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CENTURY CLASS TRUCKS MAINTENANCE MANUAL

Models: Argosy

COE

C112 Conventional

C120 Conventional

Coronado

STI-341-1 (8/11)

Published by

Daimler Trucks North America LLC

4747 N. Channel Ave.

Portland, OR 97217

Printed in U.S.A.

Summary of content (149 pages)

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CENTURY CLASS TRUCKS MAINTENANCE MANUAL Models: Argosy® COE C112 Conventional C120 Conventional Coronado® STI-341-1 (8/11) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
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Foreword Scheduled maintenance provides a key element for the safe operation of your vehicle. A proper maintenance program also helps to minimize downtime and to safeguard warranties. This maintenance manual provides information necessary for years of safe, reliable, and cost-efficient vehicle operation. 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.
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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 Manual Workshop/service manuals contain service and repair information for all vehicle systems and components, except for major components such as engines, transmissions, and rear axles.
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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.
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Introduction Page Description For an example of a Century Class Trucks Maintenance Manual, see Fig. 1. A B C D E f020044 11/20/95 A. B. C. D. E. Maintenance Operation Number consists of the Group Number followed by the Sequence Number Group Title Group Number Release Date Group Number/Page Number Fig.
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Introduction Maintenance Manual Contents Group No. Group Title 00 . . . . . . . . . . . . . . . . . . . . . . General Information 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Intake 15 . . . . . . . . . . . . . . . . . . . Alternators and Starters 20 . . . . . . . . . . . . . . . . . . . Engine Cooling/Radiator 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch 26 . . . . . . . . . . . .
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General Information 00 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Determining Scheduled Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–01 Initial Maintenance (IM) Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00–05 Lubrication and Fluid Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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00 General Information Determining Scheduled Maintenance Intervals: 00–01 Determining Scheduled Maintenance Intervals Performing regular maintenance on your Freightliner will help ensure that your Freightliner delivers safe reliable service and optimum performance for years to come. Failure to follow a regular maintenance program can result in inefficient operation and unscheduled down time.
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00 General Information Service Schedule Table: 00–02 Service Schedule Schedule I* (Severe Service) vehicles that annually travel less than 6000 miles (10 000 km) Schedule II† (Short-Haul Transport) vehicles that annually travel less than 60,000 miles (100 000 km) Schedule III† (Long-Haul Transport) vehicles that annually travel over 60,000 miles (100 000 km) Schedule IV† (Long-Haul Transport for Optimized Vehicle Configuration) vehicles that annually travel over 60,000 miles (100 000 km) Maintenance Int
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00 General Information Vehicle Maintenance Schedule Tables: 00–03 1st through 30th Maintenance for Service Schedules I and II Maint. No.
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00 General Information Vehicle Maintenance Schedule Tables: 00–03 31st through 60th Maintenance for Service Schedules I and II Maint. No.
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00 General Information Vehicle Maintenance Schedule Tables: 00–03 61st through 90th Maintenance for Service Schedules I and II Maint. No.
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00 General Information Vehicle Maintenance Schedule Tables: 00–03 91st through 100th Maintenance for Service Schedules I and II Maint. No.
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00 General Information Vehicle Maintenance Schedule Tables: 00–03 20th through 40th Maintenance for Service Schedules III and IV Maint. No.
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00 General Information Lubrication and Fluid Level Check: 00–04 Maintenance Operation 00–04, Lubrication and Fluid Level Check Operation Table 8 summarizes all operations that must be performed to complete the Lubrication and Fluid Level Check operation 00–04 called for as an M1 maintenance interval for Service Schedule I, II, and III vehicles, and as an M2 maintenance interval for Service Schedule IV vehicles.
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00 General Information Initial Maintenance (IM) Operations: 00–05 The Initial Maintenance table lists all maintenance operations that are to be performed at the initial maintenance (IM) interval. Maintenance operation numbers are reference numbers used to help you find detailed instructions in this manual on the mainMaintenance Operation Number tenance operations to be performed.
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00 General Information M1 Maintenance Interval Operations: 00–06 The M1 Maintenance Interval Operations tables list all maintenance operations that are to be performed at the M1 maintenance interval. Maintenance operation numbers are reference numbers used to help you find detailed instructions in this manual on the maintenance operations to be performed.
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00 General Information M1 Maintenance Interval Operations: 00–06 Maintenance Operation Number 88–01 M1 Maintenance Interval Operations for Service Schedule IV Check Hood Rear Support Lubrication Table 11, M1 Maintenance Interval Operations for Service Schedule IV Century Class Trucks Maintenance Manual, August 2011 00/11
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00 General Information M2 Maintenance Interval Operations: 00–07 The M2 Maintenance Interval Operations tables list all maintenance operations that are to be performed at the M2 maintenance interval. Maintenance operation numbers are reference numbers used to help Maintenance Operation Number 00/12 you find detailed instructions in this manual on the maintenance operations to be performed. Perform all M1 maintenance interval operations at the M2 maintenance interval.
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00 General Information M2 Maintenance Interval Operations: 00–07 Maintenance Operation Number M2 Maintenance Interval Operations for Service Schedules I, II, and III 47–02 Fuel Separator Sight Bowl Cleaning and Element Replacement 60–01 Cab Suspension Air Bag Inspection 60–03 Cab Access Stairs Inspection, Argosy COE 60–04 Mirror Folding Check 83–01 Air Conditioner Inspection 83–02 Air Filter Replacement‡ Check * Inspect Meritor Unitized Wheel Ends at 200,000 miles (321 870 km0, then every
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00 General Information M2 Maintenance Interval Operations: 00–07 Maintenance Operation Number M2 Maintenance Interval Operations for Service Schedule IV 33–07 Basic Inspection, Meritor Unitized Wheel Ends* 33–08 End-Play Check, Meritor Unitized Wheel Ends† 40–01 Wheel Nut and Rim Nut Check 41–01 Driveline Inspection 42–01 Air Brake System Valve Inspection 42–03 Air Dryer Inspection 42–04 Alcohol Evaporator Cleaning and Inspection 46–01 Drag Link Inspection 46–06 Rack and Pinion Steerin
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00 General Information M3 Maintenance Interval Operations: 00–08 The M3 Maintenance Interval Operations table lists all maintenance operations that are to be performed at the M3 maintenance interval. Maintenance operation numbers are reference numbers used to help Maintenance Operation Number you find detailed instructions in this manual on the maintenance operations to be performed. Perform all maintenance interval operations in M1 and M2 when performing M3 maintenance interval operations.
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00 General Information Maintenance Operation Sets Table: 00–09 Maintenance Operation Sets for Groups 00 through 83 Maint. No.
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00 General Information Maintenance Operation Sets Table: 00–09 Maintenance Operation Sets for Groups 00 through 83 Maint. No.
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00 General Information Maintenance Operation Sets Table: 00–09 Maintenance Operation Sets for Groups 00 through 83 Maint. No. Operation Description 83–02 Air Filter Replacement§ 88–01 Hood Rear Support Lubrication Service Schedules I, II, and III Service Schedule IV IM IM M1 M2 M3 • • • M1 M2 M3 • • • * At engine overhaul, and whenever the engine has been removed, inspect the lower and upper isolators, and replace them if they are worn.
