Freightliner Recreational Vehicle Chassis (MC/MCL/XCL/XCM/XCP/XCR/XCS) OEM Maintenance Manual

RECREATIONAL VEHICLE CHASSIS MAINTENANCE MANUAL Models: MC MCL XCL XCM XCP XCR XCS STI-425-6 (3/14) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.

For an example of a maintenance manual page, see Fig. 1. f020075 B C A D E 33 Front Axle 33-01 Knuckle Pin Lubricating 33-02 Tie-Rod End Lubricating and Inspecting 33-03 Toe-In Inspection (See Fig. 1) 11/11/2002 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 Maintenance Manual Page Introduction Page Description Recreational Vehicle Chassis Maintenance Manual, July 2013 I–3

Group No. Group Title 00 ...................... General Information 01 ................................ Engine 09 .............................. Air Intake 15 ................... Alternators and Starters 20 ................... Engine Cooling/Radiator 26 ........................... Transmission 30 .......................... Throttle Control 32 ............................. Suspension 33 .............................. Front Axle 35 .............................. Rear Axle 40 ........................ Wheels and Tires 41 ............................... Driveline 42 ................................ Brakes 46 ............................... Steering 47 .................................. Fuel 49 ............................... Exhaust 54 ............................... Electrical 83 ................. Heater and Air Conditioner Introduction Maintenance Manual Contents I–4 Recreational Vehicle Chassis Maintenance Manual, July 2013

Title of Maintenance Operation (MOP) MOP Number 15,000 Mile or 12 Month Maintenance................................................... 00–04 30,000 Mile or 24 Month Maintenance................................................... 00–05 45,000 Mile or 36 Month Maintenance................................................... 00–06 60,000 Mile or 48 Month Maintenance................................................... 00–07 6000 Mile or 6 Month Initial Maintenance ................................................ 00–03 General Maintenance Schedule Information............................................... 00–01 Metric/U.S. Customary Conversion Tables ................................................ 00–10 Noise Emission Controls Maintenance................................................... 00–08 Torque Speciﬁcations Tables .......................................................... 00–11 Vehicle Maintenance Schedule Table ................................................... 00–02 Veriﬁcation of Inspections Log......................................................... 00–09 General Information 00 Index, Alphabetical Recreational Vehicle Chassis Maintenance Manual, March 2014

General Maintenance Schedule Information General Maintenance Schedule Information Performing regular maintenance on your 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. When the vehicle reaches the distance or time (whichever comes first) given for a maintenance interval, see the Vehicle Maintenance Schedule Table for a list of the maintenance operations to be performed at that maintenance interval. Use the maintenance operation reference numbers to find detailed instructions in the manual for each operation. 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. For specific engine maintenance information, see the Cummins Operation and Maintenance Manual. IMPORTANT: Maintenance operations appearing in italics in the following tables are for emission control components. Numbers in the table are reference numbers matching those in the text of this manual. Camp Freightliner Owner Training Owners who want to learn more about their vehicle can attend a two-day training class, offered at the Freightliner Custom Chassis Service Center in Gaff- ney, South Carolina. Some of the items covered during the training include the air brake system, electrical system, vehicle storage, weight distribution, and maintenance intervals. To learn more about the class or to register, go to www.freightlinerchassis.com. After entering the website, click "Motorhomes" and select "Owner Info". A class description and the registration form are lo- cated under the "Camp Freightliner" tab. If needed, service work can be scheduled for your vehicle at the service center during your stay. Tear-Out Checklists IMPORTANT: Additional copies of the checklists should be made before giving this to a dealer, as they may not be returned to you. The correct number of checklists are included to cover the warranty period, however, if you want copies of the checklists for future maintenance after the warranty expires, you will need to make them. Freightliner Custom Chassis Corporation (FCCC) will not be able to send you additional copies. At the back of the maintenance manual, there are checklists for each maintenance interval up to 60,000 miles (96 540 km). When a maintenance interval needs to be performed, take the vehicle to an autho- rized Freightliner dealer, remove the appropriate checklist, and give it to the dealer. These are the items that will be inspected for maintenance. General Information 00 General Maintenance Schedule Information: 00–01 Recreational Vehicle Chassis Maintenance Manual, March 2014 00/1

