Home

BUSINESS CLASS M2 MAINTENANCE MANUAL

1. Maintenance Interval Service Date m 1st IM and M1 8000 12 000 10 000 16 000 2nd M1 and M2 16 000 24 000 20 000 32 000 3rd M1 24 000 36 000 30 000 48 000 4th M1 M2 and M3 32 000 48 000 40 000 64 000 5th M1 40 000 60 000 50 000 80 000 eth M1 and M2 48 000 72 000 60 000 96 000 7th M1 56 000 84 000 70 000 112 000 8th M1 M2 M3 and M4 64 000 96 000 80 000 128 000 9th M1 72 000 108 000 90 000 144 000 10th M1 and M2 80 000 120 000 100 000 160 000 11th M1 88 000 132 000 110 000 176 000 12th M1 M2 and M3 96 000 144 000 120 000 192 000 13th M1 104 000 156 000 130 000 208 000 14th M1 and M2 112 000 168 000 140 000 224 000 15th M1 120 000 180 000 150 000 240 000 16th M1 M2 M3 M4 and M5 128 000 192 000 160 000 256 000 17th M1 136 000 204 000 170 000 272 000 18th M1 and M2 144 000 216 000 180 000 288 000 19th M1 152 000 228 000 190 000 304 000 20th M1 M2 and M3 160 000 240 000 200 000 320 000 21st M1 168 000 252 000 210 000 336 000 22nd M1 and M2 176 000 264 000 220 000 352 000 23rd M1 184 000 276 000 230 000 368 000 24th M1 M2 M3 and M4 192 000 288 000 240 000 384 000 25th M1 200 000 300 000 250 000 400 000 26th M1 and M2 208 000 312 000 260 000 416 000 27th M1 216 000 324 000 270 000 432 000 28th M1 M2 and M3 224 000 336 000 280 000 448 000 29th M1 232 000 348 000 290 000 464 000 30th M1 and M2 240 000 360 000 300 000 480 000 31st M1 248 000 372 000 3
2. Max relay 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 51 36 2 1 4 57 16 20 2 51 Long Stroke 24 24 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 Business Class M2 Maintenance Manual January 2010 42 13 42 Brakes Brake Chamber Stroke Specifications Chamber Max Applied Stroke inch mm Manufacturer Type Sizet 9 Less than 1 1 2 38 12 Standard Stroke 16 Less than 1 3 4 44 Meritor 20 24 Less than 1 7 8 48 Long Stroke 24 Less than 2 51 Standard Stroke 30 Long stroke design is indicated by a tag or embossing on the brake chamber t Specifications are relative to a brake application with 80 to 90 psi 550 to 620 kPa air pressure in the brake chambers t If type 36 chamber is used slack length should be less than 6 inches Table 1 Brake Chamber Stroke Specifications 42 14 Business Class M2 Maintenance Manual January 2010 Steering 46 Index Alphabetical Title of Maintenance Operation MOP MOP Number Drag Line TInspecliligis secos tied ude pak a seque bed wb
3. 00 6 Business Class M2 Maintenance Manual September 2011 General Information 00 Overview of Maintenance Operations 00 05 Maintenance Operation No Maintenance Operations for Groups 00 through 88 Title of Maintenance Operation Maintenance Intervals M1 M2 M3 M4 M5 47 06 CNG High Pressure Fuel Filter Element Replacing 47 07 CNG Fuel Cylinder Inspecting 49 01 Exhaust System Inspecting Noise Emission Control 49 02 CAT Bellows and Piping Inspection 49 03 CAT Bellows Replacement 60 01 Mirror Folding Check 72 01 Door Seals Lubricating 83 01 Air Conditioner Inspecting 83 02 HVAC Air Filter Replacing 88 01 Hood Rear Support Lubrication Change petroleum based lubricants at M2 including M3 M4 and M5 Change synthetic lubricants at M5 only t Schedule and Schedule III vehicles only t If equipped with an oil coalescing desiccant cartridge replace the cartridge once a year regardless of mileage Otherwise use the M5 maintenance interval Replace the HVAC air filter at the recommended interval or every six months Table 4 Maintenance Operations for Groups 00 through 88 Business Class M2 Maintenance Manual September 2011 00 7 00 General Information Initial Maintenance IM Operations 00
4. Schedule III vehicles only t If equipped with an oil coalescing desiccant cartridge replace the cartridge once a year regardless of mileage Otherwise use the M5 maintenance interval M1 maintenance interval should be used as a general guideline the actual frequency of filter element replace ment will vary depending on cleanliness of the fuel station system Table 6 M1 Maintenance Operations 00 10 Business Class M2 Maintenance Manual September 2011 General Information 00 M2 Maintenance Operations 00 08 NOTE The M2 Maintenance Operations include the maintenance operations in Table 9 M1 Maintenance maintenance operations in Table 7 and all of the Operations M2 Maintenance Operations Maintenance Operation No Title of Maintenance Operation 00 07 Perform All M1 Maintenance Operations 00 13 Lubrication and Fluid Level Check Eaton Fuller Transmission Fluid Changing and Magnetic Plug Cleaning Meritor Camshaft Bracket Lubricating 13 01 Air Compressor Inspecting 20 01 Radiator Cap Inspecting 20 03 Fan Drive Inspecting Noise Emission Control 26 04 Eaton Fuller Transmission Air Filter Regulator Element Cleaning 33 05 Wheel End Inspection and Maintenance 6 000 Pound and 8 000 Pound Steer Axles with Oil Lubricated Hubst 42 10 Air Dryer AD 9 AD IP and AD IS DRM Checking 42 12 Brake Pedal Linkage and Mounting Plate Inspecting 47 05 CNG Fuel System Insp
5. 00 07 Perform All M1 Maintenance Operations 00 08 Perform All M2 Maintenance Operations 00 09 Perform All M3 Maintenance Operations 00 10 Perform All M4 Maintenance Operations 25 04 Clutch Hydraulic Fluid Changing Mercedes Benz Transmission Fluid Changing and Magnetic Plug 26 06 Cleaning 26 07 Mercedes Benz Transmission Leak Checking 42 02 Bendix AD 9 Air Dryer Desiccant Replacing 42 05 Bendix AD IP Air Dryer Desiccant Replacing 42 09 Bendix AD IS Air Dryer Desiccant Replacing 42 14 Foot Control Valve E6 Inspecting and Lubricating 46 06 Power Steering Filter Changing 49 03 CAT Bellows Replacement Table 10 M5 Maintenance Operations 00 14 Business Class M2 Maintenance Manual September 2011 General Information 00 M1 Lubrication and Fluid Level Check 00 12 Table 11 MOP 00 12 lists the lubrication and fluid level check maintenance operations that must be performed at the M1 Maintenance Interval MOP 00 12 M1 Lubrication and Fluid Level Check Maintenance Operation No Title of Maintenance Operation 25 01 25 02 Eaton Fuller Clutch Release Bearing Lubricating Eaton Fuller Clutch Release Cross Shaft Lubricating 25 03 Clutch Hydraulic Fluid Level Checking 26 01 Manual Transmission Fluid Level Checking 31 03 Fifth Wheel Lubricating 31 04 Trailer Electrical Connector Lubricating 32 02 Suspension Lubricating
6. 34 to 48 N m for Eaton Fuller transmissions with 3 4 inch pipe threads e 60 to 75 Ibf ft 81 to 102 N m for Eaton Fuller transmissions with 1 1 4 inch pipe threads 26 03 Allison and Eaton Fuller Transmission Breather Checking Transmission housing breathers if equipped must remain clear A plugged breather could result in pres sure build up which could cause oil leakage If the breather is plugged clean or replace it See Fig 2 Check more often if the vehicle is operating under very dusty conditions 26 2 Business Class M2 Maintenance Manual March 2005 Transmission 26 LA 05 27193 2 260007 NOTE Location of the transmission breather will vary Eaton Fuller Transmission Lubricant Capacities Lubricant Transmission Model Capacity qt L 5 Speed FS 4205A B 5 5205 6 25 5 9 FS 6305A B 9 75 9 2 6 Speed 5 5406 9 75 9 2 FS 6406A FSO 6406A 9 75 9 2 6406 FO 8406 10 5 10 0 FSO 8406A 9 75 9 2 7 Speed T 14607A B 18 17 5 TX 14607B 18 17 5 9 Speed RT 6609A 6 5 7 RT 8709B 13 0 12 3 RT 8608L 13 5 12 7 10 Speed FR 9210B 11 75 11 FRO 14210C FRO 15210C 11 75 11 RT 8908LL 14 13 2 RTO 10910B AS2 13 12 3 RTO 11908LL 14 13 2 11 Speed RTO 11909ALL 14 13 2 13 Speed RTLO 14913A 14 13 2 18 Speed RTLO 14918B 14 13 2 RTLO 16918
7. 41 2 Business Class M2 Maintenance Manual December 2001 Brakes 42 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Brake Inspecting and Leak 42 13 Air Brake System Valve Inspectlng DE EAEE R Sue 42 01 Air Dryer AD 9 AD IP AD IS DRM 0 42 10 Bendix AD 9 Air Dryer Desiccant Replacing RR RR RR 42 02 Bendix AD IP Air Dryer Desiccant 0 42 05 Bendix AD IS Air Dryer Desiccant 0 42 09 Bendix Hydro Max Brake System Inspecting 42 16 Bosch Hydraulic Brake System 0 42 04 rs merear 42 15 Brake Lines and Fittings Inspecting Hydraulic 42 11 Brake Pedal Linkage and Mounting Plate 0 42 12 Foot Control Valve E 6 Inspecting and Lubricating 42 14 Gavemor sas u band det qd tan Quand sb 42 03 Haldex and Gunite Slack Adjuster 0 42 06 Meritor
8. S d od sda acm 25 04 Clutch Hydraulic Fluid Level 0 25 03 Eaton Fuller Clutch Release Bearing 0 25 01 Eaton Fuller Clutch Release Cross Shaft 0 25 02 Business Class M2 Maintenance Manual June 2006 25 Clutch 25 01 Eaton Fuller Clutch Release Bearing Lubricating The standard clutch release bearing is sealed and does not require lubrication If the vehicle is not equipped with a maintenance free sealed clutch re lease bearing lubricate the bearing as follows 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Remove the clutch inspection plate NOTE Some clutch release bearings are equipped with a lubrication extension that ex tends outside of the clutch housing It is not necessary to remove the clutch inspection plate when the lubrication extension is used NOTE For lubricating the release bearing Eaton Fuller recommends a lithium base high temperature grease that meets the NLGI grade one or two specification 3 Wipe the dirt away from the grease fitting See Fig 1 Use a low pressure type grease gun equipped with the recommended grease and lubricate the bearing until excess grease purges from the rear of the release bearing toward the transmission
9. aoe RU ree te Ro B Na 47 07 CNG Fuel System IRSPOCITGS s 2 4 ect ap ded n Dae s dug t rh RORIS dub ede Ba 47 05 CNG High Pressure Fuel Filter Element 47 06 Fuel Tank Band 42520 e ar dene ud 47 01 Fuel Water Separator Element Replacing ren 47 02 LNG Fuel System Inspectihg so 2 aim xao ee 080 pedo ange ee una ae S ge 47 03 LNG Vacu m Integrity Testing uuu 5 5 Sub ddp sre ra deer o B obra et dae s u Su Es 47 04 Business Class M2 Maintenance Manual July 2011 Fuel 47 01 Fuel Tank Band Nut Tightening IMPORTANT Do not overtighten the nuts Rectangular Fuel Tank Hold the retention nut on the fuel tank band with a wrench while backing off the jam nut Then tighten the retention nut 13 to 17 18 to 23 N m After the retention nut has been tightened hold the reten tion nut with a wrench while tightening the jam nut 13 to 17 Ibf ft 18 to 23 N m Cylindrical Fuel Tank Hold the retention nut on the fuel tank band with a wrench while backing off the jam nut Then tighten the retention nut 30 to 35 41 to 46 N m After the retention nut has been tightened hold the reten tion nut with a wrench while tightening the jam nut 30 to 35 Ibf ft 41 to 46 N m 47 02 Fuel Water Separator Element Replacing Alliance
10. Business Class M2 Maintenance Manual January 2010 42 11 42 Brakes Parking Brake Operational Check Ay 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 Putthe 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 Business Class M2 Workshop Manual for repair procedures 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 WARNING Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mechanical problem Adjustment is not repairing Before adjusting an automatic slack adjuster troubleshoot the foundation brake system and inspect it for worn or damaged com ponents Improperly maintaining the vehicle brak 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
11. 3 Check to see if the colored over stroke band on each brake chamber pushrod is exposed If band shows the stroke is too long Check the foundation brake components for wear or damage and repair as needed See Group 42 of the Business Class M2 Workshop Manual for inspection troubleshooting and repair proce dures 4 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 matic slack adjuster See Group 42 of the Business Class M2 Workshop Manual for in spection and troubleshooting procedures 5 Start the engine and build air pressure to at least 100 psi 689 kPa Shut down the engine 6 Check all of the foundation brake components for damage wear and loose or missing parts Re pair as needed See Group 42 of the Business Class M2 Workshop Manual for repair proce dures 42 16 Bendix Hydro Max Brake System Inspecting 1 Check the fluid level in the hydraulic brake fluid reservoir If needed fill the reservoir up to the ridge that surrounds the reservoir See Fig 9 Use only heavy duty brake fluid DOT 6 10 31 94 1460513a A Open caps and check fluid level B Fill to this level Fig 9 Hydraulic Brake Fluid Reservoir 2 Check all hydraulic lines and fittings for damage leakage or looseness Replac
12. 00 Torque Specifications 00 18 General Information Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threadst Regular Hex Flanged Thread Grade5orB Grade 8 or 8 2 Grade 8 or C Grade 8 or 82 a Grade 5 Bolt Nut Bolt Nut Bolt Grade G Nut Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m Br io Exe 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 7 16 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 3 410 240 325 340 461 340 461 3 4 16 270 366 380 515 7 8 9 385 522 540 732 7 8 14 425 576 600 813 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 15 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation Table 16 Torque Values for U S Customary Thread Fasten
13. 12 Check the moisture indicator on the receiver drier See Fig 1 If the indicator is a deep cobalt blue the refrigerant charge is dry If the indicator is not blue the system is contaminated with water If the system is contaminated recover the refrigerant replace the receiver drier evacuate the system and add a full refrigerant charge For instructions see Section 83 00 Subject 220 of the Business Class M2 Workshop Manual 13 Close the hood and remove the chocks from the tires i 3 y 4 12 21 2001 1543878 1 Fan Cycling Switch 3 Binary Switch 2 Moisture Indicator 4 Receiver Drier Fig 1 Receiver Drier 83 02 HVAC Air Filter Replacing The HVAC air filter must be replaced every six months or 60 000 miles 97 000 km to permit proper operation of the HVAC system 1 With the vehicle parked apply the parking brakes and chock the tires Business Class M2 Maintenance Manual December 2001 83 1 83 N 10 04 2001 1 Remove the lower HVAC cover in the cab For instructions see Group 60 of the Business Class M2 Workshop Manual Disconnect the wiring harness from the evapora tor probe Remove the capscrews that attach the evapora tor service cover to the HVAC assembly Remove the evaporator service cover Pull the filter out of the HVAC assembly Install a new filter in the HVAC assembly Be sure that the arrow on the filter is pointing toward the evaporator
14. 20 servicing the cooling system always verify that the coolant level is between the MIN and MAX lines on the surge tank 7 Fill the radiator with coolant Use a mixture of 50 percent water and 50 percent corrosion inhibiting antifreeze to protect the engine to 34 F 37 C year round See Table 1 for engine cooling system capaci ties See Table 2 for approved antifreezes Coolant Capacities pre EPA07 engines Coolant Volume Engine Make and Model quarts liters Caterpillar 3126 35 33 1 MBE904 32 30 3 MBE906 37 35 Table 1 Coolant Capacities pre EPA07 engines Approved Coolants Coolant Manufacturer Coolant Designation Texaco JC04 Antifreeze Van Waters and Rogers Diesel Antifreeze No 6038 Ltd Canada Freightliner approved antifreeze must meet one of the following condi tions A Ethylene glycol solution that meets GM 6038 M Engineering Stan dards B Ethylene glycol solution that has less than 0 196 anhydrous so dium metasilicate and meets either GM 1825 M or GM 1899 M Engineering Standards Table 2 Approved Coolants 20 03 Fan Drive Inspecting Noise Emission Control Horton Advantage Fan Clutch 1 Check the fan for loose rivets and missing weights Check for bent cracked or missing blades Tighten loose components Replace the fan drive if necessary 2 Check for adequate clearance between the fan and the
15. 02 Radiator Pressure Flushing and Coolant Changing NOTE For additional instructions on cleaning and flushing the cooling system see the engine maintenance and operation manual Drain the coolant only when the coolant and en gine are cool Draining it when these are hot could cause severe personal injury due to scalding 1 Drain the radiator as follows 1 1 Place a large container under the radia tor 1 2 Remove the surge tank cap 1 3 Open the petcock at the bottom of the radiator to drain the engine coolant 2 Disconnect the radiator inlet and outlet hose con nections 3 Flush the radiator as follows 3 1 Attach a flushing gun nozzle to the radia tor outlet 3 2 Add water to the radiator until it is full CAUTION When flushing the radiator do not apply more than 20 psi 138 kPa air pressure Excessive pres sure can damage the radiator or heater core 3 3 Apply no more than 20 psi 138 kPa air pressure intermittently to help dislodge sediment buildup in the core 4 Drain the radiator then flush the radiator until clean water flows from it Remove the flushing gun Close the petcock 6 Using clamps connect the hoses to the radiator Torque the clamps 33 to 38 Ibf in 370 to 430 N cm IMPORTANT On vehicles with EPAO7 compliant engines the coolant capacity varies depending on the engine and accessory installation After Business Class M2 Maintenance Manual July 2009 20 1
16. 26 04 Eaton Fuller Transmission Air Filter Regulator Element Cleaning 26 05 Allison Transmission Fluid and Filter Changing 26 06 dcin Transmission Fluid Changing and Magnetic ug Cleaning 26 07 Mercedes Benz Transmission Leak Checking 31 01 Frame Fastener Torque Checking 31 02 Fifth Wheel Inspecting 31 03 Fifth Wheel Lubricating 31 04 Trailer Electrical Connector Lubricating 32 01 Suspension Inspecting 32 02 Suspension Lubricating 32 03 Suspension U Bolt Torque Checking 33 01 Kingpin Lubricating 33 02 Tie Rod End Lubricating 33 03 Draw Key Nut Torque Checking 33 04 Tie Rod End Inspecting Business Class M2 Maintenance Manual September 2011 00 5 00 General Information Overview of Maintenance Operations 00 05 Maintenance Operations for Groups 00 through 88 plici Title of Maintenance Operation T M T 33 05 Wheel End Inspection and Maintenance 6 000 Pound and 8 000 Pound Steer Axles with Oil Lubricated Hubst 35 01 Axle Lubricant Level Checking 35 02 Axle Breather Checking 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning 40 01 Wheel Nut Checking 41 01 Driveline Inspecting
17. 41 02 Driveline Lubricating 42 01 Air Brake System Valve Inspecting 42 02 Bendix AD 9 Air Dryer Desiccant Replacingt 42 03 Governor D 2A Checking 42 04 Bosch Hydraulic Brake System Inspecting 42 05 Bendix AD IP Air Dryer Desiccant Replacing 42 06 Haldex and Gunite Slack Adjuster Lubricating 42 07 Meritor Camshaft Bracket Lubricating 42 08 Meritor Slack Adjuster Lubricating 42 09 Bendix AD IS Air Dryer Desiccant Replacingt 42 10 Air Dryer AD 9 AD IP and AD IS DRM Checking 42 11 Brake Lines and Fittings Inspecting Hydraulic Brakes 42 12 Brake Pedal Linkage and Mounting Plate Inspecting 42 13 Air Brake Inspecting and Leak Testing 42 14 Foot Control Valve E6 Inspecting and Lubricating 42 15 Brake Inspecting 42 16 Bendix Hydro Max Brake System Inspecting 46 01 Drag Link Inspecting 46 02 Power Steering Fluid Changing 46 03 Power Steering Fluid Level Inspecting 46 04 Power Steering Gear Lubricating 46 05 Drag Link Lubricating 46 06 Power Steering Filter Changing 47 01 Fuel Tank Band Nut Tightening 47 02 Fuel Water Separator Element Replacing 47 03 LNG Fuel System Inspecting 47 04 LNG Vacuum Integrity Testing 47 05 CNG Fuel System Inspecting
18. Axles With Unitized Wheel Ends NOTE This procedure applies to 921 931 932 933 934 941 942 943 951 961 963 966 967 971 and 975 Series Easy Steer sealed front axles Refer to the identification tag on the front of the axle beam On sealed and Easy Steer Plus front axles the grease fittings are on the top and bottom kingpin caps of the knuckle 1 Shut off the engine apply the brakes and chock the rear tires 2 Make sure the tires touch the ground Do not raise the vehicle 3 Clean off all grease fittings prior to lubrication IMPORTANT Meritor recognizes that industry trends are moving toward increased selection and usage of synthetic grease in vehicle mainte nance However some seals are known to ex pand when in contact with synthetic grease Consult your local Meritor representative for synthetic grease application references before using any synthetic grease when performing axle service and maintenance 4 Using a multipurpose grease NLGI grade 1 or 2 lubricate the kingpins through the grease fittings on the top and bottom of the knuckle See Fig 1 5 Apply lubricant until new lubricant comes from the thrust bearing seal and the upper shim pack 6 Remove the chocks from the tires Easy Steer Kingpins Axles With Unitized Wheel Ends NOTE This procedure applies to Easy Steer Plus MFS 10 2015 N and MFS 12 2015 N sealed front axles Refer to the identification tag on the front of
19. The only maintenance necessary on an Alliance fuel water separator is to replace the filter element WARNING Diesel fuel is flammable and can ignite if exposed to an open flame intense heat or other ignition source Do not drain fuel near or expose fuel vapor to open flame or intense heat Exposure to open flame or intense heat could start a fire pos sibly resulting in personal injury or property dam age When working on a fuel system have a fire extinguisher within easy reach 1 Drain off some fuel by loosening the vent plug and opening the drain valve See Fig 1 2 Disconnect the water sensor and heater connec tions if equipped 3 Remove the element and bowl together by turn ing counterclockwise 47 2 1 3 4 11 d 5 10 9 T 6 7 8 06 25 97 1470147 1 Mounting Head 7 Water Sensor Probe 2 Fuel Primer Pump 8 Heater Connector 3 Vent Plug 9 Drain Plug 4 Bowl O Ring 10 Sight Bowl 5 Bowl Gasket 11 Filter Element 6 Bowl Probe Plug Fig 1 Alliance Fuel Water Separator 4 Remove the bowl from the element and clean the O ring gland 5 Apply a coating of clean fuel or motor oil to the new O ring and element seal 6 Spin the bowl onto the new element then spin them both onto the filter head snugly by hand only IMPORTANT Do not use tools to tighten the bowl and element 7 Connect the water sensor and heater connectors if equipped 8 If equipped with a primer pum
20. NOTE Desiccant cartridge torque should not exceed 50 68 N m 15 Place the housing over the desiccant cartridge and align the mounting holes with the end cover 16 Install the six bolts 12 washers and six new nuts Torque the nuts in a star pattern 270 to 385 Ibf in 3060 to 4340 N cm See Fig 2 17 Install the air dryer on the lower mounting bracket Install the two previously marked bolts four washers and two new nuts Torque the two remaining nuts 270 to 385 Ibf in 3060 to 4340 N cm Install the bolt two washers and a new nut in the upper mounting bracket strap Torque the upper mounting bracket strap nut 80 to 120 Ibf in 904 to 1356 N cm Business Class M2 Maintenance Manual January 2010 42 1 42 Brakes 08 09 95 Bracket Capscrew 10 O Ring 1 5 16 x 4 1 2 Upper Mounting 9 Desiccant Cartridge 18 Purge Valve 2 Upper Mounting Bracket Strap 11 Drain Valve 20 Purge Valve Housing 3 5 16 Inch Lockwasher 12 Lower Mounting Bracket 21 Heater and Thermostat 4 5 16 Inch Nylok Nut 13 3 8 Inch Bolt long Housing 5 Upper Mounting Bracket 14 Check Valve Assembly 22 Return Spring 6 Housing 15 Purge Valve Assembly 23 Purge Piston 7 Nylok Nut 16 Purge Valve Bolt 24 3 8 Inch Capscrew 8 3 8 Inch Special Washer 17 Exhaust Diaphragm 25 End Cover 1421383 19 1 4 Inch Screw Fig 1 AD 9 Air Dryer 18 Connect and tighten the three air lines
21. See Fig 2 1543921 Evaporator 2 Filter 10 11 Fig 2 HVAC Assembly Filter Remove the condensate seal from the evapora tor service cover and install a new condensate seal on the cover Using capscrews attach the evaporator service cover to the HVAC assembly Connect the wiring harness to the evaporator probe Attach the lower HVAC cover to the dash panel For instructions see Group 60 of the Business Class M2 Workshop Manual Remove the chocks from the tires Heater and Air Conditioner 83 2 Business Class M2 Maintenance Manual December 2001 Hood Grille and Cab Fenders 88 Index Alphabetical Title of Maintenance Operation MOP MOP Number Hood Rear Support EUDFCASUDFE cues c co da 3 o ox bU dat ve dra ut p aaa teca 88 01 Business Class M2 Maintenance Manual July 2010 Hood Grille and Cab Fenders 88 01 Hood Rear Support Lubrication Apply the parking brakes and chock the tires 2 Open the hood 3 Clean both the hood and cab mounted hood rear support components with a soapy water so lution 4 Cover all contact surfaces of the hood rear sup port brackets and isolators with an approved multi purpose lithium complex soap based grease see Table 1 5 Close the hood Approved Suppliers of Multi Purpose Lithium Grease Supplier Grease Chevron Delo Heavy Duty EP Exxon Unirex EP2 Mobil Mobil Grease XHP 222 Sh
22. Water contamination is normally characterized as a milky discoloration of the transmission fluid Obvious contamination of the transmission fluid indicates a leak between the water and fluid areas of the trans mission cooler Inspect and pressure test the cooler to confirm the leak replace leaking transmission coolers 1000 2000 2400 Series 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 26 4 Business Class M2 Maintenance Manual March 2005 Transmission CAUTION To prevent dirt from entering the transmission use only clean containers and fillers for the trans mission fluid Do not use fillers or containers that have been used for water or antifreeze Dirt water or antifreeze could damage the transmission 3 Clean the area around the drain plug Place a drain pan under the transmission and remove the drain plug Examine the fluid while it drains If only the filter is being changed do not drain the fluid NOTE A lot of fluid will drain when the filter is removed 4 Using a standard strap type filter wrench remove the filter by turning it counterclockwise 5 Remove the magnet from the filter attachment tube or from the top of the filter element 6 Clean any metal debris from the magnet Then install t
23. and overall fan clutch operation If the fan clutch does not operate correctly see Group 20 of the Business Class M2 Workshop Manual for troubleshooting and repair proce dures 8 With the air system charged to 120 psi 827 kPa check the fan clutch for audible air leaks using a suitable listening device Check at the solenoid valve the air filter assem bly and the air hoses and fittings See Fig 1 Using a wet finger or a soapy water solution check for a leak in the same areas 05 30 2002 1200581 Fig 1 Checking for Air Leaks Horton DriveMaster 9 Ifaleak is detected remove the fan blade In stall a new seal kit See Group 20 of the Business Class M2 Workshop Manual for repair procedures Business Class M2 Maintenance Manual July 2009 20 3 20 10 Check the fan drive for discoloration or any other signs of slipping or overheating NOTE The fan clutch may slip if the air supply pressure is below 70 psi 483 kPa or if there is a leak inside the fan clutch Any leak must be remedied 11 Check the fan clutch bearings 11 1 Turn the fan in both directions and feel for worn hub bearings 11 2 If possible remove the drive belt and check for worn sheave bearings by turn ing the sheave in both directions 11 3 If either the hub or sheave bearings are worn replace them using a Horton Drive Master Super Kit For instructions and kit part number see Group 20 of the Busines
24. such as stones bolts or nuts from the battery box 9 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 Business Class M2 Maintenance Manual January 2009 15 1 15 9 5 Coat the battery terminals with dielectric grease 10 Check the terminals on the battery shut off switch and the magnetic switch Make sure the terminal connections are clean and tight Coat the terminal connections with dielectric red enamel after cleaning Alternators and Starters 15 2 Business Class M2 Maintenance Manual January 2009 Engine Cooling Radiator 20 Index Alphabetical Title of Maintenance Operation MOP MOP Number Fan Drive Inspecting Noise Emission 20 03 Hybrid Electric System Coolant Changings 2 uuu de teem 20 04 Radiator 2 5 Chek Fees Rees Sce be xb RF Veo 20 01 Radiator Pressure Flushing and Coolant 0 20 02 Business Class M2 Maintenance Manual July 2009 Engine Cooling Radiator 20 01 Radiator Cap Inspecting 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 pressu
