Freightliner Century Class Argosy COE, C112 Conventional, C120 Conventional, CST120 Conventional, Coronado Truck Maintenance Manual
Below you will find brief information for Truck Century Class Argosy COE, Truck Century Class C112 Conventional, Truck Century Class C120 Conventional, Truck Century Class Coronado. This maintenance manual will guide you through the routine maintenance procedures and intervals for your vehicle components and systems, ensuring you get the most out of your Freightliner truck. It provides information on lubrication procedures, fluid replacement, capacities, specifications, and procedures for adjustments and checking fastener tightness. This manual does not contain detailed repair or service information.
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CENTURY CLASS
STI-341-1
A24-00691-000
Maintenance Manual
CENTURY CLASS TRUCKS MAINTENANCE MANUAL
Models: Argosy® COE
C112 Conventional
C120 Conventional
CST120 Conventional
Coronado®
STI-341-1 (1/16)
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.
Perform the operations in this maintenance manual at scheduled intervals. Perform the pretrip and post-trip inspections, and daily/weekly/monthly maintenance, as outlined in the vehicle driver’s manual. Major components, such as engines, transmissions, and rear axles, are covered in their own maintenance and operation manuals, that are provided with the vehicle. Perform any maintenance operations listed at the intervals scheduled in those manuals. Your Freightliner Dealership has the qualified technicians and equipment to perform this maintenance for you. They can also set up a scheduled maintenance program tailored specifically to your needs. Optionally, they can assist you in learning how to perform these maintenance procedures.
IMPORTANT: Descriptions and specifications in this manual were in effect at the time of printing. Freightliner Trucks reserves the right to discontinue models and to change specifications or design at any time without notice and without incurring obligation.
Descriptions and specifications contained in this publication provide no warranty, expressed or implied, and are subject to revision and editions without notice.
Refer to
www.Daimler-TrucksNorthAmerica.com
and
www.FreightlinerTrucks.com
for more information, or contact Daimler Trucks North America LLC at the address below.
Environmental Concerns and Recommendations
Whenever you see instructions in this manual to discard materials, you should attempt to reclaim and recycle them. To preserve our environment, follow appropriate environmental rules and regulations when disposing of materials.
NOTICE: Parts Replacement Considerations
Do not replace suspension, axle, or steering parts (such as springs, wheels, hubs, and steering gears) with used parts. Used parts may have been subjected to collisions or improper use and have undetected structural damage.
© 1996–2016 Daimler Trucks North America LLC
All rights reserved. No part of this publication, in whole or in part, may be translated, reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of Daimler Trucks North
America LLC. Daimler Trucks North America LLC is a Daimler company.
Daimler Trucks North America LLC
Service Systems and Documentation (CVI-SSD)
P.O. Box 3849
Portland, OR 97208–3849
Introduction
Descriptions of Service Publications
Daimler Trucks North America LLC distributes the following major service publications in paper and electronic
(via ServicePro®) formats.
Workshop/Service
Manual
Maintenance Manual
Driver’s/Operator’s
Manual
Service Bulletins
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. Each workshop/service manual section is divided into subjects that can include general information, principles of operation, removal, disassembly, assembly, installation, and specifications.
Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems. They have information such as lubrication procedures and tables, fluid replacement procedures, fluid capacities, specifications, and procedures for adjustments and for checking the tightness of fasteners. Maintenance manuals do not contain detailed repair or service information.
Driver’s/operator’s manuals contain information needed to enhance the driver’s understanding of how to operate and care for the vehicle and its components.
Each manual contains a chapter that covers pretrip and post-trip inspections, and daily, weekly, and monthly maintenance of vehicle components.
Driver’s/operator’s manuals do not contain detailed repair or service information.
Service bulletins provide the latest service tips, field repairs, product improvements, and related information. Some service bulletins are updates to information in the workshop/service manual. These bulletins take precedence over workshop/service manual information, until the latter is updated; at that time, the bulletin is usually canceled. The service bulletins manual is available only to dealers. When doing service work on a vehicle system or part, check for a valid service bulletin for the latest information on the subject.
Parts Technical Bulletins
IMPORTANT: Before using a particular service bulletin, check the current service bulletin validity list to be sure the bulletin is valid.
Parts technical bulletins provide information on parts. These bulletins contain lists of parts and BOMs needed to do replacement and upgrade procedures.
Web-based repair, service, and parts documentation can be accessed using the following applications on the
AccessFreightliner.com website.
ServicePro
PartsPro
EZWiring
ServicePro® provides Web-based access to the most up-to-date versions of the publications listed above. In addition, the Service Solutions feature provides diagnostic assistance with Symptoms Search, by connecting to a large knowledge base gathered from technicians and service personnel. Search results for both documents and service solutions can be narrowed by initially entering vehicle identification data.
PartsPro® is an electronic parts catalog system, showing the specified vehicle’s build record.
EZWiring
™ makes Freightliner, Sterling, Western Star, Thomas Built Buses, and
Freightliner Custom Chassis Corporation products’ wiring drawings and floating pin lists available online for viewing and printing. EZWiring can also be accessed from within PartsPro.
Century Class Trucks Maintenance Manual, March 2011
I–1
Introduction
Descriptions of Service Publications
Warranty-related service information available on the AccessFreightliner.com website includes the following documentation.
Recall Campaigns
Field Service Campaigns
Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice. These campaigns pertain to matters of vehicle safety. All recall campaigns are distributed to dealers; customers receive notices that apply to their vehicles.
Field service campaigns are concerned with non-safety-related service work or replacement of parts. All field service campaigns are distributed to dealers; customers receive notices that apply to their vehicles.
I–2
Century Class Trucks Maintenance Manual, March 2011
Page Description
For an example of a Century Class Trucks Maintenance Manual, see
A B C
Introduction
D E
11/20/95
A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number
B. Group Title
C. Group Number
D. Release Date
E. Group Number/Page Number
Fig. 1, Example of a Century Class Trucks Maintenance Manual Page
f020044
Century Class Trucks Maintenance Manual, March 2011
I–3
Introduction
Group No.
Group Title
00 . . . . . . . . . . . . . . . . . . . . . . General Information
01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine
09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Intake
13 . . . . . . . . . . . . . . . . . . . . . . . . . Air Compressor
15 . . . . . . . . . . . . . . . . . . . Alternators and Starters
20 . . . . . . . . . . . . . . . . . . . Engine Cooling/Radiator
25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch
26 . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission
31 . . . . . . . . . . . . . Frame and Frame Components
32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension
33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle
35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle
40 . . . . . . . . . . . . . . . . . . . . . . . . Wheels and Tires
41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driveline
42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes
46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering
47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel
49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust
60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab
72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doors
83 . . . . . . . . . . . . . . . . . Heater and Air Conditioner
88 . . . . . . . . . . . . . . Hood, Grille, and Cab Fenders
Maintenance Manual Contents
I–4
Century Class Trucks Maintenance Manual, March 2011
General Information
00
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
General Information
00
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.
To determine the correct maintenance intervals for your vehicle you must first determine the type of service or conditions the vehicle will be operating in.
Generally, most vehicles operate under conditions that fall within one of the four types of service described. Before placing your new vehicle in service, determine the type of service (Service Schedule I, II,
III, or IV) that applies to the intended use of the vehicle. After determining the vehicle’s type of service, refer to the service schedule table or the vehicle maintenance schedule table, to determine how often maintenance should be performed.
When the vehicle reaches the distance given for a maintenance interval, see the Maintenance Interval
Operation Table for a list of the maintenance operations to be performed at that maintenance interval.
Use the maintenance operation reference numbers to find detailed instructions in the manual on each operation.
Types of Service
Service Schedule I (severe service) applies to vehicles that annually travel less than 6000 miles (10
000 kilometers) or that operate under severe conditions. Examples of severe service, Schedule I usage include: operation on extremely poor roads or where there is heavy dust accumulation; constant exposure to extreme hot, cold, salt-air, or other extreme climates; frequent short-distance travel; constructionsite operation; city operation (fire truck); or farm operation.
Service Schedule II (short-haul transport) applies to vehicles that annually travel less than 60,000 miles
(100 000 kilometers) and operate under normal conditions. Examples of Schedule II usage are: operation primarily in cities and densely populated areas; local transport with infrequent freeway travel; or high percentage of stop-and-go travel.
Service Schedule III (long-haul transport) is for vehicles that annually travel more than 60,000 miles
(100 000 kilometers) with minimal city or stop-and-go operation. Examples of Schedule III usage are: regional delivery that is mostly freeway miles; interstate transport; or any road operation with high annual mileage.
Service Schedule IV (long haul transport for Optimized Vehicle Configuration) is for vehicles that annually travel over 60,000 miles (100 000 km) and meet the following qualifications:
• Meritor 15-1/2 inch dampened/ceramic Lite
Pedal LTD clutch with sealed release bearing.
• Synthetic transmission fluid used in transmission.
• Meritor FF–961 or FF–981 front axle (12,000 lb.
capacity) with synthetic lubricant.
• Front suspension with maintenance-free rubber bushings for 12,000 lb. capacity suspension.
• Meritor RPL series, or Spicer SPL series driveline U-joints.
• Synthetic lubricant used in rear axle.
• Equipped with any Freightliner AirLiner suspension.
• Equipped with Meritor Q-Plus extended-lube cam brakes and automatic slack adjusters, front and rear.
• Standard brake system package including Bendix AD-9 air dryer—mounted on the right-hand frame rail, located directly behind the front bumper—with heater, and a Bendix air compressor.
• TRW TAS–65 power steering.
NOTE: Maintenance instructions in this manual are based on average vehicle use and normal operating conditions. Unusual vehicle operating conditions may require service at more frequent intervals.
Century Class Trucks Maintenance Manual, January 2016
00/1
00
Service Schedule Table: 00–02
General Information
Service Schedule
Schedule I
*
(Severe Service) vehicles that annually travel less than 6000 miles (10 000 km)
Maintenance Interval Operation
Initial Maintenance (IM)
Maintenance 1 (M1)
Maintenance 2 (M2)
Maintenance 3 (M3)
Frequency
first every every every
Maintenance Interval
Miles
1000
1000
5000
15,000
km
1600
1600
8000
24 000
Hours
50
50
500
1500
Schedule II
†
(Short-Haul Transport) vehicles that annually travel less than 60,000 miles (100 000 km)
Initial Maintenance (IM)
Maintenance 1 (M1) first every
10,000
10,000
16 000
16 000
—
Maintenance 2 (M2)
Maintenance 3 (M3) every every
50,000
150,000
80 000
240 000
Schedule III
†
(Long-Haul Transport) vehicles that annually travel over
60,000 miles (100 000 km)
Initial Maintenance (IM)
Maintenance 1 (M1)
Maintenance 2 (M2) first every every
25,000
25,000
100,000
40 000
40 000
161 000
—
Schedule IV
†
(Long-Haul Transport for
Optimized Vehicle Configuration) vehicles that annually travel over
60,000 miles (100 000 km)
Maintenance 3 (M3)
Initial Maintenance (IM)
Maintenance 1 (M1)
Maintenance 2 (M2) every first every every
300,000
25,000
25,000
100,000
483 000
40 000
40 000
161 000
—
Maintenance 3 (M3) every 300,000 483 000
* For Schedule I (severe service) vehicles equipped with an hourmeter, use maintenance intervals based on hours of operation rather than distance traveled.
†
Use Schedule I (severe service) maintenance intervals for vehicles that operate under severe conditions, such as extremely poor roads, heavy dust accumulation, extreme climate, frequent short distance travel, construction-site operation, city operation (garbage truck), or farm operation.
Table 1, Service Schedule
00/2
Century Class Trucks Maintenance Manual, January 2016
General Information
00
Vehicle Maintenance Schedule Tables: 00–03
Maint. No.
18th
19th
20th
21st
22nd
23rd
24th
25th
13th
14th
15th
16th
17th
26th
27th
28th
29th
30th
1st
2nd
3rd
4th
5th
6th
7th
8th
9th
10th
11th
12th
1st through 30th Maintenance for Service Schedules I and II
Service Schedule I
Maintenance
Interval
Service
Date
Miles km Hours
IM and M1 1000 1600 100
M1
M1
M1
M1 and M2
M1
M1
M1
2000
3000
4000
5000
6000
7000
8000
3200
4800
6400
8000
9600
11 200
12 800
200
300
400
500
600
700
800
M1
M1 and M2
M1
M1
M1
M1
M1, M2, and M3
M1
M1
9000
10,000
11,000
12,000
13,000
14,000
15,000
16,000
17,000
14 400
16 000
17 600
19 200
20 800
22 400
24 000
25 600
27 200
900
1000
1100
1200
1300
1400
1500
1600
1700
M1
M1
M1 and M2
M1
M1
M1
M1
M1 and M2
M1
M1
M1
18,000
19,000
20,000
21,000
22,000
23,000
24,000
25,000
26,000
27,000
28,000
28 800
30 400
32 000
33 600
35 200
36 800
38 400
40 000
41 600
43 200
44 800
1800
1900
2000
2100
2200
2300
2400
2500
2600
2700
2800
M1
M1, M2, and M3
29,000
30,000
46 400
48 000
2900
3000
Table 2, 1st through 30th Maintenance for Service Schedules I and II
290,000
300,000
180,000
190,000
200,000
210,000
220,000
230,000
240,000
250,000
260,000
270,000
280,000
90,000
100,000
110,000
120,000
130,000
140,000
150,000
160,000
170,000
Service Schedule II
Miles
10,000
km
16 000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
32 000
48 000
64 000
80 000
96 000
112 000
128 000
144 000
160 000
176 000
192 000
208 000
224 000
240 000
256 000
272 000
288 000
304 000
320 000
336 000
352 000
368 000
384 000
400 000
416 000
432 000
448 000
464 000
480 000
00/3
Century Class Trucks Maintenance Manual, January 2016
00
Vehicle Maintenance Schedule Tables: 00–03
General Information
Maint. No.
48th
49th
50th
51st
52nd
53rd
54th
55th
43rd
44th
45th
46th
47th
56th
57th
58th
59th
60th
31st
32nd
33rd
34th
35th
36th
37th
38th
39th
40th
41st
42nd
31st through 60th Maintenance for Service Schedules I and II
Service Schedule I
Maintenance
Interval
Service
Date
Miles km Hours
M1 31,000 49 600 3100
M1
M1
M1
M1 and M2
M1
M1
M1
32,000
33,000
34,000
35,000
36,000
37,000
38,000
51 200
52 800
54 400
56 000
57 600
59 200
60 800
3200
3300
3400
3500
3600
3700
3800
M1
M1 and M2
M1
M1
M1
M1
M1, M2, and M3
M1
M1
39,000
40,000
41,000
42,000
43,000
44,000
45,000
46,000
47,000
62 400
64 000
65 600
67 200
68 800
70 400
72 000
73 600
75 200
3900
4000
4100
4200
4300
4400
4500
4600
4700
M1
M1
M1 and M2
M1
M1
M1
M1
M1 and M2
M1
M1
M1
48,000
49,000
50,000
51,000
52,000
53,000
54,000
55,000
56,000
57,000
58,000
76 800
78 400
80 000
82 000
83 700
85 300
86 900
88 500
90 100
91 700
93 300
4800
4900
5000
5100
5200
5300
5400
5500
5600
5700
5800
M1
M1, M2, and M3
59,000
60,000
94 900
96 500
5900
6000
Table 3, 31st through 60th Maintenance for Service Schedules I and II
590,000
600,000
480,000
490,000
500,000
510,000
520,000
530,000
540,000
550,000
560,000
570,000
580,000
390,000
400,000
410,000
420,000
430,000
440,000
450,000
460,000
470,000
Service Schedule II
Miles
310,000
km
496 000
320,000
330,000
340,000
350,000
360,000
370,000
380,000
512 000
528 000
544 000
560 000
576 000
592 000
608 000
624 000
640 000
656 000
672 000
688 000
704 000
720 000
736 000
752 000
768 000
784 000
800 000
820 000
837 000
853 000
869 000
885 000
901 000
917 000
933 000
949 000
965 000
00/4
Century Class Trucks Maintenance Manual, January 2016
General Information
00
Vehicle Maintenance Schedule Tables: 00–03
Maint. No.
78th
79th
80th
81st
82nd
83rd
84th
85th
73rd
74th
75th
76th
77th
86th
87th
88th
89th
90th
61st
62nd
63rd
64th
65th
66th
67th
68th
69th
70th
71st
72nd
61st through 90th Maintenance for Service Schedules I and II
Service Schedule I
Maintenance
Interval
Service
Date
Miles km Hours
M1 61,000 98 200 6100
M1
M1
M1
M1 and M2
M1
M1
M1
62,000
63,000
64,000
65,000
66,000
67,000
68,000
99 800
101 400
103 000
104 600
106 200
107 800
109 400
6200
6300
6400
6500
6600
6700
6800
M1
M1 and M2
M1
M1
M1
M1
M1, M2, and M3
M1
M1
69,000
70,000
71,000
72,000
73,000
74,000
75,000
76,000
77,000
111 000
112 700
114 300
115 900
117 500
119 100
120 700
122 300
123 900
6900
7000
7100
7200
7300
7400
7500
7600
7700
M1
M1
M1 and M2
M1
M1
M1
M1
M1 and M2
M1
M1
M1
78,000
79,000
80,000
81,000
82,000
83,000
84,000
85,000
86,000
87,000
88,000
125 500
127 100
128 700
130 400
132 000
134 000
135 200
137 000
138 400
140 000
141 600
7800
7900
8000
8100
8200
8300
8400
8500
8600
8700
8800
M1
M1, M2, and M3
89,000
90,000
143 200
144 800
8900
9000
Table 4, 61st through 90th Maintenance for Service Schedules I and II
890,000
900,000
780,000
790,000
800,000
810,000
820,000
830,000
840,000
850,000
860,000
870,000
880,000
690,000
700,000
710,000
720,000
730,000
740,000
750,000
760,000
770,000
Service Schedule II
Miles
610,000
km
982 000
620,000
630,000
640,000
650,000
660,000
670,000
680,000
998 000
1 014 000
1 030 000
1 046 000
1 062 000
1 078 000
1 094 000
1 110 000
1 127 000
1 143 000
1 159 000
1 175 000
1 191 000
1 207 000
1 223 000
1 239 000
1 255 000
1 271 000
1 287 000
1 304 000
1 320 000
1 340 000
1 352 000
1 370 000
1 384 000
1 400 000
1 416 000
1 432 000
1 448 000
00/5
Century Class Trucks Maintenance Manual, January 2016
00
Vehicle Maintenance Schedule Tables: 00–03
General Information
Maint. No.
91st
92nd
93rd
94th
95th
96th
97th
98th
99th
100th
91st through 100th Maintenance for Service Schedules I and II
Service Schedule I
Maintenance
Interval
Service
Date
Miles km Hours
M1
M1
M1
M1
M1 and M2
M1
M1
M1
M1
M1 and M2
91,000
92,000
93,000
94,000
95,000
96,000
97,000
98,000
99,000
100,000
146 500
148 100
150 000
151 300
153 000
155 000
156 100
157 700
159 300
160 900
9100
9200
9300
9400
9500
9600
9700
9800
9900
10,000
Service Schedule II
Miles
910,000
km
1 465 000
920,000
930,000
940,000
950,000
960,000
970,000
980,000
990,000
1,000,000
Table 5, 91st through 100th Maintenance for Service Schedules I and II
1 481 000
1 500 000
1 513 000
1 530 000
1 550 000
1 561 000
1 577 000
1 593 000
1 609 000
11
12
13
14
8
9
10
1st through 19th Maintenance for Service Schedules III and IV
Maint. No.
Maintenance Interval
Service
Date
Service Schedules III and IV
Miles km
25,000 40 000 1
2
3
4
5
6
7
IM and M1
M1
M1
M1 and M2
M1
M1
M1
50,000
75,000
100,000
125,000
150,000
175,000
80 000
121 000
161 000
201 000
241 000
281 000
M1 and M2
M1
M1
M1
M1, M2, and M3
M1
M1
200,000
225,000
250,000
275,000
300,000
325,000
350,000
322 000
362 000
402 000
443 000
483 000
523 000
563 000
15
16
17
18
M1
M1 and M2
M1
M1
375,000
400,000
425,000
450,000
604 000
644 000
684 000
724 000
19 M1 475,000 764 000
Table 6, 1st through 19th Maintenance for Service Schedules III and IV
00/6
Century Class Trucks Maintenance Manual, January 2016
General Information
00
Vehicle Maintenance Schedule Tables: 00–03
20th through 40th Maintenance for Service Schedules III and IV
Service Schedules III and IV
Maint. No.
Maintenance Interval
Service
Date
Miles km
20 M1 and M2 500,000 805 000
21
22
23
24
25
26
27
M1
M1
M1
M1, M2, and M3
M1
M1
M1
525,000
550,000
575,000
600,000
625,000
650,000
675,000
845 000
885 000
925 000
966 000
1 005 800
1 046 000
1 086 000
32
33
34
35
36
28
29
30
31
M1 and M2
M1
M1
M1
M1 and M2
M1
M1
M1
M1, M2, and M3
700,000
725,000
750,000
775,000
800,000
825,000
850,000
875,000
900,000
1 127 000
1 167 000
1 207 000
1 248 000
1 287 000
1 328 000
1 368 000
1 408 000
1 448 000
37
38
39
40
M1
M1
M1
M1 and M2
925,000
950,000
975,000
1,000,000
1 490 000
1 529 000
1 569 000
1 609 000
Table 7, 20th through 40th Maintenance for Service Schedules III and IV
00/7
Century Class Trucks Maintenance Manual, January 2016
00
Lubrication and Fluid Level Check: 00–04
General Information
Maintenance Operation 00–04, Lubrication and Fluid
Level Check Operation
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.
Maintenance operation numbers given in the table are reference numbers used to help you find detailed instructions in the manual on the lubrication or fluid check.
42–11
46–06
Maint.
Operation
Number
33–09
33–10
Maintenance Operation 00–04
Lubrication and Fluid Level Check for Service Schedules I, II, III, and IV
Operation Description
Service
Schedules I, II, and III (at M1)
Service
Schedule IV
(at M2)
• Eaton Fuller Clutch Release Bearing Lubrication
Clutch Release Cross-Shaft Lubrication
Sleeve Assembly Bronze Bushing Lubrication
•
•
• Transmission Fluid Level Inspection
Fifth Wheel Lubrication
Trailer Electrical Connector Lubrication
Suspension Lubrication
•
•
•
•
•
Knuckle Pin Lubrication, Meritor Axles
Tie Rod Lubrication, Meritor Axles
Knuckle Pin Lubrication, Dana Spicer Axles
Tie Rod Lubrication, Dana Spicer Axles
Kingpin Lubrication, Detroit
™
Axles
*
Tie Rod Lubrication, Detroit ™ Axles
*
Axle Breather and Axle Lubricant Level Inspection
•
•
•
•
•
•
•
• Driveline Lubrication
Dana Spicer Camshaft Bracket Lubrication
Dana Spicer, Haldex, and Gunite Slack Adjuster
Lubrication
Meritor Camshaft Bracket Lubrication
Versajust Slack Adjuster Inspection and Lubrication
†
Power Steering Fluid Level Inspection
•
•
•
•
Power Steering Gear Lubrication
Drag Link Lubrication
Rack and Pinion Steering Inspection
Cab Tilt Pump Reservoir Fluid Level and System Check
Door Seal, Door Latch, and Door Hinge Lubrication
•
•
•
•
•
•
Check
00/8
Century Class Trucks Maintenance Manual, January 2016
General Information
00
Lubrication and Fluid Level Check: 00–04
Maint.
Operation
Number
88–01
Maintenance Operation 00–04
Lubrication and Fluid Level Check for Service Schedules I, II, III, and IV
Operation Description
Service
Schedules I, II, and III (at M1)
Service
Schedule IV
(at M2)
Hood Rear Support Lubrication •
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.
†
Complete this procedure every 25,000 miles (40 225 km), 3 months, or 500 operating hours, whichever comes first.
Table 8, Maintenance Operation 00-04, Lubrication and Fluid Level Check for Service Schedules I, II, III, and IV
Century Class Trucks Maintenance Manual, January 2016
00/9
00
Initial Maintenance (IM) Operations: 00–05
General Information
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 maintenance operations to be performed. All operations listed in the table, along with the operations listed in the applicable M1 maintenance interval table, must be performed to complete the initial maintenance
(IM).
Maintenance
Operation Number
Initial Maintenance (IM) Operations for Service Schedules I, II, III, and IV
Perform all M1 Operations
Frame Fastener Torque Check
Premier 690 Coupling Inspection
Suspension U-Bolt Torque Check
All-Axle Alignment Check
Wheel Nut and Rim Nut Check
Fuel Tank Band-Nut Tightening
Table 9, Initial Maintenance (IM) Operations for Service Schedules I, II, III, and IV
Check
00/10
Century Class Trucks Maintenance Manual, January 2016
General Information
00
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.
IMPORTANT: After performing all operations listed in this table, perform all daily, weekly, and monthly maintenance operations listed in the "Pretrip and
Post-Trip Inspections and Maintenance" chapter of the Century Class® Driver’s Manual.
Maintenance
Operation Number
M1 Maintenance Interval Operations for Service Schedules I, II, and III
13–01
40–02
42–10
42–11
Lubrication and Fluid Level Check (includes the following):
• Eaton Fuller Clutch Release Bearing Lubrication
• Fifth Wheel Lubrication
• Trailer Electrical Connector Lubrication
• Suspension Lubrication
• Knuckle Pin Lubrication, Dana Spicer Axles
• Tie Rod Lubrication, Dana Spicer Axles
• Driveline Lubrication
• Dana Spicer Camshaft Bracket Lubrication
• Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication
• Cab Tilt Pump Reservoir Fluid Level and System Check
• Door Seal, Door Latch, and Door Hinge Lubrication
• Hood Rear Support Lubrication
Air Compressor Inspection
Fan Clutch Check (noise emission control)
Fifth Wheel Inspection
Premier 690 Coupling Inspection
Tire Check
Driveline Inspection
Meritor Camshaft Bracket Lubrication
Brake Inspection
Versajust Slack Adjuster Inspection and Lubrication
Exhaust System Inspection (noise emission control)
*
*
Complete this procedure every 25,000 miles (40 225 km), 3 months, or 500 operating hours, whichever comes first.
Table 10, M1 Maintenance Interval Operations for Service Schedules I, II, and III
Check
Maintenance
Operation Number
13–01
M1 Maintenance Interval Operations for Service Schedule IV
Air Compressor Inspection
Fan Clutch Check (noise emission control)
Fifth Wheel Inspection
Fifth Wheel Lubrication
Check
00/11
Century Class Trucks Maintenance Manual, January 2016
00
M1 Maintenance Interval Operations: 00–06
General Information
Maintenance
Operation Number
40–02
42–10
42–11
88–01
M1 Maintenance Interval Operations for Service Schedule IV
Trailer Electrical Connector Lubrication
Tire Check
Meritor Camshaft Bracket Lubrication
Brake Inspection
Versajust Slack Adjuster Inspection and Lubrication *
Exhaust System Inspection (noise emission control)
Cab Tilt Pump Reservoir Fluid Level and System Check
Door Seal, Door Latch, and Door Hinge Lubrication
Hood Rear Support Lubrication
* Complete this procedure every 25,000 miles (40 225 km), 3 months, or 500 operating hours, whichever comes first.
