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freightliner Custom Classic MT45 2022, Maintenance Manual

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Title of Maintenance Operation (MOP)

MOP Number

Drag Link Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–01

Power Steering Fluid and Filter Changing, Electric Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–07

Power Steering Hose Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–02

Power Steering Motor Lubrication, Electric Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–06

Power Steering Reservoir Fluid and Filter Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–05

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–00

Steering Driveline Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–03

Steering Gear Bolts Torque Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–04

Steering

46

Index, Alphabetical

Walk-In Van Chassis Maintenance Manual, January 2022

Summary of Contents for Custom Classic MT45 2022

Page 1: ...WALK IN VAN CHASSIS MAINTENANCE MANUAL Models MT45 MT45 G MT50e MT55 MT55 G STI 471 7 06 18 2022 Published by Daimler Truck North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A...

Page 2: ......

Page 3: ...cation provide no warranty expressed or implied and are subject to revision and editions without notice Refer to https northamerica daimlertruck com and www FreightlinerChassis com for more informatio...

Page 4: ...in a retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Daimler Truck North America LLC Daimler...

Page 5: ...r s operator s manuals do not contain detailed repair or service information Service Bulletins Service bulletins provide the latest service tips field repairs product improve ments and related informa...

Page 6: ...l campaigns cover situations that involve service work or replacement of parts in connection with a recall notice These campaigns pertain to matters of vehicle safety All recall campaigns are distribu...

Page 7: ...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 Maintenance Manual P...

Page 8: ...oling Radiator 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 54 Electrical Instrument...

Page 9: ...l Maintenance Schedule Information 00 01 Noise Emission Controls Maintenance 00 03 Vehicle Maintenance Schedule Table 00 02 Verification of Inspections Log 00 04 General Information 00 Index Alphabeti...

Page 10: ......

Page 11: ...e operation reference numbers to find detailed instructions in the manual for each op eration NOTE Maintenance instructions in this manual are based on average vehicle use and normal operating conditi...

Page 12: ...spect the air filter every six months Replace the air filter every 12 months or when filter restriction reaches 25 inH20 for Cummins diesel engines OR when the air restriction indicator is completely...

Page 13: ...Torque Checking 33 01 Grease Lubricated Wheel Bearing Cleaning Inspecting Repacking and Adjusting Front Axle 33 02 Knuckle Pin Lubricating 33 03 Tie Rod End Lubricating and Inspecting Lubricate twice...

Page 14: ...hever comes first 42 10 Bendix Automatic Drain Valve Operating and Leakage Tests The automatic drain valve should be inspected every 6 months or 1500 operating hours whichever comes first 46 01 Drag L...

Page 15: ...port every 16 000 miles 25 750 km or 12 months whichever comes first 54 07 Battery Pack Desiccant Replacement Electric Vehicle Replace the battery pack desiccant every 16 000 miles 25 750 km or 12 mo...

Page 16: ...mation concerning noise emission controls Tampering With Noise Controls is Prohibited Federal law prohibits the following acts or the caus ing thereof 1 The removal or rendering inoperative by any per...

Page 17: ...Inspections Log Groups 20 and 49 Date Mileage Item Cost Maintenance Facility Group 20 Fan Clutch Group 49 Exhaust System Components General Information 00 Verification of Inspections Log 00 04 Walk I...

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Page 19: ...anging Gasoline Engines 01 03 Engine Support Fasteners Checking 01 01 Evaporative Control System Inspecting Gasoline Engines 01 05 Safety Precautions 01 00 Spark Plugs and Wires Inspecting and Replaci...

Page 20: ......

Page 21: ...d set of belts always replace both belts at the same time Matched belts must be from the same manufacturer To inspect a belt gently twist the belt to view the belt sidewalls and bottom Visually in spe...

Page 22: ...the grooves Belt Tension Inspection Spring Tension Type On belts equipped with a spring tensioner the belt tension is automatically adjusted Check that the ten sioner is holding tension on the belt b...

Page 23: ...il drain plug Tighten the plug 18 lbf ft 24 N m 8 When determining the type of engine oil to use look for the API starburst symbol shown in Fig 4 Also look for the Dexos 1 Approved Gen 2 symbol for 6...

Page 24: ...5 Put a small amount of dielectric grease on each end of the spark plug wire electrode then install the wire 6 Repeat the above steps for the remaining spark plugs and wires 7 Install the engine acce...

Page 25: ...e of Maintenance Operation MOP MOP Number Electric Motor Inspection Electric Vehicle 08 01 Safety Precautions 08 00 Electric Drive 08 Index Alphabetical Walk In Van Chassis Maintenance Manual January...

