freightliner PE116DC Page 47 Maintenance Manual Download

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Title of Maintenance Operation (MOP)

MOP Number

Clutch Release Bearing Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–01

Fluid Change, Hydraulic Clutch Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–03

Fluid Level Check, Hydraulic Clutch Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–02

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–00

Clutch

Index, Alphabetical

New Cascadia Maintenance Manual, September 2018

Summary of Contents for PE116DC

Page 1: ...NEW CASCADIA MAINTENANCE MANUAL Models PT126SLP PT126DC PE116SLP PE116DC STI 500 10 02 03 2022 Published by Daimler Trucks North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A...

Page 2: ......

Page 3: ...inue 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 express...

Page 4: ...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 Tr...

Page 5: ...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 Driv...

Page 6: ...s 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...

Page 7: ...yoke and yoke nut Replace the prevailing torque locknut end y oke nut if it was removed for yoke replacement seal replacement or any other reason 4 Check U jointassemblies for wear by moving the drive...

Page 8: ...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 Co...

Page 9: ...ons 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 0...

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Page 11: ...ance Interval Operation Table for a list of the maintenance opera tions to be performed at that maintenance interval Use the maintenance operation reference numbers to find detailed instructions in th...

Page 12: ...6 000 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 firs...

Page 13: ...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 2...

Page 14: ...1 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...

Page 15: ...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 0...

Page 16: ...5 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 0...

Page 17: ...es 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 Inf...

Page 18: ...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...

Page 19: ...shaft Bracket Lubrication 42 10 WABCO System Saver Air Dryer Desiccant Cartridge Replacement 42 11 Versajust Slack Adjuster Inspection and Lubrication 42 12 Bendix Automatic Drain Valve Operating and...

Page 20: ...uller Manual Transmission Air Filter Regulator Check Cleaning or Replacement 32 01 Suspension Inspection 32 02 Suspension U Bolt Torque Check 33 01 Knuckle Pin Lubrication 33 02 Tie Rod Inspection 33...

Page 21: ...or Pressure Flushing and Coolant Change 25 03 Fluid Change Hydraulic Clutch Control 26 03 Eaton Fuller Transmission Fluid Change and Magnetic Plug Cleaning 35 01 Axle Lubricant and Filter Change and M...

Page 22: ...uid Level Inspection 26 05 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 Ch...

Page 23: ...eeper Access Door Release Cable and Latch Lubrication 83 01 Air Conditioner Inspection 83 02 Air Filter Replacement 83 03 Battery Powered HVAC System BPHS Inspection On vehicles equipped with Detroit...

Page 24: ...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 or re...

Page 25: ...n 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 Faci...

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Page 27: ...Title of Maintenance Operation MOP MOP Number Air Cleaner Inspection 09 01 Air Intake 09 Index Alphabetical New Cascadia Maintenance Manual January 2017...

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Page 29: ...essary replace the air cleaner element For air cleaner element replacement instructions see Group 09 of the New Cascadia Workshop Manual 3 Inspect the air cleaner housing for cracks leaks or any other...

Page 30: ...t 6 Clamp 7 Intake Duct 8 Clamp Fig 3 Air Cleaner Assembly 01 17 2012 f090496 1 2 1 Steel Plate 2 Rubber Fig 4 Mounting Isolator f090530 06 02 2016 1 2 A 3 A Check this connection 1 Air Cleaner 2 Reso...

Page 31: ...Title of Maintenance Operation MOP MOP Number Air Compressor Inspection 13 01 Safety Precautions 13 00 Air Compressor 13 Index Alphabetical New Cascadia Maintenance Manual January 2017...

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Page 33: ...th 13 01 Air Compressor Inspection 1 Inspect the air compressor intake hoses and connections at the air intake at the air cleaner the resonator and the air compressor for physi cal damage or loose con...

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Page 35: ...Maintenance Operation MOP MOP Number Alternator Battery and Starter Connections Check 15 01 Safety Precautions 15 00 Alternators and Starters 15 Index Alphabetical New Cascadia Maintenance Manual Janu...

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Page 37: ...all charging system electrical connections including the connections at the starter B terminal and ground terminal and where the alternator charg ing cable terminates 4 Inspect the battery cables for...

