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freightliner CENTURY CLASS 2011 Maintenance Manual

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CENTURY CLASS
Maintenance Manual
STI-341-1
A24-00691-000

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  • Page 1 CENTURY CLASS Maintenance Manual STI-341-1 A24-00691-000...
  • Page 2 CENTURY CLASS TRUCKS MAINTENANCE MANUAL Models: Argosy® COE C112 Conventional C120 Conventional CST120 Conventional Coronado® STI-341-1 (8/17) Published by Daimler Trucks North America LLC 4747 N. Channel Ave. Portland, OR 97217 Printed in U.S.A.
  • Page 4 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.
  • Page 6 ™ EZWiring 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.
  • Page 7 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.
  • Page 8 Introduction Page Description For an example of a Century Class Trucks Maintenance Manual, see Fig. 11/20/95 f020044 A. Maintenance Operation Number consists of the Group Number followed by the Sequence Number B. Group Title C. Group Number D. Release Date E.
  • Page 9 Introduction Maintenance Manual Contents Group No. Group Title 00 ..... . General Information 01 ....... . Engine 09 .

  • Page 10: Table Of Contents

    General Information Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Determining Scheduled Maintenance Intervals..........00–01 Initial Maintenance (IM) Operations.

  • Page 12: Determining Scheduled Maintenance Intervals

    Performing regular maintenance on your Freightliner mileage. will help ensure that your Freightliner delivers safe Service Schedule IV (long haul transport for Opti- reliable service and optimum performance for years mized Vehicle Configuration) is for vehicles that an- to come.
  • Page 13 General Information Service Schedule Table: 00–02 Maintenance Interval Service Schedule Maintenance Interval Operation Frequency Miles Hours Initial Maintenance (IM) first 1000 1600 Schedule I Maintenance 1 (M1) every 1000 1600 (Severe Service) vehicles that annually travel less Maintenance 2 (M2) every 5000 8000...
  • Page 14 General Information Vehicle Maintenance Schedule Tables: 00–03 1st through 30th Maintenance for Service Schedules I and II Service Schedule I Service Schedule II Maintenance Service Maint. No. Interval Date Miles Hours Miles IM and M1 1000 1600 10,000 16 000 2000 3200 20,000...
  • Page 15 General Information Vehicle Maintenance Schedule Tables: 00–03 31st through 60th Maintenance for Service Schedules I and II Service Schedule I Service Schedule II Maintenance Service Maint. No. Interval Date Miles Hours Miles 31st 31,000 49 600 3100 310,000 496 000 32nd 32,000 51 200...
  • Page 16 General Information Vehicle Maintenance Schedule Tables: 00–03 61st through 90th Maintenance for Service Schedules I and II Service Schedule I Service Schedule II Maintenance Service Maint. No. Interval Date Miles Hours Miles 61st 61,000 98 200 6100 610,000 982 000 62nd 62,000 99 800...
  • Page 17 General Information Vehicle Maintenance Schedule Tables: 00–03 91st through 100th Maintenance for Service Schedules I and II Service Schedule I Service Schedule II Maintenance Service Maint. No. Interval Date Miles Hours Miles 91st 91,000 146 500 9100 910,000 1 465 000 92nd 92,000 148 100...
  • Page 18 General Information Vehicle Maintenance Schedule Tables: 00–03 20th through 40th Maintenance for Service Schedules III and IV Service Schedules III and IV Service Maint. No. Maintenance Interval Date Miles M1 and M2 500,000 805 000 525,000 845 000 550,000 885 000 575,000 925 000 M1, M2, and M3...
  • Page 19 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.
  • Page 20 General Information Lubrication and Fluid Level Check: 00–04 Maintenance Operation 00–04 Lubrication and Fluid Level Check for Service Schedules I, II, III, and IV Maint. Service Service Operation Operation Description Schedules I, II, Schedule IV Check Number and III (at M1) (at M2) 88–01 Hood Rear Support Lubrication...

  • Page 21: Initial Maintenance (Im) Operations

    General Information 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.

  • Page 22: Lubrication And Fluid Level Check

    General Information M1 Maintenance Interval Operations: 00–06 The M1 Maintenance Interval Operations tables list IMPORTANT: After performing all operations listed in all maintenance operations that are to be performed this table, perform all daily, weekly, and monthly at the M1 maintenance interval. Maintenance opera- maintenance operations listed in the "Pretrip and tion numbers are reference numbers used to help Post-Trip Inspections and Maintenance"...
  • Page 23 General Information M1 Maintenance Interval Operations: 00–06 Maintenance M1 Maintenance Interval Operations for Service Schedule IV Check Operation Number 31–02 Fifth Wheel Lubrication 31–04 Trailer Electrical Connector Lubrication 33–11 Steer Axle Hub Cap Vent Plug Inspection 40–02 Tire Check 42–07 Meritor Camshaft Bracket Lubrication 42–10 Brake Inspection...