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Page 27: ...ing Failure to do so could cause severe personal injury or death 1 Park the vehicle on a level surface shut down the engine and set the parking brake DANGER Do not touch the high voltage cables Doing...

Page 28: ......

Page 29: ...lement Inspecting and Replacing 09 01 Air Cleaner Filter Minder Gauge Checking 09 02 Air Intake System Inspecting 09 03 Charge Air Cooler Checking 09 04 Safety Precautions 09 00 Air Intake 09 Index Al...

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Page 31: ...er than visual inspection to determine if servicing the air filter element is necessary Removal of the air fil ter element can cause damage to the primary seal which may allow contaminants into the en...

Page 32: ...is connected to the air in take tube by a vacuum hose and a small vacuum filter The gauge takes its measurements when the engine is running at full load and then locks in place until reset See Fig 1...

Page 33: ...s If the charge air cooler core fins are bent use a small pair of needle nose pliers or a small screw driver to straighten them If the fins are clogged use compressed air or water directed from the fa...

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Page 35: ...Title of Maintenance Operation MOP MOP Number Air Compressor Inspection 13 01 Safety Precautions 13 00 Air Compressor 13 Index Alphabetical Walk In Van Chassis Maintenance Manual July 2015...

Page 36: ......

Page 37: ...ious 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 ho...

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Page 39: ...intenance Operation MOP MOP Number Alternator Battery and Starter Connections Check 15 01 Safety Precautions 15 00 Alternators and Starters 15 Index Alphabetical Walk In Van Chassis Maintenance Manual...

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Page 41: ...clean Clean and tighten all charging system electrical connections as needed Spray each electrical connection at the alternator and starter with dielectric red enamel Trace and inspect all wiring and...

Page 42: ...n objects such as stones bolts and nuts are removed 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 gen...

Page 43: ...nt Heater Check Webasto 20 03 Coolant Replacement 20 01 Coolant Replacement Electric Vehicle 20 04 Cooling Fan Inspection 20 02 Safety Precautions 20 00 Engine Cooling Radiator 20 Index Alphabetical W...

Page 44: ......

Page 45: ...onal injury due to scalding 3 Shut down the engine Remove the lower radia tor hose and drain the coolant Draining may be speeded up by removing the plug from the bot tom of the water inlet NOTICE Duri...

Page 46: ...gine coolant passages Any air trapped in the system can cause severe engine damage NOTE The maximum fill rate of the radiator is 2 gallons per minute 4 Connect the lower radiator hose and install the...

Page 47: ...ns or damage and repair or replace the tube if nec essary 4 Check the exhaust system for restrictions or cor rosion Replace any damaged parts 5 Change the fuel filter if so equipped Inspect the fuel l...

Page 48: ...and return lines from the high voltage battery pack Drain any coolant in the lines or batteries into a bucket See Fig 6 f200973 10 15 2021 1 1 Drain Valve Fig 3 Radiator Drain Valve f200975 10 15 2021...

Page 49: ...cid technology OAT cool ant at a rate of 3 gallons per minute GPM 16 Once the vehicle is filled to the COLD FULL mark start the vehicle and allow it to run for 10 minutes 17 After the vehicle has run...

Page 50: ......

Page 51: ...llison Transmission Fluid Level Checking 26 02 Allison Transmission Fluid and Filter Changing 26 03 Safety Precautions 26 00 Transmission Breather Checking 26 01 Transmission 26 Index Alphabetical Wal...

Page 52: ......

Page 53: ...luids or multiviscosity lubricants IMPORTANT For oil and filter change intervals see the applicable Allison Operator s Manual Cold Check IMPORTANT After replacing the transmission fluid or changing th...

Page 54: ...nge add or drain fluid as needed to bring the level to the top of the HOT RUN band See Table 1 for approved transmission lubricants and Table 2 for lubricant capacities 26 03 Allison Transmission Flui...

Page 55: ...llison approved fluids go to the Allison Transmission website at www allisontransmission com my allison customer Lubricants listed in order of preference Do not mix types of oil Table 1 Approved Allis...

Page 56: ......

Page 57: ...tle of Maintenance Operation MOP MOP Number Interlube Chassis Lubrication System Inspecting 31 01 Safety Precautions 31 00 Frame 31 Index Alphabetical Walk In Van Chassis Maintenance Manual January 20...

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Page 59: ...kage 4 Inspect the bottom of the Interlube pump for leaks If there are any signs of lubricant on the pump use a 12 mm wrench and turn all of the injectors and blanking plugs 1 8 to 1 4 inch clockwise...