Table 11, M1 Maintenance Interval Operations for Service Schedule IV
Check
00/12
Century Class Trucks Maintenance Manual, January 2016
General Information
00
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 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.
33–09
33–10
46–06
Maintenance
Operation Number
09–01
M2 Maintenance Interval Operations for Service Schedules I, II, and III
Perform All M1 Operations
Engine Noise Panel Inspection (noise emission control)
Engine Drive Belt Inspection
Engine-Support Fasteners Check (noise emission control)
Air Cleaner Element Inspection and Replacement
Alternator, Battery, and Starter Check
Pressure Relief Cap Check
Clutch Release Cross-Shaft Lubrication
Sleeve Assembly Bronze Bushing Lubrication
Meritor Clutch Release Bearing Lubrication
Allison Transmission Fluid and Filter Change
Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement
Transmission Fluid Level Inspection
Suspension Inspection
Suspension U-Bolt Torque Check
Knuckle Pin Lubrication, Meritor Axles
Tie Rod Inspection
Tie Rod Lubrication, Meritor Axles
Basic Inspection, Meritor Unitized Wheel Ends
*
End-Play Check, Meritor Unitized Wheel Ends
†
Kingpin Lubrication, Detroit
™
Axles
‡
Tie Rod Lubrication, Detroit ™ Axles
‡
Axle Breather and Axle Lubricant Level Inspection
Wheel Nut and Rim Nut Check
Air Brake System Valve Inspection
Air Dryer Inspection
Alcohol Evaporator Cleaning and Inspection
Meritor Slack Adjuster Lubrication
Drag Link Inspection
Power Steering Fluid Level Inspection
Power Steering Gear Lubrication
Drag Link Lubrication
Rack and Pinion Steering Gear Inspection
Check
00/13
Century Class Trucks Maintenance Manual, January 2016
00
M2 Maintenance Interval Operations: 00–07
General Information
Maintenance
Operation Number
M2 Maintenance Interval Operations for Service Schedules I, II, and III
Fuel Filter Replacement
Fuel Separator Sight Bowl Cleaning and Element Replacement
Cab Suspension Air Bag Inspection
Cab Access Stairs Inspection, Argosy COE
Mirror Folding Check
Air Conditioner Inspection
Air Filter Replacement
§
* Inspect Meritor Unitized Wheel Ends at 200,000 miles (321 870 km0, then every 50,000 miles (80 470 km).
†
Check the end play at 200,000 miles (321 870 km), then every 200,000 miles (321 870 km).
‡
For Schedule II vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), whichever comes first.
§
Replace the HVAC filters every 6 months regardless of mileage.
Table 12, M2 Maintenance Interval Operations for Service Schedules I, II, and III
Check
Maintenance
Operation Number
09–01
M2 Maintenance Interval Operations for Service Schedule IV
Lubrication and Fluid Level Check (includes the following):
• Clutch Release Cross-Shaft Lubrication
• Sleeve Assembly Bronze Bushing Lubrication
• Transmission Fluid Level Inspection
• Knuckle Pin Lubrication, Meritor Axles
• Tie Rod Lubrication, Meritor Axles
• Kingpin Lubrication, Detroit
™
Axles
• Tie Rod Lubrication, Detroit
™ Axles
• Axle Breather and Axle Lubricant Level Inspection
• Driveline Lubrication
• Power Steering Fluid Level Inspection
• Power Steering Gear Lubrication
• Drag Link Lubrication
• Cab Tilt Pump Reservoir Fluid Level and System Check
• Door Seal, Door Latch, and Door Hinge Lubrication
Perform All M1 Operations
Engine Noise Panel Inspection (noise emission control)
Engine Drive Belt Inspection
Engine-Support Fasteners Check (noise emission control)
Air Cleaner Element Inspection and Replacement
Alternator, Battery, and Starter Check
Pressure Relief Cap Check
Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement
Check
00/14
Century Class Trucks Maintenance Manual, January 2016
General Information
00
M2 Maintenance Interval Operations: 00–07
Maintenance
Operation Number
46–06
M2 Maintenance Interval Operations for Service Schedule IV
Suspension Inspection
Suspension U-Bolt Torque Check
Tie Rod Inspection
Basic Inspection, Meritor Unitized Wheel Ends
*
End-Play Check, Meritor Unitized Wheel Ends
†
Wheel Nut and Rim Nut Check
Driveline Inspection
Air Brake System Valve Inspection
Air Dryer Inspection
Alcohol Evaporator Cleaning and Inspection
Drag Link Inspection
Rack and Pinion Steering Inspection
Fuel Filter Replacement
Fuel Separator Sight Bowl Cleaning and Element Replacement
Cab Suspension Air Bag Inspection
Cab Access Stairs Inspection, Argosy COE
Mirror Folding Check
Air Conditioner Inspection
Air Filter Replacement
‡
*
Inspect Meritor Unitized Wheel Ends at 200,000 miles (321 870 km0, then every 50,000 miles (80 470 km).
†
Check the end play at 200,000 miles (321 870 km), then every 200,000 miles (321 870 km).
‡
Replace the HVAC filters every 6 months regardless of mileage.
Table 13, M2 Maintenance Interval Operations for Service Schedule IV
Check
00/15
Century Class Trucks Maintenance Manual, January 2016
00
M3 Maintenance Interval Operations: 00–08
General Information
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 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.
Maintenance
Operation Number
42–09
46–07
M3 Maintenance Interval Operations for Service Schedules I, II, III, and IV
Perform All M1 Operations
Perform All M2 Operations
Radiator Pressure-Flushing and Coolant Change
Manual Transmission Fluid Change, and Magnetic Plug Cleaning (synthetic lubricant)
Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning
Air Dryer Desiccant Replacement
Bendix E–6 Foot Control Valve Inspection and Lubrication
Power Steering Fluid and Filter Change
Bellows Replacement, Rack and Pinion Steering Gear
CAT CGI Bellows Replacement
Table 14, M3 Maintenance Interval Operations for Service Schedules I, II, III, and IV
Check
00/16
Century Class Trucks Maintenance Manual, January 2016
General Information
00
Maintenance Operation Sets Table: 00–09
Maint.
No.
Maintenance Operation Sets for Groups 00 through 83
Operation Description
Lubrication and Fluid Level Check
Service Schedules
I, II, and III
Service Schedule
IV
IM M1 M2 M3 IM M1 M2 M3
• • • • • •
Engine Noise Panel Inspection (noise emission control)
Engine Drive Belt Inspection
Engine Mount Inspection (noise emission control)
*
Engine-Support Fasteners Check (noise emission control)
Air Cleaner Element Inspection and Replacement
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• •
13–01
Air Compressor Inspection
Alternator, Battery, and Starter Check
Pressure Relief Cap Check
Radiator Pressure-Flushing and Coolant Change
Fan Clutch Check (noise emission control)
Eaton Fuller Clutch Release Bearing Lubrication
Clutch Release Cross-Shaft Lubrication
Sleeve Assembly Bronze Bushing Lubrication
Meritor Clutch Release Bearing Lubrication
Manual Transmission Fluid Change, and Magnetic Plug Cleaning
(synthetic lubricant)
Allison Transmission Fluid and Filter Change
Manual Transmission Air Filter/Regulator Check, Cleaning, or
Replacement
Transmission Fluid Level Inspection
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Fifth Wheel Inspection
Fifth Wheel Lubrication
Frame Fastener Torque Check
Trailer Electrical Connector Lubrication
Premier 690 Coupling Inspection
Suspension Inspection
Suspension Lubrication
Suspension U-Bolt Torque Check
Knuckle Pin Lubrication, Meritor Axles
Tie Rod Inspection
Tie Rod Lubrication, Meritor Axles
All-Axle Alignment Check
Knuckle Pin Lubrication, Dana Spicer Axles
Tie Rod Lubrication, Dana Spicer Axles
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
00/17
Century Class Trucks Maintenance Manual, January 2016
00
Maintenance Operation Sets Table: 00–09
General Information
Maint.
No.
Maintenance Operation Sets for Groups 00 through 83
Operation Description
Service Schedules
I, II, and III
Service Schedule
IV
IM M1 M2 M3 IM M1 M2 M3
• • • •
Basic Inspection, Meritor Unitized Wheel Ends
†
End-Play Check, Meritor Unitized Wheel Ends
‡
33–09
Kingpin Lubrication, Detroit ™ Axles
§
33–10
Tie Rod Lubrication, Detroit
™
Axles
§
Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning
Axle Breather and Axle Lubricant Level Inspection
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
40–02
Wheel Nut and Rim Nut Check
Tire Check
Driveline Inspection
Driveline Lubrication
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• •
•
•
•
•
•
Air Brake System Valve Inspection
Air Dryer Desiccant Replacement
Air Dryer Inspection
Alcohol Evaporator Cleaning and Inspection
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Dana Spicer Camshaft Bracket Lubrication
Dana Spicer, Haldex, and Gunite Slack Adjuster Lubrication
Meritor Camshaft Bracket Lubrication
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• • • • •
Meritor Slack Adjuster Lubrication
Bendix E–6 Foot Control Valve Inspection and Lubrication
42–10
Brake Inspection
42–11
Versajust Slack Adjuster Inspection and Lubrication
¶
• •
•
•
•
•
•
•
•
•
• • •
•
•
•
Drag Link Inspection
Power Steering Fluid and Filter Change
Power Steering Fluid Level Inspection
Power Steering Gear Lubrication
46–06
46–07
Bellows Replacement, Rack and Pinion Steering Gear
Drag Link Lubrication
Rack and Pinion Steering Gear Inspection
Fuel Filter Replacement
Fuel Separator Sight Bowl Cleaning and Element Replacement
Fuel Tank Band-Nut Tightening
Exhaust System Inspection (noise emission control)
•
• •
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
• •
•
•
•
•
•
•
•
•
•
•
•
CAT CGI Bellows Replacement
Cab Suspension Air Bag Inspection •
•
•
• •
•
•
•
•
•
•
•
•
00/18
Century Class Trucks Maintenance Manual, January 2016
General Information
00
Maintenance Operation Sets Table: 00–09
Maint.
No.
Maintenance Operation Sets for Groups 00 through 83
Operation Description
Cab Tilt Pump Reservoir Fluid Level and System Check
Service Schedules
I, II, and III
Service Schedule
IV
IM M1 M2 M3 IM M1 M2 M3
• • • • • • • •
Cab Access Stairs Inspection, Argosy COE
Mirror Folding Check
Door Seal, Door Latch, and Door Hinge Lubrication
Air Conditioner Inspection
Air Filter Replacement **
88–01
Hood Rear Support Lubrication
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
* At engine overhaul, and whenever the engine has been removed, inspect the lower and upper isolators, and replace them if they are worn.
†
Inspect Meritor Unitized Wheel Ends at 200,000 miles (321 870 km), and then every 50,000 miles (80 470 km).
‡
Check the end play at 200,000 miles (321 870 km), and then every 200,000 miles (321 870 km).
§
For Schedule II vehicles with Detroit axles, complete this procedure once a year or every 25,000 miles (40 000 km), whichever comes first.
¶
Complete this procedure every 25,000 miles (40 225 km), 3 months, or 500 operating hours, whichever comes first.
** Replace the HVAC filters every 6 months regardless of mileage.
Table 15, Maintenance Operation Sets
Century Class Trucks Maintenance Manual, January 2016
00/19
00
Noise Emission Controls Maintenance: 00–10
General Information
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 degradation throughout the life of the vehicle. In compliance with the law, the noise emission controls maintenance information in each applicable group of this manual, in conjunction with the vehicle workshop manual, provides these instructions to owners.
Recommendations for
Replacement Parts
Replacement parts used for maintenance or repair of noise emission controls should be genuine Freightliner parts. If other than genuine Freightliner parts are used for replacement or repair of components affecting noise emission control, the owner should be sure that such parts are warranted by their manufacturer to be equivalent to genuine Freightliner parts in performance and durability.
Freightliner Noise Emission
Controls Warranty
Refer to the vehicle owner’s warranty information book for warranty information concerning noise emission controls.
Tampering With Noise Controls is
Prohibited
Federal law prohibits the following acts or the causing thereof:
1.
The removal or rendering inoperative by any person (other than for purposes of maintenance, repair, or replacement) of any device or element of design incorporated into any new vehicle for the purpose of noise control, prior to its sale or delivery to the ultimate purchaser, or while it is in use.
2.
The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
A. Removal of engine noise-deadening panels.
B. Removal of cab-tunnel or hood noisedeadening panels.
C. Removal of, or rendering inoperative, the engine speed governor so as to allow engine speed to exceed manufacturer’s specifications.
D. Removal of, or rendering inoperative, the fan clutch, including bypassing the control on any thermostatic fan drive to cause it to operate continuously.
E. Removal of the fan shroud.
F.
Removal of, or rendering inoperative, exhaust components, including exhaust pipe clamping.
G. Removal of air intake components.
Maintenance Instructions
Scheduled intervals are in the maintenance tables in this group. A "Verification of Inspections Log (Groups
01, 20, and 49)" follows, and should be filled in each time noise emission controls on the vehicle are maintained or repaired.
00/20
Century Class Trucks Maintenance Manual, January 2016
General Information
00
Verification of Inspections Log: 00–11
Verification of Inspections Log
Date Mileage
Verification of Inspections Log, Groups 01, 20, and 49
Item Cost Maintenance Facility
Group 01 — Engine Noise Panels, Engine Mounts, and Engine-Support Fasteners
Group 20 — Fan Clutch
Group 49 — Exhaust System Components
00/21
Century Class Trucks Maintenance Manual, January 2016
Engine
01
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Engine
01
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 can not drop. Failure to follow these steps could result in serious personal injury or death.
01–01 Engine Noise Panel
Inspection (Noise
Emission Control)
If equipped, inspect for torn engine noise panels.
See
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
11/29/95
1.
Oil Pan Noise Panel (C10 engine only)
2.
Left-Side Noise Panel (3406 engine only)
Fig. 1, Caterpillar Engine Noise Panels
f011040
01–02 Engine Drive Belt
Inspection
Worn or loose drive belts may cause premature bearing failure or engine overheating. Excessive tension, or too little tension on the belt may result in excessive and premature belt wear. Poly-V belts, or serpentine belts are retained by a belt tensioner that requires no tension adjustment. Replace the belt if any conditions described in "Visual Inspection" are found. V-belts are installed as individual belts, and as matched sets. When replacing matched sets of belts, always replace both belts at the same time. Matched belts must be from the same manufacturer. To inspect a belt, gently twist the belt to view the belt sidewalls and bottom. Inspect all drive belts for the following conditions, then perform the "Belt Tension
Inspection":
Visual Inspection
1.
Inspect the belt for glazing. See
Glazing is represented by shiny sidewalls, and is caused by friction created when a loose belt slips in the pulleys. It can also be caused by oil or grease on the pulleys.
2.
Check the belt for ply separation. See
Ref. B. Oil, grease, or belt dressing can cause the belt to fall apart in layers. Repair any oil or coolant leaks that are affecting the belts before replacing the drive belts. Do not use belt dressing on any belt.
3.
Check the belt for a jagged or streaked sidewall.
See
, Ref. C. Jagged or streaked sidewalls
are the result of foreign objects, such as sand or gravel in the pulley, or a rough pulley surface.
4.
Check for tensile breaks; breaks in the cord body. See
, Ref. D. Cuts in a belt are usu-
ally caused by foreign objects in the pulley, or by prying or forcing the belt during removal or installation.
5.
Check for uneven ribs on serpentine (poly-V) belts. See
, Ref. E. Foreign objects in the
pulley will erode the undercord ribs, causing the belt to lose its gripping power.
6.
Check the drive belts for cracks. See
F. Small irregular cracks are usually signs of an old belt.
Century Class Trucks Maintenance Manual, January 2016
01/1
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.
If belt tension is not correct, see Group 01 of the
Century Class Trucks Workshop Manual.
Spring-Tension Type
On belts equipped with a spring tensioner, the belt tension is automatically adjusted. Check that the tensioner is holding tension on the belt by inserting the end of a breaker bar in the 1/2-inch square hole on the forward face of the tensioner, and rotating the tensioner down, away from the belt. When the breaker bar is slowly released, the tensioner should
A
B
D
E
C
F
11/21/94
A. Glazing
B. Separating Layers
C. Streaked Sidewalls
D. Tensile Break
E. Uneven Ribs
F.
Cracks f150010a
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
for belt tension specifications.
return to its original position. If not, see Group 01 of the Century Class Trucks Workshop Manual for replacement instructions.
01/2
Century Class Trucks Maintenance Manual, January 2016
Engine
01
01–03 Engine Mount Inspection
(Noise Emission
Control)
NOTE: At engine overhaul, and whenever the engine has been removed, inspect the lower
Engine
Caterpillar C10 (3176)
Caterpillar 3406E
Cummins M11
Cummins N14
Detroit Diesel Series 60 and upper isolators (see
, Refs. 1 and 6), and replace them if they are worn. See Group
01 of the Century Class Trucks Workshop
Manual for procedures.
Drive Belt Tension
Component
Refrigerant Compressor
Alternator and Refrigerant Compressor
Fan
Alternator
Fan
Refrigerant Compressor
Alternator
Fan
Refrigerant Compressor
Alternator and Refrigerant Compressor
Fan
Table 1, Drive Belt Tension
Belt Tension: lbf (kg)
80 to 100 (36 to 45)
40 to 50 (18 to 23), per belt
80 to 100 (36 to 45)
90 to 120 (41 to 55)
155 to 165 (70 to 75)
80 to 100 (36 to 45)
40 to 50 (18 to 23), per belt
80 to 120 (36 to 55)
80 to 100 (36 to 45)
80 to 100 (36 to 45), Power Band
60 to 80 (27 to 36)
Periodically inspect the rubber isolators for cracks, cuts, wear, or damage, and replace them if necessary. See Group 01 of the Century Class Trucks
Workshop Manual for isolator replacement procedures.
01–04 Engine-Support
Fasteners Check (Noise
Emission Control)
Front and rear engine supports for vehicles built from
January 2007 require no periodic maintenance.
Mounts should be inspected when the engine is removed for service. For vehicles manufactured prior to
January 2007, perform the following check.
Check the rear engine-support fasteners (see
Ref. 4) for tightness. Tighten the 3/4-inch fasteners
215 to 265 lbf·ft (292 to 359 N·m).
5
2
6
1
4
3
2
10/05/94
1.
Lower Isolator
2.
Engine-Support
Washer
3.
3/4–10 Capscrew
4.
3/4–10 Hexnut
5.
Engine Mount
6.
Upper Isolator f220047a
Fig. 3, Rear Engine Mount Isolators and Fasteners
Century Class Trucks Maintenance Manual, January 2016
01/3
01
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
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.
Engine
01/4
Century Class Trucks Maintenance Manual, January 2016
Air Intake
09
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, November 2014
Air Intake
09
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 (
go/no-go restriction indicator without graduations
1.
Inspect the air restriction indicator to see if air restriction equals or exceeds the maximum allowable restriction. For instructions, see the vehicle Driver’s Manual.
NOTICE
Do not use aftermarket air-cleaner elements. Aftermarket air-cleaner elements may not seal the housing correctly, which can lead to engine damage and potentially the loss of warranty. When replacing an air-cleaner element, use only the part listed in PartsPro for the serial number of the vehicle.
2.
If necessary, replace the air cleaner element. For air cleaner element replacement instructions, see
Group 09 of the vehicle Workshop Manual.
3.
Inspect the air cleaner housing for cracks, leaks, or any other damage. If the air cleaner housing or element is damaged, replace it.
4.
Reset the air restriction indicator.
5.
Each time the air cleaner housing is replaced, perform the procedures in MOP 13–01.
08/07/2007 f090452
Fig. 1, Manual-Reset Air Restriction Indicator,
Graduated
04/08/2005 f090431
Fig. 2, Manual-Reset Air Restriction Indicator, Go/
No-Go
09/1
Century Class Trucks Maintenance Manual, November 2014
Air Compressor
13
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Air Compressor
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 can not drop. Failure to follow these steps could result in serious personal injury or death.
13–01 Air Compressor
Inspection
1.
Inspect the air compressor intake hoses and connections at the air intake and air compressor for physical damage. If needed, change the hoses, and/or tighten or replace the connections.
2.
Inspect the coolant supply and return lines for tight connections. Tighten the connections and replace the lines and fasteners if needed.
3.
For the air governor, inspect the piping and connections for leaks. Replace gaskets and faulty components as needed.
13
13/1
Century Class Trucks Maintenance Manual, January 2016
Alternators and Starters
15
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Alternators and Starters
15
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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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. Always wear a face shield and protective clothing when working around batteries.
Damaged, chafed, or kinked wiring can cause electrical short-circuits and lead to fires, causing property damage, injury, or death. Clean, inspect, and maintain wiring and connections carefully.
1.
Disconnect the batteries.
2.
Check the tightness of the alternator bracket fasteners; tighten the fasteners as needed. For torque values, see Group 15 of the Century
Class Trucks Workshop Manual.
3.
See
Group 01
for belt tension specifications.
Check the alternator drive belt tension, using a tension gauge at the belt’s longest span. Some engines are equipped with more than one alternator belt; check all of them for correct tension.
Adjust the belt tension if necessary.
Engines equipped with a serpentine or poly-V belt have automatic belt tensioners, and do not require belt tension inspection.
4.
Check that all electrical connections at the alternator and starter are clean. Clean and tighten all charging system electrical connections including the connections at the starter B terminal and ground terminal, and where the alternator charging cable terminates.
Trace and inspect all wiring and cables connected to:
• Alternator
• Starter and depopulation studs
• Batteries
• Magnetic switch
• Cab
• Jump-start studs
• Battery isolation relays
• Battery shutoff switches
5.
Check wires and cables for wear, chafing, kinks, discolored insulation, or loose clamps or ties.
Find the cause of any problems and repair, replace, and reroute wires and clamps as necessary.
6.
Check the alternator wiring for missing insulation, kinks, and heat damage. Replace or repair as needed.
7.
On the bundled cable that runs from the batteries to the starter, ensure that tie straps are installed at least every 12 inches (300 mm). Replace any missing tie straps, and add tie straps where spacing between them exceeds 12 inches (300 mm).
8.
Ensure that all cables have sufficient slack to allow for engine movement, and that there is no pressure on any wiring connectors.
9.
If any convoluted tubing is damaged, check the wiring inside it. Replace any damaged or missing convoluted tubing.
10. Clean the cable connector terminals with a wire brush. See Group 54 of the Century Class
Trucks Workshop Manual for troubleshooting instructions, and for adjustment, repair, or replacement instructions.
Century Class Trucks Maintenance Manual, January 2016
15/1
15
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.
10.4
After cleaning, connect the cables to the batteries, and tighten them to the torque specifications listed on the battery, generally 10 to 15 lbf·ft (14 to 20 N·m).
10.5
Coat the battery terminals with dielectric grease.
11. 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.
Alternators and Starters
15/2
Century Class Trucks Maintenance Manual, January 2016
Engine Cooling/Radiator
20
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Engine Cooling/Radiator
20
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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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. If the radiator cap must be replaced, make sure that it is the correct cap for the cooling system of the vehicle. Because the radiator cap pressure rating affects the operating temperature of the engine, installing an improperly rated radiator cap may have adverse effects on the cooling system, and engine operating temperatures. This could cause premature engine wear or damage.
1.
Remove the fill cap first, to relieve the cooling system pressure, then remove the SAE cap.
2.
Using a radiator-cap tester, check the pressure cap to see if it maintains pressure to within 10% of the pressure rating marked on the cap. If it doesn’t, replace the cap. See
or
Make sure that the replacement radiator cap is correctly rated for the cooling system of the vehicle.
3.
There is a second valve in the radiator cap that opens under vacuum. This prevents the collapse of hoses and other parts that are not internally supported when the system cools. Inspect the vacuum-relief valve to be sure it is not stuck.
4.
Make sure that the cap seals properly on the coolant filler neck seat, and that the radiator cap gasket is not damaged. On vehicles with screw on caps with O-rings, make sure that the O-ring is not cracked or deteriorated. Replace the cap if the gasket shows deterioration or damage.
20–02 Radiator Pressure-
Flushing and Coolant
Change
NOTE: For additional instructions on cleaning and flushing the engine’s cooling system, see the applicable engine manufacturer’s maintenance and operation manual.
1.
Park the vehicle, apply the parking brakes. Tilt the hood or cab. For instructions on tilting the cab, see Group 60 of the Century Class Trucks
Workshop Manual.
2.
Place a suitable container under the elbow of the radiator outlet pipe and under the radiator. The container should hold at least 60 quarts (58.6
liters) of fluid for single radiator applications, or
80 quarts (76 liters) for Argosy’s with auxiliary radiators.
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.
3.
Remove the surge tank cap.
4.
On Argosy’s with auxiliary radiators, open the remote bleed valve. See
Century Class Trucks Maintenance Manual, January 2016
20/1
20
Engine Cooling/Radiator
1
2
3
06/08/95
1.
Low-Coolant-Level Sensor
2.
SAE Cap (for coolant overflow pressure relief only)
3.
Fill Cap
Fig. 1, Surge Tank, Century Class Conventional
1
2
3
07/21/98
1.
Radiator/Charge Air Cooler Assembly
2.
Fill Cap
3.
Surge Tank
Fig. 2, Surge Tank, Argosy COE
f200465 f500244
cooling system prior to the system cooling could cause severe personal injury due to scalding.
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
6.
Install and tighten the drain plug(s) and the radiator outlet pipe drain plug after the radiator has been drained. Do not overtighten the plugs.
7.
Flush the radiator(s) as follows.
7.1
Disconnect the radiator upper and lower hoses.
7.2
Attach the flushing gun nozzle to the radiator at the lower radiator hose opening.
Run the water until the radiator is full.
NOTICE
WARNING
Do not attempt to drain the cooling system until the coolant and engine are cool. Draining the
When flushing the radiator, do not apply more than 15 psi (100 kPa) air pressure. Excessive pressure can damage the radiator.
20/2
Century Class Trucks Maintenance Manual, January 2016
Engine Cooling/Radiator
1
9
20
4
5
6 2
3
8
7
08/19/2009
NOTE: The main radiator drain plug is not shown.
1.
Surge Tank
2.
Remote Bleed Valve
3.
Main Radiator
4.
Auxiliary Radiator
5.
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
7.4
7.5
7.6
Gradually, apply air pressure to help dislodge sediment built up in the radiator core. Do not apply more than 15 psi (103 kPa) air pressure to the radiator. Pressures exceeding 15 psi (103 kPa) could damage the radiator core.
Shut off the air at the pressure gun nozzle and allow the radiator to refill with water.
