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Daimler Freightliner Business class M2 Series Maintenance Manual

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BUSINESS CLASS M2 MAINTENANCE MANUAL
Models: M2 100
M2 106
M2 106V
M2 112
M2 112V
STI-455-6 (11/16)
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.
Published by

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  • Page 1 BUSINESS CLASS M2 MAINTENANCE MANUAL Models: M2 100 M2 106 M2 106V M2 112 M2 112V STI-455-6 (11/16) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
  • Page 2 All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks North America LLC. Daimler Trucks North America LLC is a Daimler company.
  • Page 3 Introduction Descriptions of Service Publications Daimler Trucks North America LLC distributes the following major service publications in paper and electronic (via ServicePro®) formats. Workshop/Service Workshop/service manuals contain service and repair information for all vehicle Manual systems and components, except for major components such as engines, trans- missions, and rear axles.
  • Page 4 Introduction Descriptions of Service Publications Warranty-related service information available on the AccessFreightliner.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 5 Introduction Page Description For an example of a Business Class M2 Maintenance Manual page, see Fig. Cooling 20−01 Coolant Replacement 20−02 Cooling Fan Inspection Business Class M2 Maintenance Manual, December 2001 12/06/2001 f020125 A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number B.
  • Page 6 Introduction Maintenance Manual Contents Group No. Group Title 00 ..... . General Information 01 ....... . Engine 09 .

  • Page 7: Table Of Contents

    General Information Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Determining Scheduled Maintenance Intervals..........00–01 Initial Maintenance (IM) Operations.

  • Page 8: Determining Scheduled Maintenance Intervals

    General Information Determining Scheduled Maintenance Intervals: 00–01 • any road operation with high annual mileage Determining Scheduled Maintenance Intervals Maintenance Schedules After determining the schedule appropriate to your Performing regular maintenance will help ensure that vehicle, refer to the Maintenance Schedules to deter- your vehicle delivers safe, reliable service and opti- mine when to perform the Initial Maintenance (IM) mum performance.
  • Page 9 General Information Maintenance Schedules: 00–02 Maintenance Schedules Maintenance Intervals Schedule Maintenance Interval Frequency Mileage Hours Initial Maintenance (IM) first 1000 1600 Maintenance 1 (M1) every 1000 1600 Schedule I Maintenance 2 (M2) every 4000 6400 (severe service) for vehicles that travel up to Maintenance 3 (M3) every 8000...
  • Page 10 General Information Maintenance Intervals for Schedule I: 00–03 Maintenance Intervals for Schedule I Maintenance Maintenance Interval Service Date Miles Hours Sequence IM and M1 1000 1600 2000 3200 3000 4800 M1 and M2 4000 6400 5000 8000 6000 9600 7000 11 200 M1, M2, and M3 8000...
  • Page 11 General Information Maintenance Intervals for Schedules II and III: 00–04 Maintenance Intervals for Schedules II and III Schedule II Schedule III Maintenance Maintenance Interval Service Date Sequence Miles Miles IM and M1 8000 12 000 10,000 16 000 M1 and M2 16,000 24 000 20,000...
  • Page 12 General Information Overview of Maintenance Operations: 00–05 Maintenance Operations for Groups 00 through 88 Maintenance Intervals Maintenance Title of Maintenance Operation Operation No. 01-01 Engine Drive Belt Inspecting • • • 01-02 Engine Support Fastener Checking • • 09-01 Air Cleaner Element Inspecting and Replacing •...
  • Page 13 General Information Overview of Maintenance Operations: 00–05 Maintenance Operations for Groups 00 through 88 Maintenance Intervals Maintenance Title of Maintenance Operation Operation No. Wheel End Inspection and Maintenance, 6,000-Pound and 33-05 • • • • • • ‡ 8,000-Pound Steer Axles with Oil-Lubricated Hubs 33-06 All-Axle Alignment Check •...
  • Page 14 General Information Overview of Maintenance Operations: 00–05 Maintenance Operations for Groups 00 through 88 Maintenance Intervals Maintenance Title of Maintenance Operation Operation No. 47-03 LNG Fuel System Inspecting • • • • • 47-04 LNG Vacuum Integrity Testing • • •...

  • Page 15: Initial Maintenance (Im) Operations

    General Information Initial Maintenance (IM) Operations: 00–06 NOTE: The IM Operations include the maintenance operations in Table 5 and all of the maintenance op- erations in Table 6, M1 Maintenance Operations. Initial Maintenance (IM) Operations Maintenance Title of Maintenance Operation Operation No.

  • Page 16: M1 Lubrication And Fluid Level Check

    General Information M1 Maintenance Operations: 00–07 IMPORTANT: After performing all operations listed in Post-Trip Inspections and Maintenance" chapter of this table, perform all daily, weekly, and monthly the Business Class® M2 Driver’s Manual. maintenance operations listed in the "Pretrip and M1 Maintenance Operations Maintenance Title of Maintenance Operation...
  • Page 17 General Information M1 Maintenance Operations: 00–07 M1 Maintenance Operations Maintenance Title of Maintenance Operation Operation No. 42-04 Bosch Hydraulic Brake System Inspection 42-09 Brake Lines and Fittings Inspection, Hydraulic Brakes 42-13 Brake Inspection 42-14 Hydro-Max ™ Brake System Inspection † 42-15 WABCO System Saver Air Dryer Desiccant Cartridge Replacement ‡...

