freightliner Custom Classic MT45 2022 Maintenance Manual
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freightliner Custom Classic MT45 2022 Maintenance Manual

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WALK-IN VAN CHASSIS MAINTENANCE MANUAL
Models: MT45
MT45 G
MT50e
MT55
MT55 G
STI-471-7 (06/18/2022)
Daimler Truck North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.
Published by

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  • Page 1 WALK-IN VAN CHASSIS MAINTENANCE MANUAL Models: MT45 MT45 G MT50e MT55 MT55 G STI-471-7 (06/18/2022) Published by Daimler Truck North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
  • Page 3 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. Descriptions and specifications contained in this publication provide no warranty, expressed or implied, and are subject to...
  • Page 4 © 1997–2022 Daimler Truck 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 Truck North America LLC.
  • Page 5 Introduction Descriptions of Service Publications Daimler Truck North America LLC distributes the following major service publications in paper and electronic formats. Refer to www.DTNAConnect.com. 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 6 EZWiring EZWiring ™ makes Freightliner Custom Chassis Corporation, Freightliner, Ster- ling, Western Star, and Thomas Built Buses 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 Page Description For a page example of a Maintenance Manual page, see Fig. 10/27/98 f020085 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.
  • Page 8 Introduction Maintenance Manual Contents Group No. Group Title 00 ..... . General Information 01 ....... . Engine 09 .
  • Page 9 General Information Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number General Maintenance Schedule Information..........00–01 Noise Emission Controls Maintenance.
  • Page 11 General Information General Maintenance Schedule Information: 00–01 General Maintenance Schedule Information Performing regular maintenance on your vehicle will help ensure that your vehicle delivers safe reliable service and optimum performance for years to come. Failure to follow a regular maintenance program can result in inefficient operation and unscheduled down time.
  • Page 12 General Information Vehicle Maintenance Schedule Table: 00–02 Vehicle Maintenance Schedule Maintenance Interval in Miles x 1000 5 10 15 20 25 30 35 40 45 50 55 60 65 95 100 Maintenance Operation Number and Description Maintenance Interval in Kilometers x 1000 8 16 24 32 40 48 56 64 72 80 88 96 104 112 120 128 136 144 152 160 01–01 Engine-Support Fasteners...
  • Page 13 • • • • • • • • • • • • • • • • • Operation Checking, Freightliner AirLiner 32–04 Suspension U-Bolt Torque • • • • • • • • • • • • • • •...
  • Page 14 General Information Vehicle Maintenance Schedule Table: 00–02 Vehicle Maintenance Schedule Maintenance Interval in Miles x 1000 5 10 15 20 25 30 35 40 45 50 55 60 65 95 100 Maintenance Operation Number and Description Maintenance Interval in Kilometers x 1000 8 16 24 32 40 48 56 64 72 80 88 96 104 112 120 128 136 144 152 160 42–02 Brake Lines Check, Hydraulic Disc...
  • Page 15 General Information Vehicle Maintenance Schedule Table: 00–02 Vehicle Maintenance Schedule Maintenance Interval in Miles x 1000 5 10 15 20 25 30 35 40 45 50 55 60 65 95 100 Maintenance Operation Number and Description Maintenance Interval in Kilometers x 1000 8 16 24 32 40 48 56 64 72 80 88 96 104 112 120 128 136 144 152 160 Inspect the fuel tank every 12 months.
  • Page 16 FCCC parts in performance tained or repaired. and durability. Freightliner Noise Emission Controls Warranty See the vehicle owner’s warranty information book for warranty information concerning noise emission controls.
  • Page 17 General Information Verification of Inspections Log: 00–04 Verification of Inspections Log Verification of Inspections Log, Groups 20 and 49 Date Mileage Item Cost Maintenance Facility Group 20 — Fan Clutch Group 49 — Exhaust System Components 00/7 Walk-In Van Chassis Maintenance Manual, May 2022...
  • Page 19 Engine Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Engine Drive Belt Inspecting............01–02 Engine Oil and Filter Checking and Changing, Gasoline Engines .
  • Page 21 Visually in- specifications, or take the vehicle to an authorized spect all drive belts for the following conditions, then Freightliner dealer. perform the belt tension inspection. Visual Inspection 1. Inspect the belt for glazing. See Fig.
  • Page 22 Engine 11/21/94 f150010a A. Glazing C. Streaked Sidewalls E. Uneven Ribs B. Separating Layers D. Tensile Break F. Cracks Fig. 2, Drive Belt Replacement Conditions Belt Tension Inspection pulley will erode the undercord ribs, causing the belt to lose its gripping power. Spring-Tension Type 6.
  • Page 23 Engine • 6.6 L engines—8.4 quarts (8 L) of oil the oil must be warm and the vehicle must be on level ground. 1. Turn off the engine and give the oil several min- utes to drain back into the oil pan. If this is not done, the oil dipstick may not show the actual level.
  • Page 24 Engine 01–05 Evaporative Control System Inspecting, Gasoline Engines Inspect the solenoid, evaporative control system can- ister, and lines. See Fig. 7. Look for damaged lines, leaking fuel, or any damage to the canister itself. Make certain the electrical connections are properly connected.
  • Page 25 Electric Drive Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Electric Motor Inspection, Electric Vehicle ..........08–01 Safety Precautions .
  • Page 27 Electric Drive 08–00 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 or motor, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure 05/29/2020 f080226...

