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Shuttle Bus Chassis Maintenance Manual

1. 06 25 97 1470147 1 Mounting Head 7 Water Sensor Probe 2 Fuel Primer Pump 8 Heater Connector 3 Vent Plug 9 Drain Plug 4 Bowl O Ring 10 Sight Bowl 5 Bowl Gasket 11 Filter Element 6 Bowl Probe Plug Fig 1 Alliance Fuel Water Separator 7 Connect the water sensor and heater connectors if equipped 8 If equipped with a primer pump prime the fuel water separator 8 1 Loosen the vent plug Then operate the primer pump until the fuel purges at the vent plug 8 2 Close the vent plug 9 Start the engine and check for fuel leaks 10 Shut down the engine and correct any fuel leaks Davco Fuel Pro 232 and 233 Replace the fuel water separator element shown in Fig 2 only when the filter element is completely covered Shuttle Bus Chassis Maintenance Manual August 2013 47 1 47 Fuel 1 2 Bem UN TA L d 4 9 tr uf J 5 10 6 l1 Cy 11 12 7 NG lu c Y Y 10 16 2001 gel ULLUS T 1470415 1 Filter Vent 6 Filter Spring 10 Check Valve Fuel Inlet 2 Vent Seal 7 Filter Element 11 Drain 3 Filter Collar 8 Temporary Filter Stud 12 Electric Filter Preheater 4 Filter Cover 9 Fuel Outlet optional 5 Cover Seal Fig 2 Davco Fuel Pro 232 and 233 Diesel fuel is flammable and can ignite if exposed to an open flame intense heat or other ignition source Do not drain fuel near or expose fuel vapor to open flame or intense heat
2. Maintenance Interval Table Maint No Maint Oper Category Category Il et miles x 100 km x 100 months miles x 100 km x 100 months 1st IM Mi 25 40 3 50 80 3 2nd M1 50 80 6 100 160 6 3rd M1 75 120 9 150 240 9 4th M2 100 160 12 200 320 12 5th M1 125 200 15 250 400 15 6th M1 150 240 18 300 480 18 7th M1 175 280 21 350 560 21 8th M2 200 320 24 400 640 24 9th M1 225 360 27 450 720 27 10th M1 250 400 30 500 800 30 11th M1 275 440 33 550 885 33 12th M3 300 480 36 600 965 36 Shuttle Bus Chassis Maintenance Manual November 2014 00 3 00 General Information Maintenance Operation Sets 00 04 NOTE Maintenance operations appearing in italics in this table are for noise emission control components Numbers in this table are maintenance operation ref erence numbers matching those in the text of this manual REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 Maintenance Operation Reference Number and Maintenance Operation 01 01 Engine Support Fasteners Checking Noise Emission Control 01 02 Engine Drive Belt Inspecting e je 09 01 Air Cleaner Inspecting and Replacing e jo 09 02 Air Intake System Inspecting e o o o 13 01 Air Compressor Inspection o o o o 15 01 Alternator Battery and Starter Connections Check o o 20 01 Radiator Cap Check o o 20 02
3. Shuttle Bus Chassis Maintenance Manual June 2008 Steering 46 01 Steering Driveline Lubricating Wipe the grease fittings clean Using a pressure gun apply a lithium based grease NLGI grade 2 to the universal joints and slip joint splines 46 02 Drag Link Lubricating 1 Using a clean rag wipe the dirt from both grease fittings on the drag link See Fig 1 10 05 94 1460926 1 Grease Fitting 2 Drag Link pitman arm end shown Fig 1 Steering Drag Link Lubricating 2 Using a pressure gun apply multipurpose chas sis grease at the grease fittings until old grease is forced out of the socket NOTE Use multipurpose chassis grease NLGI grade 1 696 12 hydroxy lithium stearate grease or NLGI grade 2 8 12 hydroxy lithium stear ate grease The grade 2 chassis grease is pre ferred 46 46 03 Power Steering Reservoir Fluid Level Checking 1 Clean around the power steering reservoir dip stick fill cap with a clean rag then remove the dipstick See Fig 2 10 05 94 ad 1 Power Steering Fluid Reservoir 2 Steering Gear 1460514a Fig 2 Power Steering Reservoir Fill only with approved clean fluid Do not mix fluid types Any mixture or any unapproved fluid could lead to seal deterioration and leaks Fluid leakage could cause loss of power steering assist possibly resulting in personal injury and property damage 2 With the power
4. 1 Pinion Shaft 2 Breather Fill Plug 3 Oil Level Plug 4 Drain Plug 5 Cross Shaft Fig 3 Mechanical Fan Drive Gearbox 4 Remove the oil level plug See Fig 3 5 Flush the fan drive gearbox with an approved nonflammalbe nontoxic solvent such as e Lubriplate Syn Flush e Lubriplate Pure Flush e Whitmore s Flushing Oil e Medallion Flushing Oil Kosher 6 Using degreaser clean the thread on the drain hole and drain plug 7 Install the drain plug 20 8 Fill the fan drive gearbox with Mobil amp Delvac 75W 90 lubricant until the lubricant starts to come out of the oil level plug hole 9 Using degreaser clean the thread on the oil level and fill holes and both plugs 10 Install the plugs making certain that the breather fill plug is used in the fill plug hole 20 05 Mechanical Fan Drive Gearbox Lubrication U Joint Lubrication 1 Wipe all old grease and dirt from each U joint grease fitting 2 Use a hand type grease gun or a high pressure gun with a low pressure adaptor to lubricate the U joints See Fig 4 NOTE If a low pressure adaptor is not used with the high pressure gun the U joints may not receive enough lubricant 3 Using lithium 12 hydroxy stearate grease NLGI grade 2 with EP additives and meeting ASTM D4950 LB specifications lubricate until new grease can be seen at both U joint seals NOTICE Fresh lubricant must be seen escaping from both of the be
5. 9 Inspect the lubricant for the presence of foreign matter Use a magnet to detect any metallic ma terials present in the lubricant If the lubricant is contaminated service the hub See the Shuttle 33 Bus Workshop Manual and manufacturer litera ture for procedures 10 Rotate the hub and check for free smooth and quiet rotation If rotation is hampered service the hub immediately See the Shuttle Bus Workshop Manual and manufacturer literature for proce dures Correct wheel bearing end play is crucial to the safe and sound operation of the vehicle If the end play is not correct the wheel bearings could fail and cause the loss of the wheel and hub assem bly and result in an accident causing property damage serious injury or death Use a dial indica tor to measure the end play IMPORTANT Do not measure the wheel bear ing end play with the wheel mounted on the hub you cannot accurately measure or adjust bearing end play with the wheel mounted on the hub Also ensure that the brakes are not ap plied so that that drum and hub can move freely 11 Using a dial indicator measure the end play as follows 11 1 Attach the magnetic base of a dial indica tor to the end of the spindle and place the measuring end of the indicator against the hub cap mounting flange See Fig 8 IMPORTANT Maintain continual pressure on the hub until you have taken both the in board and outboard measurements If you release the h
6. FREIGHTLINER Y Maintenance Manual STI 472 6 A24 01452 000 zT SHUTTLE BUS CHASSIS MAINTENANCE MANUAL Models MBC STI 472 6 11 14 XBP XBR XBS Published by Daimler Trucks North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A Foreword Scheduled maintenance provides a key element for safe operation of your vehicle A proper maintenance program also helps to minimize downtime and to safeguard warranties This mainte nance manual provides information necessary for years of safe reliable and cost efficient vehicle operation IMPORTANT The maintenance operations in this manual are not all inclusive Also refer to other component and body manufacturers instructions for specific inspection and mainte nance instructions Perform daily pre trip inspection and maintenance as outlined in the vehicle operators manual Perform the operations in this maintenance manual at scheduled intervals based upon distance traveled or months of operation Your authorized servicing dealer has the qualified technicians and equipment to perform this maintenance for you Your dealership can also set up a scheduled maintenance program tailored specifically to your needs Optionally your dealership can assist you in learning how to perform the maintenance procedures in this manual IMPORTANT Descriptions and specifications in this manual were in effect at the time of printing Freightliner Custom Chassi
7. Table 2 Detroit Drive Axle Lubricant Capacities Meritor Axles Axle Draining and Flushing 1 Remove the plug at the bottom of the housing and drain the lubricant while the unit is warm See Fig 2 for an example of the rear axle differ ential on an MB Shuttle Bus and Fig 3 for an example of the axle housing on an XB Shuttle Bus Allow enough time for all of the old lubricant to drain completely 2 Flush the unit with clean flushing oil then drain it completely IMPORTANT Do not flush axles with solvent such as kerosene 3 Clean the drain plugs For magnetic drain plugs a piece of key stock or any other convenient steel slug may be used to short the two magnetic poles and divert the magnetic field NOTE Meritor recommends using magnetic plugs with elements having a minimum pickup capacity of 2 pounds 1 kg of low carbon steel in plate or bar form Magnets will rapidly lose effectiveness as collected material bridges the gap between the two poles Clean or change the plugs before this occurs It may be neces sary to clean or change the plugs one or more times between lubrication change intervals 4 After cleaning the drain plugs install and tighten them 35 Ibf ft 47 N m Shuttle Bus Chassis Maintenance Manual August 2013 35 3 35 Axle Filling 1 With the vehicle on a level surface fill the axle housing to the bottom of the oil fill hole in the carrier or housing with an SAE 80W 90 multi purpo
8. 1 Drain the fuel below the collar level See Fig 3 2 Using Davco wrench 380134 or 382002 remove the filter collar Then remove the filter cover 3 Remove the element and dispose of it properly 4 Install a new element Make sure the grommet is in place on the filter stud 5 Install a new cover seal on the filter cover 6 Using the collar attach the filter cover with the spring to the base IMPORTANT Tighten the collar by hand only 7 Remove the filter vent Then fill the fuel water separator with fuel until the fuel level is 1 inch 2 5 cm above the collar 8 Install the filter vent on the fuel water separator 9 Start the engine and raise the rpm for one min ute to purge air 47 47 03 CNG Fuel Block Housing Draining Compressed natural gas is highly flammable See the safety precautions listed in Chapter 8 of the Shuttle Bus Chassis Operator s Manual or Group 47 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Failure to observe these precautions could lead to the ignition of the natural gas which could cause severe bodily harm or death or property damage Shut off the fuel supply at the fuel tanks Vent the system Remove the drain nut at the bottom of the engine internal fuel filter which is mounted on the left hand side of the engine See the engine manufacturer s operation and mainte nance manual for further information 47
9. Midland e o 42 17 Air Dryer Desiccant and Coalescent Filter Replacing Midlandtt 42 18 Air Actuated Parking Brake Cable Checking and Adjusting e o o 0 42 19 Brake Inspection o je 46 01 Steering Driveline Lubricating o je 46 02 Drag Link Lubricating o je 46 03 Power Steering Reservoir Fluid Level Checking e 0 o 0 46 04 Power Steering Reservoir Fluid and Filter Changing 46 05 Steering Gear Lubricating e o o o 47 01 Diesel Fuel Tank Draining and Vent Checking o o 47 02 Fuel Water Separator Element Replacing e o 47 03 CNG Fuel Block Housing Draining e o o 0 47 04 CNG Fuel Leak Testing e o o 0 Shuttle Bus Chassis Maintenance Manual November 2014 00 5 00 General Information Maintenance Operation Sets 00 04 REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 Maintenance Operation Reference Number and Maintenance Operation 47 05 CNG Fuel Tank Visual Inspecting83 47 06 CNG High Pressure Fuel Filter Replacing e o o o 47 07 CNG Low Pressure Fuel Filter Replacing e o o o 47 08 Inline Fuel Strainer Replacing Cummins Engine 49 01 Exhaust System Inspecting Noise Emission Control e o o o 54 01 Ground Cables Checking and Cleaning e e 54 02 Battery Voltage Checking o o o o 83 01 Air Conditioner Checking R 134a Refrigerant System e o o o Inspect the air filter every 6 months Replace the air filter every 12
10. Preliminary Checks 1 Park the vehicle on a level surface shut down the engine apply the parking brake and chock the tires 2 Make sure that the refrigerant compressor drive belt is not damaged and that it is correctly ten sioned Also check the tightness of the compres sor mounting fasteners For instructions and torque values see Group 01 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 3 Using a feeler gauge check for correct clutch clearance For instructions see Group 83 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 4 Inspect the compressor clutch coil wire Check the connector for damage or looseness Replace the wire if it is damaged 5 Check for broken burst or cut hoses Also check for loose fittings on all parts Wear eye protection when using compressed air to clean parts as permanent harm to eyes could result from flying debris 6 Check for a build up of road debris on the con denser fins Using a whiskbroom and air pres sure or a spray of soapy water carefully clean off the condenser be careful not to bend the fins Cooling Checking 1 Start the engine and set engine speed at 1500 rpm Close the doors and windows IMPORTANT When outside temperature and humidity are high it will take longer to cool the interior especially if fresh air vents are left open 2 Turn on the air c
11. Tighten the filter housing Turn the fuel supply on at the tanks 47 07 CNG Low Pressure Fuel Filter Replacing Compressed natural gas is highly flammable See the safety precautions listed in Chapter 8 of the Shuttle Bus Chassis Operator s Manual or Group 47 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Failure to observe these precautions could lead to the ignition of the natural gas which could cause severe bodily harm or death or property damage drain 1 Shut off the fuel supply at the tanks 2 Vent the fuel supply system 3 After the system has been vented remove the filer bowl See Fig 5 Using a 26 mm wrench remove the bowl nut Then remove the bowl the element retainer and the filter element NOTE Be sure that the O ring is positioned properly inside of the filter head 4 Install the new element the element retainer the bowl and the bowl nut 5 Turn the fuel supply on at the tanks 47 08 Inline Fuel Strainer Replacing Cummins Engine NOTE Vehicles with a Cummins engine have an inline fuel strainer located on the left hand side of the engine 1 Remove the tie bands that secure the fuel strainer 47 6 Shuttle Bus Chassis Maintenance Manual August 2013 Fuel 1 3 4 2 5 08 23 96 1470238 1 Fuel Filter Head 4 Filter Bowl 2 Filter Element 5 Bowl Nut 3 Element Retainer Fig 5 CNG Low Pre
12. Workshop Manual or take the vehicle to an autho rized Freightliner dealer Shuttle Bus Chassis Maintenance Manual June 2008 83 1 83 12 16 93 Y Y 1 Moisture Indicator Sight Glass 2 Receiver Drier Sight Glass f250177b Fig 1 Receiver Drier 83 2 Heater and Air Conditioner Shuttle Bus Chassis Maintenance Manual June 2008
13. bottom cam roller 6 Lift the top brake shoe and then by pulling on the roller retaining clip remove the top cam roller 7 Clean the rollers retaining clips and the roller pin recesses in the brake shoes thoroughly 4h CAUTION Do not apply grease to the outer diameters of the rollers where they contact the cam head 8 Apply a good quality multipurpose chassis grease to the retaining clips brake spider and the shoe rollers where they contact the brake shoes 42 10 Shuttle Bus Chassis Maintenance Manual August 2013 Brakes 9 One at a time pull each brake shoe away from the cam and install the top and the bottom shoe rollers 10 Install the brake drums and the wheels Do not operate the vehicle until the brakes have been adjusted and checked for proper operation To do so could result in inadequate or no braking ability which could cause personal injury or death or property damage IMPORTANT See the slack adjuster manufac turer s service information and adjust the brakes at the slack adjusters 11 Remove the safety stands lower the vehicle and remove the chocks from the tires 12 In a safe area drive the vehicle and check for proper brake operation 42 16 Air Dryer Inspecting Midland 1 Check the reservoirs for moisture A small amount a teaspoon or less is normal Larger amounts may mean that the desiccant needs to be replaced Check the mounting and connecting lines 2
14. Axle 09 06 96 f320032a Pump lubricant into each grease fitting until fresh grease comes out at A 1 Grease Fitting Fig 3 Meritor Axle Grease Fittings during lubrication Even if grease leaks out around the top or bottom plate continue pump ing until new grease is seen at the seal on the bushing opposite the grease fitting When lubricating knuckle pin bushings at M1 through M3 do not raise the front axle Wipe the lube fittings clean and apply multipurpose chassis grease until new grease is seen at the grease seal on the bush ing opposite the fittings 33 02 Tie Rod End Lubricating For any Detroit or Meritor axle that requires lubrica tion of the tie rod ends wipe the grease fittings clean then pump multipurpose chassis grease NLGI Grade 1 696 12 hydroxy lithium stearate grease or NLGI Grade 2 8 12 hydroxy lithium stearate grease into the tie rod ends until all used grease is forced out and fresh grease is seen at the ball stud neck See Fig 4 33 03 Tie Rod End Inspecting IMPORTANT DOT roadside tie rod assembly replacement criteria specifies that if tie rod end play is 1 8 inch 3 mm or greater measured on the road the vehicle must be taken out of ser TM 06 12 2012 f330273 NOTE No grease should emit from the tie rod boot If grease emits from the tie rod boot the boot is dam aged 1 Grease Fit
15. CAUTION An accumulation of road salt dirt and debris on the antilock braking system ABS tone rings and sensors can cause the ABS warning light to illumi nate IMPORTANT During winter months in areas where corrosive materials are used on the high ways periodically clean the underside of the vehicle to ensure proper ABS functioning Thor oughly clean the wheel ABS sensor tone ring areas removing all corrosive materials Brakes 42 15 Drum Brake Shoe Roller Lubricating Breathing brake lining dust asbestos or non asbestos could cause lung cancer or lung dis ease 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 1 Park the vehicle on a level surface Shut down the engine set the parking brake and chock the tires 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 3 Remove the wheels and the brake drums 4h CAUTION Before you back off automatic slack adjusters see the slack adjuster manufacturer s service informa tion for instructions Failure to do so could result in damage to the slack adjusters 4 Back off the slack adjusters 5 Push down on the bottom brake shoe and then by pulling on the roller retaining clip remove the
16. Electrical Instruments and Controls 54 01 Ground Cables Checking and Cleaning Check that the ground cables are clean undamaged and tight If necessary disconnect them and clean the mating surfaces with a soda solution Then con nect them securely Spray the ground cable connec tions with dielectric red enamel See Table 1 for ap proved protectants Approved Dielectric Protectants Protectant Material Approved Brand Dielectric Grease Lubriplate FLP DS ES 3M 1602 IVI Spray Sealer order Dielectric Red Enamel from the PDC Spray On Application P m Spray On B 6 665 Glyptal 1201EW Low VOC Red Dielectric Red Enamel nbn order at www glyptal com or Brush On Application 1 800 GLP 1201 Table 1 Approved Dielectric Protectants 54 02 Battery Voltage Checking Check the battery open circuit voltage using an accu rate voltmeter If the voltmeter registers 12 5V or below fully charge the battery to 12 65V A fully charged battery will have a voltage of 12 65V with the charger disconnected 54 Shuttle Bus Chassis Maintenance Manual June 2008 54 1 Heater and Air Conditioner 83 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Conditioner Checking R 134a Refrigerant System llli ee 83 01 Shuttle Bus Chassis Maintenance Manual June 2008 Heater and Air Conditioner 83 01 Air Conditioner Checking R 134a Refrigerant System
