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Thomas SAF-T-LINER C2, Maintenance Manual

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Title of Maintenance Operation (MOP)

MOP Number

Coolant Change, Electric Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–06

Coolant Heater Check, Webasto. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–04

Coolant System Maintenance, Electric Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–05

Fan Drive Inspection (Noise Emission Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–03

Radiator Cap Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–01

Radiator Pressure Flush and Coolant Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–02

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–00

Engine Cooling/Radiator

20

Index, Alphabetical

Saf-T-Liner C2 School Bus Maintenance Manual, May 2021

Summary of Contents for SAF-T-LINER C2

Page 1: ...SAF T LINER C2 SCHOOL BUS MAINTENANCE MANUAL Models C2 C2 G C2 LPG eC2 STI 466 8 09 20 2021 Published by Daimler Trucks North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A...

Page 2: ......

Page 3: ...and www ThomasBus com for more information or contact Daimler Trucks North America LLC at the address below Environmental and Safety Concerns and Recommendations Whenever you see instructions in this...

Page 4: ...trieval 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...

Page 5: ...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 bull...

Page 6: ...n 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...

Page 7: ...tenance 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 Example of the Printed Manual In...

Page 8: ...ission 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 Instruments and Controls 72 Doors...

Page 9: ...Intervals for Schedule I 00 03 Maintenance Intervals for Schedule II 00 04 Maintenance Schedules 00 02 Noise Emission Controls 00 06 Overview of Maintenance Operations 00 05 Verification of Inspection...

Page 10: ......

Page 11: ...er to the Maintenance Schedules to de termine when to perform the Initial Maintenance IM and the frequency of performing subsequent mainte nance intervals for each schedule Maintenance Intervals Refer...

Page 12: ...32 000 51 200 24 Maintenance 5 M5 every 48 000 77 200 30 Schedule II vehicles that travel over 20 000 miles 32 000 km annually Initial Maintenance IM first 4000 6400 6 Maintenance 1 M1 every 8000 12 8...

Page 13: ...20 000 32 000 6th M1 and M2 24 000 38 400 7th M1 28 000 44 800 8th M1 M2 M3 and M4 32 000 51 200 24 9th M1 36 000 58 000 10th M1 and M2 40 000 64 300 11th M1 44 000 70 800 12th M1 M2 M3 and M5 48 000...

Page 14: ...40 000 64 300 7th M1 M2 and M4 48 000 44 800 24 8th M1 56 000 90 100 9th M1 M2 M3 and M5 64 000 103 000 36 10th M1 72 000 115 800 11th M1 and M2 80 000 128 700 42 12th M1 88 000 141 600 13th M1 M2 M3...

Page 15: ...adiator Pressure Flush and Coolant Change 20 03 Fan Drive Inspection Noise Emission Control 20 04 Coolant Heater Check Webasto 20 05 Coolant System Maintenance Electric Vehicle 20 06 Coolant Change El...

Page 16: ...ubricating 42 05 Meritor Camshaft Bracket Lubricating 42 06 Air Dryer AD 9 AD IP Checking 42 07 Brake Lines and Fittings Inspecting Hydraulic Brakes 42 08 Brake Pedal Linkage and Mounting Plate Inspec...

Page 17: ...l Fitting and Injector Inspecting Propane Engine 47 07 Fuel Filter Replacing Propane Engine 47 08 CNG Fuel System Inspection 47 09 CNG Fuel Filter Replacement 47 10 CNG Fuel Cylinder Inspection 49 01...

Page 18: ...y 500 hours of operation The chain wheels should be removed during the spring and summer months For Detroit axles complete this procedure once a year or at the following applicable interval whichever...

Page 19: ...hicle 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 ac...

Page 20: ...s 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 Inspection...

Page 21: ...enance Operation MOP MOP Number Engine Drive Belt Inspecting 01 01 Engine Support Fastener Checking 01 02 Safety Precautions 01 00 Engine 01 Index Alphabetical Saf T Liner C2 School Bus Maintenance Ma...

Page 22: ......

