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freightliner BUSINESS CLASS M2 100, Maintenance Manual

The Freightliner BUSINESS CLASS M2 100 Maintenance Manual is a comprehensive guide essential for keeping your vehicle in optimal condition. Providing detailed instructions and troubleshooting tips, this manual ensures hassle-free maintenance. Download this manual for free from manualshive.com and keep your Freightliner at its best.

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02/23/2011

f490458

A

A

2

1

3

A. At least 7/16 inch (10 mm)
1.

Forward CGI Pipe

2.

CGI Bellows

3.

Aft CGI Pipe

Fig. 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

Business Class M2 Maintenance Manual, November 2015

49/9

Summary of Contents for BUSINESS CLASS M2 100

Page 1: ...BUSINESS CLASS M2 MAINTENANCE MANUAL Models M2 100 M2 106 M2 106V M2 112 M2 112V STI 455 6 03 01 2020 Published by Daimler Trucks North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A ...

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Page 3: ...s or design at any time without notice and without incurring obligation Descriptions and specifications contained in this publication provide no warranty expressed or implied and are subject to revision and editions without notice Refer to www Daimler TrucksNorthAmerica com and www FreightlinerTrucks com for more information or contact Daimler Trucks North America LLC at the address below Environm...

Page 4: ...etrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Daimler Trucks North America LLC Daimler Trucks North America LLC is a Daimler company Daimler Trucks North America LLC Service Systems and Documentation CVI SSD P O Box 3849 Portland Oregon 97208 3849 ...

Page 5: ...nforma 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 ...

Page 6: ...ertain 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 Introduction Descriptions o...

Page 7: ...20 01 Coolant Replacement 20 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 Example of a Business Class M2 Maintenance Manual Page Introduction Page Description Business Class M2 Maintenance Manual July 2018 I 3 ...

Page 8: ...r 25 Clutch 26 Transmission 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 Grille and Cab Fenders Introduction Maintenance Manual Contents I 4 Business Class M2 Maintenance Manual July 2018 ...

Page 9: ...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 00 Index Alphabe...

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Page 11: ...ort with infrequent freeway 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 Examples of Schedule III usage are regional delivery that is mostly freeway miles interstate transport any road operation with high annual mileage Maintenance Schedules Aft...

Page 12: ...aintenance 1 M1 every 8000 12 000 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 that travel over 60 000 miles 100 000 km annually Initial Maintenance IM first 10 000 16 000 Maintenance 1 M1 every 10 000 16 000 Maintenance 2 M2 every 20 000 32 000 Mai...

Page 13: ...4 000 1500 16th M1 M2 M3 and 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 23 000 36 800 2300 24th M1 M2 and M3 24 000 38 400 2400 25th M1 25 000 40 000 2500 26th M1 26 000 41 600 2600 27th M1 27 000 43 200 2700 28th M1 and M2 28 000 44 800 2800 2...

Page 14: ...0 000 16th M1 M2 M3 M4 and M5 128 000 192 000 160 000 256 000 17th M1 136 000 204 000 170 000 272 000 18th M1 and M2 144 000 216 000 180 000 288 000 19th M1 152 000 228 000 190 000 304 000 20th M1 M2 and M3 160 000 240 000 200 000 320 000 21st M1 168 000 252 000 210 000 336 000 22nd M1 and M2 176 000 264 000 220 000 352 000 23rd M1 184 000 276 000 230 000 368 000 24th M1 M2 M3 and M4 192 000 288 0...

Page 15: ... Adjusting Manually Adjusted 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 Fuller Transmission Air Filter Regulator Element Cleaning 26 05 Allison Transmission Fluid and Filter Changing 26 06 Mercedes Benz Transmission Fluid Changing and Magnetic Pl...

Page 16: ...Adjuster Lubrication 42 06 Meritor Camshaft 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 and Mounting Plate Inspection 42 11 Air Brake Inspection and Leak Test 42 12 Bendix E 6 Foot Control Valve Inspection and Lubrication 42 13 Brake Inspection 42 14 ...

Page 17: ...ng M3 M4 and M5 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 vehicles every 25 000 miles 40 000 km for Schedule II vehicles or every 100 000 miles 161 000 km for Schedule III vehicles Schedule II and Schedule III vehicles only If equipped with an oil...

Page 18: ...r Torque Checking 32 03 Suspension U Bolt Torque Checking 33 03 Draw Key Nut Torque Checking 33 06 All Axle Alignment Check 42 17 Bendix Automatic Drain Valve Operating and Leakage Tests 47 01 Fuel Tank Band Nut Tightening The automatic drain valve should be inspected every 6 months or 1500 operating hours whichever comes first Table 5 Initial Maintenance IM Operations General Information 00 Initi...

Page 19: ...ne Lubricating Haldex and Gunite 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 Lubrication 25 05 Clutch Adjusting Manually Adjusted Clutches 26 03 Allison and Eaton Fuller Transmission Breather Checking 31 02 Fifth Wheel Inspecting 32 01 Suspension In...

Page 20: ...namic 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 Otherwise use the M5 maintenance interval Complete this procedure every 25 000 miles 40 225 km 3 months or 500 operating hours whichever comes first The automatic drain valve should be inspected every 6...

Page 21: ...e Emission Control 26 04 Eaton Fuller Transmission Air Filter Regulator Element Cleaning 33 05 Wheel End Inspection and Maintenance 6 000 Pound and 8 000 Pound Steer Axles with Oil Lubricated Hubs 42 08 Air Dryer AD 9 AD IP and AD IS DRM Check 42 10 Brake Pedal Linkage and Mounting Plate Inspection 47 05 CNG Fuel System Inspecting 47 07 CNG Fuel Cylinder Inspecting 49 01 Exhaust System Inspecting ...

