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49–02 CAT CGI Bellows

Replacement

On vehicles with CAT EPA07 compliant engines, re-
place the CGI bellows at the M3 maintenance inter-
val to prevent a later failure.

NOTICE

A leak in the CGI piping, including the bellows,
will allow unfiltered air and contaminants into the
engine intake, and can cause serious engine
damage.

1.

Park the vehicle, set the parking brake, chock
the wheels.

2.

Open the hood.

3.

Remove the right side inner fender/splash shield
as needed.

4.

Remove the CGI piping between the engine and
aftertreatment device (ATD).

See

Fig. 5

.

5.

On the workbench, remove the CGI bellows from
the exhaust piping. Do not damage the piping.

NOTE: The following step, and its substeps, is
to be done without the bellows installed. This
will align the pipes so that the bellows can be
installed correctly.

6.

Install the CGI piping (without CGI bellows) and
align piping.

6.1

Attach the aft CGI pipe to the ATD.

6.2

Attach the forward CGI pipe to the en-
gine.

f490024a

1

2

3

06/01/93

4

1.

Flex Hose

2.

V-Band Coupling

3.

Exhaust Pipe

4.

Turbocharger Exhaust
Outlet

Fig. 6, V-Band Coupling and Flex Hose

08/25/95

f490127

1

2

3

1.

Exhaust Pipe

2.

Exhaust Elbow Isolator

3.

Mounting Nut

Fig. 7, Exhaust Elbow Isolator

f490025a

05/28/93

Fig. 8, Donaldson Sealclamp Wide-Band Exhaust

Clamp

Exhaust

49

Cascadia Maintenance Manual, November 2015

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Содержание Cascadia CA113DC

Страница 1: ...Maintenance Manual CASCADIA Part Number STI 478 Publication Number STI 478 6...

Страница 2: ...CASCADIA MAINTENANCE MANUAL Models CA113DC CA113SLP CA125DC CA125SLP STI 478 6 3 16 Published by Daimler Trucks North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A...

Страница 3: ...Freightliner Trucks reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation Descriptions and specifications containe...

Страница 4: ...y weekly and monthly maintenance of vehicle components Driver s operator s manuals do not contain detailed repair or service information Service Bulletins Service bulletins provide the latest service...

Страница 5: ...s Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice These campaigns pertain to matters of vehicle safety All recall campaigns are d...

Страница 6: ...end 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 d...

Страница 7: ...ransmission 31 Frame and Frame Components 32 Suspension 33 Front Axle 35 Rear Axle 40 Wheels and Tires 41 Driveline 42 Brakes 46 Steering 47 Fuel 49 Exhaust 54 Electrical Instruments and Controls 60 C...

Страница 8: ...tions 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...

Страница 9: ...enance 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...

Страница 10: ...0 16 000 Maintenance 2 M2 every 50 000 80 000 Maintenance 3 M3 every 150 000 240 000 Schedule II Long Haul Transport vehicles that annually travel over 60 000 miles 100 000 km Initial Maintenance IM f...

Страница 11: ...M2 and M3 150 000 240 000 16th M1 160 000 256 000 17th M1 170 000 272 000 18th M1 180 000 288 000 19th M1 190 000 304 000 20th M1 and M2 200 000 320 000 21st M1 210 000 336 000 22nd M1 220 000 352 00...

Страница 12: ...M1 and M2 500 000 800 000 51st M1 510 000 820 000 52nd M1 520 000 837 000 53rd M1 530 000 853 000 54th M1 540 000 869 000 55th M1 and M2 550 000 885 000 56th M1 560 000 901 000 57th M1 570 000 917 00...

Страница 13: ...30 000 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 90...

Страница 14: ...0 15 M1 375 000 604 000 16 M1 and M2 400 000 644 000 17 M1 425 000 684 000 18 M1 450 000 724 000 19 M1 475 000 764 000 20 M1 and M2 500 000 805 000 21 M1 525 000 845 000 22 M1 550 000 885 000 23 M1 57...

Страница 15: ...Miles km 36 M1 M2 and M3 900 000 1 448 000 37 M1 925 000 1 490 000 38 M1 950 000 1 529 000 39 M1 975 000 1 569 000 40 M1 and M2 1 000 000 1 609 000 Table 3 Maintenance for Service Schedule II General...

