Freightliner Cascadia CA113DC CA113SLP CA125DC CA125SLP Operation & Maintenance Manual

Maintenance Manual ® CASCADIA Part Number STI 478 Publication Number STI-478-6

CASCADIA MAINTENANCE MANUAL Models: CA113DC CA113SLP CA125DC CA125SLP STI-478-6 (6/14) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.

Foreword Scheduled maintenance provides a key element for the safe operation of your vehicle. A proper maintenance program also helps to minimize downtime and to safeguard warranties. This maintenance manual provides information necessary for years of safe, reliable, and cost-efficient vehicle operation. IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also refer to other component and body manufacturers’ instructions for specific inspection and maintenance instructions. Perform the operations in this maintenance manual at scheduled intervals. Perform the pretrip inspection and daily/weekly/monthly maintenance, as outlined in the vehicle driver’s manual. Major components, such as engines, transmissions, and rear axles, are covered in their own maintenance and operation manuals, that are provided with the vehicle. Perform any maintenance operations listed at the intervals scheduled in those manuals. Your Freightliner Dealership has the qualified technicians and equipment to perform this maintenance for you. They can also set up a scheduled maintenance program tailored specifically to your needs. Optionally, they can assist you in learning how to perform these maintenance procedures. IMPORTANT: Descriptions and 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 and without incurring obligation. 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.Daimler-TrucksNorthAmerica.com and www.FreightlinerTrucks.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. © 2007–2014 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 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, transmissions, 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 fasteners. Maintenance manuals do not contain detailed repair or service information. Troubleshooting Manual Troubleshooting manuals contain diagnostic procedures for determining causes of problems in vehicle components and systems. Information on multiplexing diagnosis is included. These manuals are organized by functional systems, such as cab, chassis, and powertrain. Troubleshooting manuals do not contain 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 pre-trip 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 website. 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 diagnostic 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. Introduction Descriptions of Service Publications Cascadia Maintenance Manual, May 2011 I–1

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. Warranty-related service information available on the AccessFreightliner.com website 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 Cascadia Maintenance Manual, May 2011

For an example of a Maintenance Manual page, see Fig. 1. f020166 C B F D E 41-01 Driveline Inspection 1. Park the vehicle on a level surface, apply the parking brakes, and chock the tires. CAUTION Dueto the extreme loadoccurring at high- speed rotation, a loose or broken capscrew at any point in the drivelinewill weaken the drivelineconnec- tion, which could eventually result in serious vehicle damage. Tightenbearing- cap capscrews or yoke- strap capscrews to specif ed torque, being careful to not overtighten. 2. For U-jointswith bearing caps,tighten bearing- cap capscrews 43 lbf·ft (49 N·m). See . Fig. 1 For Arvin Meritor RPL series U-joints, tighten bearing-capcapscrews 125 lbf·ft (169 N·m). See Fig. 2 . For U-jointswith 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-y okes for looseness. See . Fig. 3 Replace cracked yokes. If any end-y oke can be moved in or out on its shaft, or can be rocked on its shaft, disconnect the driveshaft and U-joint from the yoke, then check the drive component’ s shaft seal for leak- age or other visible damage that may have been caused by the loose yoke. Replace the seal if needed, then tighten the yoke nut. Refer to Group 41 of the Cascadia TM Workshop Manual for torque specifications. If the yoke is still loose after tightening the yoke nut, replace the 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-joint assemblies for wear by moving the driveshaft up and down, and from side to side. If any movement of the U-joint cross in the bear- ings can be felt or seen, replace the U-joint assembly . 5. Check if the midship bearing and mounting are loose or have deteriorated, by attempting to move the driveshaft up and down, and from side to side. If the bearing is loose on its shaft, or rattles, replace it. If the bearing mount is loose on the frame, tighten the mounting fasteners to the proper torque value. See of the Group 41 Cascadia Y Workshop Manual for torque specif- cations. Replace the midship bearing assembly if the rubber cushion is deteriorated or oil-soak ed. 6. Check slip joints for spline wear by moving the sleeve-yoke and splined shaft back and forth. See . If the slip joint can be twisted in a Fig. 4 clockwise, or counterclockwise movement f410155a 04/13/98 1 1 1 2 M E R I T O R Capscrew 2. Adhesive Band Fig. 1, Arvin Meritor U-Joint Fasteners for Bearing Caps 12/09/97 f410182 Fig. 2, Arvin Meritor RPL Series U-Joint 41 Cascadia TM Maintenance Manual, July 2007 41/1 Driveline 1. Self-Locking A 06/11/2007 A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number B. Group Title C. Group Number D. Vehicle Name E. Release Date F. Group Number/Page Number Fig. 1, Example of a Maintenance Manual Page Introduction Page Description Cascadia Maintenance Manual, May 2011 I–3