Page 22: ...e Operations 01 01 Engine Drive Belt Inspecting 26 05 Allison Transmission Fluid and Filter Changing 32 03 Suspension U Bolt Torque Checking 33 03 Draw Key Nut Torque Checking 40 01 Wheel Nut Checking 42 11 Air Brake Inspection and Leak Test 46 01 Drag Link Inspecting 47 04 LNG Vacuum Integrity Testing 83 02 HVAC Air Filter Replacing Replace the HVAC air filter at the recommended interval or every...

Page 23: ...tenance Operations 01 02 Engine Support Fastener Checking 09 01 Air Cleaner Element Inspecting and Replacing 15 01 Alternator Battery and Starter Checking 20 02 Radiator Pressure Flushing and Coolant Changing 20 04 Hybrid Electric System Coolant Changing 31 01 Frame Fastener Torque Checking 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning 42 03 Governor D 2A Check 46 02 Power Steering Flui...

Page 24: ...0 09 Perform All M3 Maintenance 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 Transmission Leak Checking 42 02 Bendix Air Dryer Desiccant Replacement 42 12 Bendix E 6 Foot Control Valve Inspection and Lubrication 42 15 WABCO System Saver Air Dryer Desiccant ...

Page 25: ...r Haldex and Gunite Slack Adjuster 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 46 05 Drag Link Lubricating 72 01 Door Seals Lubricating 88 01 Hood Rear Support Lubrication For Detroit axles complete this procedure once a year or at the following appli...

Page 26: ...eck Maintenance Operation No 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 M2 Lubrication and Fluid Level Check General Information 00 M2 Lubrication and Fluid Level Check 00 13 Business Class M2 Maintenance Manual March 2018 00 16 ...

Page 27: ... vehicle owner s warranty information book for warranty information concerning noise emis sion control systems Tampering With the Noise Control System is Prohibited Federal law prohibits the following acts or the caus ing thereof 1 The removal or rendering inoperative by any per son other than for purposes of maintenance re pair or replacement of any device or element of design incorporated into a...

Page 28: ...ns Log Group 20 Verification of Inspections Log Group 20 Engine Cooling Radiator Date Mileage Repair Description Cost Repair Facility Verification of Inspections Log Group 49 Verification of Inspections Log Group 49 Exhaust Date Mileage Repair Description Cost Repair Facility General Information 00 Verification of Inspections Log 00 16 Business Class M2 Maintenance Manual March 2018 00 18 ...

Page 29: ...aintenance Operation MOP MOP 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 ...

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Page 31: ...s before replacing the drive 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 power 5 Check the belt for a jagged or streaked sidewall Jagged or streaked sidewalls are the result of foreign material such as sand or gravel in the pulley or a rough pulley s...

Page 32: ...s 136 lbf ft 327 N m NOTE When 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 5 Streaked Sidewalls 6 Cracks Fig 1 Drive Belt Replacement Conditions 07 12 2001 f011990 Fig 2 Belt Tensioner on Caterpillar 3126 Engine Engine 01 Business Class M2 Maintena...

Page 33: ...Title of Maintenance Operation MOP MOP Number Air Cleaner Element Inspection and Replacement 09 01 Air Intake 09 Index Alphabetical Business Class M2 Maintenance Manual November 2014 ...

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Page 35: ...ts 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 ve hicle 2 If necessary replace the air cleaner element For air cleaner element replacement instructions see Group 09 of the vehicle Workshop Manual 3 In...

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Page 37: ...Title of Maintenance 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 ...

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Page 39: ...s 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 coolant supply and return lines for tight connections Tighten the connections and replace the lines and fasteners if needed 3 For the air gover...

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Page 41: ... of Maintenance Operation MOP 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 ...

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Page 43: ...or correct tension Adjust the belt tension if necessary Engines equipped with a serpentine or poly V belt have automatic belt tensioners and do not require belt tension inspection 4 Check that all electrical connections at the alter nator and starter are clean Clean and tighten all charging system electrical connections including the connections at the starter B terminal and ground terminal and wh...

Page 44: ... any foreign objects such as 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 20 N m 10 5 Coat the battery terminals with dielectric grease 11 Check the terminals on the battery shut off switch and the magnetic switch Make sure the terminal connectio...

Page 45: ...e Emission Control 20 03 Hybrid 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 Business Class M2 Maintenance Manual April 2019 ...

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Page 47: ... the cap If it does not replace the cap Make sure that the replace ment radiator cap is correctly rated for the cool ing system of the vehicle Use the recommended tool in Table 1 Tool Part Number Radiator Cap Tester TA53 Table 1 Snap On Tool For Pressure Relief Cap Test 2 There is a second valve in the radiator cap that opens under vacuum This prevents the collapse of hoses and other parts that ar...

Page 48: ...ysor K22RA K22FA and K26RA Fan Drives 1 Check the fan for missing cracked chipped or damaged blades Tighten loose components Re place damaged fans if necessary 2 Check for adequate clearance around the fan The fan should be centered in the shroud to pre vent contact between the fan and the shroud 3 Check the fan belt for proper alignment and con dition If the belt is worn or frayed replace the bel...

Page 49: ...ance between the fan and other components 5 Check the fan belt for wear tension and align ment Correct if necessary 6 Check for wear on the friction facing Replace the friction facing if it is worn to a 3 16 inch 4 8 mm thickness or less Also check the facing for signs of oil contamination or burn marks If evi dence of oil or burn marks are found replace the friction facing 7 Connect the battery c...

Page 50: ... the cap from the coolant reser voir 2 3 If equipped with a petcock open it at the bottom of the hybrid radiator to drain the coolant 2 4 Disconnect the lower radiator hose and drain the remaining coolant 2 5 Close the petcock if equipped 3 Install the lower radiator hose 4 Fill the system with a coolant mixture of 50 per cent ethylene glycol and 50 percent water 5 Using ServiceRanger1 activate th...