Страница 16: ...n the applicable M1 maintenance interval table must be performed to complete the initial maintenance IM Maintenance Operation Number Initial Maintenance IM Operations for Service Schedules I and II Ch...

Страница 17: ...rication 42 10 WABCO System Saver Air Dryer Desiccant Cartridge Replacement 42 11 Versajust Slack Adjuster Inspection and Lubrication 47 04 LNG Fuel System Inspecting 47 06 CNG Fuel System Inspecting...

Страница 18: ...r Manual Transmission Air Filter Regulator Check Cleaning or Replacement 31 04 Fairing Bumper Wear Check 32 01 Suspension Inspection 32 02 Suspension U Bolt Torque Check 33 01 Knuckle Pin Lubrication...

Страница 19: ...complete this procedure once a year or every 25 000 miles 40 000 km whichever comes first The fuel cylinder should be inspected every year or 100 000 miles 160 900 km whichever comes first Table 6 M2...

Страница 20: ...d Magnetic Plug Cleaning 35 01 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning 42 02 Bendix Air Dryer Desiccant Replacement 42 09 Bendix E 6 Foot Control Valve Inspection and Lubricati...

Страница 21: ...ller Transmission Fluid Change and Magnetic Plug Cleaning 26 05 Eaton Fuller Transmission Transmission Fluid Level Inspection 26 06 Eaton Fuller Manual Transmission Air Filter Regulator Check Cleaning...

Страница 22: ...Drag Link Lubrication 46 06 Rack and Pinion Steering Gear Inspection 46 07 Bellows Replacement Rack and Pinion Steering Gear 47 01 Fuel Filter Replacement 47 02 Fuel Water Separator Element Checking...

Страница 23: ...ore than 80 000 lb 36 000 kg change the transmission fluid at 200 000 mile 322 000 km intervals For Eaton Fuller transmissions fluid change intervals are extended to 500 000 miles 800 000 km on vehicl...

Страница 24: ...ith 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...

Страница 25: ...Fan Clutch Date Mileage Item Cost Maintenance Facility Verification of Inspections Log Group 49 Verification of Inspections Log Group 49 Exhaust System Components Date Mileage Item Cost Maintenance Fa...

Страница 26: ...Title of Maintenance Operation MOP MOP Number Air Cleaner Inspection 09 01 Air Intake 09 Index Alphabetical Cascadia Maintenance Manual November 2014...

Страница 27: ...isted in PartsPro for the serial number of the ve hicle 2 If necessary replace the air cleaner element For air cleaner element replacement instructions see Group 09 of the Cascadia Workshop Manual 3 I...

Страница 28: ...t 3 Forward Mounting Isolator 4 Air Cleaner Housing 5 Aft Mounting Bracket 6 Capscrews 7 Aft Mounting Isolator Fig 3 Air Cleaner Assembly 01 17 2012 f090496 1 2 1 Steel Plate 2 Rubber Fig 4 Mounting I...

Страница 29: ...Title of Maintenance Operation MOP MOP Number Air Compressor Inspection 13 01 Safety Precautions 13 00 Air Compressor 13 Index Alphabetical Cascadia Maintenance Manual August 2015...

Страница 30: ...rious 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 h...

Страница 31: ...of Maintenance Operation MOP MOP Number Alternator Battery and Starter Connections Check 15 01 Safety Precautions 15 00 Alternators and Starters 15 Index Alphabetical Cascadia Maintenance Manual Augus...

Страница 32: ...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 wea...

Страница 33: ...er 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 Alphabeti...

Страница 34: ...rts that are not internally supported when the system cools Inspect the vacuum relief valve to be sure it is not stuck 4 Make sure that the cap seals properly on the coolant filler neck seat and that...

Страница 35: ...hose clamps tighten the clamps 55 lbf in 620 N cm These clamps are now standard on hoses with an inside diam eter greater than 2 inches 51 mm When installing Breeze Constant Torque hose clamps the cl...

Страница 36: ...re to the air cylinder the bearing housing will move backwards disengaging the clutch Again measure the distance from the back surface of the retaining plate to the forward most edge of the fan belt p...

