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BUSINESS CLASS M2 PLUS MAINTENANCE MANUAL
Models: M2 Plus
STI-522-1 (02/10/2023)
Published by
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.

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  • Page 1 BUSINESS CLASS M2 PLUS MAINTENANCE MANUAL Models: M2 Plus STI-522-1 (02/10/2023) Published by Daimler Trucks 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 Trucks 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 revision and editions without notice.
  • Page 4 © 2023–2023 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 Search results for both documents and service solutions can be narrowed by initially entering vehicle identification data. PartsProX PartsProX® is an electronic parts catalog system, showing the specified vehicle’s build record. I–1 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 6 Descriptions of Service Publications EZWiring EZWiring ™ makes Freightliner, Sterling, Western Star, Thomas Built Buses, and Freightliner Custom Chassis Corporation products’ wiring drawings and floating pin lists available online for viewing and printing. EZWiring can also be accessed from within PartsPro.
  • Page 7 Introduction Page Description For an example of a Business Class M2 Plus 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 8 83 ....Heater and Air Conditioner 88 ....Hood, Grille, and Cab Fenders I–4 Business Class M2 Plus Maintenance Manual, 02/10/2023...

  • Page 9: Table Of Contents

    Overview of Maintenance Operations ........... 00–05 Business Class M2 Plus Maintenance Manual, 02/120/2023...

  • Page 11: Determining Scheduled Maintenance Intervals

    60,000 miles (100 000 kilometers) annually with minimal city or stop-and-go operation. Examples of Schedule III usage are: • regional delivery that is mostly freeway miles • interstate transport 00/1 Business Class M2 Plus Maintenance Manual, 02/120/2023...
  • Page 12 129 000 Maintenance 5 (M5) every 160,000 257 000 For Schedule I vehicles equipped with an hourmeter, use maintenance intervals based on hours of operation rather than mileage. Table 1, Maintenance Schedules 00/2 Business Class M2 Plus Maintenance Manual, 02/120/2023...
  • Page 13 29,000 46 700 2900 30th 30,000 48 300 3000 31st 31,000 50 000 3100 32nd M1, M2, M3, M4, and M5 32,000 51 500 3200 Table 2, Maintenance Intervals for Schedule I 00/3 Business Class M2 Plus Maintenance Manual, 02/120/2023...
  • Page 14 300,000 483 000 31st 248,000 400 000 310,000 500 000 32nd M1, M2, M3, M4, and M5 256,000 412 000 320,000 515 000 Table 3, Maintenance Intervals for Schedules II and III 00/4 Business Class M2 Plus Maintenance Manual, 02/120/2023...
  • Page 15 • • • 35-01 Axle Lubricant Level Checking • • • • • 35-02 Axle Breather Checking • • • • • 35-03 Axle Lubricant Changing and Magnetic Plug Cleaning • • 00/5 Business Class M2 Plus Maintenance Manual, 02/120/2023...
  • Page 16 Mirror Folding Check • • 60-02 Aerodynamic Component Inspection • • • • • 83-01 Air Conditioner Inspecting • • • • • ¶ 83-02 HVAC Air Filter Replacing • • • 00/6 Business Class M2 Plus Maintenance Manual, 02/120/2023...
  • Page 17 Complete this procedure every 25,000 miles (40 200 km), 3 months, or 500 operating hours, whichever comes first. ¶ Replace the HVAC air filter at the recommended interval or every six months. Table 4, Maintenance Operations 00/7 Business Class M2 Plus Maintenance Manual, 02/120/2023...

  • Page 18: Initial Maintenance (Im) Operations

    31-01 Frame Fastener Torque Checking 32-02 Suspension U-Bolt Torque Checking 33-03 Draw Key Nut Torque Checking 33-06 All-Axle Alignment Check 47-01 Fuel Tank Band Nut Tightening Table 5, Initial Maintenance (IM) Operations 00/8 Business Class M2 Plus Maintenance Manual, 02/120/2023...

