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Freightliner Manual in PDF for Maintenance

1. Fem 09 30 2004 f321018 1 Steering Knuckle Bearing Grease Fitting upper 2 Steering Knuckle 3 Steering Knuckle Bearing Grease Fitting lower 08 13 2013 1321166 Fig 3 ZF IFS Jack Placement 2 IS LEI SQ In AA 1 A e Lal LO gt INIA AG Fig 4 Pressure Grease Fitting Positions RL 75E 09 30 2004 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 5 Pressure Grease Fitting Positions RL 75EM 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 Recreational Vehicle Chassis Maintenance Manual June 2015 32 5 32 exist replace the spring assembly See Group 32 of the Recreational Vehicle Chassis Workshop Manual for instructions or take the vehicle to an authorized Freightliner dealer Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring as sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves R
2. 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 3 New Cartridge with Rubber Spring damaged For grease seal replacement instructions see Group 42 of the Recreational 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 Fig 4 Cartridge Rotation and Engagement lubrication interval chassis grease Grease them only when the camshaft is disassembled for servicing 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 Recreational Vehicle Chassis Maintenance Manual June 2015 42 5 42 Brakes 05 28 93 A Grease Exit 1 Brake Chamber 2 Slack Adjuster 3 Non Pressure Relief Grease Fitting f420011a Fig 5 Camshaft Bracket Bushing Lubrication Failure to lubricate slack adjusters could lead to dragging brakes or a brake failure resulting in property damage personal injury or death Haldex
3. 42 09 Brake Lines Checking ao uga aga A A Pa es a KA A EI ORT KA PA ene EY Hydraulic Disc or Air Brakes 42 10 Brake Lining Wear Checking Hydraulic Disc Brakes ejolololol o o ol ol ol o o o o o o o o e front engine diesel chassis 42 11 Brake Inspecting elelelele e e e e e e e e e e e e e 42 12 Meritor Roller Pin wlelelele e leletletletletleletletletletle Lubricating 46 01 Drag Link Lubricating ejlolololol o e olo lolol ol ol ol ol ol ol olo 46 02 Power Steering Reservoir a lice Wea lal a a Ga cas Hat tee e ee PESE EST iss lee EP ay a Fluid Level Checking 46 03 Power Steering Fluid and wlelelele 2l ga slg eg ns rre dele ue a Filter Changing 46 04 Steering Driveline ele lelelel a ee ll age e eus d desti besitos a ee ag Lubricating 46 05 Steering Gear Lubricating ejojojojoj o e o o o fe ol lolol olo 46 06 Hydraulic Reservoir Filter 7 7 7 Changing metal reservoir only 47 01 Fuel Tank Mounts and Fuel 7 a Line Checking 47 02 Fuel Water Separator Element Replacing See the applicable engine operation and maintenance manual for fuel water separator element replacing intervals 00 4 Recreational Vehicle Chassis Maintenance Manual June 2015 General Information 00 Vehicle Maintenance Schedule Table 00 02 Maintenance Operation Procedures and Schedule Maintenance
4. Procedure Perdi z 6000 Mile 9654 km or 6 Month Initial Maintenance MOP initial Lubricate A Slack Adjuster Lubricating 42 05 Lubricate Foot Brake Valve Actuator Lubricating 42 06 Inspect ne a Brake System Inspecting front 42 07 Lubricate bA a E Lubricating Bosch Brakes front 42 08 Check Brake Lines Checking Hydraulic Disc or Air Brakes 42 09 Check o ace ied Checking Hydraulic Disc Brakes 42 10 Inspect 1 Brake Inspecting air brakes 42 11 Drain ___ Air Tanks Lubricate Drag Link Lubricating 46 01 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 Fuel Filters Inspect A 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 For vehicles with Detroit axles complete this procedure once a year or every 25 000 miles 40 000 km which ever comes first 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
5. Procedure Eerformed 30 000 Mile 48 270 km or 24 Month Maintenance MOP initial Inspect a 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 Inspect d ne mn ue Brake System Inspecting front 42 07 Lubricate area une D Lubricating Bosch Brakes front 42 08 Check Brake Lines Checking Hydraulic Disc or Air Brakes 42 09 Cheek ieu dn Checking Hydraulic Disc Brakes 42 10 Inspect ___ Brake Inspecting air brakes 42 11 Lubricate ____ x Meritor Roller Pin Lubricating 42 12 Drain Air Tanks Lubricate Drag Link Lubricating 46 01 Change Power Steering 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 73 Fuel Tank Mounts and Fuel Line Checking 47 01 Change Fuel Filters Inspect 1A 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 For vehicles with Detroit axles complete this procedure once a year or every
6. 22 has 00 05 45 000 Mile or 36 Month Maintenance dad ee da id a 00 06 60 000 Mile or 48 Month Maintenance hs 00 07 6000 Mile or 6 Month Initial Maintenance nh 00 03 General Maintenance Schedule Information eee ees 00 01 Noise Emission Controls Maintenance 1 aoa Re Sacer e nod Roane oT aware rurarinami 00 08 Vehicle Maintenance Schedule Table eee eee 00 02 Verification of Inspectors LOG eed iaa E EE ine eter PEG a a ea eds 00 09 Recreational Vehicle Chassis Maintenance Manual June 2015 General Information 00 General Maintenance Schedule Information 00 01 General Maintenance Schedule Information General Maintenance Schedule Information Performing regular maintenance on your vehicle will help ensure that your vehicle delivers safe reliable service and optimum performance for years to come Failure to follow a regular maintenance program can result in inefficient operation and unscheduled down time When the vehicle reaches the distance or time whichever comes first given for a maintenance in terval see the Vehicle Maintenance Schedule Table for a list of the maintenance operations to be per formed at that maintenance interval Use the mainte nance operation reference numbers to find detailed instructions in the manual for each operation NOTE Maintenance instructions in this manual are based on average vehicle use and normal operating cond
7. Fig 4 Grease Fitting and Boot Detroit axle shown 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 5 Replace the parts if this cannot be done For instructions see the axle manufacturer s service manual 2 8 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 N m For Detroit axles see Table 1 for tie rod end nut torque specifications and Table 2 for tie rod end clamp nut torque specifications 33 2 Recreational Vehicle Chassis Maintenance Manual June 2015 Front Axle DAT 02 27 2007 f320033a IMPORTANT The tie rod end threads must be visible throughout the entire length of the split NOTE Pinch bolt not shown to provide clarity 1 Cross Tube Split Fig 5 Tie Rod End Adjustment Detroit Axle Tie Rod End Nut Thread Torque Ibf ft N m 5 816 60 to 1
8. Measurement Suspension Inches 1 4 mm 6 10 254 or AS120 front P bay AS140 front 11 279 IFS114 front IFS ZF front ADL RS17 19 21 17 1 2 445 15 3 4 400 10 1 4 260 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 ADL123 rear 11 279 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 Inspection Inspect the components and check their operation as described below Failure to perform these in spections and checks could result in separation of worn suspension components and loss of vehicle control possibly causing personal injury or death or property damage 1 Chock the front or the rear tires Working at the front of the vehicle or at the rear of the vehicle raise the vehicle so that the tires just clear the ground and the suspension is fully extended Place safety stands under the vehicle frame 2 Squeeze all air springs to check for complete deflation 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 Hecreational Ve hicle Chassis Workshop Manual
9. Recreational Vehicle Chassis Maintenance Manual June 2015 00 7 00 General Information 15 000 Mile or 12 Month Maintenance 00 04 Procedure Eerformed 15 000 Mile 24 135 km or 12 Month Maintenance MOP initial Inspect Engine Drive Belt Inspecting 01 01 Check ___ Engine Support Fasteners Checking 01 02 Change Engine Oil and Filter see the engine manufacturer s u manual Inspect A AirCleaner Inspection 09 01 Inspect o cc cee d ee Inspection and Cleaning if 09 02 Inspect ____ Air Compressor Inspection 13 01 Check Alternator Battery and Starter Connections Check 15 01 Inspect Radiator radiator cap coolant freeze points SCA levels A S Check hose routing for chaffing and leaks 20 03 Lubricate Mechanical Fan Drive Gearbox Lubrication 20 05 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 Check ____ Suspension Fastener Torque Check 32 01 Check ___ Suspension Height Control Valve Check 32 02 Lubricate 1 ZF IFS Lubrication 32 04 Check ___ Suspension U Bolt Torque Check 32 06 Inspection V Ride Rear Suspension Inspection 32 07 Lubricate ___ Knuckle Pin Lubricatingt 33 01 Lubricate _____ Tie Rod End Lubricating and Inspectingt 33 02
10. Before placing the vehicle in service perform the test below 10 1 Start the engine and build air pressure to 120 psi 827 kPa Listen for the purge valve to open and release air A large volume of air will be expelled followed by a slow flow of air lasting approximately 30 seconds 10 2 10 3 10 4 Shut down the engine Perform the inspections in Maintenance Operation 42 02 Bendix AD IP 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires Using a wrench or a socket loosen the desiccant cartridge bolt Then separate the desiccant car tridge from the end cover Pull the cartridge bolt out of the cover and re move the cartridge Do not attempt to disassemble the desiccant car tridge assembly Parts for the assembly are not available and the cartridge contains a 150 Ib spring that cannot be mechanically caged Disas sembly could release the spring resulting in per sonal injury 4 Remove and discard both O rings from the car tridge bolt 42 Using a clean rag wipe clean the inside of the end cover Clean the cartridge bolt bore in the end cover and the sealing surfaces for the large and small diameter desiccant cartridge sealing rings Inspect the end cover for physical damage then inspect all air line fittings for corrosion replace as necessary Clean and inspect the bolt paying attention to the threads and O ring grooves
11. 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 air purifying respirator approved by MSHA or NIOSH at all times when servicing the brakes starting with removal of the wheels and continuing through assembly To minimize the possibility of creating airborne brake lining dust clean the dust from the brake rotor brake caliper and brake assembly using an industrial type vacuum cleaner equipped with a high efficiency filter System Then using a rag soaked in water and wrung until nearly dry remove any remaining dust Do not use compressed air or dry brushing to clean the brake assembly 1 Apply the brake and 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
12. 1 Cam Roller Pin Lube Point Q Series 2 Cam Roller Pin Lube Points Q Q Plus and P 1430370 3 Cam Anchor Pin Lube Points Q Q Plus and P Fig 11 Cam and Anchor Roller Pin Lubrication Points Recreational Vehicle Chassis Maintenance Manual June 2015 42 11 Steering 46 Index Alphabetical Title of Maintenance Operation MOP MOP Number Brad Link LUDA is i eiea CEDE 46 01 Hydraulic Reservoir Filter Changing metal reservoir only llli 46 06 Power Steering Fluid and Filter Changing liliis 46 03 Power Steering Reservoir Fluid Level Checking elis 46 02 Safety Precautions s2 24se0554200 ariba nidad KAWANIHAN ORE nnd Steering Driveline Eubricating 133 23 ded drm eR esee ede LABAHAN aan hh 46 04 Steering Gear Peru tiorem PR ketene BADA GENE SO dade hese ALA IT NP 46 05 Recreational Vehicle Chassis Maintenance Manual June 2015 Steering Safety Precautions When working on the vehicle shut down the en gine set the parking brake and chock the tires Before working under the vehicle always place jack stands under the frame rails to ensure the vehicle can not drop Failure to follow these steps could result in serious personal injury or death 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 t
13. FREIGHTLINER Y Maintenance Manual STI 425 6 A24 00788 000 zT RECREATIONAL VEHICLE CHASSIS MAINTENANCE MANUAL Models MC MCL XCL XCM XCP XCR XCS STI 425 6 6 15 Published by Daimler Trucks North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A Foreword Scheduled maintenance provides a key element for safe operation of your vehicle A proper maintenance program also helps to minimize downtime and to safeguard warranties This mainte nance manual provides information necessary for years of safe reliable and cost efficient vehicle operation IMPORTANT The maintenance operations in this manual are not all inclusive Also refer to other component and body manufacturers instructions for specific inspection and mainte nance instructions Perform 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 p
14. 41 N m for Detroit axles or 35 Ibf ft 47 N m for Meritor axles 3 After filling the carrier and housing assembly with lubricant drive the vehicle unloaded for one or two miles two or three kilometers at speeds not to exceed 25 mph 40 km h to thoroughly circu late the lubricant throughout the assembly Detroit Drive Axle Lubricant Capacities Axle Model Capacity pints L ARS 13 0 2 15 7 ARS 15 0 2 15 7 ARS 17 5 2 15 7 ARS 19 0 2 15 7 ARS 20 0 2 15 7 ARS 21 0 2 15 7 ARS 21 0 4 23 11 ARS 23 0 4 23 11 Model code may have a D in the prefix for example DA RS 13 0 2 t Quantities listed are approximate and include 1 pint 0 5 liter for each wheel end and with the drive pinion at 3 degrees Table 3 Detroit Drive Axle Lubricant Capacities Recreational Vehicle Chassis Maintenance Manual June 2015 35 3 35 Meritor Drive Axle Lubricant Capacities Axle Model Capacity pints L MS 10 113D 14 6 6 MS 12 113D 15 7 1 RS 13 120 18 4 8 7 RS 15 120 14 3 6 8 RS 17 145 33 6 15 9 RS 17 144 32 3 15 3 RS 19 144 32 3 15 3 RS 19 145 33 2 15 7 RS 21 145 32 3 15 3 RS 21 160 39 5 18 7 RS 21 230 38 9 18 4 RS 23 160 39 5 18 7 RS 23 161 39 5 18 7 RS 23 186 47 3 22 4 RS 23 240 37 4 17 7 RS 26 185 38 0 18 0 RS 30 185 38 0 18 0 Quantities listed are approximat
15. Before working under the vehicle always place jack stands under the frame rails to ensure the vehicle can not drop Failure to follow these steps could result in serious personal injury or death 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 Longitudinal direction of belt length cracks that intersect with transverse cracks are not accept able 2 Replace the belt if it has unacceptable cracks is frayed or has pieces of material missing For additional information see the Cummins 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 Ibf ft 213 N m Tighten the insulator to frame mount bracket bolts 91 Ibf ft 123 N m Tighten the engine mount bracket to engine bolts 62 Ibf ft 84 N m 2 Check the 3 4 10 front engine 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 Ibf ft 128 N m 01 gt 11 08 2005 ML 10120111 1 Front and Rear Engine Rear Mount Bolt 2 Engine Mount Bracket to Engine Bolts 3 Frame Mount Bracket Bolts Fig 1 Front and Re
16. Check ___ Suspension U Bolt Torque Check 32 06 Inspection V Ride Rear Suspension Inspection 32 07 Lubricate ___ Knuckle Pin Lubricatingt 33 01 Lubricate _____ Tie Rod End Lubricating and Inspectingt 33 02 Inspect 1 Wheel End Inspecting 33 04 33 05 ous ____ Oil Filled Hubs Oil Changing front and tag axle rug 35 05 Check Axle Seals for Leaks Lem ET Check Axle Breather Checking 35 03 Check Tire Pressure m Lubricate ___ Driveline Inspection and Lubrication 41 01 Inspect _____ Brake System Valves Inspecting 42 01 Inspect ee and Air Lines for Proper Routing Chaffing and 42 02 Change Air Dryer Desiccant and Coalescent Filter Replacing 43 03 00 12 Recreational Vehicle Chassis Maintenance Manual June 2015 General Information 00 45 000 Mile or 36 Month Maintenance 00 06 Procedure Performed check off or 45 000 Mile 72 405 km or 36 Month Maintenance MOP initial Lubricate Camshaft Bracket Bushing Lubricating 42 04 Lubricate Slack Adjuster Lubricating 42 05 Lubricate Foot Brake Valve Actuator Lubricating 42 06 Inspect Bendix Hydro Max Brake System Inspecting front 42 07 engine only Brake Caliper Slide Pin Lubricating Bosch Brakes front mia engine diesel chassis ee Check Brake Lines Checking Hydraulic Disc or Air Brakes 42 09 Brake Lining Wear Checking Hydraulic Disc Brakes C