  • Page 24: M2 Maintenance Interval Operations

    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 numbers used to help tenance interval.
  • Page 25 General Information M2 Maintenance Interval Operations: 00–07 Maintenance M2 Maintenance Interval Operations for Service Schedules I, II, and III Check Operation Number 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...
  • Page 26 General Information M2 Maintenance Interval Operations: 00–07 Maintenance M2 Maintenance Interval Operations for Service Schedule IV Check Operation Number 32–01 Suspension Inspection 32–03 Suspension U-Bolt Torque Check 33–02 Tie Rod Inspection 33–07 Basic Inspection, Meritor Unitized Wheel Ends † 33–08 End-Play Check, Meritor Unitized Wheel Ends 40–01 Wheel Nut and Rim Nut Check...

  • Page 27: M3 Maintenance Interval Operations

    General Information 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.

  • Page 28: Maintenance Operation Sets Table

    General Information Maintenance Operation Sets Table: 00–09 Maintenance Operation Sets for Groups 00 through 83 Maint. Service Schedules Service Schedule Operation Description I, II, and III M2 M3 00–04 Lubrication and Fluid Level Check • • • • • • 01–01 Engine Noise Panel Inspection (noise emission control) •...
  • Page 29 General Information Maintenance Operation Sets Table: 00–09 Maintenance Operation Sets for Groups 00 through 83 Maint. Service Schedules Service Schedule Operation Description I, II, and III M2 M3 † 33–07 Basic Inspection, Meritor Unitized Wheel Ends • • • • ‡...
  • Page 30 General Information Maintenance Operation Sets Table: 00–09 Maintenance Operation Sets for Groups 00 through 83 Maint. Service Schedules Service Schedule Operation Description I, II, and III M2 M3 60–01 Cab Suspension Air Bag Inspection • • • • 60–02 Cab Tilt Pump Reservoir Fluid Level and System Check •...

  • Page 31: Noise Emission Controls Maintenance

    Maintenance Instructions sure that such parts are warranted by their manufac- turer to be equivalent to genuine Freightliner parts in performance and durability. Scheduled intervals are in the maintenance tables in this group. A "Verification of Inspections Log (Groups Freightliner Noise Emission 01, 20, and 49)"...