  • Page 29: Table Of Contents

    Air Intake Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Element Inspecting and Replacing ..........09–01 Air Cleaner Filter Minder Gauge Checking.

  • Page 31: Air Cleaner Element Inspecting And Replacing

    See Group 09 of the Walk-In Replacing Van Workshop Manual for removal and installation instructions, or take the vehicle to an authorized Freightliner dealer. NOTICE Engine damage can occur if the air intake system is All air intake components and connections must not properly maintained.

  • Page 32: Air Cleaner Filter Minder Gauge Checking

    See Group 09 of the Walk-In Van Work- shop Manual for removal and installation in- structions, or take the vehicle to an authorized Freightliner dealer. 09–02 Air Cleaner Filter Minder Gauge Checking The filter minder gauge measures the amount of air restriction (in inches or millimeters of water vacuum) in the air intake system.

  • Page 33: Charge Air Cooler Checking

    Air Intake 09–04 Charge Air Cooler Checking Good airflow through the radiator and charge air cooler core is essential for proper engine cooling. The cores allow air passage, but form a barrier that tends to collect insects and airborne debris. If the charge air cooler core fins are bent, use a small pair of needle-nose pliers or a small screw- driver to straighten them.
  • Page 35 Air Compressor Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspection ............13–01 Safety Precautions .

