Thomas SAF-T-LINER C2 Maintenance Manual
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Thomas SAF-T-LINER C2 Maintenance Manual

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SAF-T-LINER C2 SCHOOL BUS MAINTENANCE MANUAL
Models: C2
C2 G
C2 LPG
eC2
STI-466-8 (09/20/2021)
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.
Published by

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Summary of Contents for Thomas SAF-T-LINER C2

  • Page 1 SAF-T-LINER C2 SCHOOL BUS MAINTENANCE MANUAL Models: C2 C2 G C2 LPG STI-466-8 (09/20/2021) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
  • Page 3 Perform the pretrip inspection and daily maintenance as outlined in the Saf-T-Liner C2 School Bus Driver’s Manual. Perform the maintenance operations in this manual at scheduled intervals based on the distance the vehicle has traveled or hours of operation.
  • Page 4 © 2004–2022 Daimler Trucks North America LLC 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.
  • Page 5 Thomas Built Buses, Freightliner, Freightliner Custom Chas- sis Corporation, Sterling, 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. I–1 Saf-T-Liner C2 School Bus Maintenance Manual, July 2018...
  • Page 6 Field Service Campaigns Field service campaigns are concerned with non-safety-related service work or replacement of parts. All field service campaigns are distributed to dealers; cus- tomers receive notices that apply to their vehicles. I–2 Saf-T-Liner C2 School Bus Maintenance Manual, July 2018...
  • Page 7 A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number B. Group Title C. Group Number D. Release Date E. Group Number/Page Number Fig. 1, Page Example of the Printed Manual I–3 Saf-T-Liner C2 School Bus Maintenance Manual, July 2018...
  • Page 8 83 ....Heater and Air Conditioner 88 ....Hood, Grille, and Cab Fenders I–4 Saf-T-Liner C2 School Bus Maintenance Manual, July 2018...

  • Page 9: Table Of Contents

    Verification of Inspections Log............00–07 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...

  • Page 11: Determining Scheduled Maintenance Intervals

    Maintenance Intervals for Schedule I Maintenance Intervals for Schedule II to determine which maintenance interval(s) should be performed when your vehicle reaches the mileage or months of operation listed in these subjects. 00/1 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 12 Maintenance 3 (M3) every 32,000 51 200 annually Maintenance 4 (M4) every 48,000 77 200 Maintenance 5 (M5) every 64,000 103 000 Use mileage or months, whichever comes first. Table 1, Maintenance Schedules 00/2 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 13 64 300 — 11th 44,000 70 800 — 12th M1, M2, M3, and M5 48,000 77 200 Use mileage or months, whichever comes first. Table 2, Maintenance Intervals for Schedule I 00/3 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...

  • Page 14: Maintenance Intervals For Schedule Ii

    80,000 128 700 12th 88,000 141 600 — 13th M1, M2, M3, and M4 96,000 154 400 Use mileage or months, whichever comes first. Table 3, Maintenance Intervals for Schedule II 00/4 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 15 Proterra Transmission Fluid Level Checking, Electric Vehicle • • ¶¶ 26–06 Proterra Transmission Fluid Changing, Electric Vehicle 31–01 Frame Fastener Torque Check • • 31–02 Automatic Tire Chain System Checking ††† 31–03 Off-Season Chain Wheel Removal 00/5 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 16 46–02 Power Steering Fluid and Filter Changing, Diesel • 46–03 Power Steering Fluid Level Inspecting • • • • • 46–04 Power Steering Gear Lubricating • • • • • • 00/6 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 17 72–01 Door Seals Lubrication • • • • • • ¶¶¶¶ 72–02 Air Door Inspection 83–01 Air Conditioner Inspection • • • • • 83–02 HVAC Air Filter Cleaning • • 00/7 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 18 Inspect the air door every 60 days or 4000 miles (6436 km), whichever comes first. ¶¶¶¶ Clean the HVAC air filter every 12 months or 8000 miles (12 872 km), whichever comes first. Table 4, Maintenance Operation Procedures and Intervals 00/8 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...

