1998-2009 Sterling Acterra MX Trucks OEM Service & Repair Manual

ACTERRA WORKSHOP MANUAL Models: MX STI-414, S19 (7/10P)

For an example of an Acterra Workshop Manual page, see Fig. 1. B C A F G D E Threaded Fasteners Fastener Replacement Fastener Selection and Installation Fastener Tightening Thread Locking Compound Application General Instructions 00.04 01/20/2000 f020104 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 an Acterra Workshop Manual Page Introduction Page Description Acterra Workshop Manual, Supplement 19, 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 Workshop Manual Contents I–4 Acterra Workshop Manual, Supplement 19, July 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 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 00.01 General Information Acterra Workshop Manual, Supplement 15, 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. All hoses from the engine hard pipes must be wrapped in convoluted tubing. 4. Hoses that are protected with convoluted tubing may be secured with tie straps to clear the inner fenders. 5. Cooling system hoses should not be twisted or kinked. 6. Cooling system hoses must be routed at least 6 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 3 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. 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. 3. A/C lines cannot be secured to air lines, fuel lines, or electrical wires. 4. 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. 5. 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 crushing. NOTE: If hoses are covered with convoluted tubing, they may touch any of the above. 6. Hoses that are protected with convoluted tubing may come in contact with the bends on frame rails and filters. 7. HVAC hoses must be routed at least 6 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 3 inches (76 mm) from the heat source. 8. 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 adjustment or replacement without the need to relocate or remove the hoses. 9. All A/C hoses in the engine compartment must have convoluted tubing. 10. If cushion clamps are used over convoluted tubing at existing clamp points, no additional tie straps or tape is needed. 11. When convoluted tubing is installed on the heater hose where it routes past the splash shield on the front right-hand side of the firewall, and if it uses existing clamps, no additional tie straps or tape is needed. Auxiliary Heater All auxiliary heater lines are deck-mounted hard pip- ing with rubber hose at both ends. No additional tie straps are required. Engine Plumbing 1. On vehicles equipped with the Cummins ISM 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 Vehicle Receipt, Storage, and Pre-Delivery Information 00.01 Hoses and Electrical Wiring Routing Standards Acterra Workshop Manual, Supplement 5, September 2002 100/1

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 3. Any wiring that will be exposed to water or heat must be covered with either loom or convoluted tubing. Loom or convoluted tubing need not butt up against Weather Pack ® connectors. 4. Any wiring routed across the vehicle, on the engine crossmember, or across the rear of the engine, must be secured with a clamp or tie strap, and covered with either convoluted tubing or a loom. 5. Any wiring that may come into contact with sharp points and edges (such as nuts, bolts, brackets, and frame rail edges), moveable parts, and sources of abrasion, cutting, pinching, or crushing, must be protected by either a loom or convoluted tubing. 6. Unprotected breakouts (individual wires) of up to 8 inches (203 mm) are acceptable as long as these wires are routed safely away from sharp points and edges, moveable parts, and sources of abrasion, cutting, pinching, or crushing. 7. Gray, flame-retardant convoluted tubing may be used to protect wiring in the cab or the chassis. Black nylon convoluted tubing may only be used in the chassis. 8. All wiring 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 adjustment or replacement without the need to relocate or remove any wiring. 9. In exposed locations, such as the road light har- ness near the headlights, loose loops of wire must be secured with tie straps. 10. All wiring should be routed a minimum of 4 inches (102 mm) from the exhaust. In situations where the wiring is less than 4 inches (102 mm) from the exhaust, a heat shield must be placed between the wiring and the exhaust. Battery Cables 1. Battery cables must be routed along an unob- structed path from the starter to the battery box. The cables must not rub or chafe on brackets, tanks, air lines, or fuel lines. 2. Battery cables and electrical wiring cannot be tied or secured to fuel lines, discharge lines, or air lines. 3. Battery cables must have support brackets no more than 30 inches (762 mm) apart. Tie straps must be within 6 inches (152 mm) of both sides of the support brackets, and every 12 inches (305 mm) between the brackets. 4. Battery cables must have convoluted tubing from the frame bracket to the batteries, and from the frame bracket to the starter. Fuel Lines 1. Fuel lines must not be clamped to A/C lines, battery cables, jumper cables, or any other electrical wiring. 2. Stand-off brackets or clamps may be used to prevent fuel lines from rubbing against the frame. 3. Fuel lines must be routed at least 6 inches (152 mm) from a heat source. If a heat shield is provided, the fuel line must be at least 3 inches (76 mm) from the heat source. 4. Fuel lines that are parallel may be fastened together. Fuel lines that cross or that rub on metal, plastic, or electrical parts, need to be separated with butterfly clamps. Chassis Air Lines and Brake Hoses 1. Hoses may come in contact with each other if they are parallel, or if they are bundled together. 2. If the hoses lie on the curve or flat surface of a bracket or crossmember, they do not need convoluted tubing. 3. Brake hoses may be clamped at the top of the axle housing, and touch or lie against the axle housing in its path to the brake chamber as this assembly moves together. Vehicle Receipt, Storage, and Pre-Delivery Information 00.01 Hoses and Electrical Wiring Routing Standards Acterra Workshop Manual, Supplement 5, September 2002 100/2

4. Brake hoses must have slack between the last clamping point on the frame rail and the brake chamber to allow for full range of suspension travel. 5. Brake hoses should have butterfly clamps at breakout points. 6. Air lines and brake hoses 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. Tie straps may be closer than 12 inches (305 mm) apart. 7. Hoses or lines that may come into contact with the sharp edge of a bracket or frame rail are to be protected by convoluted tubing. 8. Air lines and brake hoses that are parallel may be fastened together. Air lines and brake hoses that cross or that rub on metal, plastic, or electrical parts need to be separated with butterfly clamps. 9. Nylon or STX (wire braid) chassis air lines may be fastened together to prevent rubbing, as long as the lines are stationary. Vehicle Receipt, Storage, and Pre-Delivery Information 00.01 Hoses and Electrical Wiring Routing Standards Acterra Workshop Manual, Supplement 5, September 2002 100/3

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 Charts 00.02 General Information Acterra Workshop Manual, Supplement 6, September 2004 050/1

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 va- lidity 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 00.03 VIN for Vehicles Built through April 30, 2000 Acterra Workshop Manual, Supplement 1, June 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 00.03 VIN for Vehicles Built through April 30, 2000 Acterra Workshop Manual, Supplement 1, June 2000 050/2

1998-2009 Sterling Acterra MX Trucks OEM Service & Repair Manual

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