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freightliner 108SD 2021, Driver Manual

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Table 7

lists all maintenance operations that are to

be performed at the M5 maintenance interval. Main-
tenance operation numbers are reference numbers
used to help you find detailed instructions in this

manual on the maintenance operations to be per-
formed. Perform all M1 (

Table 3

), M2 (

Table 4

), M3

(

Table 5

), and M4 (

Table 6

) maintenance interval

operations at the M5 maintenance interval.

M5 Maintenance Interval Operations

Number

Title

00-03

Perform All M1 Maintenance Interval Operations

00-04

Perform All M2 Maintenance Interval Operations

00-05

Perform All M3 Maintenance Interval Operations

00-06

Perform All M4 Maintenance Interval Operations

25-04

Fluid Change, Hydraulic Clutch Control

42-08

Foot-Control Valve, E-6, Inspection and Lubrication

Table 7, M5 Maintenance Interval Operations

General Information

00

00–07 M5 Maintenance Interval Operations

108SD and 114SD Maintenance Manual, April 2021

00/9

Summary of Contents for 108SD 2021

Page 1: ...est you call 1 800 FTL HELP www freightlinertrucks com FTL TSD S 496 Specifications are subject to change without notice Freightliner Trucks is a division of Daimler Trucks North America which is regi...

Page 2: ...108SD AND 114SD MAINTENANCE MANUAL Models 108SD 114SD STI 496 7 09 20 2021 Published by Daimler Trucks North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A...

Page 3: ......

Page 4: ...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 revisio...

Page 5: ...trieval 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...

Page 6: ...orma tion 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...

Page 7: ...tain 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 w...

Page 8: ...on lubricant specifications and suppliers call 1 800 826 4357 or see w roadranger com ww 6 Clean the fill plug then install it Tighten the plug as follows 25 to 35 lbf ft 34 to 48 N m for transmis sio...

Page 9: ...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 60 Cab 72 Doors 83 Heater and...

Page 10: ...0 04 M2 Maintenance Interval Operations 00 04 00 05 M3 Maintenance Interval Operations 00 05 00 06 M4 Maintenance Interval Operations 00 06 00 07 M5 Maintenance Interval Operations 00 07 00 08 Mainten...

Page 11: ......

Page 12: ...der normal conditions Ex amples of Schedule II usage are operation primarily in cities and densely popu lated areas local transport with infrequent freeway travel high percentage of stop and go travel...

Page 13: ...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 Schedule III long haul transp...

Page 14: ...rmed to complete the initial maintenance IM Initial Maintenance IM Operations Number Title 00 03 Perform All M1 Maintenance Interval Operations 31 01 Frame Fastener Torque Check 32 03 Suspension U Bol...

Page 15: ...her Check 31 02 Fifth Wheel Inspection 31 03 Fifth Wheel Lubrication 31 04 Trailer Electrical Connector Protection 32 01 Suspension Inspection 32 02 Suspension Lubrication 33 01 Knuckle Pin Lubricatio...

Page 16: ...or Meritor drivelines see the M2 maintenance interval If equipped with an oil coalescing desiccant cartridge replace the cartridge once a year regardless of mileage Otherwise use the M5 maintenance in...

Page 17: ...ange and Magnetic Plug Cleaning 41 02 Driveline Lubrication 42 03 Governor Check 42 04 Air Dryer Check 42 07 Meritor Camshaft Bracket Lubrication 46 04 Power Steering Gear Lubrication 47 02 Fuel Water...

Page 18: ...Perform All M1 Maintenance Interval Operations 00 04 Perform All M2 Maintenance Interval Operations 01 01 Engine Drive Belt Inspection 26 04 Allison Transmission Fluid and Filter Change 32 03 Suspensi...

Page 19: ...ion and Replacement 15 01 Alternator Battery and Starter Connections Check 20 02 Radiator Pressure Flush and Coolant Change 31 01 Frame Fastener Torque Check 33 05 Wheel End Inspection Front Axle 35 0...

Page 20: ...at the M5 maintenance interval M5 Maintenance Interval Operations Number Title 00 03 Perform All M1 Maintenance Interval Operations 00 04 Perform All M2 Maintenance Interval Operations 00 05 Perform A...