  • Page 19: Noise Emission Controls

    00/9 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...

  • Page 20: Verification Of Inspections Log

    Verification of Inspections Log, Group 20, Engine Cooling/Radiator Date Mileage Repair Description Cost Repair Facility Verification of Inspections Log, Group 49 Verification of Inspections Log, Group 49, Exhaust Date Mileage Repair Description Cost Repair Facility 00/10 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 21 Safety Precautions ..............01–00 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 23 Inspection" are found. If the engine drive belt needs to be replaced, see Group 01 of the Saf-T-Liner C2 School Bus Visually inspect all drive belts. To inspect a belt, gen- Workshop Manual, or take the vehicle to an au- tly twist the belt to view the belt sidewalls and the thorized Freightliner dealer.
  • Page 24 NOTE: Mounts should be inspected when the engine is removed for service. Whenever the engine is removed, inspect the lower and upper isolators for wear. Replace the isolators if nec- essary. 01/2 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 25 Transmission Inspection, Electric Vehicle..........08–03 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...

  • Page 27: Electric Motor Inspection, Electric Vehicle

    Do not touch the Electric vehicles are equipped with a high-voltage cables. See Fig. system. Do not attempt any type of electrical work on the vehicle unless you have completed HV3 08/1 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...

  • Page 28: Transmission Inspection, Electric Vehicle

    Fig. 3. Inspect the transmission pneumatic connections. Fig. 4. Tighten the connections as needed if they are loose. 4. Remove the chocks from the tires. 08/2 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 29 Electric Drive 05/27/2020 f080224 1. Transmission Pneumatic Connections Fig. 4, Transmission Pneumatic Connections (top view) 08/3 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 31 Air Cleaner Element Inspecting and Replacing ..........09–01 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 33 O) could indicate an indicator reading (0 to 4 inH air intake system problem such as a damaged air filter, loose or disconnected air intake piping, or a disconnected or damaged air restriction indicator. 09/1 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 34 PUSH TO RESET 08/21/96 f090165 A. Partial Restriction B. Full Restriction Fig. 1, Air Restriction Indicator, Diesel Engines 12/02/2011 f090495 A. Partial Restriction B. Full Restriction Fig. 2, Air Restriction Indicator, Propane Engines 09/2 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 35 Safety Precautions ..............13–00 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...

  • Page 37: Air Compressor Filter Replacement, Propane Engine

    12. Position and properly orient the first section of the separator housing against the compressor. 4. Install the cover, then tighten the spring clip. Fig. 13. Reference the alignment lines when installing the separator housing. 13/1 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 38 IMPORTANT: Ensure that the end cap plug seal sor. Reference the alignment lines made earlier. is in place on the end cap plug. See Fig. Use the six end cap bolts to attach the end cap 13/2 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 39 See Fig. 5 for refer- 20. Replace the fill plug seal (Viton seal) on the fill ence. plug. See Fig. 18. Using a 17 mm wrench, install the drain plug. Fig. 13/3 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...

  • Page 40: Vehicle

    2. Locate the air compressor filter cannister. Re- Fig. lease the two latches that attach the outer cover, 22. Remove the chocks from the tires. then remove the cover. See Fig. 22 Fig. 13/4 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 41 Fig. 24, and the inner filter element. discard the outer filter element. 5. Install a new inner filter element in the filter can- nister. Ensure that the element is fully seated. 13/5 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...

  • Page 42: Rebuild Air Compressor Air-End, Electric Vehicle

    7. Install the cover on the filter cannister. Make cer- compressor air-end, see Section 13.04, Subject 100 tain that the cover is installed correctly with the in the Saf-T-Liner C2 School Bus Workshop Manual. top arrow pointing up, then secure the two latches. See Fig.
  • Page 43 1. Air Compressor Filter Cannister 2. Latch (qty. 2) Fig. 22, Air Compressor Filter Cannister 06/05/2020 f130194 1. Fill Plug 06/02/2020 f130169 Fig. 21, Installing the Fill Plug Fig. 23, Removing the Filter Cannister Cover 13/7 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 44 2. Remove the fill plug, with the temperature probe Fig. 25, Removing the Air Compressor Inner Filter installed, shown in Fig. 27, items 2 and 3, and Element discard the fill plug Viton seal. 13/8 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 45 28. If compressor oil is not at the top of the thermal well (so that it surrounds the temperature probe), add compressor oil. 2. Fill a squeeze bottle with Hydrovane FluidForce HPO-198-5 compressor oil. 13/9 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 47 Safety Precautions ..............15–00 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...

