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Group No.

Group Title

00 . . . . . . . . . . . . . . . . . . . . . . General Information
01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine
09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Intake
13 . . . . . . . . . . . . . . . . . . . . . . . . . Air Compressor
15 . . . . . . . . . . . . . . . . . . . Alternators and Starters
20 . . . . . . . . . . . . . . . . . . . Engine Cooling/Radiator
25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch
26 . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission
31 . . . . . . . . . . . . . Frame and Frame Components
32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Suspension
33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Axle
35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Axle
40 . . . . . . . . . . . . . . . . . . . . . . . . Wheels and Tires
41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driveline
42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brakes
46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering
47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel
49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust
60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cab
72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Doors
83 . . . . . . . . . . . . . . . . . Heater and Air Conditioner
88 . . . . . . . . . . . . . . Hood, Grille, and Cab Fenders

Introduction

Maintenance Manual Contents

I–4

Century Class Trucks Maintenance Manual, March 2011

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Summary of Contents for Argosy COE 2011

Page 1: ...Maintenance Manual CENTURY CLASS STI 341 1 A24 00691 000...

Page 2: ...S 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 9721...

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Page 4: ...ting 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 con...

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Page 6: ...n 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 bulletin...

Page 7: ...rtain 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...

Page 8: ...enance Operation Number consists of the Group Number followed by the Sequence Number B Group Title C Group Number D Release Date E Group Number Page Number Fig 1 Example of a Century Class Trucks Main...

Page 9: ...5 Clutch 26 Transmission 31 Frame and Frame Components 32 Suspension 33 Front Axle 35 Rear Axle 40 Wheels and Tires 41 Driveline 42 Brakes 46 Steering 47 Fuel 49 Exhaust 60 Cab 72 Doors 83 Heater and...

Page 10: ...Interval Operations 00 06 M2 Maintenance Interval Operations 00 07 M3 Maintenance Interval Operations 00 08 Maintenance Operation Sets Table 00 09 Noise Emission Controls Maintenance 00 10 Service Sch...

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Page 12: ...e 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 II usage are opera tion...

Page 13: ...very 25 000 40 000 Maintenance 2 M2 every 100 000 161 000 Maintenance 3 M3 every 300 000 483 000 Schedule IV Long Haul Transport for Optimized Vehicle Configuration vehicles that annually travel over...

Page 14: ...24 000 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...

Page 15: ...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...

Page 16: ...9 100 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...

Page 17: ...Table 5 91st through 100th Maintenance for Service Schedules I and II 1st through 19th Maintenance for Service Schedules III and IV Maint No Maintenance Interval Service Date Service Schedules III an...

Page 18: ...00 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...

Page 19: ...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...

Page 20: ...ule II vehicles with Detroit axles complete this procedure once a year or every 25 000 miles 40 000 km whichever comes first Complete this procedure every 25 000 miles 40 225 km 3 months or 500 operat...

Page 21: ...t be performed to complete the initial maintenance IM Maintenance Operation Number Initial Maintenance IM Operations for Service Schedules I II III and IV Check 00 06 Perform all M1 Operations 31 03 F...

Page 22: ...Camshaft Bracket Lubrication Dana Spicer Haldex and Gunite Slack Adjuster Lubrication Cab Tilt Pump Reservoir Fluid Level and System Check Door Seal Door Latch and Door Hinge Lubrication Hood Rear Su...

Page 23: ...r Inspection and Lubrication 49 01 Exhaust System Inspection noise emission control 60 02 Cab Tilt Pump Reservoir Fluid Level and System Check 72 01 Door Seal Door Latch and Door Hinge Lubrication 88...

Page 24: ...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...

Page 25: ...dule IV Check 00 04 Lubrication and Fluid Level Check includes the following Clutch Release Cross Shaft Lubrication Sleeve Assembly Bronze Bushing Lubrication Transmission Fluid Level Inspection Knuck...

Page 26: ...g 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...

Page 27: ...06 Perform All M1 Operations 00 07 Perform All M2 Operations 20 02 Radiator Pressure Flushing and Coolant Change 26 01 Manual Transmission Fluid Change and Magnetic Plug Cleaning synthetic lubricant...