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Page 39: ...Fan Clutch Check Noise Emission Control 20 03 Pressure Relief Cap Check 20 01 Radiator Pressure Flushing and Coolant Change 20 02 Safety Precautions 20 00 Engine Cooling Radiator 20 Index Alphabetical...

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Page 41: ...place ment cap is correctly rated for the cooling system of the vehicle Use the recommended tool in Table 1 Tool Part Number Radiator Cap Tester TA53 Table 1 Snap On Tool For Pressure Relief Cap Test...

Page 42: ...lamps see Fig 2 or Breeze Constant Torque clamps see Fig 3 When working with T bolt hose clamps tighten the clamps 55 lbf in 620 N cm These clamps are now standard on hoses with an in diameter greater...

Page 43: ...Warner Service Alert Tool is available at no cost To get one contact your Borg Warner representative If the tool is not available use a 0 062 inch 1 57mm feeler gauge to check the clutch wear 2 Using...

Page 44: ...ir system to 120 psi 827 kPa Manually engage and disengage the fan clutch Check the fan and fan clutch from a distance Look for vibration fan blade contact fan clutch slippage and overall fan clutch o...

Page 45: ...ove the drive belt and check for worn sheave bearings by turn ing the sheave in both directions 11 3 If either the hub or sheave bearings are worn replace them using a Horton Drive Master Super Kit se...

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Page 47: ...umber Clutch Release Bearing Lubrication 25 01 Fluid Change Hydraulic Clutch Control 25 03 Fluid Level Check Hydraulic Clutch Control 25 02 Safety Precautions 25 00 Clutch 25 Index Alphabetical New Ca...

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Page 49: ...e clutch inspection plate to see the release bearing while lubricating it See Fig 1 3 Clean the grease fitting On some vehicles a lube tube will be used and the fitting may be at the 9 o clock positio...

Page 50: ...anual bleeding requires two WARNING Hydraulic clutch control fluid DOT 4 brake fluid is hazardous It may be a skin irritant and can cause blindness if it gets in your eyes Always wear safety glasses w...

Page 51: ...t 0 5 liter of fluid It may need to be refilled during the bleeding process to pre vent air from re entering the system 2 Remove the reservoir lid and fill the reservoir see Fig 3 with new DOT 4 brake...

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Page 53: ...n Fluid Level Inspection 26 02 Eaton Fuller Manual Transmission Air Filter Regulator Check Cleaning or Replacement 26 05 Eaton Fuller Transmission Fluid Change and Magnetic Plug Cleaning 26 03 Eaton F...

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Page 55: ...ission to neu tral N and shut down the engine 1 Apply the parking brakes and chock the rear tires Place a large drain pan under the transmis sion 2 Clean the area around the fill plug then remove it f...

Page 56: ...wer edge of the fill opening See the Transmission Fluid Service Information bro chure at http dtna info DT12FluidsManual for approved transmission lubricants 5 Clean the fill plug and install a new se...

Page 57: ...es to firmly tighten the filter Wipe the filter clean of any fluid after it is tightened 6 Add fluid until it is level with the lower edge of the fill opening See Fig 2 If the transmission has two fil...

Page 58: ...luid level For transmissions not so equipped check the fluid level at the fill plug Checking at the Fill Plug 1 Clean the area around the fill plug and remove it from the side of the gear case 2 Using...

Page 59: ...If the air regulator is not keep ing air pressure between 58 and 63 psi 400 and 435 kPa replace the air filter regulator It cannot be repaired 1 Drain Plug 2 Fill Plug 3 Sight Glass Fig 3 Eaton Fulle...

Page 60: ...g with a clean dry lint free rag Clean and inspect the O rings and end cap Replace any parts that are damaged 5 Install the large O ring then the filter element small end first into the filter housing...

Page 61: ...MOP MOP Number Fifth Wheel Inspection 31 01 Fifth Wheel Lubrication 31 02 Frame Fastener Torque Check 31 03 Safety Precautions 31 00 Frame and Frame Components 31 Index Alphabetical New Cascadia Main...

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Page 63: ...les while servicing the fifth wheel Failure to do so can result in personal injury due to parts ejecting with force Holland FW35 1 Disconnect the tractor from the trailer For in structions see the veh...

Page 64: ...unter clockwise to 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 u...

