Freightliner School Bus Chassis Service Repair Workshop Manual

SCHOOL BUS CHASSIS WORKSHOP MANUAL Models: Type C SB FS65 STI-347, S20 (10/10P) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.

Foreword The purpose of this manual is to assist the service technician when the vehicle is serviced. Major drivetrain component service information is not included in this manual, but is located in each manufacturer’s service manual. Instructions and procedures are those recommended by Freightliner Custom Chassis Corpora- tion (FCCC) or the component manufacturer. Maintenance schedules and additional service information are included in the School Bus Chassis Maintenance Manual. IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Freightliner Custom Chassis Corporation reserves the right to discontinue models at any time, or change specifications and design without notice and without incurring obligation. Descriptions and specifications contained in this publication provide no warranty, expressed or implied, and are subject to revision and editions without notice. Refer to www.Daimler-TrucksNorthAmerica.com and www.FreightlinerChassis.com for more information, or contact Daimler Trucks North America LLC at the address below. Environmental Concerns and Recommendations Whenever you see instructions in this manual to discard materials, you should attempt to reclaim and recycle them. To preserve our environment, follow appropriate environmental rules and regulations when disposing of materials. NOTICE: Parts Replacement Considerations Do not replace suspension, axle, or steering parts (such as springs, wheels, hubs, and steering gears) with used parts. Used parts may have been subjected to collisions or improper use and have undetected structural damage. © 1996–2010 Daimler Trucks North America LLC All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks North America LLC. Daimler Trucks North America LLC is a Daimler company. Daimler Trucks North America LLC Service Systems and Documentation (CVI-SSD) P.O. Box 3849 Portland, OR 97208-3849

Daimler Trucks North America LLC distributes the following major service publications in paper and electronic (via ServicePro ® ) formats. Workshop/Service Manual Workshop/service manuals contain service and repair information for all vehicle systems and components, except for major components such as engines, trans- missions, and rear axles. Each workshop/service manual section is divided into subjects that can include general information, principles of operation, removal, disassembly, assembly, installation, specifications, and troubleshooting. Maintenance Manual Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems. They have information such as lubrication procedures and tables, fluid replacement procedures, fluid capacities, specifications, and procedures for adjustments and for checking the tightness of fasteners. Maintenance manuals do not contain detailed repair or service information. Driver’s/Operator’s Manual Driver’s/operator’s manuals contain information needed to enhance the driver’s understanding of how to operate and care for the vehicle and its components. Each manual contains a chapter that covers pretrip and post-trip inspections, and daily, weekly, and monthly maintenance of vehicle components. Driver’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 information. Some service bulletins are updates to information in the workshop/service manual. These bulletins take precedence over workshop/service manual information, until the latter is updated; at that time, the bulletin is usually canceled. The service bulletins manual is available only to dealers. When doing service work on a vehicle system or part, check for a valid service bulletin for the latest information on the subject. IMPORTANT: Before using a particular service bulletin, check the current service bulletin validity list to be sure the bulletin is valid. Parts Technical Bulletins Parts technical bulletins provide information on parts. These bulletins contain lists of parts and BOMs needed to do replacement and upgrade procedures. Web-based repair, service, and parts documentation can be accessed using the following applications on the AccessFreightliner.com website. ServicePro ServicePro ® provides Web-based access to the most up-to-date versions of the publications listed above. In addition, the Service Solutions feature provides diagnostic assistance with Symptoms Search, by connecting to a large knowledge base gathered from technicians and service personnel. Search results for both documents and service solutions can be narrowed by initially entering vehicle identification data. PartsPro PartsPro ® is an electronic parts catalog system, showing the specified vehicle’s build record. EZWiring EZWiring ™ makes Freightliner, Sterling, Western Star, Thomas Built Buses, and Freightliner Custom Chassis Corporation products’ wiring drawings and floating pin lists available online for viewing and printing. EZWiring can also be accessed from within PartsPro. Introduction Descriptions of Service Publications School Bus Chassis Workshop Manual, Supplement 20, October 2010 I–1

Warranty-related service information available on the AccessFreightliner.com website includes the following documentation. Recall Campaigns Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice. These campaigns pertain to matters of vehicle safety. All recall campaigns are distributed to dealers; customers receive notices that apply to their vehicles. Field Service Campaigns Field service campaigns are concerned with non-safety-related service work or replacement of parts. All field service campaigns are distributed to dealers; customers receive notices that apply to their vehicles. Introduction Descriptions of Service Publications I–2 School Bus Chassis Workshop Manual, Supplement 20, October 2010

For an example of a School Bus Chassis Workshop Manual page, see Fig. 1. f020055 B C A FG D E 10/02/96 A. Section Title B. Section Number (made up of the Group Number— first two digits, followed by a sequence number—last two digits) C. Subject Title D. Manual Title E. Release (Supplement) Date F. Subject Number G. Subject Page Number Fig. 1, Example of a School Bus Chassis Workshop Manual Page Introduction Page Description School Bus Chassis Workshop Manual, Supplement 20, October 2010 I–3

