Freightliner Business Class M2 Workshop Manual

Foreword

Thepurposeofthismanualistoassisttheservicetechnicianwhenthevehicleisserviced.Major drivetraincomponentserviceinformationisnotincludedinthismanual,butislocatedineach manufacturer’sservicemanual.

InstructionsandproceduresarethoserecommendedbyFreightlinerTrucksorthecomponent manufacturer.

Maintenanceschedulesandadditionalserviceinformationareincludedinthe BusinessClass® M2MaintenanceManual.

IMPORTANT:Descriptionsandspecificationsinthismanualwereineffectatthetime ofprinting.FreightlinerTrucksreservestherighttodiscontinuemodels,andtochange specificationsordesignatanytimewithoutnoticeandwithoutincurringobligation.

Descriptionsandspecificationscontainedinthispublicationprovidenowarranty, expressedorimplied,andaresubjecttorevisionandeditionswithoutnotice.

Referto www.Daimler-TrucksNorthAmerica.com and www.FreightlinerTrucks.com for moreinformation,orcontactDaimlerTrucksNorthAmericaLLCattheaddressbelow.

EnvironmentalConcernsandRecommendations

Wheneveryouseeinstructionsinthismanualtodiscardmaterials,youshouldattempttoreclaim andrecyclethem.Topreserveourenvironment,followappropriateenvironmentalrulesand regulationswhendisposingofmaterials.

NOTICE:PartsReplacementConsiderations

Donotreplacesuspension,axle,orsteeringparts(suchassprings,wheels,hubs,andsteering gears)withusedparts.Usedpartsmayhavebeensubjectedtocollisionsorimproperuseand haveundetectedstructuraldamage.

©2002–2010DaimlerTrucksNorthAmericaLLC

Allrightsreserved.Nopartofthispublication,inwholeorinpart,maybetranslated,reproduced, storedinaretrievalsystem,ortransmittedinanyformbyanymeans,electronic,mechanical, photocopying,recording,orotherwise,withoutthepriorwrittenpermissionofDaimlerTrucks NorthAmericaLLC.DaimlerTrucksNorthAmericaLLCisaDaimlercompany.

DaimlerTrucksNorthAmericaLLC

ServiceSystemsandDocumentation(CVI-SSD)

P.O.Box3849 Portland,OR97208-3849

DescriptionsofServicePublications

DaimlerTrucksNorthAmericaLLCdistributesthefollowingmajorservicepublicationsinpaperandelectronic (viaServicePro®)formats.

Workshop/Service Manual

Workshop/servicemanualscontainserviceandrepairinformationforallvehicle systemsandcomponents,exceptformajorcomponentssuchasengines,transmissions,andrearaxles.Eachworkshop/servicemanualsectionisdividedinto subjectsthatcanincludegeneralinformation,principlesofoperation,removal, disassembly,assembly,installation,specifications,andtroubleshooting.

MaintenanceManual

Maintenancemanualscontainroutinemaintenanceproceduresandintervalsfor vehiclecomponentsandsystems.Theyhaveinformationsuchaslubrication proceduresandtables,fluidreplacementprocedures,fluidcapacities,specifications,andproceduresforadjustmentsandforcheckingthetightnessoffasteners.Maintenancemanualsdonotcontaindetailedrepairorserviceinformation.

Driver’s/Operator’s Manual

Driver’s/operator’smanualscontaininformationneededtoenhancethedriver’s understandingofhowtooperateandcareforthevehicleanditscomponents. Eachmanualcontainsachapterthatcoverspretripandpost-tripinspections, anddaily,weekly,andmonthlymaintenanceofvehiclecomponents.Driver’s/ operator’smanualsdonotcontaindetailedrepairorserviceinformation.

ServiceBulletins

Servicebulletinsprovidethelatestservicetips,fieldrepairs,productimprovements,andrelatedinformation.Someservicebulletinsareupdatestoinformationintheworkshop/servicemanual.Thesebulletinstakeprecedenceover workshop/servicemanualinformation,untilthelatterisupdated;atthattime,the bulletinisusuallycanceled.Theservicebulletinsmanualisavailableonlyto dealers.Whendoingserviceworkonavehiclesystemorpart,checkforavalid servicebulletinforthelatestinformationonthesubject.

IMPORTANT:Beforeusingaparticularservicebulletin,checkthecurrent servicebulletinvaliditylisttobesurethebulletinisvalid.

PartsTechnicalBulletins

Partstechnicalbulletinsprovideinformationonparts.Thesebulletinscontain listsofpartsandBOMsneededtodoreplacementandupgradeprocedures.

Web-basedrepair,service,andpartsdocumentationcanbeaccessedusingthefollowingapplicationsonthe AccessFreightliner.comwebsite.

ServicePro

ServicePro® providesWeb-basedaccesstothemostup-to-dateversionsofthe publicationslistedabove.Inaddition,theServiceSolutionsfeatureprovidesdiagnosticassistancewithSymptomsSearch,byconnectingtoalargeknowledge basegatheredfromtechniciansandservicepersonnel.Searchresultsforboth documentsandservicesolutionscanbenarrowedbyinitiallyenteringvehicle identificationdata.