  • Page 18: M2 Lubrication And Fluid Level Check

    General Information M2 Maintenance Operations: 00–08 NOTE: The M2 Maintenance Operations include the maintenance operations in Table 6, M1 Maintenance maintenance operations in Table 7 and all of the Operations. M2 Maintenance Operations Maintenance Title of Maintenance Operation Operation No. 00-07 Perform All M1 Maintenance Operations 00-13...

  • Page 19: M3 Maintenance Operations

    General Information M3 Maintenance Operations: 00–09 NOTE: The M3 Maintenance Operations include the maintenance operations in Table 8 and all of the maintenance operations in Table 6, M1 Maintenance Operations, and Table 7, M2 Maintenance Opera- tions. M3 Maintenance Operations Maintenance Title of Maintenance Operation Operation No.

  • Page 20: M4 Maintenance Operations

    General Information M4 Maintenance Operations: 00–10 NOTE: The M4 Maintenance Operations include the Operations, Table 7, M2 Maintenance Operations, maintenance operations in Table 9 and all of the Table 8, M3 Maintenance Operations. maintenance operations in Table 6, M1 Maintenance M4 Maintenance Operations Maintenance Title of Maintenance Operation...

  • Page 21: M5 Maintenance Operations

    General Information M5 Maintenance Operations: 00–11 NOTE: The M5 Maintenance Operations include the Operations, Table 7, M2 Maintenance Operations, maintenance operations in Table 10 and all of the Table 8, M3 Maintenance Operations, and Table maintenance operations in Table 6, M1 Maintenance M4 Maintenance Operations.
  • Page 22 General Information M1 Lubrication and Fluid Level Check: 00–12 Table 11, MOP 00-12, lists the lubrication and fluid level check maintenance operations that must be performed at the M1 Maintenance Interval. MOP 00-12, M1 Lubrication and Fluid Level Check Maintenance Title of Maintenance Operation Operation No.
  • Page 23 General Information M2 Lubrication and Fluid Level Check: 00–13 Table 12, MOP 00-13, lists the lubrication and fluid level check maintenance operations that must be performed at the M2 Maintenance Interval. MOP 00-13, M2 Lubrication and Fluid Level Check Maintenance Title of Maintenance Operation Operation No.

  • Page 24: Noise Emission Controls

    General Information Noise Emission Controls: 00–15 Noise Emission Controls 2. The use of the vehicle after such device or ele- ment of design has been removed or rendered inoperative by any person. Federal Law, Part 205: Among those acts presumed to constitute tampering Transportation Equipment Noise are the acts listed below: Emission Controls...