Group No. Group Title 00 ...................... General Information 01 ................................ Engine 09 .............................. Air Intake 13 ......................... Air Compressor 15 ................... Alternators and Starters 20 ................... Engine Cooling/Radiator 25 ................................ Clutch 26 ........................... Transmission 30 ......................... Throttle Control 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 60 .................................. Cab 82 ............. Windshield Wipers and Washer 88 .............. Hood, Grille, and Cab Fenders 98 ................................. Paint Introduction Workshop Manual Contents I–4 School Bus Chassis Workshop Manual, Supplement 20, October 2010

The following is a list of definitions for abbreviations and symbols used in Freightliner publications. A .......... amperes ABS ....... antilock braking system ABS ....... acrylonitrile-butadiene-styrene A/C ........ air conditioner AC ......... alternating current ACPU ..... air conditioning protection unit ADLO ..... auto-disengagement lockout a.m. ....... ante meridiem (midnight to noon) AM ........ amplitude modulation amp(s) .... ampere(s) AMU ....... air management unit ANSI ...... American National Standards Institute API ........ American Petroleum Institute ARI ........ Air Conditioning and Refrigeration Institute ASA ....... American Standards Association ASF ....... American Steel Foundries ASR ....... automatic spin regulator assy . ...... assembly ASTM ..... American Society for Testing and Materials ATC ....... automatic temperature control ATC ....... automatic traction control ATC ....... automatic transmission control ATF ........ automatic transmission fluid attn ........ attention aux. ....... auxiliary av ......... avoirdupois (British weight system) AWG ...... American wire gauge AWS ....... American Welding Society BAT ....... battery BBC ....... bumper-to-back-of-cab BOM ....... bill of material BTDC ...... before top dead center Btu(s) ..... British thermal unit(s) C .......... common (terminal) CAC ....... charge air cooler CAN ....... controller area network CARB ..... California Air Resources Board CAT ....... Caterpillar CB ......... circuit breaker CB ......... citizens’ band CCA ....... cold cranking amperes CD-ROM .. compact-disc/read-only memory CDTC ...... constant discharge temperature control CEL ....... check-engine light CFC ....... chlorofluorocarbons (refrigerant-12) cfm ........ cubic feet per minute CFR ....... Code of Federal Regulations CLS ....... coolant level sensor cm ......... centimeters cm 3 ........ cubic centimeters CMVSS .... Canadian Motor Vehicle Safety Standard Co. ........ company COE ....... cab over engine Corp. ...... corporation CPU ....... central processing unit cSt ........ centistokes (unit of measurement for describing the viscosity of general liquids) cu ft ....... cubic feet cu in ...... cubic inches CUM ....... Cummins CWS ....... collision warning system DC ......... direct current DDA ....... Detroit Diesel Allison DDC ....... Detroit Diesel Corporation DDE ....... Detroit Diesel Engines DDEC ..... Detroit Diesel Electronic (engine) control DDR ....... diagnostic data reader DDU ....... driver display unit DGPS ..... differential global positioning system dia. ........ diameter DIP ........ dual inline package (switch) DLA ....... data link adaptor DLU ....... data logging unit DMM ...... digital multimeter DOT ....... Department of Transportation DRL ....... daytime running lights DRM ....... dryer reservoir module DSM ....... district service manager DTC ....... discharge temperature control DVOM ..... digital volt/ohm meter ea. ......... each EBS ....... electronic braking system ECAP ...... electronic control analyzer programmer ECAS ...... electronically controlled air suspension ECI ........ electronically controlled injection ECM ....... electronic control module ECU ....... electronic control unit EDM ....... electronic data monitor EEPROM . . electrically erasable programmable read-only memory EMI ........ electromagnetic interference EOA ....... electric over air EP ......... extreme pressure (describes an antiwear agent added to some lubricants) EPA ....... Environmental Protection Agency EPS ....... engine position sensor etc. ........ et cetera (and so forth) ETEC ...... electronic truck engine control EUI ........ electronic unit (fuel) injectors FAS ....... Freightliner air suspension Fig. ........ figure fl oz ....... fluid ounces FLA ....... post-1984 advancements Freightliner COE FLB ....... enhanced Freightliner FLA COE FLC ....... steel-cab Freightliner 112 Conventional FLD ....... post-1984 advancements Freightliner 112/120 aluminum-cab Conventional FM ......... frequency modulation FMCSA .... Federal Motor Carrier Safety Administration FMI ........ failure mode identifier FMSI ...... Friction Materials Standards Institute FMVSS .... Federal Motor Vehicle Safety Standard FRP ....... fiberglass reinforced plastic FSA ....... field service authorization ft .......... feet ft 3 ......... cubic feet ft 3 /min ..... cubic feet per minute FTL ........ Freightliner F.U.E.L. .... fuel usage efficiency level g .......... grams List of Abbreviations 00.01 List of Abbreviations School Bus Chassis Workshop Manual, Supplement 13, May 2004 050/1

