Sterling Cargo Truck Service Repair Workshop Manual

CARGO WORKSHOP MANUAL STI-448, S11 (9/08P)

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 2008 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 2008

CARGO WORKSHOP MANUAL STI-448, S11 (9/08P) 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.Daimler-TrucksNorthAmerica.com, www.FreightlinerTrucks.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. © 1998–2009 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 (POC-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 2008 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 2008

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 2008 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 2008

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Sterling Cargo Truck Service Repair Workshop Manual

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