Страница 37: ...friction facing 7 Connect the battery cables Start the engine and charge the air system to 120 psi 827 kPa Manually engage and disengage the fan clutch Check the fan and fan clutch from a distance Loo...

Страница 38: ...and feel for worn hub bearings 11 2 If possible remove 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 re...

Страница 39: ...ing Lubrication 25 01 Clutch Replacement Detroit Automated Transmissions 25 04 Fluid Change Hydraulic Clutch Control 25 03 Fluid Level Check Hydraulic Clutch Control 25 02 Safety Precautions 25 00 Clu...

Страница 40: ...hile 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 position on the left side of the bell housing see Fig 2 NOTIC...

Страница 41: ...fluid is hazardous It may be a skin irritant and can cause blindness if it gets in your eyes Always wear safety glasses when handling it or bleeding hydraulic lines If you get it on your skin wash it...

Страница 42: ...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 fluid from a tightly se...

Страница 43: ...Replace the clutch assembly for a Detroit Automated transmission at 750 000 mile 1 200 000 km inter vals Follow the procedure published on the Detroit Diesel Customer Support Network DDCSN www ddcsn c...

Страница 44: ...01 Detroit Automated Transmission Fluid Level Inspection 26 02 Eaton Fuller Manual Transmission Air Filter Regulator Check Cleaning or Replacement 26 06 Eaton Fuller Transmission Fluid Change and Mag...

Страница 45: ...is warm If not already warm run the en gine until the transmission fluid reaches operat ing temperature Shift the transmission to neu tral N and shut down the engine 1 Apply the parking brakes and ch...

Страница 46: ...02 Detroit Automated Transmission Fluid Level Inspection NOTICE Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage Do not overfill the tra...

Страница 47: ...Fluid Change and Magnetic Plug Cleaning NOTE Information in this MOP applies to Eaton Fuller manual and automated transmissions Fluid change intervals are extended to 500 000 miles 800 000 km on any v...

Страница 48: ...er CAUTION To prevent skin burns from hot transmission fluid wear protective gloves when removing the filter 5 2 Place a strap or chain wrench around the filter canister and rotate it in a counter clo...

Страница 49: ...damage Do not overfill the transmis sion Overfilling will force fluid out of the case through the main shaft openings Do not mix types or brands of fluid because of possible incompatibility Do not use...

Страница 50: ...ranger com 26 06 Eaton Fuller Manual Transmission Air Filter Regulator Check Cleaning or Replacement 1 Apply the parking brakes and chock the rear tires Drain the air reservoirs WARNING Drain the air...

Страница 51: ...ilter element will last the life of the vehicle Wipe out the filter housing 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 la...

Страница 52: ...ber Fairing Bumper Wear Check 31 04 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 Alphabetic...

Страница 53: ...ld result in a possible disengagement of the trailer from the tractor which could result in personal injury or property damage Parts are under spring compression Wear safety goggles while servicing th...

Страница 54: ...closing the locks See Fig 3 7 After inspecting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease See MOP 31 02 in this manual for lubrication instructions Fontaine 1 D...

Страница 55: ...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...

Страница 56: ...Replace or re pair as needed 4 Inspect the bracket pin bolts Make sure the lock ing tabs are properly securing the bolts in place See Fig 5 5 Check the fifth wheel for bent worn or broken parts Repla...

Страница 57: ...nboard slider is adjustable for frame width and plunger engagement For ad justment refer to the fifth wheel installa tion instructions 10 Replace cracked worn or damaged parts with new parts Replace a...

Страница 58: ...rface 2 Inspect the trailer kingpin plate and top surface of the fifth wheel to make sure each is properly greased A liberal coating of grease should be applied to the complete surfaces of both the tr...

Страница 59: ...additive to the trailer contact surface of the fifth wheel NOTE If the fifth wheel is equipped with low lube plates the top plate only requires lubrication at the new product break in stage The low l...

Страница 60: ...l Legs Fifth Wheel Mountings Frame Crossmembers and Gussets Front Frame Brackets Front Suspension Spring Brackets Fuel Tank Brackets Radius Rods Rear Suspension Spring Brackets Shock Absorbers All Oth...

