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Channel Ave. Portland, OR 97217 Printed in Foreword Scheduled maintenance offers a key element with the safe operation of one's vehicle. A proper maintenance program can also help to minimize downtime and also to safeguard warranties. This maintenance manual provides information needed for years of safe, reliable, and cost-efficient vehicle operation. Descriptions of Service Publications Daimler Trucks North America LLC distributes the subsequent major service publications in paper and electronic via ServicePro formats. Workshop/Service Workshop/service manuals contain service and repair information for many vehicle Manual systems and components, excluding major components for instance engines, trans- missions, and rear axles. Introduction Warranty-related service information positioned on the website includes the next docu- mentation. Recall Campaigns Recall campaigns cover situations which involve service work or replacing of parts associated with a recall notice. These campaigns relate to matters of vehicle safety. Page Description For an instance of an Acterra Maintenance Manual page, see Frame and Fifth Wheel 31 01 Frame Fastener Torque Checking CAUTION: 31 02 Fifth Wheel Inspecting and Lubricating FONTANE Acterra Trucks Maintenance Manual, April 2000 02/11/2002 A. Maintenance Operation Number consists on the Group Number as well as the Sequence Number B. Introduction Maintenance Manual Contents Group No. Group Title General Information Engine 09. General Information Index, Alphabetical Title of Maintenance Operation MOP MOP Number Initial Maintenance IM Operations 00 09 Lubrication and Fluid Level Check M1. General Information Noise Emission Control Systems Maintenance: 00 01 General Information Federal Law, Part 205: Transportation Equipment Noise Emission Controls Part 205, Transportation Equipment Noise Emission Controls, necessitates vehicle manufacturer to fur- nish, with each new vehicle, such written instructions for your proper maintenance, use, and repair on the vehicle through the ultimate purchaser to offer reason- able assurance in the elimination or minimization General Information Torque Values for Metric Thread Fasteners With Lubricated Thread Diameter Pitch M8 x 1 M10 x 1.25 M12 x 1.5 M14 x 1.5 M16 x 1.5 M18 x 1.5 M20 x 1.5 M22 x 1.5 M24 x 2 M27 x 2 M30 x 2 Sterling recommends that each one plated and unplated fasteners be coated with oil before installation. Customary Conversion Tables: 00 04 When You Know Multiply Customary Length inches in 25.4 inches by 50 percent.54 feet ft 0.3048 yards yd 0.9144 miles mi 1.609 Area square inches in 645.16 square inches in 6.452 sq ft ft 0.0929 Volume cubic inches in General Information Description Schedule I severe service relates to vehicles that annually travel around 6000 miles 10 000 kilometers or that operate under severe conditions. Examples of Schedule I usage include: operation on extremely poor roads or high is heavy dust accumula- Maintenance Schedule Table: 00 06 Maintenance Schedule Schedule I Severe Service vehicles that annually travel approximately 6000 miles 10 000 km Schedule II Short-Haul Transport vehicles that annually travel approximately 60, 000 miles 100 000 km Schedule III Long-Haul Transport vehicles that annually travel over 60, 000 miles 100 000 General Information Maint. No. Maintenance Interval M1, M2, M3, M4, and M5 Acterra Maintenance Manual, October 2008 Maintenance Interval Tables: 00 07 Maintenance Intervals for Schedule I Miles IM and M1 1000 2000 3000 M1and M2 4000 5000 6000 7000 M1, M2, and M3 8000 9000 Maintenance Interval Tables: 00 07 Maintenance Intervals for Schedules II and III all models Maint. Maintenance Interval IM and M1 M1 and M2 M1, M2, and M3 M1 and M2 M1, M2, M3, and M4 M1 and M2 M1, M2, and M3 M1, and M2 M1, M2, M3, M4, and M5 M1 and General Information IMPORTANT: At each Maintenance Operation Set, in addition towards the maintenance operations listed in this particular table, perform all daily, weekly, and monthly mainte- nance operations listed inside the Pretrip and Post-trip Inspections and Maintenance chapter from the Acterra Initial Maintenance IM Operations Table: 00 09 IMPORTANT: After performing all operations with this table, perform all daily and weekly maintenance op- erations listed inside Pretrip Inspection and Daily Maintenance chapter in the vehicle driver s manual. Also, perform all M1 Maintenance Interval Operations in the Initial Maintenance IM. General Information IMPORTANT: After performing all operations listed within this table, perform all daily, weekly, and monthly maintenance operations listed inside Pretrip and Post-Trip Inspections