Pre- and Post-Trip Inspections and Maintenance

Safety Precautions

When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle can not drop. Failure to follow these steps could result in serious personal injury or death.

Daily Pretrip Inspection and Maintenance

Complete the following inspection and maintenance procedures to ensure that vehicle components are in good working condition before each trip. A driver who is familiar with the vehicle and drives it regularly can perform the daily inspections, then add the weekly and monthly post-trip inspections as scheduled.

If the driver does not operate the vehicle on a consistent basis, all daily, weekly, and monthly inspection and maintenance procedures should be performed before the trip.

IMPORTANT: The pre- and post-trip checklists, inspections, and maintenance procedures detailed in this chapter are not all-inclusive . Refer to other component and body manufacturers' instructions for specific inspection and maintenance instructions, as well as local, state, and federal guidelines.

NOTE: If any system or component does not pass this inspection, it must be corrected before operating the vehicle. Whenever equipment requires adjustment, replacement, and/or repair, see the Cascadia Workshop Manual for procedures and specifications.erticfied

Suspension and Slack Adjuster Inspection

Walk around the vehicle and visually inspect suspension and slack adjuster components.

Inspect the following suspension components for signs of structural damage, cracks, or wear.

springs

spring hangers

shocks

suspension arms

suspension brackets

axle seats

bushings

Inspect slack adjusters for signs of damage. See Fig. 21.1 , Fig. 21.2 , or Fig. 21.3 .

1. 7/16-inch Adjusting Nut
2. Grease Fitting
3. Boot
4. Link
5. Brake Chamber Piston Rod
6. Clevis
7. ½-inch Clevis Pin
8. 1/4-inch Clevis Pin
9. Grease Relief Opening
10. Slack Adjuster Spline

Fig. 21.1, Gunite Automatic Slack Adjuster

1. Clevis
2. Slack Adjuster
3. Clevis Pin
4. Manual Adjusting Nut
5. Control Arm
6. Control-Arm Washers and Nut
7. Anchor Strap Slot
8. Anchor Strap
9. Brake Chamber

Fig. 21.2, Haldex Automatic Slack Adjuster

1. Grease Fitting (if equipped)
2. Slack Adjuster Housing
3. Brake Chamber Pushrod
4. Clevis
5. Clevis Pin (large)
6. Clevis Pin (small)
7. Actuator Rod
8. Boot
9. Manual Adjusting Nut
10. Camshaft Splines

Fig. 21.3, Meritor Automatic Slack Adjuster

Inspect slack adjuster boots, if equipped, for cuts or tears.

Inspect anchor straps, if equipped, for damage.

Look for worn clevis pins on brake chamber pushrods.

Look for missing or damaged cotter pins on the clevis pins.

Ensure chamber piston rods are in line with the slack adjusters.

Wheel and Tire Inspection

Walk around the vehicle and visually inspect each wheel and tire assembly.

IMPORTANT: Wheel covers decrease drag force as a vehicle moves, thereby improving fuel efficiency. If replacement of a wheel cover is necessary, the replacement cover must meet or exceed the drag reduction performance of the originally installed cover in order to maintain compliance with greenhouse gas and fuel efficiency regulations (GHG14).

If the vehicle was originally equipped with wheel covers, ensure all wheel covers are present. Inspect wheel covers for damage or wear. Remove wheel covers from rear drive wheels, if equipped, prior to inspecting the tires and wheel components.

NOTE: During wheel cover installation, ensure the V-notch in the liner inner retaining ring is centered on the valve stem. The inner and outer retaining rings should be uniformly aligned to each other and to the wheel rim. The outer retaining ring of the liner is equipped with two canvas flaps. When installing the face cover, make sure the cover retaining ring is inserted between the two canvas flaps on the liner outer retaining ring so that the Velcro strips line up between the face cover and the liner. Make certain the detachable view cover is centered on the face cover, and the Velcro strips are pressed firmly in place.