Page 65: ...Grease Fitting 6 Bracket 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 S...

Page 66: ...rs are loose in spect and replace locking mechanism parts as needed 9 5 The inboard slider is adjustable for frame width and plunger engagement For ad justment refer to the fifth wheel installa tion i...

Page 67: ...tial amount of grease may be required initially to fill the reservoir Tilt the fifth wheel ramps down the rear of the fifth wheel is down and repeat the greasing pro cedure Rock the top plate back and...

Page 68: ...he release handle and spring see Fig 8 Grease the mounting bracket supports through the grease fittings A low temp grade grease rated for 30 F 34 C or lower such as Cato Oil and Grease 5213 Craftsman...

Page 69: ...cking torque torque the nut not the bolt head whenever possible This will give a true torque read ing by eliminating bolt body friction When checking the torque of frame fasteners inspect the frame fo...

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Page 71: ...of Maintenance Operation MOP MOP Number Safety Precautions 32 00 Suspension Inspection 32 01 Suspension U Bolt Torque Check 32 02 Suspension 32 Index Alphabetical New Cascadia Maintenance Manual 03 01...

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Page 73: ...ension Shock Absorber Check Make sure the shock absorber brackets are tight and the shock absorber is not striking or rubbing the frame or some other part of the chassis Striking or rubbing the frame...

Page 74: ...ng studs are threaded into the valve body loosening the nuts without holding the studs can tighten the studs which can crush the valve body and damage the valve Conversely tightening the nuts without...

Page 75: ...320838b 02 21 2017 A Measure Point Suspension Height Measurement Min Target Max A Measure Here 2 3 8 inch 60 mm 2 5 8 inch 67 mm 2 7 8 inch 73 mm Table 1 Suspension Ride Height Measurement Dual Leaf S...

Page 76: ...Suspension Ride Height Measurement Single Leaf Spring 40k Low and Mid Ride f321046a 02 21 2017 A Measure Point Suspension Height Measurement Min Target Max A Measure Here 2 3 4 inch 70 mm 3 inch 76 m...

Page 77: ...wn in Fig 3 Set a click type torque wrench to the mid point torque value for the fas tener being checked Turn the wrench in a clock wise motion looking up until the torque wrench clicks then release p...

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Page 79: ...e Alignment Check 33 04 Knuckle Pin Lubrication 33 01 Safety Precautions 33 00 Steer Axle Hub Cap Vent Plug Inspection 33 05 Tie Rod Inspection 33 02 Tie Rod Lubrication 33 03 Front Axle 33 Index Alph...

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Page 81: ...lubricating knuckle pin bushings do not raise the front axle Wipe the lube fittings clean and apply multipurpose chassis grease NLGI Grade 1 6 12 hydroxy lithium stearate grease or NLGI Grade 2 8 12...

Page 82: ...cations in Group 35 of the New Cascadia Workshop Manual Toe In Inspection For vehicle alignment to be accurate the shop floor must be level in every direction The turn plates for the front wheels must...

Page 83: ...s from the rear tires and release the parking brakes Move the vehicle backward then for ward about six feet two meters 6 Place a trammel bar at the rear of the front tires locate the trammel pointers...

Page 84: ...ater to enter the hub and contaminate the oil For examples of a leaking vent plug see Fig 9 and Fig 10 Evidence of a leaking vent plug may appear as Oil splatter around the wheel Gooey gummy oil aroun...

Page 85: ...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...

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Page 87: ...P Number Axle Breather and Axle Lubricant Level Inspection 35 02 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning 35 01 Safety Precautions 35 00 Rear Axle 35 Index Alphabetical New Casc...

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Page 89: ...including tandem drive axles and two speed axles perform the applicable procedures under the heading All Axle Models For a two speed axle with a shift unit also change the shift unit lubricant see un...

Page 90: ...ig 5 5 2 Install and tighten the fill plug 30 lbf ft 41 N m Detroit Drive Axle Lubricant Model 4 and Model 6 Lubricant Type Ambient Temperature Mobil Delvac 1 Gear Oil 75W 90 Synthetic 40 F 40 C and u...

Page 91: ...tiveness as collected mate rial bridges the gap between the two poles 4 3 After the first oil is changed inspect the drain plug each time for large quantities of metal particles 5 Fill the axle with t...

