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freightliner MC Maintenance Manual

freightliner MC Maintenance Manual

Recreational vehicle chassis
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RECREATIONAL VEHICLE
CHASSIS
Maintenance Manual
Part Number A24-00788-000
Publication Number STI-425-6

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  • Page 1 RECREATIONAL VEHICLE CHASSIS Maintenance Manual Part Number A24-00788-000 Publication Number STI-425-6...
  • Page 2 RECREATIONAL VEHICLE CHASSIS MAINTENANCE MANUAL Models: MC STI-425-6 (7/18) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
  • Page 4 IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Freightliner Custom Chassis Corporation (FCCC) reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation.
  • Page 6 EZWiring EZWiring ™ makes Freightliner Custom Chassis Corporation, Freightliner, Ster- ling, Thomas Built Buses, and Western Star products’ wiring drawings and float- ing pin lists available online for viewing and printing. EZWiring can also be ac- cessed from within PartsPro.
  • Page 7 Introduction Descriptions of Service Publications Warranty-related service information available on the www.DTNAConnect.com website 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.
  • Page 8 Vehi c le C ha ss i s W or ks hop M anual for re− moval and installation procedures, or take the vehicle to an authorized Freightliner dealer. A typical air cleaner mounting is shown in Fig. 1.
  • Page 9 Introduction Maintenance Manual Contents Group No. Group Title 00 ..... . General Information 01 ....... . Engine 09 .
  • Page 10 General Information Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number 15,000 Mile or 12 Month Maintenance........... 00–04 30,000 Mile or 24 Month Maintenance.
  • Page 12 Owners who want to learn more about their vehicle can attend a two-day training class, offered at the Freightliner Custom Chassis Service Center in Gaff- ney, South Carolina. Some of the items covered dur- ing the training include the air brake system, electri- cal system, vehicle storage, weight distribution, and maintenance intervals.
  • Page 13 General Information Vehicle Maintenance Schedule Table: 00–02 Maintenance Operation Procedures and Schedule Maintenance Interval in Miles x 1000 6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 Maintenance Interval in Kilometers x 1000 Maintenance Operation Number and Description 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458...
  • Page 14 General Information Vehicle Maintenance Schedule Table: 00–02 Maintenance Operation Procedures and Schedule Maintenance Interval in Miles x 1000 6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 Maintenance Interval in Kilometers x 1000 Maintenance Operation Number and Description 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458...
  • Page 15 General Information Vehicle Maintenance Schedule Table: 00–02 Maintenance Operation Procedures and Schedule Maintenance Interval in Miles x 1000 6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 Maintenance Interval in Kilometers x 1000 Maintenance Operation Number and Description 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458...
  • Page 16 General Information Vehicle Maintenance Schedule Table: 00–02 Maintenance Operation Procedures and Schedule Maintenance Interval in Miles x 1000 6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 Maintenance Interval in Kilometers x 1000 Maintenance Operation Number and Description 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458...
  • Page 17 General Information 6000 Mile or 6 Month Initial Maintenance: 00–03 Procedure Performed 6000 Mile (9654 km) or 6 Month Initial Maintenance (check off or initial) Inspect _____ Engine Drive Belt Inspecting 01–01 Check _____ Engine-Support Fasteners Checking 01–02 Engine Oil and Filter (see the engine manufacturer’s Change _____ —...
  • Page 18 _____ Air Conditioner Component Inspection 83–01 § Customer _____________________________________ Date ____________ Additional copies are available on the Freightliner Custom Chassis Corporation website (www.freightlinerchas- sis.com). † For vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), which- ever comes first.
