Freightliner S2 Chassis Maintenance Manual-20f17479

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S2 CHASSIS MAINTENANCE MANUAL

STI-479 (8/08P)
Published by
Daimler Trucks North America LLC
4747 N. Channel Ave.
Portland, OR 97217
Printed in U.S.A.

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 Foreword
Performing scheduled maintenance operations is important in obtaining safe, reliable operation
of your vehicle. A proper maintenance program will also help to minimize downtime and
safeguard warranties.
IMPORTANT: The maintenance operations in this manual are not all-inclusive. Also
refer to other component and body manufacturers’ instructions for specific inspection
and maintenance instructions.
Perform the pretrip inspection and daily/weekly/monthly maintenance as outlined in the S2
Chassis Operator’s Manual. Perform the maintenance operations in this manual at scheduled
intervals based on the distance the vehicle has traveled or hours of operation. Your Freightliner
dealership has qualified technicians and equipment to perform this maintenance.
IMPORTANT: Descriptions and specifications in this manual were in effect at the time of
printing. Freightliner Custom Chassis Corporation (FCCC) reserves the right to discon-
tinue models and to change specifications or design at any time without notice and
without incurring obligation. Descriptions and specifications contained in this publication
provide no warranty, expressed or implied, and are subject to revision and editions
without notice.
Refer to www.Daimler-TrucksNorthAmerica.com and www.FreightlinerChassis.com for more
information, or contact Daimler Trucks North America LLC at the address below.

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.

© 2007–2008 Daimler Trucks North America 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 Daimler Trucks
North America LLC. Daimler Trucks North America LLC is a Daimler company.

Daimler Trucks North America LLC

Service Systems and Documentation (POC-SSD)
P.O. Box 3849
Portland, Oregon 97208-3849
 Introduction
Descriptions of Service Publications

Daimler Trucks North America LLC distributes the following major service publications in paper and electronic
(via ServicePro®) formats.
Workshop/Service Workshop/service manuals contain service and repair information for all vehicle
Manual 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, and specifications.
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, and procedures for adjustments and for checking the tightness of fasten-
ers. Maintenance manuals do not contain detailed repair or service information.
Driver’s/Operator’s Driver’s/operator’s manuals contain information needed to enhance the driver’s
Manual understanding of how to operate and care for the vehicle and its components.
Each manual contains a chapter that covers pre-trip and post-trip inspections,
and daily, weekly, and monthly maintenance of vehicle components.
Driver’s/operator’s manuals do not contain detailed repair or service information.
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.
Parts Technical Bulletins Parts technical bulletins provide information on parts. These bulletins contain
lists of parts and BOMs needed to do replacement and upgrade procedures.

Web-based repair, service, and parts documentation can be accessed using the following applications on the
AccessFreightliner.com website.
ServicePro ServicePro® provides Web-based access to the most up-to-date versions of the
publications listed above. In addition, the Service Solutions feature provides di-
agnostic assistance with Symptoms Search, by connecting to a large knowledge
base gathered from technicians and service personnel. Search results for both
documents and service solutions can be narrowed by initially entering vehicle
identification data.
PartsPro PartsPro® is an electronic parts catalog system, showing the specified vehicle’s
build record.
EZWiring EZWiring™ 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 PartsPro.

S2 Chassis Maintenance Manual, August 2008 I–1

Introduction
Descriptions of Service Publications

Warranty-related service information available on the AccessFreightliner.com website includes the following
documentation.
Recall Campaigns Recall campaigns cover situations that involve service work or replacement of
parts in connection with a recall notice. These campaigns pertain to matters of
vehicle safety. All recall campaigns are distributed to dealers; customers receive
notices that apply to their vehicles.
Field Service Campaigns Field service campaigns are concerned with non-safety-related service work or
replacement of parts. All field service campaigns are distributed to dealers; cus-
tomers receive notices that apply to their vehicles.

I–2 S2 Chassis Maintenance Manual, August 2008

 Introduction
Page Description

For a page example of the printed manual, see Fig. 1.