Page 60: ...12 1 0 18 0 10 23 00 20 29 000 30 34 Do not use heavy tacky grease or clay based high temperature grease Table 1 Approved Grease 6 2 Using approved grease fill the reservoir through the grease fill fi...

Page 61: ...and Operation Checking Freightliner AirLiner 32 03 Freightliner Suspension Inspecting 32 02 Safety Precautions 32 00 Suspension Inspecting 32 01 Suspension U Bolt Torque Checking 32 04 Suspension 32 I...

Page 62: ......

Page 63: ...The minimum compressor cut out pres sure is 110 psi 758 kPa 4 Shut down the engine and wait one minute for the air pressure to stabilize Note the reading on the air pressure gauge 5 Wait one addition...

Page 64: ...and to attempt to move each of the radius rod ends up down in and out If there is any move ment replace the torque arm 2 Inspect the weld seams between the torque arm tube and the shorter bushing tube...

Page 65: ...s are cracked take the vehicle to an authorized Freightliner dealer for repair 5 Move the axle up and down while checking for signs of looseness due to worn parts at the front pivot connections Replac...

Page 66: ...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...

Page 67: ...aning Inspecting Repacking and Adjusting Front Axle 33 01 Knuckle Pin Lubricating 33 02 Oil Filled Hubs Oil Changing 33 06 Oil Filled Hubs Oil Level Checking 33 05 Safety Precautions 33 00 Tie Rod End...

Page 68: ......

Page 69: ...ating the knuckle assemblies otherwise damage could re sult to the knuckle caps Detroit Axles On the front axle grease fittings are on the top and bottom caps of each knuckle 1 Park the vehicle on a l...

Page 70: ...ed maintenance intervals do not raise the front axle Wipe the lube fittings clean and apply multipurpose chassis grease until new grease is seen at the grease seal on the bushing opposite the fittings...

Page 71: ...rallelism and thrust angle measurements for the rear drive axle Use the applicable procedure and specifications in Group 35 of the Walk In Van Chassis Workshop Manual or take the vehicle to an authori...

Page 72: ...rammel bar at the front of the tires and adjust the scale end so that the pointers line up with the scribe lines See Fig 6 and Fig 7 8 Read the toe in from the scale and compare it to the toe in speci...

Page 73: ...t in loss of vehicle control and lead to personal injury and property damage 1 With the vehicle on a level surface rotate the front wheels so that the front hub drain plugs are positioned downward 2 C...

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Page 75: ...Operation MOP MOP Number Axle Breather Checking 35 03 Axle Lubricant Changing 35 01 Axle Lubricant Checking 35 02 Safety Precautions 35 00 Rear Axle 35 Index Alphabetical Walk In Van Chassis Maintena...

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Page 77: ...le the unit is warm Allow enough time for all the old lubricant to drain completely 4 Clean the drain plug For magnetic drain plugs a piece of key stock or any other convenient steel slug may be used...

Page 78: ...tipur pose synthetic gear lubricant See Table 3 for axle lubricant capacities Either type of lubricant must meet MIL L 2105 D and be suitable for American Petroleum Institute service classifica tion G...

Page 79: ...gear lubricant or an SAE 75W 90 multipur pose synthetic gear lubricant Either type of lubri cant must meet MIL L 2105 D and be suitable for American Petroleum Institute service classifica tion GL 5 I...

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Page 81: ...Title of Maintenance Operation MOP MOP Number Wheel Nut Checking 40 01 Wheels and Tires 40 Index Alphabetical Walk In Van Chassis Maintenance Manual January 2008...

Page 82: ......

Page 83: ...nuts in the same se quence CAUTION Too little wheel nut torque can cause wheel shimmy resulting in wheel damage stud break age and extreme tire tread wear Too much wheel nut torque can break studs da...

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Page 85: ...Title of Maintenance Operation MOP MOP Number Driveline Inspection and Lubrication 41 01 Safety Precautions 41 00 Driveline 41 Index Alphabetical Walk In Van Chassis Maintenance Manual July 2015...

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Page 87: ...for debris buildup Remove any buildup If any balance weights are missing re move the driveshaft and have it balanced For instructions see Group 41 of the vehicle Work shop Manual or take the vehicle...

Page 88: ...rease from the seals and grease fittings Slip Joint Spline Lubrication 1 Wipe all old grease and dirt from the slip joint grease fitting 2 Use a hand type grease gun or a high pressure gun with a low...

Page 89: ...ax Brake System Inspection 42 01 Brake Caliper Slide Pin Lubrication Bosch Brakes 42 04 Brake Inspection 42 05 Brake Lines Check Hydraulic Disc Brakes 42 02 Brake Lining Wear Check Hydraulic Disc Brak...

