Sterling-trucks Acterra MX User Manual

ACTERRA MAINTENANCE MANUALModels: MXSTI-403-1 (10/08P)Published byDaimler Trucks North America LLC4747 N. Channel Ave.Portland, OR 97217Printed in U.S

Torque Values for U.S. Customary Thread Fasteners With Lubricated*or Plated Threads†ThreadDiameter–PitchRegular Hex FlangedGrade 5BoltGrade 5 orBNutGr

NOTE: If a low-pressure adapter is not usedwith the high-pressure gun, the U-joints may notreceive enough lubricant.3. Using lithium 12-hydroxy steara

screws, then loosen the bearing cup capscrews(at the bearing with the dry seal) to relieve sealtension. Lubricate the U-joint until the oldgrease is p

Title of Maintenance Operation (MOP) MOP NumberAir Brake Valve Disassembly, Cleaning, and Inspecting, Bendix E–8P, R–12,R–14, SR–1, ST–3, TC–6, and TP

42–01 Air Dryer Inspecting,Bendix AD–91. Check the reservoirs for moisture. A smallamount (teaspoon or less) is normal. Largeramounts may mean that th

3. Clean any road grime from the relay valve andany debris from the valve exhaust port.4. Listen for air leakage around the fittings or ex-haust port.

2. Check each brake chamber for correct installa-tion.2.1 Check each mounting stud for the pres-ence of prevailing torque locknuts andhardened flatwash

spring which, if released, could cause serious in-jury or death.7. Inspect the exterior surfaces of the chamber fordamage. Make sure the breather hole

3.3 If leakage persists, use the instructions inGroup 42 of theActerra®WorkshopManualto replace the service brake dia-phragm.3.4 Using soapy water, co

42–08 Camshaft BracketBushing LubricatingIMPORTANT: Perform MOP 42–24 before lubri-cating the camshaft brackets.Pump multipurpose chassis grease (NLGI

42–11 Automatic SlackAdjuster Inspecting,MeritorIMPORTANT: Perform MOP 42–24 before lubri-cating the slack adjusters.1. Remove the pull-pawl assembly.

Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated)*Plain (Unplated) Threads†ThreadDiameter–PitchRegular Hex FlangedGrade 5 Bolt

42–16 Air Brake ValveDisassembly, Cleaning,and Inspecting, BendixE–8P, R–12, R–14, SR–1,ST–3, TC–6, and TP–3DCDisassemble each brake valve, clean the

adjuster at the grease fitting until grease appears onthe camshaft.42–21 Automatic SlackAdjuster Inspecting,GuniteWARNINGManually adjusting an automati

Lubricate a Haldex automatic slack adjuster at thegrease fitting with any extreme-pressure NLGI Grade1 or Grade 2 grease if the operating temperature i

12. Apply two level teaspoons of Aeroshell Grade 5(ES1246) grease on each side of the assembly.Apply it evenly along the full length of the V-waygroov

theActerra®Workshop Manualfor inspection,troubleshooting, and repair procedures.4. Measure the applied chamber stroke. SeeTable 3 for the proper strok

Brake Chamber Stroke SpecificationsChamberMax Applied Stroke: inch (mm)Manufacturer Type*Size†MeritorStandard Stroke9Less than 1-1/2 (38)1216Less than

Title of Maintenance Operation (MOP) MOP NumberDrag Link Lubricating...46–02Power Steering

46–01 Steering DrivelineLubricatingWipe the grease fittings clean. See Fig. 1. Using apressure gun, apply a lithium-based grease (NLGIgrade 2) sparingl

46–03 Power SteeringReservoir Fluid LevelCheckingMetal Ventra Reservoir1. Turn off the engine, apply the parking brakes,and chock the tires.2. Open th

Plastic Ventra ReservoirNOTE: If the power steering reservoir in the ve-hicle looks like the reservoir shown in Fig. 4,use the following procedure.1.