Inspect each tire for the following:

valve stem caps on every tire, screwed on finger-tight

bulges, cracks, cuts, and penetrations

oil contamination (petroleum derivatives will soften the rubber and destroy the tire)

tread depth—if tread is less than 4/32 inch (3 mm) on any front tire, or less than 2/32 inch (1.5 mm) on any rear tire, replace the tire

debris lodged between duel tire sets

IMPORTANT: Low-rolling resistance (LRR) tires minimize wasted energy as a tire rolls, thereby decreasing rolling effort and improving fuel efficiency. If tire replacement is necessary, replacement tires must meet or exceed the rolling resistance of the originally installed tires in order to maintain compliance with greenhouse gas and fuel efficiency regulations (GHG14).

Contact your tire manufacturer/supplier to determine the rolling resistance of the originally installed tires. Visitwww.epa.gov/smartwayfor additional information and resources.

Check tire inflation.

For inflation pressures and maximum loads, see the tire manufacturer's guidelines. Inflate the tires to the applicable pressures if needed.

If a tire has been run flat or under-inflated, check the wheel and tire for damage before adding air.

Keep compressed air reservoirs and lines dry during tire inflation. Use well-maintained inline moisture traps and service them regularly.

Do not operate the vehicle with underinflated or overinflated tires. Incorrect inflation can stress the tires and make the tires and rims more susceptible to damage, possibly leading to rim or tire failure and loss of vehicle control, resulting in serious personal injury or death.

NOTICE

A weekly pressure loss of 4 psi (28 kPa) or more in a tire may indicate damage. The tire should be inspected and, if necessary, repaired or replaced by a qualified tire service facility.

IMPORTANT: The load and cold inflation pressure must not exceed the rim or wheel manufacturer's recommendations, even though the tire may be approved for a higher load inflation. Consult the rim or wheel manufacturer for the correct tire inflation pressure for the vehicle load.

Examine each rim and wheel component.

4.1

Remove all dirt and debris from the assembly. Rust streaks or metal build-up around stud holes, or out-of-round or worn stud holes, may be caused by loose wheel nuts.

Have any worn or damaged wheel components replaced by a qualified person using the wheel manufacturer's instructions and the wheel industry's standard safety precautions and equipment. Otherwise a vehicle or workshop accident could occur, possibly resulting in serious personal injury or death.

4.2

Inspect for broken, cracked, badly worn, bent, rusty, or sprung rings and rims.

NOTICE

Use the recommended torque values and follow the proper tightening sequence. Insufficient wheel nut torque can cause wheel shimmy, resulting in wheel damage, stud breakage, and extreme tire tread wear. Excessive wheel nut torque can break studs, damage threads, and crack discs in the stud hole area.

4.3

Make sure all wheel nuts are tightened. If tightening is necessary, use the tightening pattern in Fig. 21.4 to initially tighten the flange nuts to 50 to 100 lbf·ft (68 to 136 N·m). Then tighten the flange nuts to 450 to 500 lbf·ft (610 to 678 N·m).

Fig. 21.4, Tightening Pattern, 10-Hole Wheels

Inspect the outboard side of all wheel hubs and the hub oil seal area on the inboard side of each wheel for signs of oil leakage. If any oil is found on wheel and tire or brake components, remove the vehicle from service until the leak has been fixed.

If needed, fill the hubs to the level indicated on the hub cap. See Group 35 of the Cascadia Maintenance Manual for recommended lubricants.

Check that mud flaps are undamaged and hang 10 inches (25.4 cm) or less from the ground.

Saddle Tank Areas Inspection

When draining the air reservoir, do not look into the air jets or direct them toward anyone. Dirt or sludge particles may be in the airstream and could cause injury.

NOTICE

If the water drained from the air reservoirs is cloudy or oily, it may indicate a problem with the compressor. If oil is allowed to contaminate the air dryer, it will not remove the water from the air brake system, which could adversely affect braking.

Drain the brake system air reservoirs (reservoirs without automatic drain valves only).

Never operate the engine with the fuel tank shutoff valves partially closed. This could damage the fuel pump, causing sudden loss of engine power, possibly resulting in serious personal injury due to reduced vehicle control.

Ensure fuel tanks are secured to their mounting brackets and that the mounting brackets are secured to the frame.

If equipped with fuel tank shutoff valves, be sure the valves are fully open.