  • Page 19 General Information 15,000 Mile or 12 Month Maintenance: 00–04 Procedure Performed 15,000 Mile (24 135 km) or 12 Month Maintenance (check off or initial) Inspect _____ Engine Drive Belt Inspecting 01–01 Check _____ Engine-Support Fasteners Checking 01–02 Engine Oil and Filter (see the engine manufacturer’s Change _____ —...
  • Page 20 _____ Air Conditioner Component Inspection 83–01 § Customer _____________________________________ Date ____________ Additional copies are available on the Freightliner Custom Chassis Corporation website (www.freightlinerchas- sis.com). † For vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), which- ever comes first.
  • Page 21 General Information 30,000 Mile or 24 Month Maintenance: 00–05 Procedure Performed 30,000 Mile (48 270 km) or 24 Month Maintenance (check off or initial) Inspect _____ Engine Drive Belt Inspecting 01–01 Check _____ Engine-Support Fasteners Checking 01–02 Engine Oil and Filter (see the engine manufacturer’s Change _____ —...
  • Page 22 _____ Air Conditioner Component Inspection 83–01 § Customer _____________________________________ Date ____________ Additional copies are available on the Freightliner Custom Chassis Corporation website (www.freightlinerchas- sis.com). † For vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), which- ever comes first.
  • Page 23 General Information 45,000 Mile or 36 Month Maintenance: 00–06 Procedure Performed 45,000 Mile (72 405 km) or 36 Month Maintenance (check off or initial) Inspect _____ Engine Drive Belt Inspecting 01–01 Check _____ Engine-Support Fasteners Checking 01–02 Engine Oil and Filter (see the engine manufacturer’s Change _____ —...
  • Page 24 _____ Air Conditioner Component Inspection 83–01 § Customer _____________________________________ Date ____________ Additional copies are available on the Freightliner Custom Chassis Corporation website (www.freightlinerchas- sis.com). † For vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), which- ever comes first.
  • Page 25 General Information 60,000 Mile or 48 Month Maintenance: 00–07 Procedure Performed 60,000 Mile (96 540 km) or 48 Month Maintenance (check off or initial) Inspect _____ Engine Drive Belt Inspecting 01–01 Check _____ Engine-Support Fasteners Checking 01–02 Engine Oil and Filter (see the engine manufacturer’s Change _____ —...
  • Page 26 _____ Air Conditioner Component Inspection 83–01 § Customer _____________________________________ Date ____________ Additional copies are available on the Freightliner Custom Chassis Corporation website (www.freightlinerchas- sis.com). † For vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), which- ever comes first.
  • Page 27 49)" follows, and should be filled in each time noise equivalent to genuine FCCC parts in performance emission controls on the vehicle are maintained or and durability. repaired. Freightliner Noise Emission Controls Warranty See the vehicle owner’s warranty information book for warranty information concerning noise emission controls.
  • Page 28 General Information Verification of Inspections Log: 00–09 Verification of Inspections Log Verification of Inspections Log, Group 49 Date Mileage Item Cost Maintenance Facility Group 49—Exhaust System Components 00/17 Recreational Vehicle Chassis Maintenance Manual, April 2018...
  • Page 30 Engine Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Engine Drive Belt Inspecting............01–01 Engine-Support Fasteners Checking .
  • Page 32 Engine 01–00 Safety Precautions 2. Check the 3/4–10 front-engine front mount bolt. Fig. 2. Tighten it 95 lbf·ft (128 N·m). Safety Precautions in this section apply to all Check the 3/4–10 rear-engine front mount bolt. Tighten it 95 lbf·ft (128 N·m). procedures within this group.
  • Page 34 Air Intake Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Inspection and Replacement..........09–01 Charge Air Cooler (CAC) Inspection and Cleaning.
  • Page 36 Safety Precautions in this section apply to all ational Vehicle Chassis Workshop Manual for re- procedures within this group. moval and installation procedures, or take the vehicle to an authorized Freightliner dealer. A typical air DANGER cleaner mounting is shown in Fig.
  • Page 37 05/22/97 f090176 Fig. 2, Air Restriction Indicator removal and installation procedures, or take the ve- hicle to an authorized Freightliner dealer. 09–02 Charge Air Cooler (CAC) Inspection and Cleaning Good airflow through the CAC core is essential for proper engine cooling. The cores allow air passage, but form a barrier that tends to collect insects and airborne debris.