  • Page 25: Verification Of Inspections Log

    General Information Verification of Inspections Log: 00–16 Verification of Inspections Log The "Verification of Inspections Log" should be filled out each time the vehicle’s noise emission controls are maintained or repaired. Verification of Inspections Log, Group 20 Verification of Inspections Log, Group 20, Engine Cooling/Radiator Date Mileage Repair Description...
  • Page 26 Engine Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Engine Drive Belt Inspecting............01–01 Engine Support Fastener Checking.
  • Page 27 Engine 01–00 Safety Precautions 4. Check for uneven ribs on serpentine (poly-V) belts. Foreign material in the pulley will erode the undercord ribs causing the belt to lose its grip- Safety Precautions in this section apply to all ping power. procedures within this group.
  • Page 28 Engine 07/12/2001 f150010b 1. Glazing 3. Separating Layers 5. Streaked Sidewalls 2. Tensile Break 4. Uneven Ribs 6. Cracks Fig. 1, Drive Belt Replacement Conditions NOTE: When the engine is removed, inspect the lower and upper isolators for wear. Replace the isolators if necessary.
  • Page 29 Air Intake Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Element Inspection and Replacement ......... . 09–01 Business Class M2 Maintenance Manual, November 2014...
  • Page 30 Air Intake 09–01 Air Cleaner Element Inspection and Replacement Restriction of air flow through the air cleaner element is measured at the tap in the air cleaner outlet. Check the restriction indicator at the air cleaner or in the cab if the vehicle is equipped with a dash- mounted restriction gauge.
  • Page 31 Air Compressor Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspection ............13–01 Safety Precautions .
  • Page 32 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 33 Alternators and Starters Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Checking..........15–01 Safety Precautions .
  • Page 34 Alternators and Starters 15–00 Safety Precautions Engines equipped with a serpentine or poly-V belt have automatic belt tensioners, and do not require belt tension inspection. Safety Precautions in this section apply to all 4. Check that all electrical connections at the alter- procedures within this group.
  • Page 35 Alternators and Starters 10.1 Clean and tighten the battery ground cable, terminal, and clamps. 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.
  • Page 36 Engine Cooling/Radiator Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fan Drive Inspecting (Noise Emission Control) ..........20–03 Hybrid Electric System Coolant Changing .
  • Page 37 Engine Cooling/Radiator 20–00 Safety Precautions 3. Make sure that the cap seals properly on the coolant filler neck seat, and that the radiator cap gasket is not damaged. On vehicles with Safety Precautions in this section apply to all screw-on caps with O-rings, make sure that the procedures within this group.
  • Page 38 Engine Cooling/Radiator 5. Close the petcock. 3. Check the fan belt for proper alignment and con- dition. If the belt is worn or frayed, replace the 6. Using clamps, connect the hoses to the radiator. belt. Torque the clamps 33 to 38 lbf·in (370 to 430 N·cm).
  • Page 39 Engine Cooling/Radiator Check at the solenoid valve, the air filter assem- WARNING bly, and the air hoses and fittings. See Fig. Using a wet finger or a soapy water solution, Make sure the batteries are disconnected before check for a leak in the same areas. checking the fan clutch.
  • Page 40 Engine Cooling/Radiator 20–04 Hybrid Electric System Coolant Changing 1. Disconnect the 12-volt vehicle batteries to isolate the high voltage power source. 2. Drain the hybrid radiator, as follows. Place a large container under the hybrid radiator. Remove the cap from the coolant reser- voir.
  • Page 41 Clutch Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch Adjusting, Manually Adjusted Clutches ..........25–05 Clutch Hydraulic Fluid Changing .
  • Page 42 Clutch 25–00 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 43 Clutch 25–02 Eaton Fuller Clutch 25–03 Clutch Hydraulic Fluid Release Cross-Shaft Level Checking Lubricating WARNING IMPORTANT: This maintenance operation per- tains only to vehicles equipped with mechanical Use only approved clutch hydraulic fluid (DOT 4 brake fluid) in the clutch hydraulic system. Do not (not hydraulic) linkages.
  • Page 44 Clutch procedures below. Fluid replacement must be done When all the old fluid has passed through at an authorized Freightliner service facility. the system and only new, clean fluid is coming out, close the bleed screw. Flushing 7. Check the fluid level in the reservoir and bleed the system according to the procedures under 1.
  • Page 45 Clutch 12/11/2001 f250582 1. Clamp-Mounting Bolt, 1/4–20 6. Hydraulic Hose 2. Plated Steel Washer 7. Slave Cylinder 3. Locknut, 1/4–20 8. Bleed Valve 4. Bell Housing Standoff Bracket 9. Bell Housing 5. Slave Cylinder Standoff Bracket 10. Slave Cylinder Mounting Capscrew, M8 Fig.
  • Page 46 Clutch 12/11/2001 f250581 1. M8 Capscrew and Washer 4. Pedal Unit 7. Cup Bracket 2. Pedal Unit Mounting Plate 5. Master Cylinder 8. Standoff Bracket 3. Reservoir 6. Hydraulic Hose 9. Mounting Bolt, M10 Fig. 7, Clutch Master Cylinder 25–05 Clutch Adjusting, Release bearing travel is the clearance between the rear surface of the release bearing housing and the Manually Adjusted...
  • Page 47 Clutch If the green end of the tool can’t be inserted in the gap, adjustment is needed. Go to the next step. If the green end of the tool fits — snugly or loosely — then no adjustment is needed. Nothing more needs to be done.
  • Page 48 Clutch 6. Adjust the clutch, using a 5/8-inch box-end or mm), turn the adjustment bolt counter- socket wrench on the adjustment bolt. See clockwise (the release bearing moves to- Fig. ward the engine). When the adjustment is complete, make sure the adjustment bolt is locked (pulled up flush with the mounting bolts).
  • Page 49 Transmission Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Allison Transmission Fluid and Filter Changing ..........26–05 Allison and Eaton Fuller Transmission Breather Checking .
  • Page 50 Transmission 26–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER f260006b 10/05/94 When working on the vehicle, shut down the en- A. Full B. Low gine, set the parking brake, and chock the tires. Before working under the vehicle, always place Fig.
  • Page 51 Transmission areas for the first 10,000 miles (16 000 km) Allison after changing to a synthetic from a petroleum- Cold Check based lubricant. 4. Clean the fill plug, then install it in the transmis- Clean all dirt away from around the end of the fluid sion.
  • Page 52 Transmission 4. With the engine idling, remove the dipstick from the tube and wipe it clean. 5. Insert the dipstick into the tube, then remove it. 6. Check the fluid level reading and repeat the check procedure to verify the reading. Safe oper- ating level is within the HOT RUN band on the dipstick.
  • Page 53 Transmission after changing to a synthetic from a petroleum- 5. For Procision transmissions, change the lubrica- tion filter as follows: based lubricant. 4. Clean the fill plug, then install it in the transmis- NOTICE sion. Tighten the plug 42 lbf·ft (57 N·m). To prevent damage to the threads, use hand tools 26–02 Eaton Fuller to remove the lubrication filter housing.

  • Page 54: Allison And Eaton Fuller Transmission Breather Checking

    Transmission NOTE: The correct fluid level is established by Eaton Fuller Transmission Lubricant Capacities checking at the fill plug opening (manual and Lubricant automated) or the oil level dipstick (Procision). † Transmission Model Capacity: qt (L) 1. On manual and automated transmssions, add fluid until it is level with the lower edge of the fill RT–8608L 13.5 (12.7)

  • Page 55: Eaton Fuller Transmission Air Filter/Regulator Element Cleaning

    Transmission f260007a 05/27/93 NOTE: Location of the transmission breather will vary depending on transmission model. Fig. 3, Transmission Breather (Eaton Fuller shown) 26–04 Eaton Fuller 10/05/2016 f260037a Transmission Air Filter/ NOTE: Location of the air filter/regulator will vary de- pending on transmission model. Regulator Element Fig.
  • Page 56 Transmission ment will last the life of the vehicle, pro- NOTICE vided it is not damaged. Wipe out the filter housing with a clean, To prevent dirt from entering the transmission, dry, lint-free rag. use only clean containers and fillers for the trans- mission fluid.
  • Page 57 Transmission Approved Allison Transmission Lubricants Lubricant Type Temperature: °F (°C) All Allison Transmissions Castrol TranSynd ™ (synthetic) Above –22 (–30) Dexron® III Above –13 (–25) Lubricants listed in order of preference. Do not mix types of oil. Table 7, Approved Allison Transmission Lubricants Allison Transmission Lubricant Capacities Fill Capacity: Transmission Model...