  • Page 19: M1 Maintenance Operations

    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 Plus Driver’s Manual. maintenance operations listed in the "Pretrip and M1 Maintenance Operations Maintenance Title of Maintenance Operation Operation No.
  • Page 20 M1 maintenance interval should be used as a general guideline; the actual frequency of filter element replacement will vary depending on cleanliness of the fuel station system. Table 6, M1 Maintenance Operations 00/10 Business Class M2 Plus Maintenance Manual, 02/120/2023...

  • Page 21: M2 Maintenance Operations

    CNG Fuel Cylinder Inspecting Petroleum-based lubricants only. † Schedule II vehicles only. ‡ The fuel cylinder should be inspected every year or 100,000 miles (161 000 km), whichever comes first. Table 7, M2 Maintenance Operations 00/11 Business Class M2 Plus Maintenance Manual, 02/120/2023...

  • Page 22: M3 Maintenance Operations

    46-01 Drag Link Inspecting 47-04 LNG Vacuum Integrity Testing 83-02 HVAC Air Filter Replacing Replace the HVAC air filter at the recommended interval or every six months. Table 8, M3 Maintenance Operations 00/12 Business Class M2 Plus Maintenance Manual, 02/120/2023...

  • Page 23: M4 Maintenance Operations

    Governor D–2A Check 46-02 Power Steering Fluid Changing 47-02 Fuel/Water Separator Element Replacing 54-01 Trailer Cable Inspection and Cleaning 54-02 Electrical Component Inspection 60-01 Mirror Folding Check Table 9, M4 Maintenance Operations 00/13 Business Class M2 Plus Maintenance Manual, 02/120/2023...

  • Page 24: M5 Maintenance Operations

    Bendix Air Dryer Desiccant Replacement 42-09 Bendix E-6 Foot Control Valve Inspection and Lubrication 42-12 WABCO System Saver Air Dryer Desiccant Cartridge Replacement 46-04 Power Steering Filter Changing Table 10, M5 Maintenance Operations 00/14 Business Class M2 Plus Maintenance Manual, 02/120/2023...

