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1. 1200726 main radiator can be either T bolt clamps see Fig 5 or Breeze Constant Torque clamps see Fig 6 When working with T bolt hose clamps tighten the clamps 55 Ibf in 620 N cm These clamps are now standard on hoses with an inside diam eter greater than 2 inches 51 mm When installing Breeze Constant Torque hose clamps the clamps must be tightened to the cor rect torque The screw tip of the clamp must ex tend about 1 4 inch 6 mm from the clamp hous ing and the Belleville washer stacks must be collapsed almost flat Use a torque wrench to 1 Surge Tank 6 Fan Power Harness 2 Remote Bleed Valve 7 Auxiliary Radiator Drain Plug 3 Main Radiator 8 Cold Coolant Hose 4 Auxiliary Radiator 9 Hot Coolant Hose 5 Auxiliary Radiator Temperature Sensor Fig 3 Coolant System Argosy with Auxiliary Radiator 8 Connect the hoses The hose clamps on the 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 Ibf in 620 N cm For Breeze Constant Torque clamps with a 3 8 inch tightening screw hex 90 Ibf in 1020 N cm 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 matically adjust and keep consistent sealing pressure During vehicle operation and shut
2. 05 30 2002 b 1200581 Fig 10 Checking for Air Leaks Horton DriveMaster 9 If a leak is detected remove the fan blade In stall a new seal kit See Group 20 of the Century Class Trucks Workshop Manual for re pair 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 turn ing the sheave in both directions Engine Cooling R adiator 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 10 Century Class Trucks Maintenance Manual September 2010 Clutch 25 Index Alphabetical Title of Maintenance Operation MOP MOP Number Clutch Release Gross Sh alt LUDA CA OM 1 comarca a need Sas 25 02 Eaton Fuller Clutch Release Bearing Lubrication liiis 25 01 Meritor Clutch Release Bearing Lubrication lille 25 04 Sleeve Assembly Bronze Bushing Lubrication lille 25 03 Century Class Trucks Maintenance Manual April 2005 Clutch
3. RS 21 160 39 5 18 7 1 Remove the shift unit housing cover See Fig 7 RS 23 160 39 5 18 7 Drain and discard the old lubricant Discard the housing cover gasket RS 23 161 37 2 17 6 RS 23 185 47 3 22 4 RS 25 160 37 2 17 6 08 06 93 1 Housing Cover Gasket 2 Oil Fill Plug 3 Shift Unit Housing Cover f350021a Fig 7 Two Speed Axle Shift Unit 2 Thoroughly wash the axle shift parts and housing cover and allow them to air dry 3 Install the housing cover and a new cover gas ket Tighten the housing cover capscrews 7 5 to 9 2 Ibf 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 18 C use SAE 10 heavy duty en gine 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 heavy duty 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 35 6 Century Class Trucks Maintenance Manual August 2013 Rear Axle 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 ho
4. 0 2 0 0 eee 46 07 Drag Link INSpeciOmas rad tee eee AAA ds Rs a dna cman Se 46 01 Drag Link LUDNCAUON vrs FERS REE ERO A Y reda A A oe ede eee ee 46 05 Power Steering Fluid Level Inspection lille 46 03 Power Steering Fluid and Filter Changing liliis ah 46 02 Power Steering Gear Lubrication 2s ie mec yk eme Redon rre ee hed ae wee Pd eee 46 04 Rack and Pinion Steering Gear Inspection o oooocccoooococccana nA 46 06 Century Class Trucks Maintenance Manual September 2012 Steering 46 01 Drag Link Inspection 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 per sonal 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 pit man arm and the steering arm end for cracks splits or other damage Replace the boot if needed 5 Grasp
5. 1st through 30th Maintenance for Service Schedules and II Maint No Maintenance Service Service Schedule I Service Schedule Il Interval Date Miles km Hours Miles km 1st IM and M1 1000 1600 100 10 000 16 000 2nd M1 2000 3200 200 20 000 32 000 3rd M1 3000 4800 300 30 000 48 000 4th M1 4000 6400 400 40 000 64 000 5th M1 and M2 5000 8000 500 50 000 80 000 eth M1 6000 9600 600 60 000 96 000 7th M1 7000 11 200 700 70 000 112 000 8th M1 8000 12 800 800 80 000 128 000 9th M1 9000 14 400 900 90 000 144 000 10th M1 and M2 10 000 16 000 1000 100 000 160 000 11th M1 11 000 17 600 1100 110 000 176 000 12th M1 12 000 19 200 1200 120 000 192 000 13th M1 13 000 20 800 1300 130 000 208 000 14th M1 14 000 22 400 1400 140 000 224 000 15th M1 M2 and M3 15 000 24 000 1500 150 000 240 000 16th M1 16 000 25 600 1600 160 000 256 000 17th M1 17 000 27 200 1700 170 000 272 000 18th M1 18 000 28 800 1800 180 000 288 000 19th M1 19 000 30 400 1900 190 000 304 000 20th M1 and M2 20 000 32 000 2000 200 000 320 000 21st M1 21 000 33 600 2100 210 000 336 000 22nd M1 22 000 35 200 2200 220 000 352 000 23rd M1 23 000 36 800 2300 230 000 368 000 24th M1 24 000 38 400 2400 240 000 384 000 25th M1 and M2 25 000 40 000 2500 250 000 400 000 26th M1 26 000 41 600 2600 260 000 416 000 27th M1 27 000 43 200 2700 270 000 432 000 28th M1 28 000 44 800 2800
6. 40 F 40 C and upt 75W 140 Synthetic Gear 40 F 40 C and upt 75W 90 Oil 40 F 40 C and up 75W 140 Lubricant used in Detroit rear axles must meet the requirements of the API GL 5 standard Recommended lubricants meet Mercedes Benz specifi cation 235 8 synthetic or 235 20 mineral see http bevo mercedes benz com for product names t Detroit rear axles do not require the use of friction modifiers t There is no upper limit on the ambient temperature but axle sump tem perature must never exceed 250 F 121 C Table 1 Detroit Drive Axle Recommended Lubricant Deiroit Rear Axle Lubricant Capacity Oil Capacity PUE Quarts liters Forward Rear 15 9 15 0 Fig 2 Axle Lubricant Level Inspection 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 ve hicle driver s manual If you are experiencing a prob 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 park ing brakes and chock the tires 2 Clean the area around and including the fill plug Remove the plug from the oil fill hole or standpipe if installed in the oil fill hole located in the axle housing rear cover See Fig 3 3 Place a dr
7. Axle Model Rear Axle Two Speed Axle Shift Unit Lubricant Changing Dana Spicer and Meritor Axles Tandem Drive Single Reduction RT 40 145 RT 40 145A Forward 302 14 3 RT 40 145P Rear 25 8 12 2 Forward 29 3 13 9 RT 44 145 RT 44 145P Rear 25 1 11 9 Forward 39 1 18 5 RT 46 160 RT 46 160P Rear 34 4 16 3 Quantities listed are approximate Fill axle until lubricant is level with bot tom of fill hole with vehicle on level ground t 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 lubri cant temperature indicator only and should not be used as a fill or level hole 9 Install and tighten the fill plug 35 Ibf 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 differ ential 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 un loaded 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
8. 6 Check slip joints for spline wear by moving the Sleeve yoke and splined shaft back and forth See Fig 4 If the slip joint can be twisted in a clockwise or counterclockwise movement Century Class Trucks Maintenance Manual July 1999 41 1 41 Driveline S Xx SN 3 16 1 2 3 05 01 95 1410067b NOTE Not all fasteners are shown 1 Transmission 6 U Joint Cross 12 Splined Stub Shaft 2 Transmission Output Shaft 7 Bearing Cup for yoke strap 13 Driveshaft Tube End Yoke yoke strap type 8 Yoke Strap and Capscrew 14 Tube Yoke bearing cap type 3 U Joint Assembly 9 Slip Joint Assembly 15 Axle Input Shaft End Yoke 4 Bearing Cap Self Locking 10 Sleeve Yoke bearing cap type yoke strap type Capscrew 11 Dust Cap 16 Rear Axle 5 Bearing Cap Fig 3 Components of a Basic Driveline greater than 0 007 inch 0 18 mm replace both the sleeve yoke and the splined shaft Visually examine the driveshaft tubes for dents bends twists or other damage If any tube ap pears to be damaged see Group 41 of the Century Class Trucks Workshop Manual for re pair and replacement instructions Examine the driveshaft for evidence of missing balance weights and for build up of foreign ma terial Remove any foreign material If there is 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
9. 83 AIR 04 15 98 A The arrow on the filter should point toward the HVAC assembly 1 Sleeper HVAC Assembly 3 Filter pleated paper filter shown 2 Screen 1831227 Fig 7 Sleeper HVAC Assembly Water Valve Controlled 3 Slide the air filter out of the sleeper HVAC as sembly See Fig 8 Discard the air filter 5 Place a new air filter in the sleeper HVAC as t sembly The edge of the filter should be flush AK with the HVAC assembly i 6 Lower the bunk panel and mattress Remove the chocks from the tires 02 26 2002 1831492 1 Air Filter Fig 8 Sleeper HVAC Assembly Blend Air Century Class Trucks Maintenance Manual April 2003 83 5 Hood Grille and Cab Fenders 88 Index Alphabetical Title of Maintenance Operation MOP MOP Number Hood Rear Support LUDNCAION 22 265 002 cnet Race ER bad a Dodoma es teehee nee 88 01 Century Class Trucks Maintenance Manual March 2010 Hood Grille and Cab Fenders 88 01 Hood Rear Support Lubrication 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 so lution 4 Cover all contact surfaces of the hood rear sup port brackets and isolators with an approved multi purpose lithium complex soap based grease see Table 1 5 Close the hood Approved Suppliers of Multi Purpose Lithium Gr
10. 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 sur rounding the plug See Fig 7 Turn the fill plug in 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 en gine 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 heavy duty 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
11. Meritor 15 1 2 inch dampened ceramic Lite Pedal LTD clutch with sealed release bearing Synthetic transmission fluid used in transmis sion 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 drive line U joints Synthetic lubricant used in rear axle Equipped with any Freightliner AirLiner suspen sion Equipped with Meritor Q Plus extended lube cam brakes and automatic slack adjusters front and rear Standard brake system package including Ben dix AD 9 air dryer mounted on the right hand frame rail located directly behind the front bumper with heater and a Bendix air com pressor e 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 August 2013 00 1 00 Service Schedule Table 00 02 General Information Service Schedule Maintenance Interval Operation Maintenance Interval Frequency Miles km Hours Initial Maintenance IM first 1000 1600 50 Schedule I Severe Service Maintenance 1 M1 every 1000 1600 50 vehicles that annually travel less Maintenance 2 M2 every 5000 8000 500
12. and washers on fifth wheel mountings After inspecting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease See Maintenance Operation 31 02 for lubrica tion instructions Jost 1 Disconnect the tractor from the trailer For in structions see the Century Class Driver s Manual Thoroughly steam clean the fifth wheel Check the mounting for missing or damaged fas teners and broken components Replace or re pair as needed Inspect the bracket pin bolts Make sure the lock ing tabs are properly securing the bolts in place See Fig 8 09 01 2009 1311101 5 Fig 8 Bracket Pin Bolt Locking Tabs Check the fifth wheel for bent worn or broken parts Replace as needed 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 side edges of the plate to pucker slightly this does not affect performance 31 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 Fig 9 Ref A The lock is too tight if the lock tester does not rotate freely
13. down the screw tip may adjust according to Century Class Trucks Maintenance Manual September 2010 20 3 20 Engine Cooling R adiator 06 29 95 f011008 NOTE Cummins M11 engine shown 1 Coolant Drain Plug Fig 4 Coolant Drain Plug Location 02 28 96 1200326 Fig 5 T Bolt Type Hose Clamp temperature and pressure changes The torque may need to be adjusted for individual applica tions 9 Place a pan under the coolant filter to catch en gine coolant 10 Remove the coolant filter with a strap or chain wrench Install a new coolant filter and tighten IMPORTANT On vehicles with EPAO7 compliant engines the coolant capacity varies depending on the engine and accessory installation After Xx 08 15 94 1200286 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 servicing the cooling system always verify that the coolant level is between the MIN and MAX lines on the surge tank NOTE Certain equipment such as fuel heaters water filters and auxiliary heaters may increase the coolant capacity and require additional cool ant The cooling system is filled when the cool ant level reaches the MAX line on the surge tank Freightliner recommends the use of a pre charged and premixed antifreeze when refilling the cooling system
14. 03 Power Steering Fluid Level Inspection 46 04 Power Steering Gear Lubrication 46 05 Drag Link Lubrication 46 06 Rack and Pinion Steering Gear Inspection 46 07 Bellows Replacement Rack and Pinion Steering Gear 47 01 Fuel Filter Replacement 47 02 Fuel Separator Sight Bowl Cleaning and Element Replacement 7 47 03 Fuel Tank Band Nut Tightening 49 01 Exhaust System Inspection noise emission control 49 02 CAT CGI Bellows Replacement 60 01 Cab Suspension Air Bag Inspection 60 02 Cab Tilt Pump Reservoir Fluid Level and System Check 60 03 Cab Access Stairs Inspection Argosy COE Century Class Trucks Maintenance Manual August 2013 00 17 00 General Information Maintenance Operation Sets Table 00 09 Maintenance Operation Sets for Groups 00 through 83 in Operation Description du e Service ES IM M1 M2 M3 IM M1 M2 M3 60 04 Mirror Folding Check 72 01 Door Seal Door Latch and Door Hinge Lubrication 83 01 Air Conditioner Inspection 83 02 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 t Inspect Mer
15. 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 hous ing See Fig 8 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 be tween the bellows and the gear housing 46 6 Century Class Trucks Maintenance Manual September 2012 46 Steering 05 30 2012 1462241 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 A 7 A a S7 f 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 Ed 11 30 2011 1462214 14 Install new Oetiker clamps on each of the bel lows as follows NOTICE Fully opening an Oetiker clamp may cause perma nent 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 prop erly seated in the clamp groove on the bellows Ali
16. 42 03 Air Dryer Inspection 42 04 Alcohol Evaporator Cleaning and Inspection 46 01 Drag Link Inspection 46 06 Rack and Pinion Steering Inspection 47 01 Fuel Filter Replacement 47 02 Fuel Separator Sight Bowl Cleaning and Element Replacement 60 01 Cab Suspension Air Bag Inspection 60 03 Cab Access Stairs Inspection Argosy COE 60 04 Mirror Folding Check 83 01 Air Conditioner Inspection 83 02 Air Filter Replacement Inspect Meritor Unitized Wheel Ends at 200 000 miles 321 870 km0 then every 50 000 miles 80 470 km t Check the end play at 200 000 miles 321 870 km then every 200 000 miles 321 870 km t Replace the HVAC filters every 6 months regardless of mileage Table 13 M2 Maintenance Interval Operations for Service Schedule IV 00 14 Century Class Trucks Maintenance Manual August 2013 General Information 00 M3 Maintenance Interval Operations 00 08 The M3 Maintenance Interval Operations table lists you find detailed instructions in this manual on the all maintenance operations that are to be performed maintenance operations to be performed Perform all at the M3 maintenance interval Maintenance opera maintenance interval operations in M1 and M2 when tion numbers are reference numbers used to help performing M3 maintenance interval operations esa M3 Maintenance Interval Operations for Service Schedules I Il Ill and IV Check 00 06 Perform All M1 Operations 00 07 Perform
17. Drain all air from the air system If equipped with an air starter drain the air starter reservoir 20 6 Century Class Trucks Maintenance Manual September 2010 Engine Cooling Radiator 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 ele ment 3 2 Clean the filter element with cleaning sol vent 3 3 Reassemble the clutch valve solenoid air filter assembly and install on the vehicle 4 Visually check the fan for bent cracked or dam aged blades Replace if damaged Check for ad equate clearance between the fan and other components 5 Check the fan belt for wear tension and align ment Correct if necessary 6 Check for wear on the friction facing See Fig 7 Replace the friction facing if it is worn to a 1 16 inch 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 08 08 94 1 System Sentry Fuse 2 Safeguard Hole 3 Friction Facing 1200290 4 Piston
18. 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 see Fig 6 until grease appears on the camshaft 42 09 17 97 1421649 1 Grease Fitting 2 Slack Adjuster Fig 5 Dana Spicer and Haldex Automatic Slack Adjuster 42 07 Meritor Camshaft Bracket Lubrication IMPORTANT Perform MOP 42 11 before lubri cating the camshaft bracket NOTE If equipped with an extended maintenance Q Plus brake system the cam shaft bracket will not have a grease fitting These camshafts use a special NLGI grade syn thetic polyurea grease and do not require lubri cation for 3 years or 500 000 miles 800 000 km whichever comes first The extended maintenance camshaft bushings are lubricated during the brake reline service interval For ser vice 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 Century Class Trucks Maintenance Manual April 2005 42 5 42 Brakes 10 27 93 1420653a 1 7 16 Inch Adjusting 6 Clevis Nut 7 1 2 Inch Clevis Pin 2 Grease Fitting 8 1 4 Inch Clevis Pin 3 Boot 9 Grease Relief 4 Link Opening 5 Brake Chamber Piston 10 Slack Adjuster Spline Rod Fig 6 Gunite Automatic Slack Adjuster Lubricate
19. than 6000 miles 10 000 km Maintenance 3 M3 every 15 000 24 000 1500 Initial Maintenance IM first 10 000 16 000 Schedule Ilt vehicles that annually travel less Maintenance 2 M2 every 50 000 80 000 than 60 000 miles 100 000 km Maintenance 3 M3 every 150 000 240 000 Initial Maintenance IM first 25 000 40 000 Schedule IlIt Long Haul Transport Maintenance 1 M1 every 25 000 40 000 vehicles that annually travel over Maintenance 2 M2 every 100 000 161 000 60 000 miles 100 000 km Maintenance 3 M3 every 300 000 483 000 Schedule IVt Initial Maintenance IM first 25 000 40 000 Long Haul Transport for Maintenance 1 M1 every 25 000 40 000 Optimized Vehicle Configuration E vehicles that annually travel over Maintenance 2 M2 every 100 000 161 000 60 000 miles 100 000 km Maintenance 3 M3 every 300 000 483 000 For Schedule severe service vehicles equipped with an hourmeter use maintenance intervals based on hours of operation rather than distance traveled t Use Schedule severe service maintenance intervals for vehicles that operate under severe conditions such as extremely poor roads heavy dust accumu lation 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 August 2013 General Information 00 Vehicle Maintenance Schedule Tables 00 03
20. 292 3 410 240 325 340 461 340 461 3 4 16 270 366 380 515 7 8 9 385 522 540 732 7 814 425 576 600 813 1 8 580 786 820 1112 1 12 635 861 900 1220 1 14 650 881 915 1241 Threads may have residual oil but will be dry to the touch t Male and female threads bolt and nut must both be unlubricated and unplated if either is plated or lubricated use Table 18 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation Table 19 Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threads Century Class Trucks Maintenance Manual August 2013 00 23 00 General Information Torque Specifications Tables 00 13 Torque Values for Metric Thread Fasteners With Lubricated or Plated Threadst Thread Class 8 8 Bolt Class 8 Nut Class 10 9 Bolt Class 10 Nut Diameter Pitch Torque Ibf ft N m Torque Ibf ft N m ES Z ON 7 N UN 88 N 8 e 109 J SS w 230010 230011 230012 230013 M6 5 7 7 9 M8 12 16 17 23 M8 x 1 13 18 18 24 M10 24 33 34 46 M10 x 1 25 27 37 38 52 M12 42 57 60 81 M12x1 5 43 58 62 84 M14 66 89 95 129 M14 x 1 5 72 98 103 140 M16 103 140 148 201 M16 x 1 5 110 149 157 213 M18 147 199 203 275 M18 x 1 5 165 224 229 310 M20 208 282 288 390 M20 x 1 5 213 313 320 4
21. 343 269 365 220 298 357 484 7 8 9 365 495 388 526 320 434 515 698 7 8 14 402 545 427 579 350 475 568 770 1 8 582 789 1 12 637 863 1 14 652 884 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation t Use these torque values if either the bolt or nut is lubricated or plated zinc phosphate conversion coated cadmium plated or waxed Table 18 Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threads 00 22 Century Class Trucks Maintenance Manual August 2013 General Information 00 Torque Specifications Tables 00 13 Torque Values for U S Customary Thread Fasteners With Dry Unlubricated Plain Unplated Threadst Regular Hex Flanged Den E Grade 5 Bolt ee or B guard 8 2 d or C icd 8 2 Grade G Nut Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m CI KIA gt OS be 1230005 lt ed s 1 4 20 8 11 10 14 1 4 28 9 12 12 16 5 16 18 15 20 22 30 22 30 5 16 24 17 23 25 34 3 8 16 28 38 40 54 40 54 3 8 24 31 42 45 61 7116 14 45 61 65 88 65 88 7 16 20 50 68 70 95 1 2 13 70 95 95 129 95 129 1 2 20 75 102 110 149 9 16 12 100 136 140 190 140 190 9 16 18 110 149 155 210 5 8 11 135 183 190 258 190 258 5 818 155 210 215
22. 40 Wheels and Tires 03 16 2012 1400057 A 8 Stud Disc Wheel C 6 Spoke Wheel B 10 Stud Disc Wheel D 5 Spoke Wheel Fig 1 Wheel Nut and Rim Nut Tightening Sequence 40 2 Century Class Trucks Maintenance Manual January 1996 Driveline 41 Index Alphabetical Title of Maintenance Operation MOP MOP Number DIveme Inepe6llO ks etna um bre A A A A a 41 01 OKVE INS EW OMCAUOM aos nu AAA e Bde coat a se 41 02 Century Class Trucks Maintenance Manual July 1999 Driveline 41 01 Driveline Inspection 41 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 connec tion which could eventually result in serious ve hicle 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 Ibf ft 49 N m See Fig 1 Ref 1 For RPL series universal joints tighten bearing cap capscrews 125 Ibf ft 169 N m See Fig 2 For driveline universal joints with yoke straps tighten yoke strap capscrews 125 Ibf ft 169 N m See Fig 3 12 09 97 1410182 04 13 98 f410155a 1 Self Locking 2 Adhesive Band Capscrew Fig 1 Meritor U Joint Fasteners for Bearing Caps 3 Check the drivel
23. CS Purge Valve 1 4 Tapping Screw Purge Valve Housing Heater and Thermostat Housing Return Spring Purge Piston 3 8 Capscrew End Cover 1421383 Ibf in 3060 to 4340 N cm Install the capscrew two washers and a new Nylok nut in the upper mounting bracket strap Torque the upper mount Fig 1 AD 9 Air Dryer exploded view ing bracket strap capscrew 80 to 120 Ibf in 904 to 1356 N cm 18 Connect and tighten the three air lines Connect the harness connector to the heater and thermo 1 stat 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 42 03 Air Dryer Inspection 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 indi 42 2 Century Class Trucks Maintenance Manual April 2005 Brakes 09 20 94 1420544a Fig 2 End Cover to Housing Torque Pattern cates 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 pro cedures The following conditions could cause small amounts of moisture to be found in the air sy