Page 51: ... Clutch Hydraulic Fluid Changing 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 25 Index Alphabetical Business Class M2 Maintenance Manual August 2015 ...

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Page 53: ...not necessary to remove the clutch inspection plate when the lubrication extension is used NOTE For lubricating the release bearing Eaton Fuller recommends a lithium base high temperature grease that meets the NLGI grade one or two specification 3 Wipe the dirt away from the grease fitting See Fig 1 Use a low pressure type grease gun equipped with the recommended grease and lubricate the bearing u...

Page 54: ...ubber parts of the system caus ing loss of clutch function and the risk of serious personal injury CAUTION Do not allow the fluid level in the reservoir to go below the MIN line If too much air enters the hy draulic system will not operate correctly and the clutch could be damaged If the fluid level is below the MIN line fill the reser voir with DOT 4 brake fluid until the level reaches the MAX li...

Page 55: ... suitable con tainer collect the fluid that drains from the slave cylinder bleed valve at least 0 5 quarts 0 5 liters 6 3 When all the old fluid has passed through the system and only new clean fluid is coming out close the bleed screw 7 Check the fluid level in the reservoir and bleed the system according to the procedures under the heading Bleeding the Clutch See Fig 7 Bleeding the Clutch 1 Remo...

Page 56: ...eel Washer 3 Locknut 1 4 20 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 Clutch 25 Business Class M2 Maintenance Manual August 2015 25 4 ...

Page 57: ... forward surface of the clutch 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 M8 Capscrew and Washer 2 Pedal Unit Mounting Plate 3 Reservoir 4 Pedal Unit 5 Master Cylinder 6 Hydraulic Hose 7 Cup Bracket 8 Standoff Bracket 9 Mounting Bolt M10 Fig 7 Clu...

Page 58: ...erted in the gap adjustment is needed Go to the next step If the green end of the tool fits snugly or loosely then no adjustment is needed Nothing more needs to be done Install the clutch inspec tion cover 4 Turn the engine flywheel until the lockstrap is aligned with the clutch inspection cover opening 5 Release the clutch by depressing the pedal Block the pedal in the released position or have s...

Page 59: ...the clutch brake is more than 9 16 inch 14 3 mm turn the adjustment bolt clock wise the release bearing moves toward the transmission To increase the gap If clearance between the release bearing housing and the clutch brake is less than 1 2 inch 12 7 mm turn the adjustment bolt counter clockwise the release bearing moves to ward the engine 6 4 When the adjustment is complete make sure the adjustme...

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Page 61: ... Air Filter Regulator Element 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 Checking 26 07 Safety Precautions 26 00 Transmission Fluid Level Checking 26 01 Transmission 26 Index Alphabetical Business Class M2 Maintenance Manual March 2016 ...

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Page 63: ...g your finger or a bent pipe 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 lubricants see Table 1 manual transmis sions or Table 2 automated transmissions For more information and a complete listing of ap proved lubricants refer to the Eaton website www r...

Page 64: ... lubricant specification All 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 NOTICE Do not allow foreign matter to enter the transmis sion Dirt or foreign matter in the hydraulic system may cause undue wear of transmission parts make valves stick and c...

Page 65: ... the reading Safe oper ating 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 the fluid level within the HOT RUN band See Fig 2 For approved Allison transmission lubricants see Table 4 Mercedes Benz 1 Park the vehicle on a level surface Apply the parkin...

Page 66: ...ain plug s 50 lbf ft 68 N m 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 hand tighten it prior to final torque 5 1 Remove the lubrication filter housing from the clutch housing 5 2 Remove the lubrication filter cartridge and the lubrication filter ...

Page 67: ... Speed FS 4205A B FS 5205A 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 RT 8709B 13 0 12 3 Eaton Fuller Transmission Lubricant Capacities Transmission Model Lubricant Capacity qt L RT 8608L 13 5 12 7 10 Speed FR 9210B 11 75 11 FRO 14210C FRO 1521...

Page 68: ...sure between 57 to 62 psi 396 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 element inside to out side to loosen surface dirt and to dry the element The sintered metallic filter ele f260007a 05 27 93 NOTE Location of the transmission breather will va...

Page 69: ...ing the transmission use only clean containers and fillers for the trans mission fluid Do not use fillers or containers that have been used for water or antifreeze Dirt water or antifreeze could damage the transmission 3 Clean the area around the drain plug Place a drain pan under the transmission and remove the drain plug Examine the fluid while it drains If only the filter is being changed do no...

Page 70: ...and apply the parking brakes 2 Operate the vehicle until the transmission reaches normal operating temperature 160 to 200 F 71 to 93 C 3 Clean the area around the drain plug and the transmission fluid pan Place a drain pan under the transmission and remove the drain plug Ex amine the fluid as it drains If only the filter is being changed do not drain the fluid 4 Remove the 12 mounting bolts six ea...

Page 71: ...t 2 3 Catch the transmission fluid in a suitable container and dispose of it properly 3 Clean the area around the fill plug See Fig 7 for the location of the fill plug 4 Remove the fill plug from the side of the case Discard the aluminum gasket NOTE Use a piece of key stock or any other convenient steel slug to short the two magnetic poles and divert the magnetic field 5 Clean the magnetic drain p...

Page 72: ...s Benz Transmission Leak Checking 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 missing cap Replace the cap if neces sary 2 2 Check the fluid level at the fill plug If the level is too high correct the fluid level 3 Check for signs of leakage at the cap ...

Page 73: ...ic lines If you get clutch hydraulic fluid on your skin wash it off as soon as possible 9 Check for signs of leakage at the clutch slave cylinder NOTICE Do not spill clutch hydraulic fluid DOT 4 brake fluid on the cab paint Clean it off immediately if any is spilled DOT 4 brake fluid can damage paint 9 1 If leakage is found on the slave cylinder body check the fittings and hose for dam age 9 2 If ...