Page 23: ...aks that are affecting the belts 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...

Page 24: ...s removed for service Whenever the engine is removed inspect the lower and upper isolators for wear Replace the isolators if nec essary f150010b 07 12 2001 1 2 3 4 5 6 1 Glazing 2 Tensile Break 3 Sepa...

Page 25: ...ic Motor Inspection Electric Vehicle 08 02 Safety Precautions 08 00 Torque Mark Inspection Electric Vehicle 08 01 Transmission Inspection Electric Vehicle 08 03 Electric Drive 08 Index Alphabetical Sa...

Page 26: ......

Page 27: ...If torque seal is not present on one or more of the four isolator bolts check and tighten the torque of the bolt s using a torque wrench set to 174 lbf ft 236 N m 4 Remove the chocks from the tires 08...

Page 28: ...rking brake Chock the rear tires 2 Inspect the transmission electrical connection and ensure that the connector is properly seated as shown in Fig 3 3 Inspect the transmission pneumatic connections Se...

Page 29: ...f080224 05 27 2020 1 1 Transmission Pneumatic Connections Fig 4 Transmission Pneumatic Connections top view Electric Drive 08 Saf T Liner C2 School Bus Maintenance Manual July 2020 08 3...

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Page 31: ...Title of Maintenance Operation MOP MOP Number Air Cleaner Element Inspecting and Replacing 09 01 Air Intake 09 Index Alphabetical Saf T Liner C2 School Bus Maintenance Manual June 2015...

Page 32: ......

Page 33: ...he air intake restriction indicator to check for air intake system damage or leaks See Fig 1 and Fig 2 Make sure the engine is off and note the existing reading on the indicator Reset the indicator by...

Page 34: ...RESET IN A B f090165 08 21 96 A Partial Restriction B Full Restriction Fig 1 Air Restriction Indicator Diesel Engines f090495 12 02 2011 A B A Partial Restriction B Full Restriction Fig 2 Air Restric...

Page 35: ...Air Compressor Inspection 13 01 Air Compressor Oil Level Checking and Filling Electric Vehicle 13 06 Air Compressor Oil Separator Element and Main Seal Replacement Electric Vehicle 13 03 Rebuild Air...

Page 36: ......

Page 37: ...e vehicle on a level surface shut down the engine and set the parking brake Chock the rear tires 2 Using a marker draw a line on the top of the air compressor housing sections This will help align the...

Page 38: ...lbf in 1085 N cm See Fig 15 IMPORTANT Ensure that the end cap plug seal is in place on the end cap plug See Fig 16 09 20 2013 f130145 1 2 3 4 5 6 1 Air Strainer Gasket 2 Spring Clip 3 Lockwashers 4 Mo...

Page 39: ...lug See Fig 18 19 Fill the compressor up to the threads with Hy drovane FluidForce HPO 198 5 compressor oil See Fig 19 IMPORTANT Replace the fill plug seal at each maintenance interval 20 Replace the...

Page 40: ...ocate the air compressor filter cannister Re lease the two latches that attach the outer cover then remove the cover See Fig 22 and Fig 23 f130179 06 04 2020 Fig 8 Removing the End Cap Bolts f130180 0...

Page 41: ...the element is fully seated f130183 06 04 2020 1 2 1 O Ring 2 Filter Fig 12 Installing the Filter Element in the Housing f130185 06 05 2020 1 1 Separator Housing first section Fig 13 Installing the F...

Page 42: ...d every three years take the vehicle to an authorized Freightliner dealer For instructions to rebuild the air compressor air end see Section 13 04 Subject 100 in the Saf T Liner C2 School Bus Workshop...

Page 43: ...Fill Plug Fig 21 Installing the Fill Plug f130172 06 02 2020 1 2 1 Air Compressor Filter Cannister 2 Latch qty 2 Fig 22 Air Compressor Filter Cannister f130169 06 02 2020 Fig 23 Removing the Filter Ca...

Page 44: ...air compressor See Fig 27 If the oil level is below the top of the sight glass add compressor oil 2 Remove the fill plug with the temperature probe installed shown in Fig 27 items 2 and 3 and discard...