25. 06 NOTE The IM Operations include the maintenance operations in Table 5 and all of the maintenance op erations in Table 6 M1 Maintenance Operations Initial Maintenance IM Operations Maintenance Operation No Title of Maintenance Operation 00 07 31 01 Perform All M1 Operations Frame Fastener Torque Checking 32 03 Suspension U Bolt Torque Checking 33 03 Draw Key Nut Torque Checking 47 01 Fuel Tank Band Nut Tightening Table 5 Initial Maintenance IM Operations 00 8 Business Class M2 Maintenance Manual September 2011 General Information IMPORTANT After performing all operations listed in this table perform all daily weekly and monthly maintenance operations listed in the Pretrip and 00 M1 Maintenance Operations 00 07 Post Trip Inspections and Maintenance chapter of the Business Class M2 Driver s Manual M1 Maintenance Operations DESEE NE Title of Maintenance Operation 00 12 Lubrication and Fluid Level Check Eaton Fuller Clutch Release Bearing Lubricating Eaton Fuller Clutch Release Cross Shaft Lubricating Clutch Hydraulic Fluid Level Checking Manual Transmission Fluid Level Checking e Fifth Wheel Lubricating Trailer Electrical Connector Lubricating Suspension Lubricating e Kingpin Lubricating e Tie Rod End Lubricating e Axle Lubricant Level Checking e Driveline Lubricating Haldex and Gun
26. 2 10 3 If the radial seal on the input shaft is leaking replace the radial seal For pro cedures see Section 26 02 Subject 120 of the Business Class M2 Workshop Manual If the cover plate on the countershaft is leaking replace the cover plate Apply liquid gasket Loctite 518 to the new cover plate when installing it If the rear radial seal on the engine crankshaft is leaking replace the rear ra dial seal For procedures see the engine manufacturer s manual 11 Remove the chocks from the tires Transmission 26 10 Business Class M2 Maintenance Manual March 2005 Frame and Frame Components 31 Index Alphabetical Title of Maintenance Operation MOP MOP Number Blaise M D EP EET 31 02 LUC umm 31 03 Frame Fastener Torque 0 4 31 01 Trailer Electrical Connector Eubticaltllig m xe S eon Scenes a a ape ecd 31 04 Business Class M2 Maintenance Manual May 2011 Frame and Frame Components 31 01 Frame Fastener Torque Checking Frame brackets and components secured with Huck bolt fasteners do not require a torque check how ever they should be inspected for damage Frame brackets and components secured with conventional bolts and nuts are to be checked at initial mainte nance IM Check the torque of frame fasteners to offset the ef fects of bedding in or sea
27. 2001 Rear Axle 35 01 Axle Lubricant Level Checking CAUTION Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage 1 Clean the oil fill hole plug located in the carrier or the side of the axle housing and the area sur rounding it See Fig 1 Remove the plug NOTE Some Meritor axles have a small tapped and plugged hole located below the housing oil fill hole This smaller hole is for the lubricant temperature sensor only and must not be used as a fill or level hole 2 When the vehicle is on level ground the lubri cant must be level with the bottom of the oil fill hole If low add lubricant See Table 1 for ap proved axle lubricants and see Table 2 or Table 3 for axle capacities 35 02 Axle Breather Checking The axle housing breather must remain clean See Fig 1 When the axle lubricant level is checked 35 06 07 94 1 Axle Housing Breathers 2 Carrier Oil Fill Plugs 3 Interaxle Differential f350062a Fig 1 Fill Hole Plug and Axle Housing Breather Locations check that the axle breather is open Check more often under poor operating conditions If the breather is plugged clean it or replace it as needed Meritor Drive Axle Recommended Lubricant Lubricant Type Ambient Temperature Viscosity Grade Meritor Specification 10 F 12 2 and 85W 140 0 76 15
28. 61 N m See Fig 3 10 11 2001 1330186 Fig 3 Draw Key Nut 33 04 Tie Rod End Inspecting IMPORTANT If the tie rod end boot is torn or missing replace the entire tie rod end Do not replace the boot only 1 Shut off the engine apply the brakes and chock the rear tires 2 Check the tie rod boot for cracks tears or other damage If the tie rod boot is damaged replace the entire tie rod end 3 Grasp by hand or use a pipe wrench with jaw protectors to avoid gouging the cross tube and 33 2 Business Class M2 Maintenance Manual July 2009 Front Axle slightly rotate the cross tube toward the front of the vehicle and then slightly toward the rear Then center the cross tube between the stop po sitions If the cross tube does not rotate in either direction replace both tie rod ends 4 Position yourself directly below the ball stud socket Using both hands grab the end as close to the socket as possible no more than 6 inches 15 2 cm from the end Firmly apply about 100 pounds of hand pressure in an up and down mo tion several times When moving the assembly check for any movement at both tie rod ends See Fig 4 If any movement is detected at one tie rod end replace both tie rod ends Always replace tie rod ends in pairs even if only one tie rod end is damaged 10 10 2001 V f330195 Fig 4 Check Movement of Tie Rod End CAUTION Do not attempt to st
29. Beam Fig 6 Unloaded RTE Spring Suspension 2 Adapter End Bushing m 3 Intermediate Tube 5 Beam Hanger spring leaves may be individually replaced If Fig 5 Three Piece Adapter Type Beam End Connection WARNING Insufficient beam end fastener torque could cause the beam to separate from the axle This will cause loss of vehicle control resulting in property damage serious personal injury or death Hendrickson Leaf Spring Assembly Inspection 1 Inspect the spring hangers for wear of the spring pin holes cams and the spring hanger legs See Fig 6 2 f equipped with the RTE series the gap be tween the rear no 2 spring hanger and the top spring leaf should measure at least 3 8 inch 9 5 mm in an unloaded condition If the measurement is less than 3 8 inch 9 5 mm install new rear no 3 extension hangers Lubricate the bolt threads with SAE 20 oil Tighten the 1 2 13 locknuts with hardened washers 85 Ibf ft 115 N m 3 Inspect the spring leaves for cracks gouges wear or abnormal bends The main no 1 and wrapper spring leaves no 2 the top two equipped with the RTE series suspension the first second and third spring leaves the top three spring leaves may be individually re placed If a spring leaf is damaged below these numbers in a pack replace the spring assembly In addition replace both spring assemblies to ensure even spring deflection Hendrickson Radius Rod Bushing Che
30. Benz transmissions Business Class M2 Maintenance Manual March 2005 26 1 26 26 02 Eaton Fuller Transmission Fluid Changing and Magnetic Plug Cleaning Eaton Fuller has a complete listing of approved lubri cants for its transmissions on its internet website Refer to the Eaton website for additional information www roadranger com Draining IMPORTANT Manual transmissions filled with approved synthetic lubricants require a lubricant drain and fill and a magnetic plug cleaning every 500 000 miles 800 000 km regardless of the service or vocation of the vehicle Manual transmissions with petroleum based lubricants require a lubricant drain and fill and a magnetic plug cleaning at each Maintenance 2 M2 inter val All transmissions regardless of lubrication used also require a check of the transmission breather at each Maintenance 1 M1 interval 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Drain the fluid while the transmission is warm as follows 2 1 Clean the area around the drain plug s Remove the drain plug s from the gear case 2 2 Clean the area around the fill plug Re move the fill plug from the gear case 3 Clean the magnetic plug s before installing it Use a piece of key stock or any other conve nient steel slug to short the two magnetic poles and divert the magnetic field 4 Install and tighten the drain plug s 50 Ibf ft 68
31. Business Class M2 Maintenance Manual March 2005 Transmission 26 01 Manual Transmission Oil Level Checking 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Check the oil level in the transmission See Fig 1 26 Approved Manual Transmission Lubricants Temperature SAE Lubricant Type E C Viscosity MobilTrans SHC DC All 50 2 A 7 2 A 7 P di pos S 5 2 Z 10 05 94 B f260006b A Full B Low Fig 1 Transmission Oil Level Checking 2 1 Clean the area around the fill plug then remove the plug from the side of the case 2 2 Using your finger or a bent pipe cleaner see if the oil is level with the lower edge of the fill opening 3 If needed fill the transmission with oil until level with the lower edge of the fill opening See Table 1 for approved lubricants Approved Manual Transmission Lubricants Temperature SAE Lubricant Type F Viscosity Eaton Fuller Transmissions MobilTrans SHC 50 RN 2952 E 5 50 Synthetic lubricant approved by Eaton 99 Heavy duty engine oil Above 10 12 40 or 50 meeting MIL L 2104D or Caterpillar TO 4 Specification Below 10 712 30 MT 1 gear oils meeting Above 10 712 80 or 90 MIL PRF 2105E specification Below 10 12 75 Mercedes Benz Transmissions
32. Connect the harness connector to the heater and thermo stat assembly until the lock tab snaps in place 19 Start the engine build the air pressure and check the air brake system for leaks If any air leaks are present see Group 42 of the Business Class M2 Workshop Manual for diagnosis and repair information 42 03 Governor D 2A Checking IMPORTANT Review the warranty policy before performing any intrusive maintenance proce dures An extended warranty may be voided if intrusive maintenance is performed during this period 42 2 Business Class M2 Maintenance Manual January 2010 42 Brakes 09 20 94 1420544 Fig 2 End Cover to Housing Torque Pattern Every 12 months 100 000 miles 160 900 km or 3600 operating hours perform the operational test below Operational Test 1 Start the vehicle engine build air pressure in the brake system and check the pressure registered by a dash or test gauge at the time the governor cuts out stopping the compression of air by the compressor Cut out pressure should be in ac cordance with the pressure setting of the piece number being used Common cut out pressures are 125 to 135 psi 862 to 931 kPa With the engine still running make a series of brake appli cations to reduce the air pressure and observe at what pressure the governor cuts in the com pressor As in the case of cut out pressure cut in pressure should be in accordance with the
33. DOC Inlet Temperature Sensor 10 SCR Outlet Temperature Port 4 Front Heat Shield Sensor 15 SCR Inlet Temperature Sensor 5 DEF Nozzle 1490355 Fig 1 One Box ATS Sensor Locations 49 2 Business Class M2 Maintenance Manual September 2011 Exhaust 49 09 16 2009 DEF Metering Unit DEF Nozzle SCR Outlet Temperature Sensor SCR Inlet Temperature Sensor gt DOC Inlet Temperature Sensor DOC Inlet Pressure Sensor DPF Inlet Temperature Sensor DPF Outlet Pressure Sensor X 4 NI J 74 MAT J 1490353 9 DPF Outlet Temperature Sensor 10 DPF Outlet NOx Sensor 11 SCR Outlet NOx Sensor Fig 2 2V2 Two Box ATS Sensor Locations 11 Check any wires lines or hoses within 4 inches 10 cm of the exhaust system for heat damage Repair or reroute as needed Diesel Exhaust Fluid DEF Filter Replacement The Environmental Protection Agency s 2010 regula tions require lower nitrogen oxide NOx exhaust emissions Selective catalytic reduction SCR uses diesel exhaust fluid DEF to lower NOx emissions in the vehicle exhaust A filter in the DEF pump pre vents clogging of the DEF metering unit injection nozzle See the engine manufacturer s maintenance manual for filter replacement instructions and maintenance intervals 7 Exhaust System Definitions of ATS Terms Refer to the following
34. F 26 1 C 80W 90 0 76 Hypoid Gear Oil Service ANE E EAT Classification GL 5 40 F 40 C and up 75W 90 0 76 40 F 409 to 35 F 2 C 75W 0 76 J 40 F 40 C and 75W 140 0 76 L 40 F 40 C and up 75W 90 0 76 Synthetic Gear 40 F 409 and up 75W 140 0 76 There is no upper limit on the ambient temperature but axle sump temperature must never exceed 250 121 C Table 1 Meritor Drive Axle Recommended Lubricant Business Class M2 Maintenance Manual December 2001 35 1 35 Rear Axle Meritor Drive Axle Lubricant Capacities for Tandem Axles Axle Model Axle Position Capacity Forward 39 1 18 5 RT 46 160 Rear 34 4 16 3 Quantities listed are approximate and include 1 pint 0 5 liter for each Meritor Drive Axle Lubricant Capacities for Single Axles Axle Model MS 10 113D 14 6 6 MS 12 113D 15 7 1 RS 13 120 18 4 8 7 15 120 14 3 6 8 RS 17 145 33 6 15 9 RS 17 144 32 3 15 3 RS 19 144 32 3 15 3 RS 19 145 33 2 15 7 5 21 145 32 3 15 3 5 21 160 39 5 18 7 5 21 230 38 9 18 4 5 23 160 39 5 18 7 RS 23 161 39 5 18 7 RS 23 186 47 3 22 4 RS 23 240 37 4 17 7 RS 26 185 38 0 18 0 RS 30 185 38 0 18 0 0 wheel end and with the drive pinion at 3 degrees Table 2 Meritor Drive
35. Fig 4 Gunite Automatic Slack Adjuster vice and lubrication instructions see Group 42 of the Business Class M2 Workshop Manual For camshaft brackets with grease fittings use an NLGI Grade 1 or Grade 2 multipurpose chassis grease Lubricate the camshaft bushings through the grease fitting on the camshaft bracket or the spider until new grease flows from the inboard seal See Fig 5 WARNING If grease leaks out under the camhead the cam shaft bracket grease seal is worn or damaged See Group 42 of the Business Class M2 Workshop Manual for grease seal replacement instructions If this seal is not replaced the brake linings could Fig 5 Camshaft Bracket Lubrication become contaminated with grease The stopping distance of the vehicle will be increased which could result in personal injury or property dam age 42 08 Meritor Slack Adjuster Lubricating IMPORTANT Perform MOP 42 15 before lubri cating the slack adjusters NOTE If equipped with an extended maintenance Q Plus brake system the slack adjuster will not have a grease fitting These slack adjusters use a special NLGI grade syn thetic polyurea grease and do not require lubri cation for 3 years or 500 000 miles 800 000 km whichever comes first Extended maintenance slack adjusters are lubricated dur ing the brake reline service interval For service and lubrication instructions see Group 42 of the Business Class M2 Workshop
36. Log Group 49 Exhaust Date Mileage Repair Description Cost Repair Facility 00 18 Business Class M2 Maintenance Manual September 2011 General Information 00 Metric U S Customary and Temperature Conversions 00 17 Metric U S Customary Conversions bred U S as To Get Metric cn 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 in 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 ft
37. Lubricants listed in order of preference Do not mix types of oil t Call 1 800 826 4357 for a complete list of Eaton approved lubricants Table 1 Approved Manual Transmission Lubricants A CAUTION Operating a manual transmission with the fluid level higher or lower than recommended can re sult in transmission damage Do not overfill the transmission overfilling will force fluid out of the case through the main shaft openings Fluid over flow may also drain onto the clutch or clutch brake causing additional problems IMPORTANT Do not mix types of oil because of possible incompatibility Do not use oil addi tives or friction modifiers Do not use multi viscosity oils or EP Extreme Pressure gear oils If switching from a petroleum based lubri cant to a synthetic all areas of each affected component must be thoroughly drained Switch ing to a synthetic lubricant when a petroleum based lubricant has been used for 50 000 miles 80 000 km or longer may affect transmission performance Monitor all seal areas for the first 10 000 miles 16 000 km after changing to a synthetic from a petroleum based lubricant 4 Clean the fill plug then install it in the transmis sion Tighten the plug as follows e 25 to 35 34 to 48 N m for Eaton Fuller transmissions with 3 4 inch pipe threads 60 to 75 Ibf ft 81 to 102 N m for Eaton Fuller transmissions with 1 1 4 inch pipe threads 42 Ibf ft 57 for all Mercedes
38. Manual For slack adjusters with grease fittings and for oper ating temperatures above 40 F 40 lt use an NLGI Grade 1 clay base grease or an NLGI Grade 1 or 2 lithium base grease For slack adjusters with grease fittings and for oper ating temperatures below 40 F 40 C and above 42 6 Business Class M2 Maintenance Manual January 2010 Brakes 65 F 549 use an NLGI Grade 2 synthetic oil or a clay base grease 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 See Fig 6 10 20 93 f420012a Brake Chamber Clevis Actuator Rod Boot Pull Pawl Seal Manual Adjusting Nut Grease Fitting or plug 4 Fig 6 Meritor Automatic Slack Adjuster 42 09 Bendix AD IS Air Dryer Desiccant Replacing IMPORTANT For vehicles equipped with an oil coalescing air dryer desiccant cartridge replace the cartridge once a year regardless of mileage 1 With the vehicle parked on a level surface apply the parking brakes and chock the tires 2 Drain the air dryer by operating the drain valve on the AD IS purge reservoir located below the dryer 3 Using a strap wrench or equivalent loosen the desiccant cartridge Spin the cartridge off by hand and discard it 4 On the new desiccant cartridge lubricate the sealing ring with silicone grease See F
39. N m Filling CAUTION Operating a manual transmission with the fluid level higher or lower than recommended can re sult in transmission damage Do not overfill the Transmission transmission overfilling will force fluid out of the case through the main shaft openings Fluid over flow may also drain onto the clutch or clutch brake causing additional problems IMPORTANT Do not mix types of fluid because of possible incompatibility Do not use multi viscosity fluids or EP Extreme Pressure gear fluids Do not use fluid additives or friction modi fiers If switching from a petroleum based lubri cant to a synthetic lubricant all areas of each affected component must be thoroughly drained Switching to a synthetic lubricant when a petroleum based lubricant has been used for 50 000 miles 80 000 km or longer may affect transmission performance Monitor all seal areas for the first 10 000 miles 16 000 km after changing to a synthetic lubricant from a petroleum based lubricant NOTE The correct fluid level is established by checking at the fill plug opening 1 Add fluid until it is level with the lower edge of the fill opening See Fig 1 If the transmission has two fill openings add fluid to the level of both fill openings See Table 1 for approved transmission lubricants and Table 2 for lubricant capacities 2 Clean the fill plug then install it in the transmis sion Tighten the plug as follows e 25 to 35
40. Replacement 20 02 Cooling Fan Inspection Business Class M2 Maintenance Manual December 2001 A 20 1 D Group Number Page Number Maintenance Operation Number consists of the Group Number followed by the Sequence Number f020125 Fig 1 Example of a Business Class M2 Maintenance Manual Page Business Class M2 Maintenance Manual May 2011 Introduction Maintenance Manual Contents Group No Group Title ar ME TREO TTE General Information IEEE crit sz dara dea Rs Air Intake PIC mm Air Compressor Alternators and Starters 90 ox Engine Cooling Radiator CERT Clutch endo cet dE E E Transmission sho esate adha xem Frame and Frame Components usia e Qua A Suspension QI PII Front Axle RENE Rear Axle di ois he fat nee IM LE Ed Wheels and Tires TD Ge sat ag ah Driveline ree dh diate une be Mui ene e Brakes a apa edem tuba ee atte Steering eds aut Fuel Cr Exhaust Oks delete ch eee ett asad oz s u cnet eee mas S Cab TEE PET er Doors c PEN Sa Sate ace Heater and Air Conditioner OB Rub Hood Grille and Cab Fenders 4 Business Class M2 Maintenance Manual 2011 General Information 00 Index Alphabetical Title of Maintenance
41. a qualified me chanic Improper or incomplete procedures could result in a possible disengagement of the trailer from the tractor which could result in personal injury or property damage Parts are under spring compression Wear safety goggles while servicing the fifth wheel Failure to do so can result in personal injury due to parts ejecting with force Fontaine 1 Disconnect the tractor from the trailer For in structions see the Business Class M2 Driver s Manual 2 Thoroughly steam clean the fifth wheel 3 Check for cracks in the fifth wheel assembly mounting brackets and mounting parts 4 Ensure that both bracket pins are in place and secured by retainer pins and cotter pins See Fig 1 5 For fifth wheels equipped with bracket liners rock the fifth wheel If it does not rock freely re move the top plate and inspect the bracket lin ers Replace liners that are broken or less than 0 125 inch 3 mm thick at the top of the liners For the liner replacement procedure see the Fontaine website www fifthwheel com 6 Check the jaw and stationary jaw for mushroom ing and check that the serrations at the jaw and wedge are in good condition 7 Test the secondary safety lock latch for ease of operation Business Class M2 Maintenance Manual May 2011 31 1 31 Frame and Frame Components 12 02 2010 Wedge Stop Rod Nut 11 2 Flat Washer 5 8 12 3 Wedge Stop Rod Spring 13 4 Wedg
42. any other convenient steel slug to short the two magnetic poles and divert the magnetic field 5 Clean the magnetic drain plug before installing it 6 Install the drain plug p n A 124 997 01 32 anda new aluminum gasket p n N 00763 024105 Tighten the drain plug 42 Ibf ft 57 N m Filling CAUTION Operating a manual transmission with the fluid level higher or lower than recommended can re sult in transmission damage Do not overfill the transmission overfilling will force fluid out of the case through the main shaft openings Fluid over flow may also drain onto the clutch or clutch brake causing additional problems 1 Add transmission fluid until it is level with the lower edge of the fill opening See Fig 8 for the correct level See Table 5 for approved transmis Table 5 MB Transmission Lubricant Types MB Transmission Lubricant Capacities Transmission Model nem MBT660S 60 9 5 9 0 MBT520S 6D 9 5 9 0 Quantities listed are approximate Fill the transmission until the lubricant is level with the bottom of the fill hole with the vehicle in normal operating position Table 6 MB Transmission Lubricant Capacities CAUTION Use only the approved Mobiltrans SHC DC fluid Do not mix fluid types Adding Mobiltrans SHC 50 RN 2952 E 5 fluid used in Eaton and Meritor transmissions could damage the radial seals 2 Clean the fill plug before installing it 3 Instal
43. apply new Loctite 680 Tighten the bolt 300 to 450 Ibf ft 406 to 610 N m 11 Remove the chocks from the tires 33 05 Wheel End Inspection and Maintenance 6 000 Pound and 8 000 Pound Steer Axles with Oil Lubricated Hubs Periodic inspection and maintenance of wheel ends on 6 000 pound and 8 000 pound steer axles is es sential to sound wheel bearing performance Check for leaks at the oil seal and hub and inspect the lu bricant per the maintenance intervals provided in Group 00 of this manual Oil Seal Leak Check Check for evidence of oil leakage at the oil seal If a leak is found replace the seal See Section 33 02 of the Business Class M2 Workshop Manual for in structions Business Class M2 Maintenance Manual July 2009 33 3 33 Hub Cap Leak Inspection Check for evidence of oil leakage between the hub cap gasket and hub surface If leakage is evident replace the gasket with a new one See Section 33 01 Subject 100 of the Business Class M2 Workshop Manual for instructions Check for a missing hub cap fill plug or vent plug See Fig 5 Replace any missing parts If a vent plug is missing the oil quality is compromised and must be replaced See Section 33 01 Subject 100 of the Business Class M2 Workshop Manual for instructions 01 05 2009 1330247 A Hub Cavity Full 1 Vent Plug 2 Magnetic Drain Fill Plug Fig 5 Stemco Hub Cap Lubricant Inspection Rotate the h
44. clamps that retain the DPF in the ATD 6 Check all sensors attached to the ATS for leaks or damaged wires No leaks are allowed See Fig 1 Fig 2 or Fig 3 for Detroit Diesel ATS sensor locations 7 Check the DPF exterior surface for dents or other damage A dent over 3 inches 76 mm in diameter and 1 4 inch 6 mm deep could cause internal damage to the DPF causing it to malfunction Exhaust 8 Check the SCR catalyst for dents and other damage 9 Check for heat discoloration on the surface of the ATD Heat discoloration may indicate internal damage especially around the DPF NOTE Diesel exhaust fluid creeps causing white crystals to form around the line fittings The presence of crystals does not mean the system has a leak Replacing fittings or trouble shooting components is not necessary unless there is a system failure or a fault code 10 Check the DEF tank pump metering unit and lines for leaks See Section 49 03 of the Business Class M2 Workshop Manual for repair procedures 08 20 2009 DOC inlet pressure sensor NOTE The sensor box item 8 contains the SCR inlet and outlet NOx sensors DPF outlet pressure sensor and the 1 DOC Outlet Temperature 6 Exhaust Outlet 11 SCR Outlet NOx Sensor Port Sensor 7 DEF Metering Unit 12 SCR Inlet NOx Sensor Port 2 DOC Inlet Pressure Sensor 8 Sensor Box see note above 13 14 Pin Connectors Port 9 Exhaust Inlet 14 DPF Outlet Pressure Sensor 3
45. covers pretrip and post trip inspections and daily weekly and monthly maintenance of vehicle components Driver s operators 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 Search results for both documents and service solutions can be narrowed by initia
46. each new vehicle with written instructions for the proper maintenance use and repair of the vehicle by the ultimate purchaser to provide reasonable as surance of the elimination or minimization of noise emission degradation throughout the life of the ve hicle In compliance with the law the Noise Emission Control Systems maintenance located in each appli cable group within this manual in conjunction with the vehicle workshop manual provides these instruc tions to owners Recommendations for Replacement Parts Replacement parts used for maintenance or repair of noise emission control systems should be genuine Freightliner parts If other than genuine Freightliner parts are used for replacement or repair of compo nents affecting noise emission control the owner should be sure that such parts are warranted by their manufacturer to be equivalent to genuine Freightliner parts in performance and durability Freightliner Noise Emissions Warranty Refer to the vehicle owner s warranty information book for warranty information concerning noise emis sion control systems Tampering With the Noise Control System 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 re pair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale o
47. fan shroud or other engine compartment components in both the engaged mode and the Engine Cooling R adiator disengaged mode If the clearance is not ad equate make the necessary adjustments 3 Check the fan belt condition and the belt align ment Replace or correct as necessary Horton HT650 Fan Drive Check for friction facing wear condition Replace when worn to 1 16 inch 1 5 mm thick when oil spotted or when burn marks are visible Kysor K22RA K22FA and K26RA Fan Drives 1 Check the fan for missing cracked chipped or damaged blades Tighten loose components Re place damaged fans if necessary 2 Check for adequate clearance around the fan The fan should be centered in the shroud to pre vent contact between the fan and the shroud 3 Check the fan belt for proper alignment and con dition If the belt is worn or frayed replace the belt 4 Verify the fan drive engagement With the engine and ignition key switch off apply at least 90 psi 620 kPa to the clutch the fan should rotate freely Remove air pressure from the clutch and the fan should not rotate 5 With the fan drive disengaged check for air leaks at the front of the clutch and between the clutch and the drive hub If an air leak is de tected the clutch seals and hub must be in spected for wear or damage If necessary the seals of the clutch can be replaced with a Kysor rebuild kit If inspection of the hub indicates ex cessive wear
48. for cracking or damage Replace any clinch pin that shows signs of dam age 7 Measure the top plate lift See Fig 4 7 1 Level the fifth wheel plate to a horizontal position Business Class M2 Maintenance Manual May 2011 31 3 Frame and Frame Components tions see the Simplex Fifth Wheel Operating and Maintenance Manual 9 Check all mounting bolts for signs of fatigue and tighten them to the proper torque For torque specifications see Group 00 Inspect all angles plates and brackets for cracks or other damage 10 Replace cracked worn or damaged parts with new parts Replace all loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and washers on fifth wheel mountings 11 After inspecting the fifth wheel lubricate all mov 04 11 2011 1310475 ing parts with a chassis 4 A Extended Top Plate Lift Height P 4 Operation 31 03 for lubrica 1 Fifth Wheel Top Plate 2 Fifth Wheel Frame Mount 3 Frame Rail Holland FWS1 4 Lifting Point 1 Disconnect the tractor from the trailer For in oh o ton Hee structions see the Business Class M2 Driver s Fig 4 Measuring Fifth Wheel Top Plate Lift Manual 72 Measure the height from a stationary Thoroughly steam clean the fifth wheel mounting point such as the frame rail to Check the fifth wheel plate for cracks Check for the top of the fifth wh