  • Page 49: Safety Precautions

    3. Check that all electrical connections at the alter- instructions, or take the vehicle to an authorized nator and starter are clean. Clean and tighten all Freightliner dealer. charging system electrical connections as 15/1 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 50 11. Check the terminals on the battery shut-off switch and the starter relay. Make sure that the terminal connections are clean and tight. Coat the terminal connections with dielectric red enamel after cleaning. 15/2 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 51 Safety Precautions ..............20–00 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 53 This prevents the collapse 10. Using clamps, connect the hoses to the radiator. of hoses and other parts that are not internally Torque the clamps 33 to 38 lbf·in (370 to 430 N·cm). 20/1 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 54 If the fan clutch does not operate correctly, see 11. Fill the radiator with coolant. Use a 50/50 mixture Group 20 of the Saf-T-Liner C2 School Bus of antifreeze and water. Refer to the engine Workshop Manual for troubleshooting and repair manufacturer’s service literature for approved...
  • Page 55 Engine Cooling/Radiator See Section 20.07 of the Saf-T-Liner C2 School Bus needed. Inspect the coolant circulation pump for Workshop Manual for replacement instructions, or leakage. Repair or replace the pump if it is dam- take the vehicle to an authorized Freightliner dealer.
  • Page 56 4. Remove the drain plug for the heater manifold, set to hot and the blower is running. shown in Fig. 3, to help drain the heater circuit. 20/4 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 57 filled; approximately 27 quarts (26 L) of coolant. 14. Start the vehicle, then set the heater control to hot and run the blower. 15. Add coolant until the sight glass is filled. 20/5 Saf-T-Liner C2 School Bus Maintenance Manual, May 2021...
  • Page 59 Safety Precautions ..............25–00 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 61 Fig. 2, Contact Points Requiring Grease transmission). 5. Install the clutch inspection plate. CAUTION 6. Remove the chocks. Do not over-lubricate the clutch release bearing. Over-lubrication could contaminate the clutch in- 25/1 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 62 1. Reservoir Cap 4. Master Cylinder 2. Reservoir 5. Hydraulic Hose 3. Pedal Unit 6. Slave Cylinder Fig. 5, Clutch Components 05/27/93 f260146a Fig. 4, Cross-Shaft Grease Fitting, Right Side 25/2 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 63 Check the fluid level in the reservoir again. 6. Flush the hydraulic system, as follows. See Fig. 8. Make sure the reservoir lid is tight. 25/3 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 64 10. Slave Cylinder Mounting 4. Bell Housing Standoff Bracket 7. Slave Cylinder Capscrew, M8 Fig. 6, Clutch Slave Cylinder 9. Lower the hood and remove the chocks from the front and rear tires. 25/4 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 65 8. Wipe the dirt from the grease fitting and lubricate with Eaton® Roadranger® CD50 or equiva- Lubrication lent E500 synthetic. IMPORTANT: For the most up-to-date Eaton approved lubricants, go to www.roadranger- .com. 25/5 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 66 Clutch 04/17/2009 f180057 Fig. 8, Cross Shaft Grease Fitting for HEVs 25/6 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 67 Safety Precautions ..............26–00 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 69 fill opening. See sions with 1-1/4-inch pipe threads. Table 1 for approved lubricants. For more information and a complete listing of approved lubricants, refer to the Eaton website, www.roadranger.com. 26/1 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 70 field. Eaton Fuller Transmission Lubricant Capacities 4. Install and tighten the drain plug(s) 50 lbf·ft (68 Transmission Model Capacity: qt (L) N·m). 5-Speed FS–5205A/B 6.25 (5.9) FS–6305A/B 9.75 (9.2) 6-Speed 26/2 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 71 5. Remove the magnet from the filter attachment tube or from the top of the filter element. 6. Clean any metal debris from the magnet. Then, install the magnet on the filter attachment tube. 26/3 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 72 11. Install six bolts in each cover, and tighten the CAUTION bolts 38 to 44 lbf·ft (51 to 61 N·m). To prevent dirt from entering the transmission, use only clean containers and fillers for the trans- 26/4 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 73 Do not mix types and brands of fluid, because of 8. Check the fluid level reading and repeat the possible incompatibility. Do not use fluid addi- check procedure to verify the reading. 26/5 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 74 • OL - LO followed by a number indicates fluid level to the middle of the COLD RUN band. the amount that is under-filled. Fig. • OL - 70 indicates that the transmission is not up to operating temperature. 26/6 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 75 HOT RUN band. See Fig. Fig. 4. If needed, fill the transmission with Shell SPIRAX Synthetic Manual Transmission Oil S6 GME 40 until it is level with the lower edge of the fill opening. 26/7 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 76 160 to 200°F (71 to 93°C). Shut down the motor. 10. Using a clean funnel in the fill port, add transmis- sion fluid until it reaches the bottom threads of the fill port. 26/8 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 77 This port will be used to fill the cooler. 13. Using a 7/8 inch (22 mm) wrench, loosen but do not remove, the fill plug on the top of the oil 26/9 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 79 Safety Precautions ..............31–00 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...