  • Page 38 Air Compressor Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspection ............13–01 Safety Precautions .
  • Page 40 Air Compressor 13–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, 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 cannot drop.
  • Page 42 Alternators and Starters Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Check ......... 15–01 Safety Precautions .
  • Page 44 See Group 54 of the vehicle Group 15 of the vehicle Workshop Manual, or Workshop Manual for troubleshooting instruc- take the vehicle to an authorized Freightliner tions, and for adjustment, repair, or replacement dealer. instructions, or take the vehicle to an authorized Freightliner dealer.
  • Page 45 Alternators and Starters 10.2 Inspect the retainer assembly (or battery hold-downs) and the battery box. Replace worn or damaged parts. Remove any cor- rosion with a wire brush, and wash with a weak solution of baking soda and water. Rinse with clean water, then dry. Paint the retainer assembly, if needed, to pre- vent rusting.
  • Page 46 Engine Cooling/Radiator Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Coolant Replacement............. . . 20–03 Mechanical Fan Drive Gearbox Lubrication .
  • Page 48 Engine Cooling/Radiator 20–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, 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 cannot drop.
  • Page 49 Engine Cooling/Radiator sound) is relieved, then press down on Disconnect all hoses from the surge tank. the cap and continue turning it counter- Remove the tank and pour out any fluid. clockwise. Scrub and clean the inside of the surge tank with soap and water.
  • Page 50 Engine Cooling/Radiator NOTE: If a low-pressure adaptor is not used with the high-pressure gun, the U-joints may not receive enough lubricant. 3. Using lithium 12-hydroxy stearate grease (NLGI grade 2, with EP additives and meeting ASTM D4950 LB specifications), lubricate until new grease can be seen at both U-joint seals.
  • Page 51 Engine Cooling/Radiator 04/24/2013 f200817 1. U-Joint Grease Fitting 2. Slip-Joint Grease Fitting Fig. 3, Slip-Joint and U-Joint Lubricating 20/4 Recreational Vehicle Chassis Maintenance Manual, October 2016...
  • Page 52 Transmission Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Allison MD/MH Series Transmission Fluid Level Checking ........26–02 Allison Transmission Fluid and Filter Changing (internal/external filter) .
  • Page 54 Transmission 26–00 Safety Precautions 26–02 Allison MD/MH Series Transmission Fluid Safety Precautions in this section apply to all Level Checking procedures within this group. Cold Check DANGER IMPORTANT: After replacing the transmission When working on the vehicle, shut down the en- fluid or changing the filter(s), it is important to gine, set the parking brake, and chock the tires.
  • Page 55 Transmission NOTE: The fluid must be warm to ensure an 1. On the transmission shift selector, press the up and down arrow keys simultaneously. See Fig. accurate check. The fluid level rises as tempera- ture increases. 2. Park the vehicle. Shift to Neutral (N) and apply the parking brake.
  • Page 56 Transmission Approved Allison Transmission Lubricants TES-295 Approval Company Product Brand Name Number AN-031003 Cognis Corporation Emgard 2805 AN-031004 International Truck & Engine Company Fleetrite Synthetic ATF AN-071006 John Deere & Company HD SynTran To check the latest Allison approved fluids, go to www.allisontransmission.com. Lubricants listed in order of preference. Do not mix types of oil. Table 1, Approved Allison Transmission Lubricants Automatic Transmission Lubricant Capacities Refill Capacity...
  • Page 58 Throttle Control Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Throttle Pedal Pivot Pin Lubricating........... . . 30–01 Recreational Vehicle Chassis Maintenance Manual, January 2010...
  • Page 60 Throttle Control 30–01 Throttle Pedal Pivot Pin Lubricating Using a silicone spray, lubricate the throttle pedal pivot pins as shown in Fig. 1 Fig. 07/09/2009 f300408a 1. Throttle Pedal 2. Pivot Pins Assembly 3. Base Plate 07/09/2009 f300409a Fig. 1, Floor-Mounted Throttle Pedal 1.

