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Heavy-Duty Trucks Maintenance Manual

1. 01 4 Heavy Duty Trucks Maintenance Manual January 2007 Engine 01 Drive Belt Tensions Cummins N14 1 Belt Tension Engine Component Ibf kg Alternator 90 to 120 41 to 55 Cummins M11 Fan 155 to 165 70 to 75 Refrigerant Compressor Alternator 80 to 100 36 to 45 40 to 50 18 to 23 per belt Fan 80 to 120 36 to 54 Refrigerant Compressor 80 to 100 36 to 45 Detroit Diesel Series 60 Alternator and Refrigerant Compressor 80 to 100 36 to 45 power band Fan 60 to 80 27 to 36 Table 2 Drive Belt Tensions Heavy Duty Trucks Maintenance Manual January 2007 01 5 Air Intake 09 Index Alphabetical Title of Maintenance Operation MOP MOP Number Air Cleaner Element Inspecting and Replacing liliis 09 01 Heavy Duty Trucks Maintenance Manual February 2004 Air Intake 09 01 Air Cleaner Element Inspecting and Replacing 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 inH O on a vehicle with a Mercedes Benz engine or 25 inH O on a vehicle with a Caterpillar or Cum mins engine For replacement instructions see Group 09 of the Heavy Duty Trucks Service Manual Reset the air restriction indicator If the maximum restriction is not reached record the air restriction value If the value
2. 05 27 93 f260030a Fig 1 Telescoping Tubes of the FLA FLB Tunnel Mounted Shifter 26 05 Allison Transmission Fluid and Filter Changing When draining transmission fluid check for evidence of dirt or water contamination A small amount of condensation will appear in the fluid during operation Water contamination is normally characterized as a milky discoloration of the transmission fluid Obvious contamination of the transmission fluid indicates a leak between the water and fluid areas of the trans mission cooler Inspect and pressure test the cooler to confirm the leak replace leaking transmission coolers 1 Park the vehicle on a level surface Apply the parking brakes and chock the tires Operate the vehicle until the transmission reaches normal operating temperature 160 to 200 F 71 to 93 C 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 If only the filter is being changed do not drain the fluid Remove the 12 mounting bolts six each from the two filter covers Remove the filter covers O rings and two square cut seals from the transmission See Fig 6 26 2 Heavy Duty Trucks Maintenance Manual November 2001 Transmission 26 05 27 93 1 Latch Cylinder f260145a 2 O Ring 4 1 B N CY N AVE 05 27 93 f260004
3. 00 14 Heavy Duty Trucks Maintenance Manual October 2009 General Information The M2 Maintenance Interval Operations table lists all maintenance operations that are to be performed at the M2 maintenance interval Maintenance opera 00 M2 Maintenance Interval Operations Table 00 08 tion numbers are reference numbers used to help ing those in the text of this manual you find detailed instructions in this manual on the maintenance operations to be performed Perform all M1 maintenance interval operations at the M2 main tenance interval M2 Maintenance Interval Operations for Service Schedules I Il and MI NOTE Maintenance operations appearing in italics in this table are for noise emission control components Numbers in this table are reference numbers match M2 Maintenance Interval Operations for Service Schedules I Il and IlI Gu on er Operation Description Check 00 07 Perform all M1 Operations 01 03 Jacobs Engine Brake Wiring Inspecting 20 01 Radiator Cap Checking 20 03 Fan Drive and Clutch Checking 26 06 Manual Transmission Magnetic Plug Cleaning Oil Changing and Oil Filter Element Changing 26 07 Transmission Air Filter Regulator Checking and Cleaning or Replacing 31 04 Holland Fifth Wheel Sliding Mechanism Inspecting 40 01 Wheel Nut and Rim Nut Checking 42 02 Camshaft Bracket Bushing Lubricating 42 04 Meritor Automatic Slac
4. Fig 16 Hendrickson RS Series Rust Inspection 05 27 93 1320318a Fig 17 Hendrickson RS Series Load Cushion Inspection 32 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 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 4 Visually inspect the cam surface of the number two spring hanger for wear due to operating mileage Also inspect the outside legs for wear which can be caused by worn spring eye bush ings NOTE RTE2 extended leaf spring suspen sions require a minimum gap of 3 8 inch 9 5 mm between the cam surface of the number two spring hanger and the top of the main leaf in the unloaded condition See Fig 18 If this gap is less than 3 8 inch 9 5 mm the extended leaf portion of the spring will not per form satisfact
5. 00 12 Heavy Duty Trucks Maintenance Manual October 2009 General Information The M1 Maintenance Interval Operations table lists all maintenance operations that are to be performed at the M1 maintenance interval Maintenance opera tion numbers are reference numbers used to help 00 M1 Maintenance Interval Operations Table 00 07 you find detailed instructions in this manual on the the vehicle driver s manual maintenance operations to be performed M1 Maintenance Interval Operations for Service Schedules I Il and III IMPORTANT After performing all operations listed in this table perform all daily weekly and monthly maintenance operations listed in the Pretrip and Post Trip Inspections and Maintenance chapter of M1 Maintenance Interval Operations for Service Schedules I Il and IlI Maintenance Operation Number Operation Description Check 00 04 Lubrication and Fluid Level Check includes the following Clutch Release Bearing Lubricating Clutch Release Cross Shaft Lubricating Clutch Linkage Components Lubricating Shift Control Telescoping Tubes Lubricating and Inspecting FLA FLB Shift Control Latch Lubricating and Cylinder Inspecting FLA FLB Selection Lever and Pivot Rod Ball Stud Lubricating FLA FLB Transmission Oil Level Checking and Breather Checking Fifth Wheel Lubricating Trailer Electrical Connector Lubricating Suspension Lubricating Front and Rear Knuckle Pin Lubricating Tie Rod
6. Fig 8 Checking Transmission Oil Level Transmission Lubricant Capacities Transmission Make and Model Capacity pt L ALLISON HD4060 4560 w shallow sump 80 38 HD4060 4560 w standard sump 96 45 FULLER AUXILIARY AT 1202 11 5 2 FULLER 7 SPEED T 8607A B 36 17 0 T 11607A 30 14 2 Heavy Duty Trucks Maintenance Manual November 2001 26 5 26 Transmission Transmission Lubricant Capacities Transmission Lubricant Capacities Transmission Make and Model Capacity pt L Transmission Make and Model Capacity pt L T TX 14607A B 36 17 0 RTX 15710B C 26 12 3 FULLER 8 SPEED RTX 16710B C 26 12 3 RTO 11607L 28 13 2 FULLER 13 SPEED RT 11608 26 12 3 RT RTO RTX 11613 8 13 2 RT 14608 28 13 2 RTLO 12713A 8 13 2 FULLER 9 SPEED RT RTO 14613 9 13 7 RTO 11607LL 31 14 7 RTLO 14613B 28 13 2 RTO 11707LL DLL 28 13 2 RTLO 14713A 8 13 2 RT 8608L 7 12 8 RT RTO 15613 9 13 7 RT 8609 15 7 1 RTLO 16713A 8 13 2 RT RTO RTX 11609A B P R 7 12 8 FULLER 15 SPEED RT RTX 11709H 6 12 3 RT RTO 11615 8 13 2 RT RTO RTX 12609A B P R 7 12 8 RT RTO RTX 11715 8 13 2 RT RTX 12709H 7 12 8 RT RTO 14615 0 14 2 RT RTX 13609A B P R 7 12 8 RT RTO RTX 1
7. f460515a Fig 11 TRW TAS Series Sector Shaft Lubricating 2 Using a hand type grease gun apply multipur pose chassis grease until grease starts coming out of the sector shaft dirt and water seal Heavy Duty Trucks Maintenance Manual November 2002 46 5 46 Steering 46 09 Sheppard Power Steering Gear Bearing Cap Lubricating Wipe the bearing cap grease fitting clean See Fig 12 Using a pressure gun apply multipurpose chassis grease to the bearing cap until old grease is forced out 05 28 93 l f460296a 1 Grease Fitting Fig 12 Sheppard Power Steering Gear Bearing Cap 46 6 Heavy Duty Trucks Maintenance Manual November 2002 Fuel Title of Maintenance Operation MOP Fuel Separator Sight Bowl Cleaning and Element Replacing Fuel Tank Band Nut Tightening FLA FLB and FLD Fuel Tank Vent Checking s siis tior ii diar cee eee 47 Index Alphabetical MOP Number Heavy Duty Trucks Maintenance Manual October 1997 Fuel 47 01 Fuel Tank Vent Checking On earlier vehicles with a screw on fuel cap remove the fuel cap and clean it with solvent Make sure the fuel cap vent is open Install the cap On vehicles with a quarter turn fuel cap check to be sure the vent line at the inboard side of the fuel tank is clean and not plugged 47 02 Fuel Tank Band Nut Tightening FLA FLB and FLD Hold each fuel tank band retention nut with a wrench
8. 7 3 Install the fifth wheel top plate bushing pins and roll pins 8 Inspect for fatigue or cracked welds 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 See Maintenance Operation 31 02 for lubrica tion instructions Castloc Il and Simplex Series 1 Disconnect the tractor from the trailer For in structions see the vehicle driver s manual 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 3 31 2 Heavy Duty Trucks Maintenance Manual October 2009 Frame and Fifth Wheel 31 17 16 14 14 11 12 1 08 29 95 13 1310472 1 Locknut 3 4 16 7 Torsion Spring 13 Lock Pin 2 Washer 8 Roll Pin 14 Lock Jaw 3 Rubber Washer 9 Secondary Lock Right Hand 15 Washer 4 Lock Adjustment Tag 10 Cam Plate 16 Right Hand Release Handle 5 Yoke Shaft 11 Lock Guard 17 Left Hand Release Handle 6 Yoke Sub Assembly 12 Pin 18 Secondary Lock Left Hand Fig 2 Holland Fifth Wheel 5 The
9. 54 02 Speedometer Tachometer Cable Lubricating e 60 01 Cab Tilt System Checking FLA FLB e fe fe fe fe 60 02 Cab Suspension Spring Center Bolt Torque Checking FLC 60 03 Cab Latch Checking FLA FLB e fe fe fede 72 01 Door Seal Door Latch and Door Hinge Lubricating 83 01 Air Conditioner Inspecting e o o Heavy Duty Trucks Maintenance Manual October 2009 00 11 00 General Information Initial Maintenance IM Operations 00 06 IMPORTANT After performing all operations listed in NOTE Numbers in this table are reference numbers this table perform all daily weekly and monthly matching those in the text of this manual maintenance operations listed in the Pretrip and Post Trip Inspections and Maintenance chapter of the vehicle driver s manual Initial Maintenance IM Operations for Service Schedules Il and Ill Initial Maintenance IM Operations for Service Schedules I II and III Doe on rer Operation Description Check 00 07 Perform all MI Operations 15 01 Alternator Battery and Starter Checking 26 06 Manual Transmission Magnetic Plug Cleaning Oil Changing and Oil Filter Element Changing 31 03 Frame Fastener Torque Checking 32 03 Suspension U bolt Torque Checking 33 03 All Axle Alignment Checking 35 02 Axle Lubricant Changing Oil Filter Replacing and Magnetic Strainer Cleaning 54 01 Electrical System Checking
10. 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 4 Torque Values for U S Customary Thread Fasteners with Lubricated or Plated Threads 00 30 Heavy Duty Trucks Maintenance Manual October 2009 General Information 00 Torque Specifications Tables 00 15 Torque Values for U S Customary Thread Fasteners with Dry Unlubricated Plain Unplated Threadst Regular Hex Flanged Thread Grade 5 or B Grade 8 or 8 2 Grade 8 or C Grade 8 or 8 2 d a Grade 5 Bolt Nut Bolt Nut Bolt Grade G Nut Torque Ibf ft N m Torque Ibf ft N m Torque Ibf ft N m 1230003 hl 1230005 1930008 oe 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 7 16 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 2
11. Chamber Size Effective Maximum Allowable Area Stroke square inches inches mm 12 1 1 2 38 16 1 3 4 44 20 1 3 4 44 24 1 3 4 44 24 long stroke 2 51 30 2 51 Adjust the brakes whenever the applied stroke exceeds the maximum Table 1 Maximum Allowable Brake Chamber Stroke with Meritor Cam Brakes 1 1 With the brakes released measure the distance from the face of the air chamber to the centerline of the clevis pin Fig 1 Ref A Record the exact distance as measurement A 1 2 Apply the service brakes and hold them on full line pressure of at least 80 psi 550 kPa Measure the distance from the face of the brake chamber to the center line of the clevis pin Fig 1 Ref B Record the exact distance as measure ment B 1 3 Subtract measurement A from measure ment B to determine the applied stroke 2 Compare this value to the maximum allowable stroke value in Table 1 If the applied stroke equals or exceeds the maximum allowable stroke adjust the brakes 2 1 Wipe clean the adjusting screw hexhead See Fig 1 Place a wrench or socket over the adjusting screw hexhead Fig 1 Measuring Brake Adjustment IMPORTANT On slack adjusters with an adjusting screw locking sleeve wipe clean the locking sleeve area and depress the locking sleeve when placing the wrench or socket over the adjusting screw Do not at tempt to turn the adjusting screw without fully depressing the locking sleeve 2
12. See Fig 8 Locate the grease fitting on the side of the steering column bracket at the end of the crossover shaft lube tube Using a pressure gun lubricate the tube with multipurpose chassis grease See Fig 9 FLD Clutch Linkage The FLD clutch linkage is equipped with two grease fittings See Fig 10 and Fig 11 25 2 Heavy Duty Trucks Maintenance Manual January 1998 Clutch 25 10 06 93 1250196 10 16 97 1250457 1 Steering Column Bracket 2 Crossover Shaft Lube Tube 3 Grease Fitting Fig 9 Lube Tube Grease Fitting FLB Right Hand Drive Fig 7 FLB and Later FLA Bellcrank Pivot Pin Grease Fitting opiSez 3 50 250447 Left hand bearing is shown right hand is similar 1 Bearing 3 Plastic Cap 2 Grease Fitting 4 Crossover Shaft Fig 8 Crossover Shaft Bearing Grease Fitting FLB Right Hand Drive Wipe the dirt from the grease fittings Using a pres sure gun lubricate the clutch linkage with multipur pose chassis grease FLC Clutch Linkage The FLC clutch relay lever is equipped with one grease fitting at the center of the shaft See Fig 12 Wipe the dirt from the fitting Using a pressure gun lubricate the clutch relay lever with multipurpose chassis grease 05 27 93 f250046a Fig 10 FLD Clutch Pedal Lever Grease Fitting 05 27 93 1250047a 1 Grease Fitting 3 Left Hand Frame Rail 2 Clutch Release Lever Fig 11 FLD Clut
13. Texaco 1537 Aircraft Hydraulic Oil 15 Union Arctic Low Pour 65 Hydraulic Fluid 04617 and Filmite 530 Hydraulic Oil f310051a 1 Fill Plug behind lever Fig 1 Power Packer Tilt Pump 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 Heavy Duty Trucks Service Manual for instruc tions Check for wear of the clevis pin and cotter pin on both tilt cylinders Check the tilt pump mounting bolts for tightness see Group 00 of this manual for torque values for lubricated or plated thread fasteners 60 60 02 Cab Suspension Spring Center Bolt Torque Checking FLC Check the torque of the cab suspension spring center bolt locknut The locknut must be tightened 85 Ibf ft 115 Nm 60 03 Cab Latch Checking FLA FLB Check the latch for correct operation For cab latch adjustment see Group 60 of the Heavy Duty Trucks Service Manual Heavy Duty Trucks Maintenance Manual January 1997 60 1 Doors 12 Index Alphabetical Title of Maintenance Operation MOP MOP Number Door Seal Door Latch and Door Hinge Lubricating SE SE Se Se eee 72 01 Heavy Duty Trucks Maintenance Manual January 1997 Door 72 01 Door Seal Door Latch and Door Hinge Lubricating Lightly coat door seals with a lubricant that is safe for rubber Apply a few drops of light engine oil to
14. and PS130 5A SPICER SST 2 Series 6 SPEED SPICER SST 2 Series 12 SPEED 38 18 0 PSO140 12B formerly 1420 30 14 2 1362B amp 1463A PS130 6B amp PSO140 6A formerly SPICER SST 2 Series 14 SPEED 1 19 4 1414 2A amp 3A 30 14 2 SPICER SST 2 Series 6 1 SPEED SPICER SST 2 Series 20 SPEED 1207 2A SPICER SST 2 Series 7 SPEED PSO140 12B formerly 1420 3B 30 14 2 30 14 2 PS140 7A amp PS125 7B formerly Table 1 Transmission Lubricant Capacities 1372A amp 1372B 48 22 7 Approved Transmission Lubricants Ma Lubricant Type Temperature SAE Viscosity ALLISON Dexron III Above 17 F 27 C Heavy Duty Engine Oil meeting MIL L 2104B C or D or Above 10 F 12 C 50 or 40 API Service Classification SF or CD previous API FULLER designations are acceptable Below 10 F 12 C 30 T M n Above 10 F 12 C 90 Mineral Gear Oil with Rust and Oxidation Inhibitor API GL 1 Below 10 F 12 C 80W Heavy Duty Engine Oil meeting API Service Classification SF Above 10 F 12 C 50 or 40 or SG or API Service Classification CD or CE or MIL L 2104B C or D Below 10 F 12 C 30 ROCKWELL Above 10 F 12 C 90 Mineral Gear Oil with Rust and Oxidation Inhibitor API GL 1 Below 10 F 12 C 80 Synthetic Engine Oil meeting Meritor Specification 0 81 All 50 He
15. at the lower rear edge of the cover then pull back on the cover to unfasten the Velcro Remove the tunnel right hand cover Ref 7 by mov ing the passenger seat up and back removing the screw Ref 4 at the upper left edge and removing the two screws Ref 6 at the lower right edge Pull the cover right and back to clear the combo cover 54 10 20 93 1540592a Fig 1 FLA Electrical Mounting Plate 05 28 93 f540040a Fig 2 FLA Electrical Junction Block and manifest box Refs 8 and 10 Then pull the cover upward between the seat and tunnel For an FLC LH DR uncover the main cab connec tors and studs by removing the right hand under dash cover See Fig 11 Ref 1 Uncover the electri cal mounting plate by opening the glove box Ref 2 then moving the stops at the upper edge of the box toward each other while swinging the glove box down and out of the dash Heavy Duty Trucks Maintenance Manual April 1998 54 1 Electrical Instruments and Controls 08 24 93 1540610a 1 Air Oil Junction Block 4 Four Position Junction 2 Electrical Mounting Block Plate 5 Two Position Junction 3 Circuit Breaker Bus Block Bar 6 Relays Fig 3 FLB Electrical Mounting Plate For an FLD uncover the electrical mounting plate by removing the access panel from the dash skirt under the center section of the dash The panel is attached
16. from the side of the case Remove each drain plug from the bottom of the transmission case Drain the oil while the transmission is warm 3 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 4 Install and tighten each drain plug 50 Ibf ft 68 N m Transmission housing breathers must remain clear A plugged breather could result in pressure build up which could cause oil leakage If the breather is plugged clean or replace it See 26 4 Heavy Duty Trucks Maintenance Manual November 2001 Transmission Fig 7 Check more often if the vehicle operates under very dusty conditions 05 27 93 1260007a Fig 7 Transmission Breather Fuller shown NOTE For a Fuller transmission equipped with an oil filter s change the filter as instructed under Fuller Transmission Oil Filter Element Changing before filling the transmission with oil IMPORTANT Do not mix types and brands of oil because of possible incompatibility Do not use oil additives friction modifiers extreme pressure gear oils or multiviscosity lubricants Do not use extreme pressure additives such as those found in multipurpose or rear axle type lubricants These additives are not required and may create transmission problems Multipurpose oils have relatively poor oxidation stability a high rate of sludge formation
17. see Fig 1 or Breeze Constant Torque clamps see Fig 2 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 Heavy Duty Trucks Maintenance Manual January 2007 20 1 20 install these clamps correctly Correct installation torque for Breeze Constant Torque hose clamps is For clamps with a 5 16 inch tightening screw hex 55 Ibf in 620 N cm For clamps with a 3 8 inch tightening screw hex 90 Ibf in 1020 N cm 02 28 96 1200326 Fig 1 T Bolt Type Hose Clamp N 08 15 94 200286 A The screw tip must extend about 1 4 inch 6 mm B The belleville washer stacks must be collapsed almost flat 1 Tightening Screw Hex Fig 2 Breeze Constant Torque Hose Clamp Installation 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 Engine Cooling R adiator pressure During vehicle operation and shut down the screw
18. system and inspect it for worn 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 Inspect each slack adjuster and anchor strap as sembly for damage See Fig 4 Replace any damaged parts 3 Check that the control arm nut is tightened 10 to 15 Ibf ft 14 to 20 N m 4 fthe control arm is in the wrong position the brakes will drag Verify that the control arm is in its full release position 4 1 Chock the rear tires then release the parking brakes 4 2 Remove the clevis pin 4 3 With your finger lightly push the slack adjuster into the clevis then release it The adjuster may move slightly due to springing of the anchor strap but will re turn to its original position holes in the adjuster and the clevis will remain in alignment This shows that the control arm is fully released 4 4 If the control arm is fully released install the clevis pin and go to the next step Brakes 10 20 93 A Rotate the control arm toward the brake chamber until you can feel it contacting the internal stop B Rotate the adjusting nut counterclockwise to increase brake shoe clearance f420014a 1 Clevis 6 Control Arm Washers 2 Slack Adjuster and Nut 3 Clevis Pin 7 Anchor Strap Slot 4 Manual Adjusting Nut 8 Anchor Strap 5 Control Arm 9 Brake Chamber Fig 4 Haldex SAB Automatic
19. 00 00 0000 eee eee 42 01 Brane INSPCCHON EC PEE 42 24 CR Brakemaster Air Dryer Cleaning Model 62 or 68 0 000 e eee eee 42 14 Gamshatt Bracket Bushing Lubricating ressa 2 3 3 6 boe UP dt EE DERS ES pe be Reh de egi 42 02 Manual Automatic Slack Adjuster Lubricating and Checking All Models 000000505 42 03 Meritor Automatic Slack Adjuster Lubricating llle 42 04 Meritor WABCO System Saver 1000 Air Dryer Desiccant Replacing 0 000000 ee ee 42 23 Midland Quick Release and Flipper Valve Checking llli 42 22 Sealco Moisture Ejection Valve Operation and Leak Testing Model 6300 005 42 21 Wedge Brake Checking 55 25 939 18202 Eo teen te den tube ok ee ated o Sos E ead ptu 42 05 Wedge Brake Inspecting and Lubricating 2 3 xem opm xor ea meer c REGES ss 42 06 Heavy Duty Trucks Maintenance Manual October 2009 Brakes 42 01 Brake Adjusting Cam Brakes With Manual Slack Adjusters 42 Meritor Brakes 1 Adjust Meritor brakes whenever the brake cham ber piston rod applied stroke equals or exceeds the maximum allowable stroke shown in Table 1 08 20 93 A B 1 D 3 420008a With the brakes released measure this distance With the brakes applied measure this distance Brake Chamber Manual Slack Adjuster typical Adjusting Screw Maximum Allowable Brake Chamber Stroke with Meritor Cam Brakes
20. 12 for a Reyco 179 2 Check the fit of springs to hangers to ensure good ride characteristics 3 Check for elongated holes in the suspension components See Group 32 of the Heavy Duty Trucks Service Manual for proper repair proce dures 4 Check bushing condition Replace any bushing that is worn cracked dry rotted or otherwise damaged See Group 32 of the Heavy Duty Trucks Service Manual for bushing removal and installation instructions 5 Check tire condition If abnormal wear is found check and replace all worn or damaged compo nents and check suspension alignment See Group 32 of the Heavy Duty Trucks Service Manual for component removal and installation procedures and for suspension alignment in Suspension 6 Inspect all suspension fasteners for proper torque values See Group 00 of this manual for proper bolt torque specifications Chalmers Walking Beam Suspension 800 Series Chock the front tires to prevent the vehicle from mov ing Place the transmission in neutral and release the parking brakes before inspecting the Chalmers rear suspension Power wash the Chalmers rear suspension or clean it with a hard bristle brush before performing a visual inspection 1 Visually inspect the rubber bushings for cracks or other damage Try to move the torque rod ends using your hands only and check for any free play If free play is felt replace the torque rod end bushing Do not use a pry bar to check f
21. 2 Turn the adjusting screw until it is tight then back off the adjustment until the drum is free Normally the adjusting screw will need to be backed off 2 or 3 clicks NOTE Check brake adjustment with the wheel on the ground Checking brake adjust ment when the wheel is off the ground may be unreliable Looseness or wear in wheel bearings will cause the drum to be mis aligned while the wheel is off the ground 2 3 To determine if the brake drum is free strike the drum with a steel tool and listen for a clear ringing sound If a dull thud is heard the brake is dragging and further adjustment is needed IMPORTANT On slack adjusters with an adjusting screw locking sleeve after adjust Heavy Duty Trucks Maintenance Manual October 2009 42 1 42 ment make sure the locking sleeve is en gaged around the adjusting screw hexhead to lock the adjusting screw in place Eaton Brakes 1 Adjust Eaton brakes when either the brake chamber piston rod applied stroke or free stroke equals or exceeds those values in Table 2 Brakes Compare this value to the maximum allowable stroke value in Table 2 If the applied stroke equals or exceeds the maximum allowable stroke check the piston rod free stroke 2 1 With the brakes released measure the distance from the face of the air chamber to the centerline of the clevis pin Fig 1 Ref A Record the exact distance as measurement A 2 2 Using a lever as shown
22. 2009 Frame and Fifth Wheel 31 01 Fifth Wheel Inspecting 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 Failure 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 vehicle driver s manual Thoroughly steam clean the fifth wheel 3 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 ease of 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 See Group 00 of this manual for bolt torque specifications 7 Visually check all springs to see if they are se curely fastened and are not deformed Do not dis
23. 3 3 To see if the drum is free strike the brake drum with a steel tool and listen for a clear ringing sound If a dull thud is heard the brake is dragging and further adjustment is needed 4 Check the free stroke again to verify that it is within the desired range IMPORTANT On slack adjusters equipped with an adjusting screw locking sleeve after adjust ment make sure that the locking sleeve is en gaged around the adjusting screw hexhead to lock the adjusting screw in place 42 02 Camshaft Bracket Bushing Lubricating IMPORTANT Perform MOP 42 24 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 3 Multipurpose chassis grease is recom mended NLGI Grade 1 6 12 hydroxy lithium stearate grease or NLGI Grade 2 8 12 hydroxy lithium stearate grease Be careful that no grease enters the drum cavity If grease leaks out under the cam head the camshaft grease seal is worn or dam aged or is installed backwards NOTE Use of meter type fittings which have a maximum 40 psi 275 kPa pressure relief at shutoff is recommended 42 Camshaft brackets without grease fittings are fitted with special seals and packed with extended lubrication interval chassis grease Grease them only when the camshaft is disassembled for servicing 3 2 V I 05 28 93 A 1420011a A Grease Exit 1 Brake Chamber 3 Non Pres
24. 8 Push Port 12 Left Tilt Cylinder Fig 2 Optional Air Hydraulic System Equipped With Hydraulic Cab Latches and Cab Air Suspension On FLBs cab latches are hydraulic and are plumbed into the cab tilt system The tilt cylinders are connected to the pump by flex ible high pressure lines Velocity fuses are built into the tilt cylinder ports They act as check valves to prevent the cab from free falling in case of hydraulic System damage such as a ruptured line There are two hydraulic circuits in the Power Packer System the pushcircuit raises the cab from the low ered position to the desired tilt position and the pull circuit brings the cab from a tilted position up and over center See Fig 3 Placing the control lever in the Raise position opens the push circuit in the hydraulic system When the mechanical cab hold down latches are released and the pump is operated hydraulic pressure builds in the tilt cylinders and the shift disconnect cylinder If equipped with hydraulic cab latches hydraulic pres sure releases the latches As pressure increases the shift disconnect cylinder releases to allow the shift tube to telescope out Then the tilt cylinder piston rods extend raising the cab When the cab goes over center it falls at a controlled rate to the full tilt position automatically relieving hydraulic system pressure When the control lever is placed in the Lower posi tion the pull circuit in the hydrau
25. 95 1310475 A Extended Top Plate Lift Height Fifth Wheel Top Plate Fifth Wheel Frame Mount Frame Rail Lifting Point Static Top Plate Height N PD Fig 5 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 8 Check all mounting bolts for signs of fatigue and tighten them to the proper torque For torque specifications see Group 00 of this manual In spect all angles plates and brackets for cracks or other damage 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 See Maintenance Operation 31 02 for lubrica tion instructions ASF Touchloc Control Mechanism General Inspection 1 Replace cracked broken bent or missing parts with new parts See Fig 6 2 The cotter pin located in the slide cam clevis pin must be in place and properly spread 31 4 Heavy Duty Trucks Maintenance Manual October 2009 Frame and Fifth Wheel 31 09 12 96 310549 1 Cotter Pin 3 Mounting Bolts 2 Locknut 4 Sli
26. BEES j EER LA TEG YY ara ti 777 YF gl SS LLA tf Ne Y 2042 274 1 pd WA A ELEK 2 Az Iiii paa LLL a 2 3 05 27 93 1320317a 1 Nut 4 Beam Hanger 2 Adapter 3 Inner Metal of Beam End Bushing Fig 7 Two Piece Adapter Type Beam End Connection Heavy Duty Trucks Maintenance Manual October 2009 32 3 32 3 1 1 EE EE EE EE E fe AAA EER EE AERA SEER S TEMERE 222222 sa AR 05 27 93 2 f320111a 1 Nut 3 Beam Hanger 2 End Tube Fig 8 Tube Type Beam End Connection 5 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 Heavy Duty Trucks Service Manual for instructions 6 Inspect the rubber bushing ends Replace the torque arm for any of the following reasons e f there are gaps between the rubber bush ing and the pin or outer steel sleeve e f either bushing end contacts a torque arm pin mounting bolt e f there are cracks in the bushing e f part of the rubber bushing extends be yond the outer circumference of the outer bushing sleeve Freightliner AirLiner Air Suspension 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
27. Do not point the air stream in the direction of other persons Rear Axle AO 2 Power Divider 05 27 93 1 Magnetic Strainer f350017a Fig 6 Eaton Tandem Drive Axle Magnetic Strainer 52 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 and drain plugs To facilitate clean ing of 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 the recommended lubricant See Table 1 for recommended drive axle lubri cants and Table 3 or Table 4 for drive axle lubri cant capacities 35 4 Heavy Duty Trucks Maintenance Manual January 1997 Rear Axle 35 Eaton Single Drive Axle Lubricant Capacities Capacity Axle Type Axle Model pints liters 230858 23085D 40 18 9 231058 23105D 48 22 7 Single Reduction 23121 41 19 4 30105S 46 21 8 Double Reduction 35
28. Drag Link and Power Steering Cylinder Lubricating 1 Using a clean rag wipe all dirt from both drag link grease fittings and if so equipped both power steering cylinder grease fittings See Fig 5 Fig 6 and Fig 7 05 28 93 1 Grease Fitting f460009a Fig 5 Drag Link pitman arm end 2 Using a pressure gun apply clean grease at the grease fittings until old grease is forced out of the socket Use multipurpose chassis grease NLGI grade 2 896 12 hydroxy lithium stearate grease or NLGI grade 1 696 12 hydroxy lithium stearate grease Grade 2 is preferred 46 05 Power Steering Reservoir Fluid Level Checking Failure to keep the power steering reservoir full could result in damage to the power steering pump and improper operation of the power steer ing system 46 2 Heavy Duty Trucks Maintenance Manual November 2002 Steering 46 05 28 93 1 Grease Fitting f460010a Fig 6 Drag Link axle steering arm end 05 28 93 1 Grease Fitting axle steering arm end 1460048 Fig 7 Power Steering Cylinder 1 Clean around the power steering reservoir dip stick fill cap with a clean rag Then remove the dipstick fill cap See Fig 8 2 3 2 X 4 j 5 05 28 93 1460012 1 Dipstick T Handle 2 Thumbscrew 3 Hose Fitting 4 Gear to Reservoir Return Hose 5 Reservoir to Pump Supply Hose Fig 8 2 Quart Power Steering Reservoir 2 L
