Daimler Freightliner Business class M2 100 Maintenance Manual Download | Manualshive

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Title of Maintenance Operation (MOP)

MOP Number

Determining Scheduled Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–01

Initial Maintenance (IM) Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–06

M1 Lubrication and Fluid Level Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–12

M1 Maintenance Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–07

M2 Lubrication and Fluid Level Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–13

M2 Maintenance Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–08

M3 Maintenance Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–09

M4 Maintenance Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–10

M5 Maintenance Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–11

Maintenance Intervals for Schedule I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–03

Maintenance Intervals for Schedules II and III . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–04

Maintenance Schedules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–02

Noise Emission Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–15

Overview of Maintenance Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–05

Verification of Inspections Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–16

General Information

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Index, Alphabetical

Business Class M2 Maintenance Manual, November 2016

Property of American Airlines

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Summary of Contents for Freightliner Business class M2 100

Page 1: ...NANCE MANUAL Models M2 100 M2 106 M2 106V M2 112 M2 112V STI 455 6 11 16 Published by Daimler Trucks North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A P r o p e r t y o f A m e r...

Page 2: ...hange 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 ar...

Page 3: ...e 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 on...

Page 4: ...cle 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...

Page 5: ...0 02 Cooling Fan Inspection 20 A Maintenance Operation Number consists of the Group Number followed by the Sequence Number B Group Title C Group Number D Release Date E Group Number Page Number Fig 1...

Page 6: ...31 Frame and Frame Components 32 Suspension 33 Front Axle 35 Rear Axle 40 Wheels and Tires 41 Driveline 42 Brakes 46 Steering 47 Fuel 49 Exhaust 60 Cab 72 Doors 83 Heater and Air Conditioner 88 Hood...

Page 7: ...00 08 M3 Maintenance Operations 00 09 M4 Maintenance Operations 00 10 M5 Maintenance Operations 00 11 Maintenance Intervals for Schedule I 00 03 Maintenance Intervals for Schedules II and III 00 04 Ma...

Page 8: ...travel high percentage of stop and go travel Schedule III long haul transport is for vehicles that travel more than 60 000 miles 100 000 kilometers annually with minimal city or stop and go operation...

Page 9: ...000 Maintenance 2 M2 every 16 000 24 000 Maintenance 3 M3 every 32 000 48 000 Maintenance 4 M4 every 64 000 96 000 Maintenance 5 M5 every 128 000 192 000 Schedule III long haul transport for vehicles...

Page 10: ...M4 16 000 25 600 1600 17th M1 17 000 27 200 1700 18th M1 18 000 28 800 1800 19th M1 19 000 30 400 1900 20th M1 and M2 20 000 32 000 2000 21st M1 21 000 33 600 2100 22nd M1 22 000 35 200 2200 23rd M1 2...

Page 11: ...5 128 000 192 000 160 000 256 000 17th M1 136 000 204 000 170 000 272 000 18th M1 and M2 144 000 216 000 180 000 288 000 19th M1 152 000 228 000 190 000 304 000 20th M1 M2 and M3 160 000 240 000 200 0...

Page 12: ...Clutches 26 01 Transmission Fluid Level Checking 26 02 Eaton Fuller Transmission Fluid Changing and Magnetic Plug Cleaning 26 03 Allison and Eaton Fuller Transmission Breather Checking 26 04 Eaton Ful...

Page 13: ...mshaft Bracket Lubrication 42 07 Meritor Slack Adjuster Lubrication 42 08 Air Dryer AD 9 AD IP and AD IS DRM Check 42 09 Brake Lines and Fittings Inspection Hydraulic Brakes 42 10 Brake Pedal Linkage...

Page 14: ...Change synthetic lubricants at M5 only For Detroit axles complete this procedure once a year or at the following applicable interval whichever comes first every 5000 miles 8000 km for Schedule I vehi...

Page 15: ...ation 00 07 Perform All M1 Operations 31 01 Frame Fastener Torque Checking 32 03 Suspension U Bolt Torque Checking 33 03 Draw Key Nut Torque Checking 33 06 All Axle Alignment Check 47 01 Fuel Tank Ban...

