CENTURY CLASS Maintenance Manual STI-341-1 A24-00691-000
CENTURY CLASS TRUCKS MAINTENANCE MANUAL Models: Argosy® COE C112 Conventional C120 Conventional CST120 Conventional Coronado® STI-341-1 (8/17) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
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.
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.
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.
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.
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 . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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
00 General Information Vehicle Maintenance Schedule Tables: 00–03 1st through 30th Maintenance for Service Schedules I and II Maint. No.
00 General Information Vehicle Maintenance Schedule Tables: 00–03 31st through 60th Maintenance for Service Schedules I and II Maint. No.
00 General Information Vehicle Maintenance Schedule Tables: 00–03 61st through 90th Maintenance for Service Schedules I and II Maint. No.
00 General Information Vehicle Maintenance Schedule Tables: 00–03 91st through 100th Maintenance for Service Schedules I and II Maint. No.
00 General Information Vehicle Maintenance Schedule Tables: 00–03 20th through 40th Maintenance for Service Schedules III and IV Maint. No.
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.
00 General Information Lubrication and Fluid Level Check: 00–04 Maintenance Operation 00–04 Lubrication and Fluid Level Check for Service Schedules I, II, III, and IV Maint. Operation Number 88–01 Operation Description Hood Rear Support Lubrication Service Schedules I, II, and III (at M1) Service Schedule IV (at M2) Check • * For Schedule II vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), whichever comes first.
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.
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.
00 General Information M1 Maintenance Interval Operations: 00–06 Maintenance Operation Number M1 Maintenance Interval Operations for Service Schedule IV 31–02 Fifth Wheel Lubrication 31–04 Trailer Electrical Connector Lubrication 33–11 Steer Axle Hub Cap Vent Plug Inspection 40–02 Tire Check 42–07 Meritor Camshaft Bracket Lubrication 42–10 Brake Inspection 42–11 Versajust Slack Adjuster Inspection and Lubrication* 49–01 Exhaust System Inspection (noise emission control) 60–02 Cab Tilt
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 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.
00 General Information M2 Maintenance Interval Operations: 00–07 Maintenance Operation Number M2 Maintenance Interval Operations for Service Schedules I, II, and III 47–01 Fuel Filter Replacement 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
00 General Information M2 Maintenance Interval Operations: 00–07 Maintenance Operation Number M2 Maintenance Interval Operations for Service Schedule IV 32–01 Suspension Inspection 32–03 Suspension U-Bolt Torque Check 33–02 Tie Rod Inspection 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
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.
00 General Information Maintenance Operation Sets Table: 00–09 Maintenance Operation Sets for Groups 00 through 83 Maint. No.
00 General Information Maintenance Operation Sets Table: 00–09 Maintenance Operation Sets for Groups 00 through 83 Maint. No.
00 General Information Maintenance Operation Sets Table: 00–09 Maintenance Operation Sets for Groups 00 through 83 Maint. No.
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
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 Century Class Trucks Maintenance Manual, August 2017 00/21
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). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
01 Engine 01–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
01 Engine 7. Inspect the pulleys for excessive play or wobble. Excessive play or wobble indicates a failure of the pulley bearing. Check for belt squealing or squeaking. Replace bearings as needed. NOTE: If it is difficult to distinguish the location of a supposed bearing noise, place a stethoscope on the component being checked, not the pulley, to isolate the area from outside interference. 8. Inspect all pulleys for foreign objects, oil, or grease in the grooves. 3.
01 Engine 01–03 Engine Mount Inspection (Noise Emission Control) and upper isolators (see Fig. 3 , Refs. 1 and 6), and replace them if they are worn. See Group 01 of the Century Class Trucks Workshop Manual for procedures.
01 Engine Check the front engine-support fasteners for tightness. Tighten the 5/8-inch fasteners 125 lbf·ft (170 N·m). NOTE: At engine overhaul, and whenever the engine has been removed, inspect the lower and upper isolators (see Fig. 3, Refs. 1 and 6), and replace them if they are worn; this applies to both the front and rear isolators. See Group 01 of the Century Class Trucks Workshop Manual for procedures.
Air Intake 09 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Element Inspection and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
09 Air Intake 09–01 Air Cleaner Element Inspection and Replacement Restriction of air flow through the air cleaner element is measured at the tap in the air cleaner outlet. Check the restriction indicator at the air cleaner or in the cab if the vehicle is equipped with a dashmounted restriction gauge. Vehicles may be equipped with either a manual-reset restriction indicator with graduations (Fig. 1), or a go/no-go restriction indicator without graduations (Fig. 2). 1.