17. 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 inH O could indicate an air intake system problem such as a damaged air filter loose or disconnected air intake piping or a disconnected or damaged air restriction indicator Replace the air filter at the recommended interval or when filter restriction equals or exceeds the maxi mum allowable restriction See the Recreational Ve hicle Chassis Operator s Manual for specific restric tion values for your engine See Group 09 of the Recreational Vehicle Chassis Workshop Manual for removal and installation procedures or take the ve hicle to an authorized Freightliner dealer Recreational Vehicle Chassis Maintenance Manual June 2015 09 1 09 H20 VACUUM IN H20 VACUUM 5 eT ia Us 7 J PUSH TO RESET g 05 22 97 1090176 Fig 2 Air Restriction Indicator 09 02 Charge Air Cooler CAC Inspection and Cleaning Good airflow through the CAC core is essential for proper engine cooling The cores allow air passage but form a barrier that tends to collect insects and airborne debris Inspect the CAC
18. 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 11 7 Install the filler plugs securely 33 Recreational Vehicle Chassis Maintenance Manual June 2015 33 7 Rear Axle 35 Index Alphabetical Title of Maintenance Operation MOP MOP Number Axle Breather CHECKING usitas en ogee Soa eee Be aos d Ra ad Ce ea eee a 35 08 Axle Lubricant Changing and Magnetic Plug Cleaning 35 02 Axle Lubricant Level Checking i 522g rra a A A de 35 01 Oil Filled Hubs Oil Changing Tag Axle 0 6 enn ee e le ded cR nnno ea ee me Ron 35 05 Oil Filled Hubs Oil Level Checking Tag Axle 2 0 2 0 00 ccc I I eh 35 04 Safety Precautions Recreational Vehicle Chassis Maintenance Manual June 2015 Rear Axle Safety Precautions When working on the vehicle shut down the en gine set the parking brake and chock the tires Before working under the vehicle always place jack stands under the frame rails to ensure the vehicle can not drop Failure to follow these steps could result in serious personal injury or death 35 01 Axle Lubricant Level Checking NOTICE Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage NOTE If the vehicle is exposed to water deep en
19. the rear tires 2 Clean around the power steering reservoir cap with a clean rag then remove the reservoir cap See Fig 1 MAX gt Min HYDRAULIC STEERING RESERVOIR FLUID DEXRON III rp 04 10 97 1461177 Fig 1 Steering System Hydraulic Fluid Reservoir rear mounted 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 Recreational Vehicle Chassis Maintenance Manual June 2015 46 1 46 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 3 Fill the reservoir to a level between the MIN and MAX marks Use only Dexron III 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 Fluid and Filter Changing Fill only with approved clean fluid Failure to use the proper fluid could cause seal deterioration and leaks Fluid leaks could eventually cause loss of power steering assist This could lead to an acci dent resulting in personal injury or property dam age Wear eye protection when changing the fluid and filter 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the rear tires 2 Plac
20. 10 Before placing the vehicle in service perform the test below 10 1 Start the engine and build air pressure to 100 psi 690 kPa and shut off the en gine 10 2 Check for air leaks at the inlet outlet and canister assembly Correct any leakage problem information in this section is provided by Haldex and is used with permis sion Brakes 3 2 1 7 01 07 2011 1422526 1 O ring 3 Mounting Bolts 2 Cartridge Fig 1 PURest Air Dryer Assembly 10 3 Restart the engine and build up pressure to cut out pressure At cut out pressure the air dryer purge valve opens and im mediately expels a large volume of air followed by a slow flow of air lasting ap proximately 30 seconds 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 42 4 Recreational Vehicle Chassis Maintenance Manual June 2015 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 AY
21. Daimler Trucks North America LLC Service Systems and Documentation CVI SSD P O Box 3849 Portland OR 97208 3849 Introduction Descriptions of Service Publications Daimler Trucks North America LLC distributes the following major service publications in paper and electronic via ServicePro formats Workshop Service Manual Maintenance Manual Driver s Operator s Manual Service Bulletins Parts Technical Bulletins Workshop service manuals contain service and repair information for all vehicle systems and components except for major components such as engines trans missions and rear axles Each workshop service manual section is divided into subjects that can include general information principles of operation removal disassembly assembly installation and specifications Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems They have information such as lubrication procedures and tables fluid replacement procedures fluid capacities specifica tions and procedures for adjustments and for checking the tightness of fasten ers Maintenance manuals do not contain detailed repair or service information Driver s operator s manuals contain information needed to enhance the driver s understanding of how to operate and care for the vehicle and its components Each manual contains a chapter that covers pre trip and post trip inspections and daily weekly and
22. MHt and 4000 MH 17 5 16 5 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 June 2015 26 3 Throttle Control 30 Index Alphabetical Title of Maintenance Operation MOP MOP Number Throttle Pedal Pivot Pin LUDNCAUNG aa pawaawa A Pee aie eRe A AAA d aod EE p ead 30 01 Recreational Vehicle Chassis Maintenance Manual January 2010 Throttle Control 30 01 Throttle Pedal Pivot Pin Lubricating 30 Using a silicone spray lubricate the throttle pedal pivot pins as shown in Fig 1 and Fig 2 07 09 2009 300408a 1 Throttle Pedal 2 Pivot Pins Assembly 3 Base Plate Fig 1 Floor Mounted Throttle Pedal 07 09 2009 f300409a 1 Throttle Pedal Assembly 2 Pivot Pin not shown Fig 2 Suspended Throttle Pedal Recreational Vehicle Chassis Maintenance Manual January 2010 30 1 Suspension 32 Index Alphabetical Title of Maintenance Operation MOP MOP Number Neway SUSPENSION Inspection aos te ioca Gade eine emen NANA AETA DA aha tn End Rd dn tues 32 03 Sale Precaution x35 qure ug o eb etis deat mag BEAN KA ace edo he Ae PD Pelee PER Pas don glad d Suspension Fa
23. NOTICE Do not use moly disulfide loaded grease or oil Both the life and reliability of the slack adjuster will be reduced if this type of grease is used Lubricate a Haldex automatic slack adjuster at the grease fitting with any extreme pressure NLGI Grade 1 or Grade 2 grease if the operating temperature is 20 F 29 C and above If the operating tempera ture is below 20 F 29 C use a low temperature extreme pressure grease Meritor Lubricate the slack adjuster at the grease fitting until grease is forced past the pressure relief capscrew or past the gear splines around the inboard snap ring Use high temperature NLGI Grade 1 waterproof grease See Fig 6 10 20 93 f420012a 1 Brake Chamber 5 Pull Pawl Seal 2 Clevis 6 Manual Adjusting Nut 3 Actuator Rod 7 Grease Fitting or 4 Boot Lube Plug Fig 6 Meritor Automatic Slack Adjuster other slack adjustors are similar 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 42 06 Foot Brake Valve Actuator Lubricating 1 Clean any dirt gravel and other foreign material from the base of the brake pedal the plunger boot and the brake base bracket 2 Use light oil to lubricate the brake pedal roller and pivot pin 3 Check the brake plun
24. NOx Sensor DPF Outlet Pressure Sensor DPF Intake Pressure Sensor DPF Inlet Temperature Sensor SCR Inlet Temperature Sensor SCR Outlet Temperature Sensor NOoRBRON Fig 1 Cummins ATD Sensor Locations seal clamps Once a seal clamp is loosened or removed it must be replaced 3 If present check the condition of the insulation material around the exhaust pipe between the turbocharger and the ATD 4 Check the ATD mounting bands for tightness Tighten to 30 Ibf ft 41 N m if needed Do not overtighten 5 Check for leaks around the clamps that attach the ATD in the ATS and around the clamps that retain the DPF in the ATD No leaks are allowed anywhere in the system 6 Check all sensors attached to the ATD for leaks or damaged wires No leaks are allowed 7 Check the DPF exterior surface for dents or other damage A dent over 3 inches 76 mm in Exhaust 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
25. Reservoir 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 or take the vehicle to an authorized Freightliner Chassis dealer 4 Check the electrical connections and harnesses Make sure the connectors are fully seated and the harnesses are not chafed or cut Repair or replace any damaged harness Disconnect any loose connectors and inspect the terminals for corrosion If corrosion is present replace the ter minals If corrosion is not present reconnect the connector 5 Check the fuse for the hydraulic brake 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 Recreational Vehicle Chassis Maintenance Manual June 2015 42 7 42 6 Check the operation of the Hydro Max brake booster as follows 6 1 With the ignition off depress the brake pedal and listen for the back up motor to engage Also note that the pedal force relieves the pedal should depress easily 6 2 With the ignition on engine running park ing brake re
26. Wheel Nut Checking 40 01 Check Tire Pressure m Lubricate Driveline Inspection and Lubrication 41 01 Inspect Brake System Valves Inspecting 42 01 00 14 Recreational Vehicle Chassis Maintenance Manual June 2015 General Information 00 60 000 Mile or 48 Month Maintenance 00 07 Procedure Eerformed 60 000 Mile 96 540 km or 48 Month Maintenance MOP initial Inspect qual 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 Inspect d ne mn ue Brake System Inspecting front 42 07 Lubricate area une D Lubricating Bosch Brakes front 42 08 Check Brake Lines Checking Hydraulic Disc or Air Brakes 42 09 Cheek ieu dn Checking Hydraulic Disc Brakes 42 10 Inspect ___ Brake Inspecting air brakes 42 11 Lubricate ____ x Meritor Roller Pin Lubricating 42 12 Drain Air Tanks Lubricate Drag Link Lubricating 46 01 Change _____ Power Steering 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 73 Fuel Tank Mounts and Fuel Line Checking 47 01 Change Fuel Filters In
27. air filter Due to the variety of possible driving conditions dirt roads paved roads etc it is critical to check the air restriction indicator if so equipped If the vehicle is not equipped with an air restric tion indicator inspect all components of the air intake system and air filter every 12 months Replace the air filter every 24 months or when filter restriction equals or exceeds the maximum allowable restriction More frequent inspec tions and or filter replacement may be needed if your vehicle is being operated in a dusty environment to avoid damaging the vehicle NOTE Remove and visually inspect the air filter for obvious damage such as holes cuts or dents Remove loose debris such as leaves or pine needles from the filter housing Inspect the air cleaner and plumbing for holes or tears at the recommended interval If the air cleaner is damaged replace it See Group 09 of the Recre 09 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 wo s SN 7090451 07 11 2007 ka 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
28. any air from the power steering pump and gear Recheck the fluid level Add fluid as needed The system is properly bled when the steering pump does not labor when turning the wheel 18 Remove the jackstands and lower the vehicle 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 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 4 shows the location of the sector shaft grease fitting 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 Recreational Vehicle Chassis Maintenance Manual June 2015 46 3 46 04 13 93 f460515a 1 Sector Shaft Grease Fitting Fig 4 Sector Shaft Lubricating 1 Drain the entire steering and fan hydraulic sys tems 2 Remove the reservoir lid and remove the nut that secures the filter 3 Remove the old filter and install the new filter 4 Install the filter nut and tighten it securely 5 Fill the reservoir with Dexron Ill 6 Start the engine run it for five sec
29. 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 47 02 Fuel Water Separator Element Replacing Alliance The only maintenance necessary on an Alliance fuel water separator is to replace the filter element Diesel fuel is flammable and can ignite if exposed to an open flame intense heat or other ignition source Do not drain fuel near or expose fuel vapor to open flame or intense heat Exposure to open flame or intense heat could start a fire pos sibly resulting in personal injury or property dam age When working on a fuel system have a fire extinguisher within easy reach 1 Drain off some fuel by loosening the ve
30. 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 49 Check all sensors attached to the ATD for leaks or damaged wires No leaks are allowed 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 Check for heat discoloration on the surface of the ATD Heat discoloration may indicate internal damage especially around the DPF Check any wires lines or hoses within 4 inches 10 cm of the exhaust system for heat damage Repair or reroute as needed Recreational Vehicle Chassis Maintenance Manual June 2015 49 3 49 Exhaust 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 June 2015 Electrical Instruments and Controls 54 Index Alphabetical Title of Maintenance Operation MOP MOP Number Battery Voltage CNSC siccus taari eos ici a tdeo dS el todas ded chard cnn laste
31. code 10 Check the DEF tank pump metering unit and lines for leaks See Group 49 of the Hecre 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 manufacturers maintenance manual for DEF filter replacement instructions and mainte nance intervals EPAO7 Exhaust System Definitions of ATS Terms Refer to the following list of definitions of ATS terms and components e Aftertreatment System ATS the entire ex haust system from the turbocharger to the tail pipe e Aftertreatment Device ATD a muffler like can ister that houses a DPF and sensors 49 2 Recreational Vehicle Chassis Maintenance Manual June 2015 Exhaust e Diesel Particulate Filter DPF a filter that col lects and holds particulate matter Soot and ash e Diesel Oxidation Catalyst DOC oxidizes hy drocarbons and reduces NOx e Sensors detect temperatures and pressure within the ATS e Diffuser a device used as a
32. cover the relief hole with your finger while continuing Recreational Vehicle Chassis Maintenance Manual June 2015 20 3 20 Engine Cooling Radiator 04 24 2013 1200817 1 U Joint Grease Fitting 2 Slip Joint Grease Fitting Fig 3 Slip Joint and U Joint Lubricating to lubricate until fresh grease appears at the slip joint seal This ensures complete lubrication of the splines 4 Wipe any excess grease from the pressure relief hole slip joint seal and grease fitting 20 4 Recreational Vehicle Chassis Maintenance Manual June 2015 Transmission 26 Index Alphabetical Title of Maintenance Operation MOP MOP Number Allison MD MH Series Transmission Fluid Level Checking llle 26 02 Allison Transmission Fluid and Filter Changing internal external filter o oooo o ooooooo 26 03 Safety Precautionis obrar e a o pai Transmission Breather Checking oee uno a Da Nh se Baw bah es bs 26 01 Recreational Vehicle Chassis Maintenance Manual June 2015 Transmission Safety Precautions When working on the vehicle shut down the en gine set the parking brake and chock the tires Before working under the vehicle always place jack stands under the frame rails to ensure the vehicle can not drop Failure to follow these steps could result in serious personal injury or death 26 01 Transmission Breather Checking Transmission housing breath
33. e e e e e e e e Inspecting Recreational Vehicle Chassis Maintenance Manual June 2015 00 3 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 1165 180 195 210 225 240 255 270 285 Maintenance Operation Number Maintenance Interval in Kilometers x 1000 and Description 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458 Maintenance Interval in Months 6 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228 42 02 Air Dryer Checking eojojojoe jo e e e e e e e e e e e e e e 42 03 Air Dryer Desiccant and 7 Coalescent Filter Replacing 42 04 Camshaft Bracket Bushing elven cet tee ta gol tae P I ee Pee we cae cae eee P ce Lubricating 42 05 Slack Adjuster Lubricating oe jolololol o e o o o o o o 0 0o 0 0 o 0 42 06 Foot Brake Valve Actuator esses A a s ilb ewe AI IA AS la Lubricating 42 07 Bendix Hydro Max Brake System Inspecting front engine ejojojojo o o o o 0o o o o o o o 0 0 0 diesel chassis 42 08 Brake Caliper Slide Pin Lubricating Bosch Brakes front engine diesel chassis