  • Page 62: Table Of Contents

    Suspension Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Neway Suspension Inspection ............32–03 Safety Precautions .

  • Page 64: Suspension Fastener Torque Check

    Suspension 32–00 Safety Precautions NOTICE Safety Precautions in this section apply to all Failure to retorque the U-bolt nuts could result in procedures within this group. spring breakage and abnormal tire wear. 4. Remove the safety stands and lower the vehicle DANGER to the ground.
  • Page 65 Group 32 of the Recreational Ve- AD200-RS17/19 9-3/4 (248) hicle Chassis Workshop Manual, or take the ve- hicle to an authorized Freightliner dealer. Inspect AD200-RS15 9-3/8 (238) the air springs for cracks, tears, or other dam- ADTB280 (rear) 17-1/4 (438) age.
  • Page 66 5. Check all of the other suspension components reational Vehicle Chassis Workshop Manual, or for any sign of damage, looseness, wear, or take the vehicle to an authorized Freightliner cracks. Replace worn or damaged parts. See dealer. Group 32 of the Recreational Vehicle Chassis 9.
  • Page 67 Always support the vehicle hicle to an authorized Freightliner dealer. with safety stands. Jacks can slip, causing the vehicle to fall, which could result in serious injury 32–04 ZF IFS Lubrication...

  • Page 68: Suspension Inspection

    1. Steering Knuckle Bearing Grease Fitting (upper) 2. Steering Knuckle Fig. 5, Pressure Grease Fitting Positions, RL-75EM 3. Steering Knuckle Bearing Grease Fitting (lower) Freightliner Spring Front and Fig. 4, Pressure Grease Fitting Positions, RL-75E Rear Suspension Spring Assemblies Inspection...