PartsPro

PartsPro® isanelectronicpartscatalogsystem,showingthespecifiedvehicle’s buildrecord.

Introduction

DescriptionsofServicePublications

Warranty-relatedserviceinformationavailableontheAccessFreightliner.comwebsiteincludesthefollowing documentation.

RecallCampaigns

Recallcampaignscoversituationsthatinvolveserviceworkorreplacementof partsinconnectionwitharecallnotice.Thesecampaignspertaintomattersof vehiclesafety.Allrecallcampaignsaredistributedtodealers;customersreceive noticesthatapplytotheirvehicles.

FieldServiceCampaigns

Fieldservicecampaignsareconcernedwithnon-safety-relatedserviceworkor replacementofparts.Allfieldservicecampaignsaredistributedtodealers;customersreceivenoticesthatapplytotheirvehicles.

ListofAbbreviations

ListofAbbreviations

ThefollowingisalistofdefinitionsforabbreviationsandsymbolsusedinFreightlinerpublications.

A.......... amperes

AAVA...... auxiliaryairvalveassembly

ABS....... antilockbrakingsystem

ABS....... acrylonitrile-butadiene-styrene

A/C........ airconditioner

AC......... alternatingcurrent acc........ accessories

ACM....... aftertreatmentcontrolmodule

ACPU airconditioningprotectionunit

ADLO auto-disengagementlockout

AGM....... absorbedglassmat

AGS....... automatedgearshift

AG2....... AluminumGeneration2 a.m........ antemeridiem (midnightto noon)

AM........ amplitudemodulation amp(s) ampere(s)

AMT....... automatedmechanical transmission

AMU....... airmanagementunit

ANSI AmericanNationalStandards Institute

API........ AmericanPetroleumInstitute

API........ applicationprogramming interface

ARI........ AirConditioningand RefrigerationInstitute

ASA....... AmericanStandards Association

ASF....... AmericanSteelFoundries

ASR....... automaticspinregulator assy. assembly

ASTM AmericanSocietyforTesting andMaterials

ATC....... automatictemperaturecontrol

ATC....... automatictractioncontrol

ATC....... automatictransmission control

ATD....... aftertreatmentdevice

ATF........ automatictransmissionfluid

ATS....... aftertreatmentsystem

attn........ attention aux. auxiliary av......... avoirdupois (Britishweight system)

AWD....... all-wheeldrive

AWG...... Americanwiregauge

AWS....... AmericanWeldingSociety

BAT....... battery

BBC....... bumper-to-back-of-cab BHM....... bulkheadmodule BOC....... back-of-cab BOM....... billofmaterial

BTDC ...... beforetopdeadcenter Btu(s)..... Britishthermalunit(s) C.......... common(terminal)

CAC....... chargeaircooler

CAN....... controllerareanetwork

CARB CaliforniaAirResources Board

CAT....... Caterpillar CB......... circuitbreaker CB......... citizens’band

CBE....... cabbehindengine CCA....... coldcrankingamperes CCR....... CaliforniaCodeof Regulations

CD-ROM.. compact-disc/read-only memory

CDTC constantdischarge temperaturecontrol CEL....... check-enginelight CFC....... chlorofluorocarbons (refrigerant-12)

cfm........ cubicfeetperminute CFR....... CodeofFederalRegulations CGI........ cleangasinduction CGW...... centralgateway CHM....... chassismodule CIP........ coldinflationpressure CLDS cabloaddisconnectswitch CLS....... coolantlevelsensor cm......... centimeters cm3 cubiccentimeters

CMVSS .... CanadianMotorVehicle SafetyStandard Co......... company

COE....... caboverengine

Corp....... corporation CPC....... commonpowertraincontroller

CPU....... centralprocessingunit

CRT....... cathoderaytube cSt........ centistokes(unitof measurementfordescribing theviscosityofgeneral liquids)

cuft....... cubicfeet cuin...... cubicinches

CUM....... Cummins

CVSA CommercialVehicleSafety Alliance

CWS....... collisionwarningsystem

DC......... directcurrent

DCA....... dieselcoolantadditive

DCDL driver-controlleddifferential lock

DDA....... DetroitDieselAllison(obs)

DDC....... DetroitDieselCorporation

DDDL DetroitDieselDiagnosticLink

DDE....... DetroitDieselEngines

DDEC DetroitDieselElectronic (engine)Control

DDR....... diagnosticdatareader

DDU....... driverdisplayunit

def........ defrost

DEF....... dieselexhaustfluid

DFI........ directfuelinjection

DGPS differentialglobalpositioning system

DHD....... dealerhelpdesk

dia......... diameter

DIAG...... diagnosis

DIP........ dualinlinepackage(switch)