  • Page 32: Verification Of Inspections Log

    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 —...
  • Page 34 Engine Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Engine Drive Belt Inspection............01–02 Engine Mount Inspection (Noise Emission Control) .
  • Page 36 Engine 01–00 Safety Precautions 01–02 Engine Drive Belt Inspection Safety Precautions in this section apply to all procedures within this group. Worn or loose drive belts may cause premature bearing failure or engine overheating. Excessive ten- DANGER sion, or too little tension on the belt may result in ex- cessive and premature belt wear.
  • Page 37 Engine 7. Inspect the pulleys for excessive play or wobble. 3. If belt tension is not correct, see Group 01 of the Excessive play or wobble indicates a failure of Century Class Trucks Workshop Manual. the pulley bearing. Check for belt squealing or Spring-Tension Type squeaking.
  • Page 38 Engine 01–03 Engine Mount Inspection and upper isolators (see Fig. 3 , Refs. 1 and 6), and replace them if they are worn. See Group (Noise Emission 01 of the Century Class Trucks Workshop Control) Manual for procedures. NOTE: At engine overhaul, and whenever the engine has been removed, inspect the lower Drive Belt Tension Engine...
  • Page 39 Engine Check the front engine-support fasteners for tight- ness. Tighten the 5/8-inch fasteners 125 lbf·ft (170 N·m). NOTE: At engine overhaul, and whenever the engine has been removed, inspect the lower and upper isolators (see Fig. 3, Refs. 1 and 6), and replace them if they are worn;...
  • Page 40 Air Intake Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Cleaner Element Inspection and Replacement ......... . 09–01 Century Class Trucks Maintenance Manual, November 2014...
  • Page 42 Air Intake 09–01 Air Cleaner Element Inspection and Replacement Restriction of air flow through the air cleaner element is measured at the tap in the air cleaner outlet. Check the restriction indicator at the air cleaner or in the cab if the vehicle is equipped with a dash- mounted restriction gauge.
  • Page 44 Air Compressor Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Compressor Inspection ............13–01 Safety Precautions .
  • Page 46 Air Compressor 13–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 48 Alternators and Starters Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Alternator, Battery, and Starter Connections Check ......... 15–01 Safety Precautions .
  • Page 50 Alternators and Starters 15–00 Safety Precautions Engines equipped with a serpentine or poly-V belt have automatic belt tensioners, and do not require belt tension inspection. Safety Precautions in this section apply to all 4. Check that all electrical connections at the alter- procedures within this group.
  • Page 51 Alternators and Starters 10.1 Clean and tighten the battery ground cable, terminal, and clamps. 10.2 Inspect the retainer assembly (or battery hold-downs) and the battery box. Replace worn or damaged parts. Remove any cor- rosion with a wire brush, and wash with a weak solution of baking soda and water.
  • Page 52 Engine Cooling/Radiator Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fan Clutch Check (Noise Emission Control) ..........20–03 Pressure Relief Cap Check.
  • Page 54 Engine Cooling/Radiator 20–00 Safety Precautions 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 Safety Precautions in this section apply to all supported when the system cools.
  • Page 55 Engine Cooling/Radiator 06/08/95 f500244 1. Low-Coolant-Level Sensor 2. SAE Cap (for coolant overflow pressure relief only) 3. Fill Cap Fig. 1, Surge Tank, Century Class Conventional cooling system prior to the system cooling could cause severe personal injury due to scalding. 5.
  • Page 56 Engine Cooling/Radiator 08/19/2009 f200726 NOTE: The main radiator drain plug is not shown. 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.
  • Page 57 Engine Cooling/Radiator 10/05/2016 f200286 A. The screw tip must extend about 1/4 inch (6 mm). B. Belleville washer stacks must be collapsed almost flat. 1. Tightening Screw Hex Fig. 6, Breeze Constant-Torque Hose Clamp Installation 06/29/95 f011008 pressure. During vehicle operation and shut- NOTE: Cummins M11 engine shown.
  • Page 58 Engine Cooling/Radiator radiator and hoses for leaks. Repair if 3. Clean the fan clutch air solenoid valve filter, if necessary. equipped. 12.5 Shut off the engine, then check the cool- Unscrew the fan clutch solenoid valve air ant level in the surge tank. Add coolant if filter assembly and remove the filter ele- the level is not between the MIN and ment.
  • Page 59 Engine Cooling/Radiator 8. With the air system charged to 120 psi (827 age means that the large O-ring (Ref. 14) kPa), and with the fan solenoid connector halves is damaged. separated, check the fan clutch for audible air Check for air leaks around the safeguard leaks, using a suitable listening device.
  • Page 60 Engine Cooling/Radiator 10.1 Connect the halves of the fan solenoid connector. 10.2 Turn the air conditioner off. 10.3 Start the engine and charge the air sys- tem to 120 psi (827 kPa). Tests must be performed with the engine temperature below 205°F (96°C) for Caterpillar en- gines, and below 200°F (93°C) for Cum- mins and Detroit Diesel engines.
  • Page 61 Engine Cooling/Radiator this procedure, the fan could engage, which could result in serious personal injury. 2. Inspect the electrical connections and wires to the fan clutch solenoid. Secure the connection if loose; replace wires and connectors if damaged. 3. Clean the fan clutch air solenoid valve filter, if equipped.
  • Page 62 Clutch Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Clutch Release Cross-Shaft Lubrication..........25–02 Eaton Fuller Clutch Release Bearing Lubrication .
  • Page 64 Clutch 25–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 65 Clutch 25–02 Clutch Release Cross- 25–03 Sleeve Assembly Bronze Shaft Lubrication Bushing Lubrication The clutch release cross-shaft is equipped with two Vehicles equipped with the sealed clutch-release grease fittings in the transmission clutch housing. bearing have a lubrication extension outside of the Fig.
  • Page 66 Clutch 4. Wipe off excess grease and apply it to both the yoke-finger and the sleeve-bushing contact points. See Fig. 5. Install the clutch inspection plate. 6. Remove the chocks. 25/3 Century Class Trucks Maintenance Manual, January 2016...
  • Page 68 Transmission Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Allison Transmission Fluid and Filter Change..........26–02 Manual Transmission Air Filter/Regulator Check, Cleaning, or Replacement .
  • Page 70 Transmission 26–00 Safety Precautions 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 Safety Precautions in this section apply to all poles and divert the magnetic field.
  • Page 71 Transmission Fuller® transmission lubricant capacities and Eaton Fuller Transmission Lubricant Capacities Table 3 for Meritor transmission lubricant capaci- † Refill Capacity ties. Transmission Model qt (L) For more information and a complete listing of 7-Speed T Series Eaton approved lubricants, refer to the Eaton All Models 18.0 (17.0) website, www.roadranger.com.
  • Page 72 Transmission • 44 lbf·ft (60 N·m) for all ZF Meritor mission reaches normal operating temperature: FreedomLine automated transmissions. 160 to 200°F (71 to 93°C). • 35 to 50 lbf·ft (48 to 67 N·m) for all other 2. Park the vehicle on a level surface. Apply the Meritor transmissions.
  • Page 73 Transmission Allison Transmission Lubricant Capacities Transmission Model Refill Capacity : qt (L) † HD4060/4560 (shallow sump) 26 (25) Quantities listed are approximate. Add listed amount of fluid, then perform a "hot check" and add fluid as needed. Do not overfill. †...
  • Page 74 Transmission through the filter element (inside to outside) to loosen surface dirt and to dry the element. If it is not damaged, the sintered metallic filter element will last the life of the vehicle. Wipe out the filter housing with a clean, dry, lint- free rag.
  • Page 75 Transmission 26–04 Transmission Fluid If the fluid level is not within the COLD RUN band, add or drain fluid as needed to adjust the Level Inspection fluid level to the middle of the COLD RUN band. Fig. Allison NOTICE Operating a transmission with the fluid level higher or lower than recommended can result in transmission damage.
  • Page 76 Transmission • 35 to 50 lbf·ft (48 to 67 N·m) for all other If the fluid level is not within the HOT RUN band, add or drain fluid as needed to bring the fluid Meritor transmissions. level within the HOT RUN band. See Fig.
  • Page 78 Frame and Frame Components Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fifth Wheel Inspection ............. . 31–01 Fifth Wheel Lubrication.