29. End Inspecting and Lubricating Axle Breather and Lubricant Level Checking Driveline Lubricating Manual Automatic Slack Adjuster Lubricating and Checking All Models Steering Driveline Lubricating Ross Manual Steering Gear Lubricant Checking Model 503 Drag Link and Power Steering Cylinder Lubricating Power Steering Reservoir Fluid Level Checking Ross Power Steering Gear Lubricating TAS Series Sheppard Power Steering Gear Bearing Cap Lubricating Cab Tilt System Checking FLA FLB Door Seal Door Latch and Door Hinge Lubricating 13 01 Bendix Air Compressor Inspecting 31 01 Fifth Wheel Inspecting 32 01 41 01 Suspension Inspecting Driveline Inspecting 42 01 Brake Adjusting Cam Brakes With Manual Slack Adjusters Heavy Duty Trucks Maintenance Manual October 2009 00 13 00 General Information M1 Maintenance Interval Operations Table 00 07 M1 Maintenance Interval Operations for Service Schedules I Il and III o ass ed r Operation Description Check 42 05 Wedge Brake Checking 42 11 Bendix Air Dryer or Anchorlok Aftercooler Inspecting Bendix AD 2 AD 4 AD 9 or Anchorlok 42 14 CR Brakemaster Air Dryer Cleaning Model 62 or 68 42 22 Midland Quick Release and Flipper Valve Checking 42 24 Brake Inspection 47 02 Fuel Tank Band Nut Tightening FLA FLB and FLD 60 03 Cab Latch Checking FLA FLB 49 01 Exhaust System Inspecting
30. Manual page see Fig 1 Introduction A Y Frame and Fifth Wheel 31 01 Frame Fastener Torque Checking Because of bedding in or seating frame fasteners must be torqued at recommended intervals When tightening fasteners check the frame for cracks and other damage CAUTION Continued vehicle operation with loose fasteners could result in bracket or frame damage Frame fasteners are used on front frame brackets axle Stops equalizer stops suspension brackets fuel tank brackets exhaust and air intake brackets engine trun nion supports rear engine supports frame crossmem bers and gussets fifth wheel mounting angles and fifth wheel legs Refer to the frame section in the vehicle service manual for additional information on frame fasteners and to the general information section in the vehicle Service manual for fastener information and torque values 31 02 Fifth Wheel Inspecting and Lubricating 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 during removal installation and rebuild ing Failure to do so can result in personal injury due to parts ejecting with force FONTAINE 1 Disconnect the tractor fr
31. Meritor Automatic Slack 35 Adjuster Lubricating IMPORTANT Perform MOP 42 24 before lubri cating the slack adjusters 1 Remove the pressure relief capscrew pawl 10 27 93 1420653a spring and pawl See Fig 5 1 7 16 Inch Adjusting 6 Clevis I 2 Examine the pawl for grease retention and condi pee En E bred Eia Er tion If the grease is in good condition install the ET ing 4 asses Hast n pressure relief capscrew pawl spring and pawl A Link j Opening then tighten the pressure relief capscrew 15 to 5 Brake Chamber Piston 10 Slack Adjuster Spline 20 Ibf ft 20 to 27 N m Lube the slack adjuster Rod through the grease fitting until lubricant is forced out through the pressure relief fitting or pawl Fig 6 Gunite Automatic Slack Adjuster slot 3 2 Rotate the worm shaft adjusting hexnut If the grease has hardened or the pawl is dry counterclockwise to move the link away and shows extreme wear remove the slack ad from the clevis About 45 Ibf ft 60 N m is juster Disassemble and clean it Inspect the in needed You will hear a clicking sound ternal parts install new seals and a new boot R the old boot f the link when assembling then install and lubricate the CMOS ME O SOGO TORIS j slack adjuster See Group 42 of the Heavy Duty 3 3 Install a new boot on the link heavy sec Trucks Service Manual for instructions tion down Be careful not to damage the boot 42 05 Wedge Brake Checking 3 4 Seat the boot so that the bottom of
32. be replaced See Group Retaining 2 f 2 gt a acd a ae ae Trucks Service Manual for Model Numbers Plate era j Fasteners 6 Release the air pressure then disconnect the 1090 05261 01 shop hose from the air inlet of the air cylinder 1090 05262 01 Bolt Connect the vehicle air hose to the inlet 1090 05261 02 Lockwasher 0 16 4 1 1090 05262 02 ana Nut 7 Connect the electrical cables to the battery If equipped with an air starter charge the air 1090 06620 01 starter reservoir 1090 06060 01 i 1090 07050 01 Capscrew 8 Start the engine The LOW WTR light and warn 1090 08000 01 p 0 17 4 3 ing buzzer should be off If the light and buzzer 1090 06620 0 Lockwasher are off the sensor is okay If the light and buzzer 1090 06060 02 are on replace the sensor 1090 07050 02 The fan clutch model number is stamped on the tag on the air cylinder Also the models can be identified by the type of retaining plate fasteners used Table 6 Kysor Dynair Fan Clutch Wear Limits 20 8 Heavy Duty Trucks Maintenance Manual January 2007 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 the solenoid valve Fig 7 Kysor Dynair and Kysor K22RA Fan Clutch Lining Wear Checking Schwitzer Viscous Fan Drive NOTE
33. by spinning the filter element off of the fuel heater water separator body 4 Remove the filter stud seal then clean the top of the unit body 5 Add fuel to the fuel heater water separator hous ing until it reaches the top of the fuel port 6 Install a new filter stud seal 7 Coat the filter gasket with clean oil Spin the filter element onto the unit housing unit it contacts the gasket then turn it 1 2 to 3 4 turns more Do not use a filter wrench to tighten the filter Heavy Duty Trucks Maintenance Manual October 1997 47 7 47 8 Start the engine then raise the rpm for 1 to 2 minutes to purge air from the system and check for fuel leaks 9 Shut down the engine and correct any fuel leaks Davco 380 The only maintenance necessary on Davco 380 fuel separators is to replace the filter element See Fig 9 Fuel 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 Note As an emergency option the Davco 380 will accept a spin on type filter onto its threaded 2 filter stud with the grommet removed 3 1 Place a suitable container under the fue
34. 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 1 Remove the fill plug from the transmission 2 Insert a finger or pipe cleaner into the transmis sion 3 Check that the fluid level is even with the base of the fill plug See Fig 8 Heavy Duty Trucks Maintenance Manual November 2001 26 11 26 Transmission The correct fluid capacity is established by the fill opening If the transmission has two fill plugs check that the fluid level is consistent at both fill plugs 4 Ifthe transmission fluid level is low check the transmission for leaks and correct as needed 5 If needed add the recommended fluid until it is level with the lower edge of the fill opening See Table 2 for approved transmission lubricants 26 12 Heavy Duty Trucks Maintenance Manual November 2001 Frame and Fifth Wheel 31 Index Alphabetical Title of Maintenance Operation MOP MOP Number Frik Wheel MSp M pr EEUU 31 01 FRR VV MOU Neuere rr umm 31 02 Frame Fastener Torque Checking 200 0 0 EE EE EE ee ee 31 03 Holland Fifth Wheel Sliding Mechanism Inspecting liliis 31 04 Trailer Electrical Connector L breating lt s cierirsricer inani dapitan iaa ran 31 05 Heavy Duty Trucks Maintenance Manual October
35. damaged hoses see Group 83 of the Heavy Duty Trucks Service Manual for replacement instructions Also check for loose fittings on all air conditioning components 7 Check for a build up of road debris on the con denser fins See Group 83 of the Heavy Duty Trucks Service Manual for cleaning instructions Refrigerant Checking Find the moisture indicator sight glass on the receiver drier and check the color of the moisture indicator See Fig 2 If the indicator is a deep cobalt blue the refrigerant charge is dry If the indicator is not blue the system is contami nated with water If the system is contaminated the refrigerant must be recovered and the receiver drier must be replaced See Group 83 of the Heavy Duty Trucks Service Manual for instructions Heavy Duty Trucks Maintenance Manual January 1997 83 1 83 Heater and Air Conditioner 7 12195 O 1830746 1 Moisture Indicator Fig 2 Receiver Drier 83 2 Heavy Duty Trucks Maintenance Manual January 1997
36. for smooth operation Castloc II and Simplex Series Use a chassis or multipurpose grease to lubricate the two grease fittings located on either side of the fifth wheel top plate Lubricate the two grease fittings 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 31 03 Frame Fastener Torque Checking 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 Check the torque of frame fasteners to offset the effects of bedding in or seating When checking torque torque the nut not the bolt head whenever possible This will give a true torque read ing by eliminating bolt body friction When checking 31 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 l
37. foundation brake system and inspect it for worn or damaged com ponents Improperly maintaining the vehicle brak ing system may lead to brake failure resulting in property damage personal injury or death 1 Lubricate the slack adjuster using high temperature waterproof grease NLGI Grade 1 such as Texaco Thermotex EP No 1 Shell Da rina No 1 Marathon 528 heavy duty Sunaplex No 1 EP Amdex No 1 EP or Philube B No 1 It should be smooth textured corrosion resistant grease free of fillers and abrasives Lubricate the slack adjuster through the grease fitting Fig 5 Ref 7 until grease is forced out past the pressure relief capscrew Ref 5 or past the gear splines around the inboard snap ring 2 Check the boot for cuts tears or other damage Replace it if necessary Gunite Automatic Slack Adjuster Lubricating and Checking Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mechanical problem Adjustment 42 10 20 93 42001 2a Brake Chamber Clevis Actuator Rod Boot Pressure Relief Capscrew Gasket Pawl Spring and Pawl Manual Adjusting Nut Grease Fitting or Lube Plug o RON NO Fig 5 Meritor Automatic Slack Adjuster is not repairing Before adjusting an automatic slack adjuster troubleshoot the foundation brake system and inspect it for worn or damaged com ponents Improperly maintaining the vehicle bra
38. if necessary 3 Lift the edge of the brake plunger boot and check the plunger for existing lubrication If the plunger is dry remove it by removing the cotter pin and clevis pin and pulling the clevis pin out Remove the piston rod and boot Lift out the plunger Lubricate the plunger and the tip of the piston rod with barium grease part number BW 246671 or Pennzoil Adhezoplex EP 2 use only these approved lubricants Install the piston rod boot clevis pin and cotter pin If the plunger has grease on it lift the edge of the brake plunger boot enough to apply 2 to 4 drops of light oil around the brake plunger do not over oil Install the plunger boot Lubricate the clevis pin with light oil 5 For E 12 valves check for leakage see Group 42 of the Heavy Duty Trucks Service Manual for instructions FLD NOTE You may need to remove tie straps and an air line to gain access to the valve bore It should not be necessary to remove the adaptor from the valve 1 Remove the three mounting bolts that hold the foot brake valve on the firewall Brakes 2 From outside the cab pull the valve away from the firewall then remove the brake valve mount ing adaptor and plunger See Group 42 of the Heavy Duty Trucks Service Manual for instruc tions 3 Thoroughly clean any grease and contaminants from the brake valve mounting adaptor bore and the plunger surface 4 Inspect the adaptor bore and the plunger sliding surfa
39. in structions For BP 1 LQ 5 PP 7 R 14 and TC 7 valves check for proper operation See Group 42 of the Heavy Duty Trucks Service Manual for instruc tions 42 20 Bendix Foot Brake Valve Actuator Lubricating E 6 or E 12 and Leak Testing E 12 FLA or FLB 1 Clean any dirt gravel and other foreign material from the base of the brake pedal the plunger boot and the brake base bracket 2 Use light oil to lubricate the brake pedal roller and roller pin 3 Check the brake plunger boot for cracks holes or deterioration Replace if necessary Heavy Duty Trucks Maintenance Manual October 2009 42 11 42 4 Lift the edge of the brake plunger boot and check the plunger for existing lubrication If the plunger is dry remove it by removing the brake pedal and brake plunger boot Lubricate the plunger and inside surface of the boot with barium grease part number BW 246671 or Pen nzoil Adhezoplex EP 2 use only these approved lubricants Install the plunger boot and brake pedal If the plunger has grease on it lift the edge of the brake plunger boot enough to apply 2 to 4 drops of light oil around the brake plunger where it slides into the brake base bracket Reinstall the plunger boot around the brake base bracket FLC 1 Clean any dirt gravel and other foreign material from the plunger boot and brake base bracket 2 Check the brake plunger boot for cracks holes or deterioration Replace
40. nents 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 Engine Cooling R adiator If the fan clutch does not operate correctly see Group 20 of the Heavy Duty Trucks Service 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 9 Using a wet finger or a soapy water solution check for a leak in the same areas 05 30 2002 i 1200581 Fig 9 Checking for Air Leaks Horton DriveMaster 9 Ifa leak is detected remove the fan blade In stall a new seal kit See Group 20 of the Heavy Duty Trucks Service Manual for repair proce dures 10 Check the fan drive for discoloration or any other signs of slipp
41. not over tighten Remove the jack stands and lower the vehicle 10 Fill the reservoir with the same fluid used above as needed Start the engine and let it idle Have someone turn the steering wheel to full stop in each direction until no bubbles are seen in the reservoir Shut down the engine 11 Install the cover and capscrew on the reservoir Tighten the capscrew 10 to 15 Ibf ft 14 to 20 N m If equipped with a thumbscrew install the cover and thumbscrew and tighten the thumb screw finger tight For a 9 quart reservoir install a new O ring the band clamp and the cover Tighten the clamp bolts 40 Ibf ft 54 N m Install the dipstick 12 Start the engine Check the reservoir for fluid leaks around the cover If fluid leaks are present 46 shut down the engine and install a new reservoir cover gasket 13 Check the power steering fluid level in the reser voir If the fluid level is low add more of the same fluid used above to bring the level up to the full mark on the dipstick 46 07 Steering Driveline Deck Bearing Lubricating FLA FLB For an FLA or an FLB apply light oil sparingly to the deck bearing Apply the oil at the deck bearing sup port cap if equipped or through the felt seal on top of the deck bearing support bracket 46 08 TRW Power Steering Gear Lubricating TAS Series 1 Wipe off debris from the grease fitting See Fig 11 04 13 93 1 Sector Shaft Grease Fitting
42. 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 See Group 32 of the Heavy Duty Trucks Service Manual for instructions Front and Rear Suspension Shock Absorber Check Make sure the shock absorber brackets are tight and the shock absorber is not striking or rubbing the frame or some other part of the chassis Striking or rubbing the frame is characterized by chafe marks on the shock absorber body and the frame rail See Fig 1 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 Heavy Duty Trucks Service Manual for replacement instructions Rear Suspension Check Freightliner Sprin
43. 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 Diesel Particulate Filter DPF a filter that col lects and holds particulate matter soot and ash Diesel Oxidation Catalyst DOC oxidizes hy drocarbons and reduces NOx e Sensors detect temperatures and pressures in the ATS Exhaust Inspection 1 Check for leakage at the clamp that attaches the exhaust pipe to the turbocharger exhaust outlet If leakage exists tighten the nut on the clamp to the required torque If leakage persists install a new clamp 2 Check the exhaust pipe bellows and each 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 loosened or removed it must be replaced 3 If present check the condition of the insulation material around the exhaust pipe between the turbocharger and the ATD 4 Check the ATD mounting bands for tightness Tighten to 30 Ibf ft 41 N m if needed Do not overtighten 5 Check for leaks around the clamps that attach the ATD in the ATS and ar
44. 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 12 26 Eaton Fuller Transmission 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 2 Using your finger or a bent pipe cleaner see if the fluid is level with the fill opening See Fig 8 3 If the transmission fluid level is low check the transmission for leaks and correct as needed 4 f needed add the recommended fluid until it is level with the lower edge of the fill opening See Table 2 for approved transmission lubricants 5 Clean the fill plug install it in the transmission then tighten it 50 Ibf ft 68 N m Meritor Transmission A CAUTION Operating a transmission with the fluid level higher or lower than recommended
45. or damaged clean or replace it as needed Meritor Axle Lubricant Level Checking CAUTION Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage 1 With the vehicle parked on level ground apply the parking brakes and chock the tires 2 Clean the fill plug in the side of the axle carrier and the area surrounding it See Fig 4 Then 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 With the vehicle on level ground lubricant should be level with the bottom of the fill hole If low check for oil leaks correct as needed then add specified lubricant See Table 2 for recom mended drive axle lubricants 35 2 Heavy Duty Trucks Maintenance Manual January 1997 Rear Axle 35 Meritor Drive Axle Recommended Lubricant Recommended Lubricant SAE Meritor Lubricant Type ambient Temperature Viscosity Grade Specification 10 F 12 2 C and up 85W 140 0 76 A 15 F 26 1 C and up 80W 140 0 76 B Hypoid Gear Oil 15 F 26 1 C and up 80W 90 0 76 D API Service m Classification GL 5 40 F 40 C and up 75W 90 0 76 E 40 F 40 C to 35 F 2 C 75W 0 76 J 40 F 40 C and up 75W 140 0 76 L l 40 F 40 C and
46. the door latch mechanism to reduce noise and wear Wipe off ex cess oil This includes baggage doors ventilator doors and the oil check door Lubricate door hinges every six months In addition lubricate new door hinges at installation Lubricate the hinges by spraying them with a light coating of silicone lubricant such as WD 408 or an equivalent For an FLC lubricate new access panel hinges at installation then once every six months by spraying them with a light coating of silicone lubricant such as WD 40 or an equivalent 72 Heavy Duty Trucks Maintenance Manual January 1997 72 1 Heater and Air Conditioner 83 Index Alphabetical Title of Maintenance Operation MOP MOP Number Ar Conditioner IEDERE us ER distri eur PD renun do M debba ers Bachan Ord RAD dipl 83 01 Heavy Duty Trucks Maintenance Manual January 1997 Heater and Air Conditioner 83 01 Air Conditioner Inspecting Wear eye protection gloves and protective 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 air conditioner compressor pulley assembly If the friction sur face of the pulley shows signs of excessive grooving due to belt slippage replace both the pulley and the drive plate Visually ins
47. the following check Visually inspect the rubber isolators see Fig 1 Ref 7 for an FLA FLB or FLD Fig 2 Refs 4 and 6 for an FLC for cracks cuts and other damage replace if damaged Also at engine overhaul or whenever the engine has been removed replace the isolators See Group 01 of the Heavy Duty Trucks Service Manual for isolator replacement procedures 1 4 5 NC A UT 8 3 F Bp 9 e 10 05 27 93 Frame Rail Upper Mounting Bolt Nut and Washers Lower Mounting Bolt Nut and Washers Engine Rear Support Bolt and Washer Engine Leg Snubbing Washers or Wear Plate s Rubber Isolator Locknut Washer and Snubbing Washer Engine Mount 10 Spacer s f010155a OONOAR WY Fig 1 Engine Rear Support Assembly FLA FLB and FLD Check the engine rear support fasteners for tight ness See Fig 1 for an FLA FLB or FLD or Fig 2 for an FLC See Table 1 for torque specifications 01 16 96 EA Overslung Crossmember Engine Support Bolt Transmission Mounted Engine Support Bracket Upper Isolator Frame Mounted Engine Support Bracket Lower Isolator Engine Support Stop Nut 1010648 Fig 2 Engine Rear Support Assembly FLC Heavy Duty Trucks Maintenance Manual January 2007 01 1 01 Engine Rear Engine Support Fasteners Torque Specifications Description Size Grade BER E m Rear Engine Support Isolator Nut FLA FLB and
48. the l boot is in the boot insert and the top is in 1 Check brake shoe lining wear to determine the the groove of the link proper reline time 3 5 Rotate the adjusting hexnut clockwise 2 Check the lining to drum clearance Automatic until the 1 4 inch hole in the clevis lines adjusters are working properly if for brakes up with the hole in the link using two parking brake chambers per wheel clearance at the inspection hole is between 42 6 Heavy Duty Trucks Maintenance Manual October 2009 Brakes 0 010 and 0 060 inch 0 25 and 1 5 mm If ad justers are not working properly schedule the vehicle for brake system service See Group 42 of the Heavy Duty Trucks Service Manual For brakes using one parking brake chamber per wheel clearance in excess of 0 035 inch 0 9 mm may require manual adjustment to obtain optimum performance until the vehicle can be scheduled for service The above numbers are established as a guide to indicate a range only and are not precise Specific situations may differ due to individual component combinations of drums and linings etc 3 Check service and parking brake air systems by cycling the respective application valves Check the service brake by actuating the treadle several times Observe the action to determine if there is correct actuating system function and correct lining to drum contact Check parking brake operation by actuating the control valve on the dashboard of the cab
49. tip may adjust according to temperature and pressure changes The torque may need to be adjusted for individual applica tions IMPORTANT On vehicles with EPAO7 compliant engines the coolant capacity varies depending on the engine and accessory installation After servicing the cooling system always verify that the coolant level is between the MIN and MAX lines on the surge tank 9 Fill the radiator with new coolant See Group 20 of the Heavy Duty Trucks Service Manual for guidelines See Table 1 for FLA FLB and FLD 120 cooling system capacities Table 2 for FLC 112 cooling system capacities Table 3 for FLD 112 cooling system capacities See Table 4 for antifreeze protection information Certain equip ment such as fuel heaters water filters and auxil iary heaters may increase the coolant capacity and require additional coolant The cooling sys tem is filled when the coolant level reaches the MAX line on the surge tank Freightliner recom mends the use of a precharged and premixed antifreeze when refilling the cooling system See Table 4 for a list of some of the precharged anti freeze available Use of an equivalent antifreeze to those listed in the table is also acceptable Always check that the antifreeze used meets Freightliner s specifications and is at the proper concentration for protection in the vehicle operat ing area See Table 5 for antifreeze protection information Freightliner specifies that the anti freeze m
50. 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 Heavy Duty Trucks Maintenance Manual October 2009 32 1 32 placed see Group 32 of the Heavy Duty Trucks Service 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 2 Re place the torque arm for any of the following rea sons e f there are gaps between the rubber bush ing and the pin or outer steel sleeve e f either bushing end contacts a torque arm pin mounting bolt e f there are cracks in the bushing e If part of the rubber bushing extends be yond the outer circumference of the outer bushing sleeve 6 Block up the frame enough to take chassis weight off the springs Attempt to move the equalizer up and down using a pry bar between the top of the equalizer and top of the equalizer bracket apply hand pressure only See Fig 3 If movement at the center of the equalizer exceeds 1 8 inch 3 mm replace the equalizer bushings See Group 32 of the Heavy Duty Trucks Service Manual for instructions 7 With the vehicle unloaded attempt to move the equalizer side to side using a pry bar between the equalizer and frame rail Apply hand pressure only See Fig 4 If clearance b
51. to extend during cab tilting General Information e A tilt strut on the right side tilt cylinder which must be used when working under a cab that has not been fully tilted The optional air hydraulic system has the same major parts as the hydraulic only system but has an additional air motor assembly attached to the tilt pump See Fig 2 The air motor normally operates the tilt pump in place of the manual pump control lever If for any reason the air motor is not working the tilt pump can be operated with the manual pump lever 17 07 03 97 f310031a A Tit Pump Enlargement 1 Tilt Strut 7 Reservoir 13 Shift Tube 2 Right Tilt Cylinder 8 Push Port Fitting 14 Shift Tube Latch Mechanism 3 Push Port Fitting 9 Pull Port Fitting 15 Shift Disconnect Cylinder 4 Pump Body 10 Push Port Fitting 16 Fill Plug 5 Pump Control Lever 11 Pull Port Fitting 17 Fittings 6 Pump Lever 12 Left Tilt Cylinder Fig 1 Hydraulic Only System Equipped With Mechanical Cab Latches 00 18 Heavy Duty Trucks Maintenance Manual October 2009 General Information 00 COE Cab Tilting FLA FLB 00 11 03 02 98 A Air supply connects here 1 Shift Disconnect Cylinder 5 Reservoir 9 Pull Port 2 Tilt Strut 6 Manual Pump Lever 10 Right Hydraulic Cab Latch 3 Right Tilt Cylinder 7 Pump Control Lever 11 Left Hydraulic Cab Latch 4 Air Motor Assembly and Button
52. until the gasket contacts the head base then turn it an additional 1 3 to 3 4 of a turn 10 Connect the water sensor probe connector and bowl heater connector if equipped 11 Remove the priming plug located at the top of the fuel water separator and manually fill the fuel water separator with clean diesel fuel Install and tighten the priming plug 12 Start the engine and check for fuel and coolant leaks Repair all leaks with the engine OFF Davco Fuel Heater Water Separator Filter Element Replacement Davco 321 The only maintenance necessary on Davco 321 fuel separators is to replace the filter element See Fig 8 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 47 1 2 3 4 5 6 f e 02 07 97 1470276 1 Filter Vent 4 Filter Stud 2 Filter Element 5 Davco Unit Body 3 Filter Stud Seal 6 Fuel Port Fig 8 Davco 321 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 Place a suitable container under the fuel heater water separator Open the filter vent using a 1 1 8 wrench then drain the fuel from the fuel heater water separator by opening the drain valve 2 Close the drain valve 3 Remove the filter element
53. up 75W 90 0 76 N Synthetic Gear Oil 7 40 F 40 C and up 75W 140 0 76 M There is no upper limit on these ambient temperatures but axle sump temperature must never exceed 250 F 121 C Table 2 Meritor Drive Axle Recommended Lubricant 4 Install and tighten the fill plug 35 Ibf ft 47 Nm NOTE When adding to or checking the oil level of non drive axles make certain the hub cap and plug are cleaned before removal of the plug this will minimize the possibility of dirt and road grime entering the assembly 5 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 e Z 2 3 06 07 94 1350062a 1 Axle Housing 2 Carrier Oil Fill Plugs Breathers 3 Interaxle Differential Fig 4 Fill Plug and Axle Housing Breather Locations Meritor Axle Breather Checking Axle housing breathers Fig 4 must remain clean Whenever the axle lubricant level is checked check the axle breather to be sure it is open Check more often under adverse operating conditions If the breather is plugged clean or replace it as needed 35 02 Axle Lubricant Changing Oil Filter Replacing and Magnetic Strainer Cleaning Eaton Axle Lubricant Changing and Magnetic Strainer Cleaner CAUTION Failure to change the axle lubricant at more fre quent intervals when adverse operating condi tions req
54. volt 120 watt end cover re sistance should be 4 0 to 4 6 ohms If the heater resistance is outside stated limits install a new or remanufactured end cover 6 Check that a good ground path exists between the air dryer end cover casting and the vehicle chassis Correct if needed If the heater resistance is within stated limits the thermostat is defective Replace the thermostat kit number 102657 or install a new or remanu factured end cover 42 7 Install the thermostat cover Ref 10 as shown in Fig 9 be sure the rubber spacer and gasket are correctly installed Bendix AD 9 During cold weather check operation of the end cover heater and thermostat assembly 1 With the ignition on check for voltage to the heater and thermostat assembly Unplug the electrical connector at the air dryer and place a test lead on each pin of the male connector If there is no voltage look for a blown fuse broken wires or corrosion in the vehicle wiring harness Check that a good ground path exists 2 Check thermostat and heater operation Turn off the ignition switch and cool the end cover as sembly to below 40 F 4 C Using an ohmmeter check resistance between the electrical pins in the female connector Resistance should be 1 5 to 3 0 ohms for the 12 volt heater and 6 8 to 9 0 ohms for the 24 volt heater Some early models of the AD 9 will have resistance readings of 1 0 to 2 5 ohms for the 12 volt heater and 4 8 to
55. while backing off its jam nut Then tighten the reten tion nuts 30 to 45 Ibf ft 41 to 60 N m After the re tention nuts have been tightened hold each with a wrench while tightening its jam nut 50 to 65 Ibf ft 68 to 88 N m Do not overtighten 47 03 Fuel Separator Sight Bowl Cleaning and Element Replacing 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 clean using a soft cloth 47 2 3 3 4 5 6 7 8 9 10 08 25 95 1470146 1 Vacuum Breaker Drain 6 Heater Assembly Valve 7 Gasket 2 Reducer Bushing 8 Sight Bowl Heater 3 Mounting Brackets Rod 4 O Ring when Sight Bowl Assembly equipped with heater 10 Vacuum Breaker Drain 5 Stainless Steel Valve V Clamp when equipped with heater Fig 1 ConMet Fuel Separator 4 Lubricate the gasket with a film of oil and rein stall it on the sight bowl If the gas
56. 0 49 600 3100 Heavy Duty Trucks Maintenance Manual October 2009 00 3 00 General Information Vehicle Maintenance Schedule Tables 00 03 i i i i Service I jin Required iss ve Operation Service Date ES Es 32nd M1 32 000 51 200 3200 33rd M1 33 000 52 800 3300 34th M1 34 000 54 400 3400 35th M1 and M2 35 000 56 000 3500 36th M1 36 000 57 600 3600 37th M1 37 000 59 200 3700 38th M1 38 000 60 800 3800 39th M1 39 000 62 400 3900 40th M1 M2 M3 and M4 40 000 64 000 4000 41st through 60th Maintenance for Service Schedule Vehicles i i i i Service I NDS Required daa aa i Operation Service Date ES s m 41st M1 41 000 65 600 4100 42nd M1 42 000 67 200 4200 43rd M1 43 000 68 800 4300 44th M1 44 000 70 400 4400 45th M1 and M2 45 000 72 000 4500 46th M1 46 000 73 600 4600 47th M1 47 000 75 200 4700 48th M1 48 000 76 800 4800 49th M1 49 000 78 400 4900 50th M1 M2 and M3 50 000 80 000 5000 51st M1 51 000 82 000 5100 52nd M1 52 000 83 700 5200 53rd M1 53 000 85 300 5300 54th M1 54 000 86 900 5400 55th M1 and M2 55 000 88 500 5500 56th M1 56 000 90 100 5600 57th M1 57 000 91 700 5700 58th M1 58 000 93 300 5800 59th M1 59 000 94 900 5900 60th M1 M2 M3 and M4 60 000 96 500 6000 00 4 Heavy Duty Trucks Maintenance Manual October 2009 General Information 00 Vehicle Mainte
57. 055P 36 17 0 Quantities listed are approximate Fill axle until lubricant is level with bot tom of fill hole with vehicle on level ground Table 3 Eaton Single Drive Axle Lubricant Capacities NOTE Some Eaton axles have a small tapped and plugged hole near and below the housing oil fill hole See Fig 1 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 Fig 2 or top of the standpipe opening 8 2 Install and tighten the fill plug 40 to 60 Ibf ft 54 to 81 Nm 8 3 For forward drive axles remove the power divider fill plug located slightly off set to the right in the top portion of the forward differential carrier See Fig 7 Add two pints 1 L of lubricant through this fill hole Do not use the hole at the top of the differential carrier as a fill hole Install and tighten the fill plug 40 to 60 Ibf ft 54 to 81 Nm Eaton Two Speed Axle Shift Unit Oil Changing 1 Remove the shift unit housing cover Fig 3 Drain and discard the old lubricant Discard the housing cover gasket 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 90 to f350019a