DIU........ driverinterfaceunit

DLA....... datalinkadaptor

DLM....... datalinkmonitor

DLU....... dataloggingunit

DMM...... digitalmultimeter

DOC....... dieseloxidationcatalyst

DOT....... DepartmentofTransportation

DPF....... dieselparticulatefilter

DRL....... daytimerunninglights

DRM....... dryerreservoirmodule

DSM....... districtservicemanager

DTC....... diagnostictroublecode

DTC....... dischargetemperaturecontrol

DTNA ...... DaimlerTrucksNorthAmerica

DVOM ..... digitalvolt/ohmmeter

ea.......... each

EBS....... electronicbrakingsystem

ECA....... electricclutchactuator

ECAP electroniccontrolanalyzer programmer

ECAS ...... electronicallycontrolledair suspension

ListofAbbreviations

ListofAbbreviations

ECI........ electronicallycontrolled injection

ECL....... enginecoolantlevel

ECM....... electroniccontrolmodule

ECT....... enginecoolanttemperature

ECU....... electroniccontrolunit

EDM....... electronicdatamonitor

EEPROM.. electricallyerasable programmableread-only memory

EFG....... electricfuelgauge

EFPA...... electronicfootpedal assembly

EGR....... exhaustgasrecirculation

ELC....... extended-lifecoolant

EMC....... electromagneticcompatibility

EMI........ electromagneticinterference

EOA....... electricoverair

EP......... extremepressure(describes anantiwearagentaddedto somelubricants)

EPA....... EnvironmentalProtection Agency

EPS....... enginepositionsensor

ESC....... electronicstabilitycontrol

ESC....... enhancedstabilitycontrol

ESD....... electrostaticdischarge

ESS....... enginesyncroshift (transmission)

etc......... etcetera (andsoforth)

ETEC ...... electronictruckenginecontrol

EUI........ electronicunit(fuel)injectors

EVA....... electronicvibrationanalyzer

EXM....... (chassis)expansionmodule

E85........ 85%ethanolfuel

FAS....... Freightlinerairsuspension

FCCC FreightlinerCustomChassis Corporation

FCU....... forwardcontrolunit

FET........ fieldeffecttransistor

Fig......... figure

floz....... fluidounces

FLA....... post-1984advancements

FreightlinerCOE

FLB....... enhancedFreightlinerFLA COE

FLC....... steel-cabFreightliner112 Conventional

FLD....... post-1984advancements Freightliner112/120 aluminum-cabConventional

FLR....... forward-lookingradar

FM......... frequencymodulation

FMCSA FederalMotorCarrierSafety Administration

FMEA ..... failuremodeeffectsanalysis

FMI........ failuremodeindicator

FMSI FrictionMaterialsStandards Institute

FMVSS .... FederalMotorVehicleSafety Standard

FRP....... fiberglassreinforcedplastic FSA....... fieldserviceauthorization

FSM....... fleetservicemanager

ft.......... feet ft3 cubicfeet ft3/min..... cubicfeetperminute FTL........ Freightliner F.U.E.L..... fuelusageefficiencylevel g.......... grams gal......... gallons GAWR..... grossaxleweightrating GHG....... greenhousegas GHG14 greenhousegasandfuel efficiencyregulations

GL......... gearlubricant GND....... ground gpm....... gallonsperminute GPS....... globalpositioningsystem GVWR grossvehicleweightrating

HBED hard-brakingeventdata HCM....... hybridcontrolmodule HCOE ..... highcaboverengine HCU....... hydrauliccontrolunit HD......... heavy-duty HDU....... hybriddriveunit HEPA...... high-efficiencyparticulateair (filter)

HEST ...... highexhaustsystem temperature HEV....... hybridelectricvehicle HFC....... hydrogenatedfluorocarbons (refrigerant-134a)

hp......... horsepower hp......... highpressure HRC....... Rockwell"C"hardness hr(s)....... hour(s)

HSA....... hillstartaid HSD....... high-sidedriver htr......... heater

HVAC...... heating,ventilating,andair conditioning

HVLP highvelocity,lowpressure H/W....... hardware Hz......... hertz IAD........ interaxledifferential ICS........ integratedchildseat

ICU........ instrumentationcontrolunit i.d.......... insidediameter ID.......... identification

IFI......... IndustrialFastenersInstitute

IFS........ independentfrontsuspension

IGN........ ignition

ILB........ intelligentlightbar ILO........ inlieuof (intheplaceof) in.......... inches in3 ......... cubicinches Inc......... incorporated inH2O..... inchesofwater inHg....... inchesofmercury I/O......... input/output IP.......... instrumentpanel

ISO........ InternationalOrganizationfor Standardization IVS........ idlevalidationswitch k........... kilo(1000) kg......... kilograms km......... kilometers km/h....... kilometersperhour kPa........ kilopascals kW........ kilowatts L.......... liters lb.......... pounds

LBCU lightbarcontrolunit lbf·ft poundsforcefeet lbf·in poundsforceinches

LCD....... liquidcrystaldisplay

LCOE ...... lowcaboverengine

LED....... light-emittingdiode

LFL........ lowerflammabilitylimit LH......... left-hand

LHD....... left-handdrive LHDR..... left-hand-drive

LHK....... litersperhundredkilometers

LHS....... low-hydrogensteel

LIN........ LocalInterconnectNetwork

LLC....... limitedliabilitycompany

L/min...... litersperminute

LNG....... liquefiednaturalgas

LPG....... liquefiedpetroleumgas

ListofAbbreviations

LPG....... liquidpropanegas

LPI........ liquidpropaneinjection

LPR....... lowpressurereservoir

LRR....... low-rollingresistance

LSD....... low-sidedriver

LVD....... low-voltagedisconnect m.......... meters max. maximum

M-B........ Mercedes-Benz

MCM...... motorcontrolmodule

MESA MiningEnforcementSafety Act

mfr......... manufacturer mi......... miles

MID........ messageidentifier

MIL........ malfunctionindicatorlamp (light)