Page 21: ...0 24 000 1500 16th M1 M2 M3 and M4 16 000 25 600 1600 17th M1 17 000 27 200 1700 18th M1 18 000 28 800 1800 19th M1 19 000 30 400 1900 20th M1 and M2 20 000 32 000 2000 21st M1 21 000 33 600 2100 22nd...

Page 22: ...h M1 120 000 180 000 16th M1 M2 M3 M4 and M5 128 000 192 000 17th M1 136 000 204 000 18th M1 and M2 144 000 216 000 19th M1 152 000 228 000 20th M1 M2 and M3 160 000 240 000 21st M1 168 000 252 000 22...

Page 23: ...15th M1 375 000 603 000 16th M1 M2 M3 and M4 400 000 643 200 17th M1 425 000 683 400 18th M1 M2 and M3 450 000 723 600 19th M1 475 000 763 800 20th M1 M2 M3 and M4 500 000 804 000 21st M1 525 000 844...

Page 24: ...g with Noise Controls is Prohibited Federal law prohibits the following acts or the caus ing thereof 1 The removal or rendering inoperative by any per son other than for purposes of maintenance repair...

Page 25: ...Inspections Log Group 20 Verification of Inspections Log Group 20 Engine Cooling Radiator Date Mileage Item Cost Maintenance Facility Verification of Inspections Log Group 49 Verification of Inspectio...

Page 26: ...Title of Maintenance Operation MOP MOP Number Engine Drive Belt Inspection 01 01 Safety Precautions 01 00 Engine 01 Index Alphabetical 108SD and 114SD Maintenance Manual September 2015...

Page 27: ......

Page 28: ...t for a jagged or streaked sidewall Jagged or streaked sidewalls are the result of foreign objects such as sand or gravel in the pulley or a rough pulley surface 5 Check for tensile breaks breaks in t...

Page 29: ...1 2 3 4 5 6 7 8 1 Abrasion 2 Chunk out 3 Improper Install 4 Cracking 5 Pilling 6 Uneven Rib Wear 7 Misalignment 8 Gravel Penetration Fig 1 Damaged Belts Engine 01 108SD and 114SD Maintenance Manual S...

Page 30: ...89 1 2 6 4 5 3 1 Front Belt 2 Rear Belt 3 AC Compressor 4 Spring Tensioner 5 Fan Clutch 6 Water Pump Fig 3 DD 13 15 16 Drive Belt Routing 01 24 2011 f012192 1 2 3 4 5 6 1 Spring Tensioner 2 Alternator...

Page 31: ......

Page 32: ...Title of Maintenance Operation MOP MOP Number Air Cleaner Element Inspection and Replacement 09 01 Air Intake 09 Index Alphabetical 108SD and 114SD Maintenance Manual November 2014...

Page 33: ......

Page 34: ...ts After market air cleaner elements may not seal the housing correctly which can lead to engine dam age and potentially the loss of warranty When re placing an air cleaner element use only the part l...

Page 35: ......

Page 36: ...Title of Maintenance Operation MOP MOP Number Air Compressor Inspection 13 01 Safety Precautions 13 00 Air Compressor 13 Index Alphabetical 108SD and 114SD Maintenance Manual September 2015...

Page 37: ......

Page 38: ...ious 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 ho...

Page 39: ......

Page 40: ...intenance Operation MOP MOP Number Alternator Battery and Starter Connections Check 15 01 Safety Precautions 15 00 Alternators and Starters 15 Index Alphabetical 108SD and 114SD Maintenance Manual Sep...

Page 41: ......

Page 42: ...insulation kinks and heat damage Replace or repair as needed 5 Check that all electrical connections at the alter nator and starter are free of corrosion Clean and tighten all charging system electric...

Page 43: ......

Page 44: ...ber Fan Drive Check Noise Emission Control 20 03 Radiator Cap Inspection 20 01 Radiator Pressure Flush and Coolant Change 20 02 Safety Precautions 20 00 Engine Cooling Radiator 20 Index Alphabetical 1...

Page 45: ......

Page 46: ...radiator cap is correctly rated for the cooling system of the vehicle 2 There is a second valve in the radiator cap that opens under vacuum This prevents the collapse of hoses and other parts that are...

Page 47: ...nspection of the hub indicates ex cessive wear rebuild the hub using a hub rebuild kit from Kysor 6 Any time the clutch is removed for repair or re placement the pulley hub and bearings should be insp...