Maintenance Operation Procedures and Schedule Maintenance Operation Number and Description Maintenance Interval in Miles x 1000 6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 Maintenance Interval in Kilometers x 1000 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458 Maintenance Interval in Months 6 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228 01–01 Engine Drive Belt Inspecting • • • • • • • • • • • • • • • • • • • • 01–02 Engine-Support Fasteners Checking • • • • • • • • • • • • • • • • • • • • 09–01 Air Cleaner Inspecting and Replacing * • • • • • • • • • • • • • • • • • • • • 09–02 Charge Air Cooler (CAC) Inspecting and Cleaning • • • • • • • • • • • • • • • • • • • • 15–01 Alternator, Battery, and Starter Checking • • • • • • • • • • • • • • • • • • • • 20–01 Radiator Cap Checking • • • • • • • • • • • • • • • • • • • • 20–02 Radiator Inspecting and Cleaning • • • • • • • • • • • • • • • • • • • • 20–03 Coolant Replacing The coolant replacement interval is every 100,000 miles (160 900 km) or 60 months, whichever comes first. You must check and, if necessary, recharge the supplemental coolant additive (SCA) levels and freeze point every 25,000 miles (40 225 km) or 6 months, whichever comes first. See the applicable engine operation and maintenance manual for further information. 20–04 Mechanical Fan Drive Gearbox Oil Changing • • • • • • • • • • 20–05 Mechanical Fan Drive Gearbox Lubricating • • • • • • • • • • • • • • • • • • • 26–01 Transmission Breather Checking • • • • • • • • • • • • • • • • • • • 26–02 Allison MD/MH Series Transmission Fluid Level Checking • • • • • • • • • • • • • • • • • • • • 26–03 Allison Transmission Fluid and Filter Changing (internal/ external filter) For oil and filter change intervals, see the applicable Allison Operator’s Manual. 30–01 Throttle Pedal Pivot Pin Lubricating • • • • • • • • • • • • • • • • • • • • 32–01 Suspension Fastener Torque Checking • • • • • • • • • • 32–02 Suspension Height Control Valve Checking • • • • • • • • • • • • • • • • • • • • 32–03 Neway Suspension Inspecting • • • • • • • • • • • • • • • • • • • • 32–04 ZF IFS Lubricating • • • • • • • • • • • • • • • • • • • • General Information 00 Vehicle Maintenance Schedule Table: 00–02 Recreational Vehicle Chassis Maintenance Manual, March 2014 00/2

Maintenance Operation Procedures and Schedule Maintenance Operation Number and Description Maintenance Interval in Miles x 1000 6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 Maintenance Interval in Kilometers x 1000 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458 Maintenance Interval in Months 6 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228 32–05 Suspension Inspecting • • • • • • • • • • • • • • • • • • • • 32–06 Suspension U-Bolt Torque Checking • • • • • • • • • • • • • • • • • • • • 33–01 Knuckle Pin Lubricating † • • • • • • • • • • • • • • • • • • • • 33–02 Tie-Rod End Lubricating and Inspecting † • • • • • • • • • • • • • • • • • • • • 33–03 All-Axle Alignment Checking • 33–04 Wheel End Inspection • • • • • • • • • • • 33–05 Oil-Filled Hubs Oil Level Checking • • • • • • • • • • • • • • • • • • • • 33–06 Oil-Filled Hubs Oil Changing • • • • • • • • • • 35–01 Axle Lubricant Level Checking • • • • • • • • • • • • • • • • • • • • 35–02 Axle Lubricant Changing and Magnetic Plug Cleaning For Detroit rear axles with petroleum-based oil, change the lubricant every 100,000 miles (160 900 km) or every 12 months, whichever comes first; if synthetic oil is used, change the lubricant every 250,000 miles (402 250 km) or every 36 months, whichever comes first. For Meritor rear axles with petroleum-based oil, change the lubricant at 100,000 miles (160 900 km) or at 12 months of service, whichever comes first, and every 24 months thereafter; if synthetic oil is used, change the lubricant every 250,000 miles (402 250 km) or every 36 months, whichever comes first. 35–03 Axle Breather Checking • • • • • • • • • • • • • • • • • • • • 35–04 Oil-Filled Hubs Oil Level Checking, Tag Axle • • • • • • • • • • • • • • • • • • • • 35–05 Oil-Filled Hubs Oil Changing, Tag Axle • • • • • • • • • • 40–01 Wheel Nut Checking • • • • • • • • • • 40–02 Wheel Cleaning and Polishing Perform these steps each time the wheels and/or the vehicle is washed. 41–01 Driveline Inspecting and Lubricating • • • • • • • • • • • • • • • • • • • • 42–01 Brake System Valves Inspecting • • • • • • • • • • • • • • • • • • • • 42–02 Air Dryer Checking • • • • • • • • • • • • • • • • • • • • 42–03 Air Dryer Desiccant and Coalescent Filter Replacing • • • • • • 42–04 Camshaft Bracket Bushing Lubricating • • • • • • • • • • • • • • • • • • • General Information 00 Vehicle Maintenance Schedule Table: 00–02 Recreational Vehicle Chassis Maintenance Manual, March 2014 00/3