MIL........ militaryspecification min........ minutes min........ minimum misc....... miscellaneous

mL........ milliliters mm........ millimeters

mod. module mpg....... milespergallon mph....... milesperhour

MSF....... modularswitchfield

MMT....... methylcyclopentadienyl manganesetricarbonyl

MSHA MiningSafetyandHealth Administration

MVDA ..... MotorVehicleDealers Association

n.......... negative(frontaxlewheel alignmentspecification)

N.......... nitrogen

N/A........ notapplicable

N·cm...... Newton-centimeters

NC......... normallyclosed(terminalor switch)

NCG....... noncondensablegases

NHTSA .... NationalHighwayTraffic SafetyAdministration

NIOSH..... NationalInstitutefor OccupationalSafetyand Health

NITE....... noidlethermalenvironment

NLA....... nolongeravailable

NLGI NationalLubricatingGrease Institute

N·m........ Newton-meters

NO........ normallyopen(terminalor switch)

NOAT...... NitritedOrganicAcid Technology

NOx....... nitrogenoxides no......... number

NPT....... nationalpipethread

NPTF ...... nationalpipethreadfitting NT......... nylontubeornylontubing

NTSB ...... NationalTransportation SafetyBoard

OAT....... OrganicAcidTechnology

OBD(s) on-boarddiagnostic(s) obs........ obsolete OC........ opencircuit OCV....... opencircuitvoltage o.d......... outsidediameter O.D........ overdrive

OEM....... originalequipment manufacturer OPD....... overfillprotectiondevice

OSHA ..... OccupationalSafetyand HealthAdministration oz......... ounces ozf·in ouncesforceinches p.......... positive(frontaxlewheel alignmentspecification)

PACE...... programmableelectronically controlledengine PAG....... polyalkyleneglycol(oil) parm...... parameter

PAS....... passengeradvisorysystem PC......... personalcomputer PCB....... printedcircuitboard

PDC(s) .... partsdistributioncenter(s) PDI........ pre-deliveryinspection PDM....... powerdistributionmodule PEC....... powerelectronicscarrier PEEC programmableelectronic enginecontrol PID........ parameteridentifier

PKP....... Purple-Kpowder PLC....... powerlinecarrier PLD....... Pumpe-Linie-Düse (pumpline-nozzle)

PNDB ..... power-netdistributionbox PM........ particulatematter p.m........ postmeridiem (noonto midnight) p/n........ partnumber PO......... purchaseorder

ListofAbbreviations

POE....... polyolester PRD....... pressurereliefdevice PRD....... productrequirements document

PSA....... pressure-sensitiveadhesive PSG....... pressuresensorgovernor psi......... poundspersquareinch psia....... poundspersquareinch, atmosphere psig....... poundspersquareinch, gauge pt.......... pints

PTCM pressuretimecontrolmodule PTO....... powertakeoff PTP....... powertrainprotection PTPDM .... powertrainpowerdistribution module

pvc........ polyvinylchloride PWM...... pulsewidthmodulation pwr........ power qt.......... quarts qty......... quantity

R&O..... rustinhibitorsandoxidants

R–12...... refrigerant-12(CFC) R–134a.... refrigerant-134a(HFC) RAM....... randomaccessmemory RC......... reservecapacity recirc...... recirculation Ref(s)...... reference(s) regen ...... regeneration

RELS ...... reducedengineloadatstop

RFI........ radiofrequencyinterference RH......... right-hand

RHD....... right-handdrive RHDR..... right-hand-drive

R/I......... removalandinstallation

RMA....... returnmaterialauthorization

ROM....... read-onlymemory rpm........ revolutionsperminute

R/R........ removalandreplacement

RSA....... roll-stabilityadvisor

RSG....... roadspeedgovernor

RSM....... regionalservicemanager RTS....... ready-to-spray

RTV....... roomtemperaturevulcanizing RV......... recreationalvehicle SA......... sourceaddress

S-ABA..... self-settingautomaticbrake adjusters

ListofAbbreviations

SAE....... SocietyofAutomotive Engineers

SB......... servicebulletin

SBT....... seatbackthickness

SBW....... shift-by-wire

SCA(s) SupplementalCoolant Additive(s)

SCR....... selectivecatalyticreduction

SCU....... systemcontrolunit (speedometer)