Page 48: ...f the 108SD and 114SD Workshop Manual for troubleshooting and repair proce dures 8 With the air system charged to 120 psi 827 kPa check for air leaks at the fan clutch sole noid valve air hoses and fi...

Page 49: ......

Page 50: ...Fuller Clutch Release Bearing Lubrication 25 01 Eaton Fuller Clutch Release Cross Shaft Lubrication 25 02 Fluid Change Hydraulic Clutch Control 25 04 Fluid Level Check Hydraulic Clutch Control 25 03 S...

Page 51: ......

Page 52: ...163 C and meets the NLGI grade two or three specifi cation 3 Wipe the dirt away from the grease fitting See Fig 1 Use a low pressure type grease gun equipped with the recommended grease and lubricate...

Page 53: ...ry NOTICE Do not allow the fluid level in the reservoir to go below the MIN line If air enters the system the hydraulic system will not operate correctly and the clutch could be damaged If the fluid l...

Page 54: ...ed valve on the bleed tank to pressurize the reservoir 4 2 Remove the cap from the bleed valve of the slave cylinder See Fig 5 On the valve install a transparent drain hose connected to a catch bottle...

Page 55: ...n 1 2 and 9 16 inch 12 7 and 14 3 mm 1 Remove the clutch inspection cover from the bell housing See Fig 6 2 Slide the clutch brake tight against the transmis sion input shaft bearing cap IMPORTANT Rel...

Page 56: ...utch brake is less than 1 2 inch 12 7 mm turn the adjustment bolt counter clockwise the release bearing moves to ward the engine 5 4 When the adjustment is complete make sure the adjustment bolt is lo...

Page 57: ......

Page 58: ...Change 26 04 Allison and Eaton Fuller Transmission Breather Check 26 03 Eaton Fuller Transmission Fluid Change and Magnetic Plug Cleaning 26 02 Safety Precautions 26 00 Transmission Fluid Level Check...

Page 59: ......

Page 60: ...s and correct as needed 5 If needed add Eaton approved fluid until it is level with the lower edge of the fill opening See Table 1 for approved transmission lubricants For more information and a compl...

Page 61: ...RAL 3 Operate the engine at idle 500 to 800 rpm until normal operating temperature is reached Check that the sump temperature is 160 to 200 F 71 to 93 C Check that the converter out temperature is 180...

Page 62: ...ate it in a counter clockwise motion to separate the filter from the mounting Carefully spin the filter off the mount and remove it from the ve hicle 6 3 Apply a light coat of transmission fluid to th...

Page 63: ...ld up which could cause oil leakage IMPORTANT Do not spray water steam or cleaning solution directly at the breather These actions can force water or cleaning solution into the transmission and contam...

Page 64: ...luid 3 Clean the area around the drain plug and the transmission fluid pan Place a drain pan under the transmission and remove the drain plug Ex amine the fluid as it drains 4 Remove the 12 mounting c...

Page 65: ...Trans mission specification TES 295 or TES 389 Cas trol TranSynd is a TES 295 fluid available through Allison distributors and dealerships See Table 4 for lubricant refill capacities Lubricant Refill...

Page 66: ...Wheel Inspection 31 02 Fifth Wheel Lubrication 31 03 Frame Fastener Torque Check 31 01 Safety Precautions 31 00 Trailer Electrical Connector Protection 31 04 Frame and Frame Components 31 Index Alpha...

Page 67: ......

Page 68: ...ly tightened Continued vehicle operation with loose fasteners could result in bracket or frame damage Check the fasteners at the following locations axle stops deck plates equalizer brackets exhaust b...

Page 69: ...rackets and mounting parts 3 Check the fastener torques on the fifth wheel assembly and fifth wheel mounting Tighten bolts and nuts as needed Replace missing or dam aged bolts 4 Inspect the fifth whee...

Page 70: ...in crease it 11 Replace cracked worn or damaged parts with new parts Replace all loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and...

Page 71: ...acket Pin 7 Bracket Retainer Pin 8 Cotter Pin 3 16 x 1 9 Bumper Spring 10 Handle Spring 11 Bolt Secondary Safety Lock 12 Flat Washer 13 Secondary Safety Lock 14 Bushing Secondary Safety Lock 15 Hex Lo...

Page 72: ...several times to test Repeat if nec essary See Fig 7 9 If the fifth wheel is equipped with a sliding mechanism inspect and adjust it as follows 9 1 Check the bracket for any cracks or miss ing and dam...