Inspect visible frame rails for missing bolts, shiny areas, or rust streaks. Check all visible crossmembers for damage or signs of looseness.

Inspect visible components of the exhaust system to ensure connections are tight.

Inspect upstream of the aftertreatment device (ATD), if equipped, for cracking or signs of leaks, such as soot trails. Inspect downstream of the ATD for signs of exhaust leaks, such as blistering or warping of nearby components.

Engine Compartment Inspection

Check the ground underneath the engine for fuel, oil, or coolant leaks.

Inspect the air intake system for leaks or damage.

NOTICE

Failure to maintain a sealed air intake system could allow the entry of dirt and contaminants into the engine. This could adversely affect engine performance and result in engine damage.

2.1

Push the reset button on the air intake restriction indicator located on the air cleaner, if equipped.

2.2

Check the air intake duct from the air cleaner to the engine intake. Make sure the duct components are secure and airtight.

Check the engine oil level.

NOTICE

Operating the engine with the oil level below the minimum fill (or "add") mark or above the maximum fill (or "full") mark could result in engine damage.

3.1

Check the oil level with the vehicle parked on a level surface. See the engine manufacturer's guidelines for engine shutdown time requirements prior to checking the oil level.

IMPORTANT: On engines that comply with EPA07 or newer regulations, use CJ-4 engine oil with less than 1% sulfated ash. Failure to use CJ-4 oil may void the warranty on emission aftertreatment components.

3.2

If the oil level is at or below the minimum fill (or "add") mark on the dipstick, add enough oil to maintain the level between the minimum and maximum fill marks. See the engine operation manual for recommended lubricants.

3.2

For natural gas vehicles, use only Exxon Busgard® Geo 15W-40 natural gas engine oil.

Check the power steering reservoir fluid level.

The power steering fluid level should be between the MIN COLD mark and the middle mark just above it. See Fig. 21.5 . If needed, fill the reservoir with automatic transmission fluid that meets Dexron III or TES-389 specifications.

NOTE: Typical reservoir shown; configurations may vary.

1. Filler Cap

Fig. 21.5, Power Steering Fluid Reservoir

NOTICE

Low coolant could result in engine overheating, which could cause engine damage.

IMPORTANT: The surge tank must be cool to check the coolant level.

Check the engine coolant level in the radiator surge tank. See Fig. 21.6 .

1. Pressure Relief Cap
2. Filler Cap
3. COLD MAX Fill Line
4. COLD MIN Fill Line
5. Coolant Level Sensor

Fig. 21.6, Coolant Surge Tank

NOTICE

Coolant must be filled to the COLD MAX line of the surge tank. Low coolant could result in engine overheating, which could cause engine damage.

5.1

If the coolant is low, fill the surge tank to the MAX line with a 50/50 mixture of water and the type of antifreeze currently installed in your vehicle.

5.1

For natural gas vehicles, use only Fleetguard ES Compleat™ EG Premix 50/50 engine coolant.

5.2

If the surge tank was empty, start the engine after refilling and check the level again when the engine is at operating temperature.

Inspect visible engine wiring for damage or looseness. Check for loose wiring, chafed insulation, and damaged or loose hold-down clamps.

Inspect visible frame rails for missing bolts, shiny areas, or rust streaks.

Cab Inspection

Push the reset button on the dash-mounted air intake restriction indicator, if equipped.

With the ignition switch in the OFF position, check the air-pressure warning system.

2.1

If not previously drained, drain the air reservoirs using moderate brake applications until pressure in both reservoirs is less than 70 psi (483 kPa).

NOTE: On the ICU3, ICU3S, and ICU4 ICUs, low air pressure is indicated by the low air pressure telltale and a buzzer. On the ICU4Me, low air pressure is indicated by a message on the ICU and a buzzer.

2.2

Turn the ignition to the ON position. The ICU will complete a full gauge sweep and bulb check, and an audible warning will sound. Ensure the low air pressure indicator remains on and an audible warning continues to sound after the gauge sweep is complete.

Check air governor cut-in and cut-out pressures.