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00 General Information Noise Emission Controls Maintenance: 00–10 Noise Emission Control Maintenance Federal Law, Part 205: Transportation Equipment Noise Emission Controls Part 205, Transportation Equipment Noise Emission Controls, requires the vehicle manufacturer to furnish, with each new vehicle, such written instructions for the proper maintenance, use, and repair of the vehicle by the ultimate purchaser to provide reasonable assurance of the elimination or minimization of noise-emission-control deg
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00 General Information Verification of Inspections Log: 00–11 Verification of Inspections Log Verification of Inspections Log, Groups 01, 20, and 49 Date Mileage Item Cost Maintenance Facility Group 01 — Engine Noise Panels, Engine Mounts, and Engine-Support Fasteners Group 20 — Fan Clutch Group 49 — Exhaust System Components 00/20 Century Class Trucks Maintenance Manual, August 2011
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00 General Information Metric/U.S. Customary Conversion Tables: 00–12 When You Know U.S. Customary Multiply By To Get Metric When You Know Metric Multiply By To Get U.S. Customary 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 meters (m) 3.281 feet (ft) yards (yd) 0.9144 meters (m) 1.094 yards (yd) miles (mi) 1.609 kilometers (km) 0.6215 miles (mi) 645.16 square millimeters (mm2) 0.
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00 General Information Torque Specifications Tables: 00–13 Torque Values for U.S. Customary Thread Fasteners With Lubricated* or Plated Threads† Regular Hex Thread Diameter– Pitch Grade 5 Bolt Grade 5 or B Nut Torque: lbf·ft (N·m) f230003 f230002 Flanged Grade 8 or 8.2 Bolt Grade 8 or C Nut Torque: lbf·ft (N·m) f230004 f230005 Grade 5 Bolt Grade B Nut Torque: lbf·ft (N·m) f230006 f230007 Grade 8 or 8.
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00 General Information Torque Specifications Tables: 00–13 Torque Values for U.S. Customary Thread Fasteners With Dry (Unlubricated)* Plain (Unplated) Threads† Regular Hex Thread Diameter–Pitch Grade 5 Bolt Grade 5 or B Nut Grade 8 or 8.2 Bolt Torque: lbf·ft (N·m) Grade 8 or C Nut Torque: lbf·ft (N·m) f230003 f230002 Flanged f230004 Grade 8 or 8.
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00 General Information Torque Specifications Tables: 00–13 Torque Values for Metric Thread Fasteners With Lubricated* or Plated Threads† Class 8.8 Bolt Class 8 Nut Thread Diameter–Pitch Torque: lbf·ft (N·m) 8.8 M6 f230011 5 (7) Class 10 Nut Torque: lbf·ft (N·m) 10.9 8 f230010 Class 10.9 Bolt 10 f230012 f230013 7 (9) M8 12 (16) 17 (23) M8 x 1 13 (18) 18 (24) M10 24 (33) 34 (46) M10 x 1.25 27 (37) 38 (52) M12 42 (57) 60 (81) M12 x 1.
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Engine 01 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Engine Drive Belt Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–02 Engine Mount Inspection (Noise Emission Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01–03 Engine Noise Panel Inspection (Noise Emission Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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01 Engine 01–01 Engine Noise Panel Inspection (Noise Emission Control) following conditions, then perform the "Belt Tension Inspection": Visual Inspection If equipped, inspect for torn engine noise panels. See Fig. 1 for Caterpillar noise panel locations. If panels are torn, replace them with new panels; see Group 01 of the Century Class Trucks Workshop Manual for procedures. Cummins M11 and N14 engines, and Detroit Diesel Series 55 and Series 60 engines do not have engine noise panels. 2 1.
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01 Engine A D B E C F 11/21/94 A. Glazing B. Separating Layers C. Streaked Sidewalls D. Tensile Break f150010a E. Uneven Ribs F. Cracks Fig. 2, Drive Belt Replacement Conditions Belt Tension Inspection Threaded-Adjustment Type 1. Apply the parking brakes, and chock the tires to prevent the vehicle from moving. 2. Install a belt tension gauge at the center of the belt’s longest free-span. Check belt tension. See Table 1 for belt tension specifications. 3.
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01 Engine Drive Belt Tension Engine Component Caterpillar C10 (3176) Refrigerant Compressor 80 to 100 (36 to 45) Alternator and Refrigerant Compressor Caterpillar 3406E Cummins M11 80 to 100 (36 to 45) Alternator 90 to 120 (41 to 55) Fan 155 to 165 (70 to 75) Refrigerant Compressor 80 to 100 (36 to 45) 40 to 50 (18 to 23), per belt Fan 80 to 120 (36 to 55) Refrigerant Compressor 80 to 100 (36 to 45) Alternator and Refrigerant Compressor Detroit Diesel Series 60 40 to 50 (18 to 23), pe
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Air Intake 09 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Element Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Air Intake 09 09–01 Air Cleaner Element Inspection and Replacement Method 1 Replace the air cleaner element at the recommended interval or when the air restriction indicator reaches 20 inH2O on a vehicle with a Detroit Diesel engine, 22 inH2O on a vehicle with an MBE engine, or 25 inH2O on a vehicle with a Caterpillar or Cummins engine. For replacement instructions, see Group 09 of the Century Class Trucks Workshop Manual. Reset the air restriction indicator.
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Alternators and Starters 15 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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15 Alternators and Starters • Magnetic switch 15–01 Alternator, Battery, and Starter Connections Check WARNING Batteries release explosive gas as a by-product of their chemical activity. Do not smoke when working around batteries. Put out all flames and remove any source of sparks or intense heat. Make sure the battery compartment is completely vented before disconnecting or connecting the battery cables. Battery acid is extremely harmful if splashed in the eyes or on the skin.
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15 9.5 Alternators and Starters Coat the battery terminals with dielectric grease. 10. Check the terminals on the battery shut-off switch and the magnetic switch. Make sure the terminal connections are clean and tight. Coat the terminal connections with dielectric red enamel after cleaning.
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Engine Cooling/Radiator 20 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fan Clutch Check (Noise Emission Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–03 Pressure Relief Cap Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20–01 Radiator Pressure-Flushing and Coolant Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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20 Engine Cooling/Radiator 20–01 Pressure Relief Cap Check WARNING Do not remove or loosen the surge tank cap until the engine and cooling system have completely cooled. Use extreme care when removing the cap. A sudden release of pressure from removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause serious personal injury. CAUTION The radiator cap currently installed may not be the same one installed when the vehicle was built.
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20 Engine Cooling/Radiator 1 2 3 06/08/95 f500244 1. Low-Coolant-Level Sensor 2. SAE Cap (for coolant overflow pressure relief only) 3. Fill Cap Fig. 1, Surge Tank, Century Class Conventional 7.2 2 3 Attach the flushing gun nozzle to the radiator at the lower radiator hose opening. Run the water until the radiator is full. NOTICE When flushing the radiator, do not apply more than 15 psi (100 kPa) air pressure. Excessive pressure can damage the radiator. 1 7.
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20 Engine Cooling/Radiator 1 4 5 9 2 6 3 8 7 08/19/2009 f200726 NOTE: The main radiator drain plug is not shown. 1. 2. 3. 4. 5. Surge Tank Remote Bleed Valve Main Radiator Auxiliary Radiator Auxiliary Radiator Temperature Sensor 6. 7. 8. 9. Fan Power Harness Auxiliary Radiator Drain Plug Cold Coolant Hose Hot Coolant Hose Fig. 3, Coolant System, Argosy, with Auxiliary Radiator 8. Connect the hoses. The hose clamps on the main radiator can be either T-bolt clamps (see Fig.