SD......... severe-duty

SDU....... stepdeploymentunit

SEL....... shutdownenginelight

SEM....... switchexpansionmodule

SEO....... stopengineoverride

SHM....... switchhubmodule

SI.......... serviceinformation

SI.......... SystèmeInternational

SID........ subsystemidentifier

SM........ systemmalfunction

SMC....... sheetmoldedcompound

S/N........ serialnumber

SOC....... state-of-charge

SPACE.... seatpretensioneractivation forcrashsurvival enhancement

SPG....... specialpurposegrease

SPN....... suspectparameternumber sqin...... squareinches

SRP....... seatingreferencepoint

SRS....... supplementalrestraintsystem

SRS....... synchronousreference sensor

SRT....... standardrepairtime

SSD....... sidesensordisplay

SSID....... smartswitchidentification

SST....... stainlesssteel std......... standard

S/W........ software

SW........ switch

TAM....... thermocoupleamplifier module

TBB....... ThomasBuiltBuses

TBS....... turboboostsensor

TCM....... transmissioncontrolmodule

TCU....... transmissioncontrolunit

TDC....... topdeadcenter

TDR....... techniciandiagnosticroutine

TEM....... truckequipmentmanufacturer

temp...... temperature

TIG........ tungsteninertgas

TIR........ totalindicatorreading

TMC....... TechnologyandMaintenance Council

TPMS ...... tirepressuremonitoring system

TPS....... thermalprotectionswitch

TPS....... throttlepositionsensor

TRS....... timingreferencesensor

TSO....... truckspecificationorder

TSU....... transmissionshiftunit

TXV....... thermalexpansionvalve

U.D........ underdrive

ULSD ultralow-sulfurdiesel

UNC....... unifiednationalcoarse

UNF....... unifiednationalfine

U.S........ UnitedStates

U.S.A...... UnitedStatesofAmerica USC....... UnitedStatescustomary (measures)

V.......... volts

VCU....... vehiclecontrolunit VDC....... vehicledatacomputer Vdc........ volts,directcurrent VIMS...... vehicleinformation managementsystem

VIN........ vehicleidentificationnumber VIP........ vehicleinstrumentationand protection(Kysor)

VIW........ vehicleinterfacewiring (connector)

VOC....... volatileorganiccompounds VOM....... volt-ohmmeter

VRS....... variableresistancesensor VSG....... variablespeedgovernor VSS....... vehiclespeedsensor

VSU....... vehiclesecurityunit WB........ wirebraid WI......... workinstructions WIF........ water-in-fuel WOT....... wideopenthrottle –........... minusornegative +........... plusorpositive ±........... plus-or-minus >........... greaterthan <........... lessthan x........... by(usedinfastenersize descriptions)

"........... inches °........... degrees(ofanangle)

ListofAbbreviations

°C......... degreesCelsius(centigrade) °F.......... degreesFahrenheit #........... number %.......... percent &.......... and ©.......... copyright ™ .......... trademark ®.......... registeredtrademark

U.S.CustomarytoMetricMetrictoU.S.Customary

WhenYouKnow Multiply By ToGetWhenYouKnow Multiply By ToGet

Length

inches(in)25.4millimeters(mm)0.03937inches(in) inches(in)2.54centimeters(cm)0.3937inches(in) feet(ft)0.3048meters(m)3.281feet(ft) yards(yd)0.9144meters(m)1.094yards(yd) miles(mi)1.609kilometers(km)0.6215miles(mi) Area

squareinches(in2)645.16squaremillimeters(mm2)0.00155squareinches(in2) squareinches(in2)6.452squarecentimeters(cm2)0.15squareinches(in2) squarefeet(ft2)0.0929squaremeters(m2)10.764squarefeet(ft2)

Volume

cubicinches(in3)16387.0cubicmillimeters(mm3)0.000061cubicinches(in3) cubicinches(in3)16.387cubiccentimeters(cm3)0.06102cubicinches(in3) cubicinches(in3)0.01639liters(L)61.024cubicinches(in3) fluidounces(floz)29.54milliliters(mL)0.03381fluidounces(floz) pints(pt)0.47318liters(L)2.1134pints(pt) quarts(qt)0.94635liters(L)1.0567quarts(qt) gallons(gal)3.7854liters(L)0.2642gallons(gal) cubicfeet(ft3)28.317liters(L)0.03531cubicfeet(ft3) cubicfeet(ft3)0.02832cubicmeters(m3)35.315cubicfeet(ft3) Weight/Force

ounces(av)(oz)28.35grams(g)0.03527ounces(av)(oz) pounds(av)(lb)0.454kilograms(kg)2.205pounds(av)(lb) U.S.tons(t)907.18kilograms(kg)0.001102U.S.tons(t) U.S.tons(t)0.90718metrictons(t)1.1023U.S.tons(t) Torque/WorkForce

inch-pounds(lbf·in)11.298Newton-centimeters(N·cm)0.08851inch-pounds(lbf·in) foot-pounds(lbf·ft)1.3558Newton-meters(N·m)0.7376foot-pounds(lbf·ft) Pressure/Vacuum inchesofmercury(inHg)3.37685kiloPascals(kPa)0.29613inchesofmercury(inHg) poundspersquareinch(psi)6.895kiloPascals(kPa)0.14503poundspersquareinch(psi)

VehicleReceipt,Storage,andPre-DeliveryInformation

VehicleReceipt

Priortosigningforvehicledeliveryfromatransporter company,thedealerisresponsibleforcheckingfor transporter-relatedshortagesordamages,andnoting thesediscrepanciesonthetransporter’sdeliveryreceipt.