Torque Values for Metric Thread Fasteners With Lubricated*or Plated Threads†ThreadDiameter–PitchClass 8.8 Bolt Class 8 Nut Class 10.9 Bolt Class 10 Nu

11. Fill the reservoir with ATF as needed. Start theengine and let it idle. Have someone turn thesteering wheel from lock to lock until no bubblesare

2. Open the hood.3. Place a drain pan under the power steering res-ervoir.4. Remove the retaining ring from the reservoir.See Fig. 4.5. Remove the filt

Title of Maintenance Operation (MOP) MOP NumberFuel Tank Draining and Vent Checking ... 47–01Fuel 47Ind

47–01 Fuel Tank Draining andVent CheckingRemove the plug or open the drain valve at the bot-tom of the fuel tank, and allow the tank to drain untilall

Title of Maintenance Operation (MOP) MOP NumberExhaust System Inspecting (Noise Emission Controls)...49–01Exhaust

49–01 Exhaust SystemInspecting (NoiseEmission Controls)NOTE: In addition to the maintenance interval inthis manual, inspect the exhaust system if thev

• Diesel Particulate Filter (DPF)—a filter that col-lects and holds particulate matter (soot andash).• Diesel Oxidation Catalyst (DOC)—oxidizes hy-droc

9. Check any wires, lines, or hoses within 4 inches(10 cm) of the exhaust system for heat damage.Repair or reroute as needed.Exhaust 49Acterra Mainten

Title of Maintenance Operation (MOP) MOP NumberCoolant Level Sensor Cleaning...54–02Electrical Sy

54–01 Electrical SystemCheckingCab1. Uncover the electrical panel (see Fig. 1)byre-moving the fasteners.2. Check the wiring harness for movement thatc

When You Know U.S.CustomaryMultiplyByTo Get MetricWhen YouKnow MetricMultiplyByTo Get U.S. CustomaryLengthinches (in) 25.4 millimeters (mm) 0.03937 in

54–02 Coolant Level SensorCleaning1. Drain enough coolant from the radiator to exposethe coolant level sensor.2. Disconnect wire 173 from the sensor i

Title of Maintenance Operation (MOP) MOP NumberWeatherstrip, Door Latch, and Door Hinge Lubricating...72–01Doors 7

72–01 Weatherstrip, DoorLatch, and Door HingeLubricatingLightly coat door weatherstrips with a lubricant that issafe (as recommended by the lubricant

Title of Maintenance Operation (MOP) MOP NumberAir Conditioner Inspecting...83–01HVAC Air Fil

83–01 Air ConditionerInspectingWARNINGWear eye protection, gloves, and protective cloth-ing when working on the air conditioning system.Leaking refrig

7. Close the hood.8. Remove the chocks from the tires.02/17/2003f8315641121. Screw 2. Filter CoverFig. 2, Air Filter ReplacementHeater and Air Conditi

DescriptionSchedule I (severe service) applies to vehicles thatannually travel up to 6000 miles (10 000 kilometers)orthat operate under severe conditi

Maintenance Schedule ModelsMaintenance IntervalOperationMaintenance IntervalsFrequency Miles Km HoursSchedule I(Severe Service)vehicles that annually

Maintenance Intervals for Schedule IMaint. No. Maintenance Interval Miles km Hours1 IM and M1 1000 1600 1002 M1 2000 3200 2003 M1 3000 4800 3004 M1and

Maintenance Intervals for Schedules II and III (all models)Maint.No.Maintenance IntervalSchedule II Schedule IIIMiles km Miles km1 IM and M1 8000 12 0

IMPORTANT: At each Maintenance Operation Set, inaddition to the maintenance operations listed in thistable, perform all daily, weekly, and monthly mai

Maintenance Operation Sets for Groups 00 through 83REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 M4 M5Maintenance Operation Number and Operation Desc

ForewordScheduled maintenance provides a key element for the safe operation of your vehicle. A propermaintenance program also helps to minimize downti

Maintenance Operation Sets for Groups 00 through 83REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 M4 M5Maintenance Operation Number and Operation Desc

IMPORTANT: After performing all operations in thistable, perform all daily and weekly maintenance op-erations listed in the "Pretrip Inspection a

IMPORTANT: After performing all operations listed inthis table, perform all daily, weekly, and monthlymaintenance operations listed in the "Pretr

Maint.Oper. No.M1 Maintenance Interval Operations42–09 Automatic Slack Adjuster Checking, Meritor42–14 Air Brake Valve Leak Checking, Bendix TC–642–17