34. 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 maintain the bright and shiny surface for years to come with out the need for special polishes 40 2 Recreational Vehicle Chassis Maintenance Manual May 2011 Driveline 41 Index Alphabetical Title of Maintenance Operation MOP MOP Number Driveline Inspection and LUpnicauon 2 2sioe8ne erate a eee digs a pee wees d 41 01 Gale Precaution estu uo dre itu Bul eher tUe DADAAN aaah nied a Resear ad eee tom ahaa d Recreational Vehicle Chassis Maintenance Manual June 2015 Driveline Safety Precautions When working on the vehicle shut down the en gine set the parking brake and chock the tires Before working under the vehicle always place jack stands under the frame rails to ensure the vehicle can not drop Failure to follow these steps could result in serious personal injury or death 41 01 Driveline Inspection and Lubrication Inspection Before lubricating the driveline U joints and slip joints make the following checks 1 Check that the yoke strap capscrews are tight ened 50 to 60 Ibf ft 68 to 81 N m NOTICE Do not overtighten the yoke strap capscrews due to the extreme load occurring at high speed rota tion A loose or broken capscrew at any point in the driveline weakens the driveline connection which could eventually result in serious
35. hoses for chafing and cracks that will allow an air leak Replace the hoses as needed Inspect the CAC for clogging or damage and clean and or repair it if necessary Soak the CAC with a non corrosive degreaser such as Simple Green Let the unit sit for several minutes to work through the CAC Using low water pressure directed from the fan side of the radiator core rinse the CAC be careful not to damage or bend the fins Depending on the condition of the CAC this process may have to be performed several times Air Intake 09 2 Recreational Vehicle Chassis Maintenance Manual June 2015 Air Compressor 13 Index Alphabetical Title of Maintenance Operation MOP MOP Number Ar Compressor Ihspeslioh us ss abd wath aa droite OE ees aii Soa adis 13 01 Salety Precautions nes cetag e Sede A sado alates Recreational Vehicle Chassis Maintenance Manual June 2015 Air Compressor 13 Safety Precautions When working on the vehicle shut down the en gine set the parking brake and chock the tires Before working under the vehicle always place jack stands under the frame rails to ensure the vehicle can not drop Failure to follow these steps could result in serious personal injury or death 13 01 Air Compressor Inspection 1 Inspect the air compressor intake hoses and connections at the air intake and air compressor for physical damage If needed change the hoses and or tighten or replace the connections 2 Inspect the
36. 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 Web based repair service and parts documentation can be accessed using the following applications on the AccessFreightliner com website ServicePro PartsPro EZWiring ServicePro provides Web based access to the most up to date versions of the publications listed above In addition the Service Solutions feature provides di agnostic assistance with Symptoms Search by connecting to a large knowledge base gathered from technicians and service personnel Search results for both documents and servic
37. or take the ve hicle to an authorized Freightliner dealer Inspect the air springs for cracks tears or other dam age 3 Inspect each air spring for wear at the pedestal connection Inspect for leaks at the upper and lower pedestal connections using a soapy solu tion Replace any worn air springs for instruc tions see Group 32 of the Hecreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 4 Inspect the bolts and nuts at the pivot connec tions the transverse beam connections and the 32 2 Recreational Vehicle Chassis Maintenance Manual June 2015 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 axle connections to ensure they are tightened to the correct torque specification 5 Check all of the other suspension components for any sign of damage looseness wear or cracks Replace worn or damaged parts See Group 32 of the Recreational Vehicle Chassis Workshop Manual or take the vehicle to an au thorized Freightliner dealer 6 Inspect for cracked welds If cracks are found contact Neway immediately for further instruc tions 7 Inspect the torque rod and track bar pivot bush ings for excessive wear Replace worn or dam aged bushings See Group 32 of the Hecre ational Vehicle Chassis Worksho
38. 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 Disconnect the batteries 2 Check the tightness of the alternator bracket fas teners and alternator mounting fasteners tighten the fasteners as needed For torque values see Group 15 of the vehicle Workshop Manual or take the vehicle to an authorized Freightliner dealer 3 Check that all electrical connections at the alter nator and starter are clean Clean and tighten all charging system electrical connections as needed Spray each electrical connection at the alternator and starter with dielectric red enamel Trace and inspect all wiring and cables con nected to 15 e alternator e starter and depopulation studs e batteries e magnetic switch e cab e jump start studs e battery isolation relays e battery shutoff switches 4 Check wires and cables for wear chafing kinks discolored insulation or loose clamps or ties Find the cause of any problems and repair re place and reroute wires and clamps as neces sary IMPORTANT Ensure that wires and cables are not near any heat sources if they are reroute them 5 Clean all circuit breakers and relays 6 Check the alternator wiring for missing insulation kinks and heat damage Replace or repair as nee
39. 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 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 Recreational Vehicle Chassis Maintenance Manual June 2015 83 1
40. 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 supplemental coolant additive SCA levels and the freeze point every 25 000 miles 40 000 km or 6 months whichever comes first See the Cummins Operation and Maintenance Manual for further information Do not remove or loosen the radiator cap until the engine and cooling system have completely cooled Use extreme care when removing the cap A sudden release of pressure from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause seri ous personal injury 1 Drain the cooling system as follows 1 1 When the engine is cool remove the ra diator cap Turn the cap slowly counterclockwise until it reaches a stop Do not press down while turning the cap Wait until any re maining pressure indicated by a hissing sound is relieved then press down on the cap and continue turning it counter clockwise Recreational Vehicle Chassis Maintenance Manual June 2015 20 1 20 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
41. 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 4h CAUTION Too little wheel nut torque can cause wheel shimmy resulting in wheel damage stud break age and extreme tire tread wear Too much wheel nut torque can break studs damage threads and crack discs in the stud hole area Tighten the wheel nuts e On 6 stud stud pilot hubs tighten the wheel nuts 450 to 500 Ibf ft 610 to 678 N m See Fig 1 for the tightening sequence e On 8 stud or 10 stud hub pilot hubs with 20 mm studs tighten the wheel nuts 280 to 310 Ibf ft 380 to 420 N m See Fig 2 or Fig 3 for the tightening sequence e On 8 stud or 10 stud hub pilot hubs with 22 mm studs tighten the wheel nuts 450 to 500 Ibf ft 610 to 678 N m See Fig 2 or Fig 3 for the tightening sequence NOTE Wheel nuts for 20 mm stud hubs require a 1 3 16 inch 30 mm socket Wheel nuts for 22 mm stud hubs require a 1 5 16 inch 33 mm socket 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 4 5 3 6 8 DIE 8 MON D NG 4 n MG Pa Sf 06 23 2000 400159 A Front and Inner Rear Dual B Outer Rear Dual Fig 2 Wheel Nut Tightening Sequence 8 stud hubs A B 9 7 7 fio 8 gt 4 4 5 O NG 6 SAGA 8 10 DO D o 2 09 28 98 1400
42. 142 A Front and Inner Rear Dual B Outer Rear Dual Fig 3 Wheel Nut Tightening Sequence 10 stud hubs Recreational Vehicle Chassis Maintenance Manual May 2011 40 1 40 Wheels and Tires 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 a 100 cotton cloth dipped in a mild soap solution to help remove built up dirt and grease Dish soap or automotive car wash soap are rec ommended 3 Rinse the remaining soap residue from the wheel 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
43. 15 81 to 156 5 818 60 to 115 81 to 156 3 4 16 90 to 170 122 to 230 7 8 14 160 to 300 217 to 407 Table 1 Detroit Axle Tie Rod End Nut Detroit Axle Tie Rod End Clamp Nut Thread Torque Ibf ft N m 1 2 13 35 to 45 47 to 61 5 8 11 40 to 60 54 to 81 5 8 18 50 to 64 73 to 87 3 4 10 155 to 175 210 to 237 Table 2 Detroit Axle Tie Rod End Clamp Nut 33 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 rear axle Use the appli cable procedure and specifications in Group 35 of the Recreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Toe In Inspection For vehicle alignment to be accurate the shop floor must be level in every direction The turn plates for the front wheels must rotate freely without friction and the alignment equipment must be calibrated every three months by a qualified technician from the equipment manufa
44. 25 000 miles 40 000 km which ever comes first 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 June 2015 00 11 00 General Information 45 000 Mile or 36 Month Maintenance 00 06 Procedure i Eerformed 45 000 Mile 72 405 km or 36 Month Maintenance MOP initial Inspect ____ Engine Drive Belt Inspecting 01 01 Check ___ Engine Support Fasteners Checking 01 02 Change Engine Oil and Filter see the engine manufacturer s u manual Inspect A AirCleaner Inspection 09 01 Inspect o cc cee d ane Inspection and Cleaning if 09 02 Inspect ____ Air Compressor Inspection 13 01 Check Alternator Battery and Starter Connections Check 15 01 Inspect Radiator radiator cap coolant freeze points SCA levels A S Check hose routing for chaffing and leaks 20 03 Lubricate 1 Mechanical Fan Drive Gearbox Lubrication 20 05 Change Transmission Fluid and Filter if required by Allison 26 03 Inspect 1 Transmission Hose Routing for Chaffing and Leaks Check ___ Suspension Fastener Torque Check 32 01 Check ___ Suspension Height Control Valve Check 32 02 Lubricate ZF IFS Lubrication 32 04
45. 3 Ice Pin EMDERCA DTI asi dogs etude EROR oe a ace c cr dp Ras tt o fcn der dc eg 33 01 OilFilled Hubs Oil Changing 332 423 3er IR IUe RE ARX RU ERU REOR eg epe eee Ree AA NDN 33 06 Oil Filled Pl bs Oll bevel Checking teh woe RUE SUN ears Wied d dose ene cote ee Ire o ee 33 05 Sale Precautions ous terciaria islas darias SEXE Tie Rod End Lubricating and Inspecting sss omm RR Rm Re am exer Seeds x 33 02 Wheel End Inspection naa aa den bs as A tesque HERMES stc RSS Ae ae Rad 33 04 Recreational Vehicle Chassis Maintenance Manual June 2015 Front Axle Safety Precautions When working on the vehicle shut down the en gine set the parking brake and chock the tires Before working under the vehicle always place jack stands under the frame rails to ensure the vehicle can not drop Failure to follow these steps could result in serious personal injury or death 33 01 Knuckle Pin Lubricating NOTICE Use regulated pressure when lubricating the knuckle assemblies otherwise damage could re sult to the knuckle caps Detroit Axles On the front axle grease fittings are on the top and bottom caps of each knuckle 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires When lubricating upper and lower knuckle assemblies do not raise the front axle 2 Wipe the grease fittings clean 3 Apply multipurpose chassis grease NLGI Grade 1 6 12 hydroxy lithium stearate grea
46. 32 04 ZF IFS Lubrication IMPORTANT Do not raise the vehicle by plac ing a jack under the control arm s The weight of the vehicle could damage the control arms and cause alignment issues See Fig 3 for cor rect jack placement 1 Chock the rear tires and apply the parking brake Raise the front of the vehicle with a jack so the tires just clear the ground and the suspension is fully extended Place safety stands under the vehicle frame Never work around or under a vehicle that is sup ported only by a jack Always support the vehicle with safety stands Jacks can slip causing the vehicle to fall which could result in serious injury or death 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 32 4 Recreational Vehicle Chassis Maintenance Manual June 2015 Suspension Grade 2 lithium based grease multipurpose grease or mineral oil on the lubricating points See Fig 4 and Fig 5 32 32 05 Suspension Inspection
47. 9 N i A H E 9 10 13 LU L 7 11 i iss 12 UU Ll 10 16 2001 1470414 1 Filter Collar 7 Filter Element 11 Drain 2 Filter Vent 8 Temporary Filter Stud 12 Bottom Plate Collar 3 Vent Seal 9 Check Valve Fuel Inlet 13 Electric Heater optional 4 Filter Cover 10 Fluid Heater Bottom Plate and 5 Cover Seal Seal 6 Filter Spring Fig 3 Davco Fuel Pro amp 382 47 4 Recreational Vehicle Chassis Maintenance Manual June 2015 Exhaust 49 Index Alphabetical Title of Maintenance Operation MOP MOP Number Exhaust System Inspecting Noise Emission Control 000 ee 49 01 Salley PIECAWONSad ue 35 duci due a Nad nG duis su ed DA DAN Sos adu OS oni d sup appa a Ane eee eto Recreational Vehicle Chassis Maintenance Manual June 2015 Exhaust Safety Precautions When working on the vehicle shut down the en gine set the parking brake and chock the tires Before working under the vehicle always place jack stands under the frame rails to ensure the vehicle can not drop Failure to follow these steps could result in serious personal injury or death 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 sh
48. Gear Oil 75W 90 and Mobilube 1 SHC 75W 90 meet specification 235 8 For more product information see http bevo mercedes benz com SAE Type Ambient Temperature Viscosity Grade Synthetic Oil 40 F 40 C and upt 75W 90 Detroit rear axles do not require the use of friction modifiers T There is no upper limit on the ambient temperature but axle sump tem perature must never exceed 250 F 121 C Table 1 Detroit Drive Axle Lubricants Drive Axle Recommended Lubricant Meritor Axles Lubricant Recommended SAE Lubricant Type Ambient Temperature Viscosity Grade 10 F 12 2 C and up 85W 140 Hypoid Gear Oil 15 F 26 1 C and up 80W 90 API Service m o x Classification 40 F 40 C and up 75W 90 GL 5 40 F 40 C to 35 F 2 C 75W 40 F 40 C and up 75W 140 Synthetic Gear 40 F 40 C and up 75W 90 Oil 40 F 40 C and up 75W 140 There is no upper limit on the ambient temperature but axle sump tem perature must never exceed 250 F 121 C Table 2 Drive Axle Recommended Lubricant Meritor Axles 35 02 Axle Lubricant Changing and Magnetic Plug Cleaning A regular schedule for changing the axle lubricant in a particular vehicle and operation can be accurately determined by analyzing oil samples taken from the axle at specified intervals or mileages Lubricant sup pliers frequently make their laboratory facilit
49. IMPORTANT Use only the grease supplied with Bendix replacement kits 8 10 Lubricate the O rings bolt O ring grooves seal ing rings and cartridge grooves Lubricate the end cover bore for the bolt Install both O rings on the cartridge bolt then using a twisting motion insert the assembled desiccant cartridge bolt in the end cover Install the desiccant cartridge on the end cover making sure the cartridge is properly seated and flush on the end cover NOTE It may be necessary to rotate the car tridge slightly until the anti rotation lugs are properly aligned and allow the cartridge to rest flush against the end cover 11 12 Using a wrench or socket tighten the desiccant cartridge bolt 50 Ibf ft 68 N m Do not over torque Before placing the vehicle in service perform the test below 12 1 12 2 Close all reservoir drain cocks Build system pressure to governor cut out and note that the AD IP air dryer purges with an audible escape of air 12 3 Fan the service brakes to reduce system air pressure to governor cut in Note that the system once again builds to full pres sure and is followed by a purge at the AD IP air dryer exhaust 12 4 Check for excessive leakage around the head of the desiccant cartridge where it contacts the end cover With the com pressor in loaded mode compressing air apply a soapy solution to these areas and observe that any leakage does not exceed a 1 inch