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20 Engine Cooling/Radiator A B 1 1 08/15/94 1 06/29/95 f011008 1. Coolant Drain Plug Fig. 4, Coolant Drain Plug Location f200326 Fig. 5, T-Bolt Type Hose Clamp temperature and pressure changes. The torque may need to be adjusted for individual applications. 9. Place a pan under the coolant filter to catch engine coolant. 10. Remove the coolant filter with a strap or chain wrench. Install a new coolant filter and tighten.
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20 Engine Cooling/Radiator coolant required to refill the system. You can mix purple-pink coolant (pre-charged with a borate/nitrate-based additive) with the common green coolant, although some color change will be apparent. 11. Fill the cooling system with new coolant. See Table 3 for pre-EPA07 vehicle’s approximate coolant capacity. Approved Antifreeze Manufacturer Antifreeze Type Caterpillar Caterpillar Diesel Engine Antifreeze/Coolant Contains supplement additives.
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20 Engine Cooling/Radiator Maximum Coolant Protection in °F (°C) at Various Antifreeze Concentrations COOLING SYSTEM CAPACITY gal (L)* ETHYLENE-GLYCOL-BASE ANTIFREEZE REQUIRED gallons (liters) 2 (8) 3 (11) 20 (76) 4 (15) 5 (19) 6 (23) 7 (26) 8 (30) 9 (34) 10 (38) 11 (42) 12 (45) 16 (–9) 10 (–12) 4 (–16) –3 (–19) –12 (–24) –22 (–30) –34 (–37) –48 (–44) –62 (–52)† * For cooling system capacities not shown, the required amount of antifreeze can be calculated, using the following: Ethyle
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20 Engine Cooling/Radiator WARNING If the engine starts during this procedure, the fan could cause personal injury. If the vehicle is equipped with an air starter, be sure that the air starter reservoir is drained. 2. Inspect the electrical connections and wires to the fan clutch solenoid. Secure the connection if loose; replace wires and connectors if damaged. 3. Clean the fan clutch air solenoid valve filter, if equipped. 3.
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20 Engine Cooling/Radiator 8 7 6 19 5 20 18 4 17 3 1 14 2 21 22 23 15 13 16 12 11 9 10 24 03/30/95 f200194a 1. Mounting Bracket 2. Rear Sheave Bearing 3. Inner and Outer Bearing Spacers 4. Forward Sheave Bearing 5. Sheave 6. Friction Facing 7. Journal Spacer 8. Socket-Head Capscrew 9. 10. 11. 12. 13. 14. 15. 16. Rear Hub Bearing Bearing Spacer Splined Hub Forward Hub Bearing Piston Friction Disc Large O-Ring Locknut Cartridge Assembly 17. 18. 19. 20. 21. 22. 23. 24.
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20 Engine Cooling/Radiator below, see Group 20 of the Century Class Trucks Workshop Manual. 3 2 1. Disconnect the batteries at the negative terminals. Drain all air from the air system. If equipped with an air starter, drain the air starter reservoir. 1 4 WARNING Make sure the batteries are disconnected before checking the fan clutch. If the engine starts during this procedure, the fan could engage, which could result in serious personal injury.
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20 Engine Cooling/Radiator If the fan clutch does not operate correctly, see Group 20 of the Century Class Trucks Workshop Manual for troubleshooting and repair procedures. 8. With the air system charged to 120 psi (827 kPa), check the fan clutch for audible air leaks, using a suitable listening device. 11.3 If either the hub or sheave bearings are worn, replace them, using a Horton DriveMaster Super Kit. For instructions and kit part number, see Group 20 of the Century Class Trucks Workshop Manual.
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Clutch 25 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch Release Cross-Shaft Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–02 Eaton Fuller Clutch Release Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–01 Meritor Clutch Release Bearing Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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25 Clutch 25–01 Eaton Fuller Clutch Release Bearing Lubrication The standard clutch release bearing is sealed, and does not require lubrication. If the vehicle is equipped with an optional clutch release bearing with a grease fitting, lubricate the bearing as follows: 1. Park the vehicle on a level surface. Apply the parking brakes, and chock the rear tires. 2. Remove the clutch inspection plate.
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25 Clutch equipped with an optional clutch release bearing with a grease fitting, lubricate the bearing as follows: 1. Park the vehicle on a level surface. Apply the parking brakes, and chock the rear tires. 2. Remove the clutch inspection plate. NOTE: Some clutch release bearings are equipped with a lubrication extension that extends outside of the clutch housing. It is not necessary to remove the clutch inspection plate when the lubrication extension is used. 1 2 10/19/93 f250048a 1.
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Transmission 26 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Allison Transmission Fluid and Filter Change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–02 Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement . . . . . . . . . . . . . . . . . . . . . . . 26–03 Manual Transmission Fluid Change, and Magnetic Plug Cleaning (Synthetic Lubricant) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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26 Transmission 26–01 Manual Transmission Fluid Change, and Magnetic Plug Cleaning (Synthetic Lubricant) formance, change the filter each time that the fluid is changed. 5. For a transmission equipped with a transmission fluid filter(s), replace the fluid filter(s). 5.1 Place a drain pan under the transmission fluid filter. CAUTION Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage. Do not overfill the transmission.
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26 Transmission Approved Manual Transmission Lubricants Transmission Model Temp. SAE Range Viscosity Lubricant Type* Eaton Fuller Transmission Lubricant Capacities Transmission Model Eaton Fuller Transmissions† MobilTrans SHC 50 (RN 2952 E-5) All Eaton Fuller All All 15-Speed Series 50W All Models 14.0 (13.2) All 18-Speed Series Synthetic transmission lubricant approved by Eaton All 50W RTLO Series 14.0 (13.
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26 Transmission • 25 to 35 lbf·ft (34 to 48 N·m) for Eaton Fuller transmissions with 3/4-inch pipe threads. 1 • 60 to 75 lbf·ft (81 to 102 N·m) for Eaton Fuller transmissions with 1-1/4-inch pipe threads. • 44 lbf·ft (60 N·m) for all ZF Meritor FreedomLine automated transmissions. 1 • 35 to 50 lbf·ft (48 to 67 N·m) for all other Meritor transmissions. 9. Operate the vehicle to check for correct operation.
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26 Transmission 10. Align each cover assembly with the holes in the channel plate sump, and push the cover assemblies in by hand to seat the seals. CAUTION 26–03 Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement Do not use the bolts to draw the filter covers to the sump. This can damage the covers, seals, or sump. Eaton Fuller 11. Install six bolts in each cover, and torque the bolts 38 to 44 lbf·ft (51 to 61 N·m). 1. Apply the parking brakes and chock the rear tires.
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26 Transmission 2 3 4 5 6 7 7. Start the engine, and build pressure in the air system. Check for air leaks at the filter housing and air line connections; repair any leaks. Meritor NOTE: This procedure does not apply to FreedomLine transmissions. 1. Park the vehicle on a level surface. Apply the parking brakes and chock the rear tires. 1 f260052a 10/17/2001 1. 2. 3. 4. Air Regulator Housing Large O-Ring Filter Element 5. Small O-Ring 6. End Cap 7. Plug Fig.