Page 74: ...11 Remove the chocks from the tires Transmission 26 Business Class M2 Maintenance Manual March 2016 26 12 ...

Page 75: ...Wheel Inspecting 31 02 Fifth 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 Maintenance Manual July 2018 ...

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Page 77: ...me 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 brackets front suspension spring brackets fuel tank brackets radius rods rear suspension spring brackets shock absorbers all other suspension fasteners all other axle fasteners all other frame fasteners...

Page 78: ...ting handle must be in proper 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 plate lift See Fig 3 7 1 Level the fifth wheel plate to a horizontal position 7 2 Measure the height from a stationary mounting point such as the frame rail to the top of the f...

Page 79: ...a chassis or multipurpose grease 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 assembly and fifth wheel mounting Tighten bolts and nuts as needed Replace missing or dam aged bolts Replace bent worn or damaged parts with genuine Holland parts 3 Using a Holla...

Page 80: ... on the underside of the top plate or by direct application Apply grease directly to the lock mechanism If lubrication fittings are present lubricate the inter face of the steel bracket shoe and bracket trunnion Holland 1 Using a water resistant lithium base grease apply grease to the top plate Grease the mount ing bracket supports through the zerk fittings See Fig 6 2 Using a light oil or diesel ...

Page 81: ...connector with a lithium based 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 July 2018 31 5 ...

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Page 83: ...ration MOP MOP Number Safety 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 ...

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Page 85: ... semblies including the brackets U bolts and related parts Freightliner Spring Rear Suspension Spring Brackets and Equalizer Brackets Tandems Inspection Inspect the forward and rear spring brackets equal izer brackets tandems and the wear pads for wear cracks and other damage If any of these con ditions exist replace the damaged bracket s and wear pad s See Group 32 of the Business Class M2 Worksh...

Page 86: ...uter bushing sleeve Freightliner Spring Tandem Suspension Equalizer Bushing Check 1 Block the frame up enough to take the weight of the chassis off of the springs Attempt to move the equalizer up and down by using a pry bar between the top of the equalizer and the top of the equalizer bracket Apply hand pressure only See Fig 2 If movement at the center of the equalizer exceeds 1 8 inch 3 mm replac...

Page 87: ...Place safety stands under the 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 air spring assem bly does not leak 4 Check the axle connection welds beam seat to equalizing beam and axle adapter to axle for cracks If welds are cracked grind them out and...

Page 88: ...rod fastener torques 3 Inspect the rubber center bearing and spring tip pads for excessive wear including de lamination of the rubber to metal shim interface and distor tion and degradation of rubber 4 Inspect the V rods and lower control rods for wear and looseness 4 1 Without disconnecting the control rods use your hand to attempt to move each of the control rod ends up down in and out If there ...

Page 89: ... main no 1 and wrapper spring 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 individually re placed If a spring leaf is damaged below these numbers in a pack replace the spring assembly In addition replace both spring assemblies to ensure even spring deflection...

Page 90: ...ck absorber Replace the shock 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 beam ends are off of the saddles All jack stands must be of sufficient strength and rigidity to safely support the vehicle Do not perform any work on or around a vehicle that ...

Page 91: ...g Hendrickson Equalizer Beam 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 multipurpose chassis grease at the spring eye pin grease fitting located on the inboard side of the spring eye pin until clean grease appears at both ends of the spring eye pi...

Page 92: ... 1 Hand tighten Stage 2 60 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 4 520 to 600 707 to 816 Tighten in a diagonal pattern as shown in Fig 9 Table 1 Spring Assembly U Bolt High Nut Torque Values f320783 10 05 2016 1 2 3 4 Fig 9 Tightening Patt...

Page 93: ...ing 33 01 Safety Precautions 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 Lubricated Hubs 33 05 Front Axle 33 Index Alphabetical Business Class M2 Maintenance Manual October 2017 ...

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Page 95: ...multipurpose chassis grease 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 fittings see Fig 1 for grease exit points see Fig 2 Sealed and Easy Steer Kingpins Axles With Unitized Wheel Ends NOTE This procedure applies to 921 931 932 933 934 941 942 ...

Page 96: ...beam On Easy Steer Plus front axles the grease fittings are on the top and bottom kingpin caps of the knuckle 1 Shut off the engine apply the brakes and chock the rear tires 2 Make sure the tires touch the ground Do not raise the vehicle 3 Clean off all grease fittings prior to lubrication IMPORTANT Meritor recognizes that industry trends are moving toward increased selection and usage of syntheti...

Page 97: ...oot NOTE If using an air pressure grease gun do not exceed 150 psi 1035 kPa 4 If the tie rod end is designed for lube service and it does not accept grease perform the following substeps 4 1 Remove the zerk fitting 4 2 Inspect the threaded zerk fitting hole in the tie rod end and remove any obstruc tions 4 3 Install a new zerk fitting 4 4 Apply lubrication to the new zerk fitting 5 Remove the choc...

Page 98: ...d ends in pairs even if only one tie rod end is damaged CAUTION Do not attempt to straighten a bent cross tube Doing so could result in damage to the axle Be sure to replace the cross tube with an original equipment cross tube with the same length diam eter and thread size as the existing cross tube 6 Check the cross tube for cracks or other dam age If the cross tube is bent or damaged re place th...

Page 99: ...00 of this manual Oil Seal Leak Check Check for evidence of oil leakage at the oil seal If a leak is found replace the seal See Section 33 02 of the Business Class M2 Workshop Manual for instructions Hub Cap Leak Inspection Check for evidence of oil leakage between the hub cap gasket and hub surface If leakage is evident replace the gasket with a new one See Section 33 01 Subject 100 of the Busine...

