1999-2010 Sterling L-Line/A-Line Trucks (A9500/A9522/L7500/L7501/L8500/L8511/L8513/L9500/L9501/L9511/L9513/L9522) OEM Service & Repair Manual

L-LINE AND A-LINE WORKSHOP MANUAL Models: A9500 A9522 L7500 L7501 L8500 L8511 L8513 L9500 L9501 L9511 L9513 L9522 STI-384, S26 (11/10P) 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 Sterling Trucks or the component manufacturer. Maintenance schedules and additional service information are included in the L-Line and A-Line Maintenance Manual. IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Sterling 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.SterlingTrucks.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, specifications, and troubleshooting. 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, procedures for adjustments and for checking the tightness of fasteners. 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 AccessSterling.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 di- agnostic assistance with Symptoms Search, by connecting to a large knowledge base gathered from technicians and service personnel. Results for both docu- ments 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 Sterling, Freightliner, 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 L-Line and A-Line Workshop Manual, Supplement 25, May 2010 I–1

Warranty-related service information available on the AccessSterling.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 L-Line and A-Line Workshop Manual, Supplement 25, May 2010

For an example of an L-Line and A-Line Workshop Manual page, see Fig. 1. A B C F G D E f020023 06/13/94 A. Subject Topic B. Section Title C. Section Number; made up of the Group Number (first two digits) followed by a sequence number (last two digits) D. Subject Title E. Manual Title F. Supplement Number and Release (Supplement) Date G. Subject Number/Subject Page Number Fig. 1, Example of an L-Line and A-Line Workshop Manual Page Introduction Page Description L-Line and A-Line Workshop Manual, Supplement 25, May 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 91 ............... Seats and Restraint Systems 98 ................................. Paint Introduction Workshop Manual Contents I–4 L-Line and A-Line Workshop Manual, Supplement 25, May 2010

Jacking WARNING Do not run the engine when jacking the vehicle. Contact of the wheels with the ground can cause the vehicle to move, which could result in personal injury. Support the vehicle prior to performing any pro- cedure requiring the vehicle to be jacked above the ground. Failure to properly support the vehicle could result in personal injury or damage to the vehicle. Make sure the jacks and jack stands are properly located to prevent the vehicle from falling. Failure to properly locate the jacks and jack stands could result in personal injury or damage to the vehicle. Wheel chocks must be used to prevent the vehicle from rolling and falling off the jack. Failure to properly chock the vehicle wheels could result in personal injury or damage to the vehicle. CAUTION If the vehicle is equipped with traction control, disable the traction system before performing any dynamic driveline maintenance, or damage to the traction control system could result. NOTE: To raise vehicles with floor jacks, follow the jack manufacturer’s recommendations for placement of the jack. Do not exceed the rated lift capacity of any jack. 1. See Fig. 1 for the front jacking points. 2. See Fig. 2 for the rear jacking points. Lifting CAUTION If the vehicle is equipped with traction control, disable the traction system before performing any dynamic driveline maintenance, or damage to the traction control system could result. Damage to the vehicle can occur if care is not used when positioning the hoist adaptors prior to lifting the vehicle. NOTE: Position the hoist adaptors for heavy- duty hoists according to the hoist manufacturer’s recommendations. Be sure the hoist has an ad- equate lifting capacity for the vehicle being lifted. 1. See Fig. 3 for the front lifting points. 2. See Fig. 4 for the rear lifting points. 01/08/98 f000871 Fig. 1, Front Jacking Points 06/11/98 f000872 Fig. 2, Rear Jacking Points 01/08/98 f000873 Fig. 3, Front Lifting Points Jacking and Lifting 00.00 Jacking and Lifting L-Line and A-Line Workshop Manual, Supplement 1, October 1998 050/1

NOTE: On vehicles equipped with tandem axles, position the hoist on the rearmost axle. 01/08/98 f000874 Fig. 4, Rear Lifting Points Jacking and Lifting 00.00 Jacking and Lifting L-Line and A-Line Workshop Manual, Supplement 1, October 1998 050/2

IMPORTANT: See Subject 060 for the vehicle identification numbering system for vehicles built May 1, 2000, or later. 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 de- fines the manufacturer, model, and major characteris- tics of the vehicle. See Table 1 for the character positions of a typical Sterling VIN, 480ALEBDXWA345678. 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. 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 — 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) VIN Positions 1, 2, and 3 (Manufacturer, Make, Vehicle Type) Code Vehicle Manufacturer Vehicle Make Vehicle Type 2FW Sterling, Canada-built Sterling Truck-Tractor 2FZ Sterling, Canada-built Sterling Incomplete Vehicle 480 Sterling, U.S.-built Sterling Truck-Tractor Vehicle Identification Numbering System 00.01 VIN for Vehicles Built through April 30, 2000 L-Line and A-Line Workshop Manual, Supplement 5, July 2000 050/1

VIN Positions 1, 2, and 3 (Manufacturer, Make, Vehicle Type) Code Vehicle Manufacturer Vehicle Make Vehicle Type 49H Sterling, U.S.-built Sterling Incomplete Vehicle 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 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 VIN Position 4 (Chassis, Front Axle Position, Brakes) Code Chassis Front Axle Position Brakes 7 Glider Setback Air 8 Glider Forward Air 9 4 x 2 Truck Setback Air/Hydraulic 0 Glider Setback Hydraulic Table 3, VIN Position 4 (Chassis, Front Axle Position, Brakes) VIN Position 5 (Vehicle Model Series, Cab) Code Sterling Models A L7500 series B L8500 series C L9501 D L8511 E L9500 series F L9522 G A9522 H A9500 series J A9513 K L9513 L L8501 M L8513 N L9511 R L7501 S ST9500 W SC8000 2 SC6000 7 SC7000 Table 4, VIN Position 5 (Vehicle Model Series, Cab) Vehicle Identification Numbering System 00.01 VIN for Vehicles Built through April 30, 2000 L-Line and A-Line Workshop Manual, Supplement 5, July 2000 050/2

1999-2010 Sterling L-Line/A-Line Trucks (A9500/A9522/L7500/L7501/L8500/L8511/L8513/L9500/L9501/L9511/L9513/L9522) OEM Service & Repair Manual

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