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26 Transmission ter in the hydraulic system may cause undue wear of transmission parts, make valves stick, and clog passages. It is important to check the fluid level cold to determine if the transmission has a sufficient amount of fluid to be safely operated until a hot check can be performed. 1. Park the vehicle on a flat, level surface. 2. Apply the parking brakes and chock the rear tires. 3. Run the engine for at least one minute. 4.
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Transmission 26 2. Using your finger or a bent pipe cleaner, see if the fluid is level with the fill opening. See Fig. 1. 3. If the fluid level is low, check the transmission for leaks, and correct as needed. 4. If needed, add the recommended fluid, until it is level with the lower edge of the fill opening. See Table 1 for approved transmission lubricants. 5. Clean the fill plug, then install it in the transmission.
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Frame and Frame Components 31 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fifth Wheel Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–01 Fifth Wheel Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31–02 Frame Fastener Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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31 Frame and Frame Components 31–01 Fifth Wheel Inspection WARNING All fifth wheel maintenance, adjustment, and rebuilding must be done only by a qualified mechanic. Improper or incomplete procedures could result in a possible disengagement of the trailer from the tractor, which could result in personal injury or property damage. Parts are under spring compression. Wear safety goggles while servicing the fifth wheel. Failure to do so can result in personal injury, due to parts ejecting with force.
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31 Frame and Frame Components 16 13 12 8 8 7 14 15 17 5 12 12 12 18 11 10 12 19 6 5 15 20 9 21 22 5 8 27 5 7 26 6 8 25 1 15 12 2 3 4 12/02/2010 12 24 23 2 f311134 NOTE: 6000 Series shown; 7000 Series fifth wheels use similar parts. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Wedge Stop Rod Nut Flat Washer, 5/8" Wedge Stop Rod Spring Wedge Stop Rod Grease Fitting Bracket Pin Bracket Retainer Pin Cotter Pin, 3/16" x 1" Bumper Spring Handle Spring 11. 12. 13. 14. 15. 16. 17. 18.
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31 Frame and Frame Components 1 Holland FW35 1. Thoroughly steam clean all fifth wheel components before inspection. 2. Check for cracks in the fifth wheel assembly, mounting brackets, and mounting parts. 2 3 3. Check the fastener torques on the fifth wheel assembly and fifth wheel mounting. Tighten bolts and nuts as needed. Replace missing or damaged bolts. 4 4. Inspect the fifth wheel for bent, worn, damaged, and missing parts; replace them as needed with genuine Holland parts.
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31 Frame and Frame Components 2. Thoroughly steam clean the fifth wheel. 1 3. Check the fifth wheel plate for cracks. Check for sharp edges on top; the chamfer should be 1/8 to 1/4 inch (3 to 6 mm). 4. When the wheel is locked, the safety latch must swing free and fall freely into position. See Fig. 5. 1 2 2 3 4 f310470 04/11/2011 1. Operating Handle 2. Lever Bar Fig. 6, Lever Bar and Operating Handle Alignment 10/26/2010 f310353b 1. Lubricant Grooves 2. Safety Latch A 3.
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31 Frame and Frame Components 8. Check all mounting bolts for signs of fatigue, and tighten them to the proper torque. For torque specifications, see Group 00. Inspect all angles, plates, and brackets for cracks or other damage. 9. Replace cracked, worn, or damaged parts with new parts. Replace all loose mounting bolts with 5/8–11 SAE grade 8 bolts, grade C locknuts, and hardened washers. Do not re-use bolts, nuts, and washers on fifth wheel mountings. 10.
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31 Frame and Frame Components C 1 E 2 D 3 A F 09/02/2009 f311100 1. Jam Nut 2. Adjustment Bolt Fig. 10, Jost Fifth Wheel H G B f311099 09/01/2009 A. B. C. D. E. F. G. H. Checking for fore/aft play Rotating tester in lock Engage hook Pull/push handle fore/aft. Check for movement of kingpin in lock Disengage hook Push/pull handle inboard/outboard Rotate lock tester Fig. 9, Jost Fifth Wheel Adjustment 10. Replace cracked, worn, or damaged parts with new parts.
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31 Frame and Frame Components • After any service that requires the removal of lubrication from the fifth wheel head or components. WARNING mating surfaces. Lubricate the top and bottom contact surfaces of the jaw and wedge. See Fig. 1. Open and close the fifth wheel several times to further distribute the grease. Lightly oil other moving parts in the fifth wheel.
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31 Frame and Frame Components wheel; see Fig. 10. Apply a light oil to all moving parts. For sliding fifth wheels spray diesel fuel on the slide path of the base plate. 1 NOTICE Do not use a power grease gun. The pressure will damage the lube line. If the fifth wheel is not equipped with low-lube plates, apply a lithium-based grease with extreme pressure (EP) additive to the trailer contact surface of the fifth wheel.
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31 Frame and Frame Components • Fifth Wheel Legs • Fifth Wheel Mountings 1 2 4 • Frame Crossmembers and Gussets 5 • Front Frame Brackets • Front Suspension Spring Brackets • Fuel Tank Brackets 3 • Radius Rods • Rear Engine Supports • Rear Suspension Spring Brackets 6 • Shock Absorbers • All Other Frame Fasteners 5 8 7 Any component that shows signs of cracking, or other damage, must be repaired or replaced. See the Century Class Trucks Workshop Manual for repair or replacement information.
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31 Frame and Frame Components WARNING If at any time the 690 coupling is bound up (jackknifed), the 294 bolt MUST be replaced immediately! Do not use the coupling until the bolt has been replaced. In addition, carefully inspect the 690 coupling, drawbar, drawbar eye, front end assembly, and tail board for damage. Failure to do so may result in trailer separation from the truck while in use, resulting in serious personal injury or property damage.
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Suspension 32 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Suspension Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–01 Suspension Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–02 Suspension U-Bolt Torque Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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32 Suspension 32–01 Suspension Inspection Front Suspension Check WARNING A Do not replace individual leaves of a damaged leaf spring assembly; replace the complete spring assembly. Visible damage (cracks or breaks) to one leaf causes hidden damage to other leaves. Replacement of only the visibly damaged part(s) is no assurance that the spring is safe. On front spring assemblies, if cracks or breaks exist in the two top leaves, a loss of vehicle control could occur.
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32 Suspension NOTICE Failure to replace the suspension crossmember or gussets if they are cracked, worn, or otherwise damaged could result in damage to the vehicle chassis. 3. Without detaching the torque arms, attempt to move (by hand) each radius-rod end up, down, in, and out. If there is any movement, replace the torque arm. If a torque arm needs to be replaced, see Group 32 of the Century Class Trucks Workshop Manual for instructions. 11/27/95 f320465 Fig.
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32 Suspension bracket; apply hand pressure only. See Fig. 4. If movement at the center of the equalizer exceeds 1/8 inch (3 mm), replace the equalizer bushings. See Group 32 of the Century Class Trucks Workshop Manual for instructions. 1 2 1 A A 3 3 4 5 05/27/93 A. 1. 2. 3. 2 05/27/93 f320022a A. Measure the change in gap at this point. 1. Equalizer Bracket 3. Pry Bar 2. Equalizer Fig. 4, Side View of the Equalizer 7.