Repeat the previous two steps until clean water flows from the radiator.
Remove the radiator side tank drain plug and allow the radiator to drain.
f200726
8.
Connect the hoses. The hose clamps on the main radiator can be either T-bolt clamps (see
) or Breeze Constant-Torque clamps (see
When working with T-bolt hose clamps, tighten the clamps 55 lbf·in (620 N·cm). These clamps are now standard on hoses with an inside diameter greater than 2 inches (51 mm).
When installing Breeze Constant-Torque hose clamps, the clamps must be tightened to the correct torque. The screw tip of the clamp must extend about 1/4 inch (6 mm) from the clamp housing, and the Belleville washer stacks must be collapsed almost flat. Use a torque wrench to
Century Class Trucks Maintenance Manual, January 2016
20/3
20
Engine Cooling/Radiator
A
B
1
1
1
06/29/95
NOTE: Cummins M11 engine shown.
1.
Coolant Drain Plug
Fig. 4, Coolant Drain Plug Location
f011008 install these hose clamps correctly. The correct installation torque is as follows:
For Breeze Constant-Torque clamps with a 5/16-
inch tightening screw hex: 55 lbf·in (620 N·cm).
For Breeze Constant-Torque clamps with a 3/8-
inch tightening screw hex: 90 lbf·in (1020 N·cm).
02/28/96 f200326
Fig. 5, T-Bolt Type Hose Clamp
NOTE: All hose clamps will lose torque after installation due to "compression set." However, when correctly installed, Breeze Constant-
Torque clamps will hold enough torque to auto-
08/15/94 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
Fig. 6, Breeze Constant-Torque Hose Clamp Installation
matically adjust and keep consistent sealing pressure. During vehicle operation and shutdown, the screw tip may adjust according to 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.
IMPORTANT: On vehicles with EPA07 compliant engines, the coolant capacity varies depending on the engine and accessory installation. After servicing the cooling system, always verify that the coolant level is between the MIN and MAX lines on the surge tank.
11. Fill the cooling system with new coolant. Refer to the engine manufacturer’s service literature for specific coolant information.
12. On single radiator applications, add coolant as follows.
12.1
Fill the cooling system at the surge tank.
12.2
Install the surge tank cap.
12.3
Return the hood or cab to the operating position. See Group 60 of the Century
Class Trucks Workshop Manual for cab tilt instructions.
12.4
Start the engine and turn on the cab heater. Allow the engine to warm up to
20/4
Century Class Trucks Maintenance Manual, January 2016
Engine Cooling/Radiator
20
normal operating temperature. Check the 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.
13.2
Fill the cooling system at the surge tank; continue adding coolant until a nonaerated coolant stream comes out of the remote bleed valve. This allows air to be expelled from the auxiliary system.
13.3
Close the remote bleed valve.
13.4
Continue filling until the coolant reaches the high level mark on the surge tank.
13.5
Run the engine for 5 minutes to allow the system to de-aerate.
13.6
Check the coolant level again; add coolant to the high level mark.
20–03 Fan Clutch Check (Noise
Emission Control)
Horton Advantage® Fan Clutch
NOTE: If any part of the fan clutch needs to be repaired or replaced, after performing the checks below, see Group 20 of the Century
Class Trucks Workshop Manual.
1.
Disconnect the electrical cables from the battery.
Drain all air from the air system. If equipped with an air starter, drain the air starter reservoir.
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.
3.1
Unscrew the fan clutch solenoid valve air filter assembly and remove the filter element.
3.2
3.3
Clean the filter element with cleaning solvent.
Reassemble the clutch valve solenoid air filter assembly and install on the vehicle.
4.
Visually check the fan for bent, cracked, or damaged blades. Replace if damaged. Check for adequate clearance between the fan and other components.
5.
Check the fan belt for wear, tension, and alignment. Correct if necessary.
6.
Check for wear on the friction facing. See
Replace the friction facing if it is worn to a 1/16inch (1.6-mm) thickness or less. Also check the facing for signs of oil contamination or burn marks. If evidence of oil or burn marks are found, replace the friction facing.
3
4
5
2
1
08/08/94
1.
System Sentry® Fuse
2.
Safeguard Hole
3.
Friction Facing
Fig. 7, Horton Advantage Fan Clutch
f200290
4.
Piston Friction Disc
5.
Air Chamber
7.
Connect the battery cables. Start the engine, and charge the air system to 120 psi (827 kPa). Shut down the engine. Separate the halves of the fan solenoid connector. The fan clutch should engage.
If the fan does not operate correctly, see Group
20 of the Century Class Trucks Workshop
Manual for troubleshooting and repair procedures.
Century Class Trucks Maintenance Manual, January 2016
20/5
20
Engine Cooling/Radiator
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. See Group 20 of the
Century Class Trucks Workshop Manual for repair procedures.
9.1
Check for a leak at the bleed hole on the fan pilot. Air leakage means that the car-
seal (Ref. 17) is damaged.
7
8
9.3
9.4
age means that the large O-ring (Ref. 14) is damaged.
Check for air leaks around the safeguard hole on the piston friction disc. Air leakage means the small O-ring (Ref. 18) is damaged.
Check for air leaking from the System
Sentry® fuse. Leaking air means the clutch has gotten so hot the lead alloy in the fuse melted. This released the clutch before the heat could damage the clutch bearings. Before replacing the fuse, find and repair the source of the heat.
6
19
20
5
1
2
3
4
14
15
17
18
21
22
23
11
12
13
16
9
10
24
03/30/95
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
9.2
9.
Rear Hub Bearing
10. Bearing Spacer
11. Splined Hub
12. Forward Hub Bearing
13. Piston Friction Disc
14. Large O-Ring
15. Locknut
16. Cartridge Assembly
17. Face Seal
18. Small O-Ring
19. Air Chamber
20. Socket-Head Capscrew
21. Stud Bolt
22. Lockwasher
23. Hexnut
24. Piston Assembly f200194a
Fig. 8, Horton Advantage Fan Clutch Components
Check for air leaks between the air chamber and the piston friction disc. Air leak-
10. If equipped with an override toggle switch on the dash, check the fan clutch operation as follows:
20/6
Century Class Trucks Maintenance Manual, January 2016
Engine Cooling/Radiator
20
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.
10.6
Set the toggle switch to the AUTO or OFF position; the air should exhaust and the fan clutch should disengage. Replace the switch if necessary.
11. If the fan stays engaged at all times on a Detroit
Diesel engine, check the circuit breaker labeled
"engine fan."
Kysor K22RA Fan Clutch
1.
Disconnect the electrical cables from the battery.
Drain all air from the air system. If equipped with an air starter, drain the air starter reservoir.
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.
Measure the distance from the back surface of the fan clutch retaining plate to the forward-most edge of the fan belt pulley. See
3.
Disconnect the line from the air inlet of the air cylinder. Connect a shop air hose to the inlet.
4.
Apply a minimum of 100 psi (690 kPa) air pressure to the air cylinder—the bearing housing will move backwards, disengaging the clutch. Again, measure the distance from the back surface of the retaining plate to the forward-most edge of the fan belt pulley.
5.
Compare the two measurements; if the difference between the two measurements exceeds 0.150
inches (3.8 mm), the clutch lining is worn and must be replaced. See Group 20 of the Century
4
5
1
2
3
6
A
05/27/93 f200237a
With the fan clutch engaged, measure the distance at A; measure it again with the fan clutch disengaged.
1.
Bearing Housing
2.
Retaining Plate
3.
Fan Pulley
4.
Air Inlet (from solenoid valve)
5.
Air Cylinder
6.
Fan
Fig. 9, Kysor K22RA Fan Clutch Lining Wear Checking
Class Trucks Workshop Manual for clutch lining replacement instructions.
6.
Release the air pressure, then disconnect the shop hose from the air inlet of the air cylinder.
Connect the vehicle air hose to the inlet.
7.
Connect the electrical cables to the battery.
8.
Start the engine.
Horton DriveMaster® Fan Clutch
NOTE: If any part of the fan clutch needs to be repaired or replaced after performing the checks below, see Group 20 of the Century Class
Trucks Workshop Manual.
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.
WARNING
Make sure the batteries are disconnected before checking the fan clutch. If the engine starts during
Century Class Trucks Maintenance Manual, January 2016
20/7
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
3.3
Clean the filter element with cleaning solvent.
Using a clean, lint free cloth, wipe off any excess solvent.
3.4
Reassemble the clutch valve solenoid air filter assembly and install on the vehicle.
4.
Visually check the fan for bent, cracked, or damaged blades. Replace if damaged. Check for adequate clearance between the fan and other components.
5.
Check the fan belt for wear, tension, and alignment. Correct, if necessary.
6.
Check for wear on the friction facing. Replace the friction facing if it is worn to a 3/16-inch (4.8mm) thickness or less. Also check the facing for signs of oil contamination or burn marks. If evidence of oil or burn marks are found, replace the friction facing.
7.
Connect the battery cables. Start the engine, and charge the air system to 120 psi (827 kPa).
Manually engage and disengage the fan clutch.
Check the fan and the fan clutch from a distance. Look for vibration, fan blade contact, fan clutch slippage, and overall fan clutch operation.
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.
Check at the solenoid valve, the air filter assembly, and the air hoses and fittings. See
Using a wet finger or a soapy water solution, check for a leak in the same areas.
05/30/2002 f200581
Fig. 10, Checking for Air Leaks (Horton DriveMaster)
9.
If a leak is detected, remove the fan blade. Install a new seal kit. See Group 20 of the
Century Class Trucks Workshop Manual for repair procedures.
10. Check the fan drive for discoloration or any other signs of slipping or overheating.
NOTE: The fan clutch may slip if the air supply pressure is below 70 psi (483 kPa) or if there is a leak inside the fan clutch. Any leak must be remedied.
11. Check the fan clutch bearings.
11.1
Turn the fan in both directions and feel for worn hub bearings.
11.2
If possible, remove the drive belt and check for worn sheave bearings by turning the sheave in both directions.
11.3
If either the hub or sheave bearings are worn, replace them, using a Horton Drive-
Master Super Kit.
For instructions and kit part number, see
Group 20 of the Century Class Trucks
Workshop Manual.
20/8
Century Class Trucks Maintenance Manual, January 2016
Clutch
25
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Clutch
25
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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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.
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.
NOTE: For lubrication of the release bearing,
Eaton fuller recommends a lithium-base hightemperature grease that meets the NLGI grade one or two specification.
3.
Wipe any dirt away from the grease fitting. See
. Use a pressure-type grease gun
equipped with the recommended grease, and lubricate the bearing until excess grease purges from the rear of the release bearing (toward the transmission).
CAUTION
Do not over-lubricate the clutch release bearing.
Over-lubrication could contaminate the clutch internally, causing clutch slippage and premature
05/27/93 f250081a
Fig. 1, Release Bearing Grease Fitting failure. Do not use chassis grease or multipurpose lubricants.
4.
Wipe off excess grease and apply it to both the yoke-finger and the sleeve-bushing contact points. See
1
2
08/10/2009
1.
Sleeve-Bushing Contact Point
2.
Yoke-Finger Contact Points
Fig. 2, Grease the Contact Points
5.
Install the clutch inspection plate.
6.
Remove the chocks.
f250444
Century Class Trucks Maintenance Manual, January 2016
25/1
25
Clutch
25–02 Clutch Release Cross-
Shaft Lubrication
The clutch release cross-shaft is equipped with two grease fittings in the transmission clutch housing.
See
and
. Wipe any dirt from the grease
fittings, then lubricate with multipurpose chassis grease.
1
2
10/19/93
1.
Clutch Release Cross-Shaft
2.
Grease Fitting f250048a
Fig. 3, Cross-Shaft Grease Fitting, Left-Side
05/27/93 f260146a
Fig. 4, Cross-Shaft Grease Fitting, Right-Side
25–03 Sleeve Assembly Bronze
Bushing Lubrication
Vehicles equipped with the sealed clutch-release bearing have a lubrication extension outside of the clutch housing. This extension is needed to provide lubrication to the bronze bushing located between the clutch bearing housing and the transmission input shaft. Use a pressure-type grease gun equipped with high-temperature grease only, and lubricate until grease flows from the release bearing housing. Depress the clutch pedal a couple of times before starting the engine.
25–04 Meritor 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.
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.
NOTE: For lubrication of the release bearing,
Meritor recommends a lithium-base hightemperature grease that meets the NLGI grade three specification.
3.
Wipe any dirt away from the grease fitting. See
. Use a pressure-type grease gun
equipped with the recommended grease, and lubricate the bearing until excess grease purges from the rear of the release bearing (toward the transmission).
CAUTION
Do not over-lubricate the clutch release bearing.
Over-lubrication could contaminate the clutch internally, causing clutch slippage and premature failure. Do not use chassis grease or multipurpose lubricants.
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Century Class Trucks Maintenance Manual, January 2016
Clutch
4.
Wipe off excess grease and apply it to both the yoke-finger and the sleeve-bushing contact points. See
5.
Install the clutch inspection plate.
6.
Remove the chocks.
25
Century Class Trucks Maintenance Manual, January 2016
25/3
Transmission
26
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Manual and Automated Transmission Fluid Change, and Magnetic Plug
Century Class Trucks Maintenance Manual, January 2016
Transmission
26
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 can not drop. Failure to follow these steps could result in serious personal injury or death.
26–01 Manual and Automated
Transmission Fluid
Change, and Magnetic
Plug Cleaning (Synthetic
Lubricant)
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.
Do not mix types and brands of fluid, because of possible incompatibility. Do not use fluid additives, friction modifiers, extreme-pressure gear fluids, or multiviscosity lubricants.
NOTE: Fluid change intervals are extended to
500,000 miles (800 000 km) on any vehicles filled with synthetic transmission fluid.
1.
Drain the transmission when the fluid is warm. If not already warm, run the engine until the transmission fluid reaches operating temperature.
Shift the transmission to neutral (N) and shut down the engine.
2.
Park the vehicle on level ground, apply the parking brakes, and chock the rear tires. Place a large drain pan under the transmission.
3.
Clean the area around the fill plug, and remove it from the side of the gear case. Remove each drain plug from the bottom of the case.
4.
Clean the fill and drain plugs. 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.
Install and tighten each drain plug 50 lbf·ft (68
N·m).
NOTE: The optional transmission fluid filter is a remote-mount, spin-on type, and is located between the transmission and the fluid cooler. The filter bracket is attached to the frame rail or some other near-by location. The filter is mounted in a vertical position, and should be filled with fluid before installation to assure the proper fluid level. For optimum transmission performance, 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
To prevent skin burns from hot transmission fluid, wear protective gloves when removing the filter.
5.2
Place a strap or chain wrench around the filter canister, and rotate in a counterclockwise motion to separate the filter from the mounting. Carefully spin the filter off the mount and remove it from the vehicle.
5.3
Apply a light coat of transmission fluid to the O-ring gasket on the new filter. Fill the filter with the specified transmission fluid, and spin the filter onto the mount.
NOTE: The filter fills slowly, so be patient to ensure the proper fluid level has been set.
5.4
Once the filter has made contact with the mount, use a strap wrench to rotate the filter canister an additional 180 to 270 degrees to firmly tighten it. Wipe it clean of any fluid after it is tightened.
6.
Add fluid until it is level with the lower edge of the fill opening. See
has two fill openings, add fluid to the level of both openings. See
for approved transmission lubricants. See
for Eaton®
Century Class Trucks Maintenance Manual, January 2016
26/1
26
Transmission
Fuller® transmission lubricant capacities and
for Meritor transmission lubricant capacities.
NOTE: In all cases, the correct fluid level is established by checking at the fill opening.
7.
Operate the engine for five minutes after filling the transmission, then check the fluid level again.
A
B
05/27/93
A. Full B. Low f260006a
Fig. 1, Checking Transmission Fluid Level
Approved Manual Transmission Lubricants
Transmission
Model
Lubricant Type *
Temp.
Range
SAE
Viscosity
Eaton Fuller Transmissions
†
All Eaton
Fuller
MobilTrans SHC 50
(RN 2952 E-5)
Synthetic transmission lubricant approved by
Eaton
Meritor Transmissions
All
All
50W
50W
FreedomLine
All other
Meritor
MobilTrans SHC 50
(RN 2952 E-5)
Synthetic engine oil meeting Meritor spec
0–81, or MIL–L–2104D or E
All
All
50W
50W
*
Do not mix types or brands of fluid. Multiweight and extreme-pressure gear fluids are not recommended.
†
For a complete list of Eaton approved lubricants, and for more information about Eaton lubricant specifications and suppliers, call 1-800-826-4357 or see
www.roadranger.com
.
Table 1, Approved Manual Transmission Lubricants
Eaton Fuller Transmission Lubricant Capacities
Transmission Model *
Refill Capacity
†
: qt (L)
7-Speed T Series
Eaton Fuller Transmission Lubricant Capacities
Transmission Model
*
Refill Capacity
†
: qt (L)
All Models 18.0 (17.0)
All 9-Speed Series
All Models 13.5 (12.8)
All 10-Speed Manual Models (except deep reduction)
FR and FRO Series
RT and RTX Series
RTLO Series
11.75 (11.0)
13.0 (12.3)
14.0 (13.2)
RTO–16210C 11.75 (11.0)
10-Speed Deep Reduction
RTO/RTX–11708LL
RTO–11908LL
14.0 (13.2)
RTO/RTX–14708LL 14.5 (13.7)
10-Speed Automated Models
Lightning Top 2 (all)
10-Speed Autoshift AS2 (all)
13-Speed RTLO Series
13.5 (12.8)
13.0 (12.3)
All Models 14.0 (13.2)
All 15-Speed Series
14.0 (13.2) All Models
All 18-Speed Series
RTLO Series
18-Speed Autoshift AS2 (all)
14.0 (13.2)
* For models not listed in this table see the Eaton Fuller website,
www.roadranger.com
.
†
Quantities listed are approximate. Fill the transmission until lubricant is level with bottom of the fill hole, with the vehicle in normal operating position.
Table 2, Eaton Fuller Transmission Lubricant
Capacities
8.
Clean the fill plug, then install it in the transmission. Tighten the plug as follows:
• 25 to 35 lbf·ft (34 to 48 N·m) for Eaton
Fuller transmissions with 3/4-inch pipe threads.
• 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.
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Century Class Trucks Maintenance Manual, January 2016
Transmission
26
• 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)
–115A/B/C/R (all)
Meritor 9- and 10-Speed
10.0 (9.5)
–125A/B/C/R (all)
–135A/B/C/R (all)
–145A/B/C/R (all)
–155A/B/C/R (all)
10.25 (9.7)
Meritor 13-Speed
RM013–145A 11.0 (10.4)
ZF Meritor FreedomLine
All 12-Speed Models
All 16-Speed Models
11.6 (11.0)
12.5 (11.8)
* Quantities listed are approximate. Fill the transmission until lubricant is level with bottom of the fill hole, with the vehicle in normal operating position.
Table 3, Meritor Transmission Lubricant Capacities
26–02 Allison Transmission
Fluid and Filter Change
When draining transmission fluid, check for evidence of dirt or water contamination. A small amount of condensation will appear in the fluid during operation.
Water contamination is normally characterized as a milky discoloration of the transmission fluid. Obvious contamination of the transmission fluid indicates a leak between the water and fluid areas of the transmission cooler. Inspect and pressure-test the cooler to confirm the leak; replace leaking transmission coolers.
1.
Drain the transmission when the fluid is warm. If not already warm, run the engine until the transmission reaches normal operating temperature:
160 to 200°F (71 to 93°C).
2.
Park the vehicle on a level surface. Apply the parking brakes and chock the rear tires.
3.
Clean the area around the drain plug and the transmission fluid pan. Place a drain pan under the transmission and remove the drain plug. Examine the fluid as it drains.
4.
Remove the 12 mounting bolts (six each) from the two filter covers.
NOTE: A lot of fluid will drain when the filter covers are removed.
5.
Remove the filter covers, O-rings, and two square-cut seals from the transmission. See
6.
Remove the filters from the bottom of the control module.
7.
Lubricate the new O-rings with transmission fluid, and install them on the cover assemblies.
8.
Install a new square-cut seal on each cover assembly, and install the fluid filter elements on the cover assemblies.
9.
Install the filter and cover assemblies into the filter compartment.
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.
NOTICE
Do not use the bolts to draw the filter covers to the sump. This can damage the covers, seals, or sump.
11. Install six bolts in each cover, and torque the bolts 38 to 44 lbf·ft (51 to 61 N·m).
12. Replace the drain plug O-ring, and install the drain plug. Tighten the drain plug 18 to 24 lbf·ft
(25 to 32 N·m).
13. Refill the transmission with fresh automatic transmission fluid and check the fluid level. See
for transmission lubricant capacities, and
for approved transmission lubricants.
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Century Class Trucks Maintenance Manual, January 2016
26
Transmission
1
5
2
3
4
1
2
3
4
1
1
09/29/97
1.
Filter Cover
2.
Filter Element
3.
Filter Element O-Ring f260317a
4.
Square-Cut Seal
5.
Drain Plug
Fig. 2, Allison Transmission Filter Location and
Components
Allison Transmission Lubricant Capacities
Transmission Model
HD4060/4560 (standard sump)
Refill Capacity
*
: qt (L)
36 (34)
†
Allison Transmission Lubricant Capacities
Transmission Model
HD4060/4560 (shallow sump)
Refill Capacity
26 (25)
†
* : qt (L)
* 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.
Table 4, Allison Transmission Lubricant Capacities
Approved Automatic Transmission Lubricants
Lubricant Type
*
Temperature: °F (°C)
All Allison Models
Castrol TranSynd (synthetic)
Dexron® III
Above –22 (–30)
Above –17 (–27)
*
Lubricants listed in order of preference. Do not mix fluid types.
Table 5, Approved Automatic Transmission
Lubricants
26–03 Manual Transmission Air
Filter/Regulator Check,
Cleaning, or
Replacement
Eaton Fuller
1.
Apply the parking brakes and chock the rear tires. Drain the air reservoirs.
WARNING
Drain the air supply; if the air supply is not drained before the air filter/regulator is serviced, serious injury and component damage could result.
2.
Clean the outside of the air filter/regulator with cleaning solvent. See
3.
Remove the end cap, large O-ring, and filter element from the filter housing. See
the small O-ring from the end cap.
NOTE: Do not remove, disassemble, or adjust the air regulator. If the air regulator is not keeping the air pressure between 58 and 63 psi (400 to 435 kPa), replace the air filter/regulator. It cannot be repaired.
26/4
Century Class Trucks Maintenance Manual, January 2016
Transmission
26
05/27/93 f260037a
Fig. 3, Air Filter/Regulator (Eaton Fuller transmission shown)
5
6
4
7
2
3
1
10/17/2001
1.
Air Regulator
2.
Housing
3.
Large O-Ring
4.
Filter Element
5.
6.
7.
Small O-Ring
End Cap
Plug f260052a
Fig. 4, Eaton Fuller Transmission Air Filter/Regulator
Components
WARNING
Wear safety goggles when using compressed air to clean parts, as permanent harm to eyes could result from flying debris.
4.
Clean the filter element by dipping it in alcohol or other cleaning solvent. Blow compressed air 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.
Install the small O-ring in the end cap, then install the end cap and tighten it until firm.
NOTICE
A leaking air filter or air lines can cause slow or hard shifting of the transmission, and eventual transmission damage.
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.
2.
Remove the element from the air filter/regulator assembly. Inspect the O-rings in the end cap; replace worn or damaged O-rings. Inspect the element for fluid contamination. If fluid is present, replace the element. Inspect the air supply system for the source of the fluid, and service it as needed.
3.
Install the element in the filter/regulator assembly.
4.
Apply a light coat of silicone grease, or an equivalent grease to the O-rings in the end cap.
Install and tighten the end cap 10 to 15 lbf·ft (14 to 20 N·m).
5.
Build air pressure in the system, check for leaks, and make any needed repairs.
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Century Class Trucks Maintenance Manual, January 2016
26
Transmission
26–04 Transmission Fluid
Level Inspection
Allison
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. Do not use fluid additives, friction modifiers, extreme-pressure gear fluids, or multiviscosity lubricants.
Cold Check
Clean all dirt from around the end of the fluid fill tube before removing the dipstick. Do not allow foreign matter to enter the transmission. Dirt or foreign matter 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.
Shift from DRIVE to NEUTRAL, and then shift to
REVERSE to fill the hydraulic system.
5.
Shift to NEUTRAL and allow the engine to idle at
500 to 800 rpm.
6.
With the engine running at idle, remove the dipstick from the tube and wipe it clean.
7.
Insert the dipstick into the tube and remove the dipstick.
8.
Check the fluid level reading and repeat the check procedure to verify the reading.
If the fluid level is within the COLD RUN band, the transmission may be operated until the fluid is hot enough to perform a hot check.
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
B
A
12/01/97
A. Cold Run Band B. Hot Run Band
Fig. 5, Dipstick Markings
f270002a
NOTICE
As the fluid temperature increases, so does the fluid level. Do not fill above the COLD RUN band if the transmission fluid is below normal operating temperature.
NOTE: Perform a hot check at the first opportunity after the normal operating temperature, 160 to 200°F (71 to 93°C), has been reached.
Hot Check
1.
Park the vehicle on a flat, level surface. Apply the parking brakes and chock the rear tires.
2.
Shift the transmission to NEUTRAL.
3.
Operate the engine at idle (500 to 800 rpm) until normal operating temperature is reached. Check that the sump temperature is 160 to 200°F (71 to
93°C). Check that the converter-out temperature is 180 to 220°F (82 to 104°C).
4.
With the engine idling, remove the dipstick from the tube and wipe it clean.
5.
Insert the dipstick into the tube and remove the dipstick.
6.
Check the fluid level reading and repeat the check procedure to verify the reading. Safe operating level is within the HOT RUN band on the dipstick. The HOT RUN band is between the
HOT FULL and HOT ADD marks.
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Century Class Trucks Maintenance Manual, January 2016
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
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.
Do not mix types and brands of fluid, because of possible incompatibility. Do not use fluid additives, friction modifiers, extreme-pressure gear fluids, or multiviscosity lubricants.
With the transmission at operating temperature, and the vehicle on a level surface, check the fluid level in the transmission.
1.
Clean the area around the fill plug, and remove it from the side of the case.
2.
Using your finger or a bent pipe cleaner, see if the fluid is level with the fill opening. See
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
for approved transmission lubricants.
5.
Clean the fill plug, then install it in the transmission. Tighten the plug as follows:
• 25 to 35 lbf·ft (34 to 48 N·m) for Eaton
Fuller transmissions with 3/4-inch pipe threads.
• 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.
• 35 to 50 lbf·ft (48 to 67 N·m) for all other
Meritor transmissions.
Century Class Trucks Maintenance Manual, January 2016
26
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Frame and Frame Components
31
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Frame and Frame Components
31
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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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.
Fontaine
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 for cracks in the fifth wheel assembly, mounting brackets, and mounting parts.
4.
Ensure that both bracket pins are in place and secured by retainer pins and cotter pins. See
5.
