fccc product familiarization newmar · fccc product familiarization newmar february 18, 2013 ......
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February 18,2013
Security Classification Line
Presenter:
Service AdministratorDewayne Wilkie
F.C.C.C. Service and Training Dept.
Daimler TrucksDepartment 3
Freightliner Custom Chassis Facilities
Off line
Pro
du
cti
on O
ffic
e
Dyno / T&D
•Gaffney, SC (50 miles
from Charlotte, NC)
•74 acre site
•ISO 9001 Certified
•283,000 square feet for production
•Over 343,550 square for completed chassis parking
•All chassis are built on a order by order process, no
stock chassis are built for stand by.
Daimler TrucksDepartment 4
FCCC Product Familiarization
• Let me introduce you to FCCC and how we build our chassis.
Daimler TrucksDepartment 5
• As you can see every chassis goes thru the roll test before it can be parked for shipping.
• Roll test checks:
• Before a chassis is rolled all fluid levels are checked.
• All Lights are hooked up and checked.
• All dash functions are checked at Roll Test
• Cruise
• Engine brake
• Transmission down shift
• Speedo and Tach
• Air pressure gauges
• All ABS functions are checked
• Then the chassis are ran 20 minutes to check performance and to make sure there are no issues when the Body Builder gets our chassis.
FCCC Product Familiarization
Daimler TrucksDepartment 6
Dutch Star Dutch Star Tag Mountain Aire Tag
Ventana TagVentana
XC-R XC-R TAG
FCCC Product Familiarization
Ventana LE
Daimler TrucksDepartment 11
Ladder Frame Construction
9” 50,000 PSI
Frame Rails
Double Dog Bone
Crossmembers
CAD Designed Chassis For RV Application
For Optimized Performance
FCCC Product Familiarization
Daimler TrucksDepartment 12
• King pin roller bearings for reduced maintenance• 55 Degree Wheel Cut• Capacity 12,000 lbs. & 14,000 lbs.
I - Beam Front Axles
FCCC Product Familiarization
1
Front Axles Technical Features and Advantages
� Bridging American and European technology, these innovative
axles, manufactured in the U.S., provide market-leading performance and value. Here are some of the offered benefits:
� Needle bearings replace bushings for greater reliability
Daimler TrucksDepartment 13
• Reduced noise due to proprietary gear machining• Capacity of 17,500,19,000 & 20,000 lbs.
Heavy Duty Rear Axle
FCCC Product Familiarization
Daimler TrucksDepartment 14
Tag AxleDrop Center Tag Axle
• Capacity of 10,000 & 13,000 lbs
FCCC Product Familiarization
Daimler TrucksDepartment 15
Spring Beams
Air Springs
Anti Sway Bar
Custom Tuned
Sachs Shocks
• Air springs located directly under the frame rail optimizes loading and force
inputs providing good roll resistance
• Spring Beams deflection contributes to the roll resistance
• Anti Sway bar and custom tuned Sachs shocks enhance roll resistance
Provides Excellent Roll Stability
Front Suspension
FCCC Product Familiarization
Daimler TrucksDepartment 16
Air System Meets
FMVSS 121
Heated AutomaticMoisture Ejector
&Air Dryer
Air Supply
Manifold
FCCC Product Familiarization
•Outboard Manual Drain Cables
•One Forward Location
Daimler TrucksDepartment 17
½” Air Line
• Ping Tanks Increase Air
Volume.
• ½” Line allows rapid transfer
of air back and forth between Ping
Tank and Air Spring.
• Providing soft ride.
Air Suspension
Air Spring
Piston
FCCC Product Familiarization
Daimler TrucksDepartment 18
Air System Color Coded Air Lines • Ease of Maintenance
Red: Front Brakes (secondary)
Green: Rear Brakes (primary)
Black: Air tank supply & emergency
park brake system
Blue: Air suspension system
White: Air suspension exhaust
Options
Silver: Air system governor control
Yellow: Park brake control supply &
optional system supply
• Push to connect fittings standard
FCCC Product Familiarization
Daimler TrucksDepartment 19
IFS (Independent Front Suspension)
51.5” Air Bag
Centerline
Custom Tuned
Sachs Shocks
Upper and Lower
Control
arms
Volumetric
Air springs
• Control arms provide precise wheel control & sensitive response to vertical impacts
• Volumetric air springs with wide center line & tuned shocks, provide excellent
roll stability and soft ride
• 17” air disc brakes w/wear sensors allow unsurpassed braking and reduced fade
• Industry leading 60 degree wheel cut for superb maneuverability
Air Disc Brakes
With ABS &
Wear Sensors
Provides Excellent Roll Stability
FCCC Product Familiarization
Daimler TrucksDepartment 20
IFS Suspension
Volumetric
Air
Spring
Piston
• Ping Tanks & Volumetric Piston
Increase Air Volume.