Page 45: ...not already done See Fig 28 If compressor oil is not at the top of the thermal well so that it surrounds the temperature probe add compressor oil 2 Fill a squeeze bottle with Hydrovane FluidForce HPO...

Page 46: ......

Page 47: ...enance Operation MOP MOP Number Alternator Battery and Starter Connections Check 15 01 Safety Precautions 15 00 Alternators and Starters 15 Index Alphabetical Saf T Liner C2 School Bus Maintenance Man...

Page 48: ......

Page 49: ...an 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 cab...

Page 50: ...bjects 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 gener...

Page 51: ...o 20 04 Coolant System Maintenance Electric Vehicle 20 05 Fan Drive Inspection Noise Emission Control 20 03 Radiator Cap Inspection 20 01 Radiator Pressure Flush and Coolant Change 20 02 Safety Precau...

Page 52: ......

Page 53: ...e is a second 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 va...

Page 54: ...e and charge the air system to 120 psi 827 kPa Manually engage and disengage the fan clutch Check the fan and the fan clutch from a dis tance Look for vibration fan blade contact fan clutch slippage a...

Page 55: ...filter if so equipped Inspect the fuel line for damage restrictions or loose con nections Repair or replace the line if it is dam aged 6 Inspect all coolant lines and clamps for leakage restrictions...

Page 56: ...ty If a pre mixed coolant water solution is used dis tilled water does not need to be added IMPORTANT The powertrain battery loop surge tank must be filled first Ensure that the dash controls are set...

Page 57: ...tely 27 quarts 26 L of coolant 14 Start the vehicle then set the heater control to hot and run the blower 15 Add coolant until the sight glass is filled f200958 05 27 2021 1 1 Drain Plug Fig 2 Radiato...

Page 58: ......

Page 59: ...c Fluid Level Checking 25 03 Eaton Fuller Clutch Release Bearing Lubricating 25 01 Eaton Fuller Clutch Release Cross Shaft Lubricating 25 02 Electronic Clutch Actuator ECA Lubrication 25 05 Safety Pre...

Page 60: ......

Page 61: ...is not necessary to remove the clutch inspection plate when the lubrication extension is used For lubricating the release bearing Eaton Fuller recommends a lithium base high temperature grease that me...

Page 62: ...r 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...

Page 63: ...cylin der 6 2 Using a drain pan or other 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 thro...

Page 64: ...ounting Bolt 1 4 20 2 Plated Steel 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 Cyl...

Page 65: ...housing See Fig 8 Wipe the dirt from the grease fitting and lubricate with Eaton Roadranger CD50 or equiva lent E500 synthetic 1 2 3 4 5 6 7 8 9 12 11 2001 f250581 1 M8 Capscrew and Washer 2 Pedal Uni...

Page 66: ...04 17 2009 f180057 Fig 8 Cross Shaft Grease Fitting for HEVs Clutch 25 Saf T Liner C2 School Bus Maintenance Manual June 2015 25 6...

Page 67: ...Eaton Fuller Transmission Fluid Changing and Magnetic Plug Cleaning 26 02 Manual Transmission Oil Level Checking 26 01 Proterra Transmission Fluid Changing Electric Vehicle 26 06 Proterra Transmissio...

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Page 69: ...2104D or Caterpillar TO 4 Specification Above 10 12 40 or 50 Below 10 12 30 Lubricants listed in order of preference Do not mix types of oil Table 1 Eaton Approved Manual Transmission Lubricants CAUT...

Page 70: ...d level higher or lower than recommended can re sult in transmission damage Do not overfill the transmission overfilling will force fluid out of the case through the main shaft openings Fluid over flo...

Page 71: ...f the trans mission cooler Inspect and pressure test the cooler to confirm the leak replace leaking transmission coolers 2100 2200 2500 Series 1 Park the vehicle on a level surface and apply the parki...

Page 72: ...ea 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 dr...

Page 73: ...Level CAUTION Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion Overfilling will force fluid out of the...