For fifth wheels equipped with bracket liners, rock the fifth wheel. If it does not rock freely, remove the top plate and inspect the bracket liners. Replace liners that are broken or less than
0.125 inch (3 mm) thick at the top of the liners.
For the liner replacement procedure, see the
Fontaine website,
www.fifthwheel.com
.
6.
Check the jaw and stationary jaw for mushrooming, and check that the serrations at the jaw and wedge are in good condition.
7.
Test the secondary safety lock latch for ease of operation.
8.
Check for loose nuts or bolts on the fifth wheel and the mounting. Set a torque wrench to the maximum torque value for the bolt being checked, and confirm that the torque is to specification. Do not loosen the bolt to check the torque. See
Group 00
for bolt torque specifications.
9.
Check all springs to see if they are securely fastened, and are not deformed.
WARNING
Do not disassemble the fifth wheel to inspect the springs. The springs are under extreme pressure, and could cause serious injury.
10. Check wedge adjustment.
10.1
Open the kingpin lock, and vertically insert a 2-inch (50-mm) diameter shaft.
10.2
Release the lock by tripping the release latch at the bottom of the throat.
10.3
Adjust the wedge stop at the end of the wedge to approximately 1/4-inch (6-mm) clearance by turning the wedge stop rod located on the right side of the top plate.
11. 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.
12. After inspecting the fifth wheel, lubricate all moving parts with a chassis or multipurpose grease.
Apply a generous coating of grease to the top plate to fill the grooves, or depressions, on the top plate. See
MOP 31–02
for lubrication instructions.
Holland FWS1
1.
Disconnect the tractor from the trailer. For instructions, see the Century Class Driver’s
Manual.
2.
Thoroughly steam clean the fifth wheel.
Century Class Trucks Maintenance Manual, January 2016
31/1
31
Frame and Frame Components
16
13
12
15
12
9
10
14
12
11
8
8
5
5
7
6
19
17
12
18
12
15
20
21
8
5
5
7
6
8
1
2
4
3
2
12/02/2010
NOTE: 6000 Series shown; 7000 Series fifth wheels use similar parts.
1.
Wedge Stop Rod Nut
2.
Flat Washer, 5/8"
3.
Wedge Stop Rod Spring
4.
Wedge Stop Rod
5.
Grease Fitting
6.
Bracket Pin
7.
Bracket Retainer Pin
8.
Cotter Pin, 3/16" x 1"
9.
Bumper Spring
10. Handle Spring
11. Bolt, Secondary Safety Lock
12. Flat Washer
13. Secondary Safety Lock
14. Bushing, Secondary Safety
Lock
15. Hex Locknut
16. Pull Handle
17. Bolt, Bumper
18. Bushing
Fig. 1, Fontaine Fifth Wheel
27
26
25
15
12
24
19. Bumper
20. Timer Spring
21. Timer
22. Operating Handle
22
12
23. Bolt, Operating Handle
23
24. Bushing, Operating Handle
25. Hair Pin Cotter
26. Wedge
27. Step Jaw f311134
31/2
Century Class Trucks Maintenance Manual, January 2016
Frame and Frame Components
31
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
1
3
2
4
10/29/2007
1.
Lubricant Grooves
2.
Safety Latch
3.
4.
Release Handle
Mount
Fig. 2, Holland FWS1 Fifth Wheel
f311052
5.
The lever bar and release handle must be in proper alignment. See
bar and release handle alignment to a new, or a properly operating lever bar and release handle.
Replace any bent or misaligned lever bar or release handle.
1
2
03/28/2013
1.
Release Handle 2.
Lever Bar f311140
Fig. 3, Lever Bar and Release Handle Alignment
6.
Check all cotter pins for cracking or damage. Replace any cotter pin that shows any signs of damage.
7.
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.
8.
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.
9.
After inspecting the fifth wheel, lubricate all moving parts with a chassis or multipurpose grease.
See
MOP 31–02
for lubrication instructions.
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.
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.
Inspect the fifth wheel for bent, worn, damaged, and missing parts; replace them as needed with genuine Holland parts.
5.
Using a Holland Kingpin Lock Tester (Holland tool number TF-TLN-5001, available through the
PDCs as HLD TFTLN5001), check the operation of the locking mechanism by opening and closing the locks. See
6.
After inspecting the fifth wheel, lubricate all moving parts with a chassis or multipurpose grease.
See
MOP 31–02
for lubrication instructions.
Castloc II and Simplex Series
1.
Disconnect the tractor from the trailer. For instructions, see the vehicle 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).
Century Class Trucks Maintenance Manual, January 2016
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31
Frame and Frame Components
1
A
2
04/11/2011
B f310887
A. The nut and washer should be snug against the fifth wheel.
B. The locks should be completely closed around the kingpin.
Fig. 4, Holland Fifth Wheel Properly Closed
4.
When the wheel is locked, the safety latch must swing free and fall freely into position. See
3
4
2
1
10/26/2010
1.
Lubricant Grooves
2.
Safety Latch
Fig. 5, Simplex Series Fifth Wheel
f310353b
3.
Lock Control Handle
4.
Mount
5.
The lever bar and operating handle must be in proper alignment. See
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.
04/11/2011
1.
Operating Handle 2.
Lever Bar f310470
Fig. 6, Lever Bar and Operating Handle Alignment
6.
Check all cotter pins for cracking or damage. Replace any cotter pin that shows any signs of damage.
7.
Level the fifth wheel plate to a horizontal position. Measure the height from a stationary mounting point (see
frame rail to the top of the fifth wheel plate (Ref.
1). Pry up on the fifth wheel plate (Ref. 4) below the pin boss, and measure the vertical movement (Ref. 5). The bracket connection provides a
9/32-inch (7-mm) vertical clearance to provide cushioning and to avoid downward pin-loading while retaining minimum plate lift. If the plate lift
(Ref. A) exceeds 5/16 inch (8 mm) as a result of wear or rubber deterioration, install new, standard or oversized bracket-shoe rubber pads; see
Group 31 of the Century Class Trucks Workshop
Manual for replacement instructions.
NOTE: Do not measure plate lift immediately after a trailer has been uncoupled from the fifth wheel. The rubber may have taken a temporary set, which will normally recover after being uncoupled for a short period of time.
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.
31/4
Century Class Trucks Maintenance Manual, January 2016
Frame and Frame Components
31
A
5
1
2
3
4
04/11/2011
A. Extended Top Plate Lift Height
1.
Fifth Wheel Top Plate
2.
Fifth Wheel Frame Mount
3.
Frame Rail
4.
Lifting Point
5.
Static Top Plate Height
Fig. 7, Measuring Fifth Wheel Top Plate Lift
f310475
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. After inspecting the fifth wheel, lubricate all moving parts with a chassis or multipurpose grease.
See
Maintenance Operation 31–02
for lubrication instructions.
Jost
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 mounting for missing or damaged fasteners, and broken components. Replace or repair as needed.
4.
Inspect the bracket pin bolts. Make sure the locking tabs are properly securing the bolts in place.
See
5.
Check the fifth wheel for bent, worn, or broken parts. Replace as needed.
6.
If the fifth wheel is equipped with low-lube plates, check the plates and replace if damaged or worn down to the securing bolts. It is normal for out-
09/01/2009 f311101
Fig. 8, Bracket Pin Bolt Locking Tabs
side edges of the plate to pucker slightly; this does not affect performance.
7.
Check the fifth wheel adjustment. Using a lock tester, lock and unlock the fifth wheel several times. Make sure that the locking mechanism works properly.
The lock is properly adjusted if: the wheel locks and unlocks easily each time and the lock tester rotates freely.
The lock is too loose if: you feel fore-aft play when pulling and pushing on the lock tester handle. See
The lock is too tight if: the lock tester does not rotate freely in the lock. See
8.
If the lock is improperly adjusted, correct as follows.
If the lock is too tight, loosen the jam nut, turn the adjustment bolt clockwise one full turn, then reset the jam nut. Lock and unlock the mechanism several times to test. Repeat if necessary.
See
If the lock is too loose, loosen the jam nut, turn the adjustment bolt counterclockwise one full turn, then reset the jam nut. Lock and unlock the mechanism several times to test. Repeat if necessary. See
9.
If the fifth wheel is equipped with a sliding mechanism, inspect and adjust it as follows.
9.1
Check the bracket for any cracks or missing and damaged parts.
9.2
Inspect the locking plungers for full engagement.
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31
Frame and Frame Components
C
E
1
2
D
A
G
F
H
B
09/01/2009
A. Checking for fore/aft play
B. Rotating tester in lock
C. Engage hook
D. Pull/push handle fore/aft.
E. Check for movement of kingpin in lock
F.
Disengage hook
G. Push/pull handle inboard/outboard
H. Rotate lock tester
Fig. 9, Jost Fifth Wheel Adjustment
9.3
f311099
Check the locking mechanism for proper operation.
If the plungers will not release, check the air cylinder or plunger adjustment.
09/02/2009
1.
Jam Nut
2.
Adjustment Bolt
3.
Grease Zerk
3 f311100
Fig. 10, Jost Fifth Wheel
9.4
If the plungers are loose, check the plunger adjustment and the plunger springs for proper compression. Replace if needed.
The outboard slider assembly requires no adjustment. If the plungers are loose, inspect and replace locking mechanism parts as needed.
9.5
The inboard slider is adjustable for frame width and plunger engagement. For adjustment, 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.
31/6
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Frame and Frame Components
31
Apply a generous coating of grease to the top plate to fill the grooves, or depressions, on the top plate. See
MOP 31–02
for lubrication instructions.
31–02 Fifth Wheel Lubrication
To maintain proper fifth wheel operation, always lubricate the fifth wheel after an inspection has been performed.
IMPORTANT: Lubricate the fifth wheel:
• After power washing, or steam cleaning.
• If the vehicle operates in harsh conditions such as salt spray from road surfaces, or in extremely dusty environments.
• After any service that requires the removal of lubrication from the fifth wheel head or components.
WARNING
Failure to properly lubricate the fifth wheel could result in a possible disengagement of the trailer from the tractor, which could result in personal injury or property damage.
Fontaine
1.
Tilt the top plate forward (the front of the fifth wheel is down) and apply grease to each bearing area through the zerk fittings located on each side of the top plate just to the front of the bracket pins. Continue to apply grease until it is coming out of the back of the bearing. It may be necessary to raise the rear of the fifth wheel with a pry bar to open up the pocket slightly and allow the grease to flow through. A substantial amount of grease may be required initially to fill the reservoir.
Tilt the fifth wheel ramps down (the rear of the fifth wheel is down) and repeat the greasing procedure. Rock the top plate back and forth several times to spread the grease over the bearing surface.
2.
Inspect the trailer kingpin plate and top surface of the fifth wheel to make sure each is properly greased. A liberal coating of grease should be applied to the complete surfaces of both the trailer kingpin plate and the top surface of the fifth wheel.
NOTE: Do not use a lube plate (high density polyethylene) on top of the fifth wheel or on the kingpin instead of grease without prior approval by Fontaine Fifth Wheel. The additional thickness of this material can prevent the proper operation of the fifth wheel and may cause a dangerous condition.
NOTE: Fontaine suggests the use of a Moly based lubricant such as Mobilgrease XHP 320 or equivalent when applying lubricant to the locking jaw and wedge.
3.
Lubricate the fifth wheel prior to opening and closing it. Separate the jaw and wedge with a screwdriver, and grease the full length of their mating surfaces. Lubricate the top and bottom contact surfaces of the jaw and wedge. See
. Open and close the fifth wheel several times
to further distribute the grease.
Lightly oil other moving parts in the fifth wheel.
4.
Apply grease to the top plate. Spread grease all over the mating surface of the top plate. Be sure the grease pockets built into the top plates are full of grease.
Holland FWS1
Apply a heavy coat of grease to the top plate, either through the grease fittings located on the underside of the top plate, or by direct application.
Holland FW35
1.
Using a water-resistant lithium-base grease, grease the top plate.
2.
Using a light oil (such as SAE 10W or 20W motor oil), lubricate the cam track and pivot. See
3.
Grease the yoke tips, locks, and the release handle and spring; see
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.
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31
Frame and Frame Components
12/03/2010 f311136
Use a light oil (such as SAE 10W or 20W motor oil) to lubricate the cam track and pivot.
1.
Cam Plate
Fig. 11, Holland FW35 Fifth Wheel, Oil Lubrication
1
2
2
3
1
3
4
12/03/2010
1.
Release Handle and
Spring
2.
Grease Fitting
3.
4.
Yoke Tip
Locks f311135
Fig. 12, Holland FW35 Fifth Wheel, Grease Lubrication
Castloc II and Simplex Series
Use a chassis or multipurpose grease to lubricate the two grease fittings located on either side of the fifth wheel top plate. Lubricate the two grease fittings located in the grease grooves on the fifth wheel top plate. Lubricate the two grease fittings located below the top plate mounting pins. Lubricate the lock mechanism.
Once the fifth wheel’s moving parts are lubricated, apply a heavy coat of grease to the top plate, either through the grease fittings located on the underside of the top plate, or by direct application. On slidemount applications, lubricate the slider lock pockets and the slider bracket.
Jost
Lubricate the kingpin lock using a hand pump grease gun through the grease zerk on the skirt of the fifth wheel; see
. Apply a light oil to all moving
parts. For sliding fifth wheels spray diesel fuel on the slide path of the base plate.
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.
NOTE: If the fifth wheel is equipped with low-lube plates, the top plate only requires lubrication at the new product break-in stage. The low-lube plates require no further lubrication.
31–03 Frame Fastener Torque
Check
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
for pre-EPA07 engine mounts. Check the torque of frame fasteners to offset the effects of "bedding in" (or seating). When possible, always check the torque of the nut, not the bolt head. This will give a true torque reading by
31/8
Century Class Trucks Maintenance Manual, January 2016
Frame and Frame Components
31
eliminating bolt body friction. When checking the torque of frame fasteners, inspect the frame for cracks and other damage. Set a click-type torque wrench to the maximum torque of the fastener you are checking. Apply pressure until the torque wrench clicks. Do not loosen the bolt to check the torque.
See the applicable torque table in
Group 00
for torque specifications.
NOTICE
Make sure frame fasteners are properly tightened.
Continued vehicle operation with loose fasteners could result in bracket or frame damage.
NOTE: Engine supports on vehicles built from
January 2007 do not require checking.
Inspect and check the fasteners at the following locations:
• Axle Stops
• Engine Trunnion Supports
• Equalizer Brackets
• Exhaust Brackets
• Fifth Wheel Legs
• Fifth Wheel Mountings
• Frame Crossmembers and Gussets
• Front Frame Brackets
• Front Suspension Spring Brackets
• Fuel Tank Brackets
• Radius Rods
• Rear Engine Supports
• Rear Suspension Spring Brackets
• Shock Absorbers
• All Other Frame Fasteners
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.
9
10
1
2
3
6
7
4
5
5
8
11
2
12
10
13
03/30/95
1.
Capscrew, 3/4– x 4.5 Inch, Grade 8
2.
Washer, 3/4 Inch
3.
Engine Leg
4.
Capscrew, 1/2–13 x 1.5 Inch, Grade 8
5.
Washer, 1/2 Inch
6.
Upper Isolator
7.
Rear Engine Mount
8.
Nut, 5/16–18
9.
Capscrew, 5/8–11 x 2.5 Inch, Grade 8
10. Washer, 5/8 Inch
11. Lower Isolator
12. Nut, 3/4–10
13. Nut, 5/8–11 f220054
Fig. 13, Rear Engine Mount Assembly (pre-EPA07 engines)
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31
Frame and Frame Components
31–04 Trailer Electrical
Connector Lubrication
In some cases, failure of trailer cables occurs due to intrusion of chloride-based road deicing chemicals into the trailer connector. Once inside the connector, the chloride-based chemicals corrode the brass terminals and create bridging between positive and ground terminals.
NOTE: The use of soap is not recommended for cleaning the electrical connector, as some soaps may increase the corrosion process.
1.
Wash out any existing grease, dirt, and corrosion on the trailer connectors with electrical contact cleaner spray.
2.
Grease the trailer connector with a lithium-based dielectric grease.
31–05 Premier 690 Coupling
Inspection
IMPORTANT: Before servicing the Premier coupling, refer to the Premier web site at
www.premier-mfg.com
for complete safety, operation, and maintenance instructions.
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.
The time-in-service of the 294 bolt located in the 690 coupling must be monitored, and maintenance performed as follows. See
For a new or replaced 294 bolt:
• Record the date of installation.
6 months after installation date:
• Remove the 294 bolt. Using dye penetrate or magnetic particle testing along the length of the bolt, inspect for fractures.
• If the 294 bolt has no damage, install it and continue to use for another 6 months.
• If the 294 bolt is fractured, DO NOT USE. Contact Premier Mfg. Co.
1 year after installation date:
• Regardless of service duty, replace the 294 bolt with a new one.
1
2
3
4
07/13/2010
1.
2.
Linch Pin
Handle
3.
Pintle Hook
4.
294 Bolt
Fig. 14, Premier 690 Trailer Coupling
f310313a
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Suspension
32
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Suspension
32
32–00 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 can not drop. Failure to follow these steps could result in serious personal injury or death.
32–01 Suspension Inspection
Front Suspension Check
WARNING
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. Failure to replace a damaged spring assembly could cause an accident resulting in property damage, serious personal injury, or death.
Inspect the front spring assemblies for cracked, broken, or abnormally bent leaves. If any of these conditions exist, replace the spring assembly. See Group
32 of the Century Class Trucks Workshop Manual for instructions.
Composite Springs
The Commercial Vehicle Safety Alliance (CVSA) defines a crack that causes out-of-service conditions for composite spring assemblies, as a separation in any axis, which passes completely through the composite spring material.
For additional information, refer to the CVSA, Out of
Service (OOS) Criteria, for composite spring assemblies, Section 9, Suspension, Pages 44 to 45.
Inspect the Liteflex spring for cracks that result in an out-of-service condition as follows (see
• a side to side crack extending beyond 3/4 of the length of the spring;
• a top to bottom crack extending beyond 3/4 of the length of the spring;
• intersecting cracks of any length.
The Liteflex composite spring should also be removed from service if splintering has occured to the point where noticeable vehicle ride height loss has occurred.
A
B
C
08/14/2008 f321135
A. Side to side crack extending beyond 3/4 of the length of the spring
B. Top to bottom crack extending beyond 3/4 of the length of the spring
C. Intersecting cracks of any length
Fig. 1, Out-of-Service Conditions, Composite Spring
Front and Rear Suspension
Shock Absorber Check
Make sure the shock absorber brackets are tight, and the shock absorber is not striking or rubbing the frame or some other part of the chassis. Striking or rubbing the frame is characterized by chafe marks on the shock absorber body and the frame rail. See
. Check the rubber mounting bushings for cracks,
cuts, swelling, and dry rot. Also, check the bushings for missing pieces. Replace the bushings as needed.
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32/1
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.
11/27/95 f320465
Fig. 2, Direct-Acting Shock Absorber (front suspension shown)
Rear Suspension Check
Freightliner Spring Suspension
WARNING
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 visibly damaged parts is no assurance that the spring is safe. Failure to replace a damaged spring assembly could cause an accident, resulting in serious personal injury or property damage.
Replace worn, cracked, or damaged spring brackets. Failure to do so could result in bracket breakage, possibly leading to loss of vehicle control and resulting in personal injury or property damage.
1.
Inspect the forward and rear spring brackets and equalizer brackets for wear, cracks, and other damage. If any of these conditions exist, replace the damaged bracket(s). See Group 32 of the
Century Class Trucks Workshop Manual for 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.
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.
4.
Inspect the weld seams between the torque arm tube and the shorter bushing tubes. If there are cracks, replace the torque arm. Do not weld the torque arm for any reason.
5.
Inspect the rubber bushing ends. See
place the torque arm for any of the following reasons:
• if there are gaps between the rubber bushing and the pin or outer steel sleeve;
• if either bushing end contacts a torque arm pin mounting bolt;
• if there are cracks in the bushing;
• if part of the rubber bushing extends beyond the outer circumference of the outer bushing sleeve.
6.
Block up the frame enough to take chassis weight off the springs. Attempt to move the equalizer up and down, using a pry bar between the top of the equalizer and top of the equalizer bracket; apply hand pressure only. See
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.
7.
With the vehicle unloaded, attempt to move the equalizer side to side, using a pry bar between the equalizer and frame rail. Apply hand pressure only. See
. If clearance between the equal-
izer assembly and any frame component or fastener is less than 1/8 inch (3 mm), replace the
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Century Class Trucks Maintenance Manual, January 2016
Suspension
32
2
1
A
3
05/27/93
1
Fig. 3, Torque Arm Bushings
A
3 f320021a
2
05/27/93
A. Measure the change in gap at this point.
1.
Equalizer Bracket
2.
Equalizer
3.
Pry Bar
Fig. 4, Side View of the Equalizer
f320022a equalizer bushings. See Group 32 of the
Century Class Trucks Workshop Manual for instructions.
Freightliner AirLiner Suspension
WARNING
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
4
05/27/93
A. 1/8" (3 mm) Clearance
1.
Frame Fasteners
2.
Frame Rail
3.
Pry Bar
4.
5.
5
Equalizer f320023a
Equalizer Bracket
Fig. 5, Top View of the Equalizer 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. If any of these conditions exist, replace the damaged bracket(s). See
Group 32 of the Century Class Trucks Workshop
Manual for instructions.
WARNING
Replace worn, cracked, or damaged spring brackets. Failure to do so could result in bracket breakage, possibly leading to loss of vehicle control and resulting in personal injury or property damage.
Inspect the crossmember(s) 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.
IMPORTANT: Before checking the AirLiner suspension height, make sure there is no load on the chassis, and the trailer is unhitched.
IMPORTANT: To prevent voiding the warranty on Barksdale height-control valves, note the following:
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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.
• 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.
NOTICE
When removing or loosening a Barksdale heightcontrol valve from a mounting bracket, always hold the valve-side mounting studs in place with an Allen wrench while loosening or tightening the nuts that attach the valve to the bracket. Because the mounting studs are threaded into the valve body, loosening the nuts without holding the studs can tighten the studs, which can crush the valve body and damage the valve. Conversely, tightening the nuts without holding the studs can back the studs out, causing a separation of the two halves of the valve body, and possibly a leak.
1.
Park the vehicle on a level surface, using a light application of the brakes. Do not apply the parking brakes. Shift the transmission into neutral, and build the secondary air pressure to at least
100 psi (690 kPa). Shut down the engine.
2.
Mark the location of the front and rear tires on the floor, and chock the tires on one axle only.
3.
Check the length of the overtravel lever between its pivot points. See
3.1
If the vehicle is equipped with an adjustable leveling valve, the length should be
8 inches (203 mm). If the length is incorrect, see Group 32 of the Century Class
Trucks Workshop Manual for adjustment procedures.
3.2
If the vehicle is equipped with a fixed leveling valve, see Group 32 of the Century
Class Trucks Workshop Manual for the overtravel lever length for the rear axle installed in your vehicle.
4.
On single-drive rear axle configurations, measure the distance from the bottom of the left axle stop to the top of the U-bolt pad. On tandem (dualdrive) rear axle configurations, measure the dis-
A
4
1
2
3
5
05/15/95 f320410
A. Measure the length of the overtravel lever between these two points.
1.
2.
V-Shaped Mark
Adjustment Locknut
3.
Overtravel Lever
4.
Cotter Pin
5.
Linkage Rod
Fig. 6, AirLiner Overtravel Lever and Linkage Rod
Measurement
tance from the bottom of the forwardmost left axle stop to the top of the axle U-bolt pad. See
, Ref. A. The correct distance for single
and dual-drive rear axles is between 2-3/8 inches and 2-7/8 inches (60 to 73 mm).
5.
If the axle stop measurement is not correct, see
Group 32 of the Century Class Trucks Workshop
Manual for adjustment procedures.
6.
Apply the parking brakes, and remove the chocks.
Chalmers Suspension
1.
Chock the front tires then place the transmission in neutral, and release the parking brakes.
2.
Power wash the suspension, or clean it with a hard-bristle brush before performing a visual inspection.
3.
Inspect the rubber bushings for cracks or other damage.
Try to move the torque rod ends using your hands only, and check for any free-play. If freeplay is felt, replace the torque rod end bushing.
Do not use a pry bar to check for free-play. Use of a pry bar may lead to premature bushing replacement.
4.
Lift the rear of the vehicle and support the frame on jack stands to unload the suspension compo-
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Suspension
32
1
A
1
A
B
08/16/96
A. Measure height here.
1.
Left Forwardmost Axle Stop
Fig. 7, AirLiner Axle Stop Measurement
f320453 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.
Manipulate the walking beam so that a micrometer, vernier, or dial caliper can be used to determine the wear area thickness on the bottom face. See
. Measurements should be taken
a minimum of 1/2 inch from the beam flange edges to eliminate any edge wear that may have occurred. Subtract the wear area thickness (see
, Ref. B) from the thickness at the non-
wear area (see
amount of wear.
If the beams show any wear greater than 0.062
inch (1.5 mm), a Chalmers wear plate must be installed, or the walking beam must be replaced.
09/27/95
A. Non-Wear Area
1.
Walking Beam
B. Wear Area
Fig. 8, Walking Beam End Wear Thickness
f320432
6.
Rotate the restrictor cans 360 degrees and visually inspect the cans for cracks, severe corrosion, and distortion. If any of these conditions are present, or the restrictor can is missing, replace the restrictor can.
WARNING
Replace all cracked or missing restrictor cans.
Failure to do so could lead to loss of vehicle control, which could result in property damage, serious personal injury, or death.
Hendrickson RS Series
1.
Inspect the frame hanger to frame attaching fasteners for the proper torque. See
Group 00
of this manual for torque specifications.
WARNING
Be sure that fasteners are torqued correctly. Fasteners that do not provide a tightly clamped joint between the frame and the hanger can cause premature fracture of the frame hanger, separation of
Century Class Trucks Maintenance Manual, January 2016
32/5
32 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
2
Suspension
1
1
09/15/95
1.
Frame Rail
2.
Crack In Inspection Area f320419
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
4.
Inspect each frame hanger for severe rust on the horizontal mounting flange adjacent to the vertical drive pin area. See
5.
Inspect the load cushions for cuts and swelling.
Cushions cut by the retaining lips of the saddles or frame hangers indicate the cushions may not be the correct hardness or configuration for the vehicle operation.
6.
Inspect the lower side of the vertical drive bushings for evidence of torn or shredded rubber.
Check that the concave washers are installed with the lips pointing downward.
7.
Inspect the saddles and saddle cap fasteners for wear. The allowable thrust washer wear in aluminum saddles is up to 3/16 inch (4.8 mm) into the saddles as measured at the top of the thrust washer diameter. Check that the locknuts are
09/15/95
1.
Crack In Inspection Area f320420
Fig. 10, Hendrickson RS Series Horizontal Mounting
Flange
torqued to specification to prevent wear of the beam center bushings into the legs of the saddles. See
Group 00
of this manual for torque specifications.