Page 100: ...lear the ground 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 The scribe must be held firmly in place so that a single straight line is scribed all the way around each front tire 5 Place a turn plate or turntable under both ...

Page 101: ...f a leaking vent plug see Fig 14 and Fig 15 Evidence of a leaking vent plug may appear as Oil splatter around the wheel Gooey gummy oil around the vent plug purge point Hub plug area is dirty and water contaminated oil in the hub Hub plug area is clean but there is water con taminated oil in the hub pressure washing is the most likely cause Inspection NOTICE Only remove vent plugs by hand They can...

Page 102: ...le end For instructions refer to Group 33 of the vehicle s Workshop Manual If there is evidence of excessive leakage re move the damaged part and replace it with a new part 5 Check the oil level in the hub and fill the hub with new approved oil as needed f330299 09 01 2016 Fig 14 Excessive Leakage f330300 09 01 2016 Fig 15 Water in Oil Front Axle 33 Business Class M2 Maintenance Manual October 201...

Page 103: ...P Number Axle Breather Checking 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 November 2016 ...

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Page 105: ...rades 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 NOTE Some Detroit axles have a small tapped and plugged hole near and below the housing oil fill hole This smaller hole is for a lubricant temperature indicator only and should not be used as a fill or level hole 4 C...

Page 106: ...E Some Meritor axles have a small tapped and plugged hole located below the housing oil fill hole This smaller hole is for the lubricant temperature sensor only and must not be used as a fill or level hole 2 When the vehicle is on level ground the lubri cant must be level with the bottom of the oil fill hole If low add lubricant See Table 3 for ap proved axle lubricants and see Table 4 or Table 5 ...

Page 107: ...ard 39 1 18 5 Rear 34 4 16 3 RT 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 pinion at 3 degrees Table 5 Meritor Drive Axle Lubricant Capacities for Tandem Axles 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning A regular schedule for changing...

Page 108: ...draining the axle oil It may be 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 and ensure that the axle is flushed 4 Clean the fill and drain plugs Change them if necessary 4 1 For magnetic plugs use a piece of key stock or any other convenient steel...

Page 109: ...ne kilogram of low carbon steel in plate or bar form Magnets will rapidly lose effectiveness as collected material bridges the gap between the two poles Clean or change the plugs before this occurs It may be necessary to clean or change the plugs one or more times between lubrication change inter vals 3 After cleaning the drain plugs install and tighten the plugs 35 lbf ft 47 N m Axle Filling 1 Wi...

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Page 111: ...Title of Maintenance 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 ...

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Page 113: ... 380 to 447 Alcoa Incorporated 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 Alcoa Incorporated Table 1 Wheel Nut Torque Specifications 40 02 Tire Check Tires should be inspected closely during the first 3000 to 10 000 miles 5000 to 16 000 km for abnor ...

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Page 115: ...tle of Maintenance Operation 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 ...

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Page 117: ...onnect the driveshaft For instruc tions see Group 41 of the Business Class M2 Workshop Manual Tighten the end yoke retain ing nut to the proper specification Refer to the axle or transmission manufacturer s service infor mation for the correct specifications 2 Inspect for worn universal joints Apply a vertical force of about 50 pounds to the driveline near the universal joints If there is any move...

Page 118: ...Phillips Petroleum Philube 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 Specification M1C 75B or part number PN C1AZ 19590 Table 1 Approved Lubricants f410486 09 19 2001 Fig 3 Examine the Slip Yoke Spline Driveline 41 Business Class M2 Maintena...

Page 119: ...09 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 ...

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Page 121: ... 04 Brake Inspection 42 13 Brake Lines and Fittings Inspection 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 Inspection 42 14 Meritor Camshaft Bracket Lubrication 42 06 Meritor Slack Adjuster Lubrication 42 07 Safety Precautions 42 00 Versajust Slack Adju...

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Page 123: ...racket strap 6 Remove the two 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 mounting bracket strap fas teners then remove the strap and the air dryer 8 Place the air dryer on a bench and remove the remaining 6 bolts 12 washers 6 Nylok nuts and the ai...

Page 124: ...s four washers and two new 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 Bracket Bolt 2 Upper Mounting Bracket Strap 3 Lockwasher 4 5 16 Inch Nylok Nut 5 Upper Mounting Bracket 6 Housing 7 Nylok Nut 8 3 8 Inch Special Washer 9 Desiccant Cartridg...

Page 125: ...tridge sealing rings 6 Inspect the end cover for physical damage then inspect all air line fittings for corrosion replace as necessary 7 Clean and inspect the bolt paying attention to the threads and O ring grooves IMPORTANT Use only the grease supplied with Bendix replacement kits 8 Lubricate the O rings bolt O ring grooves seal ing rings and cartridge grooves Lubricate the end cover bore for the...

Page 126: ...auge at the time the governor cuts out stopping the compression of air by the compressor Cut out pressure should be in ac cordance with the pressure setting of the piece number being used Common cut out pressures are 125 to 135 psi 862 to 931 kPa With the engine still running make a series of brake appli cations to reduce the air pressure and observe at what pressure the governor cuts in the com p...

Page 127: ... water and wrung until nearly dry remove any remaining dust Do not use compressed air or dry brushing to clean the brake assembly 1 Check lining wear as follows 1 1 Apply the parking brakes Chock the tires to prevent vehicle movement 1 2 Remove one or more of the lining inspec tion plugs and measure brake lining thickness 1 3 On front and rear axles replace linings worn to less than 1 16 inch 1 6 ...

Page 128: ...itor Camshaft Bracket Lubrication IMPORTANT Perform MOP 42 15 before lubri cating the camshaft brackets NOTE If equipped with an extended maintenance Q Plus brake system the cam shaft bracket will not have a grease fitting These camshafts use a special NLGI grade syn thetic polyurea grease and do not require lubri cation for 3 years or 500 000 miles 800 000 km whichever comes first Extended mainte...