  • Page 58: Mercedes-Benz Transmission Fluid Changing And Magnetic Plug Cleaning

    Transmission 9. Install the filter and cover assemblies into the filter compartment. 10. Align each cover assembly with the holes in the channel plate sump, and push the cover assem- blies in by hand to seat the seals. NOTICE Do not use the bolts to draw the filter covers to the sump.

  • Page 59: Mercedes-Benz Transmission Leak Checking

    Transmission 26–07 Mercedes-Benz Transmission Leak Checking 1. Park the vehicle on a level surface. Apply the parking brakes and chock the rear tires. f260006b 10/05/94 2. Check for signs of leakage at the breather. See A. Full B. Low Fig. Fig.
  • Page 60 Transmission NOTE: There are two cover plates on the coun- 9. Check for signs of leakage at the clutch slave cylinder. tershaft, one at the front and one at the rear. 5. Check for signs of leakage at the rear cover NOTICE plate on the countershaft (next to the output yoke).
  • Page 61 Transmission 11. Remove the chocks from the tires. 26/12 Business Class M2 Maintenance Manual, March 2016...
  • Page 62 Frame and Frame Components Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fifth Wheel Inspecting ............. . 31–02 Fifth Wheel Lubricating.

  • Page 63: Safety Precautions

    Frame and Frame Components • Frame Crossmembers and Gussets 31–00 Safety Precautions • Front Frame Brackets Safety Precautions in this section apply to all • Front Suspension Spring Brackets procedures within this group. • Fuel Tank Brackets • Radius Rods DANGER •...
  • Page 64 Frame and Frame Components Push on the wedge stop rod with hand pressure. It should move in 1/4 inch (6 mm) and spring back out on release. If the free travel is not 1/4 inch (6 mm), adjust the distance to 1/4 inch (6 mm) by turning the wedge stop rod, on the right side of the top plate, clockwise to reduce the gap and counter-clockwise to in-...
  • Page 65 Frame and Frame Components Pry up on the fifth wheel plate below the 3. Using a Holland Kingpin Lock Tester, part num- pin boss, and measure the vertical move- ber TF-TLN-1000 or TF-TLN-5000, check the ment. operation of the locking mechanism by opening and closing the locks.
  • Page 66 Frame and Frame Components ConMet Simplex greased. A liberal coating of grease should be applied to the complete surfaces of both the trailer kingpin plate and the top surface of the Apply a heavy coat of grease to the top plate, either fifth wheel.
  • Page 67 Frame and Frame Components 09/06/2001 f310885 1. Pivot 3. Cam Plate 2. Cam Track Fig. 7, Holland Fifth Wheel Cam Plate 2. Grease the trailer connector with a lithium-based dielectric grease. 31/5 Business Class M2 Maintenance Manual, March 2016...
  • Page 68 Suspension Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Safety Precautions ..............32–00 Suspension Inspecting .

  • Page 69: Safety Precautions

    Suspension 32–00 Safety Precautions Freightliner Spring Rear Suspension Spring Brackets and Safety Precautions in this section apply to all Equalizer Brackets (Tandems) procedures within this group. Inspection DANGER Inspect the forward and rear spring brackets, equal- izer brackets (tandems), and the wear pads, for When working on the vehicle, shut down the en- wear, cracks, and other damage.
  • Page 70 Suspension Freightliner Spring Tandem on the frame or some other part of the chassis. Check the rubber mounting bushings and replace if Suspension Equalizer Bushing worn. Inspect the shock absorber for oil leakage, which is defined as being drips of oil on the sides of Check the shock absorber.
  • Page 71 Suspension Freightliner AirLiner Component Inspection and Operation Check WARNING Inspect the components and check their operation as described below. Failure to perform these in- spections and checks could result in separation of worn suspension components and loss of vehicle control, possibly causing personal injury or death, or property damage.
  • Page 72 Suspension ends up, down, in, and out. If there is any move- 4. Inspect the V-rods and lower control rods for ment, examine the control rods for wear or dam- wear and looseness. age. Replace if necessary. Without disconnecting the control rods, 2.
  • Page 73 Suspension Hendrickson Leaf Spring Assembly Inspection 1. Inspect the spring hangers for wear of the spring pin holes, cams, and the spring hanger legs. See Fig. 05/27/93 f320039a 1. Beam Hanger 3. Jack 2. Equalizer Beam Fig. 4, Raising the Beam End f320112a 05/27/93 A.
  • Page 74 Suspension Hendrickson Radius Rod Keep the vehicle supported by the jack stands for the next operation. Bushing Check 4. Manipulate the walking beam so that a microm- eter, vernier, or dial caliper can be used to deter- 1. Without detaching the torque arms, use your mine the wear area thickness on the bottom hand to attempt to move each of the radius-rod face.

