FREIGHTLINER CARGO Service Repair Manual

CARGO WORKSHOP MANUAL STI-377, S14 (9/10P) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.

Foreword The purpose of this manual is to assist the service technician when the vehicle is serviced. Major drivetrain component service information is not included in this manual, but is located in each manufacturer’s service manual. Instructions and procedures are those recommended by vehicle manufacturer or the component manufacturer. Maintenance schedules and additional service information are included in the Cargo Mainte- nance Manual. IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. The vehicle manufacturer reserves the right to discontinue models at any time, or change specifications and design without notice and without incurring obliga- tion. Descriptions and specifications contained in this publication provide no warranty, expressed or implied, and are subject to revision and editions without notice. Refer to www.FreightlinerTrucks.com, and www.SterlingTrucks.com, and www.Daimler- TrucksNorthAmerica.com for more information, or contact Daimler Trucks North America LLC at the address below. Environmental Concerns and Recommendations Whenever you see instructions in this manual to discard materials, you should attempt to reclaim and recycle them. To preserve our environment, follow appropriate environmental rules and regulations when disposing of materials. NOTICE: Parts Replacement Considerations Do not replace suspension, axle, or steering parts (such as springs, wheels, hubs, and steering gears) with used parts. Used parts may have been subjected to collisions or improper use and have undetected structural damage. © 1998–2010 Daimler Trucks North America LLC All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks North America LLC. Daimler Trucks North America LLC is a Daimler company. Daimler Trucks North America LLC Service Systems and Documentation (CVI-SSD) P.O. Box 3849 Portland, OR 97208-3849

Daimler Trucks North America LLC distributes the following major service publications in paper and electronic (via ServicePro ® ) formats. Workshop/Service Manual Workshop/service manuals contain service and repair information for all vehicle systems and components, except for major components such as engines, trans- missions, and rear axles. Each workshop/service manual section is divided into subjects that can include general information, principles of operation, removal, disassembly, assembly, installation, and specifications. Maintenance Manual Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems. They have information such as lubrication procedures and tables, fluid replacement procedures, fluid capacities, specifications, and procedures for adjustments and for checking the tightness of fasten- ers. Maintenance manuals do not contain detailed repair or service information. Driver’s/Operator’s Manual Driver’s/operator’s manuals contain information needed to enhance the driver’s understanding of how to operate and care for the vehicle and its components. Each manual contains a chapter that covers pretrip and post-trip inspections, and daily, 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 tips, field repairs, product improve- ments, and related information. Some service bulletins are updates to information 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 bulletins manual is available only to dealers. When doing service work on a vehicle system or part, check for a valid service bulletin for the latest information on the subject. IMPORTANT: Before using a particular service bulletin, check the current service bulletin validity list to be sure the bulletin is valid. Parts Technical Bulletins Parts technical bulletins provide information on parts. These bulletins contain lists of parts and BOMs needed to do replacement and upgrade procedures. Web-based repair, service, and parts documentation can be accessed using the following applications on the AccessFreightliner.com and AccessSterling.com websites. ServicePro ServicePro ® provides Web-based access to the most up-to-date versions of the publications listed above. In addition, the Service Solutions feature provides di- agnostic assistance with Symptoms Search, by connecting to a large knowledge base gathered from technicians and service personnel. Search results for both documents and service solutions can be narrowed by initially entering vehicle identification data. PartsPro PartsPro ® is an electronic parts catalog system, showing the specified vehicle’s build record. EZWiring EZWiring ™ makes Freightliner, Sterling, Western Star, Thomas Built Buses, and Freightliner Custom Chassis Corporation products’ wiring drawings and floating pin lists available online for viewing and printing. EZWiring can also be accessed from within PartsPro. Introduction Descriptions of Service Publications Cargo Workshop Manual, Supplement 13, September 2010 I–1