17. Fig 2 and Fig 3 Rear Axle 35 4 Shuttle Bus Chassis Maintenance Manual August 2013 Wheels and Tires 40 Index Alphabetical Title of Maintenance Operation MOP MOP Number Wheel Nutr Ceci aio os ences toast d i o ahd eiie i aod mina te re tad peto ei it or eite 40 01 Shuttle Bus Chassis Maintenance Manual June 2008 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 The vehicle should be taken to a Freightliner dealer to ensure that the wheel nuts are tightened correctly 4h CAUTION Too little wheel nut torque can cause wheel shimmy resulting in wheel damage stud break age and extreme tire tread wear Too much wheel nut torque can break studs damage threads and crack discs in the stud hole area For hub piloted 8 and 10 stud wheels torque val ues vary with the stud size See Fig 1 for the tight ening sequence of hub piloted 8 and 10 stud wheels Before tightening apply 2 drops of SAE 30W oil to a point between the nuts and flanges Tighten the wheel nuts IMPORTANT The vehicle should be taken to a Freightliner dealer to ensure that the wheel nuts are tightened correctly e On 8 stud or 10 stud hub pilot hubs with 20 mm studs tighten the wheel nuts 280 to 310 Ibf ft 380 to 420 N m For the corre
18. Level Checking lille 35 Index Alphabetical MOP Number Shuttle Bus Chassis Maintenance Manual August 2013 Rear Axle 35 01 Axle Lubricant Level Checking 35 NOTICE Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage NOTE If the vehicle is exposed to water deep enough to cover the hubs disassemble and in spect them for water damage and or contamina tion See Group 35 of the Shuttle Bus 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 2 If the vehicle has just been driven allow a few minutes for the lubricant to settle 3 Clean the fill plug and the area surrounding the fill plug on the side of the axle carrier Remove the plug Check lubricant level when the axle is cold or near room temperature See Fig 1 for a Detroit axle or Fig 2 or Fig 3 for a Meritor axle NOTE Some axles have a small tapped and plugged hole located near and below the hous ing oil fill hole This smaller hole is for the lubri cant temperature sensor only and must not be used as a fill or level hole 4 Check that the lubricant is level with the bottom of the fill hole See Fig 4 If low check for oil leaks and correct as needed Add oil to the level of the fill plug For a Detro
19. Rod End Nut Detroit Axle Tie Rod End Clamp Nut Thread Torque Ibf ft N m 1 213 35 to 45 47 to 61 5 8 11 40 to 60 54 to 81 5 8 18 50 to 64 73 to 87 3 4 10 155 to 175 210 to 237 Table 2 Detroit Axle Tie Rod End Clamp Nut Shuttle Bus Chassis Maintenance Manual August 2013 33 3 33 33 04 Wheel Alignment Checking Front Axle See Group 33 of the Shuttle Bus Chassis Workshop Manual for wheel alignment checking and adjusting procedures or take the vehicle to an authorized Freightliner dealer 33 05 Oil Filled Hubs Oil Level Checking Be careful not to overfill the hubs Overfilling may cause oil to be forced out of the hubs and to con taminate the brake linings and other brake compo nents This could result in loss of vehicle control and lead to personal injury and property damage 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 3 If necessary remove the filler caps in the ends of the hub caps and add enough oil 80 90 hy poid gear oil to bring the oil to the proper level 4 Rotate the wheels allow the oil to settle and check the levels again 5 Install the filler caps securely 6 Remove the chocks from the tires 33 06 Oil Filled Hubs Oil Changing Be carefu
20. Tighten the fasteners attaching the air dryer to the vehicle Use the following torque values 28 Ibf ft 38 N m for SAE grade 5 3 8 16 fas teners 135 Ibf ft 183 N m for SAE grade 5 5 8 11 fas teners Check all air lines fittings and electrical connec tions for damage leakage or looseness 3 Replace damaged or leaking parts and tighten loose fittings or electrical connections 42 42 17 Air Dryer Desiccant and Coalescent Filter Replacing Midland NOTE Desiccant change intervals may vary from vehicle to vehicle Typical desiccant car tridge life is three years However if experience has shown that extended or shortened life has resulted on a particular installation then the in terval can be increased or decreased accord ingly For air dryer desiccant and filter replacement order either kit DQ6022 or kit DQ6026 The DQ6022 kit contains 1 desiccant cartridge 1 coalescent filter and 2 O rings The DQ6026 kit contains 1 desiccant cartridge 1 coalescent filter and a heater cover Fol low the replacement procedure below Heplacement 1 Park the vehicle on a level surface Shut down the engine set the parking brake and chock the tires 2 Completely drain all air reservoirs Air pressure gauges should read 0 psi 0 kPa 3 Loosen the desiccant cartridge with a strap wrench at the base of the cartridge Spin off the cartridge and discard it 4 Remove the O ring from the threaded neck and dis
21. again and note the level of restriction on the indi cator A decrease from the previous level of restric tion or a very low air restriction indicator reading 0 to 4 inH5O could indicate an air intake system prob lem such as a damaged air filter loose or discon nected air intake piping or a disconnected or dam aged air restriction indicator H20 VACUUM IN H20 VACUUM 5 20 rr Pra lio lo MW PUSH TO RESET gg 05 22 97 090176 7 FH A i Da 1090451 07 11 2007 Fig 1 Air Cleaner Mounting Fig 2 Air Restriction Indicator Replace the air filter at the recommended interval or when filter restriction reaches 25 inH O See the Shuttle Bus Chassis Operator s Manual for specific restriction values for your engine See Group 09 of the Shuttle Bus Chassis Workshop Manual for re moval and installation procedures or take the vehicle to an authorized Freightliner dealer 09 02 Air Intake System Inspecting Check the air intake system for damaged or cracked hoses and for loose clamps Make repairs as neces sary Shuttle Bus Chassis Maintenance Manual April 2013 09 1 Air Compressor 13 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Compressor Inspection us uus ch etoile wade A KANAN NT a EU Puts 13 01 Shuttle Bus Chassis Maintenance Manual November 2014 Air Compr
22. fluid and check the fluid level See Table 1 See Table 2 for lubricant capacities 14 Check and adjust the fluid level using the proce dures under MOP 26 03 Transmission Fluid Level Checking 26 03 Transmission Fluid Level Checking 4h CAUTION Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion Overfilling will force fluid out of the case through the main shaft openings Do not mix types and brands of fluid because of possible incompatibility Do not use fluid addi tives friction modifiers extreme pressure gear fluids or multiviscosity lubricants Cold Check Clean all dirt away from around the end of the fluid fill tube before removing the dipstick 4h CAUTION Do not allow foreign matter to enter the transmis sion Dirt or foreign matter in the hydraulic system may cause undue wear of transmission parts make valves stick and clog passages Shuttle Bus Chassis Maintenance Manual October 2009 26 3 26 NOTE After replacing the transmission fluid or changing the filter s it is important to check the fluid level cold to determine if the transmission has a sufficient amount of fluid to be safely op erated until a hot check can be performed 1 Acold check may be made when the sump tem perature is 160 to 200 F 71 to 93 C 2 Run the engine for at least one minute to clear the fluid system of ai
23. genuine Alliance parts in perfor mance and durability Freightliner Noise Emissions Warranty See the vehicle owner s warranty information book for warranty information concerning noise emission controls Tampering With the Noise Controls is Prohibited Federal law prohibits the following acts or the caus ing thereof 1 the removal or rendering inoperative by any person other than for purposes of mainte nance repair or replacement of any device or ele ment of design incorporated into any new vehicle for the purpose of noise control prior to its sale or deliv ery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or ele ment of design has been removed or rendered inop erative by any person Among those acts presumed to constitute tampering are the acts listed below A Removal of engine noise deadening panels B Removal of or rendering inoperative the engine speed governor so as to allow engine speed to exceed manufacturer s specifications C Removal of or rendering inoperative the fan clutch including by passing the control on any thermostatic fan drive to cause it to operate con tinuously D Removal of the fan shroud E Removal of or rendering inoperative exhaust system components including exhaust pipe clamping F Removal of air intake components G Removal of hood liners noise deadening pan els Maintenance Instructions Scheduled int
24. ing system may lead to brake failure resulting in property damage personal injury or death Haldex NOTICE Do not use moly disulfide loaded grease or oil Both the life and reliability of the slack adjuster will be reduced if this type of grease is used Lubricate a Haldex automatic slack adjuster at the grease fitting with any extreme pressure NLGI Grade 1 or Grade 2 grease if the operating temperature is 20 F 29 C and above If the operating tempera 42 4 Shuttle Bus Chassis Maintenance Manual August 2013 Brakes ture is below 20 F 29 C use a low temperature extreme pressure grease Meritor Lubricate the slack adjuster at the grease fitting until grease is forced past the pressure relief capscrew or past the gear splines around the inboard snap ring Use high temperature NLGI Grade 1 waterproof grease See Fig 5 10 20 93 i li 6 1420012a 1 Brake Chamber 5 Pull Pawl Seal 2 Clevis 6 Manual Adjusting Nut 3 Actuator Rod 7 Grease Fitting or 4 Boot Lube Plug 42 06 17 2010 1430511 1 Yoke 5 Boot 2 Yoke Pin 6 Lube Fitting 3 Link Pin 7 Worm Gear 4 Link Fig 6 Bendix Automatic Slack Adjuster ridge that surrounds the reservoir See Fig 7 Use only heavy duty brake fluid DOT 3 Fig 5 Meritor Automatic Slack Adjuster other slack adjustors are similar Bendix Using a quality multipurpose chassis lubricant NLGI Grade 2 lubricate the aut
25. initially entering vehicle identification data PartsPro is an electronic parts catalog system showing the specified vehicle s build record 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 Shuttle Bus Chassis Maintenance Manual December 2012 I 1 Introduction Descriptions of Service Publications Warranty related service information available on the AccessFreightliner com website includes the following documentation Recall Campaigns Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice These campaigns pertain to matters of vehicle safety All recall campaigns are distributed to dealers customers receive notices that apply to their vehicles 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 Shuttle Bus Chassis Maintenance Manual December 2012 Page Description For a page example of the printed manual see Fig 1 Introduction A B 32 01 Suspension Inspecting Freightliner Spring FRONT AND REAR SUSPENSION SPRING ASSEMBLIES REAR
26. injury or death 2 Remove the wheel hub See Group 33 of the Shuttle Bus Chassis Workshop Manual for wheel bearing service procedures or take the vehicle to an authorized Freightliner dealer 3 Lubricate the steering knuckle control arm at indi cated maintenance intervals Use only an NLGI Grade 2 lithium based grease multipurpose 32 6 Shuttle Bus Chassis Maintenance Manual December 2013 Suspension 32 08 13 2013 1321166 09 30 2004 1321018 1 Steering Knuckle Bearing Grease Fitting upper 2 Steering Knuckle 3 Steering Knuckle Bearing Grease Fitting lower Fig 7 Pressure Grease Fitting Positions RL 75E Fig 6 ZF IFS Jack Placement 09 30 2004 Steering Knuckle Bearing Grease Fitting upper Control Arm Grease Fitting upper Control Arm Grease Fitting lower Steering Knuckle Bearing Grease Fitting lower ON 321019 Fig 8 Pressure Grease Fitting Positions RL 75EM Shuttle Bus Chassis Maintenance Manual December 2013 32 7 Front Axle 33 Index Alphabetical Title of Maintenance Operation MOP MOP Number Knuckle Pin LUC CNG T pP nns 33 01 OilFille
27. injury or death Clean inspect and maintain wiring and connections carefully 1 Disconnect the batteries 2 Check the tightness of the alternator bracket fas teners and alternator mounting fasteners tighten the fasteners as needed For torque values see Group 15 of the vehicle Workshop Manual or take the vehicle to an authorized Freightliner dealer 3 Check that all electrical connections at the alter nator and starter are clean Clean and tighten all charging system electrical connections as needed Spray each electrical connection at the alternator and starter with dielectric red enamel Trace and inspect all wiring and cables con nected to e alternator e starter and depopulation studs e batteries e magnetic switch e cab e jump start studs e battery isolation relays e battery shutoff switches 15 4 Check wires and cables for wear chafing kinks discolored insulation or loose clamps or ties Find the cause of any problems and repair re place and reroute wires and clamps as neces sary IMPORTANT Ensure that wires and cables are not near any heat sources if they are reroute them 5 Clean all circuit breakers and relays 6 Check the alternator wiring for missing insulation kinks and heat damage Replace or repair as needed 7 On the bundled cable that runs from the batteries to the starter ensure that tie straps are installed at least every 12 inches 30 cm Replace any missing ti
28. ka paa 25 hd da RB KG NDN S LPA qupd xd AN AA ap rede e dr 32 12 Shuttle Bus Chassis Maintenance Manual December 2013 Suspension 32 01 Suspension Inspecting Freightliner Spring Front and Rear Suspension Spring Assemblies Inspect the front and rear suspension spring assem blies for pitted cracked broken or abnormally bent leaves and extreme rust If any of these conditions exist replace the spring assembly See Group 32 of the Shuttle Bus Chassis Workshop Manual for in structions or take the vehicle to an authorized Freightliner dealer Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring as sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Re placement of only the visibly damaged part s is no assurance that the spring is safe On front spring assemblies if cracks or breaks exist in the two top leaves a loss of vehicle control could occur Failure to replace a damaged spring assem bly could cause an accident resulting in property damage serious personal injury or death IMPORTANT On multi leaf suspensions closely inspect each component of the leaf spring as semblies including the brackets U bolts and related parts Rear Suspension Spring Brackets Inspect the forward and rear spring brackets and the wear pads for wear cracks and other damage If any of these conditions exist replace the damaged bracket s and
29. months or when filter restriction reaches 25 inH 0 if equipped with an air restriction gauge t For oil and filter change intervals see the applicable Allison Operator s Manual t For Detroit axles complete this procedure once a year or at the following applicable interval whichever comes first every 5000 miles 8000 km for Category vehicles or every 10 000 miles 16 000 km for Category II vehicles For Detroit rear axles with petroleum based oil change the lubricant every 100 000 miles 161 000 km or every 12 months whichever comes first if syn thetic oil is used change the lubricant every 250 000 miles 402 000 km or every 36 months whichever comes first For Meritor rear axles with petroleum based oil change the lubricant at 100 000 miles 161 000 km or at 12 months of service whichever comes first and every 24 months thereafter if synthetic oil is used change the lubricant every 250 000 miles 402 000 km or every 36 months whichever comes first 1 IMPORTANT Lubricate every 6 months or every 18 000 miles 30 000 km whichever comes first See the Bosch Pin Slide Disc Brakes Service Manual for more information tt This operation applies specifically to vehicles used during winter months in areas where corrosive materials are used on the highways tt Replace the desiccant and coalescent filter every 18 000 miles 30 000 km or every 18 months Visually inspect the fuel tank every 6 months The fuel tank m
30. steering fluid at operating tem perature check the fluid level on the dipstick If below the add mark add enough fluid to bring the level up to the full mark on the dipstick See Table 1 for approved power steering fluid 3 Install the dipstick fill cap in the power steering reservoir Shuttle Bus Chassis Maintenance Manual June 2008 46 1 46 Approved Power Steering Fluid Fluid Type Approved Fluid Automatic Transmission Fluid Dexron Ill or equivalent Use the same lubricant when assembling parts as is used in the power steering system See the Warning above Table 1 Approved Power Steering Fluid 46 04 Power Steering Reservoir Fluid and Filter Changing 1 Remove the dipstick 3 8 16 hexnut and cover See Fig 2 2 Drain the power steering reservoir by disconnect ing the power steering hydroboost hose from the reservoir Keep the hose in an upright position to prevent drainage of fluid 3 Catch the fluid from the reservoir in a drain bucket then cap the reservoir port 4 Lift out the spring and filter element 5 Thoroughly clean the reservoir with a lint free cloth 6 Install a new filter element and position the spring on top of the filter element 7 Fill the reservoir with approved power steering fluid see Table 1 Fill only with approved clean fluid Do not mix fluid types Any mixture or any unapproved fluid could lead to seal deterioration and leaks F
31. the vehicle per sonal injury or property damage may result 1 With the engine running and air pressure at cut out pressure set the parking brake 2 Put the vehicle in the lowest gear and gently at tempt to move it forward The vehicle should not move If the vehicle moves the parking brakes are not operating correctly and must be repaired before the vehicle is returned to service Brake Component Inspection 1 Park the vehicle on a level surface set the park ing brake and chock the tires Once the tires are chocked release the parking brake Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is 42 likely masking a mechanical problem Adjustment is not repairing Before adjusting an automatic slack adjuster troubleshoot the foundation brake system and inspect it for worn or damaged com ponents Improperly maintaining the vehicle brak ing system may lead to brake failure resulting in property damage personal injury or death 2 With the engine off and 100 psi 689 kPa of air tank pressure have an assistant apply and hold an 80 to 90 psi 550 to 620 kPa brake applica tion 3 Check to see if the colored over stroke band on each brake chamber pushrod is exposed If a band shows the stroke is too long Check the foundation brake components for wear or damage and repair as needed 4 Measure the applied chamber stroke See Table 1 for the proper stroke for t