  • Page 81: Automatic Tire Chain System Checking

    January 2007 require the same maintenance as premature wear. shown below. 8. Actuate the solenoid valve to keep it clean and Inspect the fasteners at the following locations: functioning correctly. 31/1 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...

  • Page 82: Off-Season Chain Wheel Removal

    This will keep the system from being un- knowingly activated during the off season. 4. Inspect the chain wheels, arm bearings, and angle joints for wear to ensure the system is ready for the next season. 31/2 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 83 Suspension U-Bolt Torque Checking ........... . 32–03 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...

  • Page 85: Safety Precautions

    Do not weld the exist, replace the spring assembly. See Group 32 of torque arm for any reason. the Saf-T-Liner C2 School Bus Workshop Manual for instructions. 3. Inspect the rubber bushing ends. See Fig.
  • Page 86 Place safety stands under the vehicle Wipe all dirt from the grease fittings at the forward frame. spring pin and the spring shackle pins. Then apply 32/2 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 87 Failure to retorque the U-bolt nuts could result in spring breakage and abnormal tire wear. 1. Park the vehicle on a flat surface and apply the parking brake. Chock the tires. 32/3 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 89 Tie Rod End Lubricating ............. 33–02 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 91 For any Detroit axle that requires lubrication of the out and fresh grease is seen at the ball stud neck. tie-rod ends, wipe the grease fittings clean, then Fig. 33/1 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 92 When moving the assembly, check for any movement at both tie rod ends. Install a new grease fitting. Fig. Apply lubrication to the new grease fitting. 33/2 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 93 9. Check that the cotter pin is in place. If it is not, tighten the tie rod end nut to the applicable value depending on the size of the stud. • 7/8–14, 160 to 300 lbf·ft (217 to 406 N·m) 33/3 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 95 Safety Precautions ..............35–00 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 97 Detroit axles or Table 2 for Meritor axles. IMPORTANT: A lubricant level close enough to be seen or touched is not sufficient. It must be level with the bottom of the fill hole. 35/1 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 98 Check Grade more often under poor operating conditions. If the † breather is plugged, clean it or replace it as needed. Mineral Oil –15°F (–26.1°C) and up 80W–90 35/2 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 99 † Axle Model Capacity : pints (L) 3. Remove the plug at the bottom of the housing ARS–13.0–2 15 (7) and drain the lubricant while the unit is warm. 35/3 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 100 38.0 (18.0) Quantities listed are approximate and include 1 pint (0.5 liter) for each wheel end and with the drive pinion at 3 degrees. Table 4, Meritor Drive Axle Lubricant Capacities 35/4 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 101 Wheel Nut Checking..............40–01 Saf-T-Liner C2 School Bus Maintenance Manual, February 2004...
  • Page 103 Accuride Corporation 450 to 500 (610 to 678) 1-1/8–16 Accuride Corporation 450 to 500 (610 to 678) 3/4–16 Accuride Corporation 450 to 500 (610 to 678) Table 1, Wheel Nut Torque Specifications 40/1 Saf-T-Liner C2 School Bus Maintenance Manual, February 2004...
  • Page 105 Safety Precautions ..............41–00 Saf-T-Liner C2 School Bus Maintenance Manual, June 2018...
  • Page 107 Group 41 of the vehicle Workshop Manual, or Table 1 for approved lubricants. take the vehicle to an authorized Freightliner dealer. 3. Examine the slip yoke spline for excessive radial movement. See Fig. 2. If excessive radial loose- 41/1 Saf-T-Liner C2 School Bus Maintenance Manual, June 2018...
  • Page 108 325°F [163°C] to –10°F [–23°C]) Shell Moly Poly Grease Kendall L424 Grease Amoco Super Chassis Grease ™ Ford Specification M1C–75B or part number PN C1AZ 19590 Dana recommended lubricant. Table 1, Approved Lubricants 41/2 Saf-T-Liner C2 School Bus Maintenance Manual, June 2018...
  • Page 109 WABCO System Saver Air Dryer Desiccant Cartridge Replacing ....... 42–16 Saf-T-Liner C2 School Bus Maintenance Manual, November 2020...
  • Page 111 Fig. 1. Discard the nuts. the upper mounting bracket strap nut 80 to 120 Remove the end-cover-to-housing O-ring. lbf·in (904 to 1356 N·cm). 9. Clamp the desiccant cartridge in a vise. 42/1 Saf-T-Liner C2 School Bus Maintenance Manual, November 2020...