50. Inspect 1 Wheel End Inspecting 33 04 33 05 ous ____ Oil Filled Hubs Oil Changing front and tag axle rug 35 05 Check Axle Seals for Leaks Lem ET Check Axle Breather Checking 35 03 Check Tire Pressure m Lubricate ___ Driveline Inspection and Lubrication 41 01 Inspect _____ Brake System Valves Inspecting 42 01 Inspect O id and Air Lines for Proper Routing Chaffing and 42 02 Lubricate Camshaft Bracket Bushing Lubricating 42 04 00 8 Recreational Vehicle Chassis Maintenance Manual June 2015 General Information 00 15 000 Mile or 12 Month Maintenance 00 04 Procedure Eerformed 15000 Mile 24 135 km or 12 Month Maintenance MOP initial Lubricate 1 Slack Adjuster Lubricating 42 05 Lubricate Foot Brake Valve Actuator Lubricating 42 06 Inspect ne a Brake System Inspecting front 42 07 Lubricate ES ded a E Lubricating Bosch Brakes front 42 08 Check Brake Lines Checking Hydraulic Disc or Air Brakes 42 09 Check o side ied Checking Hydraulic Disc Brakes 42 10 Inspect A Brake Inspecting air brakes 42 11 Lubricate 1 Meritor Roller Pin Lubricating 42 12 Drain Air Tanks Lubricate Drag Link Lubricating 46 01 Change Power Steering Fluid and Filter Changing 46 03 Lubricate ___ Steering Driveline Lubricating 46 04 Lubricate Steering Gear Lubricating 46 05 Change H
51. Inspecting IMPORTANT This procedure should be per formed prior to lubrication of the brake compo nents Parking Brake Operational Check 4h CAUTION Perform the following check in a clear safe area If the parking brakes fail to hold the vehicle per sonal injury or property damage may result 1 With the engine running and air pressure at cut out pressure set the parking brake 2 Putthe vehicle in the lowest gear and gently at tempt to move it forward The vehicle should not move If the vehicle moves the parking brakes are not operating correctly and must be repaired before the vehicle is returned to service See Group 42 of the Recreational Vehicle Chassis Workshop Manual for repair procedures or take the vehicle to an authorized Freightliner dealer Brake Component Inspection 1 Park the vehicle on a level surface set the park ing brake and chock the tires Once the tires are chocked release the parking brake 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 June 2015 42 9 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
52. Interval in Miles x 1000 6 15 30 45 bo 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 pe 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458 Maintenance Interval in Months 6 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228 49 01 Exhaust System Inspecting Noise Emission Control 54 01 Ground Cables Checking and Cleaning 54 02 Battery Voltage Checking 83 01 Air Conditioner Inspecting For vehicles with Detroit axles complete this procedure once a year or every 25 000 miles 40 000 km whichever comes first Table 1 Maintenance Operation Procedures and Schedule Recreational Vehicle Chassis Maintenance Manual June 2015 00 5 00 General Information 6000 Mile or 6 Month Initial Maintenance 00 03 Procedure ed 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 cd Engine Oil and Filter see the engine manufacturer s manual Inspect cd e a in Inspection and Cleaning if 09 02 Check ___ Alternator Battery and Starter Connections Check 15 01 Inspect Radiator radiator cap coolant
53. able 1 Torque Values 4 Perform the operational and leakage tests listed below Recreational Vehicle Chassis Maintenance Manual June 2015 42 1 42 Operational and Leakage Tests LE Check all lines and fittings leading to and from the air dryer for leakage and integrity Repair any leaks found Build system pressure to governor cutout and note that the dryer purges with an audible es cape of air Watch the system pressure and note the pressure fall off for a 10 minute period If the pressure drop exceeds 1 psi minute from either service reservoir inspect the vehicle air systems for sources of leakage and repair them Refer to troubleshooting information in Bendix or Haldex service literature Check for excessive leakage around the purge valve with the compressor in the loaded mode compressing air Apply a soap solution to the purge valve exhaust port and observe that leak age does not exceed a 1 inch 25 mm bubble in 1 second If the leakage exceeds the maximum specified refer to troubleshooting information in the Bendix or Haldex service literature Build system pressure to governor cutout and note that the dryer purges with an audible es cape of air Fan the service brakes to reduce system air pressure to governor cut in Note that the system once again builds to full pressure and is followed by a dryer purge If the system does not follow this pattern refer to troubleshooting information in the Bendix or Hal
54. aes ney diti Bra dens 54 02 Ground Cables Checking and Cleaning s su acere eR RE x Rune A A 54 01 Recreational Vehicle Chassis Maintenance Manual September 2007 Electrical Instruments and Controls 54 01 Ground Cables Checking and Cleaning Check that the ground cables are clean undamaged and tight 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 registers 12 5V or below fully charge the battery to 12 65V A fully charged battery will have a voltage of 12 65V with the charger disconnected 54 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 Inspectih sisi a adi a GAB nh NAG 83 01 Satety Trecautigfis uu ur chai duo bes etus Bob RP O tolus PO grani anes teed eta Recreational Vehicle Chassis Maintenance Manual June 2015 Heater and Air Conditioner Safety Precautions When working on the vehicle shut down the en gine set the parking brake and chock the tires Before working under the vehicle always place jack stands under the frame rails to ensure the vehicle can not drop Failure to follow these steps could res
55. air and meters this mixture into the exhaust flow via an injection nozzle 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 for Cum mins ATD sensor locations If any discrepancies are discovered refer to the engine manufactur er s service literature for repair instructions 1 Check for leakage at the clamp that attaches the exhaust pipe to the turbocharger exhaust outlet If leakage exists tighten the nut on the clamp to the required torque If leakage persists install a new clamp 2 Check the exhaust pipe bellows and each ex haust seal clamp for leakage wear cracks or damage Replace damaged components as needed If leakage exists at a clamp tighten the nuts to the required torque If leakage persists install a new exhaust seal clamp Do not reuse Recreational Vehicle Chassis Maintenance Manual June 2015 49 1 49 10 20 2009 1490386 Exhaust Outlet SCR Outlet
56. ance MOP initial Inspect ____ Engine Drive Belt Inspecting 01 01 Check Engine Support Fasteners Checking 01 02 Change cd Engine Oil and Filter see the engine manufacturer s u manual Change Air Cleaner Replacement 09 01 Inspect cd Fieri d ne Inspection and Cleaning if 09 02 Inspect ____ Air Compressor Inspection 13 01 Check Alternator Battery and Starter Connections Check 15 01 Inspect Radiator radiator cap coolant freeze points SCA levels A S Check hose routing for chaffing and leaks 20 03 Change Mechanical Fan Drive Gearbox Oil Change 20 04 Lubricate 1 Mechanical Fan Drive Gearbox Lubrication 20 05 Change Transmission Fluid and Filter if required by Allison 26 03 Inspect A Transmission Hose Routing for Chaffing and Leaks Lubricate ___ Throttle Pedal Pivot Pin Lubricating 30 01 Check ___ Suspension Fastener Torque Check 32 01 Check Suspension Height Control Valve Check 32 02 Lubricate ZF IFS Lubrication 32 04 Check Suspension U Bolt Torque Check 32 06 Inspection V Ride Rear Suspension Inspection 32 07 Lubricate Knuckle Pin Lubricatingt 33 01 Lubricate Tie Rod End Lubricating and Inspectingt 33 02 Inspect ____ Wheel End Inspecting 33 04 33 05 Pi _____ Oil Filled Hubs Oil Changing front and tag axle D 35 05 Check ____ Axle Seals for Leaks T na ee ae Check __ Axle Breather Checking 35 03 Check
57. ansmis 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 e OL OK indicates an acceptable oil level e OL HI followed by a number indicates the amount that is over filled Recreational Vehicle Chassis Maintenance Manual June 2015 26 1 26 All son Transmission 03 04 2008 270159 1 Shift Selector Display Screen Fig 3 Transmission Shift Selector e OL LO followed by a number indicates the amount that is under filled e OL 70 indicates that the transmission is not up to operating temperature Alternate Method 1 Operate the transmission in a Drive D range until normal operating temperature 160 to 200 F 71 to 93 C is reached NOTE The fluid must be warm to ensure an accurate check The fluid level rises as tempera ture increases Transmission 2 Park the vehicle Shift to Neutral N and apply the parking brake Let the engine run at idle 3 Wipe the dipstick clean and check the fluid level A safe operating level is any level within the HOT RUN upper band on the dipstick See Fig 2 4 Ifthe fluid is not within this range add or drain fluid as needed to bring the le
58. ar Engine Rear Mount ISB chassis built after 2002 5 by NG A PR SAN DI O O 11 08 2005 f012110 1 Front and Rear Engine Front Mount Bolt Fig 2 Front and Rear Engine Front Mount ISB chassis built after 2002 Recreational Vehicle Chassis Maintenance Manual June 2015 01 1 Air Intake Title of Maintenance Operation MOP Air Cleaner Inspection and Replacement Charge Air Cooler CAC Inspection and Cleaning Safety Precautions iuo px ex oe rd 09 Index Alphabetical MOP Number Recreational Vehicle Chassis Maintenance Manual June 2015 Air Intake Safety Precautions When working on the vehicle shut down the en gine set the parking brake and chock the tires Before working under the vehicle always place jack stands under the frame rails to ensure the vehicle can not drop Failure to follow these steps could result in serious personal injury or death 09 01 Air Cleaner Inspection and Replacement NOTICE Do not use aftermarket air cleaner elements After market air cleaner elements may not seal the housing correctly which can lead to engine dam age and potentially the loss of warranty When re placing an air cleaner element use only the part listed in PartsPro for the serial number of the vehicle IMPORTANT When first purchased if the Rec reational Vehicle is older than the current model year replace the
59. ar is elongated or dam aged 6 Check the suspension alignment and adjust if necessary For instructions see Section 32 05 in the Hecreational Vehicle Chassis Workshop Suspension D Pin Bushing Visual Inspection It is not necessary to disassemble the D pin connec tion to perform a visual inspection of the D pin bush ing The D pin bushing is designed with a layer of rubber in the bushing It is acceptable to see a bead of rubber protruding from the bushing See Fig 10 04 15 2014 f321193 1 Bead of Rubber Fig 10 Acceptable D Pin D pin bushing replacement is required when metal to metal contact wear marks on the D pin outer metal are evident or the D pin outer metal is distorted See Fig 11 V Rod Assembly Inspection The V Ride rear air suspension incorporates V torque rods for vehicle stability If these compo nents are disconnected or are non functional the vehicle should not be operated Failure to do so can result in adverse vehicle handling and pos sible tire contact with the frame Operating a ve hicle with non functional V torque rods can result in the loss of vehicle control severe personal in jury and component damage NOTE Grade 8 bolts and Grade C locknuts are recommended for all torque rod attachments 1 Visually inspect the torque rod bushing for metal to metal contact Inspect for bent cracked or broken torque rods and for end hubs with an elongated oval shape Any of t
60. arter Connections Check 15 01 Inspect Radiator radiator cap coolant freeze points SCA levels A S Check hose routing for chaffing and leaks 20 03 Change Mechanical Fan Drive Gearbox Oil Change 20 04 Lubricate 1 Mechanical Fan Drive Gearbox Lubrication 20 05 Change Transmission Fluid and Filter if required by Allison 26 03 Inspect A Transmission Hose Routing for Chaffing and Leaks Lubricate ___ Throttle Pedal Pivot Pin Lubricating 30 01 Check ___ Suspension Fastener Torque Check 32 01 Check Suspension Height Control Valve Check 32 02 Lubricate ZF IFS Lubrication 32 04 Check Suspension U Bolt Torque Check 32 06 Inspection V Ride Rear Suspension Inspection 32 07 Lubricate Knuckle Pin Lubricatingt 33 01 Lubricate Tie Rod End Lubricating and Inspectingt 33 02 Inspect 1 Wheel End Inspecting 33 04 33 05 Pi _____ Oil Filled Hubs Oil Changing front and tag axle D 35 05 Check Axle Seals for Leaks TECUM ae Check __ Axle Breather Checking 35 03 Check Wheel Nut Checking 40 01 Check ___ Tire Pressure Lubricate 7573 Driveline Inspection and Lubrication 41 01 Inspect A Brake System Valves Inspecting 42 01 00 10 Recreational Vehicle Chassis Maintenance Manual June 2015 General Information 00 30 000 Mile or 24 Month Maintenance 00 05
61. ase from the pressure relief hole slip joint seal and grease fitting Driveline 41 2 Recreational Vehicle Chassis Maintenance Manual June 2015 Brakes 42 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Dyer Checking soriga a ace salt nte en RE ne thy ta dace A aan DAAN bod coed 42 02 Air Dryer Desiccant and Coalescent Filter Replacing 000 ee eee 42 03 Bendix Hydro Max Brake System Inspecting front engine diesel chassis 42 07 Brake Caliper Slide Pin Lubricating Bosch Brakes front engine diesel chassis 42 08 Brake Inspecing 32saxe BABANGGA NS ka hehe Geeeadcehasdik sng dandaksesdaeee Lege d 42 11 Brake Lines Checking Hydraulic Disc or Air Brakes 2 20 000 ee 42 09 Brake Lining Wear Checking Hydraulic Disc Brakes front engine diesel ChasSiS s vicaerCi viene NG PLA o aUe Rud ewe e LORE b see PSdqadad Edd x ud Redde e bs 42 10 Brake System Valves nspectiligis scusa caet ep bbes Des PE te BUE a V be NANG 42 01 Camshaft Bracket Bushing Bbubricatiligi tn RE ER Rm REMARKS RR Hum aca A acr EUR A A coeds 42 04 Foot Brake Valve Actuator Lubricating uai Sete e dom re pEr ied hae oe 42 06 Meritor Roller Pim LUDNICA ees supiera eon HD aao art d 42 12 Sale Preta cora ina o oia ao slack Adjuster LUDNCAING 2d raoba AR RP hA e m id Seeds dps 42 05 Recreational Vehicle Chassis Maintenance Manual June 2015 Brakes Safe
62. ate grease or NLGI Grade 2 8 12 hydroxy lithium stearate grease into the tie rod ends until all used grease is forced out and fresh grease is seen at the ball stud neck See Fig 4 Fig 3 Meritor Axle Grease Fittings 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 opposite the grease fitting When lubricating knuckle pin bushings after the IM maintenance interval first wipe the lube fittings clean Then apply multipurpose chassis grease until new grease is seen at the grease seal on the bush ing opposite the fittings 33 02 Tie Rod End Lubricating and Inspecting 06 12 2012 f330273 NOTE No grease should emit from the tie rod boot If grease emits from the tie rod boot the boot is dam aged 1 Grease Fitting 2 Boot IMPORTANT DOT roadside tie rod assembly replacement criteria specifies that if tie rod end play is 1 8 inch 8 mm or greater measured on the road the vehicle must be taken out of ser vice immediately If less than 1 8 inch 3 mm the vehicle does not have to be taken out of service but a major out of service inspection and maintenance must be scheduled as soon as possible 1 For any Detroit or Meritor axle that requires lubri cation of the tie rod ends wipe the grease fit tings clean then pump multipurpose chassis
63. ber Mount Locknut Size Torque Ibf ft N m 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 Recreational Vehicle Chassis Maintenance Manual June 2015 32 1 32 Suspension Suspension Torque Specifications lubricated threads Description Size Torque Ibf ft N m Transverse Beam Bushing Locknuts 1 1 4 12 600 to 700 814 to 949 Equalizing Beam Center Bushing Locknut 3 4 16 150 to 200 203 to 271 u 1 1 8 12 Equalizing Beam Front Bushing Locknut TAGS 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 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
64. bolts In a diagonal pattern tighten all 5 8 18 U bolt nuts 205 Ibf ft 278 N m tighten all 3 4 16 U bolt nuts 300 Ibf ft 407 N m and tighten all 7 8 14 U bolt nuts 460 Ibf ft 624 N m NOTICE Failure to retorque the U bolt nuts could result in spring breakage and abnormal tire wear 32 4 Remove the safety stands and lower the vehicle to the ground 32 02 Suspension Height Control Valve Check 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 Shock Absor