  • Page 80: Fifth Wheel Inspection

    Frame and Frame Components 31–00 Safety Precautions 6. Check the jaw and stationary jaw for mushroom- ing, and check that the serrations at the jaw and wedge are in good condition. Safety Precautions in this section apply to all 7. Test the secondary safety lock latch for ease of procedures within this group.
  • Page 81 Frame and Frame Components 12/02/2010 f311134 NOTE: 6000 Series shown; 7000 Series fifth wheels use similar parts. 1. 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.
  • Page 82 Frame and Frame Components 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).
  • Page 83 Frame and Frame Components 5. The lever bar and operating handle must be in proper alignment. See Fig. 6. Compare the lever bar and operating handle alignment to a new, or a properly operating lever bar and operating handle. Replace any bent or misaligned lever bar or operating rod.
  • Page 84 Frame and Frame Components 4. Inspect the bracket pin bolts. Make sure the lock- ing tabs are properly securing the bolts in place. Fig. 04/11/2011 f310475 A. Extended Top Plate Lift Height 1. Fifth Wheel Top Plate 09/01/2009 f311101 2. Fifth Wheel Frame Mount 3.
  • Page 85 Frame and Frame Components 09/02/2009 f311100 1. Jam Nut 3. Grease Zerk 2. Adjustment Bolt Fig. 10, Jost Fifth Wheel Check the bracket for any cracks or miss- ing and damaged parts. Inspect the locking plungers for full en- gagement. Check the locking mechanism for proper 09/01/2009 f311099...

  • Page 86: Fifth Wheel Lubrication

    Frame and Frame Components justment, refer to the fifth wheel installa- Tilt the fifth wheel ramps down (the rear of the tion instructions. fifth wheel is down) and repeat the greasing pro- cedure. Rock the top plate back and forth sev- 10.
  • Page 87 Frame and Frame Components 3. Grease the yoke tips, locks, and the release handle and spring; see Fig. 12. Grease the mounting bracket supports through the grease fittings. A “low temp” grade grease rated for -30°F (-34°C) or lower such as Cato Oil and Grease #5213, Craftsman Chemical Co.

  • Page 88: Frame Fastener Torque Check

    Frame and Frame Components 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).

  • Page 89: Premier 690 Coupling Inspection

    Frame and Frame Components • Remove the 294 bolt. Using dye penetrate or Century Class Trucks Workshop Manual for repair or replacement information. magnetic particle testing along the length of the bolt, inspect for fractures. • If the 294 bolt has no damage, install it and 31–04 Trailer Electrical continue to use for another 6 months.
  • Page 90 Suspension Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Safety Precautions ..............32–00 Suspension Inspection .