24. 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 46 4 Century Class Trucks Maintenance Manual September 2012 Steering 46 07 24 2009 1 Steering Tie Rod Arm 10 Input Shaft Seal Cover 17 I shaft Slip Joint 2 Power Steering Fluid Lines 11 I shaft Upper Yoke 18 Transfer Lines 3 Large Bellows Clamp 12 I shaft Lower Yoke Boot Clamp 19 Rack and Pinion Gear 4 Bellows 13 I shaft Lower Yoke Boot 20 Pinch Bolt 5 Small Bellows Clamp 14 I shaft Lower End Yoke 21 Tie Rod Clamp 6 Driver Side Outer Tie Rod 15 Transfer Line Tube Fittings 22 Tie Rod Clamp Nut 7 Tie Rod Jam Nut 16 Power Steering Fluid Line 23 Passenger Side Outer Tie Rod 8 Inner Tie Rod Flat Fittings 9 Inner Tie Rod Ball Joint 1462151 Fig 6 Rack and Pinion Steering System 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 re place the input shaft seal See Group 46 of the Century Class Trucks Workshop Manual for in structions Check the steering system pressure and return lines and fittings for leaks and damaged lines or hoses Repair or replace lines hoses and fit tings as necessary NOTICE Do not tighten the tube fittings on the hard trans fer lines Tightening the tube fittings can cause tearing of the O ring
25. Friction Disc 5 Air Chamber Fig 7 Horton Advantage Fan Clutch 10 20 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 en gage If the fan does not operate correctly see Group 20 of the Century Class Trucks Workshop Manual for troubleshooting and repair proce dures 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 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 re pair procedures 9 1 Check for a leak at the bleed hole on the fan pilot Air leakage means that the car tridge assembly Fig 8 Ref 16 or face seal Ref 17 is damaged 9 2 Check for air leaks between the air cham ber and the piston friction disc Air leak age means that the large O ring Ref 14 is damaged 9 3 Check for air leaks around the safeguard hole on the piston friction disc Air leak age means the small O ring Ref 18 is damaged 9 4 Check for air leaking from the System Sentry fuse Leaking air means the clutch has gotten so hot the lead alloy in the fuse m
26. HD4060 4560 shallow sump Quantities listed are approximate Add listed amount of fluid then perform a hot check and add fluid as needed Do not overfill t 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 Above 22 30 Above 17 27 Castrol TranSynd synthetic Dexron III Lubricants listed in order of preference Do not mix fluid types Table 5 Approved Automatic Transmission Lubricants P 05 27 93 f260037a Fig 3 Air Filter Regulator Eaton Fuller transmission shown 3 Remove the end cap large O ring and filter ele ment from the filter housing See Fig 4 Remove the small O ring from the end cap 26 4 Century Class Trucks Maintenance Manual April 2005 Transmission 10 17 2001 f260052a 1 Air Regulator 5 Small O Ring 2 Housing 6 End Cap 3 Large O Ring 7 Plug 4 Filter Element Fig 4 Eaton Fuller Transmission Air Filter Regulator Components NOTE Do not remove disassemble or adjust the air regulator If the air regulator is not keep ing the air pressure between 58 and 63 psi 400 to 435 kPa replace the air filter regulator It cannot be repaired Wear safety goggles when using compressed air to clean parts as permanent harm to eyes could r
27. LH Side B Lower View LH Side 1 33 Front Axle Grease Fitting 06 12 2012 1330273 NOTE No grease should emit from the tie rod boot If grease emits from the tie rod boot the boot is dam aged 1 Grease Fitting 2 Boot Fig 7 Grease Fittings Detroit Axles 09 13 2012 1330275 33 6 Fig 8 Kingpin Grease Exit Points Detroit Axles Fig 9 Grease Fitting and Boot Detroit Axles Century Class Trucks Maintenance Manual January 2013 Rear Axle 35 Index Alphabetical Title of Maintenance Operation MOP MOP Number Axle Breather and Axle Lubricant Level Inspection llis 35 02 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning 000000 e eee 35 01 Century Class Trucks Maintenance Manual August 2013 Rear Axle 35 01 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning 35 NOTICE Failure to change the axle lubricant at more fre quent intervals when adverse operating condi tions require could result in axle damage NOTE Axle lubricant change intervals are ex tended to 500 000 miles 800 000 km on ve hicles 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
28. Replacement Conditions Belt Tension Inspection Threaded Adjustment Type 1 Apply the parking brakes and chock the tires to prevent the vehicle from moving 2 Install a belt tension gauge at the center of the belt s longest free span Check belt tension See Table 1 for belt tension specifications 3 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 ten sioner 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 return to its original position If not see Group 01 of the Century Class Trucks Workshop Manual for re placement instructions 01 03 Engine Mount Inspection Noise Emission Control NOTE At engine overhaul and whenever the engine has been removed inspect the lower and upper isolators see Fig 3 Refs 1 and 6 and replace them if they are worn See Group 01 of the Century Class Trucks Workshop Manual for procedures 01 2 Century Class Trucks Maintenance Manual January 2007 Engine 01 Drive Belt Tension Engine Component Belt Tension Ibf kg Caterpillar C10 3176 Refrigerant Compressor 80 to 10
29. See Group 32 of the Century Class Trucks Workshop Manual for instructions Composite Springs The Commercial Vehicle Safety Alliance CVSA de fines 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 assem blies Section 9 Suspension Pages 44 to 45 Inspect the Liteflex spring for cracks that result in an out of service condition as follows see Fig 1 e aside to side crack extending beyond 3 4 of the length of the spring e atop to bottom crack extending beyond 3 4 of the length of the spring e intersecting cracks of any length The Liteflex composite spring should also be re moved from service if splintering has occured to the point where noticeable vehicle ride height loss has occurred 32 b MEA oy y C 08 14 2008 3821135 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 ru
30. See Table 1 for a list of some of the precharged antifreeze available Use of an equivalent antifreeze to those listed in the table is also acceptable Always check that the antifreeze used meets Freightliner s specifi cations and is at the proper concentration for protection in the vehicle operating area See Table 2 for antifreeze protection information Freightliner specifies that the antifreeze must be an ethylene glycol solution that meets GM 6038 M Engineering Standards or a ethylene glycol solution that has less than 0 1 anhydrous so dium metasilicate and meets either GM 1825 M or GM 1899 M Engineering Standards If supplemental coolant additives are being used add the supplements to the coolant as neces sary See the coolant additive manufacturer s instructions for the correct amount of additive required Don t forget to consider the volume of the supplemental coolant additive being added to the system when determining the amount of 20 4 Century Class Trucks Maintenance Manual September 2010 Engine Cooling Radiator 20 coolant required to refill the system You can 11 Fill the cooling system with new coolant See mix purple pink coolant pre charged with a Table 3 for pre EPAO7 vehicle s approximate borate nitrate based additive with the common coolant capacity green coolant although some color change will be apparent Approved Antifreeze Manufacturer Antifreeze Type y f Contains
31. 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 Century Class Trucks Maintenance Manual April 2003 83 3 83 tion 60 08 of the Century Class Trucks Work shop Manual 3 Remove the retainer that holds the recirculation air filter in place See Fig 6 4 02 26 2002 831491 1 Retainer 2 Recirculation Air Filter Fig 6 Cab Recirculation Air Filter Blend Air 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 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 4h CAUTION If the sleeper air filter is not replaced every six months damage to the heater and air conditioner 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
32. 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 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 pry ing 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 oppo site the dry seal while continuing to lubricate If grease still does not appear loosen the cap screws 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 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 Century Cl
33. between the two terminals on the air dryer s harness connector If voltage is not found repair the open in the ground circuit wiring Use an ohmmeter to check resistance between the terminals on the end cover See Fig 3 The end cover contains the heater thermostat If the heater thermostat is between 40 and 90 F 5 to 32 C the heater thermostat measured resis tance will be infinite ohms If the measured resis tance is less than infinity replace the heater thermostat 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 resis tance 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 mea sured resistance should be infinite ohms If the heater thermostat does not operate as outlined replace it Century Class Trucks Maintenance Manual April 2005 42 3 42 06 04 96 1421384 1 End Cover Assembly 2 Heater Thermostat Terminals Fig 3 End Cover Terminals Location 42 04 Alcohol Evaporator Cleaning and Inspection Midland Maintenance is required during both the freeze sea son and the off season to keep the alcohol evapora tor in good working order Off Season During the off season drain the unit of alco
34. in the lock See Fig 9 Ref B If the lock is improperly adjusted correct as fol lows 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 mecha nism several times to test Repeat if necessary See Fig 10 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 nec essary See Fig 10 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 miss ing and damaged parts 9 2 Inspect the locking plungers for full en gagement 9 3 Check the locking mechanism for proper operation If the plungers will not release check the air cylinder or plunger adjustment If the plungers are loose check the plunger adjustment and the plunger springs for proper compression Replace if needed 9 4 The outboard slider assembly requires no adjustment If the plungers are loose in spect and replace locking mechanism parts as needed 9 5 The inboard slider is adjustable for frame width and plunger engagement For ad justment refer to the fifth wheel installa tion instructions Century Class Trucks Maintenance Manual August 2011 31 5 31 Frame and Frame Components 09 01 2009 Checking for fore aft play Rotating t
35. 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 Fig 7 4 Lift the filter out of the sleeper HVAC assembly and discard the filter 5 Place a new filter in the sleeper HVAC assembly The pleated paper filter has an arrow on the edge of the filter that should point toward the heater assembly See Fig 7 The foam filter can be installed in any direction 6 Slide the screen into the frame on the sleeper HVAC assembly 7 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 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 posi tion If there is a baggage compartment the sleeper HVAC assembly may be accessed through the baggage door on the right side of the vehicle 83 4 Century Class Trucks Maintenance Manual April 2003 Heater and Air Conditioner
36. of 34 000 to 40 000 Ib 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 Fig 1 Ah CAUTION Be careful when draining the axle oil lt may be very hot and could cause personal injury if it con tacts the skin 3 Place a drain pan under the rear axle drain plug Drain the oil when it is warm At this tempera 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 12 07 2010 A PON gt f350509a B Rear View Front View Axle Breather Breather Hose Temperature Sensor Port Oil Fill Plug Fig 1 Detroit Tandem Axle forward axle shown to short the two magnetic poles and divert the magnetic field 4 2 Clean away the collected material depos ited on each pole Magnets will rapidly lose their effectiveness as collected mate rial bridges the gap between the two poles Century Class Trucks Maintenance Manual August 2013 35 1
37. 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 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 20 below see Group 20 of the Century Class Trucks Workshop Manual 1 Disconnect the batteries at the negative termi nals Drain all air from the air system If equipped with an air starter drain the air starter reservoir Ah WARNING Make sure the batteries are disconnected before checking the fan clutch If the engine starts during this procedure the fan could engage which could result in serious personal injury 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 ele ment 3 2 Clean the filter element with cleaning sol vent 3 3 Using a clean lint free cloth wip
38. regulator assem bly 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 Ibf ft 14 to 20 N m 5 Build air pressure in the system check for leaks and make any needed repairs 26 04 Transmission Fluid Level Inspection Allison 4h CAUTION Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion Do not mix types and brands of fluid because of possible incompatibility Do not use fluid addi tives 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 mat Century Class Trucks Maintenance Manual April 2005 26 5 26 ter in the hydraulic system may cause undue wear of transmission parts make valves stick and clog pas sages It is important to check the fluid level cold to deter mine 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 Shift from DRIVE to NEUTRAL and then shift to REVERSE to fill the hydraulic system 5 Shift
39. seal and increased fluid leak age Century Class Trucks Maintenance Manual September 2012 46 5 46 10 Check the tube fittings on the hard transfer lines of the gear see Fig 6 Item 15 If there is leak age from either of the fittings replace the steer ing 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 sup port 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 re moval 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 Fig 6 Note the number of exposed 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 Fig 6 8 Remove the bellows from both sides of the gear NOTE A thin film of leftov
40. supplement additives Available as a Caterpillar Caterpillar Diesel Engine Antifreeze Coolant premixed solution Cummins Fleetguard Compleat Premix Premixed solution with supplement additives Detroit Diesel Detroit Diesel Power Cool Premixed solution with supplement additives Old World s industries Fleet Charge With supplement additives Table 1 Approved Antifreeze Maximum Coolant Protection in F C at Various Antifreeze Concentrations COOLING ETHYLENE GLYCOL BASE ANTIFREEZE REQUIRED SYSTEM gallons liters CAPACITY gal L 2 8 3 11 4 15 5 19 6 23 7 26 8 30 9 34 10 38 11 42 12 45 10 38 12 94 62 09 169 4 16 C24 C37 s2yt aD 188 8019 6620 Cen cao cest 10 15 34 57 1245 196 49 918 og 37 49 13 25 45 62 13 49 2109 41 3 18 2C29 31 43 csat 14 53 15 9 6 414 5 19 Gi m We 15 57 16 9 8 13 0 18 on quo Gi a 16 61 17 8 10 12 2 17 8 22 m on E 17 64 18 8 1260 5 15 a0 6 Coy C n C0 18 68 19 7 14 10 7 14 0 18 m us We os at 19 72 20 7 15 9 968 2 17 22 z es e D Century Class Trucks Maintenance Manual September 2010 20 5 20 Engine Cooling R adiator Maximum Coolant Protection in F C at Various Antifreeze Concentrations COOLING ETHYLENE GLYCOL B
41. the Maintenance Operation Chart for axles that require only those lubricants rec ommended in Table 5 1 Park the vehicle on level ground apply the park ing brakes and chock the tires 35 2 Remove the axle carrier fill plug see Fig 3 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 Ambient Temperature Meritor Drive Axle Recommended Lubricant Lubricant SAE Viscosity Grade Meritor Specification 40 F 40 C and up 75W 90 0 76 N Synthetic Gear Oil 40 F 40 C and up 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 Fig 6 Discard the filter 1350119a 05 27 93 Fig 6 Axle Oil Filter Removal 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 ov
42. the camshaft bushings through the grease fitting on the camshaft bracket or the spider until new grease flows from the inboard seal See If grease leaks out under the camhead the cam shaft 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 dam age 42 08 Meritor Slack Adjuster Lubrication IMPORTANT Perform MOP 42 11 before lubri cating the slack adjusters NOTE If equipped with an extended maintenance Q Plus brake system the slack adjuster will not have a grease fitting These slack adjusters use a special NLGI Grade syn thetic polyurea grease and do not require lubri cation for 3 years or 500 000 miles 800 000 km whichever comes first The extended maintenance slack adjusters are lubricated dur ing 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 oper ating 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 oper ating temperatures below 40 F 40 C and above 65 F 54 C
43. 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 Fig 1 or Fig 2 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 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 mainte nance
44. the pipe ends that attach to the bel lows 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 en gine causing engine damage 7 Once the pipes are aligned measure the pipe gap between the CGI pipes and record the dis tance See Fig 9 Ref A 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 49 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 bel lows between the two pipes 9 Once the pipes are correctly aligned and sepa rated 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 Fig 10 for proper installation 1 y 5 m 01 29 2010 2 1490415 1 Aft CGI Pipe 4 Slip Clam
45. 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 Ibf ft 54 to 81 N m Dana Spicer Drive Axle Recommended Lubricant Lubricant Type Dana Spicer Roadranger Synthetic Drive Axle Lubricants or Equivalent with Military Specification Lubricant SAE Under Extra Condition Viscosity Grade Over the Road Service Tao Off Highway Equipment or 80W 140 MIL L 2105D Heavy Loads Table 3 Dana Spicer Drive Axle Recommended Lubricant Dana Spicer Drive Axle Lubricant Capacities Capacity Axle Type Axle Model pints liters Single Drive Axle Installation Single 230808 23080D 40 18 9 Reduction 23105S 23105D 48 22 Dual Drive Axle Installation DD404 DD404 P 31 14 7 t Single E t Reduction DS404 D8404 P 39 18 5 DS461 P 43 20 3 t DT402 402 P 34 16 1 T Dual Range E t 2 Speed DT451 P 39 18 5 DT461 P 43 20 3 t Double DP451 P 34 16 1 Reduction DP461 P 43 20 3 t Quantities listed are approximate Fill axle until lubricant is level with bot tom of fill hole with vehicle on level ground t Add 2 pints 1 L of additional lubricant to the power divider Table 4 Dana Spicer Drive Axle Lubricant Capacities 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
46. to pul ley 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 in structions see Section 83 00 Subject 140 of the Century Class Trucks Workshop Manual 5 Inspect the compressor clutch coil wire Check that the connector is not damaged or loose Re place the wire if it is damaged 83 08 25 94 1830641 Fig 1 Drive Plate Clearance Inspection 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 compo nents 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 con denser Be careful not to bend the fins 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 op eration of the HVAC system Ah 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 cho
47. torque rod ends using your hands only and check for any free play If free play 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 re placement 4 Lift the rear of the vehicle and support the frame on jack stands to unload the suspension compo nents The vehicle is lifted high enough when the beam ends are off of the sadales 32 4 Century Class Trucks Maintenance Manual November 2009 Suspension 32 08 16 96 A Measure height here 1 Left Forwardmost Axle Stop 1320453 Fig 7 AirLiner Axle Stop Measurement Inspect the walking beam for cracks or other damage If damage is found replace the walking beam Keep the vehicle supported by the jack stands for the next operation 5 Manipulate the walking beam so that a microme ter vernier or dial caliper can be used to deter mine the wear area thickness on the bottom face See Fig 8 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 Fig 8 Ref B from the thickness at the non wear area see Fig 8 Ref A to determine the 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 6 Rotate the restrictor cans 360 degrees and visu ally inspect th
48. use a NLGI Grade 2 synthetic oil clay base grease Lubricate the slack adjuster at the grease fitting see Fig 7 until grease is forced past the pressure relief capscrew or past the gear splines around the in board snap ring 42 09 Bendix AD IS Air Dryer Desiccant Replacement 1 Park the vehicle shut down the engine apply the parking brakes and chock the tires 2 Drain the air reservoirs 3 Using a strap wrench or equivalent loosen the desiccant cartridge See Fig 8 Spin the car tridge off by hand and discard it 4 On the new desiccant cartridge lubricate the sealing rings with silicone grease IMPORTANT Only use the silicone grease sup plied with AlliedSignal replacement kits 5 Screw the desiccant cartridge onto the body by hand until the seal makes contact with the body 42 6 Century Class Trucks Maintenance Manual April 2005 Brakes 10 20 93 f420012a Brake Chamber Clevis Actuator Rod Boot Pressure Relief Capscrew Gasket Pawl Spring and Pawl Manual Adjusting Nut Grease Fitting or plug o RON NO 42 42 10 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 Fig 9 Fig 7 Meritor Automatic Slack Adjuster 04 16 98 14219
49. use belt dress ing on any belt 3 Check the belt for a jagged or streaked sidewall See Fig 2 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 Fig 2 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 instal lation 5 Check for uneven ribs on serpentine poly V belts See Fig 2 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 Fig 2 Ref F Small irregular cracks are usually signs of an old belt 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 stetho scope on the component being checked not the pulley to isolate the area from outside interfer ence 8 Inspect all pulleys for foreign objects oil or grease in the grooves Century Class Trucks Maintenance Manual January 2007 01 1 01 Engine 11 21 94 A Glazing B Separating Layers C Streaked Sidewalls D Tensile Break f150010a E Uneven Ribs F Cracks Fig 2 Drive Belt
50. 0 4 Inspect each frame hanger for severe rust on the horizontal mounting flange adjacent to the verti cal drive pin area See Fig 11 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 bush ings 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 alumi num 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 torqued to specification to prevent wear of the beam center bushings into the legs of the Fig 10 Hendrickson RS Series Horizontal Mounting Flange 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 ve hicle 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