  • Page 69: Suspension U-Bolt Torque Check

    Recreational Vehicle Chassis Workshop Manual Inspect the rear shackle brackets for bushing wear or for instructions, or take the vehicle to an authorized cracks. Freightliner dealer. Inspect the stabilizer bar, if present, for irregular bushing wear or cracks in the brackets. Check the WARNING rubber helper spring, if present, for cracks.
  • Page 70 Suspension could be worn and a pivot bushing physical in- spection is required. • If the pivot bushing shows signs of torn, sepa- rated, or disconnected rubber, as shown in Fig. 7, it could be the result of axle misalign- ment.
  • Page 71 Suspension D-Pin Bushing Visual Inspection It is not necessary to disassemble the D-pin connec- tion to perform a visual inspection of the D-pin bush- ing. The D-pin bushing is designed with a layer of rubber in the bushing. It is acceptable to see a bead of rubber protruding from the bushing.
  • Page 72 Suspension 04/15/2014 f321195 1. Torque Rod Assembly 2. Torque Rod Shims 3. V-Rod Bracket Fig. 12, V-Rod Assembly 04/15/2014 f321194 1. Distorted Outer Metal 2. Evidence of Metal-to-Metal Contact Fig. 11, Unacceptable D-Pin formed with a long pry bar placed under each rod end and pressure applied.
  • Page 74 Front Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Checking ............33–03 Knuckle Pin Lubricating .
  • Page 76 Front Axle 33–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, 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 cannot drop.
  • Page 77 Front Axle 1. For any Detroit or Meritor axle that requires lubri- cation of the tie-rod ends, wipe the grease fit- tings clean, then pump multipurpose chassis grease, NLGI Grade 1 (6% 12-hydroxy lithium stearate grease) or NLGI Grade 2 (8% 12- hydroxy lithium stearate grease), into the tie-rod ends until all used grease is forced out and fresh grease is seen at the ball stud neck.
  • Page 78 02/27/2007 f320033a the Recreational Vehicle Chassis Workshop Manual, IMPORTANT: The tie-rod end threads must be visible or take the vehicle to an authorized Freightliner throughout the entire length of the split. dealer. NOTE: Pinch bolt not shown to provide clarity.
  • Page 79 Group 33 of the Recre- ational Vehicle Chassis Workshop Manual, or IMPORTANT: For ZF IFS axles, ZF recom- take the vehicle to an authorized Freightliner mends that all grease fittings be lubricated once dealer. If corrections are needed, see Group 33 of the Recreational Vehicle Chassis Workshop a year, preferably before periods of inactivity.
  • Page 80 Front Axle 1. Park the vehicle on a level surface, shut down Workshop Manual and manufacturer literature for the engine, and set the parking brake. Chock the procedures. tires. WARNING WARNING Correct wheel-bearing end play is crucial to the Never work around or under a vehicle that is sup- safe and sound operation of the vehicle.
  • Page 81 Front Axle 33–05 Oil-Filled Hubs Oil Level necessary. If the end play exceeds the limit, service the hub. See the Recre- Checking ational Vehicle Workshop Manual and manufacturer literature for procedures. WARNING Be careful not to overfill the hubs. Overfilling may cause oil to be forced out of the hubs and to con- taminate the brake linings and other brake compo- nents.
  • Page 82 Front Axle 07/09/2009 f330247b A. Hub Cavity Full 1. Fill Plug/Magnetic Drain 2. Drain Plug Fig. 11, Oil-Filled Hub Cap 4. Install the drain plugs and tighten 25 lbf·in (282 N·cm). 5. Add approximately 1 to 1-1/2 pints (0.5 to 0.7 L) of oil (80W–90 hypoid gear oil) to each hub.
  • Page 84 Rear Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Axle Breather Checking ............. 35–03 Axle Lubricant Changing and Magnetic Plug Cleaning .
  • Page 86 See Group 35 of the Recreational Vehicle Chassis Workshop Manual for instructions, or take the vehicle to an authorized Freightliner dealer. 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
  • Page 87 Rear Axle Detroit Drive Axle Lubricants IMPORTANT: Lubricant used in Detroit rear axles must meet Mercedes-Benz specification 235.20 (mineral) or 235.8 (synthetic). Mobil Delvac ™ Gear Oil A 80W-90 and ™ Mobilube HD-A Plus 80W-90 meet specification 235.20. Mobil Delvac 1 Gear Oil 75W-90 and Mobilube 1 SHC 75W-90 meet specification 235.8.
  • Page 88 Rear Axle be necessary to clean or change the plugs one related to lubricant changes that are governed by climatic conditions and magnetic plug maintenance. or more times between lubrication change inter- Change lubricant type and viscosity as climatic tem- vals.
  • Page 89 Rear Axle 35–04 Oil-Filled Hubs Oil Level Meritor Drive Axle Lubricant Capacities Checking, Tag Axle Axle Model Capacity : pints (L) MS–10–113D 14 (6.6) MS–12–113D 15 (7.1) WARNING RS–13–120 18.4 (8.7) Be careful not to overfill the hubs. Overfilling may RS–15–120 14.3 (6.8) cause oil to be forced out of the hubs and to con-...
  • Page 90 Rear Axle NOTICE Do not overtighten the cap head. Too much force will strip the screw. 7. Install the hub cap and tighten the cap head just until snug. 35–05 Oil-Filled Hubs Oil Changing, Tag Axle WARNING Be careful not to overfill the hubs. Overfilling may 07/09/2009 f330247b cause oil to be forced out of the hubs and to con-...
  • Page 92 Wheels and Tires Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Wheel Cleaning and Polishing ............40–02 Wheel Nut Checking.
  • Page 94 Wheels and Tires 40–01 Wheel Nut Checking IMPORTANT: In addition to the maintenance interval in this manual, check the wheel nut torque the first 50 to 100 miles (80 to 160 km) of operation after a wheel has been removed and installed.
  • Page 95 Wheels and Tires 40–02 Wheel Cleaning and Polishing Accuride® Machined and Polished Aluminum Wheels IMPORTANT: Do not scrub the wheels before rinsing off particles with high-pressure water. Rubbing debris against the surface of the wheel can result in scratches. Synthetic cleaning pads and wire brushes should not be used to clean the wheels.
  • Page 96 Driveline Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspection and Lubrication ........... . 41–01 Safety Precautions .
  • Page 98 Group 41 of the vehicle Work- receive enough lubricant. shop Manual, or take the vehicle to an autho- rized Freightliner dealer. 3. Using lithium 12-hydroxy stearate grease (NLGI 4. Check that the yoke plug is not loose or missing.
  • Page 99 U-joint assembly. For instructions, see Group 41 of the vehicle Workshop Manual, or take the ve- hicle to an authorized Freightliner dealer. 5. Check the old grease. If it appears rusty, gritty, or burned, replace the U-joint assembly. For instruc-...
  • Page 100 Brakes Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Dryer Checking..............42–02 Air Dryer Desiccant and Coalescent Filter Replacing .