49. full service brake application Replace damaged or leaking components and tighten loose fittings 42 12 Brake Pedal Linkage and Mounting Plate Inspecting Inspect the pedal pedal linkage and mounting plate assembly for proper operation to ensure that any problems believed to be valve related are not actu ally mechanism issues 42 13 Air Brake Inspecting and Leak Testing IMPORTANT If any of the tests in the following procedure fail refer to Group 42 of the Business Class M2 Workshop Manual to test individual air brake components and valves Some steps in this operation require the parking brakes to be released Make sure the vehicle is on a level surface and all tires are chocked Failure to do so could result in the vehicle rolling causing personal injury and or vehicle damage 1 With the vehicle parked on a level surface shut down the engine apply the parking brakes and chock all tires Business Class M2 Maintenance Manual January 2010 42 9 42 Completely drain all air reservoirs Install accurate test gauges in the primary and secondary reservoirs 15 Brakes Completely drain the secondary front axle res ervoir On vehicles equipped with a Dryer Reser voir Module DRM or AD IS with the air dryer attached to the reservoir the primary rear axle 4 Start the engine and run it at a fast idle reservoir pressure should not drop below 65 psi 5 Record reservoir pressures
50. literature Check operation of the end cover heater and thermostat assembly during cold weather as fol lows 5 1 Electric Power to the Dryer With the igni tion or engine kill switch in the ON posi tion check for voltage to the heater and thermostat assembly using a voltmeter or testlight Unplug the electrical connector at the air dryer and place the test leads on each of the connections of the female connector on the vehicle power lead If there is no voltage look for a blown fuse broken wires or corrosion in the vehicle 42 8 Business Class M2 Maintenance Manual January 2010 Brakes wiring harness Check to see if a good ground path exists 5 2 Thermostat and Heater Assembly Opera tion These tests are not possible except in cold weather operation Turn off the ignition switch and cool the thermostat and heater assembly to below 40 F 4 C Using an ohmmeter check resis tance between the electrical pins in the air dryer connector half Resistance should be 1 5 to 3 0 ohms for the 12 volt heater assembly and 6 0 to 9 0 ohms for the 24 volt heater assembly NOTE Some models of the AD 9 may have a resistance reading of 1 0 to 2 5 ohms Warm the thermostat and heater assem bly to approximately 90 F 32 C and again check the resistance Resistance should exceed 1000 ohms If resistance values obtained are within stated limits the thermostat and heater assembly is operating properly If resistance v
51. of the compressor mounting fasteners The torque value for the mounting fas teners is 15 to 19 20 to 26 N m 7 Inspect the drive plate If the friction surface of the drive plate shows visible signs of damage due to excessive heat make sure the refrigerant compressor turns freely If the compressor does turn freely replace the drive plate and clutch as sembly For instructions see Section 83 01 Subject 140 of the Business Class M2 Work shop Manual f the compressor does not turn freely replace the compressor For instructions see Section 83 01 Subject 120 of the Business Class M2 Workshop Manual 8 Use a feeler gauge to check that the drive plate clutch clearance is 0 016 to 0 031 inch 0 4 to 0 8 mm If the gap is not even around the clutch gently tap down at the high areas If the overall gap is out of spec remove the drive plate assembly and change the shims as necessary For instructions see Section 83 01 Subject 140 of the Business Class M2 Workshop Manual 9 Check that the wiring harness connector is not damaged or loose Replace the wiring harness if it is damaged 10 Check the overall condition of the air conditioning hoses Look for cracks cuts and abrasions on the hoses Replace damaged hoses 83 11 Check for a buildup of road debris on the con denser fins Using air pressure and a whisk broom or a soapy spray of water carefully clean off the condenser Be careful not to bend the fins
52. of the oil fill hole in the carrier or housing with lubricant See Table 1 for approved axle lubricants and see Table 2 or Table 3 for axle capacities NOTE Some Meritor axles have a small tapped and plugged hole located below the housing oil fill hole This smaller hole is for the lubricant temperature sensor only and must not be used as a fill or level hole 2 Install the fill hole plug and tighten it 35 47 N m 3 After filling the carrier and housing assembly with lubricant drive the vehicle unloaded for one or two miles two or three kilometers at speeds not to exceed 25 mph 40 km h to thoroughly circu late the lubricant throughout the assembly 35 Business Class M2 Maintenance Manual December 2001 35 3 Wheels and Tires 40 Index Alphabetical Title of Maintenance Operation MOP MOP Number Wheel rat Ire e ER xr LP EC ETT 40 01 Business Class M2 Maintenance Manual December 2001 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 When checking wheel nuts on a stud piloted dual disc assembly remove one outer nut at a time tighten the inner nut then reinstall the outer nut Re peat this procedure for all of the inner wheel nuts in the sequence shown in Fig 1 then tighten all of the out
53. rebuild the hub using a hub rebuild kit from Kysor 6 Any time the clutch is removed for repair or re placement the pulley hub and bearings should be inspected for play roughness or damage Hub bearing service kits are available from Kysor 7 Check the lining with the System Alert Tool If the lining is worn install the appropriate lining kit A lining that is prematurely worn is caused by control air supply problems Inspect and correct the vehicle control system before placing the ve hicle back in service 20 2 Business Class M2 Maintenance Manual July 2009 Engine Cooling Radiator 8 Check the air line entry and routing at the front or rear of the fan drive Look for cracked dam aged or improperly routed air lines Make sure the connections are tight and that there are no air leaks 9 Check the electrical connections at the solenoid valve The solenoid valve is part of the air mod ule unit AMU which is located on the rear crossmember Check the exhaust port for restric tions If a restriction is found clear it Horton DriveMaster Fan Clutch NOTE If any part of the fan clutch needs to be repaired or replaced after performing the checks below see Group 20 of the Business Class M2 Workshop Manual 1 Disconnect the batteries at the negative termi nals Drain all air from the air system If equipped with an air starter drain the air starter reservoir Make sure the batteries are disconnecte
54. relief See Fig 4 42 02 01 2001 1 Grease Fitting 2 Slack Adjuster 1421649 Fig 3 Haldex Slack Adjuster Grease Fitting The newest Gunite automatic slack adjusters are produced without a grease relief During lubrication with a grease gun the lubricant is forced through the drilled worm wheel onto the camshaft Lubricate the automatic slack adjuster at the grease fitting until grease appears on the camshaft See Fig 5 42 07 Meritor Camshaft Bracket Lubricating IMPORTANT Perform MOP 42 15 before lubri cating the camshaft brackets NOTE If equipped with an extended maintenance Q Plus brake system the cam shaft bracket will not have a grease fitting These camshafts use a special NLGI grade syn thetic polyurea grease and do not require lubri cation for 3 years or 500 000 miles 800 000 km whichever comes first Extended maintenance camshaft bushings are lubricated during the brake reline service interval For ser Business Class M2 Maintenance Manual January 2010 42 5 42 Brakes 4 1 5 6 3 7 3 8 3 05 28 93 1420011 A Grease Exit 1 Brake Chamber 1 2 Slack Adjuster 3 Non Pressure Relief Grease Fitting 10 10 27 93 1420653 1 7 16 Inch Adjusting 6 Clevis Nut 7 1 2 Inch Clevis Pin 2 Grease Fitting 8 1 4 Inch Clevis Pin 3 Boot 9 Grease Relief 4 Link Opening 5 Brake Chamber Piston 10 Slack Adjuster Spline Rod
55. shutoff valves see Fig 9 e Coolant hoses and fittings e Fuel lines and fittings e All fittings connections and joints 8 Replace leaking or damaged fuel lines Repair or replace leaking or damaged fittings 47 06 CNG High Pressure Fuel Filter Element Replacing 04 22 2010 1470554 1 Fuel Cylinder Storage 5 Fuel Fill Port Box 6 Dust Cap 2 Fuel Oylinder Shutoff 7 Manual Shutoff Valve Valves aty 5 8 Fuel Panel Access 3 High Pressure Gauge Door 4 Low Pressure Gauge CNG filter element replacement cycles are an impor tant factor in maintaining the CNG fuel system integ rity and ensuring maximum operating performance Actual frequency of the filter element replacement could increase or decrease depending on the cleanli ness of the fill station fueling system 1 Shut down the engine and apply the parking brake Fig 9 CNG Fuel Cylinder Storage Box 5 cylinder system shown 2 Close the CNG fuel cylinder shutoff valves 3 Start the engine and let it idle until the fuel lines are empty and the engine stops The gauges on the fuel panel should now read at or near 0 psi 4 Close the manual fuel shutoff valve on the fuel panel 5 Remove the two capscrews that secure the ac cess cover to the fill panel then remove the ac cess c
56. the axle beam 33 SY 10 10 2001 1330185 A Apply lubricant until new lubricant comes from these areas 1 Grease Fitting Fig 1 Sealed Easy Steer Kingpin Lubrication On Easy Steer Plus front axles the grease fittings are on the top and bottom kingpin caps of the knuckle 1 Shut off the engine apply the brakes and chock the rear tires 2 Make sure the tires touch the ground Do not raise the vehicle 3 Clean off all grease fittings prior to lubrication IMPORTANT Meritor recognizes that industry trends are moving toward increased selection and usage of synthetic grease in vehicle mainte nance However some seals are known to ex pand when in contact with synthetic grease Consult your local Meritor representative for synthetic grease application references before using any synthetic grease when performing axle service and maintenance 4 Using a multipurpose grease NLGI grade 1 or 2 lubricate the kingpins through the grease fittings on the top and bottom of the knuckle See Fig 2 5 Force lubricant into the upper and lower kingpin grease fitting caps until new lubricant flows from between the upper axle beam end and the Business Class M2 Maintenance Manual July 2009 33 1 33 Front Axle 1 x N oa A L 54 10 11 2001 1330184 A Apply lubricant until new lubricant comes from these areas 1 Grease Fitting Fig 2 Sealed Easy Stee
57. the filter housing 8 Remove and discard the filter element 9 Install a new filter element in the filter housing 10 Inspect the O ring on the filter housing for dam age or cracks If necessary replace the O ring 11 Install the filter bowl on the filter housing Tighten 90 Ibf ft 122 N m 14 Using a methane detector leak test all fuel sys tem components between the fuel cylinders and the solenoid valve A bubble solution can be used to pinpoint the exact location of leaks Repair or replace any leaking components 15 Using the two capscrews removed previously install the access cover on the fill panel 47 07 CNG Fuel Cylinder Inspecting Have a qualified inspector inspect compressed natu ral gas CNG fuel cylinders for damage or deteriora tion Note cuts cracks gouges abrasions discolora tion broken fibers loose brackets damaged gaskets or isolators heat damage or other problems 4710 Business Class M2 Maintenance Manual July 2011 Fuel Refer to Compressed Gas Assocation CGA pam phlet C 6 4 Methods for External Visual Inspection of Natural Gas Fuel Containers and Their Installations for inspection requirements and inspector qualifica tions For more information go to www cganet com After inspection an accurate and reliable written re port should be provided for each container inspected Place an inspection label stating the inspection date and inspecting agency identific
58. tions 31 03 Fifth Wheel Lubricating Fontaine 1 Tilt the top plate forward the front of the fifth wheel is down and apply grease to each bearing area through the zerk fittings located on each side of the top plate just to the front of the bracket pins Continue to apply grease until it is coming out of the back of the bearing It may be necessary to raise the rear of the fifth wheel with a pry bar to open up the pocket slightly and allow the grease to flow through A substantial amount of grease may be required initially to fill the reservoir Tilt the fifth wheel rearward the rear of the fifth wheel is down and repeat the greasing proce dure Rock the top plate back and forth several times to spread the grease over the bearing sur face 2 Inspect the trailer kingpin plate and top surface of the fifth wheel to make sure each is properly greased A liberal coating of grease should be applied to the complete surfaces of both the trailer kingpin plate and the top surface of the fifth wheel NOTE Do not use a lube plate high density polyethylene on top of the fifth wheel or on the kingpin instead of grease without prior approval by Fontaine Fifth Wheel The additional thick ness of this material can prevent the proper op eration of the fifth wheel and may cause a dan gerous condition Business Class M2 Maintenance Manual May 2011 31 7 31 3 Lubricate the fifth wheel prior to opening and closing Greas
59. voir to the mounting bracket 7 Fill the reservoir with an approved power steer ing fluid to the line between the MIN COLD and MAX HOT lines See Fig 1 See Table 1 for ap proved power steering fluids Approved Power Steering Fluids Fluid Type Approved Fluid Automatic Transmission Dexron Ill Fluid Dexron II Do not mix fluid types Refer to the text in this group for a detailed warn ing statement Table 1 Approved Power Steering Fluids 8 Raise the front of the vehicle and support it with jack stands Business Class M2 Maintenance Manual June 2002 46 1 46 9 Start the engine and operate it at idle Turn the steering wheel from full left to full right several times until clean oil starts flowing from the power steering filter Add fluid to the reservoir to main tain the fluid level between the MIN COLD and MAX HOT lines 10 Shut down the engine and install the filter and filter cover in the reservoir Make sure that the gasket under the filter cover is not damaged If the gasket is damaged replace it Install the gas ket on the reservoir 11 Attach the retaining ring to the reservoir to se cure the filter and filter cover 12 Start the engine and check that the power steer ing fluid level is between the MIN COLD and MAX HOT lines Add more power steering fluid if needed 13 Raise the vehicle remove the jack stands and lower the vehicle 14 Remove the chock
60. with a DRM or AD IS with the air allowing the pressure to stabilize for one minute dryer attached to the reservoir the secondary Observe the installed service reservoir gauges reservoir pressure should not drop below 65 psi The pressure should not drop more than 15 psi 448 kPa On vehicles equipped with single 103 kPa in five minutes check valves where the air dryer is not attached 13 With the air system at full pressure and the en to the reservoir the secondary reservoir should gine idling perform the following not lose air pressure On trucks operate the parking brake con 19 On tractors only trol valve and note that the parking brakes 19 1 Start the engine and build the system air apply and release promptly as the control pressure to governor cut out valve knob is pulled out and pushed in on the spring brake axles only 19 2 Shut down the engine and leave the park ing brakes released e On tractors operate the trailer supply con trol valve knob Note the air coming out of 19 3 Completely drain the primary reservoir the trailer control coupling Operate the 19 4 Make a modulated service brake applica park control knob and note that the parking tion by depressing the brake pedal The brakes apply and release promptly as the front brakes should apply and release knob is pulled out and pushed in Block the and the brake lights should illuminate In trailer supply coupling and push the trailer addition to the front bra
61. 1 Drain the fuel below the collar level 2 Using Davco wrench 232002 remove the filter collar Then remove the filter cover 3 Remove the element and dispose of it properly 4 Install a new element Make sure the grommet is in place on the filter stud Install a new cover seal on the filter cover 6 Using the collar attach the filter cover with the spring to the base IMPORTANT Tighten the collar by hand only 7 Remove the filter vent Then fill the fuel water separator with fuel until the fuel level is 1 inch 2 5 cm above the collar Install the filter vent on the fuel water separator 9 Start the engine and raise the rpm for one minute to purge air Davco Fuel Pro 382 Replace the fuel water separator element only when the filter element is completely covered In the event of an emergency when the filter needs replacement but a Davco filter is not available a temporary filter can be used For instructions see Chapter 13 of the Business Class M2 Driver s Manual Diesel fuel is flammable and can ignite if exposed to an open flame intense heat or other ignition source Do not drain fuel near or expose fuel vapor to open flame or intense heat Exposure to open flame or intense heat could start a fire pos sibly resulting in personal injury or property dam 47 age When working on a fuel system have a fire extinguisher within easy reach 1 Drain the fuel below the collar level See Fig 3
62. 10 000 496 000 32nd M1 M2 M3 M4 and M5 256 000 384 000 320 000 512 000 Table 3 Maintenance Intervals for Schedules Il and Ill 00 4 Business Class M2 Maintenance Manual September 2011 General Information 00 Overview of Maintenance Operations 00 05 Maintenance Operations for Groups 00 through 88 UNO Title of Maintenance Operation T ML Tr 01 01 Engine Drive Belt Inspecting 01 02 Engine Support Fastener Checking 09 01 Air Cleaner Element Inspecting and Replacing 13 01 Air Compressor Inspecting 15 01 Alternator Battery and Starter Checking 20 01 Radiator Cap Inspecting 20 02 Radiator Pressure Flushing and Coolant Changing 20 03 Fan Drive Inspecting Noise Emission Control 20 04 Hybrid Electric System Coolant Changing 25 01 Eaton Fuller Clutch Release Bearing Lubricating 25 02 Eaton Fuller Clutch Release Cross Shaft Lubricating 25 03 Clutch Hydraulic Fluid Level Checking 25 04 Clutch Hydraulic Fluid Changing 25 05 Clutch Adjusting Manually Adjusted Clutches 26 01 Manual Transmission Fluid Level Checking 26 02 Eaton Fuller Transmission Fluid Changing and Magnetic Plug N Cleaning 26 03 Allison and Eaton Fuller Transmission Breather Checking
63. 16 inch 10 mm past the face of the flange Install the slip clamp with the retaining ring and graphite gasket ring onto the forward pipe See Fig 10 for proper installation Slide the end of the forward CGI pipe into the bellows and properly align the pipe Secure the forward CGI pipe to the engine and any CGI pipe support brackets Using the yellow marks center the bellows be tween the exhaust pipes Verify that the pipe is inserted at least 7 16 inch 10 mm past the face of the flange See Fig 9 Ref A Install the slip clamps on the bellows Tighten the slip clamps 11 15 Start the engine and check for exhaust leaks Tighten any clamps as needed Business Class M2 Maintenance Manual September 2011 49 7 49 Exhaust uu Pu tr 9 7 8 3 10 1 02 24 2011 1490456 1 Clamp 5 Slip Clamp 8 Center Pipe 2 Inlet Pipe 6 CGI Bellows 9 Clamp 3 U Clamp 7 Center Pipe Support Brace 10 Outlet Pipe 4 Forward Pipe Support Brace Fig 6 CAT 07 Exhaust Installation with CGI Bellows 1 Y H 67 LEH 02 23 2011 1490457 01 29 2010 1490415 A Measure the pipe gap 1 Aft 4 Slip Clamp 1 CGI Aft Pipe 2 Forwar
64. 2 Using Davco wrench 380134 or 382002 remove the filter collar Then remove the filter cover 3 Remove the element and dispose of it properly 4 Install a new element Make sure the grommet is in place on the filter stud Install a new cover seal on the filter cover 6 Using the collar attach the filter cover with the spring to the base IMPORTANT Tighten the collar by hand only 7 Remove the filter vent Then fill the fuel water separator with fuel until the fuel level is 1 inch 2 5 cm above the collar Install the filter vent on the fuel water separator 9 Start the engine and raise the rpm for one minute to purge air 47 03 LNG Fuel System Inspecting WARNING Natural gas is highly flammable See the safety precautions listed in Chapter 16 of the Business Class M2 Driver s Manual or Group 47 of the Business Class M2 Workshop Manual Failure to observe these precautions could lead to the igni tion of the natural gas which could cause serious bodily injury or death The following inspections must be performed by a qualified technician in accordance with the manufac turer s established inspection criteria All tank components should be allowed to defrost before conducting the following inspections NOTICE Do not use a high pressure washer or steam cleaner on natural gas fuel system plumbing com ponents as this can introduce moisture and con taminants into the threads of the fittings an
65. 3 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 tons t 1 1023 U S tons t Torque Work Force inch pounds lbf in 11 298 Newton centimeters N cm 0 08851 inch pounds Ibf in foot pounds 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 13 Metric U S Customary Conversions Business Class M2 Maintenance Manual September 2011 00 19 00 General Information Metric U S Customary and Temperature Conversions 00 17 Temperature Conversions Then When You Multiply Then Divide By T Cet Know By Add When You Know Subtract To Get degrees Fahrenheit F 32 1 8 degrees Celsius C 1 8 32 degrees Fahrenheit F Table 14 Temperature Conversions 00 20 Business Class M2 Maintenance Manual September 2011 General Information 00 Torque Specifications 00 18 Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threadst Regular Hex Flanged Hi Grade 5 Grade 5 or Grade 8 or Grade 8 or Grade 5 Grade B Grade 8 or Grade G Pitch Bolt B Nu
66. 3 Filter Element O Ring 4 Square Cut Seal Fig 5 Allison MD and HD Series Transmission Filter Locations and Components 6 Remove the filters from the bottom of the control module 7 Lubricate the new O rings with transmission fluid and install them on the cover assemblies 8 Install a new square cut seal on each cover as sembly and install the fluid filter elements on the cover assemblies Transmission 9 Install the filter and cover assemblies into the filter compartment 10 Align each cover assembly with the holes in the channel plate sump and push the cover assem blies in by hand to seat the seals CAUTION Do not use the bolts to draw the filter covers to the sump This can damage the covers seals or sump 11 Install six bolts in each cover and torque the bolts 38 to 44 51 to 61 N m 12 Install a new drain plug O ring and install the drain plug Tighten the drain plug 18 to 24 25 to 32 N m 13 Refill the transmission with fresh Dexron trans mission fluid see Table 3 and check the fluid level See Table 4 for lubricant capacities 14 Check and adjust the fluid level using the proce dures under Checking the Fluid Level Checking the Fluid Level CAUTION Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion Do not mix types and brands of fluid because of
67. 33 01 Kingpin Lubricating 33 03 Tie Rod End Lubricating 35 01 Axle Lubricant Level Checking 41 02 Driveline Lubricating 42 06 42 08 Haldex and Gunite Slack Adjuster Lubricating Meritor Slack Adjuster Lubricating 46 03 Power Steering Fluid Level Inspecting 46 04 Power Steering Gear Lubricating 46 05 Drag Link Lubricating 72 01 Door Seals Lubricating 88 01 Hood Rear Support Lubrication Table 11 MOP 00 12 M1 Lubrication and Fluid Level Check Business Class M2 Maintenance Manual September 2011 00 15 00 General Information M2 Lubrication and Fluid Level Check 00 13 Table 12 MOP 00 13 lists the lubrication and fluid level check maintenance operations that must be performed at the M2 Maintenance Interval MOP 00 13 M2 Lubrication and Fluid Level Check Maintenance Operation No Title of Maintenance Operation Eaton Fuller Transmission Fluid Changing and Magnetic Plug Cleaning 42 07 Meritor Camshaft Bracket Lubrication 26 02 Petroleum based lubricants only Table 12 MOP 00 13 M2 Lubrication and Fluid Level Check 00 16 Business Class M2 Maintenance Manual September 2011 General Information Noise Emission Controls Federal Law Part 205 Transportation Equipment Noise Emission Controls Part 205 Transportation Equipment Noise Emission Controls requires the vehicle manufacturer to furnish
68. 4 270 to 330 367 to 449 Business Class M2 Maintenance Manual July 2010 32 7 32 Size Torque Ibf ft N m Spring Assembly U Bolt High Nut Torque Values Stage 1 Hand tighten Stage 2 60 81 Stage 3 200 271 Stage 4 420 to 500 571 to 680 7 8 14 Stage 1 Hand tighten 1 14 2 60 81 Stage 3 200 271 Stage 4 520 to 600 707 to 816 Tighten in a diagonal pattern as shown in Fig 9 Table 1 Spring Assembly U Bolt High Nut Torque Values 03 10 2011 2 3 1320783 Fig 9 Tightening Pattern for U Bolt High Nuts Suspension 32 8 Business Class M2 Maintenance Manual July 2010 Front Axle 33 Index Alphabetical Title of Maintenance Operation MOP MOP Number Draw Key Nut Torque y patent ERU x Ege s E pawa dub dU OE ea dodo eue 33 03 sue decino Pr Peer 33 01 Tie Rod End Inspectirig sss 5 24 9 ko eek d SEGRE ONO EDGER Pee de RR OED ES hee 33 04 Tie Rod End EUIS as scs ad neqoe qd abt e q sk khuspa e gabe de lid rq Ends 33 02 Wheel End Inspection and Maintenance 6 000 Pound and 8 000 Pound Steer Axles with Oil Lubricated HUDS u u u u ata hber nom ama ham perdre nri bd SG gee 33 05 Business Class M2 Maintenance Manual July 2009 Front Axle 33 01 Kingpin Lubricating Sealed and Easy Steer Kingpins
69. Axle Lubricant Capacities for Single Axles Meritor Drive Axle Lubricant Capacities for Tandem Quantities listed are approximate and include 1 pint 0 5 liter for each wheel end and with the drive pinion at 3 degrees Table 3 Meritor Drive Axle Lubricant Capacities for Tandem Axles 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning A regular schedule for changing the axle lubricant in a particular vehicle and operation can be accurately determined by analyzing oil samples taken from the axle at specified intervals or mileages Lubricant sup pliers frequently make their laboratory facilities avail able for determining the useful life of their product under actual service conditions The final schedule that is recommended may for economic reasons be related to lubricant changes that are governed by climatic conditions and magnetic plug maintenance Change lubricant type and viscosity as climatic tem peratures demand regardless of vehicle mileage or established change schedule The normal operating temperature of compounded lubricants during the summer season is about 160 to 220 F 71 to 104 C The chemicals and additives that give these lubricants increased load carrying ca Axles pacity oxidize faster at temperatures above 220 Axle Model Axle Position Capacity 104 C contributing to more rapid lubricant deterio Forward 30 2 14 3 ration For this reason lubr
70. B 14 13 2 Quantities listed are approximate Fill the transmission until the lubricant is level with the bottom of the fill hole with the vehicle in normal operating position Table 2 Eaton Fuller Transmission Lubricant Capacities depending on transmission model Fig 2 Transmission Breather Eaton Fuller shown 26 04 Eaton Fuller Transmission Air Filter Regulator Element Cleaning NOTE Eaton Fuller FS FO and T TX transmis sions do not have an air filter regulator element that can be serviced WARNING Exhaust the air supply before servicing the air filter regulator otherwise serious personal injury and component damage could result 1 Exhaust the air from the air reservoirs 2 Clean the outside of the air filter regulator with cleaning solvent then let it air dry See Fig 3 3 Remove the end cap large O ring and filter ele ment from the filter housing See Fig 4 Remove the small O ring from the end cap NOTE Do not remove disassemble or adjust the air regulator If the air regulator is not keep ing the air pressure between 57 to 62 psi 396 to 431 kPa replace the air filter regulator It cannot be repaired 4 Clean the filter element Business Class M2 Maintenance Manual March 2005 26 3 26 05 27 93 260037 NOTE Location of the air filter regulator will vary de pending on transmission model Fig 3 Eaton Fuller Tr