Hendrickson RT2 and RTE2 Series
1.
Park the vehicle on a level surface, apply the parking brakes, and chock the front tires.
Raise the rear of the vehicle until the rear wheels are suspended in the air, then support the vehicle with safety stands.
2.
Check the torque of the number-one spring hanger (double-lock-bolt design) lock bolt nuts. If a loose connection has caused pin hole wear, replace the hanger.
3.
Inspect the pin hole in the outboard leg of the number-one spring hanger (draw-key design) for wear or elongation.
WARNING
Wear at this point requires hanger replacement, or premature fracture of the spring hanger pin may occur, with possible separation of components
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Century Class Trucks Maintenance Manual, January 2016
Suspension
32
1
1
4
A
2
3
05/27/93
A. Minimum gap of 3/8" (9.5 mm).
1.
Forward (no. 1) Spring Hanger
2.
Spring Eye Pin
3.
Rear (no. 2) Spring Hanger
4.
Rear (no. 3) Extension
Fig. 12, RTE Suspension (unloaded)
f320112a
09/15/95
1.
Rust Inspection Area f320421
Fig. 11, Hendrickson RS Series Rust Inspection 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.
Also, inspect the outside legs for wear, which can be caused by worn spring eye bushings.
NOTE: RTE2 (extended-leaf-spring) suspensions require a minimum gap of 3/8 inch (9.5
mm) between the cam surface of the numbertwo spring hanger and the top of the main leaf in the unloaded condition. See
gap is less than 3/8 inch (9.5 mm), the extended-leaf portion of the spring will not perform satisfactorily for an empty ride.
5.
Inspect the cam surface on the number-three spring hanger (extended-leaf-springs only) for wear. Excessive wear will reduce the gap available at the number-two spring hanger. See the previous note.
6.
Place a block of wood on the leaf spring. See
. Place a pry bar on the block of wood
and insert the end of the pry bar under the frame
4
1
08/16/96
1.
Frame Bracket
2.
Leaf Spring
2
3
3.
Wood Block
4.
Pry Bar f320422
Fig. 13, Hendrickson RT2 and RTE2 Series Frame
Bracket Inspection
hanger. Attempt to lift the frame hanger, as shown in
and the brakes applied, attempt to rock the chassis back and forth while observing the spring eye. In either case, if 1/8 inch or more of movement is observed, the bushing and pin should be replaced. This also could indicate that a broken
Century Class Trucks Maintenance Manual, January 2016
32/7
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
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.
2.
Inspect the rear suspension for any signs of damage, loose components, wear, or cracks. Replace any damaged components to prevent failure or equipment breakdown.
3.
Inspect all bolts and nuts at the pivot and axle connections to ensure they are properly torqued.
Check all other nuts and bolts for proper torque.
See
Group 00
of this manual for proper torque specifications.
4.
Check the air pressure gauge to confirm that there is in excess of 65 psi (448 kPa) in the air system, and inspect the air springs for sufficient and equal firmness.
NOTE: Height control valves control all air springs. Check for air leaks by applying a soapy solution, then checking for bubbles, at all air connections and fittings.
5.
Check the riding height of the air suspension by measuring the distance from the centerline of the rear axle (see
rail. If the riding height is incorrect, adjust the air suspension.
Reyco
Check all suspension fasteners for the proper torque values. See
Group 00
of this manual for proper bolt torque specifications. Inspect the frame for elongated holes at the suspension mounting points, and have the frame repaired as needed. If elongated holes are found on the frame, check the suspension alignment.
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.
NOTE: Service Schedule IV vehicles equipped with a 12,000 lb (5452 kg) front axle are fitted with maintenance-free rubber bushings, and do not require lubrication.
Rear Suspension
Chalmers
No lubrication is required on the Chalmers rear suspension.
Freightliner Spring
Single Axle
No lubrication is required on Freightliner single-axle rear suspensions.
Tandem Axle
Lubricate the equalizer cap-and-tube assembly bushings by applying multipurpose chassis grease at the grease fitting until the old grease is forced out from the cap-and-tube assembly. See
Hendrickson
The Hendrickson RS Series suspension does not require lubrication.
For Hendrickson RT2 and RTE2 Series, lubricate the bronze, ball-indented bushings in the spring eye, as follows:
1.
Park the vehicle on a level surface, apply the parking brakes, and chock the front tires.
2.
Raise the rear of the vehicle until the rear wheels are suspended in the air, then support the vehicle with safety stands. This relieves the load on the bushings and pins to allow the proper flow of lubricant around them.
3.
Use a multipurpose chassis grease and lubricate the bronze, ball-indented bushings in the spring eyes at the grease fitting. See
32/8
Century Class Trucks Maintenance Manual, January 2016
Suspension
32
1
4
09/15/95
1.
Frame Rail
2.
Axle Housing
3
1
2
3.
Axle Centerline
4.
Suspension Ride Height
Fig. 14, Neway Ride Height Inspection
4
2
A f320423
3
1
05/27/93
A. Lubricate here.
1.
Cap-and-Tube Assembly Bushing
Fig. 15, Equalizer Assembly Lubrication
320020a 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. Remove the safety stands and lower the vehicle after lubrication is complete.
09/15/95
1.
Bronze Bushing
2.
Lubrication Hole
4
1
2 f320424
3.
Grease Fitting
4.
Lubrication Groove
Fig. 16, Hendrickson RT2 and RTE2 Series Bushing
Lubrication
Century Class Trucks Maintenance Manual, January 2016
32/9
32
Suspension
Neway
No lubrication is required on Neway rear suspensions.
Reyco
No lubrication is required on Reyco rear suspensions.
32–03 Suspension U-Bolt
Torque Check
CAUTION
Failure to retorque the U-bolt nuts could result in spring breakage and abnormal tire wear.
1.
Park the vehicle on a flat surface and apply the parking brakes. Chock the tires to prevent the vehicle from moving.
2.
Check the U-bolt high nut torque in a diagonal pattern. Set a click-type torque wrench to the highest torque value for the fastener being checked. See
for U-bolt torque specifications. Turn the wrench in a clockwise motion
(looking up) until the torque wrench clicks.
Remove the chocks.
Spring Assembly U-Bolt High Nut Torque Values *
Size
5/8–18
3/4–16
Torque: lbf·ft (N·m)
Stage 1: Hand Tighten
Stage 2: 60 (81)
Stage 3: 200 (271)
Stage 4: 180 to 230 (245 to 313)
Stage 1: Hand Tighten
Stage 2: 60 (81)
Stage 3: 200 (271)
Stage 4: 270 to 330 (367 to 449)
7/8–14
Stage 1: Hand Tighten
Stage 2: 60 (81)
Stage 3: 200 (271)
Stage 4: 420 to 500 (571 to 680)
Spring Assembly U-Bolt High Nut Torque Values
*
Size Torque: lbf·ft (N·m)
1–14
Stage 1: Hand tighten
Stage 2: 60 (81)
Stage 3: 200 (271)
Stage 4: 520 to 600 (707 to 816)
* Tighten in a diagonal pattern as shown in
Table 1, Spring Assembly U-Bolt High Nut Torque
Values
4
1
03/10/2011
2 3 f320783
Fig. 17, Tightening Pattern for U-Bolt High Nuts
32/10
Century Class Trucks Maintenance Manual, January 2016
Front Axle
33
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Front Axle
33
33–00 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 can not drop. Failure to follow these steps could result in serious personal injury or death.
33–01 Knuckle Pin Lubrication,
Meritor Axles
CAUTION
Use regulated pressure when lubricating the knuckle assemblies, otherwise damage could result to the knuckle caps.
When lubricating knuckle pin bushings, do not raise the front axle. Wipe the lube fittings clean, and apply multipurpose chassis grease, NLGI Grade 1 (6% 12hydroxy lithium stearate grease) or NLGI Grade 2
(8% 12-hydroxy lithium stearate grease) until new grease is seen at the bushing grease seal opposite the fittings. The grease seal will accept grease pressure without damage, and is designed to have grease pumped out through it during lubrication.
Even if grease leaks out around the top, or bottomplate gasket, continue pumping until new grease is seen at the bushing seal opposite the grease fitting.
See
33–02 Tie Rod Inspection
Inspect the tie-rod ends as follows:
1.
Shake the cross-tube. A loose fit, or movement between the tapered shaft of the ball and the 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
the components if this cannot be done. For in-
OK
OK
1
1
A
09/06/96
A. Grease Exit
1.
Grease Fitting
1
Fig. 1, Meritor Knuckle Pin Lubrication
f320032a structions, see Group 33 of the Century Class
Trucks Workshop Manual.
02/27/2007 f320033a
NOTE: Shown without pinch bolt to provide clarity.
1.
Cross-Tube Split
Fig. 2, Tie-Rod End Adjustment
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33/1
33
Front Axle
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.
33–04 All-Axle Alignment
Check
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. The turn plates for the front wheels must rotate freely without friction, and the alignment equipment must be calibrated every three months by a qualified technician from the equipment manufacturer. Freightliner dealers must have proof of this calibration history.
1.
Apply the parking brakes, and chock the rear tires.
2.
Raise the front of the vehicle until the tires clear the ground. Check that the safety stands will support the combined weight of the cab, axle, and frame. Place safety stands under the axle.
3.
Using spray paint or a piece of chalk, mark the entire center rib of each front tire.
4.
Place a scribe or pointed instrument against the marked center rib of each tire, and turn the tires.
The scribe must be held firmly in place so that a single straight line is scribed all the way around each front tire.
5.
Place a turn-plate or turntable under both front tires. Remove the safety stands from under the axle, then lower the vehicle. Remove the lockpins from the gauges; make sure the tires are exactly straight ahead.
NOTE: If turn-plates or turntables are not available, lower the vehicle. Remove the chocks from the rear tires and release the parking brakes. Move the vehicle backward and then forward about six feet (two meters).
6.
Place a trammel bar at the rear of the front tires; locate the trammel pointers at spindle height, and adjust the pointers to line up with the scribe lines on the center ribs of the front tires. See
. Lock in place. Check that the scale is set
on zero.
A
B
08/29/94
NOTE: B minus A equals toe-in.
Fig. 3, Wheel Toe-In (overhead view)
f330082a
7.
Place the trammel bar at the front of the tires, see
, and adjust the scale end so that the
pointers line up with the scribe lines. See
08/30/94 f330014a
Fig. 4, Trammel Bar Positioning
8.
Read the toe-in from the scale, and compare it to the toe-in specification in Group 33 of the
Century Class Trucks Workshop Manual. If cor-
33/2
Century Class Trucks Maintenance Manual, January 2016
Front Axle
33
1
A
08/30/94 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.
33–05 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. When lubricating upper and lower knuckle assemblies, do not raise the front axle. Wipe the fittings clean, then apply multipurpose chassis grease, NLGI Grade 1 (6% 12hydroxy lithium stearate grease) or NLGI Grade 2
(8% 12-hydroxy lithium stearate grease), until new grease is seen at the junctions of the axle beam and knuckles. See
fittings are permanently lubricated.
1
11/21/95
A. Grease Exit
1.
Grease Fitting f330129
Fig. 6, Dana Spicer Knuckle Pin Lubrication
33–06 Tie Rod Lubrication,
Dana Spicer Axles
For any Dana Spicer 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.
33–07 Basic Inspection, Meritor
Unitized Wheel Ends
1.
Park the vehicle on a level surface, set the parking brakes, shut down the engine, and chock the rear tires.
2.
Raise the vehicle until the front tires are clear of the ground. Support the vehicle with safety stands.
WARNING
Never work under a vehicle that is supported only by a jack. Jacks can slip, causing the vehicle to fall. This could result in serious injury or death.
IMPORTANT: A clicking sound while rotating the wheel end (hub) is normal and does not indicate a problem.
Century Class Trucks Maintenance Manual, January 2016
33/3
33
Front Axle
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. Using about 50 pounds
(23 kg) of force, check for vertical and horizontal movement.
5.
If no movement or looseness is detected, raise the vehicle to remove the safety stands, lower the vehicle, and remove the chocks from the tires.
If any movement or loosenes is detected, go to the next step.
6.
Check the wheel-to-hub mounting. Make sure the wheel and tire assembly is mounted correctly and that all the hardware is secure.
7.
Apply the service brakes to lock the hub and axle spindle together. Check again for movement and looseness.
If movement is detected, the king pin or king pin bushings are probably worn.
If applying the service brake eliminates the movement, the problem is probably caused by incorrect wheel bearing end play. Go to "End-
Play Check, Meritor Unitized Wheel Ends."
33–08 End-Play Check, Meritor
Unitized Wheel Ends
1.
Park the vehicle on a level surface, set the parking brakes, shut down the engine, and chock the rear tires.
2.
Remove the hub cap.
3.
Raise the vehicle until the front tires are clear of the ground. Support the vehicle with safety stands.
WARNING
Never work under a vehicle that is supported only by a jack. Jacks can slip, causing the vehicle to fall. This could result in serious injury or death.
4.
Remove the tire and wheel assembly.
NOTE: It is normal for small amounts of grease to be visible around the inner and outer wheel bearings.
5.
Remove the brake drum. If needed, back off the slack adjuster.
6.
Attach the magnetic base of a dial indicator to the end of the axle spindle.
7.
Touch the dial indicator stem to the surface of the hub, making sure the stem is perpendicular to the surface of the hub.
8.
Set the dial indicator to zero.
9.
Without rotating the hub, grasp it at the 3 and 9 o’clock positions, and push it straight in. Note the reading on the dial indicator.
Pull the hub straight out. Note the reading on the dial indicator.
The difference between the two measurements is the end play.
10. If the end play is less than 0.003 inch (0.08 mm), go to the step for installing the hub cap.
If the end play is 0.003 inch (0.08 mm) or greater, go to the next step.
11. Remove the outer locknut and tabbed washer from the axle spindle.
12. Loosen, but don’t remove, the inner locknut.
13. While rotating the hub a minimum of five rotations, tighten the inner locknut 600 lbf·ft (813
N·m).
14. Install the tabbed washer and the outer locknut.
Tighten 250 lbf·ft (339 N·m).
15. Repeat the procedure for checking the end play.
16. If the end play is greater than 0.003 inch (0.08
mm) but less than 0.006 inch (0.15 mm), record it in the vehicle maintenance log. Go to the next step.
If the end play is 0.006 inch (0.15 mm) or greater, replace the entire wheel end assembly.
33/4
Century Class Trucks Maintenance Manual, January 2016
Front Axle
33
For instructions, see Group 33 of the Century
Class Trucks Workshop Manual.
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.
If the hub rotates smoothly and without noise, go to the next step.
18. Bend an opposing tab of the tabbed washer over a flat of the outer locknut.
19. Install the wheel and tire assembly. Hand tighten the wheel nuts.
20. Raise the vehicle, remove the jackstands, then lower the vehicle.
21. Tighten the wheel nuts 500 lbf·ft (678 N·m).
22. Install the hub cap.
If installing a metal hub cap, go to the next step.
If installing a plastic hub cap, do the following:
22.1
Apply a continuous 1/8-inch (3-mm) bead of RTV silicone sealant to the outside first thread of the hub cap. Apply the sealant around the entire circumference.
IMPORTANT: Use only the following RTV sealants on the hub cap:
• Meritor part number 2297-Z-7098
• Three Bond®
• Loctite® Ultra Grey Adhesive Sealant 18581
22.2
Install the hub cap by hand until it is seated.
NOTE: Disregard the torque value embossed on the hub cap.
22.3
Using a torque wrench, tighten the hub cap 75 lbf·ft (102 N·m).
If you cannot tighten the hub cap to the correct torque value, or if it makes a popping sound while being tightened, replace it with a new one.
23. If installing a metal hub cap, do the following:
23.1
Using a wire brush, clean the unitized wheel-end inner threads and the hub cap external threads.
23.2
Apply Loctite® 17430 gasket sealant to the external hub cap threads.
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).
NOTE: If you cannot tighten the hub cap to the correct torque value, or if it makes a popping sound while being tightened, replace it with a new one.
24. Remove the chocks from the tires.
33–09 Kingpin Lubrication,
Detroit
™
Axles
1.
Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires. When lubricating the kingpin, do not raise the front axle.
2.
Wipe the fittings clean.
3.
Apply multipurpose chassis grease, NLGI Grade
1 (6% 12-hydroxy lithium stearate grease) or
NLGI Grade 2 (8% 12-hydroxy lithium stearate grease), until new grease is seen at the junctions of the axle beam and knuckles. For locations of grease fittings, see
see
33–10 Tie Rod Lubrication,
Detroit
™
Axles
For any Detroit 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.
See
Century Class Trucks Maintenance Manual, January 2016
33/5
33
Front Axle
1
A
B
1
06/07/2012
A Upper View, LH Side
1.
Grease Fitting
Fig. 7, Grease Fittings, Detroit Axles
f330272
B Lower View, LH Side
2
1
06/12/2012 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
09/13/2012 f330275
Fig. 8, Kingpin Grease Exit Points, Detroit Axles
33/6
Century Class Trucks Maintenance Manual, January 2016
Rear Axle
35
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Rear Axle
35
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 can not drop. Failure to follow these steps could result in serious personal injury or death.
35–01 Axle Lubricant and Filter
Change, and Magnetic
Strainer Cleaning
NOTICE
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.
Detroit
™
IMPORTANT: On Detroit axles, the oil change interval for long haul vehicles can be extended to 500,000 miles (800 000 km) for axles with weight ratings of 34,000 to 40,000 lb (15 000 to
18 000 kg) using synthetic lubricant if a lubricant analysis shows adequate quality. Oil must be changed at least every four years, and more often if the axle is exposed to high temperatures and steep grades.
1.
Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
2.
Clean the fill plug and the area around it. In the axle housing rear cover, remove the plug from the oil fill hole. See
2
A
1
2
4
3
B
12/07/2010
A. Front View
1.
Axle Breather
2.
Breather Hose
3.
Temperature Sensor Port
4.
Oil Fill Plug
B. Rear View f350509a
Fig. 1, Detroit Tandem Axle (forward axle shown)
CAUTION
Be careful when draining the axle oil. It may be very hot, and could cause personal injury if it contacts the skin.
3.
Place a drain pan under the rear axle drain plug.
Drain the oil when it is warm. At this tempera-
Century Class Trucks Maintenance Manual, January 2016
35/1
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
4.3
4.4
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.
After the first oil is changed, inspect the drain plug each time for large quantities of metal particles.
After cleaning, install the drain plug(s) and tighten to 30 lbf·ft (41 N·m).
5.
Fill the axle with the recommended lubricant.
See
for recommended drive axle lubricants and
for lubricant capacities.
NOTE: Some Detroit 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.
5.1
5.2
Fill the axle through the oil fill hole. Lubricant should be level with the bottom of the oil fill hole. To check fluid level, see
Install and tighten the fill plug 30 lbf·ft (41
N·m).
Detroit Drive Axle Lubricants
*
IMPORTANT: Lubricant used in Detroit rear axles must meet Mercedes-Benz specification 235.20 (mineral) or
235.8 (synthetic). Mobil Delvac ™ Gear Oil A 80W-90 and
Mobilube
™
HD-A Plus 80W-90 meet specification 235.20.
Mobil Delvac 1 Gear Oil 75W-90 and Mobilube 1 SHC
75W-90 meet specification 235.8. For more product information, see http://bevo.mercedes-benz.com.
Type Ambient Temperature
SAE
Viscosity
Grade
Mineral Oil –15°F (–26.1°C) and up
†
80W–90
Detroit Drive Axle Lubricants
*
IMPORTANT: Lubricant used in Detroit rear axles must meet Mercedes-Benz specification 235.20 (mineral) or
235.8 (synthetic). Mobil Delvac ™ Gear Oil A 80W-90 and
Mobilube ™ HD-A Plus 80W-90 meet specification 235.20.
Mobil Delvac 1 Gear Oil 75W-90 and Mobilube 1 SHC
75W-90 meet specification 235.8. For more product information, see http://bevo.mercedes-benz.com.
Type Ambient Temperature
SAE
Viscosity
Grade
75W–90 Synthetic Oil –40°F (–40°C) and up
†
*
Detroit rear axles do not require the use of friction modifiers.
†
There is no upper limit on the ambient temperature, but axle sump temperature must never exceed 250°F (121°C).
Table 1, Detroit Drive Axle Lubricants
Detroit Rear Axle Lubricant Capacity
Axle
Forward-Rear
Single and Rearmost Tandem
Oil Capacity:
Quarts (liters)
15.9 (15.0)
*
10.6 (10.0)
*
*
Actual oil capacity might vary slightly depending on gear ratio.
Table 2, Detroit Rear Axle Lubricant Capacity
A
B
08/17/2009
A. Correct (lube level at bottom of fill hole)
B. Incorrect (lube level below fill hole)
Fig. 2, Axle Lubricant Level Inspection
f350061a
Dana Spicer
Dana Spicer does not recommend the use of friction modifiers in any of their rear axles. Friction modifiers should be used in Dana Spicer rear axles only if a slip-stick condition is found, as described in the vehicle driver’s manual. If you are experiencing a prob-
35/2
Century Class Trucks Maintenance Manual, January 2016
Rear Axle
35
lem 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
1
2
2
05/27/93
1.
Oil Fill Plug 2.
Drain Plug
Fig. 3, Axle Housing Drain and Fill Plugs
f350018a
3.
Place a drain pan under the rear axle drain plug.
Remove the drain plug at the bottom of the axle housing and allow sufficient time for all old lubricant to run out. See
4.
On dual-drive axles, also remove the plug at the bottom of the power divider to drain oil from the power divider.
NOTE: Some dual-drive axles are equipped with a cylindrical magnetic strainer, below the lube pump on the front of the power divider cover, that must be removed and cleaned at each axle oil change. All rear axles are fitted with magnetic drain and fill plugs. See
5.
Remove and clean the magnetic strainer, if so equipped.
5.1
Remove the magnetic strainer from the power divider cover.
1
05/27/93
1.
Magnetic Strainer 2.
Power Divider f350017a
Fig. 4, Dana Spicer Dual-Drive-Axle Magnetic Strainer
WARNING
Always wear eye protection when using compressed air to clean parts, as flying debris could cause permanent damage to unprotected eyes. Do not point the air stream in the direction of other persons.
5.2
Wash the strainer in solvent, and blow it dry with compressed air to remove oil and metal particles.
5.3
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.
IMPORTANT: Magnets will rapidly lose effectiveness as collected material bridges the gap between the two poles. Clean or change the plugs before this occurs. It may be necessary to clean or change the plugs one or more times between lubrication change intervals.
7.
After cleaning, install and tighten the drain plug(s) 40 to 60 lbf·ft (54 to 81 N·m).
Century Class Trucks Maintenance Manual, January 2016
35/3
35
Rear Axle
8.
Fill the axle with recommended lubricant. See
for recommended drive axle lubricants, and
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
8.2
8.3
Using recommended lubricant, fill the axle through the oil fill hole or standpipe opening. Lubricant should be level with the bottom of the oil fill hole (see
top of the standpipe opening.
Install and tighten the fill plug 40 to 60 lbf·ft (54 to 81 N·m).
For forward drive axles, remove the power divider fill plug, located slightly offset to the right in the top portion of the forward differential carrier. See
Add two pints (1 L) of lubricant through this fill hole. Do not use the hole at the
top of the differential carrier as a fill hole.
Install and tighten the fill plug 40 to 60 lbf·ft (54 to 81 N·m).
Dana Spicer Drive Axle Recommended Lubricant
Lubricant Type Condition
Lubricant SAE
Viscosity
Grade
Dana Spicer
Roadranger®
Synthetic Drive Axle
Lubricants, or
Equivalent with
Military Specification
MIL–L–2105D
Over-the-Road
Service
Off-Highway
Equipment, or
Under Extra
Heavy Loads
75W–90
80W–140
Table 3, Dana Spicer Drive Axle Recommended
Lubricant
Dana Spicer Drive Axle Lubricant Capacities
Axle Type Axle Model
Capacity * : pints (liters)
Single
Reduction
Single-Drive Axle Installation
23080S, 23080D 40 (18.9)
23105S, 23105D 48 (22.7)
Dual-Drive Axle Installation
Dana Spicer Drive Axle Lubricant Capacities
Axle Type
Single
Reduction
Dual Range
(2-Speed)
Double
Reduction
Axle Model
DD404, DD404–P
DS404, DS404–P
DS461–P
DT402, 402–P
DT451–P
DT461–P
DP451–P
DP461–P
Capacity * : pints (liters)
31 (14.7)
†
39 (18.5)
†
43 (20.3)
†
34 (16.1)
†
39 (18.5)
†
43 (20.3)
†
34 (16.1)
†
43 (20.3)
†
* Quantities listed are approximate. Fill axle until lubricant is level with bottom of fill hole with vehicle on level ground.
†
Add 2 pints (1 L) of additional lubricant to the power divider.
Table 4, Dana Spicer Drive Axle Lubricant Capacities
2
1
3
05/27/93
1.
Fill Plug
2.
Power Divider f350019a
3.
Forward Differential
Carrier
Fig. 5, Power Divider Fill Plug
9.
For a two-speed axle with a shift unit, change the shift unit lubricant; see elsewhere in this maintenance operation for the shift unit lubricant changing procedure.
Meritor
Single drive axles equipped with traction equalizers may require a "limited-slip friction modifier" to correct a slip-stick condition, as described in the vehicle
35/4
Century Class Trucks Maintenance Manual, January 2016
Rear Axle
35
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. For Mobilube SHC (synthetic) use Mobil No. 204
(Mobil Oil Corporation). Add 1.1 ounces (23 mL) of additive for each pint (0.5 L) of lube capacity.
IMPORTANT: These friction modifiers generally deteriorate faster than conventional extremepressure additives, so the lubricant change schedule must be shortened when using these additives. The traction equalizer additive (and recommended drive axle lubricant) must be changed at the Maintenance 2 (M2) interval, instead of the Maintenance 3 (M3) interval recommended in the Maintenance Operation Chart for axles that require only those lubricants recommended in
1.
Park the vehicle on level ground, apply the parking brakes, and chock the tires.
2.
Remove the axle carrier fill plug (see
then remove the drain plug from the bottom of the housing and completely drain the lubricant while the unit is warm. Allow sufficient time for all old lubricant to drain. On dual drive axles, it is also necessary to remove the plug at the bottom of the interaxle differential housing to drain the lubricant.
Lubricant Type
Synthetic Gear Oil
Meritor Drive Axle Recommended Lubricant
Ambient Temperature
–40°F (–40°C) and up
–40°F (–40°C) and up
*
*
Lubricant SAE Viscosity Grade Meritor Specification
75W–90 0–76–N
75W–140 0–76–M
* There is no upper limit on these outside temperatures, but axle sump temperature must never exceed 250°F (121°C).
Table 5, Meritor Drive Axle Recommended Lubricant
3.
If so equipped, replace the axle oil filter. Remove the oil filter, using a suitable filter strap wrench.
See
NOTE: There may be about one pint (0.5 L) of lubricant remaining in the filter. Be careful not to spill it when removing the filter.