32. 04 CNG Fuel Leak Testing Compressed natural gas is highly flammable See the safety precautions listed in Chapter 8 of the Shuttle Bus Chassis Operator s Manual or Group 47 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Failure to observe these precautions could lead to the ignition of the natural gas which could cause severe bodily harm or death or property damage Inspect and test the fuel tanks and the fuel lines Use a natural gas detector to check for any leaks Replace leaking fuel tanks repair or replace any lines or connections that are leaking For procedures and safety precautions see Group 47 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Shuttle Bus Chassis Maintenance Manual August 2013 47 3 47 Fuel 1 lrn IN TAI pa pe 2 3 LI 9 4 A KX Cl HTH 6 3 10 13 Eu E l 4 11 KI 7 Nae 12 EAE T Y Lol 10 16 2001 L 1470414 1 Filter Collar 7 Filter Element 11 Drain 2 Filter Vent 8 Temporary Filter Stud 12 Bottom Plate Collar 3 Vent Seal 9 Check Valve Fuel Inlet 13 Electric Heater optional 4 Filter Cover 10 Fluid Heater Bottom Plate and 5 Cover Seal Seal 6 Filter Spring Fig 3 Davco Fuel Pro 382 47 05 CNG Fuel Tank Visual Inspecting Compressed natural gas is highly flammable See the safety precautions listed in Ch
33. Canister cartridge assembly shown upside down B Rotate the cartridge counterclockwise 45 degrees to release it from the canister 1 Fig 2 Releasing the Cartridge 01 07 2011 1422526 1 O ring 3 Mounting Bolts 2 Cartridge Fig 1 PURest Air Dryer Assembly 10 1 Start the engine and build air pressure to 100 psi 690 kPa and shut off the en gine 10 2 Check for air leaks at the inlet outlet and canister assembly Correct any leakage problem 10 3 Restart the engine and build up pressure to cut out pressure At cut out pressure the air dryer purge valve opens and im mediately expels a large volume of air followed by a slow flow of air lasting ap proximately 30 seconds 01 07 2011 1422528 Fig 3 New Cartridge with Rubber Spring 42 03 Air Dryer Inspecting 1 Check the reservoirs for moisture A small amount a teaspoon or less is normal Larger amounts may mean that the desiccant needs to be replaced Check the mounting and connecting lines Shuttle Bus Chassis Maintenance Manual August 2013 42 3 01 10 2011 1422529 A Install the new cartridge into the canister B Press the cartridge into the canister and rotate clockwise 45 degrees to engage the cartridge Fig 4 Cartridge Rotation and Engagement 2 Tighten t
34. E Lubricant Type Ampient Tempera tare Viscosity Grade 10 F 12 2 C and upt 85W 140 Hypoid Gear Oil 15 F 26 1 C and upt 80W 90 API Service n Classification 40 F 40 C and up 75W 90 GL 5 40 F 40 C to 35 F 2 C 75W 40 F 40 C and upt 75W 140 Drive Axle Recommended Lubricant t Lubricant Recomm oe Ambient Temperature ys Grade Synthetic Gear _ 40 F 40 C and upt 75W 90 Oil 40 F 40 C and upt 75W 140 Lubricant used in Detroit rear axles must meet the requirements of the API GL 5 standard Recommended lubricants meet Mercedes Benz specifi cation 235 8 synthetic or 235 20 mineral see http bevo mercedes benz com for product names t Detroit rear axles do not require the use of friction modifiers t There is no upper limit on the ambient temperature but axle sump tem perature must never exceed 250 F 121 C Table 1 Drive Axle Recommended Lubricant Detroit Axles 35 02 Axle Lubricant Changing and Magnetic Plug Cleaning A regular schedule for changing the axle lubricant in a particular vehicle and operation can be accurately determined by analyzing oil samples taken from the axle at specified intervals or mileages Lubricant sup pliers frequently make their laboratory facilities avail able for determining the useful life of their product under actual service conditions The final schedule that is recommended may for eco
35. Exposure to open flame or intense heat could start a fire pos sibly resulting in personal injury or property dam age When working on a fuel system have a fire extinguisher within easy reach 1 Drain the fuel below the collar level 2 Using Davco wrench 232002 remove the filter collar Then remove the filter cover 3 Remove the element and dispose of it properly 4 Install a new element Make sure the grommet is in place on the filter stud 5 Install a new cover seal on the filter cover Using the collar attach the filter cover with the spring to the base 47 2 Shuttle Bus Chassis Maintenance Manual August 2013 Fuel IMPORTANT Tighten the collar by hand only 7 Remove the filter vent Then fill the fuel water separator with fuel until the fuel level is 1 inch 2 5 cm above the collar 8 Install the filter vent on the fuel water separator 9 Start the engine and raise the rpm for one min ute to purge air Davco Fuel Pro 382 Replace the fuel water separator element only when the filter element is completely covered Diesel fuel is flammable and can ignite if exposed to an open flame intense heat or other ignition source Do not drain fuel near or expose fuel vapor to open flame or intense heat Exposure to open flame or intense heat could start a fire pos sibly resulting in personal injury or property dam age When working on a fuel system have a fire extinguisher within easy reach
36. Freightliner Spring Rear NOTICE Continued use with loose fasteners could result in bracket and frame damage Torque the fasteners that attach the forward and rear spring brackets and equalizer brackets to the frame rail Tighten 1 2 13 locknuts with hardened washers 85 Ibf ft 115 N m Tighten 5 8 11 locknuts with hardened washers 170 Ibf ft 230 N m Tighten 3 4 10 locknuts with hardened washers 305 Ibf ft 414 N m See Group 00 for other frame fastener torque val ues 32 05 Fastener Torque Checking Freightliner AirLiner Suspension 32 06 Component Clearance Checking Freightliner AirLiner NOTICE Failure to relocate obstructing parts could result in damage to the air spring Check that the air line support brackets are posi tioned so that air lines do not rub against anything Reposition any configurations that could contact and result in friction and wear There must be at least 1 inch 25 mm clearance around the rubber air spring when inflated If the clearance is less than 1 inch 25 mm relocate the obstructing parts Torque Values for Freightliner AirLiner Suspensions ee Torque Description Size Ibf ft N m Leveling Valve Adjustment Nut 1 4 20 5 7 vi Valve Mounting Bolt 5 16 18 14 19 uts Air Spring Upper Mounting 3 4 16 45 61 Locknuts 1 2213 23 31 Air Spring Lower Mounting Locknilfe 1 2 13 55 75 Leaf Spring Mounting Eye Bolt 3 416 270 865 Locknut
37. If not the U joint may fail prematurely 4 If the bearing will not take grease replace the 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 tions see Group 41 of the vehicle Workshop Manual or take the vehicle to an authorized Freightliner dealer Shuttle Bus Chassis Maintenance Manual November 2014 41 1 4 6 Sli 1 1 Wipe any excess grease from the seals and grease fittings p Joint Spline Lubrication Wipe all old grease and dirt from the slip joint grease fitting Use a hand type grease gun or a high pressure gun with a low pressure adaptor to lubricate the slip joint Using lithium 12 hydroxy stearate grease NLGI grade 1 or 2 with EP additives lubricate until fresh grease appears at the pressure relief hole in the yoke plug Then cover the relief hole with your finger as shown in Fig 1 while continuing to lubricate until fresh grease appears at the slip joint seal This en sures complete lubrication of the splines Wipe any excess grease from the pressure relief hole slip joint seal and grease fitting Driveline 41 2 Shuttle Bus Chassis Maintenance Manual November 2014 Brakes 42 Index Alphabetical Title of Maintenance Operation MOP MOP Number ABS Tone Rings Clean spp k
38. It is not necessary to exceed 4000 psi 27 560 kPa The best distribution of new lubricant and the best purg ing of old lubricant occurs when about 4000 psi 27 560 kPa pressure is applied at the grease gun nozzle Using a 40 to 1 booster the air should be limited to 100 psi 689 kPa using a 50 to 1 booster the air should be limited to 80 psi 551 kPa Higher or lower pressures are not recommended When lubricating Meritor knuckle pin bushings for Initial Maintenance raise the front axle until the front tires are off of the ground Wipe the lube fittings clean and slowly feed multipurpose chassis grease NLGI grade 1 or 2 into each bushing area while turning the wheels from extreme right to left and back again lock to lock This will eliminate small air pockets and improve grease distribution Lower the front axle so that the tires are on the ground and regrease both top and bottom bushings 06 07 2012 1330272 A Upper View LH Side B Lower View LH Side 1 Grease Fitting Fig 1 Grease Fittings Detroit Axles 09 13 2012 1330275 Fig 2 Knuckle Pin Grease Exit Points Detroit Axles until new grease is seen at the seal on the bushing opposite the fittings NOTE The grease seal will accept the grease pressure without damaging the seal and is de signed to have grease pumped out through it Shuttle Bus Chassis Maintenance Manual August 2013 33 1 33 Front
39. LLC Service Systems and Documentation CVI SSD P O Box 3849 Portland OR 97208 3849 Introduction Descriptions of Service Publications Daimler Trucks North America LLC distributes the following major service publications in paper and electronic via ServicePro formats Workshop Service Manual Maintenance Manual Driver s Operator s Manual Service Bulletins Parts Technical Bulletins Workshop service manuals contain service and repair information for all vehicle systems and components except for major components such as engines trans missions and rear axles Each workshop service manual section is divided into subjects that can include general information principles of operation removal disassembly assembly installation and specifications Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems They have information such as lubrication procedures and tables fluid replacement procedures fluid capacities specifica tions and procedures for adjustments and for checking the tightness of fasten ers Maintenance manuals do not contain detailed repair or service information Driver s operator s manuals contain information needed to enhance the driver s understanding of how to operate and care for the vehicle and its components Each manual contains a chapter that covers pre trip and post trip inspections and daily weekly and monthly maintenance of vehicl
40. Maintenance Intervals lille ee 00 01 Maintenance Intergal Tables tasas dano e bowed dey ROB o ee 00 03 Maintenance Operation Sets 0 0 000 ehh 00 04 Noise Emission Controls Maintenances ions PAWA TERA a wee ees Ae a e opc d E 00 05 Vehicle Maintenance Schedule Table l i 00 02 Velification of Inspectors LOG ma aaa kag ATA mn ha a tata BADA wa ebbe hi acne Sane gop 00 06 Shuttle Bus Chassis Maintenance Manual November 2014 General Information 00 Determining Scheduled Maintenance Intervals 00 01 Description Category I urban transport applies to vehicles that annually travel up to 20 000 miles 32 000 kilome ters Category Il rural transport applies to vehicles that annually travel over 20 000 miles 32 000 kilome ters The table under Vehicle Maintenance Schedule Table shows the two categories of vehicle usage For each category the appropriate distance and time intervals are given for performing initial maintenance and for repeating each maintenance operation set M1 through M3 The table under Maintenance Interval Table shows which maintenance operation set must be performed at the actual distances miles and kilometers or ac tual months of operation for each maintenance cat egory The schedule of actual distances and months is based on the intervals given in the Ve hicle Maintenance Schedule Table The table under Maintenance Operation Sets lists in numerical o
41. Operation Sets 00 04 REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 Maintenance Operation Reference Number and Maintenance Operation 33 06 Oil Filled Hubs Oil Changing 33 07 Wheel End Inspection 35 01 Axle Lubricant Level Checking e o o o 35 02 Axle Lubricant Changing and Magnetic Plug Cleaning 35 03 Axle Breather Checking o o o o 40 01 Wheel Nut Checking e o o o 41 01 Driveline Inspection and Lubrication e 0 o o 42 01 Air Dryer Checking o o 42 02 Air Dryer Desiccant and Coalescent Filter Replacing 42 03 Air Dryer Inspecting o o 42 04 Air Reservoir Automatic Drain Valve Disassembling Cleaning and Inspecting Wie Bendix DV 2 42 05 Slack Adjuster Lubricating e o o 0 42 06 Bendix Hydro Max Brake System Inspecting e 0 o 0 42 07 Brake Lines Checking Hydraulic Disc Brakes e o o o 42 08 Brake Lining Wear Checking Hydraulic Disc Brakes e o o o 42 09 Camshaft Bracket Bushing Lubricating e o 42 10 Foot Brake Valve Actuator Lubricating Bendix E 6 e o 42 11 Relay Valve Checking Midland e 0 o 0 42 12 Brake Caliper Slide Rail Lubricating Bosch Hydraulic Brakes l e jojojo 42 13 Brake Caliper Slide Pin Lubricating Bosch Brakes 42 14 ABS Tone Rings Cleaningtt o o o jo 42 15 Drum Brake Shoe Roller Lubricating o o 42 16 Air Dryer Inspecting
42. Radiator Pressure Flush and Coolant Change 20 03 Eaton Viscous Fan Drive Check Noise Emission Control o o 20 04 Mechanical Fan Drive Gearbox Oil Change 20 05 Mechanical Fan Drive Gearbox Lubrication o 0 26 01 Transmission Breather Checking 26 02 Transmission Fluid and Filter Changing 26 03 Transmission Fluid Level Checking e o o 0 31 01 Frame Fastener Torque Checking 32 01 Suspension Inspecting Freightliner Spring e o o o 32 02 Suspension Lubricating Freightliner Spring e o o o 32 03 U Bolt Torque Checking Freightliner Spring 32 04 Spring Bracket Fastener Torque Checking Freightliner Spring Rear e 32 05 Fastener Torque Checking Freightliner AirLiner 32 06 Component Clearance Checking Freightliner AirLiner 32 07 Component Inspecting and Operation Checking Freightliner AirLiner 32 08 U Bolt Torque Checking Freightliner AirLiner 32 09 Shock Absorber Checking Freightliner Spring 32 10 Torque Arm Bushing Checking Freightliner AirLiner e o o 0 32 11 Suspension Inspecting Neway 32 12 ZF IFS Lubricating o o o o 33 01 Knuckle Pin Lubricatingt e o ojo 33 02 Tie Rod End Lubricatingt e e ojo 33 03 Tie Rod End Inspecting o o o o 33 04 Wheel Alignment Checking Front Axle 33 05 Oil Filled Hubs Oil Level Checking o o o o 00 4 Shuttle Bus Chassis Maintenance Manual November 2014 General Information 00 Maintenance
43. SUSPENSION SPRING BRACKETS 32 02 Suspension Lubricating Freightliner Spring FRONT SUSPENSION Shuttle Bus Chassis Maintenance Manual July 2000 Y Suspension 32 REAR SUSPENSION 32 01 U Bolt Torque Checking Freightliner Spring Suspension Fittir D 08 03 2000 Group Title Group Number Release Date Group Number Page Number MOO W gt Maintenance Operation Number consists of the Group Number followed by the Sequence Number f020107 Fig 1 Page Example of the Printed Manual Shuttle Bus Chassis Maintenance Manual December 2012 Introduction Maintenance Manual Contents Group No Group Title OU olco tt ae oak eee General Information OT Beate aid asks here apa eaa Aut a Beane i AN Engine 09 1 enn o ba Air Intake opp DTP Air Compressor we bod okie de BABA e obio Alternators and Starters 20 ce Peace eb hee ee Engine Cooling Radiator 20 NN Transmission lirica Frame and Frame Components c Em Suspension cop PME ae es ate Ge Front Axle c CDI Rear Axle AO een tort eheu wR eR ET Wheels and Tires LEITET Driveline DCN PEE Brakes A Steering OT Vas a NAMES RE een RU Fuel nip Serta Tio cas eta A APA ee Exhaust DA acide paths Electrical Instruments and Controls BI PEPPER Heater and Air Conditioner 4 Shuttle Bus Chassis Maintenance Manual December 2012 General Information 00 Index Alphabetical Title of Maintenance Operation MOP MOP Number Determining Scheduled
44. TS the entire ex haust system from the turbocharger to the tail pipe including the Selective Catalytic Reduction SCR components Aftertreatment Device ATD a device that re moves pollutants from exhaust gas after the gas leaves the combustion chamber BlueTec Daimler s proprietary SCR technol ogy Diesel Oxidation Catalyst DOC a flow through device that enhances the oxidation of hydrocarbons in the ATD Diesel Particulate Filter DPF a component in the ATD that traps particulate matter from the exhaust gas Diesel Exhaust Fluid DEF the chemical agent that reacts with the exhaust gases in the SCR to reduce NOx DEF Pump filters and supplies DEF to the DEF metering unit 49 e DEF Tank holds DEF and regulates its tem perature e DEF Metering Unit mixes DEF with com pressed air and meters this mixture into the exhaust flow via an injection nozzle e SCR Catalyst the housing containing a treated ceramic flow through block where the DEF and exhaust gases undergo selective catalytic re duction e Selective Catalytic Reduction SCR a process used to reduce NOx emissions Inspection IMPORTANT The Environmental Protection Agency s 2010 regulations mandate lowered exhaust emissions thus requiring exhaust sys tem components that reduce emissions In par ticular the aftertreatment device ATD which is part of the aftertreatment system ATS requires special attention during re
45. U bolt nuts 300 Ibf ft 407 N m and tighten all 7 8 14 U bolt nuts 460 Ibf ft 624 N m 32 09 Shock Absorber Checking Freightliner Spring Make sure that the shock absorber brackets are tight and that the shock absorber is not striking or rubbing on the frame or some other part of the chas sis See Fig 2 Check the rubber mounting bushings and replace if worn Inspect the shock absorber for oil leakage If the shock absorber is worn or damaged replace it with a new one 32 10 Torque Arm Bushing Checking Freightliner AirLiner 1 Without detaching the torque arms attempt to move by hand each of the rod ends up down in and out See Fig 3 If there is any move ment replace the torque arm 2 Inspect the rubber bushing ends Replace the torque arm if there are gaps between the rubber bushing and the pin or the outer steel sleeve If either bushing end contacts a torque arm pin mounting bolt if there are cracks in the bushing or if part of the rubber bushing extends beyond Shuttle Bus Chassis Maintenance Manual December 2013 32 3 32 10 05 94 f320267a 1 Upper Mounting Bracket 2 Shock Absorber 3 Lower Mounting Bracket Fig 2 Shock Absorber Installation front suspension shown the outside circumference of the outer bushing sleeve replace the torque arm lt 3 2 M NG i 1 Ae E LE E Y 04 01 2000 i 1350396 1 Torque Arm 3 Rear Axle Housing 2 Ex
46. aaa Da T a KANG koba Raa DE A A NG 42 14 Air Dryer CheckinGive od 24 makina ar MAGNA PATAMA tae e NER orca A eas eRe HANG 42 01 Air Dryer Desiccant and Coalescent Filter Replacing 0000 eee 42 02 Air Dryer Desiccant and Coalescent Filter Replacing Midland 0c cece eee eee 42 17 Ar Diver spectu sad sib dp tie I QAI BAN Eu SUR o fitu See xdi 42 03 Air Dryer Inspecting Midland oss 2c meom emm erem use pare ta x Eee ere dee eee dp Rede apie 42 16 Air Reservoir Automatic Drain Valve Disassembling Cleaning and Inspecting Bendix DV 2 422554094 8S a a qv POM AE MRE TORI EEE eRe SMES Ge Ha 42 04 Air Actuated Parking Brake Cable Checking and Adjusting 0c eee eee 42 18 Bendix Hydro Max Brake System Inspecting 42 06 Brake Caliper Slide Pin Lubricating Bosch Brakes eel 42 13 Brake Caliper Slide Rail Lubricating Bosch Hydraulic Brakes l i elles 42 12 Bare seu sitas qi BOR denda UR he ag e o qe ede Shetek Gas bad dva aL n 42 19 Brake Lines Checking Hydraulic Disc BrakeS 1 2 0 000 eee 42 07 Brake Lining Wear Checking Hydraulic Disc Brakes ra 42 08 Camshaft Bracket Bushing Lubricatiligi aimi sisas er a FEAR 42 09 Drum Brake Shoe Roller Lubricating 0000 ee 42 15 Foot Brake Valve Actuator Lubricating Bendix E 6 0 0 00 ees 42 10 Relay Valve Checking Midland x i baaa pe ex eR ees dare dae RUNE gd gee see ne 42 11 Slack Adjuster Lubric