  • Page 102: Air Dryer Checking

    Brakes 42–00 Safety Precautions Because no two vehicles operate under identical conditions, maintenance and maintenance intervals will vary. Experience is a valuable guide in determin- Safety Precautions in this section apply to all ing the best maintenance interval for any one particu- procedures within this group.

  • Page 103: Air Dryer Desiccant And Coalescent Filter Replacing

    Brakes Operational and Leakage Tests and heater assembly to below 40°F (4°C). Using an ohmmeter, check the re- 1. Check all lines and fittings leading to and from sistance between the electrical pins in the the air dryer for leakage and integrity. Repair any air dryer connector half.
  • Page 104 Brakes IMPORTANT: Lubricate the new O-rings prior to 5. Using a clean rag, wipe clean the inside of the end cover. Clean the cartridge bolt bore in the installation. end cover, and the sealing surfaces for the large- 6. Install the new small O-ring in the groove on the and small-diameter desiccant cartridge sealing bottom of the new coalescent filter.
  • Page 105 Brakes second. If leakage exceeds this measure, remove and re-install the desiccant cartridge. Haldex PURest NOTE: The PURest cartridge contains both the desiccant and filter in one piece. 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
  • Page 106 Brakes 01/10/2011 f422527 A. Canister/cartridge assembly shown upside-down. B. Rotate the cartridge counterclockwise 45 degrees to release it from the canister. Fig. 2, Releasing the Cartridge 01/10/2011 f422529 A. Install the new cartridge into the canister. B. Press the cartridge into the canister and rotate clockwise 45 degrees to engage the cartridge.
  • Page 107 Both the life and reliability of the slack adjuster Workshop Manual, or take the vehicle to an autho- will be reduced if this type of grease is used. rized Freightliner dealer. Lubricate a Haldex automatic slack adjuster at the Camshaft brackets without grease fittings are fitted grease fitting with any extreme-pressure NLGI Grade...
  • Page 108 Brakes –20°F (–29°C) and above. If the operating tempera- ture is below –20°F (–29°C), use a low-temperature extreme-pressure grease. Meritor Lubricate the slack adjuster at the grease fitting until grease is forced past the pressure-relief capscrew or past the gear splines around the inboard snap ring. Use high-temperature, NLGI Grade 1 waterproof grease.

  • Page 109: Bendix Hydro-Max® Brake System Inspecting (Front-Engine Diesel Chassis)

    Apply 1/8 oz (3.5 g) Aeroshell grade 5 grease to Workshop Manual for replacement instructions, each of the two guide pin and guide pin bore sets. or take the vehicle to an authorized Freightliner See the Bosch Pin Slide Disc Brakes Service Manual Chassis dealer.