  • Page 112 2. Completely drain all air reservoirs. Air pressure Liner C2 School Bus Workshop Manual for diag- gauges should read 0 psi (0 kPa). nosis and repair information. IMPORTANT: The compressor discharge line may contain residual air pressure. 42/2 Saf-T-Liner C2 School Bus Maintenance Manual, November 2020...
  • Page 113 Every 12 months perform the operational tests as listed below. 9. Lubricate the O-rings, bolt O-ring grooves, the sealing rings, and the cartridge grooves. Lubri- cate the end cover bore for the bolt. 42/3 Saf-T-Liner C2 School Bus Maintenance Manual, November 2020...
  • Page 114 Apply soap solution around the cover and to the ex- 5. Make sure that the brake rotor and linings are haust port. Slight bubble leakage is permitted. Exces- free of oil and grease. 42/4 Saf-T-Liner C2 School Bus Maintenance Manual, November 2020...
  • Page 115 For service and lubrication Gunite instructions, see Group 42 of the Saf-T-Liner C2 School Bus Workshop Manual. For operating temperatures of –20°F (–29°C) and higher, use Texaco Multifak EP-2 or Mobil Grease For slack adjusters with grease fittings and for oper-...
  • Page 116 Fig. Bracket Lubricating If grease leaks out under the camhead, the camshaft bracket grease seal is worn or damaged. See Group 42 of the Saf-T-Liner C2 School Bus Workshop IMPORTANT: Perform MOP 42-15 before lubri- Manual for grease seal replacement instructions.
  • Page 117 • Air usage is exceptionally high and not nor- not follow this pattern, refer to troubleshooting mal. This may be due to high air system information in the Bendix service literature. leakage. 42/7 Saf-T-Liner C2 School Bus Maintenance Manual, November 2020...
  • Page 118 If any of the tests in the following procedure fail, sistance between the electrical pins in the air dryer connector half. The resistance refer to Group 42 of the Saf-T-Liner C2 School should be 1.5 to 3.0 ohms for the 12-volt Bus Workshop Manual to test individual air heater assembly and 6.0 to 9.0 ohms for...
  • Page 119 See 20. Completely drain the primary reservoir. Group 42 of the Saf-T-Liner C2 School Bus Workshop Manual for replacement instructions, 21. Make a modulated service brake application. or take the vehicle to an authorized Freightliner Both front and rear brakes should modulate.
  • Page 120 fill-neck. continuing through assembly. Fig. 8, Hydraulic Brake Reservoir, Alternate Mounting NOTE: See the Bosch Pin Slide Disc Brakes Angle Service Manual for more information. replace any damaged harness. Disconnect any 42/10 Saf-T-Liner C2 School Bus Maintenance Manual, November 2020...
  • Page 121 2. Raise the front or the rear axle and then place safety stands under the frame or axle. Be sure that the stands will support the weight of the ve- hicle. 42/11 Saf-T-Liner C2 School Bus Maintenance Manual, November 2020...
  • Page 122 2. With your foot off of the brake pedal, verify that 1. Remove the brake valve. For instructions, see the vehicle is stationary, the ignition key is in the Group 42 of the Saf-T-Liner C2 School Bus ON position, and the dash electronic control unit Workshop Manual.
  • Page 123 3. Remove all of the wheel assemblies. For instruc- 16.1 Perform the same steps used for entering tions, see Group 40 of the Saf-T-Liner C2 maintenance mode. School Bus Workshop Manual. NOTE: In all steps that require a torque wrench, 16.2...
  • Page 124 Table 1, Torque Check with 47 Inch (119 cm) Torque Wrench and Tool DDC DSNCHA018005 5. Install the wheel assemblies. For instructions, 2. Raise the vehicle and support it on jack stands. see Group 40 of the Saf-T-Liner C2 School Bus 3. Remove all of the wheel assemblies. For instruc- Workshop Manual.
  • Page 125 Fig. 12, Bendix Radial Mounted Caliper Tightening Pattern (viewed from below) 5. Install the wheel assemblies. For instructions, 2. With the engine off, and 100 psi (690 kPa) of air see Group 40 of the Saf-T-Liner C2 School Bus tank pressure, have an assistant apply and hold Workshop Manual.
  • Page 126 Specifications are relative to a brake application with 80 to 90 psi (550 to 620 kPa) air pressure in the brake chambers. ‡ If type 36 chamber is used, slack length should be less than 6 inches. Table 2, Brake Chamber Stroke Specifications 42/16 Saf-T-Liner C2 School Bus Maintenance Manual, November 2020...
  • Page 127 filter in the adapter which should be replaced. If the drain valve does not function properly, repair or replace it. See Section 42.18 of the Saf-T-Liner C2 School Bus Workshop Manual. Leakage Test...
  • Page 129 Safety Precautions ..............46–00 Saf-T-Liner C2 School Bus Maintenance Manual, August 2020...