Page 28: ...eeve Assembly Bronze Bushing Lubrication 25 04 Meritor Clutch Release Bearing Lubrication 26 01 Manual Transmission Fluid Change and Magnetic Plug Cleaning synthetic lubricant 26 02 Allison Transmissi...

Page 29: ...ion 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...

Page 30: ...en removed inspect the lower and upper isolators and replace them if they are worn Inspect Meritor Unitized Wheel Ends at 200 000 miles 321 870 km and then every 50 000 miles 80 470 km Check the end p...

Page 31: ...ise 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 repla...

Page 32: ...e 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 General Information 00 Verificat...

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Page 34: ...Engine Mount Inspection Noise Emission Control 01 03 Engine Noise Panel Inspection Noise Emission Control 01 01 Engine Support Fasteners Check Noise Emission Control 01 04 Safety Precautions 01 00 En...

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Page 36: ...ame manufacturer To in spect a belt gently twist the belt to view the belt sidewalls and bottom Inspect all drive belts for the following conditions then perform the Belt Tension Inspection Visual Ins...

Page 37: ...sion 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...

Page 38: ...nt Compressor 80 to 100 36 to 45 Power Band Fan 60 to 80 27 to 36 Table 1 Drive Belt Tension Periodically inspect the rubber isolators for cracks cuts wear or damage and replace them if neces sary See...

Page 39: ...l and whenever the engine has been removed inspect the lower and upper isolators see Fig 3 Refs 1 and 6 and replace them if they are worn this applies to both the front and rear isolators See Group 01...

Page 40: ...Title of Maintenance Operation MOP MOP Number Air Cleaner Element Inspection and Replacement 09 01 Air Intake 09 Index Alphabetical Century Class Trucks Maintenance Manual November 2014...

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Page 42: ...After market air cleaner elements may not seal the housing correctly which can lead to engine dam age and potentially the loss of warranty When re placing an air cleaner element use only the part lis...

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Page 44: ...Title of Maintenance Operation MOP MOP Number Air Compressor Inspection 13 01 Safety Precautions 13 00 Air Compressor 13 Index Alphabetical Century Class Trucks Maintenance Manual January 2016...

Page 45: ......

Page 46: ...ersonal injury or death 13 01 Air Compressor Inspection 1 Inspect the air compressor intake hoses and connections at the air intake and air compressor for physical damage If needed change the hoses an...

Page 47: ......

Page 48: ...tenance Operation MOP MOP Number Alternator Battery and Starter Connections Check 15 01 Safety Precautions 15 00 Alternators and Starters 15 Index Alphabetical Century Class Trucks Maintenance Manual...

Page 49: ......

Page 50: ...for correct tension Adjust the belt tension if necessary Engines equipped with a serpentine or poly V belt have automatic belt tensioners and do not require belt tension inspection 4 Check that all el...

Page 51: ...y foreign objects such as stones bolts or nuts from the battery box 10 4 After cleaning connect the cables to the batteries and tighten them to the torque specifications listed on the battery gener al...

Page 52: ...Clutch Check Noise Emission Control 20 03 Pressure Relief Cap Check 20 01 Radiator Pressure Flushing and Coolant Change 20 02 Safety Precautions 20 00 Engine Cooling Radiator 20 Index Alphabetical Cen...

Page 53: ......

Page 54: ...ement 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 th...

Page 55: ...hten the plugs 7 Flush the radiator s as follows 7 1 Disconnect the radiator upper and lower hoses 7 2 Attach the flushing gun nozzle to the ra diator at the lower radiator hose opening Run the water...

Page 56: ...e clamps tighten the clamps 55 lbf 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...

Page 57: ...engine and accessory installation After servicing the cooling system always verify that the coolant level is between the MIN and MAX lines on the surge tank 11 Fill the cooling system with new coolant...

Page 58: ...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 f...

Page 59: ...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 melted This released the clutch before the heat could dam...

Page 60: ...um 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 fo...

Page 61: ...fan blade contact fan clutch slippage and overall fan clutch operation If the fan clutch does not operate correctly see Group 20 of the Century Class Trucks Workshop Manual for troubleshooting and re...

