Home

00 - JustAnswer

1. 1 26 01 Recreational Vehicle Chassis Maintenance Manual January 2010 Transmission 26 01 Transmission Breather Checking Transmission housing breathers must remain clear A plugged breather could result in pressure build up which could cause lubricant leakage If the breather is plugged clean or replace it See Fig 1 Check more often if the vehicle is operating under very dusty conditions 05 27 93 1260007 Fig 1 Transmission Breather 26 02 Allison MD MH Series Transmission Fluid Level Checking Cold Check IMPORTANT After replacing the transmission fluid or changing the filter s it is important to check the fluid level cold to determine if the transmission has a sufficient amount of fluid to be safely operated until a hot check can be performed 1 Acold check may be made when the sump tem perature is 60 to 104 F 15 to 40 C 2 Run the engine for at least one minute to clear the fluid system of air 3 With the engine running wipe the dipstick clean and check the fluid level Any level within the 26 COLD RUN lower band is satisfactory for oper ating the vehicle See Fig 2 If the level is not within the COLD RUN band add or drain fluid until it reaches the middle of the COLD RUN band 359 Cx SD f 25 Oz gt Oo 11 16 2000 1270074 Fig 2 Transmission Dipstick 4 Perform
2. 00 04 30 000 Mile or 24 Month 00 05 45 000 Mile or 36 Month 00 06 60 000 Mile or 48 Month 00 07 6000 Mile or 6 Month Initial 00 03 General Maintenance Schedule 00 01 Customary Conversion Tables s uou qase Okeke Sor xime 00 10 Noise Emission Controls 00 08 Torque Specitications Tables a risi euis eee eee eee he deme ER dpa de ex e EEE OREN Rw OE re 00 11 Vehicle Maintenance Schedule 00 02 Verification Of Inspections Log is dass quc d st oed Bub RSS ne ebb gid Rehan EVERE Awe has 00 09 Recreational Vehicle Chassis Maintenance Manual February 2012 General Information 00 General Maintenance Schedule Information 00 01 General Maintenance Schedule Information Performing regular maintenance on your vehicle will help ensure that your vehicle delivers safe reliable service and optimum performance for years to come Failure to follow a regular maint
3. 00 2 Recreational Vehicle Chassis Maintenance Manual February 2012 General Information 00 Vehicle Maintenance Schedule Table 00 02 Maintenance Operation Procedures and Schedule Maintenance Operation Number and Description Maintenance Interval in Miles x 1000 15 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 Maintenance Interval i n Kilome ters x 1000 he 72 96 120 145 169 193 217 241 265 290 314 38 362 386 410 434 458 Mai nten ance Interval in M onths 96 48 60 72 84 96 108 120 132 144 180 192 204 216 228 33 02 Tie Rod End Lubricating and Inspecting 33 03 All Axle Alignment Checking 33 04 Wheel Bearing Removal Cleaning Checking Repacking and Adjusting 33 05 Oil Filled Hubs Oil Level Checking 33 06 Oil Filled Hubs Oil Changing 35 01 Axle Lubricant Checking 35 02 Axle Lubricant Changing 35 03 Axle Breather Checking 35 04 Oil Filled Hubs Oil Level Checking Tag Axle 35 05 Oil Filled Hubs Oil Changing Tag Axle 40 01 Wheel Nut Checking 40 02 Wheel Cleaning and Polishing 41 01 Driveline Inspecting and Lubricating 42 01 Brake System Valves Inspecting 42 02 Air Dryer Inspecting 42 03 Air Dryer Desiccan
4. AD200 RS17 19 9 3 4 248 AD200 RS15 9 3 8 238 ADTB280 rear 17 1 4 438 Airliner 15k rear 8 3 4 222 AD123 rear 18 457 Some vehicles have a different shock location When this is the case the vehicle will have a 55 degree wheel cut Ride height for these vehicles should be set at 10 1 2 inches 267 mm Table 2 Height Control Valve Adjustment Measurements 32 03 Neway Suspension Inspecting WARNING Inspect the components and check their operation as described below Failure to perform these in spections and checks could result in separation of worn suspension components and loss of vehicle control possibly causing personal injury or death or property damage 1 Chock the front or the rear tires Working at the front of the vehicle or at the rear of the vehicle Suspension raise the vehicle so that the tires just clear the ground and the suspension is fully extended Place safety stands under the vehicle frame Squeeze all air springs to check for complete deflation It may take ten minutes for the pres sure to bleed down from the air spring See Fig 2 If any air springs remain partially or fully inflated see Group 32 of the Recreational Ve hicle Chassis Workshop Manual or take the ve hicle to an authorized Freightliner dealer Inspect the air springs for cracks tears or other dam age Inspect each air spring for wear at the pedestal connection Inspect
5. 1 40 15 01 Recreational Vehicle Chassis Maintenance Manual April 2010 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 completely vented before disconnecting or connecting the battery cables Battery acid is extremely harmful if splashed in the eyes or on the skin Always wear a face shield and protective clothing when working around bat teries Damaged chafed or kinked wiring can cause electrical short circuits and lead to fires causing property damage injury or death Clean inspect and maintain wiring and connections carefully 1 Check the tightness of the alternator bracket fas teners and alternator mounting fasteners tighten the fasteners as needed For torque values see Group 15 of the Hecreational Vehicle Chassis Workshop Manual or take the vehicle to an au thorized Freightliner dealer 2 Check that all electrical connections at the alter nator and starter are clean Clean and tighten all charging system electrical connections as needed Spray each electrical connection at the alternator and starter with dielectric red enamel Trace and inspect all wiring and cables con nected to e alternator e starter and depopulation
6. 22 Lubricating Bosch Brakes 42 08 Check Lines Checking Hydraulic Disc or Air Brakes 42 09 Check 2 1 on Checking Hydraulic Disc Brakes 42 10 Inspect Brake Inspecting Air Brakes 42 11 Lubricate A Meritor Roller Pin Lubricating 42 12 Drain Air Tanks Lubricate Drag Link Lubricating 46 01 Change Power Steering Reservoir Fluid and Filter Changing 46 03 Lubricate Steering Driveline Lubricating 46 04 Lubricate Steering Gear Lubricating 46 05 Change Hydraulic Reservoir Filter Changing including TRW 46 06 Inspect Fuel Tank Mounts and Fuel Line Checking 47 01 Change FuelFilters Inspect Exhaust System Inspecting 49 01 Check J Ground Cables Checking and Cleaning 54 01 Inspect A Air Conditioner Component Inspection 83 01 Customert Date Recreational Vehicle Chassis Maintenance Manual February 2012 00 15 00 General Information Noise Emission Controls Maintenance 00 08 Noise Emission Control Maintenance Federal Law Part 205 Transportation Equipment Noise Emission Controls Part 205 Transportation Equipment Noise Emission Controls requires the vehicle manufacturer to fur nish with each new vehicle such written instructions for the proper maintenance use and repair of the vehicle by the ultimate purchaser to provide reason able assurance of the elimination or minimization of noise emission control degradation throughout the
7. 32 2 Recreational Vehicle Chassis Maintenance Manual April 2010 Suspension 32 09 28 98 A Measure here for suspension ride height 1 Frame Rail 2 Axle Housing f320423a 3 Axle Centerline Fig 1 Ride Height Inspection typical Neway suspension shown 10 Inspect the shock absorbers for oil leaks and worn rubber bushings Replace the shock ab sorbers and or rubber bushings if wear or dam age is noted For instructions see Group 32 of the Hecreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 11 Remove the safety stands and lower the vehicle to the ground Run the engine until air pressure of at least 100 psi 689 kPa is maintained throughout the system IMPORTANT Repeat this check at both ends of the vehicle 12 Check that all air springs are inflated If the air springs do not inflate see Group 32 of the Hec reational Vehicle Chassis Workshop Manual for possible causes and corrections or take the ve hicle to an authorized Freightliner dealer 32 04 ZF IFS Lubricating IMPORTANT Do not raise the vehicle by plac ing a jack under the control arm s The weight of the vehicle could damage the control arms and cause alignment issues 1 Chock the rear tires and apply the parking brake Raise the front of the vehicle with a jack so the tires just clear the ground and the suspension is fully extended Place safety stands under the vehi
8. Fig 2 Front and Rear Engine Front Mount ISB chassis built after 2002 1 With the engine turned off use Pacbrake Syn thetic Lube or Synco Super Lube and spray or coat a sufficient amount on the restricter air cylin der valve shaft and the attaching locations at each end of the actuation cylinder See Fig 3 for the exhaust brake lubrication points 2 Using your hands or a pair of pliers slide the valve several times to distribute the lubricant down the shaft and the attaching locations Recreational Vehicle Chassis Maintenance Manual April 2010 01 1 03 20 2003 f012035 1 Air Cylinder 2 Pacbrake Fig 3 Pacbrake Exhaust Brake Lube Point Locations NOTE Operation of the Pacbrake could be af fected by starting the engine and idling for short periods of time During a cold engine start up moisture occurs in the engine and the exhaust system that creates a corrosion hazard The brake housing may trap water in the valve shaft bore causing corrosion resulting in an improper or non functioning brake If it is necessary to periodically start the engine reach normal oper ating temperatures before shutting down the en gine Engine 01 2 Recreational Vehicle Chassis Maintenance Manual April 2010 Air Intake Title of Maintenance Operation MOP Air Cleaner Inspecting and Charge Air Cooler Inspecting and Cleaning 09 Index A
9. Meritor Roller Pin Lubricating 42 12 Drain Tanks Lubricate Drag Link Lubricating 46 01 Change Power steering fluid reservoir fluid and filter changing 46 03 inline filter changing including TRW 46 06 Lubricate Steering Driveline Lubricating 46 04 Lubricate Steering Gear Lubricating 46 05 Inspect Fuel Tank Mounts and Fuel Line Checking 47 01 Change FuelFilters Inspect 1 Exhaust System Inspecting 49 01 Check Ground Cables Checking and Cleaning 54 01 Inspect Air Conditioner Component Inspection 83 01 Customert Date Additional copies are available on the Freightliner Custom Chassis Corporation website www freightlinerchas sis com t Your signature on this form indicates that you have reviewed and agree to the service items to be performed Any items you wish to exclude should be indicated with a no to the left of that service item Recreational Vehicle Chassis Maintenance Manual February 2012 00 11 00 General Information 45 000 Mile or 36 Month Maintenance 00 06 Procedure 45 000 Mile 72 405 km 36 Month Maintenance MOP initial Inspect Engine Drive Belt Inspecting 01 01 Check Engine Support Fasteners Checking 01 02 Inspect A Pacbrake Inspecting and Maintenance 01 03 Change 1 and Filter see the engine manufacturer s u Change Air
10. A ZF IFS Lubricating 32 04 Check Suspension U Bolt Torque Checking 32 06 Lubricate Knuckle Pin Lubricating 33 01 Lubricate End Lubricating and Inspecting 33 02 Check All Axle Alignment Checking 33 03 Check Wheel Bearing Removal Cleaning Checking Repacking 33 04 Lubricate and Adjusting 33 05 4 Oil Filled Hubs Level Checking front and tag axle 35 05 Check _____ Seals for Leaks Change Axle Lubricant Changing Freightliner axle only 35 02 Check Axle Breather Checking 35 03 Check Wheel Nut Checking 40 01 Check Tire Pressure Lubricate Driveline Inspecting and Lubricating 41 01 Inspect A Brake System Valves Inspecting 42 01 00 6 Recreational Vehicle Chassis Maintenance Manual February 2012 General Information 00 6000 Mile or 6 Month Initial Maintenance 00 03 Procedure i Ferformed 6000 Mile 9654 km or 6 Month Initial Maintenance initial Inspect and Air Lines for Proper Routing Chaffing and 42 02 Lubricate Camshaft Bracket Bushing Lubricating 42 04 Lubricate Slack Adjuster Lubricating 42 05 Lubricate Foot Brake Valve Actuator Lubricating 42 06 4 s d Brake System Inspecting front 42 07 Lubricate Lubricating Bosch Brakes front 42 08 Check Brake Lines Checking Hydr
11. Model qt L 1000 2000 and 2000 MH 16 0 15 1 26 2 Recreational Vehicle Chassis Maintenance Manual January 2010 Transmission Automatic Transmission Lubricant Capacities Refill Capacity qt L 3000 and 4000 MH 17 5 16 5 Model Quantities listed are approximate Add the recommended amount of fluid as listed under refill capacity Do not overfill t Some Allison 3000 MH transmissions have a deeper oil sump than other models These models require 3 additional quarts 2 8 L of ATF Table 2 Automatic Transmission Lubricant Capacities 26 Recreational Vehicle Chassis Maintenance Manual January 2010 26 3 Throttle Control 30 Index Alphabetical Title of Maintenance Operation MOP MOP Number Throtle Pedal Pivot Pin DIT sea orici Beene 30 01 Recreational Vehicle Chassis Maintenance Manual January 2010 Throttle Control 30 01 Throttle Pedal Pivot Pin Lubricating Using a silicone spray lubricate the throttle pedal pivot pins as shown in Fig 1 and Fig 2 07 09 2009 1300408a 1 Throttle Pedal 2 Pivot Pins Assembly 3 Base Plate Fig 1 Floor Mounted Throttle Pedal 30 07 09 2009 1 Throttle Pedal Assembly 2 Pivot Pin not shown Fig 2 Suspended Throttle Pedal 1300409 Recreational Vehicle Chassis Maintenance Manual January 2010 30 1 Suspension 32 Index Alphabe
12. and daily weekly and monthly maintenance of vehicle components Driver s operator s manuals do not contain detailed repair or service information Service bulletins provide the latest service tips field repairs product improve ments and related information Some service bulletins are updates to informa tion in the workshop service manual These bulletins take precedence over workshop service manual information until the latter is updated at that time the bulletin is usually canceled The service bulletins manual is available only to dealers When doing service work on a vehicle system or part check for a valid service bulletin for the latest information on the subject IMPORTANT Before using a particular service bulletin check the current service bulletin validity list to be sure the bulletin is valid Parts technical bulletins provide information on parts These bulletins contain lists of parts and BOMs needed to do replacement and upgrade procedures parts documentation can be accessed using the following applications on the ServicePro provides Web based access to the most up to date versions of the publications listed above In addition the Service Solutions feature provides di agnostic assistance with Symptoms Search by connecting to a large knowledge base gathered from technicians and service personnel Search results for both documents and service solutions can be narrowed by initially entering vehicle identification dat
13. zT RECREATIONAL VEHICLE CHASSIS MAINTENANCE MANUAL Models MC MCL XCL XCM XCP XCR XCS STI 425 4 2 12 Published by Daimler Trucks North America LLC 4747 N Channel Ave Portland 97217 Printed in U S A Foreword Scheduled maintenance provides a key element for safe operation of your vehicle A proper maintenance program also helps to minimize downtime and to safeguard warranties This mainte nance manual provides information necessary for years of safe reliable and cost efficient vehicle operation IMPORTANT The maintenance operations in this manual are not all inclusive Also refer to other component and body manufacturers instructions for specific inspection and mainte nance instructions Perform the pretrip inspection and daily weekly monthly maintenance as outlined in the vehicle operator s manual Perform the operations in this maintenance manual at scheduled intervals based upon distance traveled or months of operation Your authorized servicing dealer has the qualified technicians and equipment to perform this maintenance for you Your dealership can also set up a scheduled maintenance program tailored specifically to your needs Optionally your dealership can assist you in learning how to perform the maintenance procedures in this manual IMPORTANT Descriptions and specifications in this manual were in effect at the time of printing Freightliner Custom Chassis Corporation FCCC reserves the right t
14. 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 3 16387 0 cubic millimeter mm3 0 000061 cubic inches cubic inches in 16 387 cubic centimeters 0 06102 cubic inches in cubic inches in 0 01639 liters L 61 024 cubic inches in 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 m 35 315 cubic feet 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 0 08851 inch pounds lbf in foot pounds 1 3558 Newton meters 0 7376 foot pounds Press
