19933-2000 Freightliner Heavy-Duty Trucks OEM Service & Repair Manual

HEAVY-DUTY TRUCKS SERVICE MANUAL Models: FLA COE FLB COE FLD Conventional FLL COE STI-206, S39 (8/10P)

For an example of a Heavy-Duty Trucks Service Manual page, see Fig. 1. B C A FG D E 02/11/98 f020022 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 Heavy-Duty Trucks Service Manual Page Introduction Page Description Heavy-Duty Trucks Service Manual, Supplement 39, July 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 88 .............. Hood, Grille, and Cab Fenders 90 ................. Fire Suppression Systems 91 ............... Seats and Restraint Systems 98 ................................. Paint Introduction Service Manual Contents I–4 Heavy-Duty Trucks Service Manual, Supplement 39, July 2010

The following is a list of definitions for abbreviations and symbols used in Freightliner publications. A .......... amperes ABS ....... antilock braking system ABS ....... acrylonitrile-butadiene-styrene A/C ........ air conditioner AC ......... alternating current acc ........ accessories ACPU ..... air conditioning protection unit ADLO ..... auto-disengagement lockout AGM ....... absorbed glass mat AGS ....... automated gear shift a.m. ....... ante meridiem (midnight to noon) AM ........ amplitude modulation amp(s) .... ampere(s) AMT ....... automated mechanical transmission AMU ....... air management unit ANSI ...... American National Standards Institute API ........ American Petroleum Institute API ........ application programming interface ARI ........ Air Conditioning and Refrigeration Institute ASA ....... American Standards Association ASF ....... American Steel Foundries ASR ....... automatic spin regulator assy . ...... assembly ASTM ..... American Society for Testing and Materials ATC ....... automatic temperature control ATC ....... automatic traction control ATC ....... automatic transmission control ATD ....... aftertreatment device ATF ........ automatic transmission fluid ATS ....... aftertreatment system attn ........ attention aux. ....... auxiliary av ......... avoirdupois (British weight system) AWD ....... all-wheel drive AWG ...... American wire gauge AWS ....... American Welding Society BAT ....... battery BBC ....... bumper-to-back-of-cab BHM ....... bulkhead module BOM ....... bill of material BTDC ...... before top dead center Btu(s) ..... British thermal unit(s) C .......... common (terminal) CAC ....... charge air cooler CAN ....... controller area network CARB ..... California Air Resources Board CAT ....... Caterpillar CB ......... circuit breaker CB ......... citizens’ band CBE ....... cab behind engine CCA ....... cold cranking amperes CD-ROM .. compact-disc/read-only memory CDTC ...... constant discharge temperature control CEL ....... check-engine light CFC ....... chlorofluorocarbons (refrigerant-12) cfm ........ cubic feet per minute CFR ....... Code of Federal Regulations CGI ........ clean gas induction CHM ....... chassis module CIP ........ cold inflation pressure CLS ....... coolant level sensor cm ......... centimeters cm 3 ........ cubic centimeters CMVSS .... Canadian Motor Vehicle Safety Standard Co. ........ company COE ....... cab over engine Corp. ...... corporation CPU ....... central processing unit CRT ....... cathode ray tube cSt ........ centistokes (unit of measurement for describing the viscosity of general liquids) cu ft ....... cubic feet cu in ...... cubic inches CUM ....... Cummins CWS ....... collision warning system DC ......... direct current DDA ....... Detroit Diesel Allison (obs) DDC ....... Detroit Diesel Corporation DDDL ...... Detroit Diesel Diagnostic Link DDE ....... Detroit Diesel Engines DDEC ..... Detroit Diesel Electronic (engine) Control DDR ....... diagnostic data reader DDU ....... driver display unit def ........ defrost DEF ....... diesel exhaust fluid DFI ........ direct fuel injection DGPS ..... differential global positioning system dia. ........ diameter DIAG ...... diagnosis DIP ........ dual inline package (switch) DLA ....... datalink adaptor DLM ....... datalink monitor DLU ....... data logging unit DMM ...... digital multimeter DOC ....... diesel oxidation catalyst DOT ....... Department of Transportation DPF ....... diesel particulate filter DRL ....... daytime running lights DRM ....... dryer reservoir module DSM ....... district service manager DTC ....... diagnostic trouble code DTC ....... discharge temperature control DVOM ..... digital volt/ohm meter ea. ......... each EBS ....... electronic braking system ECAP ...... electronic control analyzer programmer ECAS ...... electronically controlled air suspension ECI ........ electronically controlled injection ECL ....... engine coolant level ECM ....... electronic control module ECT ....... engine coolant temperature ECU ....... electronic control unit EDM ....... electronic data monitor EEPROM . . electrically erasable programmable read-only memory EFPA ...... electronic foot pedal assembly EGR ....... exhaust gas recirculation ELC ....... extended-life coolant EMC ....... electromagnetic compatibility EMI ........ electromagnetic interference EOA ....... electric over air EP ......... extreme pressure (describes an antiwear agent added to some lubricants) List of Abbreviations 00.01 List of Abbreviations Heavy-Duty Trucks Service Manual, Supplement 38, July 2009 050/1