Air Compressor 13 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13–01 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Compressor 13 13–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death. 13–01 Air Compressor Inspection 1.
Alternators and Starters 15 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–01 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15 Alternators and Starters 15–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
15 Alternators and Starters 10.1 Clean and tighten the battery ground cable, terminal, and clamps. 10.2 Inspect the retainer assembly (or battery hold-downs) and the battery box. Replace worn or damaged parts. Remove any corrosion with a wire brush, and wash with a weak solution of baking soda and water. Rinse with clean water and dry. To prevent rusting, paint the retainer assembly. 10.3 Check for and remove any foreign objects such as stones, bolts, or nuts, from the battery box. 10.
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20 Engine Cooling/Radiator 20–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
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 cooling system prior to the system cooling could cause severe personal injury due to scalding. 2 3 5. Remove the drain plugs from the radiator side tank, the lower tank on auxiliary radiators, and at the lower radiator outlet pipe elbow, if equipped. See Fig. 4. Allow the coolant to drain. 1 6.
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 7.3 Gradually, apply air pressure to help dislodge sediment built up in the radiator core.
20 Engine Cooling/Radiator B A 1 f200286 A. The screw tip must extend about 1/4 inch (6 mm). B. Belleville washer stacks must be collapsed almost flat. 1. Tightening Screw Hex 1 06/29/95 10/05/2016 1 f011008 NOTE: Cummins M11 engine shown. 1. Coolant Drain Plug Fig. 4, Coolant Drain Plug Location install these hose clamps correctly. The correct installation torque is as follows: For Breeze Constant-Torque clamps with a 5/16inch tightening screw hex: 55 lbf·in (620 N·cm).
20 Engine Cooling/Radiator radiator and hoses for leaks. Repair if necessary. 12.5 Shut off the engine, then check the coolant level in the surge tank. Add coolant if the level is not between the MIN and MAX lines on the surge tank. 13. On Argosy’s with auxiliary radiators, bleed the system while adding coolant as follows. 13.1 Open the remote bleed valve on the left side of the frontwall. 13.
20 Engine Cooling/Radiator age means that the large O-ring (Ref. 14) is damaged. 8. With the air system charged to 120 psi (827 kPa), and with the fan solenoid connector halves separated, check the fan clutch for audible air leaks, using a suitable listening device. 9. If a leak is detected, remove the fan blade. Using a soapy water solution, check the fan clutch at the following locations to locate the source of the leak. Install a new seal kit.
20 Engine Cooling/Radiator 10.1 Connect the halves of the fan solenoid connector. 10.2 Turn the air conditioner off. 10.3 Start the engine and charge the air system to 120 psi (827 kPa). Tests must be performed with the engine temperature below 205°F (96°C) for Caterpillar engines, and below 200°F (93°C) for Cummins and Detroit Diesel engines. 10.4 Set the toggle switch to the ON position; the fan clutch should engage. 10.5 Apply the foot brake, and release the parking brakes. 10.
20 Engine Cooling/Radiator this procedure, the fan could engage, which could result in serious personal injury. 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. 3.1 Unscrew the fan clutch solenoid valve air filter assembly and remove the filter element. 3.2 Clean the filter element with cleaning solvent. 3.
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 Clutch 25–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
25 Clutch 25–02 Clutch Release CrossShaft Lubrication 25–03 Sleeve Assembly Bronze Bushing Lubrication The clutch release cross-shaft is equipped with two grease fittings in the transmission clutch housing. See Fig. 3 and Fig. 4. Wipe any dirt from the grease fittings, then lubricate with multipurpose chassis grease. Vehicles equipped with the sealed clutch-release bearing have a lubrication extension outside of the clutch housing.
Clutch 25 4. Wipe off excess grease and apply it to both the yoke-finger and the sleeve-bushing contact points. See Fig. 2. 5. Install the clutch inspection plate. 6. Remove the chocks.
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 and Automated Transmission Fluid Change, and Magnetic Plug Cleaning (Synthetic Lubricant). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 Transmission 26–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
26 Transmission Fuller® transmission lubricant capacities and Table 3 for Meritor transmission lubricant capacities. For more information and a complete listing of Eaton approved lubricants, refer to the Eaton website, www.roadranger.com. For more information and a complete listing of Meritor approved lubricants, refer to the ZF Meritor website, www.zf.com. NOTE: In all cases, the correct fluid level is established by checking at the fill opening. 7.