Page 92: ...extreme pressure additives so the lubricant change schedule must be shortened when using these additives The traction equalizer additive and recommended drive axle lubricant must be changed at the Mai...

Page 93: ...OTE Some Meritor axles have a small tapped and plugged hole near and below the housing lubricant fill hole This smaller hole is for a lubricant temperature indicator only and should not be used as a f...

Page 94: ...e the magnetic strainer from the power divider cover WARNING Always wear eye protection when using com pressed air to clean parts as flying debris could cause permanent damage to unprotected eyes Do n...

Page 95: ...ted are approximate Fill axle until lubricant is level with bot tom of fill hole with vehicle on level ground Add 2 pints 1 L of additional lubricant to the power divider Table 8 Dana Spicer Drive Axl...

Page 96: ...king brake Chock the tires 2 If the vehicle has just been driven allow a few minutes for the lubricant to settle 3 Clean the fill plug and the area surrounding the fill plug on the side of the axle ca...

Page 97: ...nt level when the axle is cold or near room temperature NOTE Some Meritor axles have a small tapped and plugged hole near and below the housing oil fill hole This smaller hole is for a lubricant tempe...

Page 98: ...Shift Unit Dana Spicer and Meritor IMPORTANT Also do the appropriate procedure under the heading All Axle Models NOTICE Failure to keep lubricant at the specified level could cause damage to the axle...

Page 99: ...a small amount of Loctite 242 or equivalent sealant Install the fill plug finger tight in the rear axle shift unit housing Using a wrench tighten it an addi tional 1 1 2 turns Rear Axle 35 New Cascadi...

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Page 101: ...Title of Maintenance Operation MOP MOP Number Tire Check 40 02 Wheel Nut Check 40 01 Wheels and Tires 40 Index Alphabetical New Cascadia Maintenance Manual January 2017...

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Page 103: ...m Oiled M22 x 1 5 450 500 610 678 NOTE If using specialty fasteners consult the manufacturer for recommended torque levels Table 1 Disc Wheel Fastener Torque 40 02 Tire Check Tires should be inspecte...

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Page 105: ...itle of Maintenance Operation MOP MOP Number Driveline Inspection 41 01 Driveline Lubrication 41 02 Safety Precautions 41 00 Driveline 41 Index Alphabetical New Cascadia Maintenance Manual January 201...

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Page 107: ...m Fig 1 Meritor RPL U joints except RPL35 125 lbf ft 169 N m Fig 2 Meritor RPL35 U joints 150 lbf ft 200 N m Fig 4 U joints with yoke straps 125 lbf ft 169 N m Fig 3 Table 1 U Joint Torque Specificat...

Page 108: ...ications Replace the midship bearing as sembly if the rubber cushion is deteriorated or oil soaked 6 Check slip joints for spline wear by moving the sleeve yoke and splined shaft back and forth See Fi...

Page 109: ...lug as needed If the yoke plug is missing the splined shaft may be hitting the plug and knocking it out contact your Regional Service Office for assistance in deter mining the correct driveshaft lengt...

Page 110: ...e with a plastic or rawhide mallet on the side oppo site the dry seal while continuing to lubricate If grease still does not appear loosen the cap screws at the bearing with the dry seal to relieve se...

Page 111: ...akage Tests 42 12 Bendix E 6 Foot Control Valve Inspection and Lubrication 42 09 Brake Inspection 42 05 Haldex Slack Adjuster Lubrication 42 06 Meritor Camshaft Bracket Lubrication 42 07 Meritor Slack...

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Page 113: ...sidual air pressure open the line slowly 3 Identify tag and disconnect the three air lines from the end cover 4 Disconnect the harness connector from the heater and thermostat assembly 5 Loosen the bo...

Page 114: ...6 bolts 12 washers and 6 new Nylok nuts Torque the Nylok nuts in a star pattern 17 to 24 lbf ft 23 to 33 N m See Fig 2 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...

Page 115: ...r tridge bolt 5 Using a clean rag wipe clean the inside of the end cover Clean the cartridge bolt bore in the end cover and the sealing surfaces for the large and small diameter desiccant cartridge se...

Page 116: ...the discharge Some trace of water in the discharge is normal A discharge of a milky gray liquid indi cates excessive moisture is present in the air system and the desiccant cartridge needs to be repla...