3.1

Start the engine and ensure the BRAKE AIR lamp goes out and the buzzer silences when pressure reaches approximately 70 psi (483 kPa) in both air reservoirs.

3.1

The air governor should cut out at approximately 120 psi (827 kPa). For vehicles with an optional dryer reservoir module (DRM), the cut-out pressure is approximately 130 psi (896 kPa).

3.2

With the engine idling, apply the brake pedal several times. The air governor should cut in when pressure in the primary air reservoir (top air gauge) reaches approximately 100 psi (689 kPa).

Check air pressure build-up time.

4.1

With the air system fully charged, make one full brake application and note the air pressure reading on the primary air gauge.

4.2

Further reduce air pressure using moderate brake applications, then run the engine at governed rpm.

4.3

Note the time that the pressure reaches the previously noted reading on the primary air gauge, then note the time that the air pressure reaches cut-out pressure.

4.4

If it takes longer than 30 seconds to reach cut-out pressure after the primary air gauge passes the previously noted pressure (noted after one full brake application), eliminate any leaks or replace the air compressor before operating the vehicle.

Check air leakage in the system.

5.1

With the parking brake applied, the transmission out of gear, and the air system fully charged, release the service brakes and shut down the engine.

5.2

Wait one minute and note the air pressure drop in psi (kPa) per minute from the primary air reservoir.

5.2

If the pressure drop exceeds the limits shown in Table 21.1 , eliminate any leaks before operating the vehicle.

Check the air pressure reserve.

With the engine still off, make one full brake application and observe the pressure drop on the primary air gauge. If pressure drops more than 25 psi (172 kPa), eliminate any leaks before operating the vehicle.

Maximum Allowable Air Leakage
Description	Pressure Drop: psi (kPa) Per Minute
Description	Released	Applied
Truck or Tractor Only	2 (14)	3 (21)
Truck or Tractor w/Single Trailer	3 (21)	4 (28)
Truck or Tractor w/Two Trailers	5 (35)	6 (42)

Table 21.1, Maximum Allowable Air Leakage

When cleaning windshields and windows, always stand on the ground or on a secure ladder or platform. Use a long-handled window cleaner. Do not use the cab steps, tires, fenders, fuel tanks, engine, or under-hood components to access the windshield or windows. Doing so could cause a fall and result in an injury.

Inspect the mirrors, window glass, and windshield for cracks or other damage.

Ensure that the horn, windshield wipers, and windshield washers are operating properly. These devices must be in good working order for safe vehicle operation.

Ensure the heater and defroster are operating properly.

10.

Check the operation of all interior lights.

10.1

Turn on the headlights and leave them on. Ensure all equipped gauge bulbs illuminate in the dash message center.

10.2

Ensure all equipped driver control switches illuminate.

10.3

Ensure both turn signal indicator bulbs illuminate in the dash message center when the turn signal switch is activated.

11.

Check the operation of all exterior lights. See Fig. 21.7 .

11.1

Activate the high-beam headlights and hazard warning lights.

1. High-Beam Headlight
2. Fog Light, or Auxiliary High-Beam Light
3. Low-Beam Headlight
4. Marker Light
5. Turn Signal
6. Side Turn Signal and Marker Light
7. Clearance Light
8. Stop Light, Taillight, and Turn Signal
9. Back-Up Light
10. Identification Light

Fig. 21.7, Exterior Lights

11.2

Exit the cab and check that all exterior lights and reflectors are clean and intact.

11.3

Check that the brake lights, taillights, headlights, turn signals, marker lights, identification lights, and clearance lights are working properly.

12.

Inspect the seat belts and tether belts.

Inspect and maintain seat belts. When any part of a seat belt system needs replacement, the entire seat belt must be replaced, both retractor and buckle side. Any time a vehicle is involved in an accident, and the seat belt system was in use, the entire vehicle seat belt system must be replaced before operating the vehicle. Do not attempt to modify the seat belt system; doing so could change the effectiveness of the system. Failure to replace worn or damaged seat belts, or making any modifications to the system, may result in personal injury or death.

12.1

Check the web for fraying, cuts, extreme dirt and dust, or for severe fading from exposure to sunlight, especially near the buckle latch plate and in the D-loop guide area.