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32 Suspension bolts 45 lbf·in (500 N·cm). Any damage to the valve housing will void the warranty. A • Do not attempt to disassemble the Barksdale valve body or the control lever. There are no serviceable parts in the valve, and any disassembly will void the warranty.
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32 Suspension 1 1 A A B f320432 09/27/95 A. Non-Wear Area 1. Walking Beam 08/16/96 B. Wear Area f320453 A. Measure height here. 1. Left Forwardmost Axle Stop Fig. 7, AirLiner Axle Stop Measurement Inspect the walking beam for cracks or other damage. If damage is found, replace the walking beam. Keep the vehicle supported by the jack stands for the next operation. 5.
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32 Suspension 2. Inspect each frame hanger for any evidence of cracks in the vertical mounting flange. See Fig. 9. 2 1 1 f320420 09/15/95 09/15/95 f320419 1. Frame Rail 2. Crack In Inspection Area Fig. 9, Hendrickson RS Series Vertical Mounting Flange 3. Inspect each frame hanger for evidence of cracks in the horizontal mounting flange adjacent to the vertical drive pin area. See Fig. 10. 4.
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32 Suspension 1 4 1 A 2 3 f320112a 05/27/93 A. 1. 2. 3. 4. Minimum gap of 3/8" (9.5 mm). Forward (no. 1) Spring Hanger Spring Eye Pin Rear (no. 2) Spring Hanger Rear (no. 3) Extension Fig. 12, RTE Suspension (unloaded) 09/15/95 f320421 1. Rust Inspection Area Fig. 11, Hendrickson RS Series Rust Inspection 4 4. Inspect the cam surface of the number-two spring hanger for wear due to operating mileage. Also, inspect the outside legs for wear, which can be caused by worn spring eye bushings.
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32 Suspension second leaf. In this case, the main leaf or the complete spring should be replaced immediately. Neway Suspension WARNING Inspect the components and check their operation as described below. Failure to perform these inspections and checks could result in separation of worn suspension components and loss of vehicle control, possibly causing personal injury or death, or property damage. 1. Park the vehicle on a level surface. Apply the parking brakes and chock the tires.
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32 Suspension 1 4 2 3 09/15/95 f320423 1. Frame Rail 2. Axle Housing 3. Axle Centerline 4. Suspension Ride Height Fig. 14, Neway Ride Height Inspection 4 1 2 3 A 1 05/27/93 320020a 2 A. Lubricate here. 1. Cap-and-Tube Assembly Bushing 4 09/15/95 Fig. 15, Equalizer Assembly Lubrication to lubricate until grease exits both ends of the bushing. If the pin will not accept lubricant, remove the pin and clean the lubrication channels where lubricant may have hardened.
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32 Suspension Neway Spring Assembly U-Bolt High Nut Torque Values* No lubrication is required on Neway rear suspensions. Size Reyco 1–14 No lubrication is required on Reyco rear suspensions. 32–03 Suspension U-Bolt Torque Check Torque: lbf·ft (N·m) Stage Stage Stage Stage 1: 2: 3: 4: Hand tighten 60 (81) 200 (271) 520 to 600 (707 to 816) * Tighten in a diagonal pattern as shown in Fig. 17.
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Front Axle 33 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–04 Basic Inspection, Meritor Unitized Wheel Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–07 End-Play Check, Meritor Unitized Wheel Ends. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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33 Front Axle 33–01 Knuckle Pin Lubrication, Meritor Axles CAUTION Use regulated pressure when lubricating the knuckle assemblies, otherwise damage could result to the knuckle caps. cross-tube socket members indicates that the tie-rod end assembly must be replaced. 2. The threaded portion of the tie-rod end assembly must be inserted all the way into the cross-tube split for adequate clamping. See Fig. 2. Replace the components if this cannot be done.
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33 Front Axle 33–04 All-Axle Alignment Check A Drive-Axle Alignment Checking Check the axle alignment, parallelism, and thrust angle measurements for the rear drive axles. Use the applicable procedure and specifications in Group 35 of the Century Class Trucks Workshop Manual. Toe-in Inspection For vehicle alignment to be accurate, the shop floor must be level in every direction.
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33 Front Axle 1 A 1 f330129 11/21/95 A. Grease Exit 1. Grease Fitting Fig. 6, Dana Spicer Knuckle Pin Lubrication 33–06 Tie Rod Lubrication, Dana Spicer Axles f400100a 08/30/94 Fig. 5, Setting Trammel Bar Pointers 33–05 Knuckle Pin Lubrication, Dana Spicer Axles CAUTION Use regulated pressure when lubricating the knuckle assemblies, otherwise damage could result to the knuckle caps. Park the vehicle on a level surface, apply the parking brakes, and chock the wheels.
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33 3. Rotate the tire and hub assembly. They should rotate smoothly and without noise. Grasp the brake chamber while rotating the hub to detect any hub vibration. If the hub rotates smoothly, go to the next step. If the tire and hub assembly do not rotate smoothly, or you hear noise during rotation, go to "End-Play Check, Meritor Unitized Wheel Ends." 4. Grasp the tire and hub assembly at the 3 o’clock and 9 o’clock positions.
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33 Front Axle For instructions, see Group 33 of the Century Class Trucks Workshop Manual. 23.2 Apply Loctite® 17430 gasket sealant to the external hub cap threads. 17. Check the rotation of the hub. If it doesn’t rotate smoothly and without noise, replace the entire wheel end assembly. For instructions, see Group 33 of the Century Class Trucks Workshop Manual. 23.3 Install the hub cap by hand until it is seated. 23.4 Using a torque wrench, tighten the hub cap 350 lbf·ft (475 N·m).
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Rear Axle 35 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Axle Breather and Axle Lubricant Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–02 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning (synthetic lubricant). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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35 Rear Axle 35–01 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning (synthetic lubricant) 1 CAUTION Failure to change the axle lubricant at more frequent intervals, when adverse operating conditions require, could result in axle damage. NOTE: Axle lubricant change intervals are extended to 500,000 miles (800 000 km) on vehicles equipped with a Meritor RT40–145P or RT46–160P rear axle. Dana Spicer 2 05/27/93 f350018a 1. Oil Fill Plug 2. Drain Plug Fig.
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35 Rear Axle cause permanent damage to unprotected eyes. Do not point the air stream in the direction of other persons. 5.2 5.3 Wash the strainer in solvent, and blow it dry with compressed air to remove oil and metal particles. Install and tighten the magnetic strainer 40 to 60 lbf·ft (54 to 81 N·m). 6. Clean the fill plugs and drain plugs. To help clean magnetic plugs, a piece of key stock or any other convenient steel slug may be used to short the two magnetic poles and divert the magnetic field.
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35 Rear Axle A. For all synthetic gear oils other than Mobil, add 1.6 ounces (35 mL) of additive for each pint (0.5 L) of lube capacity: A • Elco No. 2 Friction Modifier (Elco Corporation). • Lubrizol No. 6178 (Lubrizol Corporation). • Hi-Tec E-336 (Edwin Cooper, Inc.). B • Equa-Torque No. 2411 (Sta-Lube Corporation). f350061a 08/17/2009 A. Correct (lube level at bottom of fill hole) B. Incorrect (lube level below fill hole) • Equa-Torque No. 2414 (Sta-Lube Corporation). B.