Page 129: ...nded maintenance Q Plus brake system the slack adjuster will not have a grease fitting These slack adjusters use a special NLGI Grade syn thetic polyurea grease and do not require lubri cation for 3 years or 500 000 miles 800 000 km whichever comes first The extended maintenance slack adjusters are lubricated dur ing the brake reline service interval For service and lubrication instructions see Gr...

Page 130: ... may be due to high air sys tem leakage 1 3 In areas where more than a 30 degree range of temperature occurs in one day small amounts of water can temporarily accumulate in the air brake system due to condensation Under these conditions the presence of small amounts of moisture is normal NOTE A small amount of oil in the system is normal and should not be considered as a rea son to replace the des...

Page 131: ... 9 0 ohms for the 24 volt heater assembly NOTE Some models of the AD 9 may have a resistance reading of 1 0 to 2 5 ohms Warm the thermostat and heater assem bly to approximately 90 F 32 C and again check the resistance Resistance should exceed 1000 ohms If resistance values obtained are within stated limits the thermostat and heater assembly is operating properly If resistance values obtained are ...

Page 132: ... application allowing the pressure 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 en gine idling perform the following On trucks operate the parking brake con trol valve and note that the parking brakes apply and release promptly as the control valve kno...

Page 133: ...in the primary reservoir 20 4 Make a modulated service brake applica tion Both front and rear brakes should modulate At a steady full brake applica tion the pressure should not drop more than 10 psi 69 kPa within five minutes 21 Drain all reservoirs and remove the gauges from the service reservoirs Close the reservoir drain cocks 22 Remove the chocks from the tires 42 12 Bendix E 6 Foot Control Va...

Page 134: ... the initial maintenance IM interval Vehicles may have both axial and radial mounted calipers Follow the instructions based on the type of calipers installed on the vehicle Axial Mounted Brakes IMPORTANT The following information applies to all types of axial mounted brake applications 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires 2 Raise the ...

Page 135: ...f580518 09 28 2018 Fig 11 DDC DSNCHA018005 30mm Air Disc Brake Caliper Brake Bolt Torque Adaptor Brakes 42 Business Class M2 Maintenance Manual November 2019 42 13 ...

Page 136: ...epair procedures 6 Remove the jack stands and lower the vehicle Radial Mounted Brakes Bendix Calipers 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires 2 Raise the vehicle and support it on jack stands 3 Remove all of the wheel assemblies For instruc tions see Group 40 of the vehicle workshop manual for repair procedures 4 Set a torque wrench to 2...

Page 137: ...icle workshop manual for repair procedures 6 Remove the jack stands and lower the vehicle WABCO Maxxus Calipers 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the tires 2 Raise the vehicle and support it on jack stands 3 Remove all of the wheel assemblies For instruc tions see Group 40 of the vehicle workshop manual for repair procedures 4 Set a torque w...

Page 138: ...perty damage personal injury or death 2 With the engine off and 100 psi 690 kPa of air tank pressure have an assistant apply and hold an 80 to 90 psi 552 to 621 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 4...

Page 139: ...components for damage wear and loose or missing parts Re pair as needed See Group 42 of the vehicle workshop manual for repair procedures f422657 07 30 2018 1 2 3 4 4 3 2 1 A B Tighten the fasteners in the order indicated A Left Hand Bottom View B Right Hand Bottom View Fig 14 Wabco Maxxus Radial Mounted Caliper Tightening Pattern Brakes 42 Business Class M2 Maintenance Manual November 2019 42 17 ...

Page 140: ... 30 2 51 Long Stroke 30 2 1 2 64 Meritor Standard Stroke 9 Less than 1 1 2 38 12 16 Less than 1 3 4 44 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 Specifications are relative to a brake application with 80 to 90 psi 550 to 620 kPa air pressure in the brake chambers If type 36 chamber is used sl...

Page 141: ...main power distri bution module PDM 5 2 Pull the fuse in position F6 for the Hydro Max relay 5 3 Inspect the relay to make sure the fuse is not damaged If the fuse is damaged in stall a new fuse If the fuse is not dam aged install the fuse in position F6 5 4 Close the PDM cover 6 Check the operation of the Hydro Max brake booster as follows 6 1 With the engine off depress the brake pedal the warni...

Page 142: ...lubricant flows from the grease relief opening in the boot 3 Perform the In Service Inspection In Service Inspection 1 Apply and release the brakes several times while observing the slack adjuster The slack adjuster and brake actuator should move freely without binding or interference and should return to the full released position Observe the looseness that exists between the clevis and adapter b...

Page 143: ...of the drain valve If no air comes out push the wire stem lo cated inside the exhaust port If no air comes out after pushing the wire stem there may be a plugged filter in the adapter which should be replaced If the drain valve does not function properly repair or replace it See Section 42 18 of the Business Class M2 Workshop Manual Leakage Test Perform the following test after repairing or replac...

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Page 145: ...ink Lubrication 46 05 Power 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 Alphabetical Business Class M2 Maintenance Manual August 2015 ...

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Page 147: ...f the vehicle Workshop Manual 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 cracks splits or other damage Replace the boot as needed Grasp the drag link near the pitman arm end then push and pull laterally to check for axial movement in the ball stud en...

Page 148: ...en the MIN COLD and MAX HOT lines Add more power steering fluid if needed 13 Raise the vehicle remove the jack stands and lower the vehicle 14 Remove the chocks from the tires 46 03 Power Steering Fluid Level Inspecting 1 Apply the parking brakes and chock the rear tires 2 With the engine cool the fluid level should be between the MIN COLD and MAX HOT lines with the engine off 3 Add or remove flui...