  • Page 110: Brake Lines Checking, Hydraulic Disc Or Air Brakes

    Brakes IMPORTANT: The later ZOH-T caliper has im- portant differences from the early ZOPS caliper. ZOPS calipers (since 1998) and ZOH-T calipers (since 2002) use different slide pins and bolts. Fig. 10 Fig. 11. The later trailing pin is identified by notches and has a rubber bushing. Flange-head instead of hexhead bolts are used with the later caliper.
  • Page 111 Workshop Manual for repair procedures, or take by MSHA or NIOSH at all times when servicing the the vehicle to an authorized Freightliner dealer. brakes, starting with removal of the wheels and continuing through assembly.
  • Page 112 Brakes Manual for inspection, troubleshooting, and re- 5. Check all of the foundation brake components for pair procedures. damage, wear, and loose or missing parts. Re- pair as needed. See Group 42 of the Recre- 4. Measure the applied chamber stroke. See ational Vehicle Chassis Workshop Manual for Table 2 for the proper stroke for the type of...
  • Page 113 Brakes Brake Chamber Stroke Specifications Chamber Max Applied Stroke: inch (mm) † Manufacturer Type Size Less than 1-1/2 (38) Standard Stroke Less than 1-3/4 (44) Meritor Less than 1-7/8 (48) Long Stroke Less than 2 (51) Standard Stroke Long stroke design is indicated by a tag, or embossing, on the brake chamber. †...