12.2

Check operation of the buckle, latch, Komfort Latch or Sliding Komfort Latch (if equipped), web retractor, and upper seat belt mount on the door pillar. Check all visible components for wear or damage.

12.3

Check the seat belt and tether belt connection points and tighten any that are loose.

Never fill fuel tanks to more than 95 percent of their liquid capacity. This could make them more likely to rupture from impact, possibly causing fire and resulting in serious personal injury or death by burning.

Do not mix gasoline or alcohol with diesel fuel. This mixture could cause an explosion, possibly resulting in serious personal injury or death. Do not fill the fuel tanks in the presence of sparks, open flames, or intense heat. These could ignite the fuel, possibly causing severe burns.

IMPORTANT: On engines that comply with EPA07 or newer regulations, use ultralow-sulfur diesel (ULSD) with 15 ppm sulfur content or less. Failure to use ULSD fuel may void the warranty on emission components.

13.

Check the fuel level in the fuel tank(s). To keep condensation to a minimum, fuel tanks should be filled at the end of each day.

14.

Adjust the rearview and down view mirrors as necessary.

15.

Test the service brakes.

15.1

With the engine running and air system fully charged, set the parking brake.

15.2

Put the vehicle in the lowest gear and gently attempt to move it forward. The vehicle should not move.

15.2

If the vehicle moves, the parking brakes are not operating correctly and must be repaired before the vehicle is operated.

16.

Test the backup alarm.

16.1

Release the parking brake and put the transmission in reverse.

16.2

Move the vehicle slightly backward to ensure that the backup alarm is operating correctly.

Natural Gas Fuel System Inspection

As with all pressure vessels, CNG/LNG storage and fuel delivery systems are inherently dangerous and should be treated as such. Beyond the visual inspections listed below, all maintenance and repairs to compressed natural gas (CNG) or liquified natural gas (LNG) systems should be performed by trained personnel. Individuals who are not trained in all aspects concerning CNG/LNG fuel delivery systems are not permitted to service, maintain, test, or inspect a system in any way. Failure to comply with safety regulations may lead to fire or explosion, resulting in property damage, personal injury, or death.

Inspect fuel tanks for dents, scratches, gouges, or other signs of damage. Inspect the fuel lines and connections for leaks.

Check that the fuel tanks are securely mounted. Look for signs of abrasion between components.

CNG Fuel System : Ensure that the CNG fuel cylinder storage box is secured to the frame. Inspect for signs of looseness.

(LNG Fuel System : Ensure that the LNG fuel tank is secured to the mounting brackets and that the mounting brackets are secured to the frame. Ensure all rubber isolator straps are secure around the LNG fuel tank.

Check for the presence of all required decals present in the following locations:

Gas detection system overhead console;

Above the door handle on both doors;

Left front bumper;

End-of-frame crossmember;

LNG fuel tank fill port (maximum psi), if equipped.

Check for the presence of vent caps on pressure relief valves and devices. See Fig. 21.8 . If any caps are missing, have the fuel system inspected by a qualified technician.

CNG Fuel System : Each fuel cylinder should have two caps (one on each end), which are visible on the back of the CNG fuel cylinder storage box. One additional cap is located on the pressure relief valve on the inboard side of the CNG fuel box, next to the fuel outlet line. If equipped with saddle tanks, there are also two vent tubes with caps between the back of the cab and the back-of-cab fuel tanks.

LNG Fuel System : A red cap should be present on the secondary relief valve. See Fig. 21.9 .

Fig. 21.8, CNG Vent Line Caps

1. Pressure Control Regulator
2. Coalescing Filter
3. Fuel Fill Fitting
4. Vapor Shutoff Valve
5. Secondary Relief Valve (red cap)
6. Fill Vent Fitting
7. Primary Relief Valve
8. Tank Pressure Gauge
9. Fuel Shutoff Valve (liquid)
10. Fuel Level Sender Box
11. Cover
12. Fill Check Valve

Fig. 21.9, LNG Tank Plumbing Components

Inspect all plumbing components, including the fuel shutoff valve(s), primary and secondary relief valves, and the LNG vapor shutoff and excess flow valves, if equipped, for signs of damage or leaks. See Fig. 21.9 or Fig. 21.10 .