Page 149: ... was re moved from the reservoir 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 and filter cover 9 Check the fluid level in the reservoir If neces sary add fluid to the reservoir to maintain the fluid level between the MIN COLD and MAX HOT lines See Tab...

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Page 151: ... 47 05 CNG High Pressure Fuel 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 47 00 Fuel 47 Index Alphabetical Business Class M2 Maintenance Manual March 2018 ...

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Page 153: ...he jam nut 30 to 35 lbf ft 41 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 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 f...

Page 154: ...vered If the fuel level has reached the top of the filter element follow the procedure below to replace the element 3 Put a clean receptacle under the fuel water sepa rator and attach a piece of hose to the drain valve to direct fuel into the receptacle The drain valve has a 1 2 inch 12 7 mm pipe use a hose with a 1 2 inch pipe thread to fit cor rectly 4 Remove the vent cap Fig 2 Item 10 and open ...

Page 155: ...ause severe personal injury due to scalding If returning fuel is released into the atmosphere its vapors can ignite in the presence of any igni tion source Do not expose the fuel to or work with the fuel system near open flame or intense heat To do so could cause fire possibly resulting in serious personal injury or property damage 1 Shut down the engine apply the parking brake and chock the tires...

Page 156: ...r and the collar Simultane ously apply downward pressure to the top of the clear cover until it is seated on the body of the lower housing and hand tighten the collar until it no longer spins freely Using the collar wrench tighten the cover 18 lbf ft 24 N m This is equivalent to rotating the collar clockwise two or three additional ribs depending on the specific filter model 10 Prime the system 10...

Page 157: ...ng 10 Cover O Ring 11 Clear Cover 12 Vent Cap O Ring 13 Vent Cap 14 Collar Fig 4 DAVCO Fuel Pro 487 1 Arrow on the endplate 2 Keyway 3 Separator Plate 4 Key 5 Endplate Fig 5 Positioning the Filter Element f470689 06 09 2016 1 2 1 Mounting Head 2 Sight Bowl Fig 6 Detroit Fuel Water Separator Fuel 47 Business Class M2 Maintenance Manual March 2018 47 5 ...

Page 158: ...er on natural gas fuel system plumbing com ponents as this can introduce moisture and con taminants into the threads of the fittings and dam age the sealants Gas detection sensors are located on the cab overhead console and in the engine compartment on the frontwall The sensors are located in high areas where rising gas vapors will pass by or ac cumulate Do not use a high pressure washer steam cle...

Page 159: ...ondary relief valve 4 Inspect the fuel tank pressure gauge for cracks in the sight glass Ensure the indicator needle is present and in working condition Inspect the gauge face for accuracy and legibility 5 Inspect all vent lines for kinks and signs of leaks or damage 6 Replace leaking or damaged fuel lines Repair or replace leaking or damaged fittings 05 29 2009 f470534 1 2 3 4 6 5 6 1 Fuel Fill F...

Page 160: ...re regulator is tightened securely 6 4 Inspect the pressure gauge for damage Ensure that the gauge sight glass is clear and legible 7 Repair or replace any leaking or damaged vapor izer components 47 04 LNG Vacuum Integrity Testing WARNING Natural gas is highly flammable See the safety precautions listed in Chapter 16 of the Business Class M2 Driver s Manual or Group 47 of the Business Class M2 Wo...

Page 161: ...uate the tank per the tank manufacturer s instructions Table 1 Vacuum Integrity Test Results 06 29 2009 f470536 2 5 6 7 8 9 10 11 12 1 3 4 1 Pressure Relief Device 2 Fuel Inlet Line 3 Check Valve 4 CNG Quick Connect Port 5 Coolant Inlet Line 6 Vaporizer 7 Fuel Shutoff Solenoid Valve 8 Coolant Outlet Line 9 Pressure Gauge 10 Overpressure Regulator 11 Pressure Relief Valve 12 Fuel Outlet Line Fig 9 ...

Page 162: ...age the sensor Use a bubble solution to check for leaks while per forming the following inspection 1 Inspect the fuel cylinders for dents or other signs of damage Replace any leaking fuel cylinders 2 Ensure that the fuel cylinders are secured within the fuel cylinder storage box 3 Ensure that the fuel cylinder storage box is se cured to the frame Inspect for any signs of looseness If necessary tig...

Page 163: ...ow read at or near 0 psi 4 Close the manual fuel shutoff valve on the fuel panel 5 Remove the two capscrews that secure the ac cess cover to the fill panel then remove the ac cess cover See Fig 13 Save the capscrews for reinstallation 6 Slowly open the bleed valve on the manifold to relieve remaining fuel pressure within the sys tem See Fig 14 HIGH PRESSURE PRESSURE LOW CYLINDERS INSPECT CYLINDERS...

Page 164: ... pinpoint the exact location of leaks Repair or replace any leaking components 15 Using the two capscrews removed previously install the access cover on the fill panel 47 07 CNG Fuel Cylinder Inspecting Have a qualified inspector inspect compressed natu ral gas CNG fuel cylinders for damage or deteriora tion Note cuts cracks gouges abrasions discolor 05 04 2010 f470557 2 2 3 4 5 6 7 8 1 1 Fuel Pan...

Page 165: ...ontainers and Their Installations for inspection requirements and inspector qualifica tions For more information go to www cganet com After inspection an accurate and reliable written re port should be provided for each container inspected Place an inspection label stating the inspection date and inspecting agency identification on each con tainer Fuel 47 Business Class M2 Maintenance Manual March...

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Page 167: ...mber CAT CGI Bellows Replacement 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 Manual November 2015 ...

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Page 169: ...ms and components Aftertreatment System ATS the entire ex haust system from the turbocharger to the ex haust stack or tail pipe Aftertreatment Device ATD a housing that contains the DOC and DPF also the SCR and the mixing tube in one box systems BlueTec Daimler s proprietary SCR technol ogy Diesel Oxidation Catalyst DOC a flow through device that oxidizes soot in the ATD Diesel Particulate Filter ...