  • Page 37: Safety Precautions

    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 or motor, 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 39 Alternators and Starters Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Check ......... 15–01 Safety Precautions .
  • Page 41 Clean the cable connector terminals Group 15 of the vehicle Workshop Manual, or with a wire brush. See Group 54 of the vehicle take the vehicle to an authorized Freightliner Workshop Manual for troubleshooting instruc- dealer. tions, and for adjustment, repair, or replacement 3.
  • Page 42 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 43 Engine Cooling/Radiator Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Coolant Heater Check, Webasto............20–03 Coolant Replacement.
  • Page 45 Engine Cooling/Radiator 20–00 Safety Precautions WARNING Safety Precautions in this section apply to all Drain the coolant only when the coolant and en- procedures within this group. gine are cool. Draining it when these are hot could cause severe personal injury due to scalding. DANGER 3.
  • Page 46 Engine Cooling/Radiator then at high idle for 1 minute. Return to Turn the cap slowly counterclockwise until it low idle for 1 minute. reaches a "stop." Do not press down while turn- ing the cap. Wait until any remaining pressure Turn the engine off.
  • Page 47 Engine Cooling/Radiator engine speed to 1200 rpm for 60 seconds, then needed. Inspect the coolant circulation pump for decrease engine speed to low idle for 60 sec- leakage. Repair or replace the pump if it is dam- onds. Top off the coolant level to the base of the aged.
  • Page 48 Engine Cooling/Radiator 10/15/2021 f200973 10/15/2021 f200974 1. Drain Valve 1. Coolant Heaters Plugs 2. Coolant Pump Inlets Fig. 3, Radiator Drain Valve Fig. 5, Coolant Heater Plugs and Pump Inlets 8. Disconnect the 5/8 inch supply and return lines from the high-voltage battery pack. Drain any coolant in the lines or batteries into a bucket.
  • Page 49 Engine Cooling/Radiator 9. Once the coolant has been drained, install and If a pre-mixed coolant/water solution is used, dis- secure the 5/8 inch supply and return lines on tilled water does not need to be added. the high-voltage battery pack. IMPORTANT: The powertrain/battery loop surge 10.
  • Page 51 Transmission Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Allison Transmission Fluid Level Checking ..........26–02 Allison Transmission Fluid and Filter Changing .
  • Page 53 Transmission 26–00 Safety Precautions 26–02 Allison Transmission Fluid Level Checking Safety Precautions in this section apply to all procedures within this group. NOTICE DANGER Operating a transmission with the fluid level higher or lower than recommended can result in When working on the vehicle, shut down the en- transmission damage.
  • Page 54 Transmission 08/27/96 f270007 1. COLD RUN Band 2. HOT RUN Band 05/17/2022 f261566 Fig. 2, Dipstick Markings Fig. 3, Allison Transmission QR Code Hot Check 1. Operate the transmission in a drive range until normal operating temperature, 160 to 200°F (71 to 93°C), is reached.
  • Page 55 Transmission Approved Allison Transmission Lubricants TES-295 Approval Company Product Brand Name Number AN-051005 ExxonMobil Lubricants and Petroleum Specialties Company Mobil Delvac Synthetic ATF AN-011001 Castrol Heavy Duty Lubricants TranSynd AN-031002 Autran Syn 295 AN-031003 Cognis Corporation Emgard 2805 AN-031004 Fleetrite Synthetic ATF AN-071006 John Deere &...
  • Page 57 Frame Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Interlube Chassis Lubrication System Inspecting ......... . . 31–01 Safety Precautions .
  • Page 59 Frame 31–00 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 or motor, 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 60 Frame Remove the dirt cap from the grease fill fitting, then wipe the grease fill fitting to remove any dirt. Approved Grease NLGI Grade Temperature Rating: Down to °F (°C) 10 (–12) 0 (–18) –10 (–23) –20 (–29) –30 (–34) Do not use heavy/tacky grease, or clay based high-temperature grease.
  • Page 61 MOP Number Component Inspecting and Operation Checking, Freightliner AirLiner ......32–03 Freightliner Suspension Inspecting ........... . . 32–02 Safety Precautions .
  • Page 63 Air-Consuming Devices Turned Off than 3 psi (21 kPa). NOTE: With all air-consuming devices turned off (service brakes released and parking brake ap- 32–02 Freightliner Suspension plied [exhausted]), pressure drop must not ex- Inspecting ceed 2 psi (14 kPa) in one minute.