65. bricating See ease appe This will e r ith 33 02 Tie Rod End Lubricating and Inspecting 11 11 2002 Group Title Group Number Release Date Group Number Page Number MOO W gt E Maintenance Operation Number consists of the Group Number followed by the Sequence Number f020075 Fig 1 Example of a Maintenance Manual Page Recreational Vehicle Chassis Maintenance Manual July 2013 Introduction Maintenance Manual Contents Group No Group Title OO ce tL AE ec General Information UP Pacco Engine 09 oss arse wud CRAS B Er s USC Air Intake s MUR aro e roo aa Alternators and Starters 20 2 sieges ede uie eis Engine Cooling Radiator 2O ut sas ed iy cd ws oed ei d ae ROSE Transmission cop Throttle Control 32 leiten RES Rae deme dove Suspension co FRETI Front Axle BO Gh aes hy ado Gans CHE Ee 0G Rear Axle 40 du ida BROCKA ma eR E Wheels and Tires BV ite oie evden eS ew een Re Aad eo YE Driveline 42 Brakes DORMI Steering noA de E ag de oats aan a pak ase EE te oa a ate Se Fuel n mp Exhaust lo T cbs AAP a Electrical O3 cri a Ka UE a ee Heater and Air Conditioner 1 4 Recreational Vehicle Chassis Maintenance Manual July 2013 General Information 00 Index Alphabetical Title of Maintenance Operation MOP MOP Number 15 000 Mile or 12 Month Maintenance ccc 62a cae aa a Ro mne a acd 00 04 30 000 Mile or 24 Month Maintenance
66. bubble in 1 Recreational Vehicle Chassis Maintenance Manual June 2015 42 3 42 second If leakage exceeds this measure remove and re install the desiccant cartridge Haldex PURest NOTE The PURest cartridge contains both the desiccant and filter in one piece 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires 2 Remove the four mounting bolts and discard See Fig 1 Lift the canister about 1 2 inch and remove 3 Place the assembly upside down as shown in Fig 2 Press the cartridge down to compress the rubber spring then rotate counterclockwise 45 degrees to release the cartridge The cartridge itself contains no hazardous material but there may be a small amount of oil from the compressor 4 Clean the inside of the canister and aluminum housing 5 Remove the cartridge O ring and discard 6 Remove the new cartridge from the kit and make certain the rubber spring is attached See Fig 3 7 Install the new cartridge into the canister Align the slots on the cartridge with the dimplets inside the canister Press the cartridge into the canister and rotate clockwise 45 degrees to engage the cartridge as shown in Fig 4 8 Place a new O ring on the aluminum housing 9 Place the cartridge assembly on the air dryer housing and install four new mounting bolts Use an alternating diagonal pattern and tighten the bolts 35 to 40 Ibf ft 47 to 54 N m
67. coolant supply and return lines for tight connections Tighten the connections and replace the lines and fasteners if needed 3 For the air governor inspect the piping and con nections for leaks Replace gaskets and faulty components as needed Recreational Vehicle Chassis Maintenance Manual June 2015 13 1 Alternators and Starters 1 5 Index Alphabetical Title of Maintenance Operation MOP MOP Number Alternator Battery and Starter Connections Check 0 0 0 llle 15 01 Satety Precaution a5 maa dug V e NAMANA dui MA NAKA SR cR a aee K EBA NENA RR d res eek a d Recreational Vehicle Chassis Maintenance Manual June 2015 Alternators and Starters Safety Precautions When working on the vehicle shut down the en gine set the parking brake and chock the tires Before working under the vehicle always place jack stands under the frame rails to ensure the vehicle can not drop Failure to follow these steps could result in serious personal injury or death 15 01 Alternator Battery and Starter Connections Check Batteries release explosive gas as a by product of their chemical activity Do not smoke when work ing around batteries Put out all flames and re move any source of sparks or intense heat Make sure the battery compartment is completely vented before disconnecting or connecting the battery cables Battery acid is extremely harmful if splashed in the eyes or on the skin Always wear a face shield and
68. 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 20 02 Radiator Inspection 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 radiator Using low water pressure rinse the radiator Be careful not to damage or bend the fins of the radiator Depending on the condition of the radiator this process may have to be performed sev eral times 20 03 Coolant Replacement At the intervals specified in the maintenance sched ule or whenever
69. cturer 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 Recreational Vehicle Chassis Maintenance Manual June 2015 33 3 33 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 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 6 Lock the pointers in place Check that
70. ded 7 On the bundled cable that runs from the batteries to the starter ensure that tie straps are installed at least every 12 inches 30 cm Replace any missing tie straps and add tie straps where spacing between them exceeds 12 inches 30 cm 8 Ensure that all cables have sufficient slack to allow for engine movement and that there is no force on any wiring connectors 9 If any convoluted tubing is damaged check the wiring inside it Replace any damaged or missing convoluted tubing 10 Inspect the battery cables for wear and replace as needed Clean the cable connector terminals with a wire brush See Group 54 of the vehicle Workshop Manual for troubleshooting instruc tions and for adjustment repair or replacement instructions or take the vehicle to an authorized Freightliner dealer 10 1 Clean and tighten the battery ground cable terminal and clamps 10 2 Inspect the retainer assembly or battery hold downs and the battery box Replace worn or damaged parts Remove any cor Recreational Vehicle Chassis Maintenance Manual June 2015 15 1 15 10 3 10 4 10 5 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 Check that foreign objects such as stones bolts and nuts are removed from the battery box After cleaning connect the cables to the batteries and tigh
71. 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 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 manufacturers 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 as well as the ex haust wrap from the ATD to the diffuser 4 Check the ATD mounting bands for tightness Tighten to 30 Ibf ft 41 N m if needed Do not overtighten 5 Check for leaks around the clamps that
72. degrees Maintain pres sure on the hub note the inboard mea surement and then pull the hub outward while oscillating it as before Maintain pressure on the hub and note the out board measurement See Fig 10 The end play is the difference between the two measurements The end play limit for PreSet hubs is 0 006 inch 0 15 mm for non PreSet hubs the acceptable range is 0 001 to 0 005 inch 0 03 to 0 13 mm inclusive If the end play does not exceed the limit and no other problems were found in the previous steps no additional service is Recreational Vehicle Chassis Maintenance Manual June 2015 33 5 33 necessary If the end play exceeds the limit service the hub See the Recre ational Vehicle Workshop Manual and manufacturer literature for procedures 330270 06 20 2011 1 Hub Cap Mounting Flange 2 Dial Indicator with magnetic base Fig 9 Dial Indicator Setup MO Y Me o sik E A e E p M gt ag 06 21 2011 1330271 A Pull and push the hub while oscillating it Fig 10 Measuring End Play Front Axle 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 rotat
73. dex service litera ture Check the operation of the end cover heater and thermostat assembly during cold weather opera tion as follows 5 1 Electric Power to the Dryer With the igni tion in the ON position check for voltage to the heater and thermostat assembly using a voltmeter or testlight Unplug the electrical connector at the air dryer and place the test leads on each of the con nections of the female connector on the vehicle power lead If there is no voltage look for a blown fuse broken wires or corrosion in the vehicle wiring harness Check to see if a good ground path ex ists 5 2 Thermostat and Heater Assembly Opera tion These tests are not possible except in cold weather operation Turn off the ignition switch and cool the thermostat Brakes and heater assembly to below 40 F 4 C Using an ohmmeter check the re sistance between the electrical pins in the air dryer connector half The resistance should be 1 5 to 3 0 ohms for the 12 volt heater assembly and 6 0 to 9 0 ohms for the 24 volt heater assembly NOTE Some models of the AD 9 may have a resistance reading of 1 0 to 2 5 ohms Warm the thermostat and heater assem bly to approximately 90 F 32 C and again check the resistance The resis tance should exceed 1000 ohms If the resistance values obtained are within the stated limits the thermostat and heater assembly is operating properly If the re sistance values obtained are outside the
74. e placement of only the visibly damaged part s is no assurance that the spring is safe On front spring assemblies if cracks or breaks exist in the two top leaves a loss of vehicle control could occur Failure to replace a damaged spring assem bly could cause an accident resulting in property damage serious personal injury or death IMPORTANT On multi leaf suspensions closely inspect each component of the leaf spring as semblies including the brackets U bolts and related parts 60 Inch Taper Leaf Spring Component Check No lubrication is required on the 60 inch taper leaf spring front and rear suspension Suspension Inspect the rear shackle brackets for bushing wear or cracks Inspect the stabilizer bar if present for irregular bushing wear or cracks in the brackets Check the rubber helper spring if present for cracks 32 06 Suspension U Bolt Torque Check Check the U bolt torque of both the front and rear axles where applicable NOTICE 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 See Fig 6 Set a click type torque wrench to the highest torque value for the fastener being checked See Table 3 for U bolt torque specifica tions Turn the wrench in a clockwise motion looking up until the torque wrench clicks 3 R
75. e a drain pan under the power steering res ervoir 3 Remove the steering gear to reservoir return hose at the reservoir and position it to drain into the pan 4 Plug the return line fitting on the reservoir 5 Remove the reservoir cover For the 1 6 and 2 quart reservoir unscrew and remove the reservoir cover See Fig 2 For the 4 quart reservoir loosen and then re move the retaining ring filter top plate and gas ket See Fig 3 NOTE Always replace the power steering reser voir filter when changing the fluid 6 Remove the power steering filter It may be nec essary to wiggle the filter to remove it from its base Do not use pliers to aid in removal of the Steering 12 16 2013 1462248 Power Steering Fluid Reservoir Gasket Reservoir Cover Dipstick gue ON Filter Fig 2 1 6 and 2 Quart Reservoir filter pliers could cause metal chips to enter the steering system 7 Clean the inside of the reservoir using a lint free cloth 8 Raise the front of the vehicle with a floor jack and support it with jack stands 9 Place the disconnected end of the steering gear to reservoir hose in a drain pan IMPORTANT Do not start the engine while draining the system 10 Have someone turn the steering wheel to full lock left and right several times until clean power steering fluid flows from the hose into the drain pan Add fluid to the reservoir as needed 11 Once clean fluid com
76. e and include 1 pint 0 5 liter for each wheel end and with the drive pinion at 3 degrees Table 4 Meritor Drive Axle Lubricant Capacities 35 03 Axle Breather Checking NOTE Detroit axles have a breather hose wrapped around the housing breather The breather hose length should not be lower than approximately 1 inch below the axle housing weld seam The axle housing breather must remain clean See Fig 1 and Fig 2 When the axle lubricant level is checked check that the axle breather is open Check more often under poor operating conditions If the breather is plugged clean it or replace it as needed Rear Axle 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 f400295 07 28 2010 1 Cap Head 2 Hub Cap Beauty Ring Fig 4 Rear Axle Hub Cap Assembly 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
77. e solutions can be narrowed by initially entering vehicle identification data PartsPro is an electronic parts catalog system showing the specified vehicle s build record EZWiring makes Freightliner Custom Chassis Corporation Freightliner Ster ling 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 July 2013 I 1 Introduction Descriptions of Service Publications Warranty related service information available on the AccessFreightliner com website includes the following documentation Recall Campaigns Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice These campaigns pertain to matters of vehicle safety All recall campaigns are distributed to dealers customers receive notices that apply to their vehicles Field Service Campaigns Field service campaigns are concerned with non safety related service work or replacement of parts All field service campaigns are distributed to dealers cus tomers receive notices that apply to their vehicles I 2 Recreational Vehicle Chassis Maintenance Manual July 2013 Page Description For an example of a maintenance manual page see Fig 1 Introduction A B C Front Axle 33 Fig 1 L 33 01 Knuckle Pin Lu
78. e the front wheels and allow the oil in the hubs to settle 2 Chock the tires IMPORTANT The oil level should be at or no more than 1 4 inch 6 mm above the level indi cators on the hub caps 3 If necessary remove the filler caps in the ends of the hub caps and add enough oil 80W 90 hypoid gear oil to bring the oil to the proper level 4 Rotate the wheels allow the oil to settle and check the levels again 5 Install the filler caps securely 6 Remove the chocks from the tires 33 06 Oil Filled Hubs Oil Changing Be careful not to overfill the hubs Overfilling may cause oil to be forced out of the hubs and to con taminate the brake linings and other brake compo nents This could result in loss of vehicle control and lead to personal injury and property damage 1 With the vehicle on a level surface rotate the front wheels so that the front hub drain plugs are positioned downward 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 11 33 6 Recreational Vehicle Chassis Maintenance Manual June 2015 Front Axle 07 09 2009 f330247b A Hub Cavity Full 1 Fill Plug Magnetic Drain 2 Drain Plug Fig 11 Oil Filled Hub Cap 4 Install the drain plugs and tighten 25 Ibf in 282 N cm 5 Add approximately 1 to 1 1 2 pints 0 5 to 0 7 L
79. e 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 June 2015 00 1 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 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 Maintenance Interval i n Kilometers x 1000 24 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458 Mainten ance Interval in Months 12 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 09 01 Air Cleaner Inspection and Replacement When first purchased if the Recreational Vehicle is older than the current model year replace the air filter Inspec
80. els 8 Install the filler plugs securely NOTICE Do not overtighten the cap head Too much force will strip the screw 9 Install the hub cap and tighten the cap head just until snug 35 07 09 2009 f330247b A Hub Cavity Full 1 Fill Plug Magnetic Drain 2 Drain Plug Fig 5 Oil Filled Hub Cap Recreational Vehicle Chassis Maintenance Manual June 2015 35 5 Wheels and Tires Title of Maintenance Operation MOP Wheel Cleaning and Polishing 00 Wheel Nut Checking llle 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 R depending on which side of the vehicle the stud is installed Studs stamped with an L are left hand threaded and are installed on the driver s side of the vehicle Studs stamped with an R are right hand threaded and are installed on the passenger s side of the vehicle When checking wheel nuts on a dual disc assembly remove one outer nut at a time tighten the inner nut then reinstall the outer nut Repeat this procedure for all of the inner
81. emove the chocks U Bolt Torque Values Description Torque Size Ibf ft N m Spring Assembly U Bolt High Nuts Stage 1 Hand tighten Stage 2 60 81 Stage 3 200 271 Stage 4 180 to 230 244 to 312 5 8 18 Stage 1 Hand tighten Stage 2 60 81 Stage 3 200 271 Stage 4 270 to 330 366 to 447 3 4 16 Tighten in the sequence shown in Fig 6 Table 3 U Bolt Torque Values 32 07 V Ride Rear Suspension Inspection Along with the specific V Ride suspension instruc tions provided all suspension components should be inspected for wear or damage and replaced if needed These components include e air spring e air supply pneumatic components e apex bracket 32 6 Recreational Vehicle Chassis Maintenance Manual June 2015 Suspension 03 10 2011 1320783 Fig 6 Tightening Sequence for U Bolt High Nuts e fasteners e frame hanger assembly e QUICK ALIGN connection e shock absorbers e torque rods e U beam assembly The pivot bushing and D pin bushing are critical components of the V Ride rear air suspension If any components appear damaged or worn the component must be replaced Failure to replace worn or damaged components can result in the deformation of parts loss of clamp force bolt fail ure loss of axle alignment loss of vehicle control property damage or personal injury There are two types of pivot bushing ins