15. 1 2 When the cap is removed run the engine until the upper radiator hose is hot this shows that the thermostat is open and the coolant is flowing through the system Use extreme care when draining coolant that is very warm It may still be hot enough to cause se rious personal injury by scalding Recreational Vehicle Chassis Maintenance Manual February 2012 20 1 20 1 3 Stop the engine Remove the lower radia tor hose to drain the coolant Drainage may be speeded by removing the plug in the bottom of the water inlet 2 Flush the cooling system as follows A CAUTION During filling air must be vented from the engine coolant passages Any air trapped in the system can cause severe engine damage 2 1 Connect the lower radiator hose and in stall the plug in the bottom of the water inlet 2 2 Open the engine venting petcock 2 3 Add water to the surge tank until the sys tem is filled 24 Start the engine Run it at low idle for 10 seconds then at high idle for 1 minute Return to low idle 2 5 Close the lower petcock when a steady stream of water is flowing from it Don t let more than 1 5 quarts 1 4 L of water escape 2 6 Close the upper petcock when a steady stream of water is flowing from it Don t let more than 1 5 quarts 1 4 L of water escape 2 7 Repeat several times until the drained liquid is nearly colorless 2 8 Completely drain the system then close the radiator and block the drai
16. 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 M30x2 792 1074 1096 1486 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation t Use these torque values if either the bolt or nut is lubricated or plated zinc phosphate conversion coated cadmium plated or waxed Geomet 321XL coated or waxed Table 7 Torque Values for Metric Thread Fasteners With Lubricated or Plated Threads 00 22 Recreational Vehicle Chassis Maintenance Manual February 2012 Engine Title of Maintenance Operation MOP Engine Drive Belt Inspecting Engine Support Fasteners 0 Pacbrake Inspecting and 01 Index Alphabetical MOP Number Recreational Vehicle Chassis Maintenance Manual April 2010 Engine 01 01 Engine Drive Belt Inspecting The engine and the belt must be cool before you check the belt Handling a hot belt can cause per sonal injury 1 Inspect the belt for damage Transverse across the belt width cracks are acceptable Longit
17. Manual for fuel water separator element replac ing intervals 4 Remove the chocks from the tires 47 Recreational Vehicle Chassis Maintenance Manual January 2010 47A Exhaust 49 Index Alphabetical Title of Maintenance Operation MOP MOP Number Exhaust System Inspecting Noise Emission 49 01 Recreational Vehicle Chassis Maintenance Manual January 2010 Exhaust 49 01 Exhaust System Inspecting Noise Emission Control The exhaust system must be free of leaks binding grounding and excessive vibrations In addition to inspecting the exhaust system at the scheduled maintenance interval inspect the exhaust system if the noise level of the vehicle has increased Replace parts that show leakage wear or damage with genuine Freightliner parts These conditions are usually caused by loose bro ken or misaligned clamps brackets or pipes If any of these conditions exist check the exhaust system components and alignment Align or replace as nec essary For alignment or adjustment instructions see Group 49 of the Recreational Vehicle Chassis Work shop Manual or take the vehicle to an authorized Freightliner dealer EPA10 Exhaust System Definitions of Aftertreatment System ATS Terms Refer to the following list of definitions of ATS terms and components Aftertreatment System ATS the entire ex haust system from the turbocharger t
18. 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 Geomet 321XL coated or waxed Table 4 Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threads Recreational Vehicle Chassis Maintenance Manual February 2012 00 19 00 Torque Specifications Tables 00 11 General Information Torque Values for Grade 8 Regular Hex Zinc Yellow Plated Capscrews and Cadmium and Wax Coated Pre
19. 93 1460515 1 Sector Shaft Grease Fitting Fig 3 Sector Shaft Lubricating 46 46 06 Hydraulic Reservoir Filter Changing metal reservoir only NOTE On XC chassis vehicles with a side mounted radiator the hydraulic reservoir sup plies both the steering and the fan circuits 1 Drain the entire steering and fan hydraulic sys tems 2 Remove the reservoir lid and remove the nut that secures the filter 3 Remove the old filter and install the new filter Install the filter nut and tighten it securely 5 Fill the reservoir with the approved hydraulic fluid See Table 1 6 Start the engine run it for five seconds then shut down the engine 7 Fill the reservoir with 15W40 hydraulic system fluid 8 Start the engine Turn the steering wheel lock to lock several times until the steering wheel turns easily Shut down the engine 9 Fill the reservoir with 15W40 hydraulic system fluid NOTE The steering circuit is now purged Fol low the remaining steps to purge the fan circuit 10 Start the engine Run the engine at half throttle until the fans engage loud chirping sound Shut down the engine 11 The fan circuit is now purged Top off the reser voir fluid and install the reservoir lid Recreational Vehicle Chassis Maintenance Manual February 2012 46 3 Fuel 47 Index Alphabetical Title of Maintenance Operation MOP MOP Number Fuel Tank Mounts and Euel Line Checki
20. Cleaner Inspecting and Replacing 09 01 Inspect Cooler Inspecting and Cleaning if cleaning is 09 02 Check Alternator Battery and Starter Checking 15 01 Inspect Radiator radiator cap coolant freeze points SCA levels T Check hose routing for chaffing and leaks 20 03 Change 7 Transmission Fluid and Filter if required by Allison 26 03 Inspect 1 Transmission Hose Routing for Chaffing and Leaks Lubricate ____ Throttle Pedal Pivot Pin Lubricating 30 01 Inspect Suspension Check Suspension Height Control Valve Checking 32 02 Lubricate ZF IFS Lubricating 32 04 Check 5 U Bolt Torque Checking 32 06 Lubricate 1 End Lubricating and Inspecting 33 02 Check Wheel Bearing Removal Cleaning Checking Repacking 33 04 Lubricate and Adjusting 33 05 era OiLFilled Hubs Oil Changing front and tag axle 35 05 Check Seals for Leaks Change Axle Lubricant Changing Freightliner and Meritor axles 35 02 Check Axle Breather Checking 35 03 Check Pressure Lubricate ___ Driveline Inspecting and Lubricating 41 01 Inspect A Brake System Valves Inspecting 42 01 Inspect Mu ud and Air Lines for Proper Routing Chaffing and 42 02 Lubricate 7 Camshaft Bracket Bushing Lubricating 42 04 Lubricate _ Slack Adjuster Lubricating 42 05 00 12 Recreational Vehicle Chassis Maintenance Manual February 2012 Ge
21. Haldex and is used with permis sion Brakes 3 2 1 01 07 2011 1422526 1 O ring 3 Mounting Bolts 2 Cartridge Fig 1 PURest Air Dryer Assembly 3 Restart the engine and build up pressure to cut out pressure At cut out pressure the air dryer purge valve opens and immediately expels a large volume of air followed by a slow flow of air lasting approximately 30 seconds 42 04 Camshaft Bracket Bushing Lubricating Pump grease into the camshaft bracket bushing until it appears at the slack adjuster end of the bracket See Fig 5 Use an NLGI Grade 1 or Grade 2 multipurpose chas sis grease If grease leaks out from under the cam head the camshaft bracket grease seal is worn or damaged For grease seal replacement instructions 42 2 Recreational Vehicle Chassis Maintenance Manual May 2011 Brakes 42 01 10 2011 1422527 A Canister cartridge assembly shown upside down B Rotate the cartridge counterclockwise 45 degrees to release it from the canister Fig 2 Releasing the Cartridge 01 07 2011 1422528 Fig 3 New Cartridge with Rubber Spring see Group 42 of the Hecreational Vehicle Chassis Workshop Manual or take the vehicle to an autho rized Freightliner dealer Camshaft brackets without grease fittings are fitted with special seals and packed with extended lubrication inter
22. Hub Cap Beauty Ring Fig 4 Rear Axle Hub Cap Assembly NOTICE Do not overtighten the cap head Too much force will strip the screw 7 Install the hub cap and tighten the cap head just until snug 35 05 Hubs Oil Changing Tag Axle Be careful not to overfill the hubs Overfilling may cause oil to be forced out of the hubs and to con taminate the brake linings and other brake compo nents This could result in loss of vehicle control and lead to personal injury and property damage 1 With the vehicle on a level surface remove the hub cap also referred to as a beauty ring 2 Rotate the rear wheels so that the rear hub drain plugs are positioned downward 3 Chock the tires 4 Place suitable containers under the hubs re move the filler plugs in the ends of the hub caps and the drain plugs and allow the hubs to drain completely See Fig 5 07 09 2009 13302476 A Hub Cavity Full 1 Fill Plug Magnetic Drain 2 Drain Plug Fig 5 Oil Filled Hub Cap 5 Install the drain plugs and tighten securely 6 Add approximately 1 to 1 1 2 pints 0 5 to 0 7 L of oil 80W 90 hypoid gear oil to each hub IMPORTANT Fill the hubs to the level indicators on the hub caps or to no more than 1 4 inch 6 mm above the indicators See Fig 5 7 Rotate the wheels allow the oil to settle and check the levels 8 Install the filler plugs securely NOTICE Do not overtigh
23. Inspecting Bode aes dU Re e UR ed gs 20 02 Recreational Vehicle Chassis Maintenance Manual February 2012 Engine Cooling Radiator 20 01 Radiator Cap Checking Do not remove or loosen the radiator cap until the engine and cooling system have completely cooled Use extreme care when removing the cap A sudden release of pressure from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause seri ous personal injury The radiator cap is the most ignored part in the cool ing system If it is suspect replace it An inspection means checking the cap with a pressure tester A radiator cap in good condition will not open below 9 psi 62 kPa A visual check is also in order look for signs of deterioration of the inner gasket Also look for cracks or breaks in the spring retainer in the cap and for corrosion or deposits on the spring itself If the spring is not in perfect condition it has probably lost tension replace it See Fig 1 05 31 2007 1200705 Fig 1 Surge Tank Coolant Fill Cap 20 02 Radiator Inspecting and Cleaning Inspect the radiator for clogging or damage and clean and or repair it if necessary Soak the radiator with a non corrosive degreaser such as Simple Green Let the unit sit for several minutes to work through the radiat
24. diagonal pattern tighten all 5 8 18 U bolt nuts 205 278 N m tighten all 3 4 16 U bolt nuts 300 Ibf ft 407 and tighten all 7 8 14 U bolt nuts 460 624 N m NOTICE Failure to retorque the U bolt nuts could result in spring breakage and abnormal tire wear 4 Remove the safety stands and lower the vehicle to the ground Inspect the height control components and check their operation Failure to perform these inspec tions and checks could result in separation of worn suspension components and loss of vehicle control possibly causing personal injury or death or property damage 1 Park the vehicle on a level surface Apply the parking brake and chock the tires to prevent the vehicle from moving 2 Inspect the front and rear suspensions for any signs of damage loose components wear or cracks Replace any damaged components to prevent failure or equipment breakdown 3 Inspect all bolts and nuts at the pivot axle con nections to assure that they are properly torqued Check all other nuts and bolts for proper torque See Group 00 of this manual for proper torque specifications 4 Check the air pressure gauge to confirm that there is in excess of 65 psi 448 kPa in the air System and inspect the air springs for sufficient and equal firmness Suspension Torque Specifications lubricated threads Description Size Torque Ibf ft N m Shock Absorber Mount
25. for leaks at the upper and lower pedestal connections using a soapy solu tion Replace any worn air springs for instruc tions see Group 32 of the Recreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Inspect the bolts and nuts at the pivot connec tions the transverse beam connections and the axle connections to ensure they are tightened to the correct torque specification Check all of the other suspension components for any sign of damage looseness wear or cracks Replace worn or damaged parts See Group 32 of the Hecreational Vehicle Chassis Workshop Manual or take the vehicle to an au thorized Freightliner dealer Inspect for cracked welds If cracks are found contact Neway immediately for further instruc tions Inspect the torque rod and track bar pivot bush ings for excessive wear Replace worn or dam aged bushings See Group 32 of the Recre ational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Move the axle up and down while checking for signs of looseness due to worn parts at the front pivot connections Replace any worn parts by following the procedures in Group 32 of the Rec reational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Check for leaks on the height control valves by applying a soapy solution then watching for bubbles at all air connections and fittings
26. grease fittings be lubricated once a year preferably before periods of inactivity The wheel hub should be disassembled inspected and the wheel bearings repacked every 1 000 000 miles 1 609 000 km Recreational Vehicle Chassis Maintenance Manual September 2011 33 3 33 08 30 94 f400100a Fig 6 Setting Trammel Bar Pointers 33 05 Oil Filled Hubs Oil Level Checking Be careful not to overfill the hubs Overfilling may cause oil to be forced out of the hubs and to con taminate the brake linings and other brake compo nents This could result in loss of vehicle control and lead to personal injury and property damage 1 With the vehicle on a level surface rotate the front wheels and allow the oil in the hubs to settle 2 Chock the tires IMPORTANT The oil level should be at or no more than 1 4 inch 6 mm above the level indi cators on the hub caps 3 If necessary remove the filler caps in the ends of the hub caps and add enough oil 80 90 hypoid gear oil to bring the oil to the proper level Front Axle 4 Rotate the wheels allow the oil to settle and check the levels again Install the filler caps securely Remove the chocks from the tires 33 06 Oil Filled Hubs Oil Changing Be careful not to overfill the hubs Overfilling may cause oil to be forced out of the hubs and to con taminate the brake linings and other brake compo nents This could result in loss of v
27. life of the vehicle In compliance with the law the noise emission controls maintenance information in each applicable group of this manual in conjunction with the chassis workshop manual provides these instructions to owners Recommendations for Replacement Parts Replacement parts used for maintenance or repair of noise emission controls should be genuine Freight liner Custom Chassis Corporation FCCC parts If other than genuine FCCC parts are used for replace ment or repair of components affecting noise emis sion control the owner should be sure that such parts are warranted by their manufacturer to be equivalent to genuine FCCC parts in performance and durability Freightliner Noise Emission Controls Warranty See the vehicle owner s warranty information book for warranty information concerning noise emission controls Tampering With Noise Controls is Prohibited Federal law prohibits the following acts or the caus ing thereof 1 The removal or rendering inoperative by any per son other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use 2 The use of the vehicle after such device or ele ment of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tam pering are the a
28. plug shown in Fig 2 to begin draining the oil 2 ON 4 08 31 2011 1200744 1 Pinion Shaft 2 Breather Fill Plug 3 Oil Level Plug 4 Drain Plug 5 Cross Shaft Fig 2 Mechanical Fan Drive Gearbox 20 2 Recreational Vehicle Chassis Maintenance Manual February 2012 Engine Cooling Radiator Remove the oil level plug See Fig 2 Flush the fan drive gearbox with an approved nonflammalbe nontoxic solvent such as e Lubriplate Syn Flush Lubriplate Pure Flush e Whitmore s Flushing e Medallion Flushing Oil Kosher Using degreaser clean the thread on the drain hole and drain plug Install the drain plug Fill the fan drive gearbox with Mobil Delvac 75W 90 lubricant until the lubricant starts to come out of the oil level plug hole Using degreaser clean the thread on the oil level and fill holes and both plugs Install the plugs making certain that the breather fill plug is used in the fill plug hole 20 Recreational Vehicle Chassis Maintenance Manual February 2012 20 3 Transmission 26 Index Alphabetical Title of Maintenance Operation MOP MOP Number Allison MD MH Series Transmission Fluid Level 0 26 02 Allison Transmission Fluid and Filter Changing internal external 26 03 Transmission Breather
