Freightliner Heavy-Duty Trucks Operation & Maintenance Manual

HEAVY-DUTY TRUCKS MAINTENANCE MANUAL Models: FLA COE FLB COE FLC 112 Conventional FLD Conventional FLL COE STI-329-1 (10/09P) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.

Foreword When performed on a regular basis, lubricating the parts of your vehicle is the least costly way of obtaining safe and reliable vehicle operation. Added benefits and savings occur when you check that the engine, undercarriage, and noise emission control parts are in good working order during lubrication. 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. © 1993–2009 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 (POC-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, 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 Heavy-Duty Trucks Maintenance Manual, October 2009 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 Heavy-Duty Trucks Maintenance Manual, October 2009

For an example of a Heavy-Duty Trucks Maintenance Manual page, see Fig. 1. 11/28/2001 f020034 A B C D E A. Maintenance Operation Number consists of Group Number followed by Sequence Number B. Group Title C. Group Number D. Release Date E. Group/Page Number Fig. 1, Example of a Heavy-Duty Trucks Maintenance Manual Page Introduction Page Description Heavy-Duty Trucks Maintenance Manual, October 2009 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 54 .......... Electrical, Instruments, and Controls 60 .................................. Cab 72 ................................ Doors 83 ................. Heater and Air Conditioner Introduction Maintenance Manual Contents I–4 Heavy-Duty Trucks Maintenance Manual, October 2009

Title of Maintenance Operation (MOP) MOP Number COE Cab Tilting, FLA/FLB ........................................................... 00–11 Determining Scheduled Maintenance Intervals............................................. 00–01 Initial Maintenance (IM) Operations ..................................................... 00–06 Lubrication and Fluid Level Check ..................................................... 00–04 M1 Maintenance Interval Operations Table: 00-07 .......................................... 00–07 M2 Maintenance Interval Operations Table: 00-08 .......................................... 00–08 M3 Maintenance Interval Operations Table ............................................... 00–09 M4 Maintenance Interval Operations Table: 00-10 .......................................... 00–10 Maintenance Operation Sets Table ..................................................... 00–05 Maintenance Service Table ........................................................... 00–02 Metric/U.S. Customary Conversion Tables ................................................ 00–14 Noise Emission Controls Maintenance................................................... 00–12 Torque Specifications Tables.......................................................... 00–15 Vehicle Maintenance Schedule Tables................................................... 00–03 Verification of Inspections Log......................................................... 00–13 General Information 00 Index, Alphabetical Heavy-Duty Trucks Maintenance Manual, October 2009

Determining Scheduled Maintenance Intervals Performing regular maintenance on your Freightliner vehicle will help ensure that your vehicle delivers safe reliable service and optimum performance for years to come. Failure to follow a regular maintenance program can result in inefficient operation and unscheduled down time. To determine the correct maintenance intervals for your vehicle you must first determine the type of service or conditions in which the vehicle will operate. Generally, most vehicles operate under conditions that fall within one of the three types of service de- scribed. Before placing your new vehicle in service, determine the type of service (Service Schedule I, II, or III) that applies to the intended use of the vehicle. After determining the vehicle’s type of service, refer to the Maintenance Service Table or the Vehicle Maintenance Schedule Tables, to determine how often maintenance should be performed. When the vehicle reaches the distance given for a maintenance interval, see the applicable Mainte- nance Interval Operations Table for a list of the maintenance operations to be performed at that maintenance interval. Use the maintenance operation numbers to find detailed instructions in the manual on each operation. Types of Service Service Schedule I (severe service) applies to vehicles that annually travel less than 6000 miles (10 000 kilometers) or that operate under severe conditions. Examples of severe service, Schedule I usage include: operation on extremely poor roads or where there is heavy dust accumulation; constant exposure to extreme hot, cold, salt-air, or other extreme cli- mates; frequent short-distance travel; construction- site operation; city operation (fire truck); or farm operation. Service Schedule II (short-haul transport) applies to vehicles that annually travel less than 60,000 miles (100 000 kilometers) and operate under normal conditions. Examples of Schedule II usage are: operation primarily in cities and densely populated areas; local transport with infrequent freeway travel; or high percentage of stop-and-go travel. Service Schedule III (long-haul transport) is for vehicles that annually travel more than 60,000 miles (100 000 kilometers) with minimal city or stop-and-go operation. Examples of Schedule III usage are: re- gional delivery that is mostly freeway miles; interstate transport; or any road operation with high annual mileage. NOTE: Maintenance instructions in this manual are based on average vehicle use and normal operating conditions. Unusual vehicle operating conditions may require service at more frequent intervals. General Information 00 Determining Scheduled Maintenance Intervals: 00–01 Heavy-Duty Trucks Maintenance Manual, October 2009 00/1