58. 1 When checking wheel nuts on a dual disc assembly remove one outer nut at a time tighten the inner nut then reinstall the outer nut Repeat this procedure for all wheel nuts using the sequence shown in Fig 1 Wheel Fastener Torque in Torque dry threads Description Nut Size Wheel Manufacturer Ibf ft N m 8 Stud Disc Wheel With Two Piece Flanged Locknuts Front and Rear Wheel Nut All 450 500 610 680 Front and Rear Wheel Nut 10 Stud Disc Wheel With Two Piece Flanged Nuts M22 x 1 5 Budd Uni Mount 10 390 440 530 600 10 Stud Disc Wheel With Inner and Outer Locknuts 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 Corrugated Channel Spacer Fig 3 Front Wheel Nut 5 and 6 Spoke 3 4 10 Gunite and Dayton 200 225 271 305 Rear Wheel Nut 5 and 6 Spoke With 2 y S x Non Corrugated Channel Spacer Fig 2 3 4 10 Gunite and Dayton 200 225 271 305 Rear Wheel Nut 9 anid 6 Spoke With 3 4 10 Gunite and Dayton 240 260 325 350 Torque values given are for lubricated threads t On front axles with over 12 000 Ibs 5448 kg capacity tigh
59. 1541818 12 03 97 SN f541830 1 Ground Stud 3 Power Stud 1 Power Stud 3 Ground Stud 2 40 Way Connector 2 40 Way Connector Fig 14 FLC RH DR 40 Way Connector Fig 13 FLC LH DR 40 Way Connector Heavy Duty Trucks Maintenance Manual April 1998 54 7 Cab Title of Maintenance Operation MOP Cab Latch Checking ELA FELEB is iuo DES SNR E nae Iber Cab Suspension Spring Center Bolt Torque Checking FLC Cab Tilt System Checking FLA FLB 0000 leen 60 Index Alphabetical MOP Number Heavy Duty Trucks Maintenance Manual January 1997 Cab 60 01 Cab Tilt System Checking FLA FLB Before checking the fluid level in the tilt pump reser voir the cab must be in the operating position with the cab latches locked Let it remain in this position for at least five minutes before checking the reser voir The reservoir is full when the fluid is at the level of the fill hole See Fig 1 If the 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 Heavy Duty Trucks Service Manual for instruc tions Add tilt system hydraulic fluid MIL H 5606 to bring the level up to the fill hole Approved tilt pump fluids are
60. 20 x 1 5 213 313 320 434 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 M30x2 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 6 Torque Values for Metric Thread Fasteners with Lubricated or Plated Threads 00 32 Heavy Duty Trucks Maintenance Manual October 2009 Engine 01 Index Alphabetical Title of Maintenance Operation MOP MOP Number Engine Drive Bel NSPECING lt viciats drin eto ate xi EAR SUE be Gees RE ED danas Dae Kad 01 04 Engine Noise Panel Inspecting Noise Emission Control llli 01 02 Engine Rear Support Assembly Checking Noise Emission Control liliis 01 01 Jacobs Engine Brake Wiring Inspecting ss deme dd eem me WEE o imos Eu p t in edades 01 03 Heavy Duty Trucks Maintenance Manual January 2007 Engine 01 01 Engine Rear Support Assembly Checking Noise Emission Control 01 Front and rear engine supports for vehicles built from January 2007 require no periodic maintenance Mounts should be inspected when the engine is re moved for service For vehicles manufactured prior to January 2007 perform
61. 3 Forward Differential Carrier 05 27 93 1 Fill Plug 2 Power Divider Fig 7 Power Divider Fill Plug 110 IDf in 1020 to 1240 N cm then remove the oil fill plug from the cover IMPORTANT When vehicle operating tempera tures are above 0 F 18 C use SAE 10 heavy duty engine oil API service classification SD sulfated ash content must not exceed 1 8596 When vehicle operating temperatures are below 0 F 18 C use one part kerosene to three parts SAE 10 heavy duty engine oil API service classification SD sulfated ash con tent must not exceed 1 85 This cold weather mixture can be safely used up to 32 F 0 C Commercially available automatic transmission fluid may be used in place of SAE 10 engine oil Automatic transmission fluid can be used for all temperatures do not mix kerosene with it To prevent component damage do not mix engine oil and automatic transmission fluid 4 Fill the shift unit housing through the oil fill hole until specified lubricant is level with the bottom of the opening 5 Apply a small amount of Loctite 242 or equiva lent sealant to the threads of the fill plug Install the plug finger tight then using a wrench tighten it 1 1 2 turns past finger tight Heavy Duty Trucks Maintenance Manual January 1997 35 5 35 Rear Axle Eaton Tandem Dri
62. 33 AN C49 20 4 Heavy Duty Trucks Maintenance Manual January 2007 Engine Cooling Radiator 20 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 16 10 4 3 12 22 34 48 62 20 76 9 12 16 19 24 30 37 44 523 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 O F 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 O F 18 C Table 5 Maximum Coolant Protection in Degrees F Degrees C at Various Antifreeze Concentrations 20 03 Fan Drive and Clutch Checking Noise Emission Control Eaton Viscous Fan Clutch Periodic maintenance is not required because an Eaton viscous fan drive is a sealed unit However periodically check it for damage and for correct op eration
63. 42 06 Wedge Brake Inspecting and Lubricating IMPORTANT Before inspection cage all parking brake units manually or by air pressure See Group 42 of the Heavy Duty Trucks Service Manual for instructions Ensure that the emer gency brake airline pressure is exhausted be fore removing the line from the brake chamber 1 Remove the wheels and brake drums Refer to the axle section in the service manual for wheel and drum removal instructions and brake lining dust warnings 2 Inspect the plunger seals See Fig 7 If seals are cut torn or otherwise ineffective disas semble and overhaul the brake actuating components 3 Remove the pawl assembly then remove the adjusting plunger and seal to check internal con dition If grease is contaminated or hardened or if parts are dry disassemble and overhaul the brake actuating components 42 10 20 93 f350020a 1 Adjusting Plunger 5 Adjusting Pawl 2 Hollow Capscrew 6 Adjusting Bolt 3 Gasket 7 Plunger Seal 4 Pawl Spring 8 Adjusting Sleeve Fig 7 Wedge Brake Adjusting Components NOTE Highly polished parts do not always re quire replacement Only components that are scored or show other unusual signs of wear must be replaced 4 Grease the unit using multipurpose chassis grease NLGI grade 1 such as Texaco Thermo tex EP No 1 Shell Darina No 1 Marathon 528 heavy duty Sunaplex No 1 EP Amdex No 1 EP or Philube B No 1 Assemble the adjus
64. 4715 8 13 2 RT RTX 13709H 7 12 8 RT RTO 15615 0 14 2 RT RTO RTX 14609A B P R 7 12 8 RT RTO RTX 15715 8 13 2 RT RTX 14709H 6 12 3 FULLER 18 SPEED RTX 16709B H 7 12 8 RTLO 14618A 28 13 2 FULLER 10 SPEED RTO 15618 28 13 2 RT 7608LL 19 5 9 2 RTLO 16618A 28 13 2 RTO 11608LL 9 13 7 MERITOR 9 SPEED RTO RTX 11708LL 8 13 2 RM9 RMO9 RMX9 115A B R 18 8 5 RTO 14608LL 9 13 7 RM9 RMO9 RMX9 125A B R 18 8 5 RTO RTX 14708LL 8 13 2 RM9 RMOS9 RMX9 135A B R 18 5 8 75 RT RTO RTX 11610 6 12 3 RM9 RMO9 RMX9 145A B R 18 5 8 75 RT RTX 11710B C 6 12 3 RM9 RMX9 155A B 18 5 8 75 RT 12610 6 12 3 MERITOR 10 SPEED RTLO 12610B 8 13 2 RMX10 115A 18 8 5 RT RTX 12710B C 6 12 3 RMX10 125A 18 8 5 RTLO 13610B 8 13 2 RMX10 135A 18 5 8 75 RT RTX 13710B C 6 12 3 RMX10 145A 18 5 8 75 RT RTO RTX 14610 6 12 3 RMX10 155A 18 5 8 75 RTLO 14610A B 8 13 2 MERITOR 13 SPEED RT RTX 14710B C 6 12 3 RMO13 145A 20 9 5 RTLO 15610B 8 13 2 SPICER AUXILIARY 4 SPEED 26 6 Heavy Duty Trucks Maintenance Manual November 2001 Transmission 26 Transmission Lubricant Capacities Transmission Make and Model Capacity pt L Transmission Make and Model Transmission Lubricant Capacities Capacity pt L AMO 1000 4 Series amp APO1000 4 Series formerly 1241 Series 14 6 6 SPICER SST 2 Series 10 SPEED 1310 2A SPICER SST 2 Series 5 SPEED 1 19 4 1452A 1453A
65. 58 190 258 5 818 155 210 215 292 3 410 240 325 340 461 340 461 3 416 270 366 380 515 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 4 Freightliner recommends that all plated and unplated fasteners be coated with oil before installation Table 5 Torque Values for U S Customary Thread Fasteners with Dry Unlubricated Plain Unplated Threads Heavy Duty Trucks Maintenance Manual October 2009 00 31 00 General Information Torque Specifications Tables 00 15 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 N 7 N N ai 88 N 8 Z tog J N is f230010 f230011 f230012 f230013 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 M12 x 1 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 M
66. 6a NOTE Before March 15 1990 the main cab harness interface connectors were located on the firewall 1 Junction Block 2 Main Cab Power Studs circuit 14 studs on junction block 3 Relays 4 Circuit Breaker Bus Bar 5 Cab to Chassis and Cab to Engine Harness Interface Connectors Fig 7 FLD Electrical Mounting Plate straps may cause breaks in the wire insulation allowing the aluminum tie strap to make contact with the wire This could cause a short circuit and damage to the wiring 2 Check all tie straps for breakage and damage Replace any broken or cracked tie straps 3 Check the wires of all sensors on or near the engine Make sure no wires are closer than 6 inches 15 cm to hot surfaces If any are and can not be rerouted make sure they are pro tected by heat shields Check that sensor con nectors are tight clean and undamaged 4 On engines with electronic controls check the wiring and connectors on the computer units Heavy Duty Trucks Maintenance Manual April 1998 54 3 54 54 02 Speedometer Tachometer Cable Lubricating Remove the cable from the housing Wash the cable in solvent and wipe it dry Examine it for breaks kinks or frayed ends Rub a thin layer of Lubriplate on the lower two thirds of the cable leave the upper one third free of grease Install the cable 2 02 16 96 1830679 1 Glove Box Liner 2 Electrical Panel Electrical Instruments an
67. 7 2 ohms for the 24 volt heater If resistance is higher than this replace the purge valve housing assembly which includes the heater and thermostat assembly 3 Warm the end cover assembly to over 90 F 32 C and again check resistance It should ex ceed 1000 ohms If it does the thermostat and heater assembly is operating properly If it doesn t replace the purge valve housing assem bly which includes the heater and thermostat assembly 42 11 Bendix Air Dryer or Anchorlok Aftercooler Inspecting Bendix AD 2 AD 4 AD 9 or Anchorlok Bendix AD 2 AD 4 or AD 9 Check reservoirs for moisture A small amount tea Spoon or less is normal An excess may indicate that desiccant replacement is necessary Heavy Duty Trucks Maintenance Manual October 2009 42 9 42 Check the mounting and connecting lines Make sure that SAE grade 5 fasteners attaching the air dryer to the vehicle are tightened 28 Ibf ft 38 N m for 3 8 16 fasteners and 45 Ibf ft 61 N m for 7 16 14 fasten ers Check all air lines fittings and electrical connec tions for damage leakage or looseness Replace damaged or leaking components and tighten loose fittings and electrical connections Anchorlok Inspect the Anchorlok aftercooler Fig 10 for loose mountings cracks or other damage from external sources Check for leakage at air fittings the drain valve and the automatic ejector valve Tighten any loose mountings and le
68. After performing the checks below if any part of the fan drive requires service or replace ment see Group 20 of the Heavy Duty Trucks Service Manual for instructions 1 Check the tightness of the fasteners attaching the fan to the fan drive and fan drive to the fan hub For torque values see Group 00 of this manual 2 Check the fan and surrounding area for signs of physical contact between the fan and other parts If there has been contact correct the cause Re place all damaged parts 3 Check the drive belts for fraying cracking and correct tension see Group 01 of the Heavy Duty Trucks Service Manual 4 Turn the fan by hand at least one full turn It should turn smoothly with some resistance If there is binding or jerkiness or if the fan spins freely replace the fan drive 20 5 Check the fan drive for fluid leakage Very slight misting and dust accumulation around the pin in the center of the front cover is normal Any other leakage is abnormal and will result in poor per formance Replace the fan drive if there is abnor mal leakage 6 Move one blade tip alternately toward and away from the radiator The allowable play is 1 16 inch 1 6 mm at a 10 inch 254 mm radius from the center of the fan See Fig 8 If there is greater movement and it can not be traced to loose fas teners or fan hub pulley bearing wear replace the fan drive 05 27 93 1200238 A 10 254 mm B 1 16 1 6 mm maximum
69. Detroit Diesel Series 55 47 0 44 4 48 0 45 3 49 0 46 3 System capacity includes all hoses fittings and the heater core Table 1 Engine Cooling System Capacity for FLA FLB and FLD 120 pre EPA07 engines Engine Cooling System Capacity for FLC 112 Radiator Core and System Capacity Engine Make Engine Model 2 Row 3 Row 4 Row quarts liters quarts liters quarts liters 3176 49 0 46 4 50 0 47 3 NA Caterpillar 3306B NA 51 0 48 3 NA 3406B NA 58 0 54 9 58 5 55 4 L10 41 0 38 8 41 5 39 3 NA Cummins Big Cam III NA 56 0 53 0 56 5 53 5 Big Cam IV low flow NA 49 5 46 8 50 0 47 3 M Series 60 NA NA 58 6 55 5 Detroit Diesel Series 55 47 0 44 4 48 0 45 3 49 0 46 3 System capacity includes all hoses fittings and the heater core Table 2 Engine Cooling System Capacity for FLC 112 Engine Cooling System Capacity for FLD 112 Radiator Core and Engine Make Engine Model System Capacity quarts liters Caterpillar 3176 3306 ATAAC 38 0 36 0 Heavy Duty Trucks Maintenance Manual January 2007 20 3 20 Engine Cooling R adiator Engine Cooling System Capacity for FLD 112 Radiator Core and Engine Make Engine Model System Capacity quarts liters 6CTA8 3 35 0 33 1 Cummins L10 33 0 31 2 System capacity includes all hoses fittings and the heater core Table 3 Engine Cooling System Capacity for FLD 112 Approved Antif
70. FLD 5 8 11 C 160 216 Rear Engine Support Isolator Stop Nut FLC 1 00 8 B 280 380 380 515 Frame Mounted Engine Support Bracket Nut 5 8 11 C 190 258 Transmission Mounted Engine Support Bracket Capscrew FLC 3 4 10 8 340 461 Overslung Crossmember Nut FLC 1 2 13 C 95 129 Torque values are for dry unplated fasteners Table 1 Rear Engine Support Fasteners Torque Specifications 01 02 Engine Noise Panel Inspecting Noise r Emission Control If so equipped inspect for torn engine noise panels See Fig 3 for a Caterpillar engine or see Fig 4 for 1 a Cummins engine If panels are torn replace them with new panels see Group 01 of the Heavy Duty 4 Trucks Service Manual for procedures Cummins M11 and N14 engines and Detroit Diesel Series 55 and Series 60 engines do not have engine noise panels 01 03 Jacobs Engine Brake 2 Wiring Inspecting 05 27 93 0108472 NOTE Caterpillar 3406E i d th ight sid Inspect the wiring from the dash switches to the en noise ae d E gine brake housings for breaks and for broken or chafed insulation Make sure that all terminal connec ae oe aid n tions are in good condition and are fastened Inspect A Lei de Meca Benel the wiring to the clutch and throttle switches See Group 01 of the Heavy Duty Trucks Service Manual for the engine brake wiring diagram NOTE Some engine brake installations do not use clutch or throttle switches 01 04 Engine Drive Belt Inspecting Worn o
71. FREIGHTLINER Run Smart HEAVY DUTY TRUCKS MAINTENANCE MANUAL Models FLA COE FLB COE FLC 112 Conventional FLD Conventional FLL COE STI 329 1 10 09P Published by Daimler Trucks North America LLC 4747 N Channel Ave Portland OR 97217 Printed in U S A Foreword When performed on a regular basis lubricating the parts of your vehicle is the least costly way of obtaining safe and reliable vehicle operation Added benefits and savings occur when you check that the engine undercarriage and noise emission control parts are in good working order during lubrication IMPORTANT The maintenance operations in this manual are not all inclusive Also refer to other component and body manufacturers instructions for specific inspection and maintenance instructions Perform the operations in this maintenance manual at scheduled intervals Perform the pretrip and post trip inspections and daily weekly monthly maintenance as outlined in the vehicle driver s manual Major components such as engines transmissions and rear axles are covered in their own maintenance and operation manuals that are provided with the vehicle Perform any maintenance operations listed at the intervals scheduled in those manuals Your Freightliner Dealership has the qualified technicians and equipment to perform this maintenance for you They can also set up a scheduled maintenance program tailored specifically to your needs Optionally they can assist you
72. If the fan drive is inoperative or damaged replace it with a new one See Group 20 of the Heavy Duty Trucks Service Manual for instructions Horton Advantage and HT 55O Fan Clutch NOTE If any part of the fan clutch needs to be fixed or replaced after performing the checks below see Group 20 of the Heavy Duty Trucks Service Manual 1 Inspect all electrical connections and wires Tighten the connections if loose and replace wires and connections if damaged 2 Charge the air system to 120 psi 627 kPa then proceed as follows A WARNING Do not jumper the thermal switch while the engine is running This could start the cooling fan which could result in serious personal injury If the vehicle is equipped with Detroit Diesel Opti mized Idling make sure this feature is not acti vated If Optimized Idling were activated the en gine could start up without warning resulting in serious personal injury 2 1 If equipped with an electric thermal switch make sure the engine is not run ning Put the ignition switch in the ON position engine shut down Place a jumper between the thermal switch con nectors located in the engine thermostat housing while observing the fan clutch The fan clutch should be seen and heard engaging If equipped with a fanstat shutterstat run the engine until its temperature is above the fanstat engagement setting of 195 F 91 C The fan clutch should en gage causing the fan to tu
73. Lubrizol Corporation Hi Tec E 336 Edwin Cooper Inc e Equa Torque No 2411 Sta Lube Corpora tion e Equa Torque No 2414 Sta Lube Corpora tion B For Mobilube HD mineral oil and Mobilube SHC synthetic use Mobil No 204 Mobil Oil Corpora tion 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 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 the Maintenance Operation Chart for axles that require only those lubricants rec ommended in Table 2 Axle Lubricant and Oil Filter Replacement Procedure 1 With the vehicle parked on level ground apply the parking brakes and chock the tires 2 Remove the axle carrier fill plug Fig 4 then remove the drain plug at the bottom of the hous ing and completely drain the lubricant while the unit is warm Allow sufficient time for all old lubri cant to drain On tandem drive axles it is also necessary to remove the plug at the bottom of the interaxle differential housing to drain the lu bricant 3 If so equipped replace the axle oil filter 35 IMPORTANT When the drive unit is equipped with an oil filter the filte
74. No Operation Description Check 25 01 Clutch Release Bearing Lubricating 25 02 Clutch Release Cross Shaft Lubricating 25 03 Clutch Linkage Components Lubricating 26 01 Shift Control Telescoping Tubes Lubricating and Inspecting FLA FLB 26 02 Shift Control Latch Lubricating and Cylinder Inspecting FLA FLB 26 04 Selection Lever and Pivot Rod Ball Stud Lubricating FLA FLB 26 08 Transmission Oil Level Checking and Breather Checking 31 02 Fifth Wheel Lubricating 31 05 Trailer Electrical Connector Lubricating 32 02 Suspension Lubricating 33 01 Knuckle Pin Lubricating 33 02 Tie Rod End Inspecting and Lubricating 35 01 Axle Breather and Lubricant Level Checking 41 02 Driveline Lubricating 42 03 Manual Automatic Slack Adjuster Lubricating and Checking All Models 46 01 Steering Driveline Lubricating 46 02 Ross Manual Steering Gear Lubricant Checking Model 503 46 04 Drag Link and Power Steering Cylinder Lubricating 46 05 Power Steering Reservoir Fluid Level Checking 46 08 Ross Power Steering Gear Lubricating TAS Series 46 09 Sheppard Power Steering Gear Bearing Cap Lubricating 60 01 Cab Tilt System Checking FLA FLB 72 01 Door Seal Door Latch and Door Hinge Lubricating Table 1 Maintenance Operation 00 04 Lubrication and Fluid Level Check for Service Schedules I Il and III 00 8 Heavy Duty Trucks Maintenance Manual October 2009 General Information IMPORTANT At each Maintenance Operation Set in addition to the maintenance operations
75. Service Schedule Maintenance Interval Operation Maintenance Intervals Frequency Miles km Hours Initial Maintenance IM first 1000 1600 100 Schedule I Maintenance 1 M1 every 1000 1600 100 Severe Service vehicles that annually travel less Maintenance 2 M2 didi 2000 8000 ae than 6000 miles 10 000 km Maintenance 3 M3 every 10 000 16 000 1000 Maintenance 4 M4 every 20 000 32 000 2000 Initial Maintenance IM first 9000 to 10 000 15 000 Schedule IIt Maintenance 1 M1 every 9000 to 10 000 15 000 Short Haul Transport Maintenance 2 M2 every 37 000 to 38 000 60000 vehicles that annually travel less than 60 000 miles 100 000 km Maintenance 3 M3 every 75 000 120 000 Maintenance 4 M4 every 150 000 240 000 Initial Maintenance IM first 12 500 20 000 Schedule IT Maintenance 1 M1 every 12 500 20 000 Long Haul Transport Maintenance 2 M2 every 50 000 80000 vehicles that annually travel over 60 000 miles 100 000 km Maintenance 3 M3 every 100 000 160 000 Maintenance 4 M4 every 300 000 480 000 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 cons
76. Slack Adjuster If the holes in the adjuster and the clevis do not remain aligned it means the con trol arm is not against the internal body stop This indicates an incorrect installa tion Move the adjuster into alignment with the clevis hole and install the clevis pin Loosen the control arm nut and ro tate the control arm toward the brake chamber until you can feel it contacting the internal stop see arrow A in Fig 4 Be sure the control arm stud moves freely in the slot of the anchor strap AN CAUTION Do not hammer on the control arm This may cause internal damage 4 5 Tighten the control arm nut 10 to 15 Ibf ft 14 to 20 N m 42 4 Heavy Duty Trucks Maintenance Manual October 2009 Brakes 4 6 Repeat this step to be certain that the control arm is fully released Final operat ing travel is obtained after the vehicle has been driven and the brakes are heated NOTE Brake shoe clearance can be in creased for inspection or brake system ser vicing by turning the manual adjusting nut counterclockwise see arrow B in Fig 4 Turning it in that direction takes considerable effort and may be accompanied by a ratch eting sound Meritor Automatic Slack Adjuster Lubricating and Checking 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
77. Then When 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 32 degrees Fahrenheit F Table 3 Temperature Conversion Heavy Duty Trucks Maintenance Manual October 2009 00 29 00 General Information Torque Specifications Tables 00 15 Torque Values for U S Customary Thread Fasteners with Lubricated or Plated Threadst Regular Hex Flanged p 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 1230002 1230003 1230004 1230005 0008 j Es ET de i 1220008 1 4 20 7 9 8 11 6 8 10 14 1 4 28 8 11 9 12 7 9 12 16 5 16 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 7 16 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 16 253 343 269 365 220 298 357 484
78. Yokes Inspecting FLA FLB Remove the tunnel top cover 2 Remove the screws that attach the center con sole tray 3 Remove the lower cover from the shift knob then disconnect the air lines from the shift knob 4 Loosen the locknut and remove the shift knob 5 Remove the screws that attach the shift boot to the tunnel then remove the shift boot 6 Using a 0 062 inch 1 6 mm feeler gauge check the clearance between the pivot block yoke and pivot block Also check the clearance between the shift lever yoke and the shift lever See Fig 4 If the shift lever yoke clearance is more than 0 062 inch 1 6 mm and the nylon washer is not worn out tighten the yoke nut 100 Ibf in 1130 N cm then back it off 1 4 turn If the nylon washer is worn remove the shift lever assembly and replace the worn parts See Group 26 of the Heavy Duty Trucks Service Manual for proce dures If the pivot block yoke clearance is more than 0 062 inch 1 6 mm remove the shift lever as sembly and replace the worn parts See Group 26 of the Heavy Duty Trucks Service Manual for procedures 26 04 Selection Lever and Pivot Rod Ball Stud Lubricating FLA FLB Wipe off the selection lever and pivot rod ball stud grease fittings See Fig 5 Apply multipurpose chas sis grease with a pressure gun at each fitting until new grease appears at the seals Heavy Duty Trucks Maintenance Manual November 2001 26 1 26 Transmission
79. a A Check shift lever yoke B Check pivot block clearance here yoke clearance here 1 Shift Lever Yoke Nut Fig 2 Shift Control Latch Cylinder Fig 4 Shift Lever and Pivot Block Yokes 05 27 93 f260003a 1 Latch Arm 2 Latch Cylinder Pivot Pin Fig 3 Shift Control Latch Arm and Locking Tab 6 Remove the filters from the bottom of the control module 7 Lubricate the new O rings with transmission fluid and install them on the cover assemblies 8 Install a new square cut seal on each cover as sembly and install the fluid filter elements on the cover assemblies 9 Install the filter and cover assemblies into the filter compartment 05 27 93 1 Selection Lever Ball Stud Grease Fitting f260005a 2 Pivot Rod Ball Stud Grease Fitting Fig 5 Selection Lever and Pivot Rod Ball Studs 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 EA CAUTION Do not use the bolts to draw the filter covers to the sump This can damage the covers seals or sump Heavy Duty Trucks Maintenance Manual November 2001 26 3 26 YA zs A ZA X Ed E SZ N ET 77 SONS T NAN dd m 2 3 44 4 1 T 08 25 95 1260317 3 Filter Element O Ring 4 Square Cut Seal 1 Filter Cover 2 Filter Element Fig 6 Allison Transmission Filter Locat
80. 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 8 to 12 Ibf ft 11 to 16 N m 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 CAUTION A leaking air filter or air lines can cause slow or hard shifting of the transmission and eventual transmission damage Spicer Transmission 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 1 Apply the parking brakes and chock the tires Drain the air from the air reservoirs 2 Clean the outside of the air filter regulator Fig 11 with cleaning solvent then let it air dry 3 Loosen or remove the air filter regulator bracket clamp then unscrew the bowl hold the regulator to prevent it from turning Remove the O ring 4 Unscrew the stud from the regulator Remove the louver upper gasket element and lower gasket from the stud Wear eye protection when using compressed air to clean parts as permanent harm to eyes could result from flying debris 05 27 93 f260053a 1 Regulator 6 Stud 2 Louver 7 O Ring 3 Upper Gasket 8 B
81. a new filter element in the reservoir and position the spring on top of the filter element If so equipped install and hand tighten the thumb screw to hold the spring and filter element in place 46 4 Heavy Duty Trucks Maintenance Manual November 2002 Steering Fill only with approved clean fluid Do not mix fluid types Any mixture or any unapproved fluid could lead to seal deterioration and leaks Fluid leakage could cause loss of power steering assist possibly resulting in personal injury and property damage 7 Fill the reservoir with approved power steering fluid See Table 1 IMPORTANT Do not start the engine while draining the system 8 Place the disconnected end of the steering gear to reservoir hose in a drain bucket Raise the front of the vehicle with a floor jack and support it with jack stands Have someone turn the steer ing wheel to full lock left and right and capture the fluid flowing from the hose in the drain bucket Add fluid to the reservoir as needed Continue turning the steering wheel until clean power steering fluid flows from the hose into the drain bucket 9 Remove the caps as applicable from the ports and fitting For a 3 line system remove the fitting from the pump to reservoir hose and attach it to the reservoir port Connect the hose s to the reservoir Tighten each hose fitting nut finger tight then tighten with a wrench until resistance is felt Tighten one sixth turn more Do
82. ace it See Fig 7 Check more often if the vehicle operates under very dusty conditions Allison Transmission A 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 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 while cold to determine if the transmission has a sufficient amount of fluid to be safely operated until a hot check can be performed 1 Park the vehicle on a flat level surface 2 Apply the parking brake and chock the tires 3 Run the engine for at least one minute 4 Shift from DRIVE to NEUTRAL and then shift to REVERSE to fill the hydraulic system 5 Shift to NEUTRAL and allow the engine to idle at 500 to 800 rpm 6 With the engine running at idle remove the 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
83. aking air fittings If the tank leaks at cracks or seams install a new tank using instructions in Group 42 of the Heavy Duty Trucks Service Manual To check operation of the automatic ejector valve start the engine and allow air pressure to build Watch the automatic ejector valve to make sure it ejects when the air compressor cuts out If the automatic ejector valve fails to operate or if it leaks air service it using instructions in Group 42 of the Heavy Duty Trucks Service Manual 01 17 94 f420006a Fig 10 Anchorlok Aftercooler 42 12 Bendix Air Dryer Desiccant Replacing AD 2 Replace or rebuild the desiccant cartridge For in structions see Group 42 of the Heavy Duty Trucks Service Manual NOTE Desiccant change intervals may vary from vehicle to vehicle however it is generally recommended that the cartridge be rebuilt or replaced at the interval given in the Mainte nance Operations Chart If experience has Brakes shown that extended or shortened life has re sulted on a particular installation then the inter val can be increased or decreased accordingly 42 13 Bendix Air Dryer Desiccant Replacing AD 4 or AD 9 Disassemble clean and inspect the Bendix air dryer Replace the desiccant cartridge See Group 42 of the Heavy Duty Trucks Service Manual for instruc tions NOTE Desiccant change intervals may vary from vehicle to vehicle Although typical desic cant cartridge life is t
84. al bearing See Fig 4 Fig 5 and Fig 6 Wipe the dirt from the grease fittings Using a pressure gun lubri cate the clutch linkage with multipurpose chassis grease Heavy Duty Trucks Maintenance Manual January 1998 25 1 25 Clutch 05 27 93 f260146a 05 27 93 f250176a Fig 3 Cross Shaft Grease Fitting Right Side SJ f250175a 05 27 93 VA LE y Fig 4 Earlier FLA Clutch Pedal Lever Grease Fitting Later FLAs and all FLBs are equipped with a grease fitting on the inboard side of the bellcrank pivot pin See Fig 7 Wipe the dirt from the fitting Using a pressure gun lubricate the pivot pin with multipur pose chassis grease Some FLAs are equipped with a grease fitting on the clutch pedal shaft Wipe the dirt from the fitting Using a pressure gun lubricate the clutch pedal shaft with multipurpose chassis grease FLB Right Hand Drive On right hand drive FLBs there are three additional lubrication points on the clutch linkage crossover shaft Remove the plastic cap from the grease fitting on both the left hand and right hand crossover shaft Fig 5 Earlier FLA Clutch Intermediate Bellcrank Grease Fittings 05 27 93 1 Left Hand Frame Rail 2 Grease Fitting f250045a 3 Clutch Release Lever Fig 6 Earlier FLA Clutch Release Lever Grease Fitting bearings Using a pressure gun lubricate each bear ing with multipurpose chassis grease
