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freightliner C SB FS65 Maintenance Manual

freightliner C SB FS65 Maintenance Manual

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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.

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  • 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 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.FreightlinerChassis.com. Environmental Concerns and Recommendations Whenever you see instructions in this manual to discard materials, you should attempt to reclaim and recycle them.
  • Page 3 Operator’s manuals do not contain detailed repair or service information. Parts Technical Manual Freightliner LLC publishes this manuals 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.
  • Page 4 Introduction Page Description For a page example of the printed manual, see Fig. Suspension 32−01 Suspension Inspecting, REAR SUSPENSION Freightliner Spring FRONT AND REAR SUSPENSION SPRING ASSEMBLIES 32−01 U−Bolt Torque Checking, Freightliner Spring Suspension REAR SUSPENSION SPRING BRACKETS 32−02 Suspension Lubricating,...
  • Page 5 Introduction Maintenance Manual Contents Group No. Group Title 00 ..... . General Information 01 ....... . Engine 09 .

  • Page 6: Table Of Contents

    General Information Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Determining Scheduled Maintenance Intervals..........00–01 Initial Maintenance (IM) Operations.

  • Page 7: Determining Scheduled Maintenance Intervals

    General Information Determining Scheduled Maintenance Intervals: 00–01 Description nance Interval Operations table. Use the mainte- nance operation reference numbers to find instructions in the manual for completion of each op- Category I (urban transport) applies to vehicles that eration. annually travel up to 20,000 miles (32 000 kilome- ters).
  • Page 8 General Information Vehicle Maintenance Schedule Table: 00–02 Vehicle Maintenance Schedule Table Maintenance Intervals Description Maintenance Operation Set Frequency Miles Months Initial Maintenance (IM) first 2500 4000 CATEGORY I Maintenance 1 (M1) every 2500 4000 (Urban Transport) vehicles that annually travel up to Maintenance 2 (M2) every 10,000...
  • Page 9 General Information Maintenance Interval Table: 00–03 Maintenance Interval Table Category I Category II Maint. Oper. Maint. No. miles x 100 km x 100 months miles x 100 km x 100 months IM + M1 10th 11th 12th 00/3 School Bus Chassis Maintenance Manual, October 2005...
  • Page 10 Clutch Release Bearing Lubricating 25–02 Clutch Release Cross-Shaft Lubricating 26–01 Eaton/Fuller Transmission Oil Level Checking 26–05 Allison Transmission Fluid Level Checking 32–02 Suspension Lubricating, Freightliner Spring 33–01 Knuckle Pin Lubricating 33–02 Tie-Rod End Lubricating 33–05 Oil-Filled Hubs Oil Level Checking 35–01 Axle Lubricant Level Checking 41–01...
  • Page 11 Suspension Lubricating, Freightliner Spring • • • • 32–03 U-Bolt Torque Checking, Freightliner Spring • • 32–04 Spring Bracket Fastener Torque Checking, Freightliner Spring (Rear) • • 32–05 Fastener Torque Checking, Freightliner AirLiner • • 32–06 Component Clearance Checking, Freightliner AirLiner •...
  • Page 12 General Information Maintenance Operation Sets: 00–05 REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 Maintenance Operation Reference Number and Maintenance Operation 33–04 All-Axle Alignment Checking • 33–05 Oil-Filled Hubs Oil Level Checking • • • 33–06 Oil-Filled Hubs Oil Changing •...
  • Page 13 General Information Maintenance Operation Sets: 00–05 REQUIRED MAINTENANCE OPERATION SET IM M1 M2 M3 Maintenance Operation Reference Number and Maintenance Operation 54–02 Electrical Wiring Checking • • 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, it will be necessary to perform preventative maintenance as instructed in Maintenance Operation 01–03.

  • Page 14: Initial Maintenance (Im) Operations

    Eaton/Fuller Transmission Oil Changing and Magnetic Plug Cleaning 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 Torque Checking, Freightliner AirLiner 32–06 Component Clearance Checking, Freightliner AirLiner 32–08 U-Bolt Torque Checking, Freightliner AirLiner 33–04...

  • Page 15: Lubrication And Fluid Level Check

    • Clutch Release Bearing Lubricating • Clutch Release Cross-Shaft Lubricating • Eaton/Fuller Transmission Oil Level Checking • Allison Transmission Fluid Level Checking • Suspension Lubricating, Freightliner Spring • Knuckle Pin Lubricating • Tie-Rod End Lubricating • Axle Lubricant Level Checking •...