  • Page 64 • There are gaps between the rubber bush- the Walk-In Van Chassis Workshop Manual for in- structions, or take the vehicle to an authorized ing and the pin or the outer steel sleeve. Freightliner dealer. • Either bushing end contacts a torque arm pin mounting bolt. WARNING •...
  • Page 65 If there is any move- Walk-In Van Chassis Workshop Manual, or take ment, examine the control rods for wear or dam- the vehicle to an authorized Freightliner dealer. age. Replace the control rod(s) if necessary. 6. Inspect the shock absorbers for oil leaks and 2.
  • Page 66 Suspension U-Bolt Torque Values Description Size Torque: lbf·ft (N·m) Stage 1: Hand tighten Stage 2: 60 (81) 5/8–18 Stage 3: 180 (244) Stage 4: 200 to 230 (271 to 312) Stage 1: Hand tighten Stage 2: 60 (81) 3/4–16 Stage 3: 200 (271) Stage 4: 270 to 330 (367 to 449) Spring Assembly U-Bolt High Nuts Stage 1: Hand tighten...
  • Page 67 Front Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Checking ............33–04 Grease-Lubricated Wheel Bearing Cleaning, Inspecting, Repacking and Adjusting, Front Axle .
  • Page 69 Adjusting, Front Axle See Group 33 of the Walk-In Van Chassis Workshop Manual for grease-lubricated wheel bearing service procedures, or take the vehicle to an authorized Freightliner dealer. 33–02 Knuckle Pin Lubricating 06/07/2012 f330272 Upper View, LH Side Lower View, LH Side NOTICE 1.
  • Page 70 Front Axle Meritor Axles during lubrication. Even if grease leaks out around the top or bottom plate, continue pump- Hold a pressure gun on each fitting until fresh grease ing until new grease is seen at the seal on the appears.
  • Page 71 Group 35 of the Walk-In Van Chassis Workshop Manual, or 02/27/2007 f320033a take the vehicle to an authorized Freightliner dealer. IMPORTANT: The tie-rod end threads must be visible throughout the entire length of the split. Toe-in Inspection NOTE: Pinch bolt not shown to provide clarity.
  • Page 72 Group 33 of the WARNING Walk-In Van Chassis Workshop Manual, or take the vehicle to an authorized Freightliner dealer. If Be careful not to overfill the hubs. Overfilling may corrections are needed, see Group 33 of the...
  • Page 73 Front Axle 1. With the vehicle on a level surface, rotate the front wheels and allow the oil in the hubs to settle. 2. Chock the tires. IMPORTANT: The oil level should be at, or no more than 1/4 inch (6 mm) above the level indi- cators on the hub caps.
  • Page 75 Rear Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Axle Breather Checking ............. 35–03 Axle Lubricant Changing.
  • Page 77 Rear Axle 35–00 Safety Precautions carrier or housing) with recommended lubricant; Table 1. Refer to Table 2 for Detroit drive axle lubricant capacities. Safety Precautions in this section apply to all 2. Install the fill hole plug and tighten it 30 lbf·ft (41 procedures within this group.
  • Page 78 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 79 See Group 35 of the Walk-In Van 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 81 Wheels and Tires Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Wheel Nut Checking..............40–01 Walk-In Van Chassis Maintenance Manual, January 2008...
  • Page 83 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 85 Driveline Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspection and Lubrication ........... . 41–01 Safety Precautions .
  • Page 87 Group 41 of the vehicle Work- shop Manual, or take the vehicle to an autho- 3. Using lithium 12-hydroxy stearate grease (NLGI rized Freightliner dealer. grade 1 or 2, with EP additives), lubricate until 4. Check that the yoke plug is not loose or missing.
  • Page 88 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 89 Brakes Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Dryer Check ..............42–08 Air Dryer Desiccant and Coalescent Filter Replacement.
  • Page 91 Manual for replacement instructions, or take the there is a hydro-max failure condition vehicle to an authorized Freightliner dealer. other than loss of back-up motor power. 4. Check the electrical connections and harnesses.
  • Page 92 Brakes 42–02 Brake Lines Check, the Walk-In Van Chassis Workshop Manual, or take the vehicle to an authorized Freightliner Hydraulic Disc Brakes dealer. Check all hydraulic lines and fittings for damage, 42–04 Brake Caliper Slide Pin leakage, or looseness. Lubrication, Bosch Replace damaged or leaking components, and tighten loose fittings.
  • Page 93 If the brakes must be repaired, or they require adjustment, see Group 42 of the Walk-In Van Chassis Workshop Manual for repair, adjust- ment, and troubleshooting procedures. Or take the vehicle to an authorized Freightliner dealer. Pneumatic (Air) Parking Brake Operational Check CAUTION...