  • Page 25: Noise Emission Controls

    1. The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for 00/15 Business Class M2 Plus Maintenance Manual, 02/120/2023...
  • Page 27 Air Cleaner Element Inspection and Replacement ......... . 09–01 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 29 If the air cleaner housing or element is damaged, replace it. 4. Reset the air restriction indicator. 5. Each time the air cleaner housing is replaced, perform the procedures in Group 09/1 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 31 Safety Precautions ..............13–00 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 33 Tighten the connections and replace the lines and fasteners if needed. 3. For the air governor, inspect the piping and connections for leaks. Replace gaskets and faulty components as needed. 13/1 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 35 Safety Precautions ..............15–00 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 37 Plus Workshop Manual for troubleshooting alternator belt; check all of them for correct instructions, and for adjustment, repair, or tension. Adjust the belt tension if necessary. replacement instructions. 15/1 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 38 11. Check the terminals on the battery shut-off switch and the magnetic switch. Make sure the terminal connections are clean and tight. Coat the terminal connections with dielectric red enamel after cleaning. 15/2 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 39 Safety Precautions ..............20–00 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 41 Attach a flushing gun nozzle to the cooling system of the vehicle. Use the radiator outlet. recommended tool in Table Add water to the radiator until it is full. 20/1 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 42 Kysor. 4. Check for harness abrasion. 6. Any time the clutch is removed for repair or 5. Check for fluid leaks from the clutch body. replacement, the pulley hub and bearings should 20/2 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 43 M2 Plus Workshop Manual. If the fan clutch does not operate correctly, see 1. Disconnect the batteries at the negative Group 20 of the Business Class M2 Plus terminals. Drain all air from the air system. If Workshop Manual for troubleshooting and repair equipped with an air starter, drain the air starter procedures.
  • Page 44 If either the hub or sheave bearings are worn, replace them, using a Horton DriveMaster Super Kit. For instructions and kit part number, see Group 20 of the Business Class M2 Plus Workshop Manual. 20/4 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 45 Safety Precautions ..............25–00 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 47 (toward the Fig. 2, Grease the Contact Points transmission). 5. Install the clutch inspection plate. NOTICE 6. Remove the chocks. Do not over-lubricate the clutch release bearing. Over-lubrication could contaminate the clutch 25/1 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 48 8. Make sure the reservoir lid is tight. 6. Flush the hydraulic system. See Fig. 9. Lower the hood and remove the chocks from the Open the bleed screw on the slave front and rear tires. cylinder. 25/2 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 49 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. 3, Clutch Slave Cylinder 25/3 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 50 (12.7 and 14.3 mm). 1. Remove the clutch inspection cover from the bell NOTE: This procedure is only required for housing. See Fig. vehicles equipped with non-synchronized transmissions and manually adjusted clutches. 25/4 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 51 NOTE: An open-end wrench is not recommended for the following step. If the blue 0.56-inch (14.3-mm) end can’t be inserted in the gap, then try to insert the green 0.50-inch (12.7-mm) end. 25/5 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 52 (14.3 mm), turn the adjustment bolt clockwise (the release bearing moves toward the transmission). To increase the gap: If clearance between the release bearing housing and the clutch brake is less than 1/2 inch (12.7 25/6 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 53 Transmission Fluid Level Checking ........... . . 26–03 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 55 Remove the drain plug from the bottom of the case. See Fig. 3. Clean the fill plug and the drain plug. A. Full B. Low Fig. 2, Checking Transmission Fluid Level 26/1 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 56 B. Low 4. If needed, add the recommended fluid until it is level with the lower edge of the fill opening. See Fig. 3, Transmission Oil Level Checking the Transmission Fluid Service Information 26/2 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 57 fluid level to the middle of the COLD RUN band. Fig. 4. For approved Allison transmission • 25 to 35 lbf·ft (34 to 48 N·m) for Eaton lubricants, see Table Fuller transmissions with 3/4-inch pipe threads. 26/3 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 58 Check Remove the drain plug(s) from the gear that the sump temperature is 160 to 200°F (71 to case. 93°C). Check that the converter-out temperature is 180 to 220°F (82 to 104°C). 26/4 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 59 RTLO–14913A 14 (13.2) Table 4 for lubricant capacities. 18-Speed 2. Check and adjust the fluid level using the applicable Eaton Transmission fluid level RTLO–14918B 14 (13.2) checking procedure in Group 26/5 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 60 Fig. 6, Eaton Fuller Transmission Air Filter/Regulator Location 3. Remove the end cap, large O-ring, and filter element from the filter housing. See Fig. Remove the small O-ring from the end cap. 26/6 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 61 NOTE: A lot of fluid will drain when the filter is removed. 4. Using a standard strap-type filter wrench, remove the filter by turning it counterclockwise. 26/7 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 62 10. Align each cover assembly with the holes in the On-Highway Transmissions channel plate sump, and push the cover assemblies in by hand to seat the seals. 1000/2000/2400 Series (standard sump) 15 (14) 26/8 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 63 Do not use the bolts to draw the filter covers to the sump. This can damage the covers, seals, or sump. 11. Install six bolts in each cover, and torque the bolts 38 to 44 lbf·ft (51 to 61 N·m). 26/9 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 65 Trailer Electrical Connector Lubricating ..........31–04 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 67 Any component that shows signs of cracking or other 31–01 Frame Fastener Torque damage must be repaired or replaced. Refer to the Check Business Class M2 Plus Workshop Manual for repair or replacement information. Frame brackets and components secured with Huckbolt® fasteners do not require a torque check, 31–02 Fifth Wheel Inspecting...
  • Page 68 See Fig. 2. Replace any bent Fig. 3, Measuring Fifth Wheel Top Plate Lift or misaligned lever bar or operating rod. Level the fifth wheel plate to a horizontal position. 31/2 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 69 For torque Fig. 4, Holland Fifth Wheel Properly Closed specifications, see Group 00 in the Business 31–03 Fifth Wheel Lubricating Class M2 Plus Workshop Manual. Inspect all angles, plates, and brackets for cracks or other damage. Fontaine 10.
  • Page 70 Once inside the connector, the chloride-based chemicals corrode the brass 1. Pull Handle 3. Wedge terminals and create bridging between positive and 2. Jaw ground terminals. Fig. 5, Fontaine Fifth Wheel 31/4 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 71 1. Wash out any existing grease, dirt, and corrosion on the trailer connectors with electrical contact cleaner spray. 2. Grease the trailer connector with a lithium-based dielectric grease. 31/5 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 73 TufTrac Suspension Gen2 I-Bolt Torque Checking ......... . 32–03 Business Class M2 Plus Maintenance Manual, 02/10/2023...