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35 Rear Axle 3. If so equipped, replace the axle oil filter. Remove the oil filter, using a suitable filter strap wrench. See Fig. 5. Discard the filter. sary to clean or change the plugs one or more times between lubrication change intervals. 7. After cleaning the drain plug(s), install and tighten to 35 lbf·ft (47 N·m). 8. With the vehicle on a level surface, fill the axle housings to the bottom of the fill hole, using specified lubricant.
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35 Rear Axle maintenance operation for the shift unit lubricant changing procedure. 12. Remove the chocks, then drive the vehicle, unloaded, for 1 or 2 miles (2 or 3 km) at speeds not to exceed 25 mph (40 km/h), to thoroughly circulate lubricant throughout the carrier and housing assemblies. Two-Speed-Axle Shift Unit Lubricant Changing Dana Spicer and Meritor Axles 1. Remove the shift unit housing cover. See Fig. 6. Drain and discard the old lubricant. Discard the housing cover gasket.
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35 Rear Axle and correct as needed. Add lubricant as required. See Table 1 for recommended drive axle lubricants. IMPORTANT: Axle housing breathers (see Fig. 7) must remain clean and unclogged. Always check the axle breather whenever checking lubricant level. Ensure that it is open and unclogged. Check the breather more frequently under adverse operating conditions. If the breather is plugged or damaged, clean or replace it as needed. 5. Install and tighten the fill plug 40 to 60 lbf·ft (54 to 81 N·m).
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35 Rear Axle This cold-weather mixture can be safely used up to 32°F (0°C). 1 Commercially available automatic transmission fluid may be used in place of SAE 10 engine oil. Automatic transmission fluid can be used for all temperatures; do not mix it with kerosene. 3. Apply a small amount of Loctite® 242, or equivalent sealant, to the threads of the fill plug. Install the fill plug finger-tight; then, using a wrench, tighten it 1-1/2 turns past finger-tight. 2 3 06/07/94 f350062a 1.
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Wheels and Tires 40 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Wheel Nut and Rim Nut Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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40 Wheels and Tires 40–01 Wheel Nut and Rim Nut Check IMPORTANT: After installing a wheel, the wheel or rim nut torque must be rechecked after 50 to 100 miles (80 to 160 km) of operation. See Table 1 for wheel nut torque specifications, and see Fig. 1 for the wheel nut tightening sequence. breakage, and extreme tire tread wear. Excessive wheel nut torque can break studs, damage threads, and crack discs in the stud hole area.
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40 Wheels and Tires 2 1 10 7 4 5 6 8 3 A 1 1 1 8 3 3 6 5 4 6 3 5 7 4 9 2 B 5 2 2 C D f400057 05/27/93 A. 8-Stud Disc Wheel B. 10-Stud Disc Wheel 4 C. 6-Spoke Wheel D. 5-Spoke Wheel Fig.
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Driveline 41 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–01 Driveline Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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41 Driveline 41–01 Driveline Inspection 1. Park the vehicle on a flat, level surface, apply the parking brakes, and chock the tires. CAUTION Due to the extreme load occurring at high-speed rotation, a loose or broken capscrew at any point in the driveline will weaken the driveline connection, which could eventually result in serious vehicle damage. Do not over-tighten bearing-cap capscrews or yoke-strap capscrews. 2.
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41 Driveline 14 15 13 3 9 8 7 16 12 11 1 2 10 6 5 4 3 05/01/95 f410067b NOTE: Not all fasteners are shown. 1. Transmission 2. Transmission Output-Shaft End-Yoke (yoke-strap type) 3. U-Joint Assembly 4. Bearing Cap Self-Locking Capscrew 5. Bearing Cap 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Splined Stub Shaft Driveshaft Tube Tube-Yoke (bearing-cap type) Axle Input-Shaft End-Yoke (yoke-strap type) 16.
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41 Driveline 41–02 Driveline Lubrication Universal Joint Lubrication NOTE: Vehicles equipped with Meritor RPL Series drivelines do not require periodic lubrication. 1. Park the vehicle on a flat surface, apply the parking brakes, and chock the tires. 2. Wipe all old grease and dirt from each U-joint grease fitting. See Fig. 5, Ref. 8. f410012a 05/27/93 Attempt to move the sleeve-yoke and splined shaft back and forth. Fig.
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41 Driveline Slip Joint Spline Lubrication NOTE: Vehicles equipped with Meritor RPL Series drivelines do not require periodic lubrication. 1. If equipped with a grease fitting, wipe all old grease and dirt from the slip joint grease fitting. See Fig. 5, Ref. 1. 2. Use a hand-type grease gun or a high-pressure gun with a low-pressure adapter, to lubricate the slip joint.
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Brakes 42 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Brake System Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–01 Air Dryer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–03 Alcohol Evaporator Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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42 Brakes 42–01 Air Brake System Valve Inspection NOTE: There is no scheduled air valve maintenance on vehicles equipped with Bendix air valves and a Bendix air dryer if the air dryer desiccant is replaced at 350,000 miles (563 000 km). If the desiccant is not changed at 350,000 miles (563 000 km), or if the vehicle is equipped with another air dryer, maintenance will have to be performed to the air brake valves. See Group 42 of the Century Class Trucks Workshop Manual for procedures.
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42 Brakes 1 2 11 9 3 4 25 5 10 8 10 14 12 10 10 10 10 23 8 6 13 10 24 22 15 7 8 21 20 18 17 19 16 08/09/95 1. 5/16" x 4-1/2" Upper Mounting Bracket Capscrew 2. Upper Mounting Bracket Strap 3. 5/16" Lockwasher 4. 5/16" Nylok® Nut 5. Upper Mounting Bracket 6. Housing 7. Nylok® Nut 8. 3/8" Special Washer f421383 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
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42 Brakes 6 sidered an indication of poor air dryer performance. 2 4 5 2. Inspect the air dryer for external damage, and check that the unit is tightly mounted on the frame. If the air dryer mounting is loose, See Group 42 of the Century Class Trucks Workshop Manual for mounting instructions. 3. Turn on the ignition switch, but don’t start the engine. 1&9 3 7 5. Connect a voltmeter to circuit 94 on the air dryer’s harness connector and to a body ground point. Check for battery voltage.
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42 Brakes 2. Remove the capscrews and reservoir from the cover. 3. Remove the cover tetraseal. 4. Drain the air tank, and disconnect the line from the evaporator outlet. Remove the check-valve retainer, spring, and disc. 5. Install the disc, spring, and check-valve retainer, and connect the line to the evaporator outlet. 6. Install the cover tetraseal. 7. Install the reservoir on the cover and tighten the capscrews. 8.
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42 Brakes aged. See Group 42 of the Century Class Trucks Workshop Manual for grease seal replacement instructions. 1 42–06 Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication IMPORTANT: Perform MOP 42–11 before lubricating the slack adjusters. Automatic slack adjusters that have a grease fitting, must be lubricated periodically to ensure proper brake operation.
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42 Brakes 42–08 Meritor Slack Adjuster Lubrication 4 5 6 NOTE: If equipped with an extendedmaintenance Q Plus™ brake system, the slack adjuster will not have a grease fitting. These slack adjusters use a special NLGI Grade synthetic polyurea grease and do not require lubrication for 3 years or 500,000 miles (800 000 km), whichever comes first. The extendedmaintenance slack adjusters are lubricated during the brake reline service interval.