EPA ....... Environmental Protection Agency EPS ....... engine position sensor ESD ....... electrostatic discharge ESS ....... engine syncro shift (transmission) etc. ........ et cetera (and so forth) ETEC ...... electronic truck engine control EUI ........ electronic unit (fuel) injectors EXM ....... (chassis) expansion module FAS ....... Freightliner air suspension FET ........ field effect transistor Fig. ........ figure fl oz ....... fluid ounces FLA ....... post-1984 advancements Freightliner COE FLB ....... enhanced Freightliner FLA COE FLC ....... steel-cab Freightliner 112 Conventional FLD ....... post-1984 advancements Freightliner 112/120 aluminum-cab Conventional FM ......... frequency modulation FMCSA .... Federal Motor Carrier Safety Administration FMEA ..... failure mode effects analysis FMI ........ failure mode indicator FMSI ...... Friction Materials Standards Institute FMVSS .... Federal Motor Vehicle Safety Standard FRP ....... fiberglass reinforced plastic FSA ....... field service authorization FSM ....... fleet service manager ft .......... feet ft 3 ......... cubic feet ft 3 /min ..... cubic feet per minute FTL ........ Freightliner F.U.E.L. .... fuel usage efficiency level g .......... grams gal ......... gallons GAWR ..... gross axle weight rating GL ......... gear lubricant GND ....... ground gpm ....... gallons per minute GPS ....... global positioning system GVWR ..... gross vehicle weight rating HCOE ..... high cab over engine HCU ....... hydraulic control unit HD ......... heavy-duty HEPA ...... high-efficiency particulate air (filter) HEST ...... high exhaust system temperature HEV ....... hybrid electric vehicle HFC ....... hydrogenated fluorocarbons (refrigerant-134a) hp ......... horsepower hp ......... high pressure HRC ....... Rockwell "C" hardness hr(s) ....... hour(s) HSD ....... high-side driver htr . ........ heater HVAC ...... heating, ventilating, and air conditioning H/W ....... hardware Hz ......... hertz ICU ........ instrumentation control unit i.d.......... inside diameter ID .......... identification IFI ......... Industrial Fasteners Institute IFS ........ independent front suspension IGN ........ ignition ILB ........ intelligent lightbar ILO ........ in lieu of (in the place of) in .......... inches in 3 ......... cubic inches Inc. ........ incorporated inH 2 O ..... inches of water inHg ....... inches of mercury I/O ......... input/output IP .......... instrument panel ISO ........ International Organization for Standardization IVS ........ idle validation switch k ........... kilo (1000) kg ......... kilograms km ......... kilometers km/h ....... kilometers per hour kPa ........ kilopascals kW ........ kilowatts L .......... liters lb .......... pounds LBCU ...... lightbar control unit lbf·ft ....... pounds force feet lbf·in ...... pounds force inches LCD ....... liquid crystal display LCOE ...... low cab over engine LED ....... light-emitting diode LH ......... left-hand LH DR ..... left-hand drive LHK ....... liters per hundred kilometers LHS ....... low-hydrogen steel LIN ........ Local Interconnect Network LLC ....... limited liability company L/min ...... liters per minute LPG ....... liquefied petroleum gas LSD ....... low-side driver LVD ....... low-voltage disconnect m .......... meters max. ....... maximum M-B ........ Mercedes-Benz MESA ..... Mining Enforcement Safety Act mfr . ........ manufacturer mi ......... miles MID ........ message identifier MIL ........ military specification min. ....... minutes min. ....... minimum misc. ...... miscellaneous mL ........ milliliters mm ........ millimeters mod. ...... module mpg ....... miles per gallon mph ....... miles per hour MSF ....... modular switch field MSHA ..... Mining Safety and Health Administration MVDA ..... Motor Vehicle Dealers Association n .......... negative (front axle wheel alignment specification) N .......... nitrogen N/A ........ not applicable N·cm ...... Newton-centimeters NC ......... normally closed (terminal or switch) NHTSA .... National Highway Traffic Safety Administration NIOSH ..... National Institute for Occupational Safety and Health NLGI ...... National Lubricating Grease Institute N·m ........ Newton-meters NO ........ normally open (terminal or switch) NOAT ...... Nitrited Organic Acid Technology List of Abbreviations 00.01 List of Abbreviations Heavy-Duty Trucks Service Manual, Supplement 38, July 2009 050/2