Page 73: ...fifth wheel top plate or compo nents WARNING Failure to properly lubricate the fifth wheel could result in a possible disengagement of the trailer from the tractor which could result in personal inju...

Page 74: ...s are full of grease Holland FWS1 Apply a heavy coat of grease to the top plate either through the grease fittings located on the underside of the top plate or by direct application Holland FW35 1 Usi...

Page 75: ...re no further lubrication 31 04 Trailer Electrical Connector Protection In some cases failure of trailer cables occurs due to intrusion of chloride based road deicing chemicals into the trailer connec...

Page 76: ...ration MOP MOP Number Safety Precautions 32 00 Suspension Inspection 32 01 Suspension Lubrication 32 02 Suspension U Bolt Torque Check 32 03 Suspension 32 Index Alphabetical 108SD and 114SD Maintenanc...

Page 77: ......

Page 78: ...eplace the bushings as needed Inspect the shock absorber for oil leakage If the shock absorber is damaged or leaking replace it with a new one See Group 32 of the 108SD and 114SD Workshop Manual for r...

Page 79: ...e vehicle unloaded attempt to move the equalizer side to side using a pry bar between the equalizer and frame rail Apply hand pressure only See Fig 3 If clearance between the equal izer assembly and a...

Page 80: ...ston for cracks chips and broken areas Check the air bag for rips tears and holes Verify that the air spring assem bly does not leak 4 Check the axle connection welds beam seat to equalizing beam and...

Page 81: ...ar tires on the floor and chock the tires on one axle only 3 Check that the height control valve vertical link age is connected and oriented correctly NOTE The stud bolt that fastens the height contro...

Page 82: ...g a visual in spection 3 Inspect the rubber bushings for cracks or other damage Try to move the torque rod ends using your hands only and check for any free play If free play is felt replace the torqu...

Page 83: ...evel surface apply the parking brakes and chock the front tires 2 Raise the rear of the vehicle until the rear wheels are suspended in the air then support the ve hicle with safety stands This relieve...

Page 84: ...alues Size Torque lbf ft N m 5 8 18 Stage 1 Hand tighten Stage 2 60 81 Stage 3 200 271 Stage 4 180 to 230 245 to 313 3 4 16 Stage 1 Hand tighten Stage 2 60 81 Stage 3 200 271 Stage 4 270 to 330 367 to...

Page 85: ......

Page 86: ...Knuckle Pin Lubrication 33 01 Safety Precautions 33 00 Steer Axle Hub Cap Vent Plug Inspection 33 06 Tie Rod Inspection 33 02 Tie Rod Lubrication 33 03 Wheel End Inspection Front Axle 33 05 Front Axl...

Page 87: ......

Page 88: ...until new grease is seen at the junctions of the axle beam and knuckles For locations of grease fittings see Fig 1 for grease exit points see Fig 2 Dana Spicer Axles Park the vehicle on a level surfac...

Page 89: ...rod boot for cracks tears or other damage If the tie rod boot is damaged replace the entire tie rod end 3 The threaded portion of the tie rod end assembly must be inserted all the way into the cross...

Page 90: ...ve no zerk fittings because they are not greaseable Do not install a zerk fitting on a nongreaseable tie rod end 10 Check that the cotter pin is in place If it is not tighten the tie rod end nut to on...

Page 91: ...st be held firmly in place so that a single straight line is scribed all the way around each front tire 5 Place a turn plate or turntable under both front tires Remove the safety stands and lower the...

Page 92: ...d brake shoes if installed If lubricant is present check the oil seal and replace it as nec essary For instructions see Section 33 02 of the 108SD and 114SD Workshop Manual 8 Inspect the lubricant for...

Page 93: ...lease the hub an accurate measurement is not possible 11 2 To seat the bearings grip the hub at the three o clock and nine o clock positions and push inward while oscillating it ap proximately 45 degr...

Page 94: ...ater to enter the hub and contaminate the oil For examples of a leaking vent plug see Fig 14 and Fig 15 Evidence of a leaking vent plug may appear as Oil splatter around the wheel Gooey gummy oil arou...

Page 95: ...vent plug clean with a rag 4 Remove the vent plug and check the oil for evi dence of water contamination If there is evidence of water contaminated oil in the hub disassemble the effected axle end cl...