Page 74: ...71 to 93 C has been reached Hot Check Recommended Method With the vehicle on a level surface and the transmis sion in neutral at operating temperature perform the steps below 1 On the transmission sh...

Page 75: ...n Fluid Level Checking Electric Vehicle 1 Park the vehicle on a level surface shut down the engine and set the parking brake Chock the rear tires 2 Clean the area around the fill plug then remove the...

Page 76: ...ature 3 Clean the area around the drain port and drain plug See Fig 9 4 Place a drain pan under the transmission 5 Using a 9 16 inch 14 mm hex wrench remove the drain plug and drain the transmission f...

Page 77: ...lly fill the oil cooler to maximum capacity approximately 4 4 qt 4 2 L 15 When the oil cooler is filled tighten the fill plug used for venting then install and tighten the fill plug on the cooler clos...

Page 78: ......

Page 79: ...r Automatic Tire Chain System Checking 31 02 Frame Fastener Torque Check 31 01 Off Season Chain Wheel Removal 31 03 Safety Precautions 31 00 Frame and Frame Components 31 Index Alphabetical Saf T Line...

Page 80: ......

Page 81: ...on with loose fasteners could result in bracket or frame damage NOTE Engine supports on vehicles built from January 2007 require the same maintenance as shown below Inspect the fasteners at the follow...

Page 82: ...are placed between the arm and the wheel When the chain wheels are once again installed for the winter months put the spacers back between the arm and the wheel as they were before 2 Although not requ...

Page 83: ...on 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 Saf T Liner C2 School Bus M...

Page 84: ......

Page 85: ...rackets U bolts and related parts Freightliner Spring Shock Absorber Check NOTE Shock absorbers are optional on spring suspensions Make sure that the shock absorber brackets are tight and that the sho...

Page 86: ...xle for cracks If the welds are cracked grind them out and reweld the parts 5 Move the axle up and down while checking for signs of looseness due to worn parts at the front pivot connections Replace a...

Page 87: ...ke Chock the tires 2 Check the U bolt torque in a diagonal pattern See Table 1 for U bolt torque specifications Turn the wrench in a clockwise motion looking up until the torque wrench clicks 3 Remove...

Page 88: ......

Page 89: ...er Draw Key Nut Inspecting 33 03 Kingpin Lubricating Detroit Axle 33 01 Safety Precautions 33 00 Tie Rod End Inspecting 33 04 Tie Rod End Lubricating 33 02 Front Axle 33 Index Alphabetical Saf T Liner...

Page 90: ......

Page 91: ...the grease fittings clean 3 Apply 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 jun...

Page 92: ...ft 41 to 61 N m See Fig 4 33 04 Tie Rod End Inspecting IMPORTANT If the tie rod end boot is torn or missing replace the entire tie rod assembly or the tie rod end Do not replace the boot only 1 Shut...

Page 93: ...in the cross tube past the clamps and the slots at the cross tube ends 8 Check the grease fittings for damage If a grease fitting is damaged replace it Some tie rod ends have no grease fittings be ca...

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Page 95: ...umber 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 Saf T Liner C2...

Page 96: ......

Page 97: ...and plugged hole located below the housing oil fill hole This smaller hole is for the lubricant temperature sensor only and must not be used as a fill or level hole 4 Check that the lubricant is level...

Page 98: ...e Lubricants Recommended Lubricant Meritor Drive Axles Recommended Lubricant Type Ambient Temperature Lubricant SAE Viscosity Grade Hypoid Gear Oil API Service Classification GL 5 10 F 12 2 C and up 8...

Page 99: ...at the bottom of the housing and drain the lubricant while the unit is warm Allow enough time for all the old lubricant to drain completely 4 Clean the drain plug For magnetic drain plugs a piece of...

Page 100: ...xle Lubricant Capacities Axle Model Capacity pints L MS 10 113D 14 6 6 MS 12 113D 15 7 1 RS 13 120 18 4 8 7 RS 15 120 14 3 6 8 RS 17 145 33 6 15 9 RS 17 144 32 3 15 3 RS 19 144 32 3 15 3 RS 19 145 33...