  • Page 94 4. If they do not turn, no further work is needed. If they turn, take the vehicle to an authorized Freightliner dealer to have all of the caliper bolts on that wheel end replaced. Due to limited caliper bolt access, it may be necessary to use tool DDC DSN- CHA018005 referenced in tool letter 18TL18.
  • Page 95 If they turn, take 1. Park the vehicle on a level surface, shut down the vehicle to an authorized Freightliner dealer to the engine, and set the parking brake. Chock the have all of the caliper bolts on that wheel end tires.
  • Page 96 Brakes 10/31/2018 f422663a A. Right-hand brake (viewed from below). C. Sheer sleeve above in this location. B. Left-hand brake (viewed from below). D. Shelf above in this location. Fig. 6, Bendix Radial Mounted Caliper Tightening Pattern (viewed from below) 5. Install the wheel assemblies. For instructions, ing system may lead to brake failure, resulting in see Group 40 of the Walk-In Van Chassis Work- property damage, personal injury, or death.
  • Page 97 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 98 Brakes 7. Insert the coalescent filter with the O-ring end going into the air dryer opening first. The end of the filter with the "X" will then be facing out. 8. Install the other new O-ring over the threaded neck of the desiccant cartridge. 9.
  • Page 99 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. 10, Releasing the Cartridge 01/07/2011 f422526 1. O-ring 3. Mounting Bolts 2. Cartridge Fig. 9, PURest Air Dryer Assembly 7.
  • Page 100 Brakes will vary. Experience is a valuable guide in determin- ing the best maintenance interval for any one particu- lar operation. Every six months: 1. Check for moisture in the air brake system by opening reservoir drain valves and checking for presence of water.
  • Page 101 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 102 Brakes 2. Inspect the slack adjuster for physical damage, With the system charged, apply the brakes several paying attention to the link, boot, and clevis. If times. Each time the brakes are applied, an exhaust any components are damaged, repair or replace of air should occur from the exhaust port of the drain them as necessary.
  • Page 103 Steering Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Drag Link Lubricating ............. . . 46–01 Power Steering Fluid and Filter Changing, Electric Vehicle.
  • Page 105 Steering 46–00 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 or motor, 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 106 Group 46 of the Walk-In Van Chassis possibly resulting in personal injury and property Workshop Manual, or take the vehicle to an autho- damage. rized Freightliner dealer. 9. Fill the reservoir with Dexron® III automatic transmission fluid (ATF), or an equivalent. WARNING...
  • Page 107 Steering 08/21/96 f461099 1. Prevailing Torque Locknut 3. Grease Fitting 5. Boot 2. Pinch Bolt 4. Universal Joint Shaft 6. Boot Retainer Fig. 2, Steering Driveline 2. Remove the reservoir cap and unscrew the 7. Install a new filter. Tighten the power steering power steering fitting shown in Fig.
  • Page 108 Steering 09/11/96 f461112 1. Pitman Arm 6. Flanged Capscrew, M16 x 2 x 60 2. Pitman Arm Pinch Bolt 7. Countersunk Capscrew, M16 x 2 x 50 3. Pitman Arm Pinch-Bolt Nut 8. Flanged Capscrew, M16 x 2 x 55 4.
  • Page 109 Steering 09/09/2010 f462193 1. Power Steering Fitting 2. Reservoir Cap Fig. 5, Steering Reservoir, Gasoline Engine 3. Evacuate the refrigerant system. For instructions, see Section 83.03, Subject 110 of the Walk-In Van Chassis Workshop Manual. 4. Remove the compressor fittings at the end of the connected hoses.
  • Page 110 Steering it by forcing grease into motor windings, as well as the centrifugal switch, causing it to malfunc- tion. IMPORTANT: Due to the high operating tem- peratures of the motor, use Darmex RPL-707 grease for motor lubrication. 7. Using a hand-type grease gun with Darmex RPL- 707 grease, insert the adaptor over the grease fittings and pump the handle two or three times to fill the grease cavity.
  • Page 111 Steering attach the filter to the filter cover. Make sure that the gasket under the filter cover is not damaged. If the gasket is damaged, replace it. Install the gasket on the reservoir. Install the filter and filter cover in the reservoir. 11.
  • Page 113 Fuel Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number CNG Fuel Block Housing Draining ........... . . 47–04 CNG Fuel Leak Test.