47. above and repeat this procedure on the opposite tie rod end 2 Inspect the tie rod ends 2 1 The threaded portion of the tie rod end assembly must be inserted all the way into the cross tube split for adequate clamping See Fig 6 Replace the parts if this cannot be done For instructions see the axle manufacturer s service manual 07 18 96 330131 NOTE If the reading is more than 0 060 inch 1 52 mm when moving the tie rod end and cross tube assembly up and down replace the tie rod end 1 Tie Rod End 2 Dial Indicator with Contour Type Base Fig 5 Measuring Tie Rod End Looseness 2 2 Check the tie rod end nut and clamp nut torques For Detroit axles see Table 1 for tie rod end nut torque specifications and Table 2 for tie rod end clamp nut torque specifications For Meritor axles tighten the tie rod end nut 100 Ibf ft 136 N m and tighten the clamp nut 40 to 55 Ibf ft 54 to 75 N m 33 02 27 2007 f320033a IMPORTANT The tie rod end threads must be visible throughout the entire length of the split NOTE Pinch bolt not shown to provide clarity 1 Cross Tube Split Fig 6 Tie Rod End Adjustment Detroit Axle Tie Rod End Nut Thread Torque Ibf ft N m 5 8 16 60 to 115 81 to 156 5 8 18 60 to 115 81 to 156 3 4 16 90 to 170 122 to 230 7 8 14 160 to 300 217 to 407 Table 1 Detroit Axle Tie
48. ace a drain pan under the transmission and remove the drain plug Ex amine the fluid as it drains If only the filter is being changed do not drain the fluid 4 Remove the 12 mounting bolts 6 each from the 2 filter covers NOTE A lot of fluid will drain when the filter covers are removed 5 Remove the filter covers O rings and two square cut seals from the transmission See Fig 2 6 Remove the filters from the bottom of the control module 7 Lubricate the new O rings with transmission fluid and install them on the cover assemblies Transmission O O O O C e 1 i AO OW ro O r 4 Q c O ii 08 25 95 1260317 1 Filter Cover 3 Filter Element O Ring 2 Filter Element 4 Square Cut Seal Fig 2 Allison 3000 B300 Series Transmission Filter Location and Components 8 Install a new square cut seal on each cover as sembly and install the fluid filter elements on the cover assemblies 26 2 Shuttle Bus Chassis Maintenance Manual October 2009 Transmission 26 Approved Allison Transmission Lubricants TES 295 Approval Number Company Product Brand Name AN 051005 E Lubricants and Petroleum Specialties Mobil Delvac Synthetic ATF AN 011001 Castrol Heavy Duty Lubricants TranSynd AN 031002 BP Autran Syn 295 AN 031003 Cognis Corporation Emgard 2805 AN 031004 In
49. aftertreatment device ATD which is part of the aftertreatment system ATS requires spe cial attention during regularly scheduled mainte nance inspections If any discrepancies are dis covered refer to the engine manufacturer s service literature for repair instructions or take the vehicle to an authorized Freightliner service facility for repair 1 Check the leakage at the clamp that attaches the exhaust pipe to the turbocharger exhaust outlet If leakage exists tighten the nut on the clamp to the required torque If leakage persists install a new clamp 2 Check the exhaust pipe bellows and each ex haust seal clamp for leakage wear cracks or damage Replace damaged components as needed If leakage exists at a clamp tighten the Shuttle Bus Chassis Maintenance Manual January 2010 49 3 49 Exhaust Y A y if 7 T 6 11 2 2006 1490284 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 DPF Outlet Pressure Sensor 4 DPF V Band Mounting Clamps 9 DPF Intake Pressure Sensor 5 Inlet Temperature Sensor Fig 3 Cummins Aftertreatment Device nuts to the required torque If leakage persists 4 Check the ATD mounting bands for tightness install a new exhaust seal clamp Do not reuse Tighten 30 Ibf ft 41 N m if needed Do n
50. apter 8 of the Shuttle Bus Chassis Operator s Manual or Group 47 of the Shuitle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Failure to observe these precautions could lead to the ignition of the natural gas which could cause severe bodily harm or death or property damage Each fuel tank must be visually inspected at speci fied intervals for external damage and deterioration The inspection must be performed by a qualified per son in accordance with the manufacturer s estab lished reinspection criteria and Compressed Gas As sociation documents Perform this maintenance procedure as indicated in the maintenance interval chart in this manual See Table 1 for the remedies to any damage found on 4714 Shuttle Bus Chassis Maintenance Manual August 2013 Fuel the tank See Group 47 of the Shuttle Bus Chassis Workshop Manual for tank repair procedures or take the vehicle to an authorized Freightliner dealer 47 CNG Tank Visual Inspection Damage Condition Remedy Abrasion on the Fiberglass Wrap Less Than 0 010 Inch 0 4 mm Deep No repair needed More Than 0 010 Inch 0 4 mm But Less Than 0 030 Inch 1 2 mm Deep Repair More Than 0 030 Inch 1 2 mm Deep Replace tank Cuts in the Fiberglass Wrap Less Than 0 020 Inch 0 8 mm Deep No repair needed More Than 0 020 Inch 0 8 mm But Less Than 0 030 Inch 1 2 mm Deep Mor
51. aring cup seals of each U joint If not the U joint may fail prematurely 4 If the bearing will not take grease replace the U joint assembly 5 Check the old grease If it appears rusty gritty or burned replace the U joint assembly 6 Wipe any excess grease from the seals and grease fittings Slip Joint Spline Lubrication 1 Check the slip joints for spline wear by trying to bend the sleeve yoke and splined shaft back and forth If looseness is greater than 0 007 inch 0 18 mm replace both the sleeve yoke and the splined shaft Shuttle Bus Chassis Maintenance Manual November 2014 20 3 20 Engine Cooling Radiator 04 24 2013 1 U Joint Grease Fitting 1200817 2 Slip Joint Grease Fitting Fig 4 Slip Joint and U Joint Lubricating Wipe all old grease and dirt from the slip joint grease fitting Use a hand type grease gun or a high pressure gun with a low pressure adaptor to lubricate the slip joint See Fig 4 Using lithium 12 hydroxy stearate grease NLGI grade 2 with EP additives and meeting ASTM D4950 LB specifications lubricate until fresh grease appears at the pressure relief hole in the yoke plug Then cover the relief hole with your finger while continuing to lubricate until fresh grease appears at the slip joint seal This ensures complete lubrication of the splines Wipe any excess grease from the pressure relief hole slip joi
52. ating uua Ua dee endo rede yop Erba e podre tur S ba E RE e aed 42 05 Shuttle Bus Chassis Maintenance Manual August 2013 42 Brakes 42 01 Air Dryer Checking During cold weather operation check the operation of the end cover heater and thermostat assembly 1 With the ignition switch in the ON position check for voltage to the heater and thermostat assem bly Unplug the electrical connector at the air dryer and place the test leads of a voltmeter on each of the pins of the male connector If there is no voltage look for a blown fuse broken wires or corrosion in the vehicle wiring harness Check that a good ground path exists 2 Check the thermostat and heater operation Turn the ignition switch to the OFF position and cool the end cover assembly to below 40 F 4 C Using an ohmmeter check the resistance be tween the electrical pins in the female connector The resistance should be 1 5 to 3 0 ohms for the 12 volt heater assembly Warm the end cover assembly to over 90 F 32 C and again check the resistance It should exceed 1000 ohms If it does the thermostat and heater assembly is operating properly If it does not replace the purge valve housing assembly which includes the heater and thermostat assem bly 42 02 Air Dryer Desiccant and Coalescent Filter Replacing NOTE Desiccant change intervals may vary from vehicle to vehicle Typical desiccant car tridge life is three years However i
53. belt for glazing See Fig 2 Ref A Glazing is indicated by shiny sidewalls and is caused by friction created when a loose belt slips in the pulleys It can also be caused by oil or grease contamination on the pulleys 2 Check the belt for ply separation See Fig 2 Ref B Oil grease or belt dressing can cause the belt to fall apart in layers Repair any oil or coolant leaks that are affecting the belts before replacing the drive belts Do not use belt dress ing on any belt 3 Check the belt for a jagged or streaked sidewall See Fig 2 Ref C Jagged or streaked sidewalls are the result of foreign objects such as sand or gravel in the pulley or a rough pulley surface 4 Check for tensile breaks breaks in the cord body See Fig 2 Ref D Cuts in a belt are usu ally caused by foreign objects in the pulley or by prying or forcing the belt during removal or instal lation 5 Check for uneven ribs on serpentine poly V belts See Fig 2 Ref E Foreign objects in the Shuttle Bus Chassis Maintenance Manual June 2008 01 1 01 Engine 11 21 94 A Glazing B Separating Layers C Streaked Sidewalls D Tensile Break E Uneven Ribs F Cracks f150010a Fig 2 Drive Belt Replacement Conditions pulley will erode the undercord ribs causing the belt to lose its gripping power 6 Check the drive belts for cracks See Fig 2 Ref F Small irregular cracks are usually the signs of an
54. card it 5 Remove the coalescent filter and discard it IMPORTANT Lubricate the new O rings prior to installation 6 Install the new small O ring in the groove on the bottom of the new coalescent filter 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 Screw on the desiccant cartridge until resistance is detected Then tighten the cartridge 1 4 to 3 4 of a turn by hand Shuttle Bus Chassis Maintenance Manual August 2013 42 11 42 Operational Check 1 Start the engine and build air pressure to 120 psi 827 kPa 2 Listen for the purge valve to open and release air A large volume of air will be expelled fol lowed by a slow flow of air lasting approximately 30 seconds 3 Shut down the engine and remove the chocks from the tires 4 Perform the inspections in Maintenance Opera tion 42 16 42 18 Air Actuated Parking Brake Cable Checking and Adjusting Brakes 6 If adjustment is required loosen the jam nut on the cable and adjust the clevis so that the pin hole in the clevis aligns with the hole in the lever Install the clevis pin and a new cotter pin 8 Tighten the clevis jam nut to 80 Ibf in 900 N cm When properly adjusted the cable should have a very slight looseness to it See Fig 14 Chec
55. ct tightening sequence see Fig 1 e On 8 stud or 10 stud hub pilot hubs with 22 mm studs tighten the wheel nuts 450 to 500 Ibf ft 610 to 678 N m For the correct tightening sequence see Fig 1 10 8 7 4 3 TOR Ave L 5 E J6 57 N 4 3 8 M A A B 09 18 2001 1400164 A 8 Stud Disc Wheel B 10 Stud Disc Wheel Fig 1 Wheel Nut Tightening Sequence 8 and 10 stud hub piloted wheels Shuttle Bus Chassis Maintenance Manual June 2008 40 1 Driveline 41 Index Alphabetical Title of Maintenance Operation MOP MOP Number Driveline Inspection and LUBCON s o i wo negated LOGS Sea eee eRe wee d 41 01 Shuttle Bus Chassis Maintenance Manual November 2014 Driveline 41 01 Driveline Inspection and Lubrication Inspection Before lubricating the driveline U joints and slip joints make the following checks 1 Check that the yoke strap capscrews are tight ened 50 to 60 Ibf ft 68 to 81 N m NOTICE Do not overtighten the yoke strap capscrews due to the extreme load occurring at high speed rota tion A loose or broken capscrew at any point in the driveline weakens the driveline connection which could eventually result in serious vehicle damage 2 Check the slip joints for spline wear by trying to bend the sleeve yoke and splined shaft back and forth If looseness is greater than 0 007 inch 0 18 mm replace both the sleeve yoke and the splined shaft 3 Check the driveshaft for missi
56. cting and Replacing IMPORTANT Due to the variety of possible driv ing conditions dirt roads paved roads etc it is critical to check the air restriction indicator if so equipped If the vehicle is not equipped with an air restriction indicator inspect all compo nents of the air intake system and air filter every six months Replace the air filter every 12 months or when filter restriction reaches 25 inH50 if equipped with an air restriction indica tor More frequent inspections and or filter replacement may be needed if your vehicle is being operated in a dusty environment to avoid damaging the vehicle NOTE Remove and visually inspect the air filter for obvious damage such as holes cuts or dents Remove loose debris such as leaves or pine needles from the filter housing Inspect the air cleaner for holes or tears at the rec ommended interval If the air cleaner is damaged replace it See Group 09 of the Shuttle Bus Chassis Workshop Manual for removal and installation proce dures or take the vehicle to an authorized Freight liner dealer A typical air cleaner mounting is shown in Fig 1 09 Engine damage can occur if the air intake system is not properly maintained Use the air intake restriction indicator to check for air intake system damage or leaks See Fig 2 Make sure the engine is off and note the existing reading on the indicator Start the engine and take a short test drive Check the indica tor
57. d by MSHA or NIOSH at all times when servicing the brakes starting with removal of the wheels and continuing through assembly To minimize the possibility of creating airborne brake lining dust clean the dust from the brake rotor brake caliper and brake assembly using an industrial type vacuum cleaner equipped with a high efficiency filter system Then using a rag soaked in water and wrung until nearly dry remove any remaining dust Do not use compressed air or dry brushing to clean the brake assembly 1 Check lining wear 1 1 Apply the parking brakes Chock the tires to prevent vehicle movement 1 2 Remove one or more of the lining inspec tion plugs and measure brake lining thickness 1 3 On front and rear axles replace linings worn to less than 3 16 inch 4 8 mm 1 4 Make sure that the brake rotor and linings are free of oil and grease 1 5 Install the inspection plug s 2 If the wheel and hub assembly is removed from the axle check lining wear Replace the linings 42 6 Shuttle Bus Chassis Maintenance Manual August 2013 Brakes on all brake assemblies if worn to less than 3 16 inch 4 8 mm at the thinnest point NOTE To replace the brake linings see the ap plicable brake section in Group 42 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 42 09 Camshaft Bracket Bushing Lubricating IMPORTANT Perform MOP 42 19 before lubri cating
58. d Hubs Oll Changing maman BAS arp WANNA MAS ANDA AA a mh Rs eg d e e SORS D meek KGG 33 06 Oil Filled Hubs Oil Level Checking RR Ren 33 05 Ine ROd End NSDO RHET P remm 33 03 To Rd End LUDICANNY su Ka occidi ardid ed ROC ced Eb hh cedex S boue dE ho athens 33 02 Wheel Alignment Checking Front Axle es 33 04 Wheel ENG Inspection s aaa BABA achat ag Reese Heads LENG ee Eee petu d DU B da 33 07 Shuttle Bus Chassis Maintenance Manual August 2013 Front Axle 33 01 Knuckle Pin Lubricating 33 NOTICE Use regulated pressure when lubricating the knuckle assemblies otherwise damage could re sult to the knuckle caps Detroit Axles On the front axle grease fittings are on the top and bottom caps of each knuckle 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires When lubricating upper and lower knuckle assemblies do not raise the front axle Wipe the grease fittings clean Apply multipurpose chassis grease NLGI Grade 1 6 12 hydroxy lithium stearate grease or NLGI Grade 2 8 12 hydroxy lithium stearate grease until new grease is seen at the junctions of the axle beam and knuckles For locations of grease fittings see Fig 1 for grease exit points see Fig 2 Meritor Axles Hold a pressure gun on each fitting until fresh grease appears See Fig 3 This will ensure that all of the old contaminated grease has been forced out
59. e Let the engine run at idle 3 Wipe the dipstick clean and check the fluid level A safe operating level is any level within the HOT RUN upper band on the dipstick See Fig 3 4 Ifthe fluid is not within this range add or drain fluid as needed to bring the level to the top of the HOT RUN band BEE CO HOT CHECK IN NEUTRAL IDLE USE DEXRON R OIL 08 23 96 f011103 Fig 3 Dipstick Markings 26 4 Shuttle Bus Chassis Maintenance Manual October 2009 Transmission Allison Transmission 03 04 2008 270159 1 Shift Selector Display Screen Fig 4 Transmission Shift Selector 26 Shuttle Bus Chassis Maintenance Manual October 2009 26 5 Frame 31 Index Alphabetical Title of Maintenance Operation MOP MOP Number Frame Fastener Torque MOCKING asd acabe oett dia Dade Daiana IP doy IAN dul aud 31 01 Shuttle Bus Chassis Maintenance Manual June 2008 Frame 31 01 Frame Fastener Torque Checking Because of bedding in or seating the frame fas teners must be torqued at the recommended inter vals These intervals apply to new vehicles and to frame fasteners that have been removed and in stalled again 4h CAUTION Make sure frame fasteners are properly tightened Continued vehicle operation with loose fasteners could result in bracket or frame damage Typical frame fastener applications include suspen sion and fuel
60. e Than 0 030 Inch 1 2 mm Deep Repair if less than 8 inches 200 mm long Replace tank Dents on Metal Ends Less Than 0 060 Inch 1 6 mm Deep No repair needed More Than 0 060 Inch 1 6 mm Deep Replace tank Gouges on Metal Ends Bare Metal is Exposed Replace tank Chipped Paint on Tank Ends No Gray Primer Seen No repair is needed Gray Primer Seen But Not Damaged Repair with two part epoxy resin Gray Primer Damaged Repair Sand and remove rust clean with pre paint solvent apply cold galvanizing zinc primer and apply two part epoxy resin Stress Cracks from Acid Cracks in Fiberglass Remove tank for inspection if exposed to acid Replace if cracks are seen Replace strap gaskets if exposed to acid Strap Gaskets Gaskets Damaged or Missing Approved gaskets must be installed between strap and tank Replace strap gaskets if exposed to acid Tank Shield Shield is Damaged Repair or replace shield Tank is Old Tank is 15 Years Old Replace tank after 15 years from date on label Vehicle Was in Accident or Fire Tank Was Hot or Damaged from Impact Replace tank or remove tank and test 47 06 CNG High Pressure Fuel Filter Replacing Table 1 CNG Tank Visual Inspection Compressed natural gas is highly flammable See 1 the safety precautions listed in Chapter 8 of the Shuttle Bus Chassis Operator s Manual or Grou
61. e Upper 6 Caliper Housing Rail Fig 10 Driving Out the Key and Spring 9 Carefully remove the brake pads to avoid dam aging them or getting grease on the pad faces Set them aside 10 Using brake cleaner or alcohol remove old grease and road accumulation from the caliper V ways the anchor plate rails and the shoe slots Also clean the key and spring See Fig 10 and Fig 11 42 8 Shuttle Bus Chassis Maintenance Manual August 2013 Brakes A n 1 10 28 94 1420595a 1 V Ways 2 Bleeder Fitting Fig 11 Caliper V Ways 11 Using a wire brush or wire wheel remove any 12 13 14 15 16 17 18 remaining debris from the V ways rails shoe slots key and spring Inspect the caliper and ensure that the piston boots are in good condition with no punctures or tears and that they are properly seated in the caliper Check to see that the heat shields are properly seated Repair or replace them if neces sary Inspect the brake hoses for twists cracks blis ters or abrasions and replace them if neces sary Apply two level teaspoons of Aeroshell Grade 5 ES 1246 grease on each side of the assembly Apply it evenly along the full length of the V way groove and anchor plate rail and apply one level teaspoon evenly on both sides of the key and spring After the caliper is installed pack any ac cumulation of grease at each end of the rail and along the top of the rail or key a