and Maintenance chapter with the Acterra Driver s Manual. M1 Maintenance Interval Operations Maint. M1 Maintenance Interval Operations Table: 00 10 Maint. Oper. No. 42 09 Automatic Slack Adjuster Checking, Meritor 42 14 Air Brake Valve Leak Checking, Bendix TC 6 42 17 Brake Lining Wear Checking, Hydraulic Disc Brakes 42 18 Brake Lines Checking, Hydraulic Disc Brakes 42 19 Power Booster Checking, Bendix Hydro-Max 42 21 Automatic Slack Adjuster Inspecting, Gunite General Information IMPORTANT: After performing all operations listed in this particular table, perform all daily, weekly, and monthly maintenance operations listed from the Pretrip and Post-Trip Inspections and Maintenance chapter from the Acterra Driver s Manual. Also, perform all M1 Maintenance Interval Operations in the M2 Mainte- nance Interval. M3 Maintenance Interval Operations Table: 00 12 IMPORTANT: After performing all operations listed with this table, perform all daily, weekly, and monthly maintenance operations listed within the Pretrip and Post-Trip Inspections and Maintenance chapter from the Acterra Driver s Manual. Also, perform all M1 and M2 Maintenance Interval Operations on the M3 Maintenance Interval. General Information IMPORTANT: After performing all operations listed within this table, perform all daily, weekly, and monthly maintenance operations listed inside Pretrip and Post-Trip Inspections and Maintenance chapter from the Acterra Driver s Manual. Also, perform all M1, M2, and M3 Maintenance Interval Operations with the M4 Maintenance Interval. M5 Maintenance Interval Operations Table: 00 14 IMPORTANT: After performing all operations listed in this particular table, perform all daily, weekly, and monthly maintenance operations listed from the Pretrip and Post-Trip Inspections and Maintenance chapter on the Acterra Driver s Manual. Also, perform all M1, M2, M3, and M4 Maintenance Interval Operations in the M5 Maintenance Interval. General Information Maintenance Operation 00 15 see marizes all Lubrication and Fluid Level Check opera- tions that needs to be performed with the M1 Maintenance Interval for Schedules I, II, and III Maint. Oper. No. 25 01 Clutch Release Bearing and Release Cross-Shaft Lubricating 25 03 Hydraulic Fluid Level Checking Lubrication and Fluid Level Check M2: 00 16 Maintenance Operation 00 16 see marizes all Lubrication and Fluid Level Check opera- tions that must definitely be performed on the M2 Maintenance Interval for Schedules I, II, and III Maint. Oper. No. 35 04 Two-Speed-Axle Shift Unit Oil Level Checking 42 08 Camshaft Bracket Bushing Lubricating Engine Index, Alphabetical Title of Maintenance Operation MOP MOP Number Engine Drive Belt 01 02 Engine-Support Fasteners Checking. Engine 01 01 Engine-Support Fasteners Checking Front and rear engine supports for vehicles made January 2007 require no periodic maintenance. Mounts needs to be inspected in the event the engine is re- moved for service. For vehicles manufactured previous to January 2007, perform the next check. Check the trunk engine-support fasteners see Ref. 11/21/94 A. Glazing B. Separating Layers C. Streaked Sidewalls checked, not the pulley, to isolate the location from outside interference. 8. Inspect all pulleys for foreign objects, oil, or grease from the grooves. Belt Tension Inspection NOTE: If engine drive belts require adjustment, Engine Engine Cummins ISB, ISC, ISM Mercedes-Benz MBE900 01 03 Pacbrake Inspecting and Maintenance With frequent use, the Pacbrake Exhaust Brake will operate maintenance-free. If the vehicle is utilized in- consistently or seasonally, it will likely be necessary to per- form preventative maintenance. If the car is ex- posed to excess moisture, or can be used only for periodical or seasonal use, perform the next Air Intake Index, Alphabetical Title of Maintenance Operation MOP MOP Number Air Cleaner Element Inspecting and 09 01 Acterra Maintenance Manual, February Air Intake 09 01 Air Cleaner Element Inspecting and Replacing Method 1 Replace the oxygen cleaner element with the recommended interval or in the event the air restriction indicator reaches 22 inH O using a vehicle through an MBE engine, or 25 O over a vehicle using a Caterpillar or Cummins engine, if equipped having an air restriction indicator. Air Compressor Index, Alphabetical Title of Maintenance Operation MOP MOP Number Air Compressor Inspecting, 13 01 Air Compressor Rebuilding/Replacing, Bendix. Air Compressor 13 01 Air Compressor Inspecting, Bendix Inspect mid-air intake line, oil supply and return lines, and coolant supply and return hoses for tight connec- tions and general condition. Tighten the connections, and replace the lines and hoses, when