no. ........ number NPT ....... national pipe thread NPTF ...... national pipe thread fitting NT ......... nylon tube or nylon tubing NTSB ...... National Transportation Safety Board OAT ....... Organic Acid Technology obs ........ obsolete OC ........ open circuit OCV ....... open circuit voltage o.d. ........ outside diameter O.D. ....... overdrive OEM ....... original equipment manufacturer OSHA ..... Occupational Safety and Health Administration oz ......... ounces ozf·in ...... ounces force inches p .......... positive (front axle wheel alignment specification) PACE ...... programmable electronically controlled engine PAG ....... polyalkylene glycol (oil) parm ...... parameter PC ......... personal computer PCB ....... printed circuit board PDC(s) .... parts distribution center(s) PDM ....... power distribution module PEC ....... power electronics carrier PEEC ...... programmable electronic engine control PID ........ parameter identifier PLC ....... power line carrier PLD ....... Pumpe-Linie-Düse (pump- line-nozzle) p.m. ....... post meridiem (noon to midnight) p/n ........ part number PRD ....... product requirements document PSA ....... pressure-sensitive adhesive PSG ....... pressure sensor governor psi ......... pounds per square inch psia ....... pounds per square inch, atmosphere psig ....... pounds per square inch, gauge pt .......... pints PTCM ..... pressure time control module PTO ....... power takeoff PTP ....... powertrain protection pvc ........ polyvinyl chloride PWM ...... pulse width modulation pwr ........ power qt .......... quarts qty . ........ quantity R&O ..... rust inhibitors and oxidants R–12 ...... refrigerant-12 (CFC) R–134a .... refrigerant-134a (HFC) RAM ....... random access memory RC ......... reserve capacity recirc. ..... recirculation Ref(s). ..... reference(s) regen ...... regeneration RFI ........ radio frequency interference RH ......... right-hand RH DR ..... right-hand drive R/I ......... removal and installation RMA ....... return material authorization ROM ....... read-only memory rpm ........ revolutions per minute R/R ........ removal and replacement RSG ....... road speed governor RSM ....... regional service manager RTV ....... room temperature vulcanizing RV ......... recreational vehicle SA ......... source address SAE ....... Society of Automotive Engineers SB ......... service bulletin SCA(s) .... Supplemental Coolant Additive(s) SCR ....... selective catalyst reduction SCU ....... system control unit (speedometer) SD ......... severe-duty SDU ....... step deployment unit SEL ....... shutdown engine light SEM ....... switch expansion module SEO ....... stop engine override SHM ....... switch hub module SI .......... service information SI .......... Système International SID ........ subsystem identifier SM ........ system malfunction SMC ....... sheet molded compound S/N ........ serial number SPACE .... seat pretensioner activation for crash survival enhancement SPG ....... special purpose grease SPN ....... suspect parameter number sq in ...... square inches SRS ....... synchronous reference sensor SRT ....... standard repair time SSD ....... side sensor display SSID ....... smart switch identification SST ....... stainless steel std. ........ standard S/W ........ software SW ........ switch TAM ....... thermocouple amplifier module TBS ....... turbo boost sensor TCU ....... transmission control unit TDC ....... top dead center TDR ....... technician diagnostic routine temp ...... temperature TIG ........ tungsten inert gas TIR ........ total indicator reading TPMS ...... tire pressure monitoring system TPS ....... thermal protection switch TPS ....... throttle position sensor TRS ....... timing reference sensor TSO ....... truck specification order TSU ....... transmission shift unit U.D. ....... underdrive UNC ....... unified national coarse UNF ....... unified national fine U.S. ....... United States U.S.A. ..... United States of America USC ....... United States customary (measures) V .......... volts VCU ....... vehicle control unit VDC ....... vehicle data computer Vdc ........ volts, direct current VIMS ...... vehicle information management system VIN ........ vehicle identification number VIP ........ vehicle instrumentation and protection (Kysor) VIW ........ vehicle interface wiring (connector) VOC ....... volatile organic compounds List of Abbreviations 00.01 List of Abbreviations Heavy-Duty Trucks Service Manual, Supplement 38, July 2009 050/3

