WALK-IN VAN CHASSIS - fccccommercial.com

1 Maintenance ManualSTI-471-6A24-01451-000 WALK-IN VANCHASSISWALK-IN VAN CHASSIS MAINTENANCE MANUALM odels: MT45MT45 GMT45 HEVMT55MT55 GMT55 HEVMT55 HHVSTI-471-6 (11/15)Published byDaimler Trucks North America LLC4747 N. Channel , OR 97217 Printed in maintenance provides a key element for safe operation of your vehicle. A propermaintenance program also helps to minimize downtime and to safeguard warranties. This mainte-nance manual provides information necessary for years of safe, reliable, and cost-efficient : The maintenance operations in this manual arenot all-inclusive. Also refer toother component and body manufacturers instructions for specific inspection and mainte-nance daily pretrip inspection and maintenance as outlined in the vehicle operator s the operations in this maintenance manual at scheduled intervals based upon distancetraveled or months of operation.

2 Your authorized servicing dealer has the qualified technicians andequipment to perform this maintenance for you. Your dealership can also set up a scheduledmaintenance program tailored specifically to your needs. Optionally, your dealership can assist you inlearning how to perform the maintenance procedures in this : Descriptions and specifications in this manual were in effect at the time ofprinting. Freightliner Custom CHASSIS Corporation (FCCC) reserves the right to discontinuemodels and to change specifications or design at any time without notice and withoutincurring obligation. Descriptions and specifications contained in this publication provide nowarranty, expressed or implied, and are subject to revision and editions without moreinformation, or contact Daimler Trucks North America LLC at the address Concerns and RecommendationsWhenever you see instructions in this manual to discard materials, you should attempt to reclaim andrecycle them.

3 To preserve our environment, follow appropriate environmental rules and regulationswhen disposing of : Parts Replacement ConsiderationsDo 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 haveundetected structural damage. 1997 2016 Daimler Trucks North America LLCAll 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 Daimler Trucks NorthAmerica LLC. Daimler Trucks North America LLC is a Daimler Trucks North America LLCS ervice Systems and Documentation (CVI-SSD) Box 3849 Portland, OR 97208 3849 Daimler Trucks North America LLC distributes the following major service publications in paper and electronic(via ServicePro ) manuals contain service and repair information for all vehiclesystems and components, except for major components such as engines, trans-missions, and rear axles.

4 Each workshop/service manual section is divided intosubjects that can include general information, principles of operation, removal,disassembly, assembly, installation, and ManualMaintenance manuals contain routine maintenance procedures and intervals forvehicle components and systems. They have information such as lubricationprocedures and tables, fluid replacement procedures, fluid capacities, specifica-tions, and procedures for adjustments and for checking the tightness of fasten-ers. Maintenance manuals do not contain detailed repair or service s/Operator sManualDriver s/operator s manuals contain information needed to enhance the driver sunderstanding of how to operate and care for the vehicle and its manual contains a chapter that covers pre-trip and post-trip inspections,and daily, weekly, and monthly maintenance of vehicle s/operator s manuals do not contain detailed repair or service BulletinsService bulletins provide the latest service tips, field repairs, product improve-ments, and related information.

5 Some service bulletins are updates to informa-tion in the workshop/service manual. These bulletins take precedence overworkshop/service manual information, until the latter is updated; at that time, thebulletin is usually canceled. The service bulletins manual is available only todealers. When doing service work on a vehicle system or part, check for a validservice bulletin for the latest information on the : Before using a particular service bulletin, check the currentservice bulletin validity list to be sure the bulletin is Technical BulletinsParts technical bulletins provide information on parts. These bulletins containlists of parts and BOMs needed to do replacement and upgrade repair, service, and parts documentation can be accessed using the following applications on provides Web-based access to the most up-to-date versions of thepublications listed above. In addition, the Service Solutions feature provides di-agnostic assistance with Symptoms Search, by connecting to a large knowledgebase gathered from technicians and service personnel.

6 Search results for bothdocuments and service solutions can be narrowed by initially entering vehicleidentification is an electronic parts catalog system, showing the specified vehicle sbuild makes Freightliner Custom CHASSIS Corporation, Freightliner, Ster-ling, Western Star, and Thomas Built Buses products wiring drawings and float-ing pin lists available online for viewing and printing. EZWiring can also be ac-cessed from within of Service PublicationsWalk-In Van CHASSIS Maintenance Manual, January 2011I 1 Warranty-related service information available on the website includes the CampaignsRecall campaigns cover situations that involve service work or replacement ofparts in connection with a recall notice. These campaigns pertain to matters ofvehicle safety. All recall campaigns are distributed to dealers; customers receivenotices that apply to their Service CampaignsField service campaigns are concerned with non-safety-related service work orreplacement of parts.