Page 16: ...ite Slack Adjuster Lubricating Meritor Slack Adjuster Lubricating Power Steering Fluid Level Inspecting Power Steering Gear Lubricating Drag Link Lubricating Door Seals Lubricating Hood Rear Support L...

Page 17: ...Component Inspection 83 01 Air Conditioner Inspecting Schedule III vehicles only If equipped with an oil coalescing desiccant cartridge replace the cartridge once a year regardless of mileage Otherwis...

Page 18: ...n Fuller Transmission Air Filter Regulator Element Cleaning 33 05 Wheel End Inspection and Maintenance 6 000 Pound and 8 000 Pound Steer Axles with Oil Lubricated Hubs 42 08 Air Dryer AD 9 AD IP and A...

Page 19: ...ve Belt Inspecting 26 05 Allison Transmission Fluid and Filter Changing 32 03 Suspension U Bolt Torque Checking 33 03 Draw Key Nut Torque Checking 40 01 Wheel Nut Checking 42 11 Air Brake Inspection a...

Page 20: ...ne Support Fastener Checking 09 01 Air Cleaner Element Inspecting and Replacing 15 01 Alternator Battery and Starter Checking 20 02 Radiator Pressure Flushing and Coolant Changing 20 04 Hybrid Electri...

Page 21: ...ce Operations 00 10 Perform All M4 Maintenance Operations 25 04 Clutch Hydraulic Fluid Changing 26 06 Mercedes Benz Transmission Fluid Changing and Magnetic Plug Cleaning 26 07 Mercedes Benz Transmiss...

Page 22: ...juster Lubrication 42 07 Meritor Slack Adjuster Lubrication 42 16 Versajust Slack Adjuster Inspection and Lubrication 46 03 Power Steering Fluid Level Inspecting 46 04 Power Steering Gear Lubricating...

Page 23: ...Title of Maintenance Operation 26 02 Eaton Fuller Transmission Fluid Changing and Magnetic Plug Cleaning 42 06 Meritor Camshaft Bracket Lubrication Petroleum based lubricants only Table 12 MOP 00 13...

Page 24: ...formation book for warranty information concerning noise emis sion control systems Tampering With the Noise Control System is Prohibited Federal law prohibits the following acts or the caus ing thereo...

Page 25: ...of Inspections Log Group 20 Engine Cooling Radiator Date Mileage Repair Description Cost Repair Facility Verification of Inspections Log Group 49 Verification of Inspections Log Group 49 Exhaust Date...

Page 26: ...P Number Engine Drive Belt Inspecting 01 01 Engine Support Fastener Checking 01 02 Safety Precautions 01 00 Engine 01 Index Alphabetical Business Class M2 Maintenance Manual August 2015 P r o p e r t...

Page 27: ...e belts Do not use belt dressing on any belt 4 Check for uneven ribs on serpentine poly V belts Foreign material in the pulley will erode the undercord ribs causing the belt to lose its grip ping powe...

Page 28: ...hen the engine is removed inspect the lower and upper isolators for wear Replace the isolators if necessary f150010b 07 12 2001 1 2 3 4 5 6 1 Glazing 2 Tensile Break 3 Separating Layers 4 Uneven Ribs...

Page 29: ...nce Operation MOP MOP Number Air Cleaner Element Inspection and Replacement 09 01 Air Intake 09 Index Alphabetical Business Class M2 Maintenance Manual November 2014 P r o p e r t y o f A m e r i c a...

Page 30: ...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 s...

Page 31: ...Operation MOP MOP Number Air Compressor Inspection 13 01 Safety Precautions 13 00 Air Compressor 13 Index Alphabetical Business Class M2 Maintenance Manual August 2015 P r o p e r t y o f A m e r i c...

Page 32: ...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...

Page 33: ...OP MOP Number Alternator Battery and Starter Checking 15 01 Safety Precautions 15 00 Alternators and Starters 15 Index Alphabetical Business Class M2 Maintenance Manual August 2015 P r o p e r t y o f...

Page 34: ...he belt tension if necessary Engines equipped with a serpentine or poly V belt have automatic belt tensioners and do not require belt tension inspection 4 Check that all electrical connections at the...