29. studs e batteries e magnetic switch e cab e jump start studs e battery isolation relays battery shutoff switches 3 Check wires and cables for wear chafing kinks discolored insulation or loose clamps or ties 15 Find the cause of any problems and repair re place and reroute wires and clamps as neces sary IMPORTANT Ensure that wires and cables are not near any heat sources if they are reroute them 4 Clean all circuit breakers and relays 5 Check the alternator wiring for missing insulation kinks and heat damage Replace or repair as needed 6 On the bundled cable that runs from the batteries to the starter ensure that tie straps are installed at least every 12 inches 80 cm Replace any missing tie straps and add tie straps where spacing between them exceeds 12 inches 30 cm 7 Ensure that all cables have sufficient slack to allow for engine movement and that there is no force on any wiring connectors 8 If any convoluted tubing is damaged check the wiring inside it Replace any damaged or missing convoluted tubing 9 Inspect the battery cables for wear and replace as needed Clean the cable connector terminals with a wire brush See Group 54 of the Recre ational Vehicle Chassis Workshop Manual for troubleshooting instructions and for adjustment repair or replacement instructions or take the vehicle to an authorized Freightliner dealer 9 1 Clean and tighten the battery groun
30. 00 km whichever comes first 88 Change the TRW inline power steering filter every 12 months TT See the Cummins Operation and Maintenance Manual for fuel water separator element replacing intervals Table 1 Maintenance Operation Procedures and Schedule Recreational Vehicle Chassis Maintenance Manual February 2012 00 5 00 General Information 6000 Mile or 6 Month Initial Maintenance 00 03 Procedure 6000 Mile 9654 km or 6 Month Initial Maintenance MOP initial Inspect Engine Drive Belt Inspecting 01 01 Check Engine Support Fasteners Checking 01 02 Change zi and Filter see the engine manufacturers u Inspect A Inspecting and Maintenance 01 03 Inspect A Air Cleaner Inspecting and Replacing 09 01 Inspect Cooler Inspecting and Cleaning if cleaning is 09 02 Check Alternator Battery and Starter Checking 15 01 Inspect Radiator radiator cap coolant freeze points SCA levels T Checkt hose routing for chaffing and leaks 20 03 Change Mechanical Fan Drive Gearbox Oil Changing 20 04 Change Transmission Fluid and Filter if required by Allison 26 03 Inspect 1 Transmission Hose Routing for Chaffing and Leaks Lubricate Throttle Pedal Pivot Pin Lubricating 30 01 Inspect Suspension Check ______ Suspension Height Control Valve Checking 32 02 Lubricate
31. 434 458 Maintenance Interval in Months 6 12 24 36 8 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228 01 01 Engine Drive Belt Inspecting 01 02 Engine Support Fasteners Checking 01 03 Pacbrake Inspecting and Maintenance 09 01 Air Cleaner Inspecting and Replacing 09 02 Charge Air Cooler Inspecting and Cleaning 15 01 Alternator Battery and Starter Checking 20 01 Radiator Cap Checking 20 02 Radiator Inspecting and Cleaning 20 03 Coolant Replacingt 20 04 Mechanical Fan Drive Gearbox Oil Changing 26 01 Transmission Breather Checking 26 02 Allison MD MH Series Transmission Fluid Level Checking 26 03 Allison Transmission Fluid and Filter Changing internal external filter 30 01 Throttle Pedal Pivot Pin Lubricating 32 01 Suspension Fastener Torque Checking 32 02 Suspension Height Control Valve Checking 32 03 Suspension Inspecting e fe 32 04 ZF IFS Lubricating e e fe J ow 32 05 Suspension Inspecting e J ow o 32 06 Suspension U Bolt Torque Checking 33 01 Knuckle Pin Lubricating fe fo eo J
32. 5 129 95 129 1 2 20 75 102 110 149 9 1612 100 136 140 190 140 190 9 16 18 110 149 155 210 5 8 11 135 183 190 258 190 258 5 818 155 210 215 292 3 410 240 325 340 461 340 461 3 4 16 270 366 380 515 7 8 9 385 522 540 732 7 814 425 576 600 813 1 8 580 786 820 1112 1 12 635 861 900 1220 1 14 650 881 915 1241 Threads may have residual oil but will be dry to the touch t Male and female threads bolt and nut must both be unlubricated and unplated if either is plated or lubricated use Table 4 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation Table 6 Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threads Recreational Vehicle Chassis Maintenance Manual February 2012 00 21 00 General Information Torque Specifications Tables 00 11 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 22 J SS w 230010 230011 1230012 230013 M6 5 7 7 9 M8 12 16 17 23 M8 x 1 13 18 18 24 M10 24 33 34 46 M10 x 1 25 27 37 38 52 M12 42 57 60 81 M12 x 1 5 43 58 62 84 M14 66 89 95
33. D P O Box 3849 Portland 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 operators manuals contain information needed to enhance the driver s understanding of how to operate and care for the vehicle and its components Each manual contains a chapter that covers pre trip and post trip inspections
34. E RR ee ee eee 35 01 Oil Filled Hubs Changing Tag 35 05 Oil Filled Hubs Oil Level Checking Tag 35 04 Recreational Vehicle Chassis Maintenance Manual September 2010 35 01 Axle Lubricant Checking NOTE If the vehicle is exposed to water deep enough to cover the hubs disassemble and in spect them for water damage and or contamina tion See Group 35 of the Hecreational Vehicle Chassis Workshop Manual for instructions or take the vehicle to an authorized Freightliner dealer 1 Clean the area around the filler plug and remove the plug 2 Make sure that the lubricant is level with the bot tom of the filler plug hole See Fig 1 08 17 2009 A Correct lube level at bottom of fill hole B Incorrect lube level below fill hole f350061a Fig 1 Axle Lubricant Checking 3 Add S A E 80W 90 multipurpose gear lubricant or an S A E 75W 90 multipurpose synthetic gear lubricant Either type of lubricant must meet Military Specification L 2105 D and be suitable for American Petroleum Institute service classifi cation GL 5 Install and tighten the filler plug 4 Inspect the axle for signs of leakage If leakage is indicated and the lubricant level is down have your dealer perform any necessary maintenance 35 02 Axle Lubricant Changing Freightliner Axle 1 Rem
35. Locknut 3 4 16 110 to 150 149 to 203 Air Spring Upper Mounting Plate Locknut 3 4 16 31 to 42 42 to 57 Air Spring Upper Mounting Plate Capscrew 1 2 13 31 to 42 42 to 57 Air Spring Lower Mounting Plate Capscrew 1 2 13 31 to 42 42 to 57 Transverse Beam Bushing Locknuts 1 1 4 12 600 to 700 814 to 949 Equalizing Beam Center Bushing Locknut 3 4 16 150 to 200 208 to 271 Equalizing Beam Front Bushing Locknut 600 to 700 814 to 949 Control Rod Ball Stud Locknut 1 1 8 12 550 to 650 746 to 881 Control and Torque Rod Mounting Locknuts 5 8 18 110 to 150 149 to 203 Table 1 Suspension Torque Specifications lubricated threads Recreational Vehicle Chassis Maintenance Manual April 2010 32 1 32 NOTE Height control valves control all front and rear suspension air springs Check for air leaks by applying a soapy solution Then check for bubbles at all air connections and fittings 5 Check the ride height of the air suspension by measuring the distance from the center of the lower shock bolt to the bottom of the frame rail See Fig 1 See Table 2 for height control valve adjustment measurements If ride height is incor rect adjust the air suspension Height Control Valve Adjustment Measurements Measurement Suspension Inches 1 4 mm 6 10 254 or AS120 front 10 02 267 5140 front 11 279 IFS114 front IFS ZF front ADL RS17 19 21 17 1 2 445 15 3 4 400 10 1 4 260
36. Power Steering Reservoir Fluid and Filter Changing 8 46 04 Steering Driveline Lubricating 46 05 Steering Gear Lubricating 46 06 Hydraulic Reservoir Filter Changing metal reservoir only 47 01 Fuel Tank Mounts and Fuel Line Checking 47 02 Fuel Water Separator Element Replacing 49 01 Exhaust System Inspecting Noise Emission Control 54 01 Ground Cables Checking and Cleaning 54 02 Battery Voltage Checking 00 4 Recreational Vehicle Chassis Maintenance Manual February 2012 General Information 00 Vehicle Maintenance Schedule Table 00 02 Maintenance Operation Procedures and Schedule Maintenance Interval in Miles x 1000 6 15 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 Maintenance Operation Number Maintenance Interval in Kilometers x 1000 and Description 9 24 hs 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458 Maintenance Interval Months 6 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228 83 01 Air Conditioner Inspecting fe fete fe fe fe fe fe fe e fe e Inspect the air cleaner every 12 months Replace the air cleaner element every 24 months or when filter restriction reaches 25 inH 0 if equipped with an air restr
37. Product ABP axle needle bear ings at the initial maintenance IM interval first wipe the lube fittings clean Then slowly feed for Meritor axles multipurpose chassis grease NLGI grade 1 or 2 into each bushing area or for ABP axles lithium 12 hydroxy stearate with molybdenum disulfide WL grade 2 grease into each needle bearing area while turning the wheels from extreme right to left and back again lock to lock This will eliminate small air pockets and improve grease distribution NOTE The grease seal will accept the grease pressure without damaging the seal and is de signed to have grease pumped out through it during lubrication Even if grease leaks out around the top or bottom plate continue pump ing until new grease is seen at the seal on the bushing or needle bearing opposite the grease fitting When lubricating knuckle pin bushings or needle bearings after the IM maintenance interval first wipe the lube fittings clean Then for Meritor axles apply multipurpose chassis grease or for ABP axles lithium 12 hydroxy stearate with molybdenum disul fide WL grade 2 grease until new grease is seen at the grease seal on the bushing or needle bearing opposite the fittings 33 02 Tie Rod End Lubricating and Inspecting IMPORTANT DOT roadside tie rod assembly replacement criteria specifies that if tie rod end play is 1 8 inch 3 mm or greater measured on the road the vehicle must be taken out of ser vi
38. Tie Rod End Adjustment 2 3 Check the tie rod end nut and clamp nut torques For Meritor axles tighten the tie rod end nut 100 Ibf ft 136 N m and tighten the clamp nut 40 to 55 Ibf ft 54 to 75 For Freightliner axles see Table 1 for tie rod end nut torque specifi cations and Table 2 for tie rod end clamp Front Axle nut torque specifications Freightliner Axle Tie Rod End Nut Thread Torque N m 5 816 60 to 115 81 to 156 5 8 18 60 to 115 81 to 156 3 4 16 90 to 170 122 to 230 7 814 160 to 300 217 to 407 Table 1 Freightliner Axle Tie Rod End Nut Freightliner Axle Tie Rod End Clamp Nut Thread Torque N m 1 2 13 35 to 45 47 to 61 5 8 11 40 to 60 54 to 81 5 8 18 50 to 64 73 to 87 3 4 10 155 to 175 210 to 237 Table 2 Freightliner Axle Tie Rod End Clamp Nut 33 03 All Axle Alignment Checking NOTE The final stage manufacturer is respon sible for setting the vehicle ride height with air suspension and some vehicle alignments On full railed chassis this includes the final toe in setting on the front axle For modular style chassis both the front axle toe in and rear axle thrust angle settings are included Drive Axle Alignment Checking NOTE The maximum tolerance from perpen dicular for rear axle alignment should be 0 25 degree Check the axle alignment parallelism and thrust angle measurements for the rea
39. a PartsPro is an electronic parts catalog system showing the specified vehicle s build record EZWiring makes Freightliner Custom Chassis Corporation Freightliner Ster ling Thomas Built Buses and Western Star products wiring drawings and float ing pin lists available online for viewing and printing EZWiring can also be ac cessed from within PartsPro Recreational Vehicle Chassis Maintenance Manual May 2011 1 Introduction Descriptions of Service Publications Warranty related service information available on the AccessFreightliner com website includes the following documentation Recall Campaigns Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice These campaigns pertain to matters of vehicle safety All recall campaigns are distributed to dealers customers receive notices that apply to their vehicles Field Service Campaigns Field service campaigns are concerned with non safety related service work or replacement of parts All field service campaigns are distributed to dealers cus tomers receive notices that apply to their vehicles I 2 Recreational Vehicle Chassis Maintenance Manual May 2011 Page Description For an example of a maintenance manual page see Fig 1 Introduction B C Front Axle 33 w 33 01 Knuckle Pin Lubricating See Fig 1 33 02 Tie Rod End Lubricating and Inspectin
40. a hot check at the first opportunity after normal operating temperature 160 to 200 F 71 to 93 C is reached Hot Check Recommended Method With the vehicle on a level surface and the transmis sion in neutral at operating temperature perform the steps below 1 On the transmission shift selector press the up and down arrow keys simultaneously See Fig 3 2 Release the arrow keys and wait for a two minute countdown 3 The transmission shift selector display screen will display one of the following messages OL OK indicates an acceptable oil level OL HI followed by a number indicates the amount that is over filled OL LO followed by a number indicates the amount that is under filled e OL 70 indicates that the transmission is not up to operating temperature Alternate Method 1 Operate the transmission in a Drive D range until normal operating temperature 160 to 200 F 71 to 93 C is reached Recreational Vehicle Chassis Maintenance Manual January 2010 26 1 26 03 04 2008 1270159 1 Shift Selector Display Screen Fig 3 Transmission Shift Selector NOTE The fluid must be warm to ensure an accurate check The fluid level rises as tempera ture increases 2 Park the vehicle Shift to Neutral N and apply the parking brake Let the engine run at idle Transmission 3 Wipe the dipstick clean and check the fluid level A safe operating level is any le
41. ance Opera tion 42 02 Haldex PURest NOTE The PURest cartridge contains both the desiccant and filter in one piece Replacement 1 Remove the four mounting bolts and discard See Fig 1 Lift the canister about 1 2 inch and remove 2 Place the assembly upside down as shown in Fig 2 Press the cartridge down to compress the rubber spring then rotate counterclockwise 45 degrees to release the cartridge The cartridge itself contains no hazardous material but there may be a small amount of oil from the compressor 3 Clean the inside of the canister and aluminum housing Remove the cartridge O ring and discard Remove the new cartridge from the kit and make certain the rubber spring is attached See Fig 3 6 Install the new cartridge into the canister Align the slots on the cartridge with the dimplets inside the canister Press the cartridge into the canister and rotate clockwise 45 degrees to engage the cartridge as shown in Fig 4 Place a new O ring on the aluminum housing 8 Place the cartridge assembly on the air dryer housing and install four new mounting bolts Use an alternating diagonal pattern and tighten the bolts 35 to 40 47 to 54 N m Operational Check 1 Start the engine and build air pressure to 100 psi 690 kPa and shut off the engine 2 Check for air leaks at the inlet outlet and canis ter assembly Correct any leakage problem Information in this section is provided by
42. anufacturer s u Inspect Pacbrake Inspecting and Maintenance 01 03 Change Air Cleaner Inspecting and Replacing 09 01 Inspect Cooler Inspecting and Cleaning if cleaning is 09 02 Check Alternator Battery and Starter Checking 15 01 Inspect Radiator radiator cap coolant freeze points SCA levels Check hose routing for chaffing and leaks 20 03 Change Transmission Fluid and Filter if required by Allison 26 03 Inspect 1 Transmission Hose Routing for Chaffing and Leaks Lubricate Throttle Pedal Pivot Pin Lubricating 30 01 Inspect Suspension A Check Suspension Height Control Valve Checking 32 02 Lubricate ZF IFS Lubricating 32 04 Check Suspension U Bolt Torque Checking 32 06 Lubricate Knuckle Pin Lubricating 33 01 Lubricate _ Tie Rod End Lubricating and Inspecting 33 02 Check Wheel Bearing Removal Cleaning Checking Repacking 33 04 Lubricate and Adjusting 33 05 era OiLFilled Hubs Oil Changing front and tag axle 35 05 Check Seals for Leaks Change Axle Lubricant Changing Freightliner and Meritor axles 35 02 Check Axle Breather Checking 35 03 Check Pressure Lubricate ___ Driveline Inspecting and Lubricating 41 01 Inspect A Brake System Valves Inspecting 42 01 Inspect Mu ud and Air Lines for Proper Routing Chaffing and 42 02 Lubricate 7 Camshaft Bracket Bushing Lubricating 42 04 Lu
43. are pointing straight ahead NOTE If turn plates or turntables are not avail able lower the vehicle Remove the chocks from the rear tires and release the parking brake Move the vehicle backward and then for ward about six feet two meters 6 Place a trammel bar at the rear of the front tires locate the trammel pointers at spindle height and adjust the pointers to line up with the scribe lines on the center ribs of the front tires See Fig 4 Lock the pointers in place Check that the scale is set to zero 7 Place the trammel bar at the front of the tires and adjust the scale end so that the pointers line up with the scribe lines See Fig 5 and Fig 6 8 Read the toe in from the scale and compare it to the toe in specification in Group 33 of the Recre ational Vehicle Chassis Workshop Manual take the vehicle to an authorized Freightliner dealer If corrections are needed see Group 33 of the Hecreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 33 D ml B gt 08 29 94 NOTE B minus A equals toe in f330082a Fig 4 Wheel Toe In overhead view 08 30 94 f330014a Fig 5 Trammel Bar Positioning 33 04 Wheel Bearing Removal Cleaning Checking Repacking and Adjusting Freightliner Meritor Check for correct end play Correct end play is be tween 1 to 0 005 inch 25 4 to 0 12 mm ZF IFS ZF recommends that all