85. and TC 7 42 20 ra Foot Brake Valve Actuator Lubricating E 6 or E 12 and Leak Testing E 42 21 Sealco Moisture Ejection Valve Operation and Leak Testing Model 6300 e 42 22 Midland Quick Release and Flipper Valve Checking 42 23 Meritor WABCO System Saver 1000 Air Dryer Desiccant Replacing 42 24 Brake Inspection 46 01 Steering Driveline Lubricating 00 10 Heavy Duty Trucks Maintenance Manual October 2009 General Information 00 Maintenance Operation Sets Table 00 05 Maint per Operation Description Maintenance Interval d IM M1 M2 M3 M4 46 02 Ross Manual Steering Gear Lubricant Checking Model 503 46 03 Ross Manual Steering Gear Lubricant Changing Model 503 e 46 04 Drag Link and Power Steering Cylinder Lubricating 46 05 Power Steering Reservoir Fluid Level Checking 46 06 Power Steering Reservoir Fluid and Filter Changing 46 07 Steering Driveline Deck Bearing Lubricating FLA FLB 46 08 Ross Power Steering Gear Lubricating TAS Series e fe fe fe fe 46 09 Sheppard Power Steering Gear Bearing Cap Lubricating e fe fe fe fe 47 01 Fuel Tank Vent Checking 47 02 Fuel Tank Band Nut Tightening FLA FLB and FLD 47 03 Fuel Separator Sight Bowl Cleaning and Element Replacing e e 49 01 Exhaust System Inspecting 54 01 Electrical System Checking e o
86. and a greater ten dency to react on or corrode steel and bronze parts NOTE The correct oil capacity is established by the fill opening 6 Add oil until it is level with the lower edge of the fill opening If the transmission has two fill open ings add oil to the level of both openings See Fig 8 See Table 1 for transmission lubricant capacities and see Table 2 for approved trans mission lubricants 26 A CAUTION Operating a Fuller or Spicer transmission with the oil level higher or lower than recommended can result in transmission damage Do not overfill the transmission On Fuller transmissions overfilling will force oil out of the case through the main shaft openings On Spicer transmissions overfill ing usually causes oil breakdown due to exces sive heat and aeration from the churning action of the gears Early breakdown of the oil causes heavy varnish and sludge deposits that plug oil ports and build up on splines and bearings Oil overflow may also drain onto the clutch or clutch brake causing additional problems 7 Fora transmission equipped with an oil pump or an oil cooler operate the engine for five minutes after filling the transmission then check the oil level again 8 Install the fill plug then tighten it 50 Ibf ft 68 N m 9 Operate the vehicle to check for correct operation JIA ED RG gt f i 7 V 7 7 A 7 j Y TT LLL LLLI 05 27 93 f260006a A Full B Low
87. and inlet valve seat for nicks or burrs Inspect all rubber parts for signs of cuts abrasion swelling or deterioration Re place as necessary ASF Touchloc Control Mechanism System Operation Check 1 Park the vehicle and chock the tires 2 With the parking brake not set pull the Touchloc control valve The air cylinder should not activate the air mechanism unit e f the air cylinder is activated check the inversion and the cab control valves for proper operation Frame and Fifth Wheel e Replace malfunctioning valves e After replacing the valves recheck for proper system operation 3 With the parking brake set determine that the brakes have been applied Pull the Touchloc con trol valve The air cylinder should activate the air mechanism unit e If the air cylinder does not function check the inversion and cab control valves for proper operation e Replace the malfunctioning valves e After replacing the valves recheck for proper system operation NOTE Neither the vehicle nor the air mecha nism system should be operated when the spring brake section is caged 4 Remove the chocks from the tires 31 02 Fifth Wheel Lubricating 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 f
88. ansmission for any reason To do so could result sure the cab latch hooks have engaged the in serious injury or death U bolts on the cab mounts and that each latch handle lockpin is engaged 1 Move the tilt strut away from the right tilt cylinder rod and lock it in the spring catch 5 Remove the pump handle from the pump shank mm Mount the handle in the baggage compartment If the cab was tilted less than 45 degrees raise it enough to release the tilt strut Move the tilt strut 6 Push the transmission shift lever forward to lock away from the tilt cylinder rod and lock it in the the shift tube latch mechanism spring catch before lowering the cab See NOTE Maintain the hydraulic fluid level at the Fig 12 oil fill plug Add fluid only when the cab is in the 2 Setthe pump control lever at Lower and work operating position Use only Freightliner the pump until the cab nears a 45 degree angle approved hydraulic fluid see Group 60 for Reduce pumping speed Once the cab goes over specified fluid center stop pumping The cab will gently de scend to the operating position To stop the cab at any position between 45 de grees and 30 degrees move the control lever to Raise and push the tilt strut down onto the right tilt cylinder rod 00 24 Heavy Duty Trucks Maintenance Manual October 2009 General Information 00 Noise Emission Controls Maintenance 00 12 General Information Federal Law Part 205 Transp
89. assemble 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 in sert a two inch diameter shaft 31 8 2 Release the lock by tripping the release latch at the bottom of the throat 8 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 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 See Maintenance Operation 31 02 for lubrication instructions Holland 1 Disconnect the tractor from the trailer For in structions see the vehicle driver s manual 2 Thoroughly steam clean the fifth wheel 3 Check for loose nuts or broken bolts on the fifth wheel assembly 4 Inspect for cracks or wear on the mounting bolts 5 Visually inspect for improper locking action and for cracks or wear on the jaw locking mecha nism 6 Check the depth of the grease grooves If the depth of the grooves is 1 8 inch o
90. avy Duty Engine Oil meeting MIL L 2104D or MIL L Above 0 F 18 C 30 40 or 50 46152B or API Service Classification SF or CD MIL L 2104B and C or MIL L 46152 are acceptable Below 0 F 18 C 30 Above 0 F 18 C 90 SPIGER Mineral Gear Oil with Rust and Oxidation Inhibitor API GL 1 n Below 0 F 18 C 80 Synthetic Engine Oil meeting MIL L 2104D or MIL L All 50 or 30 46152B or API Service Classification SF or CD Lubricants listed in order of preference Do not mix types or brands of oil Multi weight and extreme pressure gear oils are not recommended Table 2 Approved Transmission Lubricants Heavy Duty Trucks Maintenance Manual November 2001 26 7 26 Fuller Transmission Oil Filter Element Changing 1 After draining the transmission case remove the attaching bolts and filter cover from either one or both power take off openings in the case Remove and discard the filter element s Install the new filter element in the power take off opening in the case 4 Attach the cover to the case with the attaching bolts See Group 00 in this manual for torque values 5 Fill the transmission with recommended clean oil as instructed under Manual Transmission Oil Changing 26 07 Transmission Air Filter Regulator Checking and Cleaning or Replacing Fuller Transmission Drain the air supply if the air supply is not drained before the air filter regulator is serviced serious injury and
91. ce Schedule Tables 00 03 Vehicle Maintenance Schedule for Service Schedule III go Required Maintenance Operation Interval Service Date Miles km 4th M1 and M2 50 000 80 000 5th M1 62 000 100 000 eth M1 75 000 120 000 7th M1 87 000 140 000 8th M1 M2 and M3 100 000 160 000 9th M1 112 000 180 000 10th M1 125 000 200 000 11th M1 137 000 220 000 12th M1 and M2 150 000 240 000 18th M1 162 000 260 000 14th M1 175 000 280 000 15th M1 187 000 300 000 16th M1 M2 and M3 200 000 320 000 17th M1 212 000 340 000 18th M1 225 000 360 000 19th M1 237 000 380 000 20th M1 and M2 250 000 400 000 21st M1 262 000 420 000 22nd M1 275 000 440 000 23rd M1 287 000 460 000 24th M1 M2 M3 and M4 300 000 480 000 Heavy Duty Trucks Maintenance Manual October 2009 00 7 00 General Information Lubrication and Fluid Level Check 00 04 Table 1 summarizes all operations that must be per Maintenance operation numbers given in the table formed to complete Lubrication and Fluid Level are reference numbers used to help you find detailed Check Operation 00 04 called for as an M1 mainte instructions in the manual on the lubrication or fluid nance interval for Service Schedule I Il and III ve check hicles Maintenance Operation 00 04 Lubrication and Fluid Level Check for Service at M1 Oparsllon
92. ce for corrosion The bore and plunger sur faces should be smooth with no pitting or rough ness Some discoloration is permissible If there is pitting roughness replace with new parts See Table 3 5 Apply one of the specified silicone greases to the sliding surfaces of the plunger and the adaptor bore See Table 4 If installing a new adaptor or plunger first apply the grease included with the it 6 Install the brake valve mounting adaptor and plunger using a new gasket E 6 and E 12 Brake Valve Service Parts List Description Part Number Qty Valve Adaptor BW 5002378 1 Plunger BW 5002379 1 Gasket 12 15695 000 1 Table 3 E 6 and E 12 Foot Brake Valve Service Parts List Silicone Greases Description Manufacturer Source BW 291126 silicone base grease spec BW 650 M 3 7 Allied Signal PDC cc packet 55 O RIng Lubricant Formerly Molykote Dow Corning Locali DC 55M Pneumatic Corporation y Grease V 755 O Ring Rhone Poulenc Lubricant Silicone VSI Inc Locally Each 3 7 cc packet is adequate to lubricate one foot valve adaptor as sembly Table 4 Silicone Greases 42 12 Heavy Duty Trucks Maintenance Manual October 2009 Brakes 42 21 Sealco Moisture Ejection Valve Operation and Leak Testing Model 6300 Operation Testing Keep away from the front of the moisture ejection valve exhaust outlet because moisture scale or other debri
93. ch Release Lever Grease Fitting Heavy Duty Trucks Maintenance Manual January 1998 25 3 25 Clutch 05 27 93 250054 Fig 12 FLC Clutch Relay Lever Grease Fitting 25 4 Heavy Duty Trucks Maintenance Manual January 1998 Transmission 26 Index Alphabetical Title of Maintenance Operation MOP MOP Number Allison Transmission Fluid and Filter Changing sseleelllees nh 26 05 Manual Transmission Magnetic Plug Cleaning Oil Changing and Oil Filter Element Ghahidilgis 3 5 OE EE ate y eed a OE HE IE RUP dui 26 06 Selection Lever and Pivot Rod Ball Stud Lubricating FLA FLB l l 26 04 Shift Control Latch Lubricating and Cylinder Inspecting FLA FLB 0 000 eee eee 26 02 Shift Control Telescoping Tubes Lubricating and Inspecting FLA FLB 0000 0 eee 26 01 Shift Lever Pivot Yokes Inspecting FEA FLB 4b EER be DE Ed ee ge eed ace teak RM a Rue 26 03 Transmission Air Filter Regulator Checking and Cleaning or Replacing 000000 eee 26 07 Transmission Oil Level Checking and Breather Checking liil 26 08 Heavy Duty Trucks Maintenance Manual November 2001 Transmission 26 01 Shift Control Telescoping Tubes Lubricating and Inspecting FLA FLB 1 Apply the parking brakes and chock the tires 2 Tilt the cab to the full tilt position using the in structions in Group 00 of this manual 3 Wipe off the telescoping tubes Fig 1 wi
94. chamber stroke See Table 5 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 Heavy Duty Trucks Service Manual for inspection and troubleshooting procedures 5 Start the engine and build air pressure to at least 100 psi 689 kPa Shut down the engine 6 Check all of the foundation brake components for damage wear and loose or missing parts Re pair as needed See Group 42 of the Heavy Duty Trucks Service Manual for repair proce dures 42 14 Heavy Duty Trucks Maintenance Manual October 2009 Brakes 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 Gunite 36t 2 1 4 57 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 Long stro
95. ck in Inspection Area Fig 14 Hendrickson RS Series Vertical Mounting Flange 3 Visually inspect each frame hanger for evidence of cracks in the horizontal mounting flange adja cent to the vertical drive pin area See Fig 15 Suspension 09 15 95 cdi 1920420 1 Crack in Inspection Area Fig 15 Hendrickson RS Series Horizontal Mounting Flange 4 Visually inspect each frame hanger for severe rust on the horizontal mounting flange adjacent to the vertical drive pin area See Fig 16 5 Inspect the load cushions for cuts and swelling See Fig 17 Cushions cut by the retaining lips of the saddles or frame hangers indicate the cush ions may not be the correct hardness or configu ration 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 saddles See Group 00 of this manual for torque specifications 32 8 Heavy Duty Trucks Maintenance Manual October 2009 Suspension 09 15 95 1320421 1 Rust Inspection Area
96. cle on a level surface apply the parking brakes and chock the tires When lubricating upper and lower knuckle assemblies do not raise the front axle Wipe the fittings clean then apply multipurpose chassis grease NLGI grade 1 696 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 See Fig 1 Knuckle pins without grease fittings are permanently lubricated 1 A Z7 N SN s 11 21 95 1330129 A Grease Exit 1 Grease Fitting Fig 1 Dana Spicer Knuckle Pin Lubrication Meritor 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 2 896 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 33 plate gasket continue pumping until new grease is seen at the bushing seal opposite the grease fitting See Fig 2 09 06 96 1 1320032a A Grease Exit 1 Grease Fitting Fig 2 Meritor Knuckle Pin Lubrication Freightliner When lubricating upper and lower knuck
97. component damage could re sult 1 Apply the parking brakes and chock the tires Drain the air from the air reservoirs 2 Clean the outside of the air filter regulator with cleaning solvent then let it air dry See Fig 9 3 Remove the end cap large O ring and filter ele ment from the filter housing See Fig 10 Re move the small O ring from the end cap 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 and 434 kPa replace the air filter regulator which is not serviceable Transmission 1260037a 05 27 93 Fig 9 Air Filter Regulator Location Fuller transmission shown 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 10 Eaton Fuller Transmission Air Filter Regulator Components WARNING Wear eye protection when using compressed air to clean parts as permanent harm to eyes could result from flying debris 26 8 Heavy Duty Trucks Maintenance Manual November 2001 Transmission 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
98. could damage the vehicle or cause personal in jury 3 Move the pump control lever to Raise 4 Operate the pump using the manual pump handle or the air control button if so equipped to disengage the hold down latches IMPORTANT Check the indicator pin on each cab latch The latches have disengaged if the pins are out See Fig 4 If air is present in the hydraulic tilt system pump operation will seem spongy or ineffec tive If this happens bleed the air from the sys running tem for instructions see Group 60 of the Heavy Duty Trucks Service Manual If the cab stops moving while it is being raised do not force it to move with the tilt pump The 00 20 Heavy Duty Trucks Maintenance Manual October 2009 General Information velocity fuses have locked up the tilt cylinders unlock them A WARNING Make sure the tilt strut is pushed down onto the right tilt cylinder rod If the tilt strut is not en gaged and the cab drops the result could be seri ous injury or death 5 When the cab reaches a 30 degree angle stop working the pump Push the free end of the tilt strut down onto the right tilt cylinder rod See Fig 5 The tilt strut prevents the cab from acci dently dropping below this position 07 26 93 f310360a Fig 4 Cab Latch Indicator Pin 00 COE Cab Tilting FLA FLB 00 11 6 To tilt the cab all the way continue working the pump until the cab nears a 45 degree an
99. coupling 85 Ibf in 940 N cm If leakage persists install a new V band coupling Inspect the turbo outlet pipe and replace it as needed Check the U bolt clamps for tightness and tighten as needed 7 Check for leakage at all wide band exhaust clamps See Fig 2 Fig 3 or Fig 4 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 Donald son Seal Clamps 05 28 93 f490025a 2 1 2 4 06 01 93 1490024a 1 Flex Hose 4 Turbocharger Exhaust 2 V Band Coupling Outlet 3 Exhaust Pipe Fig 2 Donaldson Seal Clamp Wide Band Exhaust Clamp 05 28 93 T f490023a Fig 1 V Band Coupling and Flex Hose Fig 3 Riker Tru Seal Wide Band Exhaust Clamp Heavy Duty Trucks Maintenance Manual January 2007 49 1 49 10 05 94 f490005a Fig 4 Torca Torctite Wide Band Exhaust Clamp EPAO7 Exhaust System Inspecting IMPORTANT The Environmental Protection Agency s 2007 regulations require lower ex haust emissions thus requiring new exhaust system components See Fig 5 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 Definitions
100. cting 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 Heavy Duty Trucks Maintenance Manual October 2009 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 2 Heavy Duty Trucks Maintenance Manual October 2009 Page Description For an example of a Heavy Duty Trucks Maintenance
101. d Air Conditioner 4 Heavy Duty Trucks Maintenance Manual October 2009 General Information 00 Index Alphabetical Title of Maintenance Operation MOP MOP Number COE Cab Mind EASTEDB Sues SE Sies Dds eee ES EES DONE ED OE Ee DE PLU GNO dd 00 11 Determining Scheduled Maintenance Intervals 2 22 ees 00 01 Initial Maintenance IM Operations liiis rn 00 06 Edbricatel and Fl id Level Check i 52 doceas apt ie eor edat Brit d dabas Des qos dod derit dedii GE 00 04 M1 Maintenance Interval Operations Table 00 07 0 0 000 eee 00 07 M2 Maintenance Interval Operations Table 00 08 EE EE EE EE ss 00 08 M3 Maintenance Interval Operations Table 000 Ee EE Ee es 00 09 M4 Maintenance Interval Operations Table 00 10 llslllleeeeelle ees 00 10 Maintenance Operation Sets Table EE EE EE ER n 00 05 Maintenance Service Tables 24 4 5 RES ESE HEES Lec athens d NR ER ae Da Reo uS ie Eg Be 00 02 Metric U S Customary Conversion Tables nanana SE EE EE EE Se ee ee ee ee ee ee ee ee 00 14 Noise Emission Controls Maintenance sisse RR EE RE N HER Feed RR RR RO EORR EE EER EE ER 00 12 Torque Speciicatons Tables eco SE aditus een da puse deua aa tege Ed epee dpa ied P agg AD des 00 15 Vehicle Maintenance Schedule Tables 0 2 0000 cece rh 00 03 Verification of Inspections Log 4204920022 chet eel PEER ER Ed pee Pao e d E ERO er RED SR oS 00 13 Heavy Duty Trucks Maintena
102. d Controls 4 08 18 97 1541743 1 Main Cab Harness Interface Connector 2 Main Cab Ground Stud black 3 Main Cab Power Stud red 4 Left Hand Side of Firewall inside cab Fig 8 FLC RH DR Electrical Panel Location Fig 9 FLC RH DR Main Cab Harness Connectors 54 4 Heavy Duty Trucks Maintenance Manual April 1998 Electrical Instruments and Controls 54 10 9 1 ac 8 7 08 27 93 D 1600675 1 Velcro 6 Lower Screws 2 Quarter Turn Fastener 7 Tunnel Right Hand 3 Tunnel Left Hand Cover Cover 8 Combo Cover 4 Upper Screw 9 Glove Box 5 Right Hand Cab Deck 10 Manifest Box Fig 10 FLB Dash and Tunnel Covers 3 a 1 08 27 93 7 7 830172a 1 Right Hand Under Dash Cover 2 Glove Box 3 Passenger Door Opening Frame Fig 11 FLC LH DR Right Hand Dash Covers Heavy Duty Trucks Maintenance Manual April 1998 54 5 54 Electrical Instruments and Controls 3 2 37 3 w es 1 2 3 6 6 lt 8 5 9 6 8 4 6 7 8 03 05 96 1541188 1 Dashboard End Cap 4 Glove Box Door 7 Heater Control Panel 2 Trimcap 5 Glove Box Liner 8 Heater Control Panel Screw 3 Dashboard End Cap Screw 6 Glove Box Liner Screw Fig 12 FLC RH DR Left Hand Dash Covers 54 6 Heavy Duty Trucks Maintenance Manual April 1998 Electrical Instruments and Controls 54 2 6 1 j 2 EN JN A S 3 3 ON 11 26 97
103. d Ill M3 Maintenance Interval Operations for Service Schedules I Il and Ill cent carne Operation Description Check 00 07 Perform all MI Operations 00 08 Perform all M2 Operations 01 01 Engine Rear Support Assembly Checking 01 02 Engine Noise Panel Inspecting 01 04 Engine Drive Belt Inspecting 09 01 Air Cleaner Element Inspecting and Replacing 15 01 Alternator Battery and Starter Checking 26 03 Shift Lever Pivot Yokes Inspecting FLA FLB 32 03 Suspension U Bolt Torque Checking 35 02 Axle Lubricant Changing Oil Filter Replacing and Magnetic Strainer Cleaning 42 06 Wedge Brake Inspecting and Lubricating 42 09 Bendix Alcohol Evaporator Gasket Replacing 42 10 Bendix Air Dryer Checking AD 2 AD 4 or AD 9 42 16 Bendix Air Brake Valve Operation Checking BP R1 and E 12 42 17 Bendix Air Brake Valve Disassembly Cleaning and Inspecting BP 1 Double Check Valve E 6 PP 7 QR 1 R 6 R 14 SR 1 ST 3 TC 7 TP 5 and TR 3 42 19 Bendix Air Brake Valve Inspecting and Testing BP 1 BP R1 LQ 5 PP 7 R 14 and TC 7 42 20 DU Foot Brake Valve Actuator Lubricating E 6 or E 12 and Leak Testing E 46 03 Ross Manual Steering Gear Lubricant Changing Model 503 54 01 Electrical System Checking 54 02 Speedometer Tachometer Cable Lubricating 00 16 Heavy Duty Trucks Maintenance Manual October 2009 General Information The M4 Maintenance In
104. de Cam Fig 6 Touchloc Control Mechanism General Inspection 3 The locknut that attaches the air cylinder to the housing weldment must be tight but should not distort the cylinder clevis legs inward 4 Check all mounting bolts for tightness NOTE A sluggish slide cam may be improved by spraying the slide cam track and inside of the rectangular slide cam housing with a prod uct such as light oil silicon lube or equivalent ASF Touchloc Control Mechanism Lubrication 1 With the air cylinder and the slide cam in the re tracted position lubricate the cam track with a light oil type lubricant See Fig 7 2 If the operating rod plate casting track is rusted apply penetrating oil with teflon to remove the rust Apply white lithium grease into the track 3 Remove the extension spring for easy access 4 Activate the cab control valve moving the oper ating rod into lockset unlocked mode position 5 Lubricate the slide cam shaft Spray lubricant into the rectangular slide cam housing 7 Replace the extension spring 10 17 96 1310548 1 Extension Spring Fig 7 Touchloc Control Mechanism Lubrication 8 Cycle the slide cam several times to ensure smooth operation 9 Lubricate the air mechanism unit each time the tractor is steam cleaned ASF Touchloc Control Mechanism Component Inspections 1 Thoroughly inspect the air cylinder Fig 8 It must retract and extend
105. djustment see Group 01 of the Heavy Duty Trucks Service Manual 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 2 for belt tension specifications 3 If belt tension is not correct see Group 01 of the Heavy Duty Trucks Service Manual to adjust belt tension Heavy Duty Trucks Maintenance Manual January 2007 01 3 01 Engine 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 Heavy Duty Trucks Service Manual for replace ment instructions 11 21 94 f150010a A Glazing D Tensile Break B Separating Layers E Uneven Ribs C Streaked Sidewalls F Cracks Fig 5 Drive Belt Replacement Conditions Drive Belt Tensions Belt Tension Engine Component Ibf kg Caterpillar C10 3176 Refrigerant Compressor 80 to 100 36 to 45 Alternator and Refrigerant Compressor 40 to 50 18 to 23 per belt Caterpillar 3406E Fan 80 to 100 36 to 45
106. e extinguisher within easy reach 1 Fuel Disconnect the water sensor probe connector and bowl heater connector if equipped See Fig 7 12 T1 1 2 11 3 4 5 10 2 6 8 7 06 26 97 f470190 1 Fuel Inlet 8 Bowl Heater 2 Head Assembly Connector 3 Filter Top Seal 9 Drain Valve 4 Filter Element 10 Contaminant 5 Bowl O Ring Seal Collection Bowl 6 Water Sensor Probe 11 Fuel Outlet Plug 12 Priming Plug 7 Water Sensor Probe Fig 7 Racor 6400 Fuel Heater Water Separator Place a suitable container under the fuel heater water separator then drain the fuel from 47 6 Heavy Duty Trucks Maintenance Manual October 1997 Fuel the fuel heater water separator by opening the drain valve 3 Remove the filter element and collection bowl together by turning the filter element off of the mounting head 4 Remove the filter element from the collection bowl by turning the collection bowl then discard the filter element 5 Remove and discard the bowl O ring then clean the bowl of debris using diesel fuel only Clean the bowl O ring seat with a shop cloth 6 Lubricate the new bowl O ring with clean diesel fuel or motor oil then seat it into the collection bowl 7 Attach the collection bowl to a new filter element hand tight Do not use tools 8 Lubricate the new filter element gasket with clean diesel fuel or motor oil 9 Spin the filter and bowl assembly onto the mounting head
107. e 1 for recommended drive axle lubricants Rr n 08 17 2009 A Correct lube level at bottom of fill hole B Incorrect lube level below fill hole f350061a Fig 2 Axle Lubricant Level Checking Eaton Drive Axle Recommended Lubricant Lubricant SAE Lubricant Type Condition Viscosity Grade Eaton Roadranger Over the Road 75W 90 Synthetic Drive Axle Service Lubricants or Off Highway Equivalent with Equipment or Military Specification Tuus Extra 80W 140 MIL L 2105D Heavy Loads Table 1 Eaton Drive Axle Recommended Lubricant 5 Install and tighten the fill plug 40 to 60 Ibf ft b4 to 81 N m 6 On non drive axles equipped with oil lubricated wheel bearings check the lubricant level at the wheels If low add the same lubricant specified for the drive axle NOTE When adding or checking lubricant of non drive axles clean the hub cap and plug be fore removing the plug This minimizes the pos sibility of dirt entering the assembly 7 Remove the chocks from the tires Heavy Duty Trucks Maintenance Manual January 1997 35 1 35 Eaton Two Speed Axle Shift Unit Oil Level A CAUTION 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 area sur rounding it See Fig 3 Remove the fill plug 08 06 93 f350021a 1 Housing Cover Gasket 3 Shift Unit Housing 2 Oil Fill P
108. 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 Suspension bolts 45 Ibf in 500 N cm Any damage to the valve housing will void the warranty Do not attempt to disassemble the Barksdale valve body or the control lever There are no serviceable parts in the valve and any 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 that the air line support brackets are posi tioned so the a
109. e correct distance for single and dual drive rear axles is between 2 3 8 inches and 2 7 8 inches 60 to 73 mm 6 If the axle stop measurement is not correct see Group 32 of the Heavy Duty Trucks Service Manual for adjustment procedures 7 Without detaching the control rods attempt to move by hand each control rod end up down in and out If there is any movement examine the control rod for wear or damage If a control rod needs to be replaced see Group 32 of the Heavy Duty Trucks Service Manual for instruc tions 8 Inspect the rubber bushings for cracks or cuts Check for any shifting of the barpin 10 Inspect the weld seams between the control rod tube and the shorter bushing tubes If there are cracks replace the control rod Do not weld the control rod for any reason 08 16 96 1320453 A Measure height here 1 Left Forwardmost Axle Stop Fig 10 AirLiner Axle Stop Measurement 11 Raise the rear of the vehicle so the tires just clear the ground and the suspension is fully ex tended Place safety stands under the vehicle frame 12 Squeeze all air springs to check for complete deflation If any air springs remain partially or fully inflated see Troubleshooting in the appro priate section in Group 32 of the Heavy Duty Trucks Service Manual 13 Inspect each air spring for wear at its connection to its pedestal Replace any worn air springs for instructions see Group 32 of the Heavy Duty Truck
110. e during the first 10 to 15 strokes stop what you are doing Make sure the shift tube latch mechanism has released 07 22 93 310041 Fig 9 Safety Hook Release Handle CAUTION Continued application of force to tilt the cab when the shift tube latch mechanism has not released could result in transmission or shift tube damage NOTE If air is present in the hydraulic tilt sys tem pump operation will seem spongy or inef fective If this happens bleed the air from the 00 COE Cab Tilting FLA FLB 00 11 system for instructions see Group 60 of the Heavy Duty Trucks Service Manual If the cab stops moving while it is being raised do not force it to move with the tilt pump The velocity fuses have locked up the tilt cylinders unlock them 7 After the safety hook has been raised above the safety catch Fig 10 let go of the release handle Tilt the cab to a 30 degree angle 07 22 93 1310042 1 Safety Catch 2 Safety Hook Fig 10 Safety Catch Mechanism Make sure the tilt strut is pushed down onto the right tilt cylinder rod If the tilt strut is not en gaged and the cab drops the result could be seri ous injury or death 8 When the cab reaches a 30 degree angle push the free end of the tilt strut down onto the right tilt cylinder rod See Fig 11 The tilt strut pre vents the cab from accidently dropping below this position 9 To tilt t
111. e metal end cover If there is no voltage look for a blown fuse broken wires or corrosion in the vehicle wiring harness 2 Turn off the ignition switch and cool the end cover assembly to below 40 F 4 C 42 8 Heavy Duty Trucks Maintenance Manual October 2009 Brakes 3 Using an ohmmeter check resistance between the electrical terminal and the metal end cover See Fig 9 Resistance should be 2 0 to 4 0 ohms for a 12 volt 60 watt end cover and 4 0 to 7 0 ohms for a 24 volt 120 watt end cover ec d 2 DOSEER XANAN NON DP 3 N A Ry 0 13 QU add 12 B 4 i 3 2 8 3 10 11 94 1420016a 1 Heater Post 8 Nut 2 Air Dryer End Cover 9 O Ring 3 Thermostat Terminal 10 Thermostat Cover Assembly 11 Screw 4 Lockwasher 12 Thermostat Cover 5 Boot Gasket 6 Washer 13 Spacer 7 Lockwasher Fig 9 Air Dryer Thermostat Assembly 4 Warm the end cover assembly to over 90 F 32 C and check resistance as above Resis tance should exceed 1000 ohms If resistance values are within stated limits the thermostat and heater are operating properly If resistance values are outside stated limits pro ceed to the next step to determine the cause 5 With the ignition or engine control switch off re move the thermostat cover See Fig 9 Using an ohmmeter check resistance between the metal end cover and the heater post For a 12 volt 60 watt end cover resistance should be 2 0 to 2 8 ohms and for a 24
112. e parking brake 2 Putthe 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 Heavy Duty Trucks Service 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 Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is Brakes likely masking a mechanical problem Adjustment is not repairing Before adjusting an automatic slack adjuster troubleshoot the foundation brake system and inspect it for worn or damaged 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 Heavy Duty Trucks Service Manual for in spection troubleshooting and repair procedures 4 Measure the applied
113. ease NLGI grade 1 6 12 hydroxy lithium stearate grease or NLGI grade 2 896 Front Axle 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 03 All Axle Alignment Checking 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 Heavy Duty Trucks Service Manual Toe In Inspection For vehicle alignment to be accurate the shop floor must be level in every direction The turn plates for the front wheels must rotate freely without friction and the alignment equipment must be calibrated every three months by a qualified technician from the equipment manufacturer Freightliner dealers must have proof of this calibration history 1 Apply the parking brakes and chock the rear tires 2 Raise the front of the vehicle until the tires clear the ground Check that the safety stands will support the combined weight of the cab axle and frame Place safety stands under the axle 3 Using spray paint or a piece of chalk mark the entire center rib of each front tire 4 Place a scribe or pointed instrument against the marked center rib of each tire and turn the tires The scribe must be held firmly in place so that a single straight line is scribed all the way around each front tire 5 Place a tur
