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2008 XC Chassis Maintenance Manual

1. Axle Model Capacity pt L t 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 RC 23 165 42 19 9 Single drive axles equipped with traction equalizers may require a friction modifier to correct a slip stick condition as described in the vehicle driver s manual Meritor s experience shows that the following additives perform ad equately Add Elco No 2 Friction Modifier 1 ounce 30 ml of additive for each 1 pint 0 5 liter of lube capacity or Lubrizol No 797 or 762 one ounce 30 mL of additive for each 1 pint 0 5 liter of lube capacity t Quantities listed are approximate and include 1 pint 0 5 liter for each wheel end and with the drive pinion at 3 degrees Table 2 Meritor Drive Axle Lubricant Capacities single axle 35 03 Axle Breather Checking NOTE On Freightliner axles the axle housing breather is located on the carrier assembly The axle housing breather must remain unob structed Whenever the axle lubricant is checked or changed also make sure that the breather is open Check more often under poor operating conditions If the breather is plugged clean or replace it as needed See Fig 2 and Fig 3 Rear Axle 4 NS 06 07 94 1350002a 1 Axle Housing Breather 2 Fill Plug 3 Temperature Indicator Plug Fig 2 Meritor Axle Housing typical IAS AN L VENAS PU EF 2 oF a WER YS pa DON
2. 42 08 Bendix Hydro Max Power Booster Checking front engine diesel chassis 42 09 Brake Caliper Slide Pin Lubricating Bosch Brakes front engine diesel chassis 42 10 Brake Lines Checking Hydraulic Disc Brakes front engine diesel chassis 42 11 Brake Lining Wear Checking Hydraulic Disc Brakes front engine diesel chassis 42 12 Brake Inspecting 46 01 Drag Link Lubricating 46 02 Power Steering Reservoir Fluid Level Checking 46 03 Power Steering Reservoir Fluid and Filter Changingtt 46 04 Steering Driveline Lubricating 46 05 Steering Gear Lubricating 46 06 Hydraulic Reservoir Filter Changing metal reservoir only 47 01 Fuel Tank Mounts and Fuel Line Checking 47 02Fuel Water Separator Element Replacingtt 47 03 Inline Fuel Strainer Replacing Cummins ISB02 Engine 49 01 Exhaust System Inspecting 54 01 Ground Cables Checking and Cleaning 54 02 Battery Voltage Checking Recreational Vehicle Chassis Maintenance Manual September 2007 00 3 00 Vehicle Maintenance Schedule Table 00 02 General Information Maintenance Operation Procedures and Intervals REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 Maintenance Operation Number and Description 83 01 Air Conditioner Inspecting With frequent use the Pacbrake Exhaust Brake will operate free of maintenance However if the vehicle is used incons
3. i i m YA Y dl NG 03 28 2007 1350484 1 Axle Housing Breather 2 Breather Tube Fig 3 Freightliner Axle Housing 35 2 Recreational Vehicle Chassis Maintenance Manual September 2007 Wheels and Tires Title of Maintenance Operation MOP Wheel Cleaning and Polishing a Wheel Nut Checking ss sauer NA BAGA ALA PARAAN DAANAN 40 Index Alphabetical MOP Number Recreational Vehicle Chassis Maintenance Manual September 2007 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 NOTE On each wheel stud the end that faces away from the vehicle is stamped with an L or an R depending on which side of the vehicle the stud is installed Studs stamped with an L are left hand threaded and are installed on the driver s side of the vehicle Studs stamped with an R are right hand threaded and are installed on the passenger s side of the vehicle When checking wheel nuts on a dual disc assembly remove one outer nut at a time tighten the inner nut then reinstall the outer nut Repeat this procedure for all of the inner wheel nuts in the sequence shown in Fig 1 Fig 2 or Fig 3 Then tighten all of the outer wheel nuts in the same sequence A B 2 1 4 5 3 6 6 3 5 4 1 2 08 20 96 f400119
4. Chock the tires 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 4 Install the drain plugs and tighten securely 5 Add approximately 1 to 1 1 2 pints 0 5 to 0 7 L of oil 80W 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 7 Install the filler caps securely 8 Remove the chocks from the tires 33 4 Recreational Vehicle Chassis Maintenance Manual September 2007 Rear Axle Title of Maintenance Operation MOP Axle Breather Checking 00 cee ee eee Axle Lubricant Changing i2 tse ERATES LRERAH ARS Axle Lubricant Checking ooo 35 Index Alphabetical MOP Number Recreational Vehicle Chassis Maintenance Manual September 2007 Rear Axle 35 01 Axle Lubricant Checking 35 35 02 Axle Lubricant Changing 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 Hecreational Vehicle Chassis Workshop Manual for instructions or take the vehicle to an authorized Freightliner dealer 1 Clean the area around the filler plug and remove the plug 2 Make sure that the lubricant is l
5. 4 Unscrew the hose barb fitting and the 90 degree hose barb elbow fitting from the old filter and in spect them for any damage If no damage is found screw the two fittings into the new 25 micron filter If damage is found in the fittings replace them with a new 1 2 14 NPT hose barb fitting and elbow IMPORTANT Ensure that the TO RESERVOIR arrow on the power steering filter if so equipped is pointing towards the power steering fluid reservoir and that the hose barb 90 degree elbow fitting is located on the bottom of the power steering filter See Fig 1 5 Place the ends of the power steering gear to reservoir hose onto the hose barb fittings and tighten the two hose clamps securely 4h WARNING 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 6 Fill the reservoir with approved power steering fluid See Table 1 7 Place the disconnected end of the steering gear to reservoir hose in a drain bucket Do not start the engine while draining the system Raise the front of the vehicle with a floor jack and support Recreational Vehicle Chassis Maintenance Manual September 2007 46 1 46 05 06 2005 1462014 1 Hose Barb Elbow Fitting 2 Hose Barb Fitting 3 25 Micron Power Steering Filt
6. FREIGHTLINER RECREATIONAL VEHICLE CHASSIS MAINTENANCE MANUAL Models XCL XCR XCP XCS MC STI 425 2 1 08P 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 maintenance 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 maintenance instructions Perform the pretrip inspection and daily weekly monthly maintenance as outlined in the vehicle operator s 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 Chassis Corporation FCCC reserves the right t
7. Introduction Descriptions of Service Publications Daimler Trucks North America L via ServicePro9 formats Workshop Service Manual Maintenance Manual Driver s Operator s Manual Service Bulletins Parts Technical Bulletins Web based repair service and AccessFreightliner com website ServicePro PartsPro EZWiring LC distributes the following major service publications in paper and electronic 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 maintenanc
8. binding grounding and excessive vibrations 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 Recreational Vehicle Chassis Work shop Manual or take the vehicle to an authorized Freightliner dealer IMPORTANT The Environmental Protection Agency s 2007 regulations require lower ex haust emissions thus requiring new exhaust system components See Fig 1 In particular the 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 Definitions of ATS Components Refer to the following list of definitions of ATS com ponents e Aftertreatment System ATS the entire ex haust system from the turbocharger to the ex haust stack or tail pipe Aftertreatment Device ATD a muffler like canister that houses a DPF and sensors Diesel Particulate Filter DPF a filter that collects and holds particulate matter soot and ash Diesel Oxidation Catalyst DOC oxidizes hydrocarbons and reduces NOx Sensors detect temperatures and pressure within the ATS Diffuser a
9. of a turn by hand 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 Recreational Vehicle Chassis Maintenance Manual September 2007 42 1 42 3 Shut down the engine and remove the chocks from the tires 4 Perform the inspections in Maintenance Opera tion 42 02 42 04 Camshaft Bracket Bushing Lubricating Pump grease into the camshaft bracket bushing until it appears at the slack adjuster end of the bracket See Fig 1 05 28 93 A Grease Exit 1 Brake Chamber 2 Slack Adjuster 3 Non Pressure Relief Grease Fitting f420011a Fig 1 Camshaft Bracket Bushing Lubrication Use an NLGI Grade 1 or Grade 2 multipurpose chas sis grease If grease leaks out from under the cam head the camshaft bracket grease seal is worn or damaged For grease seal replacement instructions see Group 42 of the Hecreational Vehicle Chassis Workshop Manual or take the vehicle to an autho rized Freightliner dealer Camshaft brackets without grease fittings are fitted with special seals and packed with extended lubrication interval chassis grease Grease them only when the camshaft is disassembled for servicing Brakes 42 05 Slack Adjuster Lubricating IMPORTANT Perform Maintenance Operation 42 12 before lub
10. 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 control degradation throughout the life of the vehicle In compliance with the law the noise emission controls maintenance information in each applicable group of this manual in conjunction with the chassis workshop manual provides these instructions to owners Recommendations for Replacement Parts Replacement parts used for maintenance or repair of noise emission controls should be genuine Freight liner Custom Chassis Corporation FCCC parts If other than genuine FCCC parts are used for replace ment or repair of components affecting noise emis sion control the owner should be sure that such parts are warranted by their manufacturer to be equivalent to genuine FCCC parts in performance and durability Freightliner Noise Emission Controls Warranty See the vehicle owner s warranty information book for warranty information concerning noise emission controls Tampering With Noise Controls is Prohibited Federal law prohibits the following acts or the caus ing thereof 1 The removal or rendering inoperative by any per son other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sa
11. 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 Recreational Vehicle Chassis Maintenance Manual September 2007 49 1 49 Exhaust 11 2 2006 1490284 Inspect this area of the canister for dents DOC Area DPF Area Inlet Temperature Sensor Marmon Fitting at Inlet from Turbocharger Sensor Housing DPF V Band Mounting Clamps Inlet Temperature Sensor Exhaust Outlet to Diffuser Outlet Temperature Sensor DPF Outlet Pressure Sensor DPF Intake Pressure Sensor 2 00 19 ANON DUST Fig 1 Cummins Aftertreatment Device 49 2 Recreational Vehicle Chassis Maintenance Manual September 2007 Electrical Instruments and Controls 54 Index Alphabetical Title of Maintenance Operation MOP MOP Number Battery Voltage Checking suce abia abs aaa e 54 02 Ground Gables Ghecking and Oleaniit uscar ARRE A 54 01 Recreational Vehicle Chassis Maintenance Manual September 2007 Electrical Instruments and Controls 54 01 Ground Cables Checking and Cleaning Check that the ground cables are clean undamaged and tight lf needed disconnect them clean the mat ing surfaces with a soda solution then connect them securely Spray the ground cable connections with dielectric red enamel See Tabl