Warranty-related service information available on the AccessFreightliner.com and AccessSterling.com websites includes 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 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 with non-safety-related service work or replacement of parts. All field service campaigns are distributed to dealers; customers receive notices that apply to their vehicles. Introduction Descriptions of Service Publications I–2 Cargo Workshop Manual, Supplement 13, September 2010

For an example of a Cargo Workshop Manual page, see Fig. 1. B C A FG D E 02/25/98 f020073 A. Section Title B. Section Number (made up of the Group Number— first two digits; followed by a sequence number—last two digits) C. Subject Title D. Manual Title E. Release (Supplement) Date F. Subject Number G. Subject Page Number Fig. 1, Example of a Cargo Workshop Manual Page Introduction Page Description Cargo Workshop Manual, Supplement 13, September 2010 I–3

Group No. Group Title 00 ...................... General Information 01 ................................ Engine 09 .............................. Air Intake 13 ......................... Air Compressor 15 ................... Alternators and Starters 20 ................... Engine Cooling/Radiator 25 ................................ Clutch 26 ........................... Transmission 30 ......................... Throttle Control 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 .................................. Cab 72 ................................ Doors 82 ............. Windshield Wipers and Washer 83 ................. Heater and Air Conditioner 91 ............... Seats and Restraint Systems 98 ................................. Paint Introduction Workshop Manual Contents I–4 Cargo Workshop Manual, Supplement 13, September 2010

Vehicle Receipt Prior to signing for vehicle delivery from a transporter company, the dealer is responsible for checking for transporter-related shortages or damages, and noting these discrepancies on the transporter’s delivery receipt. The dealer is also responsible for ensuring that the vehicle was built according to the Truck Sales Order/ Invoice. Refer to Section 3 of the Freightliner LLC Warranty Manual for details. Vehicle Storage There may be times when a vehicle is stored for long periods before customer delivery. To protect all vehicles from deterioration and weather, they must be properly maintained. Adequate protection and storage of new vehicles is the responsibility of the dealer. Claims arising from loss and damage to improp- erly stored vehicles will not be reimbursed. See Section 3 of the Freightliner LLC Warranty Manual for instructions on storage of new vehicles. Pre-Delivery Information All pre-delivery inspections and services must be performed at an authorized Freightliner LLC facility, assigned to fully qualified service personnel and re- corded on the "New Vehicle Pre-Delivery Inspection" form. Refer to Section 3 of the Freightliner LLC Warranty Manual for details. It is recommended the pre-delivery inspection be performed within 30 days of vehicle receipt. Vehicle Receipt, Storage, and Pre-Delivery Information 00.01 General Information Cargo Workshop Manual, Supplement 10, September 2005 050/1