• ½” Line allows rapid transfer
of air back and forth between Ping
Tank and Air Spring.
• Providing soft ride.
FCCC Product Familiarization
Daimler TrucksDepartment 21
Maneuverability
How to tell if ZF IFS has 56 degree or 60 Degree
Older 56 degree has round holes Present 60 degree has FTL Logo
FCCC Product Familiarization
Daimler TrucksDepartment 22
Maneuverability
I-Beam
Inside Wheel Cut Left and Right
ZF IFS
60 Degree55 Degree
FCCC Product Familiarization
Daimler TrucksDepartment 23
Rear Suspension
Rigid Trailing
BladeCustom Tuned
Sachs Shocks
• Rigid Trailing blade controls vertical load
• Transverse Beam allows wide load centers on axle and maintains a high
resistance to coach roll• Air springs and Custom tuned shocks provide a smooth ride and
contribute to roll resistance
Transverse Beam
Volumetric Air Springs
Provides Excellent Roll Stability
FCCC Product Familiarization
Daimler TrucksDepartment 24
Rear Suspension
•Torque Reactive Suspension
• Non-Torque Reactive
or Parallelogram Suspension
•Torque Rod
• Keeps Driveline Angle with in 1&1/2 degrees
Through out the full suspension travel.
• This reduces driveline vibrations, noise, and wear
FCCC Product Familiarization
Daimler TrucksDepartment 25
Tag Axle Suspension
• Rated 10,000 lb and 13,000 lb Capacity
• Custom Tuned Sachs Shocks
• Non-Steer/Non-Lift
• Automatic Air Dump in Reverse
• Rubber Bushed connections for extended life and smooth ride, no lubrication required
• Lightweight.
Neway CA SeriesTag Axle Suspension
FCCC Product Familiarization
Daimler TrucksDepartment 26
Air Springs mounted inboard clear of debris thrown from tires
Freightliner Outboard Air Spring
Air springs mounted outboardsubject to debris thrown from tires
Suspension
Daimler TrucksDepartment 27
Sachs Shocks
• Premium Performance• Twin Tube Hydraulic• Custom Tuned• Improved Ride & Handling• Standard Equipment On
• Mercedes• BMW• Audi• Rolls Royce• Maserati
Exclusive To Freightliner
FCCC Product Familiarization
Daimler TrucksDepartment 28
• Provides a smooth steering responseunder all conditions
• Bell crank design/steering gear location virtually
55º Wheel Cut
Bell Crank
Steering Geometry
FCCC Product Familiarization
Daimler TrucksDepartment 29
Front:17” Disc Rotors STD. IFS17” Disc Rotors STD I -beam
Rear: 16.5” x 7” Drums
With Automatic Slack Adjusters
Air Brakes
With Front
Wear Sensors
FCCC Product Familiarization
Daimler TrucksDepartment 30
Electrical
GXL Wiring
• Flame retardant
• Heat resistant up to 135 (C)
• Color coded
• Circuit number coded
• Circuit description labeled
FCCC Product Familiarization
Daimler TrucksDepartment 31
Electrical
Tow Power Connector
7 Pin Connector
FCCC Product Familiarization
Daimler TrucksDepartment 33
ControlsSuspended Adjustable Pedals
On Mountain Aire, and Dutch Star and Dutch Star Tag
FCCC Product Familiarization
Daimler TrucksDepartment 34
Controls:
TRW column drive, infinitely adjustable tilt/telescoping steering column On the Mountain Aire Tag, Dutch Star Tag, Dutch Star, Ventana Tag, Ventana
Foot Pedal
Control
FCCC Product Familiarization
TRW Infinitely Adjustable Tilt &
Telescoping Steering Column
On the Ventana LE
Daimler TrucksDepartment 35
Information Center
Integrated in the Warning Light Bar
Remote Mounted Joy Stick to Toggle
Through Info Center
August 2006
Chassis production
(1)
FCCC Product Familiarization
Daimler TrucksDepartment 36
Information CenterInfo Screens
(2) (3)
(4) (5)
(6)
(8)
(7)
FCCC Product Familiarization
Daimler TrucksDepartment 37
Different Engine Brakes
• Increased Brake Life• Increase Tire Life• More Vehicle Control• Illuminates Brake Lamps• Communicates With Transmission
Compression BrakeISC & ISL (Two Stage)
Cummins VGTISB & ISC
FCCC Product Familiarization