IMPORTANT: After performing all operations listed inthis table, perform all daily, weekly, and monthlymaintenance operations listed in the "Pretr

IMPORTANT: After performing all operations listed inthis table, perform all daily, weekly, and monthlymaintenance operations listed in the "Pretr

IMPORTANT: After performing all operations listed inthis table, perform all daily, weekly, and monthlymaintenance operations listed in the "Pretr

IMPORTANT: After performing all operations listed inthis table, perform all daily, weekly, and monthlymaintenance operations listed in the "Pretr

Maintenance Operation 00–15 (see Table 10), sum-marizes all Lubrication and Fluid Level Check opera-tions that must be performed at the M1 Maintenance

Maintenance Operation 00–16 (see Table 11), sum-marizes all Lubrication and Fluid Level Check opera-tions that must be performed at the M2 Maintenance

Daimler Trucks North America LLC distributes the following major service publications in paper and electronic(via ServicePro®) formats.Workshop/Servic

Title of Maintenance Operation (MOP) MOP NumberEngine Drive Belt Inspecting...01–02Engine-Suppo

01–01 Engine-SupportFasteners CheckingFront and rear engine supports for vehicles built fromJanuary 2007 require no periodic maintenance.Mounts should

checked, not the pulley, to isolate the area fromoutside interference.8. Inspect all pulleys for foreign objects, oil, orgrease in the grooves.Belt Te

Engine ComponentBelt Tension:lbf (kg)Cummins ISB, ISC, ISM Refrigerant Compressor 100 (45)Mercedes-Benz MBE900Fan and Alternator 29.5 (27.9)Refrigeran

Title of Maintenance Operation (MOP) MOP NumberAir Cleaner Element Inspecting and Replacing ... 09–01Air Inta

09–01 Air Cleaner ElementInspecting andReplacingMethod 1Replace the air cleaner element at the recommendedinterval or when the air restriction indicat

Title of Maintenance Operation (MOP) MOP NumberAir Compressor Inspecting, Bendix...13–01Air Compress

13–01 Air CompressorInspecting, BendixInspect the air intake line, oil supply and return lines,and coolant supply and return hoses for tight connec-ti

Title of Maintenance Operation (MOP) MOP NumberAlternator, Battery, and Starter Connections Checking...15–01Altern

15–01 Alternator, Battery, andStarter ConnectionsCheckingWARNINGBatteries generate explosive gas as a by-productof their chemical process. Do not smok

Warranty-related service information available on the AccessSterling.com website includes the following docu-mentation.Recall Campaigns Recall campaig

Title of Maintenance Operation (MOP) MOP NumberFan Clutch Checking (Noise Emission Control) ... 20–03Radiator

20–01 Radiator Cap CheckingWARNINGDo not remove or loosen the radiator cap until theengine and cooling system have completelycooled. Use extreme care

4. Drain the radiator, and flush the radiator untilclean water flows from the radiator. Remove theflushing gun.5. Close the petcock at the bottom of the

the coolant level is between the MIN and MAXlines on the surge tank.7. Fill the radiator with coolant.Use a mixture of 50 percent water and 50 per-cen

2. Inspect the electrical connections and wires tothe fan clutch solenoid. Secure the connection, ifloose; replace wires and connectors if damaged.3.

10.6 Set the toggle switch to the AUTO or OFFposition; the air should exhaust and thefan clutch should disengage. Replace theswitch, if necessary.Kyso

6. Release the air pressure, then disconnect theshop hose from the air inlet of the air cylinder.Connect the vehicle air hose to the inlet.7. Connect

10. Check the fan drive for discoloration or any othersigns of slipping or overheating.NOTE: The fan clutch may slip if the air supplypressure is belo

Title of Maintenance Operation (MOP) MOP NumberClutch (Pull-Type) Inspecting and Adjusting...25–02Clutch R

25–01 Clutch Release Bearingand Release Cross-ShaftLubricatingClutch Release BearingCAUTIONDo not over-lubricate the clutch release bearing.Over-lubri

For an example of anActerra Maintenance Manualpage, see Fig. 1.02/11/2002f020103ABCDEFrame and Fifth Wheel3131−01 Frame Fastener TorqueChecking31−02 F

procedures below. Fluid replacement must be doneat an authorized Freightliner service facility.Draining and Filling1. Shut down the engine.2. Apply th

4.3 Press down on the pedal several times,until no more fluid drains from the reser-voir.4.4 Cover the hose to avoid contamination ofthe clutch hydraul

hose. When no bubbles appear in the fluid, closethe valve on the slave cylinder. Release theclutch pedal and then close the valve at thebleeder unit.8.