26 Transmission • 44 lbf·ft (60 N·m) for all ZF Meritor FreedomLine automated transmissions. • 35 to 50 lbf·ft (48 to 67 N·m) for all other Meritor transmissions. 9. Operate the vehicle to check for correct operation. Meritor Transmission Lubricant Capacities Transmission Model Refill Capacity*: qt (L) Meritor M/MO Series M/MO (all) 10.25 (9.7) Meritor 9- and 10-Speed –115A/B/C/R (all) 10.0 (9.5) –125A/B/C/R (all) mission reaches normal operating temperature: 160 to 200°F (71 to 93°C). 2.
26 Transmission Allison Transmission Lubricant Capacities Transmission Model 1 Refill Capacity*: qt (L) 26 (25)† HD4060/4560 (shallow sump) * Quantities listed are approximate. Add listed amount of fluid, then perform a "hot check" and add fluid as needed. Do not overfill. † Add 3 quarts (3 liters) if equipped with a PTO.
26 Transmission through the filter element (inside to outside) to loosen surface dirt and to dry the element. If it is not damaged, the sintered metallic filter element will last the life of the vehicle. Wipe out the filter housing with a clean, dry, lintfree rag. Clean and inspect the O-rings and the end cap. Replace any parts that are damaged. 5. Install the large O-ring, then the filter element (small end first) into the filter housing. 6.
26 Transmission 26–04 Transmission Fluid Level Inspection If the fluid level is not within the COLD RUN band, add or drain fluid as needed to adjust the fluid level to the middle of the COLD RUN band. See Fig. 5. Allison B NOTICE Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage. Do not overfill the transmission. Do not mix types and brands of fluid, because of possible incompatibility.
26 Transmission If the fluid level is not within the HOT RUN band, add or drain fluid as needed to bring the fluid level within the HOT RUN band. See Fig. 5. • 35 to 50 lbf·ft (48 to 67 N·m) for all other Meritor transmissions. Eaton Fuller and Meritor NOTICE Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage. Do not overfill the transmission. Overfilling will force fluid out of the case through the main shaft openings.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31 Frame and Frame Components 31–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
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.
31 Frame and Frame Components Holland FWS1 1 1. Disconnect the tractor from the trailer. For instructions, see the Century Class Driver’s Manual. 2. Thoroughly steam clean the fifth wheel. 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. 2. 2 f311140 03/28/2013 1 1. Release Handle 2. Lever Bar Fig.
31 Frame and Frame Components 5. The lever bar and operating handle must be in proper alignment. See Fig. 6. Compare the lever bar and operating handle alignment to a new, or a properly operating lever bar and operating handle. Replace any bent or misaligned lever bar or operating rod. A 1 B 04/11/2011 f310887 A. The nut and washer should be snug against the fifth wheel. B. The locks should be completely closed around the kingpin. 2 Fig. 4, Holland Fifth Wheel Properly Closed 2.
31 Frame and Frame Components 4. Inspect the bracket pin bolts. Make sure the locking tabs are properly securing the bolts in place. See Fig. 8. A 5 1 2 3 4 04/11/2011 A. 1. 2. 3. 4. 5. f310475 Extended Top Plate Lift Height Fifth Wheel Top Plate Fifth Wheel Frame Mount Frame Rail Lifting Point Static Top Plate Height Fig. 7, Measuring Fifth Wheel Top Plate Lift set, which will normally recover after being uncoupled for a short period of time. 8.
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 9.1 Check the bracket for any cracks or missing and damaged parts. 9.2 Inspect the locking plungers for full engagement. 9.3 Check the locking mechanism for proper operation. 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.
31 Frame and Frame Components justment, refer to the fifth wheel installation instructions. 10. 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. 11. After inspecting the fifth wheel, lubricate all moving parts with a chassis or multipurpose grease.
31 Frame and Frame Components 3. Grease the yoke tips, locks, and the release handle and spring; see Fig. 12. Grease the mounting bracket supports through the grease fittings. A “low temp” grade grease rated for -30°F (-34°C) or lower such as Cato Oil and Grease #5213, Craftsman Chemical Co. #LTF 2, Mystic LP-200, or equivalent is recommended. 1 2 2 1 3 3 4 12/03/2010 f311135 1. Release Handle and Spring 2. Grease Fitting 3. Yoke Tip 4. Locks Fig.