  • Page 114: Versajust Slack Adjuster Inspection And Lubrication

    Brakes Brake Chamber Stroke Specifications Chamber Max Applied Stroke: inch (mm) † Manufacturer Type Size Less than 1-1/2 (38) Standard Stroke Less than 1-3/4 (44) Meritor Less than 1-7/8 (48) Long Stroke Less than 2 (51) Standard Stroke Long stroke design is indicated by a tag, or embossing, on the brake chamber. †...
  • Page 115 Brakes Leakage Test Actuator Stroke–Standard Stroke Recommended Maximum Perform the following test after repairing or replacing Brake Actuator Size Operating Stroke (Inches) the DV-2 valve, to ensure that the valve is function- ing properly. 1-3/4 With the system charged and pressure stabilized in the system, there should be no leaks at the drain 1-3/4 valve exhaust port.
  • Page 116 Steering Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Drag Link Lubricating ............. . . 46–01 Hydraulic Reservoir Filter Changing (metal reservoir only) .
  • Page 118 Steering 46–00 Safety Precautions leakage could cause loss of power steering assist, possibly resulting in personal injury and property damage. Safety Precautions in this section apply to all 3. With the power steering fluid at operating tem- procedures within this group. perature, check the fluid level on the dipstick.
  • Page 119 Steering WARNING Fill only with approved clean fluid. Do not mix fluid types. Any mixture or any unapproved fluid could lead to seal deterioration and leaks. Fluid leakage could cause loss of power steering assist, possibly resulting in personal injury and property damage.
  • Page 120 Steering For the 4-quart reservoir, install the gasket, filter top plate, and retaining ring, then hand-tighten the retaining ring. 15. Fill the power steering reservoir with Dexron III. Fill the 1.6- and 2-quart reservoir to the MAX COLD mark. Fill the 4-quart reservoir to the mark between the MIN COLD and MAX HOT marks.
  • Page 121 Steering 10. Start the engine. Run the engine at half-throttle until the fans engage (loud chirping sound). Shut down the engine. 11. The fan circuit is now purged. Top off the reser- voir fluid and install the reservoir lid. 04/13/93 f460515a 1.
  • Page 122 Fuel Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fuel Tank Mounts and Fuel Line Checking ..........47–01 Fuel/Water Separator Element Replacing .
  • Page 124 Fuel 47–00 Safety Precautions 47–02 Fuel/Water Separator Element Replacing Safety Precautions in this section apply to all procedures within this group. Alliance DANGER The only maintenance necessary on an Alliance fuel/water separator is to replace the filter element. When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires.
  • Page 125 Fuel There is no significant restriction to fuel flow until the element is completely clogged. 1. Shut down the engine, apply the parking brake, and chock the tires. 2. Check the fuel level in the fuel filter. Replace the fuel/water separator element only when the filter element is completely covered.
  • Page 126 Fuel FOR REMOVAL OF TOP COLLAR ONLY 02/16/2009 f470277 Fig. 3, DAVCO Collar Wrench three additional ribs, depending on the specific filter model. 11. Prime the system. 11.1 Ensure that the drain valve is closed. 11.2 Fill the housing to the top of the filter ele- ment with clean diesel fuel.
  • Page 127 Fuel 06/09/2016 f470689 1. Mounting Head 2. Sight Bowl Fig. 5, Detroit Fuel/Water Separator If returning fuel is released into the atmosphere, its vapors can ignite in the presence of any igni- tion source. Do not expose the fuel to, or work with the fuel system near, open flame or intense heat.
  • Page 128 Fuel IMPORTANT: Do not use tools to tighten the bowl and element. 8. Spin the bowl onto the onto the upper housing by hand only. 9. Connect the water sensor and heater connectors if equipped. 10. If equipped with a primer pump, prime the fuel/water separator as follows.
  • Page 130 Exhaust Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Exhaust System Inspecting (Noise Emission Control)........49–01 Safety Precautions .
  • Page 132 Replace ceramic flow-through block where the DEF and parts that show leakage, wear, or damage, with exhaust gases undergo selective catalytic re- genuine Freightliner parts. duction. These conditions are usually caused by loose, bro- • Selective Catalytic Reduction (SCR)—a process ken, or misaligned clamps, brackets, or pipes.
  • Page 133 Exhaust 6. Check all sensors attached to the ATD for leaks or damaged wires. No leaks are allowed. 7. Check the DPF exterior surface for dents or other damage. A dent over 3 inches (76 mm) in diameter and 1/4-inch (6-mm) deep could cause internal damage to the DPF, causing it to mal- function.
  • Page 134 Exhaust • Aftertreatment Device (ATD)—a muffler-like can- retain the DPF in the ATD. No leaks are allowed ister that houses a DPF and sensors. anywhere in the system. • Diesel Particulate Filter (DPF)—a filter that col- 6. Check all sensors attached to the ATD for leaks lects and holds particulate matter (soot and or damaged wires.
  • Page 135 Exhaust 11/2/2006 f490284 A. Inspect this area of the canister for dents. C. DPF Area B. DOC Area 1. Inlet Temperature Sensor 6. Exhaust Outlet to Diffuser 2. Marmon Fitting at Inlet from Turbocharger 7. Outlet Temperature Sensor 3. Sensor Housing 8.
  • Page 136 Electrical, Instruments, and Controls Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Battery Voltage Checking ............54–02 Ground Cables Checking and Cleaning.
  • Page 138 Electrical, Instruments, and Controls 54–01 Ground Cables Checking and Cleaning Check that the ground cables are clean, undamaged, and tight. If needed, disconnect them, clean the mat- ing surfaces with a soda solution, then connect them securely. Spray the ground cable connections with dielectric red enamel.
  • Page 140 Heater and Air Conditioner Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspecting............83–01 Safety Precautions .
  • Page 142 83 of the Recreational Vehicle Chassis Work- procedures within this group. shop Manual for replacement instructions, or take the vehicle to an authorized Freightliner DANGER dealer. Also, visually check for loose fittings on all air conditioning components. Do not over- When working on the vehicle, shut down the en- tighten the fittings.

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