4.
Using the specified drive axle lubricant, coat the face of the gasket on a new oil filter. Install the filter over the adapter, and tighten the filter one full turn after the gasket contacts the base; do not overtighten the filter.
5.
For a new or reconditioned axle, flush the axle with clean flushing oil, then drain it thoroughly. It is necessary to flush the axle the first time (only) that the axle lubricant is changed.
IMPORTANT: Axles should not be flushed with any solvent, such as kerosene.
05/27/93
Fig. 6, Axle Oil Filter Removal
f350119a
Century Class Trucks Maintenance Manual, January 2016
35/5
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. It may be necessary 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. See
for recommended axle lubricants, and
for drive axle lubricant capacities.
Meritor Drive Axle Lubricant Capacities
Axle Model
Capacity
*
: pints (liters)
Single-Drive, Single Reduction
†
RS–21–160
RS–23–160
39.5 (18.7)
39.5 (18.7)
RS–23–161
RS–23–185
37.2 (17.6)
47.3 (22.4)
RS–25–160
Tandem-Drive, Single Reduction
37.2 (17.6)
RT–40–145, RT–40–145A,
RT–40–145P
RT–44–145, RT–44–145P
RT–46–160, RT–46–160P
Forward
Rear
Forward
Rear
Forward
Rear
30.2 (14.3)
25.8 (12.2)
29.3 (13.9)
25.1 (11.9)
39.1 (18.5)
34.4 (16.3)
* Quantities listed are approximate. Fill axle until lubricant is level with bottom of fill hole with vehicle on level ground.
†
See "Traction Equalizer Additives" in the text.
Table 6, Meritor Drive Axle Lubricant Capacities
NOTE: Some Meritor axles have a small tapped and plugged hole near and below the housing lubricant fill hole. This smaller hole is for a lubricant temperature indicator only, and should not be used as a fill or level hole.
9.
Install and tighten the fill plug 35 lbf·ft (47 N·m).
10. Whenever the interaxle differential housing has been drained, add an additional 2 pints (1 L) of specified lubricant directly into the interaxle differential housing.
11. For a two-speed axle with a shift unit, change the shift unit lubricant; see elsewhere in this 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
Drain and discard the old lubricant. Discard the housing cover gasket.
1
3
2
08/06/93
1.
Housing Cover Gasket
2.
Oil Fill Plug
3.
Shift Unit Housing Cover
Fig. 7, Two-Speed-Axle Shift Unit
f350021a
2.
Thoroughly wash the axle shift parts and housing cover, and allow them to air dry.
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Century Class Trucks Maintenance Manual, January 2016
Rear Axle
35
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%). 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%).
This cold-weather mixture can be safely used up to 32°F (0°C).
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. To prevent component damage, do not mix engine oil and automatic transmission fluid.
4.
Fill the shift unit housing through the oil fill hole until specified lubricant is level with the bottom of the opening.
5.
Apply a small amount of Loctite® 242, or equivalent sealant, to the threads of the fill plug. Install the plug finger-tight on the rear axle housing.
Use a wrench and tighten it an additional 1-1/2 turns.
35–02 Axle Breather and Axle
Lubricant Level
Inspection
Detroit
™
NOTICE
Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage.
1.
Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
2.
If the vehicle has just been driven, allow a few minutes for the lubricant to settle.
IMPORTANT: On Detroit axles, the oil change interval for long haul vehicles can be extended to 500,000 miles (800 000 km) for axles with weight ratings of 34,000 to 40,000 lb (15 000 to
18 000 kg) using synthetic lubricant if a lubricant analysis shows adequate quality. Oil must be changed at least every four years, and more often if the axle is exposed to high temperatures and steep grades.
3.
Clean the fill plug and the area surrounding the fill plug on the side of the axle carrier. Remove the plug. Check lubricant level when the axle is cold, or near room temperature.
NOTE: Some Detroit 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.
4.
Check that the lubricant is level with the bottom of the fill hole. See
leaks, and correct as needed. Add oil to the level of the fill plug, using the lubricant recommended in
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.
5.
Install and tighten the fill plug 30 lbf·ft (41 N·m).
IMPORTANT: Always check the axle breather whenever checking the lubricant level. Check the breather more frequently under adverse operating conditions.
6.
Check the axle housing breather. Make sure that it is open and unclogged. If the breather is plugged or damaged, clean or replace it as needed.
Dana Spicer Axle
NOTICE
Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage.
1.
Park the vehicle on level ground, apply the parking brakes, and chock the tires.
Century Class Trucks Maintenance Manual, January 2016
35/7
35
Rear Axle
2.
If the vehicle has just been driven, allow a few minutes for the lubricant to settle.
3.
Clean the oil fill plug and area surrounding it, then remove the plug from the fill hole (see
), 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
or the top of the standpipe opening.
4.
Lubricant should be level with the bottom of the fill hole (see
), or with the top of the stand-
pipe opening. If low, check the axle for oil leaks, and correct as needed. Add lubricant as required. See
for recommended drive axle lubricants.
IMPORTANT: Axle housing breathers (see
) must remain clean and unclogged. Al-
ways 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).
6.
For a two-speed axle with a shift unit, check the lubricant level of the shift unit; see elsewhere in this maintenance operation for the shift unit lubricant level inspection procedure.
7.
Remove the chocks from the tires.
Meritor Axle
NOTICE
Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage.
1.
Park the vehicle on level ground, apply the parking brakes, and chock the tires.
2.
Clean the fill plug and the area surrounding the fill plug on the side of the axle carrier. See
NOTE: Some Meritor axles have a small tapped and plugged hole near and below the housing
3
2
1
06/07/94
1.
Axle Housing Breather
2.
Fill Plug
3.
Temperature Indicator Plug f350002a
Fig. 8, Dana Spicer Axle Housing Breather
oil fill hole. This smaller hole is for a lubricant temperature indicator only, and should not be used as a fill or level hole.
3.
Check that the lubricant is level with the bottom of the fill hole. See
leaks, and correct as needed. Add the specified lubricant. See
for recommended drive axle lubricants.
4.
Install and tighten the fill plug 35 lbf·ft (47 N·m).
IMPORTANT: Axle housing breathers (see
) must remain clean and unclogged. Al-
ways 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.
For a two-speed axle with a shift unit, check the lubricant level of the shift unit; see elsewhere in this maintenance operation for the shift unit lubricant level inspection procedure.
6.
On non-drive axles using oil-lubricated wheel bearings, check oil level at the wheels, and add oil if low. Use the same lubricant as specified for the drive axle.
35/8
Century Class Trucks Maintenance Manual, January 2016
Rear Axle
35
1
2
06/07/94
1.
Axle Housing Breathers
2.
Carrier Oil Fill Plugs
3.
Interaxle Differential
3
Fig. 9, Meritor Axle Housing Breathers
f350062a
NOTE: When adding to or checking the oil level, make certain the hub cap and plug are clean before removing the plug; this will minimize the possibility of dirt and road grime entering the assembly.
Two-Speed-Axle Shift Unit
Lubricant Level Inspection
Dana Spicer and Meritor Axles
If equipped with a two-speed-axle shift unit, use the following directions.
NOTICE
Failure to keep lubricant at the specified level could cause damage to the axle shift unit.
1.
Clean the shift unit oil fill plug, and the area surrounding the plug. See
a counterclockwise motion and remove the plug.
2.
Insert a finger or pipe cleaner into the fill plug hole and check the fluid level. The lubricant level should be maintained at the bottom of the fill hole. If low, add the specified lubricant.
NOTICE
Before adding additional lubricant, make sure of the type currently in the shift unit. To prevent component damage, do not mix engine oil with automatic transmission fluid.
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%).
This cold-weather mixture can be safely used up to 32°F (0°C).
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.
35/9
Century Class Trucks Maintenance Manual, January 2016
Wheels and Tires
40
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Wheels and Tires
40
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
for wheel nut torque specifications, and see
for the wheel nut tightening sequence.
NOTICE
Insufficient wheel nut (rim nut) torque can cause wheel shimmy, resulting in wheel damage, stud breakage, and extreme tire tread wear. Excessive wheel nut torque can break studs, damage threads, and crack discs in the stud hole area.
Use the recommended torque values, and follow the tightening sequence shown in
When checking wheel nuts on a dual disc assembly, remove one outer nut at a time, torque the inner nut, then reinstall and torque the outer nut. Repeat this procedure for all wheel nuts, using the tightening sequence shown in
Description Nut Size Wheel Manufacturer Torque: lbf·ft (N·m)
8-Stud Disc Wheel With Two-Piece Flanged Locknuts (with lubricated threads)
Front and Rear Wheel Nut — All 450–500 (610–680)
10-Stud Disc Wheel With Two-Piece Flanged Nuts (with lubricated threads)
Front and Rear Wheel Nut M22 x 1.5
Budd (Uni–Mount 10) 390–440 (530–600)
Front Wheel Nut
Rear Wheel Inner Nut
10-Stud Disc Wheel With Inner and Outer Locknuts (with dry threads)
Alcoa
1-1/8–16
400–500 (540–680)
All Others 450–500 (610–680)
3/4–16
Alcoa
All Others
400–500 (540–680)
450–500 (610–680)
Rear Wheel Outer Nut
Wheel Stud Retainer Nut
1-1/8–16
Alcoa
All Others
3/4–16 All
Spoke Wheel Rim Nuts (with dry threads)
3/4–10 Gunite
400–500 (540–680)
450–500 (610–680)
175–200 (235–270)
Front Wheel Nut, 5- and 6-Spoke
Rear Wheel Nut, 5- and 6-Spoke With
Non-Corrugated Channel Spacer
3/4–10 Gunite
200–225 (271–305)
200–225 (271–305)
*
Rear Wheel Nut, 5- and 6-Spoke With
Corrugated Channel Spacer
3/4–10 Gunite 240–260 (325–350)
* On front axles with over 12,000 lbs (5448 kg) capacity, tighten the wheel nuts 240 to 265 lbf·ft (325 to 359 N·m). Gunite part number W–854 nut with a phosphate-and-oil coating must be used.
Table 1, Wheel Fastener Torque
40–02 Tire Check
Tires should be inspected closely during the first
3000 to 10,000 miles (5000 to 16 000 km) for abnormal wear.
Maintain the proper pressures for carried loads, per the tire manufacturers’ recommendations, or the tire pressure label on the driver’s door.
Have the wheel alignment checked after the first
10,000 miles (16 000 km), then every 40,000 miles
(60 000 km) thereafter.
Century Class Trucks Maintenance Manual, January 2016
40/1
40
Wheels and Tires
1
2
1
1
7
4
3
10
8
6
3 6
3
5 4
5
6
5 4
3
A
07/23/2015
A. 8-Stud Disc Wheel
B. 10-Stud Disc Wheel
8
7
2
B
9
2
C
C. 6-Spoke Wheel
D. 5-Spoke Wheel
Fig. 1, Wheel Nut and Rim Nut Tightening Sequence
Do not continue to drive the vehicle if tires develop any of the following:
• blisters;
• cuts or punctures that reach to the cord;
• a nail, screw, rock, or other puncturing object;
• flat spots or irregular wear;
• tread worn to a minimum depth;
• inability to maintain proper tire pressure.
5
1
D
2
4 f400057b
40/2
Century Class Trucks Maintenance Manual, January 2016
Driveline
41
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Driveline
41
41–00 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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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.
For driveline universal joints with bearing caps,
tighten bearing-cap capscrews 43 lbf·ft (49 N·m).
See
For RPL series universal joints, tighten bearingcap capscrews 125 lbf·ft (169 N·m). See
For driveline universal joints with yoke straps,
tighten yoke-strap capscrews 125 lbf·ft (169
N·m). See
3.
Check the driveline yokes for cracks, and check end-yokes for looseness. See
Replace cracked yokes.
If any end-yoke can be moved in or out on its shaft, or can be rocked on its shaft, disconnect the driveshaft and U-joint from the yoke, then check the drive component’s shaft seal for leakage or other visible damage that may have been caused by the loose yoke. Replace the seal if needed, then tighten the yoke nut. See Group
41 of the Century Class Trucks Workshop
Manual for torque specifications. If the yoke is
ME
R I TOR
1
2
1 1
04/13/98
1.
Self-Locking
Capscrew
2.
Adhesive Band f410155a
Fig. 1, Meritor U-Joint Fasteners for Bearing Caps
12/09/97 f410182
Fig. 2, Meritor RPL Series U-Joint
still loose after tightening the yoke nut, replace the end-yoke and yoke nut.
Replace the prevailing torque locknut (end-yoke nut) if it was removed for yoke replacement, seal replacement, or any other reason.
4.
Check U-joint assemblies for wear by moving the driveshaft up and down, and from side to side. If any movement of the U-joint cross in the bearings can be felt or seen, replace the U-joint assembly.
Century Class Trucks Maintenance Manual, January 2016
41/1
41
Driveline
14
15
13
16
3
7
8
9
12
11
1
2
6
10
5
4
3
05/01/95
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.
U-Joint Cross
7.
Bearing Cup (for yoke strap)
8.
Yoke Strap and Capscrew
9.
Slip-Joint Assembly
10. Sleeve-Yoke (bearing-cap type)
11. Dust Cap f410067b
12. Splined Stub Shaft
13. Driveshaft Tube
14. Tube-Yoke (bearing-cap type)
15. Axle Input-Shaft End-Yoke
(yoke-strap type)
16. Rear Axle
Fig. 3, Components of a Basic Driveline
5.
Check if the midship bearing and mounting are loose or have deteriorated, by attempting to move the driveshaft up and down, and from side to side. If the bearing is loose on its shaft, or rattles, replace it. If the bearing mount is loose on the frame, tighten the mounting fasteners to the proper torque value. See Group 41 of the
Century Class Trucks Workshop Manual for torque specifications. Replace the midship bearing assembly if the rubber cushion is deteriorated or oil-soaked.
6.
Check slip joints for spline wear by moving the sleeve-yoke and splined shaft back and forth.
See
. If the slip joint can be twisted in a
clockwise, or counterclockwise movement greater than 0.007 inch (0.18 mm), replace both the sleeve-yoke and the splined shaft.
7.
Visually examine the driveshaft tubes for dents, bends, twists, or other damage. If any tube appears to be damaged, see Group 41 of the
Century Class Trucks Workshop Manual for repair and replacement instructions.
8.
Examine the driveshaft for evidence of missing balance weights, and for build-up of foreign material. Remove any foreign material. If there is
41/2
Century Class Trucks Maintenance Manual, January 2016
Driveline
41
5
1
3
2
3
7
4
05/27/93 f410012a
Attempt to move the sleeve-yoke and splined shaft back and forth.
Fig. 4, Slip Joint Spline Wear Checking
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
Ref. 2. Repair or replace the yoke plug as needed. If the yoke plug is missing, the splined shaft may be hitting the plug and knocking it out; contact your Regional Service Office for assistance in determining the correct driveshaft length.
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
3.
Use a hand-type grease gun, or a high-pressure gun with a low-pressure adapter, to lubricate
U-joints. If a low-pressure adapter is not used,
U-joints may not receive enough grease.
Using lithium 12-Hydroxy stearate grease (NLGI
Grade 1 or Grade 2, with EP additives), lubricate until new grease can be seen at all four U-joint seals. Fresh grease must be seen escaping from
all four bearing-cap seals of each U-joint. On yokes equipped with a yoke-bearing cap, if most of the grease being added to a U-joint can be
6
8
3
1
A
10/20/93 f410050a
A. After grease appears, cover the pressure-relief hole while continuing to lubricate.
1.
Slip Joint Grease Fitting (with grease gun attached)
2.
Yoke Plug
3.
Grease
4.
Half-Round Yoke
5.
Yoke Plug Pressure-Relief Hole
6.
Slip Joint Seal
7.
Full-Round Yoke
8.
U-Joint Grease Fitting
Fig. 5, Slip Joint and U-Joint Lubrication
seen escaping from just one of the U-joint seals, check the torque on the capscrews at that seal.
4.
Tighten the bearing-cap capscrews 43 lbf·ft (49
N·m). If the capscrews were already tight, or all of the U-joint seals still do not purge, remove the bearing cap at that seal, and examine the seal for damage. If the seal is damaged, replace the complete U-joint.
5.
If grease does not appear at one seal, use a prying tool to pry the U-joint trunnion away from the non-purging seal, or tap the driveshaft or yoke with a plastic or rawhide mallet on the side opposite the dry seal, while continuing to lubricate. If grease still does not appear, loosen the capscrews at the bearing with the dry seal, to relieve seal tension. Lubricate the U-joint until new grease is seen at the seal, then tighten the cap-
Century Class Trucks Maintenance Manual, January 2016
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41
screws 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.
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
2.
Use a hand-type grease gun or a high-pressure gun with a low-pressure adapter, to lubricate the slip joint. Add multipurpose chassis grease
(lithium 12-hydroxy stearate, NLGI Grade 1 or
Grade 2, with EP additives) until it appears at the pressure-relief hole in the yoke plug. Then cover the relief hole with your finger, while continuing to apply gun pressure until new grease appears at the slip joint seal. See
complete lubrication of the splines.
3.
Wipe the purged grease from the pressure-relief hole and slip joint seal, and any excess grease from the grease fitting.
Driveline
41/4
Century Class Trucks Maintenance Manual, January 2016
Brakes
42
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Brakes
42
42–00 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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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 Work-
shop Manual for procedures.
42–02 Air Dryer Desiccant
Replacement
Bendix AD-9 Air Dryers
1.
Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
2.
Completely drain all air reservoirs. Air pressure gauges should read 0 psi (0 kPa).
CAUTION
The compressor discharge line may still contain residual air pressure.
3.
Identify, tag, and disconnect the three air lines from the end cover.
4.
Disconnect the harness connector from the heater and thermostat assembly.
5.
Loosen the capscrew securing the upper mounting bracket strap.
6.
Remove the two capscrews that secure the air dryer to the lower mounting bracket. Mark the position of the mounting bracket to the end cover, and mark the capscrews to ease installation.
7.
Remove the upper mounting bracket strap capscrew, and remove the air dryer from the vehicle.
8.
Place the air dryer on a bench and remove the remaining 6 capscrews, 12 washers, 6
Nylok®nuts, and the air dryer housing. See
. Discard the Nylok nuts. Remove the end-
cover-to-housing O-ring.
9.
Clamp the desiccant cartridge in a vise.
CAUTION
Clamping the end cover or housing in a vise could seriously compromise the air dryer’s ability to hold air pressure, which could cause a failure in the brake system.
10. Twist the end cover counterclockwise to release the cartridge from the end cover. Rotate the end cover until it completely separates from the desiccant cartridge.
NOTE: A substantial torque, up to 50 lbf·ft (68
N·m), may be necessary to remove the desiccant cartridge.
11. Inspect the condition of the O-ring seals. If they are cracked, crimped, or otherwise damaged, replace them to ensure an airtight seal. Clean the O-ring grooves of any dirt or obstruction.
CAUTION
Dirt or obstructions in the O-ring grooves can cause an O-ring failure that will result in an air leak.
12. Lubricate the O-rings with silicone or lithium grease and install them in the end cover.
13. Install the desiccant cartridge on the end cover.
Turn the cartridge clockwise until the desiccant cartridge makes contact with the end cover.
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42
Brakes
1
2
11
5
3
4
6
7
8
10
9
10
12
8
13
10
14
15
18
17
10
10
10
10
23
22
21
20
19
25
8
24
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
9.
Desiccant Cartridge
10. O-Ring
11. Safety Valve
12. Lower Mounting Bracket
13. 3/8" Capscrew (long)
14. Check Valve Assembly
15. Purge Valve Assembly
16. Purge Valve Bolt
17. Exhaust Diaphragm
Fig. 1, AD-9 Air Dryer (exploded view)
18. Purge Valve
19. 1/4" Tapping Screw
20. Purge Valve Housing
21. Heater and Thermostat
Housing
22. Return Spring
23. Purge Piston
24. 3/8" Capscrew
25. End Cover
14. Place the desiccant cartridge in a vise, and turn the end cover clockwise an additional 180 to 225 degrees to fully tighten the desiccant cartridge to the end cover.
NOTE: Desiccant cartridge torque should not exceed 50 lbf·ft (68 N·m).
15. Place the housing over the desiccant cartridge and align the mounting holes with the end cover.
f421383
IMPORTANT: Replace, do not reuse the Nylok nuts on the air dryer cover.
16. Install the 6 capscrews, 12 washers, and 6 new
Nylok nuts. Tighten the capscrews in a star pattern 270 to 385 lbf·in (3050 to 4350 N·cm). See
17. Install the air dryer on the lower mounting bracket. Install the two previously marked capscrews, four washers, and two new Nylok nuts.
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Century Class Trucks Maintenance Manual, January 2016
Brakes
42
4
1 & 9
6
2
5
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). Install the capscrew, two washers, and a new Nylok nut in the upper mounting bracket strap. Torque the upper mounting bracket strap capscrew 80 to 120 lbf·in (904 to 1356 N·cm).
18. Connect and tighten the three air lines. Connect the harness connector to the heater and thermostat assembly until the lock tab snaps in place.
19. Start the engine, build the air pressure, and check the air brake system for leaks. If any air leaks are present, see Group 42 of the Century
Class Trucks Workshop Manual for diagnosis and repair information.
Bendix AD–IP Air Dryers
1.
Park the vehicle on a level surface, apply the parking brakes, and chock the tires.
2.
Using a wrench or a socket, loosen the desiccant cartridge bolt. Then separate the desiccant cartridge from the end cover.
3.
Pull the cartridge bolt out of the cover and remove the cartridge.
WARNING
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.
5.
Using a clean rag, wipe clean the inside of the end cover. Clean the cartridge bolt bore in the end cover, and the sealing surfaces for the largeand small-diameter desiccant cartridge sealing rings.
6.
Inspect the end cover for physical damage, then inspect all air line fittings for corrosion; replace as necessary.
7.
Clean and inspect the bolt, paying attention to the threads and O-ring grooves.
IMPORTANT: Use only the grease supplied with
Bendix replacement kits.
8.
Lubricate the O-rings, bolt O-ring grooves, sealing rings, and cartridge grooves. Lubricate the end cover bore for the bolt.
9.
Install both O-rings on the cartridge bolt, then, using a twisting motion, insert the assembled desiccant cartridge bolt in the end cover.
10. Install the desiccant cartridge on the end cover, making sure the cartridge is properly seated and flush on the end cover.
NOTE: It may be necessary to rotate the cartridge slightly until the anti-rotation lugs are properly aligned and allow the cartridge to rest flush against the end cover.
11. Using a wrench or socket, tighten the desiccant cartridge bolt 70 lbf·ft (95 N·m). Do not overtighten.
12. Before placing the vehicle in service, perform the test below.
12.1
Close all reservoir drain cocks.
12.2
Build system pressure to governor cutout, and note that the AD-IP air dryer purges with an audible escape of air.
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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. If leakage exceeds this measure, remove and re-install the desiccant cartridge.
Bendix AD-9si and AD–IS Air
Dryers
1.
Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
2.
Drain the air reservoirs.
3.
Using a strap wrench or equivalent, loosen the desiccant cartridge. See
tridge off by hand and discard it.
1
2
3
04/16/98
1.
Desiccant Cartridge
2.
Cartridge Sealing Ring
Fig. 3, Desiccant Cartridge Replacement
f421910
3.
Threaded Base Post
4.
On the new desiccant cartridge, lubricate the sealing rings with silicone grease.
IMPORTANT: Only use the silicone grease supplied with Bendix replacement kits.
5.
Screw the desiccant cartridge onto the body, by hand, until the seal makes contact with the body.
Rotate the cartridge clockwise about one full turn. Firmly tighten the cartridge.
WABCO System Saver Air
Dryers
NOTE: The following instructions apply to the
System Saver 1200, 1200 Plus, and Twin air dryers.
NOTICE
The WABCO System Saver air dryers can use either a standard or oil coalescing desiccant cartridge. When replacing the desiccant cartridge, it is very important to use the same type of cartridge that was originally installed on the dryer. Oil coalescing cartridges can be used in any application, but require more frequent service intervals
(every 1 to 2 years instead of every 2 to 3 years for a standard cartridge). Do not replace an oil coalescing cartridge with a standard cartridge, as this may result in contamination and malfunctioning of downstream air system components.
Refer to
for cartridge replacement.
1.
Drain the air system.
2.
Using a strap wrench, turn the desiccant cartridge counterclockwise and remove it.
3.
Remove and discard the O-ring.
4.
Clean the top surface of the dryer base with a commercial cleaning solvent.
IMPORTANT: If the air dryer base is damaged, preventing a tight seal, replace the air dryer.
5.
Using a multipurpose, high-temperature grease that resists water, steam, and alkali, lightly coat the surfaces of the new O-ring and the dryer base. Install the O-ring.
6.
Thread the desiccant cartridge onto the dryer base (turn clockwise). When the seal contacts the base, tighten the cartridge one complete turn more. Do not overtighten.
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Brakes
42
1
2
3
08/05/94
1.
Seal
2.
O-Ring
3.
Air Dryer Base
Fig. 4, Desiccant Cartridge Replacement
f421292
42–03 Air Dryer Inspection
1.
Check for moisture in the air brake system by opening the reservoir drain cocks. Examine the discharge. Some trace of water in the discharge is normal. A discharge of a milky gray liquid indicates excessive moisture is present in the air system and the desiccant cartridge needs to be replaced. See Group 42 of the Century Class
Trucks Workshop Manual for troubleshooting procedures. The following conditions could cause small amounts of moisture to be found in the air system:
• An outside air source has been used to charge the air brake system. This air did not pass through the drying bed.
• Air usage is unusually high and not normal.
This may be due to accessory air demands or some unusual air requirement that does not allow the compressor to load and unload in a normal fashion. Check for air system leaks.
• The air dryer has been installed on a system that had previously been operated without an air dryer. This type of system will be saturated with moisture, and several weeks of operation may be needed to fully dry the system.
• 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.
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.
4.
Disconnect the harness connector from the air dryer.
5.
Connect a voltmeter to circuit 94 on the air dryer’s harness connector and to a body ground point. Check for battery voltage. If voltage is not found, check and repair the open or short to ground in wire 94.
6.
Connect a voltmeter between the two terminals on the air dryer’s harness connector. If voltage is not found, repair the open in the ground circuit wiring.
7.
Use an ohmmeter to check resistance between the terminals on the end cover. See
end cover contains the heater/thermostat. If the heater/thermostat is between 40° and 90°F (5° to
32°C), the heater/thermostat measured resistance will be infinite ohms. If the measured resistance is less than infinity, replace the heater/thermostat.
8.
Remove the heater/thermostat assembly and place it in a freezer for about five minutes to cool it below 40°F (5°C). Remove the cold heater/thermostat assembly and check resistance between the heater/thermostat terminals.
Resistance should be 1.5 to 3.0 ohms. As the temperature of the heater/thermostat assembly increases, the ohm reading will increase. When the temperature goes above 45°F (7°C) measured resistance should be infinite ohms. If the heater/thermostat does not operate as outlined, replace it.