44. ass description and the registration form are lo cated under the Camp Freightliner tab If needed service work can be scheduled for your vehicle at the service center during your stay Tear Out Checklists IMPORTANT Additional copies of the checklists should be made before giving this to a dealer as they may not be returned to you The correct number of checklists are included to cover the warranty period however if you want copies of the checklists for future maintenance after the warranty expires you will need to make them Freightliner Custom Chassis Corporation FCCC will not be able to send you additional copies At the back of the maintenance manual there are checklists for each maintenance interval up to 60 000 miles 96 540 km When a maintenance interval needs to be performed take the vehicle to an autho rized Freightliner dealer remove the appropriate checklist and give it to the dealer These are the items that will be inspected for maintenance Recreational Vehicle Chassis Maintenance Manual February 2012 00 1 00 General Information Vehicle Maintenance Schedule Table 00 02 Maintenance Operation Procedures and Schedule Maintenance Interval in Miles x 1000 6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 Maintenance Operation Number Maintenance Interval in Kilometers x 1000 and Description 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410
45. aulic Disc or Air Brakes 42 09 Check Checking Hydraulic Disc Brakes 42 10 Inspect _ A Inspecting Air Brakes 42 11 Drain __ Air Tanks Lubricate _ Link Lubricating 46 01 Lubricate _ Driveline Lubricating 46 04 Lubricate A Steering Gear Lubricating 46 05 Change ____ Hydraulic Reservoir Filter Changing metal reservoir only 46 06 Inspect Fuel Tank Mounts and Fuel Line Checking 47 01 Change FuelFilters Inspect 1 Exhaust System Inspecting 49 01 Check A Ground Cables Checking and Cleaning 54 01 Inspect 7 Conditioner Component Inspection 83 01 Customert Date Additional copies are available on the Freightliner Custom Chassis Corporation website www freightlinerchas sis com t Your signature on this form indicates that you have reviewed and agree to the service items to be performed Any items you wish to exclude should be indicated with a no to the left of that service item Recreational Vehicle Chassis Maintenance Manual February 2012 00 7 00 General Information 15 000 Mile or 12 Month Maintenance 00 04 Procedure ceca or 15 000 Mile 24 135 km or 12 Month Maintenance initial Inspect Engine Drive Belt Inspecting 01 01 Check Engine Support Fasteners Checking 01 02 Change zi and Filter see the engine m
46. bricate Knuckle Pin Lubricating 33 01 Lubricate Tie Rod End Lubricating and Inspecting 33 02 Check Wheel Bearing Removal Cleaning Checking Repacking 33 04 Lubricate and Adjusting 33 05 a Oi Filled Hubs Oil Level Checking front and tag axle 35 05 Check Axle Seals for Leaks Change Axle Lubricant Changing Freightliner axle only 35 02 Check Axle Breather Checking 35 03 Check Wheel Nut Checking 40 01 Check Tire Pressure Lubricate Driveline Inspecting and Lubricating 41 01 Inspect Brake System Valves Inspecting 42 01 Inspect and Air Lines for Proper Routing Chaffing and 42 02 00 10 Recreational Vehicle Chassis Maintenance Manual February 2012 General Information 00 30 000 Mile or 24 Month Maintenance 00 05 Procedure i Ferformed 30 000 Mile 48 270 km or 24 Month Maintenance initial Lubricate _____ Camshaft Bracket Bushing Lubricating 42 04 Lubricate Adjuster Lubricating 42 05 Lubricate Foot Brake Valve Actuator Lubricating 42 06 Inspect 2 4 Brake System Inspecting 42 07 Lubricate 22 Lubricating Bosch Brakes 42 08 Check Lines Checking Hydraulic Disc or Air Brakes 42 09 Check 2 1 on Checking Hydraulic Disc Brakes 42 10 Inspect Brake Inspecting Air Brakes 42 11 Lubricate
47. bricate _ Slack Adjuster Lubricating 42 05 00 8 Recreational Vehicle Chassis Maintenance Manual February 2012 General Information 00 15 000 Mile or 12 Month Maintenance 00 04 Procedure i Ferformed 15 000 Mile 24 135 km or 12 Month Maintenance initial Lubricate Foot Brake Valve Actuator Lubricating 42 06 Inspect 00 e 7 Brake System Inspecting 42 07 Lubricate 2 Lubricating Bosch Brakes front 42 08 Check Lines Checking Hydraulic Disc or Air Brakes 42 09 Check 00 2 2 Checking Hydraulic Disc Brakes 42 10 Inspect _ A Brake Inspecting Air Brakes 42 11 Lubricate Meritor Roller Pin Lubricating 42 12 Drain Air Tanks Lubricate Drag Link Lubricating 46 01 Change Power Steering Reservoir Fluid and Filter Changing 46 03 Lubricate Steering Driveline Lubricating 46 04 Lubricate _ Steering Gear Lubricating 46 05 Change 7 Hydraulic Reservoir Filter Changing including TRW 46 06 Inspect Fuel Tank Mounts and Fuel Line Checking 47 01 Change FuelFilters Inspect Exhaust System Inspecting 49 01 Check Ground Cables Checking and Cleaning 54 01 Inspect Air Conditioner Component Inspection 83 01 Customert Date Additional copies are available on the Freightliner Custom Chassis Corporation website www freightlinerchas sis com t Your signature o
48. ce immediately If less than 1 8 inch 3 mm the vehicle does not have to be taken out of service but a major out of service inspection and maintenance must be scheduled as soon as possible 1 Wipe the tie rod end grease fittings clean then for Meritor axles pump multipurpose chassis grease NLGI grade 1 or 2 or for Freightliner axles lithium 12 hydroxy stearate with molyb denum disulfide WL grade 2 grease to the tie rod ends until all used grease is forced out and new grease appears at the ball stud neck Recreational Vehicle Chassis Maintenance Manual September 2011 33 1 33 NOTE Inspect the tie rod end boots for cracks wear or damage If a boot is cracked worn or damaged replace the tie rod assembly 2 Inspect the tie rod ends as follows 2 1 Shake the cross tube Movement or looseness between the tapered shaft of the ball and the cross tube socket mem bers means that the tie rod end assembly must be replaced 2 2 The threaded portion of the tie rod end assembly must be inserted all the way into the cross tube split for adequate clamping See Fig 3 Replace the parts if this cannot be done For instructions see the axle manufacturer s service manual 02 27 2007 1320033 IMPORTANT tie rod end threads must be visible throughout the entire length of the split NOTE Pinch bolt not shown to provide clarity 1 Cross Tube Split Fig 3
49. cle frame A WARNING Never work around or under a vehicle that is sup ported only by a jack Always support the vehicle with safety stands Jacks can slip causing the vehicle to fall which could result in serious injury or death Recreational Vehicle Chassis Maintenance Manual April 2010 32 3 32 Suspension 02 21 2005 1321032 Fig 2 Holland ADL 120 123 Suspension IMPORTANT Every 50 000 miles 80 450 km ZF recommends that the wheel hub be removed to check the wheel bearing lash and adjust as needed 2 Remove the wheel hub See Group 33 of the Recreational Vehicle Chassis Workshop Manual for wheel bearing service procedures or take the vehicle to an authorized Freightliner dealer 3 Lubricate the steering knuckle control arm at indi cated maintenance intervals Use only an NLGI Grade 2 lithium based grease multipurpose grease or mineral oil on the lubricating points See Fig 3 and Fig 4 32 05 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 Recreational Vehicle Chassis Workshop Manual for instructions or take the vehicle to an authorized Freightliner dealer WARNING Do not replace individual
50. cts listed below A Removal of or rendering inoperative the en gine speed governor so as to allow engine speed to exceed manufacturer s specifica tions B Removal of or rendering inoperative the fan clutch including bypassing the control on any thermostatic fan drive to cause it to op erate continuously C Removal of the fan shroud D Removal of or rendering inoperative ex haust components including exhaust pipe clamping E Removal of air intake components Maintenance Instructions Scheduled intervals are in the maintenance table in this group A Verification of Inspections Log Group 49 follows and should be filled in each time noise emission controls on the vehicle are maintained or repaired 00 16 Recreational Vehicle Chassis Maintenance Manual February 2012 General Information Verification of Inspections Log 00 Verification of Inspections Log 00 09 Verification of Inspections Log Group 49 Date Mileage Item Cost Maintenance Facility Group 49 Exhaust System Components Recreational Vehicle Chassis Maintenance Manual February 2012 00 17 00 General Information Metric U S Customary Conversion Tables 00 10 S Us EU To Get Metric aoe ric To Get 5 Customary Length inches in 25 4 millimeters mm
51. d 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 then dry Paint the retainer assembly if needed to pre vent rusting 9 3 Check that foreign objects such as stones bolts and nuts are removed 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 Recreational Vehicle Chassis Maintenance Manual April 2010 15 1 15 9 5 Coat the battery terminals with dielectric grease 10 Check the terminals on the battery shut off Switch and the starter relay Make sure that the terminal connections are clean and tight Coat the terminal connections with dielectric red enamel after cleaning Alternators and Starters 15 2 Recreational Vehicle Chassis Maintenance Manual April 2010 Engine Cooling Radiator 20 Index Alphabetical Title of Maintenance Operation MOP MOP Number Coclant bad dU eet Danes Peles Ba ENS 20 03 Mechanical Fan Drive Gearbox Oil Changing sso nd Re REIR 20 04 Radiator Cap Checking TRY IW CA RR OCR qug E 20 01 Radiator
52. e correct pins bolts and bolt torque must be used If not brake function could be impaired and lead to loss of control of the vehicle which could result in personal injury death or property dam age IMPORTANT The ZOH T caliper assembly is similar in appearance to the existing ZOPS cali per The only obvious difference is that one of the anchor plate slide pins trailing side has notches for identification With ZOH T calipers install the solid pin no bushing only in the an chor plate leading hole position Install the pin with the rubber bushing and notches only in the 42 6 Recreational Vehicle Chassis Maintenance Manual May 2011 Brakes anchor plate trailing hole position Tighten the leading side pin first then tighten the trailing side pin Tighten ZOH T bolts 93 to 107 Ibf ft 126 to 145 N m Tighten ZOPS bolts 70 to 80 95 to 108 N m 42 09 Brake Lines Checking Hydraulic Disc or Air Brakes Check all hydraulic air lines and fittings for damage leakage or looseness Replace damaged or leaking components and tighten loose fittings 42 10 Brake Lining Wear Checking Hydraulic Disc Brakes front engine diesel chassis Before checking lining wear with the wheel removed review the following brake lining exposure warnings 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 a
53. e interval for lubricating pin slide hydraulic disc brake cali pers Apply 1 8 oz 3 5 g Aeroshell grade 5 grease to each of the two guide pin and guide pin bore sets See the Bosch Pin Slide Disc Brakes Service Manual for additional information IMPORTANT The later ZOH T caliper has im portant differences from the early ZOPS caliper ZOPS calipers since 1998 and ZOH T calipers since 2002 use different slide pins and bolts See Fig 9 and Fig 10 The later trailing pin is identified by notches and has a rubber bushing Flange head instead of hexhead bolts are used with the later caliper The later bolts have a fine thread rather than a coarse thread pitch are longer differently colored and are tightened to a higher torque specification Use only the ZOH T bolts to assemble a ZOH T caliper The ZOPS caliper bolts have a different thread pitch and will not assemble correctly in a ZOH T caliper mounting Also the ZOH T bolts will not as semble correctly in a ZOPS caliper Do not in terchange parts It is permissible to use both ZOH T pins and ZOH T bolts in a ZOPS anchor plate but they must be replaced as sets Both the pins and the bolts must be changed Brakes 06 20 2002 1422357 1 Flange Head Bolt 2 Leading Pin 3 Trailing Pin 4 Rubber Bushing Fig 9 ZOH T Slide Pins and Bolts 06 20 2002 1422358 1 Hexhead Bolt 2 Blue Patch 3 Slide Pin Fig 10 ZOPS Slide Pins and Bolts Th
54. e to an authorized Freightliner dealer 4 Check that the yoke plug is not loose or missing Replace the yoke plug if needed If the yoke plug is missing the splined shaft may be hitting the yoke plug and knocking it out check the drive shaft for proper length U Joint Lubricating 1 Wipe all old grease and dirt from each U joint grease fitting 2 Use a hand type grease gun or a high pressure gun with a low pressure adaptor to lubricate the U joints See Fig 1 NOTE If a low pressure adaptor is not used with the high pressure gun the U joints may not receive enough lubricant 10 20 93 1410050 A After grease appears cover the pressure relief hole while continuing to lubricate 1 Slip Joint Grease 5 Yoke Plug Pressure Fitting with grease Relief Hole gun attached 6 Slip Joint Seal 2 Yoke Plug 7 Full Round Yoke 3 Grease 8 U Joint Grease Fitting 4 Half Round Yoke Fig 1 Slip Joint and U Joint Lubricating 3 Using lithium 12 hydroxy stearate grease NLGI grade 1 or 2 with EP additives lubricate until new grease can be seen at all four U joint seals NOTICE Fresh lubricant must be seen escaping from all four of the bearing cup seals of each U joint If not the U joint may fail prematurely 4 Ifthe bearing will not take grease replace the U joint assembly For instructions see Group 41 of the Recreational Vehicle Chassis Workshop Manual or take the vehicle to an authoriz
55. eather is plugged clean or replace it as needed See Fig 2 and Fig 3 06 07 94 1 Axle Housing Breather 2 Fill Plug 3 Temperature Indicator Plug f350002a Fig 2 Meritor Axle Housing typical Rear Axle Worl DAY S ALES 5 03 28 2007 1350484 1 Axle Housing Breather 2 Breather Tube Fig 3 Freightliner Axle Housing 35 04 Oil Filled Hubs Oil Level Checking Tag Axle Be careful not to overfill the hubs Overfilling may cause oil to be forced out of the hubs and to con taminate the brake linings and other brake compo nents This could result in loss of vehicle control and lead to personal injury and property damage 1 With the vehicle on a level surface remove the hub cap also referred to as a beauty ring See Fig 4 2 Rotate the rear wheels and allow the oil in the hubs to settle 3 Chock the tires IMPORTANT The oil level should be at or no more than 1 4 inch 6 mm above the level indi cators on the hub caps 4 f necessary remove the filler caps in the ends of the hub caps and add enough oil 80W 90 hypoid gear oil to bring the oil to the proper level 5 Rotate the wheels allow the oil to settle and check the levels again 6 Install the filler caps securely 35 2 Recreational Vehicle Chassis Maintenance Manual September 2010 35 f400295 07 28 2010 1 Cap Head 2
56. ectrical connections and harnesses Make sure the connectors are fully seated and the harnesses are not chafed or cut Repair or replace any damaged harness Disconnect any loose connectors and inspect the terminals for corrosion If corrosion is present replace the ter minals If corrosion is not present reconnect the connector 5 Check the fuse for the hydraulic brake 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 Max relay 5 3 Inspect the relay to make sure the fuse is not damaged If the fuse is damaged in stall a new fuse If the fuse is not dam aged install the fuse in position F6 5 4 Close the PDM cover 6 Check the operation of the Hydro Max brake booster as follows 6 1 With the ignition off depress the brake pedal and listen for the back up motor to Recreational Vehicle Chassis Maintenance Manual May 2011 42 5 42 engage Also note that the pedal force relieves the pedal should depress easily 6 2 With the ignition on engine running park ing brake released ensure that the BRAKE warning indicator light is not on This is a dual indicator and indicates that the parking brake is set and warns if there is a hydro max failure other than loss of back up motor power 42 08 Brake Caliper Slide Pin Lubricating Bosch Brakes front engine diesel chassis NOTE There is no set maintenanc