Страница 61: ...03 13 2007 f311034 Fig 12 Bumper Location Frame and Frame Components 31 Cascadia Maintenance Manual March 2016 31 9...

Страница 62: ...MOP Number Lubrication of Front Suspensions with Grease Fittings 32 03 Safety Precautions 32 00 Suspension Inspection 32 01 Suspension U Bolt Torque Check 32 02 Suspension 32 Index Alphabetical Casca...

Страница 63: ...king or rubbing the frame is characterized by chafe marks on the shock absorber body and the frame rail see Fig 1 Check the rubber mounting bushings for cracks cuts swelling dry rot or missing pieces...

Страница 64: ...back the studs out causing a separation of the two halves of the valve body and possibly a leak 1 Park the vehicle on a level surface using a light application of the brakes Do not apply the park ing...

Страница 65: ...U bolt torque specifications Tighten in a diagonal pat tern as shown 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 wi...

Страница 66: ...Height Measurement Single Leaf Spring 10k 12k 15k 18k Mid Ride and 40k Low and Mid Ride f321046a A 09 28 2005 Measure Point Suspension Height Measurement Min Target Max A Measure Here 2 3 4 inch 70 mm...

Страница 67: ...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 Table 6 Spring U Bolt High Nut Torque Values 32 03 Lubrication of Front Suspensions with Grease Fittings Wipe al...

Страница 68: ...on MOP MOP Number All Axle Alignment Check 33 04 Knuckle Pin Lubrication 33 01 Safety Precautions 33 00 Tie Rod Inspection 33 02 Tie Rod Lubrication 33 03 Front Axle 33 Index Alphabetical Cascadia Mai...

Страница 69: ...n 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...

Страница 70: ...ecifications in Group 35 of the 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 mus...

Страница 71: ...vail able lower the vehicle Remove the chocks 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...

Страница 72: ...f400100a 08 30 94 Fig 8 Setting Trammel Bar Pointers Front Axle 33 Cascadia Maintenance Manual August 2015 33 4...

Страница 73: ...MOP 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 Casca...

Страница 74: ...dels For a two speed axle with a shift unit also change the shift unit lubricant see under the heading Two Speed Axles With Shift Unit All Axle Models Detroit IMPORTANT On Detroit axles the oil change...

Страница 75: ...the oil fill hole Lubri cant should be level with the bottom of the oil fill hole To check fluid level see Fig 2 5 2 Install and tighten the fill plug 30 lbf ft 41 N m Detroit Drive Axle Lubricants IM...

Страница 76: ...Then remove the drain plug from the bottom of the housing Completely drain the lubricant while the unit is warm to allow the lubricant to drain faster On tandem drive axles it is also necessary to rem...

Страница 77: ...t L RT 46 160 RT 46 160P Forward 39 1 18 5 Rear 34 4 16 3 Quantities listed are approximate Fill axle until lubricant is level with bot tom of fill hole with vehicle on level ground See Traction Equal...

Страница 78: ...ach time for large quantities of metal particles 5 4 After cleaning install the drain plug s and tighten to 40 to 60 lbf ft 54 to 81 N m 6 Fill the axle with the recommended lubricant See Table 5 for...

Страница 79: ...horoughly wash the axle shift parts and housing cover and allow them to air dry 3 Install the housing cover and a new cover gas ket Tighten the housing cover capscrews 90 to 110 lbf in 1020 to 1240 N...

Страница 80: ...e Fig 2 If low check for oil leaks and correct as needed Add oil to the level of the fill plug using the lubricant recommended in Table 2 IMPORTANT A lubricant level close enough to be seen or touched...

Страница 81: ...ded lubricant can result in rear axle damage 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires 2 If the vehicle has just been driven allow a few minu...

Страница 82: ...hole If low add the recommended lubricant NOTICE Before adding additional lubricant make sure of the type currently in the shift unit To prevent component damage do not mix engine oil with automatic...

Страница 83: ...Title of Maintenance Operation MOP MOP Number Tire Check 40 02 Wheel Nut Check 40 01 Wheels and Tires 40 Index Alphabetical Cascadia Maintenance Manual November 2015...

Страница 84: ...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...

Страница 85: ...Title of Maintenance Operation MOP MOP Number Driveline Inspection 41 01 Driveline Lubrication 41 02 Safety Precautions 41 00 Driveline 41 Index Alphabetical Cascadia Maintenance Manual August 2015...