82. 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 4 Recreational Vehicle Chassis Maintenance Manual June 2015 Rear Axle 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 Oil Filled 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 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 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 lev
83. enough to cause se rious personal injury by scalding 1 3 Stop the engine Remove the lower radia tor hose to drain the coolant Drainage may be speeded by removing the plug in the bottom of the water inlet 2 Flush the cooling system as follows NOTICE 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 2 4 Start the engine Run it at low idle for 10 seconds then at high idle for 1 minute Return to low idle 2 5 Close the lower petcock when a steady stream of water is flowing from it Don t let more than 1 5 quarts 1 4 L of water escape 2 6 Close the upper petcock when a steady stream of water is flowing from it Don t let more than 1 5 quarts 1 4 L of water escape 2 7 Repeat several times until the drained liquid is nearly colorless 2 8 Completely drain the system then close the radiator and block the drain valves 2 9 Disconnect all hoses from the surge tank Remove the tank and pour out any fluid Scrub and clean the inside of the surge tank with soap and water Flush it with Engine Cooling Radiator clean water then drain it Install the surge tank and hoses IMPORTANT On vehicles with EPAO7 compliant engines the c
84. ers 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 FA 05 27 93 f260007a 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 26 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 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 22 O SS A TS ES gt Oo 11 16 2000 1270074 Fig 2 Transmission Dipstick 4 Perform a hot check at the first opportunity after normal operating temperature 160 to 200 F 71 to 93 C is reached Hot Check Recommended Method With the vehicle on a level surface and the tr
85. es out of the hose remove the plug from the reservoir and reconnect the steering gear to reservoir hose to the reservoir 46 2 Recreational Vehicle Chassis Maintenance Manual June 2015 Steering 08 23 2013 1462246 Power Steering Fluid Reservoir Reservoir Fill Cap Retaining Ring Filter Top Plate Gasket Filter og omc Fig 3 4 Quart Reservoir 12 Install a new power steering filter in the reservoir 13 Inspect the reservoir cover and gasket for any damage Replace the reservoir cover or gasket if needed 14 Install the reservoir cover For the 1 6 and 2 quart reservoir install the cover and hand tighten For the 4 quart reservoir install the gasket filter top plate and retaining ring then hand tighten the retaining ring 15 Fill the power steering reservoir with Dexron Ill Fill the 1 6 and 2 quart reservoir to the MAX COLD mark 46 Fill the 4 quart reservoir to the mark between the MIN COLD and MAX HOT marks IMPORTANT Do not allow the reservoir to empty and pull air into the power steering sys tem 16 Start the engine and let it idle for about 15 sec onds then check the reservoir and add fluid as needed Since the power steering lines were drained this will need to be done several times before the reservoir will remain full 17 Start the engine and operate it at idle Turn the steering wheel to full lock left and right to adjust the fluid level and remove
86. freeze points SCA levels E Check hose routing for chaffing and leaks eine Change Mechanical Fan Drive Gearbox Oil Change 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 Check ___ Suspension Fastener Torque Check 32 01 Check ___ Suspension Height Control Valve Check 32 02 Lubricate ZF IFS Lubrication 32 04 Check ____ Suspension U Bolt Torque Check 32 06 Inspection V Ride Rear Suspension Inspection 32 07 Lubricate Knuckle Pin Lubricatingt 33 01 Lubricate Tie Rod End Lubricating and Inspectingt 33 02 Check ____ AlI Axle Alignment Checking 33 03 Inspect 1 Wheel End Inspecting 33 04 33 05 a _____ Oil Filled Hubs Oil Changing front and tag axle a ae 35 05 Check Axle Seals for Leaks e mer E a Check Axle Breather Checking 35 03 Check Wheel Nut Checking 40 01 Check Tire Pressure m Lubricate ____ Driveline Inspection and Lubrication 41 01 Inspect _____ Brake System Valves Inspecting 42 01 Inspect O id and Air Lines for Proper Routing Chaffing and 42 02 Lubricate Camshaft Bracket Bushing Lubricating 42 04 00 6 Recreational Vehicle Chassis Maintenance Manual June 2015 General Information 00 6000 Mile or 6 Month Initial Maintenance 00 03
87. ger boot for cracks holes or deterioration Replace it if necessary 4 Lift the edge of the brake plunger boot and check the plunger for existing lubrication 4 1 If the plunger is dry remove it by remov ing the brake pedal and brake plunger boot Lubricate the plunger and the inside surface of the boot with barium grease p n BW 246671 or Pennzoil Adhezoplex 42 6 Recreational Vehicle Chassis Maintenance Manual June 2015 Brakes 42 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 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 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 1460513a 04 26 2012 A Open caps and check fluid level B Fill to this level Fig 8 Hydraulic Brake Fluid
88. 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 3 NOTE If a low pressure adaptor is not used with the high pressure gun the U joints may not receive enough lubricant 3 Using lithium 12 hydroxy stearate grease NLGI grade 2 with EP additives and meeting ASTM D4950 LB specifications lubricate until new grease can be seen at both U joint seals NOTICE Fresh lubricant must be seen escaping from both of the 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 5 Check the old grease If it appears rusty gritty or burned replace the U joint assembly 6 Wipe any excess grease from the seals and grease fittings Slip Joint Spline Lubrication 1 Check the slip joints for spline wear by trying to bend the sleeve yoke and splined shaft back and forth If looseness is greater than 0 007 inch 0 18 mm replace both the sleeve yoke and the splined shaft 2 Wipe all old grease and dirt from the slip joint grease fitting 3 Use a hand type grease gun or a high pressure gun with a low pressure adaptor to lubricate the slip joint See Fig 3 Using lithium 12 hydroxy stearate grease NLGI grade 2 with EP additives and meeting ASTM D4950 LB specifications lubricate until fresh grease appears at the pressure relief hole in the yoke plug Then
89. he socket NOTE Use multipurpose chassis grease NLGI grade 1 6 12 hydroxy lithium stearate grease or NLGI grade 2 8 12 hydroxy lithium stear ate grease The grade 2 chassis grease is pre ferred 46 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 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 46 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 Dexron III Use the same lubricant when assembling parts as is used in the power steering system Table 1 Approved Power Steering Fluid Automatic Transmission Fluid 4 Install the dipstick fill cap in the power steering reservoir Rear Mounted 1 Park the vehicle on a level surface shut down the engine and apply the parking brake Chock
90. heck o front engine only se Ne Inspect ___ Brake Inspecting air brakes 42 11 Lubricate ____ x Meritor Roller Pin Lubricating 42 12 Drain Air Tanks Lubricate _____ Drag Link Lubricating 46 01 Change Power Steering Fluid and Filter Changing 46 03 Lubricate ___ Steering Driveline Lubricating 46 04 Lubricate A 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 Fuel Filters 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 For vehicles with Detroit axles complete this procedure once a year or every 25 000 miles 40 000 km which ever comes first 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 June 2015 00 13 00 General Information 60 000 Mile or 48 Month Maintenance 00 07 Procedure i Eerformed 60 000 Mile 96 540 km or 48 Month Mainten
91. hese conditions require component replacement Manual 2 Inspect the torque rods for looseness With the vehicle shut down a lever check can be per 32 8 Recreational Vehicle Chassis Maintenance Manual June 2015 Suspension 32 04 15 2014 f321194 1 Distorted Outer Metal 04 15 2014 f321195 1 Torque Rod Assembly 2 Torque Rod Shims 3 V Rod Bracket 2 Evidence of Metal to Metal Contact Fig 11 Unacceptable D Pin formed with a long pry bar placed under each rod end and pressure applied NOTE Torque rod length is determined by the vehicle manufacturer to center the axles under the frame If the lateral alignment of the axles is incorrect it may be necessary to shim the torque rod end that attaches to the V rod bracket See Fig 12 For lateral alignment instructions see Section 32 05 Subject 180 in the Hecreational Vehicle Chassis Workshop Manual 3 Inspect the V rod bracket for cracks movement or damage and replace the V rod bracket if needed The torque rod may be renewed by pressing out the worn bushings and replacing them For in structions see Section 32 05 Subjects 120 and 130 in the Recreational Vehicle Chassis Work shop Manual Fig 12 V Rod Assembly Recreational Vehicle Chassis Maintenance Manual June 2015 32 9 Front Axle 33 Index Alphabetical Title of Maintenance Operation MOP MOP Number Al Axte Alignment Checklist A Cok meee ae d i eds 33 0
92. ience is a valuable guide in determin 42 ing the best maintenance interval for any one particu lar operation Every 12 months 1 Check for moisture in the air brake system by opening reservoir drain valves and checking for presence of water If moisture is present the desiccant cartridge may require replacement however the following conditions can also cause water accumulation and should be considered before replacing the desiccant e An outside air source has been used to charge the system This air did not pass through the drying bed Air usage is exceptionally high and not nor mal This may be due to high air system leakage In areas where more than a 30 degree range of temperature occurs in one day small amounts of water can temporarily accumulate in the air brake system due to condensation Under these conditions the presence of small amounts of moisture is normal NOTE A small amount of oil in the system is normal and should not be considered as a rea son to replace the desiccant cartridge Some oil at the dryer exhaust is normal 2 Visually check for physical damage such as chaffed or broken air and electrical lines and bro ken or missing parts 3 Check the mounting bolts for tightness See Table 1 for torque values Torque Values Torque Vendor Size Ibf ft N m Grade 5 3 8 16 28 38 Bendix Grade 5 5 8 11 135 183 Haldex 1 2 13 45 to 55 61 to 75 T
93. ies avail able for determining the useful life of their product under actual service conditions The final schedule that is recommended may for economic reasons be 35 2 Recreational Vehicle Chassis Maintenance Manual June 2015 Rear Axle related to lubricant changes that are governed by climatic conditions and magnetic plug maintenance Change lubricant type and viscosity as climatic tem peratures demand regardless of vehicle mileage or established change schedule The normal operating temperature of compounded lubricants during the summer season is about 160 to 220 F 71 to 104 C The chemicals and additives that give these lubricants increased load carrying ca pacity oxidize faster at temperatures above 220 F 104 C contributing to more rapid lubricant deterio ration For this reason lubricants of this type that operate continuously at high temperatures must be changed more frequently NOTICE Failure to change the axle lubricant at more fre quent intervals when adverse operating condi tions require could result in axle damage Axle Draining 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires 2 Clean the fill plug and the area around it Re move the plug from the oil fill hole See Fig 1 4h CAUTION Be careful when draining the axle oil It may be very hot and could cause personal injury if it con tacts the skin 3 Remove the plug at
94. ine rear configuration shown engine front configuration is similar Rear View Front View Axle Housing Breather Breather Hose Oil Fill Plug Oil Drain Plug PON WS Fig 1 Component Locations Detroit Axles Recreational Vehicle Chassis Maintenance Manual June 2015 35 1 35 Rear Axle 12 05 2003 1350436 1 Axle Housing Breather 2 Oil Fill Plug Fig 2 Component Locations Meritor Axles 08 17 2009 1350061a A Correct lube level at bottom of fill hole B Incorrect lube level below fill hole Fig 3 Checking Axle Lubricant Level Detroit Drive Axle Lubricants IMPORTANT Lubricant used in Detroit rear axles must meet Mercedes Benz specification 235 20 mineral or 235 8 synthetic Mobil Delvac Gear Oil A 80W 90 and Mobilube HD A Plus 80W 90 meet specification 235 20 Mobil Delvac 1 Gear Oil 75W 90 and Mobilube 1 SHC 75W 90 meet specification 235 8 For more product information see http bevo mercedes benz com SAE Type Ambient Temperature Viscosity Grade Mineral Oil 15 F 26 1 C and upt 80W 90 Detroit Drive Axle Lubricants IMPORTANT Lubricant used in Detroit rear axles must meet Mercedes Benz specification 235 20 mineral or 235 8 synthetic Mobil Delvac Gear Oil A 80W 90 and Mobilube HD A Plus 80W 90 meet specification 235 20 Mobil Delvac 1
95. ion 1 Remove the U beam assembly For instructions see Section 32 05 Subject 140 in the Recre ational Vehicle Chassis Workshop Manual 2 After removal inspect the pivot bushing connec tions and inner metal areas 3 No replacement is needed if the pivot bushing exhibits a tight joint See Fig 8 An imprinted two line wear pattern on the bushing inner metal indicates the pivot bushing is securely clamped in the frame hanger 4 Inspect the pivot bushing See Fig 9 Any of the following items could be the result of axle mis alignment or loose fasteners and require replace ment of the pivot bushing e an elongated or damaged bore e distorted separated or torn rubber e signs of rust 5 Inspect the inside of the frame hanger legs and the QUICK ALIGN collars If any of the following Recreational Vehicle Chassis Maintenance Manual June 2015 32 7 32 04 15 2014 1321191 Fig 8 Good Joint with an Imprinted Two Line Wear Pattern 04 15 2014 1321192 NOTE All of these examples exhibit a loose joint 1 Elongated Damaged Bore 2 Distorted Rubber 3 Rust Fig 9 Inspecting for Indications of a Loose Joint are present the pivot bushing and one or more of the mating components may require replace ment e Evidence of wear marks on the inside of the frame hanger legs indicating metal to metal contact or movement e The snout of the QUICK ALIGN concentric or eccentric coll
96. itions 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 Gaff ney South Carolina Some of the items covered dur ing the training include the air brake system electri cal 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 class 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 mak
97. k Always support the vehicle with safety stands Jacks can slip causing the vehicle to fall which could result in serious injury or death 2 Raise the front of the vehicle and support it with safety stands 3 Remove the front wheel and tire assemblies For instructions see Group 40 of the Recreational Vehicle Workshop Manual 4 Remove the brake drum For more information see Group 33 of the Recreational Vehicle Work shop Manual 5 Check for loose damaged or missing fasteners and hubcaps 6 Check for lubricant around the hub cap and wheel If lubricant is present investigate the cause and take corrective action 7 Check for lubricant around the hub brake hard ware and brake shoes if installed If lubricant is present check the oil seal and replace it as nec essary For instructions see Section 33 03 of the Hecreational Vehicle Workshop Manual 8 Inspect the lubricant for discoloration Under nor mal conditions the lubricant will darken a white or milky appearance indicates water contamina tion If the lubricant is discolored service the wheel end See the Recreational Vehicle Work shop Manual and manufacturer literature for pro cedures IMPORTANT Do not mix different types of lubri cants 9 Inspect the lubricant for the presence of foreign matter Use a magnet to detect any metallic ma terials present in the lubricant If the lubricant is contaminated service the hub See the Hecre ationa