114. ecurely seated without binding If the locking plungers do not operate properly see Group 31 of the Heavy Duty Trucks Service Manual for adjustment pro cedures 3 Turn the adjusting bolt in clockwise until it con tacts the rack Turn the adjusting bolt an addi tional 1 2 turn then securely tighten the locking nut 31 05 Trailer Electrical Connector Lubricating 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 Frame and Fifth Wheel NOTE The use of soap is not recommended for cleaning the electrical connector as some soaps may increase the corrosion process 1 Wash out any existing grease dirt and corrosion on the trailer connectors with electrical contact cleaner spray 2 Grease the trailer connector with a lithium based dielectric grease 31 8 Heavy Duty Trucks Maintenance Manual October 2009 Suspension Title of Maintenance Operation MOP Suspension Inspecting 0 0 00 eee eee SUSPENSION Lubricating 6 cient due DEERE dad tert esate Suspension U Bolt Torque Checking 32 Index Alphabetical MOP Number Heavy Duty Trucks Maintenance Manual October 2009 Suspension 32 01 Suspension Inspecting Front Suspension Check Do
115. edule Tables 00 03 General Information Hn Required ME ie Operation Service Date T Semice I TT 92nd M1 92 000 148 100 9200 93rd M1 93 000 150 000 9300 94th M1 94 000 151 300 9400 95th M1 and M2 95 000 153 000 9500 96th M1 96 000 155 000 9600 97th M1 97 000 156 100 9700 98th M1 98 000 157 700 9800 99th M1 99 000 159 300 9900 100th M1 M2 M3 and M4 100 000 160 900 10 000 1st through 16th Maintenance for Service Schedule II Vehicles pos Required Maintenance Operation Interval Service Date Miles km 1st Initial Maintenance IM M1 10 000 16 000 2nd M1 19 000 30 000 3rd M1 28 000 45 000 4th M1 and M2 38 000 60 000 5th M1 47 000 75 000 6th M1 56 000 90 000 7th M1 66 000 105 000 8th M1 M2 and M3 75 000 120 000 9th M1 84 000 135 000 10th M1 94 000 150 000 11th M1 103 000 165 000 12th M1 and M2 112 000 180 000 13th M1 122 000 195 000 14th M1 131 000 210 000 15th M1 141 000 225 000 16th M1 M2 M3 and M4 150 000 240 000 1st through 24th Maintenance for Service Schedule III Vehicles Vehicle Maintenance Schedule for Service Schedule III a Required Maintenance Operation Interval Service Date Miles km 1st Initial Maintenance IM M1 12 500 20 000 2nd M1 25 000 40 000 3rd M1 37 000 60 000 00 6 Heavy Duty Trucks Maintenance Manual October 2009 General Information 00 Vehicle Maintenan
116. el leaks Repair all fuel leaks with the engine OFF Racor 460R 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 When working on a fuel system have a fire extinguisher within easy reach 1 Disconnect the water sensor probe connector if equipped See Fig 3 2 Disconnect the bowl heater connector if equipped 3 Place a suitable container under the fuel heater water separator then loosen the vent plug and drain the fuel from the fuel heater water separator by opening the drain valve 4 Remove the filter element and collection bowl together by turning the filter element off of the mounting head 5 Remove the filter element from the collection bowl by turning the collection bowl then discard the filter element 47 05 28 97 EA LL 2 3 4 N 4 5 5 6 6 2 4 4 7 10 1470261 Mounting Head 7 Filter Element Vent Plug 8 Collection Bowl Fuel Outlet 9 Water Sensor Probe Fuel Inlet 10 Fuel Heater Wire Fuel Priming Pump 11 Drain Valve Mounting Hole Fig 3 Racor 460R Fuel Heater Water Separator Remove and discard the bowl O ring then clean the bowl of debris using diesel fuel only Clean the bowl O ring seat
117. er within easy reach 1 Drain off some fuel by loosening the vent plug and opening the drain valve See Fig 5 3 10 9 S i u 8 oe 5 6 7 09 15 95 1470148 Heater Connector Bowl Drain Valve Assembly 1 Mounting Head 2 Metal Plug 3 8 NPT 3 Bowl O Ring 4 Bowl Bevel Cut Bowl with Drain and Gasket Water Sensor Bowl Probe Plug 10 Service Element Water Sensor Probe O ocn oo Fig 5 Racor 690R Fuel Water Separator 6120R Similar 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 47 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 5 Ref 2 and manually fill the unit with diesel fuel 8 2 Install 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 Racor 900FG and 1000FG Diesel fuel is flammable and can ignite if exposed to an open flame intense heat or othe
118. ess Connectors Cab Exterior For an FLC check the 40 way connector on the fire wall left side for a RH DR vehicle and right side for a LH DR vehicle and check the power and ground studs Check the terminals for tightness damage corrosion and dirt See Fig 13 LH DR or Fig 14 RH DR Chassis 1 Check the main chassis wiring harness Check the wiring insulation for damage from chafing or 54 2 Heavy Duty Trucks Maintenance Manual April 1998 Electrical Instruments and Controls LH HDLP RH HDLP HTR CONT COMP CLT SHTR SHTDN 15 15 15 10 30 5 5 5 5 PNLLP MKR LP RH HDLP AIC HTR HT AC FUEL vH FANG HTRHI 15 10 10 10 10 10 5 x LOAD WIPER MID MIR RADIO ACCESS AR DRY STGAD INSTR 15 15 20 30 20 20 30 15 5 d 1A 1B 10 ACG ACC LHHDLP ciG Lt RDLP TRBRN DIR SIG SILP TRBLK HORN CLOCK 3A 3B ac PNL N LPS GND t 4A 4B 4C TRLR BRN MKRLP TRLR BLK PNLLP 07 20 95 1540607 Fig 5 FLC LH DR Electrical Mounting Plate 08 24 93 1540629 Bottom of Dash Main Cab Power Stud Red Main Cab Harness Interface Connector Main Cab Ground Stud Right Hand Side of Firewall Inside Cab Or doy Fig 6 FLC LH DR Main Cab Harness Connectors heat Also check for kinks Reroute repair or replace wires as needed A CAUTION Do not use flat strip aluminum tie straps for hold ing electrical wiring The sharp edges on these tie 10 20 93 154027
119. etween the equal izer assembly and any frame component or fas tener is less than 1 8 inch 8 mm replace the equalizer bushings See Group 32 of the Heavy Duty Trucks Service Manual for instructions Hendrickson Spring Walking Beam Suspension Models RT RTE and RTEA 1 Inspect the suspension assembly for loose fas teners wear cracks and damage to its compo nents Replace the component s if any wear cracks or damage exist If any of these condi tions exist replace the damaged bracket s See Group 32 of the Heavy Duty Trucks Service Manual for instructions Suspension 05 27 93 f320021a Fig 2 Torque Arm Bushings pe 2 05 27 93 f320022a A Measure the change in gap at this point 1 Equalizer Bracket 3 Pry Bar 2 Equalizer Fig 3 Side View of the Equalizer 2 Check for distorted or frayed rubber at the beam end bushings If the bushings are damaged re place them 3 Check that the ends of the equalizer beam are not lower in the beam hanger If the equalizer beam ends appear lower use a jack to raise each beam end and check for movement of the inner metal of the rubber end bushing See Fig 5 Movement cannot be corrected by tightening the fastener because parts could be damaged If there is movement replace the rubber end bush ings and all connecting parts See Group 32 of the Heavy Duty Trucks Service Manual for instructions 32 2 Heavy Duty Trucks Maintena
120. fth wheel assembly Inspect for cracks or wear on the mounting bolts Check for improper locking action and for cracks or wear on the jaw locking mechanism Heavy Trucks Maintenance Manual November 1993 A 31 1 11 28 2001 A B Group Title C Group Number D Release Date E Group Page Number D Maintenance Operation Number consists of Group Number followed by Sequence Number 1020034 Fig 1 Example of a Heavy Duty Trucks Maintenance Manual Page Heavy Duty Trucks Maintenance Manual October 2009 Introduction Maintenance Manual Contents Group No Group Title O ee RM NR E E ER ET General Information EER MET RA ME IE ED EM Engine OE luas EE AE me DE adu uude idea OE Air Intake PE reggadebdaedpeqages3ed 3 rds Air Compressor EE SEN OD HA Alternators and Starters AE OE a X Re dre E d Engine Cooling Radiator EED OAR EL AE EE RR AS Clutch OB P P Pr T Transmission c MT Frame and Frame Components UE isa ded Reda Yd d S XE E Suspension Oo Stade oo q dude qx nas dui d de id Front Axle v sea hee Sa eer Bee EE ED Rear Axle EB UN Re DE MES OE ETE Wheels and Tires EER SEER T RC PERCIPIAT HOS Driveline ER DEE PERE e Raus Hands EN A Brakes EE AAN EER di fett eic dod Steering MEERDERE VET RE T d i queis qaas Fuel OER N SORA ET d xcd Exhaust D acad ET ee Electrical Instruments and Controls E MES ORE E PR a Cab WE Iu EE AU d m E LEE rU E Doors BOO Ei idend dua dms Heater an
121. g Suspension A WARNING 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 32 11 27 95 f320465 Fig 1 Direct Acting Shock Absorber front suspension shown 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 loose fasteners wear cracks and other damage If any of these condi tions exist replace the damaged bracket s See Group 32 of the Heavy Duty Trucks Service Manual for instructions 2 Inspect the tandem axle frame crossmember and gussets for loose fasteners wear cracks and other damage If any of these conditions exist replace the damaged parts See Group 32 of the Heavy Duty Trucks Service Manual for instruc tions 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
122. gle Re duce pumping speed Once the cab goes beyond 45 degrees stop working the pump The cab will gently descend to a full tilt position To stop the cab at any position between 45 degrees and full tilt move the control lever to Lower IMPORTANT If the cab unintentionally stops after it has gone beyond 45 degrees do not force it down with the tilt pump The velocity fuses have locked the tilt cylinders unlock them Returning the FLB Cab from the Tilted Position Stay completely clear of the cab s travel path at all times Once the tilt strut has been released do not lean over the frame rails the engine or the transmission for any reason To do so could result in serious injury or death 1 Move the tilt strut away from the right tilt cylinder rod and lock it in the spring catch If the cab was tilted less than 45 degrees raise it enough to release the tilt strut Move the tilt strut away from the tilt cylinder rod and lock it in the spring catch before lowering the cab See Fig 6 04 15 93 f310358a ke iid ds 1 Tilt Strut 3 Tilt Cylinder Ti ru Tilt Oylin 1 Tilt Cylinder Rod 2 Tilt Strut 2 Tilt Cylinder Rod Fig 5 Tilt Strut Positioning Fig 6 Releasing the Tilt Strut Heavy Duty Trucks Maintenance Manual October 2009 00 21 00 COE Cab Tilting FLA FLB 00 11 2 Set the pump control lever at Lower and work the pump until the cab nears a 45 degree angle Reduce pump
123. grease is seen at the seal then tighten the capscrews to the above specifications and bend the tabs of the lockstrap against a flat side of each capscrew head If the bearing will not take grease replace the U joint For U joint replacement follow the procedure in Group 41 of the Heavy Duty Trucks Service Manual 3 Check the purged grease If it appears rusty gritty or burned replace the U joint 4 Wipe the purged grease from the seals and any excess grease from the grease fitting Slip Joint Spline Lubricating 1 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 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 Driveline 3 Wipe the purged grease from the pressure relief hole and slip joint seal and any excess grease from the grease fitting 41 4 Heavy Duty Trucks Maintenance Manual April 1998 Brakes 42 Index Alphabetical Title of Maintenance Operation MOP MOP Number AlceliolEvaparalaf CHECKING i vec a it dr ci ER BR puto patte epg n an abet UE rb
124. he cab all the way continue working the pump until the cab nears a 45 degree angle Re duce pumping speed Once the cab goes beyond 45 degrees stop pumping The cab will gently descend to a full tilt position To stop the cab at any position between 45 degrees and full tilt move the control lever to Lower IMPORTANT If the cab unintentionally stops after it has gone beyond 45 degrees do not Heavy Duty Trucks Maintenance Manual October 2009 00 23 00 General Information COE Cab Tilting FLA FLB 00 11 07 21 93 f310043 1 Tilt Cylinder Rod 2 Tilt Strut 07 22 93 310044 1 Til Tilt Cylind Fig 11 Tilt Strut Positioning A W da Eod E Elise force it down with the tilt pump The velocity Fig 12 Releasing the Tilt Strut fuses have locked the tilt cylinders unlock them IMPORTANT If the cab unintentionally stops Returning the FLA Cab from after it has gone beyond 45 degrees do not 5 as force it down with the tilt pump The tilt strut is the Tilted Position in the locked position or the velocity fuses have locked the tilt cylinders Release the tilt strut or A DANGER unlock the velocity fuses 3 When the cab is lowered all the way make sure Stay completely clear of the cab s travel path at all the pump control lever is set at Lower times Once the tilt strut has been released do not lean over the frame rails the engine or the 4 Lock the cab latch handles See Fig 7 Make tr
125. heat 6 2 HT 550 Fan Clutch Fig 4 Check the rotary air union for air leaks Make sure the air line at the air union is not restricted due to kinking or bending If air leakage is found replace the rotary air union Fig 6 Ref 10 Check for air leaks around the piston Ref 15 and air chamber Ref 13 If air leakage is found replace the O ring seal Ref 11 20 6 Heavy Duty Trucks Maintenance Manual January 2007 Engine Cooling Radiator 20 N 24 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 Fig 5 Horton Type S and HT S Fan Clutch Components Kysor Dynair and Kysor K22RA Fan Clutch NOTE Check the lining wear at the first M3 maintenance interval the lining wear does not require checking at the first M2 interval Subse quent checks must be made at each M2 mainte nance interval 1 Disconnect the electrical cables from the battery Drain all air from the air system If equipped with an air starter drain the air starter reservoir A WARNING If
126. hen raise the rpm for 1 minute to purge air from the system and check for fuel leaks 10 Shut down the engine and correct any fuel leaks Heavy Duty Trucks Maintenance Manual October 1997 47 9 Exhaust 49 Index Alphabetical Title of Maintenance Operation MOP MOP Number Exhaust System Inspecting Noise Emission Control llli 49 01 Heavy Duty Trucks Maintenance Manual January 2007 Exhaust 49 01 Exhaust System Inspecting Noise Emission Control Pre EPAO7 Exhaust System Inspecting 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 1 On all vehicles check the condition of the muffler body top stack or top stack silencer Check the inlet outlet tubes for leakage dents and corro 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 Heavy Duty Trucks Service Manual for replacement procedures 2 Inspect the exhaust flex hose see Fig 1 for leakage wear or damage Replace with new parts if replacement is needed 3 Check for leakage at the V band coupling that attaches the exhaust pipe to the turbocharger exhaust outlet See Fig 1 49 If leakage exists tighten the nut on the V band
127. hree years many will per form adequately for a longer period of time To take maximum advantage of desiccant life and assure that replacement occurs only when nec essary it is important to perform the other main tenance operations in this group 42 14 CR Brakemaster Air Dryer Cleaning Model 62 or 68 Thoroughly steam clean the cooling fins of the CR Brakemaster air dryer to remove road grime Check that the cooling fins have not been painted if so re move the paint 42 15 Anchorlok Aftercooler Automatic Ejector Valve Clearing Remove the 1 8 inch pipe plug from the bottom of the automatic ejector valve Cycle the air compressor three or four times to blow out any moisture build up in the valve and to ensure that lines to the valve are clear Install and tighten the pipe plug 10 to 12 Ibf ft 14 to 16 N m 42 10 Heavy Duty Trucks Maintenance Manual October 2009 Brakes 42 16 Bendix Air Brake Valve Operation Checking BP R1 and E 12 Check for proper operation see Group 42 of the Heavy Duty Trucks Service Manual for instructions 42 17 Bendix Air Brake Valve Disassembly Cleaning and Inspecting BP 1 Double Check Valve E 6 PP 7 QR 1 R 6 R 14 SR 1 ST 3 TC 7 TP 5 and TR 3 NOTE See Group 42 of the Heavy Duty Trucks Service Manual for valve removal disassembly inspection assembly and leakage checking instructions Remove and disassemble the valves Clean the val
128. icant will drain faster if the fill plug is also removed See Fig 4 After all lu 05 28 93 4600064 1 Intermediate Shaft U Joint Grease Fitting Fig 2 Steering Driveline Intermediate Universal Joint bricant has drained install and tighten the drain plug 14 Ibf ft 19 N m Heavy Duty Trucks Maintenance Manual November 2002 46 1 46 05 28 93 1 1 Slip Joint Grease Fitting f460007a Fig 3 Steering Driveline Slip Joint L F N Lu MR 2 4 be B B 3 05 28 93 1460044 Fill Plug Steering Gear Attachment Fasteners Drain Plug Pitman Arm Pinch Bolt and Nut Input Shaft End Yoke Pinch Bolt and Nut Input Shaft End Yoke U Joint Grease Fitting DARREN Fig 4 TRW Model 503 Manual Steering Gear Use only an approved lubricant Failure to fill the steering gear with approved lubricant could ad versely affect steering ease under certain condi tions and could hamper vehicle control This could lead to an accident resulting in injury or property damage 2 Fill the steering gear with clean lubricant to within 1 2 inch 13 mm of the fill hole Use hy Steering poid gear oil API service classification GL 5 with no zinc additive At operating temperatures con tinuously above 30 F 1 C use viscosity grade SAE 90 At operating temperatures continuously below 30 F 1 C use viscosity grade SAE 75 3 Install and tighten the fill plug 14 Ibf ft 19 N m 46 04
129. in Fig 2 move the slack adjuster piston rod until the brake shoes contact the drum Measure the distance from the face of the brake chamber to the centerline of the clevis pin Fig 2 Ref B Record the exact dis tance as measurement B Brake Chamber Stroke with Eaton Cam Brakes Maximum iain Size Allowable Desired Free Stroke ective Area s Stroke inches mm square inches inches mm 12 1 3 8 35 3 8 to 1 2 10 to 13 16 1 3 4 44 3 8 to 1 2 10 to 13 20 1 3 4 44 3 8 to 1 2 10 to 13 24 1 3 4 44 3 8 to 5 8 10 to 16 24 long stroke 2 51 3 8 to 5 8 10 to 16 30 2 51 3 8 to 5 8 10 to 16 Adjust the brakes whenever the applied stroke exceeds the maximum Table 2 Brake Chamber Stroke with Eaton Cam Brakes 1 1 With the brakes released measure the distance from the face of the air chamber to the centerline of the clevis pin Fig 1 Ref A Record the exact distance as measurement A To be allowable mea surement A must be within this range 2 9 16 to 2 11 16 inches 65 to 68 mm NOTE If measurement A is outside this range reposition the clevis Remove the cle vis pin loosen the clevis jam nut and turn the clevis in or out until measurement A is within the specified range Then install the clevis pin and tighten the clevis jam nut 1 2 Apply the service brakes and hold them on full line pressure of at least 80 psi 550 kPa Measure the distance from the face of
130. 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 1993 2009 Daimler Trucks North America LLC All rights reserved No part of this publication in whole or in part may be translated reproduced stored in a retrieval system or transmitted in any form by any means electronic mechanical photocopying recording or otherwise
131. ine typical 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 2 With the power steering fluid at operating tem perature check the fluid level on the dipstick If low add enough fluid to bring the level up to the full mark on the dipstick See Table 1 for ap proved power steering fluid 3 Install the dipstick fill cap in the power steering reservoir 46 06 Power Steering Reservoir Fluid and Filter Changing 1 For a 2 quart or a 4 quart power steering reser voir remove the dipstick thumbscrew or cover capscrew and cover See Fig 8 Heavy Duty Trucks Maintenance Manual November 2002 46 3 46 Approved Power Steering Fluids Fluid Type Approved Fluid Automatic Transmission Dexron II Fluid Dexron III Heavy Duty Engine Oil Union 10W 40 IMPORTANT Do not use Texaco 10W 40 heavy duty engine oil in Chevron 10W 40 vehicles built from Union 15W 40 November 4 2002 Shell Rotella T 30W Steering For a 3 line system drain the power steering reservoir by disconnecting the steering gear to reservoir return hose from the reservoir and catch the fluid in a drain bucket Disconnect the power steering pump to reservoir re
132. ing 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 20 10 Heavy Duty Trucks Maintenance Manual January 2007 Engine Cooling Radiator 11 3 If either the hub or sheave bearings are worn replace them using a Horton Drive Master Super Kit For instructions and kit part number see Group 20 of the Heavy Duty Trucks Ser vice Manual 20 Heavy Duty Trucks Maintenance Manual January 2007 20 11 Clutch Title of Maintenance Operation MOP Clutch Linkage Components Lubricating Clutch Release Bearing Lubricating Clutch Release Cross Shaft Lubricating 25 Index Alphabetical MOP Number Heavy Duty Trucks Maintenance Manual January 1998 Clutch 25 01 Clutch Release Bearing Lubricating NOTE For a clutch with a sealed release bear ing the release bearing is lubricated at the time of manufacture and requires no additional grease for the life of the bearing This type of release bearing is not equipped with a grease fitting For a clutch with a grease type release bearing see Fig 1 wipe the dirt from the grease f
133. ing speed Once the cab goes over center stop working the pump The cab will gen tly descend to the operating position To stop the cab at any position between 45 de grees and 30 degrees move the control lever to Raise and push the tilt strut down onto the right tilt cylinder rod IMPORTANT If the cab unintentionally stops after it has gone beyond 45 degrees do not force it down with the tilt pump The tilt strut is in the locked position or the velocity fuses have locked the tilt cylinders Release the tilt strut or unlock the velocity fuses 3 When the cab is lowered all the way make sure the pump control lever is set at Lower 4 Check the indicator pin on each cab latch See Fig 4 The latches are locked when the pins have moved back into the piston and cylinder spring assembly 5 Push the transmission shift lever forward to lock the shift tube latch mechanism NOTE Maintain the hydraulic fluid level at the oil fill plug Add fluid only when the cab is in the operating position Use only Freightliner approved hydraulic fluid see Group 60 for specified fluid Tilting the FLA Cab A CAUTION Before tilting the cab make sure the vehicle is parked on level ground both side to side and front to rear Tilting the cab while the vehicle is parked on unlevel ground such as a sloping high way shoulder may damage the cab mounts and prevent you from returning the cab to the operat ing position 1 Apply
134. ion and Components 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 Ibf ft 25 to 32 N m 13 Refill the transmission with fresh Dexron III transmission fluid and check the fluid level Transmission NOTE Do not overfill the transmission Follow instructions in Maintenance Operation 26 08 26 06 Manual Transmission Magnetic Plug Cleaning Oil Changing and Oil Filter Element Changing Manual Transmission Oil Changing IMPORTANT For all transmissions that are filled with approved synthetic lubricants the lubricant must be changed every 500 000 miles 800 000 km Transmissions with petroleum based lubri cants must have the lubricant changed at each Maintenance 2 M2 interval All transmissions with synthetic or petroleum based lubricants must have the transmission breather checked and the magnetic plugs cleaned at each M1 interval NOTE For vehicles equipped with auxiliary transmissions use this procedure to change the auxiliary transmission oil and to check the auxil iary transmission breather whenever changing the main transmission oil and checking the main transmission breather 1 With the vehicle parked on level ground apply the parking brakes and chock the tires Place a large drain pan under the transmission 2 Clean the area around the fill plug and remove it
135. ir or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use 2 The use of the vehicle after such device or ele ment of design has been removed or rendered inoperative by any person Among those acts presumed to constitute tam pering are the acts listed below A Removal of engine noise deadening panels B Removal of cab tunnel or hood noise deadening panels C Removal of or rendering inoperative the en gine speed governor so as to allow engine speed to exceed manufacturer s specifica tions D Removal of or rendering inoperative the fan clutch including bypassing the control on any thermostatic fan drive to cause it to op erate continuously Removal of the fan shroud Removal of or rendering inoperative ex haust components including exhaust pipe clamping G Removal of air intake components Maintenance Instructions Scheduled intervals are in the maintenance tables in this group A Verification of Inspections Log Groups 01 20 and 49 follows and should be filled in each time noise emission controls on the vehicle are main tained or repaired Heavy Duty Trucks Maintenance Manual October 2009 00 25 00 General Information Verification of Inspections Log 00 13 Verification of Inspections Log Verification of Inspections Log Grou
136. ir lines do not rub against any thing Reposition any configurations that could contact and result in friction or wear There must be at least 1 inch 25 mm clearance around the rubber air spring when inflated If clearance is less than 1 inch 25 mm relocate the obstruct ing parts 4 Check the length of the overtravel lever between its pivot points See Fig 9 Ref A 4 1 If the vehicle is equipped with an adjust able leveling valve the length should be 8 inches 203 mm If the length is incor rect see Group 32 of the Heavy Duty Trucks Service Manual for adjustment procedures 4 2 If the vehicle is equipped with a fixed lev eling valve see Group 32 of the Heavy Duty Trucks Service Manual for the over travel lever length for the rear axle installed in your vehicle 32 4 Heavy Duty Trucks Maintenance Manual October 2009 Suspension 32 05 15 95 1320410 A Measure the length of the overtravel lever between these two points 1 V Shaped Mark 2 Adjustment Locknut 3 Overtravel Lever 4 Cotter Pin 5 Linkage Rod Fig 9 AirLiner Overtravel Lever and Linkage Rod Measurement 5 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 10 Ref A Th
137. 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 air 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 inH O on a vehicle with a Mercedes Benz engine or 25 inH4O on a vehicle with a Caterpillar or Cum mins engine For replacement instructions see Group 09 of the Heavy Duty Trucks Service 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 Heavy Duty Trucks Maintenance Manual February 2004 09 1 Air Compressor 13 Index Alphabetical Title of Maintenance Operation MOP MOP Number Bendix Air Compressor InspectilT uu fines PRE BERE oooh RR dearer eee eee Pon BR E EE 13 01 Heavy Duty Trucks Maintenance Manual January 1997 Air Compressor 13 01 Bendix Air Compressor Inspecting Inspect the air intake line oil supply and return lines and coolant supply and return hoses for tight con nections a
138. is not drained before the air filter regulator is serviced serious injury and component damage could re sult 1 Apply the parking brakes and chock the tires Drain the air from the air reservoirs 2 Clean the outside of the air filter regulator with cleaning solvent then let it air dry 3 Remove the end cap from the air filter regulator assembly then inspect the O rings in the end cap Replace worn or damaged O rings 4 Remove the element from the filter regulator as sembly 5 Inspect the element for oil If oil is in the ele ment replace the element Inspect the air supply System for the source of oil and service it as needed 6 Install the element in the filter regulator assem bly 7 Apply a light coat of Dow Corning DC7 silicone grease or an equivalent to the O rings in the end cap 8 Install and tighten the end cap 10 to 15 Ibf ft 14 to 20 N m 9 Build air pressure in the system check for leaks and make any needed repairs 26 08 Transmission Oil Level Checking and Breather Checking NOTE For vehicles with auxiliary transmissions use this procedure to check the auxiliary trans mission oil level and breather whenever check ing the main transmission oil level and breather Breather Checking Transmission housing breathers must remain clear A plugged breather could result in pressure build up which could cause oil leakage Transmission If the breather is plugged clean or repl
139. itting 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 05 27 93 f250081a Fig 1 Release Bearing Grease Fitting IMPORTANT If the release bearing is not equipped with a grease fitting extension that extends outside the bell housing lubricate the bearing with the engine stopped If equipped with a grease fitting extension that does extend 25 outside the bell housing lubricate the bearing with the engine running Using a pressure gun and high temperature grease only lubricate the release bearing at the grease fit ting until grease starts coming out of the fitting Do not use chassis lube or multipurpose lubricants 25 02 Clutch Release Cross Shaft Lubricating The clutch release cross shaft is equipped with two grease fittings in the transmission clutch housing See Fig 2 and Fig 3 Wipe the dirt from the grease fittings Using a pressure gun lubricate the clutch release cross shaft with multipurpose chassis grease 10 19 93 f250048a 1 Clutch Release Cross Shaft 2 Grease Fitting Fig 2 Cross Shaft Grease Fitting Left Side 25 03 Clutch Linkage Components Lubricating FLA FLB Clutch Linkage For earlier FLAs the clutch linkage is equipped with four grease fittings one at each rod end spheric
140. ive enough grease Using lithium 12 Hydroxy stearate grease NLGI grade 1 or grade 2 with EP additives lubricate until new grease can be seen at all four U joint seals IMPORTANT Fresh grease must be seen es caping from all four bearing cap seals of each U joint On full round yokes if most of the grease being added to a U joint can be seen escaping from just one of the U joint seals bend the tabs of the lockstrap if equipped away from the heads of the bearing cap cap screws then check the torque on the capscrews at that seal Tighten the bearing cap capscrews Heavy Duty Trucks Maintenance Manual April 1998 41 3 41 to the torque values given in Table 1 If equipped bend the lockstrap tabs up against a flat side of each capscrew head If the cap screws 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 If grease does not appear at one seal use a screwdriver to pry the U joint trunnion away from the non purging seal or tap the driveshaft or yoke with a plastic or rawhide mallet on the side opposite the dry seal while continuing to lubricate If grease still does not appear bend the tabs of the lockstrap away from the heads of the bearing cap capscrews then loosen the capscrews at the bearing with the dry seal to relieve seal tension Lubricate the U joint until new
141. joint splines For an FLA or an FLB lubricate the slip joint splines only when the cab is in the operating position Turn the front wheels to the left for better access to the driveline 46 02 TRW Manual Steering Gear Lubricant Checking Model 503 1 Remove the fill plug from the top of the steering gear housing See Fig 4 Use only an approved lubricant Failure to add ap proved lubricant could adversely affect steering ease under certain conditions and could hamper vehicle control This could lead to an accident re sulting in injury or property damage 2 Check the lubricant level If low add enough lu bricant to bring the level to within 1 2 inch 13 mm of the fill hole Use hypoid gear oil API ser vice classification GL 5 with no zinc additive At operating temperatures continuously above 30 F 1 C use viscosity grade SAE 90 At operating temperatures continuously below 30 F 1 C use viscosity grade SAE 75 3 Install and tighten the fill plug 14 Ibf ft 19 N m 46 03 TRW Manual Steering Gear Lubricant Changing Model 503 05 28 93 d f460005a 1 U Joint Grease Fitting 2 Steering Column End Yoke Pinch Bolt and Nut Fig 1 Steering Driveline Upper Universal Joint NOTE In climates with extreme temperature changes lubricant should be changed every six months 1 While the steering gear lubricant is still warm remove the steering gear drain plug and drain the old lubricant Lubr