62. e components Driver s operator s manuals do not contain detailed repair or service information Service bulletins provide the latest service tips field repairs product improve ments and related information Some service bulletins are updates to informa tion in the workshop service manual These bulletins take precedence over workshop service manual information until the latter is updated at that time the bulletin is usually canceled The service bulletins manual is available only to dealers When doing service work on a vehicle system or part check for a valid service bulletin for the latest information on the subject IMPORTANT Before using a particular service bulletin check the current service bulletin validity list to be sure the bulletin is valid Parts technical bulletins provide information on parts These bulletins contain lists of parts and BOMs needed to do replacement and upgrade procedures Web based repair service and parts documentation can be accessed using the following applications on the AccessFreightliner com website ServicePro PartsPro EZWiring ServicePro provides Web based access to the most up to date versions of the publications listed above In addition the Service Solutions feature provides di agnostic assistance with Symptoms Search by connecting to a large knowledge base gathered from technicians and service personnel Search results for both documents and service solutions can be narrowed by
63. e distance months for the 13th Main tenance Number add your category s distance months for the 1st Maintenance Number to the distance months for the 12th Maintenance Num ber then perform the operations listed in the appli cable table in the Maintenance Interval Operations tables For the 14th Maintenance Number add the distance months for the 2nd to the distance months for the 12th continue this pattern for each succes sive Maintenance Number Shuttle Bus Chassis Maintenance Manual November 2014 00 1 00 General Information Vehicle Maintenance Schedule Table 00 02 Vehicle Maintenance Schedule Table Vehicle Maintenance Schedule Table Maintenance Intervals Description Maintenance Operation Set Frequency Miles km Months Initial Maintenance IM first 2500 4000 3 CATEGORY Urban Transport Maintenance 1 M1 every 2500 4000 3 vehicles that annually travel up to Maintenance 2 M2 every 10 000 16 000 12 20 000 miles 32 000 km Maintenance 3 M3 every 30 000 48 000 36 Initial Maintenance IM first 5000 8000 3 CATEGORY II Rural Transport Maintenance 1 M1 every 5000 8000 3 vehicles that annually travel over 20 000 Maintenance 2 M2 every 20 000 32 000 12 miles 32 000 km Maintenance 3 M3 every 60 000 96 500 36 00 2 Shuttle Bus Chassis Maintenance Manual November 2014 General Information Maintenance Interval Table 00 Maintenance Interval Table 00 03
64. e 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 7 Using transmission fluid lubricate the gasket on the filter Shuttle Bus Chassis Maintenance Manual October 2009 26 1 26 8 Using your hand install the filter by turning it clockwise until the filter gasket contacts the con verter housing or cooler manifold Then turn the filter one more complete turn 9 Install the drain plug and sealing washer Tighten the plug 22 to 30 Ibf ft 30 to 40 N m 10 Clean the area around the fill tube and remove the dipstick Using a clean funnel in the fill tube add transmission fluid See Table 1 for approved transmission lubricants and Table 2 for lubricant capacities 11 Check and adjust the fluid level using the proce dure under MOP 26 03 Transmission Fluid Level Checking 3000 B300 Series 4h CAUTION To prevent dirt from entering the transmission use only clean containers and fillers for the trans mission fluid Do not use fillers or containers that have been used for water or antifreeze Dirt water or antifreeze could damage the transmission 1 Park the vehicle on a level surface and apply the parking brakes 2 Operate the vehicle until the transmission reaches normal operating temperature 160 to 200 F 71 to 93 C 3 Clean the area around the drain plug and the transmission fluid pan Pl
65. e straps and add tie straps where spacing between them exceeds 12 inches 30 cm 8 Ensure that all cables have sufficient slack to allow for engine movement and that there is no force on any wiring connectors 9 If any convoluted tubing is damaged check the wiring inside it Replace any damaged or missing convoluted tubing 10 Inspect the battery cables for wear and replace as needed Clean the cable connector terminals with a wire brush See Group 54 of the vehicle Workshop Manual for troubleshooting instruc tions and for adjustment repair or replacement instructions or take the vehicle to an authorized Freightliner dealer 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 Rinse with clean water then dry Paint the retainer assembly if needed to pre vent rusting 10 3 Check that foreign objects such as stones bolts and nuts are removed from the battery box 10 4 After cleaning connect the cables to the batteries and tighten them to the torque Shuttle Bus Chassis Maintenance Manual November 2014 15 1 15 specifications listed on the battery gener ally 10 to 15 Ibf ft 14 to 20 N m 10 5 Coat the battery terminals with dielectric grease 11 Check the terminal
66. ear in the fluid during operation Water contamination is normally characterized as a milky discoloration of the transmission fluid Obvious contamination of the transmission fluid indicates a leak between the water and fluid areas of the trans mission cooler Inspect and pressure test the cooler to confirm the leak replace leaking transmission coolers 1000 2100 2200 B210 B220 Series 1 Park the vehicle on a level surface and apply the parking brake 2 Run the engine until the transmission fluid reaches the operating temperature of 160 to 200 F 71 to 93 C Shift the transmission to neutral N and shut down the engine 26 4h CAUTION To prevent dirt from entering the transmission use only clean containers and fillers for the trans mission fluid Do not use fillers or containers that have been used for water or antifreeze Dirt water or antifreeze could damage the transmission 3 Clean the area around the drain plug Place a drain pan under the transmission and remove the drain plug Examine the fluid while it drains If only the filter is being changed do not drain the fluid 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 See Fig 1 03 31 2000 1261061 1 Magnet 2 External Filter Fig 1 1000 2100 2200 B210 B220 Series Transmission External Filter 5 Remove the magnet from th
67. er pump as follows 5 1 Open the cover to the main power distri bution module PDM 5 2 Pull the fuse in position F6 for the Hydro Max relay 5 3 Inspect the relay to make sure the fuse is not damaged If the fuse is damaged in stall a new fuse If the fuse is not dam aged install the fuse in position F6 5 4 Close the PDM cover 6 Check the operation of the Hydro Max brake booster as follows 6 1 With the ignition off depress the brake pedal and listen for the back up motor to engage The operator should also feel the pedal force relieve and the pedal should depress easily 6 2 With the engine running and the parking brake released ensure that the BRAKE warning indicator light is not on This is a dual indicator and indicates that the park ing brake is set and warns if there is a Hydro Max failure condition other than loss of back up motor power Brakes 42 07 Brake Lines Checking Hydraulic Disc Brakes Check all hydraulic lines and fittings for damage leakage or looseness Replace damaged or leaking components and tighten loose fittings 42 08 Brake Lining Wear Checking Hydraulic Disc Brakes Before checking lining wear with the wheel removed review the following brake lining exposure warnings Breathing brake lining dust asbestos or non asbestos could cause lung cancer or lung dis ease Unless exposure can be reduced below legal limits wear an air purifying respirator approve
68. erse beam connections and the axle connections to ensure they are tightened to the correct torque specification 5 Check all of the other suspension components for any sign of damage looseness wear or cracks Replace worn or damaged parts See Group 32 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 32 4 Shuttle Bus Chassis Maintenance Manual December 2013 Suspension 32 02 21 2005 1321032 Fig 4 Holland Neway ADL 120 123 Suspension 6 Inspect for cracked welds If cracks are found contact Neway immediately for further instruc tions 7 Inspect the torque rod and track bar pivot bush ings for excessive wear Replace worn or dam aged bushings See Group 32 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 8 Move the axle up and down while checking for signs of looseness due to worn parts at the front pivot connections Replace any worn parts by following the procedures in Group 32 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 9 Check for leaks on the height control valves by applying a soapy solution then watching for bubbles at all air connections and fittings 10 Inspect the shock absorbers for oil leaks and 11 worn rubber bushings Replace the shock ab sorbers and or rubber bushings if wear or dam age is noted F
69. ervals are in the maintenance table in this Group A Verification of Inspections Log follows and should be filled in each time the noise emission controls on the vehicle are maintained or repaired Shuttle Bus Chassis Maintenance Manual November 2014 00 7 00 General Information Verification of Inspections Log 00 06 Verification of Inspections Log Verification of Inspections Log Groups 01 20 and 49 Date Mileage Repair Description Cost Repair Facility Group 01 Engine Support Fasteners Group 20 Engine Cooling Fan Drive Group 49 Exhaust System 00 8 Shuttle Bus Chassis Maintenance Manual November 2014 Engine 01 Index Alphabetical Title of Maintenance Operation MOP MOP Number Engine Drive Belt Inspecllhg gto o fug eodein a TEKA Mey Edda A UE PGKA 01 02 Engine Support Fasteners Checking Noise Emission Control 0c eee eee eee 01 01 Shuttle Bus Chassis Maintenance Manual June 2008 Engine 01 01 Engine Support Fasteners Checking Noise Emission Control Mounts should be inspected when the engine is re moved for service Perform the following check Check the front and rear engine support fasteners for tightness See Fig 1 See Chapter 14 of the Shuttle Bus Chassis Operator s Manual for torque specifica tions or take the vehicle to an autho
70. essor 13 13 01 Air Compressor Inspection 1 Inspect the air compressor intake hoses and connections at the air intake and air compressor for physical damage If needed change the hoses and or tighten or replace the connections 2 Inspect the coolant supply and return lines for tight connections Tighten the connections and replace the lines and fasteners if needed 3 For the air governor inspect the piping and con nections for leaks Replace gaskets and faulty components as needed Shuttle Bus Chassis Maintenance Manual November 2014 13 1 Alternator and Starter 1 5 Index Alphabetical Title of Maintenance Operation MOP MOP Number Alternator Battery and Starter Connections Check llle 15 01 Shuttle Bus Chassis Maintenance Manual November 2014 Alternator and Starter 15 01 Alternator Battery and Starter Connections Check Batteries release explosive gas as a by product of their chemical activity Do not smoke when work ing around batteries Put out all flames and re move any source of sparks or intense heat Make sure the battery compartment is completely vented before disconnecting or connecting the battery cables Battery acid is extremely harmful if splashed in the eyes or on the skin Always wear a face shield and protective clothing when working around bat teries Damaged chafed or kinked wiring can cause electrical short circuits and lead to fires causing property damage
71. f experience has shown that extended or shortened life has resulted on a particular installation then the in terval can be increased or decreased accord ingly Bendix AD 9 1 Park the vehicle on a level surface Apply the parking brakes and chock the tires 2 Completely drain all air reservoirs Air pressure gauges should read 0 psi 0 kPa 3 Loosen the desiccant cartridge with a strap wrench at the base of the cartridge Spin off the cartridge and discard it 4 Remove the O ring from the threaded neck and discard it 5 Remove the coalescent filter and discard it IMPORTANT Lubricate the new O rings prior to installation 6 Install the new small O ring in the groove on the bottom of the new coalescent filter 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 Screw on the desiccant cartridge until resistance is detected Then tighten the cartridge 1 4 to 3 4 of a turn by hand 10 Before placing the vehicle in service perform the test below 10 1 Start the engine and build air pressure to 120 psi 827 kPa 10 2 Listen for the purge valve to open and release air A large volume of air will be expelled followed by a slow flow of air lasting approximately 30 seconds 10 3 Shut down the engine 10 4 Perform the ins
72. fy that the coolant level is between the MIN and MAX lines on the surge tank 7 Fill the radiator with coolant Use a mixture of 50 percent water and 50 per cent corrosion inhibiting antifreeze to protect the engine to 34 F 37 C year round See Table 1 for engine cooling system capacities and Table 2 for approved antifreezes Coolant Capacities Radiator Core and System Capacity quarts liters Engine Make and Model Cummins B Series and ISB 30 5 28 9 System capacity includes all hoses fittings and the heater core Table 1 Coolant Capacities Approved Coolants Coolant Designation Fleet Charge JC04 Antifreeze Van Waters and Rogers Ltd Diesel Antifreeze No Canada 6038 Coolant Manufacturer Old World Industries Texaco Freightliner approved antifreeze must meet one of the following condi tions A Ethylene glycol solution that meets GM 6038 M Engineering Stan dards B Ethylene glycol solution that has less than 0 1 anhydrous so dium metasilicate and meets either GM 1825 M or GM 1899 M Engineering Standards Table 2 Approved Coolants 20 03 Eaton Viscous Fan Drive Check Noise Emission Control 4h CAUTION If the fan drive assembly is damaged replace the unit as soon as possible Operating a seized or otherwise damaged clutch reduces fuel economy and could cause serious engine damage See Section 20 02 of the Shuttle Bus Chas
73. g Lubricant formerly Molykote DC 55M or Loctite V 755 O Ring Lubricant 6 Using a new gasket install the plunger and brake valve following the instructions in Group 42 of the Shuttle Bus Chassis Workshop Manual 42 11 Relay Valve Checking Midland Chock the tires Start the engine and run it long enough to pressurize the air system to at least 80 psi 550 kPa then shut down the engine Repeat as necessary to maintain 80 psi 550 kPa pressure during this check Clean off road grime from the relay valve and any debris from the valve exhaust port Listen for air leakage around the fittings or exhaust port Tighten the fittings as necessary Use two wrenches to avoid twisting the tubing If the valve fails this check or is damaged repair or replace it see the Midland Service Manual for in structions Remove the chocks from the tires Shuttle Bus Chassis Maintenance Manual August 2013 42 7 42 42 12 Brake Caliper Slide Rail Lubricating Bosch Hydraulic Brakes Breathing brake lining dust asbestos or non asbestos could cause lung cancer or lung dis ease 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 IMPORTANT Lubricate every 6 months or every 18 000 miles 28 800 km whichever comes first 1 Park the vehicle on a level
74. gularly scheduled maintenance inspections See Fig 1 and Fig 2 for Cummins ATD sensor locations If any dis crepancies are discovered refer to the engine manufacturer s service literature for repair instructions 1 Check for leakage at the clamp that attaches the exhaust pipe to the turbocharger exhaust outlet If leakage exists tighten the nut on the clamp to the required torque If leakage persists install a new clamp 2 Check the exhaust pipe bellows and each ex haust seal clamp for leakage wear cracks or damage Replace damaged components as needed If leakage exists at a clamp tighten the nuts to the required torque If leakage persists install a new exhaust seal clamp Do not reuse seal clamps Once a seal clamp is loosened or removed it must be replaced 3 If present check the condition of the insulation material around the exhaust pipe between the turbocharger and the ATD 4 Check the ATD mounting bands for tightness Tighten to 30 Ibf ft 41 N m if needed Do not overtighten 5 Check for leaks around the clamps that attach the ATD in the ATS and around the clamps that Shuttle Bus Chassis Maintenance Manual January 2010 49 1 49 10 20 2009 1490386 Exhaust Outlet SCR Outlet NOx Sensor DPF Outlet Pressure Sensor DPF Intake Pressure Sensor DPF Inlet Temperature Sensor SCR Inlet Temperature Sensor SCR Outlet Temperature Sensor NOoRON Fig 1 Cummins ATD Sensor Locati
75. haust Pipe Fig 3 Torque Arm Suspension IMPORTANT Be sure to follow the maintenance schedule for checking the torque of the control rod fasteners see Table 1 for control rod torque values 32 11 Suspension Inspecting Neway Inspect the components and check their operation as described below Failure to perform these in spections and checks could result in separation of worn suspension components and loss of vehicle control possibly causing personal injury or death or property damage 1 Chock the front or the rear tires Working at the front of the vehicle or at the rear of the vehicle raise the vehicle so that the tires just clear the ground and the suspension is fully extended Place safety stands under the vehicle frame 2 Squeeze all air springs to check for complete deflation See Fig 4 and Fig 5 If any air springs remain partially or fully inflated see Group 32 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Inspect the air springs for cracks tears or other damage 3 Inspect each air spring for wear at the pedestal connection Inspect for leaks at the upper and lower pedestal connections using a soapy solu tion Replace any worn air springs for instruc tions see Group 32 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an au thorized Freightliner dealer 4 Inspect the bolts and nuts at the pivot connec tions the transv
76. he fasteners attaching the air dryer to the vehicle Use the following torque values 28 Ibf ft 38 N m for SAE grade 5 3 8 16 fas teners 135 Ibf ft 183 N m for SAE grade 5 5 8 11 fas teners Check all air lines fittings and electrical connec tions for damage leakage or looseness 3 Replace damaged or leaking parts and tighten loose fittings or electrical connections Brakes 42 04 Air Reservoir Automatic Drain Valve Disassembling Cleaning and Inspecting Bendix DV 2 Disassemble the drain valve clean the parts with mineral spirits and inspect the parts Replace all rub ber parts and any worn or damaged parts use only genuine Bendix replacement parts or kits Assemble and install the valve then check for proper operation and leakage For instructions see Group 42 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 42 05 Slack Adjuster Lubricating IMPORTANT Perform MOP 42 19 before lubri cating the slack adjusters Automatic slack adjusters must be lubricated periodi cally to ensure proper brake operation Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mechanical problem Adjustment is not repairing Before adjusting an automatic slack adjuster troubleshoot the foundation brake system and inspect it for worn or damaged com ponents Improperly maintaining the vehicle brak
