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freightliner Run Smart ECASCADIA PE116DC 2022, Maintenance Manual

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freightliner Run Smart ECASCADIA PE116DC 2022 Maintenance Manual Download Page 68

IMPORTANT: The lubricant used in eCarrier
(eMotor) must meet Detroit Fluids Specification
(DFS) 93K230. For more product information,
see DDC-SVC-BRO-121 on the DTNA Connect
Portal.

11. Install the oil fill plug. Tighten the fill plug 85 lbf·ft

(115 N·m).

eCarrier Lubricant Capacity

Axle

Oil Capacity:

Quarts (liters)

Front-Rear and Single

6.7 (7.1)

Rearmost Tandem

10.4 (11.0)

Table 2, eCarrier Lubricant Capacity

f350826

09/ 8/20

0

22

Fig. 4, Oil Mesh Filter

f350827

09/ 8/20

0

22

Fig. 5, eCarrier Fluid Fill Plug

Rear Axle

35

eCascadia Maintenance Manual, 10/25/2022

35/4

Summary of Contents for Run Smart ECASCADIA PE116DC 2022

Page 1: ...ECASCADIA MAINTENANCE MANUAL Models PE116DC STI 511 1 11 01 2022 Published by Daimler Truck North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A...

Page 2: ......

Page 3: ...d specifications in this manual were in effect at the time of printing Freightliner Trucks reserves the right to discontinue models and to change specifications or design at any time without notice an...

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 Truck North America LLC Daimler Tr...

Page 5: ...g manuals do not contain repair or service information NOTE The eCascadia Electrical Systems and Troubleshooting Manual is available in an online format only Driver s Operator s Manual Driver s operat...

Page 6: ...information available on the www DTNAPortal com website includes the following documentation Recall Campaigns Recall campaigns cover situations that involve service work or replacement of parts in co...

Page 7: ...d 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 dri...

Page 8: ...adiator 31 Frame and Frame Components 32 Suspension 33 Front Axle 35 Rear Axle 40 Wheels and Tires 42 Brakes 46 Steering 54 Electrical Instruments and Controls 60 Cab 83 Heater and Air Conditioner Int...

Page 9: ...ions 00 05 M2 Maintenance Interval Operations 00 06 M3 Maintenance Interval Operations 00 07 M4 Maintenance Interval Operations 00 08 Maintenance Operation Sets Table 00 09 Noise Emission Controls Mai...

Page 10: ......

Page 11: ...able for a list of the maintenance operations to be performed at that maintenance interval Use the maintenance operation reference numbers to find detailed instructions in the manual on each operation...

Page 12: ...less than 60 000 miles 100 000 km Initial Maintenance IM first 10 000 16 000 Maintenance 1 M1 every 10 000 16 000 Maintenance 2 M2 every 50 000 80 000 Maintenance 3 M3 every 100 000 160 000 Maintenanc...

Page 13: ...2 and M4 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 M2 and M3 200 000 320 000 21st M1 210 000 336 000 22nd M1 220 000 352 0...

Page 14: ...M2 and M3 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 00...

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 M3 and M4 9...

Page 16: ...h the operations listed in the applicable M1 maintenance interval table must be performed to complete the initial maintenance IM Maintenance Operation Number Initial Maintenance IM Operations for Serv...

Page 17: ...r M1 Maintenance Interval Operations for Service Schedule I Check 13 01 Air Compressor Inspection 31 01 Fifth Wheel Inspection 31 02 Fifth Wheel Lubrication 33 05 Steer Axle Hub Cap Vent Plug Inspecti...

Page 18: ...hange 20 01 Surge Tank Filler Cap Check 32 02 Suspension U Bolt Torque Check 33 01 Knuckle Pin Lubrication 33 02 Tie Rod Inspection 33 03 Tie Rod Lubrication 35 02 Axle Breather and Axle Lubricant Lev...

Page 19: ...and M2 maintenance interval operations at the M3 maintenance interval Maintenance Operation Number M3 Maintenance Interval Operations for Service Schedule I Check 00 05 Perform All M1 Operations 00 0...