31 Frame and Frame Components 31–03 Frame Fastener Torque Check 1 4 Frame brackets and components secured with Huckbolt® fasteners do not require a torque check, however, they should be inspected for damage. Frame brackets and components secured with conventional bolts and nuts are to be checked at initial maintenance (IM). See Fig. 13 for pre-EPA07 engine mounts. Check the torque of frame fasteners to offset the effects of "bedding in" (or seating).
31 Frame and Frame Components Century Class Trucks Workshop Manual for repair or replacement information. • Remove the 294 bolt. Using dye penetrate or magnetic particle testing along the length of the bolt, inspect for fractures. 31–04 Trailer Electrical Connector Lubrication • If the 294 bolt has no damage, install it and continue to use for another 6 months. In some cases, failure of trailer cables occurs due to intrusion of chloride-based road deicing chemicals into the trailer connector.
Suspension 32 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–00 Suspension Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32–01 Suspension Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 Suspension 32–00 Safety Precautions • a side to side crack extending beyond 3/4 of the length of the spring; Safety Precautions in this section apply to all procedures within this group. • a top to bottom crack extending beyond 3/4 of the length of the spring; DANGER When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
32 Suspension Inspect the shock absorber for oil leakage. If the shock absorber is damaged or leaking, replace it with a new one. See Group 32 of the Century Class Trucks Workshop Manual for replacement instructions. 2. Inspect the tandem-axle frame crossmember and gussets for wear, cracks, and other damage. If any of these conditions exist, replace the damaged parts. See Group 32 of the Century Class Trucks Workshop Manual for instructions.
32 Suspension 2 1 A 3 4 05/27/93 f320021a A. 1. 2. 3. Fig. 3, Torque Arm Bushings 1 5 05/27/93 1/8" (3 mm) Clearance Frame Fasteners Frame Rail Pry Bar f320023a 4. Equalizer 5. Equalizer Bracket A Fig. 5, Top View of the Equalizer 3 occur. Failure to replace a damaged spring assembly could cause an accident resulting in property damage, serious personal injury, or death. Inspect the forward and rear spring brackets for wear, cracks, and other damage.
32 Suspension • Do not overtighten the bolts in the Barksdale height-control valve housing. The bolts should not be loose, and should not require tightening. Only if necessary, tighten the valve housing bolts 45 lbf·in (500 N·cm). Any damage to the valve housing will void the warranty. A 4 1 • 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.
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 nents. The vehicle is lifted high enough when the beam ends are off of the saddles. 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.
32 Suspension components, loss of vehicle control, and possible personal injury or property damage. 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 1. Crack In Inspection Area 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.
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 and loss of vehicle control. This could result in serious personal injury or property damage. 4. Inspect the cam surface of the number-two spring hanger for wear due to operating mileage.
32 Suspension spring eye and spring are connected to the spring hanger through the wrapper eye of the second leaf. In this case, the main leaf or the complete spring should be replaced immediately. Neway Suspension WARNING 32–02 Suspension Lubrication Front Suspension Wipe all dirt away from the grease fittings (if equipped) on the spring-eye bushings. Apply multipurpose chassis grease with a pressurized grease gun until the old grease is forced out.
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.
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.
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33 Front Axle 33–00 Safety Precautions 1 Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
33 33–03 Tie Rod Lubrication, Meritor Axles For any Meritor axle that requires lubrication of the tie-rod ends, wipe the grease fittings clean, then pump multipurpose chassis grease, NLGI Grade 1 (6% 12-hydroxy lithium stearate grease) or NLGI Grade 2 (8% 12-hydroxy lithium stearate grease), into the tie-rod ends until all used grease is forced out and fresh grease is seen at the ball stud neck. Front Axle NOTE: If turn-plates or turntables are not available, lower the vehicle.
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 10/05/2016 f400100a Fig. 5, Setting Trammel Bar Pointers rections are needed, see Group 33 of the Century Class Trucks Workshop Manual for instructions on adjusting the toe-in.
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.
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).