Page 62: ...brication 25 02 Eaton Fuller Clutch Release Bearing Lubrication 25 01 Meritor Clutch Release Bearing Lubrication 25 04 Safety Precautions 25 00 Sleeve Assembly Bronze Bushing Lubrication 25 03 Clutch...

Page 63: ......

Page 64: ...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...

Page 65: ...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...

Page 66: ...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 Clutch 25 Century Class Trucks Maintenance Manual...

Page 67: ......

Page 68: ...on Air Filter Regulator Check Cleaning or Replacement 26 03 Manual and Automated Transmission Fluid Change and Magnetic Plug Cleaning Synthetic Lubricant 26 01 Safety Precautions 26 00 Transmission Fl...

Page 69: ......

Page 70: ...el slug to short the two magnetic poles and divert the magnetic field Install and tighten each drain plug 50 lbf ft 68 N m NOTE The optional transmission fluid filter is a remote mount spin on type an...

Page 71: ...ssion Lubricant Capacities Transmission Model Refill Capacity qt L 7 Speed T Series All Models 18 0 17 0 All 9 Speed Series All Models 13 5 12 8 All 10 Speed Manual Models except deep reduction FR and...

Page 72: ...ion 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...

Page 73: ...egulator Check Cleaning or Replacement Eaton Fuller 1 Apply the parking brakes and chock the rear tires Drain the air reservoirs WARNING Drain the air supply if the air supply is not drained before th...

Page 74: ...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 choc...

Page 75: ...ading 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 f...

Page 76: ...cleaner see if the fluid is level with the fill opening See Fig 1 3 If the fluid level is low check the transmission for leaks and correct as needed 4 If needed add the recommended fluid until it is...

Page 77: ......

Page 78: ...Fifth Wheel Lubrication 31 02 Frame Fastener Torque Check 31 03 Premier 690 Coupling Inspection 31 05 Safety Precautions 31 00 Trailer Electrical Connector Lubrication 31 04 Frame and Frame Components...

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Page 80: ...om 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...

Page 81: ...Pin 7 Bracket Retainer Pin 8 Cotter Pin 3 16 x 1 9 Bumper Spring 10 Handle Spring 11 Bolt Secondary Safety Lock 12 Flat Washer 13 Secondary Safety Lock 14 Bushing Secondary Safety Lock 15 Hex Locknut...

Page 82: ...specting the fifth wheel lubricate all mov ing parts with a chassis or multipurpose grease See MOP 31 02 for lubrication instructions Holland FW35 1 Thoroughly steam clean all fifth wheel compo nents...

Page 83: ...ure the vertical move ment Ref 5 The bracket connection provides a 9 32 inch 7 mm vertical clearance to provide cushioning and to avoid downward pin loading while retaining minimum plate lift If the p...

Page 84: ...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 7 Check the fifth wheel adjustment Using a lock tester lo...

Page 85: ...ssion 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 fo...

Page 86: ...ir 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...

Page 87: ...pockets and the slider bracket Jost Lubricate the kingpin lock using a hand pump grease gun through the grease zerk on the skirt of the fifth wheel see Fig 10 Apply a light oil to all moving parts For...

Page 88: ...ly tightened Continued vehicle operation with loose fasteners could result in bracket or frame damage NOTE Engine supports on vehicles built from January 2007 do not require checking Inspect and check...

Page 89: ...und 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 s...

Page 90: ...ation MOP MOP Number Safety Precautions 32 00 Suspension Inspection 32 01 Suspension Lubrication 32 02 Suspension U Bolt Torque Check 32 03 Suspension 32 Index Alphabetical Century Class Trucks Mainte...

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Page 92: ...ce 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...

Page 93: ...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...

Page 94: ...structions 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 pr...

Page 95: ...tury 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 leve...

Page 96: ...tor cans 360 degrees and visu ally inspect the cans for cracks severe corro sion and distortion If any of these conditions are present or the restrictor can is missing replace the restrictor can WARNI...

Page 97: ...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 saddles See Group 00 of this...

Page 98: ...g 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 f...

Page 99: ...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 t...

Page 100: ...f320423 1 4 3 2 1 Frame Rail 2 Axle Housing 3 Axle Centerline 4 Suspension Ride Height Fig 14 Neway Ride Height Inspection 320020a 05 27 93 1 1 A A Lubricate here 1 Cap and Tube Assembly Bushing Fig 1...