98. l Vehicle Workshop Manual and manufac turer literature for procedures 10 Rotate the hub and check for free smooth and quiet rotation If rotation is hampered service the hub immediately See the Recreational Vehicle 33 Workshop Manual and manufacturer literature for procedures Correct wheel bearing end play is crucial to the safe and sound operation of the vehicle If the end play is not correct the wheel bearings could fail and cause the loss of the wheel and hub assem bly and result in an accident causing property damage serious injury or death Use a dial indica tor to measure the end play IMPORTANT Do not measure the wheel bear ing end play with the wheel mounted on the hub you cannot accurately measure or adjust bearing end play with the wheel mounted on the hub Also ensure that the brakes are not ap plied so that that drum and hub can move freely 11 Using a dial indicator measure the end play as follows 11 1 Attach the magnetic base of a dial indica tor to the end of the spindle and place the measuring end of the indicator against the hub cap mounting flange See Fig 9 IMPORTANT Maintain continual pressure on the hub until you have taken both the in board and outboard measurements If you release the hub an accurate measurement is not possible 11 2 To seat the bearings grip the hub at the three o clock and nine o clock positions and push inward while oscillating it ap proximately 45
99. leased 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 maintenance interval for lubricating pin slide hydraulic disc brake cali pers Apply 1 8 oz 3 5 g Aeroshell grade 5 grease to each of the two guide pin and guide pin bore sets See the Bosch Pin Slide Disc Brakes Service Manual for additional information IMPORTANT The later ZOH T caliper has im portant differences from the early ZOPS caliper ZOPS calipers since 1998 and ZOH T calipers since 2002 use different slide pins and bolts See Fig 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 mus
100. nd 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 points 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 10 Recreational Vehicle Chassis Maintenance Manual June 2015 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 f 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 2 Brake Chamber Stroke Specifications 03 02 2004 Series Series
101. noperative 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 June 2015 General Information 00 Verification of Inspections Log 00 09 Verification of Inspections Log Verification of Inspections Log Group 49 Date Mileage Item Cost Maintenance Facility Group 49 Exhaust System Components Recreational Vehicle Chassis Maintenance Manual June 2015 00 17 Engine Title of Maintenance Operation MOP Engine Drive Belt Inspecting Engine Support Fasteners Checking Safety Precautions s eeaeee arumana inen a E 01 Index Alphabetical MOP Number Recreational Vehicle Chassis Maintenance Manual June 2015 Engine Safety Precautions When working on the vehicle shut down the en gine set the parking brake and chock the tires
102. nt plug and opening the drain valve See Fig 1 2 Disconnect the water sensor and heater connec tions if equipped 3 Remove the element and bowl together by turn ing counterclockwise 4 Remove the bowl from the element and clean the O ring seating surface 5 Apply a coating of clean fuel or motor oil to the new O ring and element seal 6 Spin the bowl onto the new element then spin them both onto the filter head snugly by hand only IMPORTANT Do not use tools to tighten the bowl and element 7 Connect the water sensor and heater connectors if equipped 8 If equipped with a primer pump prime the fuel water separator 8 1 Loosen the vent plug Then operate the primer pump until the fuel purges at the vent plug 8 2 Close the vent plug 9 Start the engine and check for fuel leaks 10 Shut down the engine and correct any fuel leaks Recreational Vehicle Chassis Maintenance Manual June 2015 47 1 47 2 1 1 3 4 11 d 4 5 10 Td 9 Egi 6 E 7 8 06 25 97 1470147 1 Mounting Head 7 Water Sensor Probe 2 Fuel Primer Pump 8 Heater Connector 3 Vent Plug 9 Drain Plug 4 Bowl O Ring 10 Sight Bowl 5 Bowl Gasket 11 Filter Element 6 Bowl Probe Plug Fig 1 Alliance Fuel Water Separator Davco Fuel Pro amp 232 and 233 Replace the fuel water separator element shown in Fig 2 only when the filter element is completely covered Die
103. onds then shut down the engine 7 Fill the reservoir with Dexron Ill 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 Dexron Ill 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 Steering 46 4 Recreational Vehicle Chassis Maintenance Manual June 2015 Fuel 47 Index Alphabetical Title of Maintenance Operation MOP Fuel Tank Mounts and Fuel Line Checking Fuel Water Separator Element Replacing Safety Precautions llli MOP Number Recreational Vehicle Chassis Maintenance Manual June 2015 Fuel Safety Precautions When working on the vehicle shut down the en gine set the parking brake and chock the tires Before working under the vehicle always place jack stands under the frame rails to ensure the vehicle can not drop Failure to follow these steps could result in serious personal injury or death 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
104. oolant 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 3 1 Slowly add a 50 50 mixture of antifreeze and water to the surge tank until the sys tem is filled See Table 1 for a list of ap proved coolants Approved Coolants Coolant Designation Fleet Charge Coolant Manufacturer Old World Industries Shell HD N Shell Antifreeze Texaco JC04 Antifreeze Van Waters and Rogers Ltd Diesel Antifreeze No Canada 6038 Freightliner approved antifreeze must meet one of the following condi tions A Ethylene glycol solution that meets GM 6038 M Engineering Stan dards B Ethylene glycol solution that has less than 0 1 anhydrous so dium metasilicate and meets either GM 1825 M or GM 1899 M Engineering Standards Table 1 Approved Coolants 3 2 With the radiator cap removed start the engine and run it at low idle for 10 sec onds then at high idle for 1 minute Re turn 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 Change 1 Park the vehicle on a level surface shut down
105. 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 Vehicle 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 2 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 Rec 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 Recre 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 a
106. ough to cover the hubs disassemble and in spect them for water damage and or contamina tion See Group 35 of the Recreational Vehicle Chassis Workshop Manual for instructions or take the vehicle to an authorized Freightliner dealer 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires 2 If the vehicle has just been driven allow a few minutes for the lubricant to settle 3 Clean the fill plug and the area surrounding the fill plug on the side of the axle carrier Remove the plug Check lubricant level when the axle is cold or near room temperature See Fig 1 and Fig 2 NOTE Some Meritor axles have a small tapped and plugged hole located below the housing oil fill hole This smaller hole is for the lubricant temperature sensor only and must not be used as a fill or level hole 4 Check that the lubricant is level with the bottom of the fill hole See Fig 3 If low check for oil leaks and correct as needed Add oil to the level of the fill plug using the lubricant in Table 1 for Detroit axles or Table 2 for Meritor axles 35 IMPORTANT A lubricant level close enough to be seen or touched is not sufficient It must be level with the bottom of the fill hole 5 Install the oil fill plug and tighten it 30 Ibf ft 41 N m for Detroit axles or 35 Ibf ft 47 N m for Meritor axles 1350574 10 17 2012 NOTE Typical eng
107. ovides these instructions to owners Recommendations for Heplacement 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 acts listed below A Removal of or rendering inoperative the en gine speed governor so as to allow engine speed to exceed manufacturer s specifica tions B Removal of or rendering i
108. ow 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 e Aftertreatment System ATS the entire ex haust system from the turbocharger to the tail pipe including the Selective Catalytic Reduction SCR components e Aftertreatment Device ATD a device that re moves pollutants from exhaust gas after the gas leaves the combustion chamber e BlueTec Daimler s proprietary SCR technol ogy 49 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 DEF Tank holds DEF and regulates its tem perature DEF Metering Unit mixes DEF with com pressed
109. p Manual or take the vehicle to an authorized Freightliner dealer 8 Move the axle up and down while checking for signs of looseness due to worn parts at the front pivot connections Replace any worn parts by following the procedures in Group 32 of the Rec 10 11 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 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 Recreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Remove the safety stands and lower the vehicle to the ground Run the engine until air pressure of at least 100 psi 689 kPa is maintained throughout the system IMPORTANT Repeat this check at both ends of the vehicle Recreational Vehicle Chassis Maintenance Manual June 2015 32 3 32 Suspension 02 21 2005 1321032 Fig 2 Holland Neway ADL 120 123 Suspension 12 Check that all air springs are inflated If the air springs do not inflate see Group 32 of the Rec reational Vehicle Chassis Workshop Manual for possible causes and corrections or take the ve hicle to an authorized Freightliner dealer
110. pections for the V Ride suspension The pivot bushing can be visually inspected by looking at the outer rubber flange s of the bushing If the visual inspection war rants a physical inspection can be conducted in which disassembly is required Pivot Bushing Visual Inspection To perform a visual inspection of the pivot bushing it is not necessary to disassemble the pivot bushing connection If the pivot bushing rubber flange s are intact and there are no signs of metal to metal con tact the bushing does not require replacement e The U beam assembly is designed with the pivot bushings centered in each U beam end hub If the pivot bushing is not centered in each hub it is an indication that the pivot bushing 32 could be worn and a pivot bushing physical in spection is required If the pivot bushing shows signs of torn sepa rated or disconnected rubber as shown in Fig 7 it could be the result of axle misalign ment If this condition is evident a pivot bushing physical inspection is required If the outer rubber flange s is missing or there are shards of rubber visible as shown in Fig 7 it could be the result of axle misalignment If this condition is evident the pivot bushing must be replaced 1 04 15 2014 1321190 1 Torn Rubber 2 Disconnected Rubber Flange 3 Missing Rubber Flange Fig 7 Inspecting for Torn Disconnected or Missing Rubber Flange Pivot Bushing Physical Inspect
111. rinting Freightliner Custom Chassis Corporation FCCC reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation Descriptions and specifications contained in this publication provide no warranty expressed or implied and are subject to revision and editions without notice Refer to www Daimler TrucksNorthAmerica com and www FreightlinerChassis com for more information or contact Daimler Trucks North America LLC at the address below Environmental Concerns and Recommendations Whenever you see instructions in this manual to discard materials you should attempt to reclaim and recycle them To preserve our environment follow appropriate environmental rules and regulations when disposing of materials NOTICE Parts Replacement Considerations Do not replace suspension axle or steering parts such as springs wheels hubs and steering gears with used parts Used parts may have been subjected to collisions or improper use and have undetected structural damage 1997 2015 Daimler Trucks North America LLC All rights reserved No part of this publication in whole or in part may be translated reproduced stored in a retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Daimler Trucks North America LLC Daimler Trucks North America is a Damiler company
112. rsonal injury or property dam age When working on a fuel system have a fire extinguisher within easy reach 1 Drain the fuel below the collar level See Fig 3 2 Using Davco wrench 380134 or 382002 remove the filter collar Then remove the filter cover 3 Remove the element and dispose of it properly 4 Install a new element Make sure the grommet is in place on the filter stud 5 Install a new cover seal on the filter cover 6 Using the collar attach the filter cover with the spring to the base IMPORTANT Tighten the collar by hand only 7 Remove the filter vent Then fill the fuel water separator with fuel until the fuel level is 1 inch 2 5 cm above the collar 8 Install the filter vent on the fuel water separator 47 2 Recreational Vehicle Chassis Maintenance Manual June 2015 Fuel 47 1 2 3 OL 8 A 4 9 TI D A 5 10 6 1 11 12 7 I l bo 10 16 2001 AO 1470415 1 Filter Vent 6 Filter Spring 10 Check Valve Fuel Inlet 2 Vent Seal 7 Filter Element 11 Drain 3 Filter Collar 8 Temporary Filter Stud 12 Electric Filter Preheater 4 Filter Cover 9 Fuel Outlet optional 5 Cover Seal Fig 2 Davco Fuel Pro amp 232 and 233 9 Start the engine and raise the rpm for one min ute to purge air Recreational Vehicle Chassis Maintenance Manual June 2015 47 3 47 Fuel 1 lrn Vn m nu Es ft LI
113. se or NLGI Grade 2 8 12 hydroxy lithium stearate grease until new grease is seen at the junctions of the axle beam and knuckles For locations of grease fittings see Fig 1 for grease exit points see Fig 2 Meritor Axles Hold a high pressure grease gun on each fitting until fresh grease appears See Fig 3 This will ensure that all of the old contaminated grease has been forced out When lubricating Meritor axle knuckle pin bushings at the initial maintenance IM interval first wipe the lube fittings clean Then slowly feed multipurpose chassis grease NLGI grade 1 or 2 into each bush ing area while turning the wheels from extreme right 33 06 07 2012 A Upper View LH Side 1 Grease Fitting 1330272 B Lower View LH Side Fig 1 Grease Fittings Detroit Axles 09 13 2012 f330275 Fig 2 Kingpin Grease Exit Points Detroit Axles to left and back again lock to lock This will elimi nate small air pockets and improve grease distribu tion NOTE The grease seal will accept the grease pressure without damaging the seal and is de Recreational Vehicle Chassis Maintenance Manual June 2015 33 1 33 09 06 96 f320032a Pump lubricant into each grease fitting until fresh grease comes out at A 1 Grease Fitting Front Axle grease NLGI Grade 1 696 12 hydroxy lithium stear
114. sel fuel is flammable and can ignite if exposed to an open flame intense heat or other ignition source Do not drain fuel near or expose fuel vapor to open flame or intense heat Exposure to open flame or intense heat could start a fire pos sibly resulting in personal injury or property dam age When working on a fuel system have a fire extinguisher within easy reach 1 Drain the fuel below the collar level 2 Using Davco wrench 232002 remove the filter collar Then remove the filter cover Fuel 3 Remove the element and dispose of it properly 4 Install a new element Make sure the grommet is in place on the filter stud 5 Install a new cover seal on the filter cover 6 Using the collar attach the filter cover with the spring to the base IMPORTANT Tighten the collar by hand only 7 Remove the filter vent Then fill the fuel water separator with fuel until the fuel level is 1 inch 2 5 cm above the collar Install the filter vent on the fuel water separator Start the engine and raise the rpm for one min ute to purge air Davco Fuel Pro 382 Replace the fuel water separator element only when the filter element is completely covered Diesel fuel is flammable and can ignite if exposed to an open flame intense heat or other ignition source Do not drain fuel near or expose fuel vapor to open flame or intense heat Exposure to open flame or intense heat could start a fire pos sibly resulting in pe
115. spect 1A 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 For vehicles with Detroit axles complete this procedure once a year or every 25 000 miles 40 000 km which ever comes first 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 June 2015 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 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 pr