12. A Front and Inner Rear Dual B Outer Rear Dual Fig 1 Wheel Nut Tightening Sequence 6 stud hubs 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 Tighten the wheel nuts e On 6 stud stud pilot hubs tighten the wheel nuts 450 to 500 Ibf ft 610 to 678 N m See Fig 1 for the tightening sequence 40 A B VA T Pus ARN Pg C 4 5 N 3 6 8 DIE 8 6 O a x O n UN S 06 23 2000 1400159 A Front and Inner Rear Dual B Outer Rear Dual Fig 2 Wheel Nut Tightening Sequence 8 stud hubs A B N Pa WE i 9 7 ON 10 8 4 E 3 6 G SING 4 8 0 O d d A MS 2 7 09 28 98 1400142 A Front and Inner Rear Dual B Outer Rear Dual Fig 3 Wheel Nut Tightening Sequence 10 stud hubs 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 See Fig 2 or Fig 3 for the tightening sequence 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 See Fig 2 or Fig 3 for the tightening sequence NOTE Wheel nuts for 20 mm stud hubs require a 1 3 16 inch 30 mm socket Wheel nuts for 22 mm stud hubs require a 1 5 16 inch 33 mm socket Recreational Vehicle Ch
13. Ghana TAYA ANG i ad HAD NAB NG 42 07 slack AGMSIS UDMA land AA AA AA d datione ANG c AA ARA a 42 05 Recreational Vehicle Chassis Maintenance Manual September 2007 Brakes 42 01 Brake System Valves Inspecting 1 Clean the valve exterior and inspect it for corro sion and damage 2 Inspect the air lines connected to the valve for signs of wear or damage Replace the lines as needed 3 Check the valve for leakage 3 1 Apply the service brakes and hold them on a full line pressure of at least 80 psi 500 kPa 3 2 Check the air line fittings for leaks tighten or replace the fittings as needed 3 3 Coat the exhaust port and body of the valve with soapy water and check for leakage Leakage is excessive if it pro duces a 1 inch 25 mm bubble within 5 seconds If the brake valve does not function as described above or if leakage is exces sive replace it with a new or remanufac tured unit Repeat the leakage checks before placing the brake valve in service 42 02 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 2 Tighten the fasteners that attach 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 ai
14. Neway Suspension Height Control Valve Checking 32 03 Neway Suspension Inspecting 32 04 Neway Suspension Lubricating 32 05 ZF IFS Lubricating 32 06 Suspension Inspecting front engine diesel chassis 32 07 Suspension U Bolt Torque Checking front engine diesel chassis 33 01 Knuckle Pin Lubricating 33 02 Tie Rod End Lubricating and Inspecting 33 03 All Axle Alignment Checking 33 04 Wheel Bearing Removal Cleaning Checking Repacking and Adjusting 00 2 Recreational Vehicle Chassis Maintenance Manual September 2007 General Information 00 Vehicle Maintenance Schedule Table 00 02 Maintenance Operation Procedures and Intervals REQUIRED MAINTENANCE OPERATION SET Mi M2 M3 Maintenance Operation Number and Description 33 05 Oil Filled Hubs Oil Level Checking 33 06 Oil Filled Hubs Oil Changing 35 01 Axle Lubricant Checking 35 02 Axle Lubricant Changing 35 03 Axle Breather Checking 40 01 Wheel Nut Checking 40 02 Wheel Cleaning and Polishing 41 01 Driveline Inspecting and Lubricating 42 01 Brake System Valves Inspecting 42 02 Air Dryer Inspecting 42 03 Air Dryer Desiccant and Coalescent Filter Replacing 42 04 Camshaft Bracket Bushing Lubricating 42 05 Slack Adjuster Lubricating 42 06 Foot Brake Valve Actuator Lubricating 42 07 Meritor Roller Pin Lubricating
15. di Sie tes 00 06 Vehicle Maintenance Schedule Table 2 1 0 0 0 eee ee 00 02 Verification of Inspections LOG 5 24 0 ii e a eee bet DA KANE rede PAPURI LENA e RR 00 04 Recreational Vehicle Chassis Maintenance Manual September 2007 General Information 00 General Maintenance Schedule Information 00 01 General Maintenance Schedule Information Performing regular maintenance on your vehicle will help ensure that your vehicle delivers safe reliable service and optimum performance for years to come Failure to follow a regular maintenance program can result in inefficient operation and unscheduled down time When the vehicle reaches the distance or time whichever comes first given for a maintenance in terval see the Vehicle Maintenance Schedule Table for a list of the maintenance operations to be per formed at that maintenance interval Use the mainte nance operation reference numbers to find detailed instructions in the manual for each operation NOTE Maintenance instructions in this manual are based on average vehicle use and normal operating conditions Unusual vehicle operating conditions may require service at more frequent intervals For specific engine maintenance information see the Cummins or the Mercedes Benz Operation and Maintenance Manual IMPORTANT Maintenance operations appearing in italics in the following tables are for emission control components Numbers in the table are reference number
16. for damage or wear 6 Remove the safety stands and lower the vehicle Remove the chocks from the tires 47 02 Fuel Water Separator Element Replacing 1 Chock the front tires Locate the fuel water separator ov See the Cummins Operation and Maintenance Manual for fuel water separator element replac ing intervals 4 Remove the chocks from the tires 47 47 03 Inline Fuel Strainer Replacing Cummins ISB02 Engine NOTE Vehicles with a Cummins ISB02 engine have an inline fuel strainer located inside the rail on the right hand side above the rear axle On front engine diesel chassis the fuel strainer is located inside the rail on the left hand side be hind the shock The inline fuel strainer does not apply to EPAO7 vehicles 1 Remove the brackets on each end of the fuel strainer 2 Remove the P clip IMPORTANT The fuel flow arrow on the fuel strainer must be pointed toward the engine 3 Remove the strainer and replace it with a new strainer Install the P clip 5 Install the brackets on each end of the fuel strainer Recreational Vehicle Chassis Maintenance Manual September 2007 47A Exhaust 49 Index Alphabetical Title of Maintenance Operation MOP MOP Number Ex alst System Is DO caian NAMANA DAA BTANA A ir Seabee 49 01 Recreational Vehicle Chassis Maintenance Manual September 2007 Exhaust 49 01 Exhaust System Inspecting The exhaust system must be free of leaks
17. operation with loose fasteners could result in bracket or frame damage Typical frame fastener applications include suspen sion brackets fuel tank 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 Recreational Vehicle Chassis Workshop Manual for additional information on fas teners and torque values or take the vehicle to an authorized Freightliner dealer 31 Recreational Vehicle Chassis Maintenance Manual September 2007 31 1 Suspension 32 Index Alphabetical Title of Maintenance Operation MOP MOP Number Neway Suspension Fastener Torque Checking ees 32 01 Neway Suspension Height Control Valve Checking 222 2 eee eee 32 02 Neway Suspension Inspecting illl 32 03 Neway Suspension bUbITalhit ka mad ds dt wats AL il A a Lahad 32 04 Suspension Inspecting front engine diesel chassis cece eee 32 06 Suspension U Bolt Torque Checking front engine diesel chassis 0 AA AA aa 32 07 ZF IFS AA shad qun a e e E ARES E diis 32 05 Recreational Vehicle Chassis Maintenance Manual September 2007 Suspension 32 01 Neway Suspension Fastener Torque Checking WARNING Inspect the suspension fasteners Failure to per for
18. reser voir fluid and install the reservoir lid 46 Recreational Vehicle Chassis Maintenance Manual September 2007 46 3 Fuel 47 Index Alphabetical Title of Maintenance Operation MOP MOP Number Fuel Tank Mounts and Fuel Line Chackilig sre NA ci GRANADA Eee don deae eene 47 01 Fuel Water Separator Element Replacing o 47 02 Inline Fuel Strainer Replacing Cummins ISB02 Engine 0 000000 ee 47 03 Recreational Vehicle Chassis Maintenance Manual September 2007 Fuel 47 01 Fuel Tank Mounts and Fuel Line Checking Inspect the components as described below Fail ure to perform these inspections could result in the failure of the fuel tank mounting assembly and loss of vehicle control possibly causing personal injury or death or property damage 1 Chock the tires Working at the front of the ve hicle or at the rear of the vehicle raise 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 Check the T bolts that attach the fuel tank mounting straps to the mounting brackets Check to see that the nuts are tight 3 Inspect the fuel tank straps for damage or wear Replace them if necessary 4 Inspect the fuel tank for leaks or damage Re place the tank if necessary IMPORTANT Do not attempt to repair a dam aged fuel tank always replace a damaged fuel tank 5 Inspect the fuel lines
19. slip joint splines 46 05 Steering Gear Lubricating 1 Wipe off debris from the grease fitting 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 06 Hydraulic Reservoir Filter Changing metal reservoir only NOTE On XC chassis vehicles with a side mounted radiator the hydraulic reservoir sup plies both the steering and the fan circuits 1 Drain the entire steering and fan hydraulic sys tems 2 Remove the reservoir lid and remove the nut that secures the filter 3 Remove the old filter and install the new filter 4 Install the filter nut and tighten it securely 5 Fill the reservoir with the approved hydraulic fluid See Table 1 6 Start the engine run it for five seconds then shut down the engine 7 Fill the reservoir with 15W40 hydraulic system fluid 8 Start the engine Turn the steering wheel lock to lock several times until the steering wheel turns easily Shut down the engine 9 Fill the reservoir with 15W40 hydraulic system fluid 46 2 Recreational Vehicle Chassis Maintenance Manual September 2007 Steering NOTE The steering circuit is now purged Fol low the remaining steps to purge the fan circuit 10 Start the engine Run the engine at half throttle until the fans engage loud chirping sound Shut down the engine 11 The fan circuit is now purged Top off the
20. that have been used for water or antifreeze Dirt water or antifreeze could damage the transmission 3 Clean the area around the drain plug See Fig 3 and Fig 4 While the transmission fluid is warm remove the drain plug and drain the fluid IMPORTANT Examine the used transmission fluid for dirt coolant or water and metal par ticles If any of these contaminants are present a problem within the transmission system may exist 4 Remove the bolts from each filter cover at the bottom of the transmission control module See Fig 3 and Fig 4 Remove the filter covers O rings seals and the two cartridge type filters 5 Lightly coat the O rings with clean transmission fluid Place the O rings seals and filters on the filter covers Push each cover assembly into the bottom of the transmission to seat the seals In stall and tighten the bolts 38 to 45 Ibf ft 52 to 61 N m Install and tighten the drain plug 18 to 24 Ibf ft 24 to 33 N m 6 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 See Table 2 for lubricant capacities 7 Check and adjust the fluid level using the proce dures under Allison MD MH Series Transmission Fluid Level Checking NOTE For additional maintenance procedures see the applicable Allison Operator s Manual 26 2 Recreational Vehicle Chassis Maintenance Manua
