freightliner C SB FS65, Maintenance Manual

Page 1: ...SCHOOL BUS CHASSIS MAINTENANCE MANUAL Models Type C SB FS65 STI 348 5 06P Published by Freightliner LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A...

Page 2: ...ny time or change specifications and design without notice and without incurring obligation For additional information please contact Freightliner LLC Service Systems and Documenta tion P O Box 3849 P...

Page 3: ...n the identification of serviceable replacement vehicle parts This manual is used in conjunction with the parts book and the service parts catalog microfiche Service Bulletins Service Bulletins provid...

Page 4: ...NT AND REAR SUSPENSION SPRING ASSEMBLIES FRONT SUSPENSION REAR SUSPENSION School Bus Chassis Maintenance Manual October 1996 32 1 REAR SUSPENSION SPRING BRACKETS A Maintenance Operation Number consist...

Page 5: ...adiator 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 Instrum...

Page 6: ...ce Interval Operations 00 08 M3 Maintenance Interval Operations 00 09 Maintenance Interval Table 00 03 Maintenance Operation Sets 00 05 Metric U S Customary Conversion Table 00 12 Noise Emission Contr...

Page 7: ...of the vehicle See the Vehicle Maintenance Schedule Table to determine the distance or time interval at which each mainte nance operation set must be performed for your cat egory of vehicle When the v...

Page 8: ...M1 every 2500 4000 3 Maintenance 2 M2 every 10 000 16 000 12 Maintenance 3 M3 every 30 000 48 000 36 CATEGORY II Rural Transport vehicles that annually travel over 20 000 miles 32 000 km Initial Maint...

Page 9: ...120 9 150 240 9 4th M2 100 160 12 200 320 12 5th M1 125 200 15 250 400 15 6th M1 150 240 18 300 480 18 7th M1 175 280 21 350 560 21 8th M2 200 320 24 400 640 24 9th M1 225 360 27 450 720 27 10th M1 25...

Page 10: ...ne Inspecting and Lubricating 42 04 Air Reservoir Automatic Drain Valve Disassembling Cleaning and Inspecting Bendix DV 2 42 05 Automatic Slack Adjuster Lubricating and Checking Meritor 42 09 Camshaft...

Page 11: ...uller Transmission Oil Changing and Magnetic Plug Cleaning 26 03 Transmission Breather Checking 26 04 Allison Transmission Fluid and Filter Changing 26 05 Allison Transmission Fluid Level Checking 31...

Page 12: ...cating and Checking Meritor 42 06 Bendix Hydro Max Power Booster Checking 42 07 Brake Lines Checking Hydraulic Disc Brakes 42 08 Brake Lining Wear Checking Hydraulic Disc Brakes 42 09 Camshaft Bracket...

Page 13: ...nance Operation 01 03 For series 2000 2400 transmissions with non TranSynd ATF change oil and filters at 50 000 miles 80 000 km or 24 months whichever comes first Perform annually during the fall This...

Page 14: ...aintenance IM Operations 00 07 Perform all M1 Operations 26 02 Eaton Fuller Transmission Oil Changing and Magnetic Plug Cleaning 31 01 Frame Fastener Torque Checking 32 03 U Bolt Torque Checking Freig...

Page 15: ...Lubricating Tie Rod End Lubricating Axle Lubricant Level Checking Driveline Inspecting and Lubricating Automatic Slack Adjuster Lubricating and Checking Meritor Steering Driveline Lubricating Drag Li...

Page 16: ...ner Element Replacing 15 01 Alternator Battery and Starter Checking 20 01 Radiator Cap Checking 20 03 Eaton Viscous Fan Drive Checking 26 03 Transmission Breather Checking 42 01 Air Dryer Checking Ben...

Page 17: ...Fluid and Filter Changing 31 01 Frame Fastener Torque Checking 32 03 U Bolt Torque Checking Freightliner Spring 32 04 Spring Bracket Fastener Torque Checking Freightliner Spring Rear 32 05 Fastener T...

Page 18: ...owner s warranty information book for warranty information concerning noise emission controls Tampering With the Noise Controls is Prohibited Federal law prohibits the following acts or the caus ing...