Group No. Group Title 00 ...................... General Information 09 .............................. Air Intake 13 ......................... Air Compressor 15 ................... Alternators and Starters 20 ................... Engine Cooling/Radiator 25 ................................ Clutch 26 ........................... Transmission 31 ............. Frame and Frame Components 32 ............................ Suspension 33 ............................. Front Axle 35 ............................. Rear Axle 40 ........................ Wheels and Tires 41 .............................. Driveline 42 ................................ Brakes 46 ............................... Steering 47 ................................. Fuel 49 ............................... Exhaust 54 .......... Electrical, Instruments, and Controls 60 .................................. Cab 83 ................. Heater and Air Conditioner 88 .............. Hood, Grille, and Cab Fenders Introduction Maintenance Manual Contents I–4 Cascadia Maintenance Manual, May 2011

Title of Maintenance Operation (MOP) MOP Number Determining Scheduled Maintenance Intervals............................................. 00–01 Initial Maintenance (IM) Operations ..................................................... 00–04 M1 Maintenance Interval Operations .................................................... 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 ............................................................. 00–02 Vehicle Maintenance Schedule Table ................................................... 00–03 General Information 00 Index, Alphabetical Cascadia Maintenance Manual, March 2014

Determining Scheduled Maintenance Intervals Performing regular maintenance on your Freightliner vehicle will help ensure that your vehicle delivers safe reliable service and optimum performance for years to come. Failure to follow a regular maintenance program can result in inefficient operation and unscheduled down time. To determine the correct maintenance intervals for your vehicle you must ﬁrst determine the type of service or conditions the vehicle will be operating in. Generally, over-the-road vehicles operate under conditions that fall within one of the two types of service described. Before placing your new vehicle in service, determine the type of service (Service Schedule I or II) that applies to the intended use of the vehicle. After determining the vehicle’s type of service, refer to the service schedule table or the vehicle maintenance schedule table, to determine how often maintenance should be performed. When the vehicle reaches the distance given for a maintenance interval, see the Maintenance Interval Operation Table 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. Types of Service Service Schedule I (short-haul transport) applies to vehicles that annually travel less than 60,000 miles (100 000 kilometers) and operate under normal conditions. Examples of Schedule I usage are: operation primarily in cities and densely populated areas; local transport with infrequent freeway travel; or high per- centage of stop-and-go travel. Service Schedule II (long-haul transport) is for vehicles that annually travel more than 60,000 miles (100 000 kilometers) with minimal city or stop-and-go operation. Examples of Schedule II usage are: re- gional delivery that is mostly freeway miles; interstate transport; or any road operation with high annual mileage. NOTE: Maintenance instructions in this manual are based on average vehicle use and normal operating conditions. Unusual vehicle operating conditions may require service at more frequent intervals. General Information 00 Determining Scheduled Maintenance Intervals: 00–01 Cascadia Maintenance Manual, March 2014 00/1

Service Schedule Maintenance Interval Operation Maintenance Interval Frequency Miles km Schedule I (Short-Haul Transport) vehicles that annually travel 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 150,000 240 000 Schedule II (Long-Haul Transport) vehicles that annually travel over 60,000 miles (100 000 km) Initial Maintenance (IM) ﬁrst 25,000 40 000 Maintenance 1 (M1) every 25,000 40 000 Maintenance 2 (M2) every 100,000 161 000 Maintenance 3 (M3) every 300,000 483 000 Table 1, Service Schedule General Information 00 Service Schedule Table: 00–02 Cascadia Maintenance Manual, March 2014 00/2

Freightliner Cascadia CA113DC CA113SLP CA125DC CA125SLP Operation & Maintenance Manual

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