  • Page 75: Suspension Lubricating

    Suspension WARNING Replace all cracked or missing restrictor cans. Failure to do so could lead to loss of vehicle con- trol, which could result in property damage, seri- ous personal injury, or death. 6. Remove the jack stands, then lower the vehicle. Check that the spring or driveline brake is ap- plied, then remove the wheel chocks.
  • Page 76 Suspension Table 1 for U-bolt torque specifications. Turn the wrench in a clockwise motion (looking up) until the torque wrench clicks. Spring Assembly U-Bolt High Nut Torque Values Size Torque: lbf·ft (N·m) Stage 1: Hand-tighten Stage 2: 60 (81) 5/8–18 Stage 3: 200 (271) Stage 4: 180 to 230 (245 to 313) Stage 1: Hand-tighten...
  • Page 77 Front Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Check ............33–06 Draw Key Nut Torque Checking .
  • Page 78 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 79 Front Axle ™ Easy Steer Kingpins—Axles 2. Make sure the tires touch the ground. Do not raise the vehicle. With Unitized Wheel Ends 3. Clean off all grease fittings prior to lubrication. NOTE: This procedure applies to Easy Steer IMPORTANT: Meritor recognizes that industry Plus ™...
  • Page 80 Front Axle 5. Force lubricant into the upper and lower kingpin 3. Using a grease gun, apply a multipurpose grease fitting caps until new lubricant flows from grease, NLGI grade 1 or 2, to the zerk fitting until between the upper axle beam end and the all the old grease is purged from the boot.
  • Page 81 Front Axle CAUTION Do not attempt to straighten a bent cross tube. Doing so could result in damage to the axle. Be sure to replace the cross tube with an original equipment cross tube with the same length, diam- eter, and thread size as the existing cross tube. 5.
  • Page 82 Front Axle 33–05 Wheel End Inspection and Maintenance, 6,000- Pound and 8,000-Pound Steer Axles with Oil- Lubricated Hubs Periodic inspection and maintenance of wheel ends on 6,000-pound and 8,000-pound steer axles is es- sential to sound wheel bearing performance. Check for leaks at the oil seal and hub, and inspect the lu- bricant per the maintenance intervals provided in Group 00...
  • Page 83 Front Axle Toe-In Inspection For vehicle alignment to be accurate, the shop floor must be level in every direction. The turn plates for the front wheels must rotate freely without friction, and the alignment equipment must be calibrated every three months by a qualified technician from the equipment manufacturer.
  • Page 84 Front Axle • Hub/plug area is dirty, and water contaminated oil in the hub. • Hub/plug area is clean, but there is water con- taminated oil in the hub. (pressure washing is the most likely cause) 10/05/2016 f400100a Fig. 11, Setting Trammel Bar Pointers 09/01/2016 f330299 Fig.
  • Page 85 Front Axle Inspection NOTICE Only remove vent plugs by hand. They can be damaged if a tool is used. Wipe the hub/plug area clean before checking the oil. Do not use a pres- sure washer to clean the hub/plug area. The plug has a vent and this can contaminate the oil with water.
  • Page 86 Rear Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Axle Breather Checking ............. 35–02 Axle Lubricant Changing and Magnetic Plug Cleaning .
  • Page 87 Rear Axle 35–00 Safety Precautions temperature indicator only, and should not be used as a fill or level hole. Safety Precautions in this section apply to all 4. Check that the lubricant is level with the bottom procedures within this group. of the fill hole.
  • Page 88 Rear Axle 2. When the vehicle is on level ground, the lubri- Detroit Drive Axle Lubricants cant must be level with the bottom of the oil fill hole. If low, add lubricant. See Table 3 for ap- IMPORTANT: Lubricant used in Detroit rear axles must proved axle lubricants and see Table 4 Table...
  • Page 89 Rear Axle Meritor Drive Axle Recommended Lubricant Lubricant Type Ambient Temperature Viscosity Grade Meritor Specification –40°F (–40°C) and up 75W–90 0–76–N Synthetic Gear Oil –40°F (–40°C) and up 75W–140 0–76–M There is no upper limit on the ambient temperature, but axle sump temperature must never exceed 250° (121°C). Table 3, Meritor Drive Axle Recommended Lubricant Meritor Drive Axle Lubricant Capacities for Single Meritor Drive Axle Lubricant Capacities for Tandem...
  • Page 90 Rear Axle erate continuously at high temperatures must be changed more frequently. NOTICE Failure to change the axle lubricant at more fre- quent intervals, when adverse operating condi- tions require, could result in axle damage. ™ Detroit IMPORTANT: On Detroit axles, the oil change interval for long haul vehicles can be extended to 500,000 miles (800 000 km) for axles with weight ratings of 34,000 to 40,000 lb (15 000 to...
  • Page 91 Rear Axle NOTE: Some Meritor axles have a small tapped 5. Fill the axle with the recommended lubricant. Table 1 for recommended lubricants and and plugged hole located below the housing oil Table 2 for lubricant capacities. fill hole. This smaller hole is for the lubricant temperature sensor only and must not be used NOTE: Some Detroit axles have a small as a fill or level hole.
  • Page 92 Wheels and Tires Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Tire Check ............... 40–02 Wheel Nut Checking.
  • Page 93 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 94 Driveline Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspecting ..............41–01 Driveline Lubricating.
  • Page 95 Driveline 41–00 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 96 Driveline 09/19/2001 f410486 Fig. 3, Examine the Slip Yoke Spline Approved Lubricants Lubricant and Specification Lubricant Brands Phillips Petroleum Philube MW–EP2 Grease Exxon 5160 Amalie All Purpose Grease with Moly–L1–2M Universal joint, slip joint, and spline grease Shell Super Duty Special FF must meet ArvinMeritor Specification O–634–B Marathon Maralube Molycode 529 (NLGI Grade No.
  • Page 97 Driveline 09/19/2001 f410485 Fig. 4, Lubrication Areas for Full-Round and Easy Service Drivelines 41/3 Business Class M2 Maintenance Manual, August 2015...
  • Page 98 Brakes Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Brake Inspecting and Leak Test ........... . . 42–11 Air Brake System Valve Inspection .