Page 35: ...s stones bolts or nuts from the battery box 10 4 After cleaning connect the cables to the batteries and tighten them to the torque specifications listed on the battery gener ally 10 to 15 lbf ft 14 to...

Page 36: ...rid Electric System Coolant Changing 20 04 Radiator Cap Inspecting 20 01 Radiator Pressure Flushing and Coolant Changing 20 02 Safety Precautions 20 00 Engine Cooling Radiator 20 Index Alphabetical Bu...

Page 37: ...ond valve in the radiator cap that opens under vacuum This prevents the collapse of hoses and other parts that are not internally supported when the system cools Inspect the vacuum relief valve to be...

Page 38: ...east 90 psi 620 kPa to the clutch the fan should rotate freely Remove air pressure from the clutch and the fan should not rotate 5 With the fan drive disengaged check for air leaks at the front of the...

Page 39: ...ch from a dis tance Look for vibration fan blade contact fan clutch slippage and overall fan clutch operation If the fan clutch does not operate correctly see Group 20 of the Business Class M2 Worksho...

Page 40: ...adiator hose 4 Fill the system with a coolant mixture of 50 per cent ethylene glycol and 50 percent water 5 Using ServiceRanger1 activate the HEV coolant pump to purge any air that may be trapped in t...

Page 41: ...nging 25 04 Clutch Hydraulic Fluid Level Checking 25 03 Eaton Fuller Clutch Release Bearing Lubricating 25 01 Eaton Fuller Clutch Release Cross Shaft Lubricating 25 02 Safety Precautions 25 00 Clutch...

Page 42: ...clutch inspection plate when the lubrication extension is used NOTE For lubricating the release bearing Eaton Fuller recommends a lithium base high temperature grease that meets the NLGI grade one or...

Page 43: ...AUTION Do not allow the fluid level in the reservoir to go below the MIN line If too much air enters the hy draulic system will not operate correctly and the clutch could be damaged If the fluid level...

Page 44: ...quarts 0 5 liters 6 3 When all the old fluid has passed through the system and only new clean fluid is coming out close the bleed screw 7 Check the fluid level in the reservoir and bleed the system ac...

Page 45: ...4 Bell Housing Standoff Bracket 5 Slave Cylinder Standoff Bracket 6 Hydraulic Hose 7 Slave Cylinder 8 Bleed Valve 9 Bell Housing 10 Slave Cylinder Mounting Capscrew M8 Fig 6 Clutch Slave Cylinder Clu...

Page 46: ...tch brake disc This dis tance must be maintained between 1 2 and 9 16 inch 12 7 and 14 3 mm 1 Remove the clutch inspection cover from the bell housing See Fig 8 1 2 3 4 5 6 7 8 9 12 11 2001 f250581 1...

Page 47: ...is needed Go to the next step If the green end of the tool fits snugly or loosely then no adjustment is needed Nothing more needs to be done Install the clutch inspec tion cover 4 Turn the engine fly...

Page 48: ...an 9 16 inch 14 3 mm turn the adjustment bolt clock wise the release bearing moves toward the transmission To increase the gap If clearance between the release bearing housing and the clutch brake is...

Page 49: ...nt Cleaning 26 04 Eaton Fuller Transmission Fluid Changing and Magnetic Plug Cleaning 26 02 Mercedes Benz Transmission Fluid Changing and Magnetic Plug Cleaning 26 06 Mercedes Benz Transmission Leak C...

Page 50: ...e cleaner see if the oil is level with the lower edge of the fill opening See Fig 1 3 If needed fill the transmission with oil until level with the lower edge of the fill opening For ap proved lubrica...

Page 51: ...l Do not mix types of oil Table 3 Eaton Approved Lubricants for Procision Transmission Allison Cold Check Clean all dirt away from around the end of the fluid fill tube before removing the dipstick NO...

Page 52: ...g level is within the HOT RUN band on the dipstick The HOT RUN band is between the HOT FULL and HOT ADD marks If the fluid level is not within the HOT RUN band add or drain fluid as needed to bring th...

Page 53: ...5 For Procision transmissions change the lubrica tion filter as follows NOTICE To prevent damage to the threads use hand tools to remove the lubrication filter housing When in stalling the housing ha...