  • Page 92: Safety Precautions

    Suspension • a side to side crack extending beyond 3/4 of the 32–00 Safety Precautions length of the spring; • a top to bottom crack extending beyond 3/4 of Safety Precautions in this section apply to all the length of the spring; procedures within this group.
  • Page 93 5. Inspect the rubber bushing ends. See Fig. 3. Re- place the torque arm for any of the following rea- Freightliner Spring Suspension sons: • if there are gaps between the rubber bush- WARNING ing and the pin or outer steel sleeve;...
  • Page 94 Inspect the crossmember(s) and gussets for wear, instructions. cracks, and other damage. If any of these conditions exist, replace the damaged parts. See Group 32 of Freightliner AirLiner Suspension the Century Class Trucks Workshop Manual for instructions. WARNING IMPORTANT: Before checking the AirLiner sus-...
  • Page 95 Suspension • Do not overtighten the bolts in the Barksdale height-control valve housing. The bolts should not be loose, and should not require tightening. Only if necessary, tighten the valve housing bolts 45 lbf·in (500 N·cm). Any damage to the valve housing will void the warranty.
  • Page 96 Suspension f320432 09/27/95 A. Non-Wear Area B. Wear Area 1. Walking Beam 08/16/96 f320453 Fig. 8, Walking Beam End Wear Thickness A. Measure height here. 1. Left Forwardmost Axle Stop 6. Rotate the restrictor cans 360 degrees and visu- ally inspect the cans for cracks, severe corro- Fig.
  • Page 97 Suspension components, loss of vehicle control, and possible personal injury or property damage. 2. Inspect each frame hanger for any evidence of cracks in the vertical mounting flange. See Fig. 09/15/95 f320420 1. Crack In Inspection Area Fig. 10, Hendrickson RS Series Horizontal Mounting Flange 09/15/95 f320419...
  • Page 98 Suspension 05/27/93 f320112a 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 f320421 1. Rust Inspection Area Fig.
  • Page 99 Single Axle 3. Inspect all bolts and nuts at the pivot and axle connections to ensure they are properly torqued. No lubrication is required on Freightliner single-axle Check all other nuts and bolts for proper torque. rear suspensions. Group 00 of this manual for proper torque specifications.
  • Page 100 Suspension 09/15/95 f320423 1. Frame Rail 3. Axle Centerline 2. Axle Housing 4. Suspension Ride Height Fig. 14, Neway Ride Height Inspection 05/27/93 320020a A. Lubricate here. 1. Cap-and-Tube Assembly Bushing 09/15/95 f320424 Fig. 15, Equalizer Assembly Lubrication 1. Bronze Bushing 3.
  • Page 101 Suspension Neway Spring Assembly U-Bolt High Nut Torque Values Size Torque: lbf·ft (N·m) No lubrication is required on Neway rear suspen- sions. Stage 1: Hand tighten Stage 2: 60 (81) 1–14 Reyco Stage 3: 200 (271) Stage 4: 520 to 600 (707 to 816) No lubrication is required on Reyco rear suspen- Tighten in a diagonal pattern as shown in Fig.
  • Page 102 Front Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number All-Axle Alignment Check ............33–04 Basic Inspection, Meritor Unitized Wheel Ends .
  • Page 104 Front Axle 33–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 105 Fig. 3, Wheel Toe-In (overhead view) equipment manufacturer. Freightliner dealers must have proof of this calibration history. 7. Place the trammel bar at the front of the tires, Fig.
  • Page 106 Front Axle 11/21/95 f330129 A. Grease Exit 1. Grease Fitting Fig. 6, Dana Spicer Knuckle Pin Lubrication 33–06 Tie Rod Lubrication, Dana Spicer Axles 10/05/2016 f400100a For any Dana Spicer axle that requires lubrication of the tie-rod ends, wipe the grease fittings clean, then Fig.
  • Page 107 Front Axle 3. Rotate the tire and hub assembly. They should WARNING rotate smoothly and without noise. Grasp the brake chamber while rotating the hub to detect Never work under a vehicle that is supported only any hub vibration. by a jack. Jacks can slip, causing the vehicle to If the hub rotates smoothly, go to the next step.
  • Page 108 Front Axle For instructions, see Group 33 of the Century 23.2 Apply Loctite® 17430 gasket sealant to Class Trucks Workshop Manual. the external hub cap threads. 17. Check the rotation of the hub. If it doesn’t rotate 23.3 Install the hub cap by hand until it is smoothly and without noise, replace the entire seated.
  • Page 109 Front Axle 06/12/2012 f330273 NOTE: No grease should emit from the tie-rod boot. If grease emits from the tie-rod boot, the boot is dam- aged. 1. Grease Fitting 2. Boot Fig. 9, Grease Fitting and Boot, Detroit Axles 33–11 Steer Axle Hub Cap Vent Plug Inspection General Information As a function of their design, hubcap vent plugs will...
  • Page 110 Front Axle 09/01/2016 f330300 09/01/2016 f330298 Fig. 12, Water in Oil Fig. 10, Normal Oil Venting clean before checking the oil. Do not use a pres- sure washer to clean the hub/plug area. The plug has a vent and this can contaminate the oil with water.
  • Page 112 Rear Axle Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Axle Breather and Axle Lubricant Level Inspection......... . 35–02 Axle Lubricant and Filter Change, and Magnetic Strainer Cleaning.
  • Page 114 Rear Axle Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 115 Rear Axle ture, the oil will run more freely and ensure that Detroit Drive Axle Lubricants the axle is flushed. IMPORTANT: Lubricant used in Detroit rear axles must 4. Clean the fill and drain plugs. Change them if meet Mercedes-Benz specification 235.20 (mineral) or necessary.
  • Page 116 Rear Axle 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.
  • Page 117 Rear Axle 8. Fill the axle with recommended lubricant. See Dana Spicer Drive Axle Lubricant Capacities Table 3 for recommended drive axle lubricants, Capacity Table 4 for drive axle lubricant capacities. Axle Type Axle Model pints (liters) NOTE: Some Dana Spicer axles have a †...
  • Page 118 Rear Axle pressure additives, so the lubricant change driver’s manual. Meritor’s experience shows that the following additives (friction modifiers) perform ad- schedule must be shortened when using these equately: additives. The traction equalizer additive (and recommended drive axle lubricant) must be A.
  • Page 119 Rear Axle lubricant fill hole. This smaller hole is for a lubri- 6. Clean the fill and drain plugs. For magnetic plugs, a piece of key stock or any other conve- cant temperature indicator only, and should not nient steel slug may be used to short the two be used as a fill or level hole.
  • Page 120 Rear Axle IMPORTANT: On Detroit axles, the oil change 3. Install the housing cover and a new cover gas- ket. Tighten the housing cover capscrews 7.5 to interval for long haul vehicles can be extended 9.2 lbf·ft (10.2 to 12.5 N·m), then remove the oil to 500,000 miles (800 000 km) for axles with fill plug from the cover.
  • Page 121 Rear Axle 2. If the vehicle has just been driven, allow a few minutes for the lubricant to settle. 3. Clean the oil fill plug and area surrounding it, then remove the plug from the fill hole (see Fig. 3), or from the standpipe (if so equipped) installed in the fill hole.
  • Page 122 Rear Axle 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...
  • Page 124 Wheels and Tires Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Tire Check ............... 40–02 Wheel Nut and Rim Nut Check.
  • Page 126 Wheels and Tires 40–01 Wheel Nut and Rim Nut breakage, and extreme tire tread wear. Excessive wheel nut torque can break studs, damage Check threads, and crack discs in the stud hole area. Use the recommended torque values, and follow IMPORTANT: After installing a wheel, the wheel the tightening sequence shown in Fig.
  • Page 127 Wheels and Tires 07/23/2015 f400057b 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 Maintain the proper pressures for carried loads, per the tire manufacturers’ recommendations, or the tire pressure label on the driver’s door.
  • Page 128 Driveline Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Driveline Inspection ..............41–01 Driveline Lubrication.
  • Page 130 Driveline 41–00 Safety Precautions Safety Precautions in this section apply to all procedures within this group. DANGER When working on the vehicle, shut down the en- gine, set the parking brake, and chock the tires. Before working under the vehicle, always place jack stands under the frame rails to ensure the vehicle cannot drop.
  • Page 131 Driveline 10/06/2016 f410067b 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.
  • Page 132 Driveline 10/06/2016 f410012a Attempt to move the sleeve-yoke and splined shaft back and forth. Fig. 4, Slip Joint Spline Wear Checking any evidence that balance weights are missing, remove the driveshaft and have it balanced. 9. For driveshafts with slip joints, check to be sure 10/07/2016 f410050a the yoke plug is not loose or missing.
  • Page 133 Driveline 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.
  • Page 134 Brakes Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Brake System Valve Inspection ........... . . 42–01 Air Dryer Desiccant Replacement .