Maintenance Service Table Service Schedule Maintenance Interval Operation Maintenance Intervals Frequency Miles km Hours Schedule I * (Severe Service) vehicles that annually travel less than 6000 miles (10 000 km) Initial Maintenance (IM) first 1000 1600 100 Maintenance 1 (M1) every 1000 1600 100 Maintenance 2 (M2) every 5000 8000 500 Maintenance 3 (M3) every 10,000 16 000 1000 Maintenance 4 (M4) every 20,000 32 000 2000 Schedule II ² (Short-Haul Transport) vehicles that annually travel less than 60,000 miles (100 000 km) Initial Maintenance (IM) first 9000 to 10,000 15 000 — Maintenance 1 (M1) every 9000 to 10,000 15 000 Maintenance 2 (M2) every 37,000 to 38,000 60 000 Maintenance 3 (M3) every 75,000 120 000 Maintenance 4 (M4) every 150,000 240 000 Schedule III ² (Long-Haul Transport) vehicles that annually travel over 60,000 miles (100 000 km) Initial Maintenance (IM) first 12,500 20 000 — Maintenance 1 (M1) every 12,500 20 000 Maintenance 2 (M2) every 50,000 80 000 Maintenance 3 (M3) every 100,000 160 000 Maintenance 4 (M4) every 300,000 480 000 * For Schedule I (severe service) vehicles equipped with an hourmeter, use maintenance intervals based on hours of operation rather than distance traveled. ² Use Schedule I (severe service) maintenance intervals for vehicles that operate under severe conditions, such as extremely poor roads, heavy dust accumulation, extreme climate, frequent short distance travel, construction-site operation, city operation (garbage truck), or farm operation. General Information 00 Maintenance Service Table: 00–02 Heavy-Duty Trucks Maintenance Manual, October 2009 00/2

1st through 20th Maintenance for Service Schedule I Vehicles Maint. No. Required Maintenance Operation Interval Service Date Service I Miles km Hours 1st Initial Maintenance (IM)/M1 1000 1600 100 2nd M1 2000 3200 200 3rd M1 3000 4800 300 4th M1 4000 6400 400 5th M1 and M2 5000 8000 500 6th M1 6000 9600 600 7th M1 7000 11 200 700 8th M1 8000 12 800 800 9th M1 9000 14 400 900 10th M1, M2, and M3 10,000 16 000 1000 11th M1 11,000 17 600 1100 12th M1 12,000 19 200 1200 13th M1 13,000 20 800 1300 14th M1 14,000 22 400 1400 15th M1 and M2 15,000 24 000 1500 16th M1 16,000 25 600 1600 17th M1 17,000 27 200 1700 18th M1 18,000 28 800 1800 19th M1 19,000 30 400 1900 20th M1, M2, M3, and M4 20,000 32 000 2000 21st through 40th Maintenance for Service Schedule I Vehicles Maint. No. Required Maintenance Operation Interval Service Date Service I Miles km Hours 21st M1 21,000 33 600 2100 22nd M1 22,000 35 200 2200 23rd M1 23,000 36 800 2300 24th M1 24,000 38 400 2400 25th M1 and M2 25,000 40 000 2500 26th M1 26,000 41 600 2600 27th M1 27,000 43 200 2700 28th M1 28,000 44 800 2800 29th M1 29,000 46 400 2900 30th M1, M2, and M3 30,000 48 000 3000 31st M1 31,000 49 600 3100 General Information 00 Vehicle Maintenance Schedule Tables: 00–03 Heavy-Duty Trucks Maintenance Manual, October 2009 00/3

Freightliner Heavy-Duty Trucks Operation & Maintenance Manual

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