Daimler TrucksDepartment 38
Fresh Air
CompressorTurbine
Nozzle RingYoke Mechanism
Shroud Plate
SpeedSensor
Actuator
Variable Geometry Turbo (VGT)
FCCC Product Familiarization
Daimler TrucksDepartment 39
Nozzle Ring Fully Open
Maximum turbine exit area
Minimum exhaust manifold pressure
Minimum shaft speed
Minimum turbo boost
Nozzle Ring Fully Closed
Minimum turbine exit area
Maximum exhaust manifold pressure
Maximum shaft speed
Maximum turbo boost
Variable Geometry Turbo (VGT)
FCCC Product Familiarization
Daimler TrucksDepartment 40
ISB & ISB XT
350 HP 660 lb ft360 HP 800 lb ft
Engines 6.7 L
FCCC Product Familiarization
VGTurbo for
Engine Brake
Daimler TrucksDepartment 41
Engines8.3L
360 HP 1050 lb ft380 HP 1050 lb ft
FCCC Product Familiarization
Compression BrakeISC & ISL (Two Stage)
Daimler TrucksDepartment 42
400 HP 1250 lb-ft
450 HP 1250 lb-ft
Engines8.9L
FCCC Product Familiarization
Compression BrakeISC & ISL (Two Stage)
Daimler TrucksDepartment 43
3 - Point Engine Mount
• Recommended by
all major engine manufacturers
• Eliminates frame railstress into the engine
Engines
FCCC Product Familiarization
Daimler TrucksDepartment 44
Electronically Controlled ViscousFan Clutch
Standard on all rear radiator chassis since 2008
Improved FuelEconomy &Performance
Fan Clutch
FCCC Product Familiarization
Daimler TrucksDepartment 46
All EPA O7 AND EPA 10Chassis will have a Exhaust Diffuser
Exhaust Diffuser
OLD STYLE Diffuser NEW STYLE Diffuser
FCCC Product Familiarization
Daimler TrucksDepartment 47
1/31/2013 47
22 Years of Emission Changes
20%
38%
52%
83%
5.0
1.2
2.5
4.0
0.20.2
0.100.010.01
90%
NO
x (
g/
hp
-hr)
PM (g/hp-hr)
19941994
19981998
20022002
20072007
20102010
2010 requires an 83% reduction in NOx—Oxides of Nitrogen an exhaust
element that contributes to acid rain, smog and greenhouse gas levels
FCCC Product Familiarization www.discoverdef.com
Daimler TrucksDepartment 48
Air Intake System
Proprietary Pre-CleanerFARR
Long Life Air Cleaner
Air Inlet RestrictionIndicator
FCCC Product Familiarization
Daimler TrucksDepartment 49
Transmissions
• 6 speed automatic• 5th & 6th gear overdrive• Electronically controlled• Lockup torque converter• Exhaust brake compatible• Automatically selects 2nd gear with exhaust brake engaged
• Synthetic Transmission Fluid “MOBIL Delvac “
FCCC Product Familiarization
Daimler TrucksDepartment 51
Shift Selector 2000MH Series
Forward Gear
Up & Down
Shift
Pushbutton Selector
Reverse
Neutral
Drive
D 1
SERVICE
ECONOMY
Range Selected
Gear Indicator
Fault Indicator
Mode on Indicator
(LED)
Transmissions
FCCC Product Familiarization
Daimler TrucksDepartment 52
Transmissions
• 6 speed automatic• 5th & 6th gear overdrive• Electronically controlled• Lockup torque converter• Exhaust brake compatible• Automatically selects 2nd gear with exhaust brake engaged
• Synthetic Transmission Fluid “MOBIL Delvac “
FCCC Product Familiarization
Daimler TrucksDepartment 54
ECONOMY
Mode on Indicator
(LED)
Economy Mode ID
Forward Gear
Up & Down
Shift
Pushbutton Selector
Shift Selector 3000/4000 MH
Transmissions
6Digital Display
Reverse
Neutral
Drive
1ECONOMY
FCCC Product Familiarization
Daimler TrucksDepartment 55
Shift Selector 3000/4000 MH
• Press up and down arrow keys simultaneously
Fluid Level Check
ECONOMY
N N
FCCC Product Familiarization
Daimler TrucksDepartment 56
Pushbutton Selector
Shift Selector 3000/4000 MH
3000 MH Transmissions Built With Prognostics
FCCC Product Familiarization
OIL LIFE WILL GIVE YOU A 0-99 READING
FILTER LIFE WILL GIVE YOU OK OR A LO READING
TRANMISSION HEALTH WILL GIVE YOU A OK OR A LO READING. IT TAKES A CLUTCH FAILURE TO ACTIVATE THE LO
Daimler TrucksDepartment 57
FCCC Product Familiarization
On Freightliner custom chassis RVs equipped with the L.B.C.U.