  • Page 136: Air Brake System Valve Inspection

    Brakes 42–00 Safety Precautions 4. Disconnect the harness connector from the heater and thermostat assembly. Safety Precautions in this section apply to all 5. Loosen the capscrew securing the upper mount- ing bracket strap. procedures within this group. 6. Remove the two capscrews that secure the air DANGER dryer to the lower mounting bracket.
  • Page 137 Brakes 08/09/95 f421383 1. 5/16" x 4-1/2" Upper Mounting 9. Desiccant Cartridge 18. Purge Valve Bracket Capscrew 10. O-Ring 19. 1/4" Tapping Screw 2. Upper Mounting Bracket Strap 11. Safety Valve 20. Purge Valve Housing 3. 5/16" Lockwasher 12. Lower Mounting Bracket 21.
  • Page 138 Brakes WARNING Do not attempt to disassemble the desiccant car- tridge assembly. Parts for the assembly are not available and the cartridge contains a 150 lb spring that cannot be mechanically caged. Disas- sembly could release the spring, resulting in per- sonal injury.
  • Page 139 Brakes IMPORTANT: Only use the silicone grease sup- 12.3 Fan the service brakes to reduce system air pressure to governor cut-in. Note that plied with Bendix replacement kits. the system once again builds to full pres- 5. Screw the desiccant cartridge onto the body, by sure and is followed by a purge at the hand, until the seal makes contact with the body.

  • Page 140: Air Dryer Inspection

    Brakes 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.

  • Page 141: Alcohol Evaporator Cleaning And Inspection

    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.

  • Page 142: Dana Spicer, Haldex, And Gunite Slack Adjuster Lubrication

    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 42–10 before lubri- cating the slack adjusters. Automatic slack adjusters that have a grease fitting, must be lubricated periodically to ensure proper brake operation.

  • Page 143: Meritor Slack Adjuster Lubrication

    Brakes 42–08 Meritor Slack Adjuster Lubrication IMPORTANT: Perform MOP 42–10 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.
  • Page 144 Brakes 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.
  • Page 145 Brakes Brake Component Inspection If a band shows, the stroke is too long. Check the foundation brake components for wear or 1. Park the vehicle on a level surface, set the park- damage, and repair as needed. See Group 42 of ing brake, and chock the tires.