Страница 86: ...with yoke straps tighten yoke strap capscrews 125 lbf ft 169 N m See Fig 3 3 Check the driveline yokes for cracks and check end yokes for looseness See Fig 3 Replace cracked yokes If any end yoke can...

Страница 87: ...ually examine the driveshaft tubes for dents bends twists or other damage If any tube ap pears to be damaged refer to Group 41 of the Cascadia Workshop Manual for repair and re placement instructions...

Страница 88: ...most of the grease being added to a U joint can be seen escaping from just one of the U joint seals check the torque on the capscrews at that seal 4 Tighten the bearing cup capscrews 43 lbf ft 58 N m...

Страница 89: ...g wipe all old grease and dirt from the slip joint grease fitting See Fig 5 2 Use a hand type grease gun or a high pressure gun with a low pressure adapter to lubricate the slip joint Add multipurpose...

Страница 90: ...oot 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 Adjuster Lubrication 42 08 Sa...

Страница 91: ...ual 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 bolt...

Страница 92: ...e 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...

Страница 93: ...ar 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 s...

Страница 94: ...ne 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 re...

Страница 95: ...7 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 Inspe...

Страница 96: ...ually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mechanical problem Adjustment is not repairing Before adjusting an automatic slack adjus...

Страница 97: ...troke 24 3 inch rated stroke 2 1 2 64 30 Haldex Standard Stroke 12 1 3 8 35 16 1 3 4 44 20 24 2 1 2 Inch Extended Stroke 24 2 51 3 Inch Extended Stroke 24 2 1 2 64 Standard Stroke 30 2 51 Long Stroke...

Страница 98: ...hicle Workshop Manual for repair procedures 42 06 Haldex Slack Adjuster Lubrication Automatic slack adjusters that have a grease fitting must be lubricated periodically to ensure proper brake operatio...

Страница 99: ...ad to 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 grea...

Страница 100: ...cle to service 42 10 WABCO System Saver Air Dryer Desiccant Cartridge Replacement NOTE The following instructions apply to the System Saver 1200 1200 Plus and Twin air dryers NOTICE The WABCO System S...

Страница 101: ...ot 3 Perform the In Service Inspection In Service Inspection 1 Apply and release the brakes several times while observing the slack adjuster The slack adjuster and brake actuator should move freely wi...

Страница 102: ...3 4 12 1 3 8 Table 2 Actuator Stroke Standard Stroke Actuator Stroke Long Stroke Brake Actuator Size Recommended Maximum Operating Stroke Inches 30 Long Stroke 2 1 2 24 Long 2 24 Long Stroke 2 1 2 20...

Страница 103: ...spection 46 01 Drag Link Lubrication 46 05 Power Steering Fluid Level Inspection 46 03 Power Steering Fluid and Filter Changing 46 02 Power Steering Gear Lubrication 46 04 Rack and Pinion Steering Gea...

Страница 104: ...300 lbf ft 217 to 407 N m 4 Inspect the boot of the drag link at both the pit man arm and the steering arm end for cracks splits or other damage Replace the boot if needed 5 Grasp the drag link near...

Страница 105: ...nd filter cover 16 Start the engine and check that the power steer ing fluid level is between the MIN COLD and MAX HOT lines Add more power steering fluid if needed 17 Lower the vehicle 46 03 Power St...

Страница 106: ...r worn replace them See Group 46 of the Cascadia Workshop Manual for replacement instructions 5 Check the steering gear mounting bolts for secu rity 6 Check that the outer tie rod castle nuts are tigh...

Страница 107: ...d Arm 2 Power Steering Fluid Lines 3 Large Bellows Clamp 4 Bellows 5 Small Bellows Clamp 6 Driver Side Outer Tie Rod 7 Tie Rod Jam Nut 8 Inner Tie Rod Flat 9 Inner Tie Rod Ball Joint 10 Input Shaft Se...

Страница 108: ...e Wipe down the housing with brake cleaner to remove all remain ing dirt and debris IMPORTANT Only apply grease to the rack shaft on the driver side Do not apply grease to the teeth of the rack shaft...