71. CAUTION Do not over lubricate the clutch release bearing Over lubrication could contaminate the clutch in ternally causing clutch slippage and premature failure Do not use chassis grease or multipurpose lubricants 4 Wipe off excess grease and apply it to both the yoke finger and sleeve bushing contact points See Fig 2 5 Install the clutch inspection plate 6 Remove the chocks 05 27 93 f250081a Fig 1 Release Bearing Grease Fitting b ES 08 10 2009 1 Sleeve Bushing Contact Point 2 Yoke Finger Contact Points 1250444 Fig 2 Grease the Contact Points 25 02 Eaton Fuller Clutch Release Cross Shaft Lubricating IMPORTANT This maintenance operation per tains only to vehicles equipped with mechanical not hydraulic linkages The clutch release cross shaft is equipped with two grease fittings in the transmission clutch housing See Fig 3 and Fig 4 Wipe the dirt from the grease Business Class M2 Maintenance Manual June 2006 25 1 25 fittings and lubricate with multipurpose chassis grease 10 19 93 1250048 1 Clutch Release Cross Shaft 2 Grease Fitting Fig 3 Cross Shaft Grease Fitting Left Side 2 05 27 93 f260146a Fig 4 Cross Shaft Grease Fitting Right Side 25 03 Clutch Hydraulic Fluid Level Checking Use only approved clutch hydraulic fl
72. Camshaft Bracket Lubricating eee 42 07 Mentor slack Adilstet EbIT6allligis uer dde ed Se Ras wh Rese ed ad does 42 08 Business Class M2 Maintenance Manual January 2010 Brakes 42 01 Air Brake System Valve Inspecting IMPORTANT There is no scheduled Bendix air valve maintenance that requires disassembly of the valve within the warranty period If the valve does not function within the warranty period do not disassemble the part as this will void the warranty See the following maintenance operations for information about Bendix air valve maintenance 42 02 Bendix AD 9 Air Dryer Desiccant Replacing IMPORTANT For vehicles equipped with an oil coalescing air dryer desiccant cartridge replace the cartridge once a year regardless of mileage 1 Park the vehicle on a level surface apply the parking brakes and chock the tires 2 Completely drain all air reservoirs Air pressure gauges should read 0 psi 0 kPa IMPORTANT The compressor discharge line may contain residual air pressure 3 Identify tag and disconnect the three air lines from the end cover 4 Disconnect the harness connector from the heater and thermostat assembly 5 Loosen the capscrew that secures the upper mounting bracket strap 6 Remove the two capscrews that sencure the air dryer to the lower mounting bracket Mark the position of the mounting bracket to the end cover and mark the capsc
73. FREIGHTLINER Run Smart BUSINESS CLASS M2 MAINTENANCE MANUAL Models M2 100 M2 106 M2 106V M2 112 M2 112V Daimler Trucks North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A Foreword Performing scheduled maintenance operations is important in obtaining safe reliable operation of your vehicle A proper maintenance program will also help to minimize downtime and safeguard warranties 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 operations in this maintenance manual at scheduled intervals Perform the pretrip and post trip inspections and daily weekly monthly maintenance as outlined in the vehicle driver s manual Major components such as engines transmissions and rear axles are covered in their own maintenance and operation manuals that are provided with the vehicle Perform any maintenance operations listed at the intervals scheduled in those manuals Your Freightliner Dealership has the qualified technicians and equipment to perform this maintenance for you They can also set up a scheduled maintenance program tailored specifically to your needs Optionally they can assist you in learning how to perform these maintenance procedures IMPORTANT Descriptions and specifications in this manual were in effect at the time of printing Freightl
74. Fig 7 Walking Beam End Wear Thickness Replace all cracked or missing restrictor cans Failure to do so could lead to loss of vehicle con trol which could result in property damage seri ous personal injury or death 6 Remove the jack stands then lower the vehicle Check that the spring or driveline brake is ap plied then remove the wheel chocks 32 02 Suspension Lubricating Freightliner Spring Front Suspension Wipe all dirt from the grease fittings at the forward spring pin and the spring shackle pins Then apply multipurpose chassis grease with a pressure gun until the old grease is forced out 32 6 Business Class M2 Maintenance Manual July 2010 Suspension Freightliner Spring Rear Suspension Single Axle Lubrication is not required on single axle spring rear suspensions Tandem Axle CAUTION If the equalizer cap and tube assembly is equipped with a nonrelief grease fitting excessive lubrication can damage the bushings Lubricate the equalizer cap and tube assembly bush ings by applying multipurpose chassis grease at the pressure relief grease fitting See Fig 8 Lubricate with a hand gun or pressure gun until grease is forced out from the base of the pressure relief fitting 05 27 93 320020a A Lubricate here 1 Cap and Tube Assembly Bushing Fig 8 Equalizer Assembly Lubrication Hendrickson Equalizer Beam End Bushings and Rubber Center Bushings No lubrication is
75. Operation MOP MOP Number Determining Scheduled Maintenance 00 01 Initial Maintenance IM c qaem sa APR Ree e sneer 00 06 M1 Lubrication and Fluid Level 00 12 Maintenance Operations 583 ddp aen dec c ahd e OD GC epe ee x Rea ane eda 2 da oe Saws 00 07 M2 Lubrication and Fluid Level 2 1 00 13 M2 Maintenance Operations Lu u i rm peret ped ege dcr E Rede dosi nd 00 08 Ma Maintelranee OpSISlloSr uy su an ieget td Gba id Gb ap d 00 09 Maintendnce Operations saudi neck ar EOS dU OR usss eather d art ir Bri eR us 00 10 5 Maintenance Operations usse x oer depu wa wa de e eR E EE ERR Rd E de N 00 11 Maintenance Intervals Tor Schedule 00 03 Maintenance Intervals for Schedules Il and 00 04 Maintenance Schedules gt ges RR peu bearer PRU GER dest e Eee uama ga 00 02 Metric U S Customary and Temperature Conversions 00 17 Noise Emission cs tom Ad a tie aka aces 00 15 Overview of Maintenanc
76. PF 52 A A Check any wires lines or hoses within 4 inches removed p musi ba replaced 10 cm of the exhaust system for heat damage i Repair or reroute as needed 3 If present check the condition of the insulation material around the exhaust pipe between the Pre EPAO7 Exhaust System turbocharger and the ATD Inspection 4 Check the ATD mounting bands for tightness Tighten to 30 Ibf ft 41 N m if needed Do not 1 Inspect the exhaust manifold at the cylinder head overtighten and at the turbocharger for leaks See the engine 5 Check for leaks around the clamps that attach oo serves Sten re forrapainproce the ATD in the ATS and around the clamps that retain the DPF in the ATD Inspect the muffler body muffler outlet stack muffler shield and inlet tubes for leakage dents 6 Check all sensors attached to the ATD for leaks corrosion or holes in the muffler or damaged wires No leaks are allowed f 7 Check the DPF exterior surface for dents or 9 Inspect ine exhaust pipe and exhaustseal clamp for leakage wear or damage Replace the exhaust pipe if needed If leakage exists at a clamp tighten the nuts to the required torque If leakage persists install a new exhaust seal Business Class M2 Maintenance Manual September 2011 49 5 49 clamp Do not reuse seal clamps Once a seal clamp is loosened or removed it must be re placed 4 Check for leakage at the clamp that attaches the exhaust
77. Remove the brake pedal 5 Check the brake pedal mounting plate adapter for signs of wear or cracks at the bosses the area from which the pivot pin was removed Re place it if necessary 6 Check the brake pedal rollers for signs of wear or cracks Replace the rollers if necessary 7 Ifthe rollers are replaced replace the roller install a new cotter pin bend it 90 degrees and apply Torque Seal OPG F900 White to the cot ter pin 8 Remove the plunger from the valve Clean the existing grease from the plunger using alcohol Check the plunger for signs of wear or cracks Replace it if necessary 42 09 10 2004 1430405 1 Foot Control Valve 5 Roll Pin E 6 6 Roller 2 Mounting Plate 7 Roller Pin 3 Nut and Washer 8 Pedal 4 Pivot Pin Fig 8 Brake Pedal and Valve Assembly 9 Lubricate the plunger with synthetic grease of NLGI Grade 1 5 such as 76 Triton synthetic EP Grease FTL Sped 48 25432 000 10 Insert the plunger in the valve 11 Install the brake pedal with the pivot pin 12 Install a new roll pin then apply Torque Seal OPG F900 White to the roll pin 13 Install the brake valve assembly See Section 42 09 Subject 110 of the Business Class M2 Workshop Manual for instructions 14 Test the brakes before returning the vehicle to Service 42 15 Brake Inspecting IMPORTANT This procedure should be per formed prior to lubrication of the brake compo nents
78. Storage Box 3 Mounting Bolts gty 12 per side Fig 7 Fuel Cylinder Storage Box Mounting Bracket passenger side shown NOTE During initial pre delivery inspection PDI tighten the storage box mounting bolts shown Fig 7 180 Ibf ft 244 N m 4 Inspect the fuel fill port for signs of damage or leaks Ensure the port dust cover and the O ring inside the port are both present and in good con dition See Fig 8 5 Inspect the pressure gauges on the fuel box for cracks Ensure the indicator needles are present and in working condition Inspect the gauge faces for accuracy and legibility 6 Ensure blue caps are present on all pressure relief devices Each fuel cylinder is equipped with two caps one on each end which are visible on the back of the CNG fuel cylinder storage box One cap is located on the pressure relief valve on the inboard side of the CNG fuel box next to 47 8 Business Class M2 Maintenance Manual July 2011 Fuel 47 G s 10 PSI OPEN VALVI 04 30 2010 1470556 1 High Pressure Gauge 2 Low Pressure Gauge 3 Manual Fuel Shutoff Valve 4 Fuel Fill Port and Dust Cap Fig 8 CNG Fuel Panel the fuel outlet line Check the primary relief valve on the inboard side of the CNG fuel box for signs of damage or leaks 7 Check the following components for signs of damage or leaks e Manual fuel shutoff valve e Fuel cylinder
79. Vaporizer 10 Overpressure Regulator 3 Check Valve 7 Fuel Shutoff Solenoid Valve 11 Pressure Relief Valve 4 CNG Quick Connect Port 8 Coolant Outlet Line 12 Fuel Outlet Line Fig 6 LNG Vaporizer Assembly 6 Wait fifteen minutes after shutting down the en 8 Use Table 1 to determine whether the pressure gine then record the fuel tank pressure and note increase is within an acceptable range the time 7 Allow the vehicle to stand for at least eight hours then record the fuel tank pressure again Vacuum Integrity Test Results Pressure Increase Over Eight Hour Period Remedy Less than 20 psi 138 kPa None Tank is normal 20 to 50 psi 138 to 345 kPa Monitor tank and test vacuum integrity again at next maintenance date More than 50 psi 345 kPa Remove vehicle from service and evacuate the tank per the tank manufacturer s instructions Table 1 Vacuum Integrity Test Results Business Class M2 Maintenance Manual July 2011 47 7 47 47 05 CNG Fuel System Inspecting Natural gas is highly flammable See the safety precautions listed in Chapter 16 of the Business Class M2 Driver s Manual or Group 47 of the Business Class M2 Workshop Manual Failure to observe these precautions could lead to the igni tion of the natural gas which could cause serious bodily injury or death The following inspections must be performed by a qualified technician in accordance with the manufac
80. a sliding mechanism inspect and adjust it as follows 31 6 Business Class M2 Maintenance Manual May 2011 Frame and Frame Components 09 02 2009 1311100 1 Jam Nut 2 Adjustment Bolt 3 Grease Zerk Fig 10 Jost Fifth Wheel 9 1 Check the bracket for any cracks or miss ing and damaged parts 9 2 Inspect the locking plungers for full en gagement 9 3 Check the locking mechanism for proper operation If the plungers will not release check the air cylinder or plunger adjustment If the plungers are loose check the plunger adjustment and the plunger springs for proper compression Replace if needed 9 4 The outboard slider assembly requires no adjustment If the plungers are loose in spect and replace locking mechanism parts as needed 9 5 The inboard slider is adjustable for frame width and plunger engagement For ad 31 justment refer to the fifth wheel installa tion instructions 10 Replace cracked worn or damaged parts with new parts Replace all loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and washers on fifth wheel mountings 11 After inspecting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease Apply a generous coating of grease to the top plate to fill the grooves or depressions on the top plate See MOP 31 03 for lubrication instruc
81. aking or damaged fittings Fuel Level Sender Component Inspecting 1 Inspect the fuel level sender wiring harness for signs of loose connections or damage Look for cracking or signs of moisture intrusion 2 Inspect the fuel level sender box Fig 5 Item 6 for signs of leaks or damage Ensure that the retainer clips are installed on the mounting ears 3 Inspect all connectors and wiring for signs of loose connections damage or chafing 4 Turn the ignition switch to the ON position and check for fuel gauge response 5 Repair or replace any damaged fuel gauge components Vaporizer Inspecting See Fig 6 for plumbing component locations 1 Ensure that the vaporizer is secured to its mounting brackets and that the mounting brackets are secured to the frame Inspect for any signs of looseness 2 Inspect the vaporizer fuel inlet and outlet lines for signs of chafing damage or leaks 3 Inspect the vaporizer coolant hoses for signs of chafing damage or leaks Inspect all fittings for leaks Inspect the fuel shutoff solenoid valve for signs of leaks or damage Inspect the solenoid mount ing bracket for looseness Fuel 6 Inspect the overpressure regulator for signs of leaks or damage 6 1 Ensure that the regulator is mounted se curely 6 2 Check the overpressure regulator fittings for signs of leaks or damage 6 3 Ensure that the adjustment handle locking nut at the bottom of the overpressure regu
82. alues obtained are outside stated limits replace the heater and thermostat assembly 6 On the AD IS dryer reservoir module DRM only observe the pressure gauges of the vehicle as System pressure builds from zero The primary gauge should rise until it reaches approximately 109 5 psi 751 34 kPa then level off or a momentary slight fall as the second pressure protection valve opens supplying the secondary reservoir When the secondary pressure gauge passes through approximately 55 5 psi 379 34 kPa and then 85 5 psi 586 34 kPa there should be an associated levelling off or momentary slight fall of pressure as the third and fourth pressure protection valves open Fi nally both the primary and secondary gauges should reach their full pressure of approximately 130 5 psi 896 34 kPa If the AD IS does not perform within the pressure ranges described above recheck using gauges known to be accu rate If readings remain outside the ranges out lined above replace the AD IS There are no kits available for servicing the pres sure protection valves 42 Do not attempt to adjust or service the pressure protection valves Incorrect pressure protection valve settings can result in automatic application of the vehicle spring brakes without prior warning This can cause personal injury or property dam age 42 11 Brake Lines and Fittings Inspecting Hydraulic Brakes Chock the tires release park brake and make a
83. amaged part s is no assurance that the spring is safe On front spring assemblies if cracks or breaks exist in the two top leaves a loss of vehicle control could occur Failure to replace a damaged spring assem bly could cause an accident resulting in property damage serious personal injury or death IMPORTANT On multi leaf suspensions closely inspect each component of the leaf spring as semblies including the brackets U bolts and related parts Freightliner Spring Rear Suspension Spring Brackets and Equalizer Brackets Tandems Inspection Inspect the forward and rear spring brackets equal izer brackets tandems and the wear pads for wear cracks and other damage If any of these con ditions exist replace the damaged bracket s and wear pad s See Group 32 of the Business Class M2 Workshop Manual for instructions Failure to replace the forward spring brackets equalizer brackets or rear spring brackets if they are worn cracked or otherwise damaged could 32 result in progressive damage to and eventual breakage of the bracket This could cause a loss of vehicle control resulting in property damage serious personal injury or death Freightliner Spring Tandem Axle Suspension Crossmember and Gussets Inspection Inspect the tandem axle frame crossmember and gussets for wear cracks and other damage If any of these conditions exist replace the damaged parts See Section 31 00 Subject 130 of the Busines
84. and garbage truck farm operation Schedule short haul transport applies to vehicles that travel up to 60 000 miles 100 000 kilometers annually and operate under normal conditions Ex amples of Schedule Il usage are e operation primarily in cities and densely popu lated areas local transport with infrequent freeway travel e high percentage of stop and go travel Schedule IlI long haul transport is for vehicles that travel more than 60 000 miles 100 000 kilometers annually with minimal city or stop and go operation Examples of Schedule usage are regional delivery that is mostly freeway miles e interstate transport any road operation with high annual mileage Maintenance Schedules After determining the schedule appropriate to your vehicle refer to the Maintenance Schedules to deter mine when to perform the Initial Maintenance IM and the frequency of performing subsequent mainte nance intervals for each schedule Maintenance Intervals Refer to Maintenance Intervals for Schedule I Schedule Il and Schedule III to determine which maintenance interval s should be performed when your vehicle reaches the mileage or hours of opera tion listed in these tables Maintenance Operations Groups 01 through 83 in this manual have an index at the beginning of each Group The index lists the Title of Maintenance Operations and the mainte nance Operation MOP Numbers for that Group Follow the i
85. ansmission Air Filter Regulator Location 10 17 2001 1260052a 1 Air Regulator 5 Small O Ring 2 Housing 6 End Cap 3 Large O Ring 7 Plug 4 Filter Element Fig 4 Eaton Fuller Transmission Air Filter Regulator Components 4 1 Dip the filter element in alcohol or other cleaning solvent Blow compressed air through the filter element inside to out side to loosen surface dirt and to dry the element The sintered metallic filter ele Transmission ment will last the life of the vehicle pro vided it is not damaged 4 2 Wipe out the filter housing with a clean dry lint free rag 5 Clean and inspect the O rings and the end cap Replace any parts that are damaged 6 Install the large O ring then the filter element small end first into the filter housing 7 Install the small O ring in the end cap then in stall the end cap on the filter housing Tighten the end cap until firm 8 Start the engine and build pressure in the air system Check for air leaks at the filter housing and air line connections and repair any leaks CAUTION Repair any air leaks A leaking air filter or air lines can cause slow or hard shifting of the transmis sion and eventual transmission damage 26 05 Allison Transmission Fluid and Filter Changing When draining transmission fluid check for evidence of dirt or water contamination A small amount of condensation will appear in the fluid during operation
86. approximately 1 4 inch 6 mm clearance by turning the wedge stop rod located on the right side of the top plate 11 Replace cracked worn or damaged parts with new parts Replace all loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and washers on fifth wheel mountings 12 After inspecting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease Apply a generous coating of grease to the top plate to fill the grooves or depressions on the top plate See MOP 31 03 for lubrication instruc tions ConMet Simplex9 1 Disconnect the tractor from the trailer For in structions see Chapter 10 of the Business Class M2 Driver s Manual Thoroughly steam clean the fifth wheel Check the fifth wheel plate for cracks Check for sharp edges on top the chamfer should be 1 8 to 1 4 inch 3 to 6 mm 4 When the wheel is locked the safety latch must swing free and fall freely into position See Fig 2 31 13103536 3 Lock Control Handle 10 26 2010 1 Lubricant Grooves 2 Safety Latch 4 Mount Fig 2 Simplex Series Fifth Wheel 5 The lever bar and operating handle must be in proper alignment See Fig 3 Replace any bent or misaligned lever bar or operating rod 04 11 2011 1310470 1 Operating Handle 2 Lever Bar Fig 3 Lever Bar and Operating Handle Alignment 6 Check all clinch pins
87. ary 2010 Brakes 12 4 Check for excessive leakage around the head of the desiccant cartridge where it contacts the end cover With the com pressor in loaded mode compressing air apply a soapy solution to these areas and observe that any leakage does not exceed a 1 inch bubble in 1 second If leakage exceeds this measure remove and re install the desiccant car tridge 42 06 Haldex and Gunite Slack Adjuster Lubricating IMPORTANT Perform MOP 42 15 before lubri cating the slack adjusters Automatic slack adjusters that have a grease fitting must be lubricated periodically to ensure proper brake operation WARNING Failure to lubricate slack adjusters could lead to dragging brakes or a brake failure resulting in property damage personal injury or death Haldex A CAUTION Do not use moly disulfide loaded grease or oil Both the life and reliability of the slack adjuster will be reduced if this type of grease is used Lubricate the automatic slack adjuster at the grease fitting See Fig 3 Use standard chassis lubricant for Haldex slack adjusters Gunite 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 use Lubriplate Aero grease Lubricate a Gunite automatic slack adjuster at the grease fitting until grease appears on the camshaft or flows from the grease
88. ase NOTE NLGI Grade 2 is the preferred grade 46 06 Power Steering Filter Changing 1 Apply the parking brakes and chock the rear tires 2 Raise the front of the vehicle and support it with jack stands 3 Remove the retaining ring from the reservoir See Fig 1 4 Remove the filter filler cover and gasket from the reservoir 5 Disconnect the filter from the filter cover and dis card the filter 6 Apply a thin film of power steering fluid on the gasket of the new filter Then attach the filter to the filter cover 46 2 Business Class M2 Maintenance Manual June 2002 Steering Check for damage to the gasket that was re moved from the reservoir If the gasket is dam aged replace it Install the gasket on the reser voir Install the filter and filter cover in the reservoir Attach the retaining ring to the reservoir to se cure the filter and filter cover Check the fluid level in the reservoir If neces sary add fluid to the reservoir to maintain the fluid level between the MIN COLD and MAX HOT lines See Table 1 for approved power steering fluids Raise the vehicle and remove the jack stands then lower the vehicle Remove the chocks from the tires 46 Business Class M2 Maintenance Manual June 2002 46 3 Fuel 47 Index Alphabetical Title of Maintenance Operation MOP MOP Number CNG F el GOylinder oues unb UB rnc pa ax eee
89. at it conforms to EPA regulations EPA10 Exhaust System Definitions of Aftertreatment ATS Terms Refer to the following list of definitions of ATS terms and components e Aftertreatment System ATS the entire ex haust system from the turbocharger to the ex haust stack or tail pipe Aftertreatment Device ATD a housing that contains the DOC and DPF also the SCR and the mixing tube in one box systems BlueTec Daimler s proprietary SCR technol ogy Diesel Oxidation Catalyst DOC a flow through device that oxidizes soot in the ATD Diesel Particulate Filter DPF a component in the ATD that traps soot from the exhaust gas 49 Diesel Exhaust Fluid DEF the chemical agent that reacts with the exhaust gases in the SCR to reduce NOx e DEF Pump filters and supplies DEF to the DEF metering unit e DEF Tank holds DEF and regulates its tem perature e DEF Metering Unit mixes DEF with com pressed air and meters this mixture into the exhaust flow via an injection nozzle e SCR Catalyst the housing containing a treated ceramic flow through block where the DEF and exhaust gases undergo selective catalytic re duction SCR e Selective Catalytic Reduction SCR a process used to reduce NOx emissions Inspection To meet EPA10 emissions regulations for vehicles domiciled in the USA or Canada engines manufac tured after December 31 2009 are equipped with an emission aftertreatm
90. ate on the countershaft next to the output yoke If leakage is found check the torque on the cover plate bolts and check the flat seal for damage 26 5 1 If the flat seal is damaged replace it 5 2 If the cover plate bolts are too loose tighten them 18 Ibf ft 25 N m If the cover plate bolts are too tight replace the flat seal and tighten to 18 25 N m 6 Check for signs of leakage at the transmission fluid fill plug If leakage is found check the torque on the plug and check the aluminum gas ket for damage 6 1 If the gasket is damaged replace it 6 2 If the fill plug is too loose tighten it 42 57 N m If the fill plug is too tight loosen it then tighten it to 42 Ibf ft 57 N m 7 Check for signs of leakage at the transmission fluid drain plug If leakage is found check the torque on the plug and check the aluminum gas ket for damage 7 1 If the gasket is damaged replace it 7 2 If the drain plug is too loose tighten it 42 57 N m If the plug is too tight loosen it then tighten it to 42 Ibf ft 57 N m 8 Check for fluid dripping at the gear case seals If substantial leakage is found at either location replace the transmission NOTE Weeping or sweating seals are not cause for transmission replacement Clutch hydraulic fluid DOT 4 brake fluid is haz ardous It may be a skin irritant and can cause blindness if it gets in your eyes Always wear safety glasses wh
91. ation on each con tainer 47 Business Class M2 Maintenance Manual July 2011 47 11 Exhaust Title of Maintenance Operation MOP CAT CGI Bellows CAT CGI Bellows and Piping Inspection Exhaust System Inspecting Noise Emission Control 49 Index Alphabetical MOP Number Business Class M2 Maintenance Manual September 2011 Exhaust 49 01 Exhaust System Inspecting Noise Emission Control In addition to inspecting the exhaust system at the scheduled maintenance interval inspect the exhaust system if the noise level of the vehicle has in creased Freightliner Trucks recommends replacing parts that show leakage wear or damage with genuine Freightliner parts The exhaust system must be free of leaks binding grounding and excessive vibrations These condi tions are usually caused by loose broken or mis aligned clamps brackets or pipes If any of these conditions exist check the exhaust system compo nents and alignment Align or replace as necessary see Group 49 of the Business Class M2 Workshop Manual or take the vehicle to an authorized Freight liner dealer It is a violation of US federal law to alter exhaust plumbing or aftertreatment in any way that would bring the engine out of compliance with certification requirements Ref 42 U S C S7522 a 3 It is the owner s responsibility to maintain the vehicle so th
92. ations in Table 6 M1 Maintenance M4 Maintenance Operations Maintenance Operation No Title of Maintenance Operation 00 07 00 08 Perform All M1 Maintenance Operations Perform All M2 Maintenance Operations 00 09 Perform All M3 Maintenance Operations 01 02 Engine Support Fastener Checking 09 01 Air Cleaner Element Inspecting and Replacing 15 01 Alternator Battery and Starter Checking 20 02 Radiator Pressure Flushing and Coolant Changing 20 04 Hybrid Electric System Coolant Changing 31 01 Frame Fastener Torque Checking 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning 42 03 Governor D 2A Checking 46 02 47 02 Power Steering Fluid Changing Fuel Water Separator Element Replacing 60 01 Mirror Folding Check Table 9 M4 Maintenance Operations Operations Table 7 M2 Maintenance Operations and Table 8 M3 Maintenance Operations Business Class M2 Maintenance Manual September 2011 00 13 00 General Information M5 Maintenance Operations 00 11 NOTE The M5 Maintenance Operations include the Operations Table 7 M2 Maintenance Operations maintenance operations in Table 10 and all of the Table 8 M3 Maintenance Operations and Table 9 maintenance operations in Table 6 M1 Maintenance M4 Maintenance Operations M5 Maintenance Operations Maintenance Operation No Title of Maintenance Operation