(Lightbar control unit ) Both the 2000 and 3000 serires transmissionsequipped vehicles display the same information in the LBCU LCD.Details are below, the 3000 has the additional indication in theAllison shift pad.
Transmission oil life Poor (“ Trans Oil Life”)TRANS OIL LIFE,
The message and speaker shall be activated if the Transmission has the Prognostics turned on.
The speaker shall emit a brief chime to capture the driver’s attention.(DRIVER_ATTENTION_WARNING_CHIME)
The message shall read “TRANS OIL LIFE”
Transmission Oil Filter Restriction Switch Clogged (“ TRANS OIL FILTER”)
TRANS OIL FILTER,The message and speaker shall be activated if the Transmission has the Prognostics turned on.The speaker Shelley met a brief chime to capture the driver’s attention
(DRIVER_ATTENTION_WARNING_CHIME)
The message shall read “TRANS OIL FILTER”
Transmission Needs Service “TRANS SERVICE”TRANS SERVICE,
The message and speaker shall be activated if the Transmission has the Prognostics
turned onThe speaker Shelley met a brief, trying to capture the driver’s attention
(DRIVER_ATTENTION_WARNING_CHIME)The message shall read “TRANS SERVICE”
Daimler TrucksDepartment 58
Pushbutton Selector with Prognostics turned on 8/26/2011
Shift Selector 3000/4000 MH
FCCC Product Familiarization
3000 Series
The shifter was in place in 7/14/2008 P35056 c/o
The wiring for Prognostics was in place 1/14/2010
Wiring number A06-75411-000, P34916 c/o
First Calibration with Prognostics Enabled 8/26/11
This was the first Production date that had the Prognostics turned On.
What does that mean to me???? It means Allison says that you can go 60 months before you have to change your Transmission Filters and Fluid and there is no 5000 mile filter change for the 3000 series
Daimler TrucksDepartment 59
Engine Cummins 5 Years 100,000 mi
Transmission Allison 5 Years 200,000 mi *
Chassis 3 Years 50,000 mi
Drive Train 3 Years 50,000 mi
Suspension 3 Years 50,000 mi
Frame Rails& Crossmembers 5 Years 100,000 mi
Transferable All of The Above
* For chassis built after 1/2/04 PLEASE REMEMBER YOU CAN ALSO PURCHASE AN EXTENDED WARRANTY FROM FCCC FOR THE CHASSISCALL 1-800-385-4357 TO CHECK PRICING
FCCC Product Familiarization
Daimler TrucksDepartment 60
What some Dealers may not know.
Who responsibility is it to keep the chassis batteries charged when the Coach has been built?
What if the steering wheel is off center?
Who installs the Cab Harness?
When does the Warranty Start?
When does Service start?
When a Chassis is sold and it has past a Service Interval who tells the customer a Service is needed?
Can you as dealers get engine codes and transmission codes?
FCCC Product Familiarization
THE RV DEALER.
You can call1-800-385-4357
To see who installed the
Steering Column.NEWMAR
When the chassis is sold or put into
Demo Service or when 36 months
from the date the chassis was built
From the day the chassis was built at FCCC
THE RV DEALER.
YES FROM THE DASH AND
3000 MH SHIFT PAD ONLY.
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