Maintenance Operation Procedures and Schedule Maintenance Operation Number and Description Maintenance Interval in Miles x 1000 6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 Maintenance Interval in Kilometers x 1000 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458 Maintenance Interval in Months 6 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228 42–05 Slack Adjuster Lubricating • • • • • • • • • • • • • • • • • • • • 42–06 Foot Brake Valve Actuator Lubricating • • • • • • • • • • • • • • • • • • • • 42–07 Bendix Hydro-Max® Brake System Inspecting (front-engine diesel chassis) • • • • • • • • • • • • • • • • • • • • 42–08 Brake Caliper Slide Pin Lubricating, Bosch Brakes (front- engine diesel chassis) Lubricate every 6 months OR every 18,000 miles (28 962 km), whichever comes ﬁrst. 42–09 Brake Lines Checking, Hydraulic Disc or Air Brakes • • • • • • • • • • • • • • • • • • • • 42–10 Brake Lining Wear Checking, Hydraulic Disc Brakes (front-engine diesel chassis) • • • • • • • • • • • • • • • • • • • • 42–11 Brake Inspecting • • • • • • • • • • • • • • • • • • • • 42–12 Meritor Roller Pin Lubricating • • • • • • • • • • • • • • • • • • • 46–01 Drag Link Lubricating • • • • • • • • • • • • • • • • • • • • 46–02 Power Steering Reservoir Fluid Level Checking • • • • • • • • • • • • • • • • • • • • 46–03 Power Steering Fluid and Filter Changing • • • • • • • • • • • • • • • • • • • 46–04 Steering Driveline Lubricating • • • • • • • • • • • • • • • • • • • • 46–05 Steering Gear Lubricating • • • • • • • • • • • • • • • • • • • • 46–06 Hydraulic Reservoir Filter Changing (metal reservoir only) • • • • • • • • • • 47–01 Fuel Tank Mounts and Fuel Line Checking • • • • • • • • • • 47–02 Fuel/Water Separator Element Replacing See the applicable engine operation and maintenance manual for fuel/water separator element replacing intervals. 49–01Exhaust System Inspecting (Noise Emission Control) • • • • • • • • • • • • • • • • • • • • 54–01 Ground Cables Checking and Cleaning • • • • • • • • • • • • • • • • • • • • 54–02 Battery Voltage Checking • • • • • • • • • • • • • • • • • • • • General Information 00 Vehicle Maintenance Schedule Table: 00–02 Recreational Vehicle Chassis Maintenance Manual, March 2014 00/4

Maintenance Operation Procedures and Schedule Maintenance Operation Number and Description Maintenance Interval in Miles x 1000 6 15 30 45 60 75 90 105 120 135 150 165 180 195 210 225 240 255 270 285 Maintenance Interval in Kilometers x 1000 9 24 48 72 96 120 145 169 193 217 241 265 290 314 338 362 386 410 434 458 Maintenance Interval in Months 6 12 24 36 48 60 72 84 96 108 120 132 144 156 168 180 192 204 216 228 83–01 Air Conditioner Inspecting • • • • • • • • • • • • • • • • • • • • * Inspect the air cleaner every 6 months. Replace the air filter every 12 months, or when filter restriction reaches 25 inH 2 0 (if equipped with an air restriction gauge). † For vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), whichever comes first. Table 1, Maintenance Operation Procedures and Schedule General Information 00 Vehicle Maintenance Schedule Table: 00–02 Recreational Vehicle Chassis Maintenance Manual, March 2014 00/5

Procedure Performed (check off or initial) 6000 Mile (9654 km) or 6 Month Initial Maintenance * MOP Inspect _____ Engine Drive Belt Inspecting 01–01 Check _____ Engine-Support Fasteners Checking 01–02 Change _____ Engine Oil and Filter (see the engine manufacturer’s manual) — Change _____ Air Cleaner Inspecting and Replacing 09–01 Inspect _____ Charge Air Cooler (CAC) Inspecting and Cleaning (if cleaning is needed) 09–02 Check _____ Alternator, Battery, and Starter Checking 15–01 Inspect/ Check _____ Radiator (radiator cap, coolant freeze points, SCA levels, hose routing for chaffing and leaks) 20–01, 20–02, 20–03 Change _____ Mechanical Fan Drive Gearbox Oil Changing 20–04 Change _____ Transmission Fluid and Filter (if required by Allison) 26–03 Inspect _____ Transmission Hose Routing for Chaffing and Leaks — Lubricate _____ Throttle Pedal Pivot Pin Lubricating 30–01 Inspect _____ Suspension 32–01, 32–06 Check _____ Suspension Height Control Valve Checking 32–02 Lubricate _____ ZF IFS Lubricating 32–04 Check _____ Suspension U-Bolt Torque Checking 32–06 Lubricate _____ Knuckle Pin Lubricating † 33–01 Lubricate _____ Tie-Rod End Lubricating and Inspecting † 33–02 Check _____ All-Axle Alignment Checking 33–03 Inspect _____ Wheel End Inspecting 33–04 Check/ Change _____ Oil-Filled Hubs Oil Changing (front and tag axle) 33–05, 33–06, 35–04, 35–05 Check _____ Axle Seals for Leaks — Change _____ Axle Lubricant Changing and Magnetic Plug Cleaning (Detroit and Meritor axles) 35–02 Check _____ Axle Breather Checking 35–03 Check _____ Wheel Nut Checking 40–01 Check _____ Tire Pressure — Lubricate _____ Driveline Inspecting and Lubricating 41–01 Inspect _____ Brake System Valves Inspecting 42–01 Inspect _____ Air Dryer and Air Lines for Proper Routing, Chaffing, and Leaks 42–02 General Information 00 6000 Mile or 6 Month Initial Maintenance: 00–03 Recreational Vehicle Chassis Maintenance Manual, March 2014 00/6

Freightliner Recreational Vehicle Chassis (MC/MCL/XCL/XCM/XCP/XCR/XCS) OEM Maintenance Manual

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