33 Front Axle 1 2 1 06/12/2012 A f330273 NOTE: No grease should emit from the tie-rod boot. If grease emits from the tie-rod boot, the boot is damaged. 1. Grease Fitting 2. Boot Fig. 9, Grease Fitting and Boot, Detroit Axles 33–11 Steer Axle Hub Cap Vent Plug Inspection B General Information 1 06/07/2012 f330272 A Upper View, LH Side 1. Grease Fitting B Lower View, LH Side Fig.
33 Front Axle 09/01/2016 f330298 09/01/2016 f330300 Fig. 12, Water in Oil Fig. 10, Normal Oil Venting clean before checking the oil. Do not use a pressure washer to clean the hub/plug area. The plug has a vent and this can contaminate the oil with water. 1. Park the vehicle on a level surface, shut down the engine and set the parking brakes. Chock the tires. 2. Inspect the axle hub cap and vent plug for evidence of excessive leakage. 3. Wipe the hub cap and vent plug clean with a rag. 4.
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35–01 Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35 Rear Axle Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
35 Rear Axle ture, the oil will run more freely and ensure that the axle is flushed. 4. Clean the fill and drain plugs. Change them if necessary. 4.1 For magnetic plugs, use a piece of key stock or any other convenient steel slug to short the two magnetic poles and divert the magnetic field. 4.2 Clean away the collected material deposited on each pole. Magnets will rapidly lose their effectiveness as collected material bridges the gap between the two poles. 4.3 4.
35 Rear Axle hicle driver’s manual. If you are experiencing a problem with a Dana Spicer rear axle, see Group 35 of the Century Class Trucks Workshop Manual. 1. Park the vehicle on level ground, apply the parking brakes, and chock the tires. 2. Clean the area around, and including, the fill plug. Remove the plug from the oil fill hole (or standpipe if installed in the oil fill hole) located in the axle housing rear cover. See Fig. 3. 2 1 1 10/05/2016 f350017a 1. Magnetic Strainer 2 2.
35 Rear Axle 8. Fill the axle with recommended lubricant. See Table 3 for recommended drive axle lubricants, and Table 4 for drive axle lubricant capacities. NOTE: Some Dana Spicer axles have a small tapped and plugged hole near and below the housing oil fill hole. This smaller hole is for a lubricant temperature indicator only, and should not be used as a fill or level hole. 8.1 Using recommended lubricant, fill the axle through the oil fill hole or standpipe opening.
35 Rear Axle driver’s manual. Meritor’s experience shows that the following additives (friction modifiers) perform adequately: 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: • Elco No. 2 Friction Modifier (Elco Corporation). • Lubrizol No. 6178 (Lubrizol Corporation). • Hi-Tec E-336 (Edwin Cooper, Inc.). • Equa-Torque No. 2411 (Sta-Lube Corporation). • Equa-Torque No. 2414 (Sta-Lube Corporation). B.
35 Rear Axle 6. Clean the fill and drain plugs. For 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. NOTE: Meritor recommends plugs with elements having a minimum pickup capacity of 1-1/2 pounds (0.7 kg) of low-carbon steel, in plate or bar form. Magnets will rapidly lose effectiveness as collected material bridges the gap between the two poles. Clean or change the plugs before this occurs.
35 Rear Axle 3. Install the housing cover and a new cover gasket. Tighten the housing cover capscrews 7.5 to 9.2 lbf·ft (10.2 to 12.5 N·m), then remove the oil fill plug from the cover. IMPORTANT: When the ambient temperature is above 0°F (–18°C), use SAE 10 heavy-duty engine oil, API service classification SD (sulfated ash content must not exceed 1.85%).
35 Rear Axle 2. If the vehicle has just been driven, allow a few minutes for the lubricant to settle. 1 3. Clean the oil fill plug and area surrounding it, then remove the plug from the fill hole (see Fig. 3), or from the standpipe (if so equipped) installed in the fill hole. IMPORTANT: A lubricant level close enough to be seen or touched is not sufficient. It must be level with the bottom of the fill hole (see Fig. 2), or the top of the standpipe opening. 4.
35 Rear Axle component damage, do not mix engine oil with automatic transmission fluid. 1 IMPORTANT: When the ambient temperature is above 0°F (–18°C), use SAE 10 heavy-duty engine oil, API service classification SD (sulfated ash content must not exceed 1.85%). When the ambient temperature is below 0°F (–18°C), use one part kerosene to three parts SAE 10 heavyduty engine oil, API service classification SD (sulfated ash content must not exceed 1.85%).