Page 101: ...Title of Maintenance Operation MOP MOP Number Wheel Nut Checking 40 01 Wheels and Tires 40 Index Alphabetical Saf T Liner C2 School Bus Maintenance Manual February 2004...

Page 102: ......

Page 103: ...age stud break age and extreme tire tread wear Too much wheel nut torque can break studs damage threads and crack discs in the stud hole area See Table 1 for wheel nut torque specifications and see Fi...

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Page 105: ...of Maintenance Operation MOP MOP Number Driveline Inspection 41 01 Driveline Lubrication 41 02 Safety Precautions 41 00 Driveline 41 Index Alphabetical Saf T Liner C2 School Bus Maintenance Manual Jun...

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Page 107: ...authorized Freightliner dealer 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 In...

Page 108: ...on Ultra Duty EP 2 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 Kenda...

Page 109: ...ic Brakes 42 12 Brake Inspection 42 15 Brake Lines and Fittings Inspecting Hydraulic Brakes 42 07 Brake Pedal Linkage and Mounting Plate Inspecting 42 08 Drum Brake Shoe Roller Lubricating 42 13 Foot...

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Page 111: ...mise the ability of the air dryer to hold air pressure which could cause a failure in the brake system resulting in personal injury or property damage 10 Twist the end cover counterclockwise to releas...

Page 112: ...discharge line may contain residual air pressure 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 Inch Upper Mounting Bracket Bol...

Page 113: ...sh on the end cover NOTE It may be necessary to rotate the car tridge slightly until the anti rotation lugs are properly aligned and allow the cartridge to rest flush against the end cover 12 Using a...

Page 114: ...ange be tween cut in and cut out is not adjustable Cut In Position Apply soap solution around the cover and to the ex haust port Slight bubble leakage is permitted Exces sive leakage indicates either...

Page 115: ...orm wheel onto the camshaft Lubricate the automatic slack adjuster at the grease fitting until grease ap pears on the camshaft Meritor NOTE If equipped with an extended mainte nance Q Plus brake syste...

Page 116: ...ittings use an NLGI Grade 1 or Grade 2 multipurpose chassis grease Lubricate the camshaft bushings through the grease fitting on the camshaft bracket or the spider until new grease flows from the inbo...

Page 117: ...s and bro ken or missing parts 3 Check mounting bolts for tightness Tighten 30 to 35 lbf ft 41 to 47 N m 4 Perform the operational and leakage tests listed below Operational and Leakage Tests 1 Check...

Page 118: ...kes Chock the tires release the parking brake and make a full service brake application Replace damaged or leaking components and tighten loose fittings 42 08 Brake Pedal Linkage and Mounting Plate In...

Page 119: ...cation Both front and rear brakes should modulate At a steady full brake application pressure should not drop more than 10 psi 69 kPa within five min utes 22 Drain all reservoirs then remove the gauge...

Page 120: ...is a dual indicator and indicates that the park ing brake is set and warns if there is a Hydro Max failure condition other than loss of back up motor power 42 12 Brake Caliper Slide Pin Lubricating B...

Page 121: ...tructions Failure to do so could result in damage to the slack adjusters 4 Back off the slack adjusters 5 Push down on the bottom brake shoe and then by pulling on the roller retaining clip remove the...

Page 122: ...n is not active no automatic setting of the park brake 1 With the vehicle on a level surface release the park brake 2 With your foot off of the brake pedal verify that the vehicle is stationary the ig...

Page 123: ...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...

Page 124: ...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 tires 2...

Page 125: ...52 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 fo...

Page 126: ...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 Stroke 9 Less than 1 1 2 38 12 16 Less than...

Page 127: ...tacts the base tighten the cartridge one complete turn more Do not overtighten 42 17 Bendix Automatic Drain Valve Operating and Leakage Tests Operating Test Perform the following test after repairing...

Page 128: ......