57. ed Freightliner dealer 5 Check the old grease If it appears rusty gritty or burned replace the U joint assembly For instruc tions see Group 41 of the Recreational Vehicle Recreational Vehicle Chassis Maintenance Manual January 2010 41 1 4 Sli 1 1 Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Wipe any excess grease from the seals and grease fittings p Joint Spline Lubricating Wipe all old grease and dirt from the slip joint grease fitting Use a hand type grease gun or a high pressure gun with a low pressure adaptor to lubricate the slip joint Using lithium 12 hydroxy stearate grease NLGI grade 1 or 2 with EP additives lubricate until fresh grease appears at the pressure relief hole in the yoke plug Then cover the relief hole with your finger as shown in Fig 1 while continuing to lubricate until fresh grease appears at the slip joint seal This en sures complete lubrication of the splines Wipe any excess grease from the pressure relief hole slip joint seal and grease fitting Driveline 41 2 Recreational Vehicle Chassis Maintenance Manual January 2010 Brakes 42 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Dryer Desiccant and Coalescent Filter 0 42 03 Air Dryer ais atur d decom e opu La fenem qd us Seu 42 02 Be
58. ehicle control and lead to personal injury and property damage 1 With the vehicle on a level surface rotate the front wheels so that the front hub drain plugs are positioned downward Chock the tires Place suitable containers under the hubs re move the filler plugs in the ends of the hub caps and the drain plugs and allow the hubs to drain completely See Fig 7 07 09 2009 f330247b A Hub Cavity Full 1 Fill Plug Magnetic Drain 2 Drain Plug Fig 7 Oil Filled Hub Cap 33 4 Recreational Vehicle Chassis Maintenance Manual September 2011 Front Axle 4 Install the drain plugs and tighten 25 Ibf in 282 N cm 5 Add approximately 1 to 1 1 2 pints 0 5 to 0 7 L of oil 80W 90 hypoid gear oil to each hub 6 Rotate the wheels allow the oil to settle and check the levels IMPORTANT Fill the hubs to the level indicators on the hub caps or to no more than 1 4 inch 6 mm above the indicators See Fig 7 7 Install the filler plugs securely 33 Recreational Vehicle Chassis Maintenance Manual September 2011 33 5 35 Index Alphabetical Title of Maintenance Operation MOP MOP Number Axle Breather Checking xx ert Ennio qe o E t bn o Roe Unc 35 03 Mubnicant tude tem o idis Sada ost d NR pupa 35 02 Axle Lubricant Checking Ee Y Eee RE U
59. enance program can result in inefficient operation and unscheduled down time When the vehicle reaches the distance or time whichever comes first given for a maintenance in terval see the Vehicle Maintenance Schedule Table for a list of the maintenance operations to be per formed at that maintenance interval Use the mainte nance operation reference numbers to find detailed instructions in the manual for each operation NOTE Maintenance instructions in this manual are based on average vehicle use and normal operating conditions Unusual vehicle operating conditions may require service at more frequent intervals For specific engine maintenance information see the Cummins Operation and Maintenance Manual IMPORTANT Maintenance operations appearing in italics in the following tables are for emission control components Numbers in the table are reference numbers matching those in the text of this manual Camp Freightliner Owner Training Owners who want to learn more about their vehicle can attend a two day training class offered at the Freightliner Custom Chassis Service Center in Gaffney South Carolina Some of the items covered during the training include the air brake system elec trical system vehicle storage weight distribution and maintenance intervals To learn more about the class or to register go to www freightlinerchassis com After entering the website click Motorhomes and select Owner Info A cl
60. ering filter if so equipped is pointing towards the power steering fluid reservoir and that the hose barb 90 degree elbow fitting is located on the bottom of the power steering filter See Fig 2 5 Place the ends of the power steering gear to reservoir hose onto the hose barb fittings and tighten the two hose clamps securely Fill only with approved clean fluid Do not mix fluid types Any mixture or any unapproved fluid could lead to seal deterioration and leaks Fluid leakage could cause loss of power steering assist possibly resulting in personal injury and property damage Steering 6 Fill the reservoir with approved power steering fluid See Table 1 ui 9 o E 05 06 2005 1462014 1 Hose Barb Elbow Fitting 2 Hose Barb Fitting 3 25 Micron Power Steering Filter Fig 2 Power Steering Filter Typical Installation if so equipped 7 Place the disconnected end of the steering gear to reservoir hose in a drain bucket Do not start the engine while draining the system Raise the front of the vehicle with a floor jack and support it with jack stands Have an assistant turn the steering wheel to full lock left and right and cap ture the fluid flowing from the hose in the drain bucket Add fluid to the reservoir as needed Continue turning the steering wheel until clean power steering fluid flows from the hose into the drain bucket Remove the pl
61. est gear and gently at tempt to move it forward The vehicle should not move If the vehicle moves the parking brakes are not operating correctly and must be repaired before the vehicle is returned to service See Group 42 of the Recreational Vehicle Chassis Workshop Manual for repair procedures or take the vehicle to an authorized Freightliner dealer Brake Component Inspection 1 Park the vehicle a level surface set the park ing brake and chock the tires Once the tires are chocked release the parking brake A WARNING Manually adjusting an 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 Recreational Vehicle Chassis Maintenance Manual May 2011 42 7 42 system and inspect it for worn or damaged com ponents Improperly maintaining the vehicle brak ing system may lead to brake failure resulting in property damage personal injury or death 2 With the engine off and 100 psi 689 kPa of air tank pressure have an assistant apply and hold an 80 to 90 psi 550 to 620 kPa brake applica tion 3 Check to see if the colored over stroke band on each brake chamber pushrod is exposed If a band shows the stroke is too long Check the foundation brake components for wear or damage and repair as needed See Group 42 of the Recreational Ve
62. g 33 03 Toe In Inspection A D E 11 11 2002 A Maintenance Operation Number consists of the Group Number followed by the Sequence Number B Group Title C Group Number D Release Date E Group Number Page Number 1020075 Fig 1 Example of Maintenance Manual Page Recreational Vehicle Chassis Maintenance Manual May 2011 Introduction Maintenance Manual Contents Group No Group Title OO Lc General Information d xoc tutes eni ice aoa eyes ates aks Engine aiid cada dee eee a ate Idee xa Air Intake cT Alternators and Starters uas s Engine Cooling Radiator PM MP PNE EE P Transmission hn Ge Throttle Control Em Suspension Glavin hice Gad te Ween MEER Front Axle hic te ne oa ea ea Rear Axle AO ee renee a Wheels and Tires dee ah dow 1 Driveline nh POMPE Brakes Oe ee eer Steering sud LE M tud Fuel ER Exhaust bu ir dut oup Ghd ab Bee heed ms Electrical runter d grecs sce n Heater and Air Conditioner 4 Recreational Vehicle Chassis Maintenance Manual 2011 General Information 00 Index Alphabetical Title of Maintenance Operation MOP MOP Number 15 000 Mile or 12 Month
63. h to exclude should be indicated with a no to the left of that service item Recreational Vehicle Chassis Maintenance Manual February 2012 00 13 00 General Information 60 000 Mile or 48 Month Maintenance 00 07 Procedure Pacco or 60 000 Mile 96 540 km or 48 Month Maintenance MOP initial Inspect A Engine Drive Belt Inspecting 01 01 Check Engine Support Fasteners Checking 01 02 Change zi and Filter see the engine manufacturers u Inspect A Inspecting and Maintenance 01 03 Inspect A Air Cleaner Inspecting and Replacing 09 01 Inspect Cooler Inspecting and Cleaning if cleaning is 09 02 Check Alternator Battery and Starter Checking 15 01 Inspect Radiator radiator cap coolant freeze points SCA levels T Check hose routing for chaffing and leaks 20 03 Change Mechanical Fan Drive Gearbox Oil Changing 20 04 Change Transmission Fluid and Filter if required by Allison 26 03 Inspect 1 Transmission Hose Routing for Chaffing and Leaks Lubricate Throttle Pedal Pivot Pin Lubricating 30 01 Inspect Suspension Check ______ Suspension Height Control Valve Checking 32 02 Lubricate A ZF IFS Lubricating 32 04 Check Suspension U Bolt Torque Checking 32 06 Lubricate Knuckle Pin Lubricating 33 01 Lubricate Tie Rod End Lubricating and In
64. hicle Chassis Maintenance Manual April 2010 Front Axle 33 Index Alphabetical Title of Maintenance Operation MOP MOP Number AIFAxIG Aligninent Gneckingd s x xe tb edat Sant dl 33 03 KOUCK Oo Fin EIGENS scs potare aduer A INS ac Geet a Gide cet d Reatard Aik aoe AR 33 01 Oil Filled Hubs Oil Changing io deba pack Peed awed ee er pe ed OE ed 33 06 OFF dled Hubs Oil Level CHeGKING es dinae tr Eoo qe eon dud toda a 33 05 Tie Rod End bubricaung and mnspeetirig x rods oa merere Pot RR ERU eh S ed te pe 33 02 Wheel Bearing Removal Cleaning Checking Repacking and 0 33 04 Recreational Vehicle Chassis Maintenance Manual September 2011 Front Axle 33 01 Knuckle Pin Lubricating Hold a high pressure grease gun on each fitting until fresh grease appears See Fig 1 or Fig 2 This will ensure that all of the old contaminated grease has been forced out 09 06 96 1320032 Pump lubricant into each grease fitting until fresh grease comes out at A 1 Grease Fitting Fig 1 Meritor Axle Grease Fittings 1 06 13 2003 1 1330213 1 Grease Fitting 2 Steering Knuckle Fig 2 ABP Axle Grease Fittings 33 When lubricating Meritor axle knuckle pin bushings or Alliance Brand
65. hicle Chassis Workshop Manual for inspection troubleshooting and re pair procedures or take the vehicle to an autho rized Freightliner dealer 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 reational Vehicle Chassis Workshop Manual for inspection and troubleshooting procedures or take the vehicle to an authorized Freightliner Brakes 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 Hecre ational Vehicle Chassis Workshop Manual for repair procedures or take the vehicle to an au thorized Freightliner dealer 42 12 Meritor Roller Pin Lubricating Remove all grease or oil from the camshaft head rollers and brake linings Always replace linings contaminated with grease or oil which can in crease stopping distances causing component damage and serious personal injury For Q and P series Meritor brakes lube the cam an chor and cam roller pins when the brake is disas sembled or every six months with Meritor specifica tion grease 0 617 A or 0 617 B See Fig 11 for roller and anchor pin lubrication poin
66. iction gauge t Beginning with model year 2002 RV chassis the coolant replacement interval is increased to 100 000 miles 161 000 km or 60 months You must check and if necessary recharge the SCA supplemental coolant additive levels and freeze point every 25 000 miles 40 000 km or 6 months See the Cummins Opera tion and Maintenance Manual for further information t For oil and filter change intervals see the applicable Allison Operator s Manual For Freightliner Meritor axles check for correct end play every 15 000 miles 24 135 km For ZF axles lubricate grease fittings annually and disassemble inspect and repack the bearings every 1 000 000 miles 1 609 000 km 1 For Freightliner rear axles with petroleum based oil change the lubricant every 100 000 miles 161 000 km or every 12 months whichever comes first if synthetic oil is used change the lubricant every 250 000 miles 402 000 km or every 12 months whichever comes first For Meritor rear axles with petroleum based oil change the lubricant every 100 000 miles 161 000 km or every 12 months whichever comes first if synthetic oil is used change the lubricant every 250 000 miles 402 000 km or every 36 months whichever comes first Perform these steps each time the wheels and or the vehicle is washed tt Replace the Bendix AD9 filter the Haldex Midland PURest air dryer filter kit every 36 months Lubricate every 6 months OR every 18 000 miles 28 0
67. ion then the in terval can be increased or decreased accord ingly Bendix AD 9 Replacement 1 Park the vehicle on a level surface Apply the parking brakes and chock the tires 2 Completely drain all air reservoirs Air pressure gauges should read 0 psi 0 kPa 3 Loosen the desiccant cartridge with a strap wrench at the base of the cartridge Spin off the cartridge and discard it 4 Remove the O ring from the threaded neck and discard it 5 Remove the coalescent filter and discard it IMPORTANT Lubricate the new O rings prior to installation 6 Install the new small O ring in the groove on the bottom of the new coalescent filter 7 Insert the coalescent filter with the O ring end going into the air dryer opening first The end of the filter with the X will then be facing out 8 Install the other new O ring over the threaded neck of the desiccant cartridge 9 Screw on the desiccant cartridge until resistance is detected Then tighten the cartridge 1 4 to 3 4 of a turn by hand Operational Check 1 Start the engine and build air pressure to 120 psi 827 kPa 2 Listen for the purge valve to open and release air A large volume of air will be expelled fol Recreational Vehicle Chassis Maintenance Manual May 2011 42 1 42 lowed by slow flow of air lasting approximately 30 seconds 3 Shut down the engine and remove the chocks from the tires 4 Perform the inspections in Mainten
68. ir purifying respirator approved by MSHA or NIOSH at all times when servicing the brakes starting with removal of the wheels and continuing through assembly To minimize the possibility of creating airborne brake lining dust clean the dust from the brake rotor brake caliper and brake assembly using an industrial type vacuum cleaner equipped with a high efficiency filter system Then using a rag soaked in water and wrung until nearly dry remove any remaining dust Do not use compressed air or dry brushing to clean the brake assembly 1 Apply the brake and chock the tires to prevent vehicle movement 42 2 Check the brake lining wear On front and rear axles replace linings worn to less than 3 16 inch 4 8 mm 3 Make sure that the brake rotor and linings are free of oil and grease NOTE To replace the brake linings see the ap plicable foundation brake section in Group 42 of the Recreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 42 11 Brake Inspecting IMPORTANT This procedure should be per formed prior to lubrication of the brake compo nents 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 low
69. ists tighten the nut on the clamp to the required torque If leakage persists install a new clamp 2 Check the exhaust pipe bellows and each ex haust seal clamp for leakage wear cracks or damage Replace damaged components as needed If leakage exists at a clamp tighten the nuts to the required torque If leakage persists install a new exhaust seal clamp Do not reuse seal clamps Once a seal clamp is loosened or removed it must be replaced 3 If present check the condition of the insulation material around the exhaust pipe between the turbocharger and the ATD as well as the ex haust wrap from the ATD to the diffuser 4 Check the ATD mounting bands for tightness Tighten to 30 41 N m if needed Do not overtighten 5 Check for leaks around the clamps that attach the ATD in the ATS and around the clamps that retain the DPF in the ATD No leaks are allowed anywhere in the system 6 Check all sensors attached to the ATD for leaks or damaged wires No leaks are allowed 7 Check the DPF exterior surface for dents or other damage See Fig 2 Item A A dent over 3 inches 76 mm in diameter and 1 4 inch 6 mm deep could cause internal damage to the DPF causing it to malfunction 8 Check for heat discoloration on the surface of the ATD Heat discoloration may indicate internal damage especially around the DPF 9 Check any wires lines or hoses within 4 inches 10 cm of the exhaust system for heat da
70. iuum Ren E Bees 46 01 Hydraulic Reservoir Filter Changing metal reservoir 46 06 Power Steering Reservoir Fluid Level 0 46 02 Power Steering Reservoir Fluid and Filter 0 46 03 Steering Driveline 0 1 2 2 4 46 04 Steering Gear bubricalting 225 veo pee Re 46 05 Recreational Vehicle Chassis Maintenance Manual February 2012 Steering 46 01 Drag Link Lubricating 1 Using a clean rag wipe the dirt from both grease fittings on the drag link 2 Using a pressure gun apply multipurpose chas Sis grease at the grease fittings until old grease is forced out of the socket NOTE Use multipurpose chassis grease NLGI grade 1 696 12 hydroxy lithium stearate grease or NLGI grade 2 896 12 hydroxy lithium stear ate grease The grade 2 chassis grease is pre ferred 46 02 Power Steering Reservoir Fluid Level Checking Side Mounted 1 Park the vehicle on a level surface shut down the engine and apply the parking brake Chock the rear tires 2 Clean around the power steering reservoir dip stick fill cap with a clean rag then remove the dipstick WARNING Fill only with approved clean fluid Do not