Page 54: ...B 6 25 5 9 FS 6305A B 9 75 9 2 6 Speed FS 5406A 9 75 9 2 FS 6406A FSO 6406A 9 75 9 2 FO 6406A FO 8406 10 5 10 0 FSO 8406A 9 75 9 2 7 Speed T 14607A B 18 17 5 TX 14607B 18 17 5 9 Speed RT 6609A 6 5 7 R...

Page 55: ...96 to 431 kPa replace the air filter regulator It cannot be repaired 4 Clean the filter element 4 1 Dip the filter element in alcohol or other cleaning solvent Blow compressed air through the filter e...

Page 56: ...ly clean containers and fillers for the trans mission fluid Do not use fillers or containers that have been used for water or antifreeze Dirt water or antifreeze could damage the transmission 3 Clean...

Page 57: ...s 2 Operate the vehicle until the transmission reaches normal operating temperature 160 to 200 F 71 to 93 C 3 Clean the area around the drain plug and the transmission fluid pan Place a drain pan unde...

Page 58: ...n fluid in a suitable container and dispose of it properly 3 Clean the area around the fill plug See Fig 7 for the location of the fill plug 4 Remove the fill plug from the side of the case Discard th...

Page 59: ...ecking 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Check for signs of leakage at the breather See Fig 9 2 1 If leakage is found check the breather for a m...

Page 60: ...hydraulic fluid on your skin wash it off as soon as possible 9 Check for signs of leakage at the clutch slave cylinder NOTICE Do not spill clutch hydraulic fluid DOT 4 brake fluid on the cab paint Cle...

Page 61: ...11 Remove the chocks from the tires Transmission 26 Business Class M2 Maintenance Manual March 2016 26 12 P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 62: ...Wheel Lubricating 31 03 Frame Fastener Torque Check 31 01 Safety Precautions 31 00 Trailer Electrical Connector Lubricating 31 04 Frame and Frame Components 31 Index Alphabetical Business Class M2 Ma...

Page 63: ...damage Check the fasteners at the following locations Axle Stops Deck Plates Equalizer Brackets Exhaust Brackets Fifth Wheel Legs Fifth Wheel Mountings Frame Crossmembers and Gussets Front Frame Brac...

Page 64: ...er alignment See Fig 2 Replace any bent or misaligned lever bar or operating rod 6 Check all clinch pins for cracking or damage Replace any clinch pin that shows signs of dam age 7 Measure the top pla...

Page 65: ...ease See Maintenance Operation 31 03 for lubrica tion instructions Holland 1 Thoroughly steam clean all fifth wheel compo nents before inspection 2 Check the fastener torques on the fifth wheel assemb...

Page 66: ...irect application Apply grease directly to the lock mechanism If lubrication fittings are present lubricate the inter face of the steel bracket shoe and bracket trunnion Holland 1 Using a water resist...

Page 67: ...ed dielectric grease 09 06 2001 f310885 1 2 3 1 Pivot 2 Cam Track 3 Cam Plate Fig 7 Holland Fifth Wheel Cam Plate Frame and Frame Components 31 Business Class M2 Maintenance Manual March 2016 31 5 P r...

Page 68: ...y Precautions 32 00 Suspension Inspecting 32 01 Suspension Lubricating 32 02 Suspension U Bolt Torque Checking 32 03 Suspension 32 Index Alphabetical Business Class M2 Maintenance Manual August 2015 P...

Page 69: ...ckets U bolts and related parts Freightliner Spring Rear Suspension Spring Brackets and Equalizer Brackets Tandems Inspection Inspect the forward and rear spring brackets equal izer brackets tandems a...

Page 70: ...liner Spring Tandem Suspension Equalizer Bushing Check 1 Block the frame up enough to take the weight of the chassis off of the springs Attempt to move the equalizer up and down by using a pry bar bet...

Page 71: ...he vehicle frame 2 Squeeze all air springs to check for complete deflation 3 Inspect the air spring piston for cracks chips and broken areas Check the air bag for rips tears and holes Verify that the...

Page 72: ...ect the rubber center bearing and spring tip pads for excessive wear including de lamination of the rubber to metal shim interface and distor tion and degradation of rubber 4 Inspect the V rods and lo...