Page 129: ...ing 46 03 Power Steering Fluid and Filter Changing Diesel 46 02 Power Steering Fluid and Filter Changing Electric Vehicle 46 07 Power Steering Gear Lubricating 46 04 Power Steering Motor Lubrication E...

Page 130: ......

Page 131: ...ized Freightliner dealer Grasp the drag link near the pitman arm end and move the drag link side to side to check for axial movement in the ball stud end If it is loose replace the drag link See Group...

Page 132: ...ded 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 brake and chock the rear tires...

Page 133: ...it to malfunc tion IMPORTANT Due to the high operating tem peratures of the motor use Darmex RPL 707 grease for motor lubrication 3 Using a hand type grease gun with Darmex RPL 707 grease insert the a...

Page 134: ...utomatic Transmission Fluid Dexron VI Do not mix fluid types Refer to the text in this group for a detailed warn ing statement Table 2 Approved Power Steering Fluid Electric Vehicle 8 Raise the front...

Page 135: ...ngine 47 07 Fuel Rail Fitting and Injector Inspecting Propane Engine 47 06 Fuel Sender Checking 47 04 Fuel Tank Band Nut Tightening 47 01 Fuel Tank and Line Inspecting Propane Engine 47 05 Fuel Water...

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Page 137: ...element and bowl together by turn ing counterclockwise 4 Remove the bowl from the element and clean the O ring gland 5 Apply a coating of clean fuel or motor oil to the new O ring and element seal 6...

Page 138: ...filter element is fully seated by firmly pushing on the endplate The filter should not rotate freely 9 Install the clear cover and the collar Simultane ously apply downward pressure to the top of the...

Page 139: ...is released into the atmosphere its vapors can ignite in the presence of any igni 1 Drain Valve Cap 2 Drain Valve 3 Inlet Port Check Valve 4 Lower Housing 5 Filter Element 6 Cover O Ring 7 Spring 8 Cl...

Page 140: ...close the drain valve 5 Using a DAVCO Collar Wrench shown in Fig 3 remove the clear cover and collar NOTE Broken vent cap and collar warranty claims will not be accepted if any tool other than a DAVC...

Page 141: ...cure the fuel strainer with tie bands 47 04 Fuel Sender Checking 1 Check the fuel sender connections for tightness and tighten if needed Apply dielectric grease to the connections if needed 2 Check th...

Page 142: ...hicle See the safety precautions listed in Chapter 17 of the Saf T Liner C2 School Bus Driver s Manual or take the vehicle to an authorized Freightliner dealer Failure to observe these precautions cou...

Page 143: ...7 08 CNG Fuel System Inspection WARNING Natural gas is highly flammable See the safety precautions listed in Chapter 18 of the Saf T Liner C2 School Bus Driver s Manual Failure to observe these precau...

Page 144: ...any signs of looseness If needed tighten the fuel panel mounting bolts See Fig 8 4 Inspect the fuel fill port for signs of damage or leaks Ensure the port dust cover and the O ring inside the port ar...

Page 145: ...or near 0 psi 5 Close the manual fuel shutoff valve on the fuel panel IMPORTANT Some pressure may remain in the fuel system between the solenoid valve and the engine Use caution as a small amount of g...

Page 146: ...Inspection of Natural Gas Fuel Containers and Their Installations for inspection requirements and inspector qualifica tions For more information go to www cganet com After inspection a written report...

Page 147: ...f Maintenance Operation MOP MOP Number Exhaust System Inspecting Noise Emission Control 49 01 Safety Precautions 49 00 Exhaust 49 Index Alphabetical Saf T Liner C2 School Bus Maintenance Manual Decemb...

Page 148: ......

Page 149: ...that re moves pollutants from exhaust gas after the gas leaves the combustion chamber BlueTec Daimler s proprietary SCR technol ogy Diesel Oxidation Catalyst DOC a flow through device that enhances t...

Page 150: ...around 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 10 20 2009 f490385 1 2 3 4 5 6 7 8 9...