Page 20: ...tenance interval Maintenance Operation Number M4 Maintenance Interval Operations for Service Schedule I Check 00 05 Perform All M1 Operations 00 06 Perform All M2 Operations 00 07 Perform All M3 Opera...

Page 21: ...Cap Vent Plug Inspection 35 01 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning 35 02 Axle Breather and Axle Lubricant Level Inspection 35 03 eCarrier Oil Filter and Fluid Change 40 01...

Page 22: ...200 000 miles 322 200 km whichever comes first For Schedule I vehicles with Detroit axles complete this procedure once a year or every 25 000 miles 40 000 km whichever comes first The lubricant used i...

Page 23: ...parts in performance and durability Tampering with Noise Controls is Prohibited Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person oth...

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Page 25: ...MOP Number Cable Gland Protection Inspection 08 03 High Voltage Electrical Component Inspection 08 01 High Voltage Wiring Check 08 02 Safety Precautions 08 00 Electric Drive 08 Index Alphabetical eCas...

Page 26: ......

Page 27: ...component function 4 Inspect the component protective cover for proper fit and function Inspect the cover for cracks broken mounting missing sealing surfaces and warped or bulged surfaces The cover m...

Page 28: ...meter of the high voltage cables is within tolerance if routed correctly this should not be a problem See Fig 1 and Fig 2 Check for the following broken clamps or ties and worn or damaged cables where...

Page 29: ...9 15 2022 1 2 3 4 5 6 7 1 Frontbox 2 Charging Fuse 3 High Voltage Batteries 4 Inverters 5 eAxles 6 Charge Ports 7 DC Boxes Fig 1 HV Cable Routing Electric Drive 08 eCascadia Maintenance Manual 10 03 2...

Page 30: ...onverter 2 Air Compressor 3 Auxiliary PDU 4 Positive Temperature Coefficient Heating Element 5 eRC Fig 2 HV Frontbox Cable Routing f080427 06 22 2022 Fig 3 Cable Gland Protection Electric Drive 08 eCa...

Page 31: ...intenance Operation MOP MOP Number Air Compressor Inspection 13 01 Air Compressor Oil and Filter Change 13 02 Safety Precautions 13 00 Air Compressor 13 Index Alphabetical eCascadia Maintenance Manual...

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Page 33: ...or replace the connections 2 Inspect the coolant supply and return lines for tight connections Tighten the connections and replace the lines and fasteners if needed 13 02 Air Compressor Oil and Filte...

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Page 35: ...Operation MOP MOP Number Radiator Pressure Flushing and Coolant Change 20 02 Safety Precautions 20 00 Surge Tank Filler Cap Check 20 01 Engine Cooling Radiator 20 Index Alphabetical eCascadia Maintena...

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Page 37: ...system of the vehicle See Fig 1 2 There is a valve in the filler cap that opens under vacuum This prevents the collapse of hoses and other parts that are not internally supported when the system cool...

Page 38: ...ter installation due to compression set However when correctly installed Breeze Constant Torque clamps will hold enough torque to automatically adjust and keep consistent sealing pressure During vehic...

Page 39: ...tion 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 eCascadia Mai...

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Page 41: ...e Holland FW35 1 Disconnect the tractor from the trailer For instructions see the vehicle Driver s Operator s Manual 2 Thoroughly steam clean all fifth wheel components before inspection 3 Check for c...

Page 42: ...rdened washers Do not re use bolts nuts and washers on fifth wheel mountings 12 After inspecting the fifth wheel lubricate all moving parts with a chassis or multipurpose grease Apply a generous coati...

Page 43: ...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 Safety Lock 15 Hex...

Page 44: ...ent refer to the fifth wheel installation instructions 10 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 harde...

Page 45: ...Rock the top plate back and forth several times to spread the grease over the bearing surface 2 Inspect the trailer kingpin plate and top surface of the fifth wheel to make sure each is properly grea...