Page 73: ...ng leaves no 2 the top two spring leaves may be individually replaced If equipped with the RTE series suspension the first second and third spring leaves the top three spring leaves may be individuall...

Page 74: ...ck absorbers if any of these conditions are found 3 Lift the rear of the vehicle and support the frame on jack stands to unload the suspension compo nents The vehicle is lifted high enough when the be...

Page 75: ...m End Bushings and Rubber Center Bushings No lubrication is required for the equalizer beam end bushings or equalizer beam rubber center bushings Hendrickson Spring Eye Pins RT and RTE Series Apply mu...

Page 76: ...81 Stage 3 200 271 Stage 4 270 to 330 367 to 449 7 8 14 Stage 1 Hand tighten Stage 2 60 81 Stage 3 200 271 Stage 4 420 to 500 571 to 680 1 14 Stage 1 Hand tighten Stage 2 60 81 Stage 3 200 271 Stage 4...

Page 77: ...33 00 Steer Axle Hub Cap Vent Plug Inspection 33 07 Tie Rod End Inspecting 33 04 Tie Rod End Lubricating 33 02 Wheel End Inspection and Maintenance 6 000 Pound and 8 000 Pound Steer Axles with Oil Lu...

Page 78: ...NLGI Grade 1 6 12 hydroxy lithium stearate grease or NLGI Grade 2 8 12 hydroxy lithium stearate grease until new grease is seen at the junctions of the axle beam and knuckles For locations of grease...

Page 79: ...nt axles the grease fittings are on the top and bottom kingpin caps of the knuckle 1 Shut off the engine apply the brakes and chock the rear tires 2 Make sure the tires touch the ground Do not raise t...

Page 80: ...ng an air pressure grease gun do not exceed 150 psi 1035 kPa 4 If the tie rod end is designed for lube service and it does not accept grease perform the following substeps 4 1 Remove the zerk fitting...

Page 81: ...mp is welded to the cross tube 7 Check for proper installation of the tie rod end clamp to the cross tube Make sure that the tie rod ends are threaded in the cross tube past the clamps and the slots a...

Page 82: ...that is free of debris especially any metallic particles Then use a magnet to probe the sample Note whether there is substantial metallic debris present and compare the oil color to new approved oil A...

Page 83: ...mmel 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 9 Lock in place Check that the scale is set on zero 7 Place the t...

Page 84: ...er con taminated oil in the hub pressure washing is the most likely cause f400100a 10 05 2016 Fig 11 Setting Trammel Bar Pointers f330298 09 01 2016 Fig 12 Normal Oil Venting f330299 09 01 2016 Fig 13...

Page 85: ...age 3 Wipe the hub cap and vent plug clean with a rag 4 Remove the vent plug and check the oil for evi dence of water contamination If there is evidence of water contaminated oil in the hub disassembl...

Page 86: ...king 35 02 Axle Lubricant Changing and Magnetic Plug Cleaning 35 03 Axle Lubricant Level Checking 35 01 Safety Precautions 35 00 Rear Axle 35 Index Alphabetical Business Class M2 Maintenance Manual No...

Page 87: ...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 NOTE Some Detroit axles have a small tapped...

Page 88: ...small tapped and plugged hole located below the housing oil fill hole This smaller hole is for the lubricant temperature sensor only and must not be used as a fill or level hole 2 When the vehicle is...

Page 89: ...44 145 RT 44 145P Forward 29 3 13 9 Rear 25 1 11 9 RT 46 160 Forward 39 1 18 5 Rear 34 4 16 3 Quantities listed are approximate and include 1 pint 0 5 liter for each wheel end and with the drive pini...

Page 90: ...e very hot and could cause personal injury if it con tacts the skin 3 Place a drain pan under the rear axle drain plug Drain the oil when it is warm At this tempera ture the oil will run more freely a...

Page 91: ...teel in plate or bar form Magnets will rapidly lose effectiveness as collected material bridges the gap between the two poles Clean or change the plugs before this occurs It may be necessary to clean...

Page 92: ...nance Operation MOP MOP Number Tire Check 40 02 Wheel Nut Checking 40 01 Wheels and Tires 40 Index Alphabetical Business Class M2 Maintenance Manual November 2015 P r o p e r t y o f A m e r i c a n A...