77. he type of chamber being used If the stroke is too short the brakes may drag or will not fully apply Check for improper operation or adjustment of the auto matic slack adjuster 5 Start the engine and build air pressure to at least 100 psi 689 kPa Shut down the engine 6 Check all of the foundation brake components for damage wear and loose or missing parts Re pair as needed Brake Chamber Stroke Specifications Chamber Max Applied Stroke inch mm Manufacturer Type Sizet 9 Less than 1 1 2 38 12 Standard Stroke 16 Less than 1 3 4 44 Meritor 20 24 Less than 1 7 8 48 Long Stroke 24 Less than 2 51 Standard Stroke 30 Long stroke design is indicated by a tag or embossing on the brake chamber t Specifications are relative to a brake application with 80 to 90 psi 550 to 620 kPa air pressure in the brake chambers Table 1 Brake Chamber Stroke Specifications Shuttle Bus Chassis Maintenance Manual August 2013 42 13 Steering 46 Index Alphabetical Title of Maintenance Operation MOP MOP Number Deg Link Buses ET 46 02 Power Steering Reservoir Fluid Level Checking 00000 cece eet eae 46 03 Power Steering Reservoir Fluid and Filter Changing liliis 46 04 Steering Driveline LUDHCAUNG s s aco toos kaanak ha pA BKA in naan Rie ah KP TA ae 46 01 Steering Gear Lubricating cs exci BA LKIHAAA AG DAAN GR KAKA biliar 46 05
78. he vehicle to an authorized Freightliner dealer 4 Check the axle connection welds beam seat to equalizing beam and axle adapter to axle for cracks If welds are cracked grind them out and reweld the parts 5 Move the axle up and down while checking for signs of looseness due to worn parts at the front pivot connections Replace any worn parts by following the procedures in Group 32 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 6 Inspect the shock absorbers for oil leaks and worn rubber bushings Replace the shock ab sorbers and or rubber bushings if wear or dam age is noted For instructions see Group 32 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 7 Remove the safety stands and lower the rear of the vehicle to the ground Run the engine until air pressure of at least 100 psi 689 kPa is maintained throughout the system 32 8 Check that all air springs are inflated If the air springs do not inflate see Group 32 of the Shuttle Bus Chassis Workshop Manual for pos sible causes and corrections or take the vehicle to an authorized Freightliner dealer 32 08 U Bolt Torque Checking Freightliner AirLiner NOTICE Failure to retorque the U bolt nuts could result in spring breakage and abnormal tire wear In a diagonal pattern tighten all 5 8 18 U bolt nuts 205 Ibf ft 278 N m tighten all 3 4A 16
79. it axle use a lubricant recommended in Table 1 For a Meritor axle add Castrol TranSynd syn thetic automatic transmission oil 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 5 Install the oil fill plug and tighten it 30 Ibf ft 41 N m for a Detroit axle or 35 Ibf ft 47 N m for a Meritor axle Y N 11 07 2012 1350575 NOTE Engine front configuration shown engine rear configuration is similar A Front View B Rear View 1 Breather Hose 3 Oil Drain Plug 2 Axle Housing Breather 4 Oil Fill Plug Fig 1 Component Locations Detroit Axles 08 19 2009 1350150 1 Ratio Tag 5 Model Number 2 Drain Plug 6 Axle Housing Breather 3 Limited Slip 7 Manufacturing Date Lubrication Tag 8 Part Number 4 Filler Plug Fig 2 Meritor Rear Axle Differential MB Shuttle Bus Shuttle Bus Chassis Maintenance Manual August 2013 35 1 35 Rear Axle 06 07 94 f350002a 1 Axle Housing Breather 2 Fill Plug 3 Temperature Indicator Plug Fig 3 Meritor Axle Housing typical XB Shuttle Bus 08 17 2009 350061a A Correct lube level at bottom of fill hole B Incorrect lube level below fill hole Fig 4 Axle Lubricant Level Inspection Drive Axle Recommended Lubricant t Lubricant Recommended SA
80. k the tires 2 Remove the four mounting bolts and discard See Fig 1 Lift the canister about 1 2 inch and remove 3 Place the assembly upside down as shown in Fig 2 Press the cartridge down to compress the rubber spring then rotate counterclockwise 45 degrees to release the cartridge The cartridge itself contains no hazardous material but there may be a small amount of oil from the compressor 4 Clean the inside of the canister and aluminum housing 5 Remove the cartridge O ring and discard 6 Remove the new cartridge from the kit and make certain the rubber spring is attached See Fig 3 7 Install the new cartridge into the canister Align the slots on the cartridge with the dimplets inside the canister Press the cartridge into the canister and rotate clockwise 45 degrees to engage the cartridge as shown in Fig 4 8 Place a new O ring on the aluminum housing Place the cartridge assembly on the air dryer housing and install four new mounting bolts Use an alternating diagonal pattern and tighten the bolts 35 to 40 Ibf ft 47 to 54 N m 10 Before placing the vehicle in service perform the test below Information in this section is provided by Haldex and is used with permis sion 42 2 Shuttle Bus Chassis Maintenance Manual August 2013 42 Brakes ITILI EELE 3 SS LEZ AY lt B 2 01 10 2011 1422527 A
81. k the air actuated parking brake cable to ensure that the actuation system is in good working order and for any adjustment that is needed 1 Park the vehicle on a level surface and chock the tires 2 Make sure the air system is fully charged then shut down the engine 3 Release the parking brake if it is applied 4 Remove the cotter pin and clevis pin from the clevis at the brake lever See Fig 13 5 Pull the brake lever until shoe to drum contact is made 08 10 93 Ba 1420605 Fig 13 Remove the Cotter Pin and Clevis Pin 07 26 93 1420390 Too Loose Correct Position of Actuating Lever Too Tight Correct Cable Adjustment Actuating Lever gt OOW gt Fig 14 Parking Brake Cable Installation typical 9 Set the parking brake and remove the chocks 10 Test the parking brake before returning the ve hicle to service 42 19 Brake Inspection IMPORTANT This procedure should be per formed prior to lubrication of the brake compo nents If the brakes must be repaired or they require adjustment see Group 42 of the Shuttle Bus 42 12 Shuttle Bus Chassis Maintenance Manual August 2013 Brakes Chassis Workshop Manual for repair adjust ment and troubleshooting procedures Or take the vehicle to an authorized Freightliner dealer Parking Brake Operational Check Ah CAUTION Perform the following check in a clear safe area If the parking brakes fail to hold
82. l not to overfill the hubs Overfilling may cause oil to be forced out of the hubs and to con taminate the brake linings and other brake compo nents This could result in loss of vehicle control and lead to personal injury and property damage Front Axle 1 With the vehicle on a level surface rotate the front wheels so that the front hub drain plugs are positioned downward 2 Chock the tires 3 Place suitable containers under the hubs re move the filler caps in the ends of the hub caps and the drain plugs and allow the hubs to drain completely See Fig 7 07 09 2009 f330247b A Hub Cavity Full 1 Fill Plug Magnetic Drain 2 Drain Plug Fig 7 Oil Filled Hub Cap 4 Install the drain plugs and tighten 25 Ibf in 282 N cm 5 Add approximately 1 to 1 1 2 pints 0 5 to 0 7 L of oil 80 90 hypoid gear oil to each hub 6 Rotate the wheels allow the oil to settle and check the levels IMPORTANT Fill the hubs to the level indicators on the hub caps or to no more than 1 4 inch 6 mm above the indicators See Fig 7 7 Install the filler caps securely 8 Remove the chocks from the tires 33 07 Wheel End Inspection IMPORTANT For ZF IFS axles ZF recom mends that all grease fittings be lubricated once 33 4 Shuttle Bus Chassis Maintenance Manual August 2013 Front Axle a year preferably before periods of inactivity The wheel hub should be disassembled in spected a
83. l tank and allow the tank to drain until all traces of water and sediment have disappeared install the plug or close the drain valve On vehicles with a quarter turn fuel cap check to be sure that the vent line at the inboard side of the fuel tank is clean and not plugged 47 02 Fuel Water Separator Element Replacing Alliance The only maintenance necessary on an Alliance fuel water separator is to replace the filter element Diesel fuel is flammable and can ignite if exposed to an open flame intense heat or other ignition source Do not drain fuel near or expose fuel vapor to open flame or intense heat Exposure to open flame or intense heat could start a fire pos sibly resulting in personal injury or property dam age When working on a fuel system have a fire extinguisher within easy reach 1 Drain off some fuel by loosening the vent plug and opening the drain valve See Fig 1 2 Disconnect the water sensor and heater connec tions if equipped 3 Remove the element and bowl together by turn ing counterclockwise 4 Remove the bowl from the element and clean the O ring seating surface 5 Apply a coating of clean fuel or motor oil to the new O ring and element seal 6 Spin the bowl onto the new element then spin them both onto the filter head snugly by hand only IMPORTANT Do not use tools to tighten the bowl and element 47 2 4 1 0 d 5 10 TI 9 eee 6 Ls 7
84. luid leakage could cause loss of power steering assist possibly resulting in personal injury and property damage 8 Place the disconnected end of the steering hyd roboost hose in a drain bucket Do not start the engine while draining the system 9 Raise the front of the vehicle with a floor jack and support it with jack stands 10 Have someone turn the steering wheel to full lock left and right and capture the fluid flowing from the hose in the drain bucket Add fluid to the reservoir as needed Steering 11 Continue turning the steering wheel until clean power steering fluid flows from the hose into the drain bucket 12 Remove the plug from the reservoir and recon nect the steering gear to reservoir hose to the reservoir 13 Tighten the hose fitting nut finger tight then with a wrench tighten until there is firm resistance Tighten one sixth turn more Do not overtighten Remove the jack stands and lower the vehicle 14 Fill the reservoir with approved fluid as needed Start the engine and let it idle Have someone turn the steering wheel from lock to lock until no bubbles are seen in the reservoir Turn off the engine 15 Install a new cover gasket the cover and the 3 8 16 hexnut Tighten the hexnut 28 Ibf ft 38 N m Install the dipstick 16 Start the engine and check the power steering reservoir fluid level If the fluid level is low add more of the approved fluid to bring the level up to the f
85. n replace it 20 02 Radiator Pressure Flush and Coolant Change NOTE For additional instructions on cleaning and flushing the cooling system see the engine manufacturer s maintenance and operation manual Drain the coolant only when the coolant and en gine are cool Draining it when these are hot could cause severe personal injury due to scalding 1 Drain the radiator 1 1 Remove the surge tank cap 1 2 Remove the plug from the bottom of the radiator on the left side of the tank to drain the engine coolant See Fig 1 2 Disconnect the radiator inlet and outlet hose con nections 3 Flush the radiator 3 1 Attach a flushing gun nozzle to the radia tor outlet 3 2 Run water in until the radiator is full 3 3 Apply no more than 20 psi 138 kPa air pressure intermittently to help dislodge sediment buildup in the core NG 03 31 Ng a Sa O o C 1500340 NOTE Front radiator shown other models will be simi lar 1 Bumper 2 Radiator Drain Plug 3 Engine Fig 1 Radiator Drain Plug CAUTION When flushing the radiator do not apply more than 20 psi 138 kPa air pressure Excessive pres sure can damage the radiator or heater core 4 Drain the radiator Then flush the radiator until clean water flows from it Remove the flushing gun 5 Install the plug in the bottom of the radiator 6 Connect the hoses When you install Breeze Constant Torque hose clamps the clamp
86. nd the wheel bearings repacked every 1 000 000 miles 1 609 000 km 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires Never work around or under a vehicle that is sup ported only by a jack Always support the vehicle with safety stands Jacks can slip causing the vehicle to fall which could result in serious injury or death 2 Raise the front of the vehicle and support it with safety stands 3 Remove the front wheel and tire assemblies For instructions see Group 40 of the Shuttle Bus Workshop Manual 4 Remove the brake drum For more information see Group 33 of the Shuttle Bus Workshop Manual 5 Check for loose damaged or missing fasteners and hubcaps 6 Check for lubricant around the hub cap and wheel If lubricant is present investigate the cause and take corrective action 7 Check for lubricant around the hub brake hard ware and brake shoes if installed If lubricant is present check the oil seal and replace it as nec essary For instructions see Section 33 03 of the Shuttle Bus Workshop Manual 8 Inspect the lubricant for discoloration Under nor mal conditions the lubricant will darken a white or milky appearance indicates water contamina tion If the lubricant is discolored service the wheel end See the Shuttle Bus Workshop Manual and manufacturer literature for proce dures IMPORTANT Do not mix different types of lubri cants
87. ng balance weights and for debris buildup Remove any buildup If any balance weights are missing re move the driveshaft and have it balanced For instructions see Group 41 of the vehicle Work shop Manual or take the vehicle to an autho rized Freightliner dealer 4 Check that the yoke plug is not loose or missing Replace the yoke plug if needed If the yoke plug is missing the splined shaft may be hitting the yoke plug and knocking it out check the drive shaft for proper length U Joint Lubrication 1 Wipe all old grease and dirt from each U joint grease fitting 2 Use a hand type grease gun or a high pressure gun with a low pressure adaptor to lubricate the U joints See Fig 1 NOTE If a low pressure adaptor is not used with the high pressure gun the U joints may not receive enough lubricant 10 20 93 f410050a A After grease appears cover the pressure relief hole while continuing to lubricate 1 Slip Joint Grease 5 Yoke Plug Pressure Fitting with grease Relief Hole gun attached 6 Slip Joint Seal 2 Yoke Plug 7 Full Round Yoke 3 Grease 8 U Joint Grease Fitting 4 Half Round Yoke Fig 1 Slip Joint and U Joint Lubricating 3 Using lithium 12 hydroxy stearate grease NLGI grade 1 or 2 with EP additives lubricate until new grease can be seen at all four U joint seals NOTICE Fresh lubricant must be seen escaping from all four of the bearing cup seals of each U joint
88. nomic reasons be correlated with lubricant changes that are governed by climatic conditions and magnetic plug mainte nance Change lubricant type and viscosity as cli matic temperatures demand regardless of vehicle mileage or established change schedule The normal operating temperature of compounded lubricants during the summer season is about 160 to 220 F 71 to 104 C The chemicals and additives that give these lubricants increased load carrying ca pacity oxidize faster at temperatures above 220 F 104 C contributing to more rapid lubricant deterio ration For this reason lubricants of this type that operate continuously at high temperatures must be changed more frequently NOTICE Failure to change the axle lubricant at more fre quent intervals when adverse operating condi tions require could result in axle damage 35 2 Shuttle Bus Chassis Maintenance Manual August 2013 Rear Axle NOTE A normal oil change does not include the hubs Detroit Axle Axle Draining 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires 2 Clean the fill plug and the area around it Re move the plug from the oil fill hole See Fig 1 4h CAUTION Be careful when draining the axle oil It may be very hot and could cause personal injury if it con tacts the skin 3 Remove the plug at the bottom of the housing and drain the lubricant while the unit is warm All
89. nt seal and grease fitting 20 4 Shuttle Bus Chassis Maintenance Manual November 2014 Transmission Title of Maintenance Operation MOP Transmission Breather Checking 005 Transmission Fluid Level Checking Transmission Fluid and Filter Changing 26 Index Alphabetical MOP Number Shuttle Bus Chassis Maintenance Manual October 2009 Transmission 26 01 Transmission Breather Checking The breather is located at the top left rear of the transmission main housing The breather prevents air pressure buildup within the transmission Transmission housing breathers must remain unob structed A plugged breather could result in pressure build up which could cause oil leakage If the breather is plugged clean or replace it Check more often if the vehicle is operating under very dusty conditions 4h CAUTION When cleaning the transmission do not spray steam water or cleaning solution directly at the breather Spraying steam water or cleaning solu tion directly at the breather can force the water or cleaning solution into the transmission and con taminate the transmission fluid 26 02 Transmission Fluid and Filter Changing IMPORTANT For oil and filter change intervals see the applicable Allison Operator s Manual When draining transmission fluid check for evidence of dirt or water contamination A small amount of condensation will app
90. old belt 7 Visually inspect the pulleys for excessive play or wobble Excessive play or wobble indicates a failure of the pulley bearing Check for belt squealing or squeaking Replace the bearings as necessary NOTE If it is difficult to distinguish the location of a supposed bearing noise obtain a stetho scope and place it on the component being checked not the pulley to isolate the area from outside interference 8 Inspect all pulleys for foreign objects oil or grease in the grooves Belt Tension Inspection Spring Tension Type On belts equipped with a spring tensioner the belt tension is automatically adjusted Check that the ten sioner is holding tension on the belt by inserting the end of a breaker bar in the 1 2 inch square hole on the forward face of the tensioner and rotating the tensioner down away from the belt When the breaker bar is slowly released the tensioner should return to its original position If not see Group 01 of the Shuttle Bus Chassis Workshop Manual for re placement instructions or take the vehicle to an au thorized Freightliner dealer 01 2 Shuttle Bus Chassis Maintenance Manual June 2008 Air Intake Title of Maintenance Operation MOP Air Cleaner Inspecting and Replacing Air Intake System Inspecting liliis 09 Index Alphabetical MOP Number Shuttle Bus Chassis Maintenance Manual April 2013 Air Intake 09 01 Air Cleaner Inspe
91. omatic slack adjuster through the lube fitting See Fig 6 Lubricate the slack adjuster until clean lubricant flows from the grease relief opening in the boot 42 06 Bendix Hydro Max Brake System Inspecting NOTE If possible remove both caps when fill ing the reservoir If only one cap can be re moved allow ample time for the reservoir to fill 1 Check the fluid level in the hydraulic brake fluid reservoir If needed fill the reservoir up to the 04 26 2012 1460513a A Open caps and check fluid level B Fill to this level Fig 7 Hydraulic Brake Fluid Reservoir Shuttle Bus Chassis Maintenance Manual August 2013 42 5 42 2 Check all hydraulic lines and fittings for damage leakage or looseness Replace damaged or leaking components and tighten loose fittings 3 Check the brake module for leaks If leaks are found repair or replace the brake module See Group 42 of the Shuttle Bus Chassis Workshop Manual for replacement instructions or take the vehicle to an authorized Freightliner dealer 4 Check the electrical connections and harnesses Make sure the connectors are fully seated and the harnesses are not chafed or cut Repair or replace any damaged harness Disconnect any loose connectors and inspect the terminals for corrosion If corrosion is present replace the ter minals If corrosion is not present reconnect the connector 5 Check the fuse for the hydraulic brake boost