  • Page 16: M2 Maintenance Interval Operations

    General Information M2 Maintenance Interval Operations: 00–08 This M2 Maintenance Interval Operations table lists matching those in the text of this manual, that can be all maintenance operations that are to be performed used to find detailed instructions for the operations to at the M2 maintenance interval.

  • Page 17: M3 Maintenance Interval Operations

    Allison Transmission 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 Torque Checking, Freightliner AirLiner 32–06 Component Clearance Checking, Freightliner AirLiner 32–07 Component Inspecting and Operation Checking, Freightliner AirLiner 32–08...

  • Page 18: Noise Emission Controls Maintenance

    FCCC parts in performance and durability. Freightliner Noise Emissions Warranty See the vehicle owner’s warranty information book for warranty information concerning noise emission controls.
  • Page 19 General Information Verification of Inspections Log: 00–11 Verification of Inspections Log Verification of Inspections Log Date Mileage Repair Description Cost Repair Facility Group 01 — Engine Support Fasteners Group 20 — Engine Cooling Fan Drive Group 49 — Exhaust System 00/13 School Bus Chassis Maintenance Manual, October 2005...
  • Page 20 General Information Metric/U.S. Customary Conversion Table: 00–12 When You Know U.S. Multiply When You Multiply To Get Metric To Get U.S. Customary Customary Know Metric Length inches (in) 25.4 millimeters (mm) 0.03937 inches (in) inches (in) 2.54 centimeters (cm) 0.3937 inches (in) feet (ft) 0.3048...