Page 93: ...ted M22 x 1 5 Accuride Corporation 450 to 500 610 to 678 Alcoa Incorporated 1 1 8 16 Accuride Corporation 450 to 500 610 to 678 Alcoa Incorporated 3 4 16 Accuride Corporation 450 to 500 610 to 678 Alc...

Page 94: ...n MOP MOP Number Driveline Inspecting 41 01 Driveline Lubricating 41 02 Safety Precautions 41 00 Driveline 41 Index Alphabetical Business Class M2 Maintenance Manual August 2015 P r o p e r t y o f A...

Page 95: ...nstruc tions see Group 41 of the Business Class M2 Workshop Manual Tighten the end yoke retain ing nut to the proper specification Refer to the axle or transmission manufacturer s service infor mation...

Page 96: ...MW EP2 Grease Exxon 5160 Amalie All Purpose Grease with Moly L1 2M Shell Super Duty Special FF Marathon Maralube Molycode 529 Shell Moly Poly Grease Kendall L424 Grease Amoco Super Chassis Grease Ford...

Page 97: ...19 2001 f410485 Fig 4 Lubrication Areas for Full Round and Easy Service Drivelines Driveline 41 Business Class M2 Maintenance Manual August 2015 41 3 P r o p e r t y o f A m e r i c a n A i r l i n e...

Page 98: ...tion Hydraulic Brakes 42 09 Brake Pedal Linkage and Mounting Plate Inspection 42 10 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication 42 05 Governor D 2A Check 42 03 Hydro Max Brake System Insp...

Page 99: ...wo bolts and Nylok nuts that se cure the air dryer to the lower mounting bracket Mark the position of the mounting bracket to the end cover and mark the bolts to ease installation 7 Remove the upper m...

Page 100: ...Nylok nuts Torque the two remaining Nylok nuts 17 to 24 lbf ft 23 08 09 95 f421383 1 2 3 4 5 9 10 11 12 13 14 15 17 18 19 21 22 23 24 25 10 10 10 10 10 10 6 7 8 8 8 20 16 1 5 16 x 4 1 2 Upper Mounting...

Page 101: ...ect the end cover for physical damage then inspect all air line fittings for corrosion replace as necessary 7 Clean and inspect the bolt paying attention to the threads and O ring grooves IMPORTANT Us...

Page 102: ...or cuts out stopping the compression of air by the compressor Cut out pressure should be in ac cordance with the pressure setting of the piece number being used Common cut out pressures are 125 to 135...

Page 103: ...ly dry remove any remaining dust Do not use compressed air or dry brushing to clean the brake assembly 1 Check lining wear as follows 1 1 Apply the parking brakes Chock the tires to prevent vehicle mo...

Page 104: ...cation IMPORTANT Perform MOP 42 15 before lubri cating the camshaft brackets NOTE If equipped with an extended maintenance Q Plus brake system the cam shaft bracket will not have a grease fitting Thes...

Page 105: ...ke system the slack adjuster will not have a grease fitting These slack adjusters use a special NLGI Grade syn thetic polyurea grease and do not require lubri cation for 3 years or 500 000 miles 800 0...

Page 106: ...tem leakage 1 3 In areas where more than a 30 degree range of temperature occurs in one day small amounts of water can temporarily accumulate in the air brake system due to condensation Under these c...

Page 107: ...eater 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 Resistan...

Page 108: ...ressure to stabilize for one minute Observe the installed service reservoir gauges The pressure should not drop more than 15 psi 103 kPa in five minutes 13 With the air system at full pressure and the...

Page 109: ...4 Make a modulated service brake applica tion Both front and rear brakes should modulate At a steady full brake applica tion the pressure should not drop more than 10 psi 69 kPa within five minutes 2...

Page 110: ...the park ing brake and chock the tires Once the tires are chocked release the parking brake WARNING Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is li...

Page 111: ...1 2 64 30 Haldex Standard Stroke 12 1 3 8 35 16 1 3 4 44 20 24 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 Meritor Standard St...