51. 0 36 to 45 Alternator and Refrigerant Compressor 40 to 50 18 to 23 per belt Caterpillar 3406E Fan 80 to 100 36 to 45 Alternator 90 to 120 41 to 55 Cummins M11 Fan 155 to 165 70 to 75 Refrigerant Compressor 80 to 100 36 to 45 Alternator 40 to 50 18 to 23 per belt Cummins N14 Fan 80 to 120 36 to 55 Refrigerant Compressor 80 to 100 36 to 45 es i Alternator and Refrigerant Compressor 80 to 100 36 to 45 Power Band Detroit Diesel Series 60 Fan 60 to 80 27 to 36 Table 1 Drive Belt Tension Periodically inspect the rubber isolators for cracks 01 04 Engine Su pport cuts wear or damage and replace them if neces gt sary See Group 01 of the Century Class Trucks Fasteners Check Noise Workshop Manual for isolator replacement Emission Control procedures Front and rear engine supports for vehicles built from January 2007 require no periodic maintenance 2 Mounts should be inspected when the engine is re moved for service For vehicles manufactured prior to 6 IN January 2007 perform the following check Check the rear engine support fasteners see Fig 3 SL Ref 4 for tightness Tighten the 3 4 inch fasteners WS 215 to 265 Ibf ft 292 to 359 N m Check the front engine support fasteners for tight ness Tighten the 5 8 inch fasteners 125 Ibf ft 170 2 N m 4 LAR gt NOTE At engine overhaul and whenever the f N engine has been removed inspect the lower ZA and upper isolator
52. 00 51st M1 51 000 82 000 5100 510 000 820 000 52nd M1 52 000 83 700 5200 520 000 837 000 53rd M1 53 000 85 300 5300 530 000 853 000 54th M1 54 000 86 900 5400 540 000 869 000 55th M1 and M2 55 000 88 500 5500 550 000 885 000 56th M1 56 000 90 100 5600 560 000 901 000 57th M1 57 000 91 700 5700 570 000 917 000 58th M1 58 000 93 300 5800 580 000 933 000 59th M1 59 000 94 900 5900 590 000 949 000 60th M1 M2 and M3 60 000 96 500 6000 600 000 965 000 Table 3 31st through 60th Maintenance for Service Schedules and II 00 4 Century Class Trucks Maintenance Manual August 2013 General Information 00 Vehicle Maintenance Schedule Tables 00 03 61st through 90th Maintenance for Service Schedules and II Maint No Maintenance Service Service Schedule Service Schedule II Interval Date Miles km Hours Miles km 61st M1 61 000 98 200 6100 610 000 982 000 62nd M1 62 000 99 800 6200 620 000 998 000 63rd M1 63 000 101 400 6300 630 000 1 014 000 64th M1 64 000 103 000 6400 640 000 1 030 000 65th M1 and M2 65 000 104 600 6500 650 000 1 046 000 66th M1 66 000 106 200 6600 660 000 1 062 000 67th M1 67 000 107 800 6700 670 000 1 078 000 68th M1 68 000 109 400 6800 680 000 1 094 000 69th M1 69 000 111 000 6900 690 000 1 110 000 70th M1 and M2 70 000 112 700 7000 700 000 1 127 000 71st M1 71 0
53. 00 114 300 7100 710 000 1 143 000 72nd M1 72 000 115 900 7200 720 000 1 159 000 73rd M1 73 000 117 500 7300 730 000 1 175 000 74th M1 74 000 119 100 7400 740 000 1 191 000 75th M1 M2 and M3 75 000 120 700 7500 750 000 1 207 000 76th M1 76 000 122 300 7600 760 000 1 223 000 77th M1 77 000 123 900 7700 770 000 1 239 000 78th M1 78 000 125 500 7800 780 000 1 255 000 79th M1 79 000 127 100 7900 790 000 1 271 000 80th M1 and M2 80 000 128 700 8000 800 000 1 287 000 81st M1 81 000 130 400 8100 810 000 1 304 000 82nd M1 82 000 132 000 8200 820 000 1 320 000 83rd M1 83 000 134 000 8300 830 000 1 340 000 84th M1 84 000 135 200 8400 840 000 1 352 000 85th M1 and M2 85 000 137 000 8500 850 000 1 370 000 86th M1 86 000 138 400 8600 860 000 1 384 000 87th M1 87 000 140 000 8700 870 000 1 400 000 88th M1 88 000 141 600 8800 880 000 1 416 000 89th M1 89 000 143 200 8900 890 000 1 432 000 90th M1 M2 and M3 90 000 144 800 9000 900 000 1 448 000 Table 4 61st through 90th Maintenance for Service Schedules and II Century Class Trucks Maintenance Manual August 2013 00 5 00 General Information Vehicle Maintenance Schedule Tables 00 03 91st through 100th Maintenance for Service Schedules and Il Maint No Maintenance Service Service Schedule Service Schedule Il Interval Date Miles km Hours Miles km 91st M1 91 000 146 500 9100 910 000 1 465 000 92nd M1 92 000 148 100 9200 920 000 1 481 000 93rd M1 93 000 150 000 9
54. 00000 ee ee 42 10 Brako INSHSCHON lt 0 untere beeen fv sura we Sq dme st A a eens 42 11 Dana Spicer Camshaft Bracket Lubrication 0 006 cece eee 42 05 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication liliis 42 06 Meritor Camshaft Bracket LUDNCallOnis s s deos ER bend A ds 42 07 Meritor Slack Adjuster Lubrication liliis 42 08 Century Class Trucks Maintenance Manual April 2005 Brakes 42 01 Air Brake System Valve Inspection NOTE There is no scheduled air valve mainte nance 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 Bendix AD 9 Air Dryer Desiccant Replacement 1 Park the vehicle on a level surface Apply the parking brakes and chock the tires 2 Completely drain all air reservoirs Air pressure gauges should read 0 psi 0 kPa Ah 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 mount ing brack
55. 013 General Information 00 Maintenance Operation Sets Table 00 09 Maintenance Operation Sets for Groups 00 through 83 gods Operation Description nd et a Service oe IM M1 M2 M3 IM M1 M2 M3 33 08 End Play Check Meritor Unitized Wheel Ends 33 09 Kingpin Lubrication Detroit Axles e o e 33 10 Tie Rod Lubrication Detroit Axles 35 01 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning 35 02 Axle Breather and Axle Lubricant Level Inspection 40 01 Wheel Nut and Rim Nut Check 41 01 Driveline Inspection 41 02 Driveline Lubrication 42 01 Air Brake System Valve Inspection 42 02 Bendix AD 9 Air Dryer Desiccant Replacement 42 03 Air Dryer Inspection 42 04 Alcohol Evaporator Cleaning and Inspection 42 05 Dana Spicer Camshaft Bracket Lubrication 42 06 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication 42 07 Meritor Camshaft Bracket Lubrication 42 08 Meritor Slack Adjuster Lubrication 42 09 Bendix AD IS Air Dryer Desiccant Replacement 42 10 Bendix E 6 Foot Control Valve Inspection and Lubrication 42 11 Brake Inspection 46 01 Drag Link Inspection 46 02 Power Steering Fluid and Filter Change 46
56. 09 32 3 32 bolts 45 Ibf in 500 N cm Any damage to the valve housing will void the warranty e Do not attempt to disassemble the Barksdale valve body or the control lever There are no serviceable parts in the valve and any disas sembly will void the warranty NOTICE When removing or loosening a Barksdale height control 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 park ing 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 Fig 6 Ref A 3 1 If the vehicle is equipped with an adjust able leveling valve the lengih should be 8 inches 203 mm If the length is incor rect see Group 32 of the Cent
57. 10 1 Desiccant Cartridge 3 Threaded Base Post 2 Cartridge Sealing Ring S ath G P s E am Xe 4 09 10 2004 1430405 1 Foot Control Valve 5 Roll Pin E 6 6 Roller 2 Mounting Plate 7 Roller Pin 3 Nut and Washer 8 Pedal 4 Pivot Pin Fig 8 Desiccant Cartridge Replacement Rotate the cartridge clockwise about one full turn Firmly tighten the cartridge 6 Remove the chocks from the tires Fig 9 Brake Pedal and Valve Assembly 3 Remove the brake pedal pivot pin 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 Re place it if necessary 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 de grees and apply torque seal OPG F900 White to the cotter pin Century Class Trucks Maintenance Manual April 2005 42 7 42 8 Remove the plunger from the valve Using alco hol 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 ne
58. 2 multipurpose chas sis grease If grease leaks out under the camhead the camshaft bracket grease seal is worn or dam 42 4 Century Class Trucks Maintenance Manual April 2005 Brakes aged See Group 42 of the Century Class Trucks Workshop Manual for grease seal replacement in structions 42 06 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication IMPORTANT Perform MOP 42 11 before lubri cating the slack adjusters Automatic slack adjusters that have a grease fitting must be lubricated periodically to ensure proper brake operation 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 A CAUTION 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 Fig 5 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 see Fig 6 until grease appears on the camshaft or flows from the grease relief The newest Gunite automatic slack adjusters are produced without a grease relief
59. 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 ex tends 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 high temperature grease that meets the NLGI grade one or two specification 3 Wipe any dirt away from the grease fitting See Fig 1 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 A CAUTION Do not over lubricate the clutch release bearing Over lubrication could contaminate the clutch in ternally causing clutch slippage and premature 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 Fig 2 5 Install the clutch inspection plate 6 Remove the chocks 25 02 Clutch Release C
60. 280 000 448 000 29th M1 29 000 46 400 2900 290 000 464 000 30th M1 M2 and M3 30 000 48 000 3000 300 000 480 000 Table 2 1st through 30th Maintenance for Service Schedules and II Century Class Trucks Maintenance Manual August 2013 00 3 00 General Information Vehicle Maintenance Schedule Tables 00 03 31st through 60th Maintenance for Service Schedules and Il Maintenance Service Service Schedule I Service Schedule Il Maint No Interval Date Miles km Hours Miles km 31st M1 31 000 49 600 3100 310 000 496 000 32nd M1 32 000 51 200 3200 320 000 512 000 33rd M1 33 000 52 800 3300 330 000 528 000 34th M1 34 000 54 400 3400 340 000 544 000 35th M1 and M2 35 000 56 000 3500 350 000 560 000 36th M1 36 000 57 600 3600 360 000 576 000 37th M1 37 000 59 200 3700 370 000 592 000 38th M1 38 000 60 800 3800 380 000 608 000 39th M1 39 000 62 400 3900 390 000 624 000 40th M1 and M2 40 000 64 000 4000 400 000 640 000 41st M1 41 000 65 600 4100 410 000 656 000 42nd M1 42 000 67 200 4200 420 000 672 000 43rd M1 43 000 68 800 4300 430 000 688 000 44th M1 44 000 70 400 4400 440 000 704 000 45th M1 M2 and M3 45 000 72 000 4500 450 000 720 000 46th M1 46 000 73 600 4600 460 000 736 000 47th M1 47 000 75 200 4700 470 000 752 000 48th M1 48 000 76 800 4800 480 000 768 000 49th M1 49 000 78 400 4900 490 000 784 000 50th M1 and M2 50 000 80 000 5000 500 000 800 0
61. 300 930 000 1 500 000 94th M1 94 000 151 300 9400 940 000 1 513 000 95th M1 and M2 95 000 153 000 9500 950 000 1 530 000 96th M1 96 000 155 000 9600 960 000 1 550 000 97th M1 97 000 156 100 9700 970 000 1 561 000 98th M1 98 000 157 700 9800 980 000 1 577 000 99th M1 99 000 159 300 9900 990 000 1 593 000 100th M1 and M2 100 000 160 900 10 000 1 000 000 1 609 000 Table 5 91st through 100th Maintenance for Service Schedules and Il 1st through 19th Maintenance for Service Schedules lll and IV Maint No Maintenance Interval a pe ate Miles km 1 IM and M1 25 000 40 000 2 M1 50 000 80 000 3 M1 75 000 121 000 4 M1 and M2 100 000 161 000 5 M1 125 000 201 000 6 M1 150 000 241 000 7 M1 175 000 281 000 8 M1 and M2 200 000 322 000 9 M1 225 000 362 000 10 M1 250 000 402 000 11 M1 275 000 443 000 12 M1 M2 and M3 300 000 483 000 13 M1 325 000 523 000 14 M1 350 000 563 000 15 M1 375 000 604 000 16 M1 and M2 400 000 644 000 17 M1 425 000 684 000 18 M1 450 000 724 000 19 M1 475 000 764 000 Table 6 1st through 19th Maintenance for Service Schedules lll and IV 00 6 Century Class Trucks Maintenance Manual August 2013 General Information 00 Vehicle Maintenance Schedule Tables 00 03 20th through 40th Maintenance for Service Schedules III and IV Maint No Mainte
62. 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 stan dard or oversized bracket shoe rubber pads see Group 31 of the Century Class Trucks Workshop Manual for replacement instructions Frame and Frame Components 04 11 2011 l 1310470 1 Operating Handle 2 Lever Bar Fig 6 Lever Bar and Operating Handle Alignment 04 11 2011 l y 1310475 A Extended Top Plate Lift Height Fifth Wheel Top Plate Fifth Wheel Frame Mount Frame Rail Lifting Point Static Top Plate Height Quot Fig 7 Measuring Fifth Wheel Top Plate Lift 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 un coupled for a short period of time 31 4 Century Class Trucks Maintenance Manual August 2011 Frame and Frame Components 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 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
63. 34 M22 283 384 392 531 M22 x 1 5 315 427 431 584 M24 360 488 498 675 M24 x 2 392 531 542 735 M27 527 715 729 988 M27 x 2 569 771 788 1068 M30 715 969 990 1342 M30 x 2 792 1074 1096 1486 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation t Use these torque values if either the bolt or nut is lubricated or plated zinc phosphate conversion coated cadmium plated or waxed Table 20 Torque Values for Metric Thread Fasteners With Lubricated or Plated Threads 00 24 Century Class Trucks Maintenance Manual August 2013 Engine 01 Index Alphabetical Title of Maintenance Operation MOP MOP Number Engine Drive Belt INSPSCHONS Lass nut A o o A A A 01 02 Engine Mount Inspection Noise Emission Control llli 01 03 Engine Noise Panel Inspection Noise Emission Control liliis 01 01 Engine Support Fasteners Check Noise Emission Control 0000 00 cece ooo 01 04 Century Class Trucks Maintenance Manual January 2007 Engine 01 01 Engine Noise Panel Inspection Noise Emission Control If equipped inspect for torn engine noise panels See Fig 1 for Caterpillar noise panel locations If panels are torn replace them with new panels see Group 01 of the Century Class Trucks Workshop Manual for procedures Cummins M11 and N14 en gines and Detroit Diesel Series 55 and Series 60 engines do not have e
64. 35 4 3 After the first oil is changed inspect the drain plug each time for large quantities of metal particles 4 4 After cleaning install the drain plug s and tighten to 30 Ibf ft 41 N m 5 Fill the axle with the recommended lubricant See Table 1 for recommended drive axle lubri cants and Table 2 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 Fill the axle through the oil fill hole Lubri cant should be level with the bottom of the oil fill hole To check fluid level see Rear Axle Detroit Rear Axle Lubricant Capacity Cil Capacity Axe Quarts liters Single and Rearmost Tandem 10 6 10 0 Actual oil capacity might vary slightly depending on gear ratio Table 2 Detroit Rear Axle Lubricant Capacity 08 17 2009 f350061a A Correct lube level at bottom of fill hole B Incorrect lube level below fill hole Fig 2 5 2 Install and tighten the fill plug 30 Ibf ft 41 N m Detroit Drive Axle Recommended Lubricant t Lubricant Recommended ambient Temperature y SAS Grade 10 F 12 2 C and upt 85W 140 Hypoid Gear Oil 15 F 26 1 C and upt 80W 90 API Service 40 40 C and upt 75W 90 Classification GL 5 40 F 40 C to 35 F 2 C 75W
65. 94 bolt is fractured DO NOT USE Con tact Premier Mfg Co 1 year after installation date e Regardless of service duty replace the 294 bolt with a new one 3 07 13 2010 1310313a 1 Linch Pin 3 Pintle Hook 2 Handle 4 294 Bolt Fig 14 Premier 690 Trailer Coupling Frame and Frame Components 31 10 Century Class Trucks Maintenance Manual August 2011 Suspension Title of Maintenance Operation MOP Suspension Inspection 0000 c eee eee Suspension Lubrication saca a eee eee wees Suspension U Bolt Torque Check o o o oooo o 32 Index Alphabetical MOP Number Century Class Trucks Maintenance Manual November 2009 Suspension 32 01 Suspension Inspection Front Suspension Check Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring as sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Re placement 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 assem bly could cause an accident resulting in property damage serious personal injury or death Inspect the front spring assemblies for cracked bro ken or abnormally bent leaves If any of these condi tions exist replace the spring assembly
66. ASE ANTIFREEZE REQUIRED SYSTEM gallons liters CAPACITY gal LY 2 8 3 11 4 5 5 19 6 23 7 26 8 30 9684 10 38 11 42 12 45 20 76 16 9 10 12 4 16 3 19 ee Con Con a eat For cooling system capacities not shown the required amount of antifreeze can be calculated using the following Ethylene glycol base antifreeze in a 25 solution protects to 10 F 12 C 33 to OF 18 C 40 to 12 F 24 C 50 to 34 F 37 C and 60 to 62 F 52 C t 60 ethylene glycol base antifreeze and 40 water by volume gives maximum coolant protection 62 F 52 C Exceeding 60 antifreeze diminishes coolant protection concentrated ethylene glycol base antifreeze will freeze at approximately 0 F 18 C Table 2 Maximum Coolant Protection in F C at Various Antifreeze Concentrations Engine Coolant Capacity pre EPA07 engines Capacity with 1000 Capacity with 1200 Engine sq inch Radiator sq inch Radiator qt L qt L Caterpillar C10 3176 39 5 37 4 40 6 38 5 Caterpill ei 2 53 2 50 4 54 1 51 5 LL 39 0 37 0 40 2 88 1 C r a S 51 1 48 4 52 3 49 5 Detroit Diesel Series 43 0 40 7 44 1 41 8 55 Detroit Diesel Series 54 8 51 9 56 0 53 0 60 Table 3 Engine Coolant Capacity pre EPA07 engines 12 On single radiator applications add coolant as follows 12 1 Fill the cooling sy
67. All M2 Operations 20 02 Radiator Pressure Flushing and Coolant Change 26 01 Manual Transmission Fluid Change and Magnetic Plug Cleaning synthetic lubricant 35 01 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning 42 02 Bendix AD 9 Air Dryer Desiccant Replacement 42 09 Bendix AD IS Air Dryer Desiccant Replacement 42 10 Bendix E 6 Foot Control Valve Inspection and Lubrication 46 02 Power Steering Fluid and Filter Change 46 07 Bellows Replacement Rack and Pinion Steering Gear 49 02 CAT CGI Bellows Replacement Table 14 M3 Maintenance Interval Operations for Service Schedules I Il Ill and IV Century Class Trucks Maintenance Manual August 2013 00 15 00 General Information Maintenance Operation Sets Table 00 09 Maintenance Operation Sets for Groups 00 through 83 in Operation Description SeT em Service ere IM M1 M2 M3 IM M1 M2 M3 00 04 Lubrication and Fluid Level Check 01 01 Engine Noise Panel Inspection noise emission control 01 02 Engine Drive Belt Inspection 01 03 Engine Mount Inspection noise emission control 01 04 Engine Support Fasteners Check noise emission control 09 01 Air Cleaner Element Inspection and Replacement 15 01 Alternator Battery and Starter Check 20 01 Pressure Relief Cap Check 20 02 Rad
68. 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 lock pins from the gauges make sure the tires are exactly straight ahead NOTE If turn plates or turntables are not avail able 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 Fig 3 Lock in place Check that the scale is set on zero Front Axle a B gt 08 29 94 f330082a NOTE B minus A equals toe in Fig 3 Wheel Toe In overhead view 7 Place the trammel bar at the front of the tires see Fig 4 and a
69. 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 bat teries 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 Check the tightness of the alternator bracket fas teners tighten the fasteners as needed For torque values see Group 15 of the Century Class Trucks Workshop Manual 2 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 alter nator 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 3 Check that all electrical connections at the alter nator 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 charg ing cable terminates Trace and inspect all wiring and cables con nected to e Alternator e Starter and depopulation studs e Batteries 15 e Magnetic switch e Cab e Jump start studs e Battery isolation relays e Battery shutoff switches Check wires and cab
70. FREIGHTLINER Run Smart Maintenance Manual TI 341 1 A24 00691 000 FREIGHTLINER D Run Smart CENTURY CLASS TRUCKS MAINTENANCE MANUAL Models Argosy COE C112 Conventional C120 Conventional CST120 Conventional Coronado STI 341 1 8 13 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 mainte nance 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 mainte nance 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
71. Inspection 46 04 Power Steering Gear Lubrication 46 05 Drag Link Lubrication 46 06 Rack and Pinion Steering Gear Inspection 00 12 Century Class Trucks Maintenance Manual August 2013 General Information 00 M2 Maintenance Interval Operations 00 07 Maintenance Operation Number M2 Maintenance Interval Operations for Service Schedules I Il and Ill Check 47 01 Fuel Filter Replacement 47 02 Fuel Separator Sight Bowl Cleaning and Element Replacement 60 01 Cab Suspension Air Bag Inspection 60 03 Cab Access Stairs Inspection Argosy COE 60 04 Mirror Folding Check 83 01 Air Conditioner Inspection 83 02 Air Filter Replacement Inspect Meritor Unitized Wheel Ends at 200 000 miles 321 870 km0 then every 50 000 miles 80 470 km t Check the end play at 200 000 miles 321 870 km then every 200 000 miles 321 870 km t 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 Il and Ill Maintenance Operation Number M2 Maintenance Interval Operations for Service Schedule IV Check 00 04 Lubrication and Fluid Level Check includes the following e Clutch Release Cross Shaft Lubrication e Sleeve Assembly Bronze Bushing Lubrication e Transmission Fluid Level Inspec
72. 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 O 1996 2013 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 transm
73. a e A A RR RR I US 00 13 Vehicle Maintenance Schedule Tables l l eh 00 03 Vernicalon ol INSPECHONS LOGh 22 ccGi4 4 a O AA a 00 11 Century Class Trucks Maintenance Manual August 2013 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 pro gram can result in inefficient operation and unsched uled down time To determine the correct maintenance intervals for your vehicle you must first determine the type of ser vice or conditions the vehicle will be operating in Generally most vehicles operate under conditions that fall within one of the four types of service de scribed Before placing your new vehicle in service determine the type of service Service Schedule Il Ill or IV that applies to the intended use of the ve hicle 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 opera tions to be performed at that maintenance interval Use the maintenance oper
74. ain 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 lubri cant to run out See Fig 3 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 35 2 Century Class Trucks Maintenance Manual August 2013 Rear Axle 05 27 93 1 Oil Fill Plug 1350018a 2 Drain Plug Fig 3 Axle Housing Drain and Fill Plugs 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 mag netic drain and fill plugs See Fig 4 5 Remove and clean the magnetic strainer if so equipped Gg 05 27 93 1 Magnetic Strainer 1350017a 2 Power Divider Fig 4 Dana Spicer Dual Drive Axle Magnetic Strainer 35 5 1 Remove the magnetic strainer from the power divider cover Ah WARNING Always wear eye protection when using com pressed 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 Ibf ft 54 to 81 Nm 6 Clean the fill plugs and
75. aine 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 31 mating surfaces Lubricate the top and bottom contact surfaces of the jaw and wedge See Fig 1 Open and close the fifth wheel several times to further distribute the grease Lightly oil other moving parts in the fifth wheel 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 Fig 11 3 Grease the yoke tips locks and the release handle and spring see Fig 12 Grease the mounting bracket supports through the grease fittings A low temp grade grease rated for 30 F 34 C or lower such as Cato Oil and Grease 5213 Craftsman Chemical Co LTF 2 Mystic LP 200 or equivalent is recommended Castloc Il and Simplex Series Use a chassis or multipurpose grease to lubricat