  • Page 75: Safety Precautions

    If any of these conditions exist, replace the damaged parts. WARNING See Group 31 of the Business Class® M2 Plus Workshop Manual for instructions. Check all Do not replace individual leaves of a damaged leaf fasteners for tightness.
  • Page 76 1. Block the frame up enough to take the weight of the chassis off of the springs. Attempt to move the equalizer up and down, by using a pry bar between the top of the equalizer and the top of 32/2 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 77 Replace any worn parts. 6. Inspect the shock absorbers for oil leaks and worn rubber bushings. Replace the shock absorbers and/or rubber bushings if wear or damage is noted. 32/3 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 78 Failure to replace a damaged spring assembly could cause an accident resulting in Check that the ends of the equalizer beam are not property damage, serious personal injury, or lower in the beam hanger. death. 32/4 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 79 3/8 inch Lubricate the bolt threads with SAE 20 oil. (9.5 mm) in an unloaded condition. Tighten the 1/2–13 locknuts with hardened washers 85 lbf·ft (115 N·m). 32/5 Business Class M2 Plus Maintenance Manual, 02/10/2023...

  • Page 80: Suspension U-Bolt Torque Checking

    Check the U-bolt torque of both the front and rear fluid leaking from the shock absorber. Replace axles where applicable. the shock absorbers if any of these conditions are found. 32/6 Business Class M2 Plus Maintenance Manual, 02/10/2023...

  • Page 81: Tuftrac Suspension Gen2 I-Bolt Torque Checking

    Check the I-bolt torque of both the front and rear Stage 1: Hand-tighten axles, where applicable. Stage 2: 60 (81) 5/8–18 Stage 3: 200 (271) Stage 4: 180 to 230 (245 to 313) 32/7 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 82 Rear Axle with Shock Tighten in a diagonal pattern as shown in Fig. and Stabilizer Table 2, Axle Clamp I-Bolt Torque Values 02/24/2022 f321295 Fig. 9, Drum Brakes Torque Pattern (looking up) 32/8 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 83 Axles with Oil-Lubricated Hubs ............33–05 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 85 fittings are on the top and bottom kingpin 967, 971, and 975 Series Easy Steer sealed caps of the knuckle. front axles. Refer to the identification tag on the front of the axle beam. 33/1 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 86 5. Apply lubricant until new lubricant comes from areas. the thrust bearing seal and the upper shim pack. 1. Grease Fitting 6. Remove the chocks. Fig. 4, Sealed, Easy Steer Plus Kingpin Lubrication 33/2 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 87 For NOTE: Synthetic lubricants are not approved for instructions, refer to Group 33 of the Business tie rod end lubrication. Class® M2 Plus Workshop Manual. 33/3 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 88 Then center the cross tube between the stop 8. Check for proper installation of the tie rod end clamp to the cross tube. Make sure that the tie 33/4 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 89 See Section Some tie rod ends have no zerk fittings because 33.01, Subject 100 of the Business Class M2 Plus they are not greaseable. Do not install a zerk Workshop Manual for instructions.
  • Page 90 Drive Axle Alignment Checking Check the axle alignment, parallelism, and thrust angle measurements for the rear drive axles. Use the applicable procedure and specifications in Group 35 of the Business Class M2 Plus Workshop Manual. Toe-In Inspection 10/05/2016 f330082a For vehicle alignment to be accurate, the shop floor NOTE: B minus A equals toe-in.
  • Page 91 Group 33 of the • Hub/plug area is dirty, and water contaminated Business Class M2 Plus Workshop Manual. If corrections are needed, refer to Group 33 of the oil in the hub. Business Class M2 Plus Workshop Manual for •...
  • Page 92 If there is evidence of water contaminated oil in the hub, disassemble the effected axle end, clean, inspect, and reassemble the axle end. For instructions, refer to Group 33 of the Business Class M2 Plus Workshop Manual. 33/8 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 93 Safety Precautions ..............35–00 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 95 Check lubricant level when the axle is cold, or near room temperature. NOTE: Some Detroit axles have a small tapped and plugged hole near and below the housing oil fill hole. This smaller hole is for a lubricant 35/1 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 96 0–76–A –15°F (–26.1°C) and up 80W–90 0–76–D Hypoid Gear Oil API Service –40°F (–40°C) and up 75W–90 0–76–E Classification GL–5 –40°F (–40°C) to 35°F (2°C) 0–76–J –40°F (–40°C) and up 75W–140 0–76–L 35/2 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 97 Forward 30.2 (14.3) carrying capacity oxidize faster at temperatures RT–40–145P above 220°F (104°C), contributing to more rapid Rear 25.8 (12.2) lubricant deterioration. For this reason lubricants of 35/3 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 98 Magnets will After cleaning, install the drain plug(s) rapidly lose their effectiveness as and tighten to 30 lbf·ft (41 N·m). collected material bridges the gap between the two poles. 35/4 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 99 1. With the vehicle on a level surface, fill the axle housings to the bottom of the oil fill hole (in the carrier or housing) with lubricant. See Table 3 approved axle lubricants and see Table 4 Table 5 for axle capacities. 35/5 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 101 Wheel Nut Checking..............40–01 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 103 3000 to 10,000 miles (5000 to 16 000 km) for abnormal wear. Maintain the proper pressures for carried loads, per the tire manufacturers’ recommendations, or the tire pressure label on the driver’s door. 40/1 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 105 Safety Precautions ..............41–00 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 107 If there is any movement, bearing defects. replace the universal joint. For instructions, see ™ Fig. 1 for an illustration of the ArvinMeritor Group 41 of the Business Class M2 Plus Full-Round driveline. See Fig. 2 for an illustration of Workshop Manual. ™...
  • Page 108 (NLGI Grade No. 2, Lithium 12-Hydroxy Stearate with Molybdenum Disulfide) Shell Moly Poly Grease Kendall L424 Grease Amoco Super Chassis Grease Ford Specification M1C–75B or part number PN ™ C1AZ 19590 Table 1, Approved Lubricants 41/2 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 109 Driveline 09/19/2001 f410485 Fig. 4, Lubrication Areas for Full-Round and Easy Service Drivelines 41/3 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 111 WABCO System Saver Air Dryer Desiccant Cartridge Replacement ......42–12 Business Class M2 Plus Maintenance Manual, 02/10/2023...