71. l line pressure of at least 80 psi 552 kPa 3 2 Check the air line fittings for leaks tighten or replace the fittings as needed 3 3 Coat the exhaust port and body of the valves with soapy water and check for leakage Leakage is excessive if it pro duces a 1 inch 25 mm bubble within 5 seconds If a brake valve does not function as de scribed above or if leakage is excessive replace it with a new or remanufactured unit Repeat the leakage checks before placing the vehicle in service 42 02 Air Dryer Inspecting 1 Check the reservoirs for moisture by pulling the lanyards A small amount a teaspoon or less is normal Larger amounts may mean that the des iccant needs to be replaced Check the mounting and connecting lines 2 Tighten the fasteners that attach the air dryer to the vehicle Use the following torque values 28 38 N m for SAE grade 5 3 8 16 fas teners 135 183 for SAE grade 5 5 8 11 fas teners Check all air lines fittings and electrical connec tions for damage leakage or looseness 3 Replace damaged or leaking parts and tighten loose fittings or electrical connections 42 42 03 Air Dryer Desiccant and Coalescent Filter Replacing NOTE Desiccant change intervals may vary from vehicle to vehicle Typical desiccant car tridge life is three years However if experience has shown that extended or shortened life has resulted on a particular installat
72. le Chassis Maintenance Manual May 2011 40 1 40 40 02 Wheel Cleaning and Polishing Accuride Machined and Polished Aluminum Wheels IMPORTANT Do not scrub the wheels before rinsing off particles with high pressure water Rubbing debris against the surface of the wheel can result in scratches Synthetic cleaning pads and wire brushes should not be used to clean the wheels Do not use strong detergents alkaline or acidic cleaners to clean Accuride aluminum wheels These solutions can etch the surface of the alu minum and leave dull areas Do not use pol ishes or wax on Accuride ACCU SHIELD alumi num wheels 1 Rinse the wheel with high pressure water to re move debris 2 Use 100 cotton cloth dipped in a mild soap solution to help remove built up dirt and grease Dish soap or automotive car wash soap are rec ommended 3 Rinse the remaining soap residue from the wheel Do not allow soap residue to dry on the surface of the wheel 4 Dry the wheel thoroughly with a 100 cotton cloth 5 Commercial bug tar grime cleaners may be used to remove stuck on particles from the wheel It is recommended that the cleaner be tested in an inconspicuous area for discoloration before treat ing the wheel 6 Do not use strong solvents to remove grease or grime from the surface of the wheel Damage to the wheel surface finish might occur 7 Do not use polishes or wax on ACCU SHIELD aluminum wheels The finish will
73. leaves of a damaged leaf spring assembly replace the complete spring as 32 4 Recreational Vehicle Chassis Maintenance Manual April 2010 Suspension 09 30 2004 f321018 1 Steering Knuckle Bearing Grease Fitting upper 2 Control Arm 3 Steering Knuckle Bearing Grease Fitting lower Fig 3 Pressure Grease Fitting Positions RL 75E 5 T 2 NIS y he e PANG EE BE 5 J J 49 09 30 2004 4 3 1321019 1 Steering Knuckle Bearing Grease Fitting upper 2 Control Arm Grease Fitting upper 3 Control Arm Grease Fitting lower 4 Steering Knuckle Bearing Grease Fitting lower Fig 4 Pressure Grease Fitting Positions RL 75EM sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Re placement of only the visibly damaged part s is no assurance that the spring is safe On front spring assemblies if cracks or breaks exist in the 32 two top leaves a loss of vehicle control could occur Failure to replace a damaged spring assem bly could cause an accident resulting in property damage serious personal 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 60 Inch Taper Leaf Spring Component Check No lubrication is required on the 60 inch taper leaf spring front and rear suspensi
74. lphabetical MOP Number Recreational Vehicle Chassis Maintenance Manual January 2010 Air Intake 09 01 Air Cleaner Inspecting and Replacing NOTE Remove and visually inspect the air cleaner element for obvious damage such as holes cuts or dents Remove loose debris such as leaves or pine needles from the filter housing Inspect the air cleaner and plumbing for holes or tears at the recommended interval If the air cleaner is damaged replace it See Group 09 of the Hecre ational Vehicle Chassis Workshop Manual for re moval and installation procedures or take the vehicle to an authorized Freightliner dealer A typical air cleaner mounting is shown in Fig 1 07 11 2007 d 1090451 Fig 1 Air Cleaner Mounting Engine damage can occur if the air intake system is not properly maintained Use the air intake restriction indicator to check for air intake system damage or leaks See Fig 2 Make sure the engine is off and note the existing reading on the indicator Reset the indicator by pushing it down See Fig 2 Start the engine and take a short test drive Check the indica tor again and note the level of restriction on the indi cator verifying it is at the same level as seen earlier A decrease from the previous level of restriction or a very low air restriction indicator reading 0 to 4 inH5O could indicate an air intake system problem such as a damaged air filter loose or disconnected 09 ai
75. lunger boot and check the plunger for existing lubrication 4 1 If the plunger is dry remove it by remov ing the brake pedal and brake plunger boot Lubricate the plunger and the inside surface of the boot with barium grease p n BW 246671 or Pennzoil Adhezoplex EP2 Install the plunger boot and the brake pedal IMPORTANT Use only these approved lubri cants 4 2 If the plunger has grease on it lift the edge of the brake plunger boot enough to apply 2 to 4 drops of light oil around the brake plunger where it slides into the brake base bracket Install the plunger boot around the brake base bracket 42 07 Bendix Hydro Max Brake System Inspecting front engine diesel chassis 10 31 94 D 1460513 A Open caps check fluid level B Fill to this level 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 8 Use only heavy duty brake fluid DOT 3 2 Check all hydraulic lines and fittings for damage leakage or looseness Replace damaged or leaking components and tighten loose fittings 3 Check the brake module for leaks If leaks are found repair or replace the brake module See Group 42 of the Recreational Vehicle Chassis Workshop Manual for replacement instructions Fig 8 Hydraulic Brake Fluid Reservoir or take the vehicle to an authorized Freightliner Chassis dealer 4 Check the el
76. ly Meritor Axle 1 Remove the filler plug then the drain plug and allow the differential to drain completely Install the drain plug Tighten it 24 34 N m Fill the differential with an SAE 80W 90 multipur pose gear lubricant or an SAE 75W 90 multipur pose synthetic gear lubricant See Table 2 for axle lubricant capacities Either type of lubricant must meet Military Specification L 2105 D and be suitable for American Petroleum Institute ser vice classification GL 5 The lubricant level within the differential must be even with the bot tom of the fill hole Recreational Vehicle Chassis Maintenance Manual September 2010 35 1 35 4 Install the fill plug Tighten it 24 34 N m Meritor Drive Axle Lubricant Capacity Axle Model Capacity pt L RS 15 120 16 7 6 RS 17 145 33 6 15 9 RS 19 145 34 4 16 3 RS 21 145 32 15 1 RS 23 160 42 19 9 RS 23 165 42 19 9 Quantities listed are approximate and include 1 pint 0 5 L for each wheel end and with the drive pinion at 3 degrees Table 2 Meritor Drive Axle Lubricant Capacity 35 03 Axle Breather Checking NOTE On Freightliner axles the axle housing breather is located on the carrier assembly The axle housing breather must remain unob structed Whenever the axle lubricant is checked or changed also make sure that the breather is open Check more often under poor operating conditions If the br
77. mage Repair or reroute as needed 49 Recreational Vehicle Chassis Maintenance Manual January 2010 49 3 49 Exhaust 53 RAKE SY 7 6 11 2 2006 1490284 A Inspect this area of the canister for dents C DPF Area B DOC Area 1 Inlet Temperature Sensor 6 Exhaust Outlet to Diffuser 2 Marmon Fitting at Inlet from Turbocharger 7 Outlet Temperature Sensor 3 Sensor Housing 8 DPF Outlet Pressure Sensor 4 DPF V Band Mounting Clamps 9 DPF Intake Pressure Sensor 5 Inlet Temperature Sensor Fig 2 Cummins Aftertreatment Device 49 4 Recreational Vehicle Chassis Maintenance Manual January 2010 Electrical Instruments and Controls 54 Index Alphabetical Title of Maintenance Operation MOP MOP Number Battery Voltage Checker suce noble Ibo aec are E db Se B RR bes ena Sb bee 54 02 Ground Cables Ghecking and Oleaniit rks Dare 54 01 Recreational Vehicle Chassis Maintenance Manual September 2007 Electrical Instruments and Controls 54 01 Ground Cables Checking and Cleaning Check that the ground cables are clean undamaged and tight If needed disconnect them clean the mat ing surfaces with a soda solution then connect them securely Spray the ground cable connections with dielectric red enamel 54 02 Battery Voltage Checking Check the battery open circuit voltage using an accu rate voltmeter If the voltmeter regi
78. maintain the bright and shiny surface for years to come with out the need for special polishes Wheels and Tires 40 2 Recreational Vehicle Chassis Maintenance Manual May 2011 Driveline 41 Index Alphabetical Title of Maintenance Operation MOP MOP Number Driveline Inspecting and Lubricating 2 2 9 adque sme die quaes dup seus Pu d mE anes Pam E pep 41 01 Recreational Vehicle Chassis Maintenance Manual January 2010 Driveline 41 01 Driveline Inspecting and Lubricating Inspecting Before lubricating the driveline U joints and slip joints make the following checks 1 Check that the yoke strap capscrews are tight ened 50 to 60 68 to 81 N m NOTICE Do not overtighten the yoke strap capscrews due to the extreme load occurring at high speed rota tion A loose or broken capscrew at any point in the driveline weakens the driveline connection which could eventually result in serious vehicle damage 2 Check the slip joints for spline wear by trying to bend the sleeve yoke and splined shaft back and forth If looseness is greater than 0 007 inch 0 18 replace both the sleeve yoke and the splined shaft 3 Check the driveshaft for missing balance weights and for debris buildup Remove any buildup If any balance weights are missing re move the driveshaft and have it balanced For instructions see Group 41 of the Hecreational Vehicle Chassis Workshop Manual or take the vehicl
79. mix fluid types Any mixture or any unapproved fluid could lead to seal deterioration and leaks Fluid leakage could cause loss of power steering assist possibly resulting in personal injury and property damage 3 With the power steering fluid at operating tem perature check the fluid level on the dipstick If below the Add mark add enough fluid to bring the level up to the Full mark on the dipstick See Table 1 for approved power steering fluid Approved Power Steering Fluid Fluid Type Approved Fluid Automatic Transmission Fluid Dexron III 46 Approved Power Steering Fluid Fluid Type Approved Fluid Hydraulic System Fluid power steering with side mounted radiator Ten Use the same lubricant when assembling parts as is used in the power Steering system Table 1 Approved Power Steering Fluid 4 Install the dipstick fill cap in the power steering reservoir Rear Mounted 1 Parkthe vehicle on a level surface shut down the engine and apply the parking brake Chock the rear tires 2 Clean around the power steering reservoir cap with a clean rag then remove the reservoir cap See Fig 1 P S gt HYDRAULIC STEERING RESERVOIR FLUID AEN DEXRON III 04 10 97 1461177 Fig 1 Steering System Hydraulic Fluid Reservoir rear mounted A WARNING Fill only with approved clean fluid Do not mix fluid types Any mixture or any
80. n this form indicates that you have reviewed and agree to the service items to be performed Any items you wish to exclude should be indicated with a no to the left of that service item Recreational Vehicle Chassis Maintenance Manual February 2012 00 9 00 General Information 30 000 Mile or 24 Month Maintenance 00 05 Procedure 30 000 Mile 48 270 km or 24 Month Maintenance MOP initial Inspect Engine Drive Belt Inspecting 01 01 Check Engine Support Fasteners Checking 01 02 Change zi and Filter see the engine manufacturers u Inspect A Inspecting and Maintenance 01 03 Inspect A Air Cleaner Inspecting and Replacing 09 01 Inspect Cooler Inspecting and Cleaning if cleaning is 09 02 Check Alternator Battery and Starter Checking 15 01 Inspect Radiator radiator cap coolant freeze points SCA levels T Check hose routing for chaffing and leaks 20 03 Change Mechanical Fan Drive Gearbox Oil Changing 20 04 Change Transmission Fluid and Filter if required by Allison 26 03 Inspect 1 Transmission Hose Routing for Chaffing and Leaks Lubricate Throttle Pedal Pivot Pin Lubricating 30 01 Inspect Suspension Check ______ Suspension Height Control Valve Checking 32 02 Lubricate A ZF IFS Lubricating 32 04 Check Suspension U Bolt Torque Checking 32 06 Lu
81. n valves 2 9 Disconnect all hoses from the surge tank Remove the tank and pour out any fluid Scrub and clean the inside of the surge tank with soap and water Flush it with clean water then drain it Install the surge tank and hoses IMPORTANT On vehicles with EPAO7 compliant engines the coolant capacity varies depending on the engine and accessory installation After servicing the cooling system always verify that the coolant level is between the MIN and MAX lines on the surge tank 3 Fill the cooling system as follows Engine Cooling R adiator 3 1 Slowly add a 50 50 mixture of antifreeze and water to the surge tank until the sys tem is filled Install the coolant fill cap 3 2 Start the engine and run it at low idle for 10 seconds then at high idle for 1 minute Return to low idle 3 3 Run the engine with the radiator cap re moved until the upper radiator hose is hot With the engine idling add coolant to the radiator until it is between the MIN and MAX lines on the surge tank Install the radiator cap 20 04 Mechanical Fan Drive Gearbox Oil Changing 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires 2 Place a drain pan under the fan drive gearbox IMPORTANT Label the plugs as they are re moved The breather fill plug must always be installed in the top of the gearbox opposite the drain plug 3 Remove the drain plug and breather fill
82. ndix Hydro Max Brake System Inspecting front engine diesel 42 07 Brake Caliper Slide Pin Lubricating Bosch Brakes front engine diesel 42 08 Brake speci seas x oa e tad nd dr RR d RR ORA Nep qe QR Rd d RR Rd d qd 42 11 Brake Lines Checking Hydraulic Disc or Air 42 09 Brake Lining Wear Checking Hydraulic Disc Brakes front engine diesel CHASSIS doce us e ru e eo ed HC Ew ed ede edet ad Kobe die e eee eee PEt ies Bites 42 10 Brake System Valves 1nspectiht a s dtp do bot Een pd heed 42 01 Camshaft Bracket Bushing 0 42 04 Foot Brake Valve Actuator Lubricating snos pre m RR REA E ER E ERES 42 06 Meritor Roller Pin Lubricating s ss sweikia Geb Sareea de 42 12 slack UGCA NO d eniro d act a dialed tard da ede trarre doceat 42 05 Recreational Vehicle Chassis Maintenance Manual May 2011 Brakes 42 01 Brake System Valves Inspecting 1 Clean the valves exterior and inspect them for corrosion and damage 2 Inspect the air lines connected to the valves for signs of wear or damage Replace the lines as needed 3 Check the valves for leakage 3 1 Apply the service brakes and hold them on a ful
83. neral Information 00 45 000 Mile or 36 Month Maintenance 00 06 Procedure i eA 45 000 Mile 72 405 km or 36 Month Maintenance initial Lubricate Foot Brake Valve Actuator Lubricating 42 06 Inspect 00 e 7 Brake System Inspecting 42 07 Lubricate 2 Lubricating Bosch Brakes front 42 08 Check Lines Checking Hydraulic Disc or Air Brakes 42 09 Check 00 2 2 Checking Hydraulic Disc Brakes 42 10 Inspect _ A Brake Inspecting Air Brakes 42 11 Lubricate Meritor Roller Pin Lubricating 42 12 Drain Tanks Lubricate 1 Drag Link Lubricating 46 01 Inspect A Power Steering Reservoir Fluid and Filter Changing 46 03 Lubricate Steering Driveline Lubricating 46 04 Lubricate Steering Gear Lubricating 46 05 Inspect _____ Hydraulic Reservoir Filter Changing including TRW 46 06 Inspect 7 Mounts and Fuel Line Checking 47 01 Change FuelFilters Inspect Exhaust System Inspecting 49 01 Check Ground Cables Checking and Cleaning 54 01 Inspect Air Conditioner Component Inspection 83 01 Customert Date Additional copies are available on the Freightliner Custom Chassis Corporation website www freightlinerchas sis com t Your signature on this form indicates that you have reviewed and agree to the service items to be performed Any items you wis