93. axles replace linings worn to less than 1 16 inch 1 6 mm 1 4 Make sure that the brake rotor and linings are free of oil and grease 1 5 Install the inspection plug s 2 If the wheel and hub assembly is removed from the axle check lining wear Replace the linings on all brake assemblies if worn to less than 1 16 inch 1 6 mm at the thinnest point Check the brake pads for wear and replace as necessary 42 05 Bendix AD IP Air Dryer Desiccant Replacing IMPORTANT For vehicles equipped with an oil coalescing air dryer desiccant cartridge replace the cartridge once a year regardless of mileage 1 With the vehicle parked on a level surface apply the parking brakes and chock the tires 2 Using a wrench or a socket loosen the desiccant cartridge bolt Then separate the desiccant car tridge from the end cover 3 Pull the cartridge bolt out of the cover and re move the cartridge WARNING Do not attempt to disassemble the desiccant car tridge assembly Parts for the assembly are not Brakes available and the cartridge contains a 150 Ib spring that cannot be mechanically caged Disas sembly could release the spring resulting in per sonal injury 4 Remove and discard both O rings from the car tridge bolt 5 Using a clean rag wipe clean the inside of the end cover Clean the cartridge bolt bore in the end cover and the sealing surfaces for the large and small diameter desiccant cartridge s
94. cal Co LTF 2 Mystic LP 200 or equivalent is recommended f311136 12 03 2010 Use a light oil such as SAE 10W or 20W motor oil to lubricate the cam track and pivot 1 Cam Plate Fig 12 Holland FW35 Fifth Wheel Oil Lubrication Jost Lubricate the kingpin lock using a hand pump grease gun through the grease zerk on the skirt of the fifth wheel see Fig 10 Apply a light oil to all moving parts For sliding fifth wheels spray diesel fuel on the slide path of the base plate NOTICE Do not use a power grease gun The pressure will damage the lube line 31 8 Business Class M2 Maintenance Manual May 2011 Frame and Frame Components 31 1 Wash out any existing grease dirt and corrosion on the trailer connectors with electrical contact cleaner spray 2 Grease the trailer connector with a lithium based dielectric grease 12 03 2010 1311135 1 Release Handle 3 Yoke Tip Spring 4 Locks 2 Grease Fitting Fig 13 Holland FW35 Fifth Wheel Grease Lubrication If the fifth wheel is not equipped with low lube plates apply a lithium based grease with extreme pressure EP additive to the trailer contact surface of the fifth wheel NOTE If the fifth wheel is equipped with low lube plates the top plate only requires lubrication at the new product break in stage The low lube plates re quire no further lubrication 31 04 T
95. ce them as needed with genuine Holland parts Using a Holland Kingpin Lock Tester Holland tool number TF TLN 5001 available through the PDCs as HLD TFTLN5001 check the operation of the locking mechanism by opening and closing the locks See Fig 7 After inspecting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease See MOP 31 03 for lubrication instructions We 04 11 2011 B A The nut and washer should be snug against the fifth B The locks should be completely closed around the 1310887 wheel kingpin Fig 7 Holland Fifth Wheel Properly Closed Jost 1 Disconnect the tractor from the trailer For in structions see the Business Class M2 Driver s Manual Thoroughly steam clean the fifth wheel Check the mounting for missing or damaged fas teners and broken components Replace or re pair as needed Business Class M2 Maintenance Manual May 2011 31 5 31 4 Inspect the bracket pin bolts Make sure the lock ing tabs are properly securing the bolts in place See Fig 8 Frame and Frame Components 09 01 2009 f311101 Fig 8 Bracket Pin Bolt Locking Tabs 5 Check the fifth wheel for bent worn or broken parts Replace as needed 6 If the fifth wheel is equipped with low lube plates check the plates and replace if damaged or
96. ch hydraulic fluid on your skin wash it off as soon as possible 3 Prepare the pressure bleeding equipment ac cording to the manufacturer s instructions Use DOT 4 brake fluid Pressurize the bleed adaptor to 15 psi 103 kPa CAUTION Do not spill clutch hydraulic fluid DOT 4 brake fluid on the cab paint Clean it off immediately if any is spilled DOT 4 brake fluid can damage paint 4 Remove the reservoir lid and install the pressure bleed adaptor on the reservoir 5 Pressurize the reservoir filling the system Open the bleed valve on the bleed tank of the adaptor NOTE A pressure bleeder hose J 29532 and a bleed adaptor J 35798 for the fluid reservoir are available through SPX Kent Moore Tools and may be used to complete the following pro cedure To order these parts call Kent Moore at 1 800 328 6657 6 Flush the hydraulic system See Fig 6 6 1 Open the bleed screw on the slave cylin der 6 2 Using a drain pan or other suitable con tainer collect the fluid that drains from the slave cylinder bleed valve at least 0 5 quarts 0 5 liters 6 3 When all the old fluid has passed through the system and only new clean fluid is coming out close the bleed screw 7 Check the fluid level in the reservoir and bleed the system according to the procedures under the heading Bleeding the Clutch See Fig 7 25 Bleeding the Clutch 1 Remove the cap from the bleed valve Install a transparent drai
97. ck 1 Without detaching the torque arms use your hand to attempt to move each of the radius rod ends up down in and out If there is any move ment replace the torque arm 2 Inspect the rubber bushing ends Replace the torque arm if there are gaps between the rubber bushing and the pin or the outer steel sleeve if either bushing end contacts a torque arm pin mounting bolt if there are cracks in the bushing or if part of the rubber bushing extends beyond the outside diameter of the outer bushing sleeve Chalmers Suspension Inspection Chock the front wheels to prevent the vehicle from moving Place the transmission in neutral and re lease the spring or driveline brakes before inspecting the rear suspension Business Class M2 Maintenance Manual July 2010 32 5 32 Power wash the Chalmers rear suspension or clean it with a hard bristle brush before performing a visual inspection 1 Visually inspect the rubber bushings for cracks or other damage Try to move the torque rod ends using your hands only and check for any free play If free play is felt replace the torque rod end bushing Do not use a pry bar to check for free play Use of a pry bar may lead to premature bushing re placement 2 If equipped with optional shock absorbers check for worn broken or damaged shock bushings heavy corrosion on the shock absorber body or fluid leaking from the shock absorber Replace the shock absorbers if any of th
98. d Pipe 5 5 CGI Bellows Big 7 Measuring the Pipe Gap typical Fig 8 Aft Facing Slip Clamp Installation 49 8 Business Class M2 Maintenance Manual September 2011 Exhaust 49 A 1 2 I 02 23 2011 1490458 A Atleast 7 16 inch 10 1 Forward CGI Pipe 3 Aft CGI Pipe 2 CGI Bellows Fig 9 CGI Bellows Installation 1 2 3 4 5 LB LA N LEY 02 08 2010 1490417 1 CGI Bellows 4 Graphite Gasket 2 Slip Clamp 5 Forward CGI Pipe 3 Retaining Ring Fig 10 Forward Facing Slip Clamp Installation Business Class M2 Maintenance Manual September 2011 49 9 Cab 60 Index Alphabetical Title of Maintenance Operation MOP MOP Number Mitror Folding 720 E 200 LESS CORTE 60 01 Business Class M2 Maintenance Manual July 2010 Cab 60 01 Mirror Folding Check For vehicles with folding main mirrors make sure that the mirrors fold freely on the pivot points Pivot each mirror fully forward and backward two times to break loose any debris that may affect the fold away feature of the mirror 60 Business Class M2 Maintenance Manual July 2010 60 1 Doors 72 Index Alphabetical Title of Maintenance Operation MOP MOP N
99. d before checking the fan clutch If the engine starts during this procedure the fan could engage which could result in serious personal injury 2 Inspect the electrical connections and wires to the fan clutch solenoid Secure the connection if loose replace wires and connectors if damaged 3 Clean the fan clutch air solenoid valve filter if equipped 3 1 Unscrew the fan clutch solenoid valve air filter assembly and remove the filter ele ment 3 2 Clean the filter element with cleaning sol vent 3 9 Using a clean lint free cloth wipe off any excess solvent 3 4 Reassemble the clutch valve solenoid air filter assembly and install it on the ve hicle 4 Visually check the fan for bent cracked or dam aged blades Replace if damaged Check for ad equate clearance between the fan and other components 20 5 Check the fan belt for wear tension and align ment Correct if necessary 6 Check for wear on the friction facing Replace the friction facing if it is worn to a 3 16 inch 4 8 mm thickness or less Also check the facing for signs of oil contamination or burn marks If evi dence of oil or burn marks are found replace the friction facing 7 Connect the battery cables Start the engine and charge the air system to 120 psi 827 kPa Manually engage and disengage the fan clutch Check the fan and the fan clutch from a dis tance Look for vibration fan blade contact fan clutch slippage
100. d dam age the sealants Business Class M2 Maintenance Manual July 2011 47 3 47 Fuel 1 8 2 3 9 4 5 6 10 13 y 11 7 12 10 16 2001 1470414 1 Filter Collar 7 Filter Element 11 Drain 2 Filter Vent 8 Temporary Filter Stud 12 Bottom Plate Collar 3 Vent Seal 9 Check Valve Fuel Inlet 13 Electric Heater optional 4 Filter Cover 10 Fluid Heater Bottom Plate and 5 Cover Seal Seal 6 Filter Spring Fig 3 Davco Fuel Pro 382 Gas detection sensors are located on the cab overhead console and in the engine compartment on the frontwall The sensors are located in high areas where rising gas vapors will pass by or ac cumulate Do not use a high pressure washer steam cleaner or silicone based chemicals on the gas detection sensors as this may permanently disable the sensors When cleaning the vehicle cover the sensors with a plastic covering Keep the sensors covered until the area has been cleared of any cleaning fumes Harsh chemicals and extremely high temperatures may damage the sensor Fuel Tank and Shroud Inspecting See Fig 4 for fuel tank and shroud component locations 1 Inspect the fuel tank outer shell for dents or other signs of damage Inspect the bottom of the tank for deep scratches flat spots or gouges Replace a leaking fuel tank 2 Ensure that the fuel tank is secured to its mount ing brackets and that the mounting brackets are 47 4 B
101. d the pin or the outer steel sleeve e Either bushing end contacts a torque arm pin mounting bolt e There are cracks in the bushing e Part of the rubber bushing extends beyond the outside diameter of the outer bushing sleeve Suspension 1 A SEF 3 A 2 05 27 93 1320022 A Measure the change in gap at this point 1 Equalizer Bracket 3 Pry Bar 2 Equalizer 1 lt NS 05 27 93 f320021a Fig 2 Side View of the Equalizer Fig 1 Torque Arm Bushings Freightliner Spring Tandem Suspension Equalizer Bushing Check 1 Block the frame up enough to take the weight of the chassis off of the springs Attempt to move the equalizer up and down by using a pry bar between the top of the equalizer and the top of the equalizer bracket Apply hand pressure only See Fig 2 If movement at the center of the equalizer exceeds 1 8 inch 3 mm replace the equalizer bushings 2 With the vehicle unloaded attempt to move the equalizer side to side using a pry bar between the equalizer and frame rail Apply hand pressure only See Fig 3 If clearance between the equal 1 2 u 3 1 UR 4 05 27 93 m 5 1820023 A 1 8 inch 8 mm Clearance 1 Frame Fasteners 4 Equalizer 2 Frame Rail 5 Equalizer Bracket 3 Pry Bar Fig 3 Top View of the Equalizer izer assembly and any frame component or fas tener is less than 1 8 inch 3 mm replace th
102. e 00 05 JZorque SpesfTIGatloS s Ol ad Bee ER eda aad 00 18 Verifioallon of INSPCCIONS 90 2 3 e wed qe qae dE td dope aoe RIDES d 00 16 Business Class M2 Maintenance Manual September 2011 General Information 00 Determining Scheduled Maintenance Intervals 00 01 Determining Scheduled Maintenance Intervals Performing regular maintenance will help ensure that your vehicle delivers safe reliable service and opti mum performance A proper maintenance program will also help to minimize downtime and safeguard warranties To determine the correct maintenance intervals for your vehicle you must first determine the type of ser vice or conditions the vehicle will be operating in Most vehicles operate in conditions that fall within one of the three schedules Before placing your ve hicle in service determine whether Schedule l Il or III applies to your vehicle Schedules I III Schedule severe service applies to vehicles that travel up to 6000 miles 10 000 kilometers annually or that operate under severe conditions Examples of Schedule usage are operation on extremely poor roads or where there is heavy dust accumulation constant exposure to extreme hot cold salt air or other extreme climates frequent short distance travel construction site operation city operation such as fire truck
103. e equalizer bushings 52 Inch Multi leaf Spring Component Check No lubrication is required on the 52 inch multi leaf spring rear suspension 32 2 Business Class M2 Maintenance Manual July 2010 Suspension Inspect the stabilizer bar if present for irregular bushing wear or cracks in the brackets Check the rubber helper spring if present for cracks 60 Inch Tapered Leaf Spring Component Check No lubrication is required on the 60 inch tapered leaf spring 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 Freightliner AirLiner Component Clearance Check Check that the air line support brackets are posi tioned so the air lines do not rub against anything Reposition any configurations that could contact and result in friction and wear There must be at least 1 inch 25 mm clearance around the rubber air spring when inflated If the clearance is less than 1 inch 25 m relocate the obstructing parts A CAUTION Failure to relocate obstructing parts could result in damage to the air spring Freightliner AirLiner Component Inspection and Operation Check 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 suspen
104. e Stop Rod 14 5 Grease Fitting 6 Bracket Pin 15 7 Bracket Retainer Pin 16 8 Cotter Pin 3 16 x 1 17 9 Bumper Spring 18 10 Handle Spring NOTE 6000 Series shown 7000 Series fifth wheels use similar parts Bolt Secondary Safety Lock Flat Washer Secondary Safety Lock Bushing Secondary Safety Lock Hex Locknut Pull Handle Bolt Bumper Bushing f311134 19 Bumper 20 Timer Spring 21 Timer 22 Operating Handle 23 Bolt Operating Handle 24 Bushing Operating Handle 25 Hair Pin Cotter 26 Wedge 27 Step Jaw Fig 1 Fontaine Fifth Wheel 31 2 Business Class M2 Maintenance Manual May 2011 Frame and Frame Components 8 Check for loose nuts or bolts on the fifth wheel and the mounting Set a torque wrench to the maximum torque value for the bolt being checked and confirm that the torque is to speci fication Do not loosen the bolt to check the torque See Group 00 for bolt torque specifica tions 9 Check all springs to see if they are securely fas tened and are not deformed WARNING Do not disassemble the fifth wheel to inspect the springs The springs are under extreme pressure and could cause serious injury 10 Check wedge adjustment 10 1 Open the kingpin lock and vertically in sert a 2 inch 50 mm diameter shaft 10 2 Release the lock by tripping the release latch at the bottom of the throat 10 3 Adjust the wedge stop at the end of the wedge to
105. e Systems and Documentation CVI SSD P O Box 3849 Portland Oregon 97208 3849 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
106. e damaged or leaking components and tighten loose fittings 3 Check the brake module for leaks If leaks are found repair or replace the brake module See 42 12 Business Class M2 Maintenance Manual January 2010 Brakes Group 42 of the Business Class M2 Workshop Manual for replacement instructions or take the vehicle to an authorized Freightliner dealer Check the electrical connections and harnesses Make sure the connectors are fully seated and the harnesses are not chafed or cut Repair or replace any damaged harness Disconnect any loose connectors and inspect the terminals for corrosion If corrosion is present replace the ter minals If corrosion is not present reconnect the connector Check the fuse for the hydraulic brake booster pump as follows 5 1 Open the cover to the main power distri bution module PDM 5 2 Pull the fuse in position F6 for the Hydro 42 5 3 Inspect the relay to make sure the fuse is not damaged If the fuse is damaged in stall a new fuse If the fuse is not dam aged install the fuse in position F6 5 4 Close the PDM cover Check the operation of the Hydro Max brake booster as follows 6 1 With the engine off depress the brake pedal the warning light and buzzer should come on and the electric motor should run 6 2 Start the engine and allow the gauges to sweep Depress the brake pedal no warning lights buzzer or electric motor should come on
107. e in the grooves If the engine drive belt needs to be replaced see Group 01 of the Business Class M2 Workshop Manual Belt Tension Inspection Engine drive belts on the Mercedes Benz and Cater pillar engines have belt tensioners that automatically adjust the tension on the belt These belts do not require adjustment Caterpillar 3126 Engine Inspect the belt tensioner for unusual noise and ex cessive looseness or shaking of the pulley bearings See Fig 2 If the belt tensioner requires disassem bly refer to the engine service manual 0742 2000 1011990 Fig 2 Belt Tensioner on Caterpillar 3126 Engine Engine 01 02 Engine Support Fastener Checking Front and rear engine supports for vehicles built from January 2007 require no periodic maintenance Mounts should be inspected when the engine is re moved for service For vehicles manufactured prior to January 2007 perform the following check 1 Check the tightness of the engine support fasten ers at the rear of the engine Tighten the fasten ers 241 Ibf ft 460 N m 2 Check the tightness of the engine support fasten ers at the front of the engine Tighten the fasten ers 136 Ibf ft 327 N m NOTE When the engine is removed inspect the lower and upper isolators for wear Replace the isolators if necessary 01 2 Business Class M2 Maintenance Manual January 2007 Air Intake 09 Index Alphabetical Title of Maintenance Opera
108. e maintenance is performed during this 2 period Because no two vehicles operate under identical conditions maintenance and maintenance intervals will vary Experience is a valuable guide in determin ing the best maintenance interval for any one particu lar operation Every 900 operating hours or 25 000 miles 40 225 km or 3 months 1 Check for moisture in the air brake system by 3 opening reservoir drain valves and checking for the presence of water If moisture is present the desiccant cartridge may require replacement however the following conditions can also cause water accumulation and should be considered before replacing the desiccant 1 1 An outside air source has been used to charge the system This air did not pass 4 through the drying bed 1 2 Air usage is exceptionally high and not normal This may be due to high air sys tem leakage 1 3 In areas where more than a 30 degree range of temperature occurs in one day small amounts of water can temporarily accumulate in the air brake system due to condensation Under these conditions the presence of small amounts of moisture is normal NOTE A small amount of oil in the system is normal and should not be considered as a rea son to replace the desiccant cartridge Some oil at the dryer exhaust is normal 2 Visually check for physical damage such as chaffed or broken air and electrical lines and bro ken or missing parts Brakes Check mount
109. e the jaw and wedge with a screw driver and distribute the grease along the full length of the jaw and wedge mating surfaces See Fig 11 Open and close the fifth wheel sev eral times to further distribute the grease Lightly oil other moving parts in the fifth wheel VAL ee Mem N T Y hmm Jam Poco l c 1 i 04 11 2011 1310884 1 Pull Handle 3 Wedge 2 Jaw Fig 11 Fontaine Fifth Wheel 4 Apply grease to the top plate Spread grease all over the mating surface of the top plate Be sure the grease pockets built into the top plates are full of grease ConMet Simplex Apply a heavy coat of grease to the top plate either through the grease fittings located on the underside of the top plate or by direct application Apply grease directly to the lock mechanism If lubrication fittings are present lubricate the inter face of the steel bracket shoe and bracket trunnion Holland FW35 1 Using a water resistant lithium base grease grease the top plate Frame and Frame Components 2 Using a light oil such as SAE 10W or 20W motor oil lubricate the cam track and pivot See Fig 12 3 Grease the yoke tips locks and the release handle and spring see Fig 13 Grease the mounting bracket supports through the grease fittings A low temp grade grease rated for 30 F 34 C or lower such as Cato Oil and Grease 5213 Craftsman Chemi
110. ealing rings 6 Inspect the end cover for physical damage then inspect all air line fittings for corrosion replace as necessary 7 Clean and inspect the bolt paying attention to the threads and O ring grooves IMPORTANT Use only the grease supplied with Bendix replacement kits 8 Lubricate the O rings bolt O ring grooves seal ing rings and cartridge grooves Lubricate the end cover bore for the bolt 9 Install both O rings on the cartridge bolt then using a twisting motion insert the assembled desiccant cartridge bolt in the end cover 10 Install the desiccant cartridge on the end cover making sure the cartridge is properly seated and flush on the end cover NOTE It may be necessary to rotate the car tridge slightly until the anti rotation lugs are properly aligned and allow the cartridge to rest flush against the end cover 11 Using a wrench or socket tighten the desiccant cartridge bolt 70 Ibf ft 95 N m Do not over torque 12 Before placing the vehicle in service perform the test below 12 1 Close all reservoir drain cocks 12 2 Build system pressure to governor cut out and note that the AD IP air dryer purges with an audible escape of air 12 3 Fan the service brakes to reduce system air pressure to governor cut in Note that the system once again builds to full pres sure and is followed by a purge at the AD IP air dryer exhaust 42 4 Business Class M2 Maintenance Manual Janu
111. ecial attention during regularly scheduled maintenance inspections see Fig 4 No leaks are allowed anywhere in the system If any discrepancies are discovered refer to the engine manufacturer s service literature for re pair instructions 1 Check for leakage at the clamp that attaches the exhaust pipe to the turbocharger exhaust outlet If leakage exists tighten the nut on the clamp to the required torque If leakage persists install a new clamp 2 Check the exhaust pipe bellows and each ex haust seal clamp for leakage wear cracks or 49 4 Business Class M2 Maintenance Manual September 2011 Exhaust 49 other damage See Item A of Fig 4 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 10 20 2006 1490283 A Inspect this area of the canister for dents 1 Marmon Fitting at Inlet from Turbocharger 6 Sensor Housing 2 DOC Temperature Sensor 7 DPF Outlet Temperature Sensor 3 ATD Mounting Band 8 Exhaust Outlet Marmon Fitting 4 DPF Intake Pressure Sensor 9 DPF Outlet Pressure Sensor 5 DPF V Band Mounting Clamps Fig 4 Typical Aftertreatment Device damage Replace damaged components as 8 Check for heat discoloration on the surface of needed If leakage exists at a clamp tighten the the ATD Heat discoloration may indicate internal nuts to the required torque If leakage persists damage especially around the D
112. ecting 49 01 Exhaust System Inspecting Noise Emission Control Petroleum based lubricants only t Schedule II vehicles only Table 7 M2 Maintenance Operations Business Class M2 Maintenance Manual September 2011 00 11 00 M3 Maintenance Operations 00 09 NOTE The M3 Maintenance Operations include the maintenance operations in Table 8 and all of the tions maintenance operations in Table 6 M1 Maintenance General Information Operations and Table 7 M2 Maintenance Opera M3 Maintenance Operations Maintenance Operation No Title of Maintenance Operation 00 07 Perform All M1 Maintenance Operations 00 08 Perform All M2 Maintenance Operations 01 01 Engine Drive Belt Inspecting 26 05 Allison Transmission Fluid and Filter Changing 32 03 Suspension U Bolt Torque Checking 33 03 Draw Key Nut Torque Checking 40 01 Wheel Nut Checking 42 13 Air Brake Inspecting and Leak Testing 46 01 Drag Link Inspecting 47 04 LNG Vacuum Integrity Testing 47 07 CNG Fuel Cylinder Inspecting 83 02 HVAC Air Filter Replacing Replace the HVAC air filter at the recommended interval or every six months Table 8 M3 Maintenance Operations 00 12 Business Class M2 Maintenance Manual September 2011 General Information NOTE The M4 Maintenance Operations include the maintenance operations in Table 9 and all of the 00 M4 Maintenance Operations 00 10 maintenance oper
113. eel plate sharp edges on top the chamfer should be 1 8 7 3 Pry up on the fifth wheel plate below the to 1 4 inch 3 to 6 mm pin boss and measure the vertical move 4 When the wheel is locked the safety latch must ment swing free and fall freely into position See Fig NOTE The bracket connection provides a 5 9 32 inch 7 mm vertical clearance to pro vide cushioning and to avoid downward pin loading while retaining minimum plate lift 7 4 If the plate lift exceeds 5 16 inch 8 mm as a result of wear or rubber deteriora tion install new standard or oversized bracket shoe rubber pads see the Sim plex Fifth Wheel Operating and Mainte nance Manual for replacement instruc tions NOTE Do not measure plate lift immediately after a trailer has been uncoupled from the fifth wheel The rubber may have taken a temporary set which will normally recover after being un 10 29 2007 1311052 coupled for short period of time 1 Lubricant Grooves 3 Release Handle 8 Check the clearance between the kingpin and 2 Safety Latch 4 Mount the jaw of the fifth wheel If the clearance is Fig 5 Holland FWS1 Fifth Wheel greater than 1 8 inch 3 mm dial out the slack using the eccentric jaw pin For detailed instruc 31 4 Business Class M2 Maintenance Manual May 2011 Frame and Frame Components 5 The lever bar and release handle must be in proper alignment See Fig 6 Compare the lever bar and release handle alignment to a new or a pr
114. een the HOT FULL and HOT ADD marks If the fluid level is not within the HOT RUN band add or drain fluid as needed to bring the fluid level within the HOT RUN band See Fig 6 26 06 Mercedes Benz Transmission Fluid Changing and Magnetic Plug Cleaning Draining 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires NOTE Drain the transmission fluid while the transmission is warm 2 Drain the transmission fluid as follows See Fig 7 2 1 Remove the magnetic drain plug from the bottom of the gear case 2 2 Discard the aluminum gasket Business Class M2 Maintenance Manual March 2005 26 7 05 22 2001 3 2 1261102 NOTE The transmission is shown from the left hand side 1 Transmission 3 Drain Plug 2 Fill Plug Transmission sion lubricants and Table 6 for lubricant capacities P 555555 NNNNNNNNNNNS S 2 2 Wee Z 10 05 94 A B f260006b A Full B Low Fig 8 MBT Fluid Level Checking MB Transmission Lubricant Types Manufacturer Type Mobil Mobiltrans SHC DC Fig 7 MBT Drain and Fill Plugs 2 3 Catch the transmission fluid in a suitable container and dispose of it properly 3 Clean the area around the fill plug See Fig 7 for the location of the fill plug 4 Remove the fill plug from the side of the case Discard the aluminum gasket NOTE Use a piece of key stock or