  • Page 113: Air Brake System Valve Inspection

    12. Lubricate the O-rings with silicone or lithium slowly. grease and install them in the end cover. 3. Identify, tag, and disconnect the three air lines from the end cover. 42/1 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 114 24 lbf·ft (23 to 33 N·m). See Fig. NOTE: Desiccant cartridge torque should not 17. Install the air dryer on the lower mounting exceed 50 lbf·ft (68 N·m). bracket. Install the two previously marked bolts, 42/2 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 115 If any air flush on the end cover. leaks are present, see Group 42 of the Business Class® M2 Plus Workshop Manual for diagnosis NOTE: It may be necessary to rotate the and repair information.
  • Page 116 If the pressure settings of the D-2 4. On the new desiccant cartridge, lubricate the governor are inaccurate or it’s necessary that sealing rings with silicone grease. they be changed, the adjustment procedure follows. 42/4 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 117 Unless exposure can be reduced below legal limits, wear an air purifying respirator approved by MSHA or NIOSH at all times when servicing the brakes, starting with removal of the wheels and continuing through assembly. 42/5 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 118 Q Plus brake system, the For operating temperatures between –20°F (–29°C) camshaft bracket will not have a grease fitting. and –40°F (–40°C), use Lubriplate Aero grease. These camshafts use a special NLGI grade 42/6 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 119 1. 7/16-Inch Adjusting 6. Clevis See Group 42 of the Business Class M2 Plus 7. 1/2-Inch Clevis Pin Workshop Manual for grease seal replacement 2. Grease Fitting 8. 1/4-Inch Clevis Pin instructions.