  • Page 146: Versajust Slack Adjuster Inspection And Lubrication

    Brakes Brake Chamber Stroke Specifications Chamber Max Applied Stroke: inch (mm) † Manufacturer Type Size 1-3/8 (35) Standard Stroke 1-3/4 (44) Haldex 2-1/2-Inch Extended Stroke 2 (51) 3-Inch Extended Stroke 2-1/2 (64) Standard Stroke 2 (51) Long Stroke 2-1/2 (64) Less than 1-1/2 (38) Standard Stroke Less than 1-3/4 (44)
  • Page 147 Brakes ness appears excessive. Make certain the brake actuator pushrod jam nut is tightened securely. 2. Inspect the slack adjuster for physical damage, paying attention to the link, boot, and clevis. If any components are damaged, repair or replace them as necessary. 3.
  • Page 148 Steering Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Bellows Replacement, Rack and Pinion Steering Gear........46-07 Drag Link Inspection.

  • Page 150: Drag Link Inspection

    Steering 46–00 Safety Precautions 46–02 Power Steering Fluid and Filter Changing Safety Precautions in this section apply to all procedures within this group. WARNING DANGER Fill only with approved clean fluid. Failure to use the proper fluid could cause seal deterioration and When working on the vehicle, shut down the en- leaks.
  • Page 151 Steering 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. Remove the clamp that holds the cover on the reservoir.

  • Page 152: Power Steering Fluid Level Inspection

    Steering Add fluid to the reservoir as needed. On Century Class Conventionals, remove the When clean power steering fluid flows dipstick and check that power steering fluid is from the hose, remove the plug from the between ADD HOT and FULL HOT. If the fluid reservoir and reconnect the steering gear- level is low, add enough fluid to bring the level to-reservoir hose to the reservoir.

  • Page 153: Rack And Pinion Steering Gear Inspection

    Steering TRW Steering Gears NOTICE Apply grease to the sector shaft with a hand-type grease gun only. Use of a high-pressure power grease gun will supply grease too quickly and could affect the high pressure seal, contaminating the hydraulic fluid. 10/07/2016 f461072 Using a hand-type grease gun, apply NLGI Grade 2...
  • Page 154 Steering 07/24/2009 f462151 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.
  • Page 155 Steering hoses. Repair or replace lines, hoses, and fit- 8. Remove the bellows from both sides of the gear. tings as necessary. NOTE: A thin film of leftover Terostat MS 939 on the rack housing is acceptable when installing NOTICE the new bellows.
  • Page 156 Steering 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.
  • Page 157 Steering 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.
  • Page 158 Steering NOTE: Use a calibrated, computerized, 20.6 With the gear on center, place a wrench on the passenger-side inner tie rod flat multi-wheel alignment tool, operated by a and align the right tire by rotating the certified service technician to complete the inner tie rod.
  • Page 160 Fuel Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Fuel Filter Replacement ............. 47–01 Fuel Separator Sight Bowl Cleaning and Element Replacement.

  • Page 162: Safety Precautions

    Fuel 47–00 Safety Precautions 5. Lightly lubricate the threads on the sight bowl with oil, then thread the sight bowl into the bot- tom of the fuel separator. Safety Precautions in this section apply to all 6. Hand-tighten until the gasket is in full contact procedures within this group.
  • Page 163 Fuel 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. Loosen the vent plug.

  • Page 164: Fuel Tank Band-Nut Tightening

    Fuel Racor 690 WARNING Diesel fuel is flammable and can ignite if exposed to an open flame, intense heat, or other ignition source. Do not drain fuel near, or expose fuel vapor to open flame or intense heat. Exposure to open flame or intense heat could start a fire, pos- sibly resulting in personal injury or property dam- age.
  • Page 166 Exhaust Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number CAT CGI Bellows Replacement............49–02 Exhaust System Inspection (Noise Emission Control).