U.S. Customary to Metric Metric to U.S. Customary When You Know Multiply By To Get When You Know Multiply By To Get Length inches (in) 25.4 millimeters (mm) 0.03937 inches (in) inches (in) 2.54 centimeters (cm) 0.3937 inches (in) feet (ft) 0.3048 meters (m) 3.281 feet (ft) yards (yd) 0.9144 meters (m) 1.094 yards (yd) miles (mi) 1.609 kilometers (km) 0.6215 miles (mi) Area square inches (in 2 ) 645.16 square millimeters (mm 2 ) 0.00155 square inches (in 2 ) square inches (in 2 ) 6.452 square centimeters (cm 2 ) 0.15 square inches (in 2 ) square feet (ft 2 ) 0.0929 square meters (m 2 ) 10.764 square feet (ft 2 ) Volume cubic inches (in 3 ) 16387.0 cubic millimeters (mm 3 ) 0.000061 cubic inches (in 3 ) cubic inches (in 3 ) 16.387 cubic centimeters (cm 3 ) 0.06102 cubic inches (in 3 ) cubic inches (in 3 ) 0.01639 liters (L) 61.024 cubic inches (in 3 ) fluid ounces (fl oz) 29.54 milliliters (mL) 0.03381 fluid ounces (fl oz) pints (pt) 0.47318 liters (L) 2.1134 pints (pt) quarts (qt) 0.94635 liters (L) 1.0567 quarts (qt) gallons (gal) 3.7854 liters (L) 0.2642 gallons (gal) cubic feet (ft 3 ) 28.317 liters (L) 0.03531 cubic feet (ft 3 ) cubic feet (ft 3 ) 0.02832 cubic meters (m 3 ) 35.315 cubic feet (ft 3 ) Weight/Force ounces (av) (oz) 28.35 grams (g) 0.03527 ounces (av) (oz) pounds (av) (lb) 0.454 kilograms (kg) 2.205 pounds (av) (lb) U.S. tons (t) 907.18 kilograms (kg) 0.001102 U.S. tons (t) U.S. tons (t) 0.90718 metric tons (t) 1.1023 U.S. tons (t) Torque/Work Force inch-pounds (lbf·in) 11.298 Newton-centimeters (N·cm) 0.08851 inch-pounds (lbf·in) foot-pounds (lbf·ft) 1.3558 Newton-meters (N·m) 0.7376 foot-pounds (lbf·ft) Pressure/Vacuum inches of mercury (inHg) 3.37685 kilo Pascals (kPa) 0.29613 inches of mercury (inHg) pounds per square inch (psi) 6.895 kilo Pascals (kPa) 0.14503 pounds per square inch (psi) When You Know Subtract Then Divide By To Get When You Know Multiply By Then Add To Get degrees Fahrenheit (°F) 32 1.8 degrees Celsius (°C) 1.8 32 degrees Fahrenheit (°F) Metric/U.S. Customary Conversion Chart 00.02 General Information Cargo Workshop Manual, Supplement 10, September 2005 050/1

IMPORTANT: For vehicles built May 1, 2000, or later, see Subject 060 for the Sterling vehicle identification numbering system or Subject 070 for the Freightliner system. Federal Motor Vehicle Safety Standard 115 specifies that all vehicles sold in the U.S. be assigned a 17- character vehicle identification number (VIN). Using a combination of letters and numerals, the VIN defines the manufacturer, model, and major characteristics of the vehicle. See Table 1 for the character positions of a typical Sterling VIN, 480ALEBDXWA345678. On Sterling vehicles, the VIN can be found on the Vehicle Specification Decal (see the driver’s manual for decal location) and stamped on the outside of the left-hand frame rail about 24 to 40 inches (60 to 100 cm) aft of the front axle centerline. On Sterling vehicles built before July 1998, the VIN is stamped on the frame rail near the front axle position. On Freightliner vehicles, the VIN can be found on the Vehicle Specification Decal (see the driver’s manual for decal location) and stamped into the left frame rail over the front axle about 2 inches (50 mm) from the top of the web, or on the top flange of the left frame rail at frame station 30. NOTE: For Freightliner vehicles assembled and sold in Mexico, the VIN appears on a plate or label attached to the driver’s door. Also, a data card placed in the glove box shows the Mexican VIN as the "CHASSIS" number. The "CABIN" number is part of the Freightliner VIN, the last six digits of which are the Freightliner serial number. IMPORTANT: A new VIN-code structure will be used for all vehicles built after April 30, 2000. Character positions 1 through 4 and 9 through 17 are nearly the same in both versions, but positions 5 through 8 have been assigned slightly different parameters. As a result, the build date of a vehicle must be determined before the VIN can be decoded. For all vehicles, a check digit (9th character) is determined by assignment of weighted values to the other 16 characters. These weighted values are processed through a series of equations designed to check validity of the VIN and to detect VIN alteration. NOTE: Always specify the VIN when ordering parts. Seventeen-Character Vehicle Identification Number (VIN) Typical VIN 480 A L EB D X W A 345678 Character Position 1, 2, 3 4 5 6, 7 8 9 10 11 12 thru 17 Decoding Table * Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 — Table 8 Table 9 — Code Description Manufacturer, Make, Vehicle Type Chassis, Front Axle Position, Brakes Vehicle Model Series, Cab Engine Model, Horsepower Range Gross Vehicle Weight Rating (GVWR) Check Digit Vehicle Model Year Plant of Manufacture Production Number * For corresponding decoding information, see the applicable tables in this subject. Table 1, Seventeen-Character Vehicle Identification Number (VIN) Vehicle Identification Numbering System 00.03 VIN for Vehicles Built through April 30, 2000 Cargo Workshop Manual, Supplement 10, September 2005 050/1