  • Page 131: Drag Link Inspecting

    If it is loose, replace 4. Remove the filter and filter cover from the reser- the drag link. See Group 46 of the Saf-T-Liner C2 voir. Disconnect the filter from the filter cover and School Bus Workshop Manual for replacement in- discard the filter.

  • Page 132: Drag Link Lubricating

    1. Apply the parking brake and chock the rear tires. 2. With the engine cool, the fluid level should be between the MIN COLD and MAX HOT lines with the engine off. 46/2 Saf-T-Liner C2 School Bus Maintenance Manual, August 2020...

  • Page 133: Power Steering Motor Lubrication, Electric Vehicle

    Do not over-lubricate the power steering motor. Over-lubrication of a motor can seriously damage it by forcing grease into motor windings, as well as the centrifugal switch, causing it to malfunc- tion. 46/3 Saf-T-Liner C2 School Bus Maintenance Manual, August 2020...
  • Page 134 5. Remove the bolts, nuts, and washers that attach the power steering reservoir to the mounting bracket. Drain the fluid from the reservoir, but do not remove the supply line to the reservoir. 46/4 Saf-T-Liner C2 School Bus Maintenance Manual, August 2020...
  • Page 135 Safety Precautions ..............47–00 Saf-T-Liner C2 School Bus Maintenance Manual, March 2019...