Page 96: ...k 35 02 Axle Lubricant Level Check 35 01 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning and Check 35 03 Safety Precautions 35 00 Wheel End Inspection Rear Axle 35 04 Rear Axle 35 Inde...

Page 97: ......

Page 98: ...l fill hole This smaller hole is for the lubricant temperature sensor only and must not be used as a fill or level hole 3 Clean the oil fill hole plug located in the carrier or the side of the axle ho...

Page 99: ...ove the plug and check the oil level If low add fluid using the same lubricant recommended for the drive axle f350062a 10 05 2016 1 2 3 1 Axle Housing Breathers 2 Carrier Oil Fill Plugs 3 Interaxle Di...

Page 100: ...Actual oil capacity might vary slightly depending on gear ratio Table 2 Detroit Rear Axle Lubricant Capacity 35 02 Axle Breather Check The axle housing breather must remain clean When the axle lubric...

Page 101: ...Forward 56 1 26 5 Rear 36 1 17 1 Quantities listed are approximate and include 1 pint 0 5 liter for each wheel end and with the drive pinion at 3 degrees Table 5 Meritor Drive Axle Lubricant Capaciti...

Page 102: ...hould be level with the bottom of the oil fill hole 5 2 Check the fluid level see Fig 4 5 3 Install and tighten the fill plug 30 lbf ft 41 N m Meritor Axles IMPORTANT If using synthetic lubricant the...

Page 103: ...o thoroughly circulate lubricant throughout the carrier and housing assemblies Dana Spicer Axles NOTE If using a Roadranger synthetic drive axle lubricant the lubricant change interval is extended to...

Page 104: ...and tighten the fill plug 50 lbf ft 68 N m 35 04 Wheel End Inspection Rear Axle 1 Park the vehicle on a level surface shut down the engine set the parking brake and chock the tires WARNING Never work...

Page 105: ...d play with the wheel mounted on the hub Also ensure that the brakes are not ap plied so that that drum and hub can move freely 12 Using a dial indicator measure the end play as follows 12 1 Attach th...

Page 106: ...Title of Maintenance Operation MOP MOP Number Tire Check 40 02 Wheel Nut Check 40 01 Wheels and Tires 40 Index Alphabetical 108SD and 114SD Maintenance Manual December 2015...

Page 107: ......

Page 108: ...t apply thread lubricant to ball seats of the nuts and wheels Wipe it off if it is applied accidentally Table 1 Disc Wheel Fastener Torques 40 02 Tire Check Tires should be inspected closely during th...

Page 109: ......

Page 110: ...e of Maintenance Operation MOP MOP Number Driveline Inspection 41 01 Driveline Lubrication 41 02 Safety Precautions 41 00 Driveline 41 Index Alphabetical 108SD and 114SD Maintenance Manual September 2...

Page 111: ......

Page 112: ...tions listed in Table 1 3 Check the driveline yokes for cracks and check end yokes for looseness see Fig 2 Replace cracked yokes If any end yoke can be moved in or out on its shaft or can be rocked on...

Page 113: ...plug and knocking it out contact your Regional Service Office for assis tance in determining the correct driveshaft length 41 02 Driveline Lubrication Universal Joint Lubrication NOTE Vehicles equipp...

Page 114: ...w 5 Bearing Cup for full round yoke 6 U Joint Cross 7 Bearing Cup for half round yoke 8 Bearing Strap and Bearing Strap Capscrew 9 Slip Joint Assembly 10 Sleeve Yoke full round 11 Dust Cap 12 Splined...

Page 115: ...d replace the U joint f410012a 10 06 2016 Attempt to move the sleeve yoke and splined shaft back and forth Fig 3 Slip Joint Spline Wear Checking f410155a 10 06 2016 1 1 1 2 MERI TOR 1 Self Locking Cap...

Page 116: ...a low pressure adapter to lubricate the slip joint Add multipurpose chassis grease lithium 12 hydroxy stearate NLGI Grade 2 with EP additives until it appears at the pressure relief hole in the yoke...

Page 117: ......

Page 118: ...ng and Leakage Tests 42 12 Brake Inspection 42 05 Foot Control Valve E 6 Inspection and Lubrication 42 08 Governor Check 42 03 Meritor Camshaft Bracket Lubrication 42 07 Safety Precautions 42 00 Slack...