VIN Positions 1, 2, and 3 (Manufacturer, Make, Vehicle Type) Code Vehicle Manufacturer Vehicle Make Vehicle Type 1FU Freightliner, U.S.A. Freightliner Truck-Tractor 1FV Freightliner, U.S.A. Freightliner Incomplete Vehicle 2FU Freightliner, Canada Freightliner Truck-Tractor 2FV Freightliner, Canada Freightliner Incomplete Vehicle 2FW Sterling, Canada-built Sterling Truck-Tractor 2FZ Sterling, Canada-built Sterling Incomplete Vehicle 3FE M-B, Mexico (before April 1996) Freightliner Truck-Tractor 3FF M-B, Mexico (before April 1996) Freightliner Incomplete Vehicle 3AK M-B, Mexico (after April 1996) Freightliner Truck-Tractor 3AL M-B, Mexico (after April 1996) Freightliner Incomplete Vehicle 480 Sterling, U.S.-built Sterling Truck-Tractor 49H Sterling, U.S.-built Sterling Incomplete Vehicle AFV M-B, South Africa Freightliner Truck KFB AIL, Israel Freightliner Truck RSA NAI, Saudi Arabia Freightliner Incomplete Vehicle RSB NAI, Saudi Arabia Freightliner Truck-Tractor Table 2, VIN Positions 1, 2, and 3 (Manufacturer, Make, Vehicle Type) VIN Position 4 (Chassis, Front Axle Position, Brakes) Code Chassis Front Axle Position Brakes A 4 x 2 Truck Forward Hydraulic B 8 x 4 Truck-Tractor Setback Air C 6 x 6 Truck-Tractor Setback Air D 4 x 4 Truck Setback Hydraulic E 4 x 4 Truck Setback Air F 8 x 4 Truck Forward Air G 8 x 4 Truck-Tractor Forward Air H 4 x 2 Truck Forward Air J 10 x 4 Truck All Air K 4 x 2 Truck-Tractor Forward Air L 6 x 2 Truck Forward Air M 6 x 2 Truck-Tractor Forward Air N 6 x 4 Truck Forward Air P 6 x 4 Truck-Tractor Forward Air R 10 x 6 Truck Forward Air VIN Position 4 (Chassis, Front Axle Position, Brakes) Code Chassis Front Axle Position Brakes S 10 x 6 Truck-Tractor Forward Air T 6 x 6 Truck Setback Air U 8 x 6 Truck All Air V 8 x 6 Truck-Tractor All Air W 4 x 2 Truck-Tractor Setback Air X 6 x 4 Truck Setback Air Y 6 x 4 Truck-Tractor Setback Air Z 6 x 2 Truck Setback Air 1 4 x 2 Truck Forward Air/Hydraulic 2 4 x 4 Truck Setback Air 3 4 x 2 Truck Setback Hydraulic 4 8 x 4 Truck Setback Air 5 6 x 2 Truck-Tractor Setback Air 6 4 x 2 Truck Setback Air 7 Glider Setback Air Vehicle Identification Numbering System 00.03 VIN for Vehicles Built through April 30, 2000 Cargo Workshop Manual, Supplement 10, September 2005 050/2

FREIGHTLINER CARGO Service Repair Manual

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