gal ......... gallons GAWR ..... gross axle weight rating GL ......... gear lubricant GND ....... ground gpm ....... gallons per minute GPS ....... global positioning system GVWR ..... gross vehicle weight rating HCU ....... hydraulic control unit HD ......... heavy-duty HEPA ...... high-efficiency particulate air (filter) HFC ....... hydrogenated fluorocarbons (refrigerant-134a) hp ......... horsepower hp ......... high pressure HRC ....... Rockwell "C" hardness hr(s) ....... hour(s) htr ......... heater HVAC ...... heating, ventilating and air conditioning H/W ....... hardware ICU ........ instrumentation control unit i.d.......... inside diameter ID .......... identification IFI ......... Industrial Fasteners Institute IGN ........ ignition ILO ........ in lieu of (in the place of) in .......... inches in 3 ......... cubic inches Inc. ........ incorporated inH 2 O ..... inches of water inHg ....... inches of mercury IP .......... instrument panel ISO ........ International Organization for Standardization k ........... kilo (1000) kg ......... kilograms km ......... kilometers km/h ....... kilometers per hour kPa ........ kilo Pascals kW ........ kilowatts L .......... liters lb .......... pounds lbf·ft ....... pounds force feet lbf·in ...... pounds force inches LCD ....... liquid crystal display LED ....... light-emitting diode LH ......... left-hand LH DR ..... left-hand drive LHK ....... liters per hundred kilometers LHS ....... low hydrogen steel LLC ....... limited liability company L/min ...... liters per minute LPG ....... liquefied petroleum gas m .......... meters max. ....... maximum MESA ..... Mining Enforcement Safety Act mfr . ........ manufacturer mi ......... miles MID ........ message identifier MIL ........ military specification min. ....... minutes min. ....... minimum misc. ...... miscellaneous mL ........ milliliters mm ........ millimeters mod. ...... module mpg ....... miles per gallon mph ....... miles per hour MSHA ..... Mining Safety and Health Administration MVDA ..... Motor Vehicle Dealers Association n .......... negative (front axle wheel alignment specification) N/A ........ not applicable N·cm ...... Newton-centimeters NC ......... normally closed (terminal or switch) NHTSA .... National Highway Traffic Safety Administration NIOSH ..... National Institute for Occupational Safety and Health NLGI ...... National Lubricating Grease Institute N·m ........ Newton-meters NO ........ normally open (terminal or switch) no. ........ number NPT ....... national pipe thread NPTF ...... national pipe thread fitting NSBU ..... neutral start/backup NT ......... nylon tube or nylon tubing OCV ....... open circuit voltage o.d. ........ outside diameter O.D. ....... overdrive OEM ....... original equipment manufacturer OSHA ..... Occupational Safety and Health Administration oz ......... ounces ozf·in ...... ounces force inches p .......... positive (front axle wheel alignment specification) parm ...... parameter PC ......... personal computer PCB ....... printed circuit board PDC ....... parts distribution center PDM ....... power distribution module PEEC ...... programmable electronic engine control PID ........ parameter identifier PLC ....... power line carrier PLD ....... Pumpe-Linie-Düse (pump- line-nozzle) p.m. ....... post meridiem (noon to midnight) p/n ........ part number PSA ....... pressure sensitive adhesive psi ......... pounds per square inch psia ....... pounds per square inch, atmosphere psig ....... pounds per square inch, gauge pt .......... pints pt .......... points PTCM ..... pressure time control module PTO ....... power take-off pvc ........ polyvinyl chloride PWM ...... pulse width modulation qt .......... quarts qty . ........ quantity R&O ..... rust inhibitors and oxidants R–12 ...... refrigerant-12 (CFC) R–134a .... refrigerant-134a (HFC) RAM ....... random access memory recirc ...... recirculation Ref(s). ..... reference(s) RFI ........ radio frequency interference RH ......... right-hand RH DR ..... right-hand drive R/I ......... removal and installation RMA ....... return material authorization ROM ....... read-only memory rpm ........ revolutions per minute R/R ........ removal and replacement RSG ....... road speed governor RTV ....... room temperature vulcanizing List of Abbreviations 00.01 List of Abbreviations School Bus Chassis Workshop Manual, Supplement 13, May 2004 050/2