21. the axle a minimum of 4 inches 10 cm to ensure that oil flows to the outer bearings Articulate the short side arm for 45 seconds and the long side arm for 90 sec onds After articulating the axle add 0 80 qt 0 75 L of lubricant through the fill hole in addi tion to the 5 8 qt 5 5 L of a normal oil change for each hub that has been removed Check the oil level again and ensure that the axle is nei ther under nor over filled 4 Install the fill plug and tighten it securely Meritor Axle 1 Remove the filler plug then the drain plug and allow the differential to drain completely 2 Install the drain plug Tighten it 24 Ibf ft 34 N m 3 Fill the differential with an S A E 80W 90 multi purpose gear lubricant or an S A E 75W 90 multipurpose synthetic gear lubricant See Table 2 for axle lubricant capacities Either type of lubricant must meet Military Specification L 2105 D and be suitable for American Petro leum Institute service classification GL 5 The Recreational Vehicle Chassis Maintenance Manual September 2007 35 1 35 lubricant level within the differential must be even with the bottom of the fill hole 4 Install the fill plug Tighten it 24 Ibf ft 34 Nm Differential Hubs Capacity qt L Differential Only 5 8 5 5 Differential and Hubs 7 4 7 0 Table 1 ABP Drive Axle Lubricant Capacities Meritor Drive Axle Lubricant Capacities single axle
22. the surge tank 3 Fill the cooling system as follows 3 1 Slowly add a 50 50 mixture of antifreeze and water to the surge tank until the sys tem is filled Install the coolant fill cap Engine Cooling R adiator Start the engine and run it at low idle for 10 seconds then at high idle for 1 minute Return to low idle Run the engine with the radiator cap re moved until the upper radiator hose is hot With the engine idling add coolant to the radiator until it is between the MIN and MAX lines on the surge tank Install the radiator cap 20 2 Recreational Vehicle Chassis Maintenance Manual September 2007 Transmission 26 Index Alphabetical Title of Maintenance Operation MOP MOP Number Allison MD MH Series Transmission Fluid Level Checking 22 26 02 Allison MD MH Series Transmission Fluid and Filter Changing internal external Mea Ad A A A Ad th dog Pug Mo Ao nd 26 03 Transmission Breather Checking uud ache ebd takisun uak aa a ERR eda 26 01 Recreational Vehicle Chassis Maintenance Manual September 2007 Transmission 26 01 Transmission Breather Checking Transmission housing breathers must remain clear A plugged breather could result in pressure build up which could cause lubricant leakage If the breather is plugged clean or replace it See Fig 1 Check more often if the vehicle is operating under very dusty conditions 05 27 93 f260007a Fig 1 Transmission Breat
23. 00 8 Recreational Vehicle Chassis Maintenance Manual September 2007 General Information 00 Torque Specifications Tables 00 06 Torque Values for Grade 8 Regular Hex Zinc Yellow Plated Capscrews and Cadmium and Wax Coated Prevailing Torque Locknuts Thread Diameter Pitch Regular Hex Grade 8 or 8 2 Bolt Grade 8 or C Nut Torque Ibf ft N m f230004 f230005 1 4 20 6 8 1 4 28 7 9 5 1618 13 18 5 16 24 14 19 3 8 16 23 31 3 8 24 26 35 7116 14 37 50 7 16 20 41 56 1 2 13 56 76 1 2 20 63 85 9 16 12 81 110 9 16 18 90 122 5 8 11 112 152 5 818 126 171 3 410 198 268 3 416 221 300 7 8 9 319 433 7 8 14 352 477 1 8 479 649 1 42 524 710 1 14 537 728 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation Table 5 Torque Values for Grade 8 Regular Hex Zinc Yellow Plated Capscrews and Cadmium and Wax Coated Prevailing Torque Locknuts Recreational Vehicle Chassis Maintenance Manual September 2007 00 9 00 Torque Specifications Tables 00 06 General Information Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threadst Regular Hex Flanged RA N Grade 5 Bolt is od B ac 8 2 x or C ine d 8 2 Grade G Nut Torque Ibf ft N m Torque Ibf ft N m
24. 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 while continuing to lubricate until fresh grease appears at the slip joint seal This ensures complete lubrication of the splines 3 Wipe any excess grease from the pressure relief hole slip joint seal and grease fitting Recreational Vehicle Chassis Maintenance Manual September 2007 41 1 Brakes 42 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Dryer Desiccant and Coalescent Filter Replacing 0000 cee eee 42 03 NN A EE TES PANGA AYA She de PAG NAA ada beer AA AG tee 42 02 Bendix Hydro Max Power Booster Checking front engine diesel chassis 42 08 Brake Caliper Slide Pin Lubricating Bosch Brakes front engine diesel chassis 42 09 Brake speci sag cc Det bada amn na ka carrera dora radio 42 12 Brake Lines Checking Hydraulic Disc Brakes front engine diesel chassis 42 10 Brake Lining Wear Checking Hydraulic Disc Brakes front engine diesel CHASSIS se ANG Redes dee Re eae xod vo ob e q e Se deed ede E SER E eee 42 11 Brake System Valves Inspeccion A Rug ERG NAG E 42 01 Camshaft Bracket Bushing LubricatinQ o oooocoooonoen nh 42 04 Foot Brake Valve Actuator Lubricating isses pr m RR RER RETE R DAA RES 42 06 Meritor Roller Pin Lubricating i ea s ss apes kk
25. 7 Driveline 41 Index Alphabetical Title of Maintenance Operation MOP MOP Number Driveline Inspecting and Lubricating 2 2 rara A Pam E pep 41 01 Recreational Vehicle Chassis Maintenance Manual September 2007 Driveline 41 01 Driveline Inspecting and Lubricating Inspecting 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 4h CAUTION 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 missing 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 Recreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized 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 ou
26. Freightliner dealer Start the engine and build air pressure to at least 100 psi 689 kPa Shut down the engine Check all of the foundation brake components for damage wear and loose or missing parts Re pair as needed See Group 42 of the Recre ational Vehicle Chassis Workshop Manual for repair procedures or take the vehicle to an au thorized Freightliner dealer Brake Chamber Stroke Specifications Chamber Max Applied Stroke inch mm Manufacturer Type Sizet 9 1 3 8 35 12 16 Standard Stroke 20 1 3 4 45 24 30 2 51 Gunite 36t 2 1 4 57 16 20 2 51 Long Stroke 24 2 1 2 inch rated stroke 24 3 inch rated stroke 2 1 2 64 30 12 1 3 8 35 16 Standard Stroke 20 1 3 4 44 24 Haldex 2 1 2 Inch Extended Stroke 24 2 51 3 Inch Extended Stroke 24 2 1 2 64 Standard Stroke 30 2 51 Long Stroke 30 2 1 2 64 42 6 Recreational Vehicle Chassis Maintenance Manual September 2007 Brakes 42 Brake Chamber Stroke Specifications Chamber a 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
27. N m and tighten the clamp nut 40 to 55 Ibf ft 54 to 75 N m For Freightliner axles see Table 1 for tie rod end nut torque specifi cations and Table 2 for tie rod end clamp nut torque specifications Front Axle 02 27 2007 1320033a IMPORTANT The tie rod end threads must be visible throughout the entire length of the split NOTE Pinch bolt not shown to provide clarity Freightliner 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 Freightliner Axle Tie Rod End Nut Freightliner Axle Tie Rod End Clamp Nut Thread Torque Ibf ft N m 1 2 13 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 Freightliner Axle Tie Rod End Clamp Nut 1 Cross Tube Split Fig 3 Tie Rod End Adjustment 33 03 All Axle Alignment Checking NOTE The final stage manufacturer is respon sible for setting the vehicle ride height with air suspension and some vehicle alignments On full railed chassis this includes the final toe in setting on the front axle For modular style chassis both the front axle toe in and rear axle thrust angle settings are included Drive Axle Alignment Checking Check the axle alignme
28. Torque Ibf ft N m NV n mme pa conos coms um zc 1 4 20 8 11 10 14 1 4 28 9 12 12 16 5 16 18 15 20 22 30 22 30 5 16 24 17 23 25 34 3 8 16 28 38 40 54 40 54 3 8 24 31 42 45 61 716 14 45 61 65 88 65 88 7 16 20 50 68 70 95 1 2 13 70 95 95 129 95 129 1 2 20 75 102 110 149 9 16 12 100 136 140 190 140 190 9 16 18 110 149 155 210 5 8 11 135 183 190 258 190 258 5 8 18 155 210 215 292 3 4 10 240 325 340 461 340 461 3 4 16 270 366 380 515 7 8 9 385 522 540 732 7 814 425 576 600 813 1 8 580 786 820 1112 1 12 635 861 900 1220 1 14 650 881 915 1241 Threads may have residual oil but will be dry to the touch t Male and female threads bolt and nut must both be unlubricated and unplated if either is plated or lubricated use Table 4 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation Table 6 Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threads 00 10 Recreational Vehicle Chassis Maintenance Manual September 2007 General Information 00 Torque Specifications Tables 00 06 Torque Values for Metric Thread Fasteners With Lubricated or Plated Threadst Thread Class 8 8 Bolt Class 8 Nut Class 10 9 Bolt Class 10 Nut Diamete
29. aintenance Manual September 2007 20 1 20 2 Flush the cooling system as follows 3 2 4h CAUTION During filling air must be vented from the engine coolant passages Any air trapped in the system can cause severe engine damage 3 3 2 1 Connect the lower radiator hose and in stall the plug in the bottom of the water inlet 2 2 Open the engine venting petcock 2 3 Add water to the surge tank until the sys tem is filled 2 4 Start the engine Run it at low idle for 10 seconds then at high idle for 1 minute Return to low idle 2 5 Close the lower petcock when a steady stream of water is flowing from it Don t let more than 1 5 quarts 1 4 L of water escape 2 6 Close the upper petcock when a steady stream of water is flowing from it Don t let more than 1 5 quarts 1 4 L of water escape 2 7 Repeat several times until the drained liquid is nearly colorless 2 8 Completely drain the system then close the radiator and block the drain valves 2 9 Disconnect all hoses from the surge tank Remove the tank and pour out any fluid Scrub and clean the inside of the surge tank with soap and water Flush it with clean water then drain it Install the surge tank and hoses IMPORTANT On vehicles with EPA07 compliant engines the coolant capacity varies depending on the engine and accessory installation After servicing the cooling system always verify that the coolant level is between the MIN and MAX lines on
30. al September 2007 General Information 00 Metric U S Customary Conversion Tables 00 05 oa Us En To Get Metric Mies um ric er To Get U S Customary Length inches in 25 4 millimeters mm 0 03937 inches in inches in 2 54 centimeters cm 0 3937 inches in feet ft 0 3048 meters m 3 281 feet ft yards yd 0 9144 meters m 1 094 yards yd miles mi 1 609 kilometers km 0 6215 miles mi Area square inches in 645 16 square millimeters mm 0 00155 square inches in square inches in 6 452 square centimeters cm 0 155 square inches in square feet ft 0 0929 square meters m 10 764 square feet ft Volume cubic inches in3 16387 0 cubic millimeter mm3 0 000061 cubic inches in3 cubic inches in3 16 387 cubic centimeters cm3 0 06102 cubic inches in3 cubic inches in3 0 01639 liters L 61 024 cubic inches in3 fluid ounces fl oz 29 54 milliliters mL 0 03381 fluid ounces fl oz pints pt 0 47318 liters L 2 1134 pints pt quarts qt 0 94635 liters L 1 0567 quarts qt gallons gal 3 7854 liters L 0 2642 gallons gal cubic feet ft3 28 317 liters L 0 03531 cubic feet ft3 cubic feet ft3 0 02832 cubic meters m3 35 315 cubic feet ft3 Weight Force ounces av oz 28 35 grams g 0 03527 ounces av oz pounds av Ib 0 454 kilograms kg 2 205 pounds av Ib U S tons t 907 18 kilograms kg 0 001102 U S tons t U S tons t 0 90718 metric