142. k ing system may lead to brake failure resulting in property damage personal injury or death 1 Lubricate the slack adjuster until grease flows from the grease relief opening See Fig 6 For temperatures to 40 F 40 C use Lubriplate Aero for temperatures to 20 F 29 C use Texaco Multifak EP 2 or MobilGrease No 77 The newest Gunite slack adjusters are produced without a grease relief During lubrication with a grease gun lubricant is forced through the drilled worm wheel onto the camshaft Lubricate the slack adjuster at the grease fitting until grease appears on the camshaft 2 Inspect the slack adjuster for structural damage Replace the slack adjuster if needed 3 Inspect the slack adjuster boot for cuts or tears If the boot is damaged replace it as follows see Fig 6 3 1 Remove the two clevis pins Heavy Duty Trucks Maintenance Manual October 2009 42 5 42 Brakes Install the 1 4 inch clevis pin and the cot ter pin 3 6 Tap the clevis upward or downward until 4 the large hole in the slack adjuster lines 5 up with one in the clevis 6 Install the 1 2 inch clevis pin and the cot ter pin 7 A WARNING Make sure both clevis pins are installed Failure to Y do so will cause the slack adjuster to work incor 2 rectly which could lead to loss of braking control 9 This could result in an accident causing personal injury or property damage 1 42 04
143. k Adjuster Inspecting 42 07 Alcohol Evaporator Checking 42 08 Bendix Alcohol Evaporator Cleaning 42 15 Anchorlok Aftercooler Automatic Ejector Valve Clearing 42 18 Bendix Air Brake Valve Disassembly Cleaning Inspecting and Lubricating DV 2 PP 3 and Single Check Valve 42 21 Sealco Moisture Ejection Valve Operation and Leak Testing Model 6300 46 06 Power Steering Reservoir Fluid and Filter Changing 46 07 Steering Driveline Deck Bearing Lubricating FLA FLB 47 01 Fuel Tank Vent Checking 47 03 Fuel Separator Sight Bowl Cleaning and Element Replacing 60 02 Cab Suspension Spring Center Bolt Torque Checking FLC 83 01 Air Conditioner Inspecting Heavy Duty Trucks Maintenance Manual October 2009 00 15 00 General Information M3 Maintenance Interval Operations Table 00 09 The M3 Maintenance Interval Operations table lists NOTE Maintenance operations appearing in italics in all maintenance operations that are to be performed this table are for noise emission control components at the M3 maintenance interval Maintenance opera Numbers in this table are reference numbers match tion numbers are reference numbers used to help ing those in the text of this manual you find detailed instructions in this manual on the maintenance operations to be performed Perform all maintenance interval operations in M1 and M2 when performing M3 maintenance interval operations M3 Maintenance Interval Operations for Service Schedules I Il an
144. ke 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 5 Brake Chamber Stroke Specifications Heavy Duty Trucks Maintenance Manual October 2009 42 15 Steering 46 Index Alphabetical Title of Maintenance Operation MOP MOP Number Drag Link and Power Steering Cylinder Lubricating lille 46 04 Power Steering Reservoir Fluid Level Checking iis SE EE SE Re ee 46 05 Power Steering Reservoir Fluid and Filter Changing liliis 46 06 Sheppard Power Steering Gear Bearing Cap Lubricating 2l 46 09 Steering Driveline Deck Bearing Lubricating FLA FLB liliis 46 07 Steering Driveline Lubricating i auiem rer pei neei E s rn Ea E 46 01 TRW Manual Steering Gear Lubricant Changing Model 503 000 eee eee 46 03 TRW Manual Steering Gear Lubricant Checking Model 503 00000 cece eee 46 02 TRW Power Steering Gear Lubricating TAS Series llle 46 08 Heavy Duty Trucks Maintenance Manual November 2002 Steering 46 01 Steering Driveline Lubricating 46 Wipe the steering driveline grease fittings clean See Fig 1 Fig 2 Fig 3 and Fig 4 Using a pressure gun apply multipurpose chassis grease sparingly to the universal joints and slip
145. ket appears dry rotted or damaged replace the gasket Heavy Duty Trucks Maintenance Manual October 1997 47A 47 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 Install and close the vacuum breaker fit ting when the unit is full of fuel IMPORTANT The fitting must be air tight and the valve closed Racor Fuel Separator Element Replacement The only service necessary on Racor fuel separators is to replace the filter element See Fig 2 Racor 325R and 330R A 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 When working on a fuel system have a fire extinguisher within easy reach 1 Disconnect the water sensor probe connector if equipped 2 Place a suitable container under the fuel heater water separator then drain the fuel from the fuel heater water separator by opening the drain
146. l heater water separator Open the filter vent 5 Drain the fuel below the collar level by opening 6 the drain valve then close the drain valve 2 Remove the filter collar using the Davco filter collar wrench See Fig 10 8 7 4 8 FOR REMOVAL OF TOP COLLAR ONLY Ye z 9 DL a mo 02 16 2009 1470277 11 Fig 10 Davco Filter Collar Wrench Davco P N 380134 3 Remove the filter cover Retain the filter cover seal for re use 12 4 Remove the filter element remove the grommet from the element then discard the element Re dl ere tain the grommet for re use 1 Filter Vent 8 G t 2 ice Men Seal 9 Threaded Filter Stud 5 Add fuel to the fuel heater water separator hous 3 Filter Spring for emergency use ing until it reaches the top of the fuel port 4 Filter Element 10 Fuel Port 1 5 Filter Cover 11 Davco Unit Body 6 Install the grommet on the new filter element 6 Filter Collar 12 Drain Valve 7 Filter Cover Seal A CAUTION Fig 9 Davco 380 Do not use the filter collar wrench to tighten the filter collar Using the filter wrench to tighten the collar can damage the collar resulting in a fuel leak 47 8 Heavy Duty Trucks Maintenance Manual October 1997 Fuel 47 7 Install the filter element filter cover and cover seal and filter collar Hand tighten the filter col lar 8 Remove the filter vent then fill with fuel until fuel is about 1 inch above the collar Install the filter vent 9 Start the engine t
147. l N ma rSh EE Ed NEE eo EE 5 5 sao ges ME N aa EEN dd EEN mem resi TEE 208 mum mima wem eTERLET Que pem ROE RT 58 180 Rear 36 1 17 Dr RT 70 380 ds 54 4 25 7 SQ 100A Forward 40 0 18 9 ear 53 1 25 1 Quantities listed are approximate Fill axle until ubricant is level with bottom of fill hole with vehicle on level ground Table 6 Meritor Tandem Drive Axle Lubricant Capacities Heavy Duty Trucks Maintenance Manual January 1997 35 9 Wheels and Tires 40 Index Alphabetical Title of Maintenance Operation MOP MOP Number Wheel Nut and Rita Nut CHECKING 2 ss SE uit m Eben He RS DEE EED ER N ab gc E b Rex itte 40 01 Heavy Duty Trucks Maintenance Manual January 1997 Wheels and Tires 40 01 Wheel Nut and Rim Nut Checking IMPORTANT In addition to the maintenance interval in the general information section check the wheel or rim nut torque the first 50 to 100 miles 80 to 160 km of operation after a wheel has been removed and installed See Table 1 for wheel nut torque specifications and see Fig 1 for the wheel nut tightening sequence A 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 sequence shown in Fig
148. le assem blies do not raise the front axle Wipe the lube fit tings clean and apply multipurpose chassis grease NLGI grade 1 696 12 hydroxy lithium stearate grease or NLGI grade 2 8 12 hydroxy lithium Stearate grease until new grease is seen at the junc tions of the axle beam and knuckles See Fig 3 33 02 Tie Rod Inspecting and Lubricating Inspect the tie rod ends as follows 1 Shake the cross tube A loose fit or movement between the tapered shaft of the ball and the cross tube socket members indicates that the tie rod end assembly must be replaced 2 The threaded portion of the tie rod end assembly must be inserted all the way into the cross tube split for adequate clamping See Fig 4 Replace the components if this cannot be done For in structions see Group 33 of the Heavy Duty Trucks Service Manual Heavy Duty Trucks Maintenance Manual June 2001 33 1 33 05 31 2005 Lad f320360a Pump lubricant into each grease fitting until fresh grease come out at point A 1 Grease Fitting Fig 3 Freightliner Knuckle Pin Lubrication 02 27 2007 NOTE Pinch bolt not shown to provide clarity 1 Cross Tube Split f320033a Fig 4 Tie Rod End Adjustment 3 For any Dana Spicer Meritor or Freightliner axle that requires lubrication of the tie rod ends wipe the grease fittings clean then pump multipurpose chassis gr
149. lever bar and operating handle must be in proper alignment See Fig 4 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 Level the fifth wheel plate to a horizontal posi tion Measure the height from a stationary mounting point see Fig 5 Ref 3 such as the Heavy Duty Trucks Maintenance Manual October 2009 31 3 31 Frame and Fifth Wheel 11 28 95 1310353b 1 Lubricant Grooves 3 Lock Control Handle 2 Safety Latch 4 Mount Fig 3 Simplex Series Fifth Wheel 1 lal i 2 09 15 95 1310470 1 Operating Handle 2 Lever Bar Fig 4 Lever Bar and Operating Handle Alignment 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 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 Heavy Duty Trucks Service Manual for replacement instructions 5 N ES a 3 4 08 31
150. lic system opens When the pump is operated hydraulic pressure forces the cab back up and over center The cab then falls at a controlled rate until it settles onto the rear mounts NOTE Whenever raising or lowering the cab stop working the pump once the cab goes over center The cab falls at a controlled rate and continued pumping could cause hydraulic lock up of the tilt cylinders Hydraulic lock up of the tilt cylinders can occur dur ing very cold weather It can also occur when the wrong hydraulic fluid is used when there is air in the system when there is sudden cab movement or when a hydraulic line is ruptured Any of these situa tions will cause the velocity fuses to function as safety check valves and lock up the tilt cylinders IMPORTANT If the tilt cylinders lock up check for a major problem such as a ruptured line or Heavy Duty Trucks Maintenance Manual October 2009 00 19 00 COE Cab Tilting FLA FLB 00 11 General Information 06 15 93 A Lowered Operating Position so l U Ri B B 45 Degree Tilt Position 1000131 C Full Tilt Position 80 Degrees leaking fitting before trying to unlock the tilt cyl inders If such a problem is found make any necessary repairs before unlocking the cylinder To unlock the cylinders the cab must be moved in the opposite direction of travel back toward the 45 degree position If the cab is moving toward the full tilt positi
151. listed in this table perform all daily weekly and monthly mainte nance operations listed in the Pretrip and Post Trip Inspections and Maintenance chapter of the vehicle driver s manual Maintenance Operation Sets for Groups 00 through 83 00 Maintenance Operation Sets Table 00 05 NOTE Maintenance operations appearing in italics in this table are for noise emission control components Numbers in this table are reference numbers match ing those in the text of this manual Main eet Operation Description Maintenance Interval IM M1 M2 M3 M4 01 01 Engine Rear Support Assembly Checking e 01 02 Engine Noise Panel Inspecting 01 03 Jacobs Engine Brake Wiring Inspecting 01 04 Engine Drive Belt Inspecting 09 01 Air Cleaner Element Inspecting and Replacing 13 01 Bendix Air Compressor Inspecting 15 01 Alternator Battery and Starter Checking e 20 01 Radiator Cap Checking 20 02 Radiator Pressure Flushing and Coolant Changing 20 03 Fan Drive and Clutch Checking 25 01 Clutch Release Bearing Lubricating 25 02 Clutch Release Cross Shaft Lubricating e fe fe fede 25 03 Clutch Linkage Components Lubricating e fe fe fe fe 26 01 Shift Control Telescoping Tubes Lubricating and Inspecting FLA FLB e fe fe fe de 26 02 Shift Control Latch Lubricating and Cylinder In
152. llllllel eh 54 02 Heavy Duty Trucks Maintenance Manual April 1998 Electrical Instruments and Controls 54 01 Electrical System Checking NOTE Tighten electrical system connections to the torque values in Table 1 Torque Values for Electrical System Connections Connection iban dien Electrical Panel Stopnut 30 340 Air Oil Junction Block Ring Terminal Nut 30 340 Battery Terminal 70 800 Main Cab Power Stud Hexnut 175 1980 Main Cab Ground Stud Hexnut 50 560 Table 1 Torque Values for Electrical System Connections Cab Interior Inspect the wiring and electrical connections at the electrical mounting plate cab to chassis interface connectors cab to engine interface connectors main cab power and cab ground studs and electrical junc tion blocks e For an FLA see Fig 1 and Fig 2 e For an FLB see Fig 3 and Fig 4 e For an FLC LH DR see Fig 5 and Fig 6 e For an FLD see Fig 7 e For an FLC RH DR see Fig 8 and Fig 9 For an FLA uncover the electrical mounting plate by removing the tunnel top cover The cover is held in place by Velcro8 Pull upward on the left front and rear corners then tip the cover up and to the right Uncover the electrical junction block by removing the tunnel right hand kick panel For an FLB uncover the electrical mounting plate by removing the tunnel left hand cover See Fig 10 Ref 3 Loosen the quarter turn fastener Ref 2
153. lt s widest span and adjust the belt tension if needed See Group 01 for belt tension specifications Some engines are equipped with dual alternator belts check both belts for correct tension Engines equipped with a serpentine or poly V belt have automatic belt tensioners and do not require belt tension inspection 3 Clean and tighten all charging system electrical connections including the connections at the starter B terminal and ground terminal and at the terminators of the alternator charging cable 4 On the bundled cable that runs from the batteries to the starter ensure that tie straps are installed at least every 12 inches 300 mm Replace any missing tie straps and add tie straps where spac ing between straps exceeds 12 inches 300 mm 5 Ensure that all cables have sufficient slack to allow for engine movement and that there is no pressure on any wiring connectors 6 Check all wiring inside of damaged convoluted tubing and replace any damaged or missing con voluted tubing 7 Inspect the battery cables for wear and replace as needed Clean the cable connector terminals 15 with a wire brush See Group 54 of the Heavy Duty Trucks Service Manual for troubleshooting adjustment repair or replacement instructions 7 1 Clean and tighten the battery ground cable terminal and clamps 7 2 Inspect the retainer assembly or battery hold downs and the battery box Replace worn or damaged parts Remove any co
154. lug Cover Fig 3 Two Speed Axle Shift Unit 2 The lubricant level should be maintained at the bottom of the fill hole If low add specified lubri cant CAUTION 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 vehicle operating tempera tures are above 0 F 18 C use SAE 10 heavy duty engine oil API service classification SD sulfated ash content must not exceed 1 85 When vehicle operating temperatures are below 0 F 18 C use one part kerosene to three parts SAE 10 heavy duty engine oil Rear Axle API service classification SD sulfated ash con tent must not exceed 1 85 This cold weather mixture can be safely used up to 32 F 0 C Commercially available automatic transmission fluid may be used in place of SAE 10 engine oil Automatic transmission fluid can be used for all temperatures do not mix kerosene with it 3 Apply a small amount of Loctite 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 Eaton Axle Breather Checking Axle housing breathers Fig 1 must remain un clogged Whenever the axle lubricant level is checked be sure the axle breather is open Check more often under adverse operating conditions If the breather is plugged
155. m 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 to prevent the vehicle from moving 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 bolts and nuts at the pivot and axle connections to assure 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 20 to the bottom of the frame rail If the riding height is incorrect adjust the air suspension 32 02 Suspension Lubricating 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 un
156. n plate or turntable under both front tires Raise the front of the vehicle 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 33 2 Heavy Duty Trucks Maintenance Manual June 2001 Front Axle 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 5 Lock in place Check that the scale is set on zero 7 Move the trammel bar to the front of the tires see Fig 6 and adjust the scale end so that the pointers line up with the scribe lines See Fig 7 8 Read the toe in from the scale and compare it to the toe in specification in Group 33 of the Heavy Duty Trucks Service Manual If corrections are needed see Group 33 of the same manual for instructions on adjusting the toe in 33 a B gt 08 29 94 1330082a B minus A equals toe in Fig 5 Wheel Toe In Overhead View 08 30 94 f330014a 08 30 94 f400100a Fig 6 Trammel Bar Positioning Fig 7 Setting the Trammel Bar Pointers Heavy Duty Trucks Mainte
157. nance Manual June 2001 33 3 Rear Axle 35 Index Alphabetical Title of Maintenance Operation MOP MOP Number Axle Breather and Lubricant Level Checking lille 35 01 Axle Lubricant Changing Oil Filter Replacing and Magnetic Strainer Cleaning 35 02 Heavy Duty Trucks Maintenance Manual January 1997 Rear Axle 35 01 Axle Breather and Lubricant Level Checking Eaton Axle Lubricant Level Checking CAUTION Failure to keep the rear axle filled to the proper level with the recommended lubricant can result in rear axle damage 1 With the vehicle parked on level ground apply the parking brakes and chock the tires 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 Fig 1 or from the standpipe if so equipped installed in the fill hole 06 07 94 f350002a 1 Axle Housing Breather 3 Temperature Indicator 2 Fill Plug Plug Fig 1 Axle Housing 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 Fig 2 or top of the standpipe opening 35 4 Lubricant should be level with the bottom of the fill hole Fig 2 or with the top of the standpipe opening If low check the axle for oil leaks and correct as needed Add lubricant as required See Tabl
158. nance Schedule Tables 00 03 61st through 80th Maintenance for Service Schedule Vehicles i i i i Service I por Required ea Operation Service Date TU Tem 61st M1 61 000 98 200 6100 62nd M1 62 000 99 800 6200 63rd M1 63 000 101 400 6300 64th M1 64 000 103 000 6400 65th M1 and M2 65 000 104 600 6500 66th M1 66 000 106 200 6600 67th M1 67 000 107 800 6700 68th M1 68 000 109 400 6800 69th M1 69 000 111 000 6900 70th M1 M2 and M3 70 000 112 700 7000 71st M1 71 000 114 300 7100 72nd M1 72 000 115 900 7200 73rd M1 73 000 117 500 7300 74th M1 74 000 119 100 7400 75th M1 and M2 75 000 120 700 7500 76th M1 76 000 122 300 7600 77th M1 77 000 123 900 7700 78th M1 78 000 125 500 7800 79th M1 79 000 127 100 7900 80th M1 M2 M3 and M4 80 000 128 700 8000 81st through 100th Maintenance for Service Schedule I Vehicles i i i i Service I jd Required jig breed Operation Service Date Tom ae 81st M1 81 000 130 400 8100 82nd M1 82 000 132 000 8200 83rd M1 83 000 134 000 8300 84th M1 84 000 135 200 8400 85th M1 and M2 85 000 137 000 8500 86th M1 86 000 138 400 8600 87th M1 87 000 140 000 8700 88th M1 88 000 141 600 8800 89th M1 89 000 143 200 8900 90th M1 M2 and M3 90 000 144 800 9000 91st M1 91 000 146 500 9100 Heavy Duty Trucks Maintenance Manual October 2009 00 5 00 Vehicle Maintenance Sch
159. nce Manual October 2009 Suspension 2 1 LZ A Y A 3 Sd 05 27 93 5 1320023a A 1 8 8 mm Clearance 1 Frame Fasteners 4 Equalizer 2 Frame Rail 5 Equalizer Bracket 3 Pry Bar Fig 4 Top View of the Equalizer 2 3 05 27 93 1320039a 1 Beam Hanger 3 Jack 2 Equalizer Beam Fig 5 Raising the Hendrickson Suspension Beam End Insufficient beam end fastener torque could cause the beam to separate from the axle This will cause loss of vehicle control resulting in property damage serious personal injury or death 4 After repairs to the suspension check the fas tener torque after the vehicle has been in service for 2500 miles 4000 km If equipped with the adapter type beam end connection see Fig 6 for the three piece adapter type beam end con nection or Fig 7 for the two piece adapter type 32 beam end connection tighten the nut 210 to 240 Ibf ft 285 to 325 N m If equipped with the tube type beam end connection see Fig 8 tighten the nut 375 to 425 Ibf ft 508 to 576 N m Do not overtorque 5 T ZZ Zen E ee eZ GEE HG i 2277 LT va al PA i WELL WELL VILLA LLLL 2 EE AGE re or os EE 3 4 05 27 93 f320110a NOTE Do not use the three piece adapter without the intermediate tube 1 Nut 4 2 Adapter 3 Intermediate Tube Inner Metal of Beam End Bushing 5 Beam Hanger Fig 6 Three Piece Adapter Type Beam End Connection 4 Jnd IE 30M 2 V pes idu
160. nce Manual October 2009 General Information 00 Determining Scheduled Maintenance Intervals 00 01 Determining Scheduled Maintenance Intervals Performing regular maintenance on your Freightliner vehicle will help ensure that your vehicle delivers safe reliable service and optimum performance for years to come Failure to follow a regular mainte nance program can result in inefficient operation and unscheduled down time To determine the correct maintenance intervals for your vehicle you must first determine the type of ser vice or conditions in which the vehicle will operate Generally most vehicles operate under conditions that fall within one of the three types of service de scribed Before placing your new vehicle in service determine the type of service Service Schedule Il or Ill that applies to the intended use of the vehicle After determining the vehicle s type of service refer to the Maintenance Service Table or the Vehicle Maintenance Schedule Tables to determine how often maintenance should be performed When the vehicle reaches the distance given for a maintenance interval see the applicable Mainte nance Interval Operations Table for a list of the main tenance operations to be performed at that mainte nance interval Use the maintenance operation numbers to find detailed instructions in the manual on each operation Types of Service Service Schedule severe service applies to ve hicles tha
161. nd general condition Tighten the connec tions and replace the lines and hoses as needed If the compressor air intake adapter is loose remove the adapter replace the adapter gaskets and se curely install the adapter Check the cooling fins on the compressor crankcase Clean the fins if they are clogged with dirt or grease 13 Heavy Duty Trucks Maintenance Manual January 1997 13 1 Alternators and Starters 15 Index Alphabetical Title of Maintenance Operation MOP MOP Number Alternator Battery and Starter Checking 22s 15 01 Heavy Duty Trucks Maintenance Manual October 2009 Alternators and Starters 15 01 Alternator Battery and Starter Checking Batteries generate explosive gas as a by product of their chemical process Do not smoke when working around batteries Put out all flames and remove any source of sparks or intense heat in the vicinity of the battery compartment Make sure the battery compartment has been completely vented before disconnecting or connecting the battery cables Battery acid is extremely harmful if splashed in the eyes or on the skin Always wear a face shield and protective clothing when working around batteries 1 Check the tightness of the alternator bracket fas teners tighten the fasteners as needed For torque values see Group 15 of the Heavy Duty Trucks Service Manual 2 Check the belt tension of the alternator drive belt Use a tension gauge at the be
162. nection which could eventually result in serious vehicle damage 1 For each full round driveline yoke with lockstraps see Fig 1 Ref A check to be sure the lock straps are locked The locking tab must be firmly locked against a flat side of the capscrew head If not locked tighten the bearing cap capscrew then bend a tab of the lockstrap upwards until it is firm against a flat side of the capscrew head For each full round driveline yoke with thread locking capscrews tighten the bearing cap cap screws See Fig 1 Ref B For each half round driveline yoke tighten the yoke strap capscrews See Fig 2 Ref 6 Tighten all U joint bearing cap fasteners to the torque values given in Table 1 08 13 96 A ONS ps A BN 7 PA SR le A B 410033b U Joint With a Lockplate for a vehicle built before April 1 1994 U Joint With Self Locking Capscrews for a vehicle built from April 1 1994 Capscrew not self locking Self Locking Capscrew Adhesive Band Lockplate Fastener Torque Values Description Size Lar ice Yoke Strap Capscrew 1 2 20 130 176 5 16 24 24 33 Bearing Cap Capscrew 3 8 24 37 50 7 16 20 60 81 Table 1 Fastener Torque Values 2 Check each input and output end yoke see Fig 2 for cracks and looseness Replace cracked yokes If any end yoke can be moved in or out on its shaft or can be rocked on its shaft disconnect the dri
163. o dd st LR m Dna BEE ava A 42 07 Anchorlok Aftercooler Automatic Ejector Valve Clearing lille 42 15 Bendix Air Brake Valve Disassembly Cleaning Inspecting and Lubricating DV 2 PP 3 and Single Check Valve lille 42 18 Bendix Air Brake Valve Disassembly Cleaning and Inspecting BP 1 Double Check Valve E 6 PP 7 QR 1 R 6 R 14 SR 1 ST 3 TC 7 TP 5 and Ee ER OE N LE OO Su ism ri i bale ee Ri EP Che de doh Bel bette he ed 42 17 Bendix Air Brake Valve Inspecting and Testing BP 1 BP R1 LQ 5 PP 7 F 14 and ie EE ER RE OR ch Ras EU EE do dote dere ba nde mais ple S arces 42 19 Bendix Air Brake Valve Operation Checking BP R1 and E 12 0 000200 eee 42 16 Bendix Air Dryer Checking AD 2 AD 4 or AD EE EE EE Re eee 42 10 Bendix Air Dryer Desiccant Replacing AD 2 llli es 42 12 Bendix Air Dryer Desiccant Replacing AD 4 or AD 9 1 0 eee 42 13 Bendix Air Dryer or Anchorlok Aftercooler Inspecting Bendix AD 2 AD 4 AD 9 JOM eie iea as aoo EA RE OE OE RT b EA EER F 42 11 Bendix Alcohol Evaporator Cleaning ss cu aom dunes mee pues donee pe e SE BE SE Rx ae pd Rug vars 42 08 Bendix Alcohol Evaporator Gasket Replacing 0 00000 cee es 42 09 Bendix Foot Brake Valve Actuator Lubricating E 6 or E 12 and Leak Testing ES cp dish s N OT OE AR gt Seas EAs PADRES oi SER DEAE Gee Read ee RE Sas N 42 20 Brake Adjusting Cam Brakes With Manual Slack Adjusters
164. om the trailer For instruc tions refer to the vehicle driver s manual 2 Thoroughly steam clean the fifth wheel 3 Look for cracks in the fifth wheel assembly mounting brackets and mounting parts 10 11 31 Check moving parts for wear or damage Test the safety lock latch for free operation Check for loose nuts or bolts in the fifth wheel and in the mounting Check all springs to see if they are securely fastened and not deformed Check wedge adjustment 8 1 Open the kingpin lock and vertically insert a 2 inch diameter shaft 8 2 Release the lock by tripping the release latch at the bottom of the throat 8 3 Adjust the wedge stop at the end of the wedge to approximately 1 4 inch 6 mm clearance If you observe any problems when doing the above steps correct them immediately For in structions refer to the fifth wheel section in the vehicle service manual Oil all moving parts on the fifth wheel and grease the top plate and the two zerk fittings for the bracket bearing area Replace cracked worn or damaged parts with new parts Replace 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 HOLLAND 1 Disconnect the tractor from the trailer For instruc tions refer to the vehicle driver s manual Thoroughly steam clean the fifth wheel Check for loose nuts or broken bolts on the fi
165. on when the lock up occurs move the con trol lever to Lower and work the pump a few strokes to unlock the cylinders Move the control lever to Raise and allow the cab to descend to a full tilt position If the cab is moving toward the low ered operating position when the lock up occurs move the control lever to Raise and work the pump a few strokes to unlock the cylinders Move the control lever to Lower and allow the cab to de scend to the operating position Tilting the FLB Cab A CAUTION Before tilting the cab make sure the vehicle is parked on level ground both side to side and front to rear Tilting the cab while the vehicle is parked on unlevel ground such as a sloping high way shoulder may damage the cab mounts and prevent you from returning the cab to the operat ing position 1 Apply the parking brakes Place the transmission shift lever in neutral Shut down the engine if it is Before tilting the cab make sure that there is ad equate clearance in front of the vehicle and that the area is free of people and all objects Do not tilt the cab with the engine running Tilting the cab could engage the transmission If the en gine is running the vehicle can move causing an accident that could result in personal injury or property damage 2 Secure all loose articles in the cab and bunk and make sure the doors are securely latched A WARNING Objects falling in the cab or a door flying open
166. onditions and magnetic plug maintenance Lubricant changes should be made as climatic tem peratures demand regardless of vehicle mileage or established change schedule Normal operating temperature of compounded lubri cants during the summer season is approximately 160 to 220 F 71 to 104 C Chemicals and additives that give these lubricants increased load carrying ca pacity oxidize faster at temperatures above 220 F 104 C contributing to more rapid lubricant deterio ration For this reason lubricants of this type that operate continuously at high temperatures must be changed more frequently to realize the inherent ad vantages they offer A CAUTION Failure to change the axle lubricant at more fre quent intervals when adverse operating condi tions require could result in axle damage Traction Equalizer Additives 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 35 6 Heavy Duty Trucks Maintenance Manual January 1997 Rear Axle er s manual Meritor s experience shows that the fol lowing additives friction modifiers perform ad equately A For all GL 5 gear oils mineral oil or synthetic other than Mobil add any of the following 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
167. ontain 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 addition the Service Solutions feature provides di agnostic assistance with Symptoms Search by conne
168. oosen the bolt to check the torque See the applicable torque table in Group 00 for torque specifications A CAUTION Make sure frame fasteners are properly tightened Continued vehicle operation with loose fasteners could result in bracket or frame damage NOTE Engine supports on vehicles built from January 2007 do not require checking Inspect and check the torque of the fasteners at these locations e Axle Stops e Deck Plates e Engine Trunnion Supports Equalizer Brackets Exhaust Brackets 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 Refer to the Heavy Duty Trucks Service Manual for repair or re placement information in the respective section for the component in question Heavy Duty Trucks Maintenance Manual October 2009 31 7 31 31 04 Holland Fifth Wheel Sliding Mechanism Inspecting 1 Loosen the locking plunger jam nut and turn the adjusting bolt out counterclockwise See Fig 9 4 3 2 11 21 95 1310371 1 Rack 3 Pocket 2 Plunger 4 Plunger Adjusting Bolt Fig 9 Locking Plungers 2 Disengage and engage the locking plungers Check that the plungers are s
169. or free play Use of a pry bar may lead to premature bushing re placement 2 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 saddles All jack stands must be of sufficient strength and rigidity to safely support the vehicle Do not perform any work on or around a vehicle that is supported solely by a lifting device Visually 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 Manipulate the walking beam so that a microme ter vernier or dial caliper may be used to deter mine the wear area thickness on the bottom face See Fig 13 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 Fig 13 Ref B from the thickness at the non wear area Fig 13 Ref A to determine the amount of wear structions 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 32 6 Heavy Duty Trucks Maintenance Manual October 2009 Suspension 32 01 04 96 1 Torque Rod Clamp ZA ZA SSSSSSSSSN 2 Torque Rod 320488 Fig 11 Reyco 79KB Torque Rod Clamp Position 01 16 96 320503 1 T