Page 101: ...on looking up until the torque wrench clicks Remove the chocks Spring Assembly U Bolt High Nut Torque Values Size Torque lbf ft N m 5 8 18 Stage 1 Hand Tighten Stage 2 60 81 Stage 3 200 271 Stage 4 18...

Page 102: ...les 33 09 Knuckle Pin Lubrication Dana Spicer Axles 33 05 Knuckle Pin Lubrication Meritor Axles 33 01 Safety Precautions 33 00 Steer Axle Hub Cap Vent Plug Inspection 33 11 Tie Rod Inspection 33 02 Ti...

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Page 104: ...rease 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 p...

Page 105: ...ray 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...

Page 106: ...rication 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...

Page 107: ...nds WARNING Never work under a vehicle that is supported only by a jack Jacks can slip causing the vehicle to fall This could result in serious injury or death 4 Remove the tire and wheel assembly NOT...

Page 108: ...t with a new one 23 If installing a metal hub cap do the following 23 1 Using a wire brush clean the unitized wheel end inner threads and the hub cap external threads 23 2 Apply Loctite 17430 gasket s...

Page 109: ...ug see Fig 11 and Fig 12 Evidence of a leaking vent plug may appear as Oil splatter around the wheel Gooey gummy oil around the vent plug purge point Hub plug area is dirty and water contaminated oil...

Page 110: ...ean with a rag 4 Remove the vent plug and check the oil for evi dence of water contamination If there is evidence of water contaminated oil in the hub disassemble the effected axle end clean inspect a...

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Page 112: ...Number Axle Breather and Axle Lubricant Level Inspection 35 02 Axle Lubricant and Filter Change and Magnetic Strainer Cleaning 35 01 Safety Precautions Rear Axle 35 Index Alphabetical Century Class T...

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Page 114: ...aul vehicles can be extended to 500 000 miles 800 000 km for axles with weight ratings of 34 000 to 40 000 lb 15 000 to 18 000 kg using synthetic lubricant if a lubricant analysis shows adequate quali...

Page 115: ...ication 235 20 Mobil Delvac 1 Gear Oil 75W 90 and Mobilube 1 SHC 75W 90 meet specification 235 8 For more product information see http bevo mercedes benz com Type Ambient Temperature SAE Viscosity Gra...

Page 116: ...tic strainer from the power divider cover 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 th...

Page 117: ...5D Over the Road Service 75W 90 Off Highway Equipment or Under Extra Heavy Loads 80W 140 Table 3 Dana Spicer Drive Axle Recommended Lubricant Dana Spicer Drive Axle Lubricant Capacities Axle Type Axle...

Page 118: ...hile 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...

Page 119: ...isted are approximate Fill axle until lubricant is level with bot tom of fill hole with vehicle on level ground See Traction Equalizer Additives in the text Table 6 Meritor Drive Axle Lubricant Capaci...

Page 120: ...ANT On Detroit axles the oil change interval for long haul vehicles can be extended to 500 000 miles 800 000 km for axles with weight ratings of 34 000 to 40 000 lb 15 000 to 18 000 kg using synthetic...

Page 121: ...round apply the park ing brakes and chock the tires 2 Clean the fill plug and the area surrounding the fill plug on the side of the axle carrier See Fig 3 Remove the plug NOTE Some Meritor axles have...

Page 122: ...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...

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Page 124: ...Title of Maintenance Operation MOP MOP Number Tire Check 40 02 Wheel Nut and Rim Nut Check 40 01 Wheels and Tires 40 Index Alphabetical Century Class Trucks Maintenance Manual January 2016...

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Page 126: ...0 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 thr...

Page 127: ...op any of the following blisters cuts or punctures that reach to the cord a nail screw rock or other puncturing object flat spots or irregular wear tread worn to a minimum depth inability to maintain...

Page 128: ...of Maintenance Operation MOP MOP Number Driveline Inspection 41 01 Driveline Lubrication 41 02 Safety Precautions 41 00 Driveline 41 Index Alphabetical Century Class Trucks Maintenance Manual January...

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Page 130: ...f ft 169 N m See Fig 3 3 Check the driveline yokes for cracks and check end yokes for looseness See Fig 3 Replace cracked yokes If any end yoke can be moved in or out on its shaft or can be rocked on...