Страница 109: ...lamps Over tightening may lead to stretching of the clamp which could allow moisture intrusion and corro sion If an Oetiker clamp stretches remove and discard the clamp and install a new clamp All thr...

Страница 110: ...appropriate tool When the alignment process requires that the steering wheel be pointed straight ahead align the steering rack on center pointers instead See Fig 11 20 1 Loosen the driver side tie ro...

Страница 111: ...ents and at least 3 4 inch 19 mm clearance between the wheels tires and moving components If this is not the case back out the stop bolts and adjust the jam nuts to limit the turning angles and to pre...

Страница 112: ...sure Fuel Filter Element Replacing 47 07 Fuel Filter Replacement 47 01 Fuel Tank Band Nut Tightening 47 03 Fuel Water Separator Element Checking and Replacement 47 02 LNG Fuel System Inspecting 47 04...

Страница 113: ...r sensor and heater connec tions if equipped 3 Remove the element and bowl together by turn ing counterclockwise 4 Remove the bowl from the element and clean the O ring land 5 Apply a coating of clean...

Страница 114: ...hread to fit cor rectly 4 Remove the vent cap Fig 2 Item 4 and open the drain valve Fig 2 Item 1 to drain the fuel completely then close the drain valve 5 Using a DAVCO Collar Wrench Fig 3 remove the...

Страница 115: ...ring and vent cap 11 4 Start the engine When the lubricating oil reaches its normal operating pressure increase engine speed to high idle for one to two minutes to purge air from the system 11 5 Whil...

Страница 116: ...d if any tool other than a DAVCO Collar Wrench part number 380134 is used for removal During installation the vent cap and collar are to be hand tightened only not tightened with a wrench 5 Remove the...

Страница 117: ...sealants Gas detection sensors are located on the cab overhead console and in the engine compartment on the frontwall The sensors are located in high areas where rising gas vapors will pass by or ac c...

Страница 118: ...r accuracy and legibility 5 Inspect all vent lines for kinks and signs of leaks or damage 6 Replace leaking or damaged fuel lines Repair or replace leaking or damaged fittings Fuel Level Sender Compon...

Страница 119: ...ING Natural gas is highly flammable See the safety precautions listed in Group 47 of the Cascadia Workshop Manual Failure to observe these pre cautions could lead to the ignition of the natural gas wh...

Страница 120: ...eaner or silicone based chemicals on the gas detection sensors as this may permanently disable the sensors When cleaning the vehicle cover the sensors with a plastic covering Keep the sensors covered...

Страница 121: ...el cylinders for damage or deteriora tion Note cuts cracks gouges abrasions discolor ation broken fibers loose brackets damaged gaskets or isolators heat damage or other prob lems Refer to the Compres...

Страница 122: ...Mounted 2 Top Plate Bolts qty 6 per side 3 Frame Rail 4 Mounting Bracket 5 Gussett Bolts qty 2 per side 6 Bracket to Frame Nuts and Bolts qty 8 per side Fig 8 Fuel Cylinder Mounting Bracket frame rail...

Страница 123: ...ERY 2000 MILES DRAIN HOUSING EVERY 1500 MILES REPLACE ELEMENT EVERY 3000 MILES 1 2 3 4 04 30 2010 f470556 1 High Pressure Gauge 2 Low Pressure Gauge 3 Manual Fuel Shutoff Valve 4 Fuel Fill Ports and D...

Страница 124: ...ance Operation MOP MOP Number CAT CGI Bellows Replacement 49 02 Exhaust System Inspection Noise Emission Control 49 01 Safety Precautions 49 00 Exhaust 49 Index Alphabetical Cascadia Maintenance Manua...

Страница 125: ...s and components Aftertreatment System ATS the entire ex haust system from the turbocharger to the ex haust stack or tail pipe Aftertreatment Device ATD a housing that contains the DOC and DPF also th...

Страница 126: ...ot necessary unless there is a system failure or a fault code 10 Check the DEF tank pump metering unit and lines for leaks See Section 49 02 of the Casca dia Workshop Manual for repair procedures 11 C...

Страница 127: ...ncluding the bellows will allow unfiltered air and contaminants into the engine intake and can cause serious engine dam age NOTE Because the CGI bellows is covered with a metal mesh it is difficult to...