Inspect the fuel fill fitting for signs of damage or leaks.

Inspect all lines for signs of leaks or damage, and check all threaded connections.

1. High Pressure Gauge
2. Low Pressure Gauge
3. Manual Fuel Shutoff Valve
4. Fuel Fill Port

Fig. 21.10, CNG Fuel Panel

Inspect all fuel gauge components for signs of leaks or damage. Inspect the fuel level sender cable and wiring.

Inspect all coolant hoses for signs of chafing, kinks, or leaks. The CNG fuel system utilizes coolant hoses between the engine and the pressure regulator inside the fuel panel. The LNG fuel system utilizes coolant hoses between the engine and the vaporizer.

If equipped with an LNG fuel system, check the fuel tank pressure gauge to ensure that pressure is within the normal range of 120 to 150 psi (827 to 1034 kPa). If tank pressure exceeds 230 psi (1586 kPa) and the pressure relief valve does not open automatically, vent the tank immediately.

Inspect the LNG vaporizer for signs of damage or leaks. See Fig. 21.9 . Inspect the vaporizer mounting brackets for signs of looseness.

On CNG systems, check the low pressure fuel filter(s) at the engine for contamination.

9.1

Turn the engine off and remove the key form the ignition.

9.2

Slowly open the drain petcock and drain any fluid into an appropriate container.

10.

When fluid stops, close the drain petcock.

11.

Examine the fluid.

11.

If more than approximately one ounce of oil or other contaminants is found, have the system checked at a qualified service center.

Weekly Post-Trip Inspections and Maintenance

Engine Compartment Inspection

Washer fluids may be flammable and poisonous. Do not expose washer fluid to an open flame or any burning material, such as a cigarette. Always comply with the washer fluid manufacturer's recommended safety precautions.

Check the windshield washer reservoir fluid level. The reservoir is usually located near the right-hand frame rail. See Fig. 21.11 .

1. Washer Fluid Filler Cap

Fig. 21.11, Windshield Washer Reservoir

After resetting the air intake restriction indicator during the daily pretrip inspection, check the indicator again with the engine off.

2.1

Check an indicator with graduations to see if air restriction exceeds the value shown in Table 21.2 .

2.1

Check a go/no-go indicator without graduations to see if the colored bar shows through the clear window.

Air Intake Maximum Restriction Values (inH₂O)
Engine Make	Pre-EPA07 Engines	EPA07 and EPA10 Engines	GHG14 and GHG17 Engines
Cummins	25	25	25
Detroit	20	22	18
Mercedes-Benz	22	22	–

Table 21.2, Air Intake Maximum Restriction Values

2.2

If air restriction exceeds the maximum allowable value, operate the vehicle for one more day, making sure not to run the engine over rated rpm. Refer to the engine operation manual for more information on rated rpm for your engine.

2.3

If air restriction exceeds the maximum value again, replace the air cleaner. For instructions, refer to Group 09 of the Cascadia Workshop Manual .

Inspect water evacuation components.

1. Air Cleaner
2. Vacuator Valve
3. Rain Tray Seal
4. Rain Tray
5. Drain Hose

Fig. 21.12, Rain Tray Assembly

3.1

Inspect the vacuator valve(s) installed on the hood interior and air cleaner. Make sure the lips of each valve are undamaged and pliable, free of debris, and remain closed during inspection. See Fig. 21.12 and Fig. 21.13 .

3.2

Inspect the rain tray installed at the base of the windshield. Ensure that the seal on the forward edge of the rain tray is in good condition.

3.3

Inspect the drain hoses installed on the rain tray. Both hoses should be securely attached to the rain tray and direct water down the aft side of the front fenders. See Fig. 21.14 .

1. Vacuator Valves

Fig. 21.13, Hood Interior

Ensure drain hoses are securely attached to the rain tray and drain down the aft side of the front fenders.