VOM ....... volt-ohmmeter VRS ....... variable resistance sensor VSG ....... variable speed governor VSS ....... vehicle speed sensor VSU ....... vehicle security unit WB ........ wire braid WI ......... work instructions WIF ........ water-in-fuel WOT ....... wide open throttle – ........... minus or negative + ........... plus or positive ± ........... plus-or-minus > ........... greater than < ........... less than x ........... by (used in fastener size descriptions) " ........... inches ° ........... degrees (of an angle) °C ......... degrees Celsius (centigrade) °F .......... degrees Fahrenheit # ........... number % .......... percent & .......... and © .......... copyright ™ .......... trademark ® ........... registered trademark List of Abbreviations 00.01 List of Abbreviations Heavy-Duty Trucks Service Manual, Supplement 38, July 2009 050/4

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 Heavy-Duty Trucks Service Manual, Supplement 32, January 2006 050/1

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 Daimler Trucks North America 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 Daimler Trucks North America 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 Daimler Trucks North America LLC facility, assigned to fully qualified service personnel and recorded on the "New Vehicle Pre-Delivery Inspection" form. Refer to Section 3 of the Daimler Trucks North America 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 00.03 General Information Heavy-Duty Trucks Service Manual, Supplement 35, January 2008 050/1

Cooling System 1. Cooling system hoses must clear all moving parts by a minimum of 1/4 inch (6 mm). 2. The 1-inch (25-mm) hose from the surge tank to the engine must be free of sumps and have al- lowance for engine torque. 3. Cooling system hoses should not be twisted or kinked. 4. Cooling system hoses must be routed at least six inches (152 mm) from a heat source if the heat source does not have a heat shield. If a heat shield is provided, the hose must be routed at least three inches (76 mm) from the heat source. HVAC System 1. Cushion clamps are required to support all A/C lines. Butterfly or figure-8 clamps (two cushion clamps) may be used to prevent rubbing or chaf- ing. 2. Tie straps may only be used to fasten together A/C lines that are parallel to each other. 3. Heater hoses that are protected with convoluted tubing may be fastened with tie straps. If not protected with convoluted tubing, only cushion clamps or butterfly clamps may be used for heater hoses. 4. A/C lines cannot be secured to air lines, fuel lines, or electrical wires. 5. HVAC hoses should be protected from damage by routing them away from hazards of heat, wheel splash (water, gravel, ice), human traffic, and moving parts of the vehicle. 6. HVAC hoses should be routed away from sharp points and edges (such as nuts, bolts, brackets, and frame rail edges), moveable parts, and sources of abrasion, cutting, pinching, or crush- ing. NOTE: If hoses are covered with convoluted tubing, they may touch any of the above. 7. Hoses that are protected with convoluted tubing may come in contact with the bends on frame rails and filters. 8. HVAC hoses must be routed at least six inches (152 mm) from a heat source if the heat source does not have a heat shield. If a heat shield is provided, the hose must be routed at least three inches (76 mm) from the heat source. 9. HVAC hoses should be clamped every 12 to 18 inches (305 to 457 mm). 10. All HVAC hoses must be routed so that regularly serviced components, such as fuel filters, fuel/ water separators, oil filters, air filters, belts, and fill and drain plugs, are readily accessible for ad- justment or replacement without the need to relo- cate or remove the hoses. 11. All Conventional sleeper heater hoses must be protected with convoluted tubing when they pass through the crossmember, and at the lower frame rail flange. 12. Hose supports for Conventional sleeper heater hoses will be where the brackets are located. Auxiliary Heater No additional tie straps or tape are needed when convoluted tubing is installed where the auxiliary heater hose routes past the edge of the frame rail. Engine Plumbing 1. On vehicles equipped with the Cummins M-11 engine and power steering, no additional tie straps or tape are needed if convoluted tubing is installed on the power steering hose where it routes under the frame rail. 2. The engine oil pressure line should not rub or chafe against the Teflon ® discharge line. Electrical Wiring 1. Wires that are bundled together should be fastened at 8- to 12-inch (203- to 305-mm) intervals. If anchor clamps are more than 12 inches (305 mm) apart, a tie strap must be used between the anchor clamps. 2. Bundles of wires that are located in an exposed area, such as under the cab or outside the frame rail, need to be fastened with heavy-duty cable ties. Vehicle Receipt, Storage, and Pre-Delivery Information 00.03 Hoses and Electrical Wiring Routing Standards Heavy-Duty Trucks Service Manual, Supplement 27, January 2002 100/1

19933-2000 Freightliner Heavy-Duty Trucks OEM Service & Repair Manual

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