Title of Maintenance Operation (MOP) MOP NumberAllison Transmission Breather Checking ... 26–03Allison T

26–01 Manual TransmissionFluid Level Checking1. Park the vehicle on a level surface. Apply theparking brakes and chock the rear tires.2. With the tran

• 42 lbf·ft (57 N·m) for all Mercedes-Benztransmissions.26–02 Eaton Fuller and TTCTransmission FluidChanging and MagneticPlug CleaningDraining1. Park

fected component must be thoroughly drained.Switching to a synthetic lubricant, when apetroleum-based lubricant has been used for50,000 miles (80 000

11. Check and adjust the fluid level using the proce-dure under "Checking the Fluid Level."Approved Allison Transmission LubricantsLubricant

11. Submerge a new oil pan gasket in transmissionfluid for five minutes. Then place the gasket onthe pan; do not use any substance as a gasketretainer.I

the transmission and remove the drain plug. Ex-amine the fluid as it drains. If only the filter isbeing changed, do not drain the fluid.4. Remove the 12

Group No. Group Title00... General Information01... Engine09... AirIntake13

CAUTIONDo not use the bolts to draw the filter covers tothe sump. This can damage the covers, seals, orsump.11. Install six bolts in each cover, and to

08/30/96f2603691234567891011121513141. Transmission Housing2. Transmission Oil Pan Gasket3. 5/16–18 Washer-HeadCapscrew4. Plug5. Transmission Oil Pan6

vented from contacting areas of the oil panflange that are inside the raised bead of theflange.NOTE: Do not use gasket-type sealing com-pounds or cement

3. Run the engine for at least one minute.4. Shift from DRIVE to NEUTRAL, and then shift toREVERSE to fill the hydraulic system.5. Shift to NEUTRAL and

26–05 Mercedes-BenzTransmission FluidChanging and MagneticPlug CleaningDraining1. Park the vehicle on a level surface. Apply theparking brakes and cho

CAUTIONUse only the approved Mobiltrans SHC®DC fluid.Do not mix fluid types. Adding SHC 50 RN 2952E-5 fluid (used in Eaton and Meritor transmis-sions) co

WARNINGClutch hydraulic fluid (DOT 3 brake fluid) is haz-ardous. It may be a skin irritant and can causeblindness if it gets in your eyes. Always wearsa

Title of Maintenance Operation (MOP) MOP NumberFifth Wheel Inspecting ... 31–02Fifth Wheel

31–01 Frame Fastener TorqueCheckingBecause of "bedding in" (or seating), frame fastenersmust be torqued at the recommended intervals.These i

Check the drive-axle-flange fasteners (see Fig. 2) fortightness. Tighten the fasteners as follows:Tighten 1/2-inch drive-axle stud nuts (with or withou

Title of Maintenance Operation (MOP) MOP NumberInitial Maintenance (IM) Operations Table ... 00–09Lubrica

8. Replace cracked, worn, or damaged parts withnew parts. Replace loose mounting bolts with5/8–11 SAE grade 8 bolts, grade C nuts, andhardened washers

Title of Maintenance Operation (MOP) MOP NumberSuspension Inspecting ...32–01Suspension Lub

32–01 Suspension InspectingSterling Front and RearSuspension Spring AssembliesInspectingInspect the front and rear suspension spring assem-blies for p

• Either bushing end contacts a torque armpin mounting bolt.• There are cracks in the bushing.• Part of the rubber bushing extends beyondthe outside d

60-Inch Taper-Leaf SpringComponent CheckNo lubrication is required on the 60-inch taper-leafspring rear suspension.Inspect the rear shackle brackets f

