Freightliner Business Class M2 Trucks OEM Maintenance Manual

Maintenance Manual STI-455-6 A24-01238-000 ® BUSINESS CLASS M2

BUSINESS CLASS M2 MAINTENANCE MANUAL Models: M2 100 M2 106 M2 106V M2 112 M2 112V STI-455-6 (3/16) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.

Foreword Performing scheduled maintenance operations is important in obtaining safe, reliable operation of your vehicle. A proper maintenance program will also help to minimize downtime and safeguard warranties. IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also refer to other component and body manufacturers’ instructions for specific inspection and maintenance instructions. Perform the operations in this maintenance manual at scheduled intervals. Perform the pretrip and post-trip inspections, and daily/weekly/monthly maintenance, as outlined in the vehicle driver’s manual. Major components, such as engines, transmissions, and rear axles, are covered in their own maintenance and operation manuals, that are provided with the vehicle. Perform any maintenance operations listed at the intervals scheduled in those manuals. Your Freightliner Dealership has the qualified technicians and equipment to perform this maintenance for you. They can also set up a scheduled maintenance program tailored specifically to your needs. Optionally, they can assist you in learning how to perform these maintenance procedures. IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Freightliner Trucks reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation. Descriptions and specifications contained in this publication provide no warranty, expressed or implied, and 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. 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. © 2001–2016 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, Oregon 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, transmissions, and rear axles. Each workshop/service manual section is divided into subjects that can include general information, principles of operation, removal, disassembly, assembly, installation, and specifications. 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 fasten- ers. 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 di- agnostic 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 Business Class M2 Maintenance Manual, May 2011 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 Business Class M2 Maintenance Manual, May 2011

For an example of a Business Class M2 Maintenance Manual page, see Fig. 1. f020125 A B C D E Cooling 12/06/2001 Business Class M2 Maintenance Manual, December 2001 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, May 2011 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 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, May 2011

Title of Maintenance Operation (MOP) MOP Number Determining Scheduled Maintenance Intervals............................................. 00–01 Initial Maintenance (IM) Operations ..................................................... 00–06 M1 Lubrication and Fluid Level Check................................................... 00–12 M1 Maintenance Operations .......................................................... 00–07 M2 Lubrication and Fluid Level Check................................................... 00–13 M2 Maintenance Operations .......................................................... 00–08 M3 Maintenance Operations .......................................................... 00–09 M4 Maintenance Operations .......................................................... 00–10 M5 Maintenance Operations .......................................................... 00–11 Maintenance Intervals for Schedule I.................................................... 00–03 Maintenance Intervals for Schedules II and III ............................................. 00–04 Maintenance Schedules ............................................................. 00–02 Noise Emission Controls............................................................. 00–15 Overview of Maintenance Operations ................................................... 00–05 Veriﬁcation of Inspections Log......................................................... 00–16 General Information 00 Index, Alphabetical Business Class M2 Maintenance Manual, March 2016

Determining Scheduled Maintenance Intervals Performing regular maintenance will help ensure that your vehicle delivers safe, reliable service and opti- mum performance. A proper maintenance program will also help to minimize downtime and safeguard warranties. To determine the correct maintenance intervals for your vehicle, you must ﬁrst determine the type of service or conditions the vehicle will be operating in. Most vehicles operate in conditions that fall within one of the three schedules. Before placing your vehicle in service, determine whether Schedule I, II, or III applies to your vehicle. Schedules I-III Schedule I (severe service) applies to vehicles that travel up to 6000 miles (10 000 kilometers) annually or that operate under severe conditions. Examples of Schedule I usage are: • operation on extremely poor roads or where there is heavy dust accumulation • constant exposure to extreme hot, cold, salt air, or other extreme climates • frequent short-distance travel • construction-site operation • city operation such as ﬁre truck and garbage truck. • farm operation Schedule II (short-haul transport) applies to vehicles that travel up to 60,000 miles (100 000 kilometers) annually and operate under normal conditions. Ex- amples of Schedule II usage are: • operation primarily in cities and densely popu- lated areas • local transport 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 After determining the schedule appropriate to your vehicle, refer to the Maintenance Schedules to determine when to perform the Initial Maintenance (IM) and the frequency of performing subsequent maintenance intervals for each schedule. Maintenance Intervals Refer to Maintenance Intervals for Schedule I, Schedule II, and Schedule III to determine which maintenance interval(s) should be performed when your vehicle reaches the mileage or hours of operation listed in these tables. Maintenance Operations Groups 01 through 83 in this manual have an index at the beginning of each Group. The index lists the Title of Maintenance Operations and the maintenance Operation (MOP) Numbers for that Group. Follow the instructions under the MOP number to perform the required maintenance. In addition to the maintenance operations required for the maintenance interval, perform all the daily maintenance procedures in Chapter 11, "Pretrip In- spection and Daily Maintenance," in the Business Class® M2 Driver’s Manual. General Information 00 Determining Scheduled Maintenance Intervals: 00–01 Business Class M2 Maintenance Manual, March 2016 00/1

Maintenance Schedules Schedule Maintenance Intervals Maintenance Interval Frequency Mileage km Hours Schedule I * (severe service) for vehicles that travel up to 6000 miles (10 000 km) annually Initial Maintenance (IM) first 1000 1600 100 Maintenance 1 (M1) every 1000 1600 100 Maintenance 2 (M2) every 4000 6400 400 Maintenance 3 (M3) every 8000 12 800 800 Maintenance 4 (M4) every 16,000 25 600 1600 Maintenance 5 (M5) every 32,000 51 200 3200 Schedule II (short-haul transport) for vehicles that travel up to 60,000 miles (100 000 km) annually Initial Maintenance (IM) first 8000 12 000 — Maintenance 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 Maintenance 3 (M3) every 40,000 64 000 Maintenance 4 (M4) every 80,000 128 000 Maintenance 5 (M5) every 160,000 256 000 * For Schedule I vehicles equipped with an hourmeter, use maintenance intervals based on hours of operation rather than mileage. Table 1, Maintenance Schedules General Information 00 Maintenance Schedules: 00–02 Business Class M2 Maintenance Manual, March 2016 00/2

Freightliner Business Class M2 Trucks OEM Maintenance Manual

You're Reading a Preview

Recently Viewed