Page 46: ...equivalent is recommended Jost Lubricate the kingpin lock using a hand pump grease gun through the grease zerk on the skirt of the fifth wheel see Fig 5 Apply a light oil to all moving parts For slidi...

Page 47: ...g bolt body friction When checking the torque of frame fasteners inspect the frame for cracks and other damage Set a click type torque wrench to the maximum torque of the fastener you are checking App...

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Page 49: ...e 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 eCascadia Maintenance Manual 10 03...

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Page 51: ...the front spring assemblies for cracked broken or abnormally bent leaves If any of these conditions exist replace the spring assembly see Group 32 of the eCascadia Workshop Manual Inspect the spring b...

Page 52: ...ts in the valve and any disassembly will void the warranty NOTICE When removing or loosening a Barksdale height control valve from a mounting bracket always hold the valve side mounting studs in place...

Page 53: ...Check the U bolt torque of both the front and rear axles where applicable 1 Park the vehicle on a level surface shut down the motor and set the parking brake Chock the tires 2 Check the U bolt torque...

Page 54: ...bf ft N m 5 8 18 180 230 245 313 3 4 16 270 330 367 449 7 8 14 420 500 571 680 1 14 520 600 707 816 M20 216 274 292 372 M20 Airtek 330 370 447 502 Table 2 Spring U Bolt High Nut Torque Values f320783...

Page 55: ...xle 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 Al...

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Page 57: ...aise the front axle 2 Wipe the fittings clean 3 Apply multipurpose chassis grease NLGI Grade 1 6 12 hydroxy lithium stearate grease or NLGI Grade 2 8 12 hydroxy lithium stearate grease until new greas...

Page 58: ...calibration history 1 Apply the parking brakes and chock the rear tires 2 Raise the front of the vehicle until the tires clear the ground Place safety stands under the axle 3 Using spray paint or a p...

Page 59: ...6 and adjust the scale end so that the pointers line up with the scribe lines See Fig 7 8 Read the toe in from the scale and compare it to the toe in specification in Group 33 of the eCascadia Worksh...

Page 60: ...in the hub pressure washing is the most likely cause Inspection NOTICE Only remove vent plugs by hand They can be damaged if a tool is used Wipe the hub plug area clean before checking the oil Do not...

Page 61: ...d axle end clean inspect and reassemble the axle end For instructions refer to Group 33 of the eCascadia Workshop Manual If there is evidence of excessive leakage remove the damaged part and replace i...

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Page 63: ...her and Axle Lubricant Level Inspection 35 02 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning 35 01 Safety Precautions 35 00 eCarrier Oil Filter and Fluid Change 35 03 Rear Axle 35 Ind...

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Page 65: ...lug Drain the oil when it is warm At this temperature the oil will run more freely and ensure that the axle is flushed 4 Clean the fill and drain plugs Change them if necessary 4 1 For magnetic plugs...

Page 66: ...Inspection For all axles including tandem drive axles and two speed axles perform the applicable procedures under All Axle Models f350828 09 16 2022 A B 1 2 3 4 5 A Top View B Rear View 1 eCarrier Bre...

Page 67: ...bottom of the fill hole 5 Install and tighten the fill plug 30 lbf ft 41 N m IMPORTANT Always check the axle breather whenever checking the lubricant level Check the breather more frequently under adv...

Page 68: ...11 Install the oil fill plug Tighten the fill plug 85 lbf ft 115 N m eCarrier Lubricant Capacity Axle Oil Capacity Quarts liters Front Rear and Single 6 7 7 1 Rearmost Tandem 10 4 11 0 Table 2 eCarrie...

Page 69: ...Title of Maintenance Operation MOP MOP Number Tire Check 40 02 Wheel Nut Check 40 01 Wheels and Tires 40 Index Alphabetical eCascadia Maintenance Manual 10 03 2022...

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Page 71: ...N 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 inspec...