  • Page 99: Air Brake System Valve Inspection

    Brakes 42–00 Safety Precautions 4. Disconnect the harness connector from the heater and thermostat assembly. Safety Precautions in this section apply to all 5. Loosen the bolt that secures the upper mounting bracket strap. procedures within this group. 6. Remove the two bolts and Nylok® nuts that se- DANGER cure the air dryer to the lower mounting bracket.
  • Page 100 Brakes 08/09/95 f421383 1. 5/16 x 4-1/2 Upper Mounting 9. Desiccant Cartridge 18. Purge Valve Bracket Bolt 10. O-Ring 19. 1/4-Inch Tapping Screw 2. Upper Mounting Bracket Strap 11. Safety Valve 20. Purge Valve Housing 3. Lockwasher 12. Lower Mounting Bracket 21.
  • Page 101 Brakes spring that cannot be mechanically caged. Disas- sembly could release the spring, resulting in per- sonal injury. 4. Remove and discard both O-rings from the car- tridge bolt. 5. Using a clean rag, wipe clean the inside of the end cover.
  • Page 102 Brakes 42–03 Governor D–2A Check 12.4 Check for excessive leakage around the head of the desiccant cartridge where it contacts the end cover. With the com- IMPORTANT: Review the warranty policy before pressor in loaded mode (compressing performing any intrusive maintenance proce- air), apply a soapy solution to these dures.

  • Page 103: Bosch Hydraulic Brake System Inspection

    Brakes When proper adjustment is obtained, Apply the parking brakes. Chock the tires tighten the adjusting screw locknut, and to prevent vehicle movement. install the top cover. The pressure range Remove one or more of the lining inspec- between cut-in and cut-out is not adjust- tion plugs, and measure brake lining able.
  • Page 104 Brakes for a Haldex slack adjuster. Use standard chassis lubricant for Haldex slack adjusters. 02/01/2001 f421649a 06/26/2007 f422363c 1. Grease Fitting 2. Slack Adjuster Fig. 5, Haldex Automatic Slack Adjuster Grease Fitting Fig. 4, Dana Spicer Automatic Slack Adjuster 42–06 Meritor Camshaft Gunite Bracket Lubrication For operating temperatures of –20°F (–29°C) and...
  • Page 105 Brakes 10/07/2016 f420011a A. Grease Exit 1. Brake Chamber 2. Slack Adjuster 3. Non-Pressure-Relief Grease Fitting Fig. 7, Camshaft Bracket Lubrication 42–07 Meritor Slack Adjuster Lubrication 10/27/93 f420653a IMPORTANT: Perform a brake inspection follow- 1. 7/16-Inch Adjusting 6. Clevis 7. 1/2-Inch Clevis Pin ing the instructions in this group before lubricat- 2.
  • Page 106 Brakes For slack adjusters with grease fittings and for oper- Every 900 operating hours, or 25,000 miles (40 225 ating temperatures below –40°F (–40°C) and above km), or 3 months: –65°F (–54°C), use an NLGI Grade 2 synthetic oil, 1. Check for moisture in the air brake system by clay-base grease.

  • Page 107: Brake Lines And Fittings Inspection, Hydraulic Brakes

    Brakes them. Refer to troubleshooting information in again check the resistance. Resistance Bendix service literature. should exceed 1000 ohms. If resistance values obtained are within stated limits, 3. Check for excessive leakage around the purge the thermostat and heater assembly is valve with the compressor in the loaded mode operating properly.

  • Page 108: Brake Pedal Linkage And Mounting Plate Inspection

    Brakes 42–10 Brake Pedal Linkage and 11. If necessary, start the engine and charge the air system. Shut down the engine and release the Mounting Plate parking brakes. Inspection 12. Make and hold a full service brake application, allowing the pressure to stabilize for one minute. Inspect the pedal, pedal linkage, and mounting plate Observe the installed service reservoir gauges.
  • Page 109 Brakes 42–12 Bendix E-6 Foot Control pressure at which the knob automatically comes out. This pressure should be 20 to 45 psi (138 to Valve Inspection and 310 kPa). Lubrication 18. Close the drain cocks, recharge the system, and completely drain the primary reservoir. On ve- hicles equipped with a DRM or AD-IS with the air 1.
  • Page 110 Brakes Brake Component Inspection Check the plunger for signs of wear or cracks. Replace it if necessary. 1. Park the vehicle on a level surface, set the park- 9. Lubricate the plunger with barium grease (BW ing brake, and chock the tires. Once the tires are 246671).
  • Page 111 Brakes Brake Chamber Stroke Specifications Chamber Max Applied Stroke: inch (mm) † Manufacturer Type Size Gunite Standard Stroke 1-3/8 (35) 1-3/4 (44) 2 (51) ‡ 2-1/4 (57) Long Stroke 2 (51) 24 (2-1/2 inch rated stroke) 24 (3 inch rated 2-1/2 (64) stroke) Haldex...

  • Page 112: Hydro-Max

    Brakes Brake Chamber Stroke Specifications Chamber Max Applied Stroke: inch (mm) † Manufacturer Type Size Dana Spicer Long Stroke 2 (51) 24LS 2-1/2 (64) 30LS Long stroke design is indicated by a tag, or embossing, on the brake chamber. † Specifications are relative to a brake application with 80 to 90 psi (550 to 620 kPa) air pressure in the brake chambers.