92. onditioner set the controls at maximum cooling and blower speed 83 3 Allow the system to run for at least 10 minutes longer on hot and humid days 4 Check air flow from the vents If there is not enough air flow check the air intake vent for blockage and the blower motor for proper opera tion If the air flow is not cold enough see Group 83 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 5 Carefully feel the system lines e The compressor discharge line should feel hot e The condenser inlet line should be notice ably warmer than the outlet line e The line from the condenser should feel warm e The inlet and outlet lines of the receiver drier should be about the same tempera ture e The line from the receiver drier to the evaporator should feel warm e The line from the evaporator to the com pressor should feel cold NOTE Oily spots on the lines or at the fittings could indicate a system leak Refrigerant Checking If equipped with a moisture indicator sight glass check the color of the moisture indicator See Fig 1 Item 1 If the moisture indicator is a deep cobalt blue the refrigerant charge is dry If the indicator is not blue the system is contaminated with water recover the refrigerant replace the receiver drier evacuate the System and add a full refrigerant charge Follow the instructions in Group 83 of the Shuttle Bus Chassis
93. ons Top Side by Side Mounting retain the DPF in the ATD No leaks are allowed anywhere in the system 6 Check all sensors attached to the ATD for leaks or damaged wires No leaks are allowed 7 Check the DPF exterior surface for dents or other damage A dent over 3 inches 76 mm in diameter and 1 4 inch 6 mm deep could cause internal damage to the DPF causing it to mal function 8 Check the SCR catalyst for dents and other damage 9 Check for heat discoloration on the surface of the ATD Heat discoloration may indicate internal damage especially around the DPF NOTE Diesel exhaust fluid creeps causing white crystals to form around the line fittings The presence of crystals does not mean the Exhaust system has a leak Replacing fittings or trouble shooting components is not necessary unless there is a system failure or a fault code 10 Check the DEF tank pump metering unit and lines for leaks See Group 49 of the Shuttle Bus Chassis Workshop Manual for repair procedures 11 Check any wires lines or hoses within 4 inches 10 cm of the exhaust system for heat damage Repair or reroute as needed Diesel Exhaust Fluid DEF Filter Replacement The Environmental Protection Agency s 2010 regula tions require lower nitrogen oxide NOx exhaust emissions Selective catalytic reduction SCR uses diesel exhaust fluid DEF to lower NOx emissions in the vehicle exhaust A filter in the DEF pump pre vent
94. or instructions see Group 32 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Remove the safety stands and lower the vehicle to the ground Run the engine until air pressure of at least 100 psi 689 kPa is maintained throughout the system IMPORTANT Repeat this check at both ends of the vehicle 12 Check that all air springs are inflated If the air springs do not inflate see Group 32 of the Shuttle Bus Chassis Workshop Manual for pos sible causes and corrections or take the vehicle to an authorized Freightliner dealer Shuttle Bus Chassis Maintenance Manual December 2013 32 5 32 Suspension 03 20 2008 1321110 Fig 5 Holland AS 120 Suspension j j grease or mineral oil on the lubricating points 32 12 ZF IFS Lubricating ag N eee IMPORTANT Do not raise the vehicle by plac ing a jack under the control arm s The weight of the vehicle could damage the control arms and cause alignment issues See Fig 6 for cor rect jack placement 1 Chock the rear tires and apply the parking brake Raise the front of the vehicle with a jack so the tires just clear the ground and the suspension is fully extended Place safety stands under the vehicle frame Never work around or under a vehicle that is sup ported only by a jack Always support the vehicle with safety stands Jacks can slip causing the vehicle to fall which could result in serious
95. ot over seal clamps Once a seal clamp is loosened or tighten removed it must be replaced 5 Check for leaks around the clamps that attach 3 If present check the condition of the insulation the ATD in the ATS and around the clamps that material around the exhaust pipe between the retain the DPF in the ATD No leaks are allowed turbocharger and the ATD anywhere in the system 6 Check all sensors attached to the ATD for leaks or damaged wires No leaks are allowed 49 4 Shuttle Bus Chassis Maintenance Manual January 2010 Exhaust 49 7 Check the DPF exterior surface for dents or other damage See Fig 3 Ref A A dent over 3 inches 76 mm in diameter and 1 4 inch 6 mm deep could cause internal damage to the DPF causing it to malfunction 8 Check for heat discoloration on the surface of the 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 Shuttle Bus Chassis Maintenance Manual January 2010 49 5 Electrical Instruments and Controls 54 Index Alphabetical Title of Maintenance Operation MOP MOP Number Battery Voltage Checking siccus taari eos ici a tdeo dS el todas ded chard cnn laste aes ney diti Bra dens 54 02 Ground Cables Checking and Cleaning s su acere eR RE x Rune A S FERT URS 54 01 Shuttle Bus Chassis Maintenance Manual June 2008
96. ow enough time for all the old lubricant to drain completely 4 Clean the drain plug For magnetic drain plugs a piece of key stock or any other convenient steel slug may be used to short the two magnetic poles and divert the magnetic field 5 After cleaning the drain plug install and tighten the plug 30 Ibf ft 41 N m Axle Filling 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 recommended lubricant see Table 1 Refer to Table 2 for Detroit drive axle lubricant capacities 2 Install the fill hole plug and tighten it 30 Ibf ft 41 N m 3 After filling the carrier and housing assembly with lubricant drive the vehicle unloaded for one or two miles two or three kilometers at speeds not to exceed 25 mph 40 km h to thoroughly circu late the lubricant throughout the assembly 35 Detroit Drive Axle Lubricant Capacities Axle Model Capacity pints liters t ARS 17 5 2 15 7 ARS 19 0 2 15 7 ARS 20 0 2 15 7 ARS 21 0 2 15 7 ARS 21 0 4 23 11 ARS 23 0 4 23 11 Detroit Drive Axle Lubricant Capacities Axle Model Capacity pints liters t ARS 13 0 2 15 7 ARS 15 0 2 15 7 Model code may have a D in the prefix for example DA RS 13 0 2 t Quantities listed are approximate and include 1 pint 0 5 liter for each wheel end and with the drive pinion at 3 degrees
97. p 2 47 of the Shuttle Bus Chassis Workshop Manual 3 or take the vehicle to an authorized Freightliner dealer Failure to observe these precautions could lead to the ignition of the natural gas which could cause severe bodily harm or death or property damage The high pressure fuel filter is located inside of the left hand frame rail near the rear of the fuel tank Shut off the fuel supply at the tanks Vent the fuel supply system After the system has been vented remove the filter housing See Fig 4 Shuttle Bus Chassis Maintenance Manual August 2013 47 5 47 4 Remove and discard the O ring used to seal the filter housing 5 Remove and discard the filter element Gy ES Fuel The low pressure fuel filter is located inside of the left hand frame rail near the center of the fuel tank Turn the valve counterclockwise to close the filter PRs 5 e a L L ba 08 26 96 1 Fuel Filter Head 2 Filter Element 3 O Ring 4 Filter Housing NIN 1470239 5 Filter Drain Fig 4 CNG High Pressure Fuel Filter Assembly 6 Install the new element and press it into place 7 Install the new O ring 8 Apply a thread lubricant to the housing threads and screw the filter housing onto the filter head 9 Check for leaks using a natural gas detector 10 11
98. pections in Maintenance Operation 42 03 Bendix AD IP 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires 2 Using a wrench or a socket loosen the desiccant cartridge bolt Then separate the desiccant car tridge from the end cover 3 Pull the cartridge bolt out of the cover and re move the cartridge Do not attempt to disassemble the desiccant car tridge assembly Parts for the assembly are not available and the cartridge contains a 150 Ib Shuttle Bus Chassis Maintenance Manual August 2013 42 1 42 spring that cannot be mechanically caged Disas sembly could release the spring resulting in per sonal injury 4 Remove and discard both O rings from the car tridge bolt 5 Using a clean rag wipe clean the inside of the end cover Clean the cartridge bolt bore in the end cover and the sealing surfaces for the large and small diameter desiccant cartridge sealing rings 6 Inspect the end cover for physical damage then inspect all air line fittings for corrosion replace as necessary 7 Clean and inspect the bolt paying attention to the threads and O ring grooves IMPORTANT Use only the grease supplied with Bendix replacement kits 8 Lubricate the O rings bolt O ring grooves seal ing rings and cartridge grooves Lubricate the end cover bore for the bolt 9 Install both O rings on the cartridge bolt then using a twisting motion inser
99. r 3 With the engine running wipe the dipstick clean and check the fluid level Any level within the COLD RUN lower band is satisfactory for oper ating the vehicle See Fig 3 If the level is not within the COLD RUN band add or drain fluid until it reaches the middle of the COLD RUN band 4 Perform a hot check at the first opportunity after normal operating temperature 160 to 200 F 71 to 93 C is reached Hot Check Recommended Method With the vehicle on a level surface and the transmis sion in neutral at operating temperature perform the steps below 1 On the transmission shift selector press the up and down arrow keys simultaneously See Fig 4 2 Release the arrow keys and wait for a two minute countdown 3 The transmission shift selector display screen will display one of the following messages e OL OK indicates an acceptable oil level e OL HI followed by a number indicates the amount that is over filled Transmission e OL LO followed by a number indicates the amount that is under filled e OL 70 indicates that the transmission is not up to operating temperature Alternate Method 1 Operate the transmission in a Drive D range until normal operating temperature 160 to 200 F 71 to 93 C is reached NOTE The fluid must be warm to ensure an accurate check The fluid level rises as tempera ture increases 2 Park the vehicle Shift to Neutral N and set the parking brak
100. rder the text reference numbers and de scriptions of all maintenance operations and indi cates all maintenance operation sets at which each operation must be performed Use Before placing your new vehicle in service determine the maintenance category Category or Il that ap plies to your intended use of the vehicle See the Vehicle Maintenance Schedule Table to determine the distance or time interval at which each mainte nance operation set must be performed for your cat egory of vehicle When the vehicle reaches the actual distance or months given for an interval see the Maintenance Interval Table to find the maintenance operation set that applies to that interval Then perform the mainte nance operations listed in the applicable Mainte nance Interval Operations table Use the mainte nance operation reference numbers to find instructions in the manual for completion of each op eration Complete each maintenance operation set at the re quired interval Then when you have completed maintenance operation set M3 under the 12th Main tenance Number listed in the Maintenance Interval Table repeat the pattern The 13th Maintenance Number will begin at maintenance operation set M1 under the 1st Maintenance Number listed in the Maintenance Interval Table NOTE When performing operations for the 13th Maintenance Number complete the M1 opera tions only not the Initial Maintenance opera tions To determine th
101. rized Freightliner dealer NOTE At engine overhaul and whenever the engine has been removed inspect the lower and upper isolators and replace them if they are worn See Fig 1 See Section 01 02 of the Shuttle Bus Chassis Workshop Manual for pro cedures or take the vehicle to an authorized Freightliner dealer 10 05 94 12200472 1 Lower Isolator 2 Engine Support Washer 4 Hexnut 5 Engine Mount 6 Upper Isolator 3 Capscrew Fig 1 Rear Engine Mount 01 01 02 Engine Drive Belt Inspecting The engine and the belt must be cool before you check the belt Handling a hot belt can cause per sonal injury Worn or loose drive belts may cause premature bearing failure or engine overheating Excessive ten sion or too little tension on the belt may result in ex cessive and premature belt wear Poly V belts or serpentine belts are retained by a belt tensioner that requires no tension adjustment Replace the engine drive belt if any conditions described in the visual description are found V belts are installed as indi vidual belts and as matched sets When replacing a matched set of belts always replace both belts at the same time Matched belts must be from the same manufacturer To inspect a belt gently twist the belt to view the belt sidewalls and bottom Visually in spect all drive belts for the following conditions then perform the belt tension inspection Visual Inspection 1 Inspect the
102. s Shock Absorber Upper Bracket Mounting Locknuts 5 8 11 125 170 Air Spring Upper Mounting 5 8 11 125 170 Tighten all suspension fasteners to the torque values in Table 1 Also tighten all suspension air line fittings and air lines Bracket Spring Hanger Mounting Loeknuts 3 4 10 210 285 Torque Arm Rod Nut 5 8 11 136 185 Table 1 Torque Values for Freightliner AirLiner Suspensions 32 2 Shuttle Bus Chassis Maintenance Manual December 2013 Suspension 32 07 Component Inspecting and Operation Checking Freightliner AirLiner Inspect the components and check their operation as described below Failure to perform these in spections and checks could result in separation of worn suspension components and loss of vehicle control possibly causing personal injury and property damage 1 Chock the front tires Raise the rear of the ve hicle so that the tires just clear the ground and so that the suspension is fully extended Place safety stands under the vehicle frame 2 Squeeze all air springs to check for complete deflation If any air springs remain partially or fully inflated see Group 32 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 3 Inspect each air spring for wear at its connection to the pedestal Replace any worn air springs for instructions see Group 32 of the Shuttle Bus Chassis Workshop Manual or take t
103. s 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 revision and editions without notice Refer to www Daimler TrucksNorthAmerica com and www FreightlinerChassis com for more information or contact Daimler Trucks North America LLC at the address below Environmental Concerns and Recommendations Whenever you see instructions in this manual to discard materials you should attempt to reclaim and recycle them To preserve our environment follow appropriate environmental rules and regulations when disposing of materials NOTICE Parts Replacement Considerations Do not replace suspension axle or steering parts such as springs wheels hubs and steering gears with used parts Used parts may have been subjected to collisions or improper use and have undetected structural damage 2000 2015 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 Daimler Trucks North America LLC is a Daimler company Daimler Trucks North America
104. s clogging of the DEF metering unit injection nozzle See the engine manufacturers maintenance manual for DEF filter replacement instructions and mainte nance intervals EPA07 Exhaust System Definitions of ATS Terms Refer to the following list of definitions of ATS terms and components e Aftertreatment System ATS the entire ex haust system from the turbocharger to the ex haust stack or tail pipe e Aftertreatment Device ATD a muffler like can ister that houses a DPF and sensors e Diesel Particulate Filter DPF a filter that col lects and holds particulate matter soot and ash e Diesel Oxidation Catalyst DOC oxidizes hy drocarbons and reduces NOx e Sensors detect temperatures and pressure within the ATS e Diffuser a device used as a deflector for dis tributing mixing and reducing the velocity of air flow 49 2 Shuttle Bus Chassis Maintenance Manual January 2010 Exhaust 49 1 SCR Inlet Temperature Sensor 2 SCR Outlet Temperature Sensor 3 SCR Outlet NOx Sensor 5 NNNM asa 10 20 2009 1490387 4 DPF Outlet Temperature Sensor 5 DPF Catalyst Outlet Temperature Sensor 6 DPF Outlet Temperature Sensor Fig 2 Cummins ATD Sensor Locations Side by Side Mounting Inspection IMPORTANT The Environmental Protection Agency s 2007 regulations require lower ex haust emissions thus requiring new exhaust system components See Fig 3 In particular the
105. s must be tightened to the correct torque The screw tip of the clamp must extend about 1 4 inch 6 mm from the clamp housing and the belleville washer stacks must be collapsed almost flat See Fig 2 Use a torque wrench to install these hose clamps The correct installation torque for Breeze Constant Torque hose clamps is as fol lows For hose clamps with a 5 16 inch tightening screw hex 40 Ibf in 460 N cm For hose clamps with a 3 8 inch tightening screw hex 90 Ibf in 1020 N cm NOTE All hose clamps will lose torque after installation due to compression set However when correctly installed Breeze Constant Torque clamps will hold enough torque to auto Shuttle Bus Chassis Maintenance Manual November 2014 20 1 20 Engine Cooling Radiator Ny 08 15 94 f200286 A The screw tip must extend about 1 4 inch 6 mm B The belleville washer stacks must be collapsed almost flat 1 Tightening Screw Hex Fig 2 Breeze Constant Torque Hose Clamp matically adjust and keep consistent sealing pressure During vehicle operation and shut down the screw tip may adjust according to temperature and pressure changes The torque may need to be adjusted for individual applica tions IMPORTANT On vehicles with EPA07 compliant engines the coolant capacity varies depending on the engine and accessory installation After servicing the cooling system always veri
106. s 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 Alternator and Starter 15 2 Shuttle Bus Chassis Maintenance Manual November 2014 Engine Cooling Radiator 20 Index Alphabetical Title of Maintenance Operation MOP MOP Number Eaton Viscous Fan Drive Check Noise Emission Control leeren 20 03 Mechanical Fan Drive Gearbox Lubrication 22 ns 20 05 Mechanical Fan Drive Gearbox Oil Change lille 20 04 Radiator CaP neck coa dans ra tulad A as 20 01 Radiator Pressure Flush and Coolant Change eee eee 20 02 Shuttle Bus Chassis Maintenance Manual November 2014 Engine Cooling Radiator 20 01 Radiator Cap Check Drain the coolant only when the coolant and en gine are cool Draining it when these are hot could cause severe personal injury due to scalding The radiator cap is the most often ignored part in the cooling system If it is suspect replace it An inspec tion means checking the cap with a pressure tester A radiator cap in good condition will not open below 9 psi 62 kPa A visual check is also in order look for signs of deterioration of the inner gasket Also look for cracks or breaks in the spring retainer in the cap and for corrosion or deposits on the spring itself If the spring is not in perfect condition it has prob ably lost tensio