  • Page 21: Torque Specifications Tables

    652 (884) — — Freightliner recommends that all plated and unplated fasteners be coated with oil before installation. † Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed). Table 3, Torque Values for U.S. Customary Thread Fasteners With Lubricated or Plated Threads...
  • Page 22 1–12 524 (710) 1–14 537 (728) Freightliner recommends that all plated and unplated fasteners be coated with oil before installation. Table 4, Torque Values for Grade 8 Regular Hex Zinc-Yellow Plated Capscrews and Cadmium- and Wax-Coated Prevailing Torque Locknuts 00/16...
  • Page 23 Male and female threads (bolt and nut) must both be unlubricated and unplated; if either is plated or lubricated, use Table 3. Freightliner recommends that all plated and unplated fasteners be coated with oil before installation. Table 5, Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated) Plain (Unplated) Threads...
  • Page 24 M30 x 2 792 (1074) 1096 (1486) Freightliner recommends that all plated and unplated fasteners be coated with oil before installation. † Use these torque values if either the bolt or nut is lubricated or plated (zinc-phosphate conversion-coated, cadmium-plated, or waxed).
  • Page 25 Engine Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Engine Drive Belt Inspecting............01–02 Engine-Support Fasteners Checking (Noise Emission Control).
  • Page 26 Engine 01–01 Engine-Support Worn or loose drive belts may cause premature bearing failure or engine overheating. Excessive ten- Fasteners Checking sion, or too little tension on the belt may result in ex- cessive and premature belt wear. Poly-V belts, or (Noise Emission serpentine belts, are retained by a belt tensioner that Control)
  • Page 27 Engine NOTE: If it is difficult to distinguish the location 01–03 Pacbrake Inspecting and of a supposed bearing noise, obtain a stetho- Maintenance scope and place it on the component being checked, not the pulley, to isolate the area from With frequent use, the Pacbrake Exhaust Brake will outside interference.
  • Page 28 Engine 03/20/2003 f012035 1. Air Cylinder 2. Pacbrake Fig. 3, Pacbrake Exhaust Brake Lube Point Locations NOTE: Operation of the Pacbrake could be af- fected by starting the engine and idling for short periods of time. During a cold engine start-up, moisture occurs in the engine and the exhaust system that creates a corrosion hazard.
  • Page 29 Air Intake Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Element Inspecting............09–01 Air Cleaner Element Replacing .
  • Page 30 Air Intake 09–01 Air Cleaner Element Inspecting Inspect the air cleaner element for holes or tears at the recommended interval. If the air cleaner element is damaged, replace it. See Group 09 of the School Bus Chassis Workshop Manual for removal and in- stallation instructions.
  • Page 31 Alternators and Starters Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Checking..........15–01 School Bus Chassis Maintenance Manual, January 1999...
  • Page 32 Alternators and Starters 15–01 Alternator, Battery, and Check that foreign objects, such as stones, bolts, and nuts are removed from Starter Checking the battery box. After cleaning, connect the cables to the 1. Check the tightness of the alternator bracket fas- batteries, and tighten them to the torque teners and alternator mounting fasteners;...
  • Page 33 Engine Cooling/Radiator Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Eaton Viscous Fan Drive Checking (Noise Emission Radiator Cap Checking............. . 20–01 Radiator Pressure Flushing and Coolant Changing .
  • Page 34 Engine Cooling/Radiator 20–01 Radiator Cap Checking Apply no more than 20 psi (138 kPa) air pressure intermittently to help dislodge sediment buildup in the core. WARNING CAUTION Drain the coolant only when the coolant and en- gine are cool. Draining it when these are hot could When flushing the radiator, do not apply more cause severe personal injury due to scalding.