7 All field service campaigns are distributed to dealers; cus-tomers receive notices that apply to their of Service PublicationsI 2 WALK-IN Van CHASSIS Maintenance Manual, January 2011 For a page example of a Maintenance Manual page, seeFig. Maintenance Operation Number consists of the Group Number followed by the Sequence NumberB. Group TitleC. Group NumberD. Release DateE. Group Number/Page NumberFig. 1, Example of a Maintenance Manual PageIntroductionPage DescriptionWalk-In Van CHASSIS Maintenance Manual, January 2011I 3 Group AirIntake15 ..Alternators and Transmission31 ..Frame and Frame Components32 ..Suspension33 ..Front Axle35 ..Rear and Tires41 .. , Instruments, and ControlsIntroductionMaintenance Manual ContentsI 4 WALK-IN Van CHASSIS Maintenance Manual, January 2011 Title of Maintenance Operation (MOP)MOP NumberGeneral Maintenance Schedule 01 Noise Emission Controls 03 Vehicle Maintenance Schedule 02 Verification of Inspections 04 General Information00 Index, AlphabeticalWalk-In Van CHASSIS Maintenance Manual, November 2015 General Maintenance ScheduleInformationPerforming regular maintenance on your vehicle willhelp ensure that your vehicle delivers safe reliableservice and optimum performance for years to to follow a regular maintenance program canresult in inefficient operation and unscheduled the vehicle reaches the distance given for amaintenance interval, see the Vehicle MaintenanceSchedule Table for a list of the maintenance opera-tions to be performed at that maintenance the maintenance operation reference numbers tofind detailed instructions in the manual for each.

8 Maintenance instructions in this manualare based on average vehicle use and normaloperating conditions. Unusual vehicle operatingconditions may require service at more specific engine maintenance information, see theCummins or Mercedes-Benz Operation and Mainte-nance : Maintenance operations appearingin italics in the following table are for noiseemission control components. Numbers in thetable are reference numbers matching those inthe text of this Information00 General Maintenance Schedule Information: 00 01 WALK-IN Van CHASSIS Maintenance Manual, November 201500/1 Vehicle Maintenance ScheduleMaintenance Operation Numberand DescriptionMaintenance Interval in Miles x 1000510152025 30354045505560 65 70 75 80 85 90 95 100 Maintenance Interval in Kilometers x 10008 16 24 32 40 48 56 64 72 80 88 96 104 112 120 128 136 144 152 16001 01 Engine-Support FastenersChecking 01 02 Engine Drive Belt Inspecting 01 03 Engine Oil Checking andChanging, Gasoline EnginesReplace the engine oil every 3000 miles (4827 km).

9 01 04 spark plugs and Wires Inspectingand Replacing, Gasoline EnginesInspect the spark plugs and wires every 12 months. Replace spark plugs andwires every 100,000 miles (160 900 km).01 05 Evaporative Control SystemInspecting, Gasoline Engines 09 01 Air Cleaner Element Inspectingand ReplacingInspect the air filter every six months. Replace the air filter every 12 months, orwhen filter restriction reaches 25 inH20 for diesel engines OR when the airrestriction indicator is completely red for gasoline engines (if equipped with anair restriction indicator).09 02 Air Cleaner Filter Minder GaugeChecking, Diesel Engines 09 03 Air Intake System Inspecting 09 04 Charge Air Cooler Checking 13 01 Air Compressor Inspection 15 01 Alternator, Battery, and StarterConnections Check 20 01 Coolant Replacement 20 02 Cooling Fan Inspection (NoiseEmission Control)

10 20 03 Coolant Heater Check, WebastoInspect the coolant heater every 12 01 Transmission Breather Checking 26 02 Allison Transmission Fluid LevelCheckingFor fluid level check intervals, see the applicable Allison Operator s 03 Allison Transmission Fluid andFilter ChangingFor oil and filter change intervals, see the applicable Allison Operator s 04 Hydraulic Hybrid MaintenanceOperationsContact Parker Hannifin at 1-866-858-5600 for instructions concerning allhydraulic hybrid maintenance items listed under this 01 Interlube CHASSIS LubricationSystem Inspecting 32 01 Suspension Inspecting 32 02 Freightliner Suspension Inspecting 32 03 Component Inspecting andOperation Checking, Freightliner AirLiner General Information00 Vehicle Maintenance Schedule Table: 00 02 WALK-IN Van CHASSIS Maintenance Manual, November 201500/2 Vehicle Maintenance ScheduleMaintenance Operation Numberand DescriptionMaintenance Interval in Miles x 1000510152025 30354045505560 65 70 75 80 85 90 95 100 Maintenance Interval in Kilometers x 10008 16 24 32 40 48 56 64 72 80 88 96 104 112 120 128 136 144 152 16032 04 Suspension U-Bolt TorqueChecking 33 01 Grease-Lubricated Wheel BearingCleaning, Inspecting, Repacking, andAdjusting, Front Axle 33 02 Knuckle Pin Lubricating* 33 03 Tie-Rod End Lubricating andInspecting Lubricate twice each month.