76. aintenance Operation MOP MOP Number Allison Transmission Fluid and Filter Change o ooococococoor ee 26 02 Manual Transmission Air Filter Regulator Check Cleaning or Replacement oooooooococooo 26 03 Manual Transmission Fluid Change and Magnetic Plug Cleaning Synthetic A A NN 26 01 Transmission Fluid Level Inspection Century Class Trucks Maintenance Manual April 2005 Transmission 26 01 Manual Transmission Fluid Change and Magnetic Plug Cleaning Synthetic Lubricant 4h CAUTION Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion 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 addi tives 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 trans mission fluid reaches operating temperature Shift the transmission to neutral N and shut down the engine 2 Park the vehicle on level ground apply the park ing brakes and chock the rear tires Place a large drain pan under the transmission 3 Clean the area around the fill pl
77. 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 mov ing parts with a chassis or multipurpose grease See MOP 31 02 for lubrication instructions 31 Holland FW35 1 Thoroughly steam clean all fifth wheel compo nents 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 dam aged 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 Fig 4 6 After inspecting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease See MOP 31 02 for lubrication instructions IPs 4 04 11 2011 B 1310887 A The nut and washer should be snug against the fifth
78. 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 N 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 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 seri ous personal injury 3 Remove the surge tank cap 4 On Argosy s with auxiliary radiators open the remote bleed valve See Fig 3 Ah WARNING Do not attempt to drain the cooling system until the coolant and engine are cool Draining the 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 Fig 4 Allow the coolant to drain 6 Install and tighten the drain plug s and the ra diator outlet pipe drain plug after the radiator has been drained Do not overtighten the plugs 7 Flush the radiator s as fol
79. arrier See Fig 3 Remove the plug NOTE Some Meritor 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 3 Check that the lubricant is level with the bottom of the fill hole See Fig 2 If low check for oil leaks and correct as needed Add the specified lubricant See Table 5 for recommended drive axle lubricants 4 Install and tighten the fill plug 35 Ibf ft 47 N m IMPORTANT Axle housing breathers see Fig 9 must remain clean and unclogged Al ways check the axle breather whenever check ing 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 re place 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 lubri cant level inspection procedure 1 06 07 94 f350062a 1 Axle Housing Breathers 2 Carrier Oil Fill Plugs 3 Interaxle Differential Fig 9 Meritor Axle Housing Breathers 35 8 Century Class Trucks Maintenance Manual August 2013 35 Rear Axle 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
80. arter drain the air starter reservoir 10 5 Apply the foot brake and release the parking brakes A WARNING 10 6 Set the toggle switch to the AUTO or OFF position the air should exhaust and the If the engine starts during this procedure the fan fan clutch should disengage Replace the could cause personal injury If the vehicle is switch if necessary equipped with an air starter be sure that the air starter reservoir is drained If the fan stays engaged at all times on a Detroit Diesel engine check the circuit breaker labeled 2 Measure the distance from the back surface of engine fan the fan clutch retaining plate to the forward most edge of the fan belt pulley See Fig 9 Ref A 3 Disconnect the line from the air inlet of the air cylinder Connect a shop air hose to the inlet 20 8 Century Class Trucks Maintenance Manual September 2010 Engine Cooling Radiator 05 27 93 1200237a With the fan clutch engaged measure the distance at A measure it again with the fan clutch disengaged 1 Bearing Housing 5 Air Cylinder 2 Retaining Plate 6 Fan 3 Fan Pulley 4 Air Inlet from solenoid valve Fig 9 Kysor K22RA Fan Clutch Lining Wear Checking 4 Apply a minimum of 100 psi 690 kPa air pres sure 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
81. ass Trucks Maintenance Manual July 1999 41 3 41 Slip Joint Spline Lubrication NOTE Vehicles equipped with Meritor RPL Se ries drivelines do not require periodic lubrication 1 If equipped with a grease fitting wipe all old grease and dirt from the slip joint grease fitting See Fig 5 Ref 1 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 Fig 5 This ensures complete lubrication of the splines 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 July 1999 Brakes 42 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Brake System Valve Inspectlofic uua a ri ee E A Baw REESE He 42 01 ADS peca ARA AAA A A AAA AA 42 03 Alcohol Evaporator Cleaning and Inspection illii 42 04 Bendix AD 9 Air Dryer Desiccant Replacement ooocoooocooooor ee 42 02 Bendix AD IS Air Dryer Desiccant Replacement lille eee 42 09 Bendix E 6 Foot Contol Valve Inspection and Lubrication
82. ate here 1 Cap and Tube Assembly Bushing 4 1 Dari Lubica 09 15 95 1320424 Fig 19 Equalizer ASsempiy Lubrication 1 Bronze Bushing 3 Grease Fitting to lubricate until grease exits both ends of the 2 Lubrication Hole 4 Lubrication Groove bushing If the pin will not accept lubricant re Fig 16 Hendrickson RT2 and RTE2 Series Bushing move the pin and clean the lubrication channels Lubrication where lubricant may have hardened Remove the safety stands and lower the vehicle after lubrica tion is complete Century Class Trucks Maintenance Manual November 2009 32 9 32 Neway No lubrication is required on Neway rear suspen sions Reyco No lubrication is required on Reyco rear suspen sions 32 03 Suspension U Bolt Torque Check Suspension Spring Assembly U Bolt High Nut Torque Values Size Torque Ibf ft N m Stage 1 Hand tighten Stage 2 60 81 Stage 3 200 271 Stage 4 520 to 600 707 to 816 1 14 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 Table 1 for U bolt torque specifica tions Turn the wrench in a clockwise motion looking up until t
83. ation reference numbers to find detailed instructions in the manual on each op eration Types of Service Service Schedule severe service applies to ve hicles that annually travel less than 6000 miles 10 000 kilometers or that operate under severe condi tions Examples of severe service Schedule 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 cli mates frequent short distance travel construction site 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 con ditions Examples of Schedule Il usage are opera tion primarily in cities and densely populated areas local transport with infrequent freeway travel or high percentage of stop and go travel Service Schedule lll long haul transport is for ve hicles 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 re gional delivery that is mostly freeway miles interstate transport or any road operation with high annual mileage Service Schedule IV long haul transport for Opti mized Vehicle Configuration is for vehicles that an nually travel over 60 000 miles 100 000 km and meet the following qualifications
84. 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 Loctite9 242 or equiva lent 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 Century Class Trucks Maintenance Manual August 2013 35 9 Wheels and Tires 40 Index Alphabetical Title of Maintenance Operation MOP MOP Number Wheel Nut and Rim Nut Check susc socorro aaa RR RUE 40 01 Century Class Trucks Maintenance Manual January 1996 Wheels and Tires 40 01 Wheel Nut and Rim Nut Check IMPORTANT After installing a wheel the wheel or rim nut torque must be rechecked after 50 to 100 miles 80 to 160 km of operation See Table 1 for wheel nut torque specifications and see Fig 1 for the wheel nut tightening sequence CAUTION Insufficient wheel nut rim nut torque can cause wheel shimmy resulting in wheel damage stud 40 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 Fig 1 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 proced
85. bbing the frame is characterized by chafe marks on the shock absorber body and the frame rail See Fig 2 Check the rubber mounting bushings for cracks cuts swelling and dry rot Also check the bushings for missing pieces Replace the bushings as needed 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 Century Class Trucks Maintenance Manual November 2009 32 1 32 11 27 95 1320465 Fig 2 Direct Acting Shock Absorber front suspension shown Rear Suspension Check Freightliner Spring Suspension Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring as sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Re placement of only visibly damaged parts is no as surance that the spring is safe Failure to replace a damaged spring assembly could cause an acci dent resulting in serious personal injury or prop erty damage Replace worn cracked or damaged spring brackets Failure to do so could result in bracket breakage possibly leading to loss of vehicle con trol 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 damag
86. charger 6 Sensor Housing 2 DOC Temperature Sensor 7 DPF Outlet Temperature Sensor 3 ATD Mounting Band 8 Exhaust Outlet Marmon Fitting 4 DPF Intake Pressure Sensor 9 DPF Outlet Pressure Sensor 5 DPF V Band Mounting Clamps Fig 7 Typical After Treatment Device e Diesel Particulate Filter DP F a filter that col lects and holds particulate matter soot and NOTICE ash aos y A leak in the CGI piping including the bellows Diesel Oxidation Catalyst DOC oxidizes hy will allow unfiltered air and contaminants into the drocarbons and reduces NOx engine intake and can cause serious engine dam e Sensors detect temperatures and pressures in age the ATS NOTE Because the CGI bellows is covered A with a metal mesh it is difficult to see cracks or Inspection damage that may cause a leak A a phas dd de Ps nre e 3 On vehicles with CAT engines inspect the CGI m Em E p n ia a is the clam to bellows and piping for evidence of damage or th e ici E tote ien e breiste El a leakage See Fig 8 If the bellows is damaged i iade que ge p or leaking replace it See 49 02 for the replace FUSE ISTIS ment procedure 2 Check the exhaust pipe bellows and each ex haust 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 l
87. check the fasteners at the following locations 31 8 Century Class Trucks Maintenance Manual August 2011 Frame and Frame Components 10 03 30 95 f220054 Capscrew 3 4 x 4 5 Inch Grade 8 Washer 3 4 Inch Engine Leg Capscrew 1 2 13 x 1 5 Inch Grade 8 Washer 1 2 Inch Upper Isolator Rear Engine Mount Nut 5 16 18 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 o0 1o Or mor Fig 13 Rear Engine Mount Assembly pre EPA07 engines e Axle Stops e Engine Trunnion Supports e Equalizer Brackets e Exhaust Brackets 31 Fifth Wheel Legs Fifth Wheel Mountings e Frame Crossmembers and Gussets Front Frame Brackets Front Suspension Spring Brackets Fuel Tank Brackets Radius Rods e Rear Engine Supports e Rear Suspension Spring Brackets e Shock Absorbers e 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 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 ter minals and create bridging between positive and ground terminals NOTE The use of soap is not recomm
88. ck the rear tires Century Class Trucks Maintenance Manual April 2003 83 1 83 Heater and Air Conditioner 2 Remove the two Torx screws that secure the HVAC air filter cover to the air intake plenum See Fig 2 p 12 18 96 s 1830768 1 HVAC Plenum 2 Filter Cover 3 Torx Screws Fig 2 HVAC Air Intake Plenum Water Valve Controlled 3 Pivot the front end of the cover out to remove the cover and pull the air filter out of the air in take 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 Fig 3 4 2 Install the air filter cover on the plenum and install the two Torx screws 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 2 N N Mia 7 Jt LE i N gt 1 1 Z gu he 12 18 96 i 830769 1 Air Filter 2 Air Flow Direction Arrow Fig 3 HVAC Air Filter Water Valve Controlled CAUTION If equipped with a fresh air filter it should be re placed every six months If the fresh air filter is not replaced every six months damage to the heater and air conditioner comp
89. dicator 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 Fig 2 If low check for oil leaks and correct as needed Add oil to the level of the fill plug using the lubricant recommended in Table 1 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 Ibf ft 41 N m IMPORTANT Always check the axle breather whenever checking the lubricant level Check the breather more frequently under adverse op erating 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 park ing brakes and chock the tires 2 Ifthe 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 Fig 3 or from the standpipe if so equipped installed in the fill hole IMPORTANT A lubricant level close enough to be seen or touched is not sufficient It must be level with the bottom of the fill hole see Fig 2 or the top of the standpipe openi
90. dition the Service Solutions feature provides di agnostic assistance with Symptoms Search by connecting to a large knowledge base gathered from technicians and service personnel Search results for both documents and service solutions can be narrowed by initially entering vehicle identification data PartsPro 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 ac cessed 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 Recall campaigns cover situations that involve service work or replacement of parts in connection with a recall notice These campaigns pertain to matters of vehicle safety All recall campaigns are distributed to dealers customers receive notices that apply to their vehicles Field Service Campaigns Field service campaigns are concerned with non safety related service work or replacement of parts All field service campaigns are distributed to dealers cus tomers receive notices that apply to their vehicles I 2 Century Class Trucks Ma
91. djust the scale end so that the pointers line up with the scribe lines See Fig 5 N 08 30 94 1330014a 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 rections are needed see Group 33 of the Century Class Trucks Workshop Manual for in structions on adjusting the toe in 33 2 Century Class Trucks Maintenance Manual January 2013 Front Axle 33 08 30 94 f400100a Fig 5 Setting Trammel Bar Pointers 33 05 Knuckle Pin Lubrication Dana Spicer Axles CAUTION Use regulated pressure when lubricating the knuckle assemblies otherwise damage could re sult 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 multi purpose chassis grease NLGI Grade 1 6 12 hydroxy lithium stearate grease or NLGI Grade 2 896 12 hydroxy lithium stearate grease until new grease is seen at the junctions of the axle beam and knuckles See Fig 6 Knuckle pins without grease fittings are permanently lubricated pA 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 a
92. 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 mag netic field IMPORTANT Magnets will rapidly lose effective ness as collected material bridges the gap be tween 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 Ibf ft 54 to 81 N m 8 Fill the axle with recommended lubricant See Table 3 for recommended drive axle lubricants and Table 4 for drive axle lubricant capacities NOTE Some Dana Spicer axles have a small tapped and plugged hole near and below the housing oil fill hole This smaller hole is for a lubricant temperature indicator only and should not be used as a fill or level hole 8 1 Using recommended lubricant fill the axle through the oil fill hole or standpipe open ing Lubricant should be level with the bottom of the oil fill hole see Fig 2 or top of the standpipe opening 8 2 Install and tighten the fill plug 40 to 60 Ibf ft 54 to 81 N m 8 3 For forward drive axles remove the power divider fill plug located slightly off Century Class Trucks Maintenance Manual August 2013 35 3 35 set to the right in the top portion of the forward differential carrier See Fig 5 Add two pints 1 L of lubricant
93. e cans for cracks severe corro sion and distortion If any of these conditions are 09 27 95 320432 A Non Wear Area B Wear Area 1 Walking Beam Fig 8 Walking Beam End Wear Thickness present or the restrictor can is missing replace the restrictor can A WARNING Replace all cracked or missing restrictor cans Failure to do so could lead to loss of vehicle con trol which could result in property damage seri ous personal injury or death Hendrickson RS Series 1 Inspect the frame hanger to frame attaching fas teners for the proper torque See Group 00 of this manual for torque specifications A WARNING Be sure that fasteners are torqued correctly Fas teners that do not provide a tightly clamped joint between the frame and the hanger can cause pre mature fracture of the frame hanger separation of components loss of vehicle control and possible personal injury or property damage Century Class Trucks Maintenance Manual November 2009 32 5 32 2 Inspect each frame hanger for any evidence of cracks in the vertical mounting flange See Fig 9 09 15 95 1 Frame Rail 2 Crack In Inspection Area 320419 Suspension 09 15 95 1 Crack In Inspection Area 1320420 Fig 9 Hendrickson RS Series Vertical Mounting Flange 3 Inspect each frame hanger for evidence of cracks in the horizontal mounting flange adjacent to the vertical drive pin area See Fig 1
94. e 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 dam aged blades Replace if damaged Check for ad equate clearance between the fan and other components 5 Check the fan belt for wear tension and align ment 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 8 mm thickness or less Also check the facing for signs of oil contamination or burn marks If evi dence 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 dis tance Look for vibration fan blade contact fan clutch slippage and overall fan clutch operation Century Class Trucks Maintenance Manual September 2010 20 9 20 If the fan clutch does not operate correctly see Group 20 of the Century Class Trucks Workshop Manual for troubleshooting and repair proce dures 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 assem bly and the air hoses and fittings See Fig 10 Using a wet finger or a soapy water solution check for a leak in the same areas
95. e 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 Fig 1 or Fig 2 Twist the 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 46 04 Power Steering Gear Lubrication Sheppard Steering Gears Sheppard power steering gears manufactured with out grease fittings are maintenance free If the power steering gear has no grease fitting it requires no pe riodic lubrication Sheppard power steering gears with grease fittings must be lubricated periodically 1 Wipe off any debris from the bearing cap grease fitting See Fig 3 05 28 93 1460296a 1 Bearing Cap Grease Fitting Fig 3 Sheppard Bearing Cap Lubrication 2 Using a hand type gr
96. e performed at the M1 maintenance interval Maintenance opera IMPORTANT After performing all operations listed in this table perform all daily weekly and monthly maintenance operations listed in the Pretrip and tion numbers are reference numbers used to help you find detailed instructions in this manual on the the Century Class Driver s Manual maintenance operations to be performed Post Trip Inspections and Maintenance chapter of o RUNE i M1 Maintenance Interval Operations for Service Schedules I Il and III Check 00 04 Lubrication and Fluid Level Check includes the following e Eaton Fuller Clutch Release Bearing Lubrication e Fifth Wheel Lubrication e Trailer Electrical Connector Lubrication e Suspension Lubrication e Knuckle Pin Lubrication Dana Spicer Axles e Tie Rod Lubrication Dana Spicer Axles e Driveline Lubrication e Dana Spicer Camshaft Bracket Lubrication e Dana Spicer Haldex and Gunite Slack Adjuster Lubrication e Cab Tilt Pump Reservoir Fluid Level and System Check e Door Seal Door Latch and Door Hinge Lubrication e Hood Rear Support Lubrication 20 03 Fan Clutch Check noise emission control 31 01 Fifth Wheel Inspection 31 05 Premier 690 Coupling Inspection 41 01 Driveline Inspection 42 07 Meritor Camshaft Bracket Lubrication 42 11 Brake Inspection 49 01 Exhaust System Inspection noise emission control Table 10 M1 Maintenance Interval O
97. e 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 indi cates that air is present in the hydraulic cab tilt sys tem 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 cylin ders 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 assem bly Check the tilt pump mounting bolts for tightness see Group 00 of this manual for torque values for lubricated or plated fasteners On Argosy COEs inspect the cab access stairs for wear damage or excessive dirt build up and verify that the step is operating properly Inspect the bump stops and replace if necessary See Fig 1 Check the step alignment using the door frame as a reference Verify that the steps are paralle
98. e the two grease fittings located on either side of the fifth wheel top plate Lubricate the two grease fittings lo cated 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 slide mount 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 Century Class Trucks Maintenance Manual August 2011 31 7 31 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 12 03 2010 1 Release Handle and 3 Yoke Tip Spring 4 Locks 2 Grease Fitting f311135 Fig 12 Holland FW35 Fifth Wheel Grease Lubrication Frame and Frame Components wheel see Fig 10 Apply a light oil to all moving parts For sliding fifth wheels spray diesel fuel on the slide path of the base plate 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 l
99. ease Supplier Grease Chevron Delo Heavy Duty EP Exxon Unirex EP2 Mobil Mobil Grease XHP 222 Shell Retinax LC Grease Texaco Starplex 2 Table 1 Approved Suppliers of Multi Purpose Lithium Grease 88 Century Class Trucks Maintenance Manual March 2010 88 1
100. ease gun apply multipur pose chassis grease until grease starts coming out of the bearing cap dirt and water seal TRW Steering Gears NOTICE Apply grease to the sector shaft with a hand type grease gun only Use of a high pressure power grease gun will supply grease too quickly and could affect the high pressure seal contaminating the hydraulic fluid Using a hand type grease gun apply NLGI Grade 2 or 3 multipurpose chassis grease until it starts to come out past the sector shaft seal See Fig 4 Century Class Trucks Maintenance Manual September 2012 46 3 46 11 28 95 1461071 1 Sector Shaft Grease Fitting Fig 4 TRW Steering Gear Lubrication 46 05 Drag Link Lubrication 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 Fig 5 3 Using a pressure gun and NLGI Grade 2 896 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 1 11 27 95 2 1 Grease Fitting at Pitman Arm 2 Grease Fitting at Axle Steering Arm 1461072 Fig 5 Drag Link Steering 46 06 Rack and Pinion Steering Gear Inspection All steering system components are critical for safe operation of the vehicle Failure to maintain
101. ective cloth ing 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 com pressor 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 compres sor drive belt for damage and check that the belt is set at the proper tension Also check the tight ness 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 Ona 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 Fig 1 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