  • Page 35 Van Waters and Rogers Diesel Antifreeze No. 6038 Ltd. (Canada) Freightliner-approved antifreeze must meet one of the following condi- 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 Clutch Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch Release Bearing Lubricating........... . . 25–01 Clutch Release Cross-Shaft Lubricating.
  • Page 37 Clutch 25–01 Clutch Release Bearing failure. Do not use chassis grease or multipurpose lubricants. Lubricating 4. Remove the chocks. 1. Park the vehicle on a level surface. Shut down 25–02 Clutch Release Cross- the engine, set the parking brake, and chock the tires.
  • Page 38 Transmission Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Allison Transmission Fluid Level Checking ..........26–05 Allison Transmission Fluid and Filter Changing .
  • Page 39 Transmission 26–01 Eaton/Fuller case through the main shaft openings. Oil over- flow may also drain onto the clutch or clutch Transmission Oil Level brake, causing additional problems. Checking IMPORTANT: Do not mix types of oil, because of possible incompatibility. Do not use oil addi- 1.
  • Page 40 05/27/93 f260007a Lubricant Capacities, Eaton/Fuller Transmissions Fig. 2, Transmission Breather (typical) Refill Capacity Model Quarts (liters) Freightliner-chassis vehicles. Allison transmis- FS–4205A/B 6.25 (6.0) sions are received partially filled with TranSynd synthetic automatic transmission fluid (ATF). FS–5205A/B 5.25 (5.0) They are then topped-off with a non-TranSynd FS–6305A/B...
  • Page 41 Transmission 3. Clean the area around the drain plug. While the 7. Remove, clean and install the governor feed line transmission fluid is warm, remove the drain plug screen, located in the control valve body. See and drain the fluid. Disconnect the fill tube from Fig.
  • Page 42 Transmission f260132a 10/05/94 1. Fluid Intake Tube 7. First/Reverse Clutch Feed Tube 2. Detent Spring 8. Governor Screen (in control valve body) 3. Detent-Spring 1-3/4" Bolt 9. Governor Pressure Tube 4. Filter Spacer 10. Governor Feed Tube 5. 2-1/4" Bolt (16 qty.) 6.
  • Page 43 Transmission Lubricant Capacities, Allison AT/MT/MD Series Transmissions Refill Capacity Model Quarts (liters) AT–542 16.0 (15.1) AT–545 21.0 (19.9) MT–643 19.0 (18.0) MD–3060P 17.5 (16.5) MD–3060PR Quantities listed are approximate. Add the recommended amount of fluid as listed under refill capacity, then perform a "hot check" and add fluid as needed.
  • Page 44 Transmission 2000/2400 Series 1. Park the vehicle on a level surface and set the parking brake. NOTE: For 2000/2400 series transmissions with 2. Operate the vehicle until the transmission non-TranSynd ATF, change oil and filters at reaches normal operating temperature: 160 to 50,000 miles (80 000 km) or 24 months, which- 200°F (71 to 93°C).
  • Page 45 Transmission 3. Wipe the dipstick clean and check the fluid level. Lubricant Capacities, Allison 2000/2400 Series A safe operating level is any level within the HOT Transmissions RUN (upper) band on the dipstick. See Fig. Refill Capacity Model quarts (liters) 4.
  • Page 46 Transmission COLD CHECK IN NEUTRAL @ IDLE USE DEXRON R OIL FILL 08/23/96 f011103 Fig. 7, Dipstick Markings 26/8 School Bus Chassis Maintenance Manual, March 2003...
  • Page 47 Frame Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Frame Fastener Torque Checking ........... . . 31–01 School Bus Chassis Maintenance Manual, March 2003...
  • Page 48 Frame 31–01 Frame Fastener Torque Checking Because of "bedding in" (or seating), the frame fas- teners must be torqued at the recommended inter- vals. These intervals apply to new vehicles, and to frame fasteners that have been removed and in- stalled again.
  • Page 49 Component Clearance Checking, Freightliner AirLiner ........32–06 Component Inspecting and Operation Checking, Freightliner AirLiner ......32–07 Control Rod Checking, Freightliner AirLiner .
  • Page 50 Suspension 32–01 Suspension Inspecting, 32–02 Suspension Lubricating, Freightliner Spring Freightliner Spring Front and Rear Suspension Spring Front Suspension Assemblies Wipe all dirt from the grease fittings at the forward spring pin and the spring shackle pins; then apply Inspect the front and rear suspension spring assem-...