31. assis Maintenance Manual September 2007 40 1 40 40 02 Wheel Cleaning and Polishing Accuride Machined and Polished Aluminum Wheels IMPORTANT Do not scrub the wheels before rinsing off particles with high pressure water Synthetic cleaning pads and wire brushes should not be used to clean the wheels Do not use strong detergents alkaline or acidic cleaners to clean Accuride aluminum wheels These solutions can etch the surface of the alu minum and leave dull areas Abrasive polishes or polishes not recommended for aluminum should not be used on aluminum wheels 1 Rinse the wheel with high pressure water to re move debris 2 Use a 100 cotton cloth dipped in a mild soap solution to help remove built up dirt and grease Dish soap or automotive car wash soap are rec ommended 3 Rinse the remaining soap residue from the wheel 4 Dry the wheel thoroughly with a 10096 cotton cloth 5 Usea metal cleaner polish that is compatible with aluminum to remove spots and stains from the surfaces of the wheel as necessary 6 Apply carnauba wax to the visible wheel sur faces Carnauba wax should be reapplied on a regular basis to maintain the wheel luster NOTE Failure to apply a protective polish wax sealant will leave the polished sur face susceptible to water spotting and or pitting from environmental contaminants Wheels and Tires 40 2 Recreational Vehicle Chassis Maintenance Manual September 200
32. bly U Bolt High Nuts Stage 1 Hand tighten iu Stage 2 60 81 icai Stage 3 200 271 Stage 4 270 to 330 367 to 449 Tighten in the sequence shown in Fig 6 Table 2 U Bolt Torque Values 01 05 99 2 1320783 Fig 6 Tightening Sequence for U Bolt High Nuts 32 6 Recreational Vehicle Chassis Maintenance Manual September 2007 Front Axle 33 Index Alphabetical Title of Maintenance Operation MOP MOP Number AIFAxIG Alignment Checking s x 9 maa c KE GAGA tenni o a 33 03 KOUCK Oo Fin EIGENS scs saint AS di AAA SARA ALENA 33 01 Oil Filled Hubs Oil Changing io deba a DAGA TONG ee Noe bee NE eee eee A 33 06 OFF dled Hubs Oil Level GHWegkIht i aeu tr ce o o a o as dud toda a 33 05 Tie Rod End bubricaung and Inspecciones 33 02 Wheel Bearing Removal Cleaning Checking Repacking and AdjustinG o ooooooooo 33 04 Recreational Vehicle Chassis Maintenance Manual September 2007 Front Axle 33 01 Knuckle Pin Lubricating Hold a high pressure grease gun on each fitting until fresh grease appears See Fig 1 or Fig 2 This will ensure that all of the old contaminated grease has been forced out 09 06 96 f320032a Pump lubricant into each grease fitting until fresh grease comes out at A 1 Grease Fitting Fig 1 Meritor Axle Grease Fittings 1 x 06 13 2003 1 1330213 1 Grease Fitting 2 Steering Kn
33. bolts have a fine thread rather than a coarse thread pitch are longer differently colored and are tightened to a higher torque specification Use only the ZOH T bolts to assemble a ZOH T caliper The ZOPS caliper bolts have a different thread pitch and will not assemble correctly in a ZOH T caliper mounting Also the ZOH T bolts will not as semble correctly in a ZOPS caliper Do not in terchange parts lt is permissible to use both ZOH T pins and ZOH T bolts in a ZOPS anchor plate but they must be replaced as sets Both the pins and the bolts must be changed 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 Brakes 06 20 2002 1 Flange Head Bolt 2 Leading Pin 1422357 3 Trailing Pin 4 Rubber Bushing Fig 4 ZOH T Slide Pins and Bolts 06 20 2002 1 Hexhead Bolt 2 Blue Patch 1422358 3 Slide Pin Fig 5 ZOPS Slide Pins and Bolts chor plate leading hole position Install the pin with the rubber bushing and notches only in the anchor plate traili
34. chock the tires to prevent vehicle movement 2 Check the brake lining wear On front and rear axles replace linings worn to less than 3 16 inch 4 8 mm 3 Make sure that the brake rotor and linings are free of oil and grease NOTE To replace the brake linings see the ap plicable foundation brake section in Group 42 of the Recreational Vehicle Chassis Workshop 42 Manual or take the vehicle to an authorized Freightliner dealer 42 12 Brake Inspecting IMPORTANT This procedure should be per formed prior to lubrication of the brake compo nents Parking Brake Operational Check Ah CAUTION Perform the following check in a clear safe area If the parking brakes fail to hold 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 See Group 42 of the Recreational Vehicle Chassis Workshop Manual for repair procedures or take the vehicle to an authorized Freightliner dealer 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 A WARNING Manually adjusting an automa
35. connections and fittings 5 Check the ride height of the air suspension by measuring the distance from the center of the Recreational Vehicle Chassis Maintenance Manual September 2007 32 1 32 lower shock bolt to the bottom of the frame rail See Fig 1 If ride height is incorrect adjust the air suspension 32 03 Neway Suspension Inspecting 4h WARNING Inspect the components and check their operation as described below Failure to perform these in spections and checks could result in separation of worn suspension components and loss of vehicle control possibly causing personal injury or death or property damage 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 09 28 98 A Measure here for suspension ride height 1 Frame Rail 2 Axle Housing Suspension Squeeze all air springs to check for complete deflation It may take ten minutes for the pres sure to bleed down from the air spring See Fig 2 If any air springs remain partially or fully inflated see Group 32 of the Recreational Ve hicle Chassis Workshop Manual or take the ve hicle to an authorized Freightliner dealer Inspect the air springs for cracks tears or other dam age Inspect each air spring for wear at the pedestal connection Inspect f
36. d by the Sequence Number B Group Title C Group Number D Release Date E Group Number Page Number 1020075 Fig 1 Example of a Maintenance Manual Page Recreational Vehicle Chassis Maintenance Manual January 2008 Introduction Maintenance Manual Contents Group No Group Title ON aaa aedes Ye ok xU E md General Information I Li abe adir Ath AG Thara DA NANGKA Engine O AA a BA A Air Intake NO essens cis Alternators and Starters OU M Engine Cooling Radiator EIE aa bA ie Rod dedo nata conci ce Mrd E Transmission QM E ttm GA kal ib Mte oes Throttle Control cl PL m Frame and Frame Components A Ad AP availa MAP pA WANG Suspension Ds rol a TERES Front Axle e WEFO Aaah haaha dS amp bind mAh Ara Rear Axle S a ANG rie o bici Wheels and Tires PA PA eed a eon ees Driveline S ocu d tags Oh ae eke vd Maes ka ae te Brakes A a ee ee ee Steering ls apd als D boven ase ees Lora cleans ead Fuel Baissea pls E P Ka wea hh natn tad de E R Exhaust c T Hara Ore Electrical A PER IE ROT E dp Heater and Air Conditioner 1 4 Recreational Vehicle Chassis Maintenance Manual January 2008 General Information 00 Index Alphabetical Title of Maintenance Operation MOP MOP Number General Maintenance Schedule Information 22 00 01 Metric U S Customary Conversion Tables searre draaien A ANDAR a RR RR CR 00 05 Noise Emission Controls Maintenance 006 rrr 00 03 Torque Specifications Tables 3 93 pA dia dia
37. device used as a deflector for distributing mixing and reducing the velocity of air flow 49 Inspection 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 as well as the ex haust wrap from the ATD to the diffuser 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 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 See Fig 1 Item 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
38. e 1 for approved part numbers Material Part Number Dielectric Grease 48 02349 000 Dielectric Red Enamel MMM 1602 IVI Spray Spray Sealer Spray On B 6 665 Table 1 Approved Dielectric Grease and Red Enamel 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 94 Recreational Vehicle Chassis Maintenance Manual September 2007 54 1 Heater and Air Conditioner 83 Index Alphabetical Title of Maintenance Operation MOP MOP Number Ar Conditioner Inspectlhit build a A E DALIN AD LAND dipl 83 01 Recreational Vehicle Chassis Maintenance Manual September 2007 Heater and Air Conditioner 83 01 Air Conditioner Inspecting Wear eye protection gloves and protective cloth ing when working on the air conditioning system Leaking refrigerant from a damaged hose or line could cause blindness or serious skin burns 1 Park the vehicle on a level surface shutdown the engine apply the parking brake and chock the tires 4h CAUTION To avoid the possibility of burns make certain that the engine and air conditioner components are not hot 2 Check the appearance of the air conditioner compressor pulley assembly If the friction sur face of the pulley shows signs of excessive gr
39. e Belt Inspecting The engine and the belt must be cool before you check the belt Handling a hot belt can cause per sonal injury 1 Inspect the belt for damage Transverse across the belt width cracks are acceptable Longitudinal direction of belt length cracks that intersect with transverse cracks are not accept able 2 Replace the belt if it has unacceptable cracks is frayed or has pieces of material missing For additional information see the Cummins or Mercedes Benz Operation and Maintenance Manual 01 02 Engine Support Fasteners Checking Mounts should be inspected when the engine is re moved for service Perform the following check 1 Check the rear engine support fasteners See Fig 1 Tighten the rear engine mount bolt 157 Ibf ft 213 N m Tighten the insulator to frame mount bracket bolts 91 Ibf ft 123 N m Tighten the engine mount bracket to engine bolts 62 Ibf ft 84 N m 2 Check the 3 4 10 front engine mount bolt See Fig 2 Tighten it 95 lbf ft 128 N m Check the 3 4 10 front engine mount bolt Tighten it 95 Ibf ft 128 N m 01 03 Pacbrake Inspecting and Maintenance With frequent use the Pacbrake Exhaust Brake will operate free of maintenance However if the vehicle is used inconsistently seasonally or is exposed to 01 11 08 2005 f0120111 1 Front and Rear Engine Rear Mount Bolt 2 Engine Mount Bracket to Engi
40. e Chamber Clevis Actuator Rod Boot Pressure Relief Capscrew Gasket Pawl Spring and Pawl 6 Manual Adjusting Nut 7 Grease Fitting or Lube Plug NAON Fig 2 Meritor Automatic Slack Adjuster other slack adjustors are similar 2 Use light oil to lubricate the brake pedal roller and pivot pin 3 Check the brake plunger boot for cracks holes or deterioration Replace it if necessary 4 Lift the edge of the brake plunger boot and check the plunger for existing lubrication 4 1 If the plunger is dry remove it by remov ing the brake pedal and brake plunger boot Lubricate the plunger and the inside surface of the boot with barium grease p n BW 246671 or Pennzoil Adhezoplex EP2 Install the plunger boot and the brake pedal IMPORTANT Use only these approved lubri cants 4 2 If the plunger has grease on it lift the edge of the brake plunger boot enough to apply 2 to 4 drops of light oil around the brake plunger where it slides into the brake base bracket Install the plunger boot around the brake base bracket 42 42 07 Meritor Roller Pin Lubricating Remove all grease or oil from the camshaft head rollers and brake linings Always replace linings contaminated with grease or oil which can in crease stopping distances causing component damage and serious personal injury For Q and P series Meritor brakes lube the cam an chor and cam roller pins when the brake is disas sembled o
41. e of vehicle 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 parts documentation can be accessed using the following applications on the 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 Results for both docu ments and service solutions can be narrowed by initially entering vehicle identi fication data PartsPro is an electronic parts catalog