Page 119: ......

Page 120: ...ing bracket strap 6 Remove the two bolts and Nylok nuts that se cure the air dryer to the lower mounting bracket Mark the position of the mounting bracket to the end cover and mark the bolts to ease i...

Page 121: ...ts four washers and two new Nylok nuts Torque the two remaining Nylok nuts 17 to 24 lbf ft 23 08 09 95 f421383 1 2 3 4 5 9 10 11 12 13 14 15 17 18 19 21 22 23 24 25 10 10 10 10 10 10 6 7 8 8 8 20 16 1...

Page 122: ...tridge sealing rings 6 Inspect the end cover for physical damage then inspect all air line fittings for corrosion replace as necessary 7 Clean and inspect the bolt paying attention to the threads and...

Page 123: ...at the time the governor cuts out stopping the compression of air by the compressor Cut out pressure should be in ac cordance with the pressure setting of the piece number being used Common cut out pr...

Page 124: ...e air source has been used to charge the system This air did not pass through the drying bed 1 2 Air usage is exceptionally high and not normal This may be due to high air sys tem leakage 1 3 In areas...

Page 125: ...replace the heater and thermostat assembly 6 On the AD IS dryer reservoir module DRM only observe the pressure gauges of the vehicle as system pressure builds from zero The primary gauge should rise u...

Page 126: ...d 114SD Workshop Manual NOTE In all steps that require a torque wrench use a Snap On torque wrench ATECH4RS600 or an equivalent with a center to handle length of 47 inches 119 cm 4 Set a torque wrench...

Page 127: ...D Work shop Manual 6 Remove the jack stands and lower the vehicle Radial Mounted Brakes Bendix Calipers 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the t...

Page 128: ...08SD and 114SD Work shop Manual 6 Remove the jack stands and lower the vehicle WABCO Maxxus Calipers 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tire...

Page 129: ...ge personal injury or death 2 With the engine off and 100 psi 690 kPa of air tank pressure have an assistant apply and hold an 80 to 90 psi 552 to 621 kPa brake applica tion 3 Check to see if the colo...

Page 130: ...components for damage wear and loose or missing parts Re pair as needed See Group 42 of the 108SD and 114SD Workshop Manual for repair procedures f422657 07 30 2018 1 2 3 4 4 3 2 1 A B Tighten the fa...

Page 131: ...30 2 51 Long Stroke 30 2 1 2 64 Meritor Standard Stroke 9 Less than 1 1 2 38 12 16 Less than 1 3 4 44 20 24 Less than 1 7 8 48 Long Stroke 24 Less than 2 51 Standard Stroke 30 Long stroke design is i...

Page 132: ...or a clay base grease Lubricate the slack adjuster at the grease fitting until grease is forced past the pressure relief capscrew or past the gear splines around the inboard snap ring See Fig 9 Haldex...

Page 133: ...grease fitting on the camshaft bracket or the spider until new grease flows from the inboard seal See Fig 13 WARNING If grease leaks out under the camhead the cam shaft bracket grease seal is worn or...

Page 134: ...te to the cot ter pin 8 Remove the plunger from the valve Clean the existing grease from the plunger using alcohol Check the plunger for signs of wear or cracks Replace it as needed 9 Lubricate the pl...

Page 135: ...s 12 Make and hold a full service brake application allowing the pressure to stabilize for one minute Observe the installed service reservoir gauges The pressure should not drop more than 15 psi 103 k...

Page 136: ...released 20 3 Completely drain the primary reservoir 20 4 Make a modulated service brake applica tion Both front and rear brakes should modulate At a steady full brake applica tion the pressure should...

Page 137: ...ween the clevis and adapter bushing and the yoke and link pins and their mating parts clevis body link Replace these parts if loose ness appears excessive Make certain the brake actuator pushrod jam n...

Page 138: ...nual Leakage Test Perform the following test after repairing or replacing the DV 2 valve to ensure that the valve is function ing properly With the system charged and pressure stabilized in the system...

Page 139: ......

Page 140: ...46 01 Drag Link Lubrication 46 05 Power Steering Fluid Level Inspection 46 03 Power Steering Fluid and Filter Change 46 02 Power Steering Gear Lubrication 46 04 Safety Precautions 46 00 Steering 46 In...

Page 141: ......