102. ed bracket s See Group 32 of the Century Class Trucks Workshop Manual for in structions 2 Inspect the tandem axle frame crossmember and gussets for wear cracks and other damage If any of these conditions exist replace the dam aged parts See Group 32 of the Century Class Trucks Workshop Manual for instructions Suspension NOTICE Failure to replace the suspension crossmember or gussets if they are cracked worn or otherwise damaged could result in damage to the vehicle chassis 3 Without detaching the torque arms attempt to move by hand each radius rod end up down in and out If there is any movement replace the torque arm If a torque arm needs to be re placed 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 Fig 3 Re place the torque arm for any of the following rea sons e if there are gaps between the rubber bush ing and the pin or outer steel sleeve e if either bushing end contacts a torque arm pin mounting bolt e if there are cracks in the bushing e if part of the rubber bushing extends be yond the outer circumference of the outer bushing sleeve 05 27 93 f320021a Fig 3 Torque Arm Bushings 6 Block up the frame enough to take chas
103. ed by All SOW AEB DENES 14 0 13 2 Eaton 18 Speed Autoshift AS2 all Meritor Transmissions Quantities listed are approximate Fill the transmission until lubricant is level with bottom of the fill hole with the vehicle in normal operating posi FreedomLine ee 20 Al 50W tion Table 2 Eaton Fuller Transmission Lubricant Synthetic engine oil Capacities All other meeting Meritor spec Meritor 0 81 orMIL L 2104p 50W or E Meritor Transmission Lubricant Capacities Do not mix types or brands of fluid Multiweight and extreme pressure T Refill Capacity gear fluids are not recommended Transmission Model qt D y T Call 1 800 826 4357 for a complete list of Eaton approved lubricants Meri M MO Seri Table 1 Approved Manual Transmission Lubricants eritor reS M MO all 10 25 9 7 Eaton Fuller Transmission Lubricant Capacities Meritor 9 and 10 Speed n 115A B C R all aida Refill Capacity 10 0 9 5 Transmission Model qt L 125A B C R all 9 5 7 Speed T Series 135A B C R all All Models 18 0 17 0 145A B C R all 10 25 9 7 All 9 Speed Series 155A B C R all All Models 13 5 12 8 Meritor 13 Speed All 10 Speed Manual Models except deep reduction RM013 145A 11 0 10 4 FR and FRO Series 11 75 11 0 ZF Meritor FreedomLine RT and RTX Series 13 0 12 3 All 12 Speed Models 11 6 11 0 RTLO Series 14 0 13 2 All 16 Speed Models 12 5 11 8 RTO 16210C 11 75 11 0 Quantities listed are approximate Fill the
104. ee Alternators and Starters 2 us da ab es Se pH RE REA Engine Cooling Radiator PRICE HP Clutch 2D ii aioe tage RU e acera io p M LO de uisa a Transmission Ol AI Frame and Frame Components S x eds Seek ins Bie ea aus Sad ea eagle dis Suspension OO vua gx ka a A duree Front Axle cT te tete id ae ies Rear Axle Aid da ri a dae Eb a Wheels and Tires iu a ia ne Ss a Driveline LP UPC Brakes 46 Sc teed dab suns dba Rue d de Steering AD METRICS Fuel A9 ia dett reo a CE Rode des dude Exhaust 60 dae da as do ee ca PERSE Cab A E NN Doors B9 nr a Heater and Air Conditioner Bcc Hood Grille and Cab Fenders 1 4 Century Class Trucks Maintenance Manual March 2011 General Information 00 Index Alphabetical Title of Maintenance Operation MOP MOP Number Determining Scheduled Maintenance Intervals 2 00 01 Initial Maintenance IM Operations 2 ener ais 00 05 Lubrication and FluidiLevel Check uode ir a a edd dus 00 04 M1 Maintenance Interval Operations 0 0000 0c ee 00 06 M2 Maintenance Interval Operations suasana aaaeeeaa 00 07 M3 Maintenance Interval Operations lilii nn 00 08 Maintenance Operation Sets Table ox am der ded ria de a ai dn ade 00 09 Metric U S Customary Conversion Tables 2 0 00060 nee ee 00 12 Noise Emission Controls Maintenance 0 000000 eee 00 10 Service schedule Table 5i suse cod dipsa dob dar dr de 00 02 Torque Specifications Tables s x e r
105. ehicle In compliance with the law the C Removal of or rendering inoperative the en gine speed governor so as to allow engine speed to exceed manufacturer s specifica noise emission controls maintenance information in tions each applicable group of this manual in conjunction D Removal of or rendering inoperative the fan with the vehicle workshop manual provides these clutch including bypassing the control on instructions to owners any thermostatic fan drive to cause it to op erate continuously Recommendations for Replacement Parts Removal of the fan shroud Removal of or rendering inoperative ex Replacement parts used for maintenance or repair of haust components including exhaust pipe noise emission controls should be genuine Freight clamping liner parts If other than genuine Freightliner parts are used for replacement or repair of components G Removal of air intake components affecting noise emission control the owner should be sure that such parts are warranted by their manufac Maintenance Instructions turer to be equivalent to genuine Freightliner parts in performance and durability Scheduled intervals are in the maintenance tables in M this group A Verification of Inspections Log Groups Freightliner Noise Emission 01 20 and 49 follows and should be filled in each time noise emission controls on the vehicle are main Controls Warranty tained or repaired Refer to the
106. elted This released the clutch before the heat could damage the clutch bearings Before replacing the fuse find and repair the source of the heat If equipped with an override toggle switch on the dash check the fan clutch operation as follows 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 sys tem to 120 psi 827 kPa Tests must be performed with the engine temperature below 205 F 96 C for Caterpillar en Century Class Trucks Maintenance Manual September 2010 20 7 20 Engine Cooling R adiator 03 30 95 f200194a 1 Mounting Bracket 9 Rear Hub Bearing 17 Face Seal 2 Rear Sheave Bearing 10 Bearing Spacer 18 Small O Ring 3 Inner and Outer Bearing 11 Splined Hub 19 Air Chamber Spacers 12 Forward Hub Bearing 20 Socket Head Capscrew 4 Forward Sheave Bearing 13 Piston Friction Disc 21 Stud Bolt 5 Sheave 14 Large O Ring 22 Lockwasher 6 Friction Facing 15 Locknut 23 Hexnut 7 Journal Spacer 16 Cartridge Assembly 24 Piston Assembly 8 Socket Head Capscrew AL 24 11 Fig 8 Horton Advantage Fan Clutch Components gines and below 200 F 93 C for Cum Kysor K22RA Fan Clutch mins and Detroit Diesel engines 10 4 Set the toggle switch to the ON position the fan clutch should engage 1 Disconnect the electrical cables from the battery Drain all air from the air system If equipped with an air st
107. en You Multiply Then When You Know Subtract Divide By To Get Know By Add To Get degrees Fahrenheit F 32 1 8 degrees Celsius C 1 8 degrees Fahrenheit F Table 17 Temperature Conversion Century Class Trucks Maintenance Manual August 2013 00 21 00 Torque Specifications Tables 00 13 General Information Torque Values for U S Customary Thread Fasteners With Lubricated or Plated Threadst Regular Hex Flanged o Grade 5 Grade 5 or Grade 8 or Grade 8 or Grade 5 Grade B Grade 8 or Grade G Pitch Bolt B Nut 8 2 Bolt C Nut Bolt Nut 8 2 Bolt Nut Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m MIS lt P f ex tesonne 1230009 1290004 1290008 soon ues A s tm 1 4 20 7 9 8 11 6 8 10 14 1 4 28 8 11 9 12 7 9 12 16 5 116 18 15 20 16 22 13 18 21 28 5 16 24 16 22 17 23 14 19 23 31 3 8 16 26 35 28 38 23 31 37 50 3 8 24 30 41 32 43 25 34 42 57 7116 14 42 57 45 61 35 47 60 81 7 16 20 47 64 50 68 40 54 66 89 1 2 13 64 87 68 92 55 75 91 123 1 2 20 72 98 77 104 65 88 102 138 9 16 12 92 125 98 133 80 108 130 176 9 16 18 103 140 110 149 90 122 146 198 5 8 11 128 173 136 184 110 149 180 244 5 8 18 145 197 154 209 130 176 204 277 3 4 10 226 306 241 327 200 271 320 434 3 4 16 253
108. enance 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 operators manuals do not contain detailed repair or service information Service bulletins provide the latest service tips field repairs product improve ments and related information Some service bulletins are updates to informa tion in the workshop service manual These bulletins take precedence over workshop service manual information until the latter is updated at that time the bulletin is usually canceled The service bulletins manual is available only to dealers When doing service work on a vehicle system or part check for a valid service bulletin for the latest information on the subject IMPORTANT Before using a particular service bulletin check the current service bulletin validity list to be sure the bulletin is valid Parts technical bulletins provide information on parts These bulletins contain lists of parts and BOMs needed to do replacement and upgrade procedures parts documentation can be accessed using the following applications on the ServicePro provides Web based access to the most up to date versions of the publications listed above In ad
109. ended 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 cou pling refer to the Premier web site at www premier mfg com for complete safety operation and maintenance instructions Century Class Trucks Maintenance Manual August 2011 31 9 31 If at any time the 690 coupling is bound up jack knifed the 294 bolt MUST be replaced immedi ately Do not use the coupling until the bolt has been replaced In addition carefully inspect the 690 coupling drawbar drawbar eye front end as sembly 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 per formed as follows See Fig 14 For a new or replaced 294 bolt e Record the date of installation 6 months after installation date e Remove the 294 bolt Using dye penetrate or magnetic particle testing along the length of the bolt inspect for fractures e If the 294 bolt has no damage install it and continue to use for another 6 months e f the 2
110. eplace a damaged spring assem bly could cause an accident resulting in property damage serious personal injury or death 1 jy A Y A e 3 hd 05 27 93 5 f320023a A 1 8 3 mm Clearance 1 Frame Fasteners 4 Equalizer 2 Frame Rail 5 Equalizer Bracket 3 Pry Bar Fig 5 Top View of the Equalizer Inspect the forward and rear spring brackets for wear cracks and other damage If any of these con ditions exist replace the damaged bracket s See Group 32 of the Century Class Trucks Workshop Manual for instructions A WARNING Replace worn cracked or damaged spring brackets Failure to do so could result in bracket breakage possibly leading to loss of vehicle con trol 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 sus pension 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 fol lowing e 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 Century Class Trucks Maintenance Manual November 20
111. er Terostat MS 939 on the rack housing is acceptable when installing the new bellows 9 f 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 Steering housing with brake cleaner to remove all remain ing 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 apply ing sealant to the inner tie rods may cause dam age to the bellows and the gear See Fig 6 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
112. er the adapter and tighten the filter one full turn after the gasket contacts the base do not overtighten the filter 5 Fora 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 6 Clean the fill and drain plugs For magnetic plugs a piece of key stock or any other conve nient steel slug may be used to short the two magnetic poles and divert the magnetic field NOTE Meritor recommends plugs with ele ments 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 ef fectiveness as collected material bridges the gap between the two poles Clean or change the plugs before this occurs It may be neces sary to clean or change the plugs one or more times between lubrication change intervals 7 After cleaning the drain plug s install and tighten to 35 Ibf 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 Table 5 for recom mended axle lubricants and Table 6 for drive axle lubricant capacities Century Class Trucks Maintenance Manual August 2013 35 5 35 Meritor Drive Axle Lubricant Capacities Capacity pints liters Single Drive Single Reduction
113. erly 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 lt 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 pro cedure Rock the top plate back and forth sev eral 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 thick ness of this material can prevent the proper op eration of the fifth wheel and may cause a dan gerous condition NOTE Font
114. ester in lock Engage hook Pull push handle fore aft Check for movement of kingpin in lock Disengage hook Push pull handle inboard outboard Rotate lock tester rommoom f311099 Fig 9 Jost Fifth Wheel Adjustment k e 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 09 02 2009 1 Jam Nut 3 Grease Zerk 2 Adjustment Bolt Fig 10 Jost Fifth Wheel f311100 11 After inspecting the fifth wheel lubricate all mov ing 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 instruc tions 31 02 Fifth Wheel Lubrication To maintain proper fifth wheel operation always lubri cate the fifth wheel after an inspection has been performed IMPORTANT Lubricate the fifth wheel e After power washing or steam cleaning e f the vehicle operates in harsh conditions such as salt spray from road surfaces or in ex tremely dusty environments 31 6 Century Class Trucks Maintenance Manual August 2011 Frame and Frame Components e After any service that requires the removal of lubrication from the fifth wheel head or compo nents Failure to prop
115. esult 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 lint free 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 in stall the end cap and tighten it until firm Ah CAUTION A leaking air filter or air lines can cause slow or hard shifting of the transmission and eventual transmission damage 26 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 sys tem for the source of the fluid and service it as needed 3 Install the element in the filter
116. et 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 installa tion 7 Remove the upper mounting bracket strap cap screw 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 Fig 1 Discard the Nylok nuts Remove the end cover to housing O ring 9 Clamp the desiccant cartridge in a vise 42 A 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 des iccant cartridge NOTE A substantial torque up to 50 Ibf ft 68 N m may be necessary to remove the desic cant 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 A 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 cart
117. etention nut with a wrench while backing off its jam nut Then tighten the reten tion nuts 30 to 35 Ibf ft 41 to 46 N m After the re tention nuts have been tightened hold each retention nut with a wrench while tightening its jam nut 30 Ibf ft 41 N m IMPORTANT Do not overtighten 10 7 09 15 95 oa PON gt Beige Mounting Head Metal Plug 3 8 NPT Bowl O Ring Bowl Bevel Cut Gasket Bowl Probe Plug Water Sensor Probe 7 8 9 10 1470148 Heater Connector Bowl Drain Valve Assembly Bowl with Drain and Water Sensor Service Element Fig 3 Racor 690 Fuel Separator Century Class Trucks Maintenance Manual April 2005 47 3 Exhaust Title of Maintenance Operation MOP CAT CGI Bellows Replacement nnan nannaa Exhaust System Inspection Noise Emission Control 49 Index Alphabetical MOP Number Century Class Trucks Maintenance Manual August 2011 Exhaust 49 01 Exhaust System Inspection Noise Emission Control In addition to inspecting the exhaust system at the scheduled maintenance interval inspect the exhaust system if the noise level of the vehicle has in creased Replace parts that show leakage wear or damage with genuine Freightliner parts Pre EPAO7 Exhaust System Inspecting 1 On all vehicles check the condition of the muffler body the top stack and the heat shield See Fig 1 Check the inlet outlet tubes for leakage dents and corro
118. gn the large Oetiker clamp ear with the small clamp ear Both clamp ears should be aligned with the rack housing casting rib See Fig 9 09 09 2009 4 1462176 4 Large Oetiker Clamp 5 Housing Casting Rib 1 Inner Tie Rod 2 Small Oetiker Clamp 3 Bellows Fig 9 Oetiker Clamp Alignment NOTICE Do not over tighten the Oetiker clamps Over tightening may lead to stretching of the clamp which could allow moisture intrusion and corro sion 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 re move 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 Fig 10 crimp the small and large Oetiker bellows clamp ears until the Century Class Trucks Maintenance Manual September 2012 46 7 46 ear width is 0 08 to 0 16 in 2 to 4 mm See Fig 11 and Fig 12 07 24 2009 1580473 Fig 10 Oetiker Clamp Tool P N 14100037 or 14100082 07 21 2009 2 1462165 1 Outer Tie Rod 2 Small Oetiker Clamp 3 Bellows 4 Large Oetiker Clamp 5 Oetiker Clamp Tool Fig 11 Oetiker Clamp Installation 15 Remove excess grease from the bellows and the gear ho
119. h the lower edge of the fill opening See Table 1 for approved transmission lubricants 5 Clean the fill plug then install it in the transmis sion Tighten the plug as follows e 25 to 35 Ibf ft 34 to 48 N m for Eaton Fuller transmissions with 3 4 inch pipe threads e 60 to 75 Ibf ft 81 to 102 N m for Eaton Fuller transmissions with 1 1 4 inch pipe threads e 44 Ibf ft 60 N m for all ZF Meritor FreedomLine automated transmissions e 35 to 50 Ibf ft 48 to 67 N m for all other Meritor transmissions Century Class Trucks Maintenance Manual April 2005 26 7 Frame and Frame Components 31 Index Alphabetical Title of Maintenance Operation MOP MOP Number FNA Wheel Mpe EESTI ii o Dr 31 01 Ent Wibieel bI STIR aran ranas OR eae 31 02 Frame Fastener Torque Check 2 0i 2cccviceeive vie G edocs eee a A A eS 31 03 Premier 690 Coupling INSpection s uid eredue hd Sa A AAA om 31 05 Trailer Electrical Connector Lubrication 0 0 0 0 ce eee 31 04 Century Class Trucks Maintenance Manual August 2011 Frame and Frame Components 31 01 Fifth Wheel Inspection All fifth wheel maintenance adjustment and re building must be done only by a qualified me chanic 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 Failu
120. haust system components See Fig 7 In particular the after treatment device ATD which is part of the after treatment system ATS requires special attention during regularly scheduled maintenance inspections If any discrepancies are discovered refer to the engine manufactur er s service literature for repair instructions Century Class Trucks Maintenance Manual August 2011 49 1 49 Exhaust 1 Flex Hose 2 V Band Coupling 3 Exhaust Pipe 4 Turbocharger Exhaust Outlet 06 01 93 f490024a Fig 2 V Band Coupling and Flex Hose 08 25 95 1490127 1 Exhaust Pipe 2 Exhaust Elbow Isolator 3 Mounting Nut Fig 3 Exhaust Elbow Isolator Definitions of ATS Components Refer to the following list of definitions of ATS com ponents e After Treatment System ATS the entire ex haust system from the turbocharger to the ex haust stack or tail pipe e After Treatment Device ATD a muffler like canister that houses a DPF DOC and sensors 05 28 93 f490025a Fig 4 Donaldson Sealclamp Wide Band Exhaust Clamp 10 05 94 f490005a Fig 5 Torca Torctite Wide Band Exhaust Clamp 09 30 99 f490214a Fig 6 Gemi Wide Band Exhaust Clamp 49 2 Century Class Trucks Maintenance Manual August 2011 Exhaust 49 10 20 2006 1490283 A Inspect this area of the canister for dents 1 Marmon Fitting at Inlet from Turbo
121. he 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 Fig 5 1 af 1831418 3 Seal Cover 4 Recirculation Filter 11 14 2000 1 HVAC Cover 2 Velcro Tape Fig 5 Cab Recirculation Air Filter Water Valve Controlled 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 Ah CAUTION If the recirculation air filter is not replaced every six months damage to the heater and air condi tioner 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
122. he 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 Fig 1 If the transmission has two fill openings add fluid to the level of both openings See Table 1 for approved trans mission lubricants See Table 2 for Eaton Fuller transmission lubricant capacities and Table 3 for Meritor transmission lubricant capacities S a AY A A A a A Y NQLLLILLLLLLELL ZA LALA De NSSNNNNNN UMMM IMI 05 27 93 A Full f260006a B Low Fig 1 Checking Transmission Fluid Level Century Class Trucks Maintenance Manual April 2005 26 1 26 Transmission Approved Manual Transmission Lubricants Eaton Fuller Transmission Lubricant Capacities Transmission x Temp SAE Refill Capacity Model Lubricant Type Range Viscosity Transmission Model qt L Eaton Fuller Transmissions All 15 Speed Series MobilTrans SHC 50 All Models 14 0 13 2 RN 2952 E 5 S All Eaton mem All 18 Speed Series Fuller ynthetic transmission lubricant approv
123. he top of the filter Install the filter spring 3 5 Clean the reservoir cover and O ring seal Inspect the O ring and the cover for cracks deformities or damage Replace the O ring seal or cover as needed 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 Fig 2 Remove the cover NOTE Always replace the power steering reservoir filter when changing the fluid Steering 1 6 2 5 07 09 98 nd eres 1461670 1 Fill Cap 4 Clamp 2 Filter Spring 5 Filter 3 Filter Top Plate 6 Reservoir Cover Fig 2 Power Steering Reservoir and Filter Argosy COE 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 steer ing 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 fl
124. he torque wrench clicks Remove the chocks Tighten in a diagonal pattern as shown in Fig 17 Table 1 Spring Assembly U Bolt High Nut Torque Values 4 1 03 10 2011 2 3 1320783 Spring Assembly U Bolt High Nut Torque Values Size Torque Ibf ft N m Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 180 to 230 245 to 313 5 8 18 Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 270 to 330 367 to 449 3 4 16 Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 420 to 500 571 to 680 7 8 14 Fig 17 Tightening Pattern for U Bolt High Nuts 32 10 Century Class Trucks Maintenance Manual November 2009 Front Axle 33 Index Alphabetical Title of Maintenance Operation MOP MOP Number AFA Alignment Checa dais a ea a AA e d de 33 04 Basic Inspection Meritor Unitized Wheel Ends 000000 ee 33 07 End Play Check Meritor Unitized Wheel Ends 00 0000 cc s 33 08 Kingpin E bricstion Detroit AXIGS s aliada deoa Sb di dd 33 09 Knuckle Pin Lubrication Dana Spicer Axles llli 33 05 Knuckle Pin Lubrication Meritor Axles o o o o o ooo r RR 33 01 ME ROA inspecto acct eee ede hes ard ines etra eed END A bh qquien s dd 33 02 Tie Rod Lubrication Dana Spicer Axles lilii 33 06 Tre Rod Lubrication Detroit AXES 20 0 ca a A a fee DSS GIS e
125. hol At regular engine service intervals open the drain cock to remove moisture from the alcohol evaporator Be fore reactivating the evaporator for the next freeze season drain disassemble inspect and steam clean the unit of any sludge that may have accumu lated 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 tet raseal Brakes 2 Remove the capscrews and reservoir from the cover 3 Remove the cover tetraseal 4 Drain the air tank and disconnect the line from the evaporator outlet Remove the check valve retainer spring and disc 5 Install the disc spring and check valve retainer and connect the line to the evaporator outlet 6 Install the cover tetraseal 7 Install the reservoir on the cover and tighten the capscrews 8 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 11 before lubri cating the camshaft bracket Pump grease into the camshaft bracket until it ap pears at the slack adjuster end of the bracket See Fig 4 05 28 93 f420011a A Grease Exit 1 Brake Chamber 2 Slack Adjuster 3 Non Pressure Relief Grease Fitting Fig 4 Camshaft Bracket Lubrication Use an NLGI Grade 1 or Grade