Wheels and Tires 40 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Tire Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40–02 Wheel Nut and Rim Nut Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
40 Wheels and Tires 2 1 10 7 4 5 6 3 6 5 4 6 3 5 7 B 4 4 9 2 A 1 8 3 8 3 1 1 5 2 2 C D 07/23/2015 f400057b A. 8-Stud Disc Wheel B. 10-Stud Disc Wheel C. 6-Spoke Wheel D. 5-Spoke Wheel Fig. 1, Wheel Nut and Rim Nut Tightening Sequence Maintain the proper pressures for carried loads, per the tire manufacturers’ recommendations, or the tire pressure label on the driver’s door.
Driveline 41 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–01 Driveline Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41–02 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41 Driveline 41–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. 1 DANGER 2 When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death. ME 41–01 Driveline Inspection 1.
41 Driveline 14 15 13 3 9 8 7 16 12 11 1 2 6 10 5 4 3 10/06/2016 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.
41 Driveline 5 1 2 7 3 4 3 6 10/06/2016 f410012a Attempt to move the sleeve-yoke and splined shaft back and forth. Fig. 4, Slip Joint Spline Wear Checking 8 3 any evidence that balance weights are missing, remove the driveshaft and have it balanced. 9. For driveshafts with slip joints, check to be sure the yoke plug is not loose or missing. See Fig. 5, Ref. 2. Repair or replace the yoke plug as needed.
41 Driveline grease is seen at the seal, then tighten the capscrews to the correct torque specifications. If the bearing will not take grease, replace the U-joint. See Group 41 of the Century Class Trucks Workshop Manual for replacement instructions. 6. Check the purged grease. If it appears rusty, gritty, or burned, replace the U-joint. 7. Wipe the purged grease from the seals, and any excess grease from the grease fitting.
Brakes 42 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Brake System Valve Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–01 Air Dryer Desiccant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–02 Air Dryer Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42 Brakes 42–00 Safety Precautions 4. Disconnect the harness connector from the heater and thermostat assembly. Safety Precautions in this section apply to all procedures within this group. 5. Loosen the capscrew securing the upper mounting bracket strap. DANGER When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
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.
42 Brakes 6 WARNING 2 4 5 Do not attempt to disassemble the desiccant cartridge assembly. Parts for the assembly are not available and the cartridge contains a 150 lb spring that cannot be mechanically caged. Disassembly could release the spring, resulting in personal injury. 4. Remove and discard both O-rings from the cartridge bolt. 1&9 3 7 8 09/20/94 f420544a Fig. 2, End Cover to Housing Torque Pattern Torque the two remaining capscrews 270 to 385 lbf·in (3050 to 4350 N·cm).
42 Brakes 12.3 Fan the service brakes to reduce system air pressure to governor cut-in. Note that the system once again builds to full pressure and is followed by a purge at the AD-IP air dryer exhaust. 12.4 Check for excessive leakage around the head of the desiccant cartridge where it contacts the end cover. With the compressor in loaded mode (compressing air), apply a soapy solution to these areas, and observe that any leakage does not exceed a 1-inch bubble in 1 second.
42 Brakes will be saturated with moisture, and several weeks of operation may be needed to fully dry the system. 2 • The temperature range in your area fluctuates more than 30 degrees in one day. Small amounts of water can accumulate in the air brake system due to condensation. Under these conditions, the presence of moisture is normal and should not be considered an indication of poor air dryer performance. 3 2.
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.
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 42–10 before lubricating the slack adjusters. Automatic slack adjusters that have a grease fitting, must be lubricated periodically to ensure proper brake operation.
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.
42 Brakes 6. Check the brake pedal rollers for signs of wear or cracks. Replace them if necessary. 1 7. If the rollers are replaced, replace the roller pin, then install a new cotter pin and bend it 90 degrees, and apply torque seal (OPG F900 White) to the cotter pin. 2 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. 3 4 9.
42 Brakes Brake Component Inspection 1. Park the vehicle on a level surface, set the parking brake, and chock the tires. Once the tires are chocked, release the parking brake. WARNING Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mechanical problem. Adjustment is not repairing. Before adjusting an automatic slack adjuster, troubleshoot the foundation brake system and inspect it for worn or damaged components.