Page 19: ...Date Mileage Repair Description Cost Repair Facility Group 01 Engine Support Fasteners Group 20 Engine Cooling Fan Drive Group 49 Exhaust System General Information 00 Verification of Inspections Log...

Page 20: ...81 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 ft3 28 317 liters L 0 03531 cubic...

Page 21: ...21 28 5 16 24 16 22 17 23 14 19 23 31 3 8 16 26 35 28 38 23 31 37 50 3 8 24 30 41 32 43 25 34 42 57 7 16 14 42 57 45 61 35 47 60 81 7 16 20 47 64 50 68 40 54 66 89 1 2 13 64 87 68 92 55 75 91 123 1 2...

Page 22: ...1 2 13 56 76 1 2 20 63 85 9 16 12 81 110 9 16 18 90 122 5 8 11 112 152 5 8 18 126 171 3 4 10 198 268 3 4 16 221 300 7 8 9 319 433 7 8 14 352 477 1 8 479 649 1 12 524 710 1 14 537 728 Freightliner rec...

Page 23: ...100 136 140 190 140 190 9 16 18 110 149 155 210 5 8 11 135 183 190 258 190 258 5 8 18 155 210 215 292 3 4 10 240 325 340 461 340 461 3 4 16 270 366 380 515 7 8 9 385 522 540 732 7 8 14 425 576 600 813...

Page 24: ...65 224 229 310 M20 208 282 288 390 M20 x 1 5 213 313 320 434 M22 283 384 392 531 M22 x 1 5 315 427 431 584 M24 360 488 498 675 M24 x 2 392 531 542 735 M27 527 715 729 988 M27 x 2 569 771 788 1068 M30...

Page 25: ...MOP MOP Number Engine Drive Belt Inspecting 01 02 Engine Support Fasteners Checking Noise Emission Control 01 01 Pacbrake Inspecting and Maintenance 01 03 Engine 01 Index Alphabetical School Bus Chass...

Page 26: ...Inspection 1 Inspect the belt for glazing See Fig 2 Ref A Glazing is represented by shiny sidewalls and is caused by friction created when a loose belt slips in the pulleys It can also be caused by o...

Page 27: ...ake Inspecting and Maintenance With frequent use the Pacbrake Exhaust Brake will operate free of maintenance However if the vehicle is used inconsistently seasonally or is exposed to excess moisture i...

Page 28: ...hazard The brake housing may trap water in the valve shaft bore causing corrosion resulting in an improper or non functioning brake If it is necessary to periodically start the engine reach normal op...

Page 29: ...itle of Maintenance Operation MOP MOP Number Air Cleaner Element Inspecting 09 01 Air Cleaner Element Replacing 09 02 Air Intake 09 Index Alphabetical School Bus Chassis Maintenance Manual January 200...

Page 30: ...in stallation instructions 09 02 Air Cleaner Element Replacing Replace the air cleaner element at the recommended interval or when filter restriction reaches 20 to 25 inH 20 See Group 09 of the Schoo...

Page 31: ...Title of Maintenance Operation MOP MOP Number Alternator Battery and Starter Checking 15 01 Alternators and Starters 15 Index Alphabetical School Bus Chassis Maintenance Manual January 1999...

Page 32: ...epair or replacement instructions 4 1 Clean and tighten the battery ground cable terminal and clamps 4 2 Inspect the retainer assembly or battery hold downs and the battery box Replace worn or damaged...

Page 33: ...MOP Number Eaton Viscous Fan Drive Checking Noise Emission Radiator Cap Checking 20 01 Radiator Pressure Flushing and Coolant Changing 20 02 Engine Cooling Radiator 20 Index Alphabetical School Bus Ch...

Page 34: ...ushing gun nozzle to the radia tor outlet 3 2 Run water in until the radiator is full 3 3 Apply no more than 20 psi 138 kPa air pressure intermittently to help dislodge sediment buildup in the core CA...

Page 35: ...di tions A Ethylene glycol solution that meets GM 6038 M Engineering Stan dards B Ethylene glycol solution that has less than 0 1 anhydrous so dium metasilicate and meets either GM 1825 M or GM 1899 M...

Page 36: ...of Maintenance Operation MOP MOP Number Clutch Release Bearing Lubricating 25 01 Clutch Release Cross Shaft Lubricating 25 02 Clutch 25 Index Alphabetical School Bus Chassis Maintenance Manual March...