Page 131: ...s 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 8 Examine the driveshaft for evidence of m...

Page 132: ...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...

Page 133: ...grease fitting wipe all old grease and dirt from the slip joint grease fitting See Fig 5 Ref 1 2 Use a hand type grease gun or a high pressure gun with a low pressure adapter to lubricate the slip joi...

Page 134: ...Valve Inspection and Lubrication 42 09 Brake Inspection 42 10 Dana Spicer Camshaft Bracket Lubrication 42 05 Dana Spicer Haldex and Gunite Slack Adjuster Lubrication 42 06 Meritor Camshaft Bracket Lu...

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Page 136: ...unt ing bracket strap 6 Remove the two capscrews that secure the air dryer to the lower mounting bracket Mark the position of the mounting bracket to the end cover and mark the capscrews to ease insta...

Page 137: ...tall the two previously marked cap screws four washers and two new Nylok nuts 08 09 95 f421383 1 2 3 4 5 9 10 11 12 13 14 15 17 18 19 21 22 23 24 25 10 10 10 10 10 10 6 7 8 8 8 20 16 1 5 16 x 4 1 2 Up...

Page 138: ...e inside of the end cover Clean the cartridge bolt bore in the end cover and the sealing surfaces for the large and small diameter desiccant cartridge sealing rings 6 Inspect the end cover for physica...

Page 139: ...Twin air dryers NOTICE The WABCO System Saver air dryers can use ei ther a standard or oil coalescing desiccant car tridge When replacing the desiccant cartridge it is very important to use the same t...

Page 140: ...tightly mounted on the frame If the air dryer mounting is loose See Group 42 of the Century Class Trucks Workshop Manual for mounting instructions 3 Turn on the ignition switch but don t start the en...

Page 141: ...m 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...

Page 142: ...l grease appears on the camshaft or flows from the grease relief See Fig 8 The newest Gunite automatic slack adjusters are produced without a grease relief During lubrication with a grease gun lubrica...

Page 143: ...shop 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...

Page 144: ...cedure should be per formed prior to lubrication of the brake compo nents Parking Brake Operational Check CAUTION Perform the following check in a clear safe area If the parking brakes fail to hold th...

Page 145: ...r 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 fo...

Page 146: ...ecifications 42 11 Versajust Slack Adjuster Inspection and Lubrication IMPORTANT Perform the Brake Inspection maintenance operation before lubricating the slack adjusters 1 Visually check for physical...

Page 147: ...ssure for this test build the system pressure up to a 100 psi 690 kPa Shut down the engine Fan the brakes to attain a 90 to 95 psi 621 to 655 kPa reading Make and hold a full brake application while t...

Page 148: ...n 46 01 Drag Link Lubrication 46 05 Power Steering Fluid Level Inspection 46 03 Power Steering Fluid and Filter Changing 46 02 Power Steering Gear Lubrication 46 04 Rack and Pinion Steering Gear Inspe...

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Page 150: ...ot drive the vehicle until the drag link is replaced 46 02 Power Steering Fluid and Filter Changing WARNING Fill only with approved clean fluid Failure to use the proper fluid could cause seal deterio...

Page 151: ...servoir filter when changing the fluid 4 2 Lift out the filter spring and the filter top plate then remove the filter It may be necessary to wiggle the filter to remove it from its base Do not use pli...

Page 152: ...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 f...

Page 153: ...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...

Page 154: ...kshop Manual for in structions Check the steering system pressure and return lines and fittings for leaks and damaged lines or f462151 11 17 12 13 14 1 6 7 5 5 9 9 4 4 3 3 18 19 20 21 23 2 10 22 15 16...

Page 155: ...e gear NOTE A thin film of leftover Terostat MS 939 on the rack housing is acceptable when installing the new bellows 9 If the housing has Terostat MS 939 on it from a previous replacement of the bell...

Page 156: ...e next step 14 2 Ensure the large Oetiker clamp is prop erly seated in the clamp groove on the bellows Align the large Oetiker clamp ear with the small clamp ear Both clamp ears should be aligned with...

Page 157: ...he 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...