115. el Tool A02 12419 000 1 2 10 14 94 A lt 1250199a A Clearance between release bearing housing and clutch brake must be 1 2 to 9 16 inch 12 7 to 14 3 mm Release Bearing Housing 2 Clutch Brake Fig 10 Release Bearing Travel Measurement NOTE An open end wrench is not recom mended for the following step 6 Adjust the clutch using a 5 8 inch box end or socket wrench on the adjustment bolt See Fig 11 6 1 Insert the 5 8 inch box end or socket wrench through the inspection cover opening 6 2 To begin the adjustment release the ad justment bolt by pressing down on the bolt head NOTE On Easy Pedal 2000 clutches each complete turn of the adjustment bolt repre sents about 0 125 inch 3 mm of release bearing movement On earlier Easy Pedal models each complete turn of the adjust 25 6 Business Class M2 Maintenance Manual June 2006 Clutch 09 15 95 1250309 Fig 11 Adjustment with Kwik Adjust shown with bell 8 housing removed ment bolt represents about 0 02 inch 0 5 mm of release bearing movement Normal wear increases the gap between the release bearing and the transmission 6 3 To decrease the gap If clearance be tween the release bearing housing and the clutch brake is more than 9 16 inch 14 3 mm turn the adjustment bolt clock wise the release bearing moves toward the transmission To increase the gap If clearance between the r
116. elease bearing housing and the clutch brake is less than 1 2 inch 12 7 mm turn the adjustment bolt counter clockwise the release bearing moves to ward the engine 6 4 When the adjustment is complete make sure the adjustment bolt is locked pulled up flush with the mounting bolts After adjusting release the pedal and check the clearance between the release bearing housing and the clutch brake When the adjustment is correct the green end of the tool should go in and the blue should not clearance of 1 2 to 9 16 inch or 12 7 to 14 3 mm Install the clutch inspection cover 25 Business Class M2 Maintenance Manual June 2006 25 7 Transmission 26 Index Alphabetical Title of Maintenance Operation MOP MOP Number Allison Transmission Fluid and Filter 0 26 05 Allison and Eaton Fuller Transmission Breather 26 03 Eaton Fuller Transmission Air Filter Regulator Element Cleaning 26 04 Eaton Fuller Transmission Fluid Changing and Magnetic Plug Cleaning 26 02 Manual Transmission Oil Level 1 26 01 Mercedes Benz Transmission Fluid Changing and Magnetic Plug Cleaning 26 06 Mercedes Benz Transmission Leak 26 07
117. ell Retinax LC Grease Texaco Starplex 2 Table 1 Approved Suppliers of Multi Purpose Lithium Grease 88 Business Class M2 Maintenance Manual July 2010 88 1
118. ely vented before disconnecting or connecting the battery cables Battery acid is extremely harmful if splashed in the eyes or on the skin Always wear a face shield and protective clothing when working around bat teries Damaged chafed or kinked wiring can cause electrical short circuits and lead to fires causing property damage injury or death Clean inspect and maintain wiring and connections carefully 1 Check the tightness of the alternator bracket fas teners tighten the fasteners as needed For torque values see Group 15 of the Business Class M2 Workshop Manual 2 See Group 01 for belt tension specifications Check the alternator drive belt tension using a tension gauge at the belt s longest span Some engines are equipped with more than one alter nator belt check all of them for correct tension Adjust the belt tension if necessary Engines equipped with a serpentine or poly V belt have automatic belt tensioners and do not require belt tension inspection 3 Check that all electrical connections at the alter nator and starter are clean Clean and tighten all charging system electrical connections including the connections at the starter B terminal and ground terminal and where the alternator charg ing cable terminates Trace and inspect all wiring and cables con nected to e Alternator e Starter and depopulation studs e Batteries Magnetic switch 15 e Cab e Jump start studs e Batte
119. en handling clutch hydraulic fluid or bleeding hydraulic lines If you get clutch hydraulic fluid on your skin wash it off as soon as possible 9 Check for signs of leakage at the clutch slave cylinder CAUTION Do not spill clutch hydraulic fluid DOT 4 brake fluid on the cab paint Clean it off immediately if any is spilled DOT 4 brake fluid can damage paint Business Class M2 Maintenance Manual March 2005 26 9 26 9 1 9 2 9 3 9 4 9 5 If leakage is found on the slave cylinder body check the fittings and hose for dam age If leakage is found on the piston seals replace the slave cylinder and bleed the clutch hydraulic system For detailed in structions see Group 25 of the Business Class M2 Workshop Manual If the slave cylinder fittings and or the hose are damaged replace them Check the torque on the slave cylinder mounting capscrews Tighten them 13 Ibf ft 18 N m If any leakage of clutch hydraulic fluid is found check the fluid level in the reser voir and add fluid if needed For detailed procedures see Group 25 of this manual NOTE There are two cover plates on the coun tershaft one at the front and one at the rear 10 Check for signs of leakage at the clutch bell housing If leakage is found check the radial seal on the input shaft the front cover plate on the countershaft inside the clutch bell housing and the rear radial seal on the crankshaft 10 1 10
120. ent system Vehicles domiciled outside of the USA and Canada may not have after treatment equipment depending upon local statutory emissions guidelines IMPORTANT The aftertreatment device ATD which is part of the aftertreatment system ATS requires special attention during regularly scheduled maintenance inspections No leaks are allowed anywhere in the system If any dis crepancies are discovered refer to the engine manufacturer s service literature for repair in structions 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 Business Class M2 Maintenance Manual September 2011 49 1 49 3 If present check the condition of the insulation material around the exhaust pipe between the turbocharger and the ATD 4 Check the 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
121. er wheel nuts in the same sequence 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 See Table 1 for wheel nut torque specifications and see Fig 1 for the tightening sequence 1 1 2 10 8 7 4 6 5 N 6 5 N 4 3 8 7 5 9 B 09 18 2001 1400164 8 Stud Disc Wheel B 10 Stud Disc Wheel Wheel Nut Torque Specifications Thread Torque oiled Size Wheel Manufacturer Ibf ft N m Accuride Corporation M20 x 1 5 p 280 to 330 380 to Alcoa Incorporated 447 Accuride Corporation M22 x 15 p 450 to 500 610 to Alcoa Incorporated 678 Accuride Corporation 450 to 500 610 to 1 1 8 16 Alcoa Incorporated 678 Accuride Corporation 450 to 500 610 to 3 4 16 678 Alcoa Incorporated Table 1 Wheel Nut Torque Specifications Fig 1 Wheel Nut Tightening Sequence Business Class M2 Maintenance Manual December 2001 40 1 Driveline 41 Index Alphabetical Title of Maintenance Operation MOP MOP Number Driveline eonun dau Ebbene d Rupe XR bd d dad rera 41 01 Driveline pure u ccc rr 41 02 Business Class M2 Maintenance Manual December 2001 Driveline 41 01 Drivel
122. ers With Dry Unlubricated Plain Unplated Threads 00 22 Business Class M2 Maintenance Manual September 2011 General Information 00 Torque Specifications 00 18 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 Diameter Pitch Torque Ibf ft N m Torque Ibf ft N m N N N N P No uds a i f230010 1230011 1230012 1230013 6 5 7 7 9 8 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 plated zinc phosphate conversion coated cadmium plated or waxed Table 17 Torque Values for Metric Thread Fasteners With Lubricated or Plated Threads Business Class M2 Mainte
123. ese conditions are found 3 Lift the rear of the vehicle and support the frame on jack stands to unload the suspension compo nents The vehicle is lifted high enough when the beam ends are off of the saddles All jack stands must be of sufficient strength and rigidity to safely support the vehicle Do not perform any work on or around a vehicle that is supported solely by a lifting device Visually inspect the walking beam for cracks or other damage If damage is found replace the walking beam Keep the vehicle supported by the jack stands for the next operation 4 Manipulate the walking beam so that a microme ter vernier or dial caliper can be used to deter mine the wear area thickness on the bottom face See Fig 7 Measurements should be taken a minimum of 1 2 inch 13 mm from the beam flange edges to eliminate any edge wear that may have occurred Subtract the wear area thickness from the nonwear area to determine the amount of wear If the beams show any wear greater than the allowable 0 062 inch 1 5 mm wear a Chalmers wear plate must be installed or the walking beam must be replaced 5 Rotate the restrictor cans 360 degrees and visu ally inspect the cans for cracks severe corro sion and distortion If any of these conditions are present or the restrictor can is missing replace the restrictor can Suspension A A gt B 09 27 95 1320432 A Non wear Area B Wear Area 1 Walking Beam
124. faulty exhaust valve seat exhaust stem O ring or O ring at the top of the piston If the governor does not function as described or if leakage is excessive it is recommended that it be replaced with a new or remanufactured unit or re paired with genuine Bendix parts 42 04 Bosch Hydraulic Brake System Inspecting Before checking lining wear with the wheel removed review the following brake lining exposure warnings 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 Business Class M2 Maintenance Manual January 2010 42 3 42 brakes starting with removal of the wheels and continuing through assembly To minimize the possibility of creating airborne brake lining dust clean the dust from the brake rotor brake caliper and brake assembly using an industrial type vacuum cleaner equipped with a high efficiency filter system Then using a rag soaked in water and wrung until nearly dry remove any remaining dust Do not use compressed air or dry brushing to clean the brake assembly 1 Check lining wear as follows 1 1 Apply the parking brakes Chock the tires to prevent vehicle movement 1 2 Remove one or more of the lining inspec tion plugs and measure brake lining thickness 1 3 On front and rear
125. he magnet on the filter attachment tube 7 Using transmission fluid lubricate the gasket on the filter 8 Using your hand install the filter by turning it clockwise until the filter gasket contacts the con verter housing or cooler manifold Then turn the filter one more complete turn 9 Install the drain plug and sealing washer Tighten the plug 22 to 30 Ibf ft 30 to 40 N m 10 Clean the area around the fill tube and remove the dipstick Using a clean funnel in the fill tube add transmission fluid See Table 3 for approved transmission lubricants and Table 4 for lubricant capacities 11 Check and adjust the fluid level using the proce dure under Checking the Fluid Level MD and HD Series CAUTION To prevent dirt from entering the transmission use only clean containers and fillers for the trans mission fluid Do not use fillers or containers that have been used for water or antifreeze Dirt water or antifreeze could damage the transmission 26 Approved Allison Transmission Lubricants Lubricant Temperature F C All Allison Transmissions Above 22 30 Above 13 25 Castrol TranSynd synthetic Dexron III Lubricants listed in order of preference Do not mix types of oil Table 3 Approved Allison Transmission Lubricants Allison Transmission Lubricant Capacities Fill Capacity Transmission Model qt L On Highway Transmis
126. icants of this type that op RT 40 145 erate continuously at high temperatures must be Rear 25 8 12 2 changed more frequently Forward 30 2 14 3 RT 40 145P Rear 25 8 12 2 A CAUTION RT 40 160 Forward 39 1 18 5 Failure to change the axle lubricant at more fre Rear 34 4 16 3 quent intervals when adverse operating condi Forward 29 3 13 9 tions require could result in axle damage 44 145 Rear 25 1 11 9 Axle Draining 1 Remove the plug at the bottom of the housing and drain the lubricant while the unit is warm Allow enough time for all the old lubricant to drain completely 35 2 Business Class M2 Maintenance Manual December 2001 Rear Axle 2 Clean the drain plugs For magnetic drain plugs a piece of key stock or any other convenient steel slug may be used to short the two magnetic poles and divert the magnetic field NOTE Meritor recommends using magnetic plugs with elements having a minimum pickup capacity of two pounds one kilogram of low carbon steel in plate or bar form Magnets will rapidly lose effectiveness as collected material bridges the gap between the two poles Clean or change the plugs before this occurs It may be necessary to clean or change the plugs one or more times between lubrication change inter vals 3 After cleaning the drain plugs install and tighten the plugs 35 Ibf ft 47 N m Axle Filling 1 With the vehicle on a level surface fill the axle housings to the bottom
127. ig 2 Manual Reset Air Restriction Indicator Go No Go Business Class M2 Maintenance Manual November 2009 09 1 Air Compressor 13 Index Alphabetical Title of Maintenance Operation MOP MOP Number Ar COMPIESSOMNSPSCHhG EE LT T 13 01 Business Class M2 Maintenance Manual December 2001 Air Compressor 13 13 01 Air Compressor Inspecting 1 Inspect the air compressor intake adaptors at both ends of the line for physical damage Re place the adaptors if necessary 2 Inspect the air intake line oil supply and return lines and coolant supply and return lines for tight connections Tighten the connections and re place the lines if needed 3 Check the cooling fins on the air compressor crankcase Clean the fins if they are clogged with debris Business Class M2 Maintenance Manual December 2001 13 1 Alternators and Starters 15 Index Alphabetical Title of Maintenance Operation MOP MOP Number Alternator Battery and Starter 0 1 40 15 01 Business Class M2 Maintenance Manual January 2009 Alternators and Starters 15 01 Alternator Battery and Starter Checking Batteries release explosive gas as a by product of their chemical activity Do not smoke when work ing around batteries Put out all flames and re move any source of sparks or intense heat Make sure the battery compartment is complet
128. ig 7 42 04 16 98 1421910 1 Desiccant Cartridge 2 Cartridge Sealing Ring 3 Threaded Base Post Fig 7 Desiccant Cartridge Replacement IMPORTANT Use only the silicone grease sup plied with Bendix replacement kits 5 Screw the desiccant cartridge onto the body by hand until the seal makes contact with the body Rotate the cartridge clockwise about one full turn Tighten the cartridge firmly 6 Before placing the vehicle in service perform the following tests 6 1 Close all reservoir drain cocks 6 2 Build system pressure to governor cut out and note that the AD IS air dryer purges with an audible escape of air 6 3 Fan the service brakes to reduce system air pressure to governor cut in Note that the system once again builds to full pres sure and is followed by a purge at the AD IS air dryer exhaust 6 4 It is recommended by Bendix that the fol lowing leakage tests be made to ensure that the AD IS air dryer will not cycle ex cessively Compressor unloader mechanism e Governor e Drain cock and safety valve in first supply reservoir Business Class M2 Maintenance Manual January 2010 42 7 42 All air connections leading to and 3 from the first supply reservoir 42 10 Air Dryer AD 9 AD IP AD IS DRM Checking IMPORTANT Review the warranty policy before 1 performing any intrusive maintenance proce dures An extended warranty may be voided if intrusiv
129. ine Inspecting Driveline Inspection Do not service or inspect a driveshaft with the en gine running A rotating driveshaft can cause seri ous personal injury Loose end yokes excessive radial looseness slip spline radial looseness bent shaft tubing or missing plugs in the slip yoke can cause universal joint and bearing defects See Fig 1 for an illustration of the ArvinMeritor Full Round driveline See Fig 2 for an illustration of the ArvinMeritor Easy Service or 1 2 Round driveline 09 19 2001 1410483 Fig 1 Full Round Driveline 09 19 2001 1410484 Fig 2 Easy Service 1 2 Round Driveline 41 1 Check the output and input end yokes on both the transmission and axle for axial looseness Refer to the axle or transmission manufacturer s service information for the correct specifications If loose disconnect the driveshaft For instruc tions see Group 41 of the Business Class M2 Workshop Manual Tighten the end yoke retain ing nut to the proper specification Refer to the axle or transmission manufacturer s service infor mation for the correct specifications 2 Inspect for worn universal joints Apply a vertical force of about 50 pounds to the driveline near the universal joints If there is any movement replace the universal joint For instructions see Group 41 of the Business Class M2 Workshop Manual 3 Examine the slip yoke spline for excessive radial mo
130. ine intake and can cause serious engine damage 1 Park the vehicle set the parking brake chock the wheels 2 Open the hood 02 24 2011 7 Center Pipe Support Brace 1 Clamp 5 Slip Clamp 2 Inlet Pipe 6 CGI Bellows 3 U Clamp 4 Forward Pipe Support Brace 10 1 1490456 8 Center Pipe 9 Clamp 10 Outlet Pipe Fig 5 CAT EPA07 Exhaust Installation with CGI Bellows 49 6 Business Class M2 Maintenance Manual September 2011 Exhaust 3 Remove the right side inner fender splash shield as needed 4 Remove the CGI piping between the engine and aftertreatment device ATD See Fig 6 5 On the workbench remove the CGI bellows from the exhaust piping Do not damage the piping NOTE The following step and its substeps is to be done without the bellows installed This will align the pipes so that the bellows can be installed correctly 6 Install the CGI piping without CGI bellows and align piping 6 1 Attach the aft CGI pipe to the ATD 6 2 Attach the forward pipe to the en gine NOTICE When the CGI pipes and bellows are installed there should be approximately 3 4 inch 19 mm clearance from the main bellows Contact between the bellows could result in an exhaust leak which in this case may allow ingestion of contaminants into the engine causing engine damage 6 3 Use a straightedge
131. iner Trucks reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation Descriptions and specifications contained in this publication provide no warranty expressed or implied and are subject to revision and editions without notice Refer to www Daimler TrucksNorthAmerica com and www FreightlinerTrucks 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 2001 2011 Daimler Trucks North America LLC All rights reserved No part of this publication in whole or in part may be translated reproduced stored in a retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Daimler Trucks North America LLC Daimler Trucks North America LLC is a Daimler company Daimler Trucks North America LLC Servic
132. ing bolts for tightness Torque 30 to 35 Ibf ft 41 to 47 N m Perform the operational and leakage tests listed below Operational and Leakage Tests Check all lines and fittings leading to and from the air dryer for leakage and integrity Repair any leaks found Build system pressure to governor cutout and note that the dryer purges with an audible es cape of air Watch the system pressure and note the pressure fall off for a 10 minute period If the pressure drop exceeds 1 psi minute from either service reservoir for a single vehicle or 3 psi minute for a tractor trailer inspect the vehicle air systems for sources of leakage and repair them Refer to troubleshooting information in Bendix service literature Check for excessive leakage around the purge valve with the compressor in the loaded mode compressing air Apply a soap solution to the purge valve exhaust port and observe that leak age does not exceed a 1 inch 25 mm bubble in 1 second If the leakage exceeds the maximum specified refer to troubleshooting information in the Bendix service literature Build system pressure to governor cutout and note that the dryer purges with an audible es cape of air Fan the service brakes to reduce System air pressure to governor cut in Note that the system once again builds to full pressure and is followed by a dryer purge If the system does not follow this pattern refer to troubleshooting information in the Bendix service
133. ing or forcing the belt during removal or installation Check the belt for ply separation Oil grease or belt dressing can cause the belt to fall apart in layers Repair any oil or coolant leaks that are affecting the belts before replacing the drive belts Do not use belt dressing on any belt Check for uneven ribs on serpentine poly V belts Foreign material in the pulley will erode the undercord ribs causing the belt to lose its grip ping power Check the belt for a jagged or streaked sidewall Jagged or streaked sidewalls are the result of 07 12 2001 f150010b 1 Glazing 3 Separating Layers 5 Streaked Sidewalls 2 Tensile Break 4 Uneven Ribs 6 Cracks Fig 1 Drive Belt Replacement Conditions Business Class M2 Maintenance Manual January 2007 01 1 01 foreign material such as sand or gravel in the pulley or a rough pulley surface 6 Check the drive belts for cracks Small irregular cracks are usually indication of an old belt 7 Visually inspect the pulleys for excessive play or wobble Excessive play or wobble indicates a failure of the pulley bearing Check for belt squealing or squeaking Replace the bearings as necessary NOTE If it is difficult to distinguish the location of a supposed bearing noise obtain a stetho scope and place it on the component being checked not the pulley to isolate the area from outside interference 8 Inspect all pulleys for foreign material oil or greas
134. ink side to side to check for axial movement in the ball stud end If it is loose replace the drag link See Group 46 of the Business Class M2 Workshop Manual for replacement instructions If there is 1 8 inch 3 mm movement or more do not drive the vehicle until the drag link is replaced 46 02 Power Steering Fluid Changing WARNING Fill only with approved clean fluid Failure to use the proper fluid could cause seal deterioration and leaks Fluid leaks could eventually cause loss of power steering assist This could lead to an acci dent resulting in personal injury or property dam age Wear eye protection when changing the fluid and filter 1 Apply the parking brakes and chock the rear tires 2 Place a drain pan under the power steering res ervoir 46 3 Remove the retaining ring from the reservoir See Fig 1 2 3 4 MAX HOT 1 MIN COLD 10 19 2001 1461917 1 Power Steering Reservoir 2 Retaining Ring 3 Filter Cover 4 Return Hose Fig 1 Power Steering Reservoir 4 Remove the filter and filter cover from the reser voir Drain the fluid from the filter into the drain pan Leave the filter hanging over the drain pan 5 Remove the bolts nuts and washers that attach the power steering reservoir to the mounting bracket Drain the power steering fluid from the reservoir but do not remove the supply line to the reservoir 6 Using bolts nuts and washers attach the reser
135. ite Slack Adjuster Lubricating Meritor Slack Adjuster Lubricating Power Steering Fluid Level Inspecting Power Steering Gear Lubricating e Drag Link Lubricating Door Seals Lubricating Hood Rear Support Lubrication 25 05 Clutch Adjusting Manually Adjusted Clutches 26 03 Allison and Eaton Fuller Transmission Breather Checking 31 02 Fifth Wheel Inspecting 32 01 Suspension Inspecting 33 04 Tie Rod End Inspecting 33 05 Wheel End Inspection and Maintenance 6 000 Pound and 8 000 Pound Steer Axles with Oil Lubricated Hubs 35 02 Axle Breather Checking 41 01 Driveline Inspecting 42 01 Air Brake System Valve Inspecting 42 02 Bendix AD 9 Air Dryer Desiccant Replacing with an oil coalescing desiccant cartridge t 42 04 Bosch Hydraulic Brake System Inspecting Business Class M2 Maintenance Manual September 2011 00 9 00 General Information M1 Maintenance Operations 00 07 M1 Maintenance Operations Maintenance Operation No Title of Maintenance Operation Bendix AD IP Air Dryer Desiccant Replacing with an oil coalescing 42 05 2 desiccant cartridge Bendix AD IS Air Dryer Desiccant Replacing with an oil coalescing 42 09 desiccant cartridge T 42 11 Brake Lines and Fittings Inspecting Hydraulic Brakes 42 15 Brake Inspecting 47 03 LNG Fuel System Inspecting 47 06 CNG High Pressure Fuel Filter Element 49 02 CAT Bellows and Piping Inspection 83 01 Air Conditioner Inspecting
136. kes with the supply control valve and park control valve trailer supply knob pushed in the trailer knobs in When the park control valve knob control coupling should deliver air during is pulled out the trailer supply knob should the brake application Build ah Comeon Tm 20 On trucks only u CHEQUE 20 1 Start the engine and charge the air sys down the engine tem until governor cut out 42 10 Business Class M2 Maintenance Manual January 2010 Brakes 20 2 Shut down the engine and leave the park ing brakes released 20 3 Completely drain the primary reservoir 20 4 Make a modulated service brake applica tion Both front and rear brakes should modulate At a steady full brake applica tion the pressure should not drop more than 10 psi 69 kPa within five minutes 21 Drain all reservoirs and remove the gauges from the service reservoirs Close the reservoir drain cocks 22 Remove the chocks from the tires 42 14 Foot Control Valve E 6 Inspecting and Lubricating This procedure will be performed during M5 mainte nance intervals e Severe service 32k e Short haul transport 128k e Long haul transport 160k 1 Remove the brake valve from the vehicle See Section 42 09 Subject 110 of the Business Class M2 Workshop Manual for instructions 2 Remove the roll pin from the brake pedal pivot pin See Fig 8 3 Remove the brake pedal pivot pin 4
137. l is the clearance between the rear surface of the release bearing housing and the forward surface of the clutch brake disc This dis Business Class M2 Maintenance Manual June 2006 25 3 25 Clutch 10 12 11 2001 1050582 1 Clamp Mounting Bolt 1 4 20 6 Hydraulic Hose 2 Plated Steel Washer 7 Slave Oylinder 3 Locknut 1 4 20 8 Bleed Valve 4 Bell Housing Standoff Bracket 9 Bell Housing 5 Slave Oylinder Standoff Bracket 10 Slave Cylinder Mounting Capscrew M8 Fig 6 Clutch Slave Cylinder tance must be maintained between 1 2 and 9 16 inch 1 Remove the clutch inspection cover from the bell 12 7 and 14 3 mm housing See Fig 8 25 4 Business Class M2 Maintenance Manual June 2006 Clutch 25 12 11 2001 1 8 Capscrew and Washer 2 Pedal Unit Mounting Plate 3 Reservoir Pedal Unit Master Cylinder Hydraulic Hose 1050581 7 Cup Bracket 8 Standoff Bracket 9 Mounting Bolt M10 Fig 7 Clutch Master Cylinder 2 Slide the clutch brake tight against the transmis sion input shaft bearing cap IMPORTANT Release bearing travel tool A02 12419 000 is available through the PDCs The fork at one end of the tool has green tape on it and has two 0 50 inch 12 7 mm diameter tips the fork at the other end has blue tape on it and has 0 56 inch 14 3 mm diameter tips See Fig 9 3 Measure the release bearing travel See Fig 10 for
138. l the fill plug p n 000908 020001 and a new aluminum gasket p n N 00763 024105 Tighten the fill plug 42 Ibf ft 57 N m 26 07 Mercedes Benz Transmission Leak Checking 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 26 8 Business Class M2 Maintenance Manual March 2005 Transmission 2 Check for signs of leakage at the breather See Fig 9 i 5 05 22 2001 8 7 6 f261101 NOTE The transmission is shown from the left hand side 1 Shift Lever Cap Seal Breather Output Shaft Radial Seal Countershaft Cover Plate Transmission Fluid Fill Plug Transmission Fluid Drain Plug Gear Case Seals Clutch Slave Cylinder 0 og c gt Input Shaft Radial Seal Fig 9 MBT Leak Check 2 1 If leakage is found check the breather for a missing cap Replace the cap if neces sary 2 2 Check the fluid level at the fill plug If the level is too high correct the fluid level 3 Check for signs of leakage at the cap seal on the shift lever If the cap seal is damaged replace it 4 Check for signs of leakage at the radial seal on the output shaft If leakage is found remove the output yoke end yoke and replace the seal For procedures see Section 26 02 Subject 120 of the Business Class M2 Workshop Manual NOTE There are two cover plates on the coun tershaft one at the front and one at the rear 5 Check for signs of leakage at the rear cover pl