42. ecifies 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 vice immediately If 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 Wipe the tie rod end grease fittings clean then for Meritor axles pump multipurpose chassis grease NLGI grade 1 or 2 or for Freightliner axles lithium 12 hydroxy stearate with molyb denum disulfide WL grade 2 grease to the tie rod ends until all used grease is forced out and new grease appears at the ball stud neck Recreational Vehicle Chassis Maintenance Manual September 2007 33 1 33 NOTE Inspect the tie rod end boots for cracks wear or damage If a boot is cracked worn or damaged replace the tie rod assembly 2 Inspect the tie rod ends as follows 2 1 Shake the cross tube Movement or looseness between the tapered shaft of the ball and the cross tube socket mem bers means that the tie rod end assembly must be replaced 2 2 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 3 Replace the parts if this cannot be done For instructions see the axle manufacturer s service manual 2 3 Check the tie rod end nut and clamp nut torques For Meritor axles tighten the tie rod end nut 100 Ibf ft 136
43. 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 See Table 1 3 Check the alternator wiring for missing insulation kinks and heat damage Replace or repair as needed 4h WARNING Batteries generate explosive gas as a by product of their chemical process Do not smoke when working around batteries Put out all flames and remove any source of sparks or intense heat in the vicinity of the battery compartment Make sure the battery compartment has been 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 4 Inspect the battery cables for wear and replace as needed Clean the cable connector terminals with a wire brush See Group 54 of the Recre ational Vehicle Chassis Workshop Manual for troubleshooting instructions and for adjustment repair or replacement instructions or take the vehicle to an authorized Freightliner dealer 4A Clean and tighten the battery ground cable terminal and clamps 4 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 o
44. er Fig 1 Power Steering Filter Typical Installation if so equipped it with jack stands Have an assistant turn the steering wheel to full lock left and right and cap ture the fluid flowing from the hose in the drain bucket Add fluid to the reservoir as needed Continue turning the steering wheel until clean power steering fluid flows from the hose into the drain bucket Remove the plug from the reservoir and reconnect the steering gear to reservoir hose to the reservoir 8 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 9 Fill the reservoir with approved fluid as needed Start the engine and let it idle for 10 seconds Have an assistant turn the steering wheel from lock to lock until no bubbles are seen in the res ervoir Shut down the engine 10 Install a new cover gasket the cover and the dipstick 11 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 full mark on the dipstick Turn the steering Steering wheel from lock to lock to flush out any air Shut down the engine 46 04 Steering Driveline Lubricating Wipe the grease fittings clean Using a pressure gun apply a lithium based grease NLGI grade 2 spar ingly to the universal joints and
45. evel with the bot tom of the filler plug hole See Fig 1 06 07 94 A Correct lube level at bottom of fill hole B Incorrect lube level below fill hole f350061a Fig 1 Axle Lubricant Checking 3 Add S A E 80W 90 multipurpose gear lubricant or an S A E 75W 90 multipurpose synthetic gear lubricant Either type of lubricant must meet Military Specification L 2105 D and be suitable for American Petroleum Institute service classifi cation GL 5 Install and tighten the filler plug 4 nspect the axle for signs of leakage If leakage is indicated and the lubricant level is down have your dealer perform any necessary maintenance Alliance Brand Product ABP Axle 1 Remove the filler plug then the drain plug in the center bottom of the axle housing and allow the differential to drain completely 2 Install the drain plug and tighten it securely 3 Fill the differential with 80 90 hypoid gear oil through the rear axle fill hole See Table 1 for axle lubricant capacities NOTE A normal oil change does not include the hubs Drain the differential and add 5 8 qt 5 5 L of SAE 80 90 hypoid gear oil through the rear axle fill hole The lubricant level should be at the bottom of the fill hole IMPORTANT The entire axle capacity axle completely dry is 7 4 qt 7 L Each hub con tains 0 80 qt 0 75 L of lubricant To protect the outer bearings from oil starvation jack up ar ticulate each side of
46. ever comes first For this interval to apply you must check and if necessary re charge the SCA supplemental coolant additive levels and the freeze point every 25 000 miles 40 000 km or 6 months whichever comes first See the Cummins Operation and Maintenance Manual for further information Do not remove or loosen the radiator cap until the engine and cooling system have completely cooled Use extreme care when removing the cap A sudden release of pressure from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause seri ous personal injury 1 Drain the cooling system as follows 1 1 When the engine is cool remove the ra diator cap Turn the cap slowly counterclockwise until it reaches a stop Do not press down while turning the cap Wait until any re maining pressure indicated by a hissing sound is relieved then press down on the cap and continue turning it counter clockwise 1 2 When the cap is removed run the engine until the upper radiator hose is hot this shows that the thermostat is open and the coolant is flowing through the system Use extreme care when draining coolant that is very warm It may still be hot enough to cause se rious personal injury by scalding 1 3 Stop the engine Remove the lower radia tor hose to drain the coolant Drainage may be speeded by removing the plug in the bottom of the water inlet Recreational Vehicle Chassis M
47. f baking soda and water 15 Rinse with clean water and dry Paint the retainer assembly if needed to prevent rusting 4 3 Check that foreign objects such as stones bolts and nuts are removed from the battery box 4 4 After cleaning connect the cables to the batteries and tighten them to the torque specifications listed on the battery gener ally 10 to 15 Ibf ft 14 to 20 N m 4 5 Coat the battery terminals with dielectric grease See Table 1 Approved Dielectric Protectants Protectant Material Approved Brand Dielectric Grease Lubriplate FLP DS ES Dielectric Red Enamel 3M 1602 IVI Spray Sealer Spray On Application Spray On B 6 665 Gyptal 1201EW Low VOC Red order at www glyptal com or 1 800 GLP 1201 Dielectric Red Enamel Brush On Application Table 1 Approved Dielectric Protectants 5 Check the terminals on the battery shut off switch and the starter relay Make sure that the terminal connections are clean and tight Coat the terminal connections with dielectric red enamel after cleaning see Table 1 Recreational Vehicle Chassis Maintenance Manual September 2007 15 1 Engine Cooling R adiator Title of Maintenance Operation MOP Godlafit RePlaCiiG one ata Pr Qui ro des Radiator Gap Checking deans Sb citando ERE A qaad Radiator Inspecting and Cleaning llli 20 Index Alphabetical MOP Number Recreational Vehicle Chassis Maintena
48. fluid is not within this range add or drain fluid as needed to bring the level to the top of the HOT RUN band See Table 1 for approved transmission lubricants See Table 2 for lubricant capacities Lubricant Type Temperature F C TranSynd Synthetic ATF 25 to 120 32 to 48 Table 1 Approved Automatic Transmission Lubricants Refill Capacity qt L 16 0 15 1 Model 1000 2000 and 2000 MH Recreational Vehicle Chassis Maintenance Manual September 2007 26 1 26 Refill Capacity Model qt L 3000 MHt and 4000 MH 17 5 16 5 Quantities listed are approximate Add the recommended amount of fluid as listed under refill capacity then perform a hot check and add fluid as needed Do not overfill t Some Allison 3000 MH transmissions have a deeper oil sump than other models These models require 3 additional quarts 2 8 L of ATF Table 2 Automatic Transmission Lubricant Capacities 26 03 Allison MD MH Series Transmission Fluid and Filter Changing internal external filter IMPORTANT For oil and filter change intervals see the applicable Allison Operator s Manual NOTE All recreational vehicle chassis manufac tured since January 1 2004 use TranSynd syn thetic automatic transmission fluid ATF IMPORTANT For vehicles manufactured before January 1 2004 extended oil and filter change intervals as advertised by Allison begin
49. h Bolt B Nut 8 2 Bolt C Nut Bolt Nut 8 2 Bolt Nut Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m pa 5 TS E 4 E lt gt K Pam E zd o a S CY SINO Z 1230003 1230003 1290004 280005 E 230007 ee Eo f230009 1 4 20 7 9 8 11 6 8 10 14 1 4 28 8 11 9 12 7 9 12 16 5 16 18 15 20 16 22 13 18 21 28 5 16 24 16 22 17 23 14 19 23 31 3 8 16 26 35 28 38 23 31 37 50 3 8 24 30 41 32 43 25 34 42 57 716 14 42 57 45 61 35 47 60 81 7 16 20 47 64 50 68 40 54 66 89 1 2 13 64 87 68 92 55 75 91 123 1 2 20 72 98 77 104 65 88 102 138 9 16 12 92 125 98 133 80 108 130 176 9 16 18 103 140 110 149 90 122 146 198 5 8 11 128 173 136 184 110 149 180 244 5 8 18 145 197 154 209 130 176 204 277 3 4 10 226 306 241 327 200 271 320 434 3 4 16 253 343 269 365 220 298 357 484 7 8 9 365 495 388 526 320 434 515 698 7 814 402 545 427 579 350 475 568 770 1 8 582 789 1 12 637 863 1 14 652 884 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation t Use these torque values if either the bolt or nut is lubricated or plated zinc phosphate conversion coated cadmium plated or waxed Table 4 Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threads
50. her 26 02 Allison MD MH Series Transmission Fluid Level Checking Cold Check IMPORTANT The purpose of the cold check is only to determine if the transmission has enough fluid to be safely operated until a hot check can be made 1 Acold check may be made when the sump tem perature is 60 to 104 F 15 to 40 C 2 Run the engine for at least one minute to clear the fluid system of air 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 2 If the level is not 26 within the COLD RUN band add or drain fluid until it reaches the middle of the COLD RUN band E Cx Se Tex TS E gt Do 11 16 2000 1270074 Fig 2 Transmission Dipstick 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 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 apply the parking brake 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 2 4 If the
51. inated grease has been forced out Lubricate the post control arm bearings at indicated maintenance intervals 03 16 99 f320791a 1 Grease Fitting 5 Subframe 2 Post 6 Lower Control Arm 3 Air Spring 7 Shock Absorber 4 Upper Control Arm Fig 3 Neway IFS 114 Grease Fittings 32 05 ZF IFS Lubricating IMPORTANT Do not raise the vehicle by plac ing a jack under the control arm s The weight Suspension of the vehicle could damage the control arms and cause alignment issues 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 injury or death 2 Remove the wheel hub See Group 33 of the Recreational Vehicle 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 grease or mineral oil on the lubricating points See Fig 4 and Fig 5 09 30 2004 f321018 1 Steering Knuckle Bearing Grease Fitting upper 2 Control Arm 3 Steering Knuc