A B C

D E
02/10/2004 f020152
A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number
B. Group Title
C. Group Number
D. Release Date
E. Group Number/Page Number
Fig. 1, Page Example of the Printed Manual

S2 Chassis Maintenance Manual, August 2008 I–3

Introduction
Maintenance Manual Contents

Group No. Group Title

00 . . . . . . . . . . . . . . . . . . . . . . General Information
01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine
09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Intake
13 . . . . . . . . . . . . . . . . . . . . . . . . . . Air Compressor
15 . . . . . . . . . . . . . . . . . . . Alternators and Starters
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

I–4 S2 Chassis Maintenance Manual, August 2008

General Information 00
Index, Alphabetical

Title of Maintenance Operation (MOP) MOP Number

Determining Scheduled Maintenance Intervals: 00-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–01
Maintenance Interval Table: 00-03. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–03
Maintenance Schedules: 00-02. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–02
Noise Emission Controls: 00-05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–05
Overview of Maintenance Operations: 00-04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–04
Verification of Inspections Log: 00-06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–06

S2 Chassis Maintenance Manual, August 2008

General Information 00
Determining Scheduled Maintenance Intervals: 00-01

Determining Scheduled schedule is choosen, continue using it for the life of

the vehicle.
Maintenance Intervals
Maintenance Operations
Performing regular maintenance will help ensure that
your vehicle delivers safe, reliable service, and opti- Groups 01 through 83 in this manual have an index
mum performance. A proper maintenance program at the beginning of each Group. The index lists the
will also help to minimize downtime and safeguard Title of Maintenance Operations and the Mainte-
warranties. nance Operation (MOP) Numbers for that Group.
Follow the instructions under the MOP number to
To determine the correct maintenance intervals for
perform the required maintenance.
your vehicle, you must first determine the type of ser-
vice or conditions the vehicle will be operating in. In addition to the maintenance operations required
Most vehicles operate in conditions that fall within for the maintenance interval, perform all of the pre-
one of two schedules. Before placing your vehicle in and post-trip inspections and maintenance proce-
service, determine whether schedule I or II applies to dures in Chapter 12 and Chapter 13, "Pre- and
your vehicle. Post-Trip Checklists" and "Pre- and Post-Trip Inspec-
tions and Maintenance," in the S2 Chassis Opera-
Schedules I and II tor’s Manual.

Schedule I (urban transport) applies to vehicles that

travel up to 20,000 miles (32 000 kilometers) annu-
ally. Examples of Schedule I usage are:
• frequent short-distance travel
• operation primarily in cities and densely popu-
lated areas
• local transport with infrequent freeway travel
• high percentage of stop-and-go travel
Schedule II (rural transport) applies to vehicles that
travel over 20,000 miles (32 000 kilometers) annu-
ally. An example of Schedule II usage is:
• less frequent stop-and-go travel

Maintenance Schedules
After determining the schedule appropriate to your
vehicle, refer to the Maintenance Schedules to de-
termine when to perform the Initial Maintenance (IM)
and the frequency of performing subsequent mainte-
nance intervals for each schedule.

Maintenance Intervals
Refer to the Maintenance Interval Table to deter-
mine which maintenance interval(s) should be per-
formed when your vehicle reaches the mileage or
months of operation listed in these subjects.
Before placing your new vehicle in service, determine
the maintenance schedule (Schedule I or II) that ap-
plies to your intended use of the vehicle. Once a

S2 Chassis Maintenance Manual, August 2008 00/1

Freightliner S2 Chassis Maintenance Manual-20f17479
Full download: http://manualplace.com/download/freightliner-s2-chassis-maintenance-manual-20f17479/

00 General Information
Maintenance Schedules: 00-02

Vehicle Maintenance Schedule Table

Vehicle Maintenance Schedule Table
Maintenance Intervals
Description Maintenance Operation Set
Frequency Miles km Months
Initial Maintenance (IM) first 2500 4000 3
Schedule I
(Urban Transport) Maintenance 1 (M1) every 2500 4000 3
vehicles that annually travel up to Maintenance 2 (M2) every 10,000 16 000 12
20,000 miles (32 000 km)
Maintenance 3 (M3) every 30,000 48 000 36
Initial Maintenance (IM) first 5000 8000 3
Schedule II
(Rural Transport) Maintenance 1 (M1) every 5000 8000 3
vehicles that annually travel over 20,000 Maintenance 2 (M2) every 20,000 32 000 12
miles (32 000 km)
Maintenance 3 (M3) every 60,000 96 500 36

00/2 S2 Chassis Maintenance Manual, August 2008

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