170. orily for an empty ride 5 Inspect the cam surface on the number three spring hanger extended leaf springs only for wear Excessive wear will reduce the gap avail able at the number two spring hanger Refer to the previous note 6 Place a block of wood on the leaf spring See Fig 19 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 19 Also with an empty chassis and the brakes applied attempt to rock the chas sis back and forth while observing the spring eye In either case if 1 8 inch or more of move Heavy Duty Trucks Maintenance Manual October 2009 32 9 32 05 27 93 A Minimum gap of 3 8 9 5 mm Forward no 1 Spring Hanger Spring Eye Pin Rear no 2 Spring Hanger Rear no 3 Extension f320112a PD ME Fig 18 RTE Suspension unloaded 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 second leaf In this case the main leaf or the complete spring should be replaced immediately SW VN 08 16 96 3 f320422 1 Frame Bracket 3 Wood Block 2 Leaf Spring 4 Pry Bar Fig 19 Hendrickson RT2 and RTE2 Series Frame Bracket Inspection Suspension Neway Inspect the components and check their operation as described below Failure to perfor
171. orque Rod Clamp 2 Torque Rod Fig 12 Reyco 179 Torque Rod Clamp Position 4 Rotate the restrictor 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 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 09 27 95 320432 A Non Wear Area 1 Walking Beam B Wear Area Fig 13 Walking Beam End Wear Thickness ous personal injury or death Vehicles with cracked or missing restrictor cans may be driven Heavy Duty Trucks Maintenance Manual October 2009 32 7 32 slowly to the nearest workshop for restrictor can replacement Hendrickson Walking Beam Suspension 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 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 2 Visually inspect each frame hanger for any evi dence of cracks in the vertical mounting flange See Fig 14 2 1 09 15 95 1320419 1 Frame Rail 2 Cra
172. ortation Equipment Noise Emission Controls Part 205 Transportation Equipment Noise Emission Controls requires the vehicle manufacturer to fur nish with each new vehicle such written instructions for the proper maintenance use and repair of the 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 vehicle In compliance with the law the noise emission controls maintenance information in each applicable group of this manual in conjunction with the vehicle service manual provides these in structions to owners Recommendations for Replacement Parts Replacement parts used for maintenance or repair of noise emission controls should be genuine Freight liner parts If other than genuine Freightliner parts are used for replacement or repair of components affecting noise emission control the owner should be sure that such parts are warranted by their manufac turer to be equivalent to genuine Freightliner parts in performance and durability Freightliner Noise Emission Controls Warranty Refer to the vehicle owner s warranty information book for warranty information concerning noise 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 repa
173. ound the clamps that retain the DPF in the ATD No leaks are allowed anywhere in the system 6 Check all sensors attached to the ATD for leaks or damaged wires No leaks are allowed 7 Check the DPF exterior surface for dents or other damage See Item A of Fig 5 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 8 Check for heat discoloration on the surface of the ATD Heat discoloration may indicate internal damage especially around the DPF 9 Check any wires lines or hoses within 4 inches 10 cm of the exhaust system for heat damage Repair or reroute as needed 49 2 Heavy Duty Trucks Maintenance Manual January 2007 Exhaust 49 10 20 2006 A OB om Inspect this area of the canister for dents Marmon Fitting at Inlet from Turbocharger DOC Temperature Sensor ATD Mounting Band DPF Intake Pressure Sensor DPF V Band Mounting Clamps DO ND Sensor Housing DPF Outlet Temperature Sensor Exhaust Outlet Marmon Fitting DPF Outlet Pressure Sensor f490283 Fig 5 Typical After Treatment Device Heavy Duty Trucks Maintenance Manual January 2007 49 3 Electrical Instruments and Controls 54 Index Alphabetical Title of Maintenance Operation MOP MOP Number El cificalisystem Checking cia iss ena eee BRESLER SU SUE dub Rud aen DEE SE 54 01 Speedometer Tachometer Cable Lubricating
174. owl 4 Element 9 Drain Valve 5 Lower Gasket Fig 11 Spicer Transmission Air Filter Regulator Components 5 Clean and inspect all parts Use only a petroleum based solvent to clean the parts Blow air through the filter element inside to outside to loosen surface dirt IMPORTANT After three cleanings replace the filter element with a new one Do not disassemble the regulator as it is not repairable If the air regulator does not work properly replace the unit 6 Install the lower gasket the cleaned or new ele ment the upper gasket and the louver on the stud Install the element so the large end of the internal taper thinnest wall section is toward the hex on the stud 7 Install and tighten the stud 5 to 10 Ibf in 60 to 100 N cm 8 Apply a light coat of Dow Corning DC7 silicone grease or an equivalent to the O ring seating surfaces on the regulator and the bowl 9 Apply a light even coat of Molykote G or an equivalent to the bowl threads Install and tighten the bowl 5 to 10 Ibf in 60 to 100 N cm 10 Install and or tighten the air filter regulator bracket clamp 11 Install and torque the drain valve if removed 10 to 15 Ibf in 120 to 160 N cm 12 Build air pressure in the system check for leaks and make any necessary repairs Heavy Duty Trucks Maintenance Manual November 2001 26 9 26 Meritor Transmission A WARNING Drain the air supply if the air supply
175. p 01 Verification of Inspections Log Group 01 Engine Rear Supports and Engine Noise Panels Date Mileage Item Cost Maintenance Facility Verification of Inspections Log Group 20 Verification of Inspections Log Group 20 Fan Drive Date Mileage Item Cost Maintenance Facility 00 26 Heavy Duty Trucks Maintenance Manual October 2009 General Information Verification of Inspections Log Group 49 00 Verification of Inspections Log 00 13 Verification of Inspections Log Group 49 Exhaust System Components Date Mileage Item Cost Maintenance Facility Heavy Duty Trucks Maintenance Manual October 2009 00 27 00 General Information Metric U S Customary Conversion Tables 00 14 ME SEE Us E To Get Metric Balls ede ii 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 square millimeters mm 0 00155 square inches in square inches in 6 452 square centimeters cm 0 155 square inches in square feet f
176. pect the refrigerant compressor drive belt for damage and check that the belt is set at the proper ten sion Also check the tightness of the compressor mounting fasteners For instructions and torque values see Group 01 of the Heavy Duty Trucks Service 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 See Group 83 of the Heavy Duty Trucks Service Manual for removal and installation procedures 4 Ona Sanden refrigerant compressor use a feeler gauge to check that the drive plate clutch clearance is 0 016 to 0 03 inch 0 4 to 0 8 mm See Fig 1 If the drive plate clutch requires ad justment see Group 83 of the Heavy Duty Trucks Service Manual On a Climate Control refrigerant compressor place a feeler gauge between the air conditioner compressor clutch and the pulley to check the compressor clutch clearance Drive plate to pul ley clearance is 0 02 to 0 03 inch 0 6 to 0 8 mm If the clearance is not correct see Group 83 of the Heavy Duty Trucks Service 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 VA 9 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
177. play Fig 8 Checking Schwitzer Viscous Fan Drive Wear NOTE When making this check use only enough force to take up the play in the clutch without bending the blade Horton DriveMaster Fan Clutch NOTE If any part of the fan clutch needs to be repaired or replaced after performing the checks below see Group 20 of the Heavy Duty Trucks Service Manual Heavy Duty Trucks Maintenance Manual January 2007 20 9 20 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 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 wipe off any excess solvent 3 4 Reassemble the clutch valve solenoid air filter assembly and install it on the ve hicle 4 Check the fan for bent cracked or damaged blades replace if damaged Check for adequate clearance between the fan and other compo
178. r rosion with a wire brush and wash with a weak solution of baking soda and water Rinse with clean water and dry Paint the retainer assembly if needed to prevent rusting 1 3 Check that there are no foreign objects Such as stones bolts and nuts in the bat tery box 7 4 After 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 7 5 Coat the battery terminals with dielectric grease Check the alternator wiring for missing insulation kinks and heat damage Replace or repair as needed 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 Heavy Duty Trucks Maintenance Manual October 2009 15 1 Engine Cooling Radiator Title of Maintenance Operation MOP Fan Drive and Clutch Checking Noise Emission Control Radiator Cap Checking a acx aca BEE REED ed usa hate BR EE ah Radiator Pressure Flushing and Coolant Changing 20 Index Alphabetical MOP Number Heavy Duty Trucks Maintenance Manual January 2007 Engine Cooling Radiator 20 01 Radiator Cap Checking Do not remove or loosen the radiator cap until the engine and cooling system have completely cooled Use extreme care when removing the cap A sudden release of pressure f
179. r Pressure Flushing and Coolant Changing NOTE For additional instructions on cleaning and flushing the cooling system see the appli 20 cable engine manufacturer s maintenance and operation manual 1 If necessary remove the aerodynamic cover from the front bumper Drain the radiator as follows For a low flow cooling system disconnect the radiator bottom tank inlet and outlet hoses and tighten the radiator cap Attach the flushing gun nozzle to the outlet hose For a high flow cooling system disconnect the radiator upper and lower hoses and tighten the radiator cap Attach the flushing gun nozzle to the lower hose Run the water until the radiator is full CAUTION Excessive pressure can damage the radiator or heater core 4 Gradually apply air pressure to help dislodge sediment built up in the radiator core Do not apply more than 15 psi 103 kPa air pressure to the radiator Pressures exceeding 15 psi 103 kPa could damage the radiator core Shut off the air at the pressure gun nozzle and allow the radiator to refill with water Repeat the previous two steps until clean water flows from the radiator Remove the radiator side tank drain plug and allow the radiator to drain Install and tighten the side tank drain plug and the radiator outlet pipe drain plug after the radiator has been drained Do not overtighten the plugs Connect the hoses Your hose clamps can be either T bolt clamps
180. r 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 Remove the lid by turning the T handle See Fig 6 2 Remove the filter element by raising the handle built into the filter element then carefully turn the filter element while lifting up 3 Remove and discard the lid gasket then replace it with and new one 4 Lubricate the lid gasket with clean diesel fuel then seat it into the lid 5 Fill the unit with clean diesel fuel Install the lid then tighten it hand tight or to 10 Ibf ft 14 N m 7 Start the engine and check for fuel leaks Repair all fuel leaks with the engine OFF Heavy Duty Trucks Maintenance Manual October 1997 47 5 47 1 2 ZIM 3 4 N Wi e SS N rh 05 28 97 1470183 1 T Handle 3 Lid Gasket 2 Lid 4 Filter Element Fig 6 Racor 900FG Fuel Heater Water Separator 1000FG similar Racor 6400 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 fir
181. r less replace the fifth wheel top plate See Group 31 of the Heavy Duty Trucks Service 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 7 1 Remove the roll pins from the bushing pins Remove the bushing pins from the slide mount Using a hoist lift the fifth wheel top plate off of the vehicle 7 2 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 Heavy Duty Trucks Maintenance Manual October 2009 31 1 31 Frame and Fifth Wheel 2 3 4 vd N 25 Ps 21 23 86 24 1 09 18 95 1310476 3 16 x 1 Cotter Pin 11 1 4 20 x 3 8 Thread Cutting 19 1 2 13 x 2 Bumper Pivot Bolt 2 Lower Bracket Retainer Pin Screw 20 Bumper 3 Grease Fitting 12 Step Jaw and Wedge 21 Flatwasher 4 Lower Bracket Pin 13 Jaw Spring 22 5 16 Bumper Pivot Bushing 5 Wedge Stop Rod 14 1 4 x 3 Cotter Pin 23 1 2 13 Locknut 6 Flatwasher 15 Timer 24 7 16 Handle Pivot Bushing 7 Wedge Stop Rod Spring 16 Wedge Spring 25 Operating Handle side release 8 Wedge Stop Rod Nut 17 Pull Handle only 9 Side Release Upper Assembly 18 Bumper Handle Spring 26 1 2 13 x 2 Handle Pivot Bolt 10 Leaf Spring Fig 1 Fontaine H5092 Series Fifth Wheel left side release shown
182. r 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 Fig 3 Caterpillar Engine Noise Panels serpentine belts are retained by a belt tensioner that requires no tension adjustment Replace the engine drive belt if any conditions described in the visual description are found V belts are installed as indi vidual belts and as matched sets When replacing a matched set of belts always replace both belts at the same time Matched belts must be from the same manufacturer To inspect a belt gently twist the belt to view the belt sidewalls and bottom Visually in spect all drive belts for the following conditions then perform the belt tension inspection 01 2 Heavy Duty Trucks Maintenance Manual January 2007 Engine 3 E 1s 2 4 4 S 01 16 06 ORA 1010646a 1 NTC Right Side Noise Panels 2 NTC Oil Pan Noise Panel 3 NTC Left Side Noise Panel 4 L10 Front Gear Cover Noise Panel Fig 4 Cummins Engine Noise Panels Visual Inspection 1 Inspect the belt for glazing See Fig 5 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 contamination on the pulleys 2 Check the belt for ply separation See Fig 5 Ref B Oil grease or belt d
183. r should be replaced every time the oil is changed 3 1 To remove the filter from the helical gear cover remove only the two relief valve cover stud nuts and washers then lift off the filter cover Do not remove the cap screws See Fig 8 3 2 Remove the oil filter using a suitable filter strap wrench See Fig 9 Discard the filter 05 27 93 f350090a Fig 8 Axle Oil Filter Cover Removal and Installation 05 27 93 S 13501192 Fig 9 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 Heavy Duty Trucks Maintenance Manual January 1997 35 7 35 3 3 Remove the capscrews washers and oil filter adapter from the gear cover then inspect the threads of the filter mounting tube and adapter casting See Fig 10 If the threads are stripped or the casting is cracked replace the damaged component 05 27 93 f350118a Fig 10 Axle Oil Filter Adapter Removal and Installation 3 4 Place the oil filter adapter in its bore In stall the washers and capscrews then tighten the capscrews 20 to 30 Ibf ft 27 to 41 N m 3 5 Using the specified drive axle lubricant coat the face of the gasket on a new oil filter Install the filter over the adapter tighten the filter one full turn after the gasket contacts the base do not over tighten the filter 3 6 Assemble the filter co
184. reeze Approved Antifreeze Manufacturer Antifreeze Type Manufacturer Antifreeze Type Contains Premixed solution Detroit Diesel Caterpillar a did ee goe Power Coal aie Antifreeze Coolant Available as a i Old World With supplement premixed solution ind stries Fleet Charge additives Fleetguard Premixed solution i RN Ee with supplement Table 4 Approved Antifreeze Premix additives Maximum Coolant Protection in F C at Various Antifreeze Concentrations Cooling Ethylene Glycol Base Antifreeze Required E gallons liters ga 26 30n aas sag ee 726 860 sen 1069 n 12 9 16 4 12 34 62 10 38 C9 C169 C24 C37 52 t 18 8 6 23 47 62 11 42 C8 C13 Een 31 44 52 t 19 10 0 15 34 57 12 45 C7 C12 C18 26 37 49 21 13 3 9 25 45 62 3309 co ct tie ea Can C43 C52 15 6 5 18 ad 54 14 53 9 14 19 28 37 748 16 8 0 12 26 43 62 15 57 C9 613 ig C24 C32 42 52t 17 10 2 8 19 34 52 62 16 61 C8 C12 C17 aa eg C37 47 C52 18 12 5 4 14 27 42 58 17 64 C8 CH C15 C20 C269 C33 C40 C50 19 14 7 0 10 21 34 50 62 bad C C10 C14 ia C23 C29 C37 C46 esat 20 15 9 2 7 16 28 42 56 19 72 C 9 13 C1 C22 C27 C
185. ressing can cause the belt to fall apart in layers Repair any oil or coolant leaks that are affecting the belts before 01 replacing the drive belts Do not use belt dress ing on any belt 3 Check the belt for a jagged or streaked sidewall See Fig 5 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 5 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 5 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 5 Ref F Small irregular cracks are usually the signs of an old belt 7 Visually 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 the bearings as necessary 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 Belt Tension Inspection NOTE If engine drive belts require a
186. ri cant temperature indicator only and should not be used as a fill or level hole 8 Install and tighten the fill plug 35 Ibf ft 47 N m 9 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 10 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 Meritor Single Drive Axle Lubricant Capacities Axle Type Axle Model Bon ier RS 23 160 39 5 18 7 RS 23 161 37 2 17 6 Single Reduction RS 23 180 47 3 22 4 RS 26 180 46 6 22 0 RS 30 180 46 6 22 0 35 8 Heavy Duty Trucks Maintenance Manual January 1997 Rear Axle Meritor Single Drive Axle Lubricant Capacities Capacity Axle Type Axle Model pints liters RS 26 380 58 2 27 5 Double Reduction RS 30 380 46 6 22 0 RS 38 380 58 2 27 5 Quantities listed are approximate Fill axle until lubricant is level with bot tom of fill hole with vehicle on level ground Table 5 Meritor Single Drive Axle Lubricant Capacities 35 Meritor Tandem Drive Axle Lubricant Capacities Rear 37 0 17 5 Axle Type Axle Model Sin EE Axle Type Axle Model re An a il EN EEN e EEN i
187. rn Wear safety goggles when draining the air system or loosening an air line because dirt or sludge could fly out at high speeds Do not direct the air stream at anyone Do not disconnect pressurized hoses since they may whip as air escapes Fail ure to take all necessary precautions could result in personal injury 2 2 If the fan clutch does not engage see if compressed air is in the fan clutch actuat ing air line With the ignition on but the engine shut down slowly loosen the fit ting that connects the actuating air line to the fan clutch do not disconnect the fit ting If compressed air escapes the fan clutch is inoperative and must be re paired If no compressed air escapes replace the solenoid valve or fanstat as applicable Tighten the fitting Heavy Duty Trucks Maintenance Manual January 2007 20 5 20 3 Check all air connections for air leaks Check for wear on the friction facing See Fig 3 Type S and HT S or Fig 4 HT 550 Replace the facing if it is worn to 1 16 inch 1 6 mm thickness or less on a Type S or HT S fan clutch or to 7 32 inch 5 6 mm on an HT 550 fan clutch 08 08 94 SS 1200290 1 System Sentry Fuse 4 Piston Friction Disc 2 Safeguard Hole 5 Air Chamber 3 Friction Facing Fig 3 Horton Type S and HT S Fan Clutch L CA m 7A FA SS f T 10 19 93 f500005a 1 O Ring Seal 4 Air Chamber 2 Friction Facing 5 Ro
188. rom removing the cap prior to the system cooling can result in a surge of scalding coolant that could cause seri ous personal injury CAUTION The radiator cap currently installed may not be the same one installed when the vehicle was built If the radiator cap must be replaced make sure that it is the correct cap for the cooling system of the vehicle Because the radiator cap pressure rating affects the operating temperature of the engine installing an improperly rated radiator cap may have adverse effects on the cooling system and engine operating temperatures This could cause premature engine wear or damage 1 Using a radiator cap tester check the pressure cap to see if it maintains pressure to within 10 percent of the pressure rating marked on the cap If it doesn t replace the cap Make sure that the replacement radiator cap is correctly rated for the cooling system of the vehicle 2 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 3 Make sure that the cap seals properly on the coolant filler neck seat and that the radiator cap gasket is not damaged On vehicles with screw on caps with O rings make sure that the O ring is not cracked or deteriorated Replace the cap if the gasket shows deterioration or damage 20 02 Radiato
189. rom road surfaces or in ex tremely dusty environments e After any service that requires the removal of lubrication from the fifth wheel head or compo nents A WARNING Failure to properly lubricate the fifth wheel could result in a possible disengagement of the trailer from the tractor which could result in personal injury or property damage Fontaine Use a multipurpose extreme pressure EP chassis grease and lubricate all moving parts on the fifth wheel When lubricating the top plate at the grease fittings for the bracket bearing area tilt the top plate forward and backward to evenly distribute the 31 6 Heavy Duty Trucks Maintenance Manual October 2009 Frame and Fifth Wheel grease Using a pry tool separate the jaw and wedge and lubricate the serrations using a brush to distribute the grease On slide mount applications lubricate the slide rail and tapered wedges for smooth operation Once the moving parts of the fifth wheel are lubri cated apply a liberal coating of grease to the top plate and the trailer kingpin plate Holland Lubricate all moving parts with a multipurpose chas sis grease Lubricate with a multipurpose chassis grease the two grease fittings located on either side of the top plate Once the fifth wheel s moving parts are lubricated apply a heavy coat of grease to the top plate by di rect application On slide mount applications lubri cate the baseplate rails and the plungers
190. s Service Manual 14 Check the axle connection welds beam seat to equalizing beam and axle adapter to axle for cracks If welds are cracked grind them out and reweld the parts 15 Move the axle up and down while checking for signs of looseness due to worn parts at the front pivot connections Replace any worn parts by Heavy Duty Trucks Maintenance Manual October 2009 32 5 32 following the procedures in Group 32 of the Heavy Duty Trucks Service Manual 16 Inspect the shock absorbers for oil leaks and worn rubber bushings Replace the shock ab sorbers and or rubber bushings if wear or dam age is noted For instructions see Group 32 of the Heavy Duty Trucks Service Manual 17 Remove the safety stands and lower the rear of the vehicle to the ground Run the engine until air pressure of at least 100 psi 689 kPa is maintained throughout the system 18 Check that all air springs are inflated If the air springs do not inflate see Group 32 of the Heavy Duty Trucks Service Manual for possible causes and corrections 19 Apply the parking brakes and remove the chocks Reyco 79KB and 179 Park the vehicle on level ground and chock the front tires to prevent the vehicle from moving Place the transmission in neutral and release the parking brakes 1 Check that the torque rod clamps are directed away from the spring to prevent possible interfer ence during operation See Fig 11 for a Reyco 79KB or Fig
191. s will be ejected with force when the compressor is cycled Use eye protection such as safety glasses when checking the moisture ejec tion valve to prevent harm to your eyes from fly ing debris When the moisture ejection valve is plumbed to the governor unloader an exhaust of air sludge will occur only when the air compressor starts or stops pump ing air With the air system charged cycle the brake foot valve until the air compressor starts pumping air Notice if an exhaust of air sludge occurs at the ex haust outlet of the moisture ejection valve Fig 11 when the air compressor starts pumping cuts in or stops pumping cuts out 1 2 3 4 5 6 05 28 93 l 1420007a 1 Reservoir Inlet 5 Body Casting 2 Upper Cap 6 Application Line 3 Guide Post 7 Exhaust Outlet 4 Column Fig 11 Sealco 6300 Moisture Ejection Valve 42 If there is no discharge repair or replace the mois ture ejection valve for instructions see Group 42 of the Heavy Duty Trucks Service Manual Check the valve again for operation Repeat the in structions under this heading until the valve operates as specified If the valve fails to operate properly install a new one Leak Testing For leak testing instructions see Group 42 of the Heavy Duty Trucks Service Manual 42 22 Midland Quick Release and Flipper Valve Checking Chock the tires 2 Start the engine and run it long enough to pres surize the air system to at lea
192. shing If the pin will not accept lubricant re move the pin and clean the lubrication channels where lubricant may have hardened Remove the safety stands and lower the vehicle after lubrica tion is complete 09 15 95 f320424 1 Bronze Bushing 2 Lubrication Hole 3 Grease Fitting 4 Lubrication Groove Fig 22 Hendrickson RT2 and RTE2 Series Bushing Lubrication Neway No lubrication is required on Neway rear suspen sions Reyco No lubrication is required on Reyco rear suspen sions Suspension Hendrickson Walking Beam Series RS No lubrication is required on RS Series suspensions equipped with rubber bushings If the equalizer beam has a bronze center bushing apply multipurpose grease at the beam grease fitting on the equalizer beam center hub until clean grease appears at both ends of the grease seals Chalmers Walking Beam No lubrication is required on the Chalmers rear sus pension 32 03 Suspension U Bolt Torque Checking 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 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 specifications Turn the wrench in a clockwise motion looking
193. sleeve yoke and splined shaft back and forth Fig 3 Slip Joint Spline Wear Checking A A 06 13 96 Measurement 3 76 mm Measurement 0 005 0 127 mm Measurement 0 010 0 254 mm Measurement 0 015 0 381 mm f410110b com Fig 4 Driveshaft Runout Specifications any evidence that balance weights are missing remove the driveshaft and have it balanced 8 For driveshafts with slip joints check to be sure the yoke plug is not loose or missing See Fig 5 Ref 2 Repair or replace the yoke plug as needed 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 02 Driveline Lubricating U joint Lubricating 1 Wipe all old grease and dirt from each U joint grease fitting See Fig 5 Ref 8 10 20 93 f410050a A After grease appears cover the pressure relief hole while continuing to lubricate 1 Slip Joint Grease 5 Yoke Plug Pressure Fitting with grease Relief Hole gun attached 6 Slip Joint Seal 2 Yoke Plug 7 Full Round Yoke 3 Grease 8 U Joint Grease Fitting 4 Half Round Yoke Fig 5 Slip Joint and U Joint Lubricating 2 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 with the high pressure gun the U joints may not rece
194. specting FLA FLB oe fe fe fe fe 26 03 Shift Lever Pivot Yokes Inspecting FLA FLB 26 04 Selection Lever and Pivot Rod Ball Stud Lubricating FLA FLB 26 05 Allison Transmission Fluid and Filter Changing 26 06 Manual Transmission Magnetic Plug Cleaning Oil Changing and Oil Filter Element Changing 26 07 Transmission Air Filter Regulator Checking and Cleaning or Replacing 26 08 Transmission Oil Level Checking and Breather Checking 31 01 Fifth Wheel Inspecting 31 02 Fifth Wheel Lubricating 31 03 Frame Fastener Torque Checking 31 04 Holland Fifth Wheel Sliding Mechanism Inspecting 31 05 Trailer Electrical Connector Lubricating 32 01 Suspension Inspecting 32 02 Suspension Lubricating e e fe ed e 32 03 Suspension U bolt Torque Checking D Heavy Duty Trucks Maintenance Manual October 2009 00 9 00 General Information Maintenance Operation Sets Table 00 05 Maint Oper No Operation Description Maintenance Interval 33 01 Knuckle Pin Lubricating 33 02 Tie Rod End Inspecting and Lubricating 33 03 All Axle Alignment Checking 35 01 Axle Breather and Lubricant Level Checking e 35 02 Axle Lubricant Changing Oil Filter Replacing and Magnetic Strainer Cleaning e 40 01 Wheel Nut and Rim Nu
195. st 80 psi 550 kPa then turn off the engine Repeat as needed to maintain 80 psi 550 kPa pressure during these checks 3 Clean off road grime from the valves and any material from all valve exhaust ports 4 Listen for air leakage around fittings and exhaust ports Tighten the fittings as needed use two wrenches to avoid twisting the tubing If any valve fails this check or is damaged re pair or replace it Refer to the Midland service manual for instructions 5 Remove the chocks from the tires 42 23 Meritor WABCO System Saver 1000 Air Dryer Desiccant Replacing Replace the desiccant cartridge For instructions see Group 42 of the Heavy Duty Trucks Service Manual NOTE Desiccant change intervals may vary from vehicle to vehicle Typical desiccant car tridge life is three years However if experience has shown that extended or shortened life has Heavy Duty Trucks Maintenance Manual October 2009 423 42 resulted on a particular installation then the in terval can be increased or decreased accord ingly 42 24 Brake Inspection IMPORTANT This procedure should be per formed prior to lubrication of the brake compo nents Parking Brake Operational Check AN 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 th
196. sure Relief 2 Slack Adjuster Grease Fitting Fig 3 Camshaft Bracket Bushing Lubrication 42 03 Manual Automatic Slack Adjuster Lubricating and Checking All Models IMPORTANT Perform MOP 42 24 before lubri cating the slack adjusters Bendix or Sloan Manual Slack Adjuster Lubricating Lubricate the slack adjuster with multipurpose chas sis grease NLGI Grade 1 or 2 Apply enough grease to completely fill the body cavity Brunner or Midland Manual Slack Adjuster Lubricating Brunner and Midland slack adjusters are greased for life at assembly However a grease fitting is fur nished to permit optional lubrication Heavy Duty Trucks Maintenance Manual October 2009 42 3 42 Haldex SAB Automatic Slack Adjuster Lubricating and Checking NOTE Under normal operating conditions do not exceed recommended lubrication intervals Under severe or adverse operating conditions lubricate more often 1 At 20 F 29 C and above lubricate the slack adjusters with any extreme pressure NLGI Grade 1 or 2 grease such as Esso Lidoc EP2 Shell Darina No 1 Texaco Thermotex EP1 or Suna plex No 1 EP Below 20 F 29 C use Texaco Low Temp EP or an equivalent A WARNING Manually adjusting an automatic slack adjuster to bring the pushrod stroke within legal limits is likely masking a mechanical problem Adjustment is not repairing Before adjusting an automatic slack adjuster troubleshoot the foundation brake
197. t 0 0929 square meters m 10 764 square feet ft Volume cubic inches in3 16387 0 cubic millimeter mm3 0 000061 cubic inches in cubic inches in 16 387 cubic centimeters cm 0 06102 cubic inches in cubic inches in 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 ft 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 Ibf in 11 298 Newton centimeters N cm 0 08851 inch pounds Ibf 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 2 Metric U S Customary Conversion 00 28 Heavy Duty Trucks Maintenance Manual October 2009 General Information 00 Metric U S Customary Conversion Tables 00 14 Temperature Conversion
198. t Checking 41 01 Driveline Inspecting 41 02 Driveline Lubricating 42 01 Brake Adjusting Cam Brakes with Manual Slack Adjusters 42 02 Camshaft Bracket Bushing Lubricating 42 03 Manual Automatic Slack Adjuster Lubricating and Checking All Models 42 04 Meritor Automatic Slack Adjuster Inspecting e 42 05 Wedge Brake Checking 42 06 Wedge Brake Inspecting and Lubricating 42 07 Alcohol Evaporator Checking eje e 42 08 Bendix Alcohol Evaporator Cleaning 42 09 Bendix Alcohol Evaporator Gasket Replacing e 42 10 Bendix Air Dryer Checking AD 2 AD 4 or AD 9 42 11 Bendix Air Dryer or Anchorlok Aftercooler Inspecting Bendix AD 2 AD 4 AD 9 or 7 E Anchorlok 42 12 Bendix Air Dryer Desiccant Replacing AD 2 42 13 Bendix Air Dryer Desiccant Replacing AD 4 or AD 9 E 42 14 CR Brakemaster Air Dryer Cleaning Model 62 or 68 42 15 Anchorlok Aftercooler Automatic Ejector Valve Clearing e 42 16 Bendix Air Brake Valve Operation Checking BP R1 and E 12 42 17 Bendix Air Brake Valve Disassembly Cleaning and Inspecting BP 1 Double Check Valve E 6 PP 7 QR 1 R 6 R 14 SR 1 ST 3 TC 7 TP 5 TR 3 42 18 Bendix Air Brake Valve Disassembly Cleaning Inspecting and Lubricating DV 2 N R PP 3 and Single Check Valve 42 19 Bendix Air Brake Valve Inspecting and Testing BP 1 BP R1 LQ 5 PP 7 R 14