needed. If the compressor air-intake adapter is loose, take off the adapter, replace its gaskets, and securely do the installation. Alternators and Starters Index, Alphabetical Title of Maintenance Operation MOP MOP Number Alternator, Battery, and Starter Connections 15 01 Acterra Maintenance Manual, October Alternators and Starters 15 01 Alternator, Battery, and Starter Connections Checking WARNING Batteries generate explosive gas being a by-product of these chemical process. Do not smoke when working around batteries. Put out all ames and take off any method to obtain sparks or intense heat inside the vicinity on the battery compartment. Engine Cooling/Radiator Index, Alphabetical Title of Maintenance Operation MOP MOP Number Fan Clutch Checking Noise Emission 20 03 Radiator Cap Checking. Engine Cooling/Radiator 20 01 Radiator Cap Checking WARNING Do not remove or loosen the radiator cap prior to the engine and cooling system have completely cooled. Use extreme caution when taking out the cap. A sudden launch of pressure from detaching the cap prior for the system cooling can lead to a surge of scalding coolant that may cause seri- ous compensation for injuries. 11/19/94 1. Radiator 2. Horn Fig. 2, Draining The Engine Coolant 4. Drain the radiator, and ush the radiator until clean water ows through the radiator. Remove the ushing gun. 5. Close the petcock on the bottom from the radiator. 6. Engine Cooling/Radiator the coolant level is between your MIN and MAX lines about the surge tank. 7. Fill the radiator with coolant. Use a combined 50 percent water and 50 per- cent corrosion-inhibiting antifreeze to guard the engine to 34 F 37 C all year round. Table 1 for engine cooling system capaci- ties. 2. Inspect the electrical connections and wires for the fan clutch solenoid. Secure the bond, if loose; replace wires and connectors if damaged. 3. Clean the fan clutch air solenoid valve lter, if equipped. Unscrew the fan clutch solenoid valve air lter assembly and take away the lter ele- ment. Engine Cooling/Radiator 03/30/95 1. Mounting Bracket 2. Rear Sheave Bearing 3. Inner and Outer Bearing Spacers 4. Forward Sheave Bearing 5. Sheave 6. Friction Facing 7. Journal Spacer 8. Socket-Head Capscrew Fig. 6, Horton Advantage Fan Clutch Components 10.6 Set the toggle switch on the AUTO or OFF 05/27/93 With the fan clutch engaged, appraise the distance at A ; measure it again together with the fan clutch disengaged. 1. Bearing Housing 5. Air Cylinder 2. Retaining Plate 6. Fan 3. Fan Pulley 4. Air Inlet from solenoid valve Fig. Engine Cooling/Radiator 05/30/2002 Fig. 8, Checking for Air Leaks Horton DriveMaster 10. Check the fan drive for discoloration or other signs of slipping or overheating. NOTE: The fan clutch may slip if the environment supply pressure is below 70 psi 483 kPa or if there can be a leak from the fan clutch. Clutch Index, Alphabetical Title of Maintenance Operation MOP MOP Number Clutch Pull-Type Inspecting and 25 02 Clutch Release Bearing and Release Cross-Shaft Lubricating. Clutch 25 01 Clutch Release Bearing and Release Cross-Shaft Lubricating Clutch Release Bearing CAUTION Do not over-lubricate the clutch release bearing. Over-lubrication could contaminate the clutch in- ternally, causing clutch slippage and premature failure. Do not use chassis grease or multipurpose lubricants. 06/17/2002 1. Reservoir 5. Hydraulic Hose 2. Reservoir Cap 6. Slave Cylinder 3. Pedal Unit 7. Reservoir Hose 4. Master Cylinder Fig. 2, Clutch Components procedures below. Fluid replacement need to be done with an authorized Freightliner service facility. Draining and Filling 1. Clutch Press down for the pedal many times, until forget about uid drains on the reser- voir. Cover the hose to prevent contamination on the clutch hydraulic uid. 5. Connect the hydraulic hose for the slave cylinder. Install the clamp, as removed. 6. hose. When no bubbles appear from the uid, close the valve about the slave cylinder. Release the clutch pedal after which close the valve on the bleeder unit. 8. Disconnect the bleeder unit, and install the cap within the slave cylinder bleeder valve. 9. Transmission Index, Alphabetical Title of Maintenance Operation MOP MOP Number Allison Transmission Breather 26 03 Allison Transmission Fluid and Filter Changing. Transmission 26 01 Manual Transmission Fluid Level Checking 1. Park the vehicle using a level surface. Apply the parking brakes and chock the spine tires. 2. With the transmission at operating temperature, confirm the uid level from the transmission. Clean the spot around the ll plug, then take off the plug through the side from the case. 42 lbf ft 57 N m for those Mercedes-Benz transmissions. 