  • Page 120: Air Dryer Ad-9, Ad-Ip, Ad-Is/Drm Check

    For procedures. An extended-warranty may be service and lubrication instructions, see Group voided if intrusive maintenance is performed 42 of the Business Class M2 Plus Workshop during this period. Manual. Because no two vehicles operate under identical For slack adjusters with grease fittings and for...
  • Page 121 Incorrect pressure protection Thermostat and Heater Assembly valve settings can result in automatic application Operation: These tests are not possible except in cold-weather operation. Turn off the ignition switch, and cool the 42/9 Business Class M2 Plus Maintenance Manual, 02/10/2023...

  • Page 122: Bendix E-6 Foot Control Valve Inspection And Lubrication

    (the See Group 42 of the Business Class M2 Plus area from which the pivot pin was removed). Workshop Manual for repair procedures.
  • Page 123 3. Remove all of the wheel assemblies. For Caliper Brake Bolt Torque Adaptor instructions, seeGroup 40 of the Business Class M2 Plus Workshop Manual for repair procedures. NOTE: In all steps that require a torque wrench, use a Snap On torque wrench ATECH4RS600, or an equivalent, with a center to handle length of 47 inches (119 cm).
  • 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 Business Class M2 Plus 3. Remove all of the wheel assemblies. For Workshop Manual for repair procedures.
  • Page 125 5. Install the wheel assemblies. For instructions, 5. Install the wheel assemblies. For instructions, seeGroup 40 of the Business Class M2 Plus see Group 40 of the Business Class M2 Plus Workshop Manual for repair procedures. Workshop Manual for repair procedures.
  • Page 126 Fig. 13, Meritor Radial Mounted Caliper Tightening Pattern 5. Install the wheel assemblies. For instructions, components. Improperly maintaining the vehicle see Group 40 of the Business Class M2 Plus braking system may lead to brake failure, Workshop Manual for repair procedures.
  • Page 127 See Group 42 of the Repair as needed. See Group 42 of the vehicle workshop manual for inspection and Business Class M2 Plus Workshop Manual for troubleshooting procedures. repair procedures. 42/15...
  • Page 128 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 Business Class M2 Plus Maintenance Manual, 02/10/2023...

  • Page 129: Hydro-Max

    See cartridge. When replacing the desiccant cartridge, Group 42 of the Business Class M2 Plus it is very important to use the same type of Workshop Manual for replacement instructions, cartridge that was originally installed on the dryer.