Page 117: ...C mea sured resistance should be infinite ohms If the heater thermostat does not operate as outlined replace it If it does operate as outlined install it 42 04 Alcohol Evaporator Cleaning and Inspect...

Page 118: ...ounted Brakes IMPORTANT The following information applies to all types of axial mounted brake applications 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock th...

Page 119: ...ia Workshop 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 120: ...New Cascadia Workshop 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 tires 2...

Page 121: ...age 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 col...

Page 122: ...for damage wear and loose or missing parts Re pair as needed See Group 42 of the New Cas cadia Workshop Manual for inspection trouble shooting and repair procedures f422657 07 30 2018 1 2 3 4 4 3 2 1...

Page 123: ...ke 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...

Page 124: ...special NLGI Grade synthetic polyurea grease and do not require lubrication for 3 years or 500 000 miles 800 000 km whichever comes first The extended maintenance camshaft bushings are lubricated duri...

Page 125: ...dragging brakes or a brake failure resulting in property damage personal injury or death NOTE If equipped with an extended maintenance Q Plus brake system the slack adjuster will not have a grease fit...

Page 126: ...a from which the pivot pin was removed Re place it if necessary 6 Check the brake pedal rollers for signs of wear or cracks Replace the rollers as needed 7 If the rollers are replaced replace the roll...

Page 127: ...4 Clean the top surface of the dryer base with a commercial cleaning solvent IMPORTANT If the air dryer base is damaged preventing a tight seal replace the air dryer 5 Using a multipurpose high temper...

Page 128: ...Inches 30 Long Stroke 2 1 2 24 Long 2 24 Long Stroke 2 1 2 20 Long 2 16 Long 2 Table 4 Actuator Stroke Long Stroke 42 12 Bendix Automatic Drain Valve Operating and Leakage Tests Operating Test Perfor...

Page 129: ...ber Drag Link Inspection 46 01 Drag Link Lubrication 46 04 Power Steering Fluid and Filter Change 46 02 Power Steering Gear Lubrication 46 03 Safety Precautions 46 00 Steering 46 Index Alphabetical Ne...

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Page 131: ...r axial movement in the ball stud end If it is loose re place the drag link See Group 46 of the New Cascadia Workshop Manual for replacement in structions If there is 1 8 inch 3 mm movement or more do...

Page 132: ...urn the steering wheel from full left to full right several times Add fluid to the reservoir as needed to maintain the fluid level between the MIN COLD and MAX HOT lines 16 Shut down the engine 17 Rai...

Page 133: ...stearate grease or NLGI Grade 1 6 12 hydroxy lithium stearate grease chassis grease apply clean grease at the grease fittings until old grease is forced out of the socket f461072 10 07 2016 2 1 1 Grea...

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Page 135: ...MOP Number Fuel Filter Replacement 47 01 Fuel Tank Band Nut Tightening 47 03 Fuel Water Separator Element Checking and Replacement 47 02 Safety Precautions 47 00 Fuel 47 Index Alphabetical New Cascadi...

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Page 137: ...and fluids have cooled Draining it when the engine is hot could cause severe personal injury due to scalding If returning fuel is released into the atmosphere its vapors can ignite in the presence of...

Page 138: ...t one to one and a half revolutions 4 Remove the vent cap shown in Fig 2 to drain the fuel completely then close the drain valve 5 Using a DAVCO Collar Wrench shown in Fig 3 remove the clear cover and...

Page 139: ...lve 3 Inlet Port Check Valve 4 12VDC Pre Heater 5 120VAC Pre Heater 6 Bypass Valve 7 Filter Element 8 Spring 9 Cover O Ring 10 Clear Cover 11 Vent Cap O Ring 12 Vent Cap 13 Collar Fig 2 DAVCO Fuel Pro...

Page 140: ...ing off its jam nut then tighten the reten tion nuts 30 to 35 lbf ft 41 to 46 N m After the re tention nuts have been tightened hold each retention nut with a wrench while tightening its jam nut 30 lb...

Page 141: ...Title of Maintenance Operation MOP MOP Number Exhaust System Inspection noise emission control 49 01 Safety Precautions 49 00 Exhaust 49 Index Alphabetical New Cascadia Maintenance Manual January 2021...