52. indicator reading 0 to 4 inH20 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 Replace the air cleaner at the recommended interval or when filter restriction reaches 25 inH O See the Recreational Vehicle Chassis Operator s Manual for specific restriction values for your engine See Group 09 of the Recreational Vehicle Chassis Work Fig 2 Air Restriction Indicator shop Manual for removal and installation procedures or take the vehicle to an authorized Freightliner dealer 09 02 Charge Air Cooler Inspecting and Cleaning Inspect the charge air cooler for clogging or damage and clean and or repair it if necessary Recreational Vehicle Chassis Maintenance Manual September 2007 09 1 Alternators and Starters 15 Index Alphabetical Title of Maintenance Operation MOP MOP Number Alternator Battery and Starter Checking eee ene eee ee 15 01 Recreational Vehicle Chassis Maintenance Manual September 2007 Alternators and Starters 15 01 Alternator Battery and Starter Checking 1 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 Recreational Vehicle Chassis Workshop Manual or take the vehicle to an au thorized Freightliner dealer 2 Check that all
53. istently seasonally or is exposed to excess moisture it will be necessary to perform preventative maintenance as instructed in Maintenance Operation 01 03 t Beginning with model year 2002 RV chassis the coolant replacement interval is increased to 100 000 miles 161 000 km or 60 months You must check and if necessary recharge the SCA supplemental coolant additive levels and freeze point every 25 000 miles 40 000 km or 6 months See the Cummins Opera tion and Maintenance Manual for further information t For oil and filter change intervals see the applicable Allison Operator s Manual Perform these steps each time the wheels and or the vehicle is washed f Replace the Bendix AD9 filter and the Haldex Midland PURest air dryer filter kit every 36 months Lubricate every 6 months OR every 18 000 miles 28 000 km whichever comes first tt Change the TRW inline power steering filter every 12 months tt See the Cummins Operation and Maintenance Manual for fuel water separator element replacing intervals Table 1 Maintenance Operation Procedures and Schedule 00 4 Recreational Vehicle Chassis Maintenance Manual September 2007 General Information 00 Noise Emission Controls Maintenance 00 03 Noise Emission Control Maintenance Federal Law Part 205 Transportation Equipment Noise Emission Controls Part 205 Transportation Equipment Noise Emission Controls requires the vehicle manufacturer to fur nish
54. jury 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 60 Inch Taper Leaf Spring Component Check No lubrication is required on the 60 inch taper leaf spring front and rear suspension Inspect the rear shackle brackets for bushing wear or cracks Inspect the stabilizer bar if present for irregular bushing wear or cracks in the brackets Check the rubber helper spring if present for cracks 32 07 Suspension U Bolt Torque Checking front engine diesel chassis Check the U bolt torque of both the front and rear axles where applicable 4h CAUTION Failure to retorque the U bolt nuts could result in spring breakage and abnormal tire wear 1 Park the vehicle on a flat surface apply the park ing brake and chock the tires 2 Check the U bolt torque in a diagonal pattern Set a click type torque wrench to the highest torque value for the fastener being checked See Table 2 for U bolt torque specifications Turn the wrench in a clockwise motion looking up until the torque wrench clicks 3 Remove the chocks Recreational Vehicle Chassis Maintenance Manual September 2007 32 5 32 Suspension U Bolt Torque Values m A Torque Description Size Ibf ft N m Stage 1 Hand tighten T Stage 2 60 81 9 8718 Stage 3 200 271 Stage 4 180 to 230 245 to 313 Spring Assem
55. ke Bearing Grease Fitting lower Fig 4 Pressure Grease Fitting Positions RL 75E 32 4 Recreational Vehicle Chassis Maintenance Manual September 2007 Suspension 4 3 09 30 2004 1321019 Steering Knuckle Bearing Grease Fitting upper Control Arm Grease Fitting upper Control Arm Grease Fitting lower Steering Knuckle Bearing Grease Fitting lower PI Fig 5 Pressure Grease Fitting Positions RL 75EM 32 06 Suspension Inspecting front engine diesel chassis Freightliner Spring Front and Rear Suspension Spring Assemblies Inspection 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 Recreational Vehicle Chassis Workshop Manual for instructions 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 32 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 in
56. l September 2007 Transmission 26 1 2 J 3 4 5 6 aN 06 04 99 e 1260130a 1 O Ring 5 Seal 2 Drain Plug 6 Filter Cover 3 Filter 7 M10 Bolt 4 O Ring 03 31 2000 f261061 1 Magnet 2 External Filter Fig 3 Allison 3000 MH Transmission Filters Fig 4 1000 2000 2400 MH Series Transmission External Filter Recreational Vehicle Chassis Maintenance Manual September 2007 26 3 Throttle Control 30 Index Alphabetical Title of Maintenance Operation MOP MOP Number Trote Pedal Pivot Pin DIT sea orici parias DID EP BTS de teed are 30 01 Recreational Vehicle Chassis Maintenance Manual September 2007 Throttle Control 30 01 Throttle Pedal Pivot Pin Lubricating Using a silicone spray lubricate the throttle pedal pivot pins 30 Recreational Vehicle Chassis Maintenance Manual September 2007 30 1 Frame 31 Index Alphabetical Title of Maintenance Operation MOP MOP Number Frame Fastener Torque OheeRIfID s eun KAG AKA e ia AAA GD HD ie od 31 01 Recreational Vehicle Chassis Maintenance Manual September 2007 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 4h CAUTION Make sure frame fasteners are properly tightened Continued vehicle
57. le or delivery to the ultimate purchaser or while it is in use 2 The use of the vehicle after such device or ele ment of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tam pering are the acts listed below A Removal of or rendering inoperative the en gine speed governor so as to allow engine speed to exceed manufacturer s specifica tions B Removal of or rendering inoperative the fan clutch including bypassing the control on any thermostatic fan drive to cause it to op erate continuously C Removal of the fan shroud D Removal of or rendering inoperative ex haust components including exhaust pipe clamping E Removal of air intake components Maintenance Instructions Scheduled intervals are in the maintenance table in this group A Verification of Inspections Log Group 49 follows and should be filled in each time noise emission controls on the vehicle are maintained or repaired Recreational Vehicle Chassis Maintenance Manual September 2007 00 5 00 General Information Verification of Inspections Log 00 04 Verification of Inspections Log Verification of Inspections Log Group 49 Date Mileage Item Cost Maintenance Facility Group 49 Exhaust System Components 00 6 Recreational Vehicle Chassis Maintenance Manu
58. m inspections 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 Check the suspension fasteners See Table 1 for correct fastener torques Suspension Torque Specifications lubricated threads j Torque Description Size Ibf ft N m Shock Absorber Mount 3 4 16 110 to 150 Locknut 149 to 203 Air Spring Upper Mounting 3 4 16 31 to 42 Plate Locknut 42 to 57 Air Spring Upper Mounting 1 2 13 31 to 42 Plate Capscrew 42 to 57 Air Spring Lower Mounting 1 2 13 31 to 42 Plate Capscrew 42 to 57 Transverse Beam Bushing 4 1 4 12 600 to 700 Locknuts 814 to 950 Equalizing Beam Center 3 4 16 150 to 200 Bushing Locknut 203 to 271 Equalizing Beam Front 1 1 8 12 600 to 700 Bushing Locknut 1 1 4 12 814 to 950 Control Rod Ball Stud 1 1 8 12 550 to 650 Locknut 746 to 880 Control and Torque Rod 5 818 110 to 150 Mounting Locknuts 149 to 203 Table 1 Suspension Torque Specifications lubricated threads 3 Check the torque of the rear axle U bolts 32 In a diagonal pattern tighten all 5 8 18 U bolt nuts 205 Ibf ft 278 N m tigh
59. nce Manual September 2007 Engine Cooling R adiator 20 01 Radiator Cap Checking 20 20 03 Coolant Replacing Do not remove or loosen the radiator cap until the engine and cooling system have completely cooled Use extreme care when removing the cap A sudden release of pressure from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause seri ous personal injury The radiator cap is the most ignored part in the cool ing system If it is suspect replace it An inspection 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 probably lost tension replace it See Fig 1 05 31 2007 f200705 Fig 1 Surge Tank Coolant Fill Cap 20 02 Radiator Inspecting and Cleaning Inspect the radiator for clogging or damage and clean and or repair it if necessary At the intervals specified in the maintenance sched ule or whenever the coolant becomes dirty flush and refill the cooling system NOTE The coolant replacement interval is in creased to 100 000 miles 161 000 km or 60 months which
60. ne Bolts 3 Frame Mount Bracket Bolts Fig 1 Front and Rear Engine Rear Mount ISB chassis built after 2002 11 08 2005 1012110 1 Front and Rear Engine Front Mount Bolt Fig 2 Front and Rear Engine Front Mount ISB chassis built after 2002 excess moisture it will be necessary to perform pre ventative maintenance using the following steps 1 With the engine turned off use Pacbrake Syn thetic Lube or Synco Super Lube and spray or coat a sufficient amount on the restricter air cylin der valve shaft and the attaching locations at each end of the actuation cylinder See Fig 3 for the exhaust brake lubrication points Recreational Vehicle Chassis Maintenance Manual September 2007 01 1 03 20 2003 1012035 1 Air Cylinder 2 Pacbrake Fig 3 Pacbrake Exhaust Brake Lube Point Locations 2 Using your hands or a pair of pliers slide the valve several times to distribute the lubricant down the shaft and the attaching locations NOTE Operation of the Pacbrake could be af fected by starting the engine and idling for short periods of time During a cold engine start up moisture occurs in the engine and the exhaust system that creates a corrosion hazard The brake housing may trap water in the valve shaft bore causing corrosion resulting in an improper or non functioning brake If it is necessary to periodically start the engine reach normal ope
61. ng hole position Tighten the leading side pin first then tighten the trailing side pin 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 4 Recreational Vehicle Chassis Maintenance Manual September 2007 Brakes 42 10 Brake Lines Checking Hydraulic Disc Brakes front engine diesel chassis Check all hydraulic lines and fittings for damage leakage or looseness Replace damaged or leaking components and tighten loose fittings 42 11 Brake Lining Wear Checking Hydraulic Disc Brakes front engine diesel chassis Before checking lining wear with the wheel removed review the following brake lining exposure warnings 4h WARNING 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 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 Apply the brake and