  • Page 168: Safety Precautions

    Replace parts that show leakage, wear, or damage, with genuine Freightliner parts. Pre-EPA07 Exhaust System Inspecting 1. On all vehicles, check the condition of the muffler body, the top stack, and the heat shield.
  • Page 169 Exhaust 06/01/93 f490024a 05/28/93 f490025a 1. Flex Hose Fig. 4, Donaldson Sealclamp Wide-Band Exhaust 2. V-Band Coupling Clamp 3. Exhaust Pipe 4. Turbocharger Exhaust Outlet Fig. 2, V-Band Coupling and Flex Hose 10/05/94 f490005a Fig. 5, Torca Torctite Wide-Band Exhaust Clamp 08/25/95 f490127 1.
  • Page 170 Exhaust maintenance inspections. If any discrepancies Inspection are discovered, refer to the engine manufactur- 1. Check for leakage at the clamp that attaches the er’s service literature for repair instructions. 10/20/2006 f490283 A. Inspect this area of the canister for dents. 1.
  • Page 171 Exhaust NOTE: Because the CGI bellows is covered 9. Check for heat discoloration on the surface of the ATD. Heat discoloration may indicate internal with a metal mesh, it is difficult to see cracks or damage; especially around the DPF. damage that may cause a leak.
  • Page 172 Exhaust 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.
  • Page 173 Exhaust 02/23/2011 f490458 A. At least 7/16 inch (10 mm) 1. Forward CGI Pipe 3. Aft CGI Pipe 2. CGI Bellows Fig. 11, CGI Bellows Installation 13. Install the slip clamp with the retaining ring and graphite gasket ring onto the forward CGI pipe. Fig.
  • Page 174 Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Cab Access Stairs Inspection, Argosy COE..........60–03 Cab Suspension Air Bag Inspection .
  • Page 176 60–01 Cab Suspension Air Bag 60–03 Cab Access Stairs Inspection Inspection, Argosy COE Inspect the cab suspension air bags at the rear of On Argosy COEs, inspect the cab access stairs for the cab. Check for wear, leakage, and damage. Re- wear, damage, or excessive dirt build-up, and verify place if necessary.
  • Page 177 01/13/2003 f602109 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...
  • Page 178 Door Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Door Seal, Door Latch, Door Hinge, and Door Check Lubrication....... 72–01 Century Class Trucks Maintenance Manual, March 2010...
  • Page 180 Door 72–01 Door Seal, Door Latch, Door Hinges on Vehicles Built on or After 8/1/2005 Door Hinge, and Door Check Lubrication On vehicles built on or after 8/1/2005, the door hinge center pin is recessed in the top loop of the hinge bracket.
  • Page 181 Door f720613 8/24/2005 A. Hinge installed on or after 8/1/2005, with dimple in the top loop of the hinge bracket. Do not lubricate. B. Hinge installed before 8/1/2005. Lubricate according to recommendations. Fig. 1, Door Hinge Identification 72/2 Century Class Trucks Maintenance Manual, March 2010...
  • Page 182 Heater and Air Conditioner Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Air Conditioner Inspection............83–01 Air Filter Replacement .
  • Page 184 Heater and Air Conditioner 83–00 Safety Precautions adjustment, see Section 83.01, Subject 140 of the Century Class Trucks Workshop Manual. Safety Precautions in this section apply to all On a Climate Control refrigerant compressor, place a feeler gauge between the air conditioner procedures within this group.
  • Page 185 filter installed. IMPORTANT: When replacing the air filter, use only a Freightliner-approved air filter. 1. Park the vehicle on a level surface. Apply the parking brakes and chock the rear tires. 2. Remove the two Torx® screws that secure the HVAC air filter cover to the air intake plenum.
  • Page 186 Controlled IMPORTANT: When replacing the air filter, use only a Freightliner-approved air filter. The cab recirculation air filter must be replaced every 1. Park the vehicle on a level surface. Apply the six months, regardless of mileage, to permit proper parking brakes and chock the rear tires.
  • Page 187 Fig. 6, Cab Recirculation Air Filter, Blend Air Sleeper Air Filter Replacement, IMPORTANT: When replacing the air filter, use only a Freightliner-approved air filter. Water-Valve Controlled 1. Park the vehicle on a level surface. Apply the Replace the air filter in the sleeper HVAC unit every parking brakes and chock the rear tires.
  • Page 188 Heater and Air Conditioner 04/15/98 f831227 A. The arrow on the filter should point toward the HVAC assembly. 1. Sleeper HVAC Assembly 3. Filter (pleated-paper filter shown) 2. Screen Fig. 7, Sleeper HVAC Assembly, Water-Valve Controlled The pleated paper filter has an arrow on the CAUTION edge of the filter that should point toward the heater assembly.
  • Page 189 Heater and Air Conditioner 5. Place a new air filter in the sleeper HVAC as- sembly. The edge of the filter should be flush with the HVAC assembly. 6. Lower the bunk panel and mattress. 7. Remove the chocks from the tires. 02/26/2002 f831492 1.
  • Page 190 Hood, Grille, and Cab Fenders Index, Alphabetical Title of Maintenance Operation (MOP) MOP Number Hood Rear Support Lubrication............88–01 Century Class Trucks Maintenance Manual, March 2010...
  • Page 192 Hood, Grille, and Cab Fenders 88–01 Hood Rear Support Lubrication 1. Apply the parking brakes and chock the tires. 2. Open the hood. 3. Clean both the hood- and cab-mounted hood rear support components with a soapy water so- lution. 4.

This manual is also suitable for:

Argosy coe 2011C112 conventional 2011C120 conventional 2011Cst120 conventional 2011Coronado 2011

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