199. t 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 III 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 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 Heavy Duty Trucks Maintenance Manual October 2009 00 1 00 Maintenance Service Table 00 02 Maintenance Service Table General Information
200. tary Air Union 3 Piston Fig 4 Horton HT 550 Fan Clutch Engine Cooling R adiator If equipped with a toggle switch on the dash run the engine with the engine temperature below 205 F 96 C for Caterpillar engines or below 200 F 93 C for all other engines Set the toggle switch to the ON position the fan clutch should engage Set the toggle switch to the AUTO or OFF position the air should exhaust and the fan clutch should disengage Replace the switch if necessary With the engine off and the fan clutch engaged use a listening device to check for air leaks If a leak is heard check for air leaks in the fan clutch by lightly brushing a soap solution in the follow ing areas 6 1 Type S and HT S Fan Clutches Fig 3 Check for air leaks at the bleed hole on the fan pilot Air leakage means that the cartridge assembly Fig 5 Ref 16 or face seal Ref 17 is damaged 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 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 Check for air leaking from the System Sentry fuse Leaking air means the clutch has gotten so hot the lead alloy in the fuse melted This released the clutch before the heat could damage the clutch bearings Before replacing the fuse find and repair the source of the
201. ten 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 Heavy Duty Trucks Maintenance Manual January 1997 40 1 40 Wheels and Tires 1 1 1 2 MO 7j O9ROWN NW 3 3 0 7oV4 5 N 2 6 9 9 N pA 5 YAN 4 8 9 2 A B C D 05 27 93 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 s MA 1 V N lv Va N N p 7 KO d N 05 30 2006 1400031a EN oy 1 Corrugated Spacer 05 6 04 LO 4400033a 2 Corrugated Channel Spacer Fig 2 Non Corrugated Channel Spacer Fig 3 Corrugated Spacers 40 2 Heavy Duty Trucks Maintenance Manual January 1997 Driveline 41 Index Alphabetical Title of Maintenance Operation MOP MOP Number Driveline Speed eonun dau ES Est DE DS EEN Edad d Rupe XR bd ERE d dad rera 41 01 Driveline LUDIC errre rr rT 41 02 Heavy Duty Trucks Maintenance Manual April 1998 Driveline 41 01 Driveline Inspecting 41 Before lubricating driveline U joints and slip joints proceed as follows CAUTION Do not over tighten bearing cap capscrews or yoke strap capscrews Due to the extreme load occurring at high speed rotation a loose or bro ken capscrew at any point in the driveline will weaken the driveline con
202. terval Operations table lists all maintenance operations that are to be performed at the M4 maintenance interval Maintenance opera 00 M4 Maintenance Interval Operations Table 00 10 tion numbers are reference numbers used to help tions you find detailed instructions in this manual on the M4 Maintenance Interval Operations for Service Schedules I Il and III maintenance operations to be performed Perform all maintenance interval operations in M1 M2 and M3 when performing M4 maintenance interval opera M4 Maintenance Interval Operations for Service Schedules I Il and III Op ration Number Operation Description Check 00 07 Perform all M1 Operations 00 08 Perform all M2 Operations 00 09 Perform all M3 Operations 20 02 Radiator Pressure Flushing and Coolant Changing 26 05 Allison Transmission Fluid and Filter Changing 42 12 Bendix Air Dryer Desiccant Replacing AD 2 42 13 Bendix Air Dryer Desiccant Replacing AD 4 or AD 9 42 23 Meritor WABCO System Saver 1000 Air Dryer Desiccant Replacing Heavy Duty Trucks Maintenance Manual October 2009 00 17 00 COE Cab Tilting FLA FLB 00 11 Cab Tilt System The Power Packer cab tilt system has four major parts see Fig 1 e A hydraulic pump consisting of a pump body a reservoir and a pump control lever e Two hydraulic tilt cylinders that raise and lower the cab e A shift disconnect cylinder that allows the shift tube
203. th a clean cloth 4 Inspect the tubes for wear or damage If worn or damaged replace them with new ones See Group 26 of the Heavy Duty Trucks Service Manual for procedures 5 Inspect the O ring located near the top of the telescoping tubes See Fig 2 If worn or dam aged install a new O ring See Group 26 of the Heavy Duty Trucks Service Manual for proce dures 6 Apply a light coating of multipurpose chassis grease on the surfaces of the telescoping tubes 7 Return the cab to the upright and locked position using the instructions in Group 00 of this manual 8 Remove the chocks from the tires 26 02 Shift Control Latch Lubricating and Cylinder Inspecting FLA FLB 1 Apply the parking brakes and chock the tires 2 Tilt the cab using the instructions in Group 00 of this manual 3 Check the latch cylinder for signs of leakage See Fig 2 If leaking replace it with a new one See Group 26 of the Heavy Duty Trucks Service Manual for procedures 4 Inspect the latch arm and locking tab areas on the shift control tube assembly for wear See Fig 3 Replace any worn parts See Group 26 of the Heavy Duty Trucks Service Manual for procedures Lubricate the latch arm locking tab and latch guide with a light coating of chassis grease 26 5 Return the cab to the upright and locked position using the instructions in Group 00 of this manual 6 Remove the chocks from the tires 26 03 Shift Lever Pivot
204. the brake chamber to the center line of the clevis pin Fig 1 Ref B Record the exact distance as measure ment B 1 3 Subtract measurement A from measure ment B to determine the applied stroke 05 27 93 f420010a Measure distance B while prying with a lever 1 Lever Fig 2 2 3 Subtract measurement A from measure ment B to determine the free stroke 3 Compare this value to the desired free stroke value in Table 2 If the free stroke equals or ex ceeds this range adjust the brakes 3 1 Wipe clean the adjusting screw hexhead See Fig 1 Position a wrench or socket over the adjusting screw hexhead IMPORTANT On slack adjusters equipped with an adjusting screw locking sleeve wipe clean the locking sleeve area and depress the locking sleeve when positioning the 42 2 Heavy Duty Trucks Maintenance Manual October 2009 Brakes wrench or socket over the adjusting screw Do not attempt to turn the adjusting screw without fully depressing the locking sleeve 3 2 Turn the adjusting screw until it is tight then back off the adjustment until the drum is free Normally the adjusting screw will need to be backed off 2 or 3 clicks NOTE Check brake adjustment with the wheel on the ground Checking brake adjust ment with the wheel off the ground may prove to be unreliable Looseness or wear anywhere in the wheel bearings will cause the drum to be misaligned while the wheel is off the ground
205. the engine starts during this procedure the fan could cause personal injury If the vehicle is equipped with an air starter be sure that the air starter reservoir is drained 2 Measure the distance from the back surface of the fan clutch retaining plate to the forwardmost edge of the fan belt pulley See Fig 7 Ref A 3 Disconnect the line from the air inlet of the air cylinder Connect a shop air hose to the inlet 4 Apply a minimum of 100 psi 690 kPa air 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 forwardmost edge of the fan belt pulley 5 Compare the two measurements if the difference exceeds the wear limit given in Table 6 for the Kysor Dynair or exceeds the wear limit of 0 15 Heavy Duty Trucks Maintenance Manual January 2007 20 7 20 Engine Cooling R adiator 05 27 93 f500006a 1 Capscrew 8 Panhead Screw 14 O Ring Seal 2 Mounting Bracket 9 Retaining Washer 15 Piston Assembly 3 Hexnut 10 Rotary Air Union 16 Friction Facing 4 Washer 11 O Ring Seal 17 Capscrew 5 Drive Sleeve 12 Setscrew 18 Washer 6 Friction Disc 13 Air Chamber Assembly 19 Compression Spring 7 Capscrew Fig 6 Horton HT 550 Fan Clutch Components inches 3 8 mm for the Kysor K22RA the clutch Kysor Dynair Fan Clutch Wear Limits lining is worn and must
206. the parking brakes Place the transmission shift lever in neutral Shut down the engine if it is General Information Before tilting the cab make sure that there is ad equate clearance in front of the vehicle and that the area is free of people and all objects Do not tilt the cab with the engine running Tilting the cab could engage the transmission If the en gine is running the vehicle can move causing an accident that could result in personal injury or property damage 2 Remove the pump handle from the baggage compartment and insert it into the pump shank 3 Secure all loose articles in the cab and bunk and make sure the doors are securely latched A WARNING Objects falling in the cab or a door flying open could damage the vehicle or cause personal in jury 4 Move the pump control lever to Raise 5 Unlock the back of cab latch handles Fig 7 by pulling them outward See Fig 8 07 22 93 810039 Fig 7 Latch Handle Locked Position A CAUTION running Do not work the tilt pump while the cab latches are locked Doing this causes stress in the back of the cab which could cause rivet and cab skin damage 00 22 Heavy Duty Trucks Maintenance Manual October 2009 General Information 07 22 93 1310040 Fig 8 Latch handle Unlocked Position 6 Pull the safety hook release handle Fig 9 while working the hydraulic pump If the cab does not begin to rais
207. 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 26 10 Heavy Duty Trucks Maintenance Manual November 2001 Transmission fluid level to the middle of the COLD RUN band See Fig 12 12 01 97 A Cold Run Band f270002a B Hot Run Band Fig 12 Dipstick Markings A CAUTION As the fluid temperature increases so does the fluid level Do not fill above the COLD RUN band if the transmission fluid is below normal operating temperature NOTE Perform a hot check at the first opportu nity after the normal operating temperature 160 to 200 F 71 to 93 C has been reached Hot Check 1 Park the vehicle on a flat level surface Apply the parking brake and chock the 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 from the tube and wipe it clean 5 Insert the dipstick into the tube and remove the dipstick 6 Check the fluid level reading and repeat the check procedure to verify the reading Safe oper ating level is within the HOT RUN band
208. throughout the operating range without any interruption of piston travel The air cylinder is in satisfactory working order upon completion of six consecutive extensions and retractions at 90 to 120 psi standard operat ing pressure If the air cylinder does not function properly re move the air cylinder Manually extend the piston to its maximum length and retract fully Any bind ing of the piston requires reconditioning or replacement 2 Inspect the slide cam and housing for any warpage damage or cracks If any cracks are found replace the components 3 Check the return spring for overextension abra sion and a rust deteriorating condition which would require replacement Heavy Duty Trucks Maintenance Manual October 2009 31 5 31 3 KS X 4 6 N E 2 5 f 1 09 12 96 Z f310550 1 Air Cylinder 4 Housing Weldment 2 Slide Cam and 5 Operating Rod Housing 6 Safety Indicator 3 Return Spring Fig 8 Touchloc Control Mechanism Component Inspection 4 Inspect the housing weldment for cracks warpage or damage If cracks are found replace the component 5 Inspect the operating rod for cracks warpage or damage If cracks are found replace the compo nent 6 Check the safety indicator for proper function When the air mechanism unit is activated the operating rod is forced into the lockset position and the safety latch will rotate toward the rear 7 Check the exhaust seat
209. til the old grease is forced out 32 10 Heavy Duty Trucks Maintenance Manual October 2009 Suspension 32 1 3 2 09 15 95 1320423 1 Frame Rail 3 Axle Centerline 2 Axle Housing 4 Suspension Ride Height Fig 20 Neway Ride Height Inspection Rear Suspension Freightliner Spring as Single Axle JAN No lubrication is required on Freightliner single axle i Oe lt A rear Suspensions N Tandem Axle E Lubricate the equalizer cap and tube assembly bush SN ings by applying multipurpose chassis grease at the NN grease fitting until the old grease is forced out from N 4 the cap and tube assembly See Fig 21 05 27 93 320020a Hendrickson Spring Suspension di RR RT2 and RTE2 Series Pii N LE EE 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 Fig 21 Equalizer Assembly Lubrication hicle with safety stands This relieves the load on the bushings and pins to allow the proper flow of lubricant around them 3 Using a multipurpose chassis grease lubricate the bronze ball indented bushings in the spring eyes at the grease fitting See Fig 22 Continue Heavy Duty Trucks Maintenance Manual October 2009 32 11 32 to lubricate until grease exits both ends of the bu
210. ting plunger replace the seal using an appropriate seal driver and assemble the pawl Then manually adjust the brake to specifications 42 07 Alcohol Evaporator Checking Bendix NOTE During freezing weather check the alco hol evaporator weekly Check that all fittings are tight and that bubbles are present in the alcohol when the compressor is com pressing See Fig 8 If the alcohol evaporator is not operating properly see the troubleshooting guide in Group 42 of the Heavy Duty Trucks Service Manual Heavy Duty Trucks Maintenance Manual October 2009 42 7 42 01 06 95 s f420005a 1 Strainer Fig 8 Bendix Alcohol Evaporator sectional view Midland Maintenance is reguired 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 alcohol 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 2 Remove the capscrews and reservoir from the cover 3 Remo
211. to the skirt by three quarter turn fasteners For an FLC RH DR uncover the main cab connec tors and studs by removing the left hand under dash cover See Fig 9 Uncover the electrical panel by removing the glove box on the left side of the dash To remove the glove box open the glove box door and remove the six screws from the glove box liner See Fig 12 Then remove the glove box door and the glove box liner from the dash This will expose the electrical panel See Fig 8 Check all wiring for chafing kinks and discolored insulation Find the cause of any problems then re pair replace or reroute wires as needed Check that all relays are firmly seated in their mount ing plates Check the tightness of the connections on the electri cal junction block s main cab power stud and cab ground stud as equipped Tighten the fasteners to the torque values in Table 1 Install all of the removed panels 10 20 93 1 Bunk Harness Connectors 2 Cable Tie Plate 3 Main Cab Ground Stud Black 4 Seven Way Receptacle Harness Connector 5 Right Hand Tunnel Side 6 7 8 9 1540630 Electrical Mounting Plate end view Dash Support Bracket end view Daytime Running Lights Module Cab to Chassis and Cab to Engine Harness Interface Connectors 10 Bulkhead Support Bracket 11 Main Cab Power Stud Red 12 Main Cab Harness 13 Main Engine Harness 14 Right Hand Cab Deck Fig 4 FLB Main Cab Harn
212. truction site operation city operation garbage truck or farm operation 00 2 Heavy Duty Trucks Maintenance Manual October 2009 General Information 00 Vehicle Maintenance Schedule Tables 00 03 1st through 20th Maintenance for Service Schedule I Vehicles i i i i Service pora Required T Operation Service Date TTE aa a 1st Initial Maintenance IM M1 1000 1600 100 2nd M1 2000 3200 200 3rd M1 3000 4800 300 4th M1 4000 6400 400 5th M1 and M2 5000 8000 500 eth M1 6000 9600 600 7th M1 7000 11 200 700 8th M1 8000 12 800 800 9th M1 9000 14 400 900 10th M1 M2 and M3 10 000 16 000 1000 11th M1 11 000 17 600 1100 12th M1 12 000 19 200 1200 13th M1 13 000 20 800 1300 14th M1 14 000 22 400 1400 15th M1 and M2 15 000 24 000 1500 16th M1 16 000 25 600 1600 17th M1 17 000 27 200 1700 18th M1 18 000 28 800 1800 19th M1 19 000 30 400 1900 20th M1 M2 M3 and M4 20 000 32 000 2000 21st through 40th Maintenance for Service Schedule Vehicles i i i i Service I jo Required kg i ende Operation Service Date E Te 21st M1 21 000 33 600 2100 22nd M1 22 000 35 200 2200 23rd M1 23 000 36 800 2300 24th M1 24 000 38 400 2400 25th M1 and M2 25 000 40 000 2500 26th M1 26 000 41 600 2600 27th M1 27 000 43 200 2700 28th M1 28 000 44 800 2800 29th M1 29 000 46 400 2900 30th M1 M2 and M3 30 000 48 000 3000 31st M1 31 00
213. turn bypass hose from the reservoir fitting Remove the fitting from the reservoir and connect it to the bypass hose then cap the bypass hose fitting and both reservoir ports See Fig 9 or Fig 10 Do not mix oil types Refer to the text in this group for a detailed warning statement Table 1 Approved Power Steering Fluids 2 For a 9 quart power steering reservoir remove the dipstick band clamp cover O ring and cover See Fig 9 08 11 93 Dipstick T Handle Band Clamp Hose Fittings oomcRON Pump to Reservoir Return bypass Hose Gear to Reservoir Return Hose Reservoir to Pump Supply Hose 1460013 05 28 93 DO REDE 1 2 f460295a Dipstick T Handle Cover Capscrew Reservoir Cover Reservoir to Pump Supply Hose Pump to Reservoir Return bypass Hose Gear to Reservoir Return Hose Fig 9 9 Quart Power Steering Reservoir 3 Line 3 For a 2 line system drain the power steering reservoir by disconnecting the steering gear to reservoir return hose from the reservoir Catch the fluid in a drain bucket Cap the reservoir port Fig 10 2 Quart Power Steering Reservoir 3 Line If equipped with a thumbscrew remove the thumbscrew and spring that hold the filter ele ment in the reservoir and lift out the filter ele ment Otherwise lift out the spring and filter ele ment from the reservoir Thoroughly clean the reservoir with a lint free cloth Install
214. uire could result in axle damage Draining is best accomplished immediately after the vehicle has completed a trip The lubricant is warm then and will run freely allowing full drainage in mini mum time This is especially desirable in cold weather 1 With the vehicle parked on level ground apply the parking brakes and chock the tires Heavy Duty Trucks Maintenance Manual January 1997 35 3 35 2 Clean the fill plug and area surrounding it then remove the plug from the oil fill hole or stand pipe if installed in the oil fill hole located in the axle housing rear cover See Fig 5 3 Remove the drain plug at the bottom of the axle housing Fig 5 and allow sufficient time for all old lubricant to run out 4 On tandem drive axles also remove the plug at the bottom of the power divider to drain oil from the power divider 05 27 93 f350018a 1 Oil Fill Plug 2 Drain Plug Fig 5 Axle Housing Drain and Fill Plugs NOTE Some tandem drive axles are equipped with a cylindrical magnetic strainer below the lube pump on the front of the power divider cover that must be removed and cleaned at each axle oil change See Fig 6 5 Remove and clean the magnetic strainer if so equipped 5 1 Remove the magnetic strainer from the power divider cover A WARNING Always wear eye protection when using com pressed air to clean parts as flying debris could cause permanent damage to unprotected eyes
215. up until the torque wrench clicks 3 Remove the chocks 32 12 Heavy Duty Trucks Maintenance Manual October 2009 Suspension 32 U Bolt Torque Values Description Size Torque Ibf ft N m 5 818 3 4 16 Spring Assembly U Bolt High Nuts Tighten in a diagonal Stage 1 Stage 2 Stage 3 Stage 4 Stage 1 Stage 2 Stage 3 Stage 4 Hand Tighten 60 81 200 271 180 to 230 245 to 313 Hand Tighten 60 81 200 271 270 to 330 367 to 449 pattern as shown in Fig 23 7 8 14 Stage 1 Stage 2 Stage 3 Stage 4 Hand Tighten 60 81 200 271 420 to 500 571 to 680 1 14 Stage 1 Stage 2 Stage 3 Stage 4 Hand tighten 60 81 200 271 520 to 600 707 to 816 Table 1 U Bolt Torque Values 01 05 99 2 1320783 Fig 23 Tightening Pattern for U Bolt High Nuts Heavy Duty Trucks Maintenance Manual October 2009 Front Axle Title of Maintenance Operation MOP All Axle Alignment Checking llle Knuckle Pin Hb IGalig sz aano iS RE SE KERE DER Tie Rod Inspecting and Lubricating 33 Index Alphabetical MOP Number Heavy Duty Trucks Maintenance Manual June 2001 Front Axle 33 01 Knuckle Pin Lubricating CAUTION Use regulated pressure when lubricating the knuckle assemblies otherwise damage could re sult to the knuckle caps Dana Spicer Park the vehi
216. ust be an ethylene glycol solution that meets GM 6038 M Engineering Standards or a ethylene glycol solution that has less than 0 1 anhydrous sodium metasilicate and meets either GM 1825 M or GM 1899 M Engineering Stan dards If supplemental coolant additives are being used add the supplements to the coolant as necessary See the coolant additive manufac turer s instructions for the correct amount of addi tive required Don t forget to consider the volume of the supplemental coolant additive being added to the system when determining the amount of coolant required to refill the system 20 2 Heavy Duty Trucks Maintenance Manual January 2007 Engine Cooling Radiator 20 Engine Cooling System Capacity for FLA FLB and FLD 120 pre EPA07 engines Radiator Core and System Capacity Engine Make Engine Model 2 Row 3 Row 4 Row quarts liters quarts liters quarts liters 3176 49 0 46 4 50 0 47 3 NA 3306 JWAC 51 9 49 1 52 9 50 0 53 9 51 0 Caterpillar 3306 ATAAC 49 5 46 8 50 5 47 8 51 5 48 7 3406 JWAC 57 2 54 1 58 2 55 1 59 2 56 0 3406 ATAAC 55 2 52 2 56 2 53 2 57 2 b4 1 L10 46 6 44 1 47 6 45 0 48 6 46 0 L10 OA low flow NA 46 0 43 5 47 0 44 5 Cummins Big Cam III 55 1 52 1 56 1 53 1 57 1 54 0 Big Cam IV low flow NA 51 1 48 4 52 1 49 3 T Series 60 56 0 53 0 57 0 53 9 58 0 54 9
217. valve 3 Remove the filter element and collection bowl together by turning the filter element off of the mounting head 4 Remove the filter element from the collection bowl by turning the collection bowl then discard the filter element Fuel 1 1 12 2 N 9 A p j 10 10 11 9 3 1 2 NN 4 5 TT 6 8 7 05 28 97 470194 1 Mounting Hole 8 Drain Valve 2 Mounting Head 9 Vacuum Switch 3 Heater Connector Connector 4 Filter Element 10 Vacuum Switch 5 Oollection Bowl 11 Fuel Outlet 6 Water Sensor 12 Fuel Inlet 7 Water Sensor Connector Fig 2 Racor 325R Fuel Heater Water Separator 330R similar 47 2 Heavy Duty Trucks Maintenance Manual October 1997 Fuel 5 Remove and discard the bowl O ring then clean the bowl of debris using diesel fuel only Clean the bowl O ring seat with a shop cloth 6 Lubricate the new bowl O ring with clean diesel fuel or motor oil then seat it into the collection bowl 7 Attach the collection bowl to a new filter element hand tight Do not use tools 8 Lubricate the new filter element square cut gas ket with clean diesel fuel or motor oil 9 Fill the filter and bowl assembly with clean diesel fuel 10 Spin the filter and bowl assembly onto the mounting head until the gasket contacts the head base then turn it an additional 1 3 to 3 4 of a turn 11 Connect the water sensor probe connector if equipped 12 Start the engine and check for fu
218. ve Axle Lubricant Capacities Axle Type Axle Model gin MSS Axle Type Axle Model SSMO DS341 39 18 5 t DT401 401 P 39 18 5 t RS341 36 17 RT401 36 17 DS381 381 P 39 18 5 t DT402 402 P 34 Us 1 t RS381 36 17 Dual Range RT 402 4 16 1 DS401 401 P 39 18 5 f 2 Speed DT451 DT451 P 39 T 8 5 f RS401 36 17 RT451 4 16 1 DS402 402 P 39 18 5 t DT461 P 43 TIEN RS402 36 17 RT461 40 18 9 Single DS404 39 18 5 t DP451 P 34 16 1 t Reduction RS404 36 17 RP451 34 16 1 DS451 451 P 39 18 5 t DP461 P 43 20 3 t RS451 36 17 RP461 40 18 9 DS460 P 44 20 8 t Pobla DP521 P 2 19 9 t RS460 40 18 9 Reduction RP521 39 18 5 DS461 P 43 20 3 t DP601 P 2 19 9 t RS461 40 18 9 RP601 39 18 5 DS581 P 2 19 9 t DP651 P 1 19 4 f RS581 39 18 5 RP651 37 17 5 Quantities listed are approximate Fill axle until lubricant is level with bottom of fill hole with vehicle on level ground t Add 2 pints 1 L of additional lubricant to the power divider Table 4 Eaton Tandem Drive Axle Lubricant Capacities Meritor Axle Lubricant Changing and Oil Filter Replacing Axle Lubricant Change Interval Information A regular schedule for changing axle lubricant in a particular vehicle and operation can be accurately determined by analysis of oil samples taken from the assembly at specific intervals or mileages The final schedule recommended may for economic reasons be correlated with lubricant changes governed by climatic c
219. ve parts with mineral spirits and inspect the parts Replace all rubber parts and any worn or damaged parts use only genuine Bendix replace ment parts or kits Assemble and install the valves then check for proper operation and for leakage 42 18 Bendix Air Brake Valve Disassembly Cleaning Inspecting and Lubricating DV 2 PP 3 and Single Check Valve NOTE See Group 42 of the Heavy Duty Trucks Service Manual for valve removal disassembly inspection assembly and leakage checking instructions Remove and disassemble the valves Clean the valve parts with mineral spirits and inspect the parts Replace all rubber parts and any worn or 42 damaged parts use only genuine Bendix replace ment parts or kits For a DV 2 valve lubricate the air reservoir auto matic drain valve If there is a filter screen in the adaptor fitting replace it with a new one Assemble and install the valves then check for proper operation and for leakage 42 19 Bendix Air Brake Valve Inspecting and Testing BP 1 BP R1 LQ 5 PP 7 R 14 and TC 7 1 Clean the exterior of the valves and check them for corrosion and damage 2 Inspect the air lines connected to the valves for signs of wear or damage Replace the lines as needed 3 Test the air line fittings for excessive leakage Tighten or replace the fittings as needed 4 Check the valves for leakage See Group 42 of the Heavy Duty Trucks Service Manual for
220. ve the cover tetraseal 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 Brakes 6 Install the cover tetraseal 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 08 Bendix Alcohol Evaporator Cleaning If a strainer is present check that it is clear See Fig 8 Clean or replace the strainer if necessary 42 09 Bendix Alcohol Evaporator Gasket Replacing Disassemble the evaporator and the check valve if so equipped Clean all parts and replace all gaskets and rubber parts 42 10 Bendix Air Dryer Checking AD 2 AD 4 or AD 9 Bendix AD 2 Check operation of the heater and thermostat This can be done by allowing the end cover assembly to cool below 50 F 10 C then placing your hand near the end cover when the ignition switch is turned on The end cover should be warm to the touch within a few minutes Warming should cease at about 85 F 30 C Bendix AD 4 Check the operation of the end cover heater and thermostat assembly during cold weather 1 With the ignition or engine control on check for power at the dryer s electrical terminal using a voltmeter or test light Check between the electri cal terminal and th
221. ver over the filter and shouldered studs and secure it with two nuts and washers Tighten the nuts 10 to 15 Ibf ft 14 to 20 N m 4 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 5 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 Rear Axle 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 6 After cleaning the drain plug s install and tighten it 35 Ibf ft 47 N m 7 With the vehicle on a level surface fill the axle housings to the bottom of the fill hole using specified lubricant See Table 2 for recom mended axle lubricants and Table 5 or Table 6 for 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 lub
222. veshaft and U joint from the end yoke then check the drive component s shaft seal for leakage or other visible damage that may have been caused by the loose yoke Replace the seal if needed then tighten the end yoke nut Fig 1 Bearing Cap Capscrews For torque values see Group 41 of the Heavy Duty Trucks Service Manual If the end yoke is still loose after tightening the yoke nut replace the yoke and yoke nut Replace the prevailing torque locknut end yoke nut if it was removed for end yoke replacement seal replacement or any other reason Check U joint assemblies for wear by attempting to move the driveshaft up and down and from side to side If movement of the U joint cross in the bearings can be felt or seen replace the complete U joint Check the midship bearing and mounting for looseness and deterioration 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 bolt nuts to the applicable torque value in the torque tables in the general information section Replace the Heavy Duty Trucks Maintenance Manual April 1998 41 1 41 Driveline 05 27 93 NOTE Not all fasteners are shown 1 Full Round End Yoke 7 Slip Joint Assembly 12 Slip Joint Seal Assembly 2 Bearing Cap 8 Driveshaft Tube 13 Sleeve Yoke Full Round 3 Lockplate and Capscre
223. w 9 Driveshaft Yoke Full Round 14 Yoke Lug 4 Main Transmission 10 Input Shaft End Yoke Half 15 U Joint Cross 5 Half Round End Yoke Round 16 U Joint Assembly 6 Yoke Strap and Capscrew 11 Splined Shaft 1410032a Fig 2 Driveline Assembly midship bearing assembly if the rubber cushion is deteriorated or oil soaked 5 Check slip joints for spline wear by attempting to bend the sleeve yoke and splined shaft back and forth See Fig 3 If radial looseness is greater than 0 007 inch 0 18 mm replace both the sleeve yoke and the splined shaft 6 Visually examine the driveshaft tubes for dents bends twists or other damage If any tube ap 7 pears to be damaged remove the driveshaft and check the run out on the tube If the tube is not straight and cannot be straightened within 0 005 inch 0 127 mm on the slip joint seal sur face of the splined shaft 0 010 inch 0 254 mm on the tube 3 inches 76 mm from the front and rear welds and 0 015 inch 0 381 mm at the center of the tube replace the tube See Fig 4 If the driveshaft tube requires straightening or replacement balance the repaired driveshaft be fore installing it Examine the driveshaft for evidence of missing balance weights and for build up of foreign ma terial Remove any foreign material If there is 41 2 Heavy Duty Trucks Maintenance Manual April 1998 Driveline VERS 05 27 93 Y f410012a Attempt to bend the
224. with a shop cloth Lubricate the new bowl O ring with clean diesel fuel or motor oil then seat it into the contaminant bowl Heavy Duty Trucks Maintenance Manual October 1997 47 3 47 8 Attach the collection bowl to a new filter element hand tight Do not use tools 9 Lubricate the new filter element square cut gas ket with clean diesel fuel or motor oil 10 Spin the filter and bowl assembly onto the mounting head until the gasket contacts the head base then turn it an additional 1 3 to 3 4 of a turn 11 Connect the water sensor probe connector if equipped 12 Connect the bowl heater connector if equipped 13 Loosen the vent plug then operate the primer pump until the fuel purges at the vent plug Then close the vent plug 14 Start the engine and check for fuel leaks Repair all fuel leaks with the engine OFF Racor 490R 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 off some fuel by loosening the vent plug and opening the drain valve See Fig 4 2 Disconnect the water sensor and heater connec tions if equipped 3 Remove the element and bowl together b
225. 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 POC SSD P O Box 3849 Portland OR 97208 3849 Introduction Descriptions of Service Publications Daimler Trucks North America L via ServicePro9 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 Maintenance manuals do not contain detailed repair or service information Driver s operators manuals c
226. y 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 Fuel 2 1 3 4 d 5 PS 9 eee 6 7 8 06 25 97 1470147 1 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 4 Racor 490R Fuel Separator 8 Prime the fuel separator 8 1 Loosen the vent plug Then operate the primer pump until the fuel purges at the vent plug 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 Racor 690R and 6120R A 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 47 4 Heavy Duty Trucks Maintenance Manual October 1997 Fuel age When working on a fuel system have a fire extinguish

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