Page 37: ...g Over lubrication could contaminate the clutch in ternally causing clutch slippage and premature failure Do not use chassis grease or multipurpose lubricants 4 Remove the chocks 25 02 Clutch Release...

Page 38: ...llison Transmission Fluid and Filter Changing 26 04 Eaton Fuller Transmission Oil Changing and Magnetic Plug Cleaning 26 02 Eaton Fuller Transmission Oil Level Checking 26 01 Transmission Breather Che...

Page 39: ...riction modifiers or synthetic lubricants 3 Clean the fill plug then install it in the transmis sion Tighten the plug as follows 20 to 25 lbf ft 27 to 34 N m for a 3 4 inch plug 60 to 75 lbf ft 81 to...

Page 40: ...s 26 04 Allison Transmission Fluid and Filter Changing IMPORTANT Extended oil and filter change in tervals as announced by Allison beginning in 2002 do not apply to Allison transmissions in Freightlin...

Page 41: ...stall the washer head screw to retain the fluid filter and tighten it 10 to 15 lbf ft 14 to 20 N m 11 Submerge a new pan gasket in transmission fluid for five minutes Then place the gasket on the pan...

Page 42: ...exron III ATF 25 to 120 F 32 to 48 C TranSynd Synthetic ATF 25 to 120 F 32 to 48 C Factory filled with Dexron III For off highway operation or where ambient temperature is consistently above 86 F 30 C...

Page 43: ...id IMPORTANT Examine the used transmission fluid for dirt coolant or water and metal par ticles If any of these contaminants are present a problem within the transmission system may exist 4 Remove the...

Page 44: ...plug Ex amine the fluid as it drains 4 Place a drain pan under the external filter Re move the external filter with a strap type filter wrench by turning it counterclockwise 5 Remove the magnet from t...

Page 45: ...y for oper ating the vehicle If the level is not within the COLD RUN band add or drain fluid until it reaches the middle of the COLD RUN band See Fig 7 4 Perform a hot check at the first opportunity a...

Page 46: ...COLD RUN CHECK IN NEUTRAL IDLE USE DEXRON R OIL HOT RUN REF FILL 08 23 96 f011103 Fig 7 Dipstick Markings Transmission 26 School Bus Chassis Maintenance Manual March 2003 26 8...

Page 47: ...Title of Maintenance Operation MOP MOP Number Frame Fastener Torque Checking 31 01 Frame 31 Index Alphabetical School Bus Chassis Maintenance Manual March 2003...

Page 48: ...d result in bracket or frame damage Typical frame fastener applications include suspen sion brackets fuel tank exhaust and engine sup ports frame crossmembers and gussets NOTE This operation is not in...

Page 49: ...er Torque Checking Hendrickson 32 12 Radius Rod Bushing Checking Hendrickson 32 10 Shock Absorber Checking Freightliner Spring 32 09 Spring Bracket Fastener Torque Checking Freightliner Spring Rear 32...

Page 50: ...s Inspect the forward and rear spring brackets and the wear pads for wear cracks and other damage If any of these conditions exist replace the damaged bracket s and wear pad s See Group 32 of the Scho...

Page 51: ...0 Description Size Torque lbf ft N m Air Spring Upper Mounting Bracket 5 8 11 125 170 Spring Hanger Mounting Locknuts 3 4 10 210 285 Lateral Control Rod Nut 5 8 11 136 185 Table 1 Torque Values for Fr...

Page 52: ...If the air springs do not inflate see Group 32 of the School Bus Chassis Workshop Manual for pos sible causes and corrections 32 08 U Bolt Torque Checking Freightliner AirLiner In a diagonal pattern...

Page 53: ...en the suspension fasteners to the torque val ues given in Table 2 All Hendrickson beam end fasteners must maintain their torque values to firmly clamp the rubber bushing inner metal tubes to the beam...

Page 54: ...hree piece adapter without the intermediate tube 1 Nut 2 Adapter 3 Intermediate Tube 4 Inner Metal of Beam End Bushing 5 Beam Hanger Fig 3 Three Piece Adapter Type Beam End Connection Suspension 32 Sc...