Страница 128: ...of Fig 4 A dent over 3 inches 76 mm in diameter or 1 4 inch 6 mm deep could cause internal damage to the DPF causing it to malfunction 9 Check for heat discoloration on the surface of the ATD Heat di...

Страница 129: ...utlet pipe and replace it as needed 6 Check the U bolt clamps for tightness and tighten as needed 7 Check the isolator at the base of the exhaust stack elbow s see Fig 7 for cracking dam age and dry r...

Страница 130: ...ing 7 DPF Outlet Temperature Sensor 8 Exhaust Outlet Marmon Fitting 9 DPF Outlet Pressure Sensor Fig 4 Typical EPA07 Aftertreatment Device 02 24 2011 f490456 1 1 2 3 4 5 6 5 3 7 8 9 3 10 1 Clamp 2 Inl...

Страница 131: ...nch remove the CGI bellows from the exhaust piping Do not damage the piping NOTE The following step and its substeps is to be done without the bellows installed This will align the pipes so that the b...

Страница 132: ...clamps This requires one or both of the CGI pipes to be shortened 8 Using a yellow paint pen mark the pipes 1 5 inches 38 mm in from the end of each pipe These two marks will be used to center the bel...

Страница 133: ...s center the bellows be tween the exhaust pipes Verify that the pipe is inserted at least 7 16 inch 10 mm past the face of the flange See Fig 11 Ref A 17 Install the slip clamps on the bellows Tighten...

Страница 134: ...Title of Maintenance Operation MOP MOP Number Trailer Cable Inspection and Cleaning 54 01 Electrical Instruments and Controls 54 Index Alphabetical Cascadia Maintenance Manual August 2007...

Страница 135: ...ht liner recommends also replacing the socket s harness as well if the corrosion has gotten into the wires and connectors inside the socket IMPORTANT If using a spray cleaner to remove corrosion be ca...

Страница 136: ...namic 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 Al...

Страница 137: ...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...

Страница 138: ...cess Door Handle 2 Baggage Door Handle 3 Cab Door Frame Driver Side Fig 2 Baggage Door and Sleeper Access Door Release Handles 05 07 2012 f602471 A NOTE Baggage door latch shown Sleeper access door la...

Страница 139: ...ration MOP MOP Number Air Conditioner Inspection 83 01 Air Filter Replacement 83 02 ParkSmart Inspection 83 03 Safety Precautions 83 00 Heater and Air Conditioner 83 Index Alphabetical Cascadia Mainte...

Страница 140: ...edures see Group 83 of the Cascadia Workshop Manual 4 Using a feeler gauge check that the drive plate clutch clearance is within limits See Table 1 for clearance specifications See Fig 1 for the check...

Страница 141: ...ented and install the tray in the slot in the plenum Make sure the tray locks into position 7 Install the intake screen 8 Return the hood to the operating position Cab Recirculation Air Filter Replace...

Страница 142: ...l it loose along the bot tom edge of the recess and slide it straight down See Fig 7 5 Slide a new filter up into the recess slots of the plenum Be sure that it fully seats into the slot all the way a...

Страница 143: ...ce with four spring clips Pull straight out to remove it In vehicles with 48 inch sleepers raise the lower bunk and lift the access panel See Fig 9 3 Lift the filter out of the slot See Fig 10 for 60...

Страница 144: ...oduce warm exhaust Drain Tube Inspection NOTICE The ParkSmart drain tube s must be kept clear of debris Failure to do so will cause excessive water build up in the base of the unit and may cause damag...

Страница 145: ...re cleaner approved for copper and aluminum cores and a low pressure water can be use to clean it 2 Clean out any debris in the module 3 Install the inspection plate 09 21 2010 f831857 1 2 Remove and...

Страница 146: ...Title of Maintenance Operation MOP MOP Number Hood Rear Support Lubrication 88 01 Hood Grille and Cab Fenders 88 Index Alphabetical Cascadia Maintenance Manual November 2014...

Страница 147: ...surfaces of the hood rear sup port brackets and isolators with an approved multi purpose lithium complex soap based grease see Table 1 5 Close the hood Approved Suppliers of Multi Purpose Lithium Grea...

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