Page 142: ...uc tions If there is 1 8 inch 3 mm movement or more do not drive the vehicle until the drag link is re placed If a ball stud nut is loose replace the nut and cotter pin See Section 46 03 of the 108SD...

Page 143: ...he new filter Then attach the filter to the filter cover Hand tighten the filter then turn it an additional 1 4 turn 13 Install the filter and filter cover in the reservoir Make sure that the gasket u...

Page 144: ...Drag Link Lubrication 1 Using a clean rag wipe all dirt from both drag link grease fittings see Fig 4 2 Using a grease gun apply clean grease at the grease fittings until old grease is forced out of...

Page 145: ......

Page 146: ...sure Fuel Filter Element Replacement 47 07 Fuel Filter Replacement 47 03 Fuel Tank Band Nut Tightening 47 01 Fuel Water Separator Element Check and Replacement 47 02 LNG Fuel System Inspection 47 04 L...

Page 147: ......

Page 148: ...RTANT When draining fluid from a fuel water separator drain the fluid into an ap propriate container and dispose of it properly Many states now issue fines for draining fuel water separators onto the...

Page 149: ...ly clogged 1 Shut down the engine apply the parking brake and chock the tires 2 Check the fuel level in the fuel filter Replace the fuel water separator element only when the filter element is complet...

Page 150: ...using and hand tighten the collar until it no longer spins freely Using the collar wrench tighten the cover 18 lbf ft 24 N m This is equivalent to rotating the collar clockwise two or three additional...

Page 151: ...es 2 Check the fuel level in the fuel filter Replace the fuel water separator element only when the filter element is completely covered If the fuel level has reached the top of the filter element fol...

Page 152: ...k may result 8 Install the new filter and grommet assembly and cover O ring on the housing Position the filter element so the key is lined up with the keyway on the separator plate of the housing Use...

Page 153: ...turned from the engine or engine coolant Drain the fuel water separator only when the engine and fluids have cooled Draining it when the engine is hot could cause severe personal injury due to scaldin...

Page 154: ...ocated in high areas where rising gas vapors will pass by or ac cumulate Do not use a high pressure washer steam cleaner or silicone based chemicals on the gas detection sensors as this may permanentl...

Page 155: ...alve fuel shutoff valve fill check valve 2 Inspect the fuel fill line for signs of damage kinked or crushed piping or chafing 3 Ensure the red cap is present on the secondary relief valve 4 Inspect th...

Page 156: ...d valve for signs of leaks or damage Inspect the solenoid mount ing bracket for looseness 6 Inspect the overpressure regulator for signs of leaks or damage 6 1 Ensure that the regulator is mounted se...

Page 157: ...tank pressure and note the time 7 Allow the vehicle to stand for at least eight hours then record the fuel tank pressure again 8 Use Table 1 to determine whether the pressure increase is within an acc...

Page 158: ...dition See Fig 12 5 Inspect the pressure gauges on the fuel box for cracks Ensure the indicator needles are present and in working condition Inspect the gauge faces for accuracy and legibility 6 Ensu...

Page 159: ...necessary replace the O ring 11 Install the filter bowl on the filter housing Tighten 90 lbf ft 122 N m 12 Close the bleed valve on the manifold and open the manual fuel shutoff valve on the fuel pan...

Page 160: ...ten re port should be provided for each container inspected Place an inspection label stating the inspection date and inspecting agency identification on each con tainer 05 04 2010 f470557 2 2 3 4 5 6...

Page 161: ......

Page 162: ...tle of Maintenance Operation MOP MOP Number Exhaust System Inspection Noise Emission Control 49 01 Safety Precautions 49 00 Exhaust 49 Index Alphabetical 108SD and 114SD Maintenance Manual December 20...

Page 163: ......

Page 164: ...owner s responsibility to maintain the vehicle so that it conforms to EPA regulations EPA10 and Newer Exhaust System Definitions of Aftertreatment ATS Terms NOTE Diagrams of ATS configurations are pr...

Page 165: ...seal clamp is loosened or removed it must be replaced 3 If present check the condition of the insulation material around the exhaust pipe between the turbocharger and the ATD 4 Check the ATD mounting...

Page 166: ...Port 3 DOC Inlet Temperature Sensor 4 Front Heat Shield 5 DEF Nozzle 6 Exhaust Outlet 7 DEF Metering Unit 8 Sensor Box see note above 9 Exhaust Inlet 10 SCR Outlet Temperature Sensor 11 SCR Outlet NO...