Page 90: ......

Page 91: ...harnesses Make sure the connectors are fully seated and the harnesses are not chafed or cut Repair or replace any damaged harness Disconnect any loose connectors and inspect the terminals for corrosio...

Page 92: ...2 of the Walk In Van Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer 42 04 Brake Caliper Slide Pin Lubrication Bosch Brakes NOTE There is no set maintenance interval f...

Page 93: ...ehicle in the lowest gear and gently at tempt to move it forward The vehicle should not move If the vehicle moves the parking brakes are not operating correctly and must be repaired before the vehicle...

Page 94: ...alent with a center to handle length of 47 inches 119 cm 4 Set a torque wrench to 350 lbf ft 475 N m and tighten the caliper mounting bolts following the tightening pattern shown in Fig 4 If they do n...

Page 95: ...Work shop Manual 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 tir...

Page 96: ...h the engine off and 100 psi 689 kPa of air tank pressure have an assistant apply and hold an 80 to 90 psi 550 to 620 kPa brake applica tion 3 Check to see if the colored over stroke band on each brak...

Page 97: ...matic slack adjusters must be lubricated periodi cally to ensure proper brake operation WARNING Failure to lubricate slack adjusters could lead to dragging brakes or a brake failure resulting in prope...

Page 98: ...2 Listen for the purge valve to open and release air A large volume of air will be expelled followed by a slow flow of air lasting approximately 30 seconds 10 3 Shut down the engine 10 4 Perform the c...

Page 99: ...ne and build air pressure to 100 psi 690 kPa and shut off the en gine 10 2 Check for air leaks at the inlet outlet and canister assembly Correct any leakage problem 10 3 Restart the engine and build u...

Page 100: ...r usage is exceptionally high and not nor mal This may be due to high air system leakage In areas where more than a 30 degree range of temperature occurs in one day small amounts of water can temporar...

Page 101: ...ion in the vehicle wiring harness Check to see if a good ground path ex ists 5 2 Thermostat and Heater Assembly Opera tion These tests are not possible except in cold weather operation Turn off the ig...

Page 102: ...erating and Leakage Tests Operating Test Perform the following test after repairing or replacing the DV 2 valve to ensure that the valve is function ing properly With the system charged apply the brak...

Page 103: ...7 Power Steering Hose Checking 46 02 Power Steering Motor Lubrication Electric Vehicle 46 06 Power Steering Reservoir Fluid and Filter Changing 46 05 Safety Precautions 46 00 Steering Driveline Lubric...

Page 104: ......

Page 105: ...lithium stearate grease or NLGI grade 2 8 12 hydroxy lithium stear ate grease The grade 2 chassis grease is preferred 46 02 Power Steering Hose Checking Check the power steering hoses for chafing Also...

Page 106: ...ose in an upright position to prevent drainage of fluid See Fig 4 4 Catch the fluid from the reservoir in a drain pan then cap the reservoir port 5 Unscrew and remove the 10 micron filter that is loca...

Page 107: ...a new filter Tighten the power steering fitting finger tight then tighten one eighth of a turn past finger tight 8 Connect the return hose to the power steering fluid reservoir WARNING Fill only with...

Page 108: ...power steering reservoir fluid level If the fluid level is low add approved fluid to bring the level up to the full mark on the dipstick 1 2 3 4 5 6 7 8 6 9 09 11 96 f461112 1 Pitman Arm 2 Pitman Arm...

Page 109: ...ts and washers that attach the compressor box bracket to the front box and remove the assembly See Fig 7 6 Using a clean rag wipe all dirt from both power steering motor grease fittings See Fig 8 for...

Page 110: ...he hood 46 07 Power Steering Fluid and Filter Changing Electric Vehicle WARNING Fill only with approved clean fluid Failure to use the proper fluid could cause seal deterioration and leaks Fluid leaks...

Page 111: ...il clean fluid starts flowing from the power steering filter cover Add fluid to the reser voir to maintain the fluid level between the MIN COLD and MAX HOT lines 10 Shut down the motor Apply a thin fi...

Page 112: ......

Page 113: ...ection 47 07 CNG High Pressure Fuel Filter Draining 47 03 CNG High Pressure Fuel Filter Replacement 47 01 CNG Low Pressure Fuel Filter Draining 47 06 CNG Low Pressure Fuel Filter Replacement 47 05 Die...

Page 114: ......

Page 115: ...ilter housing 11 Turn the fuel supply back on at the tanks 47 02 CNG Fuel Leak Test WARNING Compressed natural gas is highly flammable See the safety precautions listed in Chapter 10 of the Walk In Va...