  • Page 137: Safety Precautions

    1. Drain off some fuel by loosening the vent plug has reached the top of the filter element, follow and opening the drain valve. the procedure below to replace the element. 47/1 Saf-T-Liner C2 School Bus Maintenance Manual, March 2019...
  • Page 138 Check for leaks and shut down the en- a DAVCO Collar Wrench (part number 482017) gine. is used for removal. During installation, the vent cap is to be hand-tightened only, not tightened with a wrench. 47/2 Saf-T-Liner C2 School Bus Maintenance Manual, March 2019...
  • Page 139 If returning fuel is released into the atmosphere, 5. Filter Element 11. Collar its vapors can ignite in the presence of any igni- 6. Cover O-Ring Fig. 2, DAVCO Diesel Pro 245 47/3 Saf-T-Liner C2 School Bus Maintenance Manual, March 2019...
  • Page 140 6. Filter Element 14. Heat Exchanger 7. Spring 10. Install the clear cover and the collar. Simultane- ously apply downward pressure to the top of the Fig. 5, DAVCO Fuel Pro 382 47/4 Saf-T-Liner C2 School Bus Maintenance Manual, March 2019...
  • Page 141 Check for leaks and shut down the en- gine. See the safety precautions listed in Chapter 17 of the Saf-T-Liner C2 School Bus Driver’s Manual, or take the vehicle to an authorized Freightliner 47–03 Inline Fuel Strainer dealer. Failure to observe these precautions could...
  • Page 142 Injector Inspecting, See the safety precautions listed in Chapter 17 of Propane Engine the Saf-T-Liner C2 School Bus Driver’s Manual, or take the vehicle to an authorized Freightliner dealer. Failure to observe these precautions could WARNING...
  • Page 143 11. Check for leaks using an electronic leak detector or a liquid-leak detection solution. The following inspections must be performed by a qualified technician, in accordance with the manufac- turer’s established inspection criteria. 47/7 Saf-T-Liner C2 School Bus Maintenance Manual, March 2019...
  • Page 144 3. Ensure that the fuel panel is secured to the • Coolant hoses and fittings frame. Inspect for any signs of looseness. If 47/8 Saf-T-Liner C2 School Bus Maintenance Manual, March 2019...
  • Page 145 7. Replace leaking or damaged fuel lines. Repair or the solenoid valve. A bubble solution can be replace leaking or damaged fittings. used to pinpoint the exact location of leaks. 47/9 Saf-T-Liner C2 School Bus Maintenance Manual, March 2019...
  • Page 146 Repair or replace any leaking components. 47–10 CNG Fuel Cylinder Inspection Have a qualified inspector inspect compressed natu- ral gas (CNG) fuel cylinders for damage or deteriora- tion. Note cuts, cracks, gouges, abrasions, discolor- 47/10 Saf-T-Liner C2 School Bus Maintenance Manual, March 2019...
  • Page 147 Safety Precautions ..............49–00 Saf-T-Liner C2 School Bus Maintenance Manual, December 2015...
  • Page 149 Align or replace as nec- essary. For alignment or adjustment instructions, see IMPORTANT: The Environmental Protection Group 49 of the Saf-T-Liner C2 School Bus Work- Agency’s 2010 regulations mandate lowered shop Manual, or take the vehicle to an authorized exhaust emissions, thus requiring exhaust sys- Freightliner dealer.
  • Page 150 Tighten to 30 lbf·ft (41 N·m) if needed. Do not install a new exhaust seal clamp. Do not reuse overtighten. seal clamps. Once a seal clamp is loosened or removed, it must be replaced. 49/2 Saf-T-Liner C2 School Bus Maintenance Manual, December 2015...
  • Page 151 DEF filter replacement instructions and mainte- quired torque. If leakage persists, install a new nance intervals. exhaust seal clamp. Do not reuse seal clamps. Once a seal clamp is loosened or removed, it must be replaced. 49/3 Saf-T-Liner C2 School Bus Maintenance Manual, December 2015...
  • Page 152 3 inches (76 mm) in diameter and 1/4-inch the ATD in the ATS, and around the clamps that (6-mm) deep could cause internal damage to the DPF, causing it to malfunction. 49/4 Saf-T-Liner C2 School Bus Maintenance Manual, December 2015...