  • Page 113: Versajust Slack Adjuster Inspection And Lubrication

    Brakes Open the cover to the main power distri- bution module (PDM). Pull the fuse in position F6 for the Hydro- Max relay. Inspect the relay to make sure the fuse is not damaged. If the fuse is damaged, in- stall a new fuse.
  • Page 114 Brakes 1. Visually check for physical damage, such as bro- Actuator Stroke–Long Stroke ken air lines and broken or missing parts. Recommended Maximum Brake Actuator Size 2. Using a quality multipurpose chassis lubricant, Operating Stroke (Inches) NLGI Grade 2, lubricate the slack adjuster 30 Long Stroke 2-1/2 through the grease fitting until clean lubricant...
  • Page 115 Steering Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Drag Link Inspection..............46–01 Drag Link Lubrication .

  • Page 116: Drag Link Inspection

    Steering 46–00 Safety Precautions If there is 1/8-inch (3-mm) movement or more, do not drive the vehicle until the drag link is replaced. Safety Precautions in this section apply to all 46–02 Power Steering Fluid procedures within this group. Changing DANGER When working on the vehicle, shut down the en- WARNING...

  • Page 117: Drag Link Lubrication

    Steering 46–03 Power Steering Fluid 5. Remove the bolts, nuts, and washers that attach the power steering reservoir to the mounting Level Inspecting bracket. Drain the power steering fluid from the reservoir, but do not remove the supply line to 1.
  • Page 118 Steering 4. Remove the filter, filter cover, and gasket from the reservoir. 5. Disconnect the filter from the filter cover, and dis- card the filter. 6. Apply a thin film of power steering fluid on the gasket of the new filter. Then attach the filter to the filter cover.
  • Page 119 Fuel Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number CNG Fuel Cylinder Inspecting............47–07 CNG Fuel System Inspecting .