Page 116: ...Fuel Filter Replacement WARNING Compressed natural gas is highly flammable See the safety precautions listed in Chapter 10 of the Walk In Van Chassis Operator s Manual or Group 47 of the Walk In Van...

Page 117: ...In Van Chassis Workshop Manual or take the vehicle to an authorized Freightliner dealer Failure to observe these precautions could lead to the ignition of the natural gas which could cause severe bodi...

Page 118: ...nk or remove tank and test Table 1 CNG Tank Visual Inspection 47 08 Diesel Fuel Filter Replacement DAVCO Diesel Pro 245 WARNING Fluid circulated through the fuel water separator to heat the fuel may b...

Page 119: ...se the arrow on the top of the end plate to align the filter See Fig 5 Ensure the filter element is fully seated by firmly pushing on the endplate The filter should not rotate freely 9 Install the cle...

Page 120: ...ut down the engine apply the parking brake and chock the tires 2 Check the fuel level in the fuel filter Replace the fuel water separator element only when the filter element is completely covered If...

Page 121: ...the system loosen the vent cap until the fuel level falls to about one inch 2 5 cm above the collar then hand tighten the vent cap 11 6 Check for leaks and shut down the en gine Alliance The only mai...

Page 122: ...he new element then spin them both onto the filter head snugly by hand only IMPORTANT Do not use tools to tighten the bowl and element 7 Connect the water sensor and heater connectors if equipped 8 St...

Page 123: ...e of Maintenance Operation MOP MOP Number Exhaust System Inspecting Noise Emission Control 49 01 Safety Precautions 49 00 Exhaust 49 Index Alphabetical Walk In Van Chassis Maintenance Manual November...

Page 124: ......

Page 125: ...ust gas after the gas leaves the combustion chamber BlueTec Daimler s proprietary SCR technol ogy Diesel Oxidation Catalyst DOC a flow through device that enhances the oxidation of hydrocarbons in the...

Page 126: ...the exhaust pipe between the turbocharger and the ATD 4 Check the ATD mounting bands for tightness Tighten to 30 lbf ft 41 N m if needed Do not overtighten 5 Check for leaks around the clamps that att...

Page 127: ...ystem ATS the entire ex haust system from the turbocharger to the ex haust stack or tail pipe Aftertreatment Device ATD a muffler like can ister that houses a DPF and sensors Diesel Particulate Filter...

Page 128: ...of the ATD Heat discoloration may indicate internal damage especially around the DPF 9 Check any wires lines or hoses within 4 inches 10 cm of the exhaust system for heat damage Repair or reroute as...

Page 129: ...ry Battery Box and Cable Checking and Cleaning 54 02 Charge Port Inspection Electric Vehicle 54 06 Electrical System Checking 54 04 Ground Cables Checking and Cleaning 54 03 Lighting System Checking 5...

Page 130: ......

Page 131: ...around batteries 1 Remove any corrosion from the battery box and the top of the battery See Fig 1 Use distilled ammonia or a soda solution to neu tralize any acid present Flush off the ammonia or sod...

Page 132: ...30 lbf in 339 N cm 7 Test the electric horn If it is not fully operational use the schematics and troubleshooting informa tion in Section 54 00 and Section 54 05 of the Walk In Van Chassis Workshop Ma...

Page 133: ...ge the batter ies 3 Open the charge port door located behind the entrance door See Fig 3 4 Plug the power feed connector into the charge port Push hard until a click sound is made See Fig 4 5 The gree...

Page 134: ...re has entered the pack The salt plugs for the desiccant area have a built in indicator for moisture contamination Fig 7 shows normal and contaminated plugs If a plug has been exposed to moisture it w...

Page 135: ...Feed Connector f547237 06 02 2020 1 2 A normal plug is yellow at the end a contaminated plug does not appear yellow at the end 1 Normal Salt Plug 2 Contaminated Salt Plug Fig 7 Normal and Contaminated...

Page 136: ...son Glow Rod all the way through the pack until the hook exits the other side as shown in Fig 13 7 Attach the hook end of the glow rod to the grom met of a new battery pack desiccant See Fig 14 f5472...

Page 137: ...esiccant chamber using a calibrated torque wrench with a 17 mm Allen socket Tighten the plugs 22 lbf ft 30 N m For refer ence refer to Fig 7 and Fig 9 12 Install the battery pack manual service discon...

Page 138: ...ack Desiccant Fig 16 Ends of the Battery Pack Desiccant Tucked into the Desiccant Chamber f547227 06 01 2020 Fig 17 Applying Thread Sealant to the Salt Plugs Electrical Instruments and Controls 54 Wal...

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