Freightliner Business Class Trucks Maintenance Manual (EN)

Introduction Business Class Trucks Maintenance Manual Contents Group No. Group Title 00 . . . . . . . . . . . . . . . . . . . . . . General Information 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Intake 13 . . . . . . . . . . . . . . . . . . . . . . . . . Air Compressor 15 . . . . . . . . . . . . . . . . . . . . . Alternator and Starter 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 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doors 83 . . . . . . . . . . . . . . . . . Heater and Air Conditioner

Стр. 1

BUSINESS CLASS TRUCKS MAINTENANCE MANUAL Models: FL50 FL60 FL70 FL80 FL106 FL112 MB50 MB60 MB70 MB80 STI-266 (2/04P) Published by Freightliner LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.

Стр. 2

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. This maintenance manual explains when you should lubricate parts and what to look for when checking for wear or damage. For daily and weekly checks, refer to the vehicle driver’s manual. IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing.

Freightliner LLC reserves the right to discontinue models at any 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, Portland, OR 97208-3849, U.S.A. or refer to http://www.Freightliner.com and http://www.FreightlinerTrucks.com. 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. © 1995-2004 Freightliner 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 Freightliner LLC. Freightliner LLC Service Systems and Documentation (POC-SSD) P.O. Box 3849 Portland, OR 97208–3849

Стр. 3

Introduction Descriptions of Service Publications Freightliner LLC distributes the following major service publications. Workshop/Service Manual Workshop/service manuals contain service and repair information for all vehicle systems and components, except for major components such as engines, trans- missions, and rear axles. Each workshop/service manual section is divided into subjects that can include general information, principles of operation, removal, disassembly, assembly, installation, specifications, and troubleshooting. 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, specifica- tions, procedures for adjustments and for checking the tightness of fasteners. 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 inspection and daily mainte- nance of vehicle components. Driver’s/operator’s manuals do not contain de- tailed repair or service information.

Parts Technical Manual Freightliner LLC publishes this manual to aid in 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 provide the latest service tips, field repairs, product improve- ments, and related information. Some service bulletins are updates to informa- tion 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. Recall Bulletins These bulletins pertain to special situations that involve service work or replace- ment of parts in connection with a recall notice. Recall bulletins pertain to mat- ters of vehicle safety. All bulletins are distributed to dealers; customers receive notices that apply to their vehicles. Field Service Modifications This publication is concerned with non-safety-related service work or replace- ment of parts.

All field service modifications are distributed to dealers; custom- ers receive notices that apply to their vehicles. Business Class Trucks Maintenance Manual, December 2002

Стр. 4