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Page 73: ...tion 42 01 Bendix E 6 Foot Control Valve Inspection and Lubrication 42 03 Brake Inspection 42 02 EAPU Electronic Air Processing Unit Air Dryer Desiccant Cartridge Replacement 42 04 Safety Precautions...

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Page 75: ...hould not move If the vehicle moves the parking brakes are not operating correctly and must be repaired before the vehicle is returned to service See Group 42 of the eCascadia Workshop Manual Brake Co...

Page 76: ...3 26 2020 1 2 4 5 3 6 Fig 1 Axial Bolt Tightening Pattern f580518 09 28 2018 Fig 2 DDC DSNCHA018005 30mm Air Disc Brake Caliper Brake Bolt Torque Adaptor Brakes 42 eCascadia Maintenance Manual 10 03 2...

Page 77: ...402 545 Table 1 Torque Check with 47 Inch 119 cm Torque Wrench and Tool DDC DSNCHA018005 5 Install the wheel assemblies For instructions see Group 40 of the eCascadia Workshop Manual 6 Remove the jack...

Page 78: ...lacing the desiccant cartridge it is very important to use the same type of cartridge that was originally installed on the dryer Oil coalescing cartridges can be used in any application but require mo...

Page 79: ...f421292 10 07 2016 1 2 3 1 Seal 2 O Ring 3 Air Dryer Base Fig 4 Desiccant Cartridge Replacement Brakes 42 eCascadia Maintenance Manual 10 03 2022 42 5...

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Page 81: ...umber 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...

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Page 83: ...lbf ft 122 to 230 N m 7 8 14 160 to 300 lbf ft 217 to 407 N m 4 Inspect the boot of the drag link at both the pitman arm and the steering arm end for cracks splits or other damage Replace the boot if...

Page 84: ...ore power steering fluid if needed 15 Turn 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 H...

Page 85: ...et f462459 09 28 2021 1 1 Sector Shaft Grease Fitting Fig 2 Steering Gear Lubrication f461072 10 07 2016 2 1 1 Grease Fitting at Pitman Arm 2 Grease Fitting at Axle Steering Arm Fig 3 Drag Link Steeri...

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Page 87: ...MOP Number Electrical Component Inspection 54 02 Gas Detection System Sensor Testing 54 03 Trailer Cable Inspection and Cleaning 54 01 Electrical Instruments and Controls 54 Index Alphabetical eCasca...

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Page 89: ...determined that a cover has not properly prevented moisture and debris from entering the component the entire component must be replaced 6 Inspect the component exterior for signs of thermal distorti...

Page 90: ...Per Title 13 CCR 935 2 gas detection systems should be tested three times per year at equal intervals The testing procedure should simulate the same operating environment in which the vehicle is used...

Page 91: ...ected and replace any blown fuses If the gas detection system is still not functioning replace the system immediately SIGNIFICANT Gas Concentration Lights Red illuminated Dangerous gas concentration d...

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Page 93: ...ntenance Operation MOP MOP Number Aerodynamic Component Inspection 60 03 Cab Shock Absorber Bracket Torque Check 60 02 Mirror Folding Check 60 01 Cab 60 Index Alphabetical eCascadia Maintenance Manual...

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Page 95: ...6 N m See Fig 1 3 From behind the cab skin check the torque of each of the two lower nuts that attach the shock absorber upper bracket to the cab while holding the bolt in place with a box wrench If l...

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Page 97: ...intenance Operation MOP MOP Number Air Conditioner Inspection 83 01 Air Filter Replacement 83 02 Safety Precautions 83 00 Heater and Air Conditioner 83 Index Alphabetical eCascadia Maintenance Manual...

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Page 99: ...s three filters that must be replaced periodically to maintain proper system operation The cabin fresh air intake filter is accessed from under the hood and the recirculation filter is accessed from i...

Page 100: ...s panel f090524 01 23 2019 1 1 Self Tapping Screw Fig 1 Intake Filter Access Panel f090526 04 13 2016 1 Airflow Directional Arrow Orientation Fig 2 Airflow Directional Arrow f090523 04 13 2016 1 Filte...

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