42 Brakes Brake Chamber Stroke Specifications Chamber Manufacturer Type* Size† Max Applied Stroke: inch (mm) 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 Standard Stroke 16 20 Meritor 24 Long Stroke 24 Standard Stroke 30 Less than 1-1/2 (38) Less than 1-3/4 (44) Less than 1-7/8 (48) Less than 2 (51) 16L 20L Dana Spicer Long Stroke 2 (5
42 Brakes ness appears excessive. Make certain the brake actuator pushrod jam nut is tightened securely. 2. Inspect the slack adjuster for physical damage, paying attention to the link, boot, and clevis. If any components are damaged, repair or replace them as necessary. 3. Measure the brake actuator pushrod stroke while making an 80 to 90 psi (552 to 621 kPa) brake application. Actuator pushrod strokes should not exceed the values shown in Table 2 and Table 3.
Steering 46 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Bellows Replacement, Rack and Pinion Steering Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46-07 Drag Link Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46–01 Drag Link Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46 Steering 46–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER 46–02 Power Steering Fluid and Filter Changing WARNING When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death. Fill only with approved clean fluid.
46 Steering 3.6 1 Install the reservoir cover over the threaded shaft. Apply a slight downward pressure while installing the rubber washer and the flanged nut. Tighten the nut until it is snug. 2 3 4. Use the following procedure for Argosy COEs. 7 4 4.1 8 Remove the clamp that holds the cover on the reservoir. See Fig. 2. Remove the cover. 9 1 5 6 3 6 2 4 5 11/28/95 f461070 1. Vented Fill Cap and Dipstick 2. Flanged Nut 3. Rubber Washer 4. Reservoir Cover 5. Filter Spring 6. 7. 8. 9.
46 Steering Add fluid to the reservoir as needed. When clean power steering fluid flows from the hose, remove the plug from the reservoir and reconnect the steering gearto-reservoir hose to the reservoir. Remove the jack stands and lower the vehicle. 4.4 Install a new filter into the reservoir. Install the filter spring and the filter top plate. 4.5 Clean the reservoir cover and O-ring seal. Inspect the O-ring and the cover for cracks, deformities, or damage. Replace the O-ring seal or cover as needed.
46 Steering TRW Steering Gears NOTICE Apply grease to the sector shaft with a hand-type grease gun only. Use of a high-pressure 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. See Fig. 4. 1 2 10/07/2016 f461072 1. Grease Fitting at Pitman Arm 2. Grease Fitting at Axle Steering Arm Fig.
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.
46 Steering hoses. Repair or replace lines, hoses, and fittings as necessary. NOTICE Do not tighten the tube fittings on the hard transfer lines. Tightening the tube fittings can cause tearing of the O-ring seal and increased fluid leakage. 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 steering gear. 46-07 Bellows Replacement, Rack and Pinion Steering Gear 1.
46 Steering NOTICE Improper installation may cause moisture and contaminants to enter the gear, which may result in severe damage. A 12. Install the new bellows on the gear. Ensure the bellows are seated properly on the gear housing and inner tie rods. 05/30/2012 B f462241 A. Do not apply Terostat near the small end of the bellows. B. Only apply Terostat to the gear where the large end of the bellows seats. Fig. 7, Apply Terostat To Large End of Bellows 13.
46 Steering NOTICE Do not over-tighten the Oetiker clamps. Overtightening may lead to stretching of the clamp, which could allow moisture intrusion and corrosion. If an Oetiker clamp stretches, remove and discard the clamp and install a new clamp. All three barbs on the clamp must be engaged. If all three barbs are not engaged after crimping, remove and discard the clamp and install a new clamp.
46 Steering NOTE: Use a calibrated, computerized, multi-wheel alignment tool, operated by a certified service technician to complete the following steps. If this type of tool is not accessible, the alignment procedure must be done by a facility that has the appropriate tool. When the alignment process requires that the steering wheel be pointed straight ahead, align the steering rack on-center pointers instead. See Fig. 13. 20.1 20.
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47 Fuel 47–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
47 Fuel 6. Spin the bowl onto the new element, then spin them both onto the filter head snugly, by hand only. 1 2 IMPORTANT: Do not use tools to tighten. 7. Connect the water sensor and heater connectors, if equipped. 3 8. Prime the fuel separator. 3 8.1 Loosen the vent plug. Then operate the primer pump until the fuel purges at the vent plug. See Fig. 2. 8.2 Close the vent plug. 9. Start the engine and check for fuel leaks. 10. Shut down the engine and correct any fuel leaks.