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42 Brakes 42–10 Bendix E–6 Foot Contol Valve Inspection and Lubrication 1 2 1. Remove the foot control valve from the vehicle. See Section 42.03, Subject 110 of the Century Class Trucks Workshop Manual for instructions. 3 2. Remove the roll pin from the brake pedal pivot pin. See Fig. 9. 4 2 5 5 7 6 10/20/93 f420012a 1. 2. 3. 4. 5. Brake Chamber Clevis Actuator Rod Boot Pressure-Relief Capscrew, Gasket, Pawl Spring, and Pawl 6. Manual Adjusting Nut 7.
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42 Brakes 8. Remove the plunger from the valve. Using alcohol, clean the existing grease from the plunger. Check the plunger for signs of wear or cracks. Replace it if necessary. 9. Lubricate the plunger with synthetic grease of NLGI Grade 1.5, such as 76 Triton synthetic EP Grease (FTL Sped 48-25432-000). 10. Insert the plunger in the valve. 11. Install the brake pedal and the pivot pin. 12. Install a new roll pin, and apply Torque Seal (OPG F900 White) to the roll pin.
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42 Brakes Brake Chamber Stroke Specifications Chamber Manufacturer Type* Size† 9 12 Max Applied Stroke: inch (mm) 1-3/8 (35) 16 Standard Stroke 20 1-3/4 (44) 24 Gunite 30 2 (51) 36‡ 2-1/4 (57) 16 20 Long Stroke 2 (51) 24 (2-1/2 inch rated stroke) 24 (3 inch rated stroke) 2-1/2 (64) 30 12 Standard Stroke Haldex 1-3/8 (35) 16 20 1-3/4 (44) 24 2-1/2-Inch Extended Stroke 24 2 (51) 3-Inch Extended Stroke 24 2-1/2 (64) Standard Stroke 30 2 (51) Long Stroke 30 2-1/2 (64) 9 12 Sta
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42 Brakes Brake Chamber Stroke Specifications Chamber Manufacturer Type* Max Applied Stroke: inch (mm) Size† 16L 20L Dana Spicer Long Stroke 2 (51) 24L 24LS 2-1/2 (64) 30LS * Long stroke design is indicated by a tag, or embossing, on the brake chamber. † Specifications are relative to a brake application with 80 to 90 psi (550 to 620 kPa) air pressure in the brake chambers. ‡ If type 36 chamber is used, slack length should be less than 6 inches.
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Steering 46 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Drag Link Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–01 Drag Link Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–05 Power Steering Fluid Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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46 Steering 46–01 Drag Link Inspection return hose at the reservoir. Drain the power steering fluid into the drain pan and dispose of the fluid properly. Plug the return line fitting on the reservoir. WARNING All steering system components are critical for safe operation of the vehicle. Failure to maintain the steering system as specified may result in loss of steering control, which could lead to personal injury and property damage. 3. Use the following procedure for Century Class Conventionals.
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46 3.2 Steering Lift out the filter spring and the filter top plate, then remove the filter. It may be necessary to wiggle the filter to remove it from its base. Do not use pliers to aid in removal of the filter; pliers could cause metal chips to enter the steering system. Clean the inside of the reservoir using a lint-free cloth. 1 6 3 4 IMPORTANT: Do not start the engine while draining the system. 3.3 3.4 Place the disconnected end of the steering gear-to-reservoir hose in the drain pan.
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46 Steering 5. Fill the power steering reservoir with approved power steering fluid to the FULL COLD mark. See Table 1. 6. Start the engine and operate it at idle. Turn the steering wheel to full lock left and right to adjust the fluid level and remove any existing air from the power steering pump and gear. Recheck the fluid level. Add fluid as needed. The system is properly bled when the steering pump does not labor when turning the wheel. 7.
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46 Steering TRW TAS Series CAUTION Apply grease to the sector shaft only with a handtype grease gun. See Fig. 4. Use of a highpressure power grease gun will supply grease too quickly and could affect the high pressure seal, contaminating the hydraulic fluid. Using a hand-type grease gun, apply NLGI Grade 2 or 3 multipurpose chassis grease until it starts to come out past the sector shaft seal. 11/27/95 1 2 f461072 1. Grease Fitting at Pitman Arm 2. Grease Fitting at Axle Steering Arm Fig.
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46 Steering 16 11 12 15 13 10 7 8 9 14 6 17 2 3 4 5 21 19 9 8 20 22 23 18 5 1 3 f462151 07/24/2009 1. 2. 3. 4. 5. 6. 7. 8. 9. Steering Tie Rod Arm Power Steering Fluid Lines Large Bellows Clamp Bellows Small Bellows Clamp Driver-Side Outer Tie Rod Tie Rod Jam Nut Inner Tie Rod Flat Inner Tie Rod Ball Joint 4 10. 11. 12. 13. 14. 15. 16.
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46 Steering Group 46 of the Century Class Trucks Workshop Manual for instructions. Check the steering system pressure and return lines and fittings for leaks and damaged lines or hoses. Repair or replace lines, hoses, and fittings as necessary. 10. Check the tube fittings on the hard transfer lines of the gear, see Fig. 6, Item 15. If there is leakage from either of the fittings, replace the rack and pinion unit.
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Fuel 47 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fuel Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–01 Fuel Separator Sight Bowl Cleaning and Element Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47–02 Fuel Tank Band-Nut Tightening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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47 Fuel 47–01 Fuel Filter Replacement 1 2 Refer to the engine manufacturer’s service manual for removal and installation procedures. 47–02 Fuel Separator Sight Bowl Cleaning and Element Replacement 3 ConMet Fuel Separator Sight Bowl Cleaning 3 The only maintenance necessary on ConMet fuel separators is to clean the sight bowl, if equipped. See Fig. 1. 4 5 WARNING Diesel fuel is flammable and can ignite if exposed to an open flame, intense heat, or other ignition source.
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47 Fuel IMPORTANT: The fitting must be air-tight and the valve closed. 2 3 1 Racor Fuel Separator Element Replacement 4 The only service necessary on Racor fuel separators is to replace the filter element. Racor 490 11 WARNING 5 Diesel fuel is flammable and can ignite if exposed to an open flame, intense heat, or other ignition source. Do not drain fuel near, or expose fuel vapor to open flame or intense heat.
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47 Fuel 4. Remove the bowl from the element, and clean the O-ring. 1 5. Apply a coating of clean fuel or motor oil to the new O-ring and element seal. 2 6. Spin the bowl onto the new element, then spin them both onto the filter head snugly, by hand only. 3 IMPORTANT: Do not use tools to tighten. 7. Connect the water sensor and heater connectors, if equipped. 10 8. Prime the fuel separator. 8.1 8.2 Remove the 3/8-inch metal plug located at the top of the fuel/water separator (see Fig. 3, Ref.
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Exhaust 49 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number CAT CGI Bellows Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–02 Exhaust System Inspection (Noise Emission Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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49 Exhaust 49–01 Exhaust System Inspection (Noise Emission Control) In addition to inspecting the exhaust system at the scheduled maintenance interval, inspect the exhaust system if the noise level of the vehicle has increased. Replace parts that show leakage, wear, or damage, with genuine Freightliner parts. 3 3 Pre-EPA07 Exhaust System Inspecting 1. On all vehicles, check the condition of the muffler body, the top stack, and the heat shield. See Fig. 1.