84. ns 2d ricus ex Euh dee ein tape 47 01 Fuel Water Separator Element 47 02 Recreational Vehicle Chassis Maintenance Manual January 2010 Fuel 47 01 Fuel Tank Mounts and Fuel Line Checking Inspect the components as described below Fail ure to perform these inspections could result in the failure of the fuel tank mounting assembly and loss of vehicle control possibly causing personal injury or death or property damage 1 Chock the tires Working at the front of the ve hicle or at the rear of the vehicle raise the ve hicle so that the tires just clear the ground and so that the suspension is fully extended Place safety stands under the vehicle frame 2 Check the T bolts that attach the fuel tank mounting straps to the mounting brackets Check to see that the nuts are tight 3 Inspect the fuel tank straps for damage or wear Replace them if necessary 4 Inspect the fuel tank for leaks or damage Re place the tank if necessary IMPORTANT Do not attempt to repair a dam aged fuel tank always replace a damaged fuel tank 5 Inspect the fuel lines for damage or wear 6 Remove the safety stands and lower the vehicle Remove the chocks from the tires 47 02 Fuel Water Separator Element Replacing 1 Chock the front tires Locate the fuel water separator See the Cummins Operation and Maintenance
85. ns ATD Sensor Locations 6 Check all sensors attached to the ATD for leaks or damaged wires No leaks are allowed 7 Check the DPF exterior surface for dents or other damage A dent over 3 inches 76 mm in diameter and 1 4 inch 6 mm deep could cause internal damage to the DPF causing it to mal function 8 Check the SCR catalyst for dents and other damage 9 Check for heat discoloration on the surface of the ATD Heat discoloration may indicate internal damage especially around the DPF NOTE Diesel exhaust fluid creeps causing white crystals to form around the line fittings The presence of crystals does not mean the system has a leak Replacing fittings or trouble shooting components is not necessary unless there is a system failure or a fault code Exhaust 10 Check the DEF tank pump metering unit and lines for leaks See Group 49 of the Recre ational Vehicle Chassis Workshop Manual for repair procedures 11 Check any wires lines or hoses within 4 inches 10 cm of the exhaust system for heat damage Repair or reroute as needed Diesel Exhaust Fluid DEF Filter Replacement The Environmental Protection Agency s 2010 regula tions require lower nitrogen oxide NOx exhaust emissions Selective catalytic reduction SCR uses diesel exhaust fluid DEF to lower NOx emissions in the vehicle exhaust A filter in the DEF pump pre vents clogging of the DEF metering unit injection nozzle See the engine ma
86. nufacturer s maintenance manual for DEF filter replacement instructions and mainte nance intervals 07 Exhaust System Definitions of ATS Terms Refer to the following list of definitions of ATS terms and components Aftertreatment System ATS the entire ex haust system from the turbocharger to the tail pipe e Aftertreatment Device ATD a muffler like can ister that houses a DPF and sensors Diesel Particulate Filter 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 pressure within the ATS e Diffuser a device used as a deflector for dis tributing mixing and reducing the velocity of air flow Inspection IMPORTANT The Environmental Protection Agency s 2007 regulations require lower ex haust emissions thus requiring new exhaust 49 2 Recreational Vehicle Chassis Maintenance Manual January 2010 Exhaust system components See Fig 2 In particular the aftertreatment device ATD which is part of the aftertreatment system ATS requires spe cial attention during regularly scheduled mainte nance inspections If any discrepancies are dis covered refer to the engine manufacturer s service literature for repair instructions 1 Check for leakage at the clamp that attaches the exhaust pipe to the turbocharger exhaust outlet If leakage ex
87. o discontinue models and to change specifications or design at any time without notice and without incurring obligation Descriptions and specifications contained in this publication provide no warranty expressed or implied and are subject to revision and editions without notice Refer to www Daimler TrucksNorthAmerica com and www FreightlinerChassis com for more information or contact Daimler Trucks North America LLC at the address below Environmental Concerns and Recommendations Whenever you see instructions in this manual to discard materials you should attempt to reclaim and recycle them To preserve our environment follow appropriate environmental rules and regulations when disposing of materials NOTICE Parts Replacement Considerations Do not replace suspension axle or steering parts such as springs wheels hubs and steering gears with used parts Used parts may have been subjected to collisions or improper use and have undetected structural damage 1997 2012 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 is a Damiler company Daimler Trucks North America LLC Service Systems and Documentation CVI SS
88. o the tail pipe including the Selective Catalytic Reduction SCR components Aftertreatment Device ATD a device that re moves pollutants from exhaust gas after the gas leaves the combustion chamber BlueTec Daimler s proprietary SCR technol ogy Diesel Oxidation Catalyst DOC a flow through device that enhances the oxidation of hydrocarbons in the ATD Diesel Particulate Filter DPF a component in the ATD that traps particulate matter from the exhaust gas Diesel Exhaust Fluid DEF the chemical agent that reacts with the exhaust gases in the SCR to reduce NOx DEF Pump filters and supplies DEF to the DEF metering unit 49 e DEF Tank holds DEF and regulates its tem perature e DEF Metering Unit mixes DEF with com pressed air and meters this mixture into the exhaust flow via an injection nozzle e SCR Catalyst the housing containing a treated ceramic flow through block where the DEF and exhaust gases undergo selective catalytic re duction Selective Catalytic Reduction SCR a process used to reduce NOx emissions Inspection IMPORTANT The Environmental Protection Agency s 2010 regulations mandate lowered exhaust emissions thus requiring exhaust sys tem components that reduce emissions In par ticular the aftertreatment device ATD which is part of the aftertreatment system ATS requires special attention during regularly scheduled maintenance inspections See Fig 1 f
89. on Inspect the rear shackle brackets for bushing wear or cracks Inspect the stabilizer bar if present for irregular bushing wear or cracks in the brackets Check the rubber helper spring if present for cracks 32 06 Suspension U Bolt Torque Checking Check the U bolt torque of both the front and rear axles where applicable A CAUTION Failure to retorque the U bolt nuts could result in spring breakage and abnormal tire wear 1 Park the vehicle on a flat surface apply the park ing brake and chock the tires 2 Check the U bolt torque in a diagonal pattern Set a click type torque wrench to the highest torque value for the fastener being checked See Table 3 for U bolt torque specifications Turn the wrench in a clockwise motion looking up until the torque wrench clicks 3 Remove the chocks Recreational Vehicle Chassis Maintenance Manual April 2010 32 5 32 Suspension U Bolt Torque Values m Torque Description Size Ibf ft N m Stage 1 Hand tighten T Stage 2 60 81 9 8718 Stage 3 200 271 Stage 4 180 to 230 245 to 313 Spring Assembly U Bolt High Nuts Stage 1 Hand tighten Stage 2 60 81 Stage 3 200 271 Stage 4 270 to 330 367 to 449 Tighten in the sequence shown in Fig 5 Table 3 U Bolt Torque Values 03 10 2011 2 1320783 Fig 5 Tightening Sequence for U Bolt High Nuts 32 6 Recreational Ve
90. or Using low water pressure rinse the radiator Be careful not to damage or bend the 20 fins of the radiator Depending on the condition of the radiator this process may have to be performed sev eral times 20 03 Coolant Replacing At the intervals specified in the maintenance sched ule or whenever the coolant becomes dirty flush and refill the cooling system NOTE The coolant replacement interval is in creased to 100 000 miles 161 000 km or 60 months whichever comes first For this interval to apply you must check and if necessary re charge the SCA supplemental coolant additive levels and the freeze point every 25 000 miles 40 000 km or 6 months whichever comes first See the Cummins Operation and Maintenance Manual for further information A WARNING Do not remove or loosen the radiator cap until the engine and cooling system have completely cooled Use extreme care when removing the cap A sudden release of pressure from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause seri ous personal injury 1 Drain the cooling system as follows 1 1 When the engine is cool remove the ra diator cap Turn the cap slowly counterclockwise until it reaches a stop Do not press down while turning the cap Wait until any re maining pressure indicated by a hissing sound is relieved then press down on the cap and continue turning it counter clockwise
91. or Cum mins ATD sensor locations If any discrepancies are discovered refer to the engine manufactur service literature for repair instructions 1 Check for leakage at the clamp that attaches the exhaust pipe to the turbocharger exhaust outlet If leakage exists tighten the nut on the clamp to the required torque If leakage persists install a new clamp 2 Check the exhaust pipe bellows and each ex haust seal clamp for leakage wear cracks or damage Replace damaged components as needed If leakage exists at a clamp tighten the nuts to the required torque If leakage persists install a new exhaust seal clamp Do not reuse seal clamps Once a seal clamp is loosened or removed it must be replaced 3 If present check the condition of the insulation material around the exhaust pipe between the turbocharger and the ATD 4 Check the ATD mounting bands for tightness Tighten to 30 41 N m if needed Do not overtighten 5 Check for leaks around the clamps that attach the ATD in the ATS and around the clamps that retain the DPF in the ATD No leaks are allowed anywhere in the system Recreational Vehicle Chassis Maintenance Manual January 2010 49 1 49 10 20 2009 1490386 Exhaust Outlet SCR Outlet NOx Sensor DPF Outlet Pressure Sensor DPF Intake Pressure Sensor DPF Inlet Temperature Sensor SCR Inlet Temperature Sensor SCR Outlet Temperature Sensor NOORONN Fig 1 Cummi
92. ove the filler plug then the drain plug in the center bottom of the axle housing and allow the differential to drain completely 2 Install the drain plug and tighten it securely 35 3 Fill the differential with 80 90 hypoid gear oil through the rear axle fill hole See Table 1 for axle lubricant capacities Freightliner Drive Axle Lubricant Capacity Differential Hubs Capacity qt L Differential Only 5 8 5 5 7 4 7 0 Table 1 Freightliner Drive Axle Lubricant Capacity Differential and Hubs NOTE A normal oil change does not include the hubs Drain the differential and add 5 8 qt 5 5 L of 80 90 hypoid gear oil through the rear axle fill hole The lubricant level should be at the bot tom of the fill hole IMPORTANT The entire axle capacity axle completely dry is 7 4 qt 7 L Each hub con tains 0 80 gt 0 75 L of lubricant To protect the outer bearings from oil starvation jack up ar ticulate each side of the axle a minimum of 4 inches 10 cm to ensure that oil flows to the outer bearings Articulate the short side arm for 45 seconds and the long side arm for 90 sec onds After articulating the axle add 0 80 qt 0 75 L of lubricant through the fill hole in addi tion to the 5 8 qt 5 5 L of a normal oil change for each hub that has been removed Check the oil level again and ensure that the axle is nei ther under nor over filled 4 Install the fill plug and tighten it secure
93. r at the grease fitting with any extreme pressure NLGI Grade 1 or Grade 2 grease if the operating temperature is 20 F 29 and above If the operating tempera ture is below 20 29 C use a low temperature extreme pressure grease Meritor Lubricate the slack adjuster at the grease fitting until grease is forced past the pressure relief capscrew or past the gear splines around the inboard snap ring Use high temperature NLGI Grade 1 waterproof grease See Fig 6 Bendix Using a quality multipurpose chassis lubricant NLGI Grade 2 lubricate the automatic slack adjuster through the lube fitting See Fig 7 Lubricate the slack adjuster until clean lubricant flows from the grease relief opening in the boot Fig 6 Meritor Automatic Slack Adjuster other slack adjustors are similar 06 17 2010 1430511 1 Yoke 5 Boot 2 Yoke Pin 6 Lube Fitting 3 Link Pin 7 Worm Gear 4 Link Fig 7 Bendix Automatic Slack Adjuster 42 4 Recreational Vehicle Chassis Maintenance Manual May 2011 Brakes 42 06 Foot Brake Valve Actuator Lubricating 42 1 Clean any dirt gravel and other foreign material from the base of the brake pedal the plunger boot and the brake base bracket 2 Use light oil to lubricate the brake pedal roller and pivot pin 3 Check the brake plunger boot for cracks holes or deterioration Replace it if necessary 4 Lift the edge of the brake p
94. r axle Use the appli cable procedure and specifications in Group 35 of the Recreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Toe In Inspection For vehicle alignment to be accurate the shop floor must be level in every direction The turn plates for 33 2 Recreational Vehicle Chassis Maintenance Manual September 2011 Front Axle the front wheels must rotate freely without friction and the alignment equipment must be calibrated every three months by a qualified technician from the equipment manufacturer Freightliner dealers must have proof of this calibration history NOTE Toe in should be within O to 1 32 inch 0 8 mm 1 Apply the parking brake and chock the rear tires 2 Raise the front of the vehicle until the tires clear the ground Check that the safety stands will support the combined weight of the body axle and frame Place safety stands under the axle 3 Using spray paint or a piece of chalk mark the entire center rib of each front tire 4 Place a scribe or pointed instrument against the marked center rib of each tire and turn the tires Hold the scribe firmly in place so that a single straight line is scribed all the way around each front tire 5 Place a turn plate or turntable under both front tires Remove the safety stands from underneath the axle then lower the vehicle Remove the lockpins from the gauges make sure that the tires
95. r intake piping or a disconnected or damaged air restriction indicator H20 VACUUM IN H90 VACUUM 25 20 1 15 10 7 ap PUSH TO RESET 05 22 97 f090176 Fig 2 Air Restriction Indicator Replace the air cleaner at the recommended interval or when filter restriction reaches 25 inH O See the Recreational Vehicle Chassis Operator s Manual for specific restriction values for your engine See Group 09 of the Hecreational Vehicle Chassis Work shop Manual for removal and installation procedures or take the vehicle to an authorized Freightliner dealer 09 02 Charge Air Cooler Inspecting and Cleaning Good airflow through the radiator and charge air cooler core is essential for proper engine cooling The cores allow air passage but form a barrier that tends to collect insects and airborne debris If the charge air cooler core fins are bent use a small pair of needle nose pliers or a small screw driver to straighten them If the fins are clogged use compressed air or water directed from the fan side of the radiator core to backflush any material restricting airflow Ensure that the hoses are not chafing and that the System is closed with no air leaks Recreational Vehicle Chassis Maintenance Manual January 2010 09 1 Alternators and Starters 15 Index Alphabetical Title of Maintenance Operation MOP MOP Number Alternator Battery and Starter 0
96. se wheel shimmy resulting in wheel damage stud break age and extreme tire tread wear Too much wheel nut torque can break studs damage threads and crack discs in the stud hole area Tighten the wheel nuts On 6 stud stud pilot hubs tighten the wheel nuts 450 to 500 Ibf ft 610 to 678 N m See Fig 1 for the tightening sequence On 8 stud or 10 stud hub pilot hubs with 20 mm studs tighten the wheel nuts 280 to 310 Ibf ft 380 to 420 N m See Fig 2 or Fig for the tightening sequence On 8 stud or 10 stud hub pilot hubs with 22 mm studs tighten the wheel nuts 450 to 500 610 to 678 N m See Fig 2 or Fig for the tightening sequence NOTE Wheel nuts for 20 mm stud hubs require a 1 3 16 inch 80 socket Wheel nuts for 22 mm stud hubs require a 1 5 16 inch 33 mm socket A B 2 1 4 5 3 6 6 3 5 4 1 2 08 20 96 400119 A Front and Inner Rear Dual B Outer Rear Dual Fig 1 Wheel Nut Tightening Sequence 6 stud hubs A B O E 1 2 bo 1 N 4 5 6 N N 8 7 7 8 6 4 G 5 D 06 23 2000 f400159 A Front and Inner Rear Dual B Outer Rear Dual Fig 2 Wheel Nut Tightening Sequence 8 stud hubs A B 2 AN AN o 9 PNE 10 M 4 5G N G 8 6 oe G A 10 D 1 d 2 gt 09 28 98 1400142 A Front and Inner Rear Dual B Outer Rear Dual Fig 3 Wheel Nut Tightening Sequence 10 stud hubs Recreational Vehic