139. lator is tightened securely 6 4 Inspect the pressure gauge for damage Ensure that the gauge sight glass is clear and legible 7 Repair or replace any leaking or damaged vapor izer components 47 04 LNG Vacuum Integrity Testing WARNING Natural gas is highly flammable See the safety precautions listed in Chapter 16 of the Business Class M2 Driver s Manual or Group 47 of the Business Class M2 Workshop Manual Failure to observe these precautions could lead to the igni tion of the natural gas which could cause serious bodily injury or death 1 Ensure the fuel tank is between 50 and 75 per cent full 2 Check the fuel tank pressure gauge Fig 5 Item 8 to ensure that pressure is within the normal range of 120 to 150 psi 827 to 1034 kPa 3 Inspect the fuel tank for signs of frost spots or outer surface sweating Frosting or condensation on the outer surface of the fuel tank may indicate a loss of vacuum 4 Check for a large variance in temperatures be tween the fuel tank and the fuel tank shroud A large variance in temperatures between the fuel tank and the shroud may indicate a loss of vacuum 5 Operate the vehicle for ten minutes Shut down the engine apply the parking brakes and note the time 47 6 Business Class M2 Maintenance Manual July 2011 Fuel 47 06 29 2009 2 t470536 1 Pressure Relief Device 5 Coolant Inlet Line 9 Pressure Gauge 2 Fuel Inlet Line 6
140. 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 Business Class M2 Maintenance Manual September 2011 49 3 49 Exhaust 09 16 2009 1490354 1 DPF Inlet Temperature Sensor 6 DPF Outlet Temperature 9 SCR Outlet Temperature 2 DOC Inlet Temperature Sensor Sensor Sensor 3 DOC Inlet Pressure Sensor 7 DPF Outlet NOx Sensor 10 SCR Sensor Box 4 DPF Sensor Box 8 SCR Inlet Temperature Sensor 11 SCR Outlet NOx Sensor 5 DPF Outlet Pressure Sensor Fig 3 2HV Two Box ATS Sensor Locations e Aftertreatment Device ATD a muffler like can ister that houses a DPF DOC and sensors e Diesel Particulate Filter DPF a filter that col lects and holds particulate matter soot and ash Diesel Oxidation Catalyst DOC oxidizes hy drocarbons and reduces NOx e Sensors detect temperatures and pressures in the ATS Inspection To meet EPA07 emissions regulations for vehicles domiciled in the USA or Canada engines manufac tured after December 31 2006 are equipped with an emission aftertreatment system Vehicles domiciled outside of the USA and Canada may not have after treatment equipment depending upon local statutory emissions guidelines IMPORTANT The aftertreatment device ATD which is part of the aftertreatment system ATS requires sp
141. lly entering vehicle identification data PartsPro is an electronic parts catalog system showing the specified vehicle s build record EZWiring makes Freightliner Sterling Western Star Thomas Built Buses and Freightliner Custom Chassis Corporation products wiring drawings and floating pin lists available online for viewing and printing EZWiring can also be ac cessed from within PartsPro Business Class M2 Maintenance Manual May 2011 1 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 Business Class M2 Maintenance Manual May 2011 Page Description For an example of a Business Class M2 Maintenance Manual page see Fig 1 Introduction 12 06 2001 Group Title Group Number Release Date moom A B C Y Y Cooling 20 20 01 Coolant
142. n hose on the bleed valve of the slave cylinder 2 Open the slave cylinder bleed screw Observe the flow of clutch hydraulic fluid through the drain hose When bubbles no longer appear in the fluid close the slave cylinder bleed screw 3 Disconnect the transparent hose Tighten the bleed screw 88 Ibf in 1000 and install the cap on the slave cylinder bleed valve 4 Close the valve on the bleed tank of the pres sure bleed adaptor Remove the pressure bleed adaptor 5 Check the fluid level in the reservoir If neces sary add or remove clutch hydraulic fluid to bring the fluid level to the MAX line Install the reser voir lid A CAUTION When removing fluid from the reservoir use a clean tool that is used only for brake fluid Using a tool contaminated with oil or chemical residue will destroy hydraulic system parts and cause the System to malfunction 6 Depress the clutch pedal a few times There should be resistance over the full pedal stroke 7 Check the entire system for leaks Tighten the connections between the components if neces sary Check the fluid level in the reservoir again Make sure the reservoir lid is tight 9 Lower the hood and remove the chocks from the front and rear tires 25 05 Clutch Adjusting Manually Adjusted Clutches NOTE This procedure is only required for ve hicles equipped with non synchronized transmis sions and manually adjusted clutches Release bearing trave
143. nance 4 M4 every 80 000 128 000 Maintenance 5 M5 every 160 000 256 000 For Schedule vehicles equipped with an hourmeter use maintenance intervals based on hours of operation rather than mileage Table 1 Maintenance Schedules 00 2 Business Class M2 Maintenance Manual September 2011 General Information 00 Maintenance Intervals for Schedule 1 00 03 Maintenance Intervals for Schedule I Maintenance Interval Service Date Hours 1st IM and M1 100 2nd M1 200 3rd M1 300 4th M1 and M2 400 5th M1 500 eth M1 600 7th M1 700 8th M1 M2 and M3 800 9th M1 900 10th M1 1000 11th M1 1100 12th M1 and M2 1200 13th M1 1300 14th M1 1400 15th M1 1500 16th M1 M2 M3 and M4 1600 17th M1 1700 18th M1 1800 19th M1 1900 20th M1 and M2 2000 21st M1 2100 22nd M1 2200 23rd M1 2300 24th M1 M2 and M3 2400 25th M1 2500 26th M1 26 000 41 600 2600 27th M1 27 000 43 200 2700 28th M1 and M2 28 000 44 800 2800 29th M1 29 000 46 400 2900 30th M1 30 000 48 000 3000 31st M1 31 000 49 600 3100 32nd M1 M2 M3 M4 and M5 32 000 51 200 3200 Table 2 Maintenance Intervals for Schedule Business Class M2 Maintenance Manual September 2011 00 3 00 General Information Maintenance Intervals for Schedules Il and Ill 00 04 Maintenance Intervals for Schedules Il and lll
144. nance Manual September 2011 00 23 Engine 01 Index Alphabetical Title of Maintenance Operation MOP MOP Number Enone Drive 4o pes eod xc trado de EDENE QR AR RE E kama lea 01 01 Engine Support Fastener CheckinGnas 55 dun de Rc ARP NOR RS 01 02 Business Class M2 Maintenance Manual January 2007 Engine 01 01 Engine Drive Belt Inspecting Worn or loose drive belts may cause premature pul ley bearing failure or engine overheating Too much or too little tension on the belt may result in exces sive or premature belt wear Replace the engine drive belt if any conditions described under Visual Inspection are found Visually inspect all drive belts then perform the belt tension inspection To inspect a belt gently twist the belt to view the belt sidewalls and the underside of the belt When replacing a matched set of belts al ways replace both belts at the same time Matched belts must be from the same manufacturer Visual Inspection For examples of drive belt conditions see Fig 1 01 Inspect the belt for glazing Shiny sidewalls are evidence of glazing which is caused by friction created when a loose belt slips in the pulleys It can also be caused by oil or grease contamina tion on the pulleys Check for tensile breaks or breaks in the cord body Cuts in a belt are usually caused by for eign material in the pulley or by pry
145. ness Check for distorted or frayed rubber at the beam end bushings If the bushings are damaged replace them Check that the ends of the equalizer beam are not lower in the beam hanger If the equalizer beam ends appear lower use a jack to raise each beam end then check for movement of the inner metal of the rubber end bushing See Fig 4 Movement cannot be corrected by tightening the fastener because parts could be damaged If there is movement replace the rubber end bushings and all connecting parts 05 27 93 1 Beam Hanger 2 Equalizer Beam 320039 3 Jack Fig 4 Raising the Beam End After repairs to the suspension check the fastener torque after the vehicle has been in service for 2500 miles 4000 km Tighten the adapter type beam end connection nut 210 to 240 Ibf ft 285 to 325 N m See Fig 5 Do not overtorque 32 4 Business Class M2 Maintenance Manual July 2010 Suspension 32 1 4 5 A I 2 N Jing Z gt I N AU rrr LEE EP N 1 lt 44 7 V Z 2 3 f aR LD A Sen 3 LL P 4 2 l CCC C i 05 27 93 f320112a 22222 wd s A Minimum gap of 3 8 inch 9 5 mm 3 4 1 Forward no 1 Spring Hanger 05 27 93 f320110a 2 Spring Eye Pin f NOTE Do not use the three piece adapter without the 3 Rear no 2 Spring Hanger intermediate tube 4 Rear no 3 Extension 1 Nut 4 Inner Metal of
146. nstructions under the MOP number to perform the required maintenance In addition to the maintenance operations required for the maintenance interval perform all the daily maintenance procedures in Chapter 11 Pretrip In spection and Daily Maintenance in the Business Class M2 Driver s Manual Business Class M2 Maintenance Manual September 2011 00 1 00 General Information Maintenance Schedules 00 02 Maintenance Schedules Maintenance Intervals Schedule Maintenance Interval Frequency Mileage km Hours Initial Maintenance IM first 1000 1600 100 Maintenance 1 M1 every 1000 1600 100 Schedule for vehicles that travel up to Maintenance 3 M3 every 8000 12 800 800 6000 miles 10 000 km annually Maintenance 4 4 every 16 000 25 600 1600 Maintenance 5 M5 every 32 000 51 200 3200 Initial Maintenance IM first 8000 12 000 Schedule II Maintenance 1 M1 every 8000 12 000 short haul transport Maintenance 2 M2 every 16 000 24 000 for vehicles that travel up to 60 000 miles 100 000 km Maintenance 3 M3 every 32 000 48 000 annually Maintenance 4 M4 every 64 000 96 000 Maintenance 5 M5 every 128 000 192 000 Initial Maintenance IM first 10 000 16 000 Schedule lll Maintenance 1 M1 every 10 000 16 000 long haul transport Maintenance 2 M2 every 20 000 32 000 for vehicles that travel over m 60 000 miles 100 000 km Maintenance 3 M3 every 40 000 64 000 annually Mainte
147. onnecting the control rods use your hand to attempt to move each of the control rod ends up down in and out If there is any move ment examine the control rods for wear or dam age Replace if necessary Inspect the rubber bushings for cracks or cuts Check for any shifting of the barpin 4 Check for cracks in the metal components and welds NOTE The Freightliner AirLiner Suspension is manufactured at numerous weight ratings up to 46 000 pounds The control rod on the 46 000 pound rated suspension is larger and is fas tened differently than on other applications Freightliner TufTrac 1 Inspect the suspension spring assemblies for pitted cracked broken or abnormally bent Business Class M2 Maintenance Manual July 2010 32 3 32 leaves and extreme rust If any of these condi tions exist replace the spring assembly WARNING Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring as sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Re placement of only the visibly damaged part s is no assurance that the spring is safe On front spring assemblies if cracks or breaks exist in the two top leaves a loss of vehicle control could occur Failure to replace a damaged spring assem bly could cause an accident resulting in property damage serious personal injury or death IMPORTANT On multi leaf suspensions closely ins
148. operly operating lever bar and release handle Replace any bent or misaligned lever bar or re lease handle 01 13 2011 1 V __ E 2 Lever Bar 1310470 Release Handle Fig 6 Lever Bar and Release Handle Alignment Check all cotter pins for cracking or damage Re place any cotter pin that shows any signs of damage Check all mounting bolts for signs of fatigue and tighten them to the proper torque For torque specifications see Group 00 Inspect all angles plates and brackets for cracks or other damage Replace cracked worn or damaged parts with new parts Replace all loose mounting bolts with 5 8 11 SAE grade 8 bolts grade C locknuts and hardened washers Do not re use bolts nuts and washers on fifth wheel mountings After inspecting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease See MOP 31 03 for lubrication instructions Holland FW35 1 2 Disconnect the tractor from the trailer For in structions see the Business Class M2 Driver s Manual Thoroughly steam clean all fifth wheel compo nents before inspection Check for cracks in the fifth wheel assembly mounting brackets and mounting parts 31 Check the fastener torques on the fifth wheel assembly and fifth wheel mounting Tighten bolts and nuts as needed Replace missing or dam aged bolts Inspect the fifth wheel for bent worn damaged and missing parts repla
149. over See Fig 10 Save the capscrews for reinstallation 6 Slowly open the bleed valve on the manifold to relieve remaining fuel pressure within the sys tem See Fig 11 Business Class M2 Maintenance Manual July 2011 47 9 47 Fuel 4 Bike SPD AI aan 3 e Y 05 04 2010 1 Fuel Panel Access Cover 2 Capscrews qty 2 3 Wiring Harness 4 Pressure Relief Valve and Cap Noo 1470557 Coolant Outlet Line Coolant Inlet Line Fuel Inlet Line to fuel cylinders Fuel Outlet Line to engine M 1 N 05 04 2010 1470558 1 Coolant Inlet Port 9 Fuel Fill Port 2 Coolant Outlet Port 10 Filter Housing 3 Pressure Relief Valve 11 Filter Bowl 4 Pressure Regulator 12 Filter Drain Plug 5 Wiring Harness 13 Solenoid Valve 6 Manifold Bleed Valve 14 Fuel Line To Oylinders 7 Manifold 8 Manual Fuel Shutoff Valve Fig 11 CNG Fuel Panel Components 12 Close the bleed valve on the manifold and open the manual fuel shutoff valve on the fuel panel 13 Open the fuel cylinder shutoff valves Fig 10 CNG Fuel Panel Assembly IMPORTANT Some pressure may remain in the fuel system between the solenoid valve and the engine Use caution when loosening fittings as a small amount of gas may leak out 7 Puta clean receptacle under the filter assembly Using a 1 1 4 inch wrench unscrew the filter bowl from
150. p prime the fuel water separator 8 1 Loosen the vent plug Then operate the primer pump until the fuel purges at the vent plug 8 2 Close the vent plug Business Class M2 Maintenance Manual July 2011 47A 47 9 Start the engine and check for fuel leaks 10 Shut down the engine and correct any fuel leaks Davco Fuel Pro 232 and 233 Replace the fuel water separator element Fig 2 only when the filter element is completely covered Fuel In the event of an emergency when the filter needs replacement but a Davco filter is not available a temporary filter can be used For instructions see Chapter 14 of the Business Class M2 Driver s Manual 1 2 3 8 4 9 5 10 6 11 12 7 10 16 2001 1470415 1 Filter Vent 6 Filter Spring 10 Check Valve Fuel Inlet 2 Vent Seal 7 Filter Element 11 Drain 3 Filter Collar 8 Temporary Filter Stud 12 Electric Filter Preheater 4 Filter Cover 9 Fuel Outlet optional 5 Cover Seal Fig 2 Davco Fuel Pro 232 and 233 47 2 Business Class M2 Maintenance Manual July 2011 Fuel Diesel fuel is flammable and can ignite if exposed to an open flame intense heat or other ignition source Do not drain fuel near or expose fuel vapor to open flame or intense heat Exposure to open flame or intense heat could start a fire pos sibly resulting in personal injury or property dam age When working on a fuel system have a fire extinguisher within easy reach
151. pde 46 01 Drag Linke FP rm 46 05 Power Steering Filter 0 2 4 46 06 Power Steering FIG Changing aus aed fec d Rd ir ud Lco d cet erg 46 02 Power Steering Fluid Level 46 03 Power Steering Gear Eubtricating i miii m erede ped Fed eps 46 04 Business Class M2 Maintenance Manual June 2002 Steering 46 01 Drag Link Inspecting All steering system components are critical for safe operation of the vehicle Failure to maintain the steering system as specified may result in loss of steering control which could lead to per sonal injury and property damage Have someone turn the steering wheel from left to right Check for movement between the ball stud end at both the pitman arm and the steering arm Also check if the ball stud nut is loose If the ball stud end is loose replace the drag link If the ball stud nut is loose replace the nut and cotter pin See Group 00 for proper torque specifications Inspect the boot of the drag link at both the pitman arm and the steering arm end for cracks splits or other damage Replace the boot as needed See Group 46 of the Business Class M2 Workshop Manual for drag link removal and installation instruc tions Grasp the drag link near the pitman arm end and move the drag l
152. pect each component of the leaf spring as semblies including the brackets U bolts and related parts 2 Inspect the brackets for cracks in the castings Inspect the V rod tower welds for cracking or other signs of damage Also check for contact between the frame rail and the upper axle clamp brackets If contact exists check the V rod bush ing for wear Check the V rod fastener torques 3 Inspect the rubber center bearing and spring tip pads for excessive wear including de lamination of the rubber to metal shim interface and distor tion and degradation of rubber 4 Inspect the V rods and lower control rods for wear and looseness 4 1 Without disconnecting the control rods use your hand to attempt to move each of the control rod ends up down in and out If there is any movement examine the control rods for wear or damage Re place if necessary 4 2 Inspect the rubber bushings for cracks or cuts 4 3 Check for any shifting of the barpin 4 4 Check for cracks in the metal compo nents and welds 5 Check all fasteners for looseness 6 Inspect the shock absorbers for oil leaks and worn rubber bushings Replace the shock ab Suspension sorbers and or rubber bushings if wear or dam age is noted Hendrickson Suspension Inspection Inspect the suspension assembly for wear cracks and damage to its components Replace the compo nent s if any wear cracks or damage exists Check all fasteners for tight
153. 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 49 02 CAT CGI Bellows and Piping Inspection On vehicles with CAT engines NOTICE A leak in the piping including the bellows will allow unfiltered air and contaminants into the engine intake and can cause serious engine dam age NOTE Because the CGI bellows is covered with a metal mesh it is difficult to see cracks or damage that may cause a leak 1 Inspect the CGI bellows and piping for evidence of damage or leakage See Fig 5 If the bellows is damaged or leaking replace it See 49 03 for the replacement procedure Exhaust 2 Check the CGI piping and each exhaust seal clamp for leakage wear cracks or damage Re place damaged components as needed If leak age exists at a clamp tighten the nuts to the re quired 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 If any of the components is damaged or leaking replace it See 49 03 for the replacement procedure 49 03 CAT CGI Bellows Replacement On vehicles with CAT 07 compliant engines re place the CGI bellows at the M3 maintenance inter val to prevent a later failure NOTICE A leak in the CGI piping including the bellows will allow unfiltered air and contaminants into the eng
154. ponent locations 05 05 2010 1 1470533 Pressure Control Regulator Vapor Shutoff Valve Fuel Fill Hose Secondary Relief Valve red cap Fuel Fill Fitting 12 Fuel Level Sender Box 7 Primary Relief Valve 8 Tank Pressure Gauge 9 Fill Vent Fitting 10 Excess Flow Valve 11 Fuel Shutoff Valve liquid Fill Check Valve Fig 5 Fuel Tank Plumbing Components Use a bubble solution to check for leaks while per forming the following visual inspection 1 Check the following components for signs of damage or leaks Pressure control regulator e Vapor shutoff valve Secondary relief valve e Primary relief valve and threaded connec tions e Excess flow valve e Fuel shutoff valve Business Class M2 Maintenance Manual July 2011 47 5 47 e Fill check valve 2 Inspect the fuel fill line for signs of damage kinked or crushed piping or chafing 3 Ensure the red cap is present on the secondary relief valve 4 Inspect the fuel tank pressure gauge for cracks in the sight glass Ensure the indicator needle is present and in working condition Inspect the gauge face for accuracy and legibility 5 Inspect all vent lines for kinks and signs of leaks or damage 6 Replace leaking or damaged fuel lines Repair or replace le
155. possible incompatibility Do not use fluid addi tives friction modifiers extreme pressure gear fluids or multiviscosity lubricants Cold Check Clean all dirt away from around the end of the fluid fill tube before removing the dipstick CAUTION Do not allow foreign matter to enter the transmis sion Dirt or foreign matter in the hydraulic system may cause undue wear of transmission parts make valves stick and clog passages It is important to check the fluid level cold to deter mine if the transmission has a sufficient amount of 26 6 Business Class M2 Maintenance Manual March 2005 Transmission fluid to be safely operated until a hot check can be performed 1 Park the vehicle on a flat level surface 2 Apply the parking brakes and chock the rear tires 3 Run the engine for at least one minute 4 Shift from DRIVE to NEUTRAL and then shift to REVERSE to fill the hydraulic system 5 Shift to NEUTRAL and allow the engine to idle at 500 to 800 rpm 6 With the engine running at idle remove the dip stick from the tube and wipe it clean 7 Insert the dipstick into the tube then remove the dipstick 8 Check the fluid level reading and repeat the check procedure to verify the reading If the fluid level is within the COLD RUN band the transmission may be operated until the fluid is hot enough to perform a HOT RUN check If the fluid level is not within the COLD RUN band add or drain fl
156. pres sure setting of the piece number being used Cut in pressure is 105 psi 724 kPa NOTE If the governor cover is marked nonad justable and the adjusting stem has been sheared off this is a non serviceable governor and it must be replaced with a new or remanu factured unit 2 Never condemn or adjust the governor pressure settings unless they re checked with an accurate test gauge or a dash gauge that s registering ac curately If the pressure settings of the D 2 gov ernor are inaccurate or it s necessary that they be changed the adjustment procedure follows 2 1 Remove the top cover from the governor 2 2 Loosen the adjusting screw locknut 2 3 To raise the pressure setting turn the ad justing screw counterclockwise to lower the setting turn the screw clockwise Be careful not to overadjust Each 1 4 turn of the adjusting screw raises or lowers the pressure setting approximately 4 psi 28 kPa 2 4 When proper adjustment is obtained tighten the adjusting screw locknut and install the top cover The pressure range between cut in and cut out is not adjust able Cut In Position Apply soap solution around the cover and to the ex haust port Slight bubble leakage is permitted Exces sive leakage indicates a faulty inlet valve or faulty lower piston O ring Cut Out Position Apply soap solution around the cover and to the ex haust port Slight bubble leakage is permitted Exces sive leakage indicates a
157. r Plus Kingpin Lubrication knuckle and between the lower axle beam end and the knuckle See Fig 2 6 Remove the chocks from the tires 33 02 Tie Rod End Lubricating This procedure applies to all tie rod ends on Meritor nondrive steering axles 1 Park the vehicle with the wheels in the straight ahead position Turn off the engine apply the brakes and chock the rear tires 2 Wipe clean the zerk fitting and the seal or boot NOTE Synthetic lubricants are not approved for tie rod end lubrication 3 Using a grease gun apply a multipurpose grease NLGI grade 1 or 2 to the zerk fitting until all the old grease is purged from the boot Dis colored old grease should come out of the purge holes near the boot crimp or bellows area Apply grease until all the old grease is purged from the boot NOTE If using an air pressure grease gun do not exceed 150 psi 1035 kPa 4 If the tie rod end is designed for lube service and it does not accept grease perform the following substeps 4 1 Remove the zerk fitting 4 2 Inspect the threaded zerk fitting hole in the tie rod end and remove any obstruc tions 4 3 Install a new zerk fitting 4 4 Apply lubrication to the new zerk fitting 5 Remove the chocks from the tires 33 03 Draw Key Nut Torque Checking Axles With Unitized Wheel Ends Check the torque of the nut that holds the draw key on the side of the knuckle The torque should be 30 to 45 Ibf ft 41 to
158. r deliv ery to the ultimate purchaser or while it is in use 00 Noise Emission Controls 00 15 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 tampering are the acts listed below 1 Removal of engine noise deadening panels in cluding cab or hood liners 2 Removal of or rendering inoperative the engine speed governor so as to allow engine speed to exceed the manufacturer s specifications 3 Removal of or rendering inoperative the fan clutch including bypassing the control on any thermostatic fan drive to cause it to operate con tinuously 4 Removal of the fan shroud Removal of or rendering inoperative exhaust sys tem components including exhaust pipe clamp ing 6 Removal of air intake system components Business Class M2 Maintenance Manual September 2011 00 17 00 General Information Verification of Inspections Log 00 16 Verification of Inspections Log The Verification of Inspections Log should be filled out each time the vehicle s noise emission controls are maintained or repaired Verification of Inspections Log Group 20 Verification of Inspections Log Group 20 Engine Cooling Radiator Date Mileage Repair Description Cost Repair Facility Verification of Inspections Log Group 49 Verification of Inspections
159. raighten a bent cross tube Doing so could result in damage to the axle Be sure to replace the cross tube with an original equipment cross tube with the same length diam eter and thread size as the existing cross tube 5 Check the cross tube for cracks or other dam age If the cross tube is bent or damaged re place the cross tube 6 Check the clamps for damage If a clamp is damaged replace the clamp Replace the entire cross tube assembly if either clamp is welded to the cross tube 33 7 Check for proper installation of the tie rod end clamp to the cross tube Make sure that the tie rod ends are threaded in the cross tube past the clamps and the slots at the cross tube ends 8 Check the zerk fittings for damage If a zerk fit ting is damaged replace it Some tie rod ends have no zerk fittings because they are not greaseable Do not install a zerk fitting on a nongreaseable tie rod end 9 Check that the cotter pin is in place If it is not tighten the tie rod end nut to one of the following specs depending on the size of the stud e 7 8 14 160 to 300 217 to 406 N m e 1 14 250 to 450 Ibf ft 339 to 610 N m 1 1 8 12 350 to 650 475 to 881 N m e 1 1 4 12 500 to 675 678 to 915 N m 10 Check the steering arm bolts for a minimum torque of 300 Ibf ft 406 N m If the steering arm bolt torque has fallen below this specification remove the bolt clean all the threads and
160. railer Electrical Connector Lubricating In some cases failure of trailer cables occurs due to intrusion of chloride based road deicing chemicals into the trailer connector Once inside the connector the chloride based chemicals corrode the brass ter minals and create bridging between positive and ground terminals NOTE The use of soap is not recommended for cleaning the electrical connector as some soaps may increase the corrosion process 31 9 Business Class M2 Maintenance Manual May 2011 Suspension Title of Maintenance Operation MOP Suspension Inspecting SUSPENSION Lubricating uncus due opi ro tert esate Suspension U Bolt Torque Checking 32 Index Alphabetical MOP Number Business Class M2 Maintenance Manual July 2010 Suspension 32 01 Suspension Inspecting 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 Business Class M2 Workshop Manual for in structions WARNING 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 d
161. re from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause seri ous personal injury CAUTION The radiator cap currently installed may not be the same one installed when the vehicle was built If the radiator cap must be replaced make sure that it is the correct cap for the cooling system of the vehicle Because the radiator cap pressure rating affects the operating temperature of the engine installing an improperly rated radiator cap may have adverse effects on the cooling system and engine operating temperatures This could cause premature engine wear or damage 1 Using a radiator cap tester check the pressure cap to see if it maintains pressure to within 10 percent of the pressure rating marked on the cap If it doesn t replace the cap Make sure that the replacement radiator cap is correctly rated for the cooling system of the vehicle 2 There is a second valve in the radiator cap that opens under vacuum This prevents the collapse of hoses and other parts that are not internally supported when the system cools Inspect the vacuum relief valve to be sure it is not stuck 3 Make sure that the cap seals properly on the coolant filler neck seat and that the radiator cap gasket is not damaged On vehicles with screw on caps with O rings make sure that the O ring is not cracked or deteriorated Replace the cap if the gasket shows deterioration or dam age 20 20