62. ning in 2002 do not apply to Allison transmissions in Freightliner chassis vehicles Allison transmis sions are received partially filled with TranSynd synthetic automatic transmission fluid ATF They are then topped off with a non TranSynd ATF Allison s recommended extended oil and filter change intervals for TranSynd only or for a mix ture of TranSynd and non TranSynd do not apply To qualify for the mixture intervals the transmission must be drained as in a standard fluid change and then filled with TranSynd See the applicable Allison Operator s Manual for specific information For 1000 2000 2400 series transmissions with non TranSynd ATF and for the 2000 MH trans mission in which only TranSynd is used change oil and filters at 50 000 miles 80 000 km or 24 months whichever comes first For MD HD and 3000 4000 MH series transmis sions change oil and filters at 25 000 miles 40 Transmission 000 km or 12 months whichever comes first See the applicable Allison Operator s Manual for specific information 1 Park the vehicle on a level surface and apply the parking brakes 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 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
63. nt parallelism and thrust angle measurements for the rear axle Use the appli cable procedure and specifications in Group 35 of the Recreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 33 2 Recreational Vehicle Chassis Maintenance Manual September 2007 33 Front Axle Toe In Inspection For vehicle alignment to be accurate the shop floor must be level in every direction The turn plates for the front wheels must rotate freely without friction and the alignment equipment must be calibrated every three months by a qualified technician from the equipment manufacturer Freightliner dealers must have proof of this calibration history 1 Apply the parking brakes and chock the rear tires 2 Raise the front of the vehicle until the tires clear the ground Check that the safety stands will support the combined weight of the body axle and frame Place safety stands under the axle 3 Using spray paint or a piece of chalk mark the entire center rib of each front tire 4 Place a scribe or pointed instrument against the marked center rib of each tire and turn the tires Hold the scribe firmly in place so that a single straight line is scribed all the way around each front tire 5 Place a turn plate or turntable under both front tires Remove the safety stands from underneath the axle then lower the vehicle Remove the lockpins from the gauges make sure that the tire
64. o discon tinue 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 2007 2008 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 Service Systems and Documentation POC SSD P O Box 3849 Portland OR 97208 3849
65. ooving due to belt slippage replace both the pulley and the drive plate Visually inspect the refrigerant compressor drive belt for damage and check that the belt is set at the proper ten sion Also check the tightness of the compressor mounting fasteners For instructions and torque values and for removal and installation proce dures see Group 83 of the Recreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 3 Inspect the drive plate If the friction surface of the drive plate shows visible signs of damage due to excessive heat replace the drive plate and pulley assembly See Group 83 of the Rec reational Vehicle Chassis Workshop Manual for removal and installation procedures or take the vehicle to an authorized Freightliner dealer 4 Ona Sanden refrigerant compressor use a feeler gauge to check the drive plate clutch clearance It should be 0 016 to 0 03 inch 0 4 to 0 8 mm See Fig 1 If the drive plate clutch re quires adjustment see Group 83 of the Recre ational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 83 08 25 94 830641 Fig 1 Drive Plate Clearance Inspection Sanden compressor shown 5 Inspect the compressor clutch coil wire Ensure that the connector is not damaged or loose Re place the wire if it is damaged 6 Check the overall condition of the air conditioning hoses Look for cracks cut
66. or 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 Recreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Inspect the bolts and nuts at the pivot connec tions the transverse beam connections and the axle connections to ensure they are tightened to the correct torque specification f320423a 3 Axle Centerline Fig 1 Ride Height Inspection typical Neway suspension shown 32 2 Recreational Vehicle Chassis Maintenance Manual September 2007 Suspension 32 02 21 2005 1321032 Fig 2 Holland Neway ADL 120 123 Suspension 5 Check all of the other suspension components following the procedures in Group 32 of the Rec for any sign of damage looseness wear or reational Vehicle Chassis Workshop Manual or cracks Replace worn or damaged parts See take the vehicle to an authorized Freightliner Group 32 of the Recreational Vehicle Chassis dealer HAGGANG AG es vehicle to an au 9 Check for leaks on the height control valves by 9 applying a soapy solution then watching for 6 Inspect for cracked welds If cracks are found bubbles at all air connections and fittings Aa Neway immediately for further instruc 10 Inspect the shock absorbers for oil leaks and worn rubber bushings Replace the shock ab 7 Inspect the torque rod and track bar pivot bush sorber
67. r Pitch Torque Ibf ft N m Torque Ibf ft N m N 7 N Ss N TOP F P No uds a E WA 230010 230011 1230012 230013 M6 5 7 7 9 M8 12 16 17 23 M8 x 1 13 18 18 24 M10 24 33 34 46 M10 x 1 25 27 37 38 52 M12 42 57 60 81 M12 x 1 5 43 58 62 84 M14 66 89 95 129 M14 x 1 5 72 98 103 140 M16 103 140 148 201 M16 x 1 5 110 149 157 213 M18 147 199 203 275 M18 x 1 5 165 224 229 310 M20 208 282 288 390 M20 x 1 5 213 313 320 434 M22 283 384 392 531 M22 x 1 5 315 427 431 584 M24 360 488 498 675 M24 x 2 392 531 542 735 M27 527 715 729 988 M27 x 2 569 771 788 1068 M30 715 969 990 1342 M30 x 2 792 1074 1096 1486 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation t Use these torque values if either the bolt or nut is lubricated or plated zinc phosphate conversion coated cadmium plated or waxed Table 7 Torque Values for Metric Thread Fasteners With Lubricated or Plated Threads Recreational Vehicle Chassis Maintenance Manual September 2007 00 11 Engine Title of Maintenance Operation MOP Engine Drive Belt Inspecting eee Engine Support Fasteners Checking aaa Pacbrake Inspecting and Maintenance 01 Index Alphabetical MOP Number Recreational Vehicle Chassis Maintenance Manual September 2007 Engine 01 01 Engine Driv
68. r ating temperatures before shutting down the en gine Engine 01 2 Recreational Vehicle Chassis Maintenance Manual September 2007 Air Intake Title of Maintenance Operation MOP Air Cleaner Inspecting and Replacing Charge Air Cooler Inspecting and Cleaning 09 Index Alphabetical MOP Number Recreational Vehicle Chassis Maintenance Manual September 2007 Air Intake 09 01 Air Cleaner Inspecting and Replacing 09 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 Recreational Vehicle Chassis Workshop Manual for removal and installa tion procedures or take the vehicle to an authorized Freightliner dealer A typical air cleaner mounting is shown in Fig 1 07 11 2007 1090451 H20 VACUUM IN H20 VACUUM 25 20 15 10 7 ap PUSH TO RESET gg 05 22 97 1 1090176 Fig 1 Air Cleaner Mounting 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 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
69. r dealer Recreational Vehicle Chassis Maintenance Manual September 2007 33 3 33 f400100a 08 30 94 Fig 6 Setting Trammel Bar Pointers 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 80W 90 hypoid gear oil to bring the oil to the proper level Front Axle 4 Rotate the wheels allow the oil to settle and check the levels again 5 Install the filler caps securely Remove the chocks from the tires 33 06 Oil Filled Hubs Oil Changing 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 so that the front hub drain plugs are positioned downward
70. r every six months with Meritor specifica tion grease 0 617 A or 0 617 B See Fig 3 for roller and anchor pin lubrication points 1 2 3 03 02 2004 1430370 1 Cam Roller Pin Lube Points Q Series 2 Cam Roller Pin Lube Points Q Q Plus and P Series 3 Cam Anchor Pin Lube Point Q Q Plus and P Series Fig 3 Cam and Anchor Roller Pin Lubrication Points 42 08 Bendix Hydro Max Power Booster Checking front engine diesel chassis Check for proper operation see Group 42 of the Recreational Vehicle Chassis Workshop Manual for instructions or take the vehicle to an authorized Freightliner dealer Recreational Vehicle Chassis Maintenance Manual September 2007 42 3 42 42 09 Brake Caliper Slide Pin Lubricating Bosch Brakes front engine diesel chassis NOTE There is no set maintenance interval for lubricating pin slide hydraulic disc brake cali pers 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 IMPORTANT The later ZOH T caliper has im portant differences from the early ZOPS caliper ZOPS calipers since 1998 and ZOH T calipers since 2002 use different slide pins and bolts See Fig 4 and Fig 5 The later trailing pin is identified by notches and has a rubber bushing Flange head instead of hexhead bolts are used with the later caliper The later
71. r 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 03 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 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 Replacement 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 O psi O 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
72. relative to a brake application with 80 to 90 psi 550 to 620 kPa air pressure in the brake chambers t If type 36 chamber is used slack length should be less than 6 inches Table 1 Brake Chamber Stroke Specifications Recreational Vehicle Chassis Maintenance Manual September 2007 42 7 Steering 46 Index Alphabetical Title of Maintenance Operation MOP MOP Number rag LOk LMONCAING narrador A a TALATANG dee ones BANANA Bees 46 01 Hydraulic Reservoir Filter Changing metal reservoir only roo 46 06 Power Steering Reservoir Fluid Level Checking 2 cc e tees 46 02 Power Steering Reservoir Fluid and Filter Changing o 46 03 Steering Driveline Lubricating RR ra 46 04 Steering Gear bubricalting i eumd ee KAKA AG ARE DNA DP LAKE DAL e Re e 46 05 Recreational Vehicle Chassis Maintenance Manual September 2007 Steering 46 01 Drag Link Lubricating 1 Using a clean rag wipe the dirt from both grease fittings on the drag link 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 2 896 12 hydroxy lithium stear ate grease The grade 2 chassis grease is pre ferred 46 02 Power Steering Reservoir Fluid Level Checking 1 Clean around the power steering reservoir dip stick fill cap
73. ricating the slack adjusters Automatic slack adjusters must be lubricated periodi cally to ensure proper brake operation Failure to lubricate slack adjusters could lead to dragging brakes or a brake failure resulting in pesonal injury or property damage Gunite IFS only Lubricate a Gunite automatic slack adjuster at the grease fitting until grease flows from the grease relief opening For operating temperatures of 20 F 29 C and higher use Texaco Multifak EP 2 or Mobil Grease No 77 For operating temperatures between 20 F 29 C and 40 F 40 C use Lubriplate Aero grease Haldex 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 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 2 42 06 Foot Brake Valve Actuator Lubricating 1 Clean any dirt gravel and other foreign material from the base of the brake pedal the plunger boot and the brake base bracket 42 2 Recreational Vehicle Chassis Maintenance Manual September 2007 Brakes 10 20 93 f420012a Brak
