table 12, Maintenance Operation 00-15, M1 Lubrication and Fluid Level Check
Operation Description
Maintenance operation numbers given in the table are reference numbers used to help you find detailed instructions in the manual on the lubrication or fluid check.
Acterra Maintenance Manual, January 2007 00/21
Lubrication and Fluid Level Check (M2): 00–16
General Information00
Maintenance Operation 00–16 (see Table 13), sum- marizes all Lubrication and Fluid Level Check opera­tions that must be performed at the M2 Maintenance Interval for Schedules I, II, and III
Maintenance Operation 00–16
M2 Lubrication and Fluid Level Check
Maint.
Oper. No.
35–04 Two-Speed-Axle Shift Unit Oil Level Checking 42–08 Camshaft Bracket Bushing Lubricating 42–15 Air Reservoir Automatic Drain Valve Disassembly, Cleaning, Inspecting,
and Lubricating, Bendix DV–2
42–23 Bosch Rail-Slide Hydraulic Brake Caliper Lubricating 46–01 Steering Driveline Lubricating
Table 13, Maintenance Operation 00-16, M2 Lubrication and Fluid Level Check
Operation Description
Maintenance operation numbers given in the table are reference numbers used to help you find detailed instructions in the manual on the lubrication or fluid check.
Acterra Maintenance Manual, January 200700/22
Engine 01
Index, Alphabetical
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
Acterra Maintenance Manual, January 2007
Engine 01
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 re­moved for service. For vehicles manufactured prior to January 2007, perform the following check.
Check the rear engine-support fasteners (see Fig. 1, Ref. 4) for tightness. Tighten the 3/4-inch fasteners 215 to 265 lbf·ft (292 to 359 N·m).
Check the front engine-support fasteners for tight­ness. Tighten the 5/8-inch fasteners 125 lbf·ft (170 N·m).
NOTE: At engine overhaul, and whenever the engine has been removed, inspect the lower and upper isolators (Refs. 1 and 6), and replace them if they are worn. See Group 01 of the
Acterra®Workshop Manual
2
6
5
10/05/94
1. Lower Isolator
2. Engine Support Washer
3. 3/4–10 Capscrew
4
Fig. 1, Engine Rear Mount
for instructions.
1
2
3
f220047a
4. 3/4–10 Hexnut
5. Engine Mount
6. Upper Isolator
01–02 Engine Drive Belt
Inspecting
Worn or loose drive belts may cause premature bearing failure or engine overheating. Excessive ten­sion, or too little tension on the belt may result in ex-
cessive and premature belt wear. Poly-V belts, or serpentine belts, are retained by a belt tensioner that requires no tension adjustment. Replace the engine drive belt if any conditions described in the visual description are found. V-belts are installed as indi­vidual belts, and as matched sets. When replacing a matched set of belts, always replace both belts at the same time. Matched belts must be from the same manufacturer. To inspect a belt, gently twist the belt to view the belt sidewalls and bottom. Inspect all drive belts for the following conditions, then perform the belt tension inspection.
Belt Condition Inspection
1. Inspect the belt for glazing. See Fig. 2, Ref. A. Glazing is represented by shiny sidewalls, and is caused by friction created when a loose belt slips in the pulleys. It can also be caused by oil or grease contamination on the pulleys.
2. Check the belt for ply separation. See Fig. 2, Ref. B. Oil, grease, or belt dressing can cause the belt to fall apart in layers. Repair any oil or coolant leaks that are affecting the belts before replacing the drive belts. Do not use belt dress­ing on any belt.
3. Check the belt for a jagged or streaked sidewall. See Fig. 2, Ref. C. Jagged or streaked sidewalls are the result of foreign objects, such as sand or gravel in the pulley, or a rough pulley surface.
4. Check for tensile breaks (breaks in the cord body). See Fig. 2, Ref. D. Cuts in a belt are usu­ally caused by foreign objects in the pulley, or by prying or forcing the belt during removal or instal­lation.
5. Check for uneven ribs on serpentine (poly-V) belts. See Fig. 2, Ref. E. Foreign objects in the pulley will erode the undercord ribs, causing the belt to lose its gripping power.
6. Check the drive belts for cracks. See Fig. 2, Ref. F. Small irregular cracks are usually the signs of an old belt.
7. Inspect the pulleys for excessive play or wobble. Excessive play or wobble indicates a failure of the pulley bearing. Check for belt squealing or squeaking. Replace the bearings as necessary.
NOTE: If it is difficult to distinguish the location of a supposed bearing noise, obtain a stetho­scope and place it on the component being
Acterra Maintenance Manual, January 2007 01/1
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