  • Page 51: Component Clearance Checking, Freightliner Airliner

    32–04 Spring Bracket Fastener Locknuts Torque Checking, Lateral Control Rod Nut 5/8–11 136 (185) Freightliner Spring Table 1, Torque Values for Freightliner AirLiner Suspensions (Rear) 32–06 Component Clearance CAUTION Checking, Freightliner AirLiner Continued use with loose fasteners could result in bracket and frame damage.

  • Page 52: Radius Rod Bushing Checking, Hendrickson

    Suspension fully inflated, see Group 32 of the School Bus 32–09 Shock Absorber Chassis Workshop Manual . Checking, Freightliner 3. Inspect each air spring for wear at the connec- Spring tion to the pedestal. Replace any worn air springs; for instructions, see Group 32 of the School Bus Chassis Workshop Manual .
  • Page 53 firmly clamp the rubber bushing inner metal tubes to the beam hanger legs. 32–11 Control Rod Checking, Freightliner AirLiner WARNING Insufficient beam end fastener torque could cause 1. Without disconnecting the control rods, attempt the beam to separate from the axle. This will...
  • Page 54 Suspension 05/27/93 f320110a NOTE: Do not use the three-piece adapter without the intermediate tube. 1. Nut 4. Inner Metal of Beam 2. Adapter End Bushing 3. Intermediate Tube 5. Beam Hanger Fig. 3, Three-Piece Adapter-Type Beam End Connection 32/5 School Bus Chassis Maintenance Manual, March 2003...
  • Page 55 Front Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Checking ............33–04 Knuckle Pin Lubricating .
  • Page 56 Front Axle 33–01 Knuckle Pin Lubricating Hold a pressure gun on each fitting until fresh grease appears. See Fig. 1 Fig. 2. This will ensure that all of the old contaminated grease has been forced out. It is not necessary to exceed 4000 psi (27 560 kPa).
  • Page 57 Front Axle 33–03 Tie-Rod End Inspecting into the cross-tube split for adequate clamping. See Fig. 4. Replace the parts if this cannot be done. For instructions, see IMPORTANT: DOT roadside tie-rod assembly the axle manufacturer’s service manual. replacement criteria specifies that if tie-rod end- Check the tie-rod end nut and clamp nut play is 1/8 inch (3 mm) or greater, measured on torques.
  • Page 58 Front Axle 33–05 Oil-Filled Hubs Oil Level Checking WARNING Be careful 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 lead to personal injury and property damage.
  • Page 59 Front Axle 4. Install the drain plugs and tighten securely. 5. Add approximately 1 to 1-1/2 pints (0.5 to 0.7 L) of oil (80/90 hypoid gear oil) to each hub. 6. Rotate the wheels, allow the oil to settle, and check the levels.
  • Page 60 Rear Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Axle Breather Checking ............. 35–03 Axle Lubricant Changing and Magnetic Plug Cleaning .
  • Page 61 Rear Axle 35–01 Axle Lubricant Level 3. On ABP axles, install the fill hole plug, and tighten it securely. Checking 4. On Meritor axles, install the fill hole plug, and tighten 35 lbf·ft (47 N·m). CAUTION ABP Drive Axle Lubricant Capacities Failure to keep the rear axle filled to the proper Differential/Hubs Capacity: quarts (liters)
  • Page 62 Rear Axle 35–02 Axle Lubricant Changing IMPORTANT: The entire axle capacity (axle completely dry) is 7.4 qts. (7 L). Each hub con- and Magnetic Plug tains 0.80 qt. (0.75 L) of lubricant. To protect the Cleaning outer bearings from oil starvation, jack up (ar- ticulate) each side of the axle a minimum of 4 inches (10 cm) to ensure that oil flows to the A regular schedule for changing the axle lubricant in...
  • Page 63 Rear Axle Axle Filling 1. With the vehicle on a level surface, fill the axle housing to the bottom of the oil fill hole (in the carrier or housing) with lubricant. See Table 2 axle lubricant capacities and see Table 3 for ap- proved axle lubricants.
  • Page 64 Wheels and Tires Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Wheel Nut and Rim Nut Checking............40–01 School Bus Chassis Maintenance Manual, October 1996...
  • Page 65 Wheels and Tires 40–01 Wheel Nut and Rim Nut Fig. 1, then tighten all of the outer wheel nuts in the same sequence. Checking CAUTION IMPORTANT: In addition to the maintenance interval in this manual, check the wheel nut Too little wheel nut torque can cause wheel shimmy, resulting in wheel damage, stud break- torque the first 50 to 100 miles (80 to 160 km) age, and extreme tire tread wear.
  • Page 66 Wheels and Tires 05/27/93 f400057 A. 8-Stud Disc Wheel C. 6-Spoke Wheel B. 10-Stud Disc Wheel D. 5-Spoke Wheel Fig. 1, Wheel Nut and Rim Nut Tightening 05/16/94 f400033a Fig. 2, Non-Corrugated Channel Spacer f400032a 10/05/94 Fig. 3, Corrugated Channel Spacer 40/2 School Bus Chassis Maintenance Manual, October 1996...
  • Page 67 Driveline Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspecting and Lubricating ........... . 41–01 School Bus Chassis Maintenance Manual, April 1998...
  • Page 68 Driveline • Spicer 1710 and 1760: 125 to 135 lbf·ft 41–01 Driveline Inspecting and (170 to 183 N·m) Lubricating CAUTION Inspecting Do not overtighten the yoke-strap capscrews, due Before lubricating the driveline U-joints and slip- to the extreme load occurring at high-speed rota- joints, make the following checks: tion.
  • Page 69 Driveline 2. Check each of the output and input end yokes (123 N·m). Replace the midship bearing assem- for cracks and looseness. See Fig. 1, Refs. 2 bly if the rubber cushion is worn or oil-soaked. and 11. Replace cracked yokes. If any end yoke 5.
  • Page 70 Driveline U-Joint Lubricating 1. Wipe all old grease and dirt from each U-joint grease fitting. See Fig. 4, Ref. 8. 2. Use a hand-type grease gun, or a high-pressure gun with a low-pressure adapter, to lubricate the U-joints. NOTE: If a low-pressure adapter is not used with the high-pressure gun, the U-joints may not f410110b 06/13/96...
  • Page 71 Driveline screw. If the bearing will not take grease, re- place the U-joint assembly; see Group 41 of the School Bus Chassis Workshop Manual . 4. Check the old grease. If it appears rusty, gritty, or burned, replace the U-joint assembly. See Group 41 of the School Bus Chassis Workshop Manual .
  • Page 72 Brakes Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number ABS Tone Rings Cleaning............42–13 Air Dryer Checking, Bendix AD–9 .

  • Page 73: Air Dryer Checking, Bendix Ad-9

    Brakes 42–01 Air Dryer Checking, amounts may mean that the desiccant needs to be replaced. Check the mounting and connecting Bendix AD–9 lines. 2. Tighten the fasteners that attach the air dryer to During cold-weather operation, check the operation the vehicle. Use the following torque values. of the end cover heater and thermostat assembly.
  • Page 74 Brakes f420012a 10/20/93 1. Brake Chamber 2. Clevis f420180a 09/27/94 3. Actuator Rod NOTE: For a drum brake, A minus B must equal 5/8" to 4. Boot 3/4" (16 to 19 mm). 5. Pressure-Relief Capscrew, Gasket, Pawl Spring, A. With the brakes applied, measure this distance. and Pawl B.
  • Page 75 Brakes Build air pressure to 100 psi (690 kPa). Shut down the engine. Fully apply the brakes, then measure the distance from the bottom of the brake chamber to the center of the large clevis pin. See Fig. Ref. B. The difference between the mea- surements is the brake chamber stroke.