126. iator Pressure Flushing and Coolant Change 20 03 Fan Clutch Check noise emission control 25 01 Eaton Fuller Clutch Release Bearing Lubrication 25 02 Clutch Release Cross Shaft Lubrication 25 03 Sleeve Assembly Bronze Bushing Lubrication 25 04 Meritor Clutch Release Bearing Lubrication 26 01 Manual Transmission Fluid Change and Magnetic Plug Cleaning n synthetic lubricant 26 02 Allison Transmission Fluid and Filter Change 2 E 26 03 Manual Transmission Air Filter Regulator Check Cleaning or Replacement 26 04 Transmission Fluid Level Inspection 31 01 Fifth Wheel Inspection 31 02 Fifth Wheel Lubrication 31 03 Frame Fastener Torque Check 31 04 Trailer Electrical Connector Lubrication 31 05 Premier 690 Coupling Inspection 32 01 Suspension Inspection 32 02 Suspension Lubrication 32 03 Suspension U Bolt Torque Check 33 01 Knuckle Pin Lubrication Meritor Axles 33 02 Tie Rod Inspection 33 03 Tie Rod Lubrication Meritor Axles 33 04 All Axle Alignment Check 33 05 Knuckle Pin Lubrication Dana Spicer Axles 33 06 Tie Rod Lubrication Dana Spicer Axles 33 07 Basic Inspection Meritor Unitized Wheel Endst 00 16 Century Class Trucks Maintenance Manual August 2
127. ine yokes for cracks and check end yokes for looseness See Fig 3 Replace cracked yokes Fig 2 Meritor RPL Series U Joint 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 leak age 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 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 bear ings can be felt or seen replace the U joint as sembly 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 bear ing assembly if the rubber cushion is deteriorated or oil soaked
128. intenance Manual March 2011 Page Description For an example of a Century Class Trucks Maintenance Manual see Fig 1 Introduction A Y Frame and Fifth Wheel 31 01 Fifth Wheel Inspection WARNING All fifth wheel maintenance adjust ment and rebuilding must be done only by a quali fied mechanic Improper or incomplete procedures could result in a possible disengagement of the trailer from the tractor which could result in per sonal 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 instruc tions see the vehicle driver s manual 2 Thoroughly steam clean the fifth wheel Look for cracks in the fifth wheel assembly mounting brackets and mounting parts 4 Check the jaw and stationary jaw for mushroom ing and check that the serrations at the jaw and wedge are in good condition 5 Test the safety lock latch for free operation NOTE The safety lock latch is located at the front of the fifth wheel on the top plate 6 Visually check for loose nuts or bolts see Fig 1 on the fifth wheel and on 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 value Refer to Grou
129. ion 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 trans mission 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 trans mission 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 Ex amine 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 Fig 2 6 Remove the filters from the bottom of the control module 09 29 97 1 2 Filter Element 3 22 Z U f260317a 4 Square Cut Seal 5 Drain Plug Filter Cover Filter Element O Ring Fig 2 Allison Transmission Filter Location and Components Lubricate the new O rings with transmission fluid and install them on the cover assemblies Install a new square cut seal on each cover as
130. ithium 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 re quire no further lubrication 31 03 Frame Fastener Torque Check Frame brackets and components secured with Huck bolt fasteners do not require a torque check how ever they should be inspected for damage Frame brackets and components secured with conventional bolts and nuts are to be checked at initial mainte nance IM See Fig 13 for pre EPAO7 engine mounts Check the torque of frame fasteners to off set 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 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
131. itor Unitized Wheel Ends at 200 000 miles 321 870 km and then every 50 000 miles 80 470 km t Check the end play at 200 000 miles 321 870 km and then every 200 000 miles 321 870 km For Schedule Il vehicles with Detroit axles complete this procedure once a year or every 25 000 miles 40 000 km whichever comes first fT Replace the HVAC filters every 6 months regardless of mileage Table 15 Maintenance Operation Sets 00 18 Century Class Trucks Maintenance Manual August 2013 General Information 00 Noise Emission Controls Maintenance 00 10 Noise Emission Control the purpose of noise control prior to its sale or E delivery to the ultimate purchaser or while it is in Maintenance use 2 The use of the vehicle after such device or ele Federal Law Part 205 ment of design has been removed or rendered Transportation Equipment Noise o ay ay parson P P A mong those acts presumed to constitute tam Emission Controls pering are the acts listed below Part 205 Transportation Equipment Noise Emission A Removal of engine noise deadening panels Controls requires the vehicle manufacturer to fur nish with each new vehicle such written instructions B Removal of cab tunnel or hood noise for the proper maintenance use and repair of the deadening panels vehicle by the ultimate purchaser to provide reason able assurance of the elimination or minimization of noise emission control degradation throughout the life of the v
132. itted 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 L via ServicePro formats Workshop Service Manual Maintenance Manual Driver s Operator s Manual Service Bulletins Parts Technical Bulletins Web based repair service and AccessFreightliner com website ServicePro PartsPro EZWiring LC distributes the following major service publications in paper and electronic Workshop service manuals contain service and repair information for all vehicle systems and components except for major components such as engines trans missions and rear axles Each workshop service manual section is divided into subjects that can include general information principles of operation removal disassembly assembly installation and specifications Maintenance manuals contain routine maintenance procedures and intervals for vehicle components and systems They have information such as lubrication procedures and tables fluid replacement procedures fluid capacities specifica tions and procedures for adjustments and for checking the tightness of fasten ers Maint
133. l 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 Century Class Trucks Maintenance Manual September 2010 60 1 60 Cab 2 3 01 13 2003 E 1602109 1 Forward Bump Stop 3 Bolt 2 Flatwasher 4 Rear Bump Stop Fig 1 Cab Access Stairs Assembly 60 2 Century Class Trucks Maintenance Manual September 2010 Door 72 Index Alphabetical Title of Maintenance Operation MOP MOP Number Door Seal Door Latch Door Hinge and Door Check Lubricati0N oo o oooooooooooo 72 01 Century Class Trucks Maintenance Manual March 2010 Door 72 01 Door Seal Door Latch Door Hinge and Door Check Lubrication NOTE Light penetrating oils such as WD 40 should not be used because they wash out ben eficial factory installed grease and they evapo rate 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 assem blies then apply liberal amounts of an approved grease to each moving join
134. les for wear chafing kinks discolored insulation or loose clamps or ties Find the cause of any problems and repair re place and reroute wires and clamps as neces sary Check the alternator wiring for missing insulation kinks and heat damage Replace or repair as needed On the bundled cable that runs from the batteries to the starter ensure that tie straps are installed at least every 12 inches 800 mm Replace any missing tie straps and add tie straps where spacing between them exceeds 12 inches 300 mm Ensure that all cables have sufficient slack to allow for engine movement and that there is no pressure on any wiring connectors If any convoluted tubing is damaged check the wiring inside it Replace any damaged or missing convoluted tubing Clean the cable connector terminals with a wire brush See Group 54 of the Century Class Trucks Workshop Manual for troubleshooting in structions and for adjustment repair or replace ment instructions 9 1 Clean and tighten the battery ground cable terminal and clamps 9 2 Inspect the retainer assembly or battery hold downs and the battery box Replace worn or damaged parts Remove any cor rosion with a wire brush and wash with a weak solution of baking soda and water Rinse with clean water and dry To pre vent rusting paint the retainer assembly 9 3 Check for and remove any foreign objects such as stones bolts or nuts from the battery box 9 4 Af
135. ll reduce the gap avail able at the number two spring hanger See the previous note 6 Place a block of wood on the leaf spring See Fig 13 Place a pry bar on the block of wood and insert the end of the pry bar under the frame hanger Attempt to lift the frame hanger as shown in Fig 13 Also with an empty chassis and the brakes applied attempt to rock the chas Fig 13 Hendrickson RT2 and RTE2 Series Frame Bracket Inspection sis back and forth while observing the spring eye In either case if 1 8 inch or more of move ment is observed the bushing and pin should be replaced This also could indicate that a broken spring eye and spring are connected to the spring hanger through the wrapper eye of the Century Class Trucks Maintenance Manual November 2009 32 7 32 second leaf In this case the main leaf or the complete spring should be replaced immediately Neway Suspension Inspect the components and check their operation as described below Failure to perform these in spections 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 Re place any damaged components to prevent fail ure or equipment breakdown 3 Inspect all bo
136. lows Century Class Trucks Maintenance Manual September 2010 20 1 20 Engine Cooling R adiator 06 08 95 500244 1 Low Coolant Level Sensor 2 SAE Cap for coolant overflow pressure relief only 3 Fill Cap Fig 1 Surge Tank Century Class Conventional 2 7 2 Attach the flushing gun nozzle to the ra 3 diator at the lower radiator hose opening Run the water until the radiator is full NOTICE 1 i SO ar P When flushing the radiator do not apply more CAP than 15 psi 100 kPa air pressure Excessive pres sure can damage the radiator 7 3 Gradually apply air pressure to help dis No SS lodge sediment built up in the radiator 4 core Do not apply more than 15 psi 103 i kPa air pressure to the radiator Pres R oe sures exceeding 15 psi 103 kPa could 1 Radiator Charge Air Cooler Assembly damage the radiator core 2 Fill Cap 3 Surge Tank 7 4 Shut off the air at the pressure gun nozzle and allow the radiator to refill with Fig 2 Surge Tank Argosy COE water 7 1 Disconnect the radiator upper and lower 7 5 Repeat the previous two steps until clean hoses water flows from the radiator 7 6 Remove the radiator side tank drain plug and allow the radiator to drain 20 2 Century Class Trucks Maintenance Manual September 2010 Engine Cooling Radiator 20 lo S dus A 08 19 2009 NOTE The main radiator drain plug is not shown
137. lts 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 Fig 14 to the bottom of the frame 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 Suspension 32 02 Suspension Lubrication Front Suspension Wipe all dirt away from the grease fittings if equipped on the spring eye bushings Apply multi purpose 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 b
138. lubricant changing procedure Rear Axle AM 3 1 27 va x p 05 27 93 1350019a 1 Fill Plug 3 Forward Differential 2 Power Divider Carrier Fig 5 Power Divider Fill Plug 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 driv er s manual Meritor s experience shows that the fol lowing additives friction modifiers perform ad equately 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 e Elco No 2 Friction Modifier Elco Corpora tion e Lubrizol No 6178 Lubrizol Corporation Hi Tec E 336 Edwin Cooper Inc Equa Torque No 2411 Sta Lube Corpora tion e Equa Torque No 2414 Sta Lube Corpora tion 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 extreme pressure additives so the lubricant change schedule must be shortened when using these 35 4 Century Class Trucks Maintenance Manual August 2013 Rear Axle 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 rec ommended in
139. ly Loctite9 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 Ibf 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 re place 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 Fig 7 for grease exit points see Fig 8 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 Fig 9 Century Class Trucks Maintenance Manual January 2013 33 5 B 4 06 07 2012 1330272 A Upper View
140. mbers used to help tenance interval rta raci n M2 Maintenance Interval Operations for Service Schedules I Il and III Check 00 06 Perform All M1 Operations 01 01 Engine Noise Panel Inspection noise emission control 01 02 Engine Drive Belt Inspection 01 04 Engine Support Fasteners Check noise emission control 09 01 Air Cleaner Element Inspection and Replacement 15 01 Alternator Battery and Starter Check 20 01 Pressure Relief Cap Check 25 02 Clutch Release Cross Shaft Lubrication 25 03 Sleeve Assembly Bronze Bushing Lubrication 25 04 Meritor Clutch Release Bearing Lubrication 26 02 Allison Transmission Fluid and Filter Change 26 03 Manual Transmission Air Filter Regulator Check Cleaning or Replacement 26 04 Transmission Fluid Level Inspection 32 01 Suspension Inspection 32 03 Suspension U Bolt Torque Check 33 01 Knuckle Pin Lubrication Meritor Axles 33 02 Tie Rod Inspection 33 03 Tie Rod Lubrication Meritor Axles 33 07 Basic Inspection Meritor Unitized Wheel Ends 33 08 End Play Check Meritor Unitized Wheel Endst 33 09 Kingpin Lubrication Detroit Axlest 33 10 Tie Rod Lubrication Detroit Axlest 35 02 Axle Breather and Axle Lubricant Level Inspection 40 01 Wheel Nut and Rim Nut Check 42 01 Air Brake System Valve Inspection 42 03 Air Dryer Inspection 42 04 Alcohol Evaporator Cleaning and Inspection 42 08 Meritor Slack Adjuster Lubrication 46 01 Drag Link Inspection 46 03 Power Steering Fluid Level
141. missing See Fig 5 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 assis tance in determining the correct driveshaft length 41 2 Century Class Trucks Maintenance Manual July 1999 Driveline za HL MY 05 27 93 Y f410012a Attempt to move the sleeve yoke and splined shaft back and forth Fig 4 Slip Joint Spline Wear Checking 10 20 93 f410050a A After grease appears cover the pressure relief hole while continuing to lubricate Slip Joint Grease Fitting with grease gun attached Yoke Plug Grease Half Round Yoke Yoke Plug Pressure Relief Hole Slip Joint Seal Full Round Yoke U Joint Grease Fitting co Ov GaN Fig 5 Slip Joint and U Joint Lubrication 41 41 02 Driveline Lubrication Universal Joint Lubrication NOTE Vehicles equipped with Meritor RPL Se ries drivelines do not require periodic lubrication 1 Park the vehicle on a flat surface apply the park ing brakes and chock the tires 2 Wipe all old grease and dirt from each U joint grease fitting See Fig 5 Ref 8 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
142. movement 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 Check the wheel to hub mounting Make sure the wheel and tire assembly is mounted correctly and that all the hardware is secure 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 park ing brakes shut down the engine and chock the rear tires Front Axle 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 t
143. n and for cracks or wear on the jaw locking mechanism 6 Check the depth of the grease grooves If the depth of the grooves is 1 8 inch or less replace the fifth wheel top plate Refer to Group 31 in the vehicle workshop manual 7 Check the condition of the X pattern cast into the underside of the fifth wheel top plate See Fig 2 The fifth wheel top plate must be removed to check the X pattern 8 Remove the roll pins from the bushing pins Remove the bushing pins from the slide mount Use a hoist and lift the fifth wheel top plate off of the vehicle 9 Turn the fifth wheel top plate over with the locks open Check the condition of the X pattern in the pockets If the X pattern is worn away replace the fifth wheel top plate 10 Inspect for fatigue or cracked welds 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 31 1 D 11 20 95 A B Group Title C Group Number D Release Date E Group Number Page Number Maintenance Operation Number consists of the Group Number followed by the Sequence Number 1020044 Fig 1 Example of a Century Class Trucks Maintenance Manual Page Century Class Trucks Maintenance Manual March 2011 Introduction Maintenance Manual Contents Group No Group Title ao ME e e oe General Information Dl ae cC ica Engine A te ans fea a e Pod d Air Intake jc M LP eee
144. n using a soft cloth 4 Lubricate the gasket with a film of oil and rein stall 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 bot tom 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 47 08 25 95 aSOND ORON 1470146 Vacuum Breaker Drain Valve Reducer Bushing Mounting Brackets O Ring when equipped with heater Stainless Steel V Clamp when equipped with heater Heater Assembly Gasket Sight Bowl Heater Rod Sight Bowl Assembly Vacuum Breaker Drain Valve Fig 1 ConMet Fuel Separator Century Class Trucks Maintenance Manual April 2005 47A 47 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 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
145. nance Interval EEE ate Miles km 20 M1 and M2 500 000 805 000 21 M1 525 000 845 000 22 M1 550 000 885 000 23 M1 575 000 925 000 24 M1 M2 and M3 600 000 966 000 25 M1 625 000 1 005 800 26 M1 650 000 1 046 000 27 M1 675 000 1 086 000 28 M1 and M2 700 000 1 127 000 29 M1 725 000 1 167 000 30 M1 750 000 1 207 000 31 M1 775 000 1 248 000 32 M1 and M2 800 000 1 287 000 33 M1 825 000 1 328 000 34 M1 850 000 1 368 000 35 M1 875 000 1 408 000 36 M1 M2 and M3 900 000 1 448 000 37 M1 925 000 1 490 000 38 M1 950 000 1 529 000 39 M1 975 000 1 569 000 40 M1 and M2 1 000 000 1 609 000 Table 7 20th through 40th Maintenance for Service Schedules Ill and IV Century Class Trucks Maintenance Manual August 2013 00 7 00 General Information Lubrication and Fluid Level Check 00 04 Maintenance Operation 00 04 Lubrication and Fluid Maintenance operation numbers given in the table Level Check Operation Table 8 summarizes all op are reference numbers used to help you find detailed erations that must be performed to complete the Lu instructions in the manual on the lubrication or fluid brication and Fluid Level Check operation 00 04 check called for as an M1 maintenance interval for Service Schedule Il and III vehicles and as an M2 mainte nance interval for Service Schedule IV vehicles Maintenance Operation 00 04 Lubrication and Fl
146. ng 4 Lubricant should be level with the bottom of the fill hole see Fig 2 or with the top of the stand pipe opening If low check the axle for oil leaks and correct as needed Add lubricant as re quired See Table 3 for recommended drive axle lubricants Century Class Trucks Maintenance Manual August 2013 35 7 35 IMPORTANT Axle housing breathers see Fig 8 must remain clean and unclogged Al ways check the axle breather whenever check ing 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 re place it as needed 5 Install and tighten the fill plug 40 to 60 Ibf 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 lubri cant 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 06 07 94 1 Axle Housing Breather 2 Fill Plug f350002a 3 Temperature Indicator Plug Fig 8 Dana Spicer Axle Housing Breather 1 Park the vehicle on level ground apply the park ing brakes and chock the tires Rear Axle 2 Clean the fill plug and the area surrounding the fill plug on the side of the axle c
147. ng is sealed and does not require lubrication If the vehicle is Clutch equipped with an optional clutch release bearing with a grease fitting lubricate the bearing as follows 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Remove the clutch inspection plate NOTE Some clutch release bearings are equipped with a lubrication extension that ex tends 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 high temperature grease that meets the NLGI grade three specification 3 Wipe any dirt away from the grease fitting See Fig 1 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 in ternally causing clutch slippage and premature 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 Fig 2 Install the clutch inspection plate 6 Remove the chocks 25 2 Century Class Trucks Maintenance Manual April 2005 Transmission 26 Index Alphabetical Title of M
148. ngine noise panels dl 11 29 95 1011040 1 Oil Pan Noise Panel C10 engine only 2 Left Side Noise Panel 3406 engine only Fig 1 Caterpillar Engine Noise Panels 01 02 Engine Drive Belt Inspection Worn or loose drive belts may cause premature bearing failure or engine overheating Excessive ten sion or too little tension on the belt may result in ex cessive 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 in spect a belt gently twist the belt to view the belt sidewalls and bottom Inspect all drive belts for the 01 following conditions then perform the Belt Tension Inspection Visual Inspection 1 Inspect the belt for glazing See Fig 2 Ref A 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 Fig 2 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
149. o the surface of the hub 8 Set the dial indicator to zero 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 rota tions tighten the inner locknut 600 Ibf ft 813 N m 14 Install the tabbed washer and the outer locknut 2 Remove the hub cap Tighten 250 Ibf ft 339 N m 3 Raise the vehicle until the front tires are clear of 15 Repeat the procedure for checking the end play the ground Support the vehicle with safety 16 If the end play is greater than 0 003 inch 0 08 stands 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 2013 Front Axle For instructions see Group 33 of the Century Class Trucks Workshop Manual 17 Check the rotation of the hub If it doesn t rota
150. of the number one spring hanger draw key design for wear or elongation Wear at this point requires hanger replacement or premature fracture of the spring hanger pin may occur with possible separation of components and loss of vehicle control This could result in serious personal injury or property damage 32 6 Century Class Trucks Maintenance Manual November 2009 Suspension 32 1 i 4 SY A EZ ES ON SY SY 05 27 93 1320112a 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 09 15 95 f 1320421 1 Rust Inspection Area Y Fig 11 Hendrickson RS Series Rust Inspection E 4 Inspect the cam surface of the number two 4 spring hanger for wear due to operating mileage Also inspect the outside legs for wear which can be caused by worn spring eye bushings F NOTE RTE2 extended leaf spring suspen sions require a minimum gap of 3 8 inch 9 5 4 mm between the cam surface of the number Jj l2 ae two spring hanger and the top of the main leaf wee L in the unloaded condition See Fig 12 If this j gap is less than 3 8 inch 9 5 mm the 2 E din of the dir will not per dois 5 30423 i ea E ee 1 Frame Bracket 3 Wood Block 5 Inspect the cam surface on the number three 2 Leaf Spring 4 Pry Bar spring hanger extended leaf springs only for wear Excessive wear wi