Page 55: ...ating 33 01 Oil Filled Hubs Oil Changing 33 06 Oil Filled Hubs Oil Level Checking 33 05 Tie Rod End Inspecting 33 03 Tie Rod End Lubricating 33 02 Wheel Bearing Removing Cleaning Checking Repacking an...

Page 56: ...shings or needle bearings until new grease is seen at the seal on the bushing or needle bearing opposite the fittings NOTE The grease seal will accept the grease pressure without damaging the seal and...

Page 57: ...52 mm replace the tie rod end 1 7 Install the dial indicator as described above and repeat this procedure on the opposite tie rod end 2 Inspect the tie rod ends 2 1 The threaded portion of the tie ro...

Page 58: ...ul not to overfill the hubs Overfilling may cause oil to be forced out of the hubs and to con taminate the brake linings and other brake compo nents This could result in loss of vehicle control and le...

Page 59: ...NT Fill the hubs to the level indicators on the hub caps or to no more than 1 4 inch 6 mm above the indicators 7 Install the filler caps securely 8 Remove the chocks from the tires 33 07 Wheel Bearing...

Page 60: ...ration MOP MOP Number Axle Breather Checking 35 03 Axle Lubricant Changing and Magnetic Plug Cleaning 35 02 Axle Lubricant Level Checking 35 01 Rear Axle 35 Index Alphabetical School Bus Chassis Maint...

Page 61: ...Drive Axle Lubricant Capacities Meritor Drive Axle Lubricant Capacities single axle Axle Model Capacity pints liters RS 13 120 16 7 6 RS 15 120 16 7 6 RS 17 145 33 6 15 9 RS 19 145 34 4 16 3 RS 21 145...

Page 62: ...n the differential and add 5 8 qts 5 5 L of SAE 80 90 hypoid gear oil through the rear axle fill hole The lubricant level should be at the bottom of the fill hole IMPORTANT The entire axle capacity ax...

Page 63: ...g and tighten it 35 lbf ft 47 N m 3 After filling the carrier and housing assembly with lubricant drive the vehicle unloaded for 1 or 2 miles 2 or 3 kilometers at speeds not to exceed 25 mph 40 km h t...

Page 64: ...Title of Maintenance Operation MOP MOP Number Wheel Nut and Rim Nut Checking 40 01 Wheels and Tires 40 Index Alphabetical School Bus Chassis Maintenance Manual October 1996...

Page 65: ...er Torque dry threads lbf ft N m Front Wheel Nut 3 4 16 1 1 8 16 Accuride 450 500 610 680 Rear Wheel Inner Nut 3 4 16 Accuride 450 500 610 680 Rear Wheel Outer Nut 1 1 8 16 Accuride 450 500 610 680 Wh...

Page 66: ...Stud Disc Wheel B 10 Stud Disc Wheel C 6 Spoke Wheel D 5 Spoke Wheel Fig 1 Wheel Nut and Rim Nut Tightening f400033a 05 16 94 Fig 2 Non Corrugated Channel Spacer f400032a 10 05 94 Fig 3 Corrugated Cha...

Page 67: ...Title of Maintenance Operation MOP MOP Number Driveline Inspecting and Lubricating 41 01 Driveline 41 Index Alphabetical School Bus Chassis Maintenance Manual April 1998...

Page 68: ...he driveline weakens the driveline connection which could eventually result in serious vehicle damage f410057a 10 06 94 1 2 3 5 6 4 2 4 7 16 15 14 13 18 17 9 8 3 7 10 11 12 NOTE Not all fasteners are...

Page 69: ...shaft up and down and from side to side If the bearing is loose on its shaft or rattles re place it If the bearing bracket is loose on the frame or the bearing mount is loose on the bracket tighten th...

Page 70: ...remove the bearing cup at that seal and exam ine the seal for damage If the seal is damaged replace the complete U joint assembly If grease does not appear at one of the seals use a screwdriver to pr...

Page 71: ...ee Fig 4 Ref 1 2 Use a hand type grease gun or a high pressure gun with a low pressure adapter to lubricate the slip joint Using lithium 12 hydroxy stearate grease NLGI grade 1 or 2 with EP additives...

Page 72: ...Checking Meritor 42 05 Bendix Hydro Max Power Booster Checking 42 06 Brake Caliper Slide Pin Lubricating Bosch Brakes 42 14 Brake Caliper Slide Rail Lubricating Bosch Brakes 42 15 Brake Lines Checking...