Page 112: ...to the bottom of the fill neck See Fig 10 Use only heavy duty brake fluid DOT 3 2 Check all hydraulic lines and fittings for damage leakage or looseness Replace damaged or leaking components and tigh...

Page 113: ...equent service intervals every 1 to 2 years instead of every 2 to 3 years for a standard cartridge Do not replace an oil co alescing cartridge with a standard cartridge as this may result in contamina...

Page 114: ...cal damage paying attention to the link boot and clevis If any components are damaged repair or replace them as necessary 3 Measure the brake actuator pushrod stroke while making an 80 to 90 psi 552 t...

Page 115: ...Steering Filter Changing 46 06 Power Steering Fluid Changing 46 02 Power Steering Fluid Level Inspecting 46 03 Power Steering Gear Lubrication 46 04 Safety Precautions 46 00 Steering 46 Index Alphabe...

Page 116: ...al for drag link removal and installation instructions See Group 00 in this manual for torque specifica tions Inspect the boot of the drag link at both the pitman arm and the steering arm end for crac...

Page 117: ...lines Add more power steering fluid if needed 13 Raise the vehicle remove the jack stands and lower the vehicle 14 Remove the chocks from the tires 46 03 Power Steering Fluid Level Inspecting 1 Apply...

Page 118: ...rvoir If the gasket is dam aged replace it Install the gasket on the reser voir 8 Install the filter and filter cover in the reservoir Attach the retaining ring to the reservoir to se cure the filter...

Page 119: ...l Filter Element Replacing 47 06 Fuel Tank Band Nut Tightening 47 01 Fuel Water Separator Element Replacing 47 02 LNG Fuel System Inspecting 47 03 LNG Vacuum Integrity Testing 47 04 Safety Precautions...

Page 120: ...1 to 46 N m 47 02 Fuel Water Separator Element Replacing Alliance The only maintenance necessary on an Alliance fuel water separator is to replace the filter element WARNING Diesel fuel is flammable a...

Page 121: ...over 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...

Page 122: ...siness Class M2 Workshop Manual Failure to f470415 10 16 2001 1 2 3 4 5 6 7 8 9 11 12 10 1 Filter Vent 2 Vent Seal 3 Filter Collar 4 Filter Cover 5 Cover Seal 6 Filter Spring 7 Filter Element 8 Tempor...

Page 123: ...threads of the fittings and dam age the sealants Gas detection sensors are located on the cab overhead console and in the engine compartment on the frontwall The sensors are located in high areas wher...

Page 124: ...hafing or loose connections 8 Inspect the fill vent fitting for signs of damage 9 Inspect the shroud cover for dents or other signs of damage Ensure that the shroud cover latches are in working condit...

Page 125: ...aks or damage Inspect the solenoid mount ing bracket for looseness 6 Inspect the overpressure regulator for signs of leaks or damage 6 1 Ensure that the regulator is mounted se curely 6 2 Check the ov...

Page 126: ...t down the engine apply the parking brakes and note the time 6 Wait fifteen minutes after shutting down the en gine then record the fuel tank pressure and note the time 7 Allow the vehicle to stand fo...

Page 127: ...e area has been cleared of any cleaning fumes Harsh chemicals and extremely high temperatures may damage the sensor Use a bubble solution to check for leaks while per forming the following inspection...

Page 128: ...ure may remain in the fuel system between the solenoid valve and the engine Use caution when loosening fittings as a small amount of gas may leak out 7 Put a clean receptacle under the filter assembly...

Page 129: ...kets or isolators heat damage or other prob lems Refer to Compressed Gas Assocation CGA pam phlet C 6 4 Methods for External Visual Inspection of Natural Gas Fuel Containers and Their Installations fo...

Page 130: ...12 13 14 1 2 3 4 5 1 Coolant Inlet Port 2 Coolant Outlet Port 3 Pressure Relief Valve 4 Pressure Regulator 5 Wiring Harness 6 Manifold Bleed Valve 7 Manifold 8 Manual Fuel Shutoff Valve 9 Fuel Fill Po...

Page 131: ...ement 49 03 CAT CGI Bellows and Piping Inspection 49 02 Exhaust System Inspecting Noise Emission Control 49 01 Safety Precautions 49 00 Exhaust 49 Index Alphabetical Business Class M2 Maintenance Manu...