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42
Brakes
1
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.
Fill the reservoir with 40 ounces (1183 mL) of methyl alcohol, then install the filler cap.
42–05 Dana Spicer Camshaft
Bracket Lubrication
IMPORTANT: Perform
MOP 42–10
before lubricating the camshaft bracket.
Pump grease into the camshaft bracket until it appears at the slack adjuster end of the bracket. See
2
06/04/96
1.
End Cover Assembly
2.
Heater/Thermostat Terminals f421384
Fig. 5, End Cover Terminals Location
42–04 Alcohol Evaporator
Cleaning and Inspection
Midland
Maintenance is required during both the freeze season and the off season to keep the alcohol evaporator in good working order.
Off Season
During the off season, drain the unit of alcohol. At regular engine service intervals, open the drain cock to remove moisture from the alcohol evaporator. Before reactivating the evaporator for the next freeze season, drain, disassemble, inspect, and steamclean the unit of any sludge that may have accumulated. It is advisable to replace any rubber parts when assembling the alcohol evaporator. Perform this service just before the freeze season.
Freeze Season Reactivation
1.
Remove the filler cap, and check the cap tetraseal.
1
2
3
A
05/28/93
A. Grease Exit
1.
2.
Brake Chamber
Slack Adjuster f420011a
3.
Non-Pressure-Relief
Grease Fitting
Fig. 6, Camshaft Bracket Lubrication
Use an NLGI Grade 1 or Grade 2 multipurpose chassis grease. If grease leaks out under the camhead, the camshaft bracket grease seal is worn or dam-
42/6
Century Class Trucks Maintenance Manual, January 2016
Brakes
42
aged. See Group 42 of the Century Class Trucks
Workshop Manual for grease seal replacement instructions.
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.
WARNING
Failure to lubricate slack adjusters could lead to dragging brakes or a brake failure, resulting in property damage, personal injury, or death.
Dana Spicer and Haldex
NOTICE
Do not use moly-disulfide-loaded grease or oil.
Both the life and reliability of the slack adjuster will be reduced if this type of grease is used.
Lubricate the automatic slack adjuster at the grease fitting. See
. Use standard chassis lubricant.
Gunite
For operating temperatures of –20°F (–29°C) and higher, use Texaco Multifak EP-2 or Mobil Grease
No. 77.
For operating temperatures between –20°F (–29°C) and –40°F (–40°C), use Lubriplate Aero grease.
Lubricate a Gunite automatic slack adjuster at the grease fitting until grease appears on the camshaft, or flows from the grease-relief. See
The newest Gunite automatic slack adjusters are produced without a grease-relief. During lubrication with a grease gun, lubricant is forced through the drilled worm wheel onto the camshaft. Lubricate the automatic slack adjuster at the grease fitting until grease appears on the camshaft. See
1
2
09/17/97
1.
Grease Fitting 2.
Slack Adjuster f421649
Fig. 7, Dana Spicer and Haldex Automatic Slack
Adjuster
42–07 Meritor Camshaft
Bracket Lubrication
IMPORTANT: Perform
before lubricating the camshaft bracket.
NOTE: If equipped with an extendedmaintenance Q Plus
™ brake system, the camshaft bracket will not have a grease fitting.
These camshafts 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 camshaft bushings are lubricated during the brake reline service interval. For service and lubrication instructions, see Group 42 of the Century Class Trucks Workshop Manual.
For camshaft brackets with grease fittings, use an
NLGI Grade 1 or Grade 2 multipurpose chassis grease.
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42
Brakes
2
1
3
4
8
7
6
10
5
9
10/27/93
1.
7/16-Inch Adjusting
Nut
2.
Grease Fitting
3.
Boot
4.
Link
5.
Brake Chamber Piston
Rod
Fig. 8, Gunite Automatic Slack Adjuster
f420653a
6.
Clevis
7.
½-Inch Clevis Pin
8.
1/4-Inch Clevis Pin
9.
Grease-Relief
Opening
10. Slack Adjuster Spline
Lubricate the camshaft bushings through the grease fitting on the camshaft bracket or the spider until new grease flows from the inboard seal. See
WARNING
If grease leaks out under the camhead, the camshaft bracket grease seal is worn or damaged. See
Group 42 of the Century Class Trucks Workshop
Manual for grease seal replacement instructions. If this seal is not replaced, the brake linings could become contaminated with grease. The stopping distance of the vehicle will be increased, which could result in personal injury or property damage.
42–08 Meritor Slack Adjuster
Lubrication
IMPORTANT: Perform
before lubricating the slack adjusters.
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. For service and lubrication instructions, see Group 42 of the Century Class Trucks Workshop Manual.
For slack adjusters with grease fittings, and for operating temperatures above –40°F (–40°C), use a
NLGI Grade 1 clay-base grease or a NLGI Grade 1 or 2 lithium-base grease.
For slack adjusters with grease fittings, and for operating temperatures below –40°F (–40°C) and above
–65°F (–54°C), use a NLGI Grade 2 synthetic oil, clay-base grease.
Lubricate the slack adjuster at the grease fitting until grease is forced past the pressure-relief capscrew, or past the gear splines around the inboard snap ring.
See
42–09 Bendix E–6 Foot Contol
Valve Inspection and
Lubrication
1.
Remove the foot control valve from the vehicle.
See Section 42.03, Subject 110 of the Century
Class Trucks Workshop Manual for instructions.
2.
Remove the roll pin from the brake pedal pivot pin. See
3.
Remove the brake pedal pivot pin.
4.
Remove the brake pedal.
5.
Check the brake pedal mounting plate adapter for signs of wear or cracks at the bosses (the area from which the pivot pin was removed). Replace it if necessary.
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Brakes
42
1
2
3
4
5
7
10/20/93
6 f420012a
1.
Brake Chamber
2.
Clevis
3.
Actuator Rod
4.
Boot
5.
Pressure-Relief Capscrew, Gasket, Pawl Spring, and Pawl
6.
Manual Adjusting Nut
7.
Grease Fitting (or plug)
Fig. 9, Meritor Automatic Slack Adjuster
2
5
1
6
3
4
7
8
09/10/2004
1.
Foot Control Valve,
E-6
2.
Mounting Plate
3.
Nut and Washer
4.
Pivot Pin
5.
6.
7.
8.
Roll Pin
Roller
Roller Pin
Pedal
Fig. 10, Brake Pedal and Valve Assembly
f430405
6.
Check the brake pedal rollers for signs of wear or cracks. Replace them if necessary.
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.
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.
13. Install the foot control valve assembly. See Sec-
tion 42.03, Subject 110 of the Century Class
Trucks Workshop Manual for instructions.
14. Test the brakes before returning the vehicle to service.
42–10 Brake Inspection
IMPORTANT: This procedure should be performed prior to lubrication of the brake components.
Parking Brake Operational Check
CAUTION
Perform the following check in a clear safe area. If the parking brakes fail to hold the vehicle, personal injury or property damage may result.
1.
With the engine running, and air pressure at cutout pressure, set the parking brake.
2.
Put the vehicle in the lowest gear and gently attempt to move it forward. The vehicle should not move. If the vehicle moves, the parking brakes are not operating correctly and must be repaired before the vehicle is returned to service. See
Group 42 of the Century Class Trucks Workshop
Manual for repair procedures.
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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. Improperly maintaining the vehicle braking system may lead to brake failure, resulting in property damage, personal injury, or death.
2.
With the engine off, and 100 psi (689 kPa) of air tank pressure, have an assistant apply and hold an 80 to 90 psi (550 to 620 kPa) brake application.
3.
Check to see if the colored over-stroke band on each brake chamber pushrod is exposed.
Manufacturer
Gunite
Brake Chamber Stroke Specifications
Chamber
Type * Size
†
9
12
Standard Stroke
Long Stroke
16
20
24
30
36
‡
16
20
24 (2-1/2 inch rated stroke)
24 (3 inch rated stroke)
30
If a band shows, the stroke is too long. Check the foundation brake components for wear or damage, and repair as needed. See Group 42 of the Century Class Trucks Workshop Manual for inspection, troubleshooting, and repair procedures.
4.
Measure the applied chamber stroke. See
for the proper stroke for the type of chamber being used. If the stroke is too short, the brakes may drag or will not fully apply. Check for improper operation or adjustment of the automatic slack adjuster. See Group 42 of the
Century Class Trucks Workshop Manual for inspection and troubleshooting procedures.
5.
Start the engine and build air pressure to at least
100 psi (689 kPa). Shut down the engine.
6.
Check all of the foundation brake components for damage, wear, and loose or missing parts. Repair as needed. See Group 42 of the Century
Class Trucks Workshop Manual for repair procedures.
Max Applied Stroke: inch (mm)
1-3/8 (35)
1-3/4 (44)
2 (51)
2-1/4 (57)
2 (51)
2-1/2 (64)
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Century Class Trucks Maintenance Manual, January 2016
Brakes
42
Manufacturer
Haldex
Brake Chamber Stroke Specifications
Chamber
Type
*
Size
†
12
Standard Stroke
2-1/2-Inch Extended Stroke
3-Inch Extended Stroke
Standard Stroke
Long Stroke
16
20
24
24
24
30
30
Max Applied Stroke: inch (mm)
1-3/8 (35)
1-3/4 (44)
2 (51)
2-1/2 (64)
2 (51)
2-1/2 (64)
Meritor
Standard Stroke
Long Stroke
Standard Stroke
24
24
30
16L
20L
9
12
16
20
Dana Spicer Long Stroke 24L
24LS
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.
Table 1, Brake Chamber Stroke Specifications
Less than 1-1/2 (38)
Less than 1-3/4 (44)
Less than 1-7/8 (48)
Less than 2 (51)
2 (51)
2-1/2 (64)
42–11 Versajust Slack Adjuster
Inspection and
Lubrication
IMPORTANT: Perform the Brake Inspection maintenance operation before lubricating the slack adjusters.
1.
Visually check for physical damage, such as broken air lines and broken or missing parts.
2.
Using a quality multipurpose chassis lubricant,
NLGI Grade 2, lubricate the slack adjuster through the grease fitting until clean lubricant flows from the grease relief opening in the boot.
3.
Perform the "In Service Inspection."
In Service Inspection
1.
Apply and release the brakes several times while observing the slack adjuster. The slack adjuster and brake actuator should move freely, without binding or interference, and should return to the full released position. Observe the looseness that exists between the clevis and adapter bushing and the yoke and link pins and their mating parts
(clevis, body, link). Replace these parts if loose-
Century Class Trucks Maintenance Manual, January 2016
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42
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
and
. To achieve the correct pressure for this
test, build the system pressure up to a 100 psi
(690 kPa). Shut down the engine. Fan the brakes to attain a 90 to 95 psi (621 to 655 kPa) reading. Make and hold a full brake application while the strokes are checked.
Actuator Stroke–Standard Stroke
Brake Actuator Size
Recommended Maximum
Operating Stroke (Inches)
30
24
2
1-3/4
20
16
12
1-3/4
1-3/4
1-3/8
Table 2, Actuator Stroke–Standard Stroke
Actuator Stroke–Long Stroke
Brake Actuator Size
30 Long Stroke
24 Long
24 Long Stroke
20 Long
Recommended Maximum
Operating Stroke (Inches)
2-1/2
2
2-1/2
2
16 Long 2
Table 3, Actuator Stroke–Long Stroke
42/12
Brakes
Century Class Trucks Maintenance Manual, January 2016
Steering
46
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Steering
46
46–00 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 can not drop. Failure to follow these steps could result in serious personal injury or death.
46–01 Drag Link Inspection
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.
1.
Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
2.
Have someone turn the steering wheel from left to right. Check for movement between the ball stud end and the pitman arm, and between the ball stud end and the steering arm.
If the ball stud end is loose, replace the drag link.
3.
Check the ball stud castle nut for looseness.
If the castle nut is loose, replace it and the cotter pin. See
Group 00
for torque specifications.
4.
Inspect the boot of the drag link at both the pitman arm and the steering arm end for cracks, splits, or other damage. Replace the boot if needed.
5.
Grasp the drag link near the pitman arm end, then push and pull laterally to check for axial movement in the ball stud end. If it is loose, replace the drag link. See Group 46 of the Century
Class Workshop Manual for replacement instructions. If there is 1/8-inch (3-mm) movement or more, do not drive the vehicle until the drag link is replaced.
46–02 Power Steering Fluid and Filter Changing
WARNING
Fill only with approved clean fluid. Failure to use the proper fluid could cause seal deterioration and leaks. Fluid leaks could eventually cause loss of power steering assist. This could lead to an accident resulting in personal injury or property damage. Wear eye protection when changing the fluid and filter.
1.
Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
2.
Place a drain pan under the power steering reservoir, and remove the steering gear-to-reservoir 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.
3.
Use the following procedure for Century Class
Conventionals. For Argosy COEs, go to the next step.
3.1
Use one hand to apply downward pressure to the power steering reservoir cover. Remove the flanged nut and rubber washer. See
cover.
NOTE: Always replace the power steering reservoir filter when changing the fluid.
3.2
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.
IMPORTANT: Do not start the engine while draining the system.
3.3
Place the disconnected end of the steering gear-to-reservoir hose in the drain pan. Raise the front of the vehicle with a floor jack and support it with jack stands.
Have someone turn the steering wheel to
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46
Steering
4
2
3
6
5
1
7
8
9
3.6
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.
4.
Use the following procedure for Argosy COEs.
4.1
Remove the clamp that holds the cover on the reservoir. See
cover.
1
6
3
4
2
5
11/28/95
1.
Vented Fill Cap and
Dipstick
2.
Flanged Nut
3.
Rubber Washer
4.
Reservoir Cover
5.
Filter Spring
6.
Filter Top Plate
7.
Reservoir Filter
8.
Threaded Shaft
9.
Power Steering
Reservoir f461070
Fig. 1, Power Steering Reservoir and Filter, Century
Class Conventional
3.4
3.5
full lock left and right. Capture the fluid flowing from the hose in the drain pan.
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.
With the larger opening at the top, install a new filter in the reservoir. Install the filter top plate so its center fits into the opening at the top of the filter. Install the filter spring.
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.
07/09/98
1.
Fill Cap
2.
Filter Spring
3.
Filter Top Plate
4.
Clamp
5.
Filter
6.
Reservoir Cover f461670
Fig. 2, Power Steering Reservoir and Filter, Argosy
COE
NOTE: Always replace the power steering reservoir filter when changing the fluid.
4.2
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.
IMPORTANT: Do not start the engine while draining the system.
4.3
Place the disconnected end of the steering gear-to-reservoir hose in the drain pan. Raise the front of the vehicle with a floor jack and support it with jack stands.
Have someone turn the steering wheel to full lock left and right. Capture the fluid flowing from the hose in the drain pan.
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Century Class Trucks Maintenance Manual, January 2016
Steering
46
4.4
4.5
4.6
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.
Install a new filter into the reservoir. Install the filter spring and the filter top plate.
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.
Install the reservoir cover and the clamp.
Tighten the clamp 25 lbf·in (280 N·cm).
5.
Using ATF fluid that meets Dexron III or TES-389 specifications, fill the power steering reservoir with approved power steering fluid to the FULL
COLD mark.
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.
Check for leaks in the power steering system, and repair as needed. Top off the power steering fluid level as needed.
46–03 Power Steering Fluid
Level Inspection
1.
Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
2.
With the engine cool, use a shop towel or clean rag to clean the area around the power steering reservoir fill cap. See
or
cap counterclockwise to remove it. Check the cold power steering fluid level. The level should be between ADD COLD and FULL COLD with the engine off.
3.
Start the engine and run it at idle until it reaches operating temperature.
On Century Class Conventionals, remove the dipstick and check that power steering fluid is between ADD HOT and FULL HOT. If the fluid level is low, add enough fluid to bring the level up to the FULL HOT mark on the dipstick.
On Argosy COEs, check that power steering fluid is between the ADD HOT and FULL HOT lines on the transparent reservoir. If necessary, add enough ATF fluid that meets Dexron III or TES-
389 specifications to bring the level up to the
FULL HOT mark on the dipstick.
46–04 Power Steering Gear
Lubrication
Sheppard Steering Gears
Sheppard power steering gears manufactured without grease fittings are maintenance-free. If the power steering gear has no grease fitting, it requires no periodic lubrication.
Sheppard power steering gears with grease fittings must be lubricated periodically.
1.
Wipe off any debris from the bearing cap grease fitting. See
1
05/28/93 f460296a
1.
Bearing Cap Grease Fitting
Fig. 3, Sheppard Bearing Cap Lubrication
2.
Using a hand-type grease gun, apply multipurpose chassis grease until grease starts coming out of the bearing cap dirt-and-water seal.
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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
1
11/28/95
1.
Sector Shaft Grease Fitting
Fig. 4, TRW Steering Gear Lubrication
46–05 Drag Link Lubrication
f461071
1.
Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
2.
Using a clean rag, wipe all dirt from both drag link grease fittings. See
3.
Using a pressure gun and NLGI Grade 2 (8%
12-hydroxy lithium stearate grease) or NLGI
Grade 1 (6% 12-hydroxy lithium stearate grease) chassis grease, apply clean grease at the grease fittings until old grease is forced out of the socket.
11/27/95
1
1.
Grease Fitting at Pitman Arm
2.
Grease Fitting at Axle Steering Arm
Fig. 5, Drag Link
2 f461072
46–06 Rack and Pinion
Steering Gear Inspection
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.
Inspect the rack and pinion steering system as described below, and repair or replace any components that are worn or damaged.
shows the components of the rack and pinion steering system.
1.
Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
2.
Check the steering I-shaft U-joints for evidence of looseness or binding. If any is found, replace the I-shaft.
3.
Check the steering I-shaft slip joint for evidence of lateral movement, looseness, or binding. If any is found, replace the I-shaft.
4.
Jack up one axle end at a time, and move the tire in and out by hand to check the tie rod ends for free play. No free play is allowed. If the outer tie rod ends are damaged or worn, replace them.
See Group 46 of the Century Class Trucks
Workshop Manual for replacement instructions.
5.
Check the steering gear mounting bolts for security.
6.
Check that the outer tie rod castle nuts are tight, and the cotter pins are properly installed.
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Century Class Trucks Maintenance Manual, January 2016
Steering
46
16
11
6
7
8
9
10
12
13
14
15
17
2
5
4
3
19
9
8
20
21
22
23
18
5
1
3
4
07/24/2009
1.
Steering Tie Rod Arm
2.
Power Steering Fluid Lines
3.
Large Bellows Clamp
4.
Bellows
5.
Small Bellows Clamp
6.
Driver-Side Outer Tie Rod
7.
Tie Rod Jam Nut
8.
Inner Tie Rod Flat
9.
Inner Tie Rod Ball Joint
10. Input Shaft Seal Cover
11. I-shaft Upper Yoke
12. I-shaft Lower Yoke Boot Clamp
13. I-shaft Lower Yoke Boot
14. I-shaft Lower End Yoke
15. Transfer Line Tube Fittings
16. Power Steering Fluid Line
Fittings f462151
17. I-shaft Slip Joint
18. Transfer Lines
19. Rack and Pinion Gear
20. Pinch Bolt
21. Tie Rod Clamp
22. Tie Rod Clamp Nut
23. Passenger-Side Outer Tie Rod
Fig. 6, Rack and Pinion Steering System
IMPORTANT: Do not remove the bellows unless they are damaged and require replacement, or there is evidence of a loose inner tie rod or there is hydraulic fluid leak.
7.
Use a clean rag to remove all dirt and debris from the bellows. Check the bellows for holes or tears. If any are found, replace the bellows.
8.
Check for evidence of hydraulic fluid leakage from the bellows. If hydraulic fluid is found to be leaking from within the bellows, replace the steering gear.
9.
Check the input shaft for any leakage around the input shaft seal cover. If there is evidence of leakage from inside the cover, remove it and replace the input shaft seal. See 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
Century Class Trucks Maintenance Manual, January 2016
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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
age from either of the fittings, replace the steering gear.
46-07 Bellows Replacement,
Rack and Pinion
Steering Gear
1.
Park the vehicle on a level surface, shut down the engine, and set the parking brake. Chock the tires.
2.
Raise the front wheels off the ground and support the vehicle with jack stands.
3.
Remove both wheels from the steer axle.
NOTE: A Tiger Tool Slack Adjuster Puller, part number 10406, may be used to assist with removal of the outer tie rods.
4.
Disconnect the outer tie rods from the steering arms, as follows.
4.1
Remove the cotter pins and castellated nuts.
4.2
On the driver’s side, loosen the jam nut.
See
threads and the position of the outer tie rod to ease installation.
4.3
Disconnect the outer tie rods from the steering arms.
5.
Use brake cleaner to remove dirt and debris from both bellows and surrounding areas.
6.
Remove the small and large Oetiker clamps from both bellows. Discard the clamps.
7.
Disconnect the outer tie rods from the inner tie rods. If necessary, use a backup wrench on the inner tie rod flat to turn the inner tie rod. See
8.
Remove the bellows from both sides of the gear.
NOTE: A thin film of leftover Terostat MS 939 on the rack housing is acceptable when installing the new bellows.
9.
If the housing has Terostat MS 939 on it from a previous replacement of the bellows, remove as much of the leftover Terostat from the housing sealing surface as possible. Wipe down the housing with brake cleaner to remove all remaining dirt and debris.
IMPORTANT: Only apply grease to the rack shaft on the driver side. Do not apply grease to the teeth of the rack shaft. Do not apply grease to the shaft on the passenger side.
10. Turn the wheels all the way to the right to fully expose the driver-side rack. Without applying grease to the teeth of the rack shaft, evenly apply a light film of Renolit CX-FO 20 grease to the metal surfaces covered by the driver-side bellows.
NOTICE
Two syringes of the Terostat MS 939 are included in the Bellows Service Kit. Ensure only Terostat, which is white in color, is applied to the rack housing.
Do not allow Terostat MS 939 sealant to come into contact with the inner tie rods. Mistakenly applying sealant to the inner tie rods may cause damage to the bellows and the gear. See
IMPORTANT: Terostat MS 939 sealant must be applied at a temperature between 41 and 104°F
(5 and 40°C) to effectively seal steering gear components. Because Terostat sealant sets within ten minutes of application, the bellows must be installed within ten minutes of sealant application to ensure a good seal.
11. Evenly apply Terostat MS 939 sealant to the outer diameter of the rack housing where the large ends of the bellows seat on the gear housing. See
46/6
Century Class Trucks Maintenance Manual, January 2016
Steering
46
A
B
05/30/2012 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
NOTICE
Improper installation may cause moisture and contaminants to enter the gear, which may result in severe damage.
12. Install the new bellows on the gear. Ensure the bellows are seated properly on the gear housing and inner tie rods.
13. Rotate the bellows back and forth approximately
15 degrees to evenly disperse the sealant between the bellows and the gear housing.
14. Install new Oetiker clamps on each of the bellows as follows.
NOTICE
Fully opening an Oetiker clamp may cause permanent damage and render it ineffective.
14.1
Rotate the ears of the large Oetiker clamp forward on the bellows to avoid pinching the clamp in the next step.
14.2
Ensure the large Oetiker clamp is properly seated in the clamp groove on the bellows. Align the large Oetiker clamp ear with the small clamp ear. Both clamp ears should be aligned with the rack housing casting rib. See
3
1 2
11/30/2011 f462214
Evenly apply a bead of Terostat MS 939 sealant where the large ends of the bellows seat on the gear housing.
Fig. 8, Terostat MS 939 Sealant Application
09/09/2009
1.
Inner Tie Rod
2.
Small Oetiker Clamp
3.
Bellows
Fig. 9, Oetiker Clamp Alignment
5
4 f462176
4.
Large Oetiker Clamp
5.
Housing Casting Rib
46/7
Century Class Trucks Maintenance Manual, January 2016
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. Oetiker clamps must be adequately crimped and the bellows must be tightly secured to the gear housing to prevent moisture intrusion and corrosion.
14.3
Using an Oetiker clamp tool like the one shown in
large Oetiker bellows clamp ears until the ear width is 0.08 to 0.16 in (2 to 4 mm).
See
and
5
4
3
07/21/2009
1
2
1.
Outer Tie Rod
2.
Small Oetiker Clamp
3.
Bellows
Fig. 11, Oetiker Clamp Installation
f462165
4.
Large Oetiker Clamp
5.
Oetiker Clamp Tool
2
2
07/24/2009 f580473
Fig. 10, Oetiker Clamp Tool, P/N 14100037 or 14100082
15. Remove excess grease from the bellows and the gear housing.
16. Install the jam nut on the driver-side inner tie rod, and the tie rod clamp on the passenger-side inner tie rod.
17. Thread the inner tie rods into the outer tie rods.
18. Attach the outer tie rods of the rack and pinion gear to the tie rod steering arms. Tighten the castellated nuts 240 lbf·ft (325 N·m). Continue to tighten until the next castellated nut slot aligns with the hole in the ball stud and insert the new cotter pin.
A
1
08/25/2009
A. Crimp the clamp ears until the ear width is
1.
Bellows
2.
Large Oetiker Clamp
Fig. 12, Oetiker Clamp Ear Width
f462172
0.08 to 0.16 inch (2 to
4 mm).
19. Tighten the jam nut on the driver side, and the tie rod clamp nut on the passenger side.
20. Align the steering gear.
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Century Class Trucks Maintenance Manual, January 2016
Steering
46
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
20.1
Loosen the driver-side tie rod jam nut. If necessary, hold the inner tie rod in place with a backup wrench on the inner tie rod flat. See
A
2
1
05/31/2007
A. Align the pointers.
1.
Input Shaft Seal
Cover
2.
f462071
Input Shaft Housing
Fig. 13, Rack and Pinion Pointer Alignment
20.2
Align the steering rack on-center pointers.
20.3
Place a wrench on the driver-side inner tie rod flat and align the left tire by rotating the inner tie rod.
20.4
Tighten the tie rod jam nut 285 to 305 lbf·ft (386 to 414 N·m).
20.5
Loosen the passenger-side tie rod clamp nut.
20.6
With the gear on center, place a wrench on the passenger-side inner tie rod flat and align the right tire by rotating the inner tie rod.
20.7
Tighten the tie rod clamp nut 30 to 36 lbf·ft (41 to 49 N·m).
IMPORTANT: Total toe-in should be between
0 and 1/8 inch (3.2 mm), and the target is
1/16 inch (1.6 mm).
20.8
Check the clearance of the front wheels.
With the tires on turnplates, and the wheels turned all the way to the right and left, there must be at least 1/2-inch (13 mm) clearance between the wheels and stationary components, and at least 3/4inch (19 mm) clearance between the wheels/tires and moving components. If this is not the case, back out the stop bolts and adjust the jam nuts to limit the turning angles and to prevent possible contact with components.
20.9
Tighten the stop-bolt jam nuts 80 to 120 lbf·ft (108 to 163 N·m).
NOTICE
Maximum wheel cut is not to exceed 46 degrees.
Excessive wheel cut may damage the inner tie rod.