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49 Exhaust 2 1 3 4 06/01/93 1. 2. 3. 4. f490024a Flex Hose V-Band Coupling Exhaust Pipe Turbocharger Exhaust Outlet 05/28/93 f490025a Fig. 4, Donaldson Sealclamp Wide-Band Exhaust Clamp Fig. 2, V-Band Coupling and Flex Hose 1 10/05/94 2 f490005a Fig. 5, Torca Torctite Wide-Band Exhaust Clamp 3 08/25/95 f490127 1. Exhaust Pipe 2. Exhaust Elbow Isolator 3. Mounting Nut Fig. 3, Exhaust Elbow Isolator Definitions of ATS Components Refer to the following list of definitions of ATS components.
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49 Exhaust 6 5 1 2 3 4 2 7 5 8 9 3 A 10/20/2006 A. 1. 2. 3. 4. 5. Inspect this area of the canister for dents. Marmon Fitting at Inlet from Turbocharger DOC Temperature Sensor ATD Mounting Band DPF Intake Pressure Sensor DPF V-Band Mounting Clamps 6. 7. 8. 9. f490283 Sensor Housing DPF Outlet Temperature Sensor Exhaust Outlet Marmon Fitting DPF Outlet Pressure Sensor Fig.
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49 Exhaust 1 2 3 4 5 6 5 3 7 8 9 3 10 02/24/2011 1. 2. 3. 4. 1 f490456 Clamp Inlet Pipe U-Clamp Forward Pipe-Support Brace 5. Slip Clamp 6. CGI Bellows 7. Center Pipe-Support Brace 8. Center Pipe 9. Clamp 10. Outlet Pipe Fig. 8, CAT EPA07 Exhaust Installation with CGI Bellows 6. Check for leaks around the clamps that attach the ATD in the ATS, and around the clamps that retain the DPF in the ATD. No leaks are allowed anywhere in the system. 7.
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49 Exhaust NOTICE When the CGI pipes and bellows are installed, there should be approximately 3/4 inch (19 mm) clearance from the main bellows. Contact between the bellows could result in an exhaust leak, which in this case may allow ingestion of contaminants into the engine causing engine damage. 6.3 Use a straightedge to align the pipes so that the pipe ends that attach to the bellows are parallel and concentric. 8. Using a yellow paint pen, mark the pipes 1.
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49 Exhaust 13. Install the slip clamp with the retaining ring and graphite gasket ring onto the forward CGI pipe. See Fig. 12 for proper installation. 1 02/08/2010 1. CGI Bellows 2. Slip Clamp 3. Retaining Ring 2 3 4 5 f490417 4. Graphite Gasket 5. Forward CGI Pipe Fig. 12, Forward Facing Slip Clamp Installation 14. Slide the end of the forward CGI pipe into the bellows, and properly align the pipe. 15. Secure the forward CGI pipe to the engine and any CGI pipe support brackets. 16.
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Cab 60 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Cab Access Stairs Inspection, Argosy COE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60–03 Cab Suspension Air Bag Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60–01 Cab Tilt Pump Reservoir Fluid Level and System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Cab 60 60–01 Cab Suspension Air Bag Inspection 60–03 Cab Access Stairs Inspection, Argosy COE Inspect the cab suspension air bags at the rear of the cab. Check for wear, leakage, and damage. Replace if necessary. On Argosy COEs, inspect the cab access stairs for wear, damage, or excessive dirt build-up, and verify that the step is operating properly. Inspect the bump stops, and replace if necessary. See Fig. 1. Inspect the cab suspension shock absorber for damage or leaking fluid.
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60 Cab 3 2 4 1 2 01/13/2003 1. Forward Bump Stop 2. Flatwasher 3 f602109 3. Bolt 4. Rear Bump Stop Fig.
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Door 72 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Door Seal, Door Latch, Door Hinge, and Door Check Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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72 Door 72–01 Door Seal, Door Latch, Door Hinge, and Door Check Lubrication NOTE: Light penetrating oils, such as WD–40, should not be used because they wash out beneficial factory-installed grease, and they evaporate. Door Seals Lightly coat the door seals with a lubricant that’s safe for rubber. Door Latches Wipe old grease and dirt from all door latch assemblies, then apply liberal amounts of an approved grease to each moving joint; see Table 1.
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72 Door A B f720613 8/24/2005 A. Hinge installed on or after 8/1/2005, with dimple in the top loop of the hinge bracket. Do not lubricate. B. Hinge installed before 8/1/2005. Lubricate according to recommendations. Fig.
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Heater and Air Conditioner 83 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–01 Air Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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83 Heater and Air Conditioner 83–01 Air Conditioner Inspection WARNING Wear eye protection, gloves, and protective clothing when working on the air conditioning system. Leaking refrigerant from a damaged hose or line could cause blindness or serious skin burns. Preliminary Checks 1. Park the vehicle on a level surface, apply the parking brakes, and chock the tires. f830641 08/25/94 Fig. 1, Drive Plate Clearance Inspection 2. Check the appearance of the refrigerant compressor pulley assembly.
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83 Heater and Air Conditioner 2. Remove the two Torx® screws that secure the HVAC air filter cover to the air intake plenum. See Fig. 2. 2 1 2 3 1 f830769 12/18/96 1. Air Filter 2. Air Flow Direction Arrow f830768 12/18/96 1. HVAC Plenum 2. Filter Cover Fig. 2, HVAC Air Intake Plenum, Water-Valve Controlled 3. Pivot the front end of the cover out to remove the cover, and pull the air filter out of the air intake plenum. 4. Install a new air filter. 4.
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83 Heater and Air Conditioner 4 2 2 1 3 2 f831493 02/26/2002 1. Air Filter Cover 2. Wire Retainer Fig. 4, HVAC Air Intake Plenum, Blend Air 8. Remove the chocks from the tires. Cab Recirculation Air Filter Replacement, Water-Valve Controlled The cab recirculation air filter must be replaced every six months, regardless of mileage, to permit proper operation of the HVAC system.
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83 Heater and Air Conditioner tion 60.08 of the Century Class Trucks Workshop Manual. 3. Remove the retainer that holds the recirculation air filter in place. See Fig. 6. 1 2 components could occur. The HVAC system should not be operated without the recirculation air filter installed. 1. Turn off the engine, apply the brakes, and chock the tires. 2. Access the sleeper HVAC housing by raising the mattress and bunk panel to the locked position.
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83 Heater and Air Conditioner A 1 2 3 04/15/98 f831227 A. The arrow on the filter should point toward the HVAC assembly. 1. Sleeper HVAC Assembly 3. Filter (pleated-paper filter shown) 2. Screen Fig. 7, Sleeper HVAC Assembly, Water-Valve Controlled 3. Slide the air filter out of the sleeper HVAC assembly. See Fig. 8. 4. Discard the air filter. 1 5. Place a new air filter in the sleeper HVAC assembly. The edge of the filter should be flush with the HVAC assembly. 6.
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Hood, Grille, and Cab Fenders 88 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Hood Rear Support Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Hood, Grille, and Cab Fenders 88 88–01 Hood Rear Support Lubrication 1. Apply the parking brakes and chock the tires. 2. Open the hood. 3. Clean both the hood- and cab-mounted hood rear support components with a soapy water solution. 4. Cover all contact surfaces of the hood rear support brackets and isolators with an approved multi-purpose, lithium-complex, soap-based grease; see Table 1. 5. Close the hood.