  • Page 153 ATD. Heat discoloration may indicate internal damage; especially around the DPF. 9. Check any wires, lines, or hoses within 4 inches (10 cm) of the exhaust system for heat damage. Repair or reroute as needed. 49/5 Saf-T-Liner C2 School Bus Maintenance Manual, December 2015...
  • Page 155 Charge Port Inspection, Electric Vehicle ..........54–02 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 157 6. The charging dispenser has a lamp to indicate 7. Once battery charging is complete, or to end a the charging status. See Table charging session, press the end charge button 54/1 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 158 The desiccant plugs may Fig. 3, Charging Dispenser be replaced based on time in service or due to a color change that indicates moisture has entered the 54/2 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 159 6. Using a calibrated torque wrench and a 1-3/8 internal leakage, indicated by the salt plug, this inch socket, tighten the desiccant plug 35 lbf·in should be diagnosed and repaired before replacing (395 N·cm). the desiccant. 54/3 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 160 Jameson Glow Rod (or equivalent) and pull the old battery pack 06/01/2020 f547221 desiccant out of the battery pack and discard it. Fig. Fig. 9, Tightening the Desiccant Plug by Hand 54/4 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 161 Glow Rod all the way through the pack until 6. Starting at the end of the battery pack with the the hook exits the other side, as shown in coolant loop, push the hooked end of the Jame- Fig. 54/5 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 162 17 mm Allen socket. NOTE: Two technicians are needed for the fol- Tighten the plugs 22 lbf·ft (30 N·m). For refer- lowing step. ence, refer to Fig. 10 Fig. 54/6 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 163 Fig. 18, Ends of the Battery Pack Desiccant Tucked into the Desiccant Chamber 12. Install the battery pack manual service discon- nect removed earlier. See Fig. 13. Remove the chocks from the tires. 54/7 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 165 Door Seals Lubrication ............. . 72–01 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 167 NOTE: The main entry door, rear emergency 3. If the door requires adjustment, see Section exit, and emergency hatch seals require lubrica- 72.02, Subject 140 in the Saf-T-Liner C2 School Bus Workshop Manual for instructions. tion. Do not lubricate the door latches or hinges.
  • Page 168 4. Hexhead Bolt 7. Washer and Locknut, 3/8–16 2. Washer 5. Primary Drive Linkage 8. Bracket 3. Air Cylinder Shaft 6. Secondary Linkage 9. Hexhead Bolt Fig. 2, Air Door Drive Linkage 72/2 Saf-T-Liner C2 School Bus Maintenance Manual, July 2020...
  • Page 169 Safety Precautions ..............83–00 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 171 8. Using a feeler gauge, check that the drive plate seal on the cover. clutch clearance is 0.016 to 0.031 inch (0.4 to 83/1 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 172 12. Attach the lower HVAC cover to the dash panel. Install the three Torx screws; two at the bottom of the cover and one on the right. 13. Connect the batteries. 83/2 Saf-T-Liner C2 School Bus Maintenance Manual, June 2015...
  • Page 173 Hood Rear Support Lubrication............88–01 Saf-T-Liner C2 School Bus Maintenance Manual, November 2014...
  • Page 175 Approved Suppliers of Multi-Purpose Lithium Grease Supplier Grease Chevron Delo Heavy Duty EP Exxon Unirex EP2 Mobil Mobil Grease XHP 222 Shell Retinax LC Grease Texaco Starplex 2 Table 1, Approved Suppliers of Multi-Purpose Lithium Grease 88/1 Saf-T-Liner C2 School Bus Maintenance Manual, November 2014...

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