Page 73: ...tridge if necessary For instructions see Group 42 of the School Bus Chassis Workshop Manual 42 03 Air Dryer Inspecting Bendix AD 9 1 Check the reservoirs for moisture A small amount teaspoon or less i...

Page 74: ...incorrect remove the pressure relief capscrew gasket pawl spring and pawl from the slack adjuster housing See Fig 1 Ref 5 If equipped with a pull pawl assembly carefully insert a screwdriver and rais...

Page 75: ...sembly carefully insert a screwdriver and raise the relief cap about 1 8 inch 3 2 mm See Fig 3 Chamber Size Effective Area square inches Maximum Allowable Stroke inches mm B minus A 12 Less than 1 3...

Page 76: ...d plastic bag To minimize the possibility of creating airborne brake lining dust clean the dust from the brake rotor brake caliper and brake assembly using an industrial type vacuum cleaner equipped w...

Page 77: ...during this check Clean off road grime from the relay valve and any debris from the valve exhaust port Listen for air leakage around the fittings or exhaust port Tighten the fittings as necessary Use...

Page 78: ...ide pin bore sets See the Bosch Pin Slide Disc Brakes Service Manual for additional information IMPORTANT The later ZOH T caliper has im portant differences from the early ZOPS caliper ZOPS calipers s...

Page 79: ...the caliper making removal easier 7 Grasping the caliper swing it out and lift it from the anchor plate Rest the caliper on the stool For ease of removal swing the caliper on the forward anchor plate...

Page 80: ...plate torque rail the large rail and swing the caliper into place Make sure that the brake hose is not twisted Do not get grease on the pad faces or rotor surfaces 16 With the caliper installed and f...

Page 81: ...46 02 Power Steering Reservoir Fluid Level Checking 46 03 Power Steering Reservoir Fluid and Filter Changing 46 04 Steering Driveline Lubricating 46 01 Steering Gear Lubricating 46 05 Steering 46 Ind...

Page 82: ...un apply multipurpose chas sis grease at the grease fittings until old grease is forced out of the socket NOTE Use multipurpose chassis grease NLGI grade 1 6 12 hydroxy lithium stearate grease or NLGI...

Page 83: ...emove the dipstick 3 8 16 hexnut and cover See Fig 3 2 Drain the power steering reservoir by disconnect ing the power steering gear to reservoir hose from the reservoir Keep the hose in an upright pos...

Page 84: ...to the reservoir 9 Tighten the hose fitting nut finger tight then with a wrench tighten until there is firm resistance Tighten one sixth turn more Do not overtighten Remove the jack stands and lower...

Page 85: ...Title of Maintenance Operation MOP MOP Number Inline Fuel Strainer Replacing Cummins ISB02 and MBE900 Engines 47 01 Fuel 47 Index Alphabetical School Bus Chassis Maintenance Manual May 2005...

Page 86: ...nd frame rail under the cowl area 1 Remove the brackets on each end of the fuel stainer 2 Remove the P clip IMPORTANT The fuel flow arrow on the fuel strainer must be pointed toward the front of the v...

Page 87: ...Title of Maintenance Operation MOP MOP Number Exhaust System Inspecting Noise Emission Controls 49 01 Exhaust 49 Index Alphabetical School Bus Chassis Maintenance Manual October 1996...

Page 88: ...ed On Caterpillar and Cummins engines check for leakage at the V type clamp that attaches the exhaust pipe to the turbocharger exhaust outlet If leakage exists tighten the nut on the V type clamp 50 l...

Page 89: ...nance Operation MOP MOP Number Electrical Wiring Checking 54 02 Ground Cables Checking and Cleaning 54 01 Electrical Instruments and Controls 54 Index Alphabetical School Bus Chassis Maintenance Manua...

Page 90: ...or out until the horn works If the horn still does not work check the wiring to it If the wiring checks out okay replace the horn 5 Check all the connectors on the right hand side of the bulkhead inb...

Page 91: ...batteries and tighten them 10 to 15 lbf ft 14 to 20 N m Cover the terminals and spray each connection with dielectric red enamel See Table 1 for ap proved brands of dielectric grease and red enamel El...