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Page 143: ...onsibility to maintain the vehicle so that it conforms to EPA regulations EPA10 and Newer Exhaust System Definitions of Aftertreatment ATS Terms Refer to the following list of definitions of ATS terms...

Page 144: ...nd the clamps that retain the DPF in the ATD 6 Check all sensors attached to the ATS for leaks or damaged wires No leaks are allowed See Fig 1 Fig 2 or Fig 3 for Detroit Diesel ATS sensor locations 7...

Page 145: ...rt 4 Exhaust Inlet 5 18 Pin Connectors 6 Particular Matter Sensor Port 7 SCR Outlet Temperature Sensor 8 SCR Outlet NOx Sensor Port 9 Exhaust Outlet 10 DEF Metering Unit 11 Sensor Box see note above 1...

Page 146: ...r 4 DOC Inlet Temperature Sensor 5 DOC Inlet Pressure Sensor 6 DPF Inlet Temperature Sensor 7 Particulate Matter Sensors 8 DPF Outlet Pressure Sensor 9 DPF Outlet Temperature Sensor 10 DPF Outlet NOx...

Page 147: ...ssure Sensor 4 DPF Sensor Box 5 DPF Outlet Pressure Sensor 6 DPF Outlet Temperature Sensor 7 DPF Outlet NOx Sensor 8 SCR Inlet Temperature Sensor 9 SCR Outlet Temperature Sensor 10 SCR Sensor Box 11 S...

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Page 149: ...nance Operation MOP MOP Number Electrical Component Inspection 54 02 Trailer Cable Inspection and Cleaning 54 01 Electrical Instruments and Controls 54 Index Alphabetical New Cascadia Maintenance Manu...

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Page 151: ...evented moisture and debris from entering the component the entire component must be replaced 6 Inspect the component exterior for signs of ther mal distortion warping bulging discoloration amperage r...

Page 152: ...isture and debris from entering the component the entire component must be replaced 11 Inspect component harnesses for secured rout ing that prevents excess harness movement and prevents the harness f...

Page 153: ...mic Component Inspection 60 03 Baggage Door and Sleeper Access Door Release Cable and Latch Lubrication 60 04 Cab Shock Absorber Bracket Torque Check 60 02 Mirror Folding Check 60 01 Cab 60 Index Alph...

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Page 155: ...components if equipped for structural damage cracks or wear These may in clude Chassis fairings Battery access kickplate Side skirts Cab side extenders Roof fairing deflector Bumper Hood Replace or re...

Page 156: ...A G E E A C C S S 1 2 1 Sleeper Access Door Handle 2 Baggage Door Handle Fig 2 Sleeper Door Release Handles 05 07 2012 f602471 A NOTE Baggage door latch shown Sleeper access door latch is similar A L...

Page 157: ...Number Air Conditioner Inspection 83 01 Air Filter Replacement 83 02 Battery Powered HVAC System BPHS Inspection 83 03 Safety Precautions 83 00 Heater and Air Conditioner 83 Index Alphabetical New Cas...

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Page 159: ...and installation procedures see Group 83 of the New Cascadia Workshop Manual 4 Using a feeler gauge check that the drive plate clutch clearance is within limits See Table 1 for clearance specificatio...

Page 160: ...ctly oriented and install the access panel Make sure the access panel locks into position 7 Install a new self tapping screw part number 23 12187 050 Tighten the screw 12 to 17 lbf in 135 to 192 N cm...

Page 161: ...hicle on a level surface set the park ing brake and shut down the engine Chock the tires 2 In vehicles with 60 inch and 72 inch sleepers remove the sleeper HVAC access panel on the inboard side of the...

Page 162: ...access panel on the inboard side of the cabinet See Fig 5 The panel is held in place with four spring clips Pull straight out to remove it 3 Pull the filter out of the slot See Fig 9 4 Install a new f...

Page 163: ...3 Check the drain tube s for debris and clean as needed 4 Install the drain tube s 5 Install any components that were removed for access External A C Condenser Inspection and Cleaning The BPHS A C con...

Page 164: ...Remove the condenser cover Fig 12 Condenser Cover Fasteners compact style condenser Heater and Air Conditioner 83 New Cascadia Maintenance Manual November 2019 83 6...

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