97. specting 33 02 Check Wheel Bearing Removal Cleaning Checking Repacking 33 04 Lubricate and Adjusting 33 05 a Oi Filled Hubs Oil Level Checking front and tag axle 35 05 Check Axle Seals for Leaks Change Axle Lubricant Changing Freightliner axle only 35 02 Check Axle Breather Checking 35 03 Check Wheel Nut Checking 40 01 Check Tire Pressure Lubricate Driveline Inspecting and Lubricating 41 01 Inspect Brake System Valves Inspecting 42 01 Inspect and Air Lines for Proper Routing Chaffing and 42 02 00 14 Recreational Vehicle Chassis Maintenance Manual February 2012 General Information 00 60 000 Mile or 48 Month Maintenance 00 07 Additional copies are available on the Freightliner Custom Chassis Corporation website www freightlinerchas sis com t Your signature on this form indicates that you have reviewed and agree to the service items to be performed Any items you wish to exclude should be indicated with a no to the left of that service item Procedure i Ferformed 60 000 Mile 96 540 km or 48 Month Maintenance initial Lubricate _ Camshaft Bracket Bushing Lubricating 42 04 Lubricate Adjuster Lubricating 42 05 Lubricate Foot Brake Valve Actuator Lubricating 42 06 Inspect 2 4 Brake System Inspecting 42 07 Lubricate
98. sters 12 5V or below fully charge the battery to 12 65V A fully charged battery will have a voltage of 12 65V with the charger disconnected 54 Recreational Vehicle Chassis Maintenance Manual September 2007 54 1 Heater and Air Conditioner 83 Index Alphabetical Title of Maintenance Operation MOP MOP Number Ar Conditioner Inspectlhit distri nani oari M debba du 83 01 Recreational Vehicle Chassis Maintenance Manual 2010 Heater and Air Conditioner 83 01 Air Conditioner Inspecting Wear eye protection gloves and protective cloth ing when working on the air conditioning system Leaking refrigerant from a damaged hose or line could cause blindness or serious skin burns 1 Park the vehicle on a level surface shutdown the engine apply the parking brake and chock the tires CAUTION To avoid the possibility of burns make certain that the engine and air conditioner components are not hot 2 Check the appearance of the air conditioner compressor pulley assembly If the friction sur face of the pulley shows signs of excessive grooving due to belt slippage replace both the pulley and the drive plate Visually inspect the refrigerant compressor drive belt for damage and check that the belt is set at the proper ten sion Also check the tightness of the compressor mounting fasteners For instructions and torque values and for removal and ins
99. t and Coalescent Filter Replacingtt 42 04 Camshaft Bracket Bushing Lubricating 42 05 Slack Adjuster Lubricating 42 06 Foot Brake Valve Actuator Lubricating 42 07 Bendix Hydro Max Brake System Inspecting front engine diesel chassis Recreational Vehicle Chassis Maintenance Manual February 2012 00 3 00 Vehicle Maintenance Schedule Table 00 02 General Information Maintenance Operation Number and Description Maintenance Operation Procedures and Schedule Maintenance Interval in Miles x 1000 15 30 45 60 90 105 120 135 150 165 180 195 210 225 240 255 270 285 Maintenance Interval i n Kilome ters x 1000 24 48 72 96 145 169 193 217 241 265 290 314 338 362 386 410 434 458 nten ance Interval in Months 12 24 96 48 72 84 96 108 120 132 144 156 168 180 192 204 216 228 42 08 Brake Caliper Slide Pin Lubricating Bosch Brakes front engine diesel chassis t 42 09 Brake Lines Checking Hydraulic Disc or Air Brakes 42 10 Brake Lining Wear Checking Hydraulic Disc Brakes front engine diesel chassis 42 11 Brake Inspecting 42 12 Meritor Roller Pin Lubricating 46 01 Drag Link Lubricating 46 02 Power Steering Reservoir Fluid Level Checking 46 03
100. tallation proce dures see Group 83 of the Recreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 3 Inspect the compressor clutch coil wire Ensure that the connector is not damaged or loose Re place the wire if it is damaged 4 Check the overall condition of the air conditioning hoses Look for cracks cuts and abrasions on the hoses Replace damaged hoses see Group 83 of the Recreational Vehicle Chassis Work shop Manual for replacement instructions or take the vehicle to an authorized Freightliner dealer Also visually check for loose fittings on all air conditioning components Do not over tighten the fittings 5 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 83 Recreational Vehicle Chassis Maintenance Manual Apirl 2010 83 1
101. ten the cap head Too much force will strip the screw 9 Install the hub cap and tighten the cap head just until snug Recreational Vehicle Chassis Maintenance Manual September 2010 35 3 Wheels and Tires Title of Maintenance Operation MOP Wheel Cleaning and Wheel Nut Checking auster beer RA RE RE RAS 40 Index Alphabetical MOP Number Recreational Vehicle Chassis Maintenance Manual May 2011 Wheels and Tires 40 01 Wheel Nut Checking 40 IMPORTANT In addition to the maintenance interval in this manual check the wheel nut torque the first 50 to 100 miles 80 to 160 km of operation after a wheel has been removed and installed NOTE On each wheel stud the end that faces away from the vehicle is stamped with an L or an depending on which side of the vehicle the stud is installed Studs stamped with an L are left hand threaded and are installed on the driver s side of the vehicle Studs stamped with an R are right hand threaded and are installed on the passenger s side of the vehicle When checking wheel nuts on a dual disc assembly remove one outer nut at a time tighten the inner nut then reinstall the outer nut Repeat this procedure for all of the inner wheel nuts in the sequence shown in Fig 1 Fig 2 or Fig 3 Then tighten all of the outer wheel nuts in the same sequence CAUTION Too little wheel nut torque can cau
102. tical Title of Maintenance Operation MOP MOP Number Neway Suspension Im paeellfft zs s decent n o pare e lor db uus RARE 32 03 suspension Fastener Torque Checking 2 eae et 32 01 Suspension Height Control Valve 0 32 02 SUSPENSION JspSctht 425 co icq 32 05 Suspension U Bolt Torque 0 32 06 ZF IFS Lubricating pase ph dope ete ole breton ple barata e ete d 32 04 Recreational Vehicle Chassis Maintenance Manual April 2010 Suspension 32 01 Suspension Fastener Torque Checking 32 32 02 Suspension Height Control Valve Checking Inspect the suspension fasteners Failure to per form inspections could result in separation of worn suspension components and loss of vehicle control possibly causing personal injury or death or property damage 1 Chock the front or the rear tires Working at the front of the vehicle or at the rear of the vehicle raise the vehicle so that the tires just clear the ground and the suspension is fully extended Place safety stands under the vehicle frame 2 Check the suspension fasteners See Table 1 for correct fastener torques 3 Check the torque of the rear axle U bolts In a
103. ts dealer Brake Chamber Stroke Specifications Chamber Max Applied Stroke inch mm Manufacturer Type Sizet 12 1 3 8 35 16 Standard Stroke 20 1 3 4 44 24 Haldex 2 1 2 Inch Extended Stroke 24 2 51 3 Inch Extended Stroke 24 2 1 2 64 Standard Stroke 30 2 51 Long Stroke 30 2 1 2 64 42 8 Recreational Vehicle Chassis Maintenance Manual May 2011 Brakes 42 Brake Chamber Stroke Specifications Chamber Max Applied Stroke inch mm Manufacturer Type Sizet 9 Less than 1 1 2 38 12 Standard Stroke 16 Less than 1 3 4 44 Meritor 20 24 Less than 1 7 8 48 Long Stroke 24 Less than 2 51 Standard Stroke 30 Long stroke design is indicated by a tag or embossing on the brake chamber t Specifications are relative to a brake application with 80 to 90 psi 550 to 620 kPa air pressure in the brake chambers Table 1 Brake Chamber Stroke Specifications 1 2 3 03 02 2004 1430370 1 Cam Roller Pin Lube Point Q Series 2 Cam Roller Pin Lube Points Q Q Plus and P Series 3 Cam Anchor Pin Lube Points Q Q Plus and P Series Fig 11 Cam and Anchor Roller Pin Lubrication Points Recreational Vehicle Chassis Maintenance Manual May 2011 42 9 Steering 46 Index Alphabetical Title of Maintenance Operation MOP MOP Number rag dens Prasad Ebr latas eM dee ones
104. udinal direction of belt length cracks that intersect with transverse cracks are not accept able 2 Replace the belt if it has unacceptable cracks is frayed or has pieces of material missing For additional information see the Cummins Op eration and Maintenance Manual 01 02 Engine Support Fasteners Checking 1 Check the rear engine support fasteners See Fig 1 Tighten the rear engine mount bolt 157 213 Tighten the insulator to frame mount bracket bolts 91 Ibf ft 123 Tighten the engine mount bracket to engine bolts 62 84 N m 2 Check the 3 4 10 front engine front mount bolt See Fig 2 Tighten it 95 Ibf ft 128 N m Check the 3 4 10 rear engine front mount bolt Tighten it 95 128 N m 01 03 Pacbrake Inspecting and Maintenance Pacbrake recommends lubricating the moving parts of the exhaust brake with a synthetic based lubricant at every oil change Once the lubricant is applied the exhaust brake should be cycled a few times to en sure that the lubricant penetrates into the mating parts 01 11 08 2005 f0120111 1 Front and Rear Engine Rear Mount Bolt 2 Engine Mount Bracket to Engine Bolts 3 Frame Mount Bracket Bolts Fig 1 Front and Rear Engine Rear Mount ISB chassis built after 2002 11 08 2005 1012110 1 Front and Rear Engine Front Mount Bolt
105. ug from the reservoir and reconnect the steering gear to reservoir hose to the reservoir 8 Tighten the hose fitting nut finger tight then with a wrench tighten until there is firm resistance Tighten one sixth turn more Do not overtighten Remove the jack stands and lower the vehicle 9 Fill the reservoir with approved fluid as needed Start the engine and let it idle for 10 seconds Have an assistant turn the steering wheel from lock to lock until no bubbles are seen in the res ervoir Shut down the engine 46 2 Recreational Vehicle Chassis Maintenance Manual February 2012 Steering 10 Install a new cover gasket the cover and the dipstick 11 Start the engine and check the power steering reservoir fluid level If the fluid level is low add more of the approved fluid to bring the level up to the full mark on the dipstick Turn the steering wheel from lock to lock to flush out any air Shut down the engine 46 04 Steering Driveline Lubricating Wipe the grease fittings clean Using a pressure gun apply a lithium based grease NLGI grade 2 spar ingly to the universal joints and slip joint splines 46 05 Steering Gear Lubricating 1 Wipe off debris from the grease fitting 2 Using a hand type grease gun apply multipur pose chassis grease until the grease starts com ing out of the sector shaft dirt and water seal Figure 3 shows the location of the sector shaft grease fitting 04 13
106. unapproved fluid could lead to seal deterioration and leaks Fluid leakage could cause loss of power steering assist possibly resulting in personal injury and property damage IMPORTANT Do not confuse coolant with hy draulic fluid Both are pink in color Recreational Vehicle Chassis Maintenance Manual February 2012 46 1 46 3 Fill the reservoir to a level between the MIN and MAX marks Use only Dexron Ill automatic trans mission fluid ATF or an equivalent See Table 1 for approved power steering fluid 4 Replace the reservoir cap 46 03 Power Steering Reservoir Fluid and Filter Changing 1 Remove the dipstick if so equipped 2 Drain the power steering reservoir by disconnect ing the power steering gear to reservoir hose from the reservoir Catch the fluid from the reser voir in a drain bucket then cap the reservoir port 3 Loosen the clamps on each end of the inline power steering filter and save them for reuse Remove the old filter if so equipped IMPORTANT Do not use teflon tape on the threads of the hose barb fittings 4 Unscrew the hose barb fitting and the 90 degree hose barb elbow fitting from the old filter and in spect them for any damage If no damage is found screw the two fittings into the new 25 micron filter If damage is found in the fittings replace them with a new 1 2 14 NPT hose barb fitting and elbow IMPORTANT Ensure that the TO RESERVOIR arrow on the power ste
107. ure Vacuum inches of mercury inHg 3 37685 kilo Pascals kPa 0 29613 inches of mercury inHg pounds per square inch psi 6 895 kilo Pascals kPa 0 14503 pounds per square inch psi Table 2 Metric U S Customary Conversion Then When You Multiply Then When You Know Subtract Divide By To Get Know By Add To Get degrees Fahrenheit F 32 1 8 degrees Celsius C 1 8 32 degrees Fahrenheit F Table 3 Temperature Conversion 00 18 Recreational Vehicle Chassis Maintenance Manual February 2012 General Information 00 Torque Specifications Tables 00 11 IMPORTANT Grade 8 regular hex zinc yellow plated scribed in Table 4 See Table 5 for torque values for capscrews and cadmium and wax coated prevailing grade 8 regular hex zinc yellow plated capscrews torque locknuts may be tightened to a lower torque and cadmium and wax coated prevailing torque value than the grade 8 regular hex fasteners de locknuts Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threadst Regular Hex Flanged Msc Grade 5 Grade 5 or Grade 8 or Grade 8 or Grade 5 Grade B Grade 8 or Grade G Pitch Bolt B Nut 8 2 Bolt C Nut Bolt Nut 8 2 Bolt Nut Torque N m Torque N m Torque N m Torque N m 1230002 1230003 1230004 1230005 SE nie m S 0 1 4 20 7 9 8 11 6 8 10 14 1 4 28 8
108. vailing Torque Locknuts Regular Hex Thread Diameter Pitch Grade 8 or 8 2 Bolt Grade 8 or C Nut Torque Ibf ft N m hos e 1 4 20 6 8 1 4 28 7 9 5 1618 13 18 5 16 24 14 19 3 8 16 23 31 3 8 24 26 35 7 16 14 37 50 7 16 20 41 56 1 2 13 56 76 1 2 20 63 85 9 16 12 81 110 9 16 18 90 122 5 8 11 112 152 5 8 18 126 171 3 4 10 198 268 3 4 16 221 300 7 8 9 319 433 7 8 14 352 477 1 8 479 649 1 12 524 710 1 14 537 728 Freightliner recommends that all plated unplated fasteners be coated with oil before installation Table 5 Torque Values for Grade 8 Regular Hex Zinc Yellow Plated Capscrews and Cadmium and Wax Coated Prevailing Torque Locknuts 00 20 Recreational Vehicle Chassis Maintenance Manual February 2012 General Information 00 Torque Specifications Tables 00 11 Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threadst Regular Hex Flanged Den E Grade 5 Bolt ee or B guard 8 2 d or C icd 8 2 Grade G Nut Torque N m Torque Ibf ft N m Torque Ibf ft N m CLS KID e OS be 1230005 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 9
109. val chassis grease Grease them only when the camshaft is disassembled for servicing NP A 01 10 2011 1422529 A Install the new cartridge into the canister B Press the cartridge into the canister and rotate clockwise 45 degrees to engage the cartridge Fig 4 Cartridge Rotation and Engagement 42 05 Slack Adjuster Lubricating IMPORTANT Perform Maintenance Operation 42 11 before lubricating the slack adjusters Automatic slack adjusters must be lubricated periodi cally to ensure proper brake operation Failure to lubricate slack adjusters could lead to dragging brakes or a brake failure resulting in property damage personal injury or death Recreational Vehicle Chassis Maintenance Manual May 2011 42 3 42 Brakes 1 N 3 4 2 i 5 05 28 93 amp 420011 A Grease Exit 1 10 4033 i 5 2 Slack Adjuster 1 Brake Chamber 5 Pull Pawl Seal 3 en 2 Clevis 6 Manual Adjusting Nut 3 Non Pressure Relief Grease Fitting Actuator Rod 7 Grease Fitting or Fig 5 Camshaft Bracket Bushing Lubrication 4 Boot Lube Plug Haldex NOTICE Do not use moly disulfide loaded grease or oil Both the life and reliability of the slack adjuster will be reduced if this type of grease is used Lubricate a Haldex automatic slack adjuste
110. vel within the HOT RUN upper band on the dipstick See Fig 2 4 If the fluid is not within this range add or drain fluid as needed to bring the level to the top of the HOT RUN band See Table 1 for approved transmission lubricants See Table 2 for lubricant capacities 26 03 Allison Transmission Fluid and Filter Changing internal external filter IMPORTANT For oil and filter change intervals see the applicable Allison Operator s Manual To request a replacement Allison Operator s Manual call 1 888 666 5799 Oil and filter change intervals can also be found at www allisontransmission com Choose Service and click Service Tips Then select the appropriate transmission to view fluid and filter change recommendations Approved Allison Transmission Lubricants ee Company Product Brand Name AN 051005 ExxonMobil Lubricants and Petroleum Specialties Company Mobil Delvac Synthetic ATF AN 011001 Castrol Heavy Duty Lubricants TranSynd AN 031002 BP Autran Syn 295 AN 031003 Cognis Corporation Emgard 2805 AN 031004 International Truck amp Engine Company Fleetrite Synthetic ATF AN 071006 John Deere amp Company HD SynTran check the latest Allison approved fluids go to www allisontransmission com Lubricants listed in order of preference Do not mix types of oil Table 1 Approved Allison Transmission Lubricants Automatic Transmission Lubricant Capacities Refill Capacity

00 - JustAnswer

Contents

Download Pdf Manuals

Related Search

Related Contents