  • Page 130: Versajust Slack Adjuster Inspection And Lubrication

    6. Thread the desiccant cartridge onto the dryer Recommended Maximum base (turn clockwise). When the seal contacts Brake Actuator Size Operating Stroke (Inches) the base, tighten the cartridge one complete turn more. Do not overtighten. 42/18 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 131 Table 3, Actuator Stroke–Standard Stroke Actuator Stroke–Long Stroke Recommended Maximum Brake Actuator Size Operating Stroke (Inches) 30 Long Stroke 2-1/2 24 Long 24 Long Stroke 2-1/2 20 Long 16 Long Table 4, Actuator Stroke–Long Stroke 42/19 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 133 Safety Precautions ..............46–00 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 135 If the ball stud end is loose, replace the drag link. If the ball stud nut is loose, replace the nut and cotter key. See Group 46 of the Business Class® M2 Plus Workshop Manual for drag link removal and installation instructions.
  • Page 136 14. Remove the chocks from the tires. 46–04 Power Steering Filter Changing 1. Apply the parking brakes and chock the rear tires. 2. Raise the front of the vehicle and support it with jack stands. 46/2 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 137 fluid level between the MIN COLD and MAX HOT lines. See Table 1 for approved power steering fluids. 9. Raise the vehicle and remove the jack stands, then lower the vehicle. 10. Remove the chocks from the tires. 46/3 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 139 Safety Precautions ..............47–00 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 141 The only maintenance necessary on an Alliance fuel/water separator is to replace the filter element. 3. Remove the element and bowl together, by turning counterclockwise. 4. Remove the bowl from the element and clean the O-ring gland. 47/1 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 142 47/2 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 143 10. Cover O-Ring 4. Inlet Port/Check Valve 11. Clear Cover 5. Lower Housing 12. Vent Cap O-Ring 6. Bypass Valve 13. Vent Cap 7. 12VDC Pre-Heater 14. Collar Fig. 2, DAVCO Fuel Pro 487 47/3 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 144 Chapter 16 of the Business If returning fuel is released into the atmosphere, Class® M2 Plus Driver’s Manual or Group 47 of its vapors can ignite in the presence of any the Business Class M2 Plus Workshop Manual.
  • Page 145 2. Inspect the fuel fill line for signs of damage, other signs of damage. Inspect the bottom of the kinked or crushed piping, or chafing. tank for deep scratches, flat spots, or gouges. 47/5 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 146 7. Repair or replace any leaking or damaged Fuel Level Sender Component vaporizer components. Inspecting 1. Inspect the fuel level sender wiring harness for signs of loose connections or damage. Look for cracking or signs of moisture intrusion. 47/6 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 147 Chapter 16 of the Business 4. Check for a large variance in temperatures Class M2 Plus Driver’s Manual or Group 47 of the between the fuel tank and the fuel tank shroud. A Business Class M2 Plus Workshop Manual.
  • Page 148 1. Inspect the fuel cylinders for dents or other signs precautions listed in Chapter 16 of the Business of damage. Class M2 Plus Driver’s Manual or Group 47 of the Replace any leaking fuel cylinders. Business Class M2 Plus Workshop Manual.
  • Page 149 6. Slowly open the bleed valve on the manifold to 8. Replace leaking or damaged fuel lines. Repair or relieve remaining fuel pressure within the replace leaking or damaged fittings. system. See Fig. 47/9 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 150 fill panel. 10. Inspect the O-ring on the filter housing for damage or cracks. If necessary, replace the O-ring. 11. Install the filter bowl on the filter housing. Tighten 90 lbf·ft (122 N·m). 47/10 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 151 Installations, for inspection requirements and inspector qualifications. For more information, go to www.cganet.com. After inspection, an accurate and reliable written report should be provided for each container inspected. Place an inspection label stating the 47/11 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 153 Safety Precautions ..............49–00 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 155 4, ref. A. Measurement Attach the aft CGI pipe to the ATD. A should be at least 7/16 inch (10 mm) past the face of the flange. Attach the forward CGI pipe to the engine. 49/1 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 156 15. Secure the forward CGI pipe to the engine and Tighten any clamps as needed. any CGI pipe support brackets. 16. Using the yellow marks, center the bellows between the exhaust pipes. Verify that the pipe is 49/2 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 157 2. CGI Bellows Fig. 4, CGI Bellows Installation 02/08/2010 f490417 1. CGI Bellows 4. Graphite Gasket 2. Slip Clamp 5. Forward CGI Pipe 3. Retaining Ring Fig. 5, Forward Facing Slip Clamp Installation 49/3 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 159 Trailer Cable Inspection and Cleaning........... 54–01 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 161 The cover Inspect connector terminals for signs of must prevent moisture and debris from entering corrosion, thermal distortion, warping, the components protected area. Missing, leaking, discoloration, high amperage heating or 54/1 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 162 Inspect fuses and relays for signs of corrosion, thermal distortion, warping, discoloration, and high amperage heating or discoloring. If loose or corroded, remove, inspect, clean, and replace as needed. 13. Connect the batteries. 54/2 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 163 Mirror Folding Check ............. . . 60–01 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 165 These may include: • chassis fairings • battery access kickplate • side skirts • cab side extenders • roof fairing/deflector • bumper • hood Replace or repair damaged or missing components as needed. 60/1 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 167 Safety Precautions ..............83–00 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 169 3. Disconnect the wiring harness from the assembly. For instructions, see Group 83 of the evaporator probe. Business Class® M2 Plus Workshop Manual. If 4. Remove the capscrews that attach the the compressor does not turn freely, replace the evaporator service cover to the HVAC assembly.
  • Page 170 See Fig. 10/04/2001 f543921 1. Evaporator 2. Filter Fig. 2, HVAC Assembly Filter 7. Remove the condensate seal from the evaporator service cover and install a new condensate seal on the cover. 83/2 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 171 Hood Rear Support Lubrication............88–01 Business Class M2 Plus Maintenance Manual, 02/10/2023...
  • Page 173 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 Business Class M2 Plus Maintenance Manual, 02/10/2023...

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