107. se gear lubricant or an SAE 75W 90 multi purpose synthetic gear lubricant See Fig 4 NOTE Meritor axles have a small tapped and plugged hole located near and below the hous ing oil fill hole This smaller hole is for the lubri cant temperature sensor only and must not be used as a fill or level hole 2 Install the fill hole plug and tighten it 35 Ibf ft 47 N m 3 After filling the carrier and housing assembly with lubricant drive the vehicle unloaded for 1 or 2 miles 2 or 3 kilometers at speeds not to exceed 25 mph 40 km h to thoroughly circulate the lubricant throughout the assembly See Table 3 for lubricant capacity Meritor Drive Axle Lubricant Capacities Axle Model Capacity pints liters RS 13 120 16 7 6 RS 15 120 16 7 6 RS 17 145 33 6 15 9 RS 19 145 34 4 16 3 RS 21 145 32 15 1 RS 23 160 42 19 9 RS 26 180 46 6 22 Quantities listed are approximate and include 1 pint 0 5 liter for each wheel end and with the drive pinion at 3 degrees Table 3 Meritor Drive Axle Lubricant Capacities 35 03 Axle Breather Checking The axle housing breather must remain unob structed Whenever the axle lubricant level is checked also check that the axle breather is open Check more often under poor operating conditions If the breather is plugged clean or replace it as needed For component locations on a Detroit axle see Fig 1 Meritor axles are shown in
108. sis Work shop Manual for replacement instructions or take the vehicle to an authorized Freightliner dealer 1 With the engine shut down rotate the fan at least one full turn by hand It should have a smooth steady drag If it does not replace the fan clutch 2 Check for physical damage to the fan or fan shroud 3 Atthe fan clutch mounting 3 1 Check for correct drive belt alignment and tension For specifications see Group 01 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an autho rized Freightliner dealer 3 2 Check for wear of the fan clutch bearings There should be no side to side or in and out movement of the fan clutch 3 3 Do all of the checks in Section 20 00 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an autho rized Freightliner dealer 20 2 Shuttle Bus Chassis Maintenance Manual November 2014 Engine Cooling Radiator 20 04 Mechanical Fan Drive Gearbox Oil Change 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires 2 Place a drain pan under the fan drive gearbox IMPORTANT Label the plugs as they are re moved The breather fill plug must always be installed in the top of the gearbox opposite the drain plug 3 Remove the drain plug and breather fill plug shown in Fig 3 to begin draining the oil 2 m d id o 4 08 31 2011 1200744
109. ssure Fuel Filter Assembly IMPORTANT The fuel flow arrow on the fuel strainer must be pointed toward the engine 2 Remove the strainer and replace it with a new one 3 Secure the fuel strainer with tie bands 47 Shuttle Bus Chassis Maintenance Manual August 2013 4717 Exhaust 49 Index Alphabetical Title of Maintenance Operation MOP MOP Number Exhaust System Inspecting Noise Emission Control 00 ee 49 01 Shuttle Bus Chassis Maintenance Manual January 2010 Exhaust 49 01 Exhaust System Inspecting Noise Emission Control The exhaust system must be free of leaks binding grounding and excessive vibrations In addition to inspecting the exhaust system at the scheduled maintenance interval inspect the exhaust system if the noise level of the vehicle has increased Replace parts that show leakage wear or damage with genuine Freightliner parts These conditions are usually caused by loose bro ken or misaligned clamps brackets or pipes If any of these conditions exist check the exhaust system components and alignment Align or replace as nec essary For alignment or adjustment instructions see Group 49 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freight liner dealer EPA10 Exhaust System Definitions of Aftertreatment System ATS Terms Refer to the following list of definitions of ATS terms and components e Aftertreatment System A
110. surface Shut down the engine set the parking brake and chock the front or the rear tires depending on which axle you are working on 2 Raise the vehicle off of the ground and securely support it with jack stands 3 Remove the wheel from each wheel end For instructions see Group 40 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 4 Place a stool near the axle to rest the caliper on after it is removed 5 Remove the key retaining fastener from the an chor plate See Fig 9 6 Using a hammer and drift carefully drive out the key and spring See Fig 10 Be careful not to nick the anchor plate rail 7 Insert a large flat bladed screwdriver through the caliper vent window and into the rotor fins Pry the caliper outward this will push the pistons back slightly into the caliper making removal easier 8 Grasp the caliper swing it out and lift it from the anchor plate Rest the caliper on the stool For ease of removal swing the caliper on the for ward anchor plate torque rail the large one op posite the key and spring rail Brakes 3 wa 2 ze ra 4 a 5 X TA v 6 N N IN 10 28 94 y f420565a 1 Caliper 4 Fastener 2 Wear Shim 5 Key 3 Spring 6 Anchor Plate Fig 9 Anchor Plate and Key Fastener 4 3 2 x ve 5 1 W i 5 VI 6 08 11 93 1420546 1 Key 4 Rotor 2 Spring 5 Outboard Brake Pad 3 Anchor Plat
111. t the V way Being careful not to get grease or dirt on the pad face reinstall each brake pad Grasp the caliper firmly rest the V ways on the forward anchor plate torque rail the large rail and swing the caliper into place Make sure that the brake hose is not twisted Do not get grease on the pad faces or rotor surfaces With the caliper installed and firmly seated on the forward rail large rail position the key and spring between the caliper V way and the anchor rail from the in board end of the anchor rail Carefully drive the key and spring into place In stall the key retaining fastener and torque it 12 to 18 Ibf ft 16 to 24 N m 42 19 Install the wheels For instructions see Group 40 of the Shuttle Bus Chassis Workshop Manual 20 Before moving the vehicle press the brake pedal several times to bring the pistons back to the normal position 21 Raise the vehicle remove the jack stands and lower the vehicle to the ground 22 Remove the chocks from the tires 23 Test drive the vehicle and ensure that the brakes operate properly 42 13 Brake Caliper Slide Pin Lubricating Bosch Brakes Breathing brake lining dust asbestos or non asbestos could cause lung cancer or lung dis ease 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 assembl
112. t the assembled desiccant cartridge bolt in the end cover 10 Install the desiccant cartridge on the end cover making sure the cartridge is properly seated and flush on the end cover NOTE It may be necessary to rotate the car tridge slightly until the anti rotation lugs are properly aligned and allow the cartridge to rest flush against the end cover 11 Using a wrench or socket tighten the desiccant cartridge bolt 50 Ibf ft 68 N m Do not over torque 12 Before placing the vehicle in service perform the test below 12 1 Close all reservoir drain cocks 12 2 Build system pressure to governor cut out and note that the AD IP air dryer purges with an audible escape of air 123 Fan the service brakes to reduce system air pressure to governor cut in Note that the system once again builds to full pres sure and is followed by a purge at the AD IP air dryer exhaust Brakes 12 4 Check for excessive leakage around the head of the desiccant cartridge where it contacts the end cover With the com pressor in loaded mode compressing air apply a soapy solution to these areas and observe that any leakage does not exceed a 1 inch bubble in 1 second If leakage exceeds this measure remove and re install the desiccant cartridge Haldex PURest NOTE The PURest cartridge contains both the desiccant and filter in one piece 1 Park the vehicle on a level surface shut down the engine and set the parking brake Choc
113. tank brackets exhaust and engine sup ports and frame crossmembers and gussets NOTE This operation is not intended to be a bolt by bolt check of the entire chassis Do a hand check of the typical frame fasteners If any fasteners are found loose tighten them to the correct torque value See Group 00 of the Shuttle Bus Chassis Workshop Manual for additional information on fasteners and torque values or take the vehicle to an authorized Freightliner dealer 31 Shuttle Bus Chassis Maintenance Manual June 2008 31 1 Suspension 32 Index Alphabetical Title of Maintenance Operation MOP MOP Number Component Clearance Checking Freightliner AirLiner llle 32 06 Component Inspecting and Operation Checking Freightliner AirLiner lise 32 07 Fastener Torque Checking Freightliner AirLiner ee 32 05 Shock Absorber Checking Freightliner Spring 0 000 es 32 09 Spring Bracket Fastener Torque Checking Freightliner Spring Rear eee eee 32 04 Suspension Inspecting Freightliner Spring llli 32 01 Suspension inspecting NEWI om dodi NGALANG TE IE e LAT os qq NAT Ham bue ped n NIRA 32 11 Suspension Lubricating Freightliner Spring llli 32 02 Torque Arm Bushing Checking Freightliner AirLiner llli 32 10 U Bolt Torque Checking Freightliner AirLiner oo 32 08 U Bolt Torque Checking Freightliner Spring cee ee 32 03 ZF IFS Lubiicatings
114. ternational Truck amp Engine Company Fleetrite Synthetic ATF AN 071006 John Deere amp Company HD SynTran To check the latest Allison approved fluids go to www allisontransmission com Lubricants listed in order of preference Do not mix types of oil Table 1 Approved Allison Transmission Lubricants Allison Transmission Lubricant Capacities m Fill Capacity Transmission Model qt L 1000 Series Standard Sump 10 6 10 1000 Series Shallow Sump 7 4 7 2100 2200 B210 B220 Series Standard S 15 14 ump 2100 2200 B210 B220 Series Shallow S 13 12 ump 3000 B300 Series 4 inch sump 29 27 3000 B300 Series 2 inch sump 26 25 Quantities listed are approximate Add the recommended amount of fluid as listed under fill capacity Do not overfill Table 2 Allison Transmission Lubricant Capacities 9 Install the filter and cover assemblies into the filter compartment 10 Align each cover assembly with the holes in the channel plate sump and push the cover assem blies in by hand to seat the seals 4h CAUTION 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 tighten the bolts 38 to 44 Ibf ft 51 to 61 N m 12 Install a new drain plug O ring and install the drain plug Tighten the drain plug 18 to 24 Ibf ft 25 to 32 N m 13 Fill the transmission with fresh transmission
115. the camshaft brackets Pump multipurpose chassis grease NLGI Grade 1 or 2 into the chamber bracket until it appears at the slack adjuster end of the bracket See Fig 8 Use care that no grease enters the drum cavity If grease leaks out under the camhead the camshaft grease seal is worn or damaged or is installed backwards NOTE The use of meter type fittings having a maximum 40 psi 275 kPa pressure relief at shutoff is recommended 05 28 93 A A Grease exit 1 Brake Chamber 2 Slack Adjuster f420011a 3 Grease Fitting Fig 8 Camshaft Bracket Bushing Lubrication 42 42 10 Foot Brake Valve Actuator Lubricating Bendix E 6 1 Remove the brake valve For instructions see Group 42 of the Shuttle Bus Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 2 From the outside of the cab pull the valve away from the frontwall and remove the brake plunger 3 Wipe off the old grease from the plunger and the adaptor 4 Inspect the bore of the adaptor and the sliding surface of the plunger While some discoloration is permissible there should be no pitting or roughness of the adaptor bore or the sliding sur face of the plunger If pitting or roughness exists replace damaged parts with new ones 5 Lubricate the adaptor bore and the sliding sur face of the plunger with an approved silicone based grease Dow Corning 55 O Rin
116. ting 2 Boot Fig 4 Grease Fitting and Boot Detroit axle shown vice immediately If there is endplay but it is less than 1 8 inch 3 mm the vehicle does not have to be taken out of service but a major out of service inspection and maintenance must be scheduled as soon as possible 1 Check the tie rod ends for looseness 141 Park the vehicle so that the front wheels are in the straight ahead position 1 2 Chock the front and rear tires 1 3 Remove dirt and grease from the seals or boots on the tie rod ends Visually inspect the tie rod ends Replace the tie rod ends if the seals or boots are cracked worn or damaged IMPORTANT Check the tie rod endplay by hand Do not use a pry bar If a pry bar is used the dial indicator will not read cor rectly NOTE For accurate readings use a dial indicator with a contour type base 1 4 Position the dial indicator so that the base of the indicator is on the bottom of the tie rod arm Place the tip of the indicator on the bottom of the tie rod end at the center of the ball stud on the surface that is most flat as shown in Fig 5 1 5 Set the dial indicator to zero 33 2 Shuttle Bus Chassis Maintenance Manual August 2013 Front Axle 1 6 By hand move the tie rod end and the cross tube assembly up and down If the dial indicator reads more than 0 060 inch 1 52 mm replace the tie rod end at once 1 7 Install the dial indicator as described
117. ub an accurate measurement is not possible 11 2 To seat the bearings grip the hub at the three o clock and nine o clock positions and push inward while oscillating it ap proximately 45 degrees Maintain pres sure on the hub note the inboard mea surement and then pull the hub outward while oscillating it as before Maintain pressure on the hub and note the out board measurement See Fig 9 The end play is the difference between the two measurements The end play limit for PreSet hubs is 0 006 inch 0 15 mm for non PreSet hubs the acceptable range Shuttle Bus Chassis Maintenance Manual August 2013 33 5 33 is 0 001 to 0 005 inch 0 03 to 0 13 mm inclusive If the end play does not exceed the limit and no other problems were found in the previous steps no additional service is necessary If the end play exceeds the limit service the hub See the Shuttle Bus Workshop Manual and manufacturer lit erature for procedures 06 20 2011 330270 1 Hub Cap Mounting Flange 2 Dial Indicator with magnetic base Fig 8 Dial Indicator Setup Front Axle 06 21 2011 1330271 A Pull and push the hub while oscillating it Fig 9 Measuring End Play 33 6 Shuttle Bus Chassis Maintenance Manual August 2013 Rear Axle Title of Maintenance Operation MOP Axle Breather Checking 0 00002 cee eee Axle Lubricant Changing and Magnetic Plug Cleaning Axle Lubricant
118. ull mark on the dipstick 46 05 Steering Gear Lubricating k Wipe off debris from the grease fitting See Fig 3 2 Using a hand type grease gun apply multipur pose chassis grease until the grease starts com ing out of the sector shaft dirt and water seal 46 2 Shuttle Bus Chassis Maintenance Manual June 2008 Steering 04 13 93 Ie Sector Shaft Grease Fitting f460515a Fig 3 Sector Shaft Lubricating TAS Series Shuttle Bus Chassis Maintenance Manual June 2008 46 3 46 Fuel 47 Index Alphabetical Title of Maintenance Operation MOP MOP Number CNG Fuel Block Housing DEAIBIFIC se a coi a RAAT KALA itor oes ec ave 47 03 CNG Fuel Leak Testi uud cretam ae ea date ze E ep MAGANG iar eu Red Reg qut pq d dte ae 47 04 CNG Fuel Tank Visual Inspecting llli rens 47 05 CNG High Presstire Fuel Filter Replacing ene cs wa eda eee oe Ree mme mento AN are goatee 47 06 CNG Low Pressure Fuel Filter Replacing 2 000 cee eee 47 07 Diesel Fuel Tank Draining and Vent Checking 2 0000 ee 47 01 Fuel Water Separator Element Replacing enemis cia md dee kk neu dead aia A a eles 47 02 Inline Fuel Strainer Replacing Cummins Engine 0 000 es 47 08 Shuttle Bus Chassis Maintenance Manual August 2013 Fuel 47 01 Diesel Fuel Tank Draining and Vent Checking Remove the plug or open the drain valve at the bot tom of the fue
119. ust be replaced every 15 years 00 6 Shuttle Bus Chassis Maintenance Manual November 2014 General Information 00 Noise Emission Controls Maintenance 00 05 General Information Federal Law Part 205 Transportation Equipment Noise Emission Controls Part 205 Transportation Equipment Noise Emission Controls requires the vehicle manufacturer to fur nish with each new vehicle such written instructions for the proper maintenance use and repair of the vehicle by the ultimate purchaser to provide reason able assurance of the elimination or minimization of noise emission degradation throughout the life of the vehicle In compliance with the law the noise emis sion controls maintenance information located in each applicable group of this manual in conjunction with the vehicle workshop manual provides these instructions to owners Normal Vehicle Use The maintenance instructions contained in this manual are based on average vehicle use and nor mal operating conditions Unusual vehicle operating conditions may require service at more frequent in tervals Recommendations for Replacement Parts Replacement parts used for maintenance or repair of noise emission controls should be genuine Alliance parts If other than genuine Alliance parts are used for replacement or repair of components affecting noise emission control the owner should be sure that such parts are warranted by their manufacturer to be equivalent to
120. wear pad s See Group 32 of the Shuttle Bus Chassis Workshop Manual for instruc tions or take the vehicle to an authorized Freightliner dealer Replace worn cracked or damaged spring brackets Failure to do so could result in bracket 32 breakage possibly leading to loss of vehicle con trol and resulting in personal injury or property damage 32 02 Suspension Lubricating Freightliner Spring Front Suspension Wipe all dirt from the grease fittings at the forward spring pin and the spring shackle pins then apply multipurpose chassis grease with a pressure gun until the old grease is forced out Hear Suspension Lubricate the spring pin by applying multipurpose chassis grease at the grease fitting See Fig 1 Lu bricate with a grease gun until grease appears at the base of the fitting 10 05 94 f320268a Fig 1 Forward Spring Bracket Spring Pin Grease Fitting 32 03 U Bolt Torque Checking Freightliner Spring Check the U bolt torque of both the front and rear axles Shuttle Bus Chassis Maintenance Manual December 2013 32 1 32 NOTICE Failure to retorque the U bolt nuts could result in spring breakage and abnormal tire wear In a diagonal pattern tighten all 5 8 18 U bolt nuts 205 Ibf ft 278 N m tighten all 3 4 16 U bolt nuts 300 Ibf ft 407 N m and tighten all 7 8 14 U bolt nuts 460 Ibf f 624 N m 32 04 Spring Bracket Fastener Torque Checking
121. y NOTE See the Bosch Pin Slide Disc Brakes Service Manual for more information or take the vehicle to an authorized Freightliner dealer Apply 1 8 oz 3 5 g Aeroshell grade 5 grease to each of the two guide pin and guide pin bore sets See the Bosch Pin Slide Disc Brakes Service Manual for additional information The correct pins bolts and bolt torque must be used If not brake function could be impaired and lead to loss of control of the vehicle which could result in personal injury death or property dam age IMPORTANT The ZOH T caliper assembly is similar in appearance to the existing ZOPS cali per The only obvious difference is that one of the anchor plate slide pins trailing side has notches for identification With ZOH T calipers install the solid pin no bushing only in the an Shuttle Bus Chassis Maintenance Manual August 2013 42 9 42 chor plate leading hole position Install the pin with the rubber bushing and notches only in the anchor plate trailing hole position See Fig 12 Tighten the leading side pin first then tighten the trailing side pin 06 20 2002 1422357 1 Flanged Bolt 2 Leading Pin 3 Trailing Pin 4 Rubber Bushing Fig 12 ZOH T Slide Pins and Bolts Tighten ZOH T bolts 93 to 107 Ibf ft 126 to 145 N m Tighten ZOPS bolts 70 to 80 Ibf ft 95 to 108 N m 42 14 ABS Tone Rings Cleaning 4h

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