Page 151: ...l for DEF filter replacement instructions and mainte nance intervals EPA07 Exhaust System Definitions of ATS Components Refer to the following list of definitions of ATS terms and components Aftertrea...

Page 152: ...the DPF exterior surface for dents or other damage See Fig 2 Reference A A dent over 3 inches 76 mm in diameter and 1 4 inch 6 mm deep could cause internal damage to the DPF causing it to malfunction...

Page 153: ...iscoloration 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 needed Exhaust 49...

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Page 155: ...and Replacement Electric Vehicle 54 03 Battery Pack Desiccant Replacement Electric Vehicle 54 04 Battery Voltage Check 54 01 Charge Port Inspection Electric Vehicle 54 02 Electrical Instruments and C...

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Page 157: ...er ies 3 Open the charge port door located behind the entrance door See Fig 1 4 Plug the power feed connector into the charge port Push hard until a click sound is made See Fig 2 5 The green lamp abov...

Page 158: ...ries are being charged Solid batteries charged to 100 capacity Red Out of service Table 1 Charging Dispenser Lamp Legend 54 03 Ancillary Bay Desiccant Plug Inspection and Replacement Electric Vehicle...

Page 159: ...e Fig 6 8 Remove the chocks from the tires 54 04 Battery Pack Desiccant Replacement Electric Vehicle Battery pack desiccant replacement should be per formed every 12 months This procedure describes th...

Page 160: ...on of rod See Fig 12 and Fig 13 5 Locate the grommet on the end of the battery pack desiccant near the cooling loop Grab the grommet with the hook end of the Jameson Glow Rod or equivalent and pull th...

Page 161: ...not appear yellow at the end 1 Normal Salt Plug 2 Contaminated Salt Plug Fig 10 Normal and Contaminated Salt Plugs f547231 06 01 2020 1 Remove the salt plugs at each end of the battery pack desiccant...

Page 162: ...See Fig 19 11 Install the salt plugs at each end of the battery pack desiccant chamber using a calibrated torque wrench with a 17 mm Allen socket Tighten the plugs 22 lbf ft 30 N m For refer ence ref...

Page 163: ...ng Desiccant Through the Battery Pack f547225 06 01 2020 1 2 1 Desiccant Chamber 2 Battery Pack Desiccant Fig 18 Ends of the Battery Pack Desiccant Tucked into the Desiccant Chamber f547227 06 01 2020...

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Page 165: ...Title of Maintenance Operation MOP MOP Number Air Door Inspection 72 02 Door Seals Lubrication 72 01 Doors 72 Index Alphabetical Saf T Liner C2 School Bus Maintenance Manual July 2020...

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Page 167: ...eaf brackets See Fig 1 2 Tighten the drive linkage locknuts 30 lbf ft 41 N m See Fig 2 items 1 and 7 3 If the door requires adjustment see Section 72 02 Subject 140 in the Saf T Liner C2 School Bus Wo...

Page 168: ...t 3 8 16 2 Washer 3 Air Cylinder Shaft 4 Hexhead Bolt 5 Primary Drive Linkage 6 Secondary Linkage 7 Washer and Locknut 3 8 16 8 Bracket 9 Hexhead Bolt Fig 2 Air Door Drive Linkage Doors 72 Saf T Liner...

Page 169: ...e Operation MOP MOP Number Air Conditioner Inspection 83 01 HVAC Air Filter Cleaning 83 02 Safety Precautions 83 00 Heater and Air Conditioner 83 Index Alphabetical Saf T Liner C2 School Bus Maintenan...

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Page 171: ...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 in...

Page 172: ...ch the lower HVAC cover to the dash panel Install the three Torx screws two at the bottom of the cover and one on the right 13 Connect the batteries 09 21 2006 f831707 Fig 1 HVAC Cover Removal 09 22 2...

Page 173: ...Title of Maintenance Operation MOP MOP Number Hood Rear Support Lubrication 88 01 Hood Grille and Cab Fenders 88 Index Alphabetical Saf T Liner C2 School Bus Maintenance Manual November 2014...

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Page 175: ...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 Suppl...

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