  • Page 76: Bendix Hydro-Max Power Booster Checking

    Brakes For instructions, see Group 42 of the To minimize the possibility of creating airborne brake School Bus Chassis Workshop Manual . lining dust, clean the dust from the brake rotor, brake caliper, and brake assembly, using an industrial-type If removed, install the pawl, pawl spring, vacuum cleaner equipped with a high-efficiency filter gasket, and pressure-relief capscrew.
  • Page 77 Brakes 42–11 Relay Valve Checking, Midland Chock the tires. Start the engine and run it long enough to pressurize the air system to at least 80 psi (550 kPa), then shut down the engine. Repeat as necessary to maintain 80 psi (550 kPa) pressure during this check.

  • Page 78: Brake Caliper Slide Pin Lubricating, Bosch Brakes

    Brakes vehicle to ensure proper ABS functioning. Thor- CAUTION oughly clean the wheel/ABS sensor/tone ring areas, removing all corrosive materials. The minimum bend radius is the bend that a hose will withstand without stressing or kinking. The 42–14 Brake Caliper Slide Pin hose should be straight for at least one hose di- ameter before starting to bend.

  • Page 79: Brake Caliper Slide Rail Lubricating, Bosch Brakes

    Brakes 42–15 Brake Caliper Slide Rail Lubricating, Bosch Brakes 1. Raise the vehicle off of the ground and securely support it with jack stands. 2. Remove the wheel from each wheel end. For instructions, see Group 40 of the School Bus Chassis Workshop Manual .
  • Page 80 Brakes 13. Apply two level teaspoons of Aeroshell Grade 5 (ES–1246) grease on each side of the assembly. Apply it evenly along the full length of the V-groove and anchor plate rail, and apply one level teaspoon evenly on both sides of the key and spring.
  • Page 81 Steering Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Drag Link Lubricating ............. . . 46–02 Power Steering Reservoir Fluid Level Checking .
  • Page 82 Steering 46–01 Steering Driveline 2. Using a pressure gun, apply multipurpose chas- sis grease at the grease fittings until old grease Lubricating is forced out of the socket. NOTE: Use multipurpose chassis grease NLGI Wipe the grease fittings clean. See Fig.
  • Page 83 Steering 10/05/94 f460926 10/05/94 f460514a 1. Grease Fitting 2. Drag Link (pitman arm end shown) 1. Power Steering Fluid Reservoir 2. Steering Gear Fig. 2, Steering Drag Link Lubricating Fig. 3, Power Steering Reservoir 46–03 Power Steering 46–04 Power Steering Reservoir Fluid Level Reservoir Fluid and Checking...
  • Page 84 Steering 7. Fill the reservoir with approved power steering 2. Using a hand-type grease gun, apply multipur- fluid. See Table pose chassis grease until the grease starts com- ing out of the sector shaft dirt and water seal. WARNING Fill only with approved clean fluid. Do not mix fluid types.
  • Page 85 Fuel Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Inline Fuel Strainer Replacing, Cummins ISB02 and MBE900 Engines......47–01 School Bus Chassis Maintenance Manual, May 2005...
  • Page 86 Fuel 47–01 Inline Fuel Strainer Replacing, Cummins ISB02 and MBE900 Engines NOTE: Vehicles with a Cummins ISB02 or MBE900 engine have an inline fuel strainer. The inline fuel strainer is located on the left-hand frame rail under the cowl area. 1.
  • Page 87 Exhaust Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Exhaust System Inspecting (Noise Emission Controls)........49–01 School Bus Chassis Maintenance Manual, October 1996...
  • Page 88 Exhaust 49–01 Exhaust System Inspecting (Noise Emission Controls) NOTE: In addition to the maintenance interval in this manual, inspect the exhaust system if the vehicle has a noticeable increase in noise level at any time. Replace parts that show leakage, wear, or damage.
  • Page 89 Electrical, Instruments, and Controls Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Electrical Wiring Checking ............54–02 Ground Cables Checking and Cleaning.
  • Page 90 Electrical, Instruments, and Controls 54–01 Ground Cables 3. Check the turn-signal flasher. Make sure that the two male and female connectors are firmly con- Checking and Cleaning nected. Check that the flasher fuse is firmly seated in its holder. Check that the ground cables are clean, undamaged, 4.
  • Page 91 Electrical, Instruments, and Controls 3. Apply dielectric grease liberally to all battery ter- minal pads. Connect the cables to the 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...

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