Page 132: ...tment System ATS the entire ex haust system from the turbocharger to the ex haust stack or tail pipe Aftertreatment Device ATD a housing that contains the DOC and DPF also the SCR and the mixing tube...

Page 133: ...lt code 10 Check the DEF tank pump metering unit and lines for leaks See Section 49 03 of the Business Class M2 Workshop Manual for repair procedures 11 Check any wires lines or hoses within 4 inches...

Page 134: ...for leaks around the clamps that attach the ATD in the ATS and around the clamps that retain the DPF in the ATD 6 Check all sensors attached to the ATD for leaks or damaged wires No leaks are allowed...

Page 135: ...pipe if 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 remo...

Page 136: ...or damage Re place damaged components as needed If leak age exists at a clamp tighten the nuts to the re quired torque If leakage persists install a new exhaust seal clamp Do not reuse seal clamps Onc...

Page 137: ...e Sensor 8 Exhaust Outlet Marmon Fitting 9 DPF Outlet Pressure Sensor Fig 4 Typical Aftertreatment Device 02 24 2011 f490456 1 1 2 3 4 5 6 5 3 7 8 9 3 10 1 Clamp 2 Inlet Pipe 3 U Clamp 4 Forward Pipe...

Page 138: ...t in an exhaust leak which in this case may allow ingestion of contaminants into the en gine causing engine damage 7 Once the pipes are aligned measure the pipe gap between the CGI pipes and record th...

Page 139: ...amp 10 Outlet Pipe Fig 6 CAT EPA07 Exhaust Installation with CGI Bellows 02 23 2011 f490457 1 2 A A Measure the pipe gap 1 CGI Aft Pipe 2 CGI Forward Pipe Fig 7 Measuring the Pipe Gap typical 01 29 20...

Page 140: ...ig 9 CGI Bellows Installation 02 08 2010 f490417 5 4 3 2 1 1 CGI Bellows 2 Slip Clamp 3 Retaining Ring 4 Graphite Gasket 5 Forward CGI Pipe Fig 10 Forward Facing Slip Clamp Installation Exhaust 49 Bus...

Page 141: ...Operation MOP MOP Number Aerodynamic Component Inspection 60 02 Mirror Folding Check 60 01 Cab 60 Index Alphabetical Business Class M2 Maintenance Manual November 2014 P r o p e r t y o f A m e r i c...

Page 142: ...ature of the mirror 60 02 Aerodynamic Component Inspection Inspect aerodynamic components if equipped for structural damage cracks or wear These may in clude Chassis fairings Battery access kickplate...

Page 143: ...itle of Maintenance Operation MOP MOP Number Door Seals Lubricating 72 01 Doors 72 Index Alphabetical Business Class M2 Maintenance Manual June 2002 P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 144: ...he door latches or hinges They come from the manufacturer with lifetime lubrication and require no maintenance Lightly coat the door seals with a lubricant that is safe for rubber Doors 72 Business Cl...

Page 145: ...er Air Conditioner Inspecting 83 01 HVAC Air Filter Replacing 83 02 Safety Precautions 83 00 Heater and Air Conditioner 83 Index Alphabetical Business Class M2 Maintenance Manual August 2015 P r o p e...

Page 146: ...earance is 0 016 to 0 031 inch 0 4 to 0 8 mm If the gap is not even around the clutch gently tap down at the high areas If the overall gap is out of spec remove the drive plate assembly and change the...

Page 147: ...sembly 9 Connect the wiring harness to the evaporator probe 10 Attach the lower HVAC cover to the dash panel For instructions see Group 60 of the Business Class M2 Workshop Manual 11 Remove the chocks...

Page 148: ...nce Operation MOP MOP Number Hood Rear Support Lubrication 88 01 Hood Grille and Cab Fenders 88 Index Alphabetical Business Class M2 Maintenance Manual November 2014 P r o p e r t y o f A m e r i c a...

Page 149: ...port brackets and isolators with an approved multi purpose lithium complex soap based grease see Table 1 5 Close the hood Approved Suppliers of Multi Purpose Lithium Grease Supplier Grease Chevron Del...

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