RV ......... recreational vehicle SAE ....... Society of Automotive Engineers SB ......... service bulletin SD ......... severe duty SDU ....... step deployment unit SEL ....... shutdown engine light SI .......... service information SI .......... Système International SID ........ subsystem identifier SMC ....... sheet molded compound S/N ........ serial number SPACE .... seat pretensioner activation for crash survival enhancement SRT ....... standard repair time SSD ....... side sensor display SST ....... stainless steel std. ........ standard S/W ........ software SW ........ switch TAM ....... thermocouple amplifier module TBS ....... turbo boost sensor TCU ....... transmission control unit TDC ....... top dead center TDR ....... technician diagnostic routine temp ...... temperature TIG ........ tungsten inert gas TPS ....... thermal protection switch TPS ....... throttle position sensor TRS ....... timing reference sensor TSO ....... truck sales order U.D. ....... underdrive UNC ....... unified national coarse UNF ....... unified national fine U.S. ....... United States U.S.A. ..... United States of America USC ....... United States customary (measures) V .......... volts VDC ....... vehicle data computer Vdc ........ volts, direct current VIN ........ vehicle identification number VIP ........ vehicle instrumentation and protection (Kysor) VOC ....... volatile organic compounds VOM ....... volt-ohmmeter VSG ....... variable speed governor VSS ....... vehicle speed sensor WB ........ wire braid WI ......... work instructions WOT ....... wide open throttle - ........... minus or negative + ........... plus or positive ± ........... plus-or-minus > ........... greater than < ........... less than x ........... by (used in fastener size descriptions) " ........... inches ° ........... degrees (of an angle) °C ......... degrees Celsius (centigrade) °F .......... degrees Fahrenheit # ........... number % .......... percent & .......... and © .......... copyright ™ .......... trademark ® ........... registered trademark List of Abbreviations 00.01 List of Abbreviations School Bus Chassis Workshop Manual, Supplement 13, May 2004 050/3

U.S. Customary to Metric Metric to U.S. Customary When You Know Multiply By To Get When You Know Multiply By To Get Length inches (in) 25.4 millimeters (mm) 0.03937 inches (in) inches (in) 2.54 centimeters (cm) 0.3937 inches (in) feet (ft) 0.3048 meters (m) 3.281 feet (ft) yards (yd) 0.9144 meters (m) 1.094 yards (yd) miles (mi) 1.609 kilometers (km) 0.6215 miles (mi) Area square inches (in 2 ) 645.16 square millimeters (mm 2 ) 0.00155 square inches (in 2 ) square inches (in 2 ) 6.452 square centimeters (cm 2 ) 0.15 square inches (in 2 ) square feet (ft 2 ) 0.0929 square meters (m 2 ) 10.764 square feet (ft 2 ) Volume cubic inches (in 3 ) 16387.0 cubic millimeters (mm 3 ) 0.000061 cubic inches (in 3 ) cubic inches (in 3 ) 16.387 cubic centimeters (cm 3 ) 0.06102 cubic inches (in 3 ) cubic inches (in 3 ) 0.01639 liters (L) 61.024 cubic inches (in 3 ) fluid ounces (fl oz) 29.54 milliliters (mL) 0.03381 fluid ounces (fl oz) pints (pt) 0.47318 liters (L) 2.1134 pints (pt) quarts (qt) 0.94635 liters (L) 1.0567 quarts (qt) gallons (gal) 3.7854 liters (L) 0.2642 gallons (gal) cubic feet (ft 3 ) 28.317 liters (L) 0.03531 cubic feet (ft 3 ) cubic feet (ft 3 ) 0.02832 cubic meters (m 3 ) 35.315 cubic feet (ft 3 ) Weight/Force ounces (av) (oz) 28.35 grams (g) 0.03527 ounces (av) (oz) pounds (av) (lb) 0.454 kilograms (kg) 2.205 pounds (av) (lb) U.S. tons (t) 907.18 kilograms (kg) 0.001102 U.S. tons (t) U.S. tons (t) 0.90718 metric tons (t) 1.1023 U.S. tons (t) Torque/Work Force inch-pounds (lbf·in) 11.298 Newton-centimeters (N·cm) 0.08851 inch-pounds (lbf·in) foot-pounds (lbf·ft) 1.3558 Newton-meters (N·m) 0.7376 foot-pounds (lbf·ft) Pressure/Vacuum inches of mercury (inHg) 3.37685 kilo Pascals (kPa) 0.29613 inches of mercury (inHg) pounds per square inch (psi) 6.895 kilo Pascals (kPa) 0.14503 pounds per square inch (psi) When You Know Subtract Then Divide By To Get When You Know Multiply By Then Add To Get degrees Fahrenheit (°F) 32 1.8 degrees Celsius (°C) 1.8 32 degrees Fahrenheit (°F) Metric/U.S. Customary Conversion Chart 00.02 General Information School Bus Chassis Workshop Manual, Supplement 0, October 1996 050/1

Freightliner School Bus Chassis Service Repair Workshop Manual

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