162. required for the equalizer beam end bushings or equalizer beam rubber center bushings 32 Hendrickson Spring Eye Pins RT and RTE Series Apply multipurpose chassis grease at the spring eye pin grease fitting located on the inboard side of the spring eye pin until clean grease appears at both ends of the spring eye pin See Fig 6 Freightliner TufTrac The TufTrac suspension is maintenance free and de signed so that lubrication is not required There are no provisions for lubrication and attempting to lubri cate the suspension could shorten component life 32 03 Suspension U Bolt Torque Checking Check the U bolt torque of both the front and rear axles where applicable 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 and apply the parking brakes Chock the tires to prevent the vehicle from moving 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 1 for U bolt torque specifications Turn the wrench in a clockwise motion looking up until the torque wrench clicks Spring Assembly U Bolt High Nut Torque Values Size Torque Ibf ft N m Stage 1 Hand tighten Stage 2 60 81 ts Stage 3 200 271 Stage 4 180 to 230 245 to 313 Stage 1 Hand tighten 3 416 Stage 2 60 81 Stage 3 200 271 Stage
163. rews to ease installation 7 Remove the upper mounting bracket strap cap Screw and remove the air dryer from the vehicle 8 Place the air dryer on a bench and remove the remaining six capscrews 12 washers six nuts and the air dryer housing See Fig 1 Discard the nuts Remove the end cover to housing O ring 9 Clamp the desiccant cartridge in a vise 42 Clamping the end cover or housing in a vise could seriously compromise the air dryer s ability to hold air pressure which could cause a failure in the brake system resulting in property damage personal injury or death 10 Twist the end cover counterclockwise to release the cartridge from the end cover Rotate the end cover until it completely separates from the des iccant cartridge NOTE A substantial torque up to 50 Ibf ft 68 N m may be necessary to remove the desic cant cartridge 11 Remove and discard desiccant cartridge O rings NOTICE Dirt or obstructions in the O ring grooves can cause an O ring failure that will result in an air leak 12 Lubricate new O rings with grease supplied in the kit and install them in the end cover 13 Install the desiccant cartridge on the end cover Turn the cartridge clockwise until the desiccant cartridge makes contact with the end cover 14 Place the desiccant cartridge in a vise and turn the end cover clockwise an additional 180 to 225 degrees to fully tighten the desiccant cartridge to the end cover
164. ry isolation relays e Battery shutoff switches Check wires and cables for wear chafing kinks discolored insulation or loose clamps or ties Find the cause of any problems and repair re place and reroute wires and clamps as neces sary Check the alternator wiring for missing insulation kinks and heat damage Replace or repair as needed On the bundled cable that runs from the batteries to the starter ensure that tie straps are installed at least every 12 inches 300 mm Replace any missing tie straps and add tie straps where spacing between them exceeds 12 inches 300 mm Ensure that all cables have sufficient slack to allow for engine movement and that there is no pressure on any wiring connectors If any convoluted tubing is damaged check the wiring inside it Replace any damaged or missing convoluted tubing Clean the cable connector terminals with a wire brush See Group 54 of the Business Class M2 Workshop Manual for troubleshooting instruc tions and for adjustment repair or replacement instructions 9 1 Clean and tighten the battery ground cable terminal and clamps 9 2 Inspect the retainer assembly or battery hold downs and the battery box Replace worn or damaged parts Remove any cor rosion with a wire brush and wash with a weak solution of baking soda and water Rinse with clean water and dry To pre vent rusting paint the retainer assembly 9 3 Check for and remove any foreign objects
165. s Class M2 Workshop Manual for instructions Check all fasteners for tightness See Group 00 of this manual for torque values A CAUTION Failure to replace the suspension crossmember or gussets if they are cracked worn or otherwise damaged could result in damage to the vehicle chassis Freightliner Spring Shock Absorber Check NOTE Shock absorbers are optional on spring suspensions Make sure that the shock absorber brackets are tight and that the shock absorber is not striking or rubbing on the frame or some other part of the chassis Check the rubber mounting bushings and replace if worn Inspect the shock absorber for oil leakage which is defined as being drips of oil on the sides of the shock absorber If the shock absorber is worn or damaged replace it with a new one Freightliner 23K 26K 30K Spring Single and Tandem Radius Rod Bushing Check 1 Without detaching the torque arms use your hand to attempt to move each of the radius rod ends up down in and out If there is any move ment replace the torque arm Business Class M2 Maintenance Manual July 2010 32 1 32 2 Inspect the weld seams between the torque arm tube and the shorter bushing tubes If there are cracks replace the torque arm Do not weld the torque arm for any reason 3 Inspect the rubber bushing ends See Fig 1 Re place the torque arm for any of the following rea sons e There are gaps between the rubber bush ing an
166. s Class M2 Workshop Manual 20 04 Hybrid Electric System Coolant Changing 1 Disconnect the 12 volt vehicle batteries to isolate the high voltage power source 2 Drain the hybrid radiator as follows 2 1 Place a large container under the hybrid radiator 2 2 Remove the cap from the coolant reser voir 2 3 If equipped with a petcock open it at the bottom of the hybrid radiator to drain the coolant 2 4 Disconnect the lower radiator hose and drain the remaining coolant 2 5 Close the petcock if equipped 3 Install the lower radiator hose Fill the system with a coolant mixture of 50 per cent ethylene glycol and 50 percent water 5 Using ServiceRanger activate the HEV coolant pump to purge any air that may be trapped in the 1 ServiceRanger is a service and diagnostic software program available from Eaton Corporation See the Eaton website www roadranger com for more information Engine Cooling R adiator System Run the cooling pump until the air bubbles stop appearing in the reservoir tank Check the coolant level and add coolant as needed The system should be filled to the mid level of the reservoir 20 4 Business Class M2 Maintenance Manual July 2009 Clutch 25 Index Alphabetical Title of Maintenance Operation MOP MOP Number Clutch Adjusting Manually Adjusted 25 05 Clutch Hydraulic Fluid Ohahgilig s soo ote a P
167. s from the tires 46 03 Power Steering Fluid Level Inspecting 1 Apply the parking brakes and chock the rear tires 2 With the engine cool the fluid level should be between the MIN COLD and MAX HOT lines with the engine off 3 Add or remove fluid as necessary to bring the fluid level to the line between the MIN COLD and MAX HOT lines See Table 1 for approved power steering fluids 4 With the engine hot the fluid level should be at the MAX HOT line with the engine off 5 Add or remove fluid as necessary to bring the fluid level to the MAX HOT line See Table 1 for approved power steering fluids 6 Remove the chocks from the tires Steering 46 04 Power Steering Gear Lubricating TRW THP Series CAUTION Apply grease to the sector shaft with only a hand type grease gun Use of a high pressure power grease gun will supply grease too quickly and could affect the high pressure seal contaminating the hydraulic fluid Using a hand type grease gun apply NLGI Grade 2 or 3 multipurpose chassis grease until it starts to come out past the sector shaft seal 46 05 Drag Link Lubricating 1 Using a clean rag wipe all dirt from both drag link grease fittings 2 Using a pressure gun apply grease at the grease fittings until old grease is forced out of the socket Use multipurpose chassis grease NLGI Grade 2 896 12 hydroxy lithium stearate grease or NLGI Grade 1 696 12 hydroxy lithium Stearate gre
168. sion components and loss of vehicle control possibly causing personal injury or death or property damage 1 Chock the front tires Raise the rear of the ve hicle so the tires just clear the ground and the suspension is fully extended Place safety stands under the vehicle frame 2 Squeeze all air springs to check for complete deflation 32 3 Inspect the air spring piston for cracks chips and broken areas Check the air bag for rips tears and holes Verify that the air spring assem bly does not leak 4 Check the axle connection welds beam seat to equalizing beam and axle adapter to axle for cracks If welds are cracked grind them out and reweld the parts 5 Move the axle up and down while checking for signs of looseness due to worn parts at the front pivot connections Replace any worn parts 6 Inspect the shock absorbers for oil leaks and worn rubber bushings Replace the shock ab sorbers and or rubber bushings if wear or dam age is noted 7 nspect the stabilizer bar if so equipped for ir regular bushing wear or cracks in the brackets The stabilizer bar is optional on 10 000 and 15 000 pound AirLiner suspension systems 8 Remove the safety stands and lower the rear of the vehicle to the ground Run the engine until air pressure of at least 100 psi 689 kPa is maintained throughout the system 9 Check that all air springs are inflated Freightliner AirLiner Control Rod Check 1 Without disc
169. sions 1000 2000 2400 Series standard sump 15 14 1000 2000 2400 Series shallow sump HD MD Series HD4060 4560 standard sump 36 34 HD4060 4560 shallow sump 26 25 t MD3060 3066 3560 standard sump 19 18 MD3060 3066 3560 shallow sump 10 5 10 Quantities listed are approximate Add the recommended amount of fluid as listed under fill capacity then perform a hot check and add fluid as needed Do not overfill t Add 3 quarts 3 liters if equipped with a PTO Table 4 Allison Transmission Lubricant Capacities 1 Park the vehicle on a level surface and apply the parking brakes 2 Operate the vehicle until the transmission reaches normal operating temperature 160 to 200 F 71 to 93 C 3 Clean the area around the drain plug and the transmission fluid pan Place a drain pan under the transmission and remove the drain plug Ex amine the fluid as it drains If only the filter is being changed do not drain the fluid 4 Remove the 12 mounting bolts six each from the two filter covers NOTE A lot of fluid will drain when the filter covers are removed 5 Remove the filter covers O rings and two square cut seals from the transmission See Fig 5 Business Class M2 Maintenance Manual March 2005 26 5 26 Ws X NY Z a N 2 2 3 4 4 1 1 5 08 25 95 1260317 1 Filter Cover 2 Filter Element
170. t 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 S CD N Z QN 1230002 1230003 mE 1230005 SS m N 01 2 SE Me nd 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 7 16 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 8 14 402 545 427 579 350 475 568 770 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 15 Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threads Business Class M2 Maintenance Manual September 2011 00 21
171. the correct dimension to measure Using both ends of the release bearing travel tool check this gap as follows Business Class M2 Maintenance Manual June 2006 25 5 Clutch we 2 s Q 05 5 22 B we K 06 22 2005 1 1261355 1 Clutch Inspection Cover 2 Hydraulic Slave Cylinder 3 Transmission Fig 8 View from Underneath the Vehicle Position the tool so that the legs of the fork at the blue 0 56 inch 14 3 mm end straddle the transmission input shaft If the tool fits loosely the gap is too wide and adjustment is needed Go to the next step If the blue 0 56 inch 14 3 mm end can be in serted in the gap then try to insert the green 0 50 inch 12 7 mm end If the green end of the tool can t be inserted in the gap adjustment is needed Go to the next step If the green end of the tool fits snugly or loosely then no adjustment is needed Nothing more needs to be done Install the clutch inspec tion cover 4 Turn the engine flywheel until the lockstrap is aligned with the clutch inspection cover opening 5 Release the clutch by depressing the pedal Block the pedal in the released position or have someone assist you by holding the pedal down during the adjustment procedure A B 03 26 96 1580133 A Green End 0 50 inch or 12 7 mm B Blue End 0 56 inch or 14 3 mm Fig 9 Release Bearing Trav
172. ting When possible always check the torque of the nut not the bolt head This will give a true torque reading by eliminating bolt body friction When checking the torque of frame fasteners in spect the frame for cracks and other damage Set a click type torque wrench to the maximum torque of the fastener you are checking Apply pressure until the torque wrench clicks Do not loosen the bolt to check the torque See the applicable torque table in Group 00 for torque specifications NOTICE Make sure frame fasteners are properly tightened Continued vehicle operation with loose fasteners could result in bracket or frame damage NOTE Engine supports on vehicles built from January 2007 do not require checking Inspect the fasteners at the following locations axle stops equalizer brackets engine trunnion supports exhaust brackets fifth wheel legs fifth wheel mountings e frame crossmembers and gussets front frame brackets front suspension spring brackets fuel tank brackets radius rods rear suspension spring brackets rear engine supports 31 e shock absorbers all other frame fasteners Any component that shows signs of cracking or dam age must be repaired or replaced See the applicable group in the Business Class M2 Workshop Manual for repair or replacement information 31 02 Fifth Wheel Inspecting WARNING All fifth wheel maintenance adjustment and re building must be done only by
173. tion MOP MOP Number Air Cleaner Element Inspection and 09 01 Business Class M2 Maintenance Manual November 2009 Air Intake 09 01 Air Cleaner Element Inspection and Replacement 09 Restriction of air flow through the air cleaner element is measured at the tap in the air cleaner outlet Check the restriction indicator at the air cleaner or in the cab if the vehicle is equipped with a dash mounted restriction gauge Vehicles may be equipped with either a manual reset restriction indicator with graduations Fig 1 or a go no go restriction indicator without graduations Fig 2 1 Inspect the air restriction indicator to see if air restriction equals or exceeds the maximum al lowable restriction For instructions see the Business Class M2 Driver s Manual 2 f necessary replace the air cleaner element For air cleaner element replacement instructions see Group 09 of the Business Class M2 Workshop Manual 3 Inspect the air cleaner housing for cracks leaks or any other damage If the air cleaner housing or element is damaged replace it 4 Reset the air restriction indicator 5 Each time the air cleaner housing is replaced perform the procedures in MOP 13 01 04 08 2005 f090431 08 07 2007 1090452 Fig 1 Manual Reset Air Restriction Indicator Graduated F
174. to align the pipes so that the pipe ends that attach to the bel lows are parallel and concentric NOTICE When shortening the pipe s it is critical to leave a minimum of 1 inch 25 4 mm of straight pipe on the end of each CGI pipe to allow for pipe insertion and clamp clearance Failure to do this could result in an exhaust leak which in this case may allow ingestion of contaminants into the en gine causing engine damage 7 Once the pipes are aligned measure the pipe gap between the CGI pipes and record the dis tance See Fig 7 Ref A The existing pipe gap is designed at 10 inches 254 mm A 10 75 inches 273 mm pipe gap is required for the replacement CGI bellows and clamps This requires or both of the pipes to be shortened 10 11 12 13 14 15 16 17 18 49 Using a yellow paint pen mark the pipes 1 5 inches 38 mm in from the end of each pipe These two marks will be used to center the bel lows between the two pipes Once the pipes are correctly aligned and sepa rated at the correct distance secure the aft CGI pipe to the ATD and to any CGI pipe support brackets Remove the forward pipe from the truck Slide the slip clamp with the retaining ring and graphite gasket ring on the aft CGI pipe See Fig 8 for proper installation Slide the new bellows onto the aft CGI pipe as far as it will go See Fig 9 Ref A Measurement A should be at least 7
175. turer s established inspection criteria NOTICE Do not use a high pressure washer or steam cleaner on natural gas fuel system plumbing com ponents as this can introduce moisture and con taminants into the threads of the fittings and dam age the sealants Gas detection sensors are located on the cab overhead console and in the engine compartment on the frontwall The sensors are located in high areas where rising gas vapors will pass by or ac cumulate Do not use a high pressure washer steam cleaner or silicone based chemicals on the gas detection sensors as this may permanently disable the sensors When cleaning the vehicle cover the sensors with a plastic covering Keep the sensors covered until the area has been cleared of any cleaning fumes Harsh chemicals and extremely high temperatures may damage the sensor Use a bubble solution to check for leaks while per forming the following inspection 1 Inspect the fuel cylinders for dents or other signs of damage Replace any leaking fuel cylinders 2 Ensure that the fuel cylinders are secured within the fuel cylinder storage box 3 Ensure that the fuel cylinder storage box is se cured to the frame Inspect for any signs of looseness If necessary tighten the storage box mounting bolts 160 Ibf ft 217 N m See Fig 7 Fuel Ui it i 05 04 2010 1470555 1 Frame Rail 2 CNG Fuel Oylinder
176. ub so that the fill plug is down and drain a small sample of hub oil into a plastic container that is free of debris especially any metallic particles Then use a magnet to probe the sample Note whether there is substantial metallic debris present and compare the oil color to new approved oil Ac ceptable oil will have a color similar to new oil and have no water or metal contaminants If the oil is not acceptable inspect the bearings for damage Replace the bearings as needed and install the hub per Section 33 01 Subject 100 of the Business Class M2 Workshop Manual Front Axle If the oil is acceptable check the oil level If it is not full see Fig 5 fill it to the bottom of the vent plug hole with approved lubricant see Table 1 Lubricant Specifications Over the Road Service Applications Lubricant SAE Lubricant Type Viscosity Grade Synthetic Drive Axle Lubricants or Equivalent with SAE Specification J2360 or Military Specification MIL L 2105E Table 1 Lubricant Specifications Over the Road Service Applications 75W 90 33 4 Business Class M2 Maintenance Manual July 2009 Rear Axle Title of Maintenance Operation MOP Axle Breather Checking de drm kusaya qg a sani Axle Lubricant Changing and Magnetic Plug Cleaning Axle Lubricant Level Checking 35 Index Alphabetical MOP Number Business Class M2 Maintenance Manual December
177. uid DOT 4 brake fluid in the clutch hydraulic system Do not mix different types of brake fluid The wrong fluid will damage the rubber parts of the system caus Clutch ing loss of clutch function and the risk of serious personal injury CAUTION Do not allow the fluid level in the reservoir to go below the MIN line If too much air enters the hy draulic system will not operate correctly and the clutch could be damaged If the fluid level is below the MIN line fill the reser voir with DOT 4 brake fluid until the level reaches the MAX line See Fig 5 1 3 lt P 12 10 2001 1 Reservoir Cap 2 Reservoir 3 Pedal Unit 1250580 4 Master Cylinder 5 Hydraulic Hose 6 Slave Oylinder Fig 5 Clutch Components 25 04 Clutch Hydraulic Fluid Changing Replace the clutch hydraulic fluid every two years to ensure clutch function is reliable and correct Use the procedures below Fluid replacement must be done at an authorized Freightliner service facility Flushing 1 Shut down the engine 2 Apply the parking brakes chock the front and rear tires and raise the hood 25 2 Business Class M2 Maintenance Manual June 2006 Clutch Clutch hydraulic fluid DOT 4 brake fluid is haz ardous It may be a skin irritant and can cause blindness if it gets in your eyes Always wear safety glasses when handling clutch hydraulic fluid or bleeding hydraulic lines If you get clut
178. uid as needed to adjust the fluid level to the middle of the COLD RUN band See Fig 6 12 01 97 A Cold Run Band 270002 B Hot Run Band Fig 6 Dipstick Markings CAUTION Do not fill above the COLD RUN band if the trans mission fluid is below normal operating tempera ture As fluid temperature increases so does the fluid level Filling above the COLD RUN band when the transmission is below normal operating temperature may result in an overfilled transmis sion which causes fluid foaming and aeration 26 Fluid foaming and aeration cause transmission overheating and erratic shifting NOTE Perform a hot check at the first opportu nity after the normal operating temperature 160 to 200 F 71 to 93 C has been reached Hot Check 1 Park the vehicle on a flat level surface Apply the parking brakes and chock the rear tires Shift the transmission to NEUTRAL Operate the engine at idle 500 to 800 rpm until normal operating temperature is reached Check that the sump temperature is 160 to 200 F 71 to 93 C Check that the converter out temperature is 180 to 220 F 82 to 104 C 4 With the engine idling remove the dipstick from the tube and wipe it clean 5 Insert the dipstick into the tube then remove it 6 Check the fluid level reading and repeat the check procedure to verify the reading Safe oper ating level is within the HOT RUN band on the dipstick The HOT RUN band is betw
179. umber E S 7L 5050 25 IT LT 72 01 Business Class M2 Maintenance Manual June 2002 Doors 72 01 Door Seals Lubricating NOTE Only the door seals require lubrication Do not lubricate the door latches or hinges They come from the manufacturer with lifetime lubrication and require no maintenance Lightly coat the door seals with a lubricant that is safe for rubber 72 Business Class M2 Maintenance Manual June 2002 72 1 Heater and Air Conditioner Title of Maintenance Operation MOP Air Conditioner Inspecting HVAC Air Filter Replacing 83 Index Alphabetical MOP Number Business Class M2 Maintenance Manual December 2001 Heater and Air Conditioner 83 01 Air Conditioner Inspecting Refrigerant Compressor Inspection 1 With the vehicle parked on a level surface apply the parking brakes and chock the tires 2 Operate the heater and if equipped with an air conditioner the air conditioner to check for proper operation in all modes 3 Open the hood Check the condition of the refrigerant compres sor clutch assembly If the friction surface of the pulley shows signs of excessive grooving due to belt slippage replace both the pulley and the drive plate 5 Inspect the refrigerant compressor drive belt for damage If needed replace the drive belt 6 Check the tightness
180. usiness Class M2 Maintenance Manual July 2011 Fuel 05 29 2009 1470534 Fuel Fill Fitting Fuel Outlet Line liquid Primary Relief Vent Line relief valve Fill Vent Fitting vent Shroud Cover Shroud Cover Latches Fig 4 Fuel Tank Outer Shell secured to the frame Inspect for any signs of looseness Ensure that all rubber isolator straps are present and secure Look for signs of abrasion between the fuel tank and mounting brackets Inspect the fuel fill fitting for signs of damage or leaks Ensure the fuel fill cap is present and in good condition and the fitting is mounted se curely on the tank Inspect the fuel outlet line and fitting for signs of leaks or damage Inspect the primary relief vent and pipe away line for damage kinks chafing or loose connections Inspect the fill vent fitting for signs of damage Inspect the shroud cover for dents or other signs of damage Ensure that the shroud cover latches are in working condition and fasten the shroud cover securely to the tank Replace leaking or damaged fuel lines Repair or replace leaking or damaged fittings 47 Plumbing Components Inspecting See Fig 5 for plumbing com
181. vement See Fig 3 If excessive radial loose ness exists between the slip yoke and the tube shaft replace the slip yoke and the tube shaft For instructions see Group 41 of the Business Class M2 Workshop Manual 1410486 09 19 2001 Y Fig 3 Examine the Slip Yoke Spline 4 Examine the shaft for damaged or bent tubing Carefully remove any foreign material such as mud or dirt on the shaft 41 02 Driveline Lubricating Driveline Lubrication The Full Round and Easy Service drivelines require periodic lubrication of the universal joints and slip Business Class M2 Maintenance Manual December 2001 41 1 41 Driveline yoke splines See Fig 4 for the areas that need lu brication See Table 1 for approved lubricants Approved Lubricants Lubricant and Specification Lubricant Brands Phillips Petroleum Philube MW EP2 Grease Exxon 5160 Amalie All Purpose Grease with Moly L1 2M Universal joint slip joint and spline grease Shell Super Duty Special FF must meet ArvinMeritor Specification O 634 B NLGI Grade No 2 Lithium 12 Hydroxy Maraihon Maralube Molycode 529 Stearate with Molybdenum Disulfide Shell Moly Poly Grease Kendall L424 Grease Amoco Super Chassis Grease Ford Specification M1C 75B or part number PN C1AZ 19590 Table 1 Approved Lubricants 09 19 2001 1410485 Fig 4 Lubrication Areas for Full Round and Easy Service Drivelines
182. when the low 448 kPa On vehicles equipped with single check valves where the air dryer is not attached pressure warning turns off to the reservoir the primary reservoir should not 6 Record governor cut out pressure and air dryer lose pressure pol dati 16 a service brake application The rear axle 7 Reduce service air pressure by applying and re brakes should apply and release and the brake leasing the service brakes several times and lights should illuminate Fee On tractors with the trailer supply knob pushed 8 Charge the air system to governor cut out shut in the trailer control coupling should deliver air down the engine and apply the parking brakes during the brake application 9 Allow pressure to stabilize for one minute 17 Push the trailer air supply valve knob in With the 10 Observe the installed service reservoir gauges secondary reservoir still completely drained The pressure should not drop more than 10 psi slowly drain the primary reservoir and record the 69 kPa within five minutes pressure at which the knob automatically comes out This pressure should be 20 to 45 psi 138 to 11 If necessary start the engine and charge the air 310 kPa system Shut down the engine and release the parking brakes 18 Close the drain cocks recharge the system and 2 completely drain the primary reservoir On ve 12 Make and hold a full service brake application hicles equipped
183. worn down to the securing bolts It is normal for out side edges of the plate to pucker slightly this does not affect performance 7 Check the fifth wheel adjustment Using a lock tester lock and unlock the fifth wheel several times Make sure that the locking mechanism works properly The lock is properly adjusted if the wheel locks and unlocks easily each time and the lock tester rotates freely The lock is too loose if you feel fore aft play when pulling and pushing on the lock tester handle See Fig 9 Ref A The lock is too tight if the lock tester does not rotate freely in the lock See Fig 9 Ref B 8 If the lock is improperly adjusted correct as fol lows If the lock is too tight loosen the jam nut turn the adjustment bolt clockwise one full turn then reset the jam nut Lock and unlock the mecha nism several times to test Repeat if necessary See Fig 10 If the lock is too loose loosen the jam nut turn the adjustment bolt counterclockwise one full turn then reset the jam nut Lock and unlock the 09 01 2009 1311099 Checking for fore aft play Rotating tester in lock Engage hook Pull push handle fore aft Check for movement of kingpin in lock Disengage hook Push pull handle inboard outboard Rotate lock tester rommoog9 Fig 9 Jost Fifth Wheel Adjustment mechanism several times to test Repeat if nec essary See Fig 10 9 If the fifth wheel is equipped with

BUSINESS CLASS M2 MAINTENANCE MANUAL

Contents

Download Pdf Manuals

Related Search

Related Contents