151. onents could occur IMPORTANT When replacing the air filter use only a Freightliner approved air filter 1 Park the vehicle on a level surface Apply the parking brakes and chock the rear tires 2 Lift the wire retainer on the air filter cover up and over the upper edge of the cover and pull the wire retainer down See Fig 4 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 Dis card 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 83 2 Century Class Trucks Maintenance Manual April 2003 Heater and Air Conditioner 83 02 26 2002 d il e 1831493 1 Air Filter Cover 2 Wire Retainer Fig 4 HVAC Air Intake Plenum Blend Air 8 Remove the chocks from the tires Cab Recirculation Air Filter Replacement Water Valve Controlled The cab recirculation air filter must be replaced every six months regardless of mileage to permit proper operation of the HVAC system CAUTION If the recirculation air filter is not replaced every six months damage to the heater and air condi tioner components could occur T
152. oop of the hinge bracket There is no dimple in the top or bot tom loop of the hinge bracket See Ref B of Fig 1 Lubricate this type of hinge every six months Wipe old grease and dirt from the hinge then force an ap proved grease into the hinge components see Table 1 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 Table 1 Use an appropriate applicator that will not leave material behind Century Class Trucks Maintenance Manual March 2010 72 1 72 Door 1720613 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 72 2 Century Class Trucks Maintenance Manual March 2010 Heater and Air Conditioner Title of Maintenance Operation MOP Air Conditioner Inspection 00000 eee eee Air Filter Replacement aces o d pei ACRES das 83 Index Alphabetical MOP Number Century Class Trucks Maintenance Manual April 2003 Heater and Air Conditioner 83 01 Air Conditioner Inspection Wear eye protection gloves and prot
153. oosened or removed it must be replaced 4 f 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 Ibf ft 41 N m if needed Do not overtighten Century Class Trucks Maintenance Manual August 2011 49 3 49 Exhaust EIU zz TEE E TE F I Al D E x gem lt A A 2 34 5 6 5 3 8 9 3 10 1 02 24 2011 f490456 1 Clamp 5 Slip Clamp 8 Center Pipe 2 Inlet Pipe 6 CGI Bellows 9 Clamp 3 U Clamp 7 Center Pipe Support Brace 10 Outlet Pipe 4 Forward Pipe Support Brace Fig 8 CAT EPAO07 Exhaust Installation with CGI Bellows 6 Check for leaks around the clamps that attach the ATD in the ATS and around the clamps that retain the DPF in the ATD No leaks are allowed anywhere in the system 7 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 Fig 7 A dent over 3 inches 76 mm in diameter and 1 4 inch 6 mm deep could cause internal damage to the DPF causing it to malfunction 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 exhau
154. or adequate clamping See Fig 2 Replace the components if this cannot be done For in 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 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 Century Class Trucks Maintenance Manual January 2013 33 1 33 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
155. or damaged com ponents Improperly maintaining the vehicle brak ing 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 applica tion 3 Check to see if the colored over stroke band on each brake chamber pushrod is exposed 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 proce dures 4 Measure the applied chamber stroke See Table 1 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 auto matic slack adjuster See Group 42 of the Century Class Trucks Workshop Manual for in spection 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 Re pair as needed See Group 42 of the Century Class Trucks Workshop Manual for repair proce dures 42 8 Century Class Trucks Maintenance Manual April 2005 Brake
156. or intense heat Exposure to open flame or intense heat could start a fire pos sibly resulting in personal injury or property dam age 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 connec tions if equipped 3 Remove the element and bowl together by turn ing 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 connec tors 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 Fig 2 8 2 Close the vent plug 9 Start the engine and check for fuel leaks 10 Shut down the engine and correct any fuel leaks Fuel 2 1 3 4 d 5 PS 9 eee 6 7 8 06 25 97 1470147 1 Beige Mounting Head 7 Water Sensor Probe 2 Fuel Primer Pump 8 Heater Connector 3 Metal Vent Plug 9 Bowl Drain Valve 4 Bowl O Ring Assembly 5 Bowl Bevel Cut 10 Bowl with Drain and Gasket Water Sensor 6 Bowl Probe Plug 11 Service Element Fig 2 Racor 490 Fuel Separator Racor 690 WARNING Diesel fuel i
157. ous 33 10 Tie Rod Lubrication Meritor Axles aes 33 03 Century Class Trucks Maintenance Manual January 2013 Front Axle 33 01 Knuckle Pin Lubrication Meritor Axles CAUTION Use regulated pressure when lubricating the knuckle assemblies otherwise damage could re sult 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 12 hydroxy 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 pres sure without damage and is designed to have grease pumped out through it during lubrication Even if grease leaks out around the top or bottom plate gasket continue pumping until new grease is seen at the bushing seal opposite the grease fitting See Fig 1 09 06 96 1 A Grease Exit 1 Grease Fitting f320032a Fig 1 Meritor Knuckle Pin Lubrication 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 33 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 f
158. p 2 Retaining Ring 5 CGI Bellows 3 Graphite Gasket 02 23 2011 1490457 A Measure the pipe gap 1 CGI Aft Pipe 2 CGl Forward Pipe Fig 10 Aft Facing Slip Clamp Installation 12 Slide the new bellows onto the aft CGI pipe as far as it will go See Fig 11 Ref A Measure ment A should be at least 7 16 inch 10 mm past the face of the flange Fig 9 Measuring the Pipe Gap typical ic LT a J 02 23 2011 1490458 A At least 7 16 inch 10 mm 1 Forward CGI Pipe 3 Aft CGI Pipe 2 CGI Bellows Fig 11 CGI Bellows Installation Century Class Trucks Maintenance Manual August 2011 49 5 49 13 Install the slip clamp with the retaining ring and graphite gasket ring onto the forward CGI pipe See Fig 12 for proper installation 3 Ay M A fE 02 08 2010 1490417 1 2 CGI Bellows 4 Graphite Gasket Slip Clamp 5 Forward CGI Pipe Retaining Ring 14 15 16 17 18 Fig 12 Forward Facing Slip Clamp Installation Slide the end of the forward CGI pipe into the bellows and properly align the pipe Secure the forward CGI pipe to the engine and any CGI pipe support brackets Using the yellow marks center the bellows be tween the exhaust pipes Verif
159. p 00 in this manual for bolt torque specifications 7 Visually check all springs to see if they are securely fastened and not deformed WARNING Do not disassemble the fifth wheel to inspect the springs The springs are under extreme pressure and could cause serious injury 8 Check wedge adjustment 8 1 Open the kingpin lock and vertically insert a two inch diameter shaft 8 2 Release the lock by tripping the release latch at the bottom of the throat Century Class Trucks Maintenance Manual January 1996 A 31 83 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 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 mov ing 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 HOLLAND 1 Disconnect the tractor from the trailer For instructions see the vehicle drivers manual Thoroughly steam clean the fifth wheel Check for loose nuts or broken bolts on the fifth wheel assembly Inspect for cracks or wear on the mounting bolts Visually inspect for improper locking actio
160. perations for Service Schedules I II and Ill o Rr ea ei M1 Maintenance Interval Operations for Service Schedule IV Check 20 03 Fan Clutch Check noise emission control 31 01 Fifth Wheel Inspection 31 02 Fifth Wheel Lubrication 31 04 Trailer Electrical Connector Lubrication 42 07 Meritor Camshaft Bracket Lubrication 42 11 Brake Inspection 49 01 Exhaust System Inspection noise emission control 60 02 Cab Tilt Pump Reservoir Fluid Level and System Check 00 10 Century Class Trucks Maintenance Manual August 2013 General Information 00 M1 Maintenance Interval Operations 00 06 Maintenance Operation Number M1 Maintenance Interval Operations for Service Schedule IV Check 72 01 Door Seal Door Latch and Door Hinge Lubrication 88 01 Hood Rear Support Lubrication Table 11 M1 Maintenance Interval Operations for Service Schedule IV Century Class Trucks Maintenance Manual August 2013 00 11 00 General Information M2 Maintenance Interval Operations 00 07 The M2 Maintenance Interval Operations tables list you find detailed instructions in this manual on the all maintenance operations that are to be performed maintenance operations to be performed Perform all at the M2 maintenance interval Maintenance opera M1 maintenance interval operations at the M2 main tion numbers are reference nu
161. place any bent or misaligned lever bar or re lease handle 6 Check all cotter pins for cracking or damage Re place any cotter pin that shows any signs of damage Century Class Trucks Maintenance Manual August 2011 31 1 31 Frame and Frame Components 12 02 2010 1311134 NOTE 6000 Series shown 7000 Series fifth wheels use similar parts Wedge Stop Rod Nut 11 Bolt Secondary Safety Lock 19 Bumper 2 Flat Washer 5 8 12 Flat Washer 20 Timer Spring 3 Wedge Stop Rod Spring 13 Secondary Safety Lock 21 Timer 4 Wedge Stop Rod 14 Bushing Secondary Safety 22 Operating Handle 5 Grease Fitting Lock 23 Bolt Operating Handle 6 Bracket Pin 15 Hex Locknut 24 Bushing Operating Handle 7 Bracket Retainer Pin 16 Pull Handle 25 Hair Pin Cotter 8 Cotter Pin 3 16 x 1 17 Bolt Bumper 26 Wedge 9 Bumper Spring 18 Bushing 27 Step Jaw 10 Handle Spring Fig 1 Fontaine Fifth Wheel 31 2 Century Class Trucks Maintenance Manual August 2011 Frame and Frame Components 10 29 2007 f311052 1 Lubricant Grooves 2 Safety Latch 3 Release Handle 4 Mount Fig 2 Holland FWS1 Fifth Wheel x Xx TREE 03 28 2013 311140 1 Release Handle 2 Lever Bar Fig 3 Lever Bar and Release Handle Alignment 7 Check all mounting bolts for signs of fatigue and tighten them to the proper torque For torque specifications see Group 00 Inspect
162. quare millimeters mm 0 00155 square inches in square inches in 6 452 square centimeters cm 0 155 square inches in square feet ft 0 0929 square meters m 10 764 square feet ft Volume cubic inches in3 16387 0 cubic millimeter mm3 0 000061 cubic inches in3 cubic inches in3 16 387 cubic centimeters cm3 0 06102 cubic inches in3 cubic inches in3 0 01639 liters L 61 024 cubic inches in3 fluid ounces fl oz 29 54 milliliters mL 0 03381 fluid ounces fl oz pints pt 0 47318 liters L 2 1134 pints pt quarts qt 0 94635 liters L 1 0567 quarts qt gallons gal 3 7854 liters L 0 2642 gallons gal cubic feet ft3 28 317 liters L 0 03531 cubic feet ft3 cubic feet ft3 0 02832 cubic meters m3 35 315 cubic feet ft3 Weight Force ounces av oz 28 35 grams g 0 03527 ounces av oz pounds av Ib 0 454 kilograms kg 2 205 pounds av Ib U S tons t 907 18 kilograms kg 0 001102 U S tons t U S tons t 0 90718 metric tons t 1 1023 U S tons t Torque Work Force inch pounds lbf in 11 298 Newton centimeters N cm 0 08851 inch pounds lbf in foot pounds Ibf ft 1 3558 Newton meters N m 0 7376 foot pounds Ibf ft Pressure Vacuum inches of mercury inHg 3 37685 kilo Pascals kPa 0 29613 inches of mercury inHg pounds per square inch psi 6 895 kilo Pascals kPa 0 14503 pounds per square inch psi Table 16 Metric U S Customary Conversion Then Wh
163. r 2012 46 Steering 05 31 2007 1462071 A Align the pointers 1 Input Shaft Seal 2 Input Shaft Housing Cover Fig 13 Rack and Pinion Pointer Alignment 20 3 Place a wrench on the driver side inner tie rod flat and align the left tire by rotat ing the inner tie rod 20 4 Tighten the tie rod jam nut 285 to 305 Ibf 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 Ibf ft 41 to 49 Nm 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 4 inch 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 Ibf 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 Adjus
164. r cleaner or air cleaner element is damaged replace it and reset the air restriction indicator Method 2 Replace the air cleaner element at the recommended interval or when the air restriction indicator reaches 20 inH5O on a vehicle with a Detroit Diesel engine 22 inH4 O on a vehicle with an MBE engine or 25 inH O on a vehicle with a Caterpillar or Cummins engine For replacement instructions see Group 09 of the Century Class Trucks Workshop Manual Reset the air restriction indicator If the maximum restriction is not reached inspect the air cleaner and air cleaner element for cracks leaks or any other damage If the air cleaner or air cleaner element is damaged replace it and reset the air re striction indicator 09 Century Class Trucks Maintenance Manual February 2004 09 1 Alternators and Starters 15 Index Alphabetical Title of Maintenance Operation MOP MOP Number Alternator Battery and Starter Connections Check oooc ooocoooocr ee 15 01 Century Class Trucks Maintenance Manual November 2008 Alternators and Starters 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 work ing around batteries Put out all flames and re move any source of sparks or intense heat Make sure the battery compartment is completely vented before disconnecting or connecting the battery cables
165. re to do so can result in personal injury due to parts ejecting with force Fontaine 1 Disconnect the tractor from the trailer For in structions see the Century Class Driver s Manual Thoroughly steam clean the fifth wheel 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 Fig 1 5 For fifth wheels equipped with bracket liners rock the fifth wheel If it does not rock freely re move the top plate and inspect the bracket lin ers 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 mushroom ing 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 speci fication Do not loosen the bolt to check the torque See Group 00 for bolt torque specifica tions 9 Check all springs to see if they are securely fas tened and are not deformed 31 Do not disassemble the fifth wheel to inspect the springs The springs are under extreme pressure and could cause seriou
166. ridge on the end cover Turn the cartridge clockwise until the desiccant cartridge makes contact with the 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 Ibf ft 68 N m 15 Place the housing over the desiccant cartridge and align the mounting holes with the end cover 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 Torque the capscrews in a star pat tern see Fig 2 270 to 385 Ibf in 3060 to 4340 N cm 17 Install the air dryer on the lower mounting bracket Install the two previously marked cap screws four washers and two new Nylok nuts Torque the two remaining capscrews 270 to 385 Century Class Trucks Maintenance Manual April 2005 42 1 42 Brakes 08 09 95 1 5 16 x 4 1 2 Upper Mounting Bracket Capscrew Upper Mounting Bracket Strap 5 16 Lockwasher 5 16 Nylok Nut Upper Mounting Bracket Housing Nylok Nut 3 8 Special Washer ONO oP MO 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 18 19 20 21 22 23 24 25 A
167. rom 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 oper ating level is within the HOT RUN band on the dipstick The HOT RUN band is between the HOT FULL and HOT ADD marks If the fluid level is not within the HOT RUN band add or drain fluid as needed to bring the fluid level within the HOT RUN band See Fig 5 Eaton Fuller and Meritor CAUTION Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage Do not overfill the transmis sion 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 addi tives 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 26 6 Century Class Trucks Maintenance Manual April 2005 Transmission 26 2 Using your finger or a bent pipe cleaner see if the fluid is level with the fill opening See Fig 1 3 If the fluid level is low check the transmission for leaks and correct as needed 4 f needed add the recommended fluid until it is level wit
168. ross Shaft Lubrication The clutch release cross shaft is equipped with two grease fittings in the transmission clutch housing 25 05 27 93 f250081a Fig 1 Release Bearing Grease Fitting b ES 08 10 2009 1 Sleeve Bushing Contact Point 2 Yoke Finger Contact Points 1250444 Fig 2 Grease the Contact Points See Fig 3 and Fig 4 Wipe any dirt from the grease fittings then lubricate with multipurpose chassis grease 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 Century Class Trucks Maintenance Manual April 2005 25 1 25 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 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 De press the clutch pedal a couple of times before start ing the engine 25 04 Meritor Clutch Release Bearing Lubrication The standard clutch release beari
169. s 40 000 km whichever comes first Table 8 Maintenance Operation 00 04 Lubrication and Fluid Level Check for Service Schedules I Il Ill and IV 00 8 Century Class Trucks Maintenance Manual August 2013 General Information 00 Initial Maintenance IM Operations 00 05 The Initial Maintenance table lists all maintenance tenance operations to be performed All operations operations that are to be performed at the initial listed in the table along with the operations listed in maintenance IM interval Maintenance operation the applicable M1 maintenance interval table must numbers are reference numbers used to help you be performed to complete the initial maintenance find detailed instructions in this manual on the main IM Maintenance m Operation Number Initial Maintenance IM Operations for Service Schedules Il IIl and IV Check 00 06 Perform all M1 Operations 31 03 Frame Fastener Torque Check 31 05 Premier 690 Coupling Inspection 32 03 Suspension U Bolt Torque Check 33 04 All Axle Alignment Check 40 01 Wheel Nut and Rim Nut Check 47 03 Fuel Tank Band Nut Tightening Table 9 Initial Maintenance IM Operations for Service Schedules l Il IIl and IV Century Class Trucks Maintenance Manual August 2013 00 9 00 General Information M1 Maintenance Interval Operations 00 06 The M1 Maintenance Interval Operations tables list all maintenance operations that are to b
170. s see Fig 3 Refs 1 and 6 10 05 94 1220047a and replace them if they are worn this applies 1 Lower Isolator 4 3 4 10 Hexnut to both the front and rear isolators See Group 2 Engine Support 9 Engine Mount 01 of the Century Class Trucks Workshop Washer 6 Upper Isolator Manual for procedures 3 3 4 10 Capscrew Fig 3 Rear Engine Mount Isolators and Fasteners Century Class Trucks Maintenance Manual January 2007 01 3 Air Intake 09 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Cleaner Element Inspection and Replacement ooooccccccoo eee 09 01 Century Class Trucks Maintenance Manual February 2004 Air Intake 09 01 Air Cleaner Element Inspection and Replacement Method 1 Replace the air cleaner element at the recommended interval or when the air restriction indicator reaches 20 inH5O on a vehicle with a Detroit Diesel engine 22 inH4 O on a vehicle with an MBE engine or 25 inH5O on a vehicle with a Caterpillar or Cummins engine For replacement instructions see Group 09 of the Century Class Trucks Workshop Manual Reset the air restriction indicator If the maximum restriction is not reached record the air restriction value If the value is higher than the previous recording reset the air restriction indicator If the value is lower than the previous recording in spect the air cleaner and air cleaner element of cracks leaks or any other damage If the ai
171. s 42 Brake Chamber Stroke Specifications Chamber Max Applied Stroke inch mm Manufacturer Type Sizet 9 1 3 8 35 12 16 Standard Stroke 20 1 3 4 44 24 30 2 51 16 20 2 51 24 2 1 2 inch rated Long Stroke stroke 24 3 inch rated stroke 2 1 2 64 30 12 1 3 8 35 16 Standard Stroke 20 1 3 4 44 24 Haldex 2 1 2 Inch Extended Stroke 24 2 51 3 Inch Extended Stroke 24 2 1 2 64 Standard Stroke 30 2 51 Long Stroke 30 2 1 2 64 9 Less than 1 1 2 38 12 Standard Stroke 16 Less than 1 3 4 44 Meritor 20 24 Less than 1 7 8 48 Long Stroke 24 Less than 2 51 Standard Stroke 30 Century Class Trucks Maintenance Manual April 2005 42 9 42 Brakes Brake Chamber Stroke Specifications Chamber r Max Applied Stroke inch mm Manufacturer Type Sizet 16L 20L 2 51 Dana Spicer Long Stroke 24L 24LS 2 1 2 64 30LS Long stroke design is indicated by a tag or embossing on the brake chamber t Specifications are relative to a brake application with 80 to 90 psi 550 to 620 kPa air pressure in the brake chambers t If type 36 chamber is used slack length should be less than 6 inches Table 1 Brake Chamber Stroke Specifications 42 10 Century Class Trucks Maintenance Manual April 2005 Steering 46 Index Alphabetical Title of Maintenance Operation MOP MOP Number Bellows Replacement Rack and Pinion Steering Gear
172. s 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 pos sibly resulting in personal injury or property dam age 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 connec tions if equipped 3 Remove the element and bowl together by turn ing counterclockwise 47 2 Century Class Trucks Maintenance Manual April 2005 Fuel 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 connec tors 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 Fig 3 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 47 Hold each fuel tank band r
173. s injury 10 Check wedge adjustment 10 1 Open the kingpin lock and vertically in sert 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 mov ing 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 instruc tions Holland FWS1 1 Disconnect the tractor from the trailer For in structions see the Century Class Driver s Manual 2 Thoroughly steam clean the fifth wheel 3 Check the fifth wheel plate for cracks Check for sharp edges on top the chamfer should be 1 8 to 1 4 inch 3 to 6 mm 4 When the wheel is locked the safety latch must swing free and fall freely into position See Fig 5 The lever bar and release handle must be in proper alignment See Fig 3 Compare the lever bar and release handle alignment to a new or a properly operating lever bar and release handle Re
174. sembly and install the fluid filter elements on the cover assemblies Install the filter and cover assemblies into the filter compartment Century Class Trucks Maintenance Manual April 2005 26 3 26 10 Align each cover assembly with the holes in the channel plate sump and push the cover assem blies in by hand to seat the seals CAUTION 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 Ibf 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 trans mission fluid and check the fluid level See Table 4 for transmission lubricant capacities and Table 5 for approved transmission lubricants Allison Transmission Lubricant Capacities Transmission 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 Drain the air supply if the air supply is not drained before the air filter regulator is serviced serious injury and component damage could re sult 2 Clean the outside of the air filter regulator with cleaning solvent See Fig 3 Refill Capacity qt L 36 34 f 26 25 t Transmission Model HD4060 4560 standard sump