Fig. 21.14, Drain Hose

If the vehicle is equipped with an Allison automatic transmission, check the automatic transmission fluid level.

Check for water in the fuel/water separator, if equipped.

IMPORTANT: When draining fluid from a fuel/water separator, drain the fluid into an appropriate container and dispose of it properly. Many jurisdictions now issue fines for draining fuel/water separators onto the ground.

5.1

Place a suitable container under the fuel/water separator.

NOTE: A hose may be used to direct water into the container. On older DAVCO models, the drain valve has a 1/2-inch (12.7-mm) pipe with threads. Use a hose with a 1/2-inch pipe thread to fit correctly and open the drain valve by turning it one-quarter revolution. On new DAVCO models, the drain valve has a 3/4-inch (19-mm) slip-on hose connection; pipe threads are no longer used. Open the drain valve by turning it one to one-and-a-half revolutions.

5.2

If the engine is equipped with a built-in water separator, loosen the drain valve, and allow the water to run out. Close the drain valve, taking care not to overtighten it.

5.3

Alliance/Racor Models : Turn the drain plug counterclockwise to open it. See Fig. 21.15 .

5.3

DAVCO Models : Remove the vent cap and open the drain. See Fig. 21.16 and Fig. 21.17 .

1. Washers (qty 2)
2. Nuts (qty 2)
3. Frame Rail
4. Fuel Outlet Port
5. Fuel Inlet Port
6. Priming Pump
7. Mounting Head
8. Mounting Bolts (qty 2)
9. Filter Element
10. Sight Bowl
11. Drain Plug

Fig. 21.15, Alliance Fuel/Water Separator Assembly and Installation

1. Inlet Port/Check Valve
2. Lower Housing
3. Bypass Valve
4. Filter Element
5. Spring
6. Cover O-Ring
7. Clear Cover
8. Vent Cap O-Ring
9. Vent Cap
10. Collar
11. 120VAC Pre-Heater
12. 12VDC Pre-Heater
13. Drain Valve

Fig. 21.16, DAVCO Fuel Pro 482

1. Drain Valve
2. Drain Valve Cap
3. 120VAC Pre-Heater
4. Inlet Port/Check Valve
5. Lower Housing
6. Bypass Valve
7. 12VDC Pre-Heater
8. Filter Element
9. Spring
10. Cover O-Ring
11. Clear Cover
12. Vent Cap O-Ring
13. Vent Cap
14. Collar

Fig. 21.17, DAVCO Fuel Pro 487

5.4

Stop draining fluid when fuel begins to drain out.

5.4

Alliance/Racor Models : turn the drain plug clockwise to close it.

5.4

DAVCO Models : close the drain valve. Install and hand-tighten the vent cap.

Inspect the steering components.

6.1

Inspect tie rods, steering arms, and the drag link for signs of looseness (i.e., shiny spots or rust tracks). See Fig. 21.18 for a rack and pinion steering gear; see Fig. 21.19 for an integral steering gear.

1. Steering Tie Rod Arm
2. Castellated Nut
3. Outer Tie Rod
4. Power Steering Fluid Lines
5. Power Steering Fluid Line Fittings
6. Steering Gear Mounting Bolts
7. Steering Gear Mounting Nuts

Fig. 21.18, Rack and Pinion Steering Gear Assembly

1. Steering Gear Mounting Bolts
2. Pitman Arm Pinch Bolt Nut
3. Drag Link Nut

Fig. 21.19, Integral Steering Gear Fasteners

6.2

Check the steering gear mounting bolts and pitman arm nut, if equipped, for signs of looseness.

6.3

Check the drag link nuts for missing cotter pins.

6.4

Inspect the steering intermediate shaft and end yokes for excessive looseness or other damage.

NOTICE

Do not drive with a drive belt that is visibly worn or damaged. If it fails, the lack of coolant flow could rapidly cause damage to engine components.

Inspect the serpentine drive belts for signs of glazing, frayed edges, breaks, cracks, or oil contamination.

Monthly Post-Trip Inspections and Maintenance

Brake Component Inspection

Walk around the vehicle and inspect brake system components for visible damage.

Inspect all visible brake system components for missing fasteners or signs of looseness, such as rust tracks.