  • Page 120: Safety Precautions

    Fuel 47–00 Safety Precautions source. Do not drain fuel near, or expose fuel vapor to open flame or intense heat. Exposure to open flame or intense heat could start a fire, pos- Safety Precautions in this section apply to all sibly resulting in personal injury or property dam- procedures within this group.
  • Page 121 Fuel 6. Spin the bowl onto the new element, then spin 6. Using the collar, attach the filter cover with the them both onto the filter head, snugly, by hand spring to the base. only. IMPORTANT: Tighten the collar by hand only. IMPORTANT: Do not use tools to tighten the 7.
  • Page 122 Fuel 10/16/2001 f470415 1. Filter Vent 6. Filter Spring 10. Check Valve Fuel Inlet 2. Vent Seal 7. Filter Element 11. Drain 3. Filter Collar 8. Temporary Filter Stud 12. Electric Filter Preheater 4. Filter Cover 9. Fuel Outlet (optional) 5.
  • Page 123 Fuel 10/16/2001 f470414 1. Filter Collar 7. Filter Element 11. Drain 2. Filter Vent 8. Temporary Filter Stud 12. Bottom Plate Collar 3. Vent Seal 9. Check Valve Fuel Inlet 13. Electric Heater (optional) 4. Filter Cover 10. Fluid Heater/Bottom Plate and 5.
  • Page 124 Fuel steam cleaner, or silicone-based chemicals on the 4. Look for signs of abrasion between the fuel tank gas detection sensors, as this may permanently and mounting brackets. disable the sensors. When cleaning the vehicle, 5. Inspect the fuel fill fitting for signs of damage or cover the sensors with a plastic covering.
  • Page 125 Fuel 5. Repair or replace any damaged fuel gauge components. Vaporizer Inspecting Fig. 6 for plumbing component locations. 1. Ensure that the vaporizer is secured to its mounting brackets and that the mounting brackets are secured to the frame. Inspect for any signs of looseness.
  • Page 126 Fuel 06/29/2009 f470536 1. Pressure Relief Device 5. Coolant Inlet Line 9. Pressure Gauge 2. Fuel Inlet Line 6. Vaporizer 10. Overpressure Regulator 3. Check Valve 7. Fuel Shutoff Solenoid Valve 11. Pressure Relief Valve 4. CNG Quick-Connect Port 8. Coolant Outlet Line 12.
  • Page 127 Fuel Vacuum Integrity Test Results Pressure Increase Over Eight- Remedy Hour Period Less than 20 psi (138 kPa) None – Tank is normal 20 to 50 psi (138 to 345 kPa) Monitor tank and test vacuum integrity again at next maintenance date Remove vehicle from service and evacuate the tank per the tank manufacturer’s More than 50 psi (345 kPa) instructions...
  • Page 128 Fuel CYLINDERS INSPECT CYLINDERS EVERY 36 MONTHS OR 36000 MILES WHICHEVER OCCURS FIRST REGULATOR INSPECT PRESSURE NATURAL RELIEF DEVICE EVERY 2000 MILES VEHICLE 110 PSIG OPEN VALVE FILTER SLOWLY DRAIN HOUSING EVERY 1500 MILES 3600 PSIG MAX. REPLACE ELEMENT SERVICE PRESSURE EVERY 3000 MILES 04/30/2010 f470556...
  • Page 129 Fuel 04/22/2010 f470554 05/04/2010 f470557 1. Fuel Cylinder Storage 5. Fuel Fill Port 6. Dust Cap 1. Fuel Panel Access 5. Coolant Outlet Line 2. Fuel Cylinder Shutoff 7. Manual Shutoff Valve Cover 6. Coolant Inlet Line Valves (qty 5) 8.
  • Page 130 Fuel 05/04/2010 f470558 1. Coolant Inlet Port 9. Fuel Fill Port 2. Coolant Outlet Port 10. Filter Housing 3. Pressure Relief Valve 11. Filter Bowl 4. Pressure Regulator 12. Filter Drain Plug 5. Wiring Harness 13. Solenoid Valve 6. Manifold Bleed Valve 14.
  • Page 131 Exhaust Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number CAT CGI Bellows Replacement............49–03 CAT CGI Bellows and Piping Inspection .
  • Page 132 DOC and DPF (also the SCR and the mixing tube in one-box systems). DANGER • BlueTec®—Daimler’s proprietary SCR technol- When working on the vehicle, shut down the en- ogy. gine, set the parking brake, and chock the tires.
  • Page 133 Exhaust 1. Check for leakage at the clamp that attaches the 11. Check any wires, lines, or hoses within 4 inches exhaust pipe to the turbocharger exhaust outlet. (10 cm) of the exhaust system for heat damage. If leakage exists, tighten the nut on the clamp to Repair or reroute as needed.
  • Page 134 Exhaust 08/20/2009 f490355 NOTE: The sensor box (item 8) contains the SCR inlet and outlet NOx sensors, DPF outlet pressure sensor, and the DOC inlet pressure sensor. 1. DOC Outlet Temperature 6. Exhaust Outlet 11. SCR Outlet NOx Sensor Port Sensor 7.
  • Page 135 Exhaust 09/16/2009 f490353 1. DEF Metering Unit 5. DOC Inlet Temperature Sensor 9. DPF Outlet Temperature 2. DEF Nozzle 6. DOC Inlet Pressure Sensor Sensor 3. SCR Outlet Temperature 7. DPF Inlet Temperature Sensor 10. DPF Outlet NOx Sensor Sensor 8.
  • Page 136 Exhaust 09/16/2009 f490354 1. DPF Inlet Temperature Sensor 6. DPF Outlet Temperature 9. SCR Outlet Temperature 2. DOC Inlet Temperature Sensor Sensor Sensor 3. DOC Inlet Pressure Sensor 7. DPF Outlet NOx Sensor 10. SCR Sensor Box 4. DPF Sensor Box 8.
  • Page 137 Exhaust 10/20/2006 f490283 A. Inspect this area of the canister for dents. 1. Marmon Fitting at Inlet from Turbocharger 6. Sensor Housing 2. DOC Temperature Sensor 7. DPF Outlet Temperature Sensor 3. ATD Mounting Band 8. Exhaust Outlet Marmon Fitting 4.
  • Page 138 Exhaust 49–03 CAT CGI Bellows NOTICE Replacement When shortening the CGI pipe(s), it is critical to leave a minimum of 1 inch (25.4 mm) of straight On vehicles with CAT EPA07 compliant engines, re- pipe on the end of each CGI pipe to allow for pipe place the CGI bellows at the M3 maintenance inter- insertion and clamp clearance.
  • Page 139 Exhaust 02/24/2011 f490456 1. Clamp 5. Slip Clamp 8. Center Pipe 2. Inlet Pipe 6. CGI Bellows 9. Clamp 3. U-Clamp 7. Center Pipe-Support Brace 10. Outlet Pipe 4. Forward Pipe-Support Brace Fig. 6, CAT EPA07 Exhaust Installation with CGI Bellows 01/29/2010 f490415 02/23/2011...
  • Page 140 Exhaust 02/23/2011 f490458 A. At least 7/16 inch (10 mm) 1. Forward CGI Pipe 3. Aft CGI Pipe 2. CGI Bellows Fig. 9, CGI Bellows Installation 02/08/2010 f490417 1. CGI Bellows 4. Graphite Gasket 2. Slip Clamp 5. Forward CGI Pipe 3.
  • Page 141 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Aerodynamic Component Inspection ........... . 60–02 Mirror Folding Check .
  • Page 142 60–01 Mirror Folding Check For vehicles with folding main mirrors, make sure that the mirrors fold freely on the pivot points. Pivot each mirror fully forward and backward two times to break loose any debris that may affect the fold-away feature of the mirror.
  • Page 143 Doors Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Door Seals Lubricating ............. . 72–01 Business Class M2 Maintenance Manual, June 2002...
  • Page 144 Doors 72–01 Door Seals Lubricating NOTE: Only the door seals require lubrication. Do not lubricate the door latches or hinges. They come from the manufacturer with lifetime lubrication and require no maintenance. Lightly coat the door seals with a lubricant that is safe for rubber.
  • Page 145 Heater and Air Conditioner Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspecting............83–01 HVAC Air Filter Replacing.
  • Page 146 Heater and Air Conditioner 83–00 Safety Precautions 8. Use a feeler gauge to check that the drive plate clutch clearance is 0.016 to 0.031 inch (0.4 to 0.8 mm). If the gap is not even around the Safety Precautions in this section apply to all clutch, gently tap down at the high areas.
  • Page 147 Heater and Air Conditioner 8. Using capscrews, attach the evaporator service cover to the HVAC assembly. 9. Connect the wiring harness to the evaporator probe. 10. Attach the lower HVAC cover to the dash panel. For instructions, see Group 60 of the Business Class®...
  • Page 148 Hood, Grille, and Cab Fenders Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Hood Rear Support Lubrication............88–01 Business Class M2 Maintenance Manual, November 2014...
  • Page 149 Hood, Grille, and Cab Fenders 88–01 Hood Rear Support Lubrication 1. Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. 2. Open the hood. 3. Clean both the hood- and cab-mounted hood rear support components with a soapy water so- lution.

This manual is also suitable for:

Freightliner business class m2 100Freightliner business class m2 106Freightliner business class m2 106vFreightliner business class m2 112Freightliner business class m2 112v

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