26 02 Eaton Fuller and TTC Transmission Fluid Changing and Magnetic Plug Cleaning Draining 1. Park the vehicle over a level surface. Apply the parking brakes and chock the spine tires. 2. Drain the uid whilst the transmission is warm. 3. Transmission fected component should be thoroughly drained. Switching with a synthetic lubricant, each time a petroleum-based lubricant has been used for 50, 000 miles 80 000 km or longer, may affect transmission performance. Monitor all seal areas for that rst 10, 000 miles 16 000 km after changing to some synthetic from your petroleum- based lubricant. 11. Check and adjust the uid level while using proce- dure under Checking the Fluid Level. Approved Allison Transmission Lubricants Lubricant Type Temperature: F C All Allison Transmissions Castrol TranSynd Above 22 30 synthetic On-Highway Transmissions 1000/2000/2400 Series Dexron Above 13 25 AT and MD Transmission 10/05/94 1. Fluid Intake Tube 5. Governor Pressure 2. Filter Spacer Tube 3. Internal Fluid Filter 6. Governor Feed Tube 4. Washer-Head Screw Fig. 3, Allison AT Series Transmission Filter 11. Submerge a whole new oil pan gasket in transmission uid for ve minutes. 10/05/94 1. Fluid Intake Tube 2. Detent Spring 3. Detent Spring 1-3/4 Bolt 4. Filter Spacer 5. 2-1/4 Bolt 16 qty. 6. First/Reverse Clutch Feed Tube 3 Bolt 2 qty., behind the transmission and take away the drain plug. Ex- amine the uid since it drains. If only the lter has been changed, tend not to drain the uid. Transmission 08/25/95 1. Filter Cover 3. Filter Element O-Ring 2. Filter Element 4. Square-Cut Seal Fig. 5, Allison MD Series Transmission Filter Locations and Components CAUTION Do not use the bolts to draw in the lter covers towards the sump. This can damage the covers, seals, or sump. 08/30/96 1. Transmission Housing 2. Transmission Oil Pan Gasket 3. 5/16 18 Washer-Head Capscrew 4. Plug 5. Transmission Oil Pan Fig. 6, Allison MT Series Transmission, Filter Removal 26/8 6. Magnet 7. Drain Plug Gasket 8. Drain Plug 9. 5/16 18 x 5/8 Capscrew 10. Transmission vented from contacting areas from the oil pan ange that are in the raised bead in the ange. NOTE: Do not use gasket-type sealing com- pounds or cement anywhere in the trans- mission or where some might get washed to the transmission. 3. Run the engine for a minimum of one minute. 4. Shift from DRIVE to NEUTRAL, then shift to REVERSE to ll the hydraulic system. 5. Shift to NEUTRAL and invite the engine to idle at 500 800 rpm. 6. With the engine running at idle, eliminate the dip- stick in the tube and wipe clean. Transmission 26 05 Mercedes-Benz Transmission Fluid Changing and Magnetic Plug Cleaning Draining 1. Park the vehicle on the level surface. Apply the parking brakes and chock a corner tires. NOTE: Drain the transmission uid even though the transmission is warm. 2. Drain the transmission uid. See Remove the magnetic drain plug in the bottom in the gear case. CAUTION Use only the approved Mobiltrans SHC Do not mix uid types. Adding SHC 50 RN 2952 E-5 uid employed in Eaton and Meritor transmis- sions could damage the radial seals. 2. Clean the ll plug before setting it up. 3. Install the ll plug p/n N000908 020001 and a brand new aluminum gasket p/n N 00763 024105. Transmission WARNING Clutch hydraulic uid DOT 3 brake uid is haz- ardous. It may be a skin irritant which enable it to cause blindness if this gets with your eyes. Always wear safety glasses when handling clutch hydraulic uid or bleeding hydraulic lines. If you get clutch hydraulic uid on the skin, wash it well as soon as possible. Frame and Frame Components Index, Alphabetical Title of Maintenance Operation MOP MOP Number Fifth Wheel 31 02 Fifth Wheel Lubricating. Frame and Frame Components 31 01 Frame Fastener Torque Checking Because of bedding in or seating, frame fasteners need to be torqued for the recommended intervals. These intervals pertain to new vehicles, as well as frame fasteners that are actually removed and installed. NOTE: For off-highway operations, retorque frame fasteners the rst 1000 miles 1600 km, then periodically, according to operating Check the drive-axle- ange fasteners see tightness. Tighten the fasteners as follows: 05/27/93 NOTE: Do not use the three-piece adapter devoid of the intermediate tube. 1. Nut 4. Inner Metal of Beam 2. Adapter End Bushing 3. Intermediate Tube 5. Beam Hanger Fig. Frame and Frame Components 8. Replace cracked, worn, or damaged parts with new parts. Replace loose products with 5/8 11 SAE grade 8 bolts, grade C nuts, and hardened washers. Do not reuse bolts, nuts, and washers on fth wheel mountings. Holland Disconnect the tractor through the trailer.

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