175. sion 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 Fig 2 for 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 Fig 2 If leakage exists tighten the nut on the V band coupling 10 Ibf ft 14 N m If leakage persists install a new V band coupling 4 Inspect the turbo outlet pipe and replace it as needed 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 Fig 3 for cracking dam age and dry rot Replace as needed 7 Check for leakage at all wide band exhaust clamps See Fig 4 Fig 5 or Fig 6 If leakage exists tighten the nuts 40 to 60 Ibf ft 54 to 81 N m If leakage persists install a new wide band exhaust clamp Do not re use Sealclamps 49 3 z D 3 q 2 2 E 01 06 99 1490170 1 Exhaust Clamp 2 Lower Heat Shield Fastener 3 Upper Heat Shield Fastener Fig 1 Vertical Exhaust Stack and Heat Shield EPAO7 Exhaust System Inspecting IMPORTANT The Environmental Protection Agency s 2007 regulations require lower ex haust emissions thus requiring new ex
176. sis 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 32 2 Century Class Trucks Maintenance Manual November 2009 32 Suspension bracket apply hand pressure only See Fig 4 If movement at the center of the equalizer exceeds 1 8 inch 3 mm replace the equalizer bushings See Group 32 of the Century Class Trucks Workshop Manual for instructions E 2 05 27 93 A Measure the change in gap at this point 1 Equalizer Bracket 3 Pry Bar 2 Equalizer f320022a Fig 4 Side View of the Equalizer 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 Fig 5 If clearance between the equal izer assembly and any frame component or fas tener is less than 1 8 inch 3 mm replace the equalizer bushings See Group 32 of the Century Class Trucks Workshop Manual for instructions Freightliner AirLiner Suspension Do not replace individual leaves of a damaged leaf spring assembly replace the complete spring as sembly Visible damage cracks or breaks to one leaf causes hidden damage to other leaves Re placement 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 r
177. st system for heat damage Repair or reroute as needed 49 02 CAT CGI Bellows Replacement On vehicles with CAT EPAO7 compliant engines re place the CGI bellows at the M3 maintenance inter val to prevent a later failure NOTICE 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 Park the vehicle set the parking brake chock the wheels 2 Open the hood 3 Remove the right side inner fender splash shield as needed 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 Attach the aft CGI pipe to the ATD 6 2 Attach the forward CGI pipe to the en gine 49 4 Century Class Trucks Maintenance Manual August 2011 Exhaust NOTICE When the CGI pipes and bellows are installed there should be approximately 3 4 inch 19 mm clearance from the main bellows Contact between the bellows could result in an exhaust leak which in this case may allow ingestion of contaminants into the engine causing engine damage 6 3 Use a straightedge to align the pipes so that
178. stem e 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 un load in a normal fashion Check for air sys tem leaks The air dryer has been installed on a sys tem 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 fluctu ates 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 con 42 sidered an indication of poor air dryer per formance 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 Turn on the ignition switch but don t start the engine Disconnect the harness connector from the air dryer Connect a voltmeter to circuit 94 on the air dry er 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 Connect a voltmeter
179. stem at the surge tank 12 5 Shut off the engine then check the cool ant 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 non aerated 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 cool ant to the high level mark 20 03 Fan Clutch Check Noise 12 2 Install the surge tank cap Emission Control 12 3 Return the hood or cab to the operating position See Group 60 of the Century Horton Advantage Fan Clutch Class Trucks Workshop M If b S NIRE Mio cM AE NOTE If any part of the fan clutch needs to be repaired or replaced after performing the 12 4 Start the engine and turn on the cab checks below see Group 20 of the Century heater Allow the engine to warm up to Class Trucks Workshop Manual normal operating temperature Check the radiator and hoses for leaks Repair if 1 Disconnect the electrical cables from the battery necessary
180. stick 7 Reservoir Filter Flanged Nut 8 Threaded Shaft Rubber Washer 9 Power Steering Reservoir Cover Reservoir Filter Spring o OIN Fig 1 Power Steering Reservoir and Filter Century Class Conventional Century Class Trucks Maintenance Manual September 2012 46 1 46 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 lt 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 steer ing 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 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 gear to reservoir hose to the reservoir Re move the jack stands and lower the ve hicle 3 4 With the larger opening at the top install a new filter in the reservoir Install the fil ter top plate so its center fits into the opening at t
181. t see Table 1 Use an appropriate applicator that will not leave material behind Approved Grease jar NLGI Application Lubricant Grade Door Latches ConocoPhillips Triton 460 1 5 Door Checks ConocoPhillips Megaplex9 XD3 2 Table 1 Approved Grease 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 Ah 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 lubri cated first identify the hinge by checking the top loop of the hinge bracket See Fig 1 72 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 bot tom loop of the hinge bracket See Ref A of Fig 1 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 l
182. t wheel cut if needed 21 Install both wheels on the steer axle 22 Remove the jack stands and lower the vehicle Century Class Trucks Maintenance Manual September 2012 46 9 Fuel 47 Index Alphabetical Title of Maintenance Operation MOP MOP Number Fuel Fiter Heplaee melle d ado euge dh dt aue anh de qi dbi S P pubs n eq bones Ea E p dran 47 01 Fuel Separator Sight Bowl Cleaning and Element Replacement ooooocccccoco eee eee 47 02 Fuel tank Band Nut Tightening osse eere Rem Pied yendo ien y er RUP A eee 47 03 Century Class Trucks Maintenance Manual April 2005 Fuel 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 Fig 1 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 pos sibly resulting in personal injury or property dam age 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 clea
183. te 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 Ibf 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 e Meritor part number 2297 Z 7098 e Three Bond e Loctite Ultra Grey Adhesive Sealant 18581 22 2 Install the hub cap by hand until it is Seated NOTE Disregard the torque value em bossed on the hub cap 22 3 Using a torque wrench tighten the hub cap 75 Ibf ft 102 N m If you cannot tighten the hub cap to the correct torque value or if it makes a pop ping 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 33 23 2 App
184. ter cleaning connect the cables to the batteries and tighten them to the torque specifications listed on the battery gener ally 10 to 15 Ibf ft 14 to 20 N m Century Class Trucks Maintenance Manual November 2008 15 1 15 9 5 Coat the battery terminals with dielectric grease 10 Check the terminals on the battery shut off switch and the magnetic switch Make sure the terminal connections are clean and tight Coat the terminal connections with dielectric red enamel after cleaning Alternators and Starters 15 2 Century Class Trucks Maintenance Manual November 2008 Engine Cooling Radiator Title of Maintenance Operation MOP Fan Clutch Check Noise Emission Control Pressure Relief Cap Check llli Radiator Pressure Flushing and Coolant Change 20 Index Alphabetical MOP Number Century Class Trucks Maintenance Manual September 2010 Engine Cooling Radiator 20 01 Pressure Relief Cap Check 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 seri ous personal injury Ah 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
185. 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 re place the drag link See Group 46 of the Century Class Workshop Manual for replacement instruc tions lf 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 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 acci dent resulting in personal injury or property dam age Wear eye protection when changing the fluid and filter 46 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 res ervoir 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 pres sure to the power steering reservoir cover Remove the flanged nut and rub ber washer See Fig 1 Remove the cover 1 2 3 4 7 ai 9 5 6 11 28 95 1461070 1 Vented Fill Cap and 6 Filter Top Plate Dip
186. the steering system as specified may result in loss of steering control which could lead to per sonal injury and property damage Inspect the rack and pinion steering system as de scribed below and repair or replace any components that are worn or damaged Figure 6 shows the com ponents 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 secu rity 6 Check that the outer tie rod castle nuts are tight and the cotter pins are properly installed 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 lf any are found replace the bellows 8
187. tion e Knuckle Pin Lubrication Meritor Axles e Tie Rod Lubrication Meritor Axles e Kingpin Lubrication Detroit Axles e Tie Rod Lubrication Detroit Axles e Axle Breather and Axle Lubricant Level Inspection e Driveline Lubrication Power Steering Fluid Level Inspection Power Steering Gear Lubrication e Drag Link Lubrication Cab Tilt Pump Reservoir Fluid Level and System Check Door Seal Door Latch and Door Hinge Lubrication 00 06 Perform All M1 Operations 01 01 Engine Noise Panel Inspection noise emission control 01 02 Engine Drive Belt Inspection 01 04 Engine Support Fasteners Check noise emission control 09 01 Air Cleaner Element Inspection and Replacement 15 01 Alternator Battery and Starter Check 20 01 Pressure Relief Cap Check 26 03 Manual Transmission Air Filter Regulator Check Cleaning or Replacement Century Class Trucks Maintenance Manual August 2013 00 13 00 General Information M2 Maintenance Interval Operations 00 07 la ei M2 Maintenance Interval Operations for Service Schedule IV Check 32 01 Suspension Inspection 32 03 Suspension U Bolt Torque Check 33 02 Tie Rod Inspection 33 07 Basic Inspection Meritor Unitized Wheel Ends 33 08 End Play Check Meritor Unitized Wheel Endst 40 01 Wheel Nut and Rim Nut Check 41 01 Driveline Inspection 42 01 Air Brake System Valve Inspection
188. to NEUTRAL and allow the engine to idle at 500 to 800 rpm 6 With the engine running at idle remove the dip stick 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 Fig 5 Pr 12 01 97 A Cold Run Band 1270002a B Hot Run Band Fig 5 Dipstick Markings 4h CAUTION As the fluid temperature increases so does the fluid level Do not fill above the COLD RUN band if Transmission the transmission fluid is below normal operating temperature NOTE Perform a hot check at the first opportu nity after the normal operating temperature 160 to 200 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 Shift the transmission to NEUTRAL 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 f
189. transmission until lubricant is 10 Speed Deep Reduction RTO RTX 11708LL RTO 11908LL 14 0 13 2 RTO RTX 14708LL 14 5 13 7 10 Speed Automated Models level with bottom of the fill hole with the vehicle in normal operating posi tion Table 3 Meritor Transmission Lubricant Capacities NOTE In all cases the correct fluid level is es tablished by checking at the fill opening Lightning Top 2 all 13 5 12 8 7 Operate the engine for five minutes after filling the transmission then check the fluid level again 10 Speed Autoshift AS2 all 13 0 12 3 Bx NORMEN MEM A f ean the fill plug then install it in the transmis is epee HIE Seles sion Tighten the plug as follows All Models 14 0 13 2 26 2 Century Class Trucks Maintenance Manual April 2005 Transmission e 25 to 35 Ibf ft 34 to 48 N m for Eaton Fuller transmissions with 3 4 inch pipe threads e 60 to 75 Ibf ft 81 to 102 N m for Eaton Fuller transmissions with 1 1 4 inch pipe threads e 44 bf ft 60 N m for all ZF Meritor FreedomLine automated transmissions e 35 to 50 Ibf ft 48 to 67 N m for all other Meritor transmissions 9 Operate the vehicle to check for correct opera tion 26 02 Allison Transmission Fluid and Filter Change 26 When draining transmission fluid check for evidence of dirt or water contamination A small amount of condensation will appear in the fluid during operat
190. ug 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 con venient steel slug to short the two magnetic poles and divert the magnetic field Install and tighten each drain plug 50 Ibf ft 68 N m NOTE The optional transmission fluid filter is a remote mount spin on type and is located be tween 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 per 26 formance change the filter each time that the fluid is changed 5 For a transmission equipped with a transmission fluid filter s replace the fluid filter s 5 1 Place a drain pan under the transmission fluid filter A 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 counter clockwise motion to separate the filter from the mounting Carefully spin the filter off the mount and remove it from the ve hicle 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 t
191. uid 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 gear to reservoir hose to the reservoir Re move the jack stands and lower the ve hicle 4 4 Install a new filter into the reservoir In stall the filter spring and the filter top plate 4 5 Clean the reservoir cover and O ring seal Inspect the O ring and the cover for 46 2 Century Class Trucks Maintenance Manual September 2012 Steering cracks deformities or damage Replace the O ring seal or cover as needed 4 6 Install the reservoir cover and the clamp Tighten the clamp 25 lbf in 280 N cm 5 Using ATF fluid that meets Dexron Ill 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 th
192. uid Level Check for Service Schedules I Il Ill and IV Maint Service Service Operation Operation Description Schedules I Il Schedule IV Check Number and Ill at M1 at M2 25 01 Eaton Fuller Clutch Release Bearing Lubrication 25 02 Clutch Release Cross Shaft Lubrication 25 03 Sleeve Assembly Bronze Bushing Lubrication 26 04 Transmission Fluid Level Inspection 31 02 Fifth Wheel Lubrication 31 04 Trailer Electrical Connector Lubrication 32 02 Suspension Lubrication 33 01 Knuckle Pin Lubrication Meritor Axles 33 03 Tie Rod Lubrication Meritor Axles 33 05 Knuckle Pin Lubrication Dana Spicer Axles 33 06 Tie Rod Lubrication Dana Spicer Axles 33 09 Kingpin Lubrication Detroit Axles 33 10 Tie Rod Lubrication Detroit Axles 35 02 Axle Breather and Axle Lubricant Level Inspection 41 02 Driveline Lubrication 42 05 Dana Spicer Camshaft Bracket Lubrication 42 06 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication 42 07 Meritor Camshaft Bracket Lubrication 46 03 Power Steering Fluid Level Inspection 46 04 Power Steering Gear Lubrication 46 05 Drag Link Lubrication 46 06 Rack and Pinion Steering Inspection 60 02 Cab Tilt Pump Reservoir Fluid Level and System Check 72 01 Door Seal Door Latch and Door Hinge Lubrication 88 01 Hood Rear Support Lubrication For Schedule II vehicles with Detroit axles complete this procedure once a year or every 25 000 mile
193. ure for all wheel nuts using the tightening se quence shown in Fig 1 Description Nut Size Wheel Manufacturer Torque Ibf 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 10 Stud Disc Wheel With Inner and Outer Locknuts with dry threads Corrugated Channel Spacer Alcoa 400 500 540 680 Front Wheel Nut 1 1 8 16 All Others 450 500 610 680 Alcoa 400 500 540 680 Rear Wheel Inner Nut 3 4 16 All Others 450 500 610 680 Alcoa 400 500 540 680 Rear Wheel Outer Nut 1 1 8 16 All Others 450 500 610 680 Wheel Stud Retainer Nut 3 4 16 All 175 200 235 270 Spoke Wheel Rim Nuts with dry threads Front Wheel Nut 5 and 6 Spoke 3 4 10 Gunite 200 225 271 305 Rear Wheel Nut 5 and 6 Spoke With 7 T i Non Corrugated Channel Spacer oa une 2007225 71305 Rear Wheel Nut 5 and 6 Spoke With 3 410 Gunite 240 260 325 350 On front axles with over 12 000 Ibs 5448 kg capacity tighten the wheel nuts 240 to 265 Ibf 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 Century Class Trucks Maintenance Manual January 1996 40 1
194. ury Class Trucks Workshop Manual for adjustment procedures 3 2 If the vehicle is equipped with a fixed lev eling 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 dual drive rear axle configurations measure the dis tance from the bottom of the forwardmost left axle stop to the top of the axle U bolt pad See Fig 7 Ref A The correct distance for single Suspension 05 15 95 1320410 A Measure the length of the overtravel lever between these two points 1 V Shaped Mark 4 Cotter Pin 2 Adjustment Locknut 5 Linkage Rod 3 Overtravel Lever Fig 6 AirLiner Overtravel Lever and Linkage Rod Measurement 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 in spection 3 Inspect the rubber bushings for cracks or other damage Try to move the
195. ushings 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 bush ings by applying multipurpose chassis grease at the grease fitting until the old grease is forced out from the cap and tube assembly See Fig 15 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 ve hicle 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 Fig 16 Continue 32 8 Century Class Trucks Maintenance Manual November 2009 Suspension 32 3 2 09 15 95 1320423 1 Frame Rail 3 Axle Centerline 2 Axle Housing 4 Suspension Ride Height Fig 14 Neway Ride Height Inspection 4 1 N 2 e O FA 1 E 05 27 93 W 320020a A Lubric
196. using 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 Ibf 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 Steering 08 25 2009 1462172 A Crimp the clamp ears 0 08 to 0 16 inch 2 to until the ear width is 4 mm 1 Bellows 2 Large Oetiker Clamp Fig 12 Oetiker Clamp Ear Width 19 Tighten the jam nut on the driver side and the tie rod clamp nut on the passenger side 20 Align the steering gear 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 ac cessible the alignment procedure must be done by a facility that has the appropriate tool When the alignment process requires that the steering wheel be pointed straight ahead align the steering rack on center pointers instead See Fig 13 20 1 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 Fig 6 20 2 Align the steering rack on center pointers 46 8 Century Class Trucks Maintenance Manual Septembe
197. using 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 equiva lent 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 Ib 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 35 temperature in
198. vehicle owner s warranty information book for warranty information concerning noise emis sion controls Tampering With Noise Controls is Prohibited Federal law prohibits the following acts or the caus ing thereof 1 The removal or rendering inoperative by any per son other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new vehicle for Century Class Trucks Maintenance Manual August 2013 00 19 00 General Information Verification of Inspections Log 00 11 Verification of Inspections Log Verification of Inspections Log Groups 01 20 and 49 Date Mileage Item Cost Maintenance Facility Group 01 Engine Noise Panels Engine Mounts and Engine Support Fasteners Group 20 Fan Clutch Group 49 Exhaust System Components 00 20 Century Class Trucks Maintenance Manual August 2013 General Information 00 Metric U S Customary Conversion Tables 00 12 oa Us En To Get Metric Mies um ric er To Get U S Customary Length inches in 25 4 millimeters mm 0 03937 inches in inches in 2 54 centimeters cm 0 3937 inches in feet ft 0 3048 meters m 3 281 feet ft yards yd 0 9144 meters m 1 094 yards yd miles mi 1 609 kilometers km 0 6215 miles mi Area square inches in 645 16 s
199. w 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 11 Brake Inspection IMPORTANT This procedure should be per formed prior to lubrication of the brake compo nents Parking Brake Operational Check A CAUTION Perform the following check in a clear safe area If the parking brakes fail to hold the vehicle per sonal injury or property damage may result 1 With the engine running and air pressure at cut out pressure set the parking brake 2 Put the vehicle in the lowest gear and gently at tempt 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 Brake Component Inspection 1 Park the vehicle on a level surface set the park ing brake and chock the tires Once the tires are chocked release the parking brake Brakes 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
200. wheel B The locks should be completely closed around the kingpin Fig 4 Holland Fifth Wheel Properly Closed Castloc Il and Simplex Series 1 Disconnect the tractor from the trailer For in structions see the vehicle driver s manual Century Class Trucks Maintenance Manual August 2011 31 3 31 Thoroughly steam clean the fifth wheel Check the fifth wheel plate for cracks Check for sharp edges on top the chamfer should be 1 8 to 1 4 inch 3 to 6 mm 4 When the wheel is locked the safety latch must swing free and fall freely into position See Fig 5 10 26 2010 f310353b 3 Lock Control Handle 4 Mount 1 Lubricant Grooves 2 Safety Latch Fig 5 Simplex Series Fifth Wheel 5 The lever bar and operating handle must be in proper alignment See Fig 6 Compare the lever bar and operating handle alignment to a new or a properly operating lever bar and operating handle Replace any bent or misaligned lever bar or operating rod 6 Check all cotter pins for cracking or damage Re place any cotter pin that shows any signs of damage 7 Level the fifth wheel plate to a horizontal posi tion Measure the height from a stationary mounting point see Fig 7 Ref 3 such as the 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 move ment Ref 5 The bracket connection provides a 9
201. xle that requires lubrication of the tie rod ends wipe the grease fittings clean then pump multipurpose chassis grease NLGI Grade 1 696 12 hydroxy lithium stearate grease or NLGI Grade 2 896 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 park ing 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 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 2013 33 3 33 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 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
202. y that the pipe is inserted at least 7 16 inch 10 mm past the face of the flange See Fig 11 Ref A Install the slip clamps on the bellows Tighten the slip clamps 11 Ibf ft 15 N m Start the engine and check for exhaust leaks Tighten any clamps as needed Exhaust 49 6 Century Class Trucks Maintenance Manual August 2011 Cab 60 Index Alphabetical Title of Maintenance Operation MOP MOP Number Cab Access Stairs Inspection Argosy COE si sissuuse eek a Daya heer Ex 60 03 Cab Suspension Air Bag Inspection anaana a AE AA AAA 60 01 Cab Tilt Pump Reservoir Fluid Level and System Check 0 000 eee eee eee 60 02 Mito Folding BUSCO TN S T ERO C ETE CO IIT 010 o TES MEER 60 04 Century Class Trucks Maintenance Manual September 2010 Cab 60 01 Cab Suspension Air Bag Inspection 60 60 03 Cab Access Stairs Inspection Argosy COE Inspect the cab suspension air bags at the rear of the cab Check for wear leakage and damage Re place if necessary Inspect the cab suspension shock absorber for dam age 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 re main in this position for at least five minutes before checking the reservoir Th

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