116. stated limits replace the heater and ther mostat assembly 42 03 Air Dryer Desiccant and Coalescent Filter Replacing NOTE Desiccant change intervals may vary from vehicle to vehicle Typical desiccant car tridge life is three years However if experience has shown that extended or shortened life has resulted on a particular installation then the in terval can be increased or decreased accord ingly Bendix AD 9 T a Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires Completely drain all air reservoirs Air pressure gauges should read 0 psi 0 kPa Loosen the desiccant cartridge with a strap wrench at the base of the cartridge Spin off the cartridge and discard it Remove the O ring from the threaded neck and discard it Remove the coalescent filter and discard it 42 2 Recreational Vehicle Chassis Maintenance Manual June 2015 Brakes IMPORTANT Lubricate the new O rings prior to installation 6 10 Install the new small O ring in the groove on the bottom of the new coalescent filter 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 Install the other new O ring over the threaded neck of the desiccant cartridge Screw on the desiccant cartridge until resistance is detected Then tighten the cartridge 1 4 to 3 4 of a turn by hand
117. stener Torque Check 0 000 cee has 32 01 Suspension Height Control Valve Check 00 anii a eee 32 02 Suspension Irispectlofl a5 a nadadora ABAKA AA SABA ADI DA b 32 05 Suspension U Bolt Torque Check suisse ER bere ker edu te te durus dake xor 32 06 V Ride heat SUSPENSION INSPSCHON cadit ace sm irradia Ae dr Bet Sn Rose qe ovs 32 07 Zr AIFS LuUbNGaN0N aaa e cad Deui de be KANG dum duoc Jed pa eiie CN dd abe E shes 32 04 Recreational Vehicle Chassis Maintenance Manual June 2015 Suspension Safety Precautions When working on the vehicle shut down the en gine set the parking brake and chock the tires Before working under the vehicle always place jack stands under the frame rails to ensure the vehicle can not drop Failure to follow these steps could result in serious personal injury or death 32 01 Suspension Fastener Torque Check 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
118. t Checking 33 04 Wheel End Inspection elo 33 05 Oil Filled Hubs Oil Level llas sz rw ome oe De E E EA Checking 33 06 Oil Filled Hubs Oil Changing 35 01 Axle Lubricant Level SS ce ee We E JO O O A O E es os A sin dag A deel Checking For Detroit rear axles with petroleum based oil change the lubricant every 100 000 miles 160 900 km or every 12 months whichever comes first if synthetic oil is used change the lubricant every 250 000 miles 402 250 km or every 36 months whichever comes first For Meritor rear axles with petroleum based oil change the lubricant at 100 000 miles 160 900 km or at 12 months of service whichever comes first and every 24 months thereafter if synthetic oil is used change the lubricant every 250 000 miles 402 250 km or every 36 months whichever comes first 35 02 Axle Lubricant Changing and Magnetic Plug Cleaning 35 03 Axle Breather Checking elolololo o o o o o o o o o o o o o e 0 35 04 Oil Filled Hubs Oil Level Checking Tag Axle 35 05 Oil Filled Hubs Oil Changing Tag Axle 40 01 Wheel Nut Checking Un Cleaning And Perform these steps each time the wheels and or the vehicle is washed 41 01 Driveline Inspection and eese ees A dl se oll aged si Wl see re Its Jes e c o Lubrication 42 01 Brake System Valves e e e e e e
119. t 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 The correct pins bolts and bolt torque must be used If not brake function could be impaired and lead to loss of control of the vehicle which could result in personal injury death or property dam age IMPORTANT The ZOH T caliper assembly is similar in appearance to the existing ZOPS cali per The only obvious difference is that one of the anchor plate slide pins trailing side has notches for identification With ZOH T calipers install the solid pin no bushing only in the an chor plate leading hole position Install the pin with the rubber bushing and notches only in the 42 8 Recreational Vehicle Chassis Maintenance Manual June 2015 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 Ibf ft 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
120. t the air cleaner every 12 months Replace the air filter every 24 months or when filter restriction exceeds the value shown in 09 01 if equipped with an air restriction gauge 09 02 Charge Air Cooler CAC e Ee Il sae Jet Me IE Ez ee Wage ll sage ell e a Mirage t Wag e e mage eas Inspection and Cleaning 13 01 Air Compressor Inspection elololol o l ol o o o o o 15 01 Alternator Battery and wlelelelel a A R 7 7 p Starter Connections Check 20 01 Radiator Cap Check e e e e e e e e e e e e e e e e e e e e 20 02 Radiator Inspection and sil esl sed leas Wi ca ete ll tes me e Kasalan lia la Ng ene a oy Cleaning 20 03 Coolant Replacement The coolant replacement interval is every 100 000 miles 160 900 km or 60 months whichever comes first You must check and if necessary recharge the supplemental coolant additive SCA levels and freeze point every 25 000 miles 40 225 km or 6 months whichever comes first See the applicable engine operation and maintenance manual for further information 20 04 Mechanical Fan Drive Gearbox Oil Change 20 05 Mechanical Fan Drive Gearbox Lubrication 26 01 Transmission Breather Checking 26 02 Allison MD MH Series Transmission Fluid Level Checking 26 03 Allison Transmission Fluid and Fil
121. ten them to the torque specifications listed on the battery gener ally 10 to 15 Ibf ft 14 to 20 N m Coat the battery terminals with dielectric grease 11 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 June 2015 Engine Cooling Radiator 20 Index Alphabetical Title of Maintenance Operation MOP MOP Number Coolant Replace mente atan A haban Bee Eh a aA ant EES 20 03 Mechanical Fan Drive Gearbox Lubrication 00 000 ee 20 05 Mechanical Fan Drive Gearbox Oil Change llli ee 20 04 Radiator Cap Check asia adi S copie nee tae had TANG tee hime i 20 01 Radiator Inspection and Cleanitig iss se RR RR Rt RR ERR RE dud pimaes 20 02 Safety Precautions Recreational Vehicle Chassis Maintenance Manual June 2015 Engine Cooling Radiator Safety Precautions When working on the vehicle shut down the en gine set the parking brake and chock the tires Before working under the vehicle always place jack stands under the frame rails to ensure the vehicle can not drop Failure to follow these steps could result in serious personal injury or death 20 01 Radiator Cap Check Do not remove or loosen the radiator cap until the engine and cooling system have completely
122. ter Changing internal external filter 30 01 Throttle Pedal Pivot Pin Lubricating 32 01 Suspension Fastener Torque Check 32 02 Suspension Height Control Valve Check 00 2 Recreational Vehicle Chassis Maintenance Manual June 2015 General Information 00 Vehicle Maintenance Schedule Table 00 02 Maintenance Operation Procedures and Schedule Maintenance Interval in Miles x 1000 6 15 30 45 bo 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 pe 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458 Maintenance Interval in Months 6 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228 32 03 Neway Suspension Inspection elolololol o o o o o o o lolo fe fe e o o le 32 04 ZF IFS Lubrication olo lolo lol o e e e 32 05 Suspension Inspection eje ojojo o ol o lol olo lol olo lo lo lolol olo 32 06 Suspension U Bolt Torque lala D n D A A A RM eee kat Ive MM Check 32 07 V Ride Rear Suspension sa o 0 el ace ce e Na e Ds Tao Tag rs lala ala Inspection 33 01 Knuckle Pin Lubricating elolololo jl olo lolo o o o o lolo lol olololeo 33 02 Tie Rod End Lubricating ees eee A i ees sre ie ie ces and Inspecting 33 03 All Axle Alignmen
123. the scale is set to zero P ENS cl a B J 08 29 94 f330082a NOTE B minus A equals toe in Fig 6 Wheel Toe In overhead view 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 7 and Fig 8 8 Read the toe in from the scale and compare it to the toe in specification in Group 33 of the Recre ational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer If corrections are needed see Group 33 of the Recreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Front Axle 08 30 94 f330014a Fig 7 Trammel Bar Positioning N imi I7 tr 08 30 94 f400100a Fig 8 Setting Trammel Bar Pointers 33 04 Wheel End Inspection IMPORTANT For ZF IFS axles ZF recom mends that all grease fittings be lubricated once a year preferably before periods of inactivity The wheel hub should be disassembled in spected and the wheel bearings repacked every 1 000 000 miles 1 609 000 km 33 4 Recreational Vehicle Chassis Maintenance Manual June 2015 Front Axle 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires Never work around or under a vehicle that is sup ported only by a jac
124. the bottom of the housing and drain the lubricant while the unit is warm Allow enough time for all the old lubricant to drain completely 4 Clean the drain plug For magnetic drain plugs a piece of key stock or any other convenient steel slug may be used to short the two magnetic poles and divert the magnetic field NOTE Meritor recommends using magnetic plugs with elements having a minimum pickup capacity of two pounds one kilogram of low carbon steel in plate or bar form Magnets will rapidly lose effectiveness as collected material bridges the gap between the two poles Clean or change the plugs before this occurs It may 35 be necessary to clean or change the plugs one or more times between lubrication change inter vals 5 After cleaning the drain plug install and tighten the plug 30 Ibf ft 41 N m for Detroit axles or 35 Ibf ft 47 N m for Meritor axles Axle Filling 1 With the vehicle on a level surface fill the axle housings to the bottom of the oil fill hole in the carrier or housing with recommended lubricant see Table 2 Refer to Table 3 for Detroit drive axle lubricant capacities or Table 4 for Meritor drive axle lubricant capacities NOTE Some Meritor axles have a small tapped and plugged hole located below the housing oil fill hole This smaller hole is for the lubricant temperature sensor only and must not be used as a fill or level hole 2 Install the fill hole plug and tighten it 30 Ibf ft
125. the engine and set the parking brake Chock the tires 20 2 Recreational Vehicle Chassis Maintenance Manual June 2015 Engine Cooling Radiator 2 Place a drain pan under the fan drive gearbox IMPORTANT Label the plugs as they are re moved The breather fill plug must always be installed in the top of the gearbox opposite the drain plug 3 Remove the drain plug and breather fill plug shown in Fig 2 to begin draining the oil 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 Remove the oil level plug See Fig 2 5 Flush the fan drive gearbox with an approved nonflammalbe nontoxic solvent such as e Lubriplate Syn Flush e Lubriplate Pure Flush e Whitmore s Flushing Oil e Medallion Flushing Oil Kosher 6 Using degreaser clean the thread on the drain hole and drain plug 7 Install the drain plug 8 Fill the fan drive gearbox with Mobil amp Delvac 75W 90 lubricant until the lubricant starts to come out of the oil level plug hole 9 Using degreaser clean the thread on the oil level and fill holes and both plugs 10 Install the plugs making certain that the breather fill plug is used in the fill plug hole 20 20 05 Mechanical Fan Drive Gearbox Lubrication U Joint Lubrication 1 Wipe all old grease and dirt from each U joint
126. ty Precautions When working on the vehicle shut down the en gine set the parking brake and chock the tires Before working under the vehicle always place jack stands under the frame rails to ensure the vehicle can not drop Failure to follow these steps could result in serious personal injury or death 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 full 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 Checking IMPORTANT Review the warranty policy before performing any intrusive maintenance proce dures An extended warranty may be voided if intrusive maintenance is performed during this period Because no two vehicles operate under identical conditions maintenance and maintenance intervals will vary Exper
127. ugh lubricant 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 Recreational Vehicle Chassis Maintenance Manual June 2015 41 1 41 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 If the bearing will not take grease replace the U joint assembly For instructions see Group 41 of the vehicle Workshop Manual or take the ve hicle to an authorized Freightliner dealer Check the old grease If it appears rusty gritty or burned replace the U joint assembly For instruc tions see Group 41 of the vehicle Workshop Manual or take the vehicle to an authorized Freightliner dealer Wipe any excess grease from the seals and grease fittings Slip Joint Spline Lubrication 1 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 gre
128. ult in serious personal injury or death 83 01 Air Conditioner Inspecting Wear eye protection gloves and protective cloth ing when working on the air conditioning system Leaking refrigerant from a damaged hose or line could cause blindness or serious skin burns 1 Park the vehicle on a level surface shutdown the engine apply the parking brake and chock the tires 4h CAUTION To avoid the possibility of burns make certain that the engine and air conditioner components are not hot 2 Check the appearance of the air conditioner compressor pulley assembly If the friction sur face of the pulley shows signs of excessive 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 installation proce dures see Group 83 of the Recreational Vehicle Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 3 Inspect the 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 83 of the Recreational Vehicle Chassis Work shop Manual for
129. vehicle damage 2 Check the slip joints for spline wear by trying to bend the sleeve yoke and splined shaft back and forth If looseness is greater than 0 007 inch 0 18 mm replace both the sleeve yoke and the splined shaft 3 Check the driveshaft for missing balance weights and for debris buildup Remove any buildup If any balance weights are missing re move the driveshaft and have it balanced For instructions see Group 44 of the vehicle Work shop Manual or take the vehicle to an autho rized Freightliner dealer 4 Check that the yoke plug is not loose or missing Replace the yoke plug if needed If the yoke plug is missing the splined shaft may be hitting the yoke plug and knocking it out check the drive shaft for proper length 41 U Joint Lubrication 1 Wipe all old grease and dirt from each U joint grease fitting 2 Use a hand type grease gun or a high pressure gun with a low pressure adaptor to lubricate the U joints See Fig 1 10 20 93 f410050a A After grease appears cover the pressure relief hole while continuing to lubricate 1 Slip Joint Grease 5 Yoke Plug Pressure Fitting with grease Relief Hole gun attached 6 Slip Joint Seal 2 Yoke Plug 7 Full Round Yoke 3 Grease 8 U Joint Grease Fitting 4 Half Round Yoke Fig 1 Slip Joint and U Joint Lubricating NOTE If a low pressure adaptor is not used with the high pressure gun the U joints may not receive eno
130. vel 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 To check the latest Allison approved fluids go to www allisontransmission com Lubricants listed in order of preference Do not mix types of oil Table 1 Approved Allison Transmission Lubricants 26 2 Recreational Vehicle Chassis Maintenance Manual June 2015 Transmission Automatic Transmission Lubricant Capacities Refill Capacity Model qt L 1000 2000 and 2000 MH 16 0 15 1 3000
131. ydraulic Reservoir Filter Changing including TRW 46 06 Inspect _____ Fuel Tank Mounts and Fuel Line Checking 47 01 Change Fuel Filters Inspect 1A 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 For vehicles with Detroit axles complete this procedure once a year or every 25 000 miles 40 000 km which ever comes first 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 June 2015 00 9 00 General Information 30 000 Mile or 24 Month Maintenance 00 05 Procedure Eerformed 30 000 Mile 48 270 km or 24 Month Maintenance MOP initial Inspect 1 A Engine Drive Belt Inspecting 01 01 Check Engine Support Fasteners Checking 01 02 Change cd Engine Oil and Filter see the engine manufacturer s u manual Change Air Cleaner Replacement 09 01 Inspect cd Fieri d ne Inspection and Cleaning if 09 02 Inspect ____ Air Compressor Inspection 13 01 Check Alternator Battery and St

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