3. Check for any shifting of the barpin.4. Check for cracks in the metal components andwelds.NOTE: The AirLiner suspension is manufacturedat numerous

cause loss of vehicle control resulting in propertydamage, serious personal injury or death.Hendrickson Leaf SpringAssembly InspectingNOTE: See Fig. 7

down, in, and out. If there is any movement, re-place the torque arm.2. Inspect the rubber bushing ends. Replace thetorque arm if there are gaps betwe

WARNINGReplace all cracked or missing restrictor cans.Failure to do so could lead to loss of vehicle con-trol, which could result in property damage,

3. Use a click-type torque wrench to check thatspring hanger bolts are tightened 190 lbf·ft (258N·m).4. Use a click-type torque wrench to check that t

General InformationFederal Law, Part 205:Transportation Equipment NoiseEmission ControlsPart 205, Transportation Equipment Noise EmissionControls, req

Hendrickson Spring-Eye Pins,RT and RTE SeriesNOTE: See Fig. 7 for this procedure.Apply multipurpose chassis grease at the spring eyepin grease fitting

01/05/99 f320783 1 2 3 4 Fig. 12, Tightening Pattern for U-Bolt High NutsSuspension32Acterra Maintenance Manual, September 200232/1

Title of Maintenance Operation (MOP) MOP NumberAll-Axle Alignment Checking...33–04All-Wheel-Dri

33–01 Knuckle Pin LubricatingStandard Meritor AxlesHold a pressure gun on each fitting until fresh greaseappears. See Fig. 1. This will ensure that all

pand when in contact with synthetic grease.Consult your local Meritor representative forsynthetic grease application references beforeusing any synthe

1. Shut off the engine, apply the brakes, and chockthe rear tires.2. Check the tie rod boot for cracks, tears, or otherdamage. If the tie rod boot is

• 1-1/8–12, 350 to 650 lbf·ft (475 to 881N·m)• 1-1/4–12, 500 to 675 lbf·ft (678 to 915N·m)10. Check the steering arm bolts for a minimumtorque of 300

2. On front-wheel-drive vehicles equipped with MT-14, MT-17, and MT-22 axles, check the oil levelin the hubs.2.1 The oil drain bore must be at the bot

10/11/2001f330186Fig. 8, Draw Key NutFront Axle33Acterra Maintenance Manual, September 200233/6

Title of Maintenance Operation (MOP) MOP NumberAxle Breather Checking ... 35–02Axle Lubrican

Verification of Inspections LogVerification of Inspections Log — Group 20Verification of Inspections Log — Group 20 — Engine Cooling/RadiatorDate Mileage

35–01 Axle Lubricant LevelCheckingCAUTIONFailure to keep the rear axle filled to the properlevel with the recommended lubricant can result inrear axle

Meritor Drive Axle LubricantCapacities, Tandem AxlesAxle Model Capacity*: pints (liters)RT–34–144Forward 29.8 (14.1)Rear 34 (16.1)RT–40–145Forward 30.

NOTE: Meritor recommends using magneticplugs with elements having a minimum pickupcapacity of 2 pounds (1 kg) of low-carbon steel,in plate or bar form

35–05 Two-Speed-Axle ShiftUnit Oil Changing1. Remove the shift unit housing cover (see Fig. 2),and drain the old lubricant. Discard the housingcover g

Title of Maintenance Operation (MOP) MOP NumberWheel Nut Checking...40–01Wheels and Tires

40–01 Wheel Nut CheckingIMPORTANT: In addition to the maintenanceinterval in this manual, check the wheel nuttorque the first 50 to 100 miles (80 to 16

1234567891012345612345f40005705/27/9312345678ABCDA. 8-Stud Disc WheelB. 10-Stud Disc WheelC. 6-Spoke WheelD. 5-Spoke WheelFig. 1, Wheel Nut and Rim Nu

Title of Maintenance Operation (MOP) MOP NumberDriveline Inspecting ... 41–01Driveline Lu

41–01 Driveline InspectingInspecting1. Check that the yoke-strap capscrews (see Fig. 1,Ref. 4) are tightened as follows:• Dana Spicer 1590 and 1610: 5

If the driveshaft tube requires straightening orreplacement, balance the repaired driveshaft be-fore installing it. See Group 41 of theActerra®Worksho