Page 167: ...ure Sensor 5 DOC Inlet Temperature Sensor 6 DOC Inlet Pressure Sensor 7 DPF Inlet Temperature Sensor 8 DPF Outlet Pressure Sensor 9 DPF Outlet Temperature Sensor 10 DPF Outlet NOx Sensor 11 SCR Outlet...

Page 168: ...nsor Box 5 DPF Outlet Pressure Sensor 6 DPF Outlet Temperature Sensor 7 DPF Outlet NOx Sensor 8 SCR Inlet Temperature Sensor 9 DEF Metering Unit 10 SCR Outlet Temperature Sensor 11 SCR Sensor Box 12 S...

Page 169: ...nsor 6 SCR Inlet Temperature Sensor 7 SCR Catalyst 8 DOC Inlet Temperature Sensor 9 DPF Inlet Temperature Sensor 10 DPF Inlet Pressure Sensor 11 DPF Outlet Temperature Sensor 12 DPF Outlet Pressure Se...

Page 170: ...PF Outlet Temperature Sensor 5 DEF Injector 6 NOx Sensor 7 SCR Outlet Temperature Sensor 8 SCR Catalyst 9 SCR Inlet Temperature Sensor 10 Mixer Tube 11 DPF Outlet Pressure Sensor 12 DPF Inlet Pressure...

Page 171: ...t Pressure Sensor 6 DEF Injector 7 Mixer Tube 8 SCR Inlet Temperature Sensor 9 SCR Outlet Temperature Sensor 10 DOC Inlet Temperature Sensor 11 DPF Inlet Temperature Sensor 12 DPF Outlet Temperature S...

Page 172: ...nce Operation MOP MOP Number Electrical Component Inspection 54 02 Trailer Cable Inspection and Cleaning 54 01 Electrical Instruments and Controls 54 Index Alphabetical 108SD and 114SD Maintenance Man...

Page 173: ......

Page 174: ...nt exterior for signs of thermal distortion warping bulging discoloration amper age related heating color variance or shading across component which could be a sign of inter nal failure requiring repl...

Page 175: ...st be replaced 11 Inspect component harnesses for secured rout ing that prevents excess harness movement and prevents the harness from pulling too tight on the connector Inspect harnesses for signs of...

Page 176: ...Title of Maintenance Operation MOP MOP Number Aerodynamic Component Inspection 60 02 Mirror Folding Check 60 01 Cab 60 Index Alphabetical 108SD and 114SD Maintenance Manual June 2012...

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Page 178: ...break loose any debris that may affect the fold away feature of the mirror 60 02 Aerodynamic Component Inspection Inspect aerodynamic components if equipped for structural damage cracks or wear These...

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Page 180: ...Title of Maintenance Operation MOP MOP Number Door Seals Lubrication 72 01 Doors 72 Index Alphabetical 108SD and 114SD Maintenance Manual April 2011...

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Page 182: ...ication Do not lubricate the door latches or hinges They come from the manufacturer with lifetime lubrication and require no maintenance Lightly coat the door seals with a lubricant that is safe for r...

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Page 184: ...ce Operation MOP MOP Number Air Conditioner Inspection 83 01 HVAC Air Filter Replacement 83 02 Safety Precautions 83 00 Heater and Air Conditioner 83 Index Alphabetical 108SD and 114SD Maintenance Man...

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Page 186: ...account for pulley misalign ment If the overall gap is out of spec remove the drive plate assembly and change the shims as necessary For instructions see Section 83 02 Subject 140 of the 108SD and 11...

Page 187: ...10 04 2001 f543921 2 1 1 Evaporator 2 Filter Fig 1 HVAC Assembly Filter Heater and Air Conditioner 83 108SD and 114SD Maintenance Manual September 2015 83 2...

Page 188: ...Title of Maintenance Operation MOP MOP Number Hood Rear Support Lubrication 88 01 Hood Grille and Cab Fenders 88 Index Alphabetical 108SD and 114SD Maintenance Manual April 2011...

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Page 190: ...rear sup port brackets and isolators with an approved multi purpose lithium complex soap based grease see Table 1 Approved Suppliers of Multi Purpose Lithium Grease Supplier Grease Chevron Delo Heavy...

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