47 Fuel Racor 690 1 WARNING 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. Exposure to open flame or intense heat could start a fire, possibly resulting in personal injury or property damage. When working on a fuel system, have a fire extinguisher within easy reach. 2 3 10 1. Drain off some fuel by loosening the vent plug and opening the drain valve. 2.
Exhaust 49 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number CAT CGI Bellows Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–02 Exhaust System Inspection (Noise Emission Control). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49–01 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49 Exhaust 49–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER 3 3 When working on the vehicle, shut down the engine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop. Failure to follow these steps could result in serious personal injury or death.
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.
49 Exhaust maintenance inspections. If any discrepancies are discovered, refer to the engine manufacturer’s service literature for repair instructions. Inspection 1. Check for leakage at the clamp that attaches the 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.
49 Exhaust NOTE: Because the CGI bellows is covered with a metal mesh, it is difficult to see cracks or damage that may cause a leak. 9. Check for heat discoloration on the surface of the ATD. Heat discoloration may indicate internal damage; especially around the DPF. 3. On vehicles with CAT engines, inspect the CGI bellows and piping for evidence of damage or leakage. See Fig. 8. If the bellows is damaged or leaking, replace it. See 49–02 for the replacement procedure. 10.
49 Exhaust 4. Remove the CGI piping between the engine and aftertreatment device (ATD). 1 2 5. On the workbench, remove the CGI bellows from the exhaust piping. Do not damage the piping. A NOTE: The following step, and its substeps, is to be done without the bellows installed. This will align the pipes so that the bellows can be installed correctly. 6. Install the CGI piping (without CGI bellows) and align piping. 6.1 Attach the aft CGI pipe to the ATD. 6.
49 Exhaust A A 1 2 3 02/23/2011 f490458 A. At least 7/16 inch (10 mm) 1. Forward CGI Pipe 3. Aft CGI Pipe 2. CGI Bellows Fig. 11, CGI Bellows Installation 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.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
Door 72 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Door Seal, Door Latch, Door Hinge, and Door Check Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
Heater and Air Conditioner 83 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–01 Air Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83–02 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83 Heater and Air Conditioner 83–00 Safety Precautions adjustment, see Section 83.01, Subject 140 of the Century Class Trucks Workshop Manual. Safety Precautions in this section apply to all procedures within this group. On a Climate Control refrigerant compressor, place a feeler gauge between the air conditioner compressor clutch and the pulley to check the compressor clutch clearance. Drive plate to pulley clearance should be 0.020 to 0.030 inch (0.50 to 0.76 mm). If the clearance is 0.035 inch (0.
83 Heater and Air Conditioner 83–02 Air Filter Replacement Cab Fresh Air Filter Replacement, 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. 4.1 The cab fresh air filter must be replaced every six months, regardless of mileage, to permit proper operation of the HVAC system. CAUTION Slide a new air filter into the air intake plenum.
83 Heater and Air Conditioner not replaced every six months, damage to the heater and air conditioner components could occur. IMPORTANT: When replacing the air filter, use only a Freightliner-approved air filter. 1. Park the vehicle on a level surface. Apply the parking brakes and chock the rear tires. 2. Lift the wire retainer on the air filter cover up and over the upper edge of the cover, and pull the wire retainer down. See Fig. 4.
83 Heater and Air Conditioner 1 2 4 2 3 2 11/14/2000 1. HVAC Cover 2. Velcro Tape 1 f831418 3. Seal Cover 4. Recirculation Filter Fig. 5, Cab Recirculation Air Filter, Water-Valve Controlled IMPORTANT: When replacing the air filter, use only a Freightliner-approved air filter. 1. Park the vehicle on a level surface. Apply the parking brakes and chock the rear tires. 2. Remove the heater and air conditioner cover and the upper dash cover. For instructions, see Section 60.
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 The pleated paper filter has an arrow on the edge of the filter that should point toward the heater assembly. See Fig. 7. The foam filter can be installed in any direction. 6. Slide the screen into the frame on the sleeper HVAC assembly. 7.
83 Heater and Air Conditioner 5. Place a new air filter in the sleeper HVAC assembly. The edge of the filter should be flush with the HVAC assembly. 6. Lower the bunk panel and mattress. 7. Remove the chocks from the tires. 1 02/26/2002 f831492 1. Air Filter Fig.
Hood, Grille, and Cab Fenders 88 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Hood Rear Support Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