  • Page 115: Cng Fuel Leak Test

    47 of the Walk-In Van Chassis Workshop Manual, place jack stands under the frame rails to ensure or take the vehicle to an authorized Freightliner the vehicle cannot drop. Failure to follow these dealer. Failure to observe these precautions could...
  • Page 116 Walk-In Van Chassis Operator’s Manual or Group 47 of the Walk-In Van Chassis Workshop Manual, Compressed natural gas is highly flammable. See or take the vehicle to an authorized Freightliner the safety precautions listed in Chapter 10 of the dealer. Failure to observe these precautions could Walk-In Van Chassis Operator’s Manual or Group...

  • Page 117: Cng Low-Pressure Fuel Filter Draining

    Walk-In Van Chassis Operator’s Manual or Group Fig. 2, CNG Low-Pressure Fuel Filter Assembly 47 of the Walk-In Van Chassis Workshop Manual, or take the vehicle to an authorized Freightliner 4. Install the new element, the element retainer, the dealer. Failure to observe these precautions could bowl, and the bowl nut.

  • Page 118: Diesel Fuel Filter Replacement

    Fuel CNG Tank Visual Inspection Damage Condition Remedy Cuts in the Fiberglass Wrap Less Than 0.020 Inch (0.5 mm) Deep No repair needed. More Than 0.020 Inch (0.5 mm) But Less Repair if less than 8 inches (200 mm) long. Than 0.030 Inch (0.8 mm) Deep More Than 0.030 Inch (0.8 mm) Deep Replace tank.
  • Page 119 Fuel 5. Using a DAVCO Collar Wrench, shown in Fig. remove the clear cover and collar. FOR REMOVAL OF TOP COLLAR ONLY 02/16/2009 f470277 Fig. 4, DAVCO Collar Wrench NOTE: Broken vent cap and collar warranty claims will not be accepted if any tool other than a DAVCO Collar Wrench (part number 482017) is used for removal.
  • Page 120 Fuel cooled. Draining it when the engine is hot could cause severe personal injury due to scalding. 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 121 Fuel 9. Install the new filter and grommet assembly and cover O-ring on the housing. 10. Install the clear cover and the collar. Simultane- ously apply downward pressure to the top of the clear cover until it is seated on the body of the lower housing and hand tighten the collar until it no longer spins freely.
  • Page 122 Fuel enough fuel to empty the filter, then close the 8. Start the engine and check for fuel leaks. drain valve. See Fig. 9. Shut down the engine and correct any fuel leaks. 05/06/2005 f470486 1. Fuel Outlet 6. Water Sensor Probe 2.
  • Page 123 Exhaust Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Exhaust System Inspecting (Noise Emission Control)........49–01 Safety Precautions .

  • Page 125: Safety Precautions

    Freightliner parts. • Selective Catalytic Reduction (SCR)—a process These conditions are usually caused by loose, bro- ken, or misaligned clamps, brackets, or pipes. If any used to reduce NOx emissions.
  • Page 126 Exhaust 10/20/2009 f490387 1. SCR Inlet Temperature Sensor 4. DPF Outlet Temperature Sensor 2. SCR Outlet Temperature Sensor 5. DPF Catalyst Outlet Temperature Sensor 3. SCR Outlet NOx Sensor 6. DPF Outlet Temperature Sensor Fig. 1, Cummins ATD Sensor Locations, Side-by-Side Mounting the required torque.
  • Page 127 Exhaust • Aftertreatment System (ATS)—the entire ex- 6. Check all sensors attached to the ATD for leaks or damaged wires. No leaks are allowed. haust system from the turbocharger to the ex- haust stack or tail pipe. 7. Check the DPF exterior surface for dents or •...
  • Page 128 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 129 Electrical, Instruments, and Controls Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Battery Pack Desiccant Replacement, Electric Vehicle........54–07 Battery Voltage Checking .
  • Page 131 Electrical, Instruments, and Controls 54–00 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 or motor, 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 132 Electrical, Instruments, and Controls lems, then repair, replace, or reroute the wires, NOTICE as needed. 4. Check that all the relays are firmly seated in their Failure to keep the batteries held securely in place mounting plates. could result in battery damage, such as loose plates or posts.
  • Page 133 Electrical, Instruments, and Controls than 6 inches (15 cm) to hot surfaces. If any are, and they cannot be rerouted, make sure they are protected by heat shields. Check the sensor con- nectors. Make sure they are tight, clean, and un- damaged.
  • Page 134 Electrical, Instruments, and Controls 03/19/2020 f547140 1. Power Feed Connector 2. Charge Port Fig. 4, Plugging the Power Feed Connector into the Charge Port Charging Dispenser Lamp Legend Lamp Color Description White Available to charge the vehicle. Solid - charging dispenser is plugged up but not communicating Green with the vehicle.
  • Page 135 Electrical, Instruments, and Controls 06/02/2020 f547237 A normal plug is yellow at the end; a contaminated plug does not appear yellow at the end. 1. Normal Salt Plug 2. Contaminated Salt Plug Fig. 7, Normal and Contaminated Salt Plugs 03/19/2020 f547139 1.
  • Page 136 Electrical, Instruments, and Controls 06/01/2020 f547231 Remove the salt plugs at each end of the battery pack desiccant chamber. 1. Salt Plug Fig. 9, Removing the Salt Plugs 4. Attach the hook end of a Jameson Glow Rod (or equivalent) to a straight section of rod. See Fig.
  • Page 137 Electrical, Instruments, and Controls 06/01/2020 f547234 The hooked end exits the other side of the battery pack. 1. Glow Rod 2. Hook Fig. 13, Pushing the Hooked End of the Rod Through the Desiccant Chamber 06/01/2020 f547226 1. Glow Rod (hook-end) NOTE: Two technicians are needed for the fol- 2.
  • Page 138 Electrical, Instruments, and Controls 06/01/2020 f547225 1. Desiccant Chamber 2. Battery Pack Desiccant Fig. 16, Ends of the Battery Pack Desiccant Tucked into the Desiccant Chamber 06/01/2020 f547227 Fig. 17, Applying Thread Sealant to the Salt Plugs 54/8 Walk-In Van Chassis Maintenance Manual, January 2022...

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