20.10 Verify that wheel cut does not exceed 46 degrees. Adjust wheel cut if needed.
21. Install both wheels on the steer axle.
22. Remove the jack stands and lower the vehicle.
46/9
Century Class Trucks Maintenance Manual, January 2016
Fuel
47
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Fuel
47
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 can not drop. Failure to follow these steps could result in serious personal injury or death.
47–01 Fuel Filter Replacement
Refer to the engine manufacturer’s service manual for removal and installation procedures.
47–02 Fuel Separator Sight
Bowl Cleaning and
Element Replacement
ConMet Fuel Separator Sight
Bowl Cleaning
The only maintenance necessary on ConMet fuel separators is to clean the sight bowl, if equipped.
See
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.
1.
Drain the fuel separator.
2.
Unscrew the sight bowl from the fuel separator.
3.
Wipe the sight bowl clean using a soft cloth.
4.
Lubricate the gasket with a film of oil, and reinstall it on the sight bowl. If the gasket appears dry-rotted or damaged, replace the gasket.
5.
Lightly lubricate the threads on the sight bowl with oil, then thread the sight bowl into the bottom of the fuel separator.
6.
Hand-tighten until the gasket is in full contact with the fuel separator, then tighten an additional
1/4 to 1/3 turn.
7.
Check that the drain valve is tightened and closed.
8.
Prime the fuel separator.
8.1
Remove the vacuum breaker fitting and fill the unit with diesel fuel.
8.2
Replace and close the vacuum breaker fitting when the unit is full of fuel.
IMPORTANT: The fitting must be air-tight and the valve closed.
Racor Fuel Separator Element
Replacement
The only service necessary on Racor fuel separators is to replace the filter element.
Racor 490
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.
1.
Drain off some fuel by loosening the vent plug and opening the drain valve.
2.
Disconnect the water sensor and heater connections, if equipped.
3.
Remove the element and bowl, together, by turning counterclockwise.
4.
Remove the bowl from the element, and clean the O-ring.
5.
Apply a coating of clean fuel or motor oil to the new O-ring and element seal.
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47
Fuel
1
6
2
8
7
3
4
5
3
9
10
08/25/95
1.
Vacuum Breaker/Drain Valve
2.
Reducer Bushing
3.
Mounting Brackets
4.
O-Ring (when equipped with heater)
5.
Stainless Steel V-Clamp (when equipped with heater)
6.
Heater Assembly
7.
Gasket
8.
Sight Bowl Heater Rod
9.
Sight Bowl Assembly
10. Vacuum Breaker/Drain Valve f470146
Fig. 1, ConMet Fuel Separator
6.
Spin the bowl onto the new element, then spin them both onto the filter head snugly, by hand only.
IMPORTANT: Do not use tools to tighten.
7.
Connect the water sensor and heater connectors, if equipped.
8.
Prime the fuel separator.
8.1
Loosen the vent plug. Then operate the primer pump until the fuel purges at the vent plug. See
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.
2
1
3
4
11
5
10
9
6
7
06/25/97
1.
2.
3.
4.
5.
6.
Gasket
8
Beige Mounting Head
Fuel Primer Pump
Metal Vent Plug
Bowl O-Ring
Bowl Bevel-Cut
Bowl Probe Plug f470147
7.
Water Sensor Probe
8.
Heater Connector
9.
Bowl Drain Valve
Assembly
10. Bowl with Drain and
Water Sensor
11. Service Element
Fig. 2, Racor 490 Fuel Separator
47/2
Century Class Trucks Maintenance Manual, January 2016
Fuel
47
Racor 690
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.
1.
Drain off some fuel by loosening the vent plug and opening the drain valve.
2.
Disconnect the water sensor and heater connections, if equipped.
3.
Remove the element and bowl, together, by turning counterclockwise.
4.
Remove the bowl from the element, and clean the O-ring.
5.
Apply a coating of clean fuel or motor oil to the new O-ring and element seal.
6.
Spin the bowl onto the new element, then spin them both onto the filter head snugly, by hand only.
IMPORTANT: Do not use tools to tighten.
7.
Connect the water sensor and heater connectors, if equipped.
8.
Prime the fuel separator.
8.1
Remove the 3/8-inch metal plug located at the top of the fuel/water separator (see
, Ref. 2), and manually fill the unit
with diesel fuel.
8.2
Replace and tighten the 3/8-inch metal plug when the unit is full.
9.
Start the engine and check for fuel leaks.
10. Shut down the engine and correct any fuel leaks.
47–03 Fuel Tank Band-Nut
Tightening
Hold each fuel tank band retention nut with a wrench while backing off its jam nut. Then tighten the retention nuts 30 to 35 lbf·ft (41 to 46 N·m). After the re-
1
10
2
3
9
4
8
5
6
7
09/15/95
1.
Beige Mounting Head
2.
Metal Plug, 3/8" NPT
3.
Bowl O-Ring
4.
Bowl Bevel-Cut
Gasket
5.
Bowl Probe Plug
6.
Water Sensor Probe
Fig. 3, Racor 690 Fuel Separator
f470148
7.
Heater Connector
8.
Bowl Drain Valve
Assembly
9.
Bowl with Drain and
Water Sensor
10. Service Element tention nuts have been tightened, hold each retention nut with a wrench while tightening its jam nut 30 lbf·ft
(41 N·m).
IMPORTANT: Do not overtighten.
Century Class Trucks Maintenance Manual, January 2016
47/3
Exhaust
49
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Exhaust
49
49–00 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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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.
Pre-EPA07 Exhaust System
Inspecting
1.
On all vehicles, check the condition of the muffler body, the top stack, and the heat shield. See
. Check the inlet/outlet tubes for leakage,
dents, and corrosion, and check for holes in the muffler. Replace parts as required. Use new parts, equivalent to parts originally installed on the vehicle. See Group 49 of the Century Class
Trucks Workshop Manual for replacement procedures.
2.
Inspect the exhaust flex hose (see
leakage, wear, or damage. Replace with new parts if replacement is needed.
3.
Check for leakage at the V-band coupling, which attaches the exhaust pipe to the turbocharger exhaust outlet. See
If leakage exists, tighten the nut on the V-band coupling 10 lbf·ft (14 N·m). If leakage persists, install a new V-band coupling.
4.
Inspect the turbo outlet pipe, and replace it as needed.
3
2
3
2
1
01/06/99
1.
Exhaust Clamp
2.
Lower Heat Shield Fastener
3.
Upper Heat Shield Fastener f490170
Fig. 1, Vertical Exhaust Stack and Heat Shield
5.
Check the U-bolt clamps for tightness, and tighten as needed.
6.
Check the isolator at the base of the exhaust stack elbow(s) (see
age, and dry rot. Replace as needed.
7.
Check for leakage at all wide-band exhaust clamps. See
If leakage exists, tighten the nuts 40 to 60 lbf·ft
(54 to 81 N·m). If leakage persists, install a new wide-band exhaust clamp. Do not re-use
Sealclamps.
Century Class Trucks Maintenance Manual, January 2016
49/1
49
Exhaust
2
1
3
4
06/01/93
1.
Flex Hose
2.
V-Band Coupling
3.
Exhaust Pipe
4.
Turbocharger Exhaust Outlet
Fig. 2, V-Band Coupling and Flex Hose
f490024a 05/28/93 f490025a
Fig. 4, Donaldson Sealclamp Wide-Band Exhaust
Clamp
1
2
3
08/25/95
1.
Exhaust Pipe
2.
Exhaust Elbow Isolator
3.
Mounting Nut
Fig. 3, Exhaust Elbow Isolator
f490127
EPA07 Exhaust System
Inspecting
IMPORTANT: The Environmental Protection
Agency’s 2007 regulations require lower exhaust emissions, thus requiring new exhaust system components. See
the after-treatment device (ATD), which is part of the after-treatment system (ATS), requires
10/05/94 f490005a
Fig. 5, Torca Torctite Wide-Band Exhaust Clamp
09/30/99 f490214a
Fig. 6, Gemi Wide-Band Exhaust Clamp
special attention during regularly scheduled
49/2
Century Class Trucks Maintenance Manual, January 2016
Exhaust
49
maintenance inspections. If any discrepancies are discovered, refer to the engine manufacturer’s service literature for repair instructions.
5
Inspection
1.
Check for leakage at the clamp that attaches the
6
5
7
2
3
4
2
1
8
9
3
10/20/2006
A. Inspect this area of the canister for dents.
1.
Marmon Fitting at Inlet from Turbocharger
2.
DOC Temperature Sensor
3.
ATD Mounting Band
4.
DPF Intake Pressure Sensor
5.
DPF V-Band Mounting Clamps
6.
7.
8.
9.
A
Sensor Housing
DPF Outlet Temperature Sensor
Exhaust Outlet Marmon Fitting
DPF Outlet Pressure Sensor
Fig. 7, Typical After-Treatment Device
Definitions of ATS Components
Refer to the following list of definitions of ATS components.
• After-Treatment System (ATS)—the entire exhaust system from the turbocharger to the exhaust stack or tail pipe.
• After-Treatment Device (ATD)—a muffler-like canister that houses a DPF, DOC, and sensors.
• Diesel Particulate Filter (DPF)—a filter that collects and holds particulate matter (soot and ash).
• Diesel Oxidation Catalyst (DOC)—oxidizes hydrocarbons and reduces NOx.
• Sensors—detect temperatures and pressures in the ATS.
exhaust pipe to the turbocharger exhaust outlet.
If leakage exists, tighten the nut on the clamp to the required torque. If leakage persists, install a new clamp.
2.
Check the exhaust pipe, bellows, and each exhaust seal clamp for leakage, wear, cracks, or damage. Replace damaged components as needed. If leakage exists at a clamp, tighten the nuts to the required torque. If leakage persists, install a new exhaust seal clamp. Do not reuse seal clamps. Once a seal clamp is loosened or removed, it must be replaced.
NOTICE
f490283
A leak in the CGI piping, including the bellows, will allow unfiltered air and contaminants into the engine intake, and can cause serious engine damage.
Century Class Trucks Maintenance Manual, January 2016
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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.
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
for the replacement procedure.
9.
Check for heat discoloration on the surface of the ATD. Heat discoloration may indicate internal damage; especially around the DPF.
10. Check any wires, lines, or hoses within 4 inches
(10 cm) of the exhaust system for heat damage.
Repair or reroute as needed.
1
2 3 4 5
02/24/2011
1.
Clamp
2.
Inlet Pipe
3.
U-Clamp
4.
Forward Pipe-Support Brace
6
5.
6.
7.
5 3
Slip Clamp
CGI Bellows
7 8
Center Pipe-Support Brace
9 3
8.
9.
10
Center Pipe
Clamp
10. Outlet Pipe
Fig. 8, CAT EPA07 Exhaust Installation with CGI Bellows
4.
If present, check the condition of the insulation material around the exhaust pipe between the turbocharger and the ATD.
5.
Check the ATD mounting bands for tightness.
Tighten to 30 lbf·ft (41 N·m) if needed. Do not overtighten.
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.
Check all sensors attached to the ATD for leaks or damaged wires. No leaks are allowed.
8.
Check the DPF exterior surface for dents or other damage. See Item A of
3 inches (76 mm) in diameter and 1/4-inch (6mm) deep could cause internal damage to the
DPF, causing it to malfunction.
49–02 CAT CGI Bellows
Replacement
NOTICE
1 f490456
On vehicles with CAT EPA07 compliant engines, replace the CGI bellows at the M3 maintenance interval to prevent a later failure.
A leak in the CGI piping, including the bellows, will allow unfiltered air and contaminants into the engine intake, and can cause serious engine damage.
1.
2.
Park the vehicle, set the parking brake, chock the wheels.
Open the hood.
3.
Remove the right side inner fender/splash shield as needed.
49/4
Century Class Trucks Maintenance Manual, January 2016
Exhaust
49
4.
Remove the CGI piping between the engine and aftertreatment device (ATD).
5.
On the workbench, remove the CGI bellows from the exhaust piping. Do not damage the piping.
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
6.2
Attach the aft CGI pipe to the ATD.
Attach the forward CGI pipe to the engine.
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.
NOTICE
When shortening the CGI pipe(s), it is critical to leave a minimum of 1 inch (25.4 mm) of straight pipe on the end of each CGI pipe to allow for pipe insertion and clamp clearance. Failure to do this could result in an exhaust leak, which in this case may allow ingestion of contaminants into the engine causing engine damage.
7.
Once the pipes are aligned, measure the pipe gap between the CGI pipes and record the distance. See
The existing pipe gap is designed at 10 inches
(254 mm). A 10.75 inches (273 mm) pipe gap is required for the replacement CGI bellows and clamps. This requires one or both of the CGI pipes to be shortened.
8.
Using a yellow paint pen, mark the pipes 1.5
inches (38 mm) in from the end of each pipe.
These two marks will be used to center the bellows between the two pipes.
1
A
2
02/23/2011
A. Measure the pipe gap.
1.
CGI Aft Pipe f490457
2.
CGI Forward Pipe
Fig. 9, Measuring the Pipe Gap (typical)
9.
Once the pipes are correctly aligned and separated at the correct distance, secure the aft CGI pipe to the ATD and to any CGI pipe support brackets.
10. Remove the forward CGI pipe from the truck.
11. Slide the slip clamp, with the retaining ring and graphite gasket ring, on the aft CGI pipe. See
for proper installation.
1
2
3
4
5
01/29/2010
1.
Aft CGI Pipe
2.
Retaining Ring
3.
Graphite Gasket
4.
5.
Slip Clamp
CGI Bellows
Fig. 10, Aft Facing Slip Clamp Installation
f490415
12. Slide the new bellows onto the aft CGI pipe as far as it will go. See
ment A should be at least 7/16 inch (10 mm) past the face of the flange.
Century Class Trucks Maintenance Manual, January 2016
49/5
49
1
A
2
A
3
02/23/2011
A. At least 7/16 inch (10 mm)
1.
Forward CGI Pipe
2.
CGI Bellows
3.
Aft CGI Pipe
Fig. 11, CGI Bellows Installation
f490458
13. Install the slip clamp with the retaining ring and graphite gasket ring onto the forward CGI pipe.
See
for proper installation.
1
2
3
4
5
Exhaust
02/08/2010
1.
CGI Bellows
2.
Slip Clamp
3.
Retaining Ring 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. Using the yellow marks, center the bellows between the exhaust pipes. Verify that the pipe is inserted at least 7/16 inch (10 mm) past the face of the flange. See
17. Install the slip clamps on the bellows. Tighten the slip clamps 11 lbf·ft (15 N·m).
18. Start the engine and check for exhaust leaks.
Tighten any clamps as needed.
49/6
Century Class Trucks Maintenance Manual, January 2016
Cab
60
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, September 2010
Cab
60
60–01 Cab Suspension Air Bag
Inspection
Inspect the cab suspension air bags at the rear of the cab. Check for wear, leakage, and damage. Replace if necessary.
Inspect the cab suspension shock absorber for damage or leaking fluid. Replace if necessary.
60–02 Cab Tilt Pump Reservoir
Fluid Level and System
Check
Before checking the hydraulic fluid level in the tilt pump reservoir on Argosy COEs, the cab must be in the operating position, with the cab latches locked and the valve lever in the "down" position. Let it remain in this position for at least five minutes before checking the reservoir. The reservoir is full when the fluid level reaches the threaded area of the fill plug location.
If the hydraulic fluid level is low, check all fittings and lines for leaks. If any fittings are loose, tighten them finger-tight, then tighten with a wrench until there is firm resistance; tighten one-sixth turn more. Replace any damaged or worn fittings or lines before adding fluid. Then bleed any air from the system; see Group
60 of the Century Class Trucks Workshop Manual for instructions. Add MIL–5606 fluid or an equivalent oil to bring the level up to the bottom of the fill tube elbow.
A "spongy" feel in the operation of the pump indicates that air is present in the hydraulic cab-tilt system. Bleed the air from the system; see Group 60 of the Century Class Trucks Workshop Manual for instructions.
Check for wear of the mounting pin on both tilt cylinders when the cab is in the raised position. Check that the pins are securely fastened by inspecting the two retaining Torx® screws at the top of each assembly. Check the tilt pump mounting bolts for tightness; see
Group 00
of this manual for torque values for lubricated or plated fasteners.
60–03 Cab Access Stairs
Inspection, Argosy COE
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
Check the step alignment using the door frame as a reference. Verify that the steps are parallel with the door frame, and that a constant gap is maintained.
Also check the side-to-side level of the step. Adjust if necessary. Refer to Section 60.20 of the Century
Class Trucks Workshop Manual for instructions.
60–04 Mirror Folding Check
For vehicles with folding main mirrors, make sure that the mirrors fold freely on the pivot points. Pivot each mirror fully forward and backward two times to break loose any debris that may affect the fold-away feature of the mirror.
60/1
Century Class Trucks Maintenance Manual, September 2010
60
Cab
2
3
4
1
01/13/2003
1.
Forward Bump Stop
2.
Flatwasher
3.
Bolt
4.
Rear Bump Stop
Fig. 1, Cab Access Stairs Assembly
2
3 f602109
60/2
Century Class Trucks Maintenance Manual, September 2010
Door
72
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, March 2010
Door
72
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
appropriate applicator that will not leave material behind.
Approved Grease
Application Lubricant
Door Latches ConocoPhillips Triton® 460
Door Checks ConocoPhillips Megaplex® XD3
Table 1, Approved Grease
NLGI
Grade
1.5
2
Door Hinges
The door hinges on vehicles built before and after
8/1/2005 have different lubrication requirements. The hinges on vehicles built before 8/1/2005 should be lubricated, while those on vehicles built on or after
8/1/2005 should not be lubricated.
CAUTION
Do not lubricate the door hinges on vehicles built on or after 8/1/2005. Lubrication of these hinges could adversely affect the performance of the bushings.
To determine if the door hinges need to be lubricated, first identify the hinge by checking the top loop of the hinge bracket. See
Door Hinges on Vehicles Built on or After 8/1/2005
On vehicles built on or after 8/1/2005, the door hinge center pin is recessed in the top loop of the hinge bracket. There is a dimple in the top and bottom loop of the hinge bracket. See Ref. A of
Do not lubricate this type of hinge. Lubrication could adversely affect the performance of the bushings. In addition, some lubricants may not be compatible with the hinge bushings.
Door Hinges on Vehicles Built
Before 8/1/2005
On vehicles built before 8/1/2005, the door hinge center pin is flush with the top of the top loop of the hinge bracket. There is no dimple in the top or bottom loop of the hinge bracket. See Ref. B of
Lubricate this type of hinge every six months. Wipe old grease and dirt from the hinge, then force an approved grease into the hinge components; see
. Use an appropriate applicator that will not leave
material behind. Wipe off any excess grease.
Door Checks
Wipe old grease and dirt from door checks. Lubricate each moving joint of the door checks at installation and every six months thereafter, with an approved grease; see
. Use an appropriate applicator
that will not leave material behind.
72/1
Century Class Trucks Maintenance Manual, March 2010
72
Door
A
B
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. 1, Door Hinge Identification
f720613
72/2
Century Class Trucks Maintenance Manual, March 2010
Heater and Air Conditioner
83
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, January 2016
Heater and Air Conditioner
83
83–00 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 can not drop. Failure to follow these steps could result in serious personal injury or death.
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.
2.
Check the appearance of the refrigerant compressor pulley assembly. If the friction surface of the pulley shows signs of excessive grooving due to belt slippage, replace both the pulley and the drive plate. Inspect the refrigerant compressor drive belt for damage, and check that the belt is set at the proper tension. Also check the tightness of the compressor mounting fasteners. For instructions and torque values, see Group 01 of the Century Class Trucks Workshop Manual.
3.
Inspect the drive plate. If the friction surface of the drive plate shows visible signs of damage due to excessive heat, replace the drive plate and pulley assembly. For instructions, see Group
83 of the Century Class Trucks Workshop
Manual.
4.
On a Sanden refrigerant compressor, use a feeler gauge to check that the drive plate clutch clearance is 0.016 to 0.031 inch (0.40 to 0.78
mm). See
. If the drive plate clutch requires
adjustment, see Section 83.01, Subject 140 of the Century Class Trucks Workshop Manual.
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
(0.89 mm) or greater, replace the clutch. For instructions, see Section 83.00, Subject 140 of the Century Class Trucks Workshop Manual.
08/25/94 f830641
Fig. 1, Drive Plate Clearance Inspection
5.
Inspect the compressor clutch coil wire. Check that the connector is not damaged or loose. Replace the wire if it is damaged.
6.
Check the overall condition of the air conditioning hoses. Look for cracks, cuts, and abrasions on the hoses. Replace damaged hoses. Check for loose fittings on all of the air conditioning components.
7.
Check for road debris buildup on the condenser fins. Using air pressure and a whisk broom or a soapy spray of water, carefully clean off the condenser. Be careful not to bend the fins.
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83
Heater and Air Conditioner
83–02 Air Filter Replacement
Cab Fresh Air Filter
Replacement, Water-Valve
Controlled
The cab fresh air filter must be replaced every six months, regardless of mileage, to permit proper operation of the HVAC system.
CAUTION
If the fresh air filter is not replaced every six months, damage to the heater and air conditioner components could occur. The HVAC system should not be operated without the fresh air filter installed.
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 two Torx® screws that secure the
HVAC air filter cover to the air intake plenum.
See
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
Slide a new air filter into the air intake plenum.
NOTE: When installing the HVAC air filter, be sure that it is oriented properly. The filter label has an arrow that indicates the air flow direction. See
4.2
Install the air filter cover on the plenum and install the two Torx screws.
2
1
1
2
3
12/18/96
1.
HVAC Plenum
2.
Filter Cover
3.
Torx Screws f830768
Fig. 2, HVAC Air Intake Plenum, Water-Valve Controlled
12/18/96
1.
Air Filter
2.
Air Flow Direction Arrow f830769
Fig. 3, HVAC Air Filter, Water-Valve Controlled
5.
Remove the chocks from the tires.
Cab Fresh Air Filter
Replacement, Blend Air
If the vehicle is equipped with a cab fresh air filter, it must be replaced every six months regardless of mileage to permit proper operation of the HVAC system.
CAUTION
If equipped with a fresh air filter, it should be replaced every six months. If the fresh air filter is
83/2
Century Class Trucks Maintenance Manual, January 2016
Heater and Air Conditioner
83 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
1
2
02/26/2002
1.
Air Filter Cover 2.
Wire Retainer
Fig. 4, HVAC Air Intake Plenum, Blend Air
f831493
3.
Note the direction of the arrow on the air filter cover, then remove the cover and the attached filter.
4.
Remove the air filter from the air filter cover. Discard the air filter.
5.
Attach a new air filter to the air filter cover. Make sure the arrow on the filter is pointing in the same direction as the arrow on the cover.
6.
Install the air filter and air filter cover in the
HVAC air intake plenum.
7.
Pull the wire retainer up and over the upper edge of the air filter cover.
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.
CAUTION
If the recirculation air filter is not replaced every six months, damage to the heater and air conditioner components could occur. The HVAC system should not be operated without the recirculation air filter installed.
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 Sec-
tion 60.08 of the Century Class Trucks Work-
shop Manual.
3.
Remove and discard the foam filter.
4.
Using velcro tape, attach a new filter to the
HVAC cover. See
5.
Install the upper dash cover and the heater and air conditioner cover. For instructions, see Sec-
tion 60.08 of the Century Class Trucks Work-
shop Manual.
6.
Remove the chocks from the tires.
Cab Recirculation Air Filter
Replacement, Blend Air
The cab recirculation air filter must be replaced every six months, regardless of mileage, to permit proper operation of the HVAC system.
CAUTION
If the recirculation air filter is not replaced every six months, damage to the heater and air conditioner components could occur. The HVAC system should not be operated without the recirculation air filter installed.
Century Class Trucks Maintenance Manual, January 2016
83/3
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 Sec-
tion 60.08 of the Century Class Trucks Work-
shop Manual.
3.
Remove the retainer that holds the recirculation air filter in place. See
4.
Remove and discard the recirculation air filter.
5.
Install a new recirculation air filter in the HVAC assembly.
6.
Install the retainer to hold the recirculation air filter in place.
7.
Install the heater and air conditioner cover and the upper dash cover. For instructions, see Sec-
tion 60.08 of the Century Class Trucks Work-
shop Manual.
02/26/2002
1.
Retainer
2.
Recirculation Air Filter f831491
Fig. 6, Cab Recirculation Air Filter, Blend Air
Sleeper Air Filter Replacement,
Water-Valve Controlled
Replace the air filter in the sleeper HVAC unit every six months, regardless of mileage. The filter should not be cleaned.
CAUTION
If the sleeper air filter is not replaced every six months, damage to the heater and air conditioner 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. If there is a baggage compartment, the sleeper
HVAC assembly may be accessed through the baggage door on the right side of the vehicle.
3.
Slide the screen off the sleeper HVAC assembly.
See
4.
Lift the filter out of the sleeper HVAC assembly and discard the filter.
5.
Place a new filter in the sleeper HVAC assembly.
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Century Class Trucks Maintenance Manual, January 2016
Heater and Air Conditioner
1
2
A
83
3
04/15/98
A. The arrow on the filter should point toward the HVAC assembly.
1.
Sleeper HVAC Assembly
2.
Screen
3.
Filter (pleated-paper filter shown)
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
be installed in any direction.
6.
Slide the screen into the frame on the sleeper
HVAC assembly.
7.
Lower the bunk panel and mattress.
8.
Remove the chocks from the tires.
Sleeper Air Filter Replacement,
Blend Air
Replace the air filter in the sleeper HVAC unit every six months, regardless of mileage. The filter should not be cleaned.
CAUTION
f831227
If the sleeper air filter is not replaced every six months, damage to the heater and air conditioner 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 assembly by raising the mattress and bunk panel to the locked position. If there is a baggage compartment, the sleeper HVAC assembly may be accessed through the baggage door on the right side of the vehicle.
3.
Slide the air filter out of the sleeper HVAC assembly. See
4.
Discard the air filter.
Century Class Trucks Maintenance Manual, January 2016
83/5
83
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
1.
Air Filter
Fig. 8, Sleeper HVAC Assembly, Blend Air
f831492
Heater and Air Conditioner
83/6
Century Class Trucks Maintenance Manual, January 2016
Hood, Grille, and Cab Fenders
88
Index, Alphabetical
Title of Maintenance Operation (MOP) MOP Number
Century Class Trucks Maintenance Manual, March 2010
Hood, Grille, and Cab Fenders
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
5.
Close the hood.
Approved Suppliers of Multi-Purpose Lithium Grease
Supplier
Chevron
Grease
Delo Heavy Duty EP
Exxon
Mobil
Unirex EP2
Mobil Grease XHP 222
Shell
Texaco
Retinax LC Grease
Starplex 2
Table 1, Approved Suppliers of Multi-Purpose Lithium
Grease
88
Century Class Trucks Maintenance Manual, March 2010
88/1
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Key features
- Lubrication procedures and tables
- Fluid replacement procedures
- Fluid capacities
- Specifications
- Procedures for adjustments
- Checking the tightness of fasteners