74. s and abrasions on the hoses Replace damaged hoses see Group 83 of the Recreational Vehicle Chassis Work shop Manual for replacement instructions or take the vehicle to an authorized Freightliner dealer Also check for loose fittings on all air conditioning components 7 Check for a buildup of road debris on the con denser fins For cleaning instructions see Sec tion 83 00 Subject 110 of the Recreational Ve hicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Recreational Vehicle Chassis Maintenance Manual September 2007 83 1
75. s and or rubber bushings if wear or dam ings for excessive wear Replace worn or dam age is noted For instructions see Group 32 of aged bushings See Group 32 of the Recre the Recreational Vehicle Chassis Workshop ational Vehicle Chassis Workshop Manual or Manual or take the vehicle to an authorized take the vehicle to an authorized Freightliner Freightliner dealer dealer 11 Remove the safety stands and lower the vehicle 8 Move the axle up and down while checking for to the ground Run the engine until air pressure signs of looseness due to worn parts at the front of at least 100 psi 689 kPa is maintained pivot connections Replace any worn parts by throughout the system Recreational Vehicle Chassis Maintenance Manual September 2007 32 3 32 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 Rec reational Vehicle Chassis Workshop Manual for possible causes and corrections or take the ve hicle to an authorized Freightliner dealer 32 04 Neway Suspension Lubricating When lubricating the front suspension Neway IFS 114 post control arm bearings wipe the lube fittings clean and slowly feed lithium based wheel bearing grease into each bearing location Hold a high pressure grease gun on each front sus pension grease fitting until fresh grease appears See Fig 3 This will ensure that all of the old con tam
76. s are pointing straight ahead NOTE If turn plates or turntables are not avail able lower the vehicle Remove the chocks from the rear tires and release the parking brake Move the vehicle backward and then for ward about six feet two meters 6 Place a trammel bar at the rear of the front tires locate the trammel pointers at spindle height and adjust the pointers to line up with the scribe lines on the center ribs of the front tires See Fig 4 Lock the pointers in place Check that the scale is set to zero 7 Place the trammel bar at the front of the tires and adjust the scale end so that the pointers line up with the scribe lines See Fig 5 and Fig 6 8 Read the toe in from the scale and compare it to the toe in specification in Group 33 of the Recre ational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer If corrections are needed see Group 33 of the Recreational Vehicle Chassis Workshop D ml B gt 08 29 94 NOTE B minus A equals toe in f330082a Fig 4 Wheel Toe In overhead view EU 08 30 94 f330014a Fig 5 Trammel Bar Positioning Manual or take the vehicle to an authorized Freightliner dealer 33 04 Wheel Bearing Removal Cleaning Checking Repacking and Adjusting See Group 33 of the Recreational Vehicle Chassis Workshop Manual for wheel bearing service proce dures or take the vehicle to an authorized Freight line
77. s matching those in the text of this manual Recreational Vehicle Chassis Maintenance Manual September 2007 00 1 00 General Information Vehicle Maintenance Schedule Table 00 02 Maintenance Intervals Maintenance Operation Set Frequency Miles km Months Initial Maintenance IM first 6000 10 000 6 Maintenance 1 M1 every 6000 10 000 6 Maintenance 2 M2 every 12 000 20 000 12 Maintenance 3 M3 every 24 000 40 000 24 Use distance or time whichever comes first Maintenance Operation Procedures and Intervals REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 Maintenance Operation Number and Description 01 01 Engine Drive Belt Inspecting 01 02Engine Support Fasteners Checking 01 03 Pacbrake Inspecting and Maintenance 09 01 Air Cleaner Inspecting and Replacing 09 02 Charge Air Cooler Inspecting and Cleaning 15 01Alternator Battery and Starter Checking 20 01 Radiator Cap Checking 20 02 Radiator Inspecting and Cleaning 20 03 Coolant Replacingt 26 01Transmission Breather Checking 26 02 Allison MD MH Series Transmission Fluid Level Checking 26 03 Allison MD MH Series Transmission Fluid and Filter Changing internal external filter 30 01 Throttle Pedal Pivot Pin Lubricating 31 01 Frame Fastener Torque Checking 32 01 Neway Suspension Fastener Torque Checking 32 02
78. system showing the specified vehicle s build record EZWiring makes Freightliner product wiring drawings and floating pin lists available online for viewing and printing EZWiring can also be accessed from within PartsPro Recreational Vehicle Chassis Maintenance Manual January 2008 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 Recreational Vehicle Chassis Maintenance Manual January 2008 Page Description For an example of a maintenance manual page see Fig 1 Introduction B C Front Axle 33 w 33 01 Knuckle Pin Lubricating See Fig 1 33 02 Tie Rod End Lubricating and Inspecting 33 03 Toe In Inspection A D E 11 11 2002 A Maintenance Operation Number consists of the Group Number followe
79. t check the drive shaft for proper length U Joint Lubricating 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 NOTE If a low pressure adaptor is not used with the high pressure gun the U joints may not receive enough lubricant 41 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 4h CAUTION Fresh lubricant must be seen escaping from all four of the bearing cup seals of each U joint If not the U joint may fail prematurely 4 Ifthe bearing will not take grease replace the U joint assembly For instructions see Group 41 of the Recreational Vehicle Chassis Workshop Manual or take the vehicle 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 Recreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 6 Wipe any excess grease from the seals and grease fittings Slip Joint Spline Lubricating 1 Wipe all old grease and dirt from the slip joint grease fitting 2 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
80. ten all 3 4 16 U bolt nuts 300 Ibf ft 407 N m and tighten all 7 8 14 U bolt nuts 460 Ibf ft 624 N m 4h CAUTION Failure to retorque the U bolt nuts could result in spring breakage and abnormal tire wear 4 Remove the safety stands and lower the vehicle to the ground 32 02 Neway Suspension Height Control Valve Checking Inspect the height control components and check their operation Failure to perform these inspec tions 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 Park the vehicle on a level surface Apply the parking brakes and chock the tires to prevent the vehicle from moving 2 Inspect the front and rear suspensions for any signs of damage loose components wear or cracks Replace any damaged components to prevent failure or equipment breakdown 3 Inspect all bolts and nuts at the pivot axle con nections to assure that they are properly torqued Check all other nuts and bolts for proper torque See Group 00 of this manual for proper torque specifications 4 Check the air pressure gauge to confirm that there is in excess of 65 psi 448 kPa in the air system and inspect the air springs for sufficient and equal firmness NOTE Height control valves control all front and rear suspension air springs Check for air leaks by applying a soapy solution Then check for bubbles at all air
81. tic 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 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 Recreational Vehicle Chassis Maintenance Manual September 2007 42 5 42 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 See Group 42of the Recreational Vehicle Chassis Workshop Manual for inspection troubleshooting and re pair procedures or take the vehicle to an autho rized Freightliner dealer Measure the applied chamber stroke See Table 1 for the proper stroke for the 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 Brakes matic slack adjuster See Group 42 of the Rec reational Vehicle Chassis Workshop Manual for inspection and troubleshooting procedures or take the vehicle to an authorized
82. tons t 1 1023 U S tons t Torque Work Force inch pounds Ibf in 11 298 Newton centimeters N cm 0 08851 inch pounds Ibf in foot pounds Ibf ft 1 3558 Newton meters N m 0 7376 foot pounds Ibf ft Pressure Vacuum inches of mercury inHg 3 37685 kilo Pascals kPa 0 29613 inches of mercury inHg pounds per square inch psi 6 895 kilo Pascals kPa 0 14503 pounds per square inch psi Table 2 Metric U S Customary Conversion Then When You Multiply Then When You Know Subtract Divide By To Get Know By Add To Get degrees Fahrenheit F 32 1 8 degrees Celsius C 1 8 degrees Fahrenheit F Table 3 Temperature Conversion Recreational Vehicle Chassis Maintenance Manual September 2007 00 7 00 Torque Specifications Tables 00 06 IMPORTANT Grade 8 regular hex zinc yellow plated capscrews and cadmium and wax coated prevailing torque locknuts may be tightened to a lower torque value than the grade 8 regular hex fasteners de General Information scribed in Table 4 See Table 5 for torque values for grade 8 regular hex zinc yellow plated capscrews and cadmium and wax coated prevailing torque locknuts Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threadst Regular Hex Flanged B Grade 5 Grade 5 or Grade 8 or Grade 8 or Grade 5 Grade B Grade 8 or Grade G Pitc
83. uckle Fig 2 ABP Axle Grease Fittings 33 When lubricating Meritor axle knuckle pin bushings or Alliance Brand Product ABP axle needle bear ings at the initial maintenance IM interval first wipe the lube fittings clean Then slowly feed for Meritor axles multipurpose chassis grease NLGI grade 1 or 2 into each bushing area or for ABP axles lithium 12 hydroxy stearate with molybdenum disulfide WL grade 2 grease into each needle bearing 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 NOTE The grease seal will accept the grease pressure without damaging the seal and is de signed to have grease pumped out through it 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 or needle bearing opposite the grease fitting When lubricating knuckle pin bushings or needle bearings after the IM maintenance interval first wipe the lube fittings clean Then for Meritor axles apply multipurpose chassis grease or for ABP axles lithium 12 hydroxy stearate with molybdenum disul fide WL grade 2 grease until new grease is seen at the grease seal on the bushing or needle bearing opposite the fittings 33 02 Tie Rod End Lubricating and Inspecting IMPORTANT DOT roadside tie rod assembly replacement criteria sp
84. with a clean rag then remove the dipstick WARNING 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 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 Fluid Type Approved Fluid Automatic Transmission Fluid Dexron VI Hydraulic System Fluid power 15W40 steering with side mounted radiator Use the same lubricant when assembling parts as is used in the power steering system Table 1 Approved Power Steering Fluid 3 Install the dipstick fill cap in the power steering reservoir 46 46 03 Power Steering Reservoir Fluid and Filter Changing 1 Remove the dipstick if so equipped 2 Drain the power steering reservoir by disconnect ing the power steering gear to reservoir hose from the reservoir Catch the fluid from the reser voir in a drain bucket then cap the reservoir port 3 Loosen the clamps on each end of the inline power steering filter and save them for reuse Remove the old filter if so equipped IMPORTANT Do not use teflon tape on the threads of the hose barb fittings

2008 XC Chassis Maintenance Manual

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