Page 170: ...s a system failure or a fault code 10 Check the DEF tank pump metering unit and lines for leaks See Section 49 03 of the Business Class M2 Workshop Manual for repair procedures 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 r...

Page 171: ...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 6 Check all sensors attached to the ATD for leaks or damaged wires No leaks are allowed 7 Check the DPF exterior surface for dents or other damage See Item A of Fig 4 A dent over 3 inches 76 mm in diameter and 1 4 inch 6 mm deep could cause internal damage to t...

Page 172: ... damage Replace the exhaust pipe if needed If leakage exists at a clamp tighten the nuts to the required torque If leakage persists install a new exhaust seal clamp Do not reuse seal clamps Once a seal clamp is loosened or removed it must be re placed 4 Check for leakage at the clamp that attaches the exhaust pipe to the turbocharger exhaust outlet If leakage exists tighten the nut on the clamp to...

Page 173: ...mp for leakage wear cracks or damage Re place damaged components as needed If leak age exists at a clamp tighten the nuts to the re quired torque If leakage persists install a new exhaust seal clamp Do not reuse seal clamps Once a seal clamp is loosened or removed it must be replaced If any of the components is damaged or leaking replace it See 49 03 for the replacement procedure 09 16 2009 f49035...

Page 174: ...ing 7 DPF Outlet Temperature 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 Support Brace 5 Slip Clamp 6 CGI Bellows 7 Center Pipe Support Brace 8 Center Pipe 9 Clamp 10 Outlet Pipe Fig 5 CAT EPA07 Exhaust Installation with CGI Bellows Exhaust 49 Bu...

Page 175: ...lure to do this could result in an exhaust leak which in this case may allow ingestion of contaminants into the en gine causing engine damage 7 Once the pipes are aligned measure the pipe gap between the CGI pipes and record the dis tance See Fig 7 Ref A The existing pipe gap is designed at 10 inches 254 mm A 10 75 inches 273 mm pipe gap is required for the replacement CGI bellows and clamps This ...

Page 176: ...rt Brace 8 Center Pipe 9 Clamp 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 2010 1 2 3 4 5 f490415 1 Aft CGI Pipe 2 Retaining Ring 3 Graphite Gasket 4 Slip Clamp 5 CGI Bellows Fig 8 Aft Facing Slip Clamp Installation Exhaust 49 Business Class M2 Maint...

Page 177: ...GI Bellows 3 Aft CGI Pipe Fig 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 Business Class M2 Maintenance Manual November 2015 49 9 ...

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Page 179: ...ht liner recommends also replacing the socket s harness as well if the corrosion has gotten into the wires and connectors inside the socket IMPORTANT If using a spray cleaner to remove corrosion be careful to protect any surrounding painted surfaces 3 Coat the inside of the sockets with a lithium based dielectric grease such as Lubriplate FLP DS ES 4 Connect the cables Electrical Instruments and C...

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Page 181: ...ping dis coloration high amperage heating or discoloring If needed disconnect cables scrub and clean as needed using a nylon brush Clean debris with vacuum or electrical contact cleaner such as CRC QD Electronic Cleaner inspect terminals and mating contact terminal plating If the termi nal plating exhibits signs of unrecoverable corro sion the component and terminal will need re placed Indications...

Page 182: ... for correct fit and that the terminals hold the fuses and relays firmly in place Inspect fuses and relays for signs of cor rosion thermal distortion warping discoloration and high amperage heating or discoloring If loose or corroded remove inspect clean and replace as needed 13 Connect the batteries Electrical Instruments and Controls 54 Business Class M2 Maintenance Manual 54 2 ...

Page 183: ...Title of Maintenance 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 ...

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Page 185: ...may affect the fold away feature 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 Side skirts Cab side extenders Roof fairing deflector Bumper Hood Replace or repair damaged or missing components as needed Cab 60 Business Class M2 Maintenance Manual Novem...

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Page 187: ...Title of Maintenance Operation MOP MOP Number Door Seals Lubricating 72 01 Doors 72 Index Alphabetical Business Class M2 Maintenance Manual June 2002 ...

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Page 189: ...rication Do not lubricate the door latches or hinges They come from the manufacturer with lifetime lubrication and require no maintenance Lightly coat the door seals with a lubricant that is safe for rubber Doors 72 Business Class M2 Maintenance Manual June 2002 72 1 ...

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Page 191: ...ance Operation MOP MOP Number 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 ...

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Page 193: ...t the drive plate clutch clearance is 0 016 to 0 031 inch 0 4 to 0 8 mm If the gap is not even around the clutch gently tap down at the high areas If the overall gap is out of spec remove the drive plate assembly and change the shims as necessary For instructions see Section 83 01 Subject 140 of the Business Class M2 Workshop Manual 9 Check that the wiring harness connector is not damaged or loose...

Page 194: ...ervice cover to the HVAC assembly 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 from the tires 12 21 2001 f543878 1 2 3 4 1 Fan Cycling Switch 2 Moisture Indicator 3 Binary Switch 4 Receiver Drier Fig 1 Receiver Drier 10 04 2001 f543921 2 1 1 Evaporato...

Page 195: ...Title of Maintenance 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 ...

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Page 197: ...faces of the hood rear sup port brackets and isolators with an approved multi purpose lithium complex soap based grease see Table 1 5 Close the hood Approved Suppliers of Multi Purpose Lithium Grease Supplier Grease Chevron Delo Heavy Duty EP Exxon Unirex EP2 Mobil Mobil Grease XHP 222 Shell Retinax LC Grease Texaco Starplex 2 Table 1 Approved Suppliers of Multi Purpose Lithium Grease Hood Grille ...

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