Thedealerisalsoresponsibleforensuringthatthe vehiclewasbuiltaccordingtotheTruckSalesOrder/ Invoice.

RefertoSection3oftheFreightlinerLLC Warranty Manual fordetails.

VehicleStorage

Theremaybetimeswhenavehicleisstoredforlong periodsbeforecustomerdelivery.Toprotectallvehiclesfromdeteriorationandweather,theymustbe properlymaintained.Adequateprotectionandstorageofnewvehiclesistheresponsibilityofthe dealer.

Claimsarisingfromlossanddamagetoimproperlystoredvehicleswillnotbereimbursed.

SeeSection3oftheFreightlinerLLC Warranty Manual forinstructionsonstorageofnewvehicles.

Pre-DeliveryInformation

Allpre-deliveryinspectionsandservicesmustbe performedatanauthorizedFreightlinerLLCfacility, assignedtofullyqualifiedservicepersonnelandrecordedonthe"NewVehiclePre-DeliveryInspection" form.

RefertoSection3oftheFreightlinerLLC Warranty Manual fordetails.

Itisrecommendedthepre-deliveryinspectionbeperformedwithin30daysofvehiclereceipt.

ThreadedFastenerTypes

Themajorityofthreadedfastenersusedthroughout thevehiclehaveU.S.customarythreads(diameter andpitcharemeasuredininches).See Fig.1.However,theengineandsomeitemsattachedtothecab usemetricfasteners(diameterandpitcharemeasuredinmillimeters).

Mostthreadedfastenersusedonthevehiclethatare 1/2-inchdiameterorlargerareplainhex-typefasteners(non-flanged); all metricfastenersarenonflanged.Specialhardenedflatwashersareused underthebolthead,andbetweenthepartbeingattachedandthehexnut,todistributetheload,andto preventlocalizedoverstressingoftheparts.The washersarecadmium-orzinc-plated,andhavea hardnessratingof38to45HRC.

Somefastenerssmallerthan1/2-inchdiameterare flangedfasteners,whichhaveintegralflangesthatfit againstthepartsbeingfastened.Theflangeseliminatetheneedforwashers.

NOTE:Thestandardfastenersusedtoassemblethevehicleframeandtoattachcomponentstothevehicleframearethreadedlockbolts(SpinHucks).Thesefastenersarecovered in Section31.00

FastenerGradesandClasses

FastenerswithU.S.customarythreadsaredivided intogradesestablishedbytheSocietyofAutomotive Engineers(S.A.E.)ortheInternationalFastenerInstitute(I.F.I.).Thefastenergradesindicatetherelative strengthofthefastener;thehigherthenumber(or letter),thestrongerthefastener.Bolt(capscrew) gradescanbeidentifiedbythenumberandpattern ofradiallinesforgedonthebolthead.See Fig.2. Hexnut(andlocknut)gradescanbeidentifiedbythe numberandpatternoflinesanddotsonvarioussurfacesofthenut.See Fig.3.Nearlyallofthebolts usedonthevehiclearegrades5,8,and8.2.Matchinggradesofhexnutsarealwaysused:grade5or gradeBhexnutsareusedwithgrade5bolts;grade 8,gradeC,orgradeG(flanged)hexnutsareused withgrade8or8.2bolts.

Fastenerswithmetricthreadsaredividedinto classesadoptedbytheAmericanNationalStandards Institute(ANSI).Thehighertheclassnumber,the strongerthefastener.Boltclassescanbeidentified

nut.See Fig.5.Class8hexnutsarealwaysused withclass8.8bolts;class10hexnutswithclass10.9 bolts.

stretchedslightly.Thisstretching(tensioning)results inapreloadthatreducesfatigueofthefasteners. Thetorquevaluesgiveninthetablesin Specifications,400 havebeencalculatedtoprovideenough clampingforceonthepartsbeingfastened,andthe correcttensioningofthebolttomaintaintheclampingforce.

10/19/93

2

Useofatorquewrenchtotightenfastenerswillhelp preventovertensioningthem.Overtensioningcauses permanentstretchingofthefasteners,whichcanresultinbreakageofthepartsorfasteners.

f310224a 3

1 4

NOTE:Grade2boltshavenogrademarking;grade2 boltsarerarelyusedbyFreightliner.Thesegrademarkingsareusedonplainhex-typeandflangedbolts (capscrews).Inadditiontothegrademarkings,the boltheadmustalsocarrythemanufacturer’strademarkoridentification.