Page 158: ...od 20 7 Tighten the tie rod clamp nut 30 to 36 lbf ft 41 to 49 N m IMPORTANT Total toe in should be between 0 and 1 8 inch 3 2 mm and the target is 1 16 inch 1 6 mm 20 8 Check the clearance of the fro...

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Page 160: ...mber Fuel Filter Replacement 47 01 Fuel Separator Sight Bowl Cleaning and Element Replacement 47 02 Fuel Tank Band Nut Tightening 47 03 Safety Precautions 47 00 Fuel 47 Index Alphabetical Century Clas...

Page 161: ......

Page 162: ...ket 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 t...

Page 163: ...5 4 3 3 2 1 1 Vacuum Breaker Drain Valve 2 Reducer Bushing 3 Mounting Brackets 4 O Ring when equipped with heater 5 Stainless Steel V Clamp when equipped with heater 6 Heater Assembly 7 Gasket 8 Sigh...

Page 164: ...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 u...

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Page 166: ...Operation MOP MOP Number CAT CGI Bellows Replacement 49 02 Exhaust System Inspection Noise Emission Control 49 01 Safety Precautions 49 00 Exhaust 49 Index Alphabetical Century Class Trucks Maintenanc...

Page 167: ......

Page 168: ...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 R...

Page 169: ...gularly scheduled f490024a 1 2 3 06 01 93 4 1 Flex Hose 2 V Band Coupling 3 Exhaust Pipe 4 Turbocharger Exhaust Outlet Fig 2 V Band Coupling and Flex Hose 08 25 95 f490127 1 2 3 1 Exhaust Pipe 2 Exhau...

Page 170: ...required torque If leakage persists install a new clamp 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...

Page 171: ...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...

Page 172: ...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 a...

Page 173: ...nserted at least 7 16 inch 10 mm past the face of the flange See Fig 11 Ref A 17 Install the slip clamps on the bellows Tighten the slip clamps 11 lbf ft 15 N m 18 Start the engine and check for exhau...

Page 174: ...Access Stairs Inspection Argosy COE 60 03 Cab Suspension Air Bag Inspection 60 01 Cab Tilt Pump Reservoir Fluid Level and System Check 60 02 Mirror Folding Check 60 04 Cab 60 Index Alphabetical Centu...

Page 175: ......

Page 176: ...tion 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...

Page 177: ...01 13 2003 f602109 1 2 3 4 3 2 1 Forward Bump Stop 2 Flatwasher 3 Bolt 4 Rear Bump Stop Fig 1 Cab Access Stairs Assembly Cab 60 Century Class Trucks Maintenance Manual September 2010 60 2...

Page 178: ...Title of Maintenance Operation MOP MOP Number Door Seal Door Latch Door Hinge and Door Check Lubrication 72 01 Door 72 Index Alphabetical Century Class Trucks Maintenance Manual March 2010...

Page 179: ......

Page 180: ...ated first identify the hinge by checking the top loop of the hinge bracket See Fig 1 Door Hinges on Vehicles Built on or After 8 1 2005 On vehicles built on or after 8 1 2005 the door hinge center pi...

Page 181: ...ter 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 Door 72 Century...

Page 182: ...nce Operation MOP MOP Number Air Conditioner Inspection 83 01 Air Filter Replacement 83 02 Safety Precautions 83 00 Heater and Air Conditioner 83 Index Alphabetical Century Class Trucks Maintenance Ma...

Page 183: ......

Page 184: ...s of damage due to excessive heat replace the drive plate and pulley assembly For instructions see Group 83 of the Century Class Trucks Workshop Manual 4 On a Sanden refrigerant compressor use a feele...

Page 185: ...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 ar...

Page 186: ...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 u...

Page 187: ...ileage 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...

Page 188: ...ts 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 ra...

Page 189: ...ter 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 1 Air Filter Fig 8 Sleeper HVAC Assembly Blend Air Heater and Air...

Page 190: ...Title of Maintenance Operation MOP MOP Number Hood Rear Support Lubrication 88 01 Hood Grille and Cab Fenders 88 Index Alphabetical Century Class Trucks Maintenance Manual March 2010...

Page 191: ......

Page 192: ...ort 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 Grease Supplier Grease Chevron Delo...

Page 193: ......

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