NOTICE

If the external breather tube or breather cap is missing or incorrectly installed, road dirt and debris can adversely affect the operation of the brake chamber. Once inside of the chamber, dirt and debris can cause the internal parts of the chamber to deteriorate faster.

Inspect the exterior surfaces of brake chambers for damage. Make sure that breather holes are open and free of debris.

NOTE: Do not route air brake lines on top of anything likely to be stepped on.

Inspect air brake lines for dents, swelling, kinks, twisting, abrasion, and damage, especially near moving parts.

Inspect flex air lines for deterioration or signs of abrasion.

Inspect for cracked, worn, or oil-contaminated brake linings and brake drums (or rotors).

Check the thickness of the brake linings. Replace brake linings on all brake assemblies on the axle if any brake linings are worn to less than approximately 1/4 inch (6.4 mm) at the thinnest point.

Saddle Tank Areas Inspection

When draining the air reservoir, do not look into the air jets or direct them toward anyone. Dirt or sludge particles may be in the airstream and could cause injury.

NOTICE

Drain the brake system air reservoirs (reservoirs with automatic drain valves only).

NOTE: Battery locations vary between vehicles.

Inspect the batteries.

Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. To prevent possible personal injury, always wash your hands after handling battery parts and related accessories.

2.1

Remove the battery box cover and inspect all visible battery cables for loose wiring or damage.

2.2

Check that the battery hold-down is secure.

IMPORTANT: Aerodynamic components decrease drag force as a vehicle moves, thereby improving fuel efficiency. If replacement of an aerodynamic component is necessary, replacement components must meet or exceed the drag reduction performance of the originally installed component in order to maintain compliance with greenhouse gas and fuel efficiency regulations (GHG14).

Inspect the following aerodynamic components, if equipped, for structural damage, cracks, or wear.

Chassis fairings

Roof fairing/deflector

Side skirts

Cab/sleeper extenders

Battery access cover

Engine Compartment Inspection and Adjustments

IMPORTANT: If replacement of the hood or bumper is necessary, the replacement component must meet or exceed the drag reduction performance of the originally installed item in order to maintain compliance with greenhouse gas and fuel efficiency regulations (GHG14).

Inspect the bumper and hood for structural damage, cracks, or wear.

Check the hydraulic clutch reservoir, if equipped. If necessary, add DOT 4 brake fluid.

Inspect the radiator and heater hoses, including the clamps and support brackets.

3.1

Inspect the radiator and charge air cooler for damage and accumulated debris. Straighten bent or damaged fins to permit airflow across all areas of the cores.

NOTE: When traveling through areas of high insect concentration, it may be necessary to clean the exterior of the radiator or the charge air cooler core as often as every 200 miles (320 km).

3.2

Make sure the radiator inlet and outlet hoses are pliable and are not cracking or ballooning.

3.3

Make sure the heater hoses are pliable and are not cracking or ballooning.

3.4

Tighten hose clamps as necessary.

IMPORTANT: Do not overtighten hose clamps, as hose life can be adversely affected.

3.5

Ensure hose support brackets are securely fastened. Make sure hoses are not located near sources of wear, abrasion, or high heat.

IMPORTANT: When replacing hoses, install service-type knitted or braided yarn-reinforced neoprene hose. Extended-service-life silicone hoses may also be used. See the Alliance Parts Catalog atwww.alliancebrandparts.comor contact your Freightliner Dealer.

Check the steering wheel for excessive play.

4.1

Start the engine. With the front tires straight ahead, turn the steering wheel until motion is observed at the front wheels.

4.2

Align a reference mark on the steering wheel to a rule, then slowly turn the steering wheel in the opposite direction until motion is again detected at the wheels.

4.3

Measure the lash (free play) at the rim of the steering wheel. Excessive lash exists if steering wheel movement exceeds 2-1/2 inches (64 mm) with a 20-inch (508-mm) steering wheel, or 2-1/4 inches (57 mm) with an 18-inch (450-mm) steering wheel.

4.4

If there is excessive lash, check the steering system for wear or incorrect adjustment before operating the vehicle.