1.Grade2 2.Grade5 3.Grade8 4.Grade8.2

FrameFasteners

Thestandardfastenersusedtoassemblethevehicle frameandtoattachmostcomponentstothevehicle framearethreadedlockbolts(SpinHucks).These fastenersarecoveredin Section31.00

Forsomeothercomponentsattachedtotheframe, grade8and8.2phosphate-andoil-coatedhexhead boltsandgradeCcadmium-platedandwax-coated prevailingtorquelocknutsareused.Theprevailing torquelocknutshavedistortedsectionsofthreadsto providetorqueretention.Forattachmentswhere clearanceisminimal,low-profilehexheadboltsand gradeCprevailingtorquelocknutsareused.See Fig.6

TighteningFasteners

Whenacapscrewistightenedtoitstorquevalueina threadedhole,oranutistightenedtoitstorque valueonabolt,theshankofthecapscreworboltis

Whentorquingafastener,typically80to90percent oftheturningforceisusedtoovercomefriction;only 10to20percentisusedtostretchthecapscrewor bolt.About40to50percentoftheturningforceis neededtoovercomethefrictionbetweentheundersideofthecapscrewheadornutandthewasher. Another30to40percentisneededtoovercomethe frictionbetweenthethreadsofthecapscrewandthe threadedhole,orthefrictionbetweenthethreadsof thenutandbolt.

Theamountoftorquerequiredtotightenafastener isreducedwhentheamountoffrictionisreduced.If afastenerisdry(unlubricated)andplain(unplated), theamountoffrictionishigh.Ifafasteneriswaxcoatedoroiled,orhasazincphosphatecoatingor cadmiumplating,theamountoffrictionisreduced. Eachofthesecoatingsandcombinationsofcoatings hasadifferenteffect.Usingzinc-platedhardened flatwashersunderthebolt(capscrew)headandnut reducestheamountoffriction.Dirtorotherforeign materialonthethreadsorclampingsurfacesofthe fastenerorclampedpartalsochangestheamountof friction.

Eventhougheachdifferentconditionaffectsthe amountoffriction,adifferenttorquevaluecannotbe givenforeachdifferentcondition.Toensuretheyare alwaystorquedaccurately,Freightlinerrecommends thatallfastenersbelubricatedwithoil(unlessspecificallyinstructedtoinstallthemdry),thentorquedto thevaluesforlubricated-andplated-threadfasteners.Whenlockingcompoundoranti-seizecompound isrecommendedforafastener,thecompoundacts asalubricant,andoilisnotneeded.

NOTE:Grade2(S.A.E.)andgradeA(I.F.I.)nutshavenoidentificationmarksornotches;theyarerarelyusedbyFreightliner.GradeB(I.F.I.)nutshavethreeidentificationmarksat120degrees,or6notches.GradeC(I.F.I.)nutshavethree identificationmarksat60degrees,or12notches.GradeG(I.F.I.)flangednutshavesixidentificationmarksasshown; eachidentificationmarkmaybeadot,line,pairofdotsorlines,oranyothersymbolatthemanufacturer’soption.

1.S.A.E.Grade2orI.F.I.GradeANut(strengthcompatiblewithgrade2bolt.)

2.S.A.E.Grade5Nut(strengthcompatiblewithgrade5bolt.)

3.I.F.I.GradeBNut(strengthcompatiblewithgrade5bolt.)

4.S.A.E.Grade8Nut(strengthcompatiblewithgrade8orgrade8.2bolt.)

5.I.F.I.GradeCNut(strengthcompatiblewithgrade8orgrade8.2bolt.)

6.I.F.I.GradeGNut(flangedlocknut;strengthcompatiblewithgrade8orgrade8.2bolt.)

1 2 3

f310006a 10/19/93

1.Grade8HexheadBolt

2.Grade8Low-ProfileHexheadBolt

3.GradeCPrevailingTorqueLocknut

Fig.6,FrameFastenerIdentification

GeneralInstructions

FastenerReplacement

Whenreplacingfasteners,useonlyidenticalbolts, washers,andnuts;theymustbethesamesize, strength,andfinishasoriginallyspecified.Seethe FreightlinerServicePartsCatalogforfastenerspecifications.

Whenreplacinggraded(ormetricclass)boltsand capscrews,useonlyfastenersthathavethemanufacturer’strademarkoridentificationonthebolthead; donotusesubstandardbolts.Inferior,counterfeitfastenersaredifficulttoidentify;buyyourfastenersfrom areputablesupplier.

FastenerSelectionand Installation

Whenusingnutswithbolts,useagrade(orclass)of nutthatmatchesthebolt.

Wheninstallingnon-flangedfasteners,usehardened steelflatwashersunderthebolt(capscrew)head, andunderthehexnutorlocknut.

Forbolts4inches(100mm)orlessinlength,make surethatatleast1-1/2threadsandnomorethan 5/8-inch(16-mm)boltlengthextendsthroughthenut afterithasbeentightened.Forboltslongerthan4 inches(100mm),allowaminimumof1-1/2threads andamaximumof3/4-inch(19-mm)boltlength.

Neverhammerorscrewboltsintoplace.Alignthe holesofthepartsbeingattached,sothatthenutand boltsurfacesareflushagainstthewashers,andthe washersareflushagainsttheparts.

Wheninstallingfastenersinaluminumorplasticparts withthreadedholes,startthefastenersbyhand,to ensurestraightstartingandtopreventdamaged threads.

Donotuselockwashers(splitortoothed)nexttoaluminumsurfaces.

Wheninstallingstudsthatdonothaveaninterferencefit,installthemwiththreadlockingcompound, asinstructedinthissubject.

Wheninstallingpartsthataremountedonstuds,use free-spinning(non-locking)nutsandhelical-spring (split)lockwashersorinternal-toothlockwashers.Do notuselocknuts,becausetheytendtoloosenthe studsduringremoval.Donotuseplainwashers(flatwashers).

Donotuselockwashersandflatwashersincombination(againsteachother);eachdefeatstheother’s purpose.

Usestainlesssteelfastenersagainstchromeplating, unpaintedaluminum,orstainlesssteel.

FastenerTightening

Beforeinstallingfasteners,cleanallfastener(and parts)threads,andallsurfacesbeingclamped.

Toensuretheyarealwaystorquedaccurately, Freightlinerrecommendsthat all fastenersbelubricatedwithoil(unlessspecificallyinstructedtoinstall themdry),thentorquedtothevaluesforlubricatedandplated-threadfasteners.Whenlockingcompound orantiseizecompoundisrecommendedforafastener,thecompoundactsasalubricant,andoilis notneeded.

Bringpartsandfastenersintocontact,withnogaps betweenthem,beforeusingatorquewrenchto tightenfastenerstotheirfinaltorquevalues. Tightenthenut,notthebolthead.Thiswillgivea truertorquereadingbyeliminatingboltbodyfriction.

Alwaysuseatorquewrenchtotightenfasteners,and useaslow,smooth,evenpullonthewrench.Donot overtorquefasteners;overtighteningcausespermanentstretchingofthefasteners,whichcanresultin breakageofthepartsorfasteners.

Ifspecifictorquevaluesarenotgivenforcountersunkbolts,usethetorquevalueforthecorrespondingsizeandgradeofregularbolt,asgivenin Specifications,400

Alwaysfollowthetorquesequenceortorqueinterval whenprovided,toensurethatclampingforcesare even,andpartsandfastenersarenotdistorted.

ThreadLockingCompound Application

Whentheuseofthreadlockingcompoundisrecommendedordesired,forstuds,capscrews,andbolts withathreaddiameterof1inch(25mm)orless,use Loctite® 271orPerma-Lok® HM-128.

Forthreaddiametersover1inch(25mm),useLoctite277.

GeneralInstructions

NOTE:Followthesafetyprecautionsgivenon thelockingcompoundcontainer.

1.Cleanthemaleandfemalethreadsofthefasteners,removingalldirt,oil,andotherforeignmaterial.Ifpartsarecontaminated,useStoddardsolventforcleaning;thenallowthefastenerstoair dryfor10minutes.Besuresolventiscompletely gonebeforeapplyingadhesive.

2.Transferasmallamountofthelockingcompoundfromthecontainertoapapercuporsmall non-metaldish.

3.Usingaplasticbrush(ametalbrushwillcontaminatethecompound),applyasmallamountof compoundtotheentirecircumferenceofthreeor fourofthemalethreadsthatwillbecoveredby thenutafterithasbeentightened.Besure enoughcompoundisappliedtofilltheinsideof thenutthreads,withaslightexcess.

4.Installandtorquethenut.Readjustmentofthe nutpositionisnotpossibleafterinstallationis complete,withoutdestroyingthelockingeffect.

NOTE:Todisassemblethefasteners,heatthe bondlineto400°F(200°C)beforeremovingthe nut.Everytimethefastenersaredisassembled, replacethem.Ifanypartsaredamagedbyoverheating,replacetheparts.

1/4–207(9)8(11)6(8)10(14)

1/4–288(11)9(12)7(9)12(16)

5/16–1815(20)16(22)13(18)21(28)

5/16–2416(22)17(23)14(19)23(31)

3/8–1626(35)28(38)23(31)37(50)

3/8–2430(41)32(43)25(34)42(57)

7/16–1442(57)45(61)35(47)60(81)

7/16–2047(64)50(68)40(54)66(89)

1/2–1364(87)68(92)55(75)91(123)

1/2–2072(98)77(104)65(88)102(138)

9/16–1292(125)98(133)80(108)130(176)

9/16–18103(140)110(149)90(122)146(198)

5/8–11128(173)136(184)110(149)180(244)

5/8–18145(197)154(209)130(176)204(277)

1/4–208(11)10(14)— 1/4–289(12)12(16)— 5/16–1815(20)22(30)22(30) 5/16–2417(23)25(34)— 3/8–1628(38)40(54)40(54) 3/8–2431(42)45(61)— 7/16–1445(61)65(88)65(88) 7/16–2050(68)70(95)— 1/2–1370(95)95(129)95(129) 1/2–2075(102)110(149)— 9/16–12100(136)140(190)140(190) 9/16–18110(149)155(210)— 5/8–11135(183)190(258)190(258) 5/8–18155(210)215(292)— 3/4–10240(325)340(461)340(461) 3/4–16270(366)380(515)— 7/8–9385(522)540(732)— 7/8–14425(576)600(813)